GT110 Rev 13 PDF

MODEL GT-110
TOW TRACTOR
OPERATION, MAINTENANCE,
& PARTS MANUAL
VOLUME 1 OF 2
ORIGINALLY ISSUED SEPTEMBER 1995
Introduction GT-110 Aircraft Tow Tractor
NOTE: The information contained in this publication is intended exclusively

for the use of TUG and its customers. Disclosure to non-TUG customers
Note may result in legal action by TUG.
NOTE: The information contained in this document is intended to be

accurate and up to date at the time of original issue. TUG reserves the right
Note
to update the information in this document, without warning, as deemed
prudent or necessary by TUG.
INTRO-ii CD276
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GT-110 Aircraft Tow Tractor Introduction
RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: Zip Code:
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual. Tug
Technologies Corporation assumes no liability for personal injury or equipment failure due to any operation
performed without heed to manual revisions.
Date of original publication: September 1995
Revision Number Date Brief Description
1 March 1997
2 April 1997
3 June 1997
4 September 1997
5 May 1998
6 June 1998
7 July 1998
8 November 1998
9 December 1999
10 January 2002
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13 July 2007
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MANUAL TABLE OF CONTENTS
Front Matter
Record of Revisions ........................................................................................................... INTRO-iii
List of Effective Pages ......................................................................................................... INTRO-v
Manual Table of Contents .................................................................................................. INTRO-xii
Copyright Notice ............................................................................................................... INTRO-xix
Introduction ........................................................................................................................ INTRO-xx
Unit Identification ............................................................................................................... INTRO-xx
Technical Assistance ........................................................................................................ INTRO-xxi
Warranty Policy Statement .............................................................................................. INTRO-xxii
How to Use This Manual ................................................................................................. INTRO-xxiv
SAFETY ............................................................................................................................... SAFETY-i
Chapter 1: General Information and Operating Instructions

SECTION 1: GENERAL DESCRIPTION ..................................................................................... 1-1-1
A. Introduction ........................................................................................................... 1-1-1
B. Unit Description .................................................................................................... 1-1-1
C. Engine .................................................................................................................. 1-1-2
D. Transmission ........................................................................................................ 1-1-2
E. Driveline Assembly ............................................................................................... 1-1-2
F. Fuel System .......................................................................................................... 1-1-2
G. Air Intake System ................................................................................................. 1-1-2
H. Exhaust System .................................................................................................... 1-1-2
I. Lubrication System ............................................................................................... 1-1-3
J. Cooling System .................................................................................................... 1-1-3
K. Hydraulic System .................................................................................................. 1-1-3
L. Hitches .................................................................................................................. 1-1-7
M. Ballast ................................................................................................................... 1-1-7
N. Cab ....................................................................................................................... 1-1-7
O. Rear Cab (Option) ................................................................................................ 1-1-8
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P. Electrical System ................................................................................................ 1-1-11

Q. Internal Jacking System (Option) ....................................................................... 1-1-19
R. Ground Power Unit (Option) ............................................................................... 1-1-19
S. Fire Supression System (Option) ....................................................................... 1-1-19
T. Back Up Alarm (Option) ...................................................................................... 1-1-19
U. Centralized On-Board Chassis Lubrication System (Option) ............................. 1-1-19
SECTION 2: OPERATION ........................................................................................................... 1-2-1

A. Preoperational Checks ......................................................................................... 1-2-1
B. Tow Tractor Controls, Indicators and Operational Equipment .............................. 1-2-3
C. Front Cab Operator's Seat.................................................................................. 1-2-26
D. Operational Procedures ...................................................................................... 1-2-28
SECTION 3: SPECIFICATIONS AND CAPABILITIES ................................................................ 1-3-1

A. General ................................................................................................................. 1-3-1
B. Engine .................................................................................................................. 1-3-2
C. Cab ....................................................................................................................... 1-3-3
D. Transmission ........................................................................................................ 1-3-3
D. Axles ..................................................................................................................... 1-3-3
E. Wheels and Tires .................................................................................................. 1-3-4
F. Brakes .................................................................................................................. 1-3-4
G. Hydraulic System .................................................................................................. 1-3-4
H. Steering System ................................................................................................... 1-3-5
I. Electrical System .................................................................................................. 1-3-5
J. Fuel System .......................................................................................................... 1-3-5
K. Lubricant and Fluid Capacities ............................................................................. 1-3-5
L. Engine Oil Grades ................................................................................................ 1-3-6
M. Transmission Oil Grades ...................................................................................... 1-3-6
SECTION 4: SHIPPING ............................................................................................................... 1-4-1

A. Introduction ........................................................................................................... 1-4-1
B. Tie-Down Points ................................................................................................... 1-4-1
C. Lifting .................................................................................................................... 1-4-1
D. Preparing Engine .................................................................................................. 1-4-1
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E. Preparing Unit ....................................................................................................... 1-4-2

F. Marking ................................................................................................................. 1-4-2
G. Receiving Equipment ............................................................................................ 1-4-2
H. Preparing Unit for Service .................................................................................... 1-4-3
SECTION 5: STORAGE .............................................................................................................. 1-5-1

A. Short Term Storage ............................................................................................... 1-5-1
B. Returning the Tractor to Operation After Short Term Storage ............................... 1-5-2
C. Long Term Storage ............................................................................................... 1-5-3
D. Returning the Tractor to Operation After Long-Term Storage ............................... 1-5-5
Chapter 2: Maintenance
SECTION 1: SERVICING ............................................................................................................ 2-1-1
A. Introduction ........................................................................................................... 2-1-1
B. Periodic Maintenance Schedule ........................................................................... 2-1-1
C. Maintenance Procedures ...................................................................................... 2-1-5
SECTION 2: TROUBLESHOOTING............................................................................................ 2-1-1

A. Introduction ........................................................................................................... 2-1-1
B. Lights .................................................................................................................... 2-1-2
C. Engine .................................................................................................................. 2-1-4
D. Transmission ........................................................................................................ 2-1-5
E. Charging System .................................................................................................. 2-1-5
F. Acessories ............................................................................................................ 2-1-6
G. Hydraulic Pump and Relief Valve ......................................................................... 2-1-7
H. Service Brakes ..................................................................................................... 2-1-8
I. Parking Brakes ..................................................................................................... 2-1-9
J. Front Cab Lift ...................................................................................................... 2-1-10
K. Steering - General .............................................................................................. 2-1-11
L. Steering - Three Mode System ........................................................................... 2-1-12
M. Cab Select Circuit ............................................................................................... 2-1-17
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N. Wiring Diagrams ................................................................................................. 2-2-19

Figure 2-1. Wiring Diagram ............................................................................... 2-2-19
Figure 2-2. Wiring Diagram with Cat/Engine ..................................................... 2-2-25
Figure 2-3. Hydraulic Schematic ....................................................................... 2-2-36
Figure 2-5. Schematic, Front & Rear Cab (Station) ........................................... 2-2-40
Figure 2-7. Schematic, Single Cab (Station) ..................................................... 2-2-58
Figure 2-9. Wiring Diagram, Single Cab (Station) ............................................. 2-2-76
Figure 2-10. Schematic, Single Cab (Station) w/Cat Engine ............................. 2-2-92
Figure 2-11. Wiring Diagram, Rear Driving Lights/Single Cab......................... 2-2-101
Figure 2-12. Wiring Diagram, Back Up Alarm .................................................. 2-2-102
Figure 2-13. Wiring Diagram, Marker Clearance Light .................................... 2-2-103
Figure 2-14. Electrical Equipment Location ..................................................... 2-2-105
Figure 2-15. Electrical Equipment Location Cat & Deutz Engines .................. 2-2-112
Figure 2-16. Schematic & Wiring Diagram,
Passive Centering Kit, Single Cab ........................................................ 2-2-123
Figure 2-17. Layout, Optional Components, Front Cab Control Panel ............ 2-2-126
Figure 2-18. Schematic, Lights through Ignition .............................................. 2-2-127
Figure 2-19. Wiring Schematic for Starting, Alternator, Ignition Switch ........... 2-2-129
Chapter 3: Overhaul
SECTION 1: OVERHAUL DATA................................................................................................. 3-1-1
A. Model GT-110 Tow Tractor Overhaul .................................................................... 3-1-1
B. Engine .................................................................................................................. 3-1-1
C. Transmission ........................................................................................................ 3-1-1
D. Axles ..................................................................................................................... 3-1-2
SECTION 2: REMOVAL AND INSTALLATION ........................................................................... 3-2-1

A. Engine and Transmission Assembly Removal ...................................................... 3-2-1
B. Engine And Transmission Assembly Installation .................................................. 3-2-3
C. Axle Removal Procedures .................................................................................... 3-2-4
D. Axle Installation Procedures ................................................................................. 3-2-5
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Chapter 4: Illustrated Parts List

SECTION 1: DESCRIPTION ...................................................................................................... 4-1-1
A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number ......................................................................... 4-1-2
2. Part Numbers and Vendor Codes ............................................................. 4-1-3
3. Description and Quantity .......................................................................... 4-1-4
4. Effectivity .................................................................................................. 4-1-4
C. Ordering Spare Parts ............................................................................................ 4-1-4
D. Consumable Parts List (Deutz Engine) ................................................................ 4-1-5
E. Vendor Code Reference List ................................................................................ 4-1-6
SECTION 2: ILLUSTRATED PARTS LIST ................................................................................. 4-2-1

Figure 4-1. Arrangement Drawing - Doors and Covers ....................................... 4-2-2
Figure 4-2. Engine Access Door Decals .............................................................. 4-2-4
Figure 4-3. Ballast Schedule (Sheet 1 of 2) ......................................................... 4-2-5
Figure 4-4. Cab Arrangements ............................................................................ 4-2-7
Figure 4-5. Open Driver's Compartment with Suspension Seat .......................... 4-2-8
Figure 4-6. Rear Bumper Assembly .................................................................... 4-2-9
Figure 4-7. Standard Cab Exterior Assembly .................................................... 4-2-10
Figure 4-8. Lift Cab Exterior Assembly .............................................................. 4-2-11
Figure 4-9. Cab Assembly (p/n 12941095) ........................................................ 4-2-12
Figure 4-10. Rear Operator's Compartment (ROC) Assembly .......................... 4-2-20
Figure 4-11. Arrangement Drawing - Rear Operator's Compartment (ROC) ..... 4-2-22
Figure 4-12. Door Assembly .............................................................................. 4-2-24
Figure 4-13. Lift Carriage Assembly .................................................................. 4-2-26
Figure 4-14. Internal Jacking System ................................................................ 4-2-28
Figure 4-15. Control Panel Assembly - Front Cab ............................................. 4-2-30
Figure 4-16. Control Panel Assembly - Rear Cab (Sheet 1 of 2) ....................... 4-2-32
Figure 4-17. Control Panel Assembly - Cab Selection (Sheet 1 of 2) ................ 4-2-34
Figure 4-18. Console Decals ............................................................................. 4-2-36
Figure 4-19. Accelerator System ....................................................................... 4-2-38
Figure 4-20. Accelerator System (with ROC Option) ......................................... 4-2-40
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Figure 4-21. Brake Pedal Assembly .................................................................. 4-2-43

Figure 4-22. Brake System ................................................................................ 4-2-44
Figure 4-23. Brake System (with ROC Option) ................................................. 4-2-46
Figure 4-24. Brake Actuator Assembly (p/n 12950599) ..................................... 4-2-48
Figure 4-25. Park Brake Assembly (Up to S/N 173) .......................................... 4-2-50
Figure 4-26. Park Brake Assembly (S/N 173 and Up) ....................................... 4-2-52
Figure 4-27. Drive Train (Sheet 1 of 2) .............................................................. 4-2-54
Figure 4-27. Drive Train (Sheet 2 of 2) .............................................................. 4-2-55
Figure 4-28. Bolt Torque Specification - Drive Train (Sheet 1 of 2) ................... 4-2-56
Figure 4-28. Bolt Torque Specification - Drive Train (Sheet 2 of 2) ................... 4-2-57
Figure 4-29. Drive Shaft Installation .................................................................. 4-2-58
Figure 4-30. Lubrication System ........................................................................ 4-2-60
Figure 4-31. Steering Column Assembly (Front) ............................................... 4-2-61
Figure 4-32. Steering Column Assembly (ROC Option) .................................... 4-2-62
Figure 4-33. Hydraulic Steering System ............................................................ 4-2-64
Figure 4-34. Hydraulic Steering System (w/ ROC Option) ................................ 4-2-66
Figure 4-35. Steering Control Box ..................................................................... 4-2-68
Figure 4-36. Hydraulic Tank Assembly .............................................................. 4-2-70
Figure 4-37. Hydraulic Control Board Assembly ................................................ 4-2-72
Figure 4-38. Hydraulic Control Board Assembly (with ROC Option) ................. 4-2-76
Figure 4-39. Hydraulic Pump Assembly ............................................................ 4-2-82
Figure 4-40. Emergency Hydraulic Pump Assembly ......................................... 4-2-83
Figure 4-41. Pump and Return Hydraulic System ............................................. 4-2-84
Figure 4-42. Cab Bulkhead Assembly ............................................................... 4-2-86
Figure 4-43. Lift Cab Hydraulic System ............................................................. 4-2-88
Figure 4-44. Engine Assembly (Side View) ....................................................... 4-2-90
Figure 4-44a. Engine Assembly (Front View) .................................................... 4-2-91
Figure 4-44b. Engine Assembly (Rear View) ..................................................... 4-2-92
Figure 4-44c. Engine and Engine Mounts ......................................................... 4-2-93
Figure 4-45. Engine Oil Pan Heater Pad ........................................................... 4-2-94
Figure 4-46. Transmission Installation ............................................................... 4-2-95
Figure 4-47. Transmission Oil System (Up to S/N 109) ..................................... 4-2-96
Figure 4-48. Transmission Oil System (S/N 109 and Up) .................................. 4-2-98
Figure 4-49. Air Intake System ........................................................................ 4-2-100
Figure 4-50. Exhaust System .......................................................................... 4-2-101
Figure 4-51. Fuel System ................................................................................ 4-2-102
Figure 4-52. Radiator, Transmission Cooler Installation .................................. 4-2-104
Figure 4-53. Battery Installation ....................................................................... 4-2-106
CD276 INTRO-xvii
Rev 13
Figure 4-54. Circuit Breaker and Fuse Installation .......................................... 4-2-107

Figure 4-55. Relay Box Assembly ................................................................... 4-2-108
Figure 4-56. Fuse Box Assembly ..................................................................... 4-2-110
Figure 4-57. Rear View Camera Option and ESM Installation ......................... 4-2-111
SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-13
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
Chapter 5: Appendices
SECTION 1: PERIODIC MAINTENANCE CHECKLIST ............................................................. 5-1-1
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS ................................................ 5-2-1

A. Description ............................................................................................................ 5-2-1
INTRO-xviii CD276
Rev 13
COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of TUG Technologies Corporation.
Neither this document, nor any information contained herein, may be reproduced or redistributed in any form
whatsoever without the express, written consent of an authorized agent of TUG Technologies Corporation.
Any attempt by any person other than an authorized agent of TUG Technologies Corporation to alter the
contents of this manual in any way shall be construed as copyright infringement, punishable by all applicable
laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors, protected
by the same laws governing this operation and maintenance manual.
© Copyright 2007 by TUG Technologies Corporation. All rights reserved.
CD276 INTRO-xix
Rev 13
INTRODUCTION
The information and instructions in this handbook are intended to acquaint the operator with the important
operating features of the TUG model MR Mid-Range Tow Tractor. The various controls, gauges, switches,
and operating features are explained and illustrated throughout this handbook. Personnel responsible for
operation of the vehicle should read this manual carefully to become familiar with vehicle operation.
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a TUG identification plate is located on the
operator's compartment of the unit.
The serial number identification of each unit will appear on the nameplate along with the date of manufacture.
The mailing address of TUG is also located on the data plate next to the TUG logo. This necessary
information will ensure the customer a fast and accurate response to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit serial number
here:
If applicable, enter your company identification number
here:
INTRO-xx CD276
Rev 13
TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the MR Mid-Range Tow Tractor to:
TUG Technologies Corporation

815 Allgood Road
Marietta, GA 30062
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
All information in this manual is based on the latest production information available at the time of
publication. Direct any questions concerning the contents or format of this manual to:

Attn: TUG Shop
815 Allgood Road
Marietta, GA 30062
Domestic: 1-800-989-8499
Fax: (770) 422-8730
Email: TugShop@tugtech..com
CD276 INTRO-xxi
Rev 13
AIRCRAFT GROUND SUPPORT EQUIPMENT

WARRANTY POLICY STATEMENT
This Policy Statement sets forth the terms of the warranty provided by TUG Technologies Corp. with respect to ground power units, air start units, tow tractors,
cargo tractors and other equipment sold for use in the commercial aviation industry (“Aircraft Ground Support Equipment”).
STATEMENT OF WARRANTY AGAINST DEFECTS
Subject to the limitations and exclusions set forth below, TUG Technologies Corp. will repair or replace any defective or malfunctioning part of the Aircraft
Ground Support equipment for a period of twenty-four (24) months from the date first placed in service, or twenty-eight (28) months from date of shipment, or
the first 2,000 hours of operation, whichever expires first. Each piece of Aircraft Ground Support Equipment shall be presumed to have been placed in service
on the date of the TUG Technologies Corp. start-up report or, if there is no such report, on the date of shipment by TUG Technologies Corp. to the first retail
purchaser (“Buyer”).
WARRANTY AGAINST PATENT INFRINGEMENT
TUG Technologies Corp. warrants that none of the Aircraft Ground Support Equipment, the use thereof within the United States, or the applications, processes
or designs employed in the manufacture thereof infringes on the valid claim of any U.S. letter patent, patent application, copyright, trade secret or any other
property right of any third party. In the event of a breach or alleged breach of this warranty TUG Technologies Corp. shall, at its own expense, defend any suit
or proceeding brought against Buyer and shall fully protect and indemnify Buyer against any liability, cost, recovery or other expense in or resulting from such
suit or claim of infringement. Buyer shall give prompt notice in writing of any notice of claim of such suit and Buyer agrees to cooperate with TUG Technolo-
gies Corp. to enable it to make such defense. If in any such proceeding, the Aircraft Ground Support Equipment or any part thereof is held to constitute an
infringement and the full or partial use of the Aircraft Ground Support Equipment is enjoined, TUG Technologies Corp. shall, at no cost to Buyer, (i) obtain for
Buyer a license to use the Aircraft Ground Support Equipment or (ii) modify the Aircraft Ground Support Equipment so as to avoid the infringement without
degradation in performance. If TUG Technologies Corp. cannot obtain such a license, or the Aircraft Ground Support Equipment cannot be so modified, or if as
a result of any suit or infringement or alleged infringement, TUG Technologies Corp. may elect not to deliver, or may be prevented from delivering, the Aircraft
Ground Support Equipment or any part or component thereof, TUG Technologies Corp. shall, as Buyer’s exclusive remedy, promptly refund to Buyer all money
paid by Buyer for the Aircraft Ground Support Equipment.
EXCLUSIONS OF LIABILITY
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TUG TECHNOLOGIES CORP.’S LIABILITY UNDER THE FOREGOING
WARRANTY SHALL BE LIMITED TO THE COSTS OF REPAIR OR REPLACEMENT BY TUG TECHNOLOGIES CORP. OF ANY DEFECTIVE PART
OR WORKMANSHIP. TUG TECHNOLOGIES CORP. SHALL NOT HAVE ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,
INCLUDING LOSS OF USE AND LOST PROFITS, IN CONNECTION WITH THE PURCHASE, SALES, SHIPMENT, SERVICE, REPAIR OR OPERATION
ARISING FROM THE FAILURE OF ANY AIRCRAFT GROUND SUPPORT EQUIPMENT OR A COMPONENT THEREOF, OR A BREACH OF ANY
WARRANTY. IN NO EVENT SHALL TUG TECHNOLOGIES CORP.’S LIABILITY TO ANY PERSON EXCEED THE PURCHASE PRICE OF THE TUG
TECHNOLOGIES CORP. AIRCRAFT GROUND SUPPORT EQUIPMENT.
TUG Technologies Corp. will, at its sole option, repair or replace any component, part or parts, if found on examination by TUG Technologies Corp. to be
defective and if the necessary return charges are prepaid by the Buyer. This applies to TUG Technologies Corp. manufactured components. Purchased compo-
nents will be handled based on their individual warranties.
Certain Aircraft Ground Support Equipment are installed on trucks or trailers supplied by TUG Technologies Corp. but manufactured by others. In addition,
most Aircraft Ground Support Equipment includes tires that are covered by the warranty issued by the original manufacturer. The warranty of TUG Technolo-
gies Corp. does not cover any failure of the chassis, drive train, cab or other part of the truck or trailer on which Aircraft Ground Support Equipment is installed
other than tow tractors or cargo tractors manufactured by TUG Technologies Corp.. Tires are specifically excluded from any warranty by TUG Technologies
Corp. and are covered only by the warranty, if any, extended by the original manufacturer.
TUG Technologies Corp. has not authorized any person to assume or create any different warranty, written or oral, express or implied, or any other liability on
behalf of TUG Technologies Corp. with respect to the Aircraft Ground Support Equipment.
TUG Technologies Corp. reserves the right to make changes in design and changes or improvements upon its products without any obligation upon itself to
install the same upon its products theretofore manufactured.
The foregoing warranty gives Buyer specific legal rights that may vary from state to state. Some states do not permit the limitation of incidental or consequential
damages or limitation of remedies under warranties. The above limitations apply only to the extent permitted by applicable law.
BUYER’S RESPONSIBILITY
TUG Technologies Corp. provides Buyer with a copy of the relevant operator manuals containing vital information relating to the proper use and maintenance
of the Aircraft Ground Support Equipment. Additional copies of operator manuals are available from TUG Technologies Corp. at a small charge. Any repairs
arising from failure to maintain the Aircraft Ground Support Equipment in accordance with the operator manuals, from operation of the Aircraft Ground
Support Equipment in a manner not recommended by the operator manual, or from the use of fuels, lubricants or coolants not meeting the specifications set
forth in the operator manuals, are for the account of Buyer.
Many factors affect the performance and reliability of the Aircraft Ground Support Equipment. Specific output ratings and operating parameters have been
established by TUG Technologies Corp.. Operation outside of the recommended parameters can adversely affect the service life of the Aircraft Ground Support
Equipment.
Buyer shall be responsible for all repairs arising from operation of Aircraft Ground Support Equipment above its output ratings, outside its recommended
operating parameters or misuse, accident, foreign object damage or damage caused by a third party.
The Aircraft Ground Support Equipment will require repairs and adjustments over time. The repairs should be performed only by TUG Technologies Corp.
authorized mechanics and with equipment and parts meeting the TUG Technologies Corp. specifications set forth in the operating manuals. Moreover, certain
items installed on the Aircraft Ground Support Equipment, such as belts and filters, wear out over a period of time and must be periodically replaced. Buyer
shall be responsible for any filters, belts, hoses or other normal maintenance items. Buyer shall be responsible for any repairs arising from alterations to the
Aircraft Ground Support Equipment, repairs performed by a person other than authorized representatives of TUG Technologies Corp. or the use of maintenance
items or parts not meeting the TUG Technologies Corp. specifications set forth in the operator manuals. The cost of routine or required maintenance and service
is the responsibility of the Buyer. The Buyer is required to keep documented evidence of when and by whom maintenance and service are performed.
INTRO-xxii CD276
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IN THE EVENT OF A FAILURE

1. Unless there is a threat to life or property, Buyer shall immediately cease using any Aircraft Ground Support Equipment that exhibits any fuel or oil leak,
vibration, unusual noise, high temperature, low oil pressure, black or white smoke, excessive fuel or oil consumption, or any other abnormal condition.
2. Do not disassemble or otherwise attempt to repair the Aircraft Ground Support Equipment. Contact TUG Technologies Corp. for the name and address of
the nearest facility authorized to repair Aircraft Ground Support Equipment. Have available all serial numbers, model numbers, date of purchase and other
information that will assist TUG Technologies Corp. to identify the equipment.
3. TUG Technologies Corp.’s Warranty Department will troubleshoot the problem and direct the Buyer to the nearest authorized repair facility, or dispatch a
field service representative to the location of the Aircraft Ground Support Equipment or provide buyer with replacement parts to be installed by Buyer.
Buyer will be asked for a purchase order or other commitment to pay any expenses that are not covered by the applicable warranty.
4. TUG Technologies Corp. will repair warranted failures during normal business hours using new or remanufactured parts at the option of TUG Technologies
Corp. Warranty Department. Buyer must pay for any repairs or charges not covered by the applicable warranty at the time services are rendered unless other
arrangements are made in advance.
5. TUG Technologies Corp. will invoice Buyer for all warranty replacement parts that are shipped for Buyer installation. Buyer shall be entitled to full credit
against the cost of such part, other than transportation charges, upon the return of the failed parts and determination by TUG Technologies Corp.’s Warranty
Department that such failure was covered by warranty. Such invoice shall be payable in full unless the failed part is returned within ten (10) days after
invoice date.
IF YOU HAVE A QUESTION
If you have any questions regarding the applicable warranty on your Aircraft Ground Support Equipment, contact:
TUG Technologies Corp.

815 Allgood Road
Marietta, GA 30062
Domestic: 1-800-989-8499
Fax: (770) 422-8730
E-mail: TugShop@tugtech.com
CD276 INTRO-xxiii
Rev 13
HOW TO USE THIS MANUAL

Important Notice: TUG recommends that the vehicle operator thoroughly study the contents of this handbook
before attempting to operate the vehicle.
This handbook is divided into five chapters. Refer to the Table of Contents at the front of this manual and each
chapter for details of chapter content.
Page numbering system uses a three-part page number. The first number represents the chapter in which the
page appears, the second number indicates the section within that chapter, while the third number is the page
number within that section.
Warnings, Cautions, and Notes are used throughout this handbook. Look for the following symbols, which
point out items of importance to the safety of the individual and protection of equipment.
SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

INJURY TO PERSONNEL OR EVEN DEATH.
SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

DAMAGE TO EQUIPMENT.
Note Relevant information for the reader, that is not hazard-related.
INTRO-xxiv CD276
Rev 13
GT-110 Aircraft Tow Tractor Safety
SAFETY
The safety precautions contained herein should be observed during all phases of operation.
1. Check to ensure that the parking (emergency) brake is set whenever the unit is intended to
remain stationary.
2. Clean or service the unit only when the engine is shut down.
3. When cleaning, use only an approved solvent to prevent damage and/or deterioration to the
equipment.
4. When filling the fuel tank, do not smoke or use an open flame in the vicinity.
5. Prior to starting the unit, ensure that no loose bars, tools, parts, and the like are lying in or on
a part of the unit, as they could cause serious damage to the unit or bodily injury to personnel.
6. When operating in an enclosed area, pipe the exhaust fumes outside.
7. Follow the manufacturer’s recommendations to properly maintain equipment.
8. In case of malfunction, resulting in a shutdown, do not attempt to restart the engine until the
trouble has been corrected. Failure to comply could result in serious damage to the
equipment.
9. In case of accident, shut down the unit immediately.
10. The tow tractor must be safely supported on blocks or other appropriate supporting devices
before personnel may attempt access underneath the tractor. Equipment used to raise
and support the tow tractor must be rated to withstand 150% (11/2 times) the tractor’s
gross vehicle weight.
11. This equipment uses both metric and S.A.E. (inch type) nuts, bolts, and screws which can
present special service requirements. Many metric measurements are very close in
dimension to S.A.E. rated nuts, bolts, and screws. The use of hardware with mismatched
threads or improperly sized components can result in damage, malfunction, or possible
personal injury. Components and hardware removed from tow tractor should be saved for
reuse when possible. If not reusable, care should be taken to select a replacement that
matches the original in dimension, strength, and pitch of threads.
CD276 SAFETY-i
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Safety GT-110 Aircraft Tow Tractor
(This page intentionally left blank.)
SAFETY-ii CD276
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Chapter 1
GT-110 Aircraft Tow Tractor Table of Contents
CHAPTER 1: GENERAL INFORMATION

AND OPERATING INSTRUCTIONS
TABLE OF CONTENTS
SECTION 1: GENERAL DESCRIPTION ..................................................................................... 1-1-1

A. Introduction ........................................................................................................... 1-1-1
B. Unit Description .................................................................................................... 1-1-1
C. Engine .................................................................................................................. 1-1-2
D. Transmission ........................................................................................................ 1-1-2
E. Driveline Assembly ............................................................................................... 1-1-2
F. Fuel System .......................................................................................................... 1-1-2
G. Air Intake System ................................................................................................. 1-1-2
H. Exhaust System .................................................................................................... 1-1-2
I. Lubrication System ............................................................................................... 1-1-3
J. Cooling System .................................................................................................... 1-1-3
K. Hydraulic System .................................................................................................. 1-1-3
L. Hitches .................................................................................................................. 1-1-7
M. Ballast ................................................................................................................... 1-1-7
N. Cab ....................................................................................................................... 1-1-7
O. Rear Cab (Option) ................................................................................................ 1-1-8
P. Electrical System ................................................................................................ 1-1-11
Q. Internal Jacking System (Option) ....................................................................... 1-1-19
R. Ground Power Unit (Option) ............................................................................... 1-1-19
S. Fire Supression System (Option) ....................................................................... 1-1-19
T. Back Up Alarm (Option) ...................................................................................... 1-1-19
U. Centralized On-Board Chassis Lubrication System (Option) ............................. 1-1-19
SECTION 2: OPERATION ........................................................................................................... 1-2-1

A. Preoperational Checks ......................................................................................... 1-2-1
B. Tow Tractor Controls, Indicators and Operational Equipment .............................. 1-2-3
C. Front Cab Operator's Seat.................................................................................. 1-2-26
D. Operational Procedures ...................................................................................... 1-2-28
CD276 1-TOC-i
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Chapter 1
Table of Contents GT-110 Aircraft Tow Tractor
SECTION 3: SPECIFICATIONS AND CAPABILITIES ................................................................ 1-3-1

A. General ................................................................................................................. 1-3-1
B. Engine .................................................................................................................. 1-3-2
C. Cab ....................................................................................................................... 1-3-3
D. Transmission ........................................................................................................ 1-3-3
D. Axles ..................................................................................................................... 1-3-3
E. Wheels and Tires .................................................................................................. 1-3-4
F. Brakes .................................................................................................................. 1-3-4
G. Hydraulic System .................................................................................................. 1-3-4
H. Steering System ................................................................................................... 1-3-5
I. Electrical System .................................................................................................. 1-3-5
J. Fuel System .......................................................................................................... 1-3-5
K. Lubricant and Fluid Capacities ............................................................................. 1-3-5
L. Engine Oil Grades ................................................................................................ 1-3-6
M. Transmission Oil Grades ...................................................................................... 1-3-6
SECTION 4: SHIPPING ............................................................................................................... 1-4-1

A. Introduction ........................................................................................................... 1-4-1
B. Tie-Down Points ................................................................................................... 1-4-1
C. Lifting .................................................................................................................... 1-4-1
D. Preparing Engine .................................................................................................. 1-4-1
E. Preparing Unit ....................................................................................................... 1-4-2
F. Marking ................................................................................................................. 1-4-2
G. Receiving Equipment ............................................................................................ 1-4-2
H. Preparing Unit for Service .................................................................................... 1-4-3
SECTION 5: STORAGE .............................................................................................................. 1-5-1

A. Short Term Storage ............................................................................................... 1-5-1
B. Returning the Tractor to Operation After Short Term Storage ............................... 1-5-2
C. Long Term Storage ............................................................................................... 1-5-3
D. Returning the Tractor to Operation After Long-Term Storage ............................... 1-5-5
1-TOC-ii CD276
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Chapter 1
GT-110 Aircraft Tow Tractor Section 1
SECTION 1: GENERAL DESCRIPTION
Figure 1-1. Model GT-110 Tow Tractor
A. INTRODUCTION
The Model GT-110 Tow Tractor is a narrow and low-profile, diesel-powered, four-wheel drive tractor
designed for aircraft push and tow. With an optional front cab that can be either stationary or
elevating, the vehicle can hold a driver and two passengers. A rear operator’s station with a platform
for a ground power unit, as well as a hydraulically powered self-jacking system, are available as
options.
B. UNIT DESCRIPTION
1. The Model GT-110 tow tractor is available in weights of 90,000 lbs (40,824 kg), 100,000 lbs
(45,400 kg), 110,000 lbs (49,940 kg), and 120,000 lbs (54,480 kg). It can generate
approximately 80,000 lbs (32,659 kg) of drawbar pull at gross weights of 100,000 lbs or more.
Powered by a six-cylinder Deutz diesel engine coupled to a ZF Powershift transmission, the
tractor is capable of a top speed of approximately 17 mph (27.4 km/h) with no vehicle in tow.
2. Mounted within the Model GT-110’s structural frame are a diesel engine, a hydraulically
powered four speed transmission, a driveline assembly, a fuel system, an air intake system, a
lubrication system, a cooling system, a steering system, a brake system, and an electrical
system.
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Section 1 GT-110 Aircraft Tow Tractor
C. ENGINE
The GT-110 is powered by a four-stroke, six cylinder, turbocharged Deutz diesel engine. From inside
the engine’s cast iron block, a single camshaft drives all valves and the fuel injector pumps. At the
engine’s forward end is a vertically aligned gear train that drives the lubricating oil pump and the fuel
pump, and connects the entire assembly with the crankshaft and camshaft. For more detailed
information, refer to the engine service manual located in Chapter 5.
D. TRANSMISSION
A ZF Powershift Transmission mounted on the rear of the engine transmits power to the drivetrain.
Four forward and three reverse speeds are selected via Electric Shift Control, and a single-stage,
three element ZF torque converter multiplies the engine to transmission torque.
E. DRIVELINE ASSEMBLY
The front and rear drive shafts are coupled to the transmission via a transfer case mounted on the
transmission’s bottom. Turned by gears in the transfer case, the drive shafts transmit torque to the
front and rear differentials which, in turn, transmit their torque to the axles, the planetary wheel
assemblies, and the wheels.
F. FUEL SYSTEM
An engine driven fuel pump pulls fuel from the fuel tank and delivers it to an engine mounted fuel
filter. The cleansed fuel is then pumped into each cylinder via fuel injectors. Surplus fuel not metered
to the engine returns to the fuel tank via a return line controlled by a pressure regulated valve. The
engine mounted fuel filter is a single unit, spin-on cartridge.
G. AIR INTAKE SYSTEM
Air is drawn through a large, single-element, air filter mounted on the side of the vehicle into the intake
side of an exhaust gas driven turbocharger. The turbocharger pressurizes the intake air that is then
cooled by an air-to-air heat exchanger to improve the combustion efficiency of the engine. The air is
then ducted to the engine’s intake manifold, which routes it to the individual cylinders.
H. EXHAUST SYSTEM
The engine’s hot exhaust gases are flushed out through its exhaust valves to the exhaust manifold. The
exhaust manifold carries the gases into the turbocharger where they spin a single-stage turbowheel.
(The turbowheel is connected to an impeller on the air intake side of the turbocharger.) After passing
over the turbowheel, the exhaust gases travel through a muffler before being directed out to the rear
of the vehicle.
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Chapter 1
I. LUBRICATION SYSTEM
1. The engine lubrication system consists of an oil pump, oil cooler, a bypass and full-flow filter, a
pressure regulator valve, and a pressure relief valve.
2. A gear type engine lube oil pump mounted on the vertical gear train pumps oil from the oil pan
into a lube oil cooler mounted on the engine block. Oil is then pumped through an oil filter past
a pressure relief valve. From the oil filter, oil progresses through the main oil gallery, which
lubricates the crankshaft, camshaft, connecting rod bearings, and, via a nozzle line, the pistons.
Tappets pick up oil from the camshaft and route it through the pushrods to the rocker arms
and valves. Some of the used engine oil is also routed to the turbocharger. Oil return lines
from the turbocharger and the engine return the oil to the oil pan sump.
J. COOLING SYSTEM
The vehicle’s cooling system consists of the engine cooling system and the components used to cool
the tractor’s transmission system.
The engine cooling system consists of a coolant filler mounted atop the engine, a thermostat that
controls the engine’s temperature, an engine-driven coolant pump, a heat exchanger behind an engine-
driven fan, a lube oil cooler, and paths within the engine to circulate coolant around the cylinder heads.
A radiator forward of the engine-mounted charge air cooler cools the hydraulic fluid from the
transmission.
K. HYDRAULIC SYSTEM
The GT-110’s hydraulic system provides for steering, braking, and optional elevating front cab and
internal self-jacking systems.
1. Main Hydraulic Pump

Hydraulic pressure for the steering, braking, front cab elevation and optional internal jacking
system is provided by a single, variable displacement, axial piston, gear driven hydraulic pump
mounted on the transmission. At an engine speed of 2400 rpm, the pump will displace 45 gpm
(170.3 L/min) of fluid at 2000 psi (13789.5 kPa).
2. Emergency Steering Pump

An electrically-driven hydraulic pump activated by the vehicle operator in conjunction with low
hydraulic pressure provides emergency steering if the main hydraulic pump fails. The
emergency steering pump is activated by pressing the momentary-ON Emergency Steering
Switch when the hydraulic pressure in the steering system is below 1800 psi.
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Chapter 1
3. Hydraulic Reservoir
The 30 gallon hydraulic reservoir contains the hydraulic fluid necessary to operate all
subsystems and provide a reserve. The reservoir contains an integral filler cap and level gage,
strainer, and vent.
4. Hydraulic Filter
A hydraulic filter assembly is located between the return manifold and the hydraulic reservoir.
A filter service indicator is mounted on the filter housing to allow a visual indication of the
relative accumulation of contaminants. A diverter/bypass valve in the filter head allows full-
flow filtration until a bypass pressure is reached.
5. Dual Check/Distribution Valve

Hydraulic fluid leaving the main hydraulic pump is distributed to the major hydraulic
subsystems by a dual check/distribution valve. The valve also routes fluid to the return
manifold, provides a pick-off for the emergency steering pump switch, and incorporates check
valves that block fluid flow in the wrong direction.
6. Steering Subsystem
The steering subsystem components change with single or dual cab options.
(a) Single Cab Steering Subsystem
(1) Char-Lynn Steering Control Unit. A 48 cubic inch displacement Char-Lynn

Steering Control Unit connected to the main hydraulic system receives
steering wheel inputs and controls the porting of hydraulic power to the front
axle steering cylinders and to Solenoid Valve 1. (Solenoid Valve 1 controls
the rear axle steering circuits.) The direction of turn determines the side of
the steering cylinders and the solenoid valve to which the unit ports power
and fluid. A left turn will send power directly to the left turn side of the front
steering cylinders. The return flow from these cylinders then drives Solenoid
Valve 1 which, in turn, ports power to the appropriate rear axle steering
cylinders. For a right turn, the unit ports power directly to Solenoid Valve 1
and then to the right turn side of the front steering cylinders.
(2) Solenoid Valve 1. Solenoid Valve 1 controls the rear axle steering cylinders.
Its porting of hydraulic power is dependent upon which steering mode is
selected. The valve incorporates an internal double pilot check valve.
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Chapter 1
(b) Dual Cab Steering Subsystem
(1) Orbital Steering Select Valve (SV1). This valve selects the front or rear
orbital steering valves. If the operator selects front cab operation, the valve
directs pressure to the front orbital steering valve and relieves pressure from
the rear orbital steering valve. Rear cab selection reverses that process.
Shutting down the tractor de-energizes the valve’s solenoids, moving it to the
center position.
(2) Orbital Steering Valves, Front & Rear. Each valve is a manually operated,
directional control valve and meter within a single valve. Rotating the
steering wheel causes the attached valve to direct fluid to the appropriate
steering cylinders on each axle.
(3) Steering Manifold. The steering manifold coordinates the movements of the
steering cylinders via two solenoid-operated directional control valves and
their associated connections. It also provides a place for test gauge ports.
(4) Steering Mode Select Valves (SV2 & SV3). The valves are mounted on the
steering manifold. When the tractor is being operated from the front cab,
valve SV2 determines the tractor’s steering mode. Valve SV3 determines the
steering mode when the tractor is being operated from the rear cab. When
track steering mode is selected, the appropriate valve is de-energized or in its
center position. Otherwise, the valves direct hydraulic fluid to obtain 4-wheel
coordinated or crab steering modes.
(5) Steering Cylinders. The steering cylinders are double-acting hydraulic

cylinders attached to the axles. When hydraulic pressure is directed into the
cylinders by a steering valve, the cylinders extend or retract and turn the
wheels in the required direction.
7. Service Brake Subsystem
The service brake subsystem is composed of five components: dual check relief valve,
accumulators, brake valve, front and rear brake master and slave cylinders, and service brake
assemblies.
(a) Dual Check Relief Valve. This valve splits the supply pressure into separate circuits
for the front and rear brakes, checks the flow in one direction, and provides pressure
relief for the service brake subsystem.
(b) Accumulators. The accumulators provide emergency service brake pressure if a loss
of normal or emergency supply pressure occurs. Each service brake circuit contains
one accumulator.
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Chapter 1
(c) Brake Valve. The Brake Valve controls service brake application via inputs from the
front or rear brakes and their slave cylinders. It receives main hydraulic system
pressure (or brake system accumulator pressure if main system pressure disappears)
and applies it to both front and rear service brakes when commanded.
(4) Front and Rear Brake Master and Slave Cylinders. Service brake control pressure is
supplied by the brake master and slave cylinders. There is one brake pedal assembly
per cab, each equipped with dual master cylinders. When the operator applies
pressure to the brake pedal, control pressure from the master cylinder acts against a
slave cylinder. The slave cylinder is mechanically linked to the service brake valve
which diverts hydraulic system supply pressure to the front and rear brakes. The
master/slave cylinder circuit uses DOT 3 brake fluid only.
(5) Service Brake Assemblies. Two service brake assemblies, a front and a rear, reside
on each wheel. Each brake assembly consists of a caliper and its internal
components, and two brake pads surrounding a large brake disc. Hydraulic pressure
applied to the caliper pushes the brake pads against the disc, providing the friction for
the braking action. For more detailed information on the wheel cylinders and brake
assemblies, refer to the brake manual located in Chapter 5.
8. Parking Brake Subsystem
The GT-110 tow tractor has two caliper disc parking brakes. These are mounted on the front
and rear axle shafts. Both parking brakes have a hydraulic parking brake release cylinder.
The parking brake is spring-applied but hydraulically released. Hydraulic pressure is supplied
by the main hydraulic pump and can be supplied by a remote hand pump. The parking brake
subsystem is composed of three major components: parking brake valve assembly, remote
hand pump and shuttle valve, and parking brake calipers.
(a) Parking Brake Valve Assembly. The parking brake valve assembly contains two
solenoid valves, which simultaneously change position to pressurize or relieve the
parking brake calipers. In their de-energized state (parking brake on), the calipers are
relieved, causing the caliper springs to apply the brakes. In their energized state
(parking brake off), the calipers are pressurized, causing the brakes to release.
(b) Remote Hand Pump and Shuttle Valve. These components provide a means of
releasing the parking brake should the main piston pump and the emergency pump
fail. Once normal operation is resumed, a check valve and passages within the
shuttle valve allow any remaining oil pressure in the hand pump circuit to return to the
reservoir.
(c) Parking Brake Calipers. When applied, the parking brake calipers prevent the
rotation of the axle pinions, effectively locking the wheels. Refer to Chapter 2 for
parking brake maintenance procedures.
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Chapter 1
9. Cab Lift Subsystem

The cab lift subsystem contains the cab lift valve assembly and the cab lift cylinder. The cab
lift valve assembly is composed of two solenoid valves which alternately change position to fill
or drain hydraulic oil from the cab cylinder. The single-acting cab lift cylinder provides 28
inches of cab lift.
L. HITCHES
There are two pin-coupler hitches, one at the center of the front bumper and one at the center of the
rear bumper. Each pin is pulled upward for removal and attached to the hitch by a short chain which
holds the pin free of ground contact when removed from its emplacement. Each hitch has a locking
device. Also available are pin-coupler type cushioned hitches
M. BALLAST
1. The standard GT-110 is ballasted to 90,000 lbs (40,825 kg) GVW. Optional ballast kits are
available to bring the GVW to 100,000 lbs (45,400 kg), 110,000 lbs (49,940 kg), or 120,000 lbs
(54,480 kg).
2. The standard 90,000-lb (40,825 kg) version uses no removable ballast weights. All required
ballast has been designed and built into the frame construction. The optional 100,000-lb
(45,400 kg) version has one 5000-lb (2268 kg) removable ballast weight in each of the lower
side ballast compartments, located between the front and rear wheels. The other optional
weight (110,000 and 120,000-lb) versions use balanced combinations of 7500-lb (3402 kg)
removable ballast weights in the ballast compartments to achieve the desired weight.
3. Each ballast weight is designed with two slots in the bottom side to allow installation and
removal with a forklift truck.
N. CAB
1. Description
Two types of full width front cabs are available for the GT-110. both the stationary cab and
the elevating cab (optional) are equipped with: two removable doors with door retainers;
sliding door windows; two fixed rear windows; roof windows; two ventilating fans; windshield
wipers and washers; sound insulation; a horizontally and vertically adjustable, cushioned
driver's seat; a two-man passenger seat with a storage compartment; a heater-defroster with
a fresh air louver; and two dome lights.
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Chapter 1
(a) Stationary Cab

The stationary cab can be either flush-mounted or mounted on a raised platform. If
flush mounted, the top of the cab will be level with the top of the tractor body, yielding
an overall vehicle height of 65 inches (165.1 cm). If mounted on a raised platform,
the height of the cab will be 81.50 inches (207 cm), yielding improved forward
visibility.
(b) Elevating Cab

The elevating cab may also be flush-mounted or mounted on a raised platform.
(c) Flush Mounted

If flush mounted, the top of the elevated cab will be level with the top of the vehicle
when the cab is in the fully lowered position, yielding an overall height of 65 inches
(165.1 cm). If fully elevated, the top of the cab will be 93.5 inches (237.5 cm) above
the ground.
(d) Raised Platform

If mounted on a raised platform, the top of the elevated cab will be 81.5 inches (207
cm) from the ground when the cab is fully lowered. Fully elevated, the raised
platform cab's top will be 109.5 inches (278.13 cm) above ground level.
(e) Elevating Cab Lift System

The elevating cab is raised and lowered by a hydraulically driven lift cylinder
controlled by two electrically operated solenoids. Through the dual check/distribution
valve, the lift cylinder is powered by the main hydraulic system. The cab is
electrically controlled via a rocker switch located on the cab lift panel which is
installed when the elevating cab option is ordered. An audible alarm that sounds a
warning whenever the cab is raised or lowered is also installed.
O. REAR CAB (OPTION)
A rear operator's station permits push back of an aircraft without the need to unhitch the tractor,
reposition it, and hook it up again. All steering and propulsion modes are controllable from the rear cab.
A Tonneau cover and rear hitch lights are available for the rear cab as additional options.
The station is mounted on the vehicle's passenger side at the rear. An optional GPU may be located
beside it.
1-1-8 CD276
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Chapter 1
Figure 1-2. Cab Arrangements
CD276 1-1-9
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Chapter 1
GENERATOR SET IN STORED POSITION
ROLLOUT
ASSY.
GENERATOR SET IN ROLLED OUT

POSITION FOR MAINTENANCE ACCESS
Figure 1-3. GPU and Rear Cab Arrangements
1-1-10 CD276
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Chapter 1
P. ELECTRICAL SYSTEM
1. The electrical system provides power and control circuits for the various electrical devices
installed on the tractor. Electrical power is provided by an engine-driven alternator and two
12V batteries connected in parallel. Interconnected relays, controls, circuit breakers, and
fuses assure proper operating sequences and provide overload protection.
2. Descriptions of individual circuits are in the same order as shown on Figure 5.1.2 in Chapter
5. These descriptions include rear cab components. If only a single cab exists, the circuits
are the same with the exception of any rear cab related components. In some cases,
connectors are jumpered to account for this difference.
3. Emergency Steering Pump
The Emergency Steering Pump (B5) is an electrically driven pump wired directly to the
battery via the Emergency Steering Pump Relay (K19). Relay K19 is controlled via a
pressure actuated switch that activates if main hydraulic system pressure falls below 1800 psi
and a manually operated switch that must be pressed and held.
4. Alternator
The engine mounted alternator (G1) provides electrical power to all vehicle systems and to
charge the batteries if the engine is running. The alternator also supplies voltages directly to
the tachometer (GA6) and to the Generator No Charge Light (DS12).
5. Starting
The starting circuits can be energized via the Stop, Run, Start switch (S22) once the
transmission has been put into Neutral (K21) and the Front Parking Brake has been put On
(S27).
Putting the Stop, Run, Start switch to its momentary Start position will then close the circuit to
the Start Motor (B1) and sends a voltage to the Electronic Control Unit (A8) on the engine.
The ECU controls the engine and regulates the Glow Plugs to aid (GP1 - GP6) engine start.
The Glow Plug Indicator (DS3) comes on as the glow plugs are warming up to their proper
temperature with the Stop, Run, Start switch in the Run position. Once the light goes out, the
engine is ready to be started.
Once the engine has started, the Stop, Run, Start switch is returned to the Run position. This
energizes the 12 V Ignition Switch and the 12V Ignition (Master Relay) busses.
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Chapter 1
6. Engine and Engine Gauges/Warning Lights
Both the Engine and Gauges/Warning Lights circuits are powered via the Ignition (Master
Relay) bus.
In the Engine circuit, power feeds from the Ignition (Master Relay) bus past the 10A Engine
Circuit Breaker (F1) to the Engine Run Solenoid (L6) via the Emergency Engine Shutdown
Switch (S21). Power is also shunted into the Engine Gauge\Warning Light circuit’s Generator
No Charge Warning Light (DS12), Oil Pressure Warning Light (DS2), Coolant Temp Warning
Light (DS8), and the Coolant Level Warning Light (DS7).
(a) Generator No Charge Warning Light (DS 12). The Generator No Charge Warning
Light (DS 12) illuminates when the alternator is not supplying any voltage. The light is
wired to diodes in the alternator. When the alternator is supplying proper voltage,
current cannot flow through the light. Once alternator voltage disappears, current can
flow through the light from the 12V Ignition (Master Relay) bus powered by the
Battery bus.
(b) Oil Pressure Warning Light (DS2, DS41). The Oil Pressure Warning Light (DS2,
DS41) is also powered from the 12V Ignition (Master Relay) bus through the F1
circuit breaker. It is turned on by the Engine Low Oil Switch (R7) when the engine
oil pressure drops below 5.8 psi and is falling.
(c) Coolant Temp Warning Light (DS8, DS44). The Coolant Temp Warning Light (DS8,
DS44) is powered from the 12V Ignition (Master Relay) bus. It is turned on by the
Engine High Coolant Temperature Switch (R4) when the engine coolant temperature
exceeds 239 °F.
(d) Coolant Level Warning Light. The Coolant Level Warning Light is also powered from
the 12V Ignition (Master Relay) bus. The Coolant Level Sensor (R1) turns on the
light whenever engine coolant gets too low.
7. Gauges and Warning Lights
The Gauges and Warning Lights circuits are also powered via the 12V Ignition (Master
Relay) or the 12V Ignition Switch busses. This group consists of the Transmission
Temperature Warning Light (DS4, DS43), the Voltmeter (GA5), the Tachometer (GA6), the
Speedometer (GA7), the Dash Lights (DS13, DS14), the Fuel Gauge (GA1), and the
Transmission Temperature Gauge (GA4). In addition, each of the gauges has its own internal
light that turns on when the Park Light switch is ON (S6) and the Dash Lights switch (S20) is
in NORMAL or the Dash Lights Switch (S20) is ON , i.e., the 12V Park switch circuit is
energized.
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Chapter 1
(a) Transmission Temperature Light (DS4, DS43). The Transmission Temperature Light
(DS4, DS43) will trigger whenever the transmission oil temperature exceeds 248°F
and is powered via the 12V Ignition (Master Relay) bus.
(b) Voltmeter. The Voltmeter (GA5) reads the voltage on the 12V Ignition Switch bus. It
can be taken as a readout of the overall system voltage. The Voltmeter’s internal light
(DS19) is powered via the 12V Park Switch bus as described above.
(c) Tachometer. The Tachometer (GA6) reads the engine rpm electrically by measuring
the alternator rotations. Its internal light is powered by the 12V Park Switch bus.
(d) Speedometer. The Speedometer (GA7) is connected to a speed sensor (R6) located
on the transmission and gets its power from the 12V Ignition Switch bus. Its internal
light is powered by the 12V Park switch bus.
(e) Fuel Gauge. The Fuel Gauge (GA1) receives its power from the 12V Ignition Switch
bus and its inputs from a sender unit (R5) mounted in the fuel tank.
(f) Transmission Temperature Gauge. The Transmission Temperature Gauge (GA4) is

also powered by the 12V Ignition Switch bus. Its inputs are from a temperature
sensor (R3) mounted on the transmission.
8. Transmission
The Transmission circuits consists of the Front Cab Control, Valve Body/Transfer Relay, and
Rear Cab Control groups. (The Rear Control Group is present if the Rear Operator’s Station
becomes an option.)
(a) Front Cab Control. This group takes its power from the 12V Ignition (Master Relay)
bus via the 10A Transmission circuit breaker (F2). Power then is routed through the
ZF Front Cab Shifter (A1). Dependent upon the shifter position, various circuits are
energized or de-energized. Recipients of voltages from the Transmission Shifter are
the Shifter In Neutral Relay (K21), the Lock Up Unit Enable Relay (K25), the
Control Unit Lock Up Clutch (A4), the Shifter Change Over Control (K6)(dual cabs
only), and the Transmission Valve Body (A3).
(b) Valve Body/Transfer Relay. This group accepts voltages (commands) from both the
FRONT Cab Control group and the Rear Cab Control group if a rear cab is present.
Two relays, the Shifter Change Over Control (K6) and the Shifter Change Over
Control (K7), interpret these commands for, and pass them to, the Transmission Vale
Body.
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Chapter 1
(c) Rear Cab Control. This group accepts power from the 12V Ignition (Master Relay)
and consists of the ZF Rear Cab Shifter (A2), the Shifter Upshift Interlock (Rear)
connector (P53), the Shifter connectors (P5, P6) and the Control Box connector
(P10).
9. Parking Brake Circuit
The Parking Brake circuit takes its power from the 12V Ignition (Master Relay) bus through
the Parking Brake, 10A circuit breaker. Power is routed to the Park Brake Switch (S27) in
the front cab and the Park Brake Switch (REAR) (S24) in the rear cab.
Putting the Stop, Run, Start switch in the Run position powers the Master Relay bus. This
turns on the Park Brake Applied Indicator (DS11) as long as the Parking Brake Pressure
Switch (S28) does not see pressure on the parking brake system, i.e., the parking brake is
engaged.
(a) Parking Brake Switch. If the Park Brake Switch (S27) is ON, power is applied to the
Front Park Brake Switch ON relay (K3). This relay turns on the Front Park Brake
Switch ON indicator light (DS28) and the Front Park Brake ON Indicator (REAR)
(DS48) and feeds a voltage to the Front Park Brake ON - Starter relay (K20) that
acts as an interlock, along with Shifters In Neutral circuits, to start the engine. (Rear
cab circuits and the Rear Parking Brake Switch (S24) work similarly.) If the parking
brake is actually on, the Parking Brake Applied relay (K4) will be energized. It turns
on the Brake Applied Indicator Light (DS30) and the Brake Applied Indicator Light
(REAR) (DS50).
(b) Parking Brake Switch (Rear). The Park Brake Switch (Rear) (S24) works similarly.
Wired through the Front Park Brake Switch (S27), if S24 is ON, the Rear Shifter
Neutral Relay (K2) is energized. This relay turns on the Rear Park Brake ON
Indicator (DS29), the Rear Park Brake ON Indicator (REAR) (DS49), and also
powers relay K4. This interlocks with the starter system during engine start and also
turns on the Brake Applied Indicator Light (DS30).
Assuming the 12V Ignition (Master Relay) bus is powered, if either Parking Brake
Switch (S27, S24) is applied and the Parking Brake Pressure Switch (S28) is closed
(system pressure is more than 1800 psi) and either transmission shifter is not in
neutral, the Transmission Not In Neutral - Parking Brake Applied Relay (K23) will be
powered. This will trip the Horn Relay (K22) and sound the horn.
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Chapter 1
10. Cab Select Circuits
If the optional rear cab exists, the Cab Select Circuits come into play. A CAB SELECT
SWITCH (S19, front cab; S36, rear cab) is located on the REAR CAB OPTIONS panel (See
Section 2-1.) The three position rocker switch selects the active cab. Indicator lights on its
panel show which cab has been selected. Indicator lights also located in this group are Rear
Shifter Not In Neutral (DS24), Brake Applied (DS30, DS50), Front Brake Switch ON (DS28,
DS48), Rear Brake Switch ON (DS29, DS49), Shifters In Neutral (DS25, DS47), and Front
Shifter Not In Neutral (DS46) indicator lights.
Conditions that must be met to change the cab selection are: (1) parking brake on, (2) parking
brake applied, and (3) axle centered.
11. Steering
The Steering circuits are composed of the Front Axle Center, Front Control, Rear Control, and
Rear Axle Center groups. These circuits all pull power through the 12V Ignition (Master
Relay) via the Steering, 10A fuse (F3).
(a) Front Axle Center. The Front Axle Center group notifies the operator when the front
axles of the vehicle are straight ahead and enables steering mode selection of CRAB
& COORD steering modes from the front cab when they are. Power from the 12V
Ignition (Master Relay) feeds directly to the Front Axle Reed Switch (S29). When
the Reed Switch senses that the wheels are directly forward, it turns on the Front
Axle Center Indicator (DS31). It also powers the Front Axle Reed Switch Relay
(K11) which, in conjunction with the Steering Mode Select Switch (S14) position, will
“set” or “reset” relays K9 and K10, the Coord Steering Front Control and Crab
Steering Front Control Relays. These relays energize the Coord Select Valve, Front
Mode Solenoid (K9) or the Crab Select Valve, Front Mode Solenoid (K10), allowing
the steering mode to change.
(b) Front Control. The Front Control group controls the actual selection of the steering
mode from the front cab. Relays in K11 respond to COORD or CRAB steering
mode selection, driving the Coord Steering Front Control Relay (K9) or the Crab
Steering Front Control Relay (K10). These relays select the Coord Steering Mode
Indicator Lights (DS21) or the Crab Steering Mode Indicator Lights (DS23), as
appropriate.
(c) Rear Control. The Rear Control group performs the same function for the REAR
CAB that the Front Control group does for the Front.
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Chapter 1
(d) Rear Axle Center. The Rear Axle Center group notifies the operator when the rear
axles of the vehicle are straight. Its power comes through the Steering, 10A circuit
breaker (F3). The Rear Axle Reed Switch (S29) senses when the axles are centered
and sends a voltage through the STEER MODE light (DS32) and the Axle Center
Indicator (Rear) (DS31) and energizes the Rear Axle Reed Switch Relay (K12). This
relay, when energized, either “sets” or “resets” relays K14 and K15, the COORD
Steering Rear Control Relay and the CRAB Steering Rear Control Relay,
respectively. These relays power solenoids L16 and L15, the CRAB Select Valve,
Rear Mode Solenoid and the COORD Select Valve, Rear Mode Solenoid that make
the steering mode changes.
12. CAB Circuit
The CAB circuit contains the controls needed to conduct life in the cab. The CAB circuit
contains the Dome Light, Horn, Heater, Cooling Fan, Windshield Wiper, and Washer Pump/
Cab Elevation circuit groups.
(a) Dome Light. The Dome Light gets its power through the Horn, 10A circuit breaker
(F11) which feeds from the 12V Battery (Breaker) bus. The light is activated by its
integral manual switch.
(b) Horn. The Horn also feeds through the Horn, 10A circuit breaker (F11) and through
relay K22, the Horn Relay. This relay is energized when an operator hits a horn
button, closing switches S23 or S37 (the Horn button front and rear), or automatically
whenever the parking brake is engaged and the tractor is in gear.
(c) Heater. The Heater circuit feeds from the 12V Ignition (Master Relay) bus. Power
travels through the Heat/Cool Fan, 20A fuse (F10) and to the Blower Fan switch (S4)
which controls the Heater Fan, Front Cab (A6). The indicator light for the Heater is
powered from the 12V Park Sw bus.
(d) Cooling Fan. The Cooling Fan circuit also pulls power through the Heater, Cool Fan
circuit breaker (F10). Two Cab Defroster/Cooling fan motors (B6, B7) are available
when the Cab Defroster units are ordered as options.
(e) Windshield Wipers. The Windshield Wipers are powered from the 12V Battery
(Breaker) bus via the Windshield Wiper, 30A fuse (F15). The wipers are controlled
through the three position Wiper Switch (S1), which has OFF, LOW speed, and HIGH
speed switch positions. Switch S1 sends its commands to the Windshield Wiper, Right
Hand (B2) and the Windshield Wiper, Left Hand (B3) motors. An independently
controlled Windshield Wiper, Roof (B8) is available as an option. If installed, it also
takes its power directly from the Windshield Wiper, 30A circuit breaker (F15).
1-1-16 CD276
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Chapter 1
(f) Washer Pump/Cab Elevation. The Washer Pump/Cab Elevation circuits (included
with the vehicle’s elevating cab option) are powered from the 12V Ignition (Master
Relay) bus through the Cab Raise/Lower, 10A circuit breaker (F6). The Cab Lift
Switch (S15) is used to raise or lower the cab. Raising the cab sends voltages to the
Cab Raise Valve (L18) via the Cab Wand, Center (S39), Cab Wand, Left Hand (S40),
and Cab Wand, Right Hand (S38) switches. Lowering the cab sends voltages through
the same wand switches and to the Cab Lower Valve (L19). During cab raising or
lowering, the Raise/Lower Alarm (AL1) is sounded.
13. Exterior Lights
Power for the Exterior Lights comes from the 12V Battery (Breaker) bus and the 12V Park
Switch bus. The 12V Battery bus feeds power through the Headlights, 20A circuit breaker
(F14). The Backup Light, Rear Dash Light, Rear Headlight, Rear Hitch Light, the Headlights,
and the Parking Lights are the lights controlled by this circuit.
(a) Backup Light. The Backup Light is powered by the Front Shifter Back Up Relay
(K24) whenever the transmission is put into Reverse.
(b) Rear Dash Light. The Rear Dash Light comes on whenever the Rear Cab is
selected.
(c) Rear Headlights. The Rear Headlights (DS 65, DS66) illuminate whenever the Rear
Cab is selected and the Rear Headlight Switch (S31) is switched to On.
(d) Rear Hitch Light. The Rear Hitch Light (DS68) illuminates when the Rear Hitch
Light Switch (S12) is On or if the Rear Cab is selected and the optional Hitch Light
Switch (S32) is On.
(e) Headlights. The Headlights (DS34, DS35) receive power from the 12V Battery
(Breaker). The Headlights illuminate whenever the Park Light Switch (S6) is On and
the Headlights Switch (S7) is in Low or High.
(f) Park Lights. The Park Lights (DS62, DS70, DS59, DS69) illuminate when the Park
Lights Switch (S6) is On.
(g) Other Exterior Lights are the Turn Signals, the Service Brake Lights, and the Beacon.
These lights are also powered by the 12V Battery (Breaker) bus.
(h) Turn Signals. The Turn Signals consist of the Left Hand group and the Right Hand
group. Both groups receive power through the Turn/Brake/Backup/Lights 15A circuit
breaker (F9), the Turn Signal Flasher Unit (FL1), and the Turn Signal Switch (S26)
mounted on the forward cab’s steering wheel. Indicator lights (DS1, DS6) are wired
directly to their appropriate turn signals.
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Chapter 1
(i) Service Brake Lights. The Service Brake Lights (DS63 for the Left Hand Brake
and DS58 for the Right Hand Brake) are powered directly from the 12V Battery
(Breaker) bus downstream of circuit breaker F9. The lights are actuated by the
Brake Pressure (Brake Lights) Switch (S43) whenever the differential pressure
between the left and right brakes hits 50 psi.
(j) Beacon. The optional Beacon circuit also receives its power through the 12V Battery
(Breaker) circuit through the Backup, Emergency Steering Control 15A circuit
breaker (F13). The Beacons activate whenever the Beacon Switch (S13) is ON.
Power to them is controlled by the Beacon Light Flasher Unit (FL2) downstream of
S13.
14. Emergency Steering
The Emergency Steering circuit also feeds from the 12V Battery (Breaker) bus. Emergency
Steering is engaged whenever the momentary contact Emergency Steering Switch (S10) is
depressed and the Emergency Steering Pressure Switch (S41) senses hydraulic system main
pressure is less than 1800 psi. The circuit for the Emergency Steering Switch (Rear) (S35) is
identical.
15. Front Hitch Light
The optional Front Hitch Light (DS39) is powered through the 12V Battery (Breaker) bus
through the Turn/Brake/Backup circuit breaker (F13) and the Front Hitch Light Switch (S11).
The Front Hitch Light will be powered anytime the Front Hitch Light Switch is On.
16. Dash Panel Light
Both the Left Hand (DS13) and the Right Hand (DS14) Dash Panel lights are powered
through the 12V Park Switch bus. These lights will illuminate when the Dash Lights Switch
(S20) is On or when the Dash Light Switch is in Normal and the Park Light Switch (S6) in
On.
17. Defroster Rear Window
An electrically operated rear window defroster is available for the front cab. Powered by the
12V Ignition (Master Relay) bus through the 20A Rear Window Defroster Fuse (F4), the
defroster is controlled through the Rear Window Touch Pad Switch (S8). The defroster is
wired through the Rear Window Defroster Timer Relay (K36) that shuts the defroster off
after it has run for 11 minutes.
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Chapter 1
18. Engine Coolant Heater
An optional, externally-powered engine coolant heater is also available. This unit provides for
better engine starting in extremely cold weather conditions. When installed, it is grounded to
the tractor frame and wired through the Run Solenoid Disconnect Relay (K35) to preclude
starting the engine while still connected to the coolant heater. The coolant heater will cut off
automatically once the engine coolant temperature reaches 120°F. See Figure 5.1.2 or Figure
5.1.3 in Chapter 5, as appropriate.
Q. INTERNAL JACKING SYSTEM (OPTION)
As an available option, the GT-110 tow tractor can be equipped with a self-powered internal jacking
system. The system allows the vehicle to be raised for maintenance or inspection without the use of
additional lifting equipment.
R. GROUND POWER UNIT (OPTION)
An external, rear-mounted 90 kVA ground power unit driven by a Deutz engine can provide portable,
external electrical power. The unit is capable of producing 115/200 VAC, 400 Hz, 3-phase power. An
optional transformer-rectifier assembly can also enable it to produce 28 VDC. The unit provides
outlets for two power cable hookups. Several models of GPU are available.
S. FIRE SUPRESSION SYSTEM (OPTION)
A manually actuated fire suppression system is available as an option for the GT110. The system
consists of lines and containers that locate fire supression points throughout the vehicle.
T. BACK UP ALARM (OPTION)
An audible back-up alarm warns personnel near the tractor that a backing maneuver is about to begin
or is in progress. The alarm installs directly into the back-up lights’ circuit.
U. CENTRALIZED ON-BOARD CHASSIS LUBRICATION SYSTEM (OPTION)
Automatic lube system designed for the GT-110 Tow Tractor is available for installation. This system
will automatically or manually provide lubricant to several points on the tow tractor.
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Chapter 1
1-1-20 CD276
Rev 13
Chapter 1
SECTION 2: OPERATION
A. PREOPERATIONAL CHECKS
CAUTION: BEFORE USING THE EQUIPMENT, THE OPERATOR

MUST CAREFULLY READ THE INSTRUCTIONS IN THE FRONT
MATTER OF THIS MANUAL AND IN THIS SECTION. THE
OPERATOR MUST ALSO BECOME FAMILIAR WITH THE TOW
TRACTOR’S CONTROLS, INDICATORS, AND EQUIPMENT AS
DESCRIBED IN TABLES 2-1 thru 2-4 OF THIS SECTION.
1. Perform the following checks prior to operating the tractor:
(a) Set the parking brake.
(b) Walk around the tractor and inspect it for damage. Look for missing equipment.
Check for:
(1) Damaged or under-inflated tires. Check that cold tire pressure is 110 psi
(758 kPa). Look for cuts and cracks in the tire’s sidewalls and for foreign
objects in the tread.
(2) Loose wheel nuts.
(3) Leaking planetary wheel end housings.
(4) Proper operation of the hitches.
(5) Damage to the vehicle’s lights.
(6) Fire extinguishers that are fully charged and in place.
(c) Look underneath the tractor for signs of leaking coolant, hydraulic fluid, transmission
fluid, or lubricating oil. If significant leaks are found, repair them as soon as possible.
(d) Check the engine oil.
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Chapter 1
WARNING: DO NOT LOOSEN OR REMOVE THE RADIATOR CAP

WHEN THE COOLANT IS HOT. HOT COOLANT UNDER
PRESSURE CAN SPRAY OR BOIL OUT, CAUSING SEVERE BURNS.
(e) Check that the engine coolant level is approximately 1-1/2 in (4 cm) below top of
radiator fill neck. If not, add coolant as necessary, being careful not to overfill.
Visually check for coolant leaks.
(f) Inspect the engine compartment for loose hardware, loose wires, and leaking lines or
fittings.
(g) Check the hydraulic fluid level in the sight glass on the hydraulic reservoir. The sight
glass is slightly above eye level on the driver’s side of the vehicle between the front
and rear axles. A very low fluid level indicates a serious leak in the system. If that is
the case, find the leak and repair it as soon as possible.
(h) Check the operation of the hazard flasher, stoplights, taillights, headlights, backup
lights, and dash panel lights.
(i) Check the fuel level.
NOTE: By keeping the fuel tank as full as possible, the tendency for
moisture to condense on the inner surfaces of the fuel tank can be
Note minimized or eliminated. Top off the fuel tank at the end of the day’s
operation as part of the post-operation maintenance routine.
CAUTION: IF THE EMERGENCY STEERING PUMP IS OPERATED

FOR MORE THAN 1 MINUTE, ITS MOTOR MAY OVERHEAT AND
BE DAMAGED. DO NOT OPERATE THE EMERGENCY PUMP ANY
LONGER THAN NECESSARY.
(j) Place one hand on the steering wheel and the other on the Emergency Steering
switch. Depress the switch and hold it down while turning the steering wheel a
quarter turn or less in each direction. Listen to the pump’s operation. The steering
wheel should turn effortlessly and the feel and sound should be smooth. Release the
switch.
(k) Start the engine and allow it to idle. When the transmission oil temperature reaches
160 °F (71.8 °C), check the transmission’s oil level. Add oil as required but do not
overfill.
1-2-2 CD276
Rev 13
Chapter 1
B. TOW TRACTOR CONTROLS, INDICATORS AND OPERATIONAL EQUIPMENT
1. Table 2-1 lists the front cab controls, indicators, and equipment not found on the instrument
panel and explains the specific function of each. Reference Figure 2-1 for location of the
items listed.
2. Table 2-2 lists the front cab instrument panel controls and indicators and explains the specific
function of each. Reference Figure 2-2 for location of the items listed.
3. Table 2-3 lists the cab lift switch option found on the cab lift panel and explains its specific
function. Reference Figure 2-3 for location of the item listed.
4. Table 2-4 lists the rear cab option controls, indicators, and equipment not found on the
instrument panel and explains the specific function of each. Reference Figure 2-4 for location
of the items listed.
5. Table 2-5 lists the rear cab option instrument panel controls and indicators and explains the
specific function of each. Reference Figure 2-5 for location of the items listed.
6. Table 2-6 rear station option panel assembly controls and indicators and explains the specific
function of each. Reference Figure 2-6 for location of the items listed.
7. Table 2-7 lists the rear cab parking brake and emergency stop controls and explains the
specific function of each. Reference Figure 2-7 for location of the items listed.
CD276 1-2-3
Rev 13
Chapter 1
1
2
REMOVABLE SEAT
5
6
7
8
10
11 19
16
12 14 17
13 15 18
23
20
21
22
Figure 2-1. Front Cab Controls, Indicators and Equipment
1-2-4 CD276
Rev 13
Chapter 1
Table 2-1. Front Cab Controls, Indicators and Equipment
ITEM NAME DESCRIPTION

1 Cab Wand Microswitch, R.H. The cab wand microswitch stops the cab lift function
when actuated.
2 Fuse Box The fuse box contains fuses for electrical system circuit
protection.
3 Turn Signal/Parking Light, R.H. The turn signals flash when the turn signal/hazard
switch is set to signal a turn or a hazard. The parking
light illuminates steadily when the parking lights
switch is ON.
4 Headlight, R.H. The headlight illuminates the area in front of the tractor
when the headlights switch is in LO or HI and the
Parking Light switch is ON.
5 AC Cable Plug The AC cable plug is used with the optional GPU.
6 Front Hitch Light This light illuminates the front hitch when the front
hitch light switch is ON.
7 Intercom Plug, Front Bumper This intercom plug accepts a communication cable
linking the aircraft and the tow tractor.
8 Heater/Defroster Unit It provides front cab heating and windshield defrosting.
Its two-speed blower is controlled by the blower fan
switch.
9 Headlight, L.H. The headlight illuminates the area in front of the tractor
when the headlights switch is in LO or HI and the
Parking Light switch is ON.
10 Turn Signal/Parking Light, L.H. The turn signals flashes when the turn signal/hazard
switch is set to signal a turn or a hazard. The parking
light will illuminate steadily when the the parking
lights switch is ON.
11 Front Cab Instrument Panel Refer to Figure 2.2 for descriptions of the instrument
panel controls and indicators.
12 Emergency Engine Shutdown This switch shuts down the engine in an emergency.
Switch To use, press down on the red button. To reset, pull up
on the button.
13 Horn Button The horn button is located in the center of the steering
wheel and sounds the horn. To sound the horn, push in
on the button.
CD276 1-2-5
Rev 13
Chapter 1
1
2
REMOVABLE SEAT
5
6
7
8
10
11 19
16
12 14 17
13 15 18
23
20
21
22
Figure 2-1. Front Cab Controls, Indicators and Equipment (Cont'd)
1-2-6 CD276
Rev 13
Chapter 1
Table 2-1. Front Cab Controls, Indicators and Equipment (Cont'd)

14 Accelerator and Service Brake The accelerator pedal is foot-operated and located in
Pedals front of the operator and on the right side of the brake
pedal. It regulates the speed of the engine. The brake
pedal is to the left of the accelerator pedal. Pushing on
it engages the service brakes.
15 Turn Signal and Hazard Switch This switch controls the turn signals and hazard
warning lights. To indicate a left turn, pull the arm
down. To indicate a right turn, push the arm up. The
arm must be manually returned to the center position
(OFF) after each turn. To actuate the hazard lights, pull
outward (away from the steering wheel) on the tab
located directly behind the turn signal switch arm. To
turn off the hazard lights, push up or pull down on the
turn signal switch arm until the tab pops back into
position.
16 Transmission Shift Selector The transmission shift selector selects the direction of
travel and speed range of the tractor.
17 Parking Brake Switch This switch is used to set the parking brake. To set the
parking brake, rotate the switch to ON and observe that
the front parking brake on and parking brake applied
indicators are illuminated. To release the parking
brake, rotate the switch to OFF.
18 Intercom Plug, Front Cab The front cab intercom plug is interconnected to plugs
located inside the rear cab, on the front bumper, and on
the rear bumper.
19 Hydraulic System Pressure Gauge This mechanical gauge indicates the hydraulic system
pressure.
20 Warning Beacon (optional) The operator actuated beacon alerts others that the tow
tractor is in operation.
21 Cab Ventilation Fans They provide cooling air circulation when activated by
the integral switches.
22 Alarm, Cab Raise/Lower (Option) The alarm is an optional component that can be
installed when an optional lift cab is also installed. The
alarm sounds whenever the cab is being raised or
lowered.
23 Dome Light When turned on by an integral switch, the dome light
illuminates the cab's interior.
CD276 1-2-7
Rev 13
1-2-8
Rev 13
Section 2
Chapter 1
6, 8, 14, 16,
4 5 7 9 10 11 12 13 15 17 18 19
3
20
P 21
2
22
23
GT-110 Aircraft Tow Tractor
Cab Lift
Panel
1 32 31 30 29 28 27 26 25 24
Figure 2-2. Front Cab Instrument Panel

Rear Cab
Option Panel
CD276
Chapter 1
Table 2-2. Front Cab Instrument Panel

1 STOP, RUN, START Switch The STOP, RUN, START switch starts and stops the
engine and connects and disconnects the electrical
controls. The switch has three positions: STOP, RUN,
and START. Moving the switch from STOP to RUN
energizes the electrical system. Moving the switch
from RUN to START starts the engine. (Once the
engine starts, release the switch.) To stop the engine,
place the transmission in neutral, set parking brake ON,
and turn the switch to STOP.
2 Dash Panel Light Switch This switch controls dash panel illumination. In
NORM, the dash lights turn on automatically if the
parking lights are turned on. In ON, the dash lights
illuminate.
3 Emergency Engine Stop Button This shuts down the engine in an emergency situation.
Press down on the button to stop the engine. To reset,
pull up on the button.
4 Fuel Level Gauge The fuel level gauge indicates how much diesel fuel is
in the fuel tank.
5 Dash Panel Lights The dash panel lights are used to illuminate the
instrument panel during low-light conditions.
6 Low Coolant Light This light turns on if the engine coolant level gets drops
too low to sustain safe engine operation.
7 Left Turn Indicator This light illuminates when the left turn signal is on.
8 High Coolant Temperature Light This light illuminates whenever the engine coolant
temperature goes above 239qF (115qC).
9 Low Oil Pressure Light This light illuminates whenever the engine oil pressure
drops below 5.8 psig (39.99 kPa).
10 Glow Plug Light This light illuminates whenever the glow plugs come
on and goes out when they reach the proper
temperature. The engine is then ready to start.
11 Engine Coolant Temperature This gauge indicates the engine's coolant temperature.
Gauge The normal operating temperature is 190 qF (88qC).
CD276 1-2-9
Rev 13
Chapter 1
23
22
21
Option Panel
20
Rear Cab
Cab Lift
Panel
18 19
26 25 24
14, 16,
13 15 17
27
P
28
12
11
29
7 9 10
30
6, 8,
5
31
4
32
3
1
2
Figure 2-2. Front Cab Instrument Panel (Cont'd)
1-2-10 CD276
Rev 13
Chapter 1
Table 2-2. Front Cab Instrument Panel (Cont'd)

12 Engine Oil Pressure Gauge This gauge indicates the engine oil pressure. The
normal operating range is 35 - 50 psi (241 - 345 kPa).
13 Transmission Oil Temperature This light illuminates whenever the transmission oil
Light temperature goes above 248qF (115qC).
14 High Beam Indicator This light tells the operator that high beam headlights
are selected.
15 Parking Brake Applied Light This light illuminates whenever the parking brake is
engaged.
16 Right Turn Indicator This light shows when the right turn indicator is on.
17 Generator No Charge Light This light illuminates when the alternator is not
charging the electrical system.
18 Windshield Wiper Switch This three position rocker switch (Off-On-On) controls
the windshield wipers. Pressing the switch once puts
the wipers into low speed. Pressing the switch again
puts the wipers into high speed.
19 Windshield Washer Switch Pressing and holding this switch will activate the
windshield washers. Once the switch is released, the
washers turn off.
20 Parking Light Switch This switch controls the front and parking lights.
Pressing the lower switch of the rocker side turns on
the lights. Pressing the upper side of the switch turns
the lights off.
21 Headlights Switch This three position switch turns the headlights on and
off. Pressing the switch to the first position turns on
the low beams and the second turns on the high.
22 Steering Mode Select Switch This switch selects one of the three available steering
modes. Indicator lights next to the switch confirm the
steering mode that has been attained.
23 Steering Mode Select Indicator Indicator lights next to the switch confirm the steering
Lights mode that has been attained.
CD276 1-2-11
Rev 13
Chapter 1
23
22
21
Option Panel
20
Rear Cab
Cab Lift
Panel
18 19
26 25 24
14, 16,
13 15 17
27
P
28
12
11
29
7 9 10
30
6, 8,
5
31
4
32
3
1
2
Figure 2-2. Front Cab Instrument Panel (Cont'd)
1-2-12 CD276
Rev 13
Chapter 1
Table 2-2. Front Cab Instrument Panel (Cont'd)

24 Warning Beacon Switch This switch turns on the warning beacon that shows the
(Optional) tractor is in use.
25 Rear Hitch Light Switch This switch controls the rear hitch light when the
(Optional) tractor is being operated from the front cab. Pressing
the lower side of the rocker switch turns the hitch light
on. Pressing the upper side of the switch turns it off.
26 Front Hitch Light Switch This switch controls the front hitch light. Pressing the
(Optional) lower side of the rocker switch turns on the light.
Pressing the upper side of the switch turns it off.
27 Speedometer and Odometer This gauge reads out the tractor's speed and records the
number of miles it has traveled.
28 Voltmeter This gauge indicates the voltage being produced by the
alternator.
29 Transmission Oil Temperature This gauge shows the transmission fluid temperature.
Gauge The normal operating range is 176 - 230 qF (80q - 110
qC)
30 RPM Gauge This gauge monitors the engine speed, measured in
revolutions per minute (RPM). It also contains an
hourmeter that tracks engine usage so scheduled
maintenance can be performed on time.
31 Blower Fan Switch The front cab's blower fan is controlled by this switch.
(Optional) The blower fan is used to heat the cab and has a HIGH
and LOW speed position.
32 Emergency Steering Pump Switch This switch activates the emergency steering pump.
Press and hold the switch to start the pump. Release
the switch to stop it. The steering pump activates only
if the hydraulic system pressure is low.
CD276 1-2-13
Rev 13
Chapter 1
Figure 2-3. Cab Lift Panel
1-2-14 CD276
Rev 13
Chapter 1
Table 2-3. Cab Lift Panel

1 Cab Lift Switch Push and hold the switch as indicated to raise or
(Optional) lower the cab.
CD276 1-2-15
Rev 13
Chapter 1
10
9
8
1
7
6
5
4 2
3
11
Figure 2-4. Rear Cab Controls, Indicators and Equipment
1-2-16 CD276
Rev 13
Chapter 1
Table 2-4. Rear Cab Controls, Indicators and Equipment

1 Intercom Plug, Rear Cab The rear cab intercom plug is interconnected to plugs
located inside the front cab, on the front bumper, and
the rear bumper.
2 Horn Button The horn button, located in the center of the steering
wheel, sounds the horn when pushed.
3 Emergency Stop Pulling up on this button will execute an emergency
stop on the engine. To reset the emergency stop
button, push down on it.
4 Park Brake Switch This switch sets the parking brake. Rotate the switch to
ON to set the parking brake. Observe that the rear
parking brake ON and park brake applied indicators are
illuminated. Rotate the switch to the OFF position to
release the parking brake.
5 Rear Cab Instrument Panel Refer to Figure 2.4 for descriptions of the instrument
panel controls and indicators.
6 Stop/Park/Turn/Backup Light Set, The stop/turn signal element flashes when the turn
R.H. signal/hazard switch (item 15 in Table 2.1) is set to
signal a turn or hazard. The stop/turn element
illuminates when the service brakes are applied. The
parking element illuminates when the park lights are
turned on. The backup light illuminates when the front
cab shift selector is set to reverse (R).
7 Intercom Plug, Rear Bumper This intercom plug accepts a communication cable
linking an aircraft and tow tractor.
8 Dash Panel Light The dash panel light illuminates the instrument panel in
low-light conditions.
9 Transmission Shift Selector The transmission shift selector selects the direction of
travel of the tractor. When operating from the rear cab,
the speed range of the tractor is four forward and three
reverse gears.
CD276 1-2-17
Rev 13
Chapter 1
10
9
8
1
7
6
5
4 2
3
11
Figure 2-4. Rear Cab Controls, Indicators and Equipment (Cont'd)
1-2-18 CD276
Rev 13
Chapter 1
Table 2-4. Rear Cab Controls, Indicators and Equipment (Cont'd)

10 Stop/Park/Turn/Backup Light Set, The stop/turn signal element flashes when the turn
L.H. signal/hazard switch (item 15 in Table 2.1) is set to
signal a turn or hazard. The stop/turn element
illuminates when the service brakes are applied. The
parking element illuminates when the park lights are
turned on. The backup light illuminates when the front
cab shift selector is set to reverse (R).
11 Service Brake Pedal The service brake pedal is in front of and to the right of
the operator. It actuates the service brake system and
operates similarly to an automobile brake pedal.
CD276 1-2-19
Rev 13
Chapter 1
1
FRONT
CAB SHIFTERS G
SELECTED IN NEUTRAL
2
7 REAR
FRONT PARK R
BRAKE SW ON
3
REAR PARK R
BRAKE SW ON
4
PARK BRAKE R
APPLIED
5
REAR
R
AXLE CENTER A
INDICATOR
6 REAR SHIFTER
NOT IN NEUTRAL
Figure 2-5. Rear Cab Option Instrument Panel
1-2-20 CD276
Rev 13
Chapter 1
Table 2-5. Rear Cab Option Instrument Panel

1 Indicator, Shifters in Neutral The indicator illuminates if both front and rear
transmission shifters are in Neutral.
2 Indicator, Front Park Brake Sw This lights is on if the front parking brake switch is set
On to ON and the STOP, RUN, START switch is in RUN.
3 Indicator, Rear Park Brake Sw On This light is on if the rear parking brake switch is ON
and the STOP, RUN, START switch is in RUN.
4 Indicator, Park Brake Applied This light comes on if the parking brake is applied and
the STOP, RUN, START switch is in RUN.
5 Indicator, Axle Center This light will be on when the rear axle is centered.
This indicates when a cab change may be made.
6 Indicator, Rear Shifter Not in This light indicates that the rear shifter is NOT in
Neutral Neutral.
7 Cab Select Switch and Indicator This switch shifts operational control from the front
Lights cab to the rear cab. It transfers control of the
accelerator, parking brake, transmission, and steering;
however, service brake control remains active in both
cabs regardless of which cab is selected.
Corresponding indicator lights show which cab is
active.
CD276 1-2-21
Rev 13
Chapter 1
10
FRONT SHIFTER
NOT IN NEUTRAL R 1
8, 9
LOW
BLANK
COOL
6, 7 SHIFTERS G
HITCH IN NEUTRAL
CAB
SELECTED
FRONT FRONT PARK R
BLANK BRAKE SW ON
FOR
FUTURE
4, 5 USE
REAR PARK R
BRAKE SW ON
REAR
PARK BRAKE R
COORD APPLIED
2
CAB
TRACK
SEL. AXLE CENTER
3 STEER INDICATOR
A
CRAB MODE
FRONT
EMERGENCY
PARK BRAKE
ENGINE STOP
OFF ON
THIS PARK
BRAKE MUST
BE ON BEFORE
1. GETTING OFF
TRACTOR
2. OPERATING
TRACTOR
FROM FRONT
STATION
Figure 2-6. Rear Station Panel Assembly
1-2-22 CD276
Rev 13
Chapter 1
Table 2-6. Rear Station Panel Assembly

1 Indicator, Front Shifter Not in The light is on whenever the front transmission shifter
Neutral is not in Neutral.
2 Emergency Steering Pump Switch This switch activates the emergency steering pump. To
activate the pump, push up and hold the switch; to stop
the pump, release the switch. The steering pump will
activate only if the hydraulic system pressure is low.
3 Steering Mode Select Switch This switch selects one of the three steering modes
available. Three indicator lights located beside the
selector switch will illuminate according to the steering
mode active.
4 Rear Headlight Switch This switch turns on the rear headlight.
5 Rear Hitch Light Switch This switch turns the (rear) hitch light on.
(Optional)
6 Generator No Charge Light This light indicates that no charge is being produced by
the alternator.
7 Low Coolant Light This light indicates that the engine coolant level is too
low.
8 Engine Oil Pressure Light This light indicates that the engine oil pressure is less
than 5.8 psig (39.99 kPa).
9 Engine Coolant Temperature This light comes on when the engine coolant
Light temperature exceeds 239qF (115qC).
10 Transmission Oil Temperature This light illuminates whenever the transmission oil
Light temperature exceeds 248qF (120qC).
CD276 1-2-23
Rev 13
Chapter 1
EMERGENCY
PARK BRAKE
ENGINE STOP
OFF ON
THIS PARK
BRAKE MUST
BE ON BEFORE
1. GETTING OFF
TRACTOR
2. OPERATING
TRACTOR
FROM FRONT
STATION
Figure 2-7. Rear Cab Parking Brake and Emergency Stop Controls
1-2-24 CD276
Rev 13
Chapter 1
Table 2-7. Rear Cab Parking Brake and Emergency Stop Controls

1 Park Brake Switch This switch turns the parking brake on and off.
2 Emergency Engine Stop Push down and locking this button initiates an
Button emergency engine shutdown. Pulling up on the
button will reset it. The button should be pulled up
to operate the tow tractor. This button is not to be
used for stopping the engine under normal
conditions.
CD276 1-2-25
Rev 13
Chapter 1
C. FRONT CAB OPERATOR'S SEAT
The operator’s seat (Figure 2-8) features several adjustments for the operator’s comfort and to
position the seat for optimum access to all controls.
NOTE: The newer GT-110 Tow Tractor has part number WM1100 seat
Note
installed.
1. Seat P/N: 012138
(a) Horizontal Adjustment. To move the seat fore and aft, pull up on the horizontal
adjustment lever. Hold the handle up, slide the seat to the desired position, and release
the handle.
(b) Weight Adjustment. Turn the weight adjustment knob until your body weight is shown
in the window at the top of the knob.
(c) Backrest Adjustment. To adjust the backrest, pull up on the lower portion of the
backrest adjustment handle. Hold the handle up, move the backrest to the position
desired, and then release the handle.
(d) Front and Rear Height and Inclination Adjustment. Pull up and hold the front handle
to raise or lower the front of the seat. Release the handle when the desired position is
reached. To raise or lower the rear of the seat, repeat the procedure using the rear
handle.
2. Seat P/N: WM1100
(a) Lumbar Adjustment. To make the lumbar adjustment, turn knob until the seat is in the
desired position. Note symbols on knob (+ or -) to increase or decrease, and turn knob
in the desired direction.
(b) Back Angle Adjustment. To adjust backrest to the desired angle, turn knob until the
backrest is in the desired position Turning the knob in the clockwise direction will
angle the seat to the rear, and turning the knob counter clockwise will angle the seat
back more forward.
(c) Height Control Adjustment. To adjust height of seat to the desired position, turn knob
as indicated by the plus (+) symbol to increase height of seat or turn knob in the
direction of the minus (-) symbol to lower the seat.
(d) Fore/Aft Adjustment. To move the seat fore or aft, pull the handle to the left, hold in
position, slide the seat to the desired position, and release the handle.
1-2-26 CD276
Rev 13
Chapter 1
P/N 012138
BACKREST ADJUSTMENT
REAR HEIGHT
AND INCLINATION
ADJUSTMENT
FRONT HEIGHT
AND INCLINATION
ADJUSTMENT
WEIGHT ADJUSTMENT
HORIZONTAL ADJUSTMENT
P/N WM1100
LUMBAR
ADJUSTMENT
FORE/AFT
ADJUSTMENT
BACK ANGLE
ADJUSTMENT
FORE/AFT HEIGHT CONTROL

ADJUSTMENT ADJUSTMENT
FRONT SIDE
Figure 2-8. Front Cab Operators Seat
CD276 1-2-27
Rev 13
Chapter 1
D. OPERATIONAL PROCEDURES
WARNING: NEVER OPERATE CONTROLS FROM OUTSIDE

OPERATOR’S COMPARTMENT. SEVERE PERSONAL INJURY OR
DEATH CAN RESULT.
1. Preoperational Checks
CAUTION: BEFORE USING THE EQUIPMENT, THE OPERATOR

SHOULD CAREFULLY READ THE INSTRUCTIONS IN THIS
SECTION AND BECOME FAMILIAR WITH THE TOW TRACTOR’S
CONTROLS AND INDICATORS DESCRIBED IN TABLES 2-1 AND 2-
2 OF THIS SECTION.
CAUTION: NEVER RUN THE ENGINE WITH 115-VAC

RECEPTACLE CONNECTED TO THE OPTIONAL ENGINE
COOLANT HEATER. A FLOW CHECK VALVE STOPS COOLANT
FLOW THROUGH THE HEATER WHILE THE ENGINE IS
RUNNING. THE HEATER WILL BE DAMAGED IF 115-VAC IS
CONNECTED TO THE HEATER RECEPTACLE WHILE THE
ENGINE IS RUNNING.
NOTE: In temperatures below 40 °F (4.4 °C), ensure that in units with an

Note engine fuel heater option, heaters are operating 10 minutes prior to
engine starting and turned off before ENGINE STOP/RUN switch is
placed in the RUN position.
NOTE: In temperatures below 40 °F (4.4 °C), ensure that units with an

Note engine coolant heater option are connected to engine external 115-VAC
power source 1 hour prior to engine starting and operation.
In order to ensure safe, reliable operation, perform the following checks prior to operating the
tractor:
(a) Place park brake switch in the ON position.
(b) Walk around and inspect tractor for damage or missing equipment. Check for the
following:
(1) Damaged or under-inflated tires. Cold-tire pressure should be 110 psi (757
kPa). Look for cuts, cracks in sidewalls, or foreign objects in treads.
(2) Loose wheel nuts.
1-2-28 CD276
Rev 13
Chapter 1
(3) Leaking planetary wheel end housings.
(4) Proper operation of hitches.
(5) Damage to lights.
(6) Fire extinguishers fully charged and in place.
(c) Look underneath tractor for leaks of coolant, hydraulic fluid, transmission fluid, or
lubricating oil. If significant leaks in any of these systems are found, repair as soon as
possible.
(d) Check engine oil.
WARNING: DO NOT LOOSEN OR REMOVE RADIATOR CAP

WHILE COOLANT IS HOT. HOT COOLANT UNDER PRESSURE
CAN CAUSE SEVERE BURNS.
(e) Check engine coolant level. Add coolant as necessary, but do not overfill. Make
visual check for leaks.
(f) Inspect engine compartment for loose hardware, loose wires, and leaking lines or
fittings.
(g) Check hydraulic system reservoir by removing filler cap to ensure there is enough
fluid for operation. A very low fluid level indicates a serious leak in the system.
Repair as soon as possible.
(h) When all mechanical checks are completed, move the driver's seat in the cab. Check
the operation of hazard flasher, stop- and taillights, headlights, backup lights, and dash
panel lights.
(i) Check fuel level gauge to ensure tank is full.
NOTE: Fuel contamination owing to moisture condensing on the inner

surfaces of the fuel tank can be minimized or eliminated by keeping the
Note fuel tank as full as possible. The fuel tank should always be topped off at
the end of the day’s operation, as part of the post-operation maintenance
routine.
(j) Ensure that parking brake switch is in the ON position. Do not start engine. Turn
engine STOP-RUN-CRANK switch to RUN position.
CD276 1-2-29
Rev 13
Chapter 1
WARNING: IF ANY MALFUNCTION OF THE BRAKE SYSTEM

OCCURS, THE TRACTOR SHOULD BE TAKEN OUT OF SERVICE
UNTIL IT IS PROPERLY REPAIRED.
(k) Start engine and allow engine to idle. When engine coolant temperature reaches 198
°F (88 °C), check transmission oil level. Add oil as required. Do not overfill.
2. Starting Procedure
WARNING: ENSURE THAT ALL PERSONNEL ARE CLEAR OF THE

TOW TRACTOR BEFORE STARTING THE ENGINE.
WARNING: DO NOT ATTEMPT TO ADJUST THE SEAT WHILE THE

TRACTOR IS IN MOTION. LOSS OF TRACTOR CONTROL MAY
RESULT.
(a) Adjust the operator’s seat so that all controls may be comfortably reached.
(b) Verify that the parking brake switches are set to ON and the shift selector is in
neutral (N), and the emergency stop button is not activated.
(c) Check that all other switches are OFF.
(d) Turn the STOP, RUN, START switch clockwise to RUN.
CAUTION: TO AVOID OVERHEATING OF STARTER MOTOR, DO

NOT OPERATE STARTER MOTOR MORE THAN 30 SECONDS
WITHOUT ALLOWING A MINIMUM COOLING PERIOD OF 2
MINUTES.
(e) Turn the STOP, RUN, START switch to START.
(f) Start the engine and then check the engine oil pressure gauges and the voltmeter.
Observe that they are within limits. Ensure that all warning indicators are
extinguished.
NORMAL OPERATING CONDITIONS
SYSTEM NORMAL
Temperature 198 °F (88 °C)

Engine Oil Pressure 30-35 psi (241-345 kPa)
Transmission Fluid Temperature 176-230 °F (80-110 °C)
Voltmeter +12 Volts
1-2-30 CD276
Rev 13
Chapter 1
(g) Allow the engine to idle for approximately 5 minutes (warm up).
(h) Turn on all necessary system switches (lights, etc.) for the operation. An operational
check of all accessory systems should be performed at this time, ensuring they
operate properly.
(i) Turn the steering wheel until the wheels are in the straight-ahead position. Set the
steering mode select switch to the desired steering mode.
(j) Depress the foot brake pedal. Release the parking brake by setting the parking brake
switch to OFF and wait until the PARK BRAKE indicator light extinguishes.
(k) Select the desired direction of travel and speed range by placing the shifter in the gear
most appropriate for the speed and weight of the tow.
WARNING: DO NOT SHIFT TRANSMISSION WHILE HANDLING

AIRCRAFT.
(l) Release the foot brake pedal and slowly depress the accelerator pedal.
3. Parking Brake Operation
WARNING: ALWAYS SET THE PARKING BRAKE ON BEFORE

SHUTTING OFF THE ENGINE OR EXITING THE CAB. FAILURE TO
SET THE PARKING BRAKE CAN RESULT IN THE TRACTOR
ROLLING AWAY, CAUSING SEVERE PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
CAUTION: THE PARKING BRAKE MUST BE RELEASED BEFORE

THE TRACTOR IS MOVED. EXCEPT IN AN EMERGENCY
SITUATION, DO NOT APPLY THE PARKING BRAKE WHILE THE
TRACTOR IS IN MOTION. PARKING BRAKE DAMAGE WILL
OCCUR.
NOTE: The parking brake must be released (set to OFF) before any
Note forward or reverse gear is selected via the transmission shift selector. If
not, the horn will sound as a warning.
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Chapter 1
4. Transmission Range Selection
(a) The transmission selector is an electronic control unit with a stick type selector.
There is a forward and reverse selector side for the transmission selector. The
selector control normally resides in the neutral position. The desired direction of
travel is always selected starting from the neutral position. To select a forward speed,
simply move the selector as desired to the speed that will be required for the operation
(1,2,3,4). To select a rear speed, pull the shifter into Neutral, push to the right, and
then push it forward into a reverse gear (R,1,2,3).
(b) The ZF Powershift transmission must be manually shifted into the desired gear. Use
the gear most appropriate for the tow conditions. Shift to the next higher speed
when the top speed in any particular gear is reached. Do not tow farther than 6.2
miles (10 km) or faster than 6 mph (10 km/hr).
(c) Generally, up shifting and down shifting is best accomplished by shifting through the
normal sequence of speeds. Down-shifting will produce a braking effect, unless the
engine is stopped. In that case, no braking will occur.
(d) Stop the tractor before shifting into any reverse speed.
CAUTION: DO NOT COAST THE TOW TRACTOR IN NEUTRAL.

DOING SO MAY RESULT IN SEVERE DAMAGE TO THE
TRANSMISSION.
CAUTION: NEVER SHIFT FROM ANY FORWARD GEAR TO

REVERSE OR FROM REVERSE TO ANY FORWARD GEAR WHILE
THE TRACTOR IS IN MOTION. THE TRACTOR CAN BE
DAMAGED OR STOP SUDDENLY.
(e) Neutral (N). Select Neutral when starting the engine, when checking the tractor’s
accessories, and when idling the engine for extended periods. Use NEUTRAL with
the parking brake set if leaving the tractor unattended with the engine running.
(f) 1-2-3-4 Range Selections. Occasionally, certain conditions make it necessary to

restrict shifting to a lower range. In addition to more pulling power at lower speeds,
these selections provide progressively greater engine braking for going down medium
grades. (The lower the gear range, the greater the braking effect.)
(g) Reverse 1-2-3. Select a speed range in Reverse adequate to the task at hand. The
reverse gears work in the same manner as the forward speed ranges.
(h) Rear Cab Shift Selector. The Rear Cab Shift Selector is tagged with four forward
speeds and three reverse. The third and fourth forward gears are the same.
Otherwise, the rear cab shifter operates identically to the front cab shifter.
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Chapter 1
5. Cab Selection
To transfer operational control between the front and rear cabs.
WARNING: MOVING THE CAB SELECT SWITCH WHILE THE

TRACTOR IS IN MOTION CAN CAUSE THE TRACTOR TO LOSE
CONTROL, POSSIBLY RESULTING IN DEATH, SEVERE PERSONAL
INJURY, OR PROPERTY DAMAGE.
(a) Stop the tractor.
(b) Turn the steering wheel until the wheels are in the straight-ahead position and observe
that the axle center indicator illuminates.
(c) Return the transmission shift selector to neutral (N).
(d) Set the parking brake switch to the ON position, and observe that the park brake
applied indicator illuminates.
CAUTION: PRESS THE RELEASE LATCH (THE RAISED PORTION

OF THE ROCKER SWITCH) PRIOR TO MAKING A SELECTION
FROM FRONT TO REAR OR FROM REAR TO FRONT CAB
CONTROL SELECTION. FORCING THE SWITCH INTO POSITION
WILL DAMAGE THE LOCKING DEVICE, ALLOWING THE SWITCH
TO BE ACCIDENTALLY ACTIVATED.
(e) To select front to rear or rear to front cab control, press the release latch (the raised
portion of the rocker switch) and press the rocker switch to make the selection. The
switch should lock in position. All controls except the service brake pedal will transfer
to the other cab. To make another cab control selection, the change must be initiated
from the cab (front or rear) that was selected.
6. Steering Mode Selection
To select a steering mode:
WARNING: MOVING THE STEERING MODE SELECT SWITCH

WHILE THE TRACTOR IS IN MOTION CAN CAUSE THE
TRACTOR TO LOSE CONTROL, RESULTING IN SEVERE
PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
(a) Bring the tractor to a full stop. Turn the steering wheel until the wheels are straight-
ahead. The STEER MODE light will illuminate.
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(b) Set the steering mode select switch to desired steering mode, i.e., four-wheel
coordinated mode (COORD), two-wheel track mode (TRACK), or (four-wheel) crab
mode (CRAB).
NOTE: When the steering mode select switch is in the CRAB or

COORD position, the steering mode will not change until the steering
Note axle at that cab is centered. When the steering mode switch is in the
TRACK position, the steering mode will not change until the other axle
is centered (the axle center indicator will not illuminate).
7. Front Cab Lift Operation
To raise or lower the front cab:
WARNING: FULLY LOWER THE CAB PRIOR TO EXITING TO

AVOID POSSIBLE INJURY.
WARNING: DO NOT LOWER THE CAB UNTIL ASSURED THAT NO

PERSONNEL ARE NEAR OR UNDERNEATH IT. DO NOT LOWER
OR RAISE THE CAB IF ANYONE ELSE IS ENTERING OR EXITING,
OR WORKING NEAR THE FRONT HITCH. OTHERWISE, SEVERE
PERSONAL INJURY MIGHT RESULT.
(a) Check that no one is entering, exiting, or close to the cab before beginning to raise or
lower the cab.
(b) Press and hold the upper part of the Cab Lift Switch to raise the cab. Press and hold
the lower portion of the Cab lift Switch to lower the cab.
(c) Once the desired cab height has been reached, release the Cab Lift Switch.
8. Moving an Aircraft
Each individual airline has established procedures for attaching the tractor to an aircraft,
detaching the tractor from an aircraft, or for towing or pushing back an aircraft. All operators
must be familiar with these procedures prior to operating the tractor in any aircraft related
operations.
9. Shutdown Procedure
(a) Bring the tractor to a full stop.
(b) Place the transmission in Neutral (N).
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(c) Set the parking brake switch to ON.
(d) Turn off all system and accessory switches.
(e) Return the front elevating cab to the lowered position (if raised).
(f) Allow the engine to run at idle for approximately 5 minutes, then shut it down by
turning the STOP, RUN, START switch to STOP.
10. Internal Jacking System (Option)
WARNING: BE CERTAIN THAT ALL PERSONNEL ARE CLEAR OF

THE UNDERSIDE AND ARE WELL AWAY FROM THE TRACTOR
PRIOR TO USING ITS SELF-JACKING FEATURE.
NOTE: The tractor's engine must be running, the parking brake set to
Note "on", and the transmission shifter must be in neutral (n) for the system to
work.
(a) To raise the tractor using the internal jacking system:
(1) Visually ensure that personnel are not near or underneath the tractor.
(2) Check that the parking brake is on and that the transmission shifter is in
neutral (n). Start the engine.
CAUTION: TO AVOID GETTING THE TRACTOR INTO A POSSIBLY

UNSTABLE POSITION, DO NOT RAISE BOTH ENDS OF IT AT THE
SAME TIME.
(3) Open the jacking system shutoff valve.
(4) Each jacking system valve handle on the jacking system valve assembly
controls one jack. Select the valve(s) that operate(s) the desired jack(s). It is
recommended that one side of the tractor be raised at a time.
(5) Pull out on the valve handle(s) to lower the jack(s) and raise the vehicle.
Hold the valve handle out until the tractor reaches the desired height.
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(6) Repeat steps (4) and (5) as necessary.
WARNING: PLACE BLOCKS OR JACK STANDS OF ADEQUATE

CAPACITY UNDERNEATH THE VEHICLE BEFORE ALLOWING
PERSONNEL TO WORK ON OR NEAR IT. DEATH OR SEVERE
INJURY COULD OTHERWISE RESULT.
(7) Place blocks or jack stands underneath the tractor before performing any
work.
(8) Shut down the engine (if prudent) to avoid unnecessary risk during any
maintenance procedures.
(b) To lower the tractor using the internal jacking system:
WARNING: BE CERTAIN THAT ALL PERSONNEL ARE CLEAR OF

THE UNDERSIDE AND ARE WELL AWAY FROM THE TRACTOR
PRIOR TO LOWERING IT.
(1) Visually ensure that personnel are not near or underneath the tractor.
(2) Remove the blocks or other supporting materials from underneath the vehicle.
(3) Check that the transmission is still in neutral (n), the parking brake is on, and
start the engine if it has been shut down.
(4) To lower the tractor, push in the appropriate jack operating valve handle(s) as
required until the tractor is completely down.
(5) Once the tractor is lowered, push in and hold the appropriate jack handle(s)
until each jack is fully retracted.
(6) Close the jacking system shutoff valve.
11. Back Up Alarm (Option)

The back-up alarm activates automatically anytime the transmission is put into Reverse (R)
and the tractor’s START-RUN-STOP switch is in RUN. Since it is wired into the same
circuit as the back-up lights, it will sound anytime the back-up lights are on.
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SECTION 3: SPECIFICATIONS AND CAPABILITIES
A. GENERAL
1. Weight
(a) Without ballast ............................................................................... 40,824 kg (90,000 lb)

(b) With ballast (Opt.) ....................................................................... 45,400 kg (100,000 lb)
(c) With ballast (Opt.) ....................................................................... 49,940 kg (110,000 lb)
(d) Fully ballasted (Opt.) ................................................................... 54,480 kg (120,000 lb)
2. Drawbar Pull (At 0.8 traction coefficient)
(a) At GVW 40,824 kg (90,000 lb) ...................................................... 32,659 kg (72,000 lb)

(b) At GVW 45,400 kg (100,000 lb) .................................................... 35,380 kg (78,000 lb)
(c) At GVW 49,940 kg (110,000 lb) .................................................... 35,380 kg (78,000 lb)
(d) At GVW 54,480 kg (120,000 lb) .................................................... 35,380 kg (78,000 lb)
(varies with surface conditions)
3. Speed
(a) Forward 1st ................................... 2.4 km/h (1.50 mph) @ 32,000 lb (14,515 kg) DBP
(b) Forward 2nd ...................................... 4.8 km/h (3.0 mph) @ 17,500 lb (7,938 kg) DBP
(c) Forward 3rd .................................... 8.05 km/h (5.0 mph) @ 11,000 lb (4,990 kg) DBP
(d) Forward 4th ..................................................................................21.7 km/h (13.5 mph)
(e) Reverse 1 ....................................... 2.4 km/h (1.5 mph) @ 32,000 lb (14,515 kg) DBP
(f) Reverse 2 ........................................5.6 km/h (3.5 mph) @ 17,500 lb (7, 938 kg) DBP
(g) Reverse 3 ....................................... 8.05 km/h (5.0 mph) @ 11,000 lb (4,990 kg) DBP
4. Length
(a) Without hitches ................................................................................... 6553 mm (258 in)

(b) With standard hitches ......................................................................... 7239 mm (285 in)
(c) With GPU and hitches ........................................................................ 8687 mm (342 in)
5. Width
Width ............................................................................................................... 2,794 mm (110 in)
6. Height
(a) Height over frame ............................................................................... 1,727 mm (68 in)

(b) Height with standard cab .................................................................. 2,070 mm (81.5 in)
(c) Height with elevated cab ..................................................................... 2,362 mm (93 in)
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7. Wheelbase
Wheelbase ...................................................................................................... 3,150 mm (124 in)
8. Turning Radius
Turning Radius ................................................................................................. 6604 mm (260 in)
Four-Wheel Coordinated Steer w/GPU
(a) Minimum Inside ..................................................................................... 2438 mm (96in)

(b) Minimum Outside ............................................................................... 6604 mm (260 in)
9. Ground Clearance
Ground Clearance .................................................................................. Nominal 216mm (8.5in)
10. Ramp Angles
(a) Approach Angle ....................................................................................................... 7.0°

(b) Breakover Angle .................................................................................................... 12.0°
(c) Departure Angle .................................................................................................... 17.0°
(d) Departure Angle w/GPU ......................................................................................... 8.0°
B. ENGINE
1. Up to S/N 347 (except S/N 337, 338 and 340)
(a) Manufacturer ................................................................................ Deutz (water cooled)

(b) Model ............................................................................................ Series BF6M1013CP
(c) Type ................................................................................................................... 4-Cycle
(d) Number of Cylinders .................................................................................................... 6
(e) Compression Ratio ................................................................................................ 17.5:1
(f) Power at Governed Speed ................................................................... 255 hp (190 kW)
(g) Governed Speed ............................................................................................. 2,300 rpm
(h) Maximum Torque ........................................................ 700 lb/ft @ 1400 rpm (949 Nm)
(i) Displacement ...................................................................................... 7.14 L (436 CID)
(j) Fuel Injection ........................................................................................................ Direct
(k) Aspiration .............................................................. Turbocharged, Charged Air Cooling
(l) Lubricating Oil .................................................................................. 15W-40 API CF-4
(m) Firing Order .................................................................................................. 1-5-3-6-2-4
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2 S/N 337, 338, 340, 347 & Up
(a) Manufacturer ................................................................................ Deutz (water cooled)

(b) Model ............................................................................................ Series BF6M1013FC
(c) Type ................................................................................................................... 4-Cycle
(d) Number of Cylinders .................................................................................................... 6
(e) Compression Ratio ................................................................................................ 17.6:1
(f) Power at Governed Speed ................................................................... 299 hp (223 kW)
(g) Governed Speed ............................................................................................. 2,300 rpm
(h) Maximum Torque ........................................................ 737 lb/ft @ 1700 rpm (999 Nm)
(i) Displacement ...................................................................................... 7.14 L (436 CID)
(j) Fuel Injection ........................................................................................................ Direct
(k) Aspiration .............................................................. Turbocharged, Charged Air Cooling
(l) Lubricating Oil .................................................................................. 15W-40 API CF-4
(m) Firing Order .................................................................................................. 1-5-3-6-2-4
C. CAB
1. Height ........................................................................................................ 55 inches (139.7 cm)

2. Width ........................................................................................................ 101 inches (256.5 cm)
3. Elevating Cab Lift ........................................................................................ 28 inches (71.1 cm)
D. TRANSMISSION
1. Manufacturer .......................................................................................................................... ZF
2. Model ......................................................................................................................... Powershift
3. Speeds ...................................................................................................... 4 Forward, 3 Reverse
4. Controls ...................................................................................................... Electric Shift Control
5. Torque Converter ........................................................................... Single-Stage, Three Element
6. Fluid Type .................................................................................................................. Mobil 1310
D. AXLES
1. Manufacturer ............................................................................................................... Rockwell
2. Type ................................... Planetary Wheel Ends, Steering Type w/High Traction Differential
3. Overall Reduction Ratio .................................................................................................... 31.9:1
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4. Suspension
(a) Front ....................................................................................................................... Rigid

(b) Rear .................................................................................................................. Trunnion
E. WHEELS AND TIRES
1. Wheel Type .............................................................................................................. Heavy Duty
2. Tire Size and Type ...................................................................................................... 16.00R-25
3. Tire Inflation Pressure
(a) Tractors with GVW 100,000 lbs (45,300 kg) and below .................. 100 psi (689.5 kPa)
(b) Tractors with GVW up to and including 120,000 lbs (54,360 kg) .... 110 psi (758.5 kPa)
F. BRAKES
1. Service Brakes (4):
Hydraulic Power Braking System w/Dual Accumulator Backup. Disc brakes on all four
wheels. Brakes on each axle are actuated through one of two independent service brake
circuits.
2. Parking Brakes
Parking Brakes (2) ............................................... Spring-Applied Disc, Hydraulically Released
G. HYDRAULIC SYSTEM
1. Main System Pump
(a) Make/Model ........................................................................... Parker Series PAVC 100

(b) Type ................................................................................ Variable Volume Piston Pump
(c) Capacity ..................................................................... 152 L/min (40 gpm) @ 2300 rpm
2. Hydraulic Oil Tank
Capacity .............................................................................................................. 113.6 L (30 gal)
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Chapter 1
3. Hydraulic Oil Tank
Type ........................................................................................................................... Removable
4. Hydraulic Oil
Type ............................................................................................................................ Mobil ATF
5. System Pressure
System Pressure ........................................................................ Approx. 2,000 psi (13,790 kPa)
H. STEERING SYSTEM
1. Closed Center, Hydraulically Powered. 3-Mode Steering with Electrical Selection of Front 2-
Wheel, 4-Wheel Coordinated, or 4-Wheel Crab.
2. Emergency Steering Pump ........ Manually operated by 12 Vdc Motor-Driven Hydraulic Pump
I. ELECTRICAL SYSTEM
1. System Voltage ................................................................................................................ 12 Vdc
2. Alternator Rating .................................................................................................................. 90A
3. Batteries (2)
(a) Type ..................................................................................................................... DEKA

(b) Cold Cranking Amps (Each) .................................................................................. 925A
(c) Group Size .................................................................................................................. 31
J. FUEL SYSTEM
Tank Capacity .....................................................................................................................246 L (65 gal)
K. LUBRICANT AND FLUID CAPACITIES
(Approximate values)
1. Total Engine Oil Capacity ...................................................................................... 22.2 qt (21 L)
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2. Transmission Lube Oil ........................................................................................... 8 gal (30.3 L)
3. Axle Lube Oil (Each)
(a) Differential Carrier ................................................................................... 40 pt (18.9 L)

(b) Planetary Ends (2) ...................................................................................... 8 pt (3.78 L)
4. Engine Cooling System
(a) Up to S/N 347 (except S/N 337, 338 and 340) ...................................... 18.4 qt (17.4 L)
(b) S/N 337, 338, 340, 347 & Up ................................................................... 25.4 qt (24 L)
5. Hydraulic System Tank .......................................................................................30 gal (113.5 L)
6. Service Brakes
Master/Slave Cylinders ................................................................................................. 2 qt (2 L)
L. ENGINE OIL GRADES
For the SAE viscosity grades of engine oil to use at various temperatures, refer to the Deutz Engine
Manual in Chapter 5.
M. TRANSMISSION OIL GRADES
For the recommended grades of transmission oil to use at various temperatures, refer to the ZF
Transmission Supplement in Chapter 5.
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Chapter 1
SECTION 4: SHIPPING
A. INTRODUCTION
This section contains instructions for the preparation of shipping the tow tractor from one location to
another. Normally, the shipping of the unit does not involve storage time. If the unit is to be stored
before or after shipment, refer to section 5 of this chapter for details of preparation. The tractor is
normally shipped in a fully operational status. The tractor can be driven to on-load or off-load from
the trailer bed of the transporting truck. Any systems that are not operational shall be appropriately
tagged on the unit and indicated on the shipping document that accompanies the tractor.
B. TIE-DOWN POINTS
The tow tractor is secured through the forward and rear hitch pins and through the designed chain
holes in the four wheel wells of the tractor. No other tie-down points are authorized.
C. LIFTING
WARNING: TO AVOID INJURY TO PERSONNEL OR DAMAGE TO

EQUIPMENT, ALWAYS USE LIFTING EQUIPMENT, SUPPORTS,
AND CHAINS WITH A SAFE MINIMUM CAPACITY OF ONE AND A
HALF (1½) TIMES THAT OF THE OBJECT BEING LIFTED AND
SUPPORTED.
If lifting points are available, these points will be stenciled on the tractor or lifting eyes will be
provided. The tow tractor may be lifted by a hydraulic lift (forklift) or by an overhead crane with
capacity of 1-1/2 times greater than the unit being lifted.
D. PREPARING ENGINE
1. Drain fuel tank; close and seal all openings.
2. Drain coolant from engine cooling system; close and seal all openings.
3. Seal end of exhaust with weatherproof tape to prevent entry of foreign matter.
4. Seal the engine air intake by enclosing the air cleaner assembly in plastic sheeting and
securing with duct tape to prevent entry of foreign matter.
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E. PREPARING UNIT
1. Batteries
(a) Disconnect battery cables and securely fasten inside enclosure to prevent them from
coming in contact with battery terminals.
(b) Ensure battery holddown devices are installed and tightened.
2. Windshields
Protect windshields with heavy cardboard or other suitable material and strapping to prevent
damage from impact by flying or loose debris.
3. Rear Cab Control Panel
Protect control panel with cardboard or other suitable material to prevent damage from impact
by loose debris.
4. Warning Beacons
(a) Remove roof-mounted beacon(s) before shipment.
(b) Securely tape a protective covering over the beacon mounting plate(s).
(c) Securely pack roof-mounted beacon(s) in a box(es), label box(es), and ship with unit.
F. MARKING
Before shipment, make sure that a warning tag of some type is securely fastened to the start switch
on the control panel. This tag should warn as to the following:
WARNING: DO NOT START ENGINE! COOLANT HAS BEEN

DRAINED! FUEL HAS BEEN DRAINED!
G. RECEIVING EQUIPMENT
1. Inventory
Inventory items received against shippers bill of lading. Note any missing items on bill of
lading.
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2. Inspection
Inspect equipment for damage. Damaged coverings require an in-depth inspection in that
area. Note any damaged items or protective coverings on bill of lading.
3. Notification
Immediately notify the shipper and any other responsible parties of missing items and/or
damage found to the unit or parts of the unit.
H. PREPARING UNIT FOR SERVICE
1. Windshields
Remove strapping and covering from windshields.
2. Warning Beacon(s)
If warning beacons are supplied on unit, remove protective tape covering from beacon
mounting plate(s), remove beacon(s) from box(es), and install beacon(s).
3. Air Cleaner
Remove protective covering from air intake of the engine air cleaner.
4. Batteries
Ensure battery holddown devices are secure. Coat battery posts with petroleum jelly and
install battery cables. Charge batteries if needed.
5. Engine
Perform the following:
(a) Remove sealing tape from end of exhaust pipe.
(b) Fill engine cooling system and radiator with coolant. Use coolant per Deutz Engine
Manual in Chapter 6.
(c) Fill fuel tank with diesel fuel per Deutz Engine Manual in Chapter 6.
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6. Control Panel
Remove cardboard from control panel.
7. Markings
Remove warning tag from start switch on the control panel. Perform Daily Maintenance
Tasks as listed in the Preventive Maintenance Schedule in Chapter 2, Section 3, of this
manual. Perform Prestart Procedures and Operation Procedures in Chapter 2, Section 3, of
this manual.
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Chapter 1
SECTION 5: STORAGE
A. SHORT TERM STORAGE
Note NOTE: Short term storage applies to equipment that is to be stored for a
period of 30 to 120 days.
1. Engine
No special requirements.
2. Transmission
3. Drive Axles
4. Tires

SUPPORTED.
(a) Using a forklift or a crane, lift the unit.
(b) Remove the tractor's weight from its tires by supporting it with blocks placed beneath
the axles or the body.
5. Batteries
Disconnect the battery cables. Maintain the batteries at full charge during storage.
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B. RETURNING THE TRACTOR TO OPERATION AFTER SHORT TERM STORAGE
1. Tires

SUPPORTED.
(a) Using a forklift or a crane, lift the unit.
(b) Remove the blocks from beneath the tractor.
(c) Lower the tractor to the ground.
(d) Check the tire pressure. If required, inflate them to 110 psi (758 kPa).
2. Batteries
(a) Clean the battery posts and cable clamps.
(b) Check the electrolyte levels and service the batteries, if required.
(c) Lightly coat the battery clamps and posts with petroleum jelly.
(d) Connect the battery cables.
(e) Charge the batteries, if required.
3. Engine
(a) Visually inspect the engine systems to ensure integrity.
(b) Check the fluid levels and service as required.
4. Transmission
Service as required. Refer to Chapter 2.
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C. LONG TERM STORAGE
Note NOTE: Long term storage is defined as a period of time exceeding 120
days.
1. Engine
It is recommended that volatile corrosion inhibitors (NOX-RUST VCI#10 oil), black or dark
colored plastic bags, and sealing tape (Kendall No. 231) be used to prevent internal engine
damage from moisture. An air compressor with a sprayer attachment can be used to apply
the oil. After application, completely seal the engine to prevent the vapors from escaping. For
additional information on VCI, contact:
Customer Service
Daubert Chemical Co.
1200 Jorie Blvd.
Oakbrook, Illinois 80521
Telephone: (312) 582-1000
(a) Cooling System. Ensure that the system is clean and filled with a 50/50 mixture of
ethylene glycol antifreeze and water, or an antifreeze mixture suitable to prevent
freezing. Start the unit and allow its temperature to rise sufficiently to circulate the
coolant. Then, stop the unit and allow it to cool. Check the coolant level and fill as
required to eliminate any air spaces. Install the radiator cap.
CAUTION: WHEN TURNING THE ENGINE OVER WITH THE

STARTING CIRCUIT DISABLED, DO NOT OPERATE THE STARTER
FOR MORE THAN 30 SECONDS. DOING SO CAN OVERHEAT AND
DAMAGE THE STARTER MOTOR.
(b) Air Intake. Remove the air intake filter element. Disable the starting circuit by
pulling F5. Turn the engine at cranking speed for approximately 15 seconds and use a
sprayer to add a mixture of 50% VCI oil and 50% engine oil into the air intake.
Minimum application rate is 2 oz (60 mL). Install the air filter element. Completely
enclose the air cleaner with dark plastic bag and seal with tape.
(c) Crankcase and Filter Elements. Oil filter elements do not need to be changed. If the
engine oil has been used 50 hours or less, leave it in the sump and add 3 to 4% by
volume of VCI . If the oil has more than 50 hours of use, change it and add 3 to 4%
of VCI . Place and seal the plastic cover over the dipstick and the crankcase
breather. Use tape to seal any openings.
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(d) Exhaust. Disconnect the exhaust system at the engine exhaust manifolds. Use a
sprayer to apply a mixture of 50% VCI oil and 50% engine oil into the exhaust
manifold openings. A minimum application is 2 oz (60 mL). Connect the exhaust
system, and seal the exhaust pipe with tape and plastic.
(e) Fuel System. Drain the fuel tank. Use a sprayer to apply 1 oz (30 mL) of VCI oil for
each 7.50 gal (30 L) of tank capacity. Seal the tank opening. Remove the fuel filter,
drain, and reinstall. Clean the primary fuel filter (if equipped). Remove the fuel
injectors, check them, and recondition them, if necessary. Spray 1 oz (30 mL) of 50%
VCI oil and 50% engine oil in each cylinder. Install the fuel injectors and tighten them
to 30 ft/lb (40 Nm). Using a bar or turning tool, turn the engine over slowly to
lubricate the cylinder walls.
(f) Belts. Loosen belt tension.
(g) Engine Exterior. Apply multipurpose grease on moving parts such as rod threads,
linkage, and joints. Check all openings of the engine to ensure that plastic covers are
in place and sealed. Secure a waterproof over the engine.
(h) Tagging. Fasten a tag to the starting switch on the control panel containing the
following:
WARNING: DO NOT START THE ENGINE!UNIT IN STORAGE!ALL

SYSTEMS DRAINED OR PRESERVED!
2. Batteries
Disconnect the battery cables and remove the batteries from the unit. Lightly coat
the cable clamps and hold down the hardware with petroleum jelly. Place the
batteries in a dry, well ventilated area. Charge the batteries, if required, to obtain a
specific gravity of 1.225. Do not store the batteries directly on the floor or the
ground.
NOTE: Remove the waterproof cover every 2 to 3 months and check the
Note engine for corrosion and integrity of its sealed areas. If any sealed
system appears open, refer to the appropriate system (listed above) and
repeat the application.
3. Drive axles
1-5-4 CD276
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Chapter 1
4. Transmission
Refer to the manufacturer's recommendations contained in the ZF Hydromedia Powershift

service manual located in Chapter 5.
5. Tires

SUPPORTED.
(a) Remove the weight from the tractor's tires by supporting the tractor with blocks
positioned beneath the axles and the body.
(b) Reduce the air pressure in the tires to 60 psi (414 kPa).
6. Windows (Cab Option Only)
Using bands to hold it, place heavy cardboard over the windows.
D. RETURNING THE TRACTOR TO OPERATION AFTER LONG-TERM STORAGE
1. Tires
(a) Inflate the tires to 110 psi (758 kPa).
(b) Remove the tractor from the blocks.
2. Windows (Cab Option Only)
Remove the cardboard and strapping.
3. Batteries
(a) Check the battery levels and service them, if required.
(b) Install the batteries in the tractor.
(c) Clean the battery cables and posts.
CD276 1-5-5
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Chapter 1
(d) Lightly coat the clamps and the battery posts with petroleum jelly.
(e) Connect the battery cables to the posts.
4. Engine
(a) Remove the plastic covers and tape from all engine and fuel tank openings.
(b) Drain the oil sump. Replace the filters, and refill the oil sump.
(c) Tighten the alternator and water pump belts.
(d) Replace the fuel filter and the water separator.
(e) Fill the fuel tank and prime the system.
(f) Check the coolant system and service it, if required.
(g) Using a bar or turning tool, turn the engine in its normal direction of rotation and
ensure that there are no hydraulic locks or resistance.
5. Transmission
Refer to the manufacturer's recommendation contained in the ZF Hydromedia Powershift

transmission service manual.
6. Drive axles
7. Preoperational checks
Perform preoperational checks, remove the warning tag from the cab and start the unit. The
unit may run rough and smoke for a few minutes until it has cleared all the preservatives from
the system. Operate the system at no load conditions to ensure that all the systems are
operating correctly before returning the unit to service.
1-5-6 CD276
Rev 13
Chapter 2
CHAPTER TWO: MAINTENANCE

TABLE OF CONTENTS
SECTION 1: SERVICING ............................................................................................................ 2-1-1

A. Introduction ........................................................................................................... 2-1-1
B. Periodic Maintenance Schedule ........................................................................... 2-1-1
C. Maintenance Procedures ...................................................................................... 2-1-5
SECTION 2: TROUBLESHOOTING............................................................................................ 2-1-1

A. Introduction ........................................................................................................... 2-1-1
B. Lights .................................................................................................................... 2-1-2
C. Engine .................................................................................................................. 2-1-4
D. Transmission ........................................................................................................ 2-1-5
E. Charging System .................................................................................................. 2-1-5
F. Acessories ............................................................................................................ 2-1-6
G. Hydraulic Pump and Relief Valve ......................................................................... 2-1-7
H. Service Brakes ..................................................................................................... 2-1-8
I. Parking Brakes ..................................................................................................... 2-1-9
J. Front Cab Lift ...................................................................................................... 2-1-10
K. Steering - General .............................................................................................. 2-1-11
L. Steering - Three Mode System ........................................................................... 2-1-12
M. Cab Select Circuit ............................................................................................... 2-1-17
N. Wiring Diagrams ................................................................................................. 2-2-19
Figure 2-1. Wiring Diagram ............................................................................... 2-2-19
Figure 2-2. Wiring Diagram with Cat/Engine ..................................................... 2-2-25
Figure 2-9. Wiring Diagram, Single Cab (Station) ............................................. 2-2-76
Figure 2-10. Schematic, Single Cab (Station) w/Cat Engine ............................. 2-2-92
Figure 2-11. Wiring Diagram, Rear Driving Lights/Single Cab......................... 2-2-101
Figure 2-12. Wiring Diagram, Back Up Alarm .................................................. 2-2-102
CD276 2-TOC-i
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Chapter 2
Figure 2-13. Wiring Diagram, Marker Clearance Light .................................... 2-2-103

Figure 2-14. Electrical Equipment Location ..................................................... 2-2-105
Figure 2-15. Electrical Equipment Location Cat & Deutz Engines .................. 2-2-112
Passive Centering Kit, Single Cab ........................................................ 2-2-123
Figure 2-17. Layout, Optional Components, Front Cab Control Panel ............ 2-2-126
Figure 2-18. Schematic, Lights through Ignition .............................................. 2-2-127
Figure 2-19. Wiring Schematic for Starting, Alternator, Ignition Switch ........... 2-2-129
2-TOC-ii CD276
Rev 13
Chapter 2
SECTION 1: SERVICING
A. INTRODUCTION
Maintain the tractor by performing the periodic maintenance procedures as listed in the Preventive
Maintenance Schedule. With normal operating conditions, follow the frequency indicated in the
schedule. Where the tractor operates under abnormally severe conditions (e.g., sand, dust, salt air, ice,
and snow, etc.), increase the frequency of maintenance of the affected systems and components as
necessary.
During the periodic maintenance of the tractor, follow the instructions for service and adjustment of
the components and systems described in this chapter and the attached service manuals and
instructions issued by component manufacturers (see Chapter 5).
B. PERIODIC MAINTENANCE SCHEDULE
1. Daily
(a) Check the units exterior for cleanliness and damage.
(b) Clean all windows with glass cleaner.
(c) Check that all controls are in good working order and door latches work properly.
(d) Check fire extinguishers are in place and fully charged.
(e) Check the operation of the windshield wipers and defogger fan.
(f) Check windshield wiper blades and fluid level, add fluid if necessary.
(g) Check tire pressure. Tire pressure should be 110 psi (758 kPa).
(h) Check fuel system for leaks, include hoses, lines, fittings and linkage.
CAUTION: OVERFILLING ENGINE CRANKCASE CAN RESULT IN

OIL LEAKS OR BEARING DAMAGE. CHECK THE OIL LEVEL
FREQUENTLY WHILE ADDING OIL TO AVOID OVERFILLING.
(i) Check fuel level, add fuel as required.
CD276 2-1-1
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Chapter 2
(j) Check engines oil system for leaks around filters and gaskets.
CAUTION: OVERFILLING ENGINE CRANKCASE CAN RESULT IN

OIL LEAKS OR BEARING DAMAGE. CHECK THE OIL LEVEL
(k) Check engine oil level, add oil as required..
(l) Check engines cooling system for leaks and cleanliness.
WARNING: THE COOLING SYSTEM IS PRESSURIZED. ESCAPING

STEAM AND HOT COOLANT CAN CAUSE SEVERE BURNS. NEVER
OPEN A RADIATOR CAP WHEN COOLANT TEMPERATURE
EXCEEDS 200 °F (95 °C). USE A CLOTH OR WEAR SUITABLE
GLOVES TO HANDLE A HOT RADIATOR PRESSURE CAP.
ETHYLENE GLYCOL ANTIFREEZE IS TOXIC AND IRRITATES THE
SKIN. WASH ANY PART OF THE BODY THAT COMES IN CONTACT
WITH ANTIFREEZE SOLUTION AS SOON AS POSSIBLE.
(m) Check engine coolant level, add coolant as required.
NOTE: Some minor coolant loss is normal due to thermal expansion. A

Note very low coolant level (down to or below the core tubes) indicates serious
leakage in the system that must be located and corrected.
(n) Check exhaust system for integrity.
(o) Check transmission for leaks, include hoses and fittings.
NOTE: Check the transmission oil level while the engine is running at its
Note normal operating temperature of 160 to 185 °f (71 to 85 °c).
CAUTION: OVERFILLING TRANSMISSION CAN RESULT IN OIL

LEAKS OR POSSIBLE DAMAGE. CHECK THE OIL LEVEL
(p) Check transmission oil level, add oil as required.
(q) Check hydraulic system for leaks, include hoses and fittings to the remote hydraulic
fluid cooler.
(r) Check hydraulic fuel level, add oil as required.
(s) Check restriction indicator.
2-1-2 CD276
Rev 13
Chapter 2
(t) Check the front/rear axle differential cases and planetary hubs for oil leaks.
(u) Check wiring for loose connectors, brittle insulation, or heat induced cracks.
(v) Check the operation of all lights.
(w) Check horn.
(x) Check that the drive, steering and brake systems are in good working order.
(y) Ensure that all vertical tracks are free of trash and foreign matter. (Lift Cab Only)
(z) With engine running, check cab operation by raising cab to maximum height and
lowering to the normal (lowest) position. (Lift Cab Only)
2. Every 50 Hours
(a) Ensure that the sliding window channels are clean and free of obstructions.
(b) Lubricate the door latches and hinges with light machine oil.
(c) Check hydraulic hoses for cracks, splits, cuts and chafing. Replace defective hoses.
(Lift Cab Only)
(d) Check all hydraulic fittings, ensure they are securely installed and not leaking. (Lift
Cab Only)
3. Every 100 Hours
(a) Check brake actuator fluid levels.
(b) Check brake fluid level in master cylinder.
4. Every 200 Hours
(a) Check oil level, axle differential and planetary wheel ends.
(b) Drain fuel/water seperator.
(c) Drain water condensate from hydraulic oil tank.
(d) Change engine oil and filters.
(e) Grease drive shafts and universal joints.
CD276 2-1-3
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Chapter 2
(f) Check torque on wheel lug nuts.
(g) Check drive belts condition and tension.
(h) Check electrical system-lights, switches and gauges for proper operation.
(i) Check generator.
(j) Check battery electrolyte level.
(k) Check radiator and heater core hoses and fittings.
(l) Check hydraulic system tubing, hoses and fittings.
(m) Check electrical harnesses, cables, wires and connections.
(n) Lubricate steering knuckles zerk fittings.
(o) Lubricate rollers and bearings. Use NLGI No. 1 grease. (Lift Cab Only)
(p) Lubricate cylinder mounting pins with all-purpose grease. (Lift Cab Only)
(q) Ensure that all components are securely installed. (Lift Cab Only)
4. Every 400 Hours
(a) Change engine fuel filters.
(b) Change engine air filters.
(c) Check engine air intake system.
(d) Check engine exhaust system.
(e) Check brake accumulator pressures.
(f) Check service brake actuator circuit, bleed air if necessary.
5. Every 600 Hours
(a) Change hydraulic oil return filter.
(b) Change transmission oil and filter.
2-1-4 CD276
Rev 13
Chapter 2
6. Every 1200 Hours.
(a) Check brake pads and calipers.
(b) Check brake assembly.
(c) Change hydraulic oil.
(d) Change axle differential and planetary wheel end oil.
(e) Drain, flush and refill engine cooling system.
C. MAINTENANCE PROCEDURES
1. Transmission: Oil and Filter Change

THE EQUIPMENT, ALWAYS USE LIFTING EQUIPMENT,
SUPPORTS, AND CHAINS WITH A SAFE MINIMUM CAPACITY OF
ONE AND A HALF (1-1/2) TIMES THAT OF THE OBJECT BEING
LIFTED OR SUPPORTED.
Note NOTE: Transmission fluid needs to be warm prior to draining.
(a) Park the unit on level ground.
(b) Apply the parking brake and chock the wheels. Place a warning tag on the control
panel stating "Unit is Out of Service."
(c) Jack up the tractor and place jack stands under the unit as required.
(d) Place a catch pan under the transmission drain plug located in the lower front of the
transmission case.
(e) Loosen and remove the drain plug and allow the fluid to drain completely.
(f) Install and tighten the drain plug.
(g) Place a container under the externally mounted filter (1, Figure 1-1).
(h) Using a filter wrench, loosen and remove the spin-on filter.
CD276 2-1-5
Rev 13
Chapter 2
(i) Inspect the filter mounting base assembly sealing surface. Ensure that the surface is
clean.
(j) Lightly coat a new filter gasket with clean transmission fluid.
(k) Carefully thread a new filter onto the filter mounting base assembly and tighten hand
tight (always refer to the filter manufacturer's directions).
1. Filter
2. Dipstick & Filler Pipe
Figure 1-1. Transmission Servicing Points
2-1-6 CD276
Rev 13
Chapter 2
(l) Fill the transmission through the filter pipe. (2, Figure 1-1) with 4 gal (15.1 L) of
approved fluid. Remove the warning tag from the control panel.
(m) Remove the unit from the jack stands.
(n) Start the engine and run it at idle speed to allow the fluid to circulate.
(o) Check the fluid level with the dipstick (2, Figure 1-1).
(p) Add fluid as required to maintain the level in the safe operating zone.
(q) Check the system for leaks before returning the unit to service.
2. Fuel Filter: Replace
(b) Apply the parking brake. Place a warning tag on the control panel stating: "Unit Out
of Service."
(c) Place a container under the fuel filter.
(d) Loosen the spin-on filter (Figure 1-1) by turning it counterclockwise. Discard it once
it has been removed.
(e) Ensure the sealing surface of the filter mounting base is clean; apply clean fuel to the
new fuel filter's gasket.
(f) Mate the new filter's sealing surfaces and then tighten the filter 3/4 turn by hand.
(Always refer to the filter manufacturer's directions.)
(g) Check for leaks.
3.. Engine Oil and Filters: Change / Replace
NOTE: Engine oil is best changed just after engine operation. The oil is
Note still warm and most contaminants are still suspended in it. Draining the
oil then carries them out of the engine.
(a) Place the unit on level ground.
(b) Apply the parking brake and chock the wheels.
CD276 2-1-7
Rev 13
Chapter 2
(c) Jack up the tractor and place jack stands under it as required. Place a warning tag
on the control panel stating: "Unit Out of Service."
(d) Place a catch pan below the engine oil drain (1, Figure 1-2).
WARNING: OIL CAN BE VERY HOT. WHEN PERFORMING AN OIL

CHANGE, PROTECT YOURSELF BY WEARING RUBBER GLOVES.
(e) Loosen and remove the engine oil drain plug (1).
(f) After the oil is drained, install and tighten the drain plug.
(g) Place a catch pan under the engine oil filter (2).
(h) Use a filter strap wrench to loosen the spin-on oil filter. Remove the filter and drain
the oil in it into the catch pan.
(i) Inspect the filter mounting base assembly for deposits or dirt. Remove any deposits
on the filter gasket sealing surface. Wipe the filter gasket sealing surface clean.
(j) Fill the new filter element with clean engine lube oil. (Refer to Table 1-1 to select
engine lube oil. Refer to Table 1-2 to select the proper oil grade.)
(k) Apply thin coat of oil to the new filter gasket.
(l) Carefully thread the new oil filter onto the mounting base assembly and hand tighten.
(Always refer to manufacturer's directions.)
CAUTION: DO NOT MIX OILS FROM DIFFERENT REFINERS OR

OF DIFFERENT VISCOSITIES. WHILE FILLING, CHECK CRANK-
CASE OIL LEVEL FREQUENTLY. OVER-FILLING CAN CAUSE
BEARING DAMAGE AND OIL LEAKS.
(m) Remove the unit from its jack stands.
(n) Fill the engine crankcase through the filler neck (3) on the rocker cover with 22 qt (21
L) of the proper oil from the engine lube oil viscosity chart (Table 1-1). Check
crankcase level with dipstick (4). Remove the warning tag.
(o) Start the unit and check the engine oil filter for leakage. If needed, tighten the filter
element with a strap wrench just enough to stop any leaks. Return the unit to service.
2-1-8 CD276
Rev 13
Chapter 2
1. Oil Drain Plug

2. Oil Filter
3. Oil Filter
4. Lube Oil Cooler
Figure 1-2. Engine Oil System
CD276 2-1-9
Rev 13
Chapter 2
Table 1-1. Engine Lube Oil Viscosity Selection Chart
Table 1-2. Engine Lube Oil Quality Grade Chart

Approved API Oils:
Naturally aspirated engines: CC
Turbocharged engines: CD CF
CE CF4
Approved CCMC Oils:
Naturally aspirated engines: D4
Turbocharged engines: D4 D5
D5 (sulfate ash ³ 1.8% by mass) corresponds to SHPD.*
*SHPD (Super High Performance Diesel) oils.
If in doubt, ask the nearest service representative.
2-1-10 CD276
Rev 13
Chapter 2
4.. Engine Air Intake Filter: Change Element
of Service."
(c) Using a large, flat bladed screwdriver, loosen the air filter access cover latch and
rotate the access cover down out of the way.
CAUTION: MAKE SURE NO DEBRIS OR DIRT ENTERS THE AIR

INLET WHILE IT IS OPEN. INGESTED DIRT OR DEBRIS CAN
CAUSE SERIOUS ENGINE DAMAGE.
(d) Loosen the T-bolts on the air cleaner housing (1, Figure 1-3) and remove the cover.
(e) Remove the moisture separator (3) and the pamic filter element (2).
(f) Wipe the air cleaner housing clean of any dirt or debris.
CAUTION: DO NOT SET THE AIR CLEANER ELEMENT DOWN ON

THE AIR OUTLET SIDE TO AVOID PICKING UP DIRT THAT CAN
BE INGESTED INTO THE ENGINE AND SERIOUSLY DAMAGE IT.
(g) Unpack the new filter element and inspect it for damage. If undamaged, insert the
element in the air cleaner housing.
CAUTION: DO NOT POUND THE ELEMENT INTO PLACE OR

PULL IT EXCESSIVELY IN ANY ONE DIRECTION. DO NOT USE
TOOLS OF ANY KIND ON THE ELEMENT. DOING SO MIGHT
DAMAGE THE ELEMENT, MAKING IT INEFFECTIVE IN
PROTECTING THE ENGINE.
(h) Press fingers in the holes at the element's opposite corners and gently work the
element into place. Ensure that it is seated against the sealing flange in the housing.
(i) Position the moisture separator against the element's elastomer face. Ensure that the
separator's drain holes are on the bottom and that the visible corrugations in the
separator screen pack are vertical.
CD276 2-1-11
Rev 13
Chapter 2
CAUTION: OVERTIGHTENING THE T-BOLTS CAN BOW THE

SIDES OF THE AIR CLEANER HOUSING AND DISTORT THE
SEALING FLANGE, ALLOWING DIRT AND DEBRIS TO REACH
AND DAMAGE THE ENGINE.
(j) Insert the T-bolt clamps into the slots in the moisture separator. Using a cross
tightening technique to draw the separator in evenly, tighten the T-bolts to 70 in-lbs.
(k) Raise the air filter access. Hold it in place while latching it closed.
(l) Reset the air filter restriction indicator, mounted behind the air filter in the outlet tube
to the engine, by pushing in the button on its bottom.
(m) Remove the warning tag and return the unit to service.
1. Air Cleaner Housing

2. Filter Element
3. Moisture Seperator
Figure 1-3. Engine Air Intake System Filter
2-1-12 CD276
Rev 13
Chapter 2
5. Service Brakes: Bleed Pedal Actuators
CAUTION: BEFORE EACH STEP OF THE BRAKE SYSTEM BLEED

PROCEDURE, CHECK THE MASTER CYLINDER RESERVOIR
FLUID LEVEL. AN ADEQUATE MAKE-UP VOLUME OF FLUID
MUST BE IN THE RESERVOIR AT ALL TIMES. PLACE A SECTION
OF HOSE OVER THE END OF THE BLEED VALVE AND A
CONTAINER UNDER THE OPPOSITE END OF THE HOSE TO
CATCH EXPELLED FLUID.
(a) Park the tractor on level ground.
(b) Chock the wheels and apply the parking brake.
(c) Jack up the unit and place jack stands under it as required. Place a warning tag on the
control panel stating: "Unit Out of Service."
WARNING: WHEN DISCONNECTING BATTERY CABLES, REMOVE

THE BATTERY'S GROUND CABLE (NEGATIVE) FIRST.
REMOVING THE POSITIVE CABLE FIRST CAN CAUSE
ELECTRICAL SPARKS THAT BURN PERSONNEL.
(d) Disconnect the battery cables at the batteries.
(e) Pump the brake pedal several times, then hold it depressed.
(f) On one rear brake assembly, open the bleed valve to allow fluid and air to escape
from the system.
(g) With the brake pedal depressed, close the brake bleed valve. Then release the
pressure on the brake pedal.
(h) Repeat the above steps until all the air has been removed from the system. A steady
stream of fluid will be observed from the brake bleed valve.
(i) Repeat the bleed procedures on the opposite rear brake assembly. Then, repeat steps
(e) through (i) on the front brakes.
WARNING: INSTALL THE BATTERY'S POSITIVE CABLE BEFORE

THE NEGATIVE (GROUND) CABLE. CONNECTING THE
NEGATIVE CABLE FIRST CAN CAUSE ELECTRICAL SPARKS
THAT BURN PERSONNEL.
(j) Reconnect the battery cables to the battery.
CD276 2-1-13
Rev 13
Chapter 2
(k) Remove the unit from its jack stands. Remove the warning tag.
(l) Drive the unit under no load conditions to ensure brake system is operating properly
before placing unit back in service.
6. Service Brakes: Bleed Wheel Cylinders
CAUTION: BEFORE EACH STEP OF THE BRAKE SYSTEM BLEED

PROCEDURE, CHECK THE MASTER CYLINDER RESERVOIR
FLUID LEVEL. AN ADEQUATE MAKE-UP VOLUME OF FLUID
MUST BE IN THE RESERVOIR AT ALL TIMES. PLACE A SECTION
OF HOSE OVER THE END OF THE BLEED VALVE AND A
CONTAINER UNDER THE OPPOSITE END OF THE HOSE TO
CATCH EXPELLED FLUID.
(a) Park the tractor on level ground.
(b) Chock the wheels and apply the parking brake.
(c) Jack up the unit and place jack stands under it as required. Start unit and allow it to
idle at normal idle speed, making sure the hydraulic pressure maintains 2000 psi.
WARNING: AT THIS POINT IT WILL BE NECESSARY FOR THE

SECOND PERSON TO BE IN AND AROUND THE TIRES AND
WHEEL END AREA. TAKE GREAT CARE WHEN PERFORMING
THE NEXT STEPS.
(d) Pump the brake pedal several times, then hold it depressed.
(e) On one of the 2 calipers at each wheel end, open the bleed valve to allow fluid and air
to escape from the system.
(f) With the brake pedal depressed, close the caliper bleed valve. Then release the
pressure on the brake pedal.
(g) Repeat the above steps until all the air has been removed from the system. A steady
steam of fluid will be observed from the caliper bleed valve.
(h) Repeat the bleed procedures on all the other brake calipers.
(i) Turn off the unit and remove it from the jack stands.
(j) Drive the unit under no load conditions to ensure the brake system is operating
properly before placing the unit back in service.
2-1-14 CD276
Rev 13
Chapter 2
7. Service Brake Assembly: Inspect / Replace

LIFTED.
WARNING: EXERCISE CAUTION WHEN HANDLING HEAVY

TRACTOR COMPONENTS SUCH AS TIRES AND BRAKE SHOES.
(b) Apply the parking brake.
(c) Jack up the unit and place jack stands under it as required. Place a warning tag on
control panel stating "Unit Out of Service."
(d) Remove the tire and wheel assembly.
(e) Using a flashlight, visually inspect the brake linings (2, Figure 1-4). If less than 0.125
in (3.2 mm) of lining remains, the linings need to be replaced. To replace the linings
(for any reason), proceed to step f. If the linings are satisfactory and do not need to
be replaced, proceed to step j.
(f) To replace the linings, begin by removing the brake housing (1) from the disc. Note if
shims are centering the brake housing. If so, keep each set together for reuse.
NOTE: Never mix new and used linings in a brake assembly. Ensure that
Note serviceable worn linings have an equal thickness of material.
(g) If the linings are being replaced due to wear, place a screwdriver between the lining
cup and the piston (3). Twist the screwdriver and pry the lining off the snap that
retains it.
(h) If the linings are relatively new but must be removed, the pistons on one side of the
brake must be pushed back until it is at the bottom of its cavity. The pistons on the
opposite side must be pushed forward until a screwdriver can be inserted between the
lining and the piston as in step g. above. (Air pressure can be applied to the inlet
while holding the pistons to facilitate moving them to that position.)
(i) Push all the pistons to the bottom of the cavity. Install the new linings into the cavities
and push them towards the pistons until the linings snap into place. Ensure that the
linings are secure by pulling on them with your fingers.
CD276 2-1-15
Rev 13
Chapter 2
(j) Inspect the disc for wear. The disc needs to be replaced when its total thickness is
less than 0.38 in (9.65 mm) or if there is more than .03 (0.76 mm) in wear per side. If
the disc is worn beyond these limits, replace the disc. Proceed to step n. unless the
linings have also been replaced. In that case, proceed to step k.
(k) Reinstall the brake housing utilizing any shims used to center it. Install the four
mounting bolts and torque to the manufacturer's recommended value.
(l) Reconnect the hydraulic inlet line.
(m) Bleed any trapped air from the brakes.
(n) Apply full brake pressure and check for fluid leaks. Check that the pistons release
when brake pressure is released.
(o) Install the wheel and tire assembly.
(p) Drive the unit under no load conditions to check the brake system. If it performs
satisfactorily, remove the warning tag and return the unit to service.
1. Brake Linings
2. Brake Housing
3. Piston
4. Bolt
5. Bleed Valve
Figure 1-4. Service Brake Assembly
2-1-16 CD276
Rev 13
Chapter 2
8. Axle Assembly: Change Oil

HALF (1-1/2) TIMES THAT OF THE OBJECT BEING LIFTED OR
SUPPORTED.
NOTE: The oil in the differential and the wheel end assemblies will drain
Note better if the oil is warm. However, even when warm, these components
will drain and fill slowly.
(b) Chock the wheels and jack up the tractor. Place jack stands as required under the
unit. Place a warning tag on the control panel stating: "Unit Out of Service."
(c) Place a container under the differential to catch the draining oil.
(d) Remove the oil fill plug (1, Figure 1-5), and oil drain plug (2).
(e) After all the oil has been drained out, install the drain plug.
(f) Fill the differential until the oil is even with fill plug opening.
(g) Install the fill plug. Repeat steps a through e for the remaining differential.
9. Wheel End Assembly: Change Oil
(a) The drain plug (4) is located at the perimeter of the wheel hub. Rotate each wheel
until the drain plug is at the bottom of the hub. The fill plug (3) is located near the
center of the hub.
(b) Place a container under the wheel hub to catch the oil.
(c) Remove the drain plug (4) and fill plug (3). Allow the hub to drain.
(d) Install the drain plug.
(e) Using a funnel, add fresh oil through the fill plug opening until the oil is level with the
opening. Install the fill plug.
CD276 2-1-17
Rev 13
Chapter 2
(f) Repeat procedures a through e for the remaining wheel end assemblies.
(g) Remove the unit from its jack stands. Remove the warning tag and return the unit to
service.
1. Axle Assembly Fill/Drain Plug

2. Wheel Assembly Fill/Drain Plug
Figure 1-5. Axle and Wheel End Assembly Servicing Points
2-1-18 CD276
Rev 13
Chapter 2
10. Fuel Filter / Water Separator: Change Element
of Service."
(c) Place a container under the separator to collect spilled fuel.
(d) Turn the T-handle (1, Figure 1-6) counterclockwise and remove it and the lid (2).
(e) Remove the element (5) (P/N 20420SM-OR, Racor 1000-FG P/N 2020SM-OR) by
slowly pulling the molded handle upward with a turning motion.
(f) Insert a replacement element over the center tube (6) with a downward, turning
motion.
(g) Pour clean diesel fuel into the filter/separator housing (4) until it is full.
(h) Inspect the lid seal (3) and replace if necessary.
(i) Replace the lid (2) and hand-tighten the T-handle (1).
(j) Remove fuel container and wipe up any excess fuel.
(k) Start the engine and check the filter/separator for leaks. Remove the warning tag and
return the unit to service.
CD276 2-1-19
Rev 13
Chapter 2
1. T-Handle
2. Lid
3. Seal
4. Housing
5. Element
6. Center Tube
Figure 1-6. Fuel Filter/Water Separator
2-1-20 CD276
Rev 13
Chapter 2
11. Steering System: Change Filter Element
(a) Park unit on level ground.
(b) Apply parking brake. Place tag on control panel stating "Unit Out of Service."
(c) Open the right top cover and locate the hydraulic oil return filter.
(d) Unscrew and remove the old filter.
(e) Lubricate the new filter gasket with a small amount of hydraulic oil, and install the
new filter onto the filter head and tighten handtight.
(f) Run the engine at idle for approximately one minute to fill the new filter with oil.
(g) Stop the engine and check the hydraulic oil level. Add oil as necessary to bring the
level into the proper range in the sight glass.
(h) Clean up any excess oil.
(i) Close the right top cover.
Figure 1-7. Location of Hydraulic Filter
CD276 2-1-21
Rev 13
Chapter 2
Figure 1-8. Hydraulic Filter
12. Steering System: Adjust Steering Sensor

LIFTED.
(a) Raise the tractor off the ground. Block it securely.
(b) Remove the applicable wheels.
(c) Place the transmission in Neutral (N) and apply the parking brake. Start the engine.
2-1-22 CD276
Rev 13
Chapter 2
(d) Steer the wheels to the straight-ahead position.
(e) Measure the distances from the wheel mount surface of the wheel hub flange to the
wheel well plate on both sides of the horizontal centerline of the hub. (Figure 1-9.)
Steer slowly and move the wheels until dimension "A" equals dimension "B". Stop
steering. Hold the wheels in that position and shut the engine off.
(f) Loosen the band on the reed switch (Figure 1-10).
(g) Being careful not to start the engine, turn the STOP, RUN, START switch to RUN.
(h) Slide the reed on the air cylinder right or left as required until the red light on the
switch illuminates. Note when it does.
(i) Continue to move the switch in the same direction until the light goes off.
(j) The distance between where the light came on and where it went off is the bandwidth
of the ON position for the reed switch. Move the switch until it is in the center of the
bandwidth.
(k) Tighten the band clamp on the reed switch to lock it in that position.
(l) Return the STOP, RUN, START switch to STOP.
(m) Repeat steps f. through h. for each steering sensor being adjusted.
(n) Replace the wheels and tighten the lug nuts to the appropriate torque.
(o) Ensure that all personnel are clear. Then, remove all blocks and lower the tractor to
the ground.
CD276 2-1-23
Rev 13
Chapter 2
Figure 1-9. Straight-Ahead Wheel Position
Figure 1-10. Steering Sensor Assembly
2-1-24 CD276
Rev 13
Chapter 2
13. Steering System: Wheel Alignment
NOTE: Use this procedure in the unlikely event that the front and rear
Note wheels do not steer synchronously, or track.
WARNING: ENSURE THAT PERSONNEL ARE WELL CLEAR OF

THE TRACTOR WHEELS BEFORE BEGINNING THIS
PROCEDURE. DEATH OR SERIOUS INJURY WILL RESULT IF
SOMEONE GETS CRUSHED BETWEEN THE WHEELS AND THE
TRACTOR.
(a) Run the engine at idle.
(b) From either cab, select the TRACK steering mode and steer either left or right as
needed to bring the rear wheels into the locked straight-ahead position.
(c) Steer either left or right to bring the front wheels into the straight-ahead position. The
axle-centered indicator will illuminate.
(d) Select coordinated steering mode (COORD) and steer full left and then full right.
Observe whether the wheels steer synchronously. As the steering wheel reaches full
rotation (left and right), continue turning the wheel against its stops until both the front
and rear wheels reach their maximum steering angles.
(e) If the wheels do not steer properly, perform troubleshooting and repair procedures.
15. Steering System: Bleeding the Steering System
WARNING: ENSURE THAT PERSONNEL ARE WELL CLEAR OF

THE TRACTOR WHEELS BEFORE BEGINNING THIS
PROCEDURE. DEATH OR SERIOUS INJURY WILL RESULT IF
SOMEONE GETS CRUSHED BETWEEN THE WHEELS AND THE
TRACTOR.
(a) Run the engine at idle.
(b) Turn the steering wheel left as far as you can.
(c) Turn the steering wheel right as far as you can.
(d) Repeat the left-to-right, right-to-left steering three complete cycles. This will bleed all
air from the steering system.
CD276 2-1-25
Rev 13
Chapter 2
2-1-26 CD276
Rev 13
Chapter 2
SECTION 2: TROUBLESHOOTING
A. INTRODUCTION
The following troubleshooting tables provide information for diagnosing and correcting problems with
the Model GT-110 tow tractor. This introduction will help you to quickly identify the problem and to
make the necessary repairs to bring the unit back into service.
CD276 2-2-1
Rev 13
Chapter 2
B. LIGHTS
PROBLEM CAUSE CORRECTION
1. Headlight(s) not working, (a) Defective headlight bulb(s). (a) Replace bulb(s).
front cab.
(b) Blown fuse (F14, 20A). (b) Replace fuse.
(c) Faulty headlight switch (S7). (c) Replace switch.
(d) Faulty relay (K6). (d) Replace relay.
2. Brake light(s) not working. (a) Defective taillight bulb(s). (a) Replace bulb(s).
(c) Faulty brake pressure switch (c) Replace pressure switch.

(S28).
(d) Faulty turn signal switch (d) Replace turn signal switch.
(S26).
3. Front or rear hitch light not (a) Defective bulb(s). (a) Replace bulb.
working.
(b) Blown fuse (F14, 20A). Check (b) Replace fuse.
if rear hitch light not working
from rear cab.
(c) Blown fuse (F13, 15A). Check (c) Replace fuse.

if front hitch light not working
from front cab.
(d) Faulty front or rear hitch light (d) Replace switch(es).

switches (S11 or S32).
4. Backup light(s) not working. (a) Defective backup light (a) Replace bulb(s).
bulb(s).
(b) Blown fuse (F9, 15A). Check (b) Replace fuse.

fuse if lights not working on
rear cab.
(c) Faulty relay (K24). Check (c) Replace relay.

relay if lights not working from
rear cab.
2-2-2 CD276
Rev 13
Chapter 2
5. Turn signal light(s) or hazard (a) Defective turn signal bulb(s). (a) Replace bulb(s).
flashers not working.
(c) Faulty flasher (FL1). (c) Replace flasher.
(d) Faulty turn signal switch (d) Replace turn signal switch.
(S26).
6. Headlight(s) not working, rear (a) Defective headlight bulb(s). (a) Replace bulb(s).
cab.
(c) Faulty headlight switch (S31). (c) Replace switch.
(d) Faulty relay (K26). (d) Replace relay.
7. Front or rear horn does not (a) Blown fuse (F11, 10A) (a) Replace fuse
sound.
(b) Faulty front or rear horn (b) Replace switch(es).
switches (S23 or S14).
(c) Faulty horn(s). (c) Replace horn(s).
(d) Faulty horn relay (K22). (d) Replace horn relay.
CD276 2-2-3
Rev 13
Chapter 2
C. ENGINE
1. Engine does not start (a) Blown fuse (F17, 20A). (a) Replace fuse.
(c) Low battery voltage. (c) Charge batteries.
(d) Faulty master switch (S22). (d) Replace master switch.
(e) Faulty front park brake – on (e) Replace relay.

starter relay (K20).
(f) Faulty starter solenoid relay (f) Replace relay.

(K31).
(g) Faulty engine starter. (g) Repair or replace starter.

Refer to Delco Remy
Service Bulletin in Chapter
6.
2. Engine speed does not reach (a) System needs servicing or (a) Check fluid level and
maximum rpm. linkage in bind. service as required. Bleed
system.
3. Engine increase speed (a) System needs servicing or (a) Check fluid level and
erratically. linkage in bind. service as required. Bleed
system.
4. Engine starts, but remains at (a) System needs servicing or (a) Check fluid level and
idle or a higher speed when linkage in bind. service as required. Bleed
the throttle pedal is system.
depressed.
2-2-4 CD276
Rev 13
Chapter 2
D. TRANSMISSION
1. Transmission does not (a) Parking brake has not been (a) Return shift selector to
change gear ranges when released. Neutral (N) and release
selections are made on shift parking brake.
selector(s).
(b) Faulty parking brake pressure (b) Replace pressure switch.
switch (S26).
(c) Faulty relays K6, K7 and/or (c) Check each relay

K25. individually, and replace as
necessary.
E. CHARGING SYSTEM
1. Batteries not charging. (a) Drive belt slipping. (a) Check and adjust drive
belt tension.
(b) Low battery electrolyte level. (b) Service batteries.
(c) Faulty alternator. (c) Repair or replace

alternator refer to Delco
Remy Service Bulletin in
Chapter 6.
2. Batteries overcharging (a) Faulty alternator. (a) Repair or replace

alternator. Refer to Delco
Remy Service Bulletin in
Chapter 6.
CD276 2-2-5
Rev 13
Chapter 2
F. ACESSORIES
1. Heater/defroster blower not (a) Blown fuse (F10, 30A). (a) Replace fuse.
working.
(b) Faulty blower switch (S4). (b) Replace switch.
(c) Faulty blower motor. (c) Replace motor.
2. Front cab will not raise or (a) Blown fuse (F6, 10A). (a) Replace fuse.
lower.
(b) Faulty cab lift switch (S15). (b) Replace switch.
(c) Faulty cab wand switch(es) (c) Replace switch(es).

(S38, S39 and S40).
(d) Faulty cab raise or lower (d) Replace solenoid.

solenoid.
3. Windshield wipers not (a) Blown fuse (F15, 30A). (a) Replace fuse.
working.
(b) Faulty windshield wiper (b) Replace switch.
switch (S1).
(c) Faulty windshield wiper (c) Replace motor(s).

motor(s).
4. Cab select switch not (a) Blown fuse (F7, 10A). (a) Replace fuse.
functioning (front cab).
(b) Faulty front axle reed switch (b) Replace reed switch.
(S25).
(c) Faulty front axle reed switch (c) Replace relay.

(K11).
(d) Faulty cab select relay (K8). (d) Replace relay.
(e) Faulty front cab selector (e) Replace switch.

switch (S19).
2-2-6 CD276
Rev 13
Chapter 2
5. Cab select switch not (a) Blown fuse (F7, 10A). (a) Replace fuse.
functioning (rear cab).
(b) Faulty rear axle reed switch (b) Replace reed switch.
(S29).
(c) Faulty rear axle reed switch (c) Replace relay.

relay (K12).
(d) Faulty cab select relay (K8). (d) Replace relay.
(e) Faulty rear cab selector (e) Replace switch.

switch (S36).
G. HYDRAULIC PUMP AND RELIEF VALVE
1. Excessive hydraulic oil (a) Main hydraulic pump (a) Adjust main pump and
temperature. pressure setting is too close relief valve to the proper
to relief valve setting. pressure setting.
2. Engine running, steering is (a) Main hydraulic pump (a) Adjust pump pressure to
sluggish, and steering wheel pressure setting is too low. proper setting.
is hard to turn.
(b) Faulty main hydraulic pump. (b) Disconnect and repair or
replace main hydraulic
pump.
(c) Pressure relief valve setting (c) Adjust relief valve pressure
too low, or valve is faulty. to the proper setting or
replace valve.
(d) Orbitrol valve failure. (d) Repair or replace valve.
CD276 2-2-7
Rev 13
Chapter 2
H. SERVICE BRAKES
1. Insufficient braking, no (a) Air trapped in circuit. (a) Bleed the brakes.
braking, brakes do not
release completely, or (b) Brake assembly bypassing oil (b) Repair or replace brake
excessive pedal travel with internally. assembly.
normal hydraulic system and
accumulator pres-sure.
2. Brakes do not perform (a) Service brake linings worn or (a) Inspect, clean, or replace
satisfactorily. contaminated. brake linings.
(b) Faulty calipers. (b) Replace calipers.
3. With engine shut down, (a) Nitrogen gas pressure in (a) Completely discharge
accumulators do not provide accumulator(s) too low or too hydraulic pressure and
at least two braking high.Nitrogen gas leaking pre-charge each
applications before brakes from accumulator(s). accumulator to specified
diminish. pressure. Replace
accumulator(s).
(b) Faulty or contaminated (b) Inspect, clean, or replace

service brake/charging valve. check valves and relief
valve.
2-2-8 CD276
Rev 13
Chapter 2
I. PARKING BRAKES
1. Parking brakes do not (a) Parking brake caliper(s) (a) Adjust caliper(s).
perform satisfactorily. misadjusted.
(b) Parking brake linings worn or (b) Inspect, clean, or replace

contaminated. linings.
(c) Faulty caliper(s). (c) Repair or replace

caliper(s).
2. Parking brakes will not set or (a) Parking brake solenoid valve (a) Inspect, clean, or replace
release with system pressure spool(s) contaminated or valve spool(s).
available. stuck.
(b) Faulty parking brake valve (b) Replace solenoid(s).

solenoid(s).
(c) Faulty parking brake (c) Replace switch(es).

switch(es) (S27 and S24).
(d) Faulty brake caliper(s). (d) Check, clean, repair, or

replace caliper(s).
(e) Parking brake manual release (e) Return the pressure

hand pump has been release lever to the
actuated. rearward position.
(f) Faulty relay (K3). (f) Replace relay.
CD276 2-2-9
Rev 13
Chapter 2
J. FRONT CAB LIFT
1. Cab will not raise/lower, or (a) Cab lift valve spool (a) Inspect, clean, or replace
cab raises very slowly. contaminated or stuck. valve.
(System pressure normal.)
Also Sect. E in Table 2.2.1. (b) Internal leakage of lift cylinder (b) Repair or replace lift
piston seals. cylinder.
(c) Defective cab toggle switch (c) Replace switch.
(d) Detached or loosely attached (d) Attach wiring securely.

wiring at the toggle switch,
unloading valve, or solenoid-
operated directional valve.
(e) Defective solenoid-operated (e) Replace solenoid-operated

unloader valve. unloader valve.
(f) Defective solenoid-operated (f) Replace solenoid-operated

directional valve. directional valve.
(g) Defective double pilot- (g) Replace double-operated

operated check valve check valve.
(h) Leaking hose, fitting or (h) Replace defective hose or

component. component. Tighten fitting,
If leak persists, replace
fitting.
2. Cab lifts slowly with jerky (a) Improperly adjusted or (a) Adjust control valve;
movement or cab lifts to defective control valve. replace if necessary.
quickly.
2-2-10 CD276
Rev 13
Chapter 2
K. STEERING - GENERAL
1. One or more of the following (a) Air in the system. (a) Bleed the system.
symptoms occur with normal
hydraulic pressure available: (b) Loose steering cylinder (b) Repair or replace piston,
soft (spongy) steering, tractor piston, or leakage of cylinder change piston seals, or
does not stay in a straight line piston seals. change cylinders.
(wanders), or slow movement
of steering wheel causes no (c) Worn bearings and pins of (c) Replace bearings and
tractor wheel movement steering axle linkages. pins.
(slip).
(d) Severe wear in orbital (d) Replace orbital steering
steering valves. valves.
2. One or more of the following (a) Faulty or contaminated orbital (a) Inspect, clean, or replace
symptoms occur with normal steering valve. orbital steering valve.
hydraulic pressure available:
slow steering, hard steering, (b) Faulty connection of orbital (b) Repair or replace column.
erratic steering, free steering steering valve and column.
wheel, or locked steering
wheel. (c) Defective steering cylinder. (c) Repair or replace cylinder.
CD276 2-2-11
Rev 13
Chapter 2
L. STEERING - THREE MODE SYSTEM
1. In four-wheel coordinated (a) Front and rear axles not (a) Steer slowly full left until
steering mode, front wheels synchronized. both front and rear axles
and rear wheels do not steer achieve maximum steer
in unison. angles. Steer slowly full
right until both front and
rear axles achieve
maximum steer angles.
(b) Air in the system. (b) Bleed the system.
(c) Excessive internal leak (c) Turn steering wheel for a

through piston seal of one or left turn; if the front wheel
more steering cylinders. steering motion is slower
than the rear wheel
motion, most likely the
front steering cylinder
piston seal is defective and
vice-versa. Identify the
defective cylinder, and
replace the seal or
cylinder.
2. In track steering mode, rear (a) Contaminated or defective (a) Replace double pilot check
wheels do not stay locked in double pilot check valve(s). valves.
the straight-ahead position.
(b) Excessive internal leak (b) Replace seal or steering
through piston seal of rear cylinder.
steering cylinder.
(c) Worn bearings and pins of (c) Replace bearings and pins
steering linkage or as required.
cylinder(s).
3. When changing from (a) Rear axle reed switch (S29) (a) Adjust reed switch.
coordinated or crab steering out of adjustment.
mode to track steering mode
(front cab), rear wheels do (b) Faulty rear axle reed switch (b) Replace reed switch.
not lock in the straight-ahead (S29).
position.
relay (K11).
(d) Faulty Right turn switch (S52) (d) Replace switch
(e) Faulty Left turn switch (S53) (e) Replace switch
2-2-12 CD276
Rev 13
Chapter 2
4. When changing from (a) Front axle reed switch (S25) (a) Adjust the reed switch.
coordinated or crab steering out of adjustment.
mode to track steering mode
(rear cab), front wheels do (b) Faulty front axle reed switch (b) Replace the reed switch.
not lock in the straight-ahead (S25).
position.
relay (K11).
(d) Faulty Right turn switch (d) Replace switch.

(S52).
(e) Faulty Left turn switch (S53). (e) Replace switch.
5. When changing from track to (a) Causes are the same as (a) Corrective actions are the
coordinated or crab steering above and dependent upon same as above.
mode, the change occurs which cab is active.
when the front wheels are not
in the straight-ahead position.
6. (Front cab active.) (a) Blown fuse (F3, 10A). (a) Replace fuse.
Track steering mode is
preselected (by setting the (b) Faulty rear axle reed switch (b) Replace the reed switch.
steering selector switch from (S29).
coordinated or crab to track
position), and the rear wheels (c) Faulty steering selector (c) Replace switch.
have crossed the straight- switch (S14).
ahead position. However, the
steering mode does not (d) Faulty rear axle relay (K12). (d) Replace relay.
change.
(e) Faulty latching relays (K9 and (e) Check each relay and
K10). replace as required.
(f) Faulty solenoid(s) (L13, L14) (f) Replace solenoid(s).

of control valve SV2 (front
axle).
(g) Control valve SV2 spool (g) Inspect, clean, or replace

contaminated or stuck. valve.
CD276 2-2-13
Rev 13
Chapter 2
7. (Rear cab active.) (a) Blown fuse (F3, 10A). (a) Replace fuse.
Track steering mode is pre-
selected (by setting the (b) Faulty front axle reed switch (b) Replace reed switch.
steering selector switch from (S25).
the coordinated or crab to
track position), and the rear (c) Faulty steering selector (c) Replace switch.
wheels have crossed the switch (S14).
straight-ahead position.
However, the steering mode (d) Faulty front axles switch relay (d) Replace relay.
does not change. (K11).
(e) Faulty latching relays (K15 (e) Check each relay and
and K14). replace as required.
Coordinated or crab steering
mode is pre-selected (by (b) Faulty front axle reed switch (b) Replace the reed switch.
setting the steering selector (S25).
switch from track to
coordinated or crab position), (c) Faulty steering selector (c) Replace switch.
and the front wheels have switch (S14).
crossed the straight-ahead
position. However, the (d) Faulty front axle reed switch (d) Replace relay.
steering mode does not relay (K11).
change.
(e) Faulty latching relays (K9 & (e) Check each relay and
(f) Faulty solenoid(s) of control (f) Replace solenoid (s).

valve SV3 (rear axle).

2-2-14 CD276
Rev 13
Chapter 2
9. (Rear cab active.) (a) Blown fuse (F3, 10A). (a) Replace fuse.
Coordinated or crab steering
mode is pre-selected (by (b) Faulty rear axle reed switch (b) Replace the reed switch.
setting the steering selector (S29).
switch from track to
coordinated or crab position), (c) Faulty steering selector (c) Replace switch.
and the front wheels have switch (S34).
crossed the straight-ahead
position. However, the (d) Faulty rear axle reed switch (d) Replace relay.
steering mode does not relay (K12).
change.
(e) Faulty latching relays (K14 (e) Check each relay and
(f) Faulty solenoid(s) of control (f) Replace solenoid(s).

valve SV3 (rear axle).

(h) Faulty Rt. turn switch (S52). (h) Replace switch.
(i) Faulty Left turn switch (S53). (i) Replace switch.
Steering mode does not
change from coordinated to (b) Faulty front axle reed switch (b) Replace the reed switch.
crab or vice-versa. (S29).
(c) Faulty steering selector (c) Replace switch.

switch (S14).
(d) Faulty front axle reed switch (d) Replace relay.

relay (K11).
(e) Faulty latching relays (K9 and (e) Check each relay and
(f) Faulty solenoid(s) of control (f) Replace solenoid(s).

valve SV2 (front axle).

(h) Blown fuse (F12, 10A). (h) Replace fuse.
CD276 2-2-15
Rev 13
Chapter 2
11. (Rear cab active.) (a) Faulty rear steering sensor (a) Replace steering sensor.
(S23).
Steering mode does not
change from coordinated to
crab or vice-versa. (b) Faulty steering selector (b) Replace switch.
switch (S21).
(c) Faulty rear axle relay (K15). (c) Replace relay.
(d) Faulty latching relays (K16 (d) Check each relay and
(e) Control valve SV2 spool (e) Inspect, clean, or replace

12. With a change of steering (a) The spool of solenoid valves (a) Identify the cause, and
mode, the steering wheel SV2 or SV3 is stuck between clean valve, replace
locks. its correct positions, due to solenoid, or replace valve.
contamination or failure of
respective solenoid.
(b) Faulty double pilot check (b) Inspect, clean, or replace

valve(s). valve(s).
13. Hard steering or locked (a) Defective front steering (a) Repair or replace
steering wheel occurs in track cylinder(s). cylinder(s).
steering mode.
(b) The spool of solenoid valves (b) Clean valve, replace
SV2 or SV3 is stuck between solenoid, or replace valve.
its correct position, due to
(c) Faulty or contaminated (c) Inspect, clean, or replace

double pilot check valve(s). valve(s).
14. Hard steering or locked (a) Defective front or rear (a) Repair or replace
steering wheel occurs in steering cylinder(s). cylinder(s).
coordinat-ed or crab steering
modes. (b) The spool of solenoid valves (b) Clean valve, replace
SV2 or SV3 is stuck between solenoid, or replace valve.
its correct position, due to
(c) Faulty or contaminated (c) Inspect, clean, or replace

double pilot check valve(s). valve(s).
2-2-16 CD276
Rev 13
Chapter 2
M. CAB SELECT CIRCUIT
1. With front cab active, cab (a) Blown fuse (F3, 10A). (a) Replace fuse.
select switch is placed in the
rear cab position, but control (b) Faulty front axle reed switch (b) Replace the reed switch.
functions do not transfer to (S25).
the rear cab.
relay (K11).
(d) Faulty cab select switch (d) Replace switch.

(S19).
(e) Faulty latching relay (K8). (e) Replace relay.
(f) Faulty cab select valve (f) Replace solenoid(s).

solenoid (SV1).
(g) Contaminated or stuck cab (g) Inspect, clean, or replace

select valve spool (SV1). valve (SV1).
2. With rear cab active, cab (a) Blown fuse (F3, 10A). (a) Replace fuse.
select switch is placed in the
front cab position, but control (b) Faulty rear axle reed switch (b) Replace the reed switch.
functions do not transfer to (S29).
the front cab.
(c) Faulty rear axle reed switch (c) Replace relay.
relay (K12).
(d) Faulty cab select switch (d) Replace switch.

(S36).
(e) Faulty latching relay (K8). (e) Replace relay.
(f) Faulty cab select valve (f) Replace solenoid(s).

solenoid (SV1).
(g) Contaminated or stuck cab (g) Inspect, clean, or replace

select valve spool (SV1). valve (SV1).
CD276 2-2-17
Rev 13
Chapter 2
2-2-18 CD276
Rev 13
Chapter 2
N. WIRING DIAGRAMS
FRONT CAB CONTROL PANEL
(+) REAR VIEW
(-) EMERGENCY
ENGINE STOP
CONTACT ARRANGEMENT SWITCH
FOR LAMPS DS1-12 S21
DS6 DS5 14 GA. DS4 DS3 DS2 DS1

(+) -234/P21 E (+) -235/S7 1 (+) -101/DS2(+) (+) -159/P8 2 (+) -101/DS4(+) (+) -229/P21 B
S2 14 GA. S1 14 GA. (+) -101/DS8(+) (+) -229/P43 6
(+) -234/P43 5 (+) -101/DS12(+)
1 -160/B2 -- 1 -118/P30 H (-) -GND2/DS5 (-) (-) -GND2/DS6(-) (-) -140/P8 10 (-) -GND2/DS5(-) (-) -131/P8 6 (-) -GND2/S4 9 (S) (P)
5 -115/P31 P 2 -118/P31 H (-) -GND2/S11 9 (-) -GND2/DS3(-) (-) -140/P7 5 (-) -GND2/DS1(-) (-) -131/P7 7 (-) -GND2/DS3(-)
S3 5 -115/S1 3 3 -115/P30 P E D
RIGHT TURN HI BEAM TRANSMISSION GLOW PLUG LOW OIL LEFT TURN
123/P28 E
101/P28-A
RESERVED 9 -GND2/S13 9 3 -115/S2 5 D E
2 1 INDICATOR INDICATOR HI OIL TEMP INDICATOR PRESSURE INDICATOR F
9 -GND2/S6 9 5 -119/P30 L LIGHT LIGHT INDICATOR LIGHT C C F
4 3 10 -224/S12 10 6 -119/P31 L INDICATOR LIGHT
LIGHT G B B G
6 5 10 -224/S6 10 9 -GND2/S11 9 LIGHT
8 7 9 -GND2/S12 9
H A A H
WINDSHIELD 10 -224/S11 10
10 9 WASHER 10 -224/S4 10 DS12 DS11 DS10 DS9 DS8 DS7 P28
CONTACT SWITCH (+) -101/DS4(+) (+) -105/S27-NO3 RESERVED RESERVED (+) -101/DS2(+) (+) -101/DS8(+) S20
101/DS7(+) A -101/S21 1
ARRANGEMENT FOR WIPER (+) -10 /P4 3 (+) -105/P7 3 REFER TO SH. 3 (+) -101/DS7(+) (+) -101/P28 A 112/P4 1 B -112/S22 BAT
SWITCH SOCKETS SWITCH (-) -129/P8 1 (-) -182/K23 86 ZONE C/B8 FOR (-) -133/P8 8 (-) -134/P8 9 121/S27 NO3 C -121/S22 ST CR16 2
(S1-15) (-) -129/P7 6 MATING CONNECTOR (-) -133/P7 8 (-) -134/P7 9 125/P4 2 D -125/S22 IGN 3 -226/P28 H
4
S7 14 GA. S6 14 GA. S5 PARK BRAKE ENGINE HIGH LOW COOLANT
123/P8 3 E -123/S21
5 -224/P28 G
RESERVED GENERATOR P19 S4 14 GA. 223/S6 5 F -223/S20 6
1 -235/P2 D 1 -226/S7 3 NO CHARGE APPLIED COOLANT TEMP LEVEL 224/S10 10 G -224/S20 5 PARK 6 -223/P28 F
1 -235/DS5(-) 1 -226/P28 H INDICATOR INDICATOR 1 -GND1/GND1 INDICATOR INDICATOR 1 -243/P44 A 226/S6 1 H -226/S20 3 LIGHT
(P) (S) LIGHT LIGHT 3 -224/S15 10 LIGHT LIGHT 3 -110/P4 8
DASH LIGHT
3 -226/S6 1 5 -223/P28 F BLOCKING SWITCH
3 -226/P7 18 5 -223/S12 5 4 -130/P8 5 5 -222/P44 B 14 GA. IGN/LIGHT 14 GA.
5 -132/P8 7 9 -GND2/S10 9 RECITFIER
C D A F 5 -230/P7 13 9 -GND2/S2 9 SWITCH
9 -GND2/S13 9 9 -GND2/S12 9 6 -135/P8 18 9 -GND2/DS1 (-)
7 -136/P8 11 10 -224/S10 10 CONNECTOR
9 -GND2/S14 9 10 -224/S2 10
B E B E 10 -224/S13 10 10 -224/S11 10 8 -139/P8 19 10 -224/S1 10
10 -224/S15 10 11 -137/P8 12
12 -138/P8 17 BLOWER FAN
C D HIGH-LO PARK LIGHT SWITCH
STEER MODE
A F BEAM SWITCH SWITCH INSTRUMENT
GAUGES
INDICATOR LIGHTS P29 CONNECTOR
DS21 S14/DS32 S13 14 GA. S12 14 GA. S11 14 GA. S22
COORD
RED A -166/P9 D (S) S10 14 GA. ST -121/P28 C REFER TO SH.3,
B -168/P9 F 2 -202/P9 G 1 -242/FL2 X 1 -225/P8 14 1 -169/P21 F S8
BLK 3 -103/P9 B 5 -113/S11 5 5 -223/S6 5 5 -113 /S10 5 IGN -125/GA1 ZONE D4 FOR
C -203 /P9 A 1 -238/P8 15 ACC
CONTINUATION
DS22 D -GND2/K25 85 3 -103/P4 11 5 -113/P4 12 5 -223/P7 15 5 -113 /S13 5 5 -113/P7 25
ST IGN -125/P28 D
TRACK RED D -GND2/P29 E 6 -206/P9 C 9 -GND2/S7 9 9 -GND2/S6 9 9 -GND2/S1 9 5 -113/S11 5 BAT -112/P28 B
8 -198/P9 E GND 14 GA.
BLK E -GND2/P29 D
9 -GND2/S15 9
9 -GND2/S2 9
10 -224/S7 10
9 -GND2/S1 9
10 -224/S2 10
9 -GND2/DS6 (-)
10 -224/S1 10
9 -GND2/S4 9 IGN BAT
ACC
DS23 E -GND2/P29 F 10 -224/S4 10 GND
CRAB RED F -GND2/P29 E 9 -GND2/S7 9 10 -224/S12 10 10 -224/S13 10 10 -224/S6 10 10 -224/P28 G REAR WINDOW STOP,
F -GND2/S15 9 10 -215/P9 H RUN, START
BLK BEACON REAR HITCH FRONT HITCH EMERGENCY DEFROSTER TOUCH
SWITCH
STEER MODE INDICATOR AXLE CENTER IND.LIGHT STEERING PAD SWITCH
SWITCH LIGHT SWITCH LIGHT SWITCH
LIGHTS CONNECTOR STEER MODE SEL.SWITCH SWITCH
L
H
(P) (S) P
B4 P30 S 4 WIRE
ZF FRONT CAB X
X CORD (REF)
SPL234
X
S15 SHIFTER ASSEMBLY P2 S

234/P8 24 1 -19/P20 6 1 -JPR/P2 7 P -115/S1 3
A1 2 -246/P7 27 K36 FRONT CAB GND1
1 -19/P104 B M H -118/S1 1 -GND1/P24 1
3 -106/P4 15 3 -147/K24 86 L.H.
FOR WIRING L -119/S1 5 87 30 -104/P4 18 -GND1/K36 85
7 -15/P20 5 4 -148/K21 86 30 85 -GND1/GND1 GROUND STUD -GND1/P19 1
7 -15/P51 E SEE ZF 5 -102/P24 3 14 GA. 87 -247/P58
9 -GND2/P29 F DRAWING 6 -GND1/P24 1 -GND1/P32 E REFER TO SH.2,
WINDSHIELD WIPER 14 GA.
9 -GND2/S14 9 7 -JPR/P2 1 85 14 GA. ZONE F7 FOR
MOTOR/CONNECTOR,
10 -224/S7 10 LEFT HAND CONTINUATION
10 -224/P19 3 ZF FRONT CAB TIMER (11 MIN) REAR WINDOW
SHIFTER CONNECTOR
(CAB) DEFROSTER RELAY
CAB LIFT NOTE:
SWITCH PIN (S) P52
NUMBERS TURN SIGNAL
4 3 2 1 1- 149/P7 11
DO NOT SWITCH/CONNECTOR
S27 CORRESPOND 8 7 6 5 FRT SHIFTER UPSHIFT P43
INTERLOCK CONNECTOR2 1
II I
P24 1 GRN/BLK
NC1 -105/P4 6 (S) 3 GRY
NC1 -105/S27 NO3 1 -GND1/P2 6
2
1 2 NC NC2 -193/P7 20 1 -GND1/GND1
2 (S) (P) 4 BLK S26
234/DS6 (+) 5 RED
NO3 -121/P28 C 2 -150/P8 21
4 229/DS1 (+) 6 GRN
4 3 2 1
3 4 NO NO4 -122/K20 86 3 -102/P2 5
6 BLU
NO3 -105/S27 NC1 3 -102/SPL102
6 8 7 6 5 P1
A4 (P) YEL
3 4 NO NO3 -105/DS11(+) 5 -245/P7 10
1 1 (S)
NO4 -192/P7 4 6 -161/K25 87a
3 2 -145/P15 A
14 GA. 3 -144/P15 E TO P15 & GND3,
PARK BRAKE 4 -143/P15 D REFER TO SH. 2,
SWITCH CONTROL UNIT (DOWNSHIFT)
LOCK-UP ASSEMBLY/ 5 ZONE B3 FOR
6 -GND3 /GND3 CONTINUATION
CONNECTOR 7 -141/P15 B 14 GA.
8 -142/K25 86 228/FL1 L
8 -142/P15 C
(S) P8 ZF FRONT CAB S23
(S) SHIFTER CONNECTOR NOT USED WITH DUAL
P7 P7 P8 (TRANSMISSION) 181/K22 86
CAB OPTION. REFER TO
1 -170/K21 87 1 -129/DS12(-) SH. 4, ZONE E8 FOR DUAL H1
NOT USED WITH 2 -173/K20 30 2 -159/DS3 (+) CAB MATING CONNECTOR P20 MOVE FROM P20 2 ON HORN
DUAL CAB OPTION 3 -105/DS11(+) 3 -123/P28 E 14 GA. OPEN CAB UNITS ONLY
4 -192/S27 NO4 SWITCH
REFER TO SH. 4, 4 -101/SPL101
5 -140/DS4 (-) 5 -130/P19 4 24 24/K22 87
ZONE H7 FOR
DUAL CAB MATING 6 -129/DS12(-) 6 -131/DS2(-) (P)
7 -131/DS2(-) 7 -132/P19 5 GND4 19 8 9
CONNECTOR 8 -133/DS8 (-) LIFT CAB VALVES
8 -133/DS8 (-) GND4/P104-A VEHICLE
14 GA. 9 -134/DS7(-) 9 -134/DS7 (-) GND4/P105-A GROUND STUD 18 7 2 10
10 -245/P24 5 10 -140/DS4 (-) HORN,
11 -149/P52 1 11 -136/P19 7 FRONT UNDER 17 6 1 3 11
12 -102/K25 30 12 -137/P19 11 (P) FLOOR
13 -230/S7 5 13 -221/SPL221
(S) FRONT AXLE
14 -231/P21 C BULKHEAD 16 5 4 12
14 -225/S12 1 (S)
15 -223/S12 5 15 -238/S10 1
16 -114/P4 14 16 -227/K24 30 15 14 13
17 -221/P21 A 17 -138/P19 12 P104 L19 CAB LOWER FUSE BOX
18 -226/S7 3 18 -135/P19 6 GND4/GND4 A RED RED
REFER TO SH. 3 P4
19 -171/K23 85 SOLENOID VALVE/
19 -139/P19 8 19/S15 1 CONNECTOR (S) FOR BOX WIRING
20 -193/S27 NC2 20 -182/K23 86
B (P) 1 -112/P28 B
21 -196/P9 M & P4 MATING 2 -125/P28 D
21 -150/P24 2 REFER TO SH. 3, REFER TO SH.3,
22 -107/P4 7 CONNECTOR 3 -101/DS12(+)
23 -181 K23 30
REFER TO SH.2 22 -229/SPL229 P105 L18 CAB RAISE ZONE C1 & E1 FOR C D A F ZONE E1 & C2 4 -GND2/GND2
JPR ZONE F7 FOR 23 -109/K24 87 GND4/GND4 A RED RED MATING CONNECTOR FL1 5 -102/K21 30
24 -101/SPL101 24 -234/SPL234 SOLENOID VALVE/ FOR CONTINUATION
25 -113/S10 5 MATING CONNECTOR25 18/P20 10 B P20 L 228/S26 YEL B E B E 6 -105/S27 NC1
-178/K20 87 CONNECTOR 109/K24 87
26 -177/K21 87a 1 -111/K22 85 7 -107/P7 22
14 GA. X 109/P4 16 L 8 -110/S4 3
27 -246/P2 2 2 - 24/K22 87 A F C D 14 GA.
MAIN HARNESS TURN SIGNAL H 10 -115/P31 P
14 GA. 4 -115/SPL115 CLOSED CAB
REAR CAB INTERFACE 5 - 15/S15 7 11 -103/S14 3
CONNECTOR (S) (P) LIGHTS FLASHER 14 GA. P44 P UNITS ONLY 12 -113/S13 5
INTERFACE 6 - 19/S15 1 ORN P31
CONNECTOR REFER TO SH.2 (S) 7 - 19/SPL19 A -243/S4 1 B3 S 13 -111/K22 30
244/P51 D + CAB 14 -114/P7 16
ZONE D7 & F8 8 -106/SPL106 242/S13 1 RED X X
AL1 RAISE/LOWER P58 B -222/S4 5 15 -106/S15 3
SPL229 M
X
9 -106/SPL106 FL2 S GND2
B(-)/A10
FOR P9 & P21 ALARM -247/K36 87 16 -109/FL1 X
B(-)/H3
229/P8 22 MATING CONNECTOR 10 - 18/P105-B C 14 GA. P -115/S2 5 -GND2/K23 87
11 -264/FL2 L BLK 18 -104/K36 30
REAR WINDOW BLK P -115/P4 10 -GND2/P4 4
12 -110/SPL110 264/P20 11 A6 D
DEFROSTER M H -118/S1 2 -GND2/K20 85 14 GA.
CONNECTOR 14 GA. CEILING 14 GA. E L -119/S1 6 -GND2/P44 F
14 GA. BEACON LIGHT
P9 P21 INTERFACE BLK FRONT CAB,
K25 K24 K23 K22 K21 K20 FLASHER (FLASHING) F -GND2/GND2 14 GA. R.H.
A -203/P29 C A -221/P7 17 CONNECTOR
B -103/S14 3 B -229/DS1(+) 87a - 161/P24 6 30 -227/P8 16 30 -181/P7 23 30 -111/P4 13 87a - 177/P51 G 30 -173/P7 2 WINDSHIELD WIPER GROUND STUD
C -206/S14 6 C -231/P7 14 30 - 102/P7 12 30 -181/K22 86 30 -111/K2 285 87a - 177/P7 26 CAB HEATER - FAN MOTOR/CONNECTOR,
SPL102 85 -GND2/K21 85 85 -GND2/GND2
X
D -166/P29 A D -235/S7 1 30 - 102/K21 30 85 -GND2/K25 85 85 -171/P51 B 85 -111/K22 30 30 - 102/K25 30 85 -GND2/K21 85 ASSEMBLY/CONNECTOR RIGHT HAND
102/P24 3 E -198/S14 8 E -234/DS6(+) 85 - GND2/P29 D 86 -147/P2 3 85 -171/P7 19 85 -111/P20 1 30 - 102/P4 5 86 -122/S27 NO4 SPL115
X
F -168/P29 B F -169/S11 1 85 - GND2/K24 85 87 -109/P8 23 86 -182/DS11(-) 86 -181/K23 30 85 - GND2/K24 85 87 -178/P8 25
G -202/S14 2 86 - 142/P1 8 87 -109/FL1 X 86 -182/P8 20 86 -181/S23 85 - GND2/K20 85 115/P20 4 SP10
H -215/S14 10 FRONT 164/SPL164 87 -GND2/GND2 87 -24/P20 2 86 - 148/P2 4 PARK BRAKE 14 GA.
14 GA. LIGHTS SPL19 19/P51 F TAPED BACK
X
SPL221 M -196/P7 21 87 - 170/P7 1 ON-STARTER
X
A F LOCK-UP UNIT 14 GA. 14 GA. 108/SP9 AND SEALED

(S) CONNECTOR SHIFTER TRANSM NOT HORN 19/P20 7 116/SP9
221/P8 13 STEERING DOWNSHIFT RELAY ENABLE RELAY WITH HEAT
BACK-UP IN N-, PARK RELAY SHIFTER IN SP9/SP9
160/S2 1
B E TO SH. 4, ZONE D5
P INTERFACE BRAKE APPLIED NEUTRAL SHRINK
E N DUAL CAB ONLY RELAY
CONNECTOR (S) RELAY SPL110 110/P20 12 14 GA.
X
C D RELAY
D NOTE: WIRE 164 NOT USED
F
A C
M
ON SINGLE CAB UNITS. 14 GA.
CAB WIRING
WIRE 142 NOT USED ON
G
B
L
DUAL CAB UNITS M B2
(TAPED BACK) WINDSHIELD WASHER
SPL106 106/P20 8
X
H K
PUMP MOTOR SEE SHEET 5 FOR NOTES
J
SPL101
X 106/P20 9
SPL101/P8 4 SPL101/P7 24 CR9-CR12

CONTACT ARRANGEMENT
A
TAPED BACK FOR RELAY SOCKET

P51
B
108/SP10 AND SEALED K20-25

116/SP10
C
B -171/K23 85 87
SP9/SP10 WITH HEAT C -JPR/P51 D 86
D
SP9 SHRINK 9 10 11 12 D -JPR/P51 C

14 GA. D -244/AL1(+) 85 87a
E -15/S15 7 30
DIODE
E
F -19/SPL19
BOARD
F
INSIDE
G -177/K21 87a
Figure 2-1. Wiring Diagram
G
P51 DIODE MODULE

H
CONNECTOR
BLOCKING
RECTIFIER
(S) Sheet 1 of 6
P51
CD276 2-2-19
Rev 13
Chapter 2
P17
P4
P40
P18
P9 P22
P20
P8
P39
P13
P32
P42
P21
(S) P P7
P33
E N
DS35
BLU - TURN
YEL - PARK
WHT - GND
HEADLIGHT
GRN - LO F
D
M P15
(P)
RED - HI
A C
P1
G L
DS37
B
P19 P2
H K
TURN LIGHT P13 J
DS69 P32 R.H. A -203 /P9 A

PARK LIGHT A B C D E HEADLIGHT B -188 /P109 A
CONNECTOR C -206 /P9 C P28 HARNESS AL2
STEERING BOX BACK-UP
(S) SEE SH.3 FOR
D -166 /P9 D
E -198 /P9 E
INTERCONNECTING DIAGRAM
ALARM
GND1 /GND1
SINGLE CAB
SPARE BOX & P13 F -168 /P9 F
235 /P21 D
231 /P21 C
234 /P21 E
221 /P21 A
MATING CONNECTOR G -202 /P9 G

SP2 /P21
H -215 /SPL215 232 /P40 A 227

REFER TO J -166 /P54 A
SH.4 FOR K -203 /P54 B
L -191 /P42 B
SPL232 X P40RED LIGHTS
CONTINUATION M -GND3 /GND3 2/0 BLK 233 /P45 B
232 /SPL232 A BRAKE DS58
X
14 GA SPL233
ZONE C6
ZONE D3
ZONE E8
BLK /E3
ZONE J5
14 GA. BLK
227 /P40 B 227 /SPL227 B
YEL
BACK-UP DS60
SPL227 234 /P22 E
X
14 GA.
199 /S41 NC K19 221 /P40 D
C
BRN
TURN DS57
SP4 SP6 /SP3 EMERGENCY STEERING 221 /SPL221 D TAIL DS59
X
SPL221 221 /P33 D P22 SPL221
X
DUAL CAB 14 GA. PUMP MOTOR/RELAY 14 GA GND8 /SPLGND8 E WHT GROUND

UNITS ONLY 2/0 BLK 232 /S43 NC A 232 /P39 A (P)
GND3 /K29 85 B5 14 GA R.H. REAR
GND3 /P10 B
GND3 /P15 F
(S)
GND3 /P1 6
BLK 227 /P8 16 B 227 /P39 B LIGHTS
SPLGND1 GND1 /P33 E CONNECTOR
X
A
(P) F F (S)A ENGINE BAY 229 /P8 22 C 229 /P39 C
R.H. WELDMENT 221 /P8 13 D 221 /P39 D A E
E A
A
B
E
C
D
F
234 /P8 24 234 /P40 C
D
C
E
F
E
B
A
(P) 233 /S34 10 F 233 /P46 B 14 GA P45 DS66
P42 REAR LIGHTS A 14 GA BLK DUAL CAB
UNITS ONLY
C D 14 GA. A A A GND8 /SPLGND8 A
JPR A -103 /SPL103
B -191 /P13 L
(S) (P) B B CONNECTORB B
233 /SPL233 B
BLK
B E
-GND3 /P13 M C C
C C
GND3 -GND3 /P109 C C -188 /SPL188

D -215 /SPL215
P100 L10 PARKING BRAKE D
E
D
D D
RIGHT REAR
(P)EF (S) (P)
E E
(P) (S) -GND3 /P38 F
SP2 /P32 A F STEERING -GND3 /P48 2 JPR E -123 /P8 3 GND6 /GND6 A RED
RED
SET SOLENOID F F
(S) F HEADLIGHT
SP3 /P33 BOX GROUND -GND3 /P15 F F -124 /P17 7 196 /P9 M B VALVE/CONNECTOR CONNECTOR
STUD
14 GA. P21 -GND3 /P1 6 NOT USED WITH DUAL REAR CAB WELDMENT ON REAR
P34 14 GA. 221 /P32 D A
FRONT AXLE
FRONT WELDMENT
CAB OR HEATER OPTIONS.
REFER TO SH.4, ZONE E5 STEERING INTERFACE P103 L11 PARKING BRAKE
REFER TO SH.4,
ZONE F3 FOR L.H. SIDE CAB RAISER
RED REAR (SINGLE
229 /P33 C B FOR DUAL CAB UNITS & CONNECTOR GND6 /SPLGND6 A RED RELEASE SOLENOID CONTINUATION (DUAL CAB
169 /P21 F 231 /P32 B C REFER TO SH.1, 196 /SPL196 B 14 GA CAB UNITS) UNITS ONLY)
ZONE B8 FOR SH.3, ZONE G3 FOR A8 VALVE/CONNECTOR
231 /P33 B C HEATER/SINGLE CAB DUAL CAB UNITS ONLY GND8 /P39 E GND8
FRONT HITCH 235 /P32 A D MATING NOT USED WITH ECU GLOW
LIGHT CONNECTOR 235 /P33 A D CONNECTOR DUAL CAB UNITS MATING CONNECTOR
PLUG ASSEMBLY/CONNECTOR
(S) (P)DUAL CAB REFER TO SH4, GND8 /P46 A REAR CAB/REAR
BLK 234 /P32 C E ZONE B1 FOR LIGHTS GROUND STUD
UNITS ONLY GND8 /P5 6
169 /P34 F TO GND1 - SPL215 6 GA. ECU S28 CONTINUATION
P39RED LIGHTS
- REFER TO SH.1 (P) 215 /P13 H P41
X
DS39 FRONT LIGHTS ZONE F1 FOR BLK /CB1 182 /P12 5 DUAL CAB
UNITS ONLY 232 /P22 A A BRAKE DS63
FRONT HITCH CONNECTOR CONTINUATION 1 -GND6 /GND6 182 /P8 20 BLK
8 REFER TO SH.4,
LIGHT GND1 /P32 E 2 GND6 /GND6 ZONE G5 FOR
227 /P22 B B
GRN
BACK-UP DS61
9 3 -101 /P8 4
PARKING BRAKE CONNECTION. 229 /P22 C C
BRN
TURN DS64
P8 4 -127 /P18 2
PRESSURE SWITCH 221 /P22 D D TAIL DS62
MAIN HARNESS 5 -159 /P8 2 WHT
BLK /E4 GND8 /GND8 E GROUND
FRONT OF TRACTOR
INTERFACE
CONNECTOR (REAR) 14 GA L.H. REAR
1 -129 /P17 2
(P) (S) (S) LIGHTS (P)
14 GA.
2 -159 /P41 5 CONNECTOR
SPLGND8
GND1 /SPLGND1
3 -123 /P42 E COORD L13

GND8 /P40 E
X
4 -101 /P41 3
SP3 /P21
E A
P54
221 /SPL221
5 -130 /P17 5 GND8 /P45 A A E

235 /P21 D
231 /P21 C
229 /P21 B
6 -131 /P17 6 GRN A -166 /P13 J P46 DS65

7 -132 /P17 3 WHT B -203 /P13 K 14 GA 14 GA DUAL CAB
8 -133 /P17 4 A BLK
A E (S) 9 -134 /P48 3 K31 COIL NC BLK C -GND6 /GND6 GND8 /GND8 A UNITS ONLY
233 /P22 F B
BLK
SPARE 10 -140 /S42
11 -136 /P17 1 COM B SELECT VALVE REFER TO SH.4,
12 -137 /P16 14 GA. SOLENOID/ LEFT REAR
A B C D E P33 L.H. 13 -221 /P22 D COIL NO CRAB L14 CONNECTOR
ZONE F3 FOR
CONTINUATION
(S) HEADLIGHT (P)
14 -225 /P47 CONNECTOR
HEADLIGHT
BLU - TURN
15 -238 /S41 C
YEL - PARK
WHT - GND
STARTER SOLENOID 238 /S35 1

CONNECTOR 16 -227 /P22 B GND6
GRN - LO
AUX. RELAY/
RED - HI
DS34 REFER TO SH.1, 17 -138 /P16

E (P) A P38 A C D E F /CONNECTOR SPLGND6 DUAL CAB UNITS ONLY STEERING VALVES DUAL CAB UNITS ONLY
HEADLIGHT ZONE D7 FOR 18 -135 /R5
MATING 19 -139 /R3 GND6 /P103 A GND6 /P100 A GROUND STUD GND6 /P50 A REFER TO SH.4,
REAR OF TRACTOR
S41
GND3 /GND3
DS36 CONNECTOR 20 -182 /S28 C 14 GA. GND6 /P108 C GND6 /P55 C ZONE C4/3 FOR
126 /F17 A
178 /P8 25
127 /P18 1
TURN LIGHT 21 -150 /P23 238 /P8 15 C GND6 /P54 C GND6 /P56 C CONTINUATION
22 -229 /P22 C GND6 /R5
DS70 23 -109 /S43 C 199 /K19 NC GND6 /S28 NC
PARK LIGHT 24 -234 /P22 E GND6 /P41 1
25 -178 /P38 D EMERG.STEERING GND6 /P23 SP8 /SP3
REFER TO SH.1, 215 /P42 D PRESSURE SWITCH SP5 SP7 /SP3
ZONE B8 FOR SP3 SP6 /SP4
SP7 /SP5
ENGINE BAY
MATING CONNECTOR 14 GA. R.H. 14 GA.
SP8 /SP5 103 /P42 A WELDMENT
P9 14 GA. SPL188 SPL103 SPL196
STEERING X X X X X
-196 /P103 B
INTERFACE SPL103 SPL215 F17 DUAL CAB UNITS ONLY
-135 /P8 18
CONNECTOR STARTER
A -203 /P13 A
188 /P42 C BLK /A8 9 S43 FUSE, 20A
MOVE TO A9. REFER TO
B -103 /P108 B P18 6 GA. ENGINE TRANSMISSION BRAKE PRESS. SH.4, ZONE C1 FOR
C -206 /P13 C
14 GA. C NC SWITCH (BRAKE R5 DETAILS.
D -166 /P13 D 1 -127 /P38 E E4 GLOW PLUG 139 /P8 19 LIGHTS) FUEL LEVEL
E -198 /P13 E 1 -127 /P18 2 POWER STUD R3 14 GA. SENDER
F -168 /P13 F L7 2 -127 /P18 1 TRANSM. 14 GA. P47
G -202 /P13 G 2 -127 /P41 4 TEMP. 232 /P22 A BLK
SENSOR 6 GA 225 /P8 14
C -GND6 /GND6
ENGINE
C -GND3 /GND3
H -215 /P108 A 109 /P8 23

B -103 /SPL103
M -196 /P100 B
A -188 /P13 B
PLUG REAR HITCH

P23/R2
BLK A -215 /P9 H

-103 /P9 B
G1 2/0 BLK 14 GA.
P (P) (P) CONNECTOR
(YEL) (S) B+ TURBINE SPEED GND6 /GND6 LIGHT/CONNECTOR
DS68
126 /P38 A
N E
(ZF) SENSOR/ 150 /P8 21
G1 W
P17 1 -136 /P8 11
GENERATOR, CONNECTOR
GND6 /GND6
(P)
BLK /A8 8
D
M F
G1 D+ 2 -129 /P8 1 12VDC, 95A
BLK /K19
C A
R4 1 3 -132 /P8 7 P16/R6 (S)
137 /P8 12 P108
WHT B
L
B
G
P109 (S) R4 2 4 -133 /P8 8
SPEED BLK /E1 REFER TO (S)
R7 G 5 -130 /P8 5 BLK 138 /P8 17 SH. 3,
RED
WHT
FRONT AXLE
RED
REAR AXLE
BLK
K
J
H
R7 WK 6 -131 /P8 6 SENSOR ZONE G5
REED SWITCH/ L6 1 REED SWITCH/
CONNECTOR (P) 7 -124 /P42 F 6 GA.
S42 140 /P8 10 6 GA. CONTINUATION CONNECTOR
S25 ENGINE (S) (P)
(P) PLUG TRANSM.
HIGH TEMP CB1 CB2
CONNECTOR B1 A7 SWITCH A3 GLOW 120A 120A MAIN CIRCUIT S29
R1 (L1-5)
PLUG BREAKER, 120A
L17
P48 REFER TO ZF CIRCUIT WHT /F17
REFER TO DEUTZ ENGINE TRANSM.FOR INTERNAL BREAKER,
2 -GND3 /GND3 M WIRING OF L1-5 & P15. 120A 14 GA
WIRING FOR INTERNAL WIRING 3 -134 /P8 9 TRANSM. VALVE BODY
OF A7, B1, G1, GP1-6, L6, L7, (S) E2 ASSEMBLY/CONNECTOR 6 GA BLK WELDMENT WIRING
L17, P17, P18, R4, AND R7. ENGINE
ENG.COOLANT LEVEL POWER STARTER
MOTOR ASM.
P15 A B C D E F E3 BATTERY POWER STUD
SENSOR/CONNECTOR STUD (SOL./MOTOR)
2/0 BLK SEE SHEET 5 FOR NOTES
ENGINE
FLYWHEEL
HOUSING 2/0 GA. BLK - -
GND3 /GND3
+ +
2/0 GA. BLK (S)
BT1 BT2
145 /P1 2
141 /P1 7
142 /P1 8
143 /P1 4
144 /P1 3
BATTERY, BATTERY,
12 VOLTS 12 VOLTS
2/0 BLK
ENGINE BAY
R.H. WELDMENT
GND7
NOT USED WITH DUAL
BATTERY
GROUND STUD
WELDMENT Figure 2-1. Wiring Diagram
TO P1, REFER TO
SH.1, ZONE E6
FOR CONTINUATION
CAB OPTION. REFER
TO SH. 4 FOR DUAL
CAB UNIT WIRING.
Sheet 2 of 6
2-2-20 CD276
Rev 13
Chapter 2
(S)
K30
FUSEHOLDER(S) P4
F16 F12 F8 F4
F15 F11 F7 F3
F14 F10 F6 F2
F13 F9 F5 F1
FUSES FUSES FUSES FUSES
E1
FUSE BOX WIRING
P26 (S)
(P)
K9 K10 K11 K12
CR1-4
P13
P26
SEE SHEET 5 FOR NOTES

HYD. STEERING CONTROL BOX WIRING - SINGLE CAB CONTROLS

Sheet 3 of 6
CD276 2-2-21
Rev 13
Chapter 2
K35 P61
TB1
(P)
P60 COLD WEATHER START ASSISTANCE

(S)
DS14 GA3/DS16 GA2/DS15 GA1/DS33

DS13
(P)
DS33 P42 A11
GA3 GA2
DS16 DS15 DS71
S38 DS38
H3 B6
P19 DS20
DS18 DS17 DS19
SPL24
X
GA5/DS18 GA4/DS17
SPLB(-)
X
GA7/DS20 GA6/DS19
GA4
(P)
P20
DS17
B8
SPL19
X
CLOSED CAB WIRING
SPL262
X
CONTROL PANEL GAUGES WIRING
SPL16
X
(P)
SPL2
X
H2
S40 S39 P58
B7
A10
FRONT CLOSED CAB WIRING

Sheet 4 of 6
2-2-22 CD276
Rev 13
Chapter 2
H
J X
K W
B G
L V
C A F
M U
D E
N T
GEN NO LOW OIL TRANS.HI
CHARGE PRESSURE OIL TEMP TAPED BACK
P S INDICATOR INDICATOR INDICATOR
R AND SEALED
LIGHT LIGHT LIGHT WITH HEAT
14 GA. SHRINK
A -155 /P5 2 TO GND3, REFER

B -GND3/GND3 TO SH.2, ZONE G7
F -153 /P5 4 FOR CONTINUATION
H -154 /P5 3
CONTROL BOX CONNECTOR
SP4 /SP1
SP5 /SP1
101 /P7 24
101 /DS43
101 /DS44
101 /DS43
101 /DS44
J -151 /P5 7
129 /P7 6
131 /P7 7
140 /P7 5
K -152 /P5 8
L -158 /P6 4
M -145 /P15 A 1 2 NC
N -162 /P15 E
P -163 /P15 D 14 GA.
3 4 NO
R -165 /P15 B
S -164 /P15 C
T -141 /P1 7 NC1 -105 /P7 3
U -142 /P1 8 NC1 -105 /S24 NO4
101 /DS40(+)
101 /DS41(+)
101 /DS41(+)
101 /DS42(+)
V -143 /P1 4 NC2 -194 /P12 3
134 /P7 9
133 /P7 8
W -144 /P1 3 NO3 -195 /P12 4
X -145 /P1 2 NO4 -105 /S24 NC1
CONTROL BOX
REFER TO SH.5 PARK BRAKE
1 -170 /P12 27 FOR BOX WIRING SWITCH
10 9
2 -173 /P12 15 & P10 & P12
3 -105 /S24 NC1 MATING
4 -192 /P12 25 CONTACT ARRANGEMENT
CONNECTOR FOR SWITCH SOCKETS
5 -140 /DS42 (-) (S31-34)
6 -129 /DS40 (-) 1 -193 /P7 20
7 -131 /DS41 (-) 2 -196 /P7 21 LOW COOLANT ENG HI
8 -133 /DS44 (-) 3 -194 /S24 NC2 LEVEL IND. COOLANT TEMP
9 -134 /DS43 (-) 4 -195 /S24 NO3 TO S28, REFER LIGHT IND.LIGHT
10 -245 /P57 E 5 -182 /S28 TO SH.2, ZONE F3
CONTROL BOX CAB SELECT CONNECTOR

11 -149 /K29 87a 6 -171 /P7 19 FOR CONTINUATION
12 -102 /K29 30 7 -180 /P37 D
13 -230 /K28 87a 8 -179 /P37 E RED
14 -231 /K28 30 9 -179 /P35 E (P) (S)
15 -223 /K26 87a 10 -176 /P37 C INDICATOR LIGHTS
16 -114 /K26 30 11 -176 /P35 C E D
17 -221 /K27 30 14 GA. 12 -175 /P37 B YEL YEL D E
REFER TO SH.1,
18 -226 /K27 87a 13 -175 /P35 B 1 -233 /S32 10 1 -241 /A9 AC R
C F F C
19 -171 /P12 6 14 -183 /P14 A 1 -233 /S31 10 5 -240 /K28 87 G B
ZONE D8 FOR B G
20 -193 /P12 1 15 -173 /P7 2 5 -240 /S32 5 5 -240 /S31 5
MATING 21 -196 /P12 2 16 -107 /P7 22 5 -240 /DS67(+) 9 -GND8/S35 9 A H H A
124 /P42 F
CONNECTOR
123 /P42 E
22 -107 /P12 16 17 -172 /P37 A 9 -GND8/S34 9 9 -GND8/S34 9
23 -181 /S37 18 -172 /P35 A 9 -GND8/DS67(-) 10 -233 /K27 87 GROUND SCREW SHIFTERS
24 -101 /DS42 (+) 19 -187 /S36 1 10 -233 /S31 1 10 -233 /S31 1 IN PLATE YEL IN NEUTRAL YEL
25 -113 /S35 5 20 -190 /P14 D 10 -233 /S35 10 G
H - 191 /P12 24
26 -177 /P35 D 21 -186 /S19 3
27 -246 /P57 C 22 -190 /S34 3 D - 177 /P7 26
23 -191 /P42 B FRONT CAB
REAR CAB 24 -191 /P35 H SELECTED FRONT PARK A - 172 /P12 18
INTERFACE TAPED BACK 25 -192 /P7 4 RED YEL BRAKE SW ON YEL
CONNECTOR BLK R C - 176 /P12 11
& SEALED WITH 27 -170 /P7 1 REAR CAB
HEATSHRINK 28 -190 /K29 86 BLK
A F STEER INTERFACE B - 175 /P12 13
CONNECTOR
C
D
F
A
B
E
E - 179 /P12 9
REFER TO RED BLK REAR PARK
F - 215 /P42 D
SP4 /SP2
SP5 /SP2
20 31 191 /P12 23- B YEL BRAKE SW ON YEL
SH.2, R
21 8 30 188 /P37 F- C ZONE G6 STEERING MODE REFER TO G - 190 /S34 3
DCBA
9 19 215 /P35 F- D INDICATOR LIGHTS SH.2, ZONE E2 REAR CAB

FOR CAB SELECT
C -246 /P7 27 10 2 18 123 /S30 - E MATING FOR CONTINUATION SELECTED EMERGENCY ENGINE
D -146 /P6 2 22 3 7 29 124 /S30 - F COORD DS54 LIGHTS
CONNECTION STOP SWITCH
18
19
21
20
E -245 /P7 10 11 1 17 CONNECTOR

23 4 6 28
E -JPR /P57 F 14 GA. ALTERNATE
HGF E
F -JPR /P57 E
12 5 16
WIRING OF TRACK BLK
13 15 2 -212 /P14 M 1 -238 /S41 C 1 -187 /P12 19 PARK BRAKE
DIODE BOARD 124B/P60 B - F PIN F 5 -113 /P7 25 2 -GND8/S35 9 YEL APPLIED YEL
DIODE MODULE 25 14 27 3 -190 /P12 22 R
INSIDE P57 24 26 FOR HEATER CRAB BLK 3 -190 /P35 G 9 -GND8/S36 2 2 -GND8/S36 9
CONNECTOR REFER TO SH.3,
DOWNSHIFT LOCK 6 -216 /P14 L 9 -GND8/S32 9 3 -185 /P14 C
BLOCKING RECTIFIER ZONE G3 FOR 8 -218 /P14 K 10 -233 /S34 10 3 -185 /S36 10
CONTINUATION C D
9 -GND8/S32 9 10 -233 /S31 10 8 -197 /DS48 AXLE CENTER
124A/P60 A 9 -GND8/S31 9 9 -GND8/S36 2 INDICATOR
SPLICE B E 10 -233 /S35 10 EMERG. STEERING 9 -GND8/P6 6 YEL YEL
124 /S30 A
A -183 /P12 14 10 -233 /P22 F SWITCH 10 -185 /S36 3
HYD.STEERING MOVE FROM A F
B -184 /S19 1 P42 F STEER MODE CAB
CONTROL BOX (OPT) C -185 /S36 3 SELECTOR SWITCH SELECT SWITCH
RED
RED
RED
REFER TO SH.5 D -190 /P12 20 RED
FOR BOX WIRING E -214 /P36 A REFER TO
& P14 MATING SH.2, ZONE G2
F -220 /P36 C FOR CONTINUATION
CONNECTOR G -220 /P55 A
H -219 /P55 B REAR STEERING MODE
J -219 /P36 B IND.LIGHTS CONNECTOR
214 /P14 E - A
220 /P14 F - C
219 /P14 J - B
K -218 /S34 8 A F
1 L -216 /S34 6
2 -145 /P10 X M -212 /S34 2 B E
3 -144 /P10 W
4 -143 /P10 V C D
5 TO GND3, REFER
REFER TO SH.1, 6 -GND3 /GND3 TO SH.2, ZONE G7 P
ZONE E6 FOR 7 -141/ P10 T FOR CONTINUATION N E
HORN
MATING CONNECTOR 8 -142 /P10 U SWITCH
D
M F
ZF FRONT CAB
SHIFTER C A
CONNECTOR
181 /P7 23
(TRANSMISSION) L G
B
K H
TO GND3, REFER
J
TO SH.2, ZONE G7
FOR CONTINUATION
TO K25 86, 164
GND3 /GND3
190 /P50 B
191 /P56 A
190 /P56 B
REFER TO SH. 1, 191 /P37 H
145 /P10 M
165 /P10 R
162 /P10 N
164 /P10 S
163 /P10 P
REFER TO SH.2,
GND8/S31 9
ZONE B7 FOR
240 /S31 5
241 /S32 1
CONTINUATION ZONE E7 FOR
CONTINUATION
TO SH.2, ZONE E2
225 /P8 14
CONTINUATION
CONTINUATION
REFER TO SH.2
REFER TO SH.2
ZONE E2 FOR
ZONE E2 FOR
D E
C F ZF REAR 4 3 2 1
B G
CAB SHIFTER
ASSEMBLY 8 7 6 5
A H
1 -JPR /P6 7
2 -146 /P57 D
E D
FOR WIRING 3 -157 /K28 86
F C SEE ZF 4 -158 /P10 L
A B C D E F 5 -102 /K29 30
RED DRAWING
G B CONNECTS TO TRANSM. 6 -GND8/S36 9
C -GND6 /GND6
RED
A -GND6 /GND6
C -GND6 /GND6
VALVE BODY CONNECTOR 6 -GND8/P5 6
A -191 /SPL191
B -190 /SPL190
B -190 /SPL190
H A
A -220 /P14 G
B -219 /P14 H
ON SH.2, ZONE C3 7 -JPR /P6 1
FRONT CAB TO GND3, REFER DASH
RED SELECTED BLK TO SH.2, ZONE G7 ZF REAR CAB LIGHT,
SHIFTERS SHIFTER CONNECTOR
IN NEUTRAL YEL
FOR CONTINUATION (CAB) DIODE MODULE REAR
YEL ASSEMBLY
G G -190 /K26 86 (CR13 & CR15)
REAR CAB H -191 /SPL191 14 GA. 14 GA. HITCH LIGHT
RED SELECTED BLK 30 -102 /P7 12 30 -231 /P7 14 30 -221 /P7 17 30 -114 /P7 16 1 -156 /K29 87 BLK BLOCKING
FRONT PARK A -172 /P12 17 CAB RECTIFIER
WHT
WHT
30 -102 /P6 5
GRN
GRN
RED
RED
BLK
BLK
YEL BRAKE SW ON YEL ORBITAL SELECT COORD/CRAB SELECT
R C -176 /P12 10 85 -GND3/GND3 85 -GND3/K29 85 85 -GND3/K28 85 85 -GND3/K27 85 REAR SHIFTER UPSHIFT
85 -GND3/K28 85 85 -GND3/K27 85 85 -GND3/K26 85 SOLENOID VALVE/ SOLENOID VALVE/ INTERLOCK CONNECTOR 2 II I 1
B -175 /P12 12 86 -190 /K27 86 86 -157 /P6 3 86 -190 /K29 86 86 -190 /K27 86 CONNECTOR CONNECTOR,
GROUND SCREW IN PANEL PLATE REAR MODE
E -179 /P12 8 86 -190 /P12 28 86 -190 /K26 86 86 -190 /P37 G REAR
87 -156 /P53 1 87 -240 /K26 87 87 -233 /S32 10 87 -240 /K28 87 HITCH
REAR PARK F -188 /P42 C 87 -240 /S32 5 4 3 2 1 LIGHT
1 -184 /P14 B BRAKE SW ON YEL -180 /P12 7 87a-149 /P7 11 87a-230 /P7 13 87a-226 /P7 18 87a-223 /P7 15
1 -184 /S19 10 R D 8 7 6 5
2 -GND /S19 9 UPSHIFT INHIBITOR REAR 14 GA. PARKING LIGHTS LIGHTS 14 GA. 1
CAB SELECT TRANSFER RELAY SHIFTER TRANSFER RELAY TRANSFER
3 -186 /P12 21 YEL LIGHTS 2 -155 /P10 A
BACK-UP RELAY
FRONT
COORD
8 -189 /DS29 3 -154 /P10 H
CRAB
CONNECTOR
REAR
9 -GND /S19 2 RELAY 4 -153 /P10 F
9 -GND/ GND 5
10 9
10 -184 /S19 1 ACCELERATOR 6 -GND8 /P6 6 REFER TO SH.2,
PARK BRAKE CONTACT ARRANGEMENT FOR TRANSFER 6 -GND8 /GND8 ZONE F1 FOR
CAB SELECT YEL APPLIED YEL RELAY SOCKET K29-26 SOLENOID 7 -151 /P10 J CONTINUATION
SWITCH R 8 -152 /P10 K
VALVE/CONNECTOR
87
YEL 86 ZF REAR CAB
SHIFTER CONNECTOR
REAR SHIFTER AXLE CENTER 85 87a (TRANSMISSION)
NOT IN NEUTRAL YEL INDICATOR YEL 30
R A
YEL YEL
Sheet 5 of 6
CD276 2-2-23
Rev 13
Chapter 2
H
(P)
X J
W K
G B

V L
F A C
U M
E D
T
S
R
P
N
Sheet 6 of 6
P10 14 GA
A -155 /K7 4
B -GND3/K1 13
F -153 /K7 4
H -154 /K6 9
J -151 /K6 4
K -152 /K7 9 171 /P12 6
L -158 /K1 14 CR14
M -145 /P10 X NEUTRAL LIGHT
N -162 /K6 11 BLOCKING RECTIFIER
P -163 /K6 1
R -165 /K7 1
S -164 /K7 11
NOTES:
T -141 /K7 5
U -142 /K7 8 K1 K2 K3 K4 1. ALL TUG WIRING TO BE 16 GA. SXL WIRE, UNLESS OTHERWISE NOTED.
V -143 /K6 5 4 -180 5 -172 /P12 18 5 -174 /K4 5 5 -174 /K3 5
REFER TO SH.4, W -144 /K6 8 4 -180 /P12 7 5 -172 /K1 5 8 -176 /P12 10 8 -179 /P12 8
ZONE H5 FOR X -145 /P10 M 5 -172 /K2 5 8 -175 /P12 13 8 -176 /P12 11 8 -179 /P12 9 2. ALL CONNECTORS SHOWN FROM MATING END VIEW, UNLESS OTHERWISE INDICATED.
MATING 5 -172 /P12 17 8 -175 /P12 12 9 -173 /K2 9 9 -183 /P12 14
CONNECTOR VENDOR WIRING
CONTROL BOX 9 -170 /P12 27
12 -107 /P12 16
9 -173 /K3 9
9 -173 /P12 15
12 -107 /K2 12
12 -107 /K4 12
12 -107 /K3 12
12 -107 /K4 14
3.
CONNECTOR 12 -107 /K2 12 12 -107 /K3 12 13 -GND3/K2 13 13 -182 /P12 5
13 -GND3/P10 B
13 -GND3/K2 13
12 -107 /K1 12
13 -GND3/K1 13
13 -GND3/K6 3
14 -192 /P12 25
14 -107 /K4 12
14 -107 /K8 11
4. S&S WIRING
14 -158 /P10 L 13 -GND3/K3 13
REAR SHIFTER
14 GA
14 -195 /P12 4
FRONT PARKING PARK BRAKE
5. (S) FOR CONNECTOR SOCKET
NEUTRAL REAR PARKING BRAKE SWITCH APPLIED
RELAY BRAKE SWITCH "ON" RELAY RELAY 6. (P) FOR CONNECTOR PIN
"ON" RELAY
8 5 7. THIS WIRING DIAGRAM HAS BEEN DRAWN TO SHOW
4 1
THE STANDARD TRACTOR PLUS REGULAR OPTIONS
INCLUDING DUAL CAB (DUAL STATION). IT MAY
14- 13+
HAVE TO BE COMPLEMENTED WITH SEPARATE WIRING
12 9 DIAGRAMS FOR TRACTORS WITH MORE COMPONENTS
P12 RELAYS K1-4 THAN SHOWN. FOR SINGLE CAB (STATION) TRACTORS
1 -193 /K8 5 CONTACT ARRANGEMENT USE SHEETS 1 TO 3.
2 -196 /K8 1
3 -194 /K8 4 K6 K7 K8
4 -195 /K2 14 1 -163 /P10 P 1 -165 /P10 R 1 -196 /P12 2
5 -182 /K4 13 2 -GND3/K7 3 2 -GND3/K8 3 2 -GND3/K8 3
REFER TO SH.4, 6 -171 /CR14 2 -GND3/K6 3 2 -GND3/K7 3 3 -GND3/K8 2 3 2 1 11 10 9
ZONE G5 FOR 7 -180 /K1 4 3 -GND3/K6 2 3 -GND3/K7 2 3 -GND3/K7 2
MATING
CONNECTOR
8 -179 /K4 8
9 -179 /K4 8
3 -GND3/K3 13
4 -151 /P10 J
3 -GND3/K6 2
4 -153 /P10 F
4 -194 /P12 3
5 -193 /P12 1 R
S REFERENCE S&S DRAWINGS:
10 -176 /K3 8 5 -143 /P10 V 4 -155 /P10 A 6 -187 /P12 19
11 -176 /K3 8
12 -175 /K2 8
6 -191 /P12 23
6 -191 /K7 6
5 -141 /P10 T
6 -191 /K8 8
8 -191 /P12 24
8 -191 /K7 6
FIGURE 5.1.2. FRONT & REAR CAB (STATIONS) SCHEMATIC
13 -175 /K2 8 4 5 6 7 8
14 -183 /K4 9
8 -144 /P10 W
9 -154 /P10 H
6 -191 /K6 6
8 -142 /P10 U
9 -190 /P12 22
9 -190 /P12 28
FIDURE 5.1.3. SINGLE CAB (STATION) SCHEMATIC
15 -173 /K2 9 10 -190 /P12 20 9 -152 /P10 K 9 -190 /K7 10 RELAYS K6-8
16 -107 /K1 12 10 -190 /K7 10 10 -190 /K6 10 10 -186 /P12 21 CONTACT ARRANGEMENT FIGURE 5.1.7 ELECTRICAL EQUIPMENT LOCATION DRAWING
17 -172 /K1 5 11 -162 /P10 N 10 -190 /K8 9 11 -107 /K4 14
18 -172 /K2 5 11 -164 /P10 S FIGURE 4.2.18 REFERENCE DESIGNATORS/PART NUMBERS/LOCATION INDEX
19 -187 /K8 6 SHIFTER CHANGE CAB SELECT
20 -190 /K6 10 OVER CONTROL SHIFTER CHANGE RELAY
21 -186 /K8 10 OVER CONTROL
RELAY
22 -190 /K8 9
23 -191 /K6 6 RELAY WIRE IDENTIFICATION
24 -191 /K8 8
25 -192 /K3 14
27 -170 /K1 9
243 / P44 A
28 -190 /K8 9
CONTROL BOX WIRE NUMBER GOES TO
CAB SELECT (P)
CONNECTOR 31 20
30 8 21
19 9
18 2 10 CONTROL BOX WIRING
29 7 3 22
17 1 11
28 6 4 23
DUAL CAB (STATIONS) ONLY
16 5 12
15 13
27 14 25
26 24
DIODE BOARD
INSIDE P27 CONNECTOR BOX MOUNTED
CR5-CR8
STEERING BLOCKING RECTIFIER MARKED WITH * P17
(S) P27 (S) (TYP.5 PLCS)
P 5 P18
E N
TO K11 RELAY, TO K12 RELAY, P4
SH.3, ZONE F6 SH.3, ZONE F6 6
D
FOR CONNECTIONS FOR CONNECTIONS
F M 7 A B C D E F G H P40
A C
K11 K12 8 P9
G L
5 -208 /K14 10 P22
B 7 -204 /P27 E P8
7 -204 /P27 F 6 -209 /K15 10 H G F E D C B A P20
H K 8 -184 /P14 B 8 -185 /P14 C STEERING
J 11 -216 /P14 L 9 -218 /P14 K DIODE MODULE P13
12 -183 /K12 12 10 -212 /P14 M P27 ASSEMBLY/
205 /K14 6- D
207 /K15 6- C
209 /K15 10- H
208 /K14 10- G
204 /K11 7- F
204 /K11 7- E
207 /K15 6- B
205 /K14 6- A
P14 12 -183 /P14 A 12 -183 /K11 12 P39

13 -GND3/K14 2 CONNECTOR
A -183 /K11 12 FRONT AXLE P14
B -184 /K11 8 REED SWITCH REAR AXLE
REFER TO SH.4, C -185 /K12 8 REED SWITCH P32 P12
D -190 /K14 11 RELAY P42
ZONE E5 FOR RELAY
MATING E -214 /K15 1
CONNECTOR F -220 /K15 9
G -220 /K15 9 P21 P10
H -219 /K14 9
J -219 /K14 9
K -218 /K12 9 3 2 1 11 10 9
L -216 /K11 11 K14 K15 P7 P15
M -212 /K12 10 1 -190 /K15 11 1 -214 /P14 E S
1 -190 /K14 11 2 -GND3/K14 3 P33
R
HYD. STEERING 2 -GND3/K12 13 2 -GND3/K15 3
CONTROL BOX 2 -GND3/K14 3 3 -GND3/K15 2
3 -GND3/K14 2 5 -217 /K14 5 5
CONNECTOR 3 -GND3/K15 2 6 -207 /P27 B
4 6 7 8
P1
5 -217 /K15 5 6 -207 /P27 C RELAYS K14, K15 P19 P2
6 -205 /P27 A 9 -220 /P14 G P6
6 -205 /P27 D 9 -220 /P14 F CONTACT ARRANGEMENT
9 -219 /P14 H 10 -209 /K12 6 P5
9 -219 /P14 J 10 -209 /P27 H
10 -208 /K12 5 11 -190 /K14 1 HYD. STEERING CONTROL BOX ADDITIONAL WIRING
10 -208 /P27 G
11 -190 /K14 1 CRAB STEER DUAL CAB (STATIONS) ONLY
P28
11 -190 /P14 D REAR CONTROL (REFER TO SH.3 FOR SINGLE CAB CONTROL CIRCUIT)
COORD STEER RELAY
REAR CONTROL LEGEND
RELAY 1. PLUG EXAMPLE: PLUG DESIGNATOR
PLG
PIN SOCKET
HARNESS INTERCONNECTING DIAGRAM
DUAL CAB (STATIONS)
DUAL CAB UNIT
2-2-24 CD276
Rev 13
Chapter 2
RIGHT SIDE
DS35
HEADLIGHT
Figure 2-2. Wiring Diagram with Cat/Engine
A10/P58
RIGHT SIDE
B8
LEFT SIDE Sheet 1 of 11
DS38
DS37
TURN LIGHT H3 H2
DS69
PARK LIGHT
BLU - TURN
YEL - PARK
WHT - GND
S38 B6 B7 S40
GRN - LO
DS71
RED - HI
S39
A E (P) P20
R.H. P21
P32 A B C D E HEADLIGHT
CONNECTOR
(S)
P32 P33 H1/P62
SPARE (UNDER HEADLIGHT ASM.)
GND1 /GND1
DS35,DS37,DS69 DS39/P34 DS34,DS36,DS70
235 /P21 D
231 /P21 C
234 /P21 E
221 /P21 A
SP2 /P21 REFERENCE LOCATIONS FOR SHEET 1
RIGHT SIDE
S38
14 GA
2 1 1 - 17 /S40 2
14 GA
2 - 18 /P20 10
3 - 19 /SPL19
4 3
SPL221 4 - 262/SPL262
X
221 /P33 D
CAB WAND
SWITCH, R.H.
SPLGND1 GND1 /P33 E
X
GND1 /P62 A 14 GA.
B(-)/SPLB(-)
20 /P20 1
2 /SPL2
24 /H2 SPL24
X
P/N 12951654 HARNESS
H3 14 GA.
(P)
FRONT OF TRACTOR
WHT
D E 24 /P20 2
BLK B6 B(-) /B6 SPLB(-)
X
C F B(-) /GND2
RED BLK B(-) /H2
14 GA B G 14 GA. M-
+ B(-) /B7
SP2 /P32 A H VEHICLE 14 GA.
(P) (S) CAB HORN CAB DEFROSTER/
SP3 /P33 COOLING FAN TO GND2, SH. 4,
R.H. (ROOF) B(-) /H3
P21 MOTOR, R.H. GRID 118
221 /P32 D A
P34 14 GA 229 /P33 C B P20
231 /P33 B C LIGHT MTG
169 /P21 F 231 /P32 B SEE SH. 3, GRID 68 S39 1 20 /DS38
235 /P33 A D FOR MATING CONNECTOR DS38 DS71 BLK 2 24 /H3
CL
MATING CONNECTOR
FRONT HITCH 235 /P32 A 2 1 1 - 15 /P20 5 CAB BEACON 3
LIGHT CONNECTOR 234 /P32 C E 2 - 16 /SPL16 DOME LIGHT, 14 GA. 115 /B8
4
CONSOLE 3 - 19 /P20 6 ROTATING RED
GRID 84 FOR
HOLE 169 /P34 F 4 3 LIGHT 15 /S39 1
5
SEE SH. 3,
BLK 24 /P62 B G 4 - 262 /P20 8 19 /S39 3
6
264 /P20 11
DS39 H
CAB WAND 115 /P20 4
19 /S40 3
7
FRONT HITCH 262 /S39 4
8
FRONT LIGHTS SWITCH,
LIGHT
CONNECTOR CENTER B8 262 /S40 4
9
18 /S38 2
10
SPL19
X
M 19 /S38 3 264 /DS71
11
GND1 /P32 E TO GND1, SH. 2, GRID 62
2 /B7 (+)
12
GND1 /SPLGND1
CAB ROOF 14 GA.

CEILING
WIPER MOTOR 262 /S38 4 SPL262
X
14 GA INTERFACE
H2 CONNECTOR
24 /P21 G
WHT SPL16
B7 16 /S39 2
X
24 /SPL24
GND1 /SPLGND1
BLK 16 /S40 1 3 2 1
B(-)/SPLB(-) RED BLK
M-
221 /SPL221
SP3 /P21
+
14 GA.
235 /P21 D
231 /P21 C
6 5 4
229 /P21 B
VEHICLE CAB DEFROSTER/

A B P62 CAB HORN COOLING FAN (P) 9 8 7
H1 L.H. (ROOF) MOTOR, L.H. 2 /B6 (+) SPL2
X
SPARE
B(-)/SPLB(-)
2 /P20 12
12 11 10
VEHICLE HORN/
CONNECTOR P33 A B C D E
(S)
FRONT, UNDER L.H.
HEADLIGHT ASM. HEADLIGHT FURNISHED WITH CAB
CONNECTOR 14 GA.
(P)
WHT - GND
(P)
GRN - LO
BLU - TURN
RED - HI
YEL - PARK
E A
247 /P58
LEFT SIDE
S40 BLK/RED P58
SEE SH. 3,
247 /A10 GRID 82 FOR
2 1 1 - 16 /SPL16
2 - 17 /S38 1 A10 REAR WINDOW
MATING CONNECTOR
4 3 3 - 19 /P20 7 CAB, DEFROSTER
DS34 4 - 262 /P20 9 REAR WINDOW BLK CONNECTOR
LEFT SIDE
HEADLIGHT CAB WAND DEFROSTER

SWITCH, L.H. ASSEMBLY B(-) /GND2
TO GND2, SH. 4, CAB WIRING
CAB FRONT GRID 118
DS36 14 GA.
TURN LIGHT
DS70
PARK LIGHT 19 20 21 22 23 24 25 26 27 28 29 30 31
SEE SHEETS 10 & 11 FOR MASTER LEGEND AND NOTES
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
CD276 2-2-25
Rev 13
Chapter 2
SEE DETAIL A FOR SWITCH - SEE DETAIL B FOR

+
CONTACT ARRANGEMENT LAMP CONTACT + - DASH PANEL
(S1-7, ARRANGEMENT LIGHT, L.H.
FRONT CAB CONTROL PANEL CAP AND TAPE
& S9-S15)
S2 14 GA. S1 14 GA.
DS14 (DS1-12) - REAR VIEW - ENDS TOGETHER DS13
+ 224 /DS20 RED + 224 /DS33 BLK
1 160 /B2 1 118 /P30 H - GND1/GA7 (-) -
5 115 /P31 P 2 118 /P31 H CAP AND GND1/GA1 G
S3 115 /S1 3 3 115 /P30 P TAPE END
RESERVED 9 GND2 /S13 9 115 /S2 5
GND2 /S6 9 5 119 /P30 L DS6 DS5 14 GA. DS4 GA3/DS16 GA2/DS15 DS3RESERVED DS2 DS1 S21
ENG. OIL PRESS. ENG.COOLANT TEMP EMERGENCY
10 224 /S12 10 6 119 /P31 L + 234 /P21 E + 235 /S7 1 + 101 /DS2 (+) GAUGE/LIGHT GAUGE/LIGHT
159 /P8 2 + 101 /DS4 (+) + 229 /P21 B GA1/DS33 ENGINE STOP
224 /S6 10 9 GND2 /S11 9 234 /P43 5 101 /DS12(+) 101 /DS8 (+) 229 /P43 6 FUEL LEVEL
DS15 - - SWITCH
GND2 /S12 9 - GND2/DS5 (-) - GND2/DS6 (-) - 140 /P8 10 + - DS16 + - GND2/DS5 (-) 131 /P8 6 GND2/S4 9 GAUGE/LIGHT
WINDSHIELD 10 224 /S11 10 GND2/S11 9 GND2/DS3 140 /P64 D GND2/DS1 (-) 131 /P64 A GND2/DS3
WASHER 224 /S4 10 - -
BLK DS33 101 /P28 A
SWITCH RIGHT TURN HI-BEAM TRANSMISSION S S LOW OIL LEFT TURN
WIPER INDICATOR INDICATOR HIGH OIL TEMP. PRESSURE INDICATOR 123 /P28 E
SWITCH LIGHT LIGHT INDICATOR + INDICATOR LIGHT G
LIGHT GA3 GA2 LIGHT I S
S7 S6 S5 S 130 /P19 4 S 132 /P19 5 S4 S8
14 GA. 14 GA.
RESERVED + 125 /GA5 I + 125 /GA4 (+)
14 GA. REAR WINDOW S20
1 235 /P21 D 1 226 /S7 3 DS12 DS11 DS10 125 /GA7 (+) 125 /GA6 (+) DS9 DS8 DS7 RESERVED G GND1 /GA6 (-) 1 243 /P44 A DEFROSTER 1
235 /DS5 (+) 226 /P28 H + 101 /DS4 (+) + 105 /S27 NO3 RESERVED - GND1/GA2 (-) - GND1/GA3 (-) RESERVED + 101 /DS2 (+) + 101 /DS8 (+) GND1/DS13 (-) 3 110 /P4 8 TOUCH PAD SW. 2
3 226 /S6 1 5 223 /P28 F 101 /P4 3 105 /P7 3 GND1/DS16 (-) GND1/DS15 (-) 101 /DS7 (+) 101 /P28 A I 125 /GA6 (+) 5 222 /P44 B 3 226 /P28 H
226 /P7 18 223 /S12 5 - 129 /P8 1 - 182 /K23 86 - 133 /P8 8 - 134 /P8 9 125 /F22 9 GND2 /S10 9 4
DS16 DS15 S 135 /P19 6 GND2/DS1 (-)
5 230 /P7 13 9 GND2/S2 9 129 /P7 6 133 /P64 B 134 /P64 C 5 224 /P28 G
9 GND2/S13 9 GND2/S12 9 + 224 /DS18 BLK + 224 /DS17 (+)
224 /DS13 (+)
10 224 /S10 10
224 /S1 10
CR16 6 223 /P28 F
GND2/S14 9 10 224 /S2 10 GENERATOR PARK BRAKE 224 /DS15 (+) 224 /DS16 (+) ENGINE HIGH LOW COOLANT PARK
10 224 /S13 10 224 /S11 10 - GND1/GA3 (-) - GND1/GA2 (-) 224 /DS19 RED DASH LIGHT
NO CHARGE APPLIED COOLANT TEMP LEVEL IND. BLOWER FAN LIGHT
224 /S15 10 INDICATOR INDICATOR GND1/GA5 G GND1/DS17 (-) INDICATOR LIGHT (OPTION) SWITCH
SWITCH BLOCKING
LIGHT LIGHT LIGHT RECITFIER
HIGH-LO PARK LIGHT P/N 12941832 HARNESS
BEAM SWITCH SWITCH
DS20 CL STEERING WHEEL P/N 12941830 HARNESS

(REF)
DS18 DS17 DS19
RED BLK RED
14 GA. 14 GA.
+ -
F22
S14/DS32 S13 S12 S11 14 GA. BLK BLK S10 14 GA. S22 5A 125 /GA1 I
2 202 /P9 G 1 242 /FL2 X 1 225 /P8 14 1 169 /P21 F G S 238 /P8 15 IGN
1
3 103 /P9 B 5 113 /S11 5 5 223 /S6 5 5 113 /S10 5 5 113 /P7 25 125 /P28 D
TWISTED PAIR, I
103 /P4 11 113 /P4 12 223 /P7 15 113 /S13 5 12 TWISTS + S 113 /S11 5 ST 121 /P28 C
6 206 /P9 C 9 GND2 /S7 9 9 GND2 /S6 9 9 GND2 /S1 9 PER FOOT, MIN. 9 GND2 /S4 9 BAT 112 /P28 B
8 198 /P9 E GND2 /S2 9 GND2 /S1 9 GND2/DS6 (-) (2 PAIR) GA5/DS18 GA4/DS17 10 224 /S4 10 GND 14 GA.
9 GND2/S15 9 10 224 /S7 10 10 224 /S2 10 10 224 /S1 10 VOLTMETER/LIGHT TRANS.OIL TEMP. 224 /P28 G ACC
GND2/S7 9 224 /S12 10 224 /S13 10 224 /S6 10
10 215 /P9 H P19 GA7/DS20 GA4 GAUGE/LIGHT GA6/DS19 EMERGENCY STOP,
GA5 ACC
BEACON REAR HITCH FRONT HITCH SPEEDOMETER/LIGHT GND1 /P19 1 S 139 /P19 8 TACHOMETER/LIGHT STEERING RUN, START ST
SEE AXLE CENTER GND1/GA5 G 1 GND1 /GND1 GA7 G GND1/DS16 (-) + 125 /GA2 (+) SWITCH SWITCH
DETAIL SWITCH LIGHT SWITCH LIGHT SWITCH 2
IND.LIGHT, GND1 /GA7 (-) 125 /GA5 I
C FOR 224 /DS20 RED 3 224 /S15 10 S 138 /P19 12 + 125 /GA2 (+) IGN BAT
STEERING MODE I 125 /GA4 (+) - GND1 /GA6 (-)
WIRING 130 /GA3 S 4 130 /P8 5 S 137 /P19 11 125 /GA1 I
SEL. SWITCH 125 /GA3 (+) GND1 /DS17 (-) GND
132 /GA2 S 5 132 /P8 7 + 125 /GA3 (+) S 136A /P19 10
TWISTED PAIR, 135 /GA1 S 135 /P8 18 - GND1 /GA5 G S 136 /P19 7
6 224 /DS20 RED TWISTED PAIR,
12 TWISTS GND1/DS14 (-) DS17 - GND1 /GA4 (-)
P29 PER FOOT, MIN.
136 /GA6 S
139 /GA4 S
7 136 /P8 11
224 /DS16 (+) GND1 /GA1 G 12 TWISTS PER
8 139 /P8 19 224 /DS14 (+) + 224 /DS15 (+) FOOT, MIN.
(2 PAIR) 9 TWISTED PAIR, 224 /DS19 RED
224 /P19 3 12 TWISTS PER 224 /DS33 BLK
136A /GA6 S 10 136A /P8 28 224 /DS18 BLK - GND1 /DS15 (-) 224 /DS17 (+) P/N 12941687 HARNESS
137 /GA7 S 11 137 /P8 12 FOOT, MIN. GND1 /GA4 (-)
138 /GA7 S 12 138 /P8 17
INSTRUMENT GAUGES CONNECTOR
(P) (S)
D E E D
3 2 1 P19 1 2 3
(P) (S) C F F C
X
6 5 4
(P) (S) 4 5 6
B G G B
S15 S A H
H A
1 19 /P20 6 7 8 9 P P28
19 /P104 B 9 8 7
3 106 /P4 15
ZF FRONT CAB P2 H 101 /S21 A 101 /DS7 (+)
SHIFTER ASSEMBLY
7 15 /P20 5 12 11 10 10 11 12 1 273 /S27 NC1 B4 P30 L 112 /S22 BAT B 112 /P4 1
15 /P51 E
GND2/P29 F
A1 2
3
246 /P7 27
147 /K24 86
X 121 /S22 ST
125 /S22 IGN
C 121 /S27 NO3
125 /P4 2
9 S D
GND2/S14 9 FOR WIRING 4 148 /K21 86 123 /S21 E 123 /P8 3
10 224 /S7 10 5 102 /P24 3 P 115 /S1 3 223 /S20 6 223 /S6 5
SEE ZF F
224 /P19 3 DRAWING 6 GND1/P24 1 M H 118 /S1 1 224 /S20 5 G 224 /S10 10
CAB LIFT 7 274 /S27 NC2 L 119 /S1 5 226 /S20 3 H 226 /S6 1
SWITCH 8
14 GA. 14 GA. IGN/LIGHT 14 GA.
ZF FRONT CAB WINDSHIELD WIPER SWITCH
SHIFTER CONNECTOR MOTOR/CONNECTOR, 4 WIRE CONNECTOR
CONTROL PANEL CAB LIFT (S) (CAB) LEFT HAND CORD (REF)
OPTION PANEL P52
TURN SIGNAL
A4 S27 1 149 /P7 11
SWITCH/CONNECTOR K36
SPL234 P24 P43
X
NC1 273 /P2 1 FRONT SHIFTER UPSHIFT 1 GRN/BLK 87 30 30 104 /P4 18

234 /P8 24
2 1 GND1 /P2 6 1 2 NC NC2 274 /P2 7 INTERLOCK CONNECTOR 2 1
3 GRY 85 GND1 /GND1
AL3 NOTE: 2 GND1 /GND1 (S) 87 247 /P58
A4 & P24 4 2 150 /P8 21 NC1 105 /P4 6 4 BLK S26
+ 101 /SPL101 PIN NUMBERS 6 3 102 /P2 5 1 2 NC 105 /S27 NO3 (S) (P) 234 /DS6 (+) 5 RED
85 14 GA.
- DO NOT NC2 193 /P7 20 229 /DS1 (+) 6 GRN
269 /P64 H 6 102 /SPL102 BLU
CORRESPOND 1 NO3 121 /P28 C TO P15, SEE TIMER (11 MIN) REAR WINDOW
5 245 /P7 10 3 4 NO
NO4 122 /K20 86 P1 SH. 6, GRID 177
(P) YEL DEFROSTER RELAY
ENGINE/TRANSMISSION 3 6 161 /K25 87a
NO3 105 /S27 NC1 FOR CONTINUATION (S)
TROUBLE WARNING 14 GA. 3 4 NO 105 /DS11(+) 1
ALARM 192 /P7 4 2 145 /P15 A TO GND3, SEE
NO4
CONTROL UNIT (DOWNSHIFT) 3 144 /P15 E SH. 5, GRID 136 FRONT CAB GND1
LOCK-UP ASSEMBLY/ 4 143 /P15 D FOR CONTINUATION L.H. GND1/P24 1
CONNECTOR PARK BRAKE 5 GROUND STUD GND1/K36 85
SWITCH 6 GND3 /GND3 14 GA. GND1/P19 1
SEE SH.3, 7 141 /P15 B P.N. 12950253
8 142 /K25 86 HARNESS 228 /FL1 L
GRID 65 FOR SEE SH. 1,
142 /P15 C GND1/P32 E
CONTINUATION S23 14 GA.
GRID 11 FOR
CONTINUATION
ZF FRONT CAB
SHIFTER CONNECTOR 181 /K22 86
(TRANSMISSION) CONTROL PANELS AND CAB WIRING
HORN (SEE SH.4 FOR UNIT LOCATION & PANEL LAYOUTS)
SWITCH
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
DETAIL A DETAIL B DETAIL C STEERING MODE CONT. ON SEE SHEETS 10 & 11 FOR MASTER LEGEND AND NOTES
GRID 32
IND. LIGHTS / CONNECTOR
(P) P29 (S)
(+) DS21 RED A 166 /P9 D A F
C D COORD B 168 /P9 F
BLK C 203 /P9 A
(-)
(P) B E DS22 RED
D GND2/K25 85 B E
(S)
10 9 TRACK GND2
BLK E C D
CONTACT ARRANGEMENT
FOR SWITCH SOCKETS
CONTACT ARRANGEMENT
FOR LAMPS DS1-12
A F
DS23
CRAB RED F
GND2
(S1-7 & S9-15) GND2/S15 9
BLK
Sheet 2 of 11
2-2-26 CD276
Rev 13
Chapter 2
SEE SH. 2,
GRID 34 FOR SP9 (B2) TAPED BACK
CONTINUATION 108 /SP10 AND SEALED
116 /SP10 WITH HEAT
SP9 /SP10 SHRINK
14 GA.
(S) P8 FRONT CAB CONSOLE
P7 (SEE SH.4 FOR UNIT LOCATION)
P7 (S) P8
1 -170 /K21 87 1 -129 /DS12(-) 1 6
2 -173 /K20 30 2 -159 /DS3
3 -105 /DS11(+) 3 -123 /P28 E 7 12
-192 /S27 NO4 GREEN
4 4 -101 /SPL101
-140 /P64 D -130 /P19 4 13 16
5 5
6 -129 /DS12(-) 6 -131 /DS2 (-) 17 22 (S)
7 -131 /P64 A 7 -132 /P19 5
8 -133 /P64 B 8 -133 /DS8 (-) 23 28
FOR MATING CONNECTOR

14 GA. 9 -134 /P64 C 9 -134 /DS7 (-)
-245 /P24 5 -140 /DS4 (-)
SEE SH. 5, GRID 129

10 10
11 -149 /P52 1 11 -136 /P19 7
12 -102 /K25 30 12 -137 /P19 11
13 -230 /S7 5 13 -221 /SPL221
14 -231 /P21 C 14 -225 /S12 1 TWISTED PAIR,
SPL229 FL1
X
15 -223 /S12 5 15 -238 /S10 1 12 TWISTS

229 /P8 22 16 -114 /P4 14 16 -227 /K24 30 PER FOOT, MIN. P20 L 228 /S26 YEL
17 -221 /P21 A 17 -138 /P19 12 (2 PAIR) 1 111 /K22 85 109 /K24 87
MATING CONNECTOR
18 -226 /S7 3 18 -135 /P19 6 2 24 /K22 87 X 109 /P4 16
19 -171 /K23 85 19 -139 /P19 8 3
SPL102 TURN SIGNAL
X
GRID 29 FOR
20 -193 /S27 NC2 20 -182 /K23 86 115 /SPL115
SEE SH. 1,
4 LIGHTS FLASHER 14 GA.
102 /P24 3 21 -196 /P9 M 21 -150 /P24 2 5 15 /S15 7
22 -107 /P4 7 22 -229 /SPL229 6 19 /S15 1
JPR -181 /K23 30
MATING CONNECTOR
23 23 -109 /K24 87 7 19 /SPL19
24 -101 /SPL101 24 -234 /SPL234 8 106 /SPL106 242 /S13 1
SPL221 -113 /S10 5 -178 /K20 87 (S) FL2
GRID 28 FOR
25 25
X
9 106 /SPL106
SEE SH. 1,
26 -177 /K21 87a 26 18 /P105 B
221 /P8 13 -246 /P2 2 14 GA. P58 10
BLK BLK
27 27 11 264 /FL2 L 264 /P20 11
14 GA. 28 28 -136A /P19 10 247 /K36 87 110 /SPL110
14 GA. 12
REAR CAB MAIN HARNESS REAR WINDOW
DEFROSTER CEILING 14 GA. BEACON LIGHT
INTERFACE INTERFACE INTERFACE (FLASHING)
CONNECTOR SEE DETAIL D FOR CONNECTOR 14 GA.
CONNECTOR CONNECTOR FLASHER
P9 RELAY CONTACT
203 /P29 C ARRANGEMENT

A
B 103 /S14 3 (K20-K25)
SEE SH. 1, GRID 10
206 /S14 6 SPL115 SEE SH. 4,

SEE SH. 5, GRID 129
C P21 14 GA. K25 K24 K23 K22 K21 K20

D 166 /P29 A X
GRID 112 FOR
E 198 /S14 8 A 221 /P7 17 87a 161 /P24 6 30 227 /P8 16 30 181 /P7 23 30 111 /P4 13 30 102 /K25 30 30 173 /P7 2
102 /P7 12 GND2/K21 85 111 102 /P4 5 GND2/GND2 CONTINUATION
F 168 /P29 B B 229 /DS1 (+) 30 85 181 /K22 86 85 SPL19 115 /P20 4
G 202 /S14 2 C 231 /P7 14 102 /K21 30 GND2/K25 85 85 171 /P51 B 85 85 GND2/K24 85 85 GND2/K21 85 19 /P51 F
X
215 /S14 10 D 235 /S7 1 85 GND2/P29 D 86 147 /P2 3 171 /P7 19 111 /P20 1 GND2/K20 85 86 122 /S27 NO4 14 GA.
H 19 /P20 7
J E 234 /DS6 (+) GND2/K24 85 87 109 /P8 23 86 182 /DS11(-) 86 181 /K23 30 86 148 /P2 4 87 178 /P8 25
K F 169 /S11 1 86 142 /P1 8 109 /FL1 X 182 /P8 20 181 /S23 87 170 /P7 1 87a
L G 24 /K22 87 87a 87 GND2/GND2 87 24 /P20 2 87a 177 /P51 G
196 /P7 21 H 87 14 GA. 87a 24 /P21 G 177 /P7 26 PARK BRAKE
M BACK-UP ON - STARTER
N LOCK-UP UNIT 87a
FRONT LIGHTS SHIFTER TRANSM NOT SHIFTER IN ENABLE RELAY
STEERING (S) CONNECTOR E D
DOWNSHIFT RELAY RELAY IN N-, PARK HORN NEUTRAL
INTERFACE P BRAKE APPLIED RELAY RELAY
CONNECTOR E N (S) F C RELAY SPL110
110 /P20 12
X
D G B
F M
A C H A 14 GA.
G B L
SPL106
106 /P20 8
X
H K
J
SPL101 X 106 /P20 9
P/N 12941830 HARNESS
101 /P8 4 101 /P7 24 TO P11
P51 SHOWN ON
101 /AL3 (+) P64 CR9-CR12 SH.5,
A
CR22-CR25 A 131 /P7 7 171 /K23 85 B
A DIODE
ZONE 147
B BOARD
DIODE 131 /DS2 (-) JPR C
BOARD
A
B
B 133 /P7 8 C
D
INSIDE SPL280
133 /DS8 (-) 244 /AL1(+) P51
12
11
10
INSIDE C D
9
P64 D
C 134 /P7 9 15 /S15 7 E
134 /DS7 (-)
25
24
22
23
19 /SPL19 E
A
F
C
D 140 /P7 5 177 /K21 87a F
(P) (S) (P) (S)
B
G
B
E 140 /DS4 (-) G
C
H
A
F E 269 H
G F 269 DIODE MODULE S53 P73 P72 S52
H G 269 CONNECTOR BLOCKING
BLU BLU
H 269 /AL3 (-) RECTIFIER A 281 /P11 B 282 /P11 C A
(S) (S) P51 WHT WHT
P64 DIODE MODULE,
CR9 RESERVED B 280 /P11 A 280 /SPL280 B
CR10 PARKING BRAKE RED RED
SEE SH. 4, GRID 100
ENGINE WARNING ALARM CR11 CAB LIFT C C FRONT CAB CONSOLE WIRING
RECTIFIER/CONNECTOR CR12 CAB LIFT (SEE SH.4 FOR UNIT LOCATION)
FOR CONTINUATION LEFT TURN RIGHT TURN
CR22 OIL PRESSURE LT. SENSING SENSING
CR23 COOLANT TEMP. LT. SWITCH/CONNECTOR SWITCH/CONNECTOR
CR24 COOLANT LEVEL LT.
CR25 TRANSM. TEMP. LT.
64 65 66 67
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
DETAIL D
CONTACT ARRANGEMENT FOR
RELAY SOCKETS K20-K25
85
87
87a 30
86
WIRE ENTRANCE
Sheet 3 of 11
CD276 2-2-27
Rev 13
Chapter 2
FRONT CAB CONTROL PANEL

S1
EMERGENCY
ENGINE STOP DS13 DS1 DS2 DS3 DS4 DS5 DS6 DS14 S2 S3
FRONT CAB CONSOLE
GA1/DS33 BLANK
GA2/DS15 GA3/DS16
BLANK
SEE SH. 3 FOR Sheet 4 of 11
S21 BLANK BLANK BLANK P
- +
FOR
FUTURE
USE
CONSOLE WIRING
E LOW F
DS7 DS8 DS9 DS10 DS11DS12 S5 S6 S7

BEHIND S20 S20 BLOWER FAN
SWITCH CR16 DASH LIGHT LOW - HI
ON
BLANK
BLANK FOR
FOR FUTURE
NORMAL USE
FUTURE
LOW
USE
S4 - +
OFF HIGH
EMERGENCY FRONT REAR

RUN STEERING HITCH HITCH P29
STOP START GA4/DS17 GA5/DS18 DS21
COORD
BLANK GA6/DS19 GA7/DS20 DS22 (P)
F22 FOR
FUTURE
USE STEER TRACK 19 8 9
MODE CRAB
S22 DS2312941721 BELOW FRONT DASH

S8 S10 S11 S12 S13 S14/DS32 18 7 2 10
BEHIND S22 CAB LIFT RIGHT SIDE
SWITCH RAISE
P19 17 6 1 3 11
P28 S15
L18/P104 16 5 4 12
L19/P105
K20-K25 GND4
15 14 13
LOWER
FUSE BOX/P4
(SEE SH. 8)
(P) (S) P4
SEE SH. 1, 1 112 /P28 B
GND2 GRIDS 24 & 29 2 125 /P28 D
REMOVABLE SEAT
C D A F
FOR CONTINUATION 3 101 /DS12(+)
4 GND2/GND2
B2 B E B E L 14 GA. 5 102 /K21 30
B3/P31 CLOSED CAB 6 105 /S27 NC1
A F C D H UNITS ONLY 7 107 /P7 22
A6/P44 12941722
P 8 110 /S4 3
B(-) /A10
B(-) /H3
CAB LIFT OPTION PANEL
FL1,FL2 P44 B3 P31 9
S 10 115 /P31 P
CONSOLE ORN X 103 /S14 3
AL1 A 243 /S4 1 X 11
P20,P21 RED S 12 113 /S13 5
M B 222 /S4 5 115 /S2 5 GND2/K23 87 13 111 /K22 30
S52/P72 P9 P 115 /P4 10 14 114 /P7 16
S53/P73
C 14 GA. GND2/P4 4
CR9-12/P51 H 118 /S1 2 GND2/K20 85 15 106 /S15 3
P8 M 109 /FL1 X
A6 D GND2/P44 F 16
CR22-25/P64
P7 L 119 /S1 6 FUSE BOX, 17 NO CONN.THIS SIDE
E
SEE SH. 8 FOR 18 104 /K36 30
CONTROL PANEL 14 GA. GND2 BOX WIRING 19
CAB LIFT OPTION/S15 BLK GND2/GND2 AND P4 MATING
F WINDSHIELD WIPER FRONT CAB, CONNECTOR
14 GA.
(SEE SH. 2) MOTOR/CONNECTOR, R.H.
P58 RIGHT HAND GROUND STUD
CAB HEATER - FAN
ASSEMBLY/CONNECTOR
P19,P28
(UNDER PANEL) SEE SH. 3,
GRID 91 FOR
CONTINUATION SP10 (P7)
B4/P30 14 GA.
TAPED BACK
108 /SP9 AND SEALED
160 /S2 1
FRONT CAB CONTROL PANEL 116 /SP9 WITH HEAT
K36 SP9 /SP9 SHRINK
S27
(UNDER PANEL)
14 GA.
GND1 A1
S23, S26/P43 P1,P2,P52 B2
M
(UNDER CONSOLE PANEL) REFERENCE LOCATIONS FOR SHEETS 2,3,& 4 WINDSHIELD WASHER
A4/P24, AL3 PUMP MOTOR
(UNDER CONSOLE PANEL)
FRONT
BULKHEAD
SEE SH. 3, GRID 68 GND4 /P104 A

FOR CONTINUATION GND4 /P105 A GND4
LIFT CAB VALVES
GROUND STUD
P/N 12941830 HARNESS (S) (P)
P104 L19 CAB LOWER
RED SOLENOID VALVE/
GND4/GND4 A RED
AL1 19 /S15 1 B CONNECTOR
244 /P51 D + UNIT WELDMENT
P105 RED L18 RED CAB RAISE
GND4/GND4 A SOLENOID VALVE/
CAB 18 /P20 10 B CONNECTOR
RAISE/LOWER
ALARM (S) (P)
CAB/WELDMENT WIRING
96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127
2-2-28 CD276
Rev 13
Chapter 2
P
E
P
N (S) (P) N
D
E Figure 2-2. Wiring Diagram with Cat/Engine
D M F TO SH.3,
F
A C
M
C A ZONE 87
Sheet 5 of 11
G L L G
B B
H K K H 1/0 BLK
J P13 P11 J
TO F21, SH. 7, F21
GRID 188
203 /P9 A A A 280 /P73 B
188 /P109 A B B 281 /P73-A 199 /S41 NC K19
206 /P9 C C C 282 /P72-A
GND3 /P13 M 166 /P9 D D D 286 /P74-A EMERGENCY STEERING
GND3 GND3 /P109 C 198 /P9 E E E GND3/P74-C PUMP MOTOR/RELAY
STEERING 168 /P9 F F F
2/0 GA
BOX GROUND 202 /P9 G G G
STUD GND3 /P15 F 215 /SPL215 H H B5 BLK
GND3 /P1 6 166 /P54 A J J
203 /P54 B K K ENGINE BAY
FRONT AXLE 191 /P42 B L L R.H. WELDMENT
FRONT WELDMENT GND3 /GND3 M M
N STEERING BOX N
P.N. 12950253 HARNESS P SEE SH.8 FOR P
BOX & P13 & P11
FRONT CONSOLE SP4
MATING CONNECTOR
X
SP6 /SP3
TO P1, SH. 2, GRID 49 14 GA. (S) (P)
TO P15, SH. 6, GRID 174
P.N. 12980014 HARNESS P100 L10 PARKING BRAKE
6 5 4 3 2 1 RED
(P) F A
GND6 /GND6 A
RED
SET SOLENOID
GREEN
12 11 10 9 8 7 A F 196 /P9 M B VALVE/CONNECTOR
P8
D
C
E
B
A
F
16 15 14 13
C
D
A
B
E
F
MAIN HARNESS 22 21 20 19 18 17
(P) P42 (S) P103 L11 PARKING BRAKE
INTERFACE 28 26 25 GND6 /SPLGND6 RED
CONNECTOR (REAR)
27 24 23 A
RED RELEASE SOLENOID
JPR A 103 /SPL103 VALVE/CONNECTOR
B 191 /P13 L 196 /SPL196 B
1 129 /P17 A C 188 /SPL188
2 (S)
215 /SPL215 (P)
X
3 123 /P42 E 215 /P13 H D

4 NO CONN.THIS SIDE SPL215 JPR E 123 /P8 3
5 130 /P17 B F 125 /P18 B
6 131 /P17 C REAR CAB 14 GA. S28
7 132 /P17 D STEERING
8 133 /P17 E INTERFACE
182 /P8 20 C
9 NO CONN.THIS SIDE 14 GA. CONNECTOR GND6 /GND6 NC

10 140 /S42
SEE SH. 3, GRID 73
11 136 /P17 F PARKING BRAKE

12 137 /P16 PRESSURE SWITCH
13 221 /P22 D B C A B C A
14 225 /P47
15 238 /S41 C SPLGND6
16 227 /P22 B
17 138 /P16
X
S25 GND6 /P103 A
18 135 /R5 S49
19 139 /R3 FRONT AXLE FRONT AXLE
20 182 /S28 C RIGHT OF CENTER (P) LEFT OF CENTER (P)
WHT
WHT
(P) (S)
RED
RED
12 TWISTS PER FT. MIN.
BLK
BLK
TWISTED PAIR (2 PAIR)
21 150 /P23 REED SWITCH/ REED SWITCH/

22 229 /P22 C CONNECTOR CONNECTOR
23 109 /S43 C
P109 C (S) P74 (S)
C
A
B
A
B
24 234 /P22 E
25 178 /P17 H L13 COORD
26
P54
GND3 /GND3
27
103/SPL103
GND3 /P11-E
188 /P13 B
28 136A /P17 G GRN
103/SPL103
286 /P11 D
A 166 /P13 J
WHT B 203 /P13 K
SP6 /SP4 BLK
SP3 SP7 /SP5 C GND6 /GND6
SP8 /SP5 215 /P42 D SELECT VALVE
P9 14 GA.
103 /P42 A
SOLENOID/
STEERING
SPL188 L14 CRAB CONNECTOR,
INTERFACE
X X X FRONT MODE
CONNECTOR
A 203 /P13 A SPL103 SPL215 SPL196 SEE SH. 7,
B 103 /P108 B 188 /P42 C X X GRID 185 FOR
196 /P103 B P.N. 12980014 HARNESS CONTINUATION
C 206 /P13 C SPL103

D 166 /P13 D
SEE SH. 3, GRID 65
E 198 /P13 E SEE SH. 6, SEE SH. 6,

F 168 /P13 F GRID 168 FOR GRID 182 FOR
G 202 /P13 G CONTINUATION CONTINUATION
H 215 /P108 A (P)
J P
K N E WELDMENT WIRING
D (SEE SH.6 FOR UNIT LOCATION)
L M F
M 196 /P100 B C A
N L
B
G
P K
H
J
129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154
CD276 2-2-29
Rev 13
Chapter 2
ENGINE 14 GA
P9
125 /P18 B
P8 133 /P17 E
SEE SH. 5, SEE SH. 5,
GRID 140 FOR L6
FUSE BOX/P4 ENGINE RUN NO GRID 153 FOR
(SEE SH. 8) CONTINUATION CONTINUATION
SOL. VALVE
C
S56 GND /K31 P.N. 12980014 HARNESS

SPARE, 14 GA
CAP & ENGINE HIGH
P.N. 12980014 HARNESS TAPE END SP9 /P18 A COOLANT TEMP.
SWITCH TRANSMISSION
131 /P17 C 132 /P17 D
130 /P17 B
REMOVABLE SEAT
R4
S55 NC R7
ENGINE ENGINE
ENGINE COOLANT
178 /P17 H
LOW OIL P
178A /K31
P42 PRESSURE OIL PRESSURE TEMP.
HYD.STEERING SWITCH C SENSOR SENSOR 139 /P8 19
CONTROL BOX/P13,P11 R3
GND3 (SEE SH. 8)
STARTER MOTOR/
GND /GND TRANSM.
SOL.ASM. TEMP.
S25/P109 L17 6 BLK SENSOR
129 /P17 A C
B
S 127 /K31 6 BLK NC P23/R2 GND6 /GND6
M JPR TURBINE SPEED
R11 B1 JPR
NO
(ZF) SENSOR/ 150 /P8 21
136 /P17 F
BAR FUSIBLE S54 CONNECTOR
G
M LINK
ENGINE SPEED,
S56 S54 136A /P17 G 1 2
START INTERLOCK P16/R6 137 /P8 12
R4 TWISTED PAIR, A7 F17 BAT SWITCH VEHICLE SPEED
G1 ENG.SPEED 138 /P8 17
6 BLK (ZF) SENSOR/
GND 12 TWISTS PER SENSOR 2/0
L6 P17, P18 FOOT, MIN. (MAGNETIC CONNECTOR
K31 PICKUP) TO E3, E3 S42 140 /P8 10
B5/K19 (LOWER EDGE)
SH. 7, G1 TRANSM.
GRID 188 HIGH TEMP
R7, S55 2/0 BLK 10 GA GENERATOR, SWITCH TWISTED PAIR
A7,B1,L17,F17 126 /K31 12VDC 12 TWISTS
P/N 12980014 HARNESS PER FOOT, MIN.
S28
A3 (L1-5) P15 R11
R6/P16 R2/P23
S42 L10/P100/L11/P103 P/N 12970982 HARNESS A3
(LOWER EDGE) F21 10 GA
178A /S54 NC
R3 10 GA P17 REFER TO ZF
(L1-5) TRANSM.FOR
GND /S56 C
GND /S55 C
S43 INTERNAL
GND /GND
S41 129/ G1 1 129 /P8 1 P18
GND /K31
A 14 GA WIRING OF L1-5 & P15.
126 /F17
127 /L17
CB2/E3 L13/L14/P54 130 /R7 B 130 /P8 5
SP9 /R7 A SP9 /SP9(CB2)
131 /S55 NC C 131 /P8 6 TRANSM. VALVE BODY
GND6 132 /R4 D 132 /P8 7 ASSEMBLY/CONNECTOR
BT1, BT2 133 /S56 NO E 133 /P8 8 125 /L6 B 125 /P42 F P15
GND7 136 /R11 F 136 /P8 11 14 GA A B C D E F
136A /R11 G 136A /P8 28 C
S29/P108 178 /S54 C H 178 /P8 25
TWISTED PAIR, J TWISTED PAIR, ENGINE
12 TWISTS PER K 12 TWISTS PER INTERFACE (S)
FOOT, MIN. FOOT, MIN. CONNECTOR
GND8
GND3 /GND3
ENGINE
R5 INTERFACE (P) (S)
145 /P1 2
141 /P1 7
142 /P1 8
143 /P1 4
144 /P1 3
K31 GND CONNECTOR (S)
P22 STARTER SOL. WELDMENT (P)
P39 P40 AUX. RELAY GROUND
STUD
DS64 DS57 P.N. 12950253 HARNESS

DS61 DS68/P47 DS60 ENGINE 2/0 GA. BLK
TO GND3,
DS62/DS63 DS59/DS58 FLYWHEEL SH. 5, GRID 136
HOUSING
DS65/P46 AL2 DS66/P45
(BUMPER) (BUMPER) TO P1, SEE
SH. 2, GRID 49
LEFT SIDE RIGHT SIDE FOR CONTINUATION WELDMENT WIRING
ENGINE BAY
R.H. WELDMENT SEE SHEETS 10 & 11 FOR MASTER LEGEND AND NOTES
REFERENCE LOCATIONS FOR SHEETS 5 - 8
157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183

Sheet 6 of 11
2-2-30 CD276
Rev 13
Chapter 2
14 GA
232 /P40 A
GND8 /P39 E GND8
GND8 /P46 A
SPL232 REAR CAB/REAR
X
LIGHTS GROUND STUD
233 /P45 B
14 GA SPL233 X
AL2
227 /P40 B BACK-UP
SPL227
X
ALARM
221 /P40 D
SPL221
X
14 GA. S41 GND6 227
STEERING VALVES P.N. 12941701 HARNESS
238 /P8 15 C
GROUND STUD P40 RED LIGHTS
199 /K19 NC GND6 /P100 A
GND6 /P108 C
14 GA P22 232 /SPL232 A BRAKE DS58
GND6 /P54 C 232 /S43 NC 232 /P39 A BLK
EMERG.STEERING
PRESSURE SWITCH GND6 /R5 227 /P8 16
A
B 227 /P39 B
227 /SPL227 B BACK-UP DS60
YEL
GND6 /S28 NC
GND6 /P23 229 /P8 22 C 229 /P39 C
234 /P22 E C
BRN
TURN DS57
SP5 SP8 /SP3 221 /P8 13 D 221 /P39 D 221 /SPL221 D TAIL DS59
ENGINE BAY SP7 /SP3 234 /P8 24 234 /P40 C GND8 /SPLGND8 WHT
E E GROUND
R.H. 14 GA. 233 /P46 B
WELDMENT F 14 GA R.H. REAR
SEE SH. 5, REAR LIGHTS A 14 GA (S) LIGHTS CONNECTOR (P)
A A
REAR OF TRACTOR
GRID 154 FOR B CONNECTOR B B
P.N. 12980014 HARNESS
C
E
D
E
B
A
CONTINUATION C C C
S43 D
E
D
E
D
E
135 /P8 18
BRAKE PRESS. F (S) (P) F F
C NC SWITCH (BRAKE
LIGHTS) R5 14 GA P45
14 GA. FUEL LEVEL GND8 /SPLGND8 A
SENSOR
232 /P22 A 233 /SPL233 B
109 /P8 23
GND6 /GND6
RIGHT REAR
(S) HEADLIGHT
215 /P9 H
103 /P9 B
CONNECTOR
SP9/P18 A
EMERGENCY PUMP
FUSE, 225A
GND6 /GND6 P39 LIGHTS
RED
232 /P22 A A
BLK
BRAKE DS63
F21 SP9 227 /P22 B B BACK-UP DS61
P108 GRN
C
A
B
BLK /E1
SEE SH. 8,
GRID 233 FOR
229 /P22 C C
BRN
TURN DS64
(S)
WHT
DS62
RED
REAR AXLE
BLK
1/0 BLK CONTINUATION 221 /P22 D D TAIL
REED SWITCH/ WHT
6 GA. BLK
TO K19, SH. 5,
K19
CONNECTOR
(P) 14 GA. P47 BLK
GND8 /GND8 E GROUND
GRID 148 14 GA
CB2 225 /P8 14 L.H. REAR
S29 (S) (P)
MAIN CIRCUIT REAR HITCH DS68 SPLGND8 LIGHTS CONNECTOR
BREAKER, 120A
LIGHT/CONNECTOR
C
E
D
E
B
A
GND8 /P46 A X
GND8 /P45 A
1/0 BLK
6 GA. BLK (S) (P) 14 GA
14 GA P46
E3 A
GND8 /GND8
BATTERY POWER STUD
233 /P22 F B
2/0 GA. BLK LEFT REAR

(S) HEADLIGHT
TO A7, SH. 6, CONNECTOR
GRID 169 A7 GND7
+ - + - BATTERY
BT1 BT2
GROUND STUD WELDMENT WIRING
BATTERY, BATTERY, WELDMENT (SEE SH.6 FOR UNIT LOCATION)
12 VOLTS 12 VOLTS SEE SHEETS 10 & 11 FOR MASTER LEGEND AND NOTES
2/0 GA. BLK
186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211

Sheet 7 of 11
CD276 2-2-31
Rev 13
Chapter 2
FUSEHOLDER(S)
(FUSES) CAVITY ARRANGEMENT
LOOKING AT BACK
OF CONNECTOR
CONNECTOR FOR K30 (S)
(WIRE ENTRANCE)
P4
85
86
FUSE BOX
CONNECTOR
F16 F12
12 GA.
F8
12 GA.
F4
12 GA. K30 10 GA. 1 112 /F12 A
B A B(+) /E1 B A 112 /P4 1 B(+) /E1 B A 108 /P4 17 128 /K30 87 B A 104 /P4 18
30 B(+) /E1 2 125 /K30 86
12 GA. B(+) /E1 101 /F1 A
B(+) /E1 B F15 A 115 /P4 10 B F11 A 111 /P4 13 128 /K30 87 B F7 A 107 /P4 7 128 /K30 87 B F3 A 103 /P4 11 85 GND2 /P4 4
3
4 GND2/K30 85
86 125 /P4 2 5 102 /F2 A
MATING CONNECTOR
F14 F10 F6 F2
SEE SH. 4, GRID 122

B(+) /E1 114 /P4 14 110 /P4 8 106 /P4 15 102 /P4 5 128 /F4 B 6 105 /F5 A
B A 128 /K30 87 B A B A B A
87 128 /F7 B 7 107 /F7 A 14 GA.
128 /F3 B 8 110 /F10 A
B F13 A 113 /P4 12 B(+) /E1 B F9 A 109 /P4 16 B F5 A 105 /P4 6 B F1 A 101 /P4 3 128 /F10 B 9
12 GA. 10 115 /F15 A
14 GA. 12 GA. 14 GA. IGNITION 11 103 /F3 A
(MASTER) RELAY 12 113 /F13 A
13 111 /F11 A
FUSES FUSES FUSES FUSES 14
15
114 /F14 A
106 /F6 A
F16 - RESERVED F12 - INSTRUMENT PANEL, 20A F8 - RESERVED F4 - REAR WINDOW DEFROSTER, 20A 16 109 /F9 A BOX COVER NOT SHOWN
F15 - WINDSHIELD WIPER, 30A F11 - HORN, 20A F7 - CAB SELECT, 10A F3 - STEERING, 10A 17 108 /F8 A
F14 - HEADLIGHTS, 20A F10 - HEATER/COOL FAN, 20A F6 - CAB RAISE/LOWER, 10A F2 - TRANSMISSION, 10A
F13 - EMERG.STEERING, BEACON, F9 - TURN/BRAKE/BACK-UP F5 - PARKING BRAKE, 10A F1 - ENGINE, 10A
18 104 /F4 A F16 F13
19
AND FRONT HITCH, 15A LIGHTS, 15A 12 GA. F12 F9
30
20
15
16
15
14
13
10
20
20
15
12
11
10
9
10
10
10
10 GA.
5
10
10
10
FUSE BOX WIRING B(+) /K30 30
1
E1 B(+) /K30 30 F8
F4
F5
F1
B(+) /F12 B
K9 K10 K11 K12 B(+) /F15 B
K30
B(+) /F9 B E1
P13 1 191 /K9 11 1 168 /P13 F 3 284/ P25 E 7 237 /P26 F FUSE BOX B(+) /F14 B
(P) 191 /K10 11 2 GND3/K9 2 5 211 /K9 10 237 /P26 E POWER STUD B(+) /F8 B
A 203 /K10 9 2 GND3/K10 2 GND3 211/ P25 F 11 206 /P13 C

P GND3 210 /K10 10 206 /P25 D 12 GA.
B 188 /SP1 6
SEE SH. 5, GRID 141
N E
C 206 /K12 11 3 GND3/K11 13 9 198 /KA 5 13 GND3/K11 13 SEE SH. 7,
D 166 /K9 9 3 GND3/P13 M 5 167 /K9 5 198 /P13 E GND3/KA 13 B(+) /CB2 GRID 192 FOR
DIODE BOARD
M
D
F E 198 /K11 9 5 167 /K10 5 6 213 /P26 B 10 202 /P13 G 14 215 /P13 H INSIDE P26 6 GA. BLK
CONTINUATION
P4
201 /P26 A 213 /P26 D GND3/K10 3
C A
F
G
168 /K10 1
202 /K11 10
6
201 /P26 C 9 203 /P13 A
13
GND3/K12 13
5
6 CR1-CR4 FUSE BOX
L
B
G H 215 /K12 14 9 166 /P13 D 203 /P13 K 14 285 /P25 A 8
J
K
166 /K9 9
203 /K10 9 10
166 /P13 J
211 /P26 G
10 210 /P26 H
210 /K11 6
7
285 /CR32 C 9
10
A P26
K H 8
J L 191 /K9 11 211 /K11 5 11 191 /K9 1 13 B A 201 /K9 6
11 283 /KB 8 B 213 /K10 6
M GND3 /K9 3 11 191 /K9 1 12
12 C
N 191 /P13 L CRAB STEERING, C 201 /K9 6
P FRONT CONTROL D D 213 /K10 6
RELAY FRONT AXLE REAR AXLE E 237 /K12 7
COORD STEERING, REED SWITCH REED SWITCH 3 4
FRONT CONTROL 1 2 F 237 /K12 7
STEERING BOX RELAY RELAY G 211 /K9 10
CONNECTOR RELAY 210 /K10 10
188 /P13-B H
SP1 188 /KB 12 E
P11
P26 (CR1-4)
KB
F
KA P.N. 12941889 HARNESS
(S) P11 1 1 283 /KB 8
G
P A 280 /KA 9 4 2 H
E N B 281 /KB 10 5 198 /K11 9 4
JPR 285 /K11 14 K9 K10 K11 K12
SEE SH.5, GRID 144
282 /KB 6 CR32 STEERING DIODE MODULE
P25 (CR28-31)
8
KA KB
C
F
D
M D 286 /KB 14
GND3/KB 13
5 JPR ASM./CONNECTOR P13
A C
E
F 6 282 /P11 C CR28-CR31 DIODE BOARD
INSIDE P25
G 8 283 /KB 1
P25
A
G L
B H 283 /K11 11
A 285 /K11 14
B
J
H K K
9 280 /KA 14 9GND3/KB 13
C
J L 280 /P11 A GND3/KA 13 B 285 BOX COVER NOT SHOWN
12 10 281 /P11 B C 280 /KA 14
D
M
GND3/K12 13 12 188 /SP1 206 /K12 11
31
30
13
28
29
N D
P
GND3/KB 9 188 /P25 H E 284 /K11 3
GND3/KB 9
14 280 /KA 9
280 /P25 C
13
GND3/P11 E
F
G
211 /K11 5
286 /KB 14 HYDRAULIC STEERING CONTROL BOX
E
PASSIVE CENTERING 14 286 /P11 D H 188 /KB 12
STEERING MODE 'ON'
F
CONNECTOR 286 /P25 G
INTERLOCK RELAY CONTROL BOXES
G
FRONT AXLE LEFT OF
(SEE SH. 6 FOR UNIT LOCATION)
CENTER RELAY
H
212 213 HYD. STEERING CONTROL BOX WIRING - SINGLE CAB CONTROLS STEERING DIODE
MODULE ASM./CONNECTOR
KB
214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238
8 6 5
KA K9 & K10 SEE SHEETS 10 & 11 FOR MASTER LEGEND AND NOTES
4 2 1
RELAY
5
8 7 6 5
K11 &
CONTACT
8
K12
3 2 1 11 10 9
4 3 2 1
4 1
SET S ARRANGEMENTS
+
14 13
R
+
12 10 9 14 13
14 13 4 5 6 7 8
+ 12 11 10 9
12 9
RESET

Sheet 8 of 11
2-2-32 CD276
Rev 13
Chapter 2
P17
P4
P18
P40
P9
P22
P20
P8
P39
P13
P32
P42
P21
P7
P33
P15
P1
P19 P2
LEGEND
P28 1. PLUG EXAMPLE: PLUG DESIGNATOR
HARNESS
INTERCONNECTING DIAGRAM
P#
SINGLE CAB
SEE SHEETS 10 & 11 FOR MASTER LEGEND AND NOTES PIN SOCKET
239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262

Sheet 9 of 11
CD276 2-2-33
Rev 13
Chapter 2
LEGEND LEGEND
SH. - GRID ITEM DESCRIPTIONS SH. GRID ITEM DESCRIPTIONS
7-210
- DS64 LIGHT TURN, REAR, LEFT HAND
2-44 A1 ASSEMBLY ZF FRONT CAB SHIFTER LEGEND
N/S DS65-67 LIGHT RESERVED (REAR)
N/S A2 ASSEMBLY RESERVED (REAR) GRID ITEM DESCRIPTIONS
7-202 DS68 LIGHT REAR HITCH SH.
6-181 A3 ASSEMBLY TRANSMISSION VALVE BODY 1-3 DS69 LIGHT PARK, FRONT, RIGHT HAND 5-151 L11 SOLENOID PARKING BRAKE RELEASE VALVE
2-37 A4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK-UP 1-3 DS70 LIGHT PARK, FRONT, LEFT HAND N/S L12 SOLENOID RESERVED (REAR)
N/S A5 ASSEMBLY RESERVED 1-22 DS71 LIGHT BEACON, ROTATING 5-148 L13 SOLENOID COORD SELECT VALVE, SV2-A (OR 1)
4-112 A6 ASSEMBLY CAB HEATER - FAN - DS*** 5-148 L14 SOLENOID CRAB SELECT VALVE, SV2-B (OR 1)
6-170 A7 ASSEMBLY STARTER MOTOR (SOLENOID AND MOTOR) 8-230 E1 STUD FUSE BOX POWER N/S L15,16 SOLENOID RESERVED (REAR)
N/S A8 ASSEMBLY RESERVED -
N/S E2 STUD RESERVED 6-172 L17 SOLENOID ENGINE STARTER
N/S A9 ASSEMBLY RESERVED (REAR) 7-189 E3 STUD BATTERY POWER 4-124 L18 SOLENOID CAB RAISE VALVE
1-21 A10 ASSEMBLY CAB, REAR WINDOW DEFROSTER N/S E4 STUD RESERVED 4-124 L19 SOLENOID CAB LOWER VALVE
- A*** - E*** - L***
4-110 AL1 ALARM CAB RAISE/LOWER 8-228 F1 FUSE ENGINE, 10A 2-46 P1 CONNECTOR SHIFTER (TRANSMISSION) FRONT CAB (ZF)
7-208 AL2 ALARM BACK-UP 8-228 F2 FUSE TRANSMISSION, 10A 2-46 P2 CONNECTOR SHIFTER (CAB) FRONT CAB (ZF)
2-34 AL3 ALARM ENGINE/TRANSMISSION TROUBLE WARNING 8-228 F3 FUSE STEERING, 10A N/S P3 CONNECTOR RESERVED
- AL*** 8-228 F4 FUSE REAR WINDOW DEFROSTER, 20A 4-122 P4 CONNECTOR FUSE BOX
6-170 B1 MOTOR STARTER 8-223 F5 FUSE PARKING BRAKE, 10A N/S P5,6 CONNECTOR RESERVED (REAR)
4-120 B2 MOTOR WINDSHIELD WASHER PUMP 8-223 F6 FUSE CAB RAISE/LOWER, 10A 3-68 P7 CONNECTOR REAR CAB INTERFACE
4-115 B3 MOTOR WINDSHIELD WIPER, RIGHT HAND 8-223 F7 FUSE CAB SELECT, 10A 3-73 P8 CONNECTOR MAIN HARNESS INTERFACE
2-51 B4 MOTOR WINDSHIELD WIPER, LEFT HAND 8-223 F8 FUSE RESERVED 3-65 P9 CONNECTOR STEERING INTERFACE
5-150 B5 MOTOR EMERGENCY STEERING PUMP 8-218 F9 FUSE TURN/BRAKE/BACK-UP LIGHTS, 15A N/S P10 CONNECTOR RESERVED (REAR)
1-23 B6 MOTOR CAB DEFROSTER/COOLING, RIGHT HAND 8-218 F10 FUSE HEATER - COOL FAN, 20A 5-144 P11 CONNECTOR PASSIVE STEERING
1-23 B7 MOTOR CAB DEFROSTER/COOLING, LEFT HAND 8-218 F11 FUSE HORN, 20A N/S P12 CONNECTOR RESERVED (REAR)
1-21 B8 MOTOR CAB ROOF WIPER 8-218 F12 FUSE INSTRUMENT PANEL, 20A 5-142 P13 CONNECTOR STEERING BOX (STANDARD)
- B*** 8-213 F13 FUSE EMERGENCY STEERING, BEACON AND FRONT HITCH, 15A N/S P14 CONNECTOR RESERVED (REAR)
7-191 BT1 BATTERY 12V 8-213 F14 FUSE HEADLIGHTS, 20A 6-180 P15 CONNECTOR TRANSMISSION SOLENOID VALVES
7-192 BT2 BATTERY 12V 8-213 F15 FUSE WINDSHIELD WIPER, 30A 6-179 P16 CONNECTOR VEHICLE SPEED SENSOR (ZF)
- BT*** 8-213 F16 FUSE RESERVED 6-171 P17 CONNECTOR ENGINE PLUG
N/S CB1 CIRCUIT B. RESERVED 7-171 F17 FUSE FUSIBLE LINK, 14 GA. 6-175 P18 CONNECTOR ENGINE PLUG
7-191 CB2 CIRCUIT B. MAIN, 120A 7-189 F21 FUSE EMERGENCY PUMP, 225A 2-41 P19 CONNECTOR INSTRUMENT GAUGES
- CB*** 2-61 F22 FUSE GAUGES, 5A 1-29 P20 CONNECTOR CEILING INTERFACE
8-227 CR1-4 RECTIFIER BLOCKING, STEERING - F*** 1-10 P21 CONNECTOR FRONT LIGHTS
N/S CR5-9 RECTIFIER RESERVED (REAR) 3-87 FL1 FLASHER TURN SIGNAL LIGHTS 7-202 P22 CONNECTOR REAR LIGHTS
3-80 CR10 RECTIFIER BLOCKING, PARKING BRAKE 3-87 FL2 FLASHER BEACON LIGHT (FLASHING BEACON) 6-179 P23 CONNECTOR TURBINE SPEED SENSOR (ZF)
3-80 CR11 RECTIFIER BLOCKING, CAB LIFT - FL*** 2-38 P24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK-UP
3-80 CR12 RECTIFIER BLOCKING, CAB LIFT 6-174 G1 GENERATOR 12 VDC 8-228 P25 CONNECTOR DIODE MODULE, STEERING, CR28-31
N/S CR13-15 RECTIFIER RESERVED (REAR) - G*** 8-228 P26 CONNECTOR DIODE MODULE, STEERING, CR1-CR4
2-61 CR16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A 2-56 GA1 GAUGE FUEL LEVEL, W/ 1/8 WARNING N/S P27 CONNECTOR RESERVED (REAR)
N/S CR17-21 RECTIFIER RESERVED 2-48 GA2 GAUGE ENGINE COOLANT TEMPERATURE 2-59 P28 CONNECTOR IGNITION/LIGHT SWITCH
3-73 CR22 RECTIFIER ENGINE WARNING ALARM, OIL PRESSURE LT. 2-46 GA3 GAUGE ENGINE OIL PRESSURE 2-40 P29 CONNECTOR STEERING MODE INDICATOR LIGHTS
3-73 CR23 RECTIFIER ENGINE WARNING ALARM, COOLANT TEMP. LT. 2-48 GA4 GAUGE TRANSMISSION OIL TEMPERATURE 2-52 P30 CONNECTOR WINDSHIELD WIPER MOTOR, LEFT HAND
3-73 CR24 RECTIFIER ENGINE WARNING ALARM, COOLANT LEVEL LT. 2-46 GA5 GAUGE VOLTMETER 4-116 P31 CONNECTOR WINDSHIELD WIPER MOTOR, RIGHT HAND
3-73 CR25 RECTIFIER ENGINE WARNING ALARM, TRANSMISSION TEMP. LT. 2-52 GA6 GAUGE TACHOMETER 1-6 P32 CONNECTOR RIGHT HAND HEADLIGHT
8-227 CR28-31 RECTIFIER BLOCKING, STEERING 2-44 GA7 GAUGE SPEEDOMETER 1-6 P33 CONNECTOR LEFT HAND HEADLIGHT
8-220 CR32 RECTIFIER BLOCKING, STEERING SYSTEM - GA*** 1-4 P34 CONNECTOR FRONT HITCH LIGHT
- CR*** 6-168 GND GROUND CH ENGINE/WELDMENT N/S P35-38 CONNECTOR RESERVED (REAR)
2-53 DS1 LIGHT LEFT TURN INDICATOR 2-60 GND1 GROUND CH FRONT CAB, LEFT HAND 7-207 P39 CONNECTOR LEFT HAND REAR LIGHTS
2-52 DS2 LIGHT LOW OIL PRESSURE INDICATOR 4-118 GND2 GROUND CH FRONT CAB, RIGHT HAND 7-207 P40 CONNECTOR RIGHT HAND REAR LIGHTS
2-50 DS3 LIGHT RESERVED 5-134 GND3 GROUND CH STEERING BOX N/S P41 CONNECTOR RESERVED
2-44 DS4 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR 4-125 GND4 GROUND CH LIFT CAB VALVES 5-136 P42 CONNECTOR REAR CAB STEERING INTERFACE
2-42 DS5 LIGHT HIGH BEAM INDICATOR N/S GND5 GROUND CH RESERVED 2-53 P43 CONNECTOR TURN SIGNAL
2-40 DS6 LIGHT RIGHT TURN INDICATOR 7-195 GND6 GROUND CH STEERING VALVES 4-113 P44 CONNECTOR HEATER - FAN, CAB
2-53 DS7 LIGHT LOW COOLANT LEVEL INDICATOR (OPT.) 7-195 GND7 GROUND CH BATTERY N/S P45,46 CONNECTOR RESERVED (REAR)
2-52 DS8 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR 7-208 GND8 GROUND CH REAR CAB 7-201 P47 CONNECTOR REAR HITCH LIGHT
2-50 DS9 LIGHT RESERVED - GND*** N/S P48,49 CONNECTOR RESERVED
2-45 DS10 LIGHT RESERVED 1-4 H1 HORN VEHICLE, FRONT N/S P50 CONNECTOR RESERVED (REAR)
2-42 DS11 LIGHT PARK BRAKE APPLIED INDICATOR 1-17 H2 HORN VEHICLE CAB, FRONT, LEFT HAND (ROOF) 3-79 P51 CONNECTOR DIODE MODULE, CR9-CR12
2-40 DS12 LIGHT GENERATOR NO CHARGE INDICATOR 1-17 H3 HORN VEHICLE CAB, FRONT, RIGHT HAND (ROOF) 2-46 P52 CONNECTOR FRONT SHIFTER UPSHIFT INTERLOCK
2-55 DS13 LIGHT FRONT DASH PANEL, LEFT HAND - H*** N/S P53 CONNECTOR RESERVED (REAR)
2-40 DS14 LIGHT FRONT DASH PANEL, RIGHT HAND 8-217 KA RELAY STEEERING MODE 'ON' INTERLOCK 5-150 P54 CONNECTOR COORD/CRAB SELECT VALVE, FRONT MODE
2-49 DS15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE 8-219 KB RELAY FRONT AXLE LEFT OF CENTER N/S P55-57 CONNECTOR RESERVED (REAR)
2-47 DS16 LIGHT ENGINE OIL PRESSURE GAUGE N/S K1-8 RELAY RESERVED (REAR) 1-28 P58 CONNECTOR REAR WINDOW DEFROSTER
2-49 DS17 LIGHT TRANSMISSION OIL TEMPERATURE GAUGE 8-217 K9 RELAY COORD STEERING, FRONT CONTROL N/S P59-61 CONNECTOR RESERVED
2-47 DS18 LIGHT VOLTMETER 8-219 K10 RELAY CRAB STEERING, FRONT CONTROL 1-4 P62 CONNECTOR HORN
2-53 DS19 LIGHT TACHOMETER 8-222 K11 RELAY FRONT AXLE REED SWITCH N/S P63 CONNECTOR RESERVED
2-45 DS20 LIGHT SPEEDOMETER 8-224 K12 RELAY REAR AXLE REED SWITCH 3-74 P64 CONNECTOR DIODE MODULE, ENGINE WARNING ALARM, CR22-CR25
2-38 DS21 LIGHT COORD STEERING MODE INDICATOR N/S K13-18 RELAY RESERVED 3-89 P72 CONNECTOR RIGHT TURN SENSING SWITCH
2-28 DS22 LIGHT TRACK STEERING MODE INDICATOR 5-150 K19 RELAY EMERGENCY STEERING PUMP MOTOR 3-85 P73 CONNECTOR LEFT TURN SENSING SWITCH
2-28 DS23 LIGHT CRAB STEERING MODE INDICATOR 3-82 K20 RELAY PARK BRAKE ON - STARTER ENABLE 5-141 P74 CONNECTOR FRONT AXLE LEFT OF CENTER REED SWITCH
N/S DS24-31 LIGHT RESERVED (REAR) 3-79 K21 RELAY SHIFTER IN NEUTRAL 5-150 P100 CONNECTOR PARK BRAKE SET VALVE
2-33 DS32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB) 3-77 K22 RELAY HORN 5-150 P103 CONNECTOR PARK BRAKE RELEASE VALVE
2-56 DS33 LIGHT FUEL LEVEL GAUGE 3-75 K23 RELAY TRANSMISSION NOT IN N-, PARK BRAKE APPLIED 4-123 P104 CONNECTOR CAB LOWER SOLENOID VALVE
1-3 DS34 LIGHT HEAD, LEFT HAND 3-73 K24 RELAY SHIFTER, BACK-UP 4-123 P105 CONNECTOR CAB RAISE SOLENOID VALVE
1-3 DS35 LIGHT HEAD, RIGHT HAND 3-71 K25 RELAY LOCK-UP UNIT (DOWNSHIFT) 7-196 P108 CONNECTOR REAR AXLE REED SWITCH
1-3 DS36 LIGHT TURN, FRONT, LEFT HAND N/S K26-29 RELAY RESERVED (REAR) 5-137 P109 CONNECTOR FRONT AXLE RIGHT OF CENTER REED SWITCH
1-3 DS37 LIGHT TURN, FRONT, RIGHT HAND 8-231 K30 RELAY IGNITION (MASTER) - P***
1-20 DS38 LIGHT CAB DOME 6-166 K31 RELAY STARTER SOLENOID AUXILIARY
1-3 DS39 LIGHT FRONT HITCH N/S K32-35 RELAY RESERVED
N/S DS40-56 LIGHT RESERVED (REAR) 2-58 K36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
7-210 DS57 LIGHT TURN, REAR, RIGHT HAND - K***
7-210 DS58 LIGHT BRAKE, RIGHT HAND 6-180 L1-5 SOLENOID TRANSMISSION VALVE BODY, ZF/ Y1-Y5
7-210 DS59 LIGHT TAIL, RIGHT HAND 6-173 L6 SOLENOID ENGINE RUN VALVE
7-210 DS60 LIGHT BACK-UP, RIGHT HAND N/S L7 SOLENOID RESERVED Figure 2-2. Wiring Diagram with Cat/Engine
7-210 DS61 LIGHT BACK-UP, LEFT HAND N/S L8,9 SOLENOID RESERVED (REAR)
7-210 DS62 LIGHT TAIL, LEFT HAND 5-151 L10 SOLENOID PARKING BRAKE SET VALVE Sheet 10 of 11
7-210 DS63 LIGHT BRAKE, LEFT HAND
2-2-34 CD276
Rev 13
Chapter 2
LEGEND
SH. - GRID ITEM DESCRIPTIONS
N/S R1 SENSOR RESERVED
6-179 R2 SENSOR TURBINE SPEED (ZF)
6-179 R3 SENSOR TRANSMISSION TEMPERATURE
6-174 R4 SENSOR ENGINE COOLANT TEMPERATURE NOTES:
7-197 R5 SENSOR FUEL LEVEL
1. ALL TUG WIRING IS 16 GA. SXL WIRE, UNLESS OTHERWISE NOTED.
6-179 R6 SENSOR VEHICLE SPEED (ZF)
6-172 R7 SENSOR ENGINE OIL PRESSURE 2. ALL CONNECTORS SHOWN FROM MATING END VIEW, UNLESS OTHERWISE INDICATED.
N/S R8-10 SENSOR RESERVED 3. VENDOR WIRING
6-167 R11 SENSOR ENGINE SPEED (MAGNETIC PICK-UP) 4. S&S WIRING
- R***
5. (S) FOR CONNECTOR SOCKET
2-38 S1 SWITCH WIPER
2-36 S2 SWITCH WINDSHIELD WASHER 6. (P) FOR CONNECTOR PIN
2-34 S3 SWITCH RESERVED 8. SPL(NO.) INDICATES POINT WHERE WIRES WITH SAME WIRE NUMBER ARE
2-58 S4 SWITCH BLOWER FAN SPLICED TOGETHER.
2-38 S5 SWITCH RESERVED
2-36 S6 SWITCH PARK LIGHT
2-34 S7 SWITCH HIGH-LOW BEAM
2-60 S8 SWITCH REAR WINDOW DEFROSTER, TOUCH PAD
N/S S9 SWITCH RESERVED
2-58 S10 SWITCH EMERGENCY STEERING
2-38 S11 SWITCH FRONT HITCH LIGHT
2-36 S12 SWITCH REAR HITCH LIGHT
2-34 S13 SWITCH BEACON
REFERENCE TUG DRAWINGS:
2-33 S14 SWITCH STEERING MODE SELECT FIGURE 5.1.17 SINGLE CAB (STATION) SCHEMATIC
2-33 S15 SWITCH CAB LIFT FIGURE 5.1.18 WIRING DIAGRAM
N/S S16-18 SWITCH RESERVED SH. 1 - CAB WIRING / REFERENCE LOCATIONS
N/S S19 SWITCH RESERVED (REAR) SH. 2 - FRONT CAB CONTROL PANEL/LEFT SIDE UNDER DASH
2-61 S20 SWITCH DASH LIGHT SH. 3 - FRONT CAB CONSOLE
2-59 S21 SWITCH EMERGENCY ENGINE STOP SH. 4 - RIGHT SIDE UNDER PANEL/WELDMENT / REFERENCE LOCATIONS
SH. 5 - WELDMENT WIRING
2-61 S22 SWITCH STOP, RUN, START
SH. 6 - WELDMENT WIRING / REFERENCE LOCATIONS
2-55 S23 SWITCH HORN SH. 7 - WELDMENT WIRING
N/S S24 SWITCH RESERVED (REAR) SH. 8 - CONTROL BOXES
5-137 S25 SWITCH FRONT AXLE RIGHT OF CENTER REED SH. 9 - COLD WEATHER START ASSISTANCE / SINGLE CAB INTERCONNECTING DIAGRAM
2-55 S26 SWITCH TURN SIGNAL SH.10 & 11 - MASTER LEGEND AND NOTES
2-41 S27 SWITCH PARK BRAKE
5-150 S28 SWITCH PARKING BRAKE PRESSURE,
OPENS AT 1800 PSI ON FALLING PRESSURE
7-196 S29 SWITCH REAR AXLE REED
N/S S30-37 SWITCH RESERVED (REAR)
1-17 S38 SWITCH CAB WAND, RIGHT HAND WIRE IDENTIFICATION
1-14 S39 SWITCH CAB WAND, CENTER 243 / P44 A
1-17 S40 SWITCH CAB WAND, LEFT HAND
7-191 S41 SWITCH EMERGENCY STEERING PRESSURE, WIRE NUMBER GOES TO
OPENS AT 1800 PSI ON FALLING PRESSURE
6-179 S42 SWITCH TRANSMISSION HIGH TEMPERATURE
7-191 S43 SWITCH BRAKE PRESSURE (BRAKE LIGHTS)
CLOSES AT 50 PSI
N/S S44-48 SWITCH RESERVED
5-141 S49 SWITCH FRONT AXLE LEFT OF CENTER REED
N/S S50,51 SWITCH RESERVED
3-90 S52 SWITCH RIGHT TURN SENSING
3-84 S53 SWITCH LEFT TURN SENSING
6-177 S54 SWITCH ENGINE SPEED, START INTERLOCK
6-170 S55 SWITCH ENGINE LOW OIL PRESSURE,
OPENS AT 10 PSI ON RISING PRESSURE Figure 2-2. Wiring Diagram with Cat/Engine
6-176 S56 SWITCH ENGINE HIGH COOLANT TEMPERATURE,
Sheet 11 of 11
CLOSES AT 205°F
- S***
CD276 2-2-35
Rev 13
Chapter 2
CAB CHAR-LYNN
STEERING CONTROL UNIT
48 CUBIC IN. DISPLACEMENT
COORD/CRAB
SELECTOR VALVE
L L
(SV) DOUBLE PILOT
b CHECK VALVE
RETURN MANIFOLD T C2
FRONT R T A REAR R
FROM PRESSURE DISTRIBUTION BLOCK P
P B L
C1
FOR STEERING CIRCUIT FOR
a (DPCV) REAR OPERATOR STATION
OPTION, SEE SHEET 2 OF 2
REMOTE
HAND PUMP
(HP)
R
SHUTTLE
VALVE (PBSV)
T
P H ACCUMULATOR
PARK BRAKE PRE-CHARGE
PARK LIGHT SWITCH 600 PSI
BRAKE C
(SET @ 1800 PSI) (ACC)
A
A B
FRONT REAR
GP P2 B BRAKE BRAKE
PARK BRAKE
DUAL CHECK
P VALVE (PBV) T
RELIEF VALVE
RELIEF SET @ ACCUMULATOR
FOR OPTIONAL T
ENGINE 2500 PSI (DCRV) PRE-CHARGE
JACKING
A BAY
SYSTEM SCHEM.
600 PSI
(ACC) REAR OPERATOR BRAKE LIGHT
COMPARTMENT OPTION SWITCH
CAB LIFT (SET @ 50 PSI)
PB CL CYLINDER
SPR 2.50 BORE 28 STROKE
RES
DUAL CHECK / RES
DIST VALVE RETURN
GP1 MANIFOLD (RM) C
EMERGENCY PUMP SWITCH (DCDV)
(SET @ 1800 PSI) P1 P2
FRONT REAR
CAB CAB A A
CAB LIFT
P VALVE T
SLAVE
(CLV) CYLINDERS
12 VDC
RETURN
T P T P BRAKE VALVE
FILTER
M (RF) 2000 PSI
(BV)
OPTION
PRESSURE SET @ 2000 PSI

PUMP @ 45 GPM @ 2400 RPM EMERGENCY PUMP NOTE: SHUTOFF VALVES SOV - 1, SOV - 2, & SOV - 3 ARE OPTIONAL
STEERING/BRAKE ENGINE SPEED RELIEF @ 2500 PSI A
(P-1)
A 2.2 GPM @ 0 PSI A
(SOV - 1) A (SOV - 2) (P-2) (SOV - 3)
NOTE: THIS SCHEMATIC EFFECTIVE WITH GT-110 TRACTORS WITH
B SERIAL NUMBERS THROUGH GT-110-172
RESERVOIR CAPACITY
30 GALLONS
Figure 2-3. Hydraulic Schematic
Sheet 1 of 2
2-2-36 CD276
Rev 13
Chapter 2
TO RETURN MANIFOLD
FROM PRESSURE DISTRIBUTION BLOCK
(SEE SHEET 1 OF 2)
P T STEERING
ORBITAL SELECT
AB VALVE (SV1)
P T P T
C C
L R L R
FRONT STEERING REAR STEERING
ORBITAL VALVE ORBITAL VALVE
DISPLACEMENT DISPLACEMENT
95 CU. IN. / REV. 95 CU. IN. / REV.
GAGE PORTS (TYP 6 PLCS)
FL GF FR RL RF GR SOLENOID (SV2)
SOLENOID (SV2) - 2 WHEEL
- 2 WHEEL a 4 WHEEL
a 4 WHEEL B CRAB
B CRAB b A B b A B
a-P TO B a a a-P TO B
b-P TO A b-P TO A
P T P T
SOLENOID SOLENOID
DIRECTIONAL DIRECTIONAL
CONTROL CONTROL
VALVE VALVE
1.1 1.2 1.4 1.6 1.5 1.8 STEERING MANIFOLD

1.3 1.7 (SM)
C1 C2 FG1 FG2 RG2 RG1 C1 C2
LEFT RIGHT LEFT RIGHT
FRONT AXLE REAR AXLE

STEERING SYSTEM SCHEMATIC WITH Sheet 2 of 2
REAR OPERATOR'S COMPARTMENT
CD276 2-2-37
Rev 13
Chapter 2
CAB CHAR-LYNN
STEERING CONTROL UNIT
48 CUBIC IN. DISPLACEMENT
COORD/CRAB
SELECTOR VALVE
L L
(SV) DOUBLE PILOT
b CHECK VALVE
RETURN MANIFOLD T C2
FRONT R T A REAR R
FROM PRESSURE DISTRIBUTION BLOCK P
P B L
C1
FOR STEERING CIRCUIT FOR
REMOTE HAND PUMP a (DPCV) REAR OPERATOR STATION
W/ INTEGRATED SHUTTLE VALVE OPTION, SEE SHEET 2 OF 2
B T
ACCUMULATOR
PARK BRAKE PRE-CHARGE
PARK 600 PSI
LIGHT SWITCH
BRAKE (ACC)
(SET @ 1800 PSI)
A
A B
FRONT REAR
GP P2 B BRAKE BRAKE
PARK BRAKE
DUAL CHECK
P VALVE (PBV) T
RELIEF VALVE
RELIEF SET @ ACCUMULATOR
FOR OPTIONAL T
ENGINE 2500 PSI (DCRV) PRE-CHARGE
JACKING
BAY 600 PSI
SYSTEM SCHEM.
(ACC) REAR OPERATOR BRAKE LIGHT
COMPARTMENT OPTION SWITCH
CAB LIFT (SET @ 50 PSI)
PB CL CYLINDER
SPR 2.50 BORE 28 STROKE
RES
DUAL CHECK / RES
DIST VALVE RETURN
GP1 MANIFOLD (RM) C
EMERGENCY PUMP SWITCH (DCDV)
(SET @ 1800 PSI) P1 P2
FRONT REAR
CAB CAB A A
CAB LIFT
P VALVE T
SLAVE
(CLV) CYLINDERS
12 VDC
RETURN
T P T P BRAKE VALVE
FILTER
M (RF) 2000 PSI
(BV)
OPTION
PRESSURE SET @ 2000 PSI

PUMP @ 45 GPM @ 2400 RPM EMERGENCY PUMP
STEERING/BRAKE ENGINE SPEED RELIEF @ 2500 PSI NOTE: SHUTOFF VALVES SOV - 1, SOV - 2, & SOV - 3 ARE OPTIONAL
(P-1) 2.2 GPM @ 0 PSI
(SOV - 1) (SOV - 2) (P-2) (SOV - 3)
NOTE: THIS SCHEMATIC EFFECTIVE WITH GT-110 TRACTORS
STARTING WITH SERIAL NUMBER GT-110-173
RESERVOIR CAPACITY
30 GALLONS Figure 2-4. Hydraulic Schematic
Sheet 1 of 2
2-2-38 CD276
Rev 13
Chapter 2
TO RETURN MANIFOLD
FROM PRESSURE DISTRIBUTION BLOCK
(SEE SHEET 1 OF 2)
P T STEERING
ORBITAL SELECT
AB VALVE (SV1)
P T P T
C C
L R L R
FRONT STEERING REAR STEERING
ORBITAL VALVE ORBITAL VALVE
DISPLACEMENT DISPLACEMENT
95 CU. IN. / REV. 95 CU. IN. / REV.
GAGE PORTS (TYP 6 PLCS)
FL GF FR RL RF GR SOLENOID (SV2)
SOLENOID (SV2) - 2 WHEEL
- 2 WHEEL a 4 WHEEL
a 4 WHEEL B CRAB
B CRAB b A B b A B
a-P TO B a a a-P TO B
b-P TO A b-P TO A
P T P T
SOLENOID SOLENOID
DIRECTIONAL DIRECTIONAL
CONTROL CONTROL
VALVE VALVE
1.1 1.2 1.4 1.6 1.5 1.8 STEERING MANIFOLD

1.3 1.7 (SM)
C1 C2 FG1 FG2 RG2 RG1 C1 C2
LEFT RIGHT LEFT RIGHT
FRONT AXLE REAR AXLE

STEERING SYSTEM SCHEMATIC WITH REAR OPERATOR'S COMPARTMENT Sheet 2 of 2
CD276 2-2-39
Rev 13
Chapter 2
E1
FUSE BOX
POWER
STUD
6 BLK
CB2 6 BLK 12V BATTERY (BREAKER) B(+)
BATTERY E3 120A 128

POWER STUD 6 BLK
B(+) 125 12V IGNITION SWITCH
BUS BAR
TO F11
2/0 BLK
F12
10A
LEGEND
E2
BT1 BT2 ITEM DESCRIPTION
65 112
A 7 ASSEMBLY STARTER MOTOR (SOLENOID & MOTOR)
+ + A 8 ASSEMBLY ECU GLOW PLUG
ENGINE
POWER CB1 P4 B 1 MOTOR STARTER
1
STUD 170 B 5 MOTOR EMERGENCY STEERING PUMP
120A
- - 112 BT 1 BATTERY BATTERY, 12 VOLTS
BT 2 BATTERY BATTERY, 12 VOLTS
P28 CB 1 CIRCUIT B. GLOW PLUG 120A
6 BLK
(-) C B
CB 2 CIRCUIT B. MAIN 120A
P7 121 121 112 DS 3 LIGHT GLOW PLUG INDICATOR
1
S22 E 1 STUD FUSE BOX POWER
WELDMENT 170 B
E 2 STUD ENGINE POWER
CONT.SH.4
31 3
34 F17 E 3 STUD BATTERY POWER
NO ST
20A 108 E 4 STUD GLOW PLUG POWER
6 BLK
IGN
4 F 12 FUSE INSTRUMENT PANEL, 10A
127 101 ACC
2 F 17 FUSE STARTER, 20 AMPS
173 P7 S27 G 1 GENERATOR 12 VDC- 95 AMPS
159
125 GP1-6 RESISTOR GLOW PLUG
173 122 D
109 K 19 RELAY EMERGENCY STEERING PUMP MOTOR
126
P28 K 20 RELAY PARK BRAKE ON -STARTER ENABLE
5 4 3 K 30 RELAY IGNITION (MASTER)
125 K 31 RELAY STARTER SOLENOID AUXILIARY
8
L 17 SOLENOID ENGINE STARTER
30 86
2 P 4 CONNECTOR FUSE BOX
P4
2/0 BLK
P 7 CONNECTOR REAR CAB INTERFACE

A8 178 87 85 P 8 CONNECTOR MAIN HARNESS INTERFACE
25 K20 P 17 CONNECTOR ENGINE PLUG
9 P41 P8
C A D B(+) P 18 CONNECTOR ENGINE PLUG (YELLOW)
1 125
36 52 P 28 CONNECTOR IGN/LIGHT SWITCH
178 P 38 CONNECTOR STARTER SOLENOID AUX. RELAY
129 136 K31 P 39 CONNECTOR L.H. REAR LIGHTS
P 41 CONNECTOR ECU GLOW PLUG
P8 P38 S 22 SWITCH STOP, RUN, START
6 BLK
2 E F
S 27 SWITCH PARK BRAKE
228 86 30
P17 1
P17 127
2
199 127 85 87
K30 NOTES:
1. ALL RELAYS AND SWITCHES SHOWN DE-ENERGIZED (DE-ACTUATED).
2. INDICATES OPTIONAL WIRING
159 128 3. INDICATES VENDOR WIRING
E4
GLOW PLUG 4. * INDICATES OPTIONAL COMPONENTS
P18 POWER STUD
1
D+ B+ W
K19 + REFERENCE S&S TUG DRAWINGS:

FIGURE 5.1.7 ELECTRICAL EQUIPMENT LOCATION
L17
FIGURE 5.1.16 WIRING DIAGRAM

G
FIGURE 4.2.18 REFERENCE DESIGNATORS/PART
M NUMBERS/LOCATION INDEX
- DS3
B5 B1 A7 GP1 GP2 GP3 GP4 GP5 GP6
G1
EMERG STEERING ALTERNATOR START MOTOR COLD START (GLOW PLUG) CONTROL CIRCUIT MASTER IGNITION RELAY
PUMP START
Figure 2-5. Schematic, Front & Rear Cab (Station)

Sheet 1 of 8
2-2-40 CD276
Rev 13
Chapter 2
B(+) 12V BATTERY (BREAKER) B(+)
128 12V IGNITION (MASTER RELAY) 128
125 12V IGNITION SWITCH 125
LEGEND
224 12V PARK SWITCH 224
BUS BAR
FROM F3 101 101
ITEM DESCRIPTION
F1 DS 2 LIGHT LOW OIL PRESSURE INDICATOR

10A P8 P7 DS 4 LIGHT TRANSMISSION HI OIL TEMP INDICATOR
4 24
DS 7 LIGHT LOW COOLANT LEVEL INDICATOR
101 101 125 101 125 101 101 101 224 224 224 224 224 DS 8 LIGHT ENGINE HI COOLANT TEMP INDICATOR
125 125 125 125 125 DS12 LIGHT GENERATOR NO CHARGE INDICATOR
P4 3 DS13 LIGHT FRONT DASH PANEL, LEFT HAND
13 DS14 LIGHT FRONT DASH PANEL, RIGHT HAND
101 101 224 101 224 101 101 101 224
DS15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE
10 101 DS16 LIGHT ENGINE OIL PRESSURE GAUGE
GA7 DS17 LIGHT TRANSMISSION OIL TEMP GAUGE
P28 GA3 GA2 GA5 GA6 GA1 GA4 DS18 LIGHT VOLTMETER
127 A
101 DS19 LIGHT TACHOMETER
+
S21 + + DS7 DS4 I + I + DS20 LIGHT SPEEDOMETER
DS33 LIGHT FUEL LEVEL GAUGE
− − G − − DS40 LIGHT GENERATOR NO CHARGE INDICATOR (REAR)
P18 S
DS2 S S S − S G S
DS41 LIGHT LOW OIL PRESSURE INDICATOR (REAR)
2 123
S
130 132 136 DS42 LIGHT TRANSMISSION HI OIL TEMP IND. (REAR)
137 138 135 139
E 4 5 DS43 LIGHT LOW COOLANT LEVEL INDICATOR (REAR)
P28 DS44 LIGHT ENGINE HI COOLANT TEMP IND. (REAR)
129 129 P19 131 P19 133 134 140
123 F 1 FUSE ENGINE, 10A
7 11 12 6 8 3
P8 P19 GA 1 GAUGE FUEL LEVEL
3
6 7 8 9 5 GA 2 GAUGE ENGINE COOLANT TEMPERATURE
127 123 P7 224 GA 3 GAUGE ENGINE OIL PRESSURE
P42 GA 4 GAUGE TRANS OIL TEMPERATURE
E 123
GA 5 GAUGE VOLTMETER
GA 6 GAUGE TACHOMETER
GA 7 GAUGE SPEEDOMETER
136 137 138 135 139 156 L 6 SOLENOID ENGINE RUN VALVE
129 130 131 132 133 134 140
L 7 SOLENOID EXCESS START FUEL ALLOWANCE
P 4 CONNECTOR FUSE BOX
L7 S30 P 7 CONNECTOR REAR CAB INTERFACE
B 124
F P 8 CONNECTOR MAIN HARNESS INTERFACE
P8 P8 11 12 17 18 19
P42 1 5 6 7 8 9 10 P 16 CONNECTOR SPEED SENSOR (ZF)
129 P 17 CONNECTOR ENGINE PLUG
124 130 131 132 133 134 140 P 18 CONNECTOR ENGINE PLUG (YELLOW)
224
4 P 19 CONNECTOR INSTRUMENT GAUGES
P17 P 28 CONNECTOR IGN/LIGHT SWITCH
7 5 6 3 4 P 42 CONNECTOR REAR CAB STEER INTERFACE
SEE GRID 235
FOR ENG.COOLANT P 48 CONNECTOR ENGINE COOLANT LEVEL SENSOR
HEATER INTERFACE 137 138 135 139 R 1 SENSOR ENGINE COOLANT LEVEL
3
R 3 SENSOR TRANSMISSION TEMPERATURE
1 G WK 1 2 224
R 4 SENSOR ENGINE HI COOLANT TEMP. SW - SENDER
CLOSES AT 239°F
P R 5 SENSOR FUEL LEVEL
JP1 136
R 6 SENSOR SPEED
R 7 SENSOR ENGINE LOW OIL SW - SENDER
2 6 AT 5.8 PSIG ON FALLING PRESSURE
R7 R4 R1 2 S42 DS13 DS14
L6 R6 R5 R3 S 21 SWITCH EMERGENCY ENGINE STOP
P48 P16 S 30 SWITCH EMERGENCY ENGINE STOP (REAR)
S 42 SWITCH TRANSMISSION HI TEMPERATURE
ACCESS RUN GENERATOR OIL COOLANT COOLANT TRANSM. VOLT TACHO SPEEDO FUEL TRANSM.
VOLUME SOLENOID NO CHARGE PRESSURE TEMP LEVEL TEMP. METERS GAUGE TEMP.
SOLENOID GAUGES/WARNING LIGHTS DASH LIGHTS GAUGE
ENGINE GAUGES/WARNING LIGHTS

Sheet 2 of 8
CD276 2-2-41
Rev 13
Chapter 2
BUS BAR
190 FROM F3
LEGEND
115
86 85
190
187 F2 ITEM DESCRIPTION
156 87 10A
90 A 1 ASSEMBLY ZF FRONT CAB SHIFTER
30 102 102 A 2 ASSEMBLY ZF REAR CAB SHIFTER
149 P6 5A
102 6 A 3 ASSEMBLY TRANSMISSION VALVE BODY
K29 5 A 4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCKUP
CR20 RECTIFIER BLOCKING, DOWNSHIFT LOCK
P7 P7 P4 CR 21 RECTIFIER BLOCKING, DOWNSHIFT LOCK
102 5
11 12 P10 61 F 2 FUSE TRANSMISSION, 10A
149 P52 7 T
P5 A2 K 6 RELAY SHIFTER CHANGE OVER CONTROL
141 141
ED2 AD1
151 7 P53 156 K 7 RELAY SHIFTER CHANGE OVER CONTROL
1 AD1 ED2
1 8 142 U 142 1 K 21 RELAY SHIFTER IN NEUTRAL
AD2 VP(+)
JPR 7 4 143 V 143 152 8 1
K 25 RELAY LOCK UP UNIT (DOWNSHIFT)
ED3 AD3 AD2 K 29 RELAY UP SHIFT INHIBITOR TRANSFER
2 A1 3 144 W 144 153 4 7 JPR L 1-5 SOLENOID TRANSMISSION VALVE BODY, ZF/Y1-Y5
ED1 AD4 AD3 ED3
P 1 CONNECTOR SHIFTER (TRANSMISSION), FRONT CAB
2 145 X 145 154 3 2
AD9 AD5 AD4 ED1 P 2 CONNECTOR SHIFTER (CAB), FRONT CAB
146
3 AD6 P1 P2 155 2 P 4 CONNECTOR FUSE BOX
P2 AD5
VVP(+) P6 P 5 CONNECTOR SHIFTER (TRANSMISSION), REAR CAB
5A 5 AD9 61
246 P 6 CONNECTOR SHIFTER (CAB), REAR CAB
P7 AD6 P 8 CONNECTOR MAIN HARNESS INTERFACE
246 27
P 10 CONNECTOR CONTROL BOX
P1 6 4
6 P2 P10 P 15 CONNECTOR TRANSMISSION SOLENOID VALVES
H J K F A
164
P 23 CONNECTOR TURBINE SPEED SENSOR (ZF)
119 114 P 24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK UP
148 P5
102 102 3 4 6 6 P 52 CONNECTOR FRONT SHIFTER UP SHIFT INTERLOCK
P6 P 53 CONNECTOR REAR SHIFTER UP SHIFT INTERLOCK
151
191
141
144
154
143
190
142
152
153
155
10
191 P 57 CONNECTOR DIODE MODULE TRANSMISSION SHIFTER
157 R 2 SENSOR TURBINE SPEED (ZF)
C P7 86 30 K25 86 30 190
8 9 5 4 6 10 6 10 8 9 5 4 194
P57 147 85 87 85 87 158
F K21
RESET
RESET
SET
SET
245
182 11 1 3 2 3 2 11 1
170
163
165
162
164
K6 K7
177 177 M N P
19 P10 S R
JPR E P10
92 112 L
164 165
P57 P24 158
D A4
145
162
163
164
245 5 6 161
1 AD2 ED1 3 165
150
P8 150 2 3 102 A E D C B 109
4 EF VP(+) 6
21 2
L5
L3
L2
L4
L1
1
P24
R2 F
146 P23
A3
90 P15
FRONT CAB CONTROL VALVE BODY/TRANSFER RELAY REAR CAB CONTROL

TRANSMISSION
SHIFTER OUTPUT SIGNAL
MARKED
SHIFTER
FORWARD REVERSE NEUTRAL
POINT
GEAR 1 2 3 4 1 2 3 NF NF NR N
AD1
AD2
AD3
AD4
AD5
AD6 Figure 2-5. Schematic, Front & Rear Cab (Station)
Sheet 3 of 8
2-2-42 CD276
Rev 13
Chapter 2

LEGEND
128 ITEM DESCRIPTION
BUS BAR BUS BAR
FROM F7 TO F6, F5 CR 10 RECTIFIER BLOCKING, PARKING BRAKE
F5 F7 117 18 86 CR 14 RECTIFIER BLOCKING, NEUTRAL LIGHT
10A 10A 108 DS 11 LIGHT PARK BRAKE APPLIED INDICATOR
DS 24 LIGHT REAR SHIFTER NOT IN NEUTRAL INDICATOR
105 170
P4 P7 107 P12 107 158 DS 25 LIGHT SHIFTERS IN NEUTRAL INDICATOR
107 107 183
P4 DS 26 LIGHT FRONT CAB SELECTED INDICATOR
6 7 22 16 P12 A DS 27 LIGHT REAR CAB SELECTED INDICATOR
P7 105 107 27 P14
105 DS 28 LIGHT FRONT PARK BRAKE "ON" INDICATOR
3 170 DS 29 LIGHT REAR PARK BRAKE "ON" INDICATOR
S27 S24
12 9 14 DS 30 LIGHT PARK BRAKE APPLIED INDICATOR
CONT.FROM
3 1 1 4 183 183
NO
DS 46 LIGHT FRONT SHIFTER NOT IN NEUT. IND.(REAR)
NC
NC
NO
SH.1
12 12 DS 47 LIGHT SHIFTERS IN NEUTRAL IND. (REAR)

4 8 1 5 13 CONT. CONT. DS 48 LIGHT FRONT PARK BRAKE ON INDICATOR (REAR)
4 2 2 3 K1 K1 SH.5 SH.5
105 106 DS 49 LIGHT REAR PARK BRAKE ON INDICATOR (REAR)
172 8 4 8 4
192 193 194 195 K11 K12 DS 50 LIGHT PARK BRAKE APPLIED INDICATOR (REAR)
107 107 172
97 DS 52 LIGHT FRONT CAB SELECT INDICATOR (REAR)
DS11 P7 195 189 184 104 DS 53 LIGHT REAR CAB SELECT INDICATOR (REAR)
4 12 1 5 14 F 5 FUSE PARKING BRAKE, 10A
P14 P14 197
B C F 7 FUSE CAB SELECT, 10A
4 8 184 184 185 K 1 RELAY REAR SHIFTER NEUTRAL
66 9 13 67
P12 CR14 K2 K 2 RELAY REAR PARKING BRAKE SW. "ON"
25
177 K 3 RELAY FRONT PARKING BRAKE SW. "ON"
177
182 192 173 10 8 1 3 8 10
K 4 RELAY PARK BRAKE APPLIED
K 8 RELAY CAB SELECT
G 14 12 K 11 RELAY FRONT AXLE REED SW
9
K 12 RELAY REAR AXLE REED SW
9 2 3 1 2 9
K 23 RELAY TRANSM NOT IN N- PARK BRAKE APPL.
P51 B 4 8 1 5 L 8 SOLENOID CAB ORBITAL SELECT VALVE
K3 13 K3 K3 S19 S36 L 9 SOLENOID CAB ORBITAL SELECT VALVE
153 99 186 187 L 10 SOLENOID PARKING BRAKE SET VALVE
195 107 171 180 107 176 175 175 174 173 L 11 SOLENOID PARKING BRAKE RELEASE VALVE
L 12 SOLENOID ACCELERATOR TRANSFER VALVE
181 171 193 194 14 12 107
1 5 P12 P 4 CONNECTOR FUSE BOX
171 172 21 19 P 7 CONNECTOR REAR CAB INTERFACE
19 P 8 CONNECTOR MAIN HARNESS INTERFACE
P7 4 8 9 186 187 107
P7 K4 13 K4 K4 P 9 CONNECTOR STEERING INTERFACE
20
193 182 183
10 6 11 P 12 CONNECTOR CONTROL BOX CAB SELECT
179 P 14 CONNECTOR STEERING BOX (OPT)
RESET
5 6 7 8 9 10 11 12 13 14 15 17 18
SET
98 P12 78 P 35 CONNECTOR CAB SELECT LIGHTS (REAR)
171 1 3 4 81 P 37 CONNECTOR CAB SELECT LIGHTS
2 3 9 8 K8
5 4 191 P 50 CONNECTOR ACCELERATOR TRANSFER SOL. VALVE
182 182 175
30 85 P 51 CONNECTOR DIODE MODULE CR9-CR12
195 182 171 190 P 56 CONNECTOR FRONT /REAR CAB ORBITAL SELECT VALVE
150 191
P 100 CONNECTOR PARK BRAKE SET VALVE
1
87 86 K8 P 103 CONNECTOR PARK BRAKE RELEASE VALVE
K23 2
110 94 92 P7 28 20 22 23 24 S 19 SWITCH CAB SELECT
176 B 26 P12
196 P12 190 S 24 SWITCH PARK BRAKE (REAR)
182 21 S 28 SWITCH PARKING BRAKE PRESSURE
191
P7 C S 36 SWITCH CAB SELECT (REAR)
P8 180 179 179 176 175 183 173 172 172 177 190 190 190 191 191
20 P9 M 196
121
116 18 B A SEE SHEET 1 FOR NOTES
P37 62 143
B B D E E C B A A D B G G WHT GRN H H
P35
L10 L11
S28 P100 A A
P103 A
197 189
COM
P37 P37 P35 P37 P35 P37 P35 P35 P35 P37 BLK C P37 P35
119 115 L9 L8
P56 P56
PARKING BRAKE BRAKE FRT BRAKE RR BRAKE SHIFTERS ORBITAL

APPLIED SW ON SW ON IN NEUTRAL
CAB SELECT - INDICATORS CAB SELECT

Sheet 4 of 8
CD276 2-2-43
Rev 13
Chapter 2
12V BATTERY (BREAKER)

12V IGNITION (MASTER RELAY)
LEGEND
F3
P14 S34
S14 P9 P13
P4
P9 DS32
K11 K12
P9
P13
P27/CR8 P26/CR4
P42
P13
S25
P109
P27/CR7 P26/CR3
P42
P26/CR1
P26/CR2
P27/CR6
P27/CR5
P13 S29
P108
P14
K9 K10
K15 K14 P42
P42
P13 P14
P9 P9

DS31 DS21 DS23 DS22 DS54 DS51
P37 P29 P29 P29 P36 P36 P36 P35
L13 L14 L16 L15
P54 P54 P55 P55
FRONT AXLE CENTER FRONT CONTROL REAR CONTROL REAR AXLE CENTER
STEERING

Sheet 5 of 8
2-2-44 CD276
Rev 13
Chapter 2

12V IGNITION (MASTER RELAY) LEGEND
12V PARK SW
F11 F10 F15 F6
P4 P4 P4 P4
*S15
K22 *S1 *S2
P20
P20 P20 H1 P20 *S39
*S4
*H2

*S40 CR12
P20 P51
*H3
CR11
P7 *S38 P51
P20
*B2
*DS38 S23 S37 *A6 *B6 *B7 *B4 *B3 *B8 *L18 *L19 *AL1
*P44 *P30 *P31 *P105 *P104
DOME LIGHT-HORN HEATER COOLING FAN WINDSHIELD WIPER/WASHER CAB LIFT

CAB

Sheet 6 of 8
CD276 2-2-45
Rev 13
Chapter 2
LEGEND
12V PARK SW.
F14
P4
P28
P7 P7
S20
P28
S6
S7
*
K26 S12
CR16
P7
P7
P8
K27
P7
K24 S31 *S32 K28
P8
P8 P7
P22 P21
P22 P21
P22
*CR15 *CR13
*A9
DS61 DS60 DS67 DS65 DS66 *DS68 DS34 DS35 DS5 DS62 DS70 DS59 DS69
*AL2 P39 P40 P46 P45 P33 P32 P39 P33 P40 P32
BACK-UP REAR REAR REAR HEADLIGHT PARK

LIGHT DASH HEADLIGHT HITCH
EXTERIOR LIGHTS
Sheet 7 of 8
2-2-46 CD276
Rev 13
Chapter 2

12V PARK SW. *P61
F9 F13
*F4 LEGEND
P4 P4
P4
P8
*S13 *S11
FL1
P7
*K36
S26
P43 *K35
S43 S35 S10
*FL2
P22 *P58
P8 P8
P20 P8 P21 *S8

P22 P21 P22 P21 *P60
*A10 M
DS1 DS64 DS36 DS6 DS57 DS37 DS63 DS58 *DS71 S41 *DS39 *A11 SEE SHEET 1 FOR NOTES
P39 P33 P40 P32 P39 P40 P34
LEFT HAND RIGHT HAND SERVICE BEACON FRONT DEFROSTER ENGINE COOLANT
BRAKE EMERG STEERING HITCH REAR WINDOW HEATER
TURN SIGNALS
LIGHT
EXTERIOR LIGHTS

Sheet 8 of 8
CD276 2-2-47
Rev 13
Chapter 2
6 BLK 6 BLK B(+)
120A 128
2/0 BLK 6 BLK
B(+) LEGEND
125
BUS BAR ITEM DESCRIPTION
2/0 BLK
TO F11
A 7 ASSEMBLY STARTER MOTOR (SOLENOID AND MOTOR)
20A A 8 ASSEMBLY ECU GLOW PLUG
14 WHT B 1 MOTOR STARTER
65 112 B 5 MOTOR EMERGENCY STEERING PUMP
+ + BT 1 BATTERY BATTERY, 12 VOLTS
1 BT 2 BATTERY BATTERY, 12 VOLTS
170 CB 1 CIRCUIT B. GLOW PLUG, 120A
120A
- - 112 CB 2 CIRCUIT B. MAIN, 120A
1/0 BLK
DS 3 LIGHT GLOW PLUG INDICATOR
6 BLK
(-) C B E 1 STUD FUSE BOX POWER
121 121 112
2/0 BLK

1
170 10 E 3 STUD BATTERY POWER
WELDMENT
3 E 4 STUD GLOW PLUG POWER
29 32
6 BLK
20A 108 NO 127 F 12 FUSE INSTRUMENT PANEL, 20A

225A 61 F 17 FUSE STARTER, 20A
4
127 101 F 21 FUSE EMERGENCY STEERING PUMP, 225A
2
173
159 F 22 FUSE GAUGES, 5A
125
173 122 G 1 GENERATOR 12 VDC- 95A
109 D
2 GP1-6 RESISTOR GLOW PLUG
126
5 4 3 K 19 RELAY EMERGENCY STEERING PUMP MOTOR
125 5A K 20 RELAY PARK BRAKE ON -STARTER ENABLE
8 125
30 86 K 30 RELAY IGNITION (MASTER)
2
1/0 BLK
K 31 RELAY STARTER SOLENOID AUXILIARY

178 87 85 L 7 SOLENOID EXCESS START FUEL ALLOWANCE
25 L 17 SOLENOID ENGINE STARTER
9
C A D B(+) P 4 CONNECTOR FUSE BOX
1 125
36 52 P 7 CONNECTOR REAR CAB INTERFACE
178 P 8 CONNECTOR MAIN HARNESS INTERFACE
129 136 P 17 CONNECTOR ENGINE PLUG
6 BLK
P 18 CONNECTOR ENGINE PLUG (YELLOW)
2 E F
P 28 CONNECTOR IGN/LIGHT SWITCH
86
228 127 30 P 38 CONNECTOR STARTER SOLENOID AUX. RELAY
2 1 B P 41 CONNECTOR ECU GLOW PLUG
199 127 85 87
S 22 SWITCH STOP, RUN, START
159 128 NOTES:

E4
1 1. ALL RELAYS AND SWITCHES SHOWN DE-ENERGIZED
D+ B+ W (DE-ACTUATED).
+ 2. INDICATES OPTIONAL WIRING
3. INDICATES VENDOR WIRING
4. INDICATES OPTIONAL COMPONENTS
G
JP1 *
-
REFERENCE S&S TUG DRAWINGS:
FUGURE 5.1.12. REFERENCE DESIGNATORS/PART
NUMBERS/LOCATION INDEX
FIGURE 5.1.14 ELECTRICAL EQUIPMENT LOCATION

Sheet 1 of 10
2-2-48 CD276
Rev 13
Chapter 2
B(+) B(+)
LEGEND
128 128 ITEM DESCRIPTION
125 125 AL 3 ALARM ENGINE/TRANSMISSION TROUBLE WARNING

CR22-25 RECTIFIER ENGINE WARNING ALARM
DS 2 LIGHT LOW OIL PRESSURE INDICATOR
BUS BAR 224 224 DS 4 LIGHT TRANSMISSION HI OIL TEMP INDICATOR
FROM F3 DS 7 LIGHT LOW COOLANT LEVEL INDICATOR
101 101 DS 8 LIGHT ENGINE HI COOLANT TEMP INDICATOR
DS 12 LIGHT GENERATOR NO CHARGE INDICATOR
DS 13 LIGHT FRONT DASH PANEL, LEFT HAND
DS 14 LIGHT FRONT DASH PANEL, RIGHT HAND
10A 4 24 DS 15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE
101 DS 16 LIGHT ENGINE OIL PRESSURE GAUGE
101 101 125 101 125 101 101 101 224 224 224 224 224 DS 17 LIGHT TRANSMISSION OIL TEMP GAUGE
125 125 125 125 125 DS 18 LIGHT VOLTMETER
3 +
DS 19 LIGHT TACHOMETER
13 - DS 20 LIGHT SPEEDOMETER
224 101 224 101 101 101 DS 33 LIGHT FUEL LEVEL GAUGE
101 101 224
101 DS 40 LIGHT GENERATOR NO CHARGE INDICATOR (REAR)
269 DS 41 LIGHT LOW OIL PRESSURE INDICATOR (REAR)
A DS 42 LIGHT TRANSMISSION HI OIL TEMP IND. (REAR)
RED
RED
BLK
BLK
DS 43 LIGHT LOW COOLANT LEVEL INDICATOR (REAR)
101 DS 44 LIGHT ENGINE HI COOLANT TEMP IND. (REAR)
E F G H I I F 1 FUSE ENGINE, 10A
GA 1 GAUGE FUEL LEVEL
GA 2 GAUGE ENGINE COOLANT TEMPERATURE
D C B A GA 3 GAUGE ENGINE OIL PRESSURE
123 136 GA 4 GAUGE TRANS OIL TEMPERATURE
130 132 135 139
E 137 138 GA 5 GAUGE VOLTMETER
129 129 4 131 5 133 134 140 GA 6 GAUGE TACHOMETER
123 7 8 9 5 GA 7 GAUGE SPEEDOMETER
6 7 11 12 6 8 3 L 6 SOLENOID ENGINE RUN VALVE
133
3
134
140
131
P 4 CONNECTOR FUSE BOX

131 133 134 140 P 7 CONNECTOR REAR CAB INTERFACE
123 224
P 8 CONNECTOR MAIN HARNESS INTERFACE
P 16 CONNECTOR SPEED SENSOR (ZF)
123 P 17 CONNECTOR ENGINE PLUG
E P 19 CONNECTOR INSTRUMENT GAUGES
P 28 CONNECTOR IGN/LIGHT SWITCH
136 137 138 135 139 156 P 42 CONNECTOR REAR CAB STEERING INTERFACE
129 130 131 132 133 134 140
P 48 CONNECTOR ENGINE COOLANT LEVEL SENSOR
P 64 CONNECTOR DIODE MODULE, ENG.WARNING ALARM, CR22-26
R 1 SENSOR ENGINE COOLANT LEVEL
124
F 5 7 8 9 10 11 12 17 18 19 R 4 SENSOR ENGINE HI COOLANT TEMP.SW.- SENDER
1 6 CLOSES AT 239°F
R 5 SENSOR FUEL LEVEL
124 129 130 131 132 133 134 140 137 138
SEE GRID 235 R 6 SENSOR SPEED (ZF)
FOR ENGINE
224 R 7 SENSOR ENGINE LOW OIL SW - SENDER
COOLANT AT 5.8 PSIG ON FALLING PRESSURE
7 HEATER 5 6 3 4 S 21 SWITCH EMERGENCY ENGINE STOP
INTERFACE 4 S 30 SWITCH EMERGENCY ENGINE STOP (REAR)
12 TWISTS PER FOOT,

3
224 137 138 135 139
1 G WK 1 2
TWISTED PAIR,
P
136
MIN
2 2 6
GAUGES/WARNING LIGHTS

Sheet 2 of 10
CD276 2-2-49
Rev 13
Chapter 2
190 BUS BAR

115 FROM F3
86 85
190 F2
187
156 87 10A
90
30 102 102
149 102
P6 6 5A
LEGEND
K29 5
ITEM DESCRIPTION
P4
P7 P7 5 A 1 ASSEMBLY ZF FRONT CAB SHIFTER
102 A 2 ASSEMBLY ZF REAR CAB SHIFTER
11 12 P10 61 A 3 ASSEMBLY TRANSMISSION VALVE BODY
P52 7 T P5
S27 149 ED2 AD1
141 141
151 7 P53 156
A 4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK-UP
1 AD1 CR 20 RECTIFIER BLOCKING, DOWNSHIFT LOCK
1 273 1 8 142 U 142 ED2 CR 21 RECTIFIER BLOCKING, DOWNSHIFT LOCK
AD2 1
VP(+)
1 S24 F 2 FUSE TRANSMISSION, 10A
NC
21, 274 7 4 143 V 143 152 8 1 276

ED3 AD3 AD2 K 6 RELAY SHIFTER CHANGE OVER CONTROL
93 2
NC
A1 95 K 7 RELAY SHIFTER CHANGE OVER CONTROL
2 3 144 W 144 153 4 7 277 K 21 RELAY SHIFTER IN NEUTRAL
ED1 AD4 AD3 ED3 2
P2 K 25 RELAY LOCK-UP UNIT (DOWNSHIFT)
AD9 2 145 X 145 154 3 2
AD5 AD4 ED1 K 29 RELAY UPSHIFT INHIBITOR TRANSFER
146 L 1-5 SOLENOID TRANSMISSION VALVE BODY, ZF/Y1-Y5
3 AD6 P1 P2 102 155 2
P2 AD5 P6 P 1 CONNECTOR ZF SHIFTER (TRANSMISSION), FRONT CAB
5 AD9 61 P 2 CONNECTOR ZF SHIFTER (CAB), FRONT CAB
5A
A2 P 5 CONNECTOR SHIFTER (TRANSMISSION), REAR CAB
P7 AD6 P 6 CONNECTOR SHIFTER (CAB), REAR CAB
P1 6 4 164 P 8 CONNECTOR MAIN HARNESS INTERFACE
6 P2 P10 P 10 CONNECTOR CONTROL BOX
H J K F A
P 15 CONNECTOR TRANSMISSION SOLENOID VALVES
148 119 114 P5 P 23 CONNECTOR TURBINE SPEED SENSOR (ZF)
3 4 6 P 24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK-UP
102 102 6
P6 P 52 CONNECTOR FRONT SHIFTER UPSHIFT INTERLOCK
144
155
154
143
151
191
190
142
152
153
141
P 53 CONNECTOR REAR SHIFTER UPSHIFT INTERLOCK
10 191
157 P 57 CONNECTOR DIODE MODULE, DOWNSHIFT LOCK, CR20,21
C P7 86 30 K25 86 30 190 R 2 SENSOR TURBINE SPEED (ZF)
S 24 SWITCH PARK BRAKE (REAR)
8 9 5 4 6 10 6 10 8 9 5 4 194 S 27 SWITCH PARK BRAKE
P57
RESET
147 85 87 85 87
RESET
158
SET
SET
F K21
245
182 11 1 3 2 3 2 11 1
165
163
164
162
K6 K7
170 177 177 M N P SEE SHEET 1 FOR NOTES AND
JPR E P10 S R
P10
19 92 112 L SHEETS 9-10 FOR MASTER LEGEND
164 165
P57 P24 158
A4
145
162
163
164
D
245 5 6 161 165
1 ED13
150 P8 2 3 102 A E D C B 109
4EF VP(+) 6
21 150 2
P24
R2 1 F
146 P23
A3
90 P15
FRONT CAB CONTROL VALVE BODY/TRANSFER RELAY REAR CAB CONTROL

TRANSMISSION
SHIFTER OUTPUT SIGNAL
MARKED
SHIFTER
FORWARD REVERSE NEUTRAL
POINT
GEAR 1 2 3 4 1 2 3 NF NF NR N
AD1
AD2
AD3
AD4
AD5
AD6
Sheet 3 of 10
2-2-50 CD276
Rev 13
Chapter 2
BUS BAR BUS BAR 128 LEGEND

FROM F7 TO F6, F5 ITEM DESCRIPTION
F5 F7 117 18 86 CR 10 RECTIFIER BLOCKING, PARKING BRAKE
10A 10A 108 CR 14 RECTIFIER BLOCKING, NEUTRAL LIGHT
105 DS 11 LIGHT PARK BRAKE APPLIED INDICATOR
P4 P7 107 P12 107 170 158
107 107 183 DS 24 LIGHT REAR SHIFTER NOT IN NEUTRAL INDICATOR
P4 P12 A DS 25 LIGHT SHIFTERS IN NEUTRAL INDICATOR
6 P7 7 22 16 27
105 105 107 P14 DS 26 LIGHT FRONT CAB SELECTED INDICATOR
170 DS 27 LIGHT REAR CAB SELECTED INDICATOR
3
S27 S24 DS 28 LIGHT FRONT PARK BRAKE SWITCH ON INDICATOR
12 9 14 DS 29 LIGHT REAR PARK BRAKE SWITCH ON INDICATOR
NC
183 183
NO
NO
3 1 1 4
NC
DS 30 LIGHT PARK BRAKE APPLIED INDICATOR
90
61
12 12 DS 46 LIGHT FRONT SHIFTER NOT IN NEUT. IND.(REAR)
143
128
4 8 1 5 13
105
4 2 2 3 K1 K1 DS 47 LIGHT SHIFTERS IN NEUTRAL IND. (REAR)
172 106 DS 48 LIGHT FRONT PARK BRAKE SWITCH ON INDICATOR (REAR)
8 4 8 4
192 193 194 195 107 107 172 K11 K12 DS 49 LIGHT REAR PARK BRAKE SWITCH ON INDICATOR (REAR)
DS11 DS 50 LIGHT PARK BRAKE APPLIED INDICATOR (REAR)
P7 195 189 184 104
4 12 1 5 14
DS 52 LIGHT FRONT CAB SELECT INDICATOR (REAR)
P14 P14 197
DS 53 LIGHT REAR CAB SELECT INDICATOR (REAR)
192 97 B C F 5 FUSE PARKING BRAKE, 10A
66
4 8 9 13 185 F 7 FUSE CAB SELECT, 10A
P12 CR14 K2 184 184 185
25 K 1 RELAY REAR SHIFTER NEUTRAL
177 K 2 RELAY REAR PARKING BRAKE SW. "ON"
182 192 173 10 8 1 3 8 10 K 3 RELAY FRONT PARKING BRAKE SW. "ON"
K 4 RELAY PARK BRAKE APPLIED
G 14 12 K 8 RELAY CAB SELECT
9
9 2 3 1 2 9 K 11 RELAY FRONT AXLE REED SWITCH
P51 B K 12 RELAY REAR AXLE REED SWITCH
4 8 1 5
K3 13 K3 K3 S19 S36 K 23 RELAY TRANSM NOT IN N-, PARK BRAKE APPLIED
L 8 SOLENOID CAB ORBITAL SELECT VALVE
153 99 186 187
175 175 173 L 9 SOLENOID CAB ORBITAL SELECT VALVE
195 107 171 180 107 176 174
L 10 SOLENOID PARKING BRAKE SET VALVE
181 171 193 194 14 L 11 SOLENOID PARKING BRAKE RELEASE VALVE
12 1 5 67 P12 107 L 12 SOLENOID ACCELERATOR TRANSFER VALVE
171 172 21 19 P 4 CONNECTOR FUSE BOX
19
P7 4 8 186 187 107 P 7 CONNECTOR REAR CAB INTERFACE
P7 K4 13 K4 9 K4 P 8 CONNECTOR MAIN HARNESS INTERFACE
20 11
193 182 10 6 P 9 CONNECTOR STEERING INTERFACE
179 183
RESET
P 12 CONNECTOR CONTROL BOX CAB SELECT
SET
5 6 7 8 9 10 11 12 13 14 15 17 18
96
P12 P12 177 78 P 14 CONNECTOR HYD. STEERING CONTROL BOX (OPT)
171 182 1 3 4 81
2 3 9 8 K8 P 35 CONNECTOR CAB SELECT LIGHTS (REAR)
5 4 191 P 37 CONNECTOR CAB SELECT LIGHTS
30 85 P 50 CONNECTOR ACCELERATOR TRANSFER SOL. VALVE
182 171
115
195 175
190 191 P 51 CONNECTOR DIODE MODULE CR9-CR12
150 P 56 CONNECTOR CAB ORBITAL SELECT VALVE (FRONT/REAR)
K8 1
87 86 98 109 94 92 P7 P 100 CONNECTOR PARK BRAKE SET VALVE
K23 2 B 28 20 22 23 24
180 179 179 176 176 175 183 173 172 26 P12 P 103 CONNECTOR PARK BRAKE RELEASE VALVE
196 P12 190 S 19 SWITCH CAB SELECT
182 182 21
191
R S 24 SWITCH PARK BRAKE (REAR)
P7 C
P8 P9 172 177 190 190 190 191 191
S 28 SWITCH PARKING BRAKE PRESSURE
20 M 196
R 121 S 36 SWITCH CAB SELECT (REAR)
P37 116 18 A D B G G 62 B A
D E E C B A 143
B B WHT GRN H H
P35
L10 L11 R R R R R G G R SEE SHEET 1 FOR NOTES AND
P100 A A
P103 A SHEETS 9-10 FOR MASTER LEGEND
197 189
S28 COM
P37 P37 P35 P37 P35 P37 P35 P35 P35 P37 BLK C P37 P35
119 115 L9 L8
P56 P56
PARKING BRAKE BRAKE FRT BRAKE RR BRAKE SHIFTERS ORBITAL

APPLIED SW ON SW ON IN NEUTRAL
CAB SELECT - INDICATORS CAB SELECT

Sheet 4 of 10
CD276 2-2-51
Rev 13
Chapter 2
128
BUS BAR
TO F2, F1 COORD
F3 COORD LEGEND
TRACK
10A
TRACK CRAB
P14 S34 ITEM DESCRIPTION
103 CRAB
S14 P9 P13 K 218 8 CR 1-4 RECTIFIER BLOCKING, STEERING
P4 8 E 198 E 198 216 L 216 6 3
CR 5-8 RECTIFIER BLOCKING, STEERING
11 DS 21 LIGHT COORD STEER MODE INDICATOR
103 3 6 C 206 C 206 M 212 2
DS 22 LIGHT TRACK STEER MODE INDICATOR
2 G 202 G DS 23 LIGHT CRAB STEER MODE INDICATOR
9 10
148 DS 31 LIGHT AXLE CENTER INDICATOR
10 9 190
188 DS 32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB)
206 218 212 215 DS 51 LIGHT AXLE CENTER INDICATOR (REAR)
202
P9 215 DS32 113 DS 54 LIGHT COORD STEER MODE INDICATOR (REAR)
B 14 10 9 11 K11 K12 11 9 10 14
233
DS 55 LIGHT TRACK STEER MODE INDICATOR (REAR)
DS 56 LIGHT CRAB STEER MODE INDICATOR (REAR)
103 P9 F 3 FUSE STEERING, 10A
H
116
119
2 1 3 3 1 2 K 9 RELAY COORD STEERING, FRONT CONTROL
B
103 215 P13 13 6 5 7 7 5 6 13 184 K 10 RELAY CRAB STEERING, FRONT CONTROL
210 211 P27/CR8 K 11 RELAY FRONT AXLE REED SWITCH
P26/CR4
237
P42 B 150 205 213 208
K 12 RELAY REAR AXLE REED SWITCH
A R 145 H K 14 RELAY COORD STEERING, REAR CONTROL
204 209 P13 K 15 RELAY CRAB STEERING, REAR CONTROL
S25 BLK 188 207 201 237 L 13 SOLENOID COORD SELECT VALVE, SV2-A (OR 1)
191 P109 A
129 215 L 14 SOLENOID CRAB SELECT VALVE, SV2-B (OR 1)
117
B WHT C P27/CR7 211 213 208 P26/CR3 L 15 SOLENOID COORD SELECT VALVE, REAR MODE, SV3-A
P42 210 209 L 16 SOLENOID CRAB SELECT VALVE, REAR MODE, SV3-B
191 A
P26/CR1
P26/CR2
P27/CR6
209 116 BLK P 9 CONNECTOR STEERING INTERFACE
P27/CR5
140
P 13 CONNECTOR STEERING BOX (STD)
P13 L 190
S29 R B 103 P 14 CONNECTOR HYD. STEERING CONTROL BOX (OPT)
201 P108 P 26 CONNECTOR DIODE MODULE, STEERING, CR1-CR4
191 P14 C WHT P 27 CONNECTOR DIODE MODULE, STEERING, CR5-CR8
D 134 P 29 CONNECTOR STEER MODE INDICATOR LIGHTS
213
191
P 35 CONNECTOR CAB SELECT LIGHTS, REAR PANEL
201 211 191 210 168 207 190 190 208 205 P 36 CONNECTOR STEER MODE INDICATOR LIGHTS (REAR)
214
P 37 CONNECTOR CAB SELECT LIGHTS
6 10 11 1 11 10 6 1
P 42 CONNECTOR REAR CAB STEER INTERFACE
RESET
RESET
188 1 11 1 11 P 54 CONNECTOR COORD /CRAB SELECT VALVE, FRONT MODE
SET
SET 6 10 10 6
RESET
RESET
P 55 CONNECTOR COORD /CRAB SELECT VALVE, REAR MODE
SET
SET
8 4 8 4
3 2 9 5 9 2 3 5 P 108 CONNECTOR REAR AXLE REED SWITCH
4 8 4 8 P 109 CONNECTOR FRONT AXLE REED SWITCH
215 215
K9 K10 5 3 2 9 5 9 2 3
166
203 S 14 SWITCH STEER MODE SELECT

K15 K14 P42 S 25 SWITCH FRONT AXLE REED
0
P42
22
167 217 217 125
D S 29 SWITCH REAR AXLE REED
C
D J K A F 219 219 S 34 SWITCH STEER MODE SELECT (REAR)
P13 P14
D A F
P9 166 203 P9 E F 220 G 219 H J 215 SEE SHEET 1 FOR NOTES
188 214 220 219
166 GRN WHT
203 168
GRN A WHT B
AND SHEETS 9-10 FOR
F A C B C B F
MASTER LEGEND
A
A A
DS31 DS21 D COM F DS23 E DS22 COM DS54 DS51

P37 P29 COORD
BLK
CRAB P29 P29 P36 P36 CRAB BLK COORD P36 P35
L16 C L15
L13 L14
P54 P54 P55 P55
FRONT AXLE CENTER COORD CRAB TRACK TRACK CRAB COORD REAR AXLE CENTER
FRONT CONTROL REAR CONTROL
STEERING

Sheet 5 of 10
2-2-52 CD276
Rev 13
Chapter 2

229
BUS BAR BUS BAR
FROM F12 128 B(+) FROM F7
LEGEND
224 12V PARK SW 224 ITEM DESCRIPTION
60 192
*A 6 ASSEMBLY CAB, HEATER - FAN
* AL 1 ALARM CAB RAISE/LOWER
F11 F10 F15 F6 *B 2 MOTOR WINDSHIELD WASHER PUMP
*B 3 MOTOR WINDSHIELD WIPER, RIGHT HAND
20A 20A 30A 10A
*B 4 MOTOR WINDSHIELD WIPER, LEFT HAND
*B 6 MOTOR CAB DEFROSTER/COOLING, R.H.
111 110 224 115 224 106 *B 7 MOTOR CAB DEFROSTER/COOLING, L.H.
P4 P4 P4 P4 *B 8 MOTOR CAB ROOF WIPER
13 8 10 15 CR 11 RECTIFIER BLOCKING, CAB LIFT
CR 12 RECTIFIER BLOCKING, CAB LIFT
115 224 106 * DS 38 LIGHT CAB DOME
F 6 FUSE CAB RAISE/LOWER, 10A
111 F 10 FUSE HEATER/COOL FAN, 20A
115 * S15 F 11 FUSE HORN, 20A
10 3 F 15 FUSE WINDSHIELD WIPER, 30A
H 1 HORN VEHICLE, FRONT
85 30 10 3 4 5 10 *H 2 HORN VEHICLE, FRONT, LEFT HAND
9 7 1
*H 3 HORN VEHICLE, FRONT, RIGHT HAND
R L
7 8 K 22 RELAY HORN
87a HI LO *L 18 SOLENOID CAB RAISE VALVE
87
K22
86 9 1 5 2 6 1 9 106 106 *L 19 SOLENOID CAB LOWER VALVE
* S1 * S2 19 P 4 CONNECTOR FUSE BOX
P21 15 *
P20 *P
P
20
21
CONNECTOR
CONNECTOR
CEILING INTERFACE
FRONT LIGHTS
G 5 6 7 8 9
111 181 24 24 15 *P 30 CONNECTOR WINDSHIELD WIPER MTR., LEFT HAND
B *P 31 CONNECTOR WINDSHIELD WIPER MTR., RIGHT HAND
160 177 19 262 *P 44 CONNECTOR HEATER - FAN, CAB
110
H1 P 51 CONNECTOR DIODE MODULE, CR9-CR12
* P20 * P20 P62 224 110 * P20 * S39 P 62 CONNECTOR HORN
1 2 12 *P 104 CONNECTOR CAB LOWER SOLENOID VALVE
A 16 262
118 119 *P 105 CONNECTOR CAB RAISE SOLENOID VALVE
*
*S 1 SWITCH WIPER
181 24 10 3
S4 *S 2 SWITCH WINDSHIELD WASHER
118 119 19 *S 4 SWITCH BLOWER FAN
91 16 170 *S 15 SWITCH CAB LIFT
9 1 5 S 23 SWITCH HORN
HI LO S 37 SWITCH HORN (REAR)
* H2 115 15
*S 38 SWITCH CAB WAND, RIGHT HAND
262
*S 39 SWITCH CAB WAND, CENTER
2
* S40 E
CR12 *S 40 SWITCH CAB WAND, LEFT HAND
20 24 * P20 17 19 P51
4
181
243 222 D SEE SHEET 1 FOR NOTES
AND SHEETS 9-10 FOR
JPR
* H3 262 CR11 MASTER LEGEND
118
119
A B
P7 115 115 160 * S38 P51
23 ORN RED 18 19
10 F C 244
* P20 19
18
* B2 * +
BLK
DS38 S23 S37 A6 * B6 *
B7* B4 *
B3 * B8 *
L18* L19*
F P44* P30* P31* P105* P104* AL1*

CAB

Sheet 6 of 10
CD276 2-2-53
Rev 13
Chapter 2
LEGEND
ITEM DESCRIPTION
* A 9 ASSEMBLY DIODE MODULE, HITCH LIGHT
BUS BAR
B(+) 224 12V PARK SW. 224 (CR13 & CR15)
175 219 * AL 2 ALARM BACK-UP
TO F13 * CR13 RECTIFIER BLOCKING, HITCH LIGHT
223 * CR15 RECTIFIER BLOCKING, HITCH LIGHT
F14 CR16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A
20A DS 5 LIGHT HI-BEAM INDICATOR
DS34 LIGHT HEADLAMP, LEFT HAND
DS35 LIGHT HEADLAMP, RIGHT HAND
114
DS59 LIGHT TAIL, RIGHT HAND
223
P4 DS60 LIGHT BACK-UP, RIGHT HAND
14 P28 G
DS61 LIGHT BACK-UP, LEFT HAND
61 199
114
P7 P7 223 223 5 1 226
F
DS62 LIGHT TAIL, LEFT HAND
DS65 LIGHT REAR LEFT HEADLIGHT
190 190 223 DS66 LIGHT REAR RIGHT HEADLIGHT
16 15
114 224 10 9 DS67 LIGHT DASH (REAR)
S20 * DS 68 LIGHT REAR HITCH
224 P28 3 1 6 DS 69 LIGHT PARK, FRONT, RIGHT HAND
S6 ON DS 70 LIGHT PARK, FRONT, LEFT HAND
86 30 5 10 H NORMAL F 14 FUSE HEADLIGHTS, 20A
4
226 OFF K 24 RELAY SHIFTER, BACK-UP
S7 3 10 2 5 K 26 RELAY LIGHTS TRANSFER
1 9 K 27 RELAY PARKING LIGHTS TRANSFER
S12
85 87a * 188 188 K 28 RELAY REAR SHIFTER BACK-UP
K26 P 4 CONNECTOR FUSE BOX
62 219 224 LO HI 5 1 9
190 233
CR16 224 P 7 CONNECTOR REAR CAB INTERFACE
240 223 225 P 8 CONNECTOR MAIN HARNESS INTERFACE
226 P7 18 P 21 CONNECTOR FRONT LIGHTS
147 109 233 P 22 CONNECTOR REAR LIGHTS
240 230 P 28 CONNECTOR IGN/LIGHT SWITCH
85 P 32 CONNECTOR R.H. HEADLIGHT
230 P7 P 33 CONNECTOR L.H. HEADLIGHT
13
233 233 240 157 86 87a P 39 CONNECTOR L.H. REAR LIGHTS
240
P 40 CONNECTOR R.H. REAR LIGHTS
P 45 CONNECTOR REAR HEADLIGHT, R.H.
10 5 10 5
P8 235 85 30 P 46 CONNECTOR REAR HEADLIGHT, L.H.
86 14 86 87a S 6 SWITCH PARK LIGHT
87a K27 S 7 SWITCH HIGH-LO BEAM
221
17 * S 12 SWITCH REAR HITCH LIGHT
85 30 9 1 9 1 225 85 30 P7 S 20 SWITCH DASH LIGHT
S 31 SWITCH REAR HEADLIGHTS (REAR)
K24 S31 S32* K28 *S 32 SWITCH REAR HITCH LIGHT (REAR)
241 P8
227 231 13 221
14 SEE SHEET 1 FOR NOTES
P8 233 233 P7 221
16
231
AND SHEETS 9-10 FOR
227 235
200 P22 P21 MASTER LEGEND
P22 233 P22 AC AC P21 D A
F 231 C D
B
*CR15 * CR13 235
227 227 233 233 221 221 221 221
231 235 235
227 149 A A
B B 240 B B B B
BLK BLK BLK * A9 GRN GRN RED BRN D YEL
D
BRN
D
YEL
D
RED
+
* DS68
* AL2
DS61 DS60 DS67 DS65 DS66 DS34 DS35 DS5 DS62 DS70 DS59 DS69
P39 P40 P46 P45 P33 P32 P39 P33 P40 P32
BACK-UP REAR REAR REAR HEADLIGHT PARK

LIGHT DASH HEADLIGHT HITCH
EXTERIOR LIGHTS
Sheet 7 of 10
2-2-54 CD276
Rev 13
Chapter 2
128 12V IGNITION (MASTER RELAY)

128
175
BUS BAR
FROM F14
B(+) LEGEND
224 12V PARK SW. * P61 ITEM DESCRIPTION
207 *A 10 ASSEMBLY CAB, REAR WINDOW DEFROSTER
* *A 11 ASSEMBLY ENG.COOLANT TANK HEATER,
20VAC OR 240VAC
F9 F13 F4 DS 1 LIGHT LEFT TURN INDICATOR
15A 15A DS 6 LIGHT RIGHT TURN INDICATOR
183 DS 36 LIGHT TURN, FRONT, LEFT HAND
109 DS 37 LIGHT TURN, FRONT, RIGHT HAND
113
* DS 39 LIGHT FRONT, HITCH
P4 109 224 P4 P4 DS 57 LIGHT TURN, REAR, RIGHT HAND
16 12 DS 58 LIGHT BRAKE, RIGHT HAND
113
DS 63 LIGHT BRAKE, LEFT HAND
109 113 DS 64 LIGHT TURN REAR, LEFT HAND
* DS 71 LIGHT BEACON, ROTATING
*F 4 FUSE REAR WINDOW DEFROSTER, 20A
* F 9 FUSE TURN/BRAKE/BACK-UP LIGHTS, 15A
S13 F 13 FUSE EMERG.STEERING,BEACON & FRT.HITCH,15A
P8
10 5 5 10
FL 1 FLASHER TURN SIGNAL LIGHTS
23 TRACTOR
* * FL 2 FLASHER BEACON LIGHT (FLASHING)
FRAME
* K 35 RELAY RUN SOLENOID DISCONNECT
9 1 1 9 S11 * K 36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
FL1 BLK P 4 CONNECTOR FUSE BOX
P7 WHT
228 P 8 CONNECTOR REAR HARNESS INTERFACE
*K36 P 20 CONNECTOR CEILING INTERFACE
U
BL P 21 CONNECTOR FRONT LIGHTS
YEL 109 30 P 22 CONNECTOR REAR LIGHTS
242 P 32 CONNECTOR R.H. HEADLIGHT
S26 P 33 CONNECTOR L.H. HEADLIGHT
BLK
P43 85 87 * K35 P 34
P 39
CONNECTOR
CONNECTOR
FRONT HITCH LIGHT
L.H. REAR LIGHTS
S35 S10 10 12 9 (+) 14 P 40 CONNECTOR R.H. REAR LIGHTS
6 5 S43 10 5 10 5
P 43 CONNECTOR TURN SIGNAL
BLK * P 58 CONNECTOR REAR WINDOW DEFROSTER
232 (-) 13 * P 60 CONNECTOR K35 RELAY (RUN SOLENOID DISCONNECT)
2 6 4 8 1 5
JUMPER * P 61 CONNECTOR 120 OR 240 VAC POWER SUPPLY
229 234 ACROSS WHEN 9 1 9 1 4 WIRE WHT RELAY *S 8 SWITCH REAR WINDOW DEFROSTER, TOUCH PAD
ROTATING FL2 * CORD (REF)
WHT PANEL S 10 SWITCH EMERGENCY STEERING
BEACON IS * S 11 SWITCH FRONT HITCH LIGHT
234 P22 FURNISHED * P58 * S 13 SWITCH BEACON
A 238 238 169 S 26 SWITCH TURN SIGNAL
S 35 SWITCH EMERGENCY STEERING (REAR)
264 S 41 SWITCH EMERGENCY STEERING PRESSURE
P8 22
P8 24 S 43 SWITCH BRAKE PRESSURE (BRAKE LIGHTS)
*
229 234
P20 P8 P21 S8
P22 P21 P22 P21 11 15 F * P60
C B E E
232 232
229 229 229 234 234 234
264 238 BLK
WHT SEE SHEET 1 FOR NOTES
C C C C A A 32 AND SHEETS 9-10 FOR
GRN BLU YEL BLU RED RED
DISCONNECT 124 FROM MASTER LEGEND
A10
* M P42-F. CONNECT 124A
TO 124 & 124B TO P42-F
DS1 DS64 DS36 DS6 DS57 DS37 DS63 DS58 DS71* S41 DS39 * WHEN ENGINE COOLANT
* A11
P39 P33 P40 P32 P39 P40 P34 HEATER IS FURNISHED
199 BLK
TURN SIGNALS
LIGHT
EXTERIOR LIGHTS

Sheet 8 of 10
CD276 2-2-55
Rev 13
Chapter 2
LEGEND LEGEND LEGEND

SH.NO.-GRID ITEM DESCRIPTION SH.NO.-GRID ITEM DESCRIPTION SH.NO.-GRID ITEM DESCRIPTION
3 - 64 A1 ASSEMBLY ZF FRONT CAB SHIFTER 8 - 217 DS37 LIGHT TURN, FRONT, RIGHT HAND 4 - 99 K1 RELAY REAR SHIFTER NEUTRAL
3 - 87 A2 ASSEMBLY ZF REAR CAB SHIFTER 6 - 152 DS38 LIGHT CAB DOME 4 - 109 K2 RELAY REAR PARKING BRAKE SWITCH "ON"
3 - 78 A3 ASSEMBLY TRANSMISSION VALVE BODY 8 - 230 DS39 LIGHT FRONT, HITCH, 12V 4 - 93 K3 RELAY FRONT PARKING BRAKE SWITCH "ON"
3 - 65 A4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK-UP 2 - 36 DS40 LIGHT GENERATOR NO CHARGE INDICATOR (REAR) 4 - 97 K4 RELAY PARK BRAKE APPLIED
N/S A5 ASSEMBLY RESERVED 2 - 40 DS41 LIGHT LOW OIL PRESSURE INDICATOR (REAR) N/S K5 RELAY RESERVED
6 - 158 A6 ASSEMBLY CAB, HEATER - FAN 2 - 49 DS42 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR (REAR) 3 - 79 K6 RELAY SHIFTER CHANGE OVER CONTROL
1 - 10 A7 ASSEMBLY STARTER MOTOR (SOLENOID AND MOTOR) 2 - 47 DS43 LIGHT LOW COOLANT LEVEL INDICATOR (REAR) 3 - 80 K7 RELAY SHIFTER CHANGE OVER CONTROL
1 - 14 A8 ASSEMBLY ECU GLOW PLUG 2 - 44 DS44 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR (REAR) 4 - 95 K8 RELAY CAB SELECT
7 - 191 A9 ASSEMBLY DIODE MODULE (DIODES CR13 AND CR15) N/S DS45 LIGHT RESERVED (REAR) 5 - 129 K9 RELAY COORD STEERING, FRONT CONTROL
8 - 233 A10 ASSEMBLY CAB, REAR WINDOW DEFROSTER 4 - 112 DS46 LIGHT FRONT SHIFTER NOT IN NEUTRAL INDICATOR (REAR) (RED) 5 - 135 K10 RELAY CRAB STEERING, FRONT CONTROL
8 - 240 A11 ASSEMBLY ENGINE COOLANT, TANK HEATER 4 - 111 DS47 LIGHT SHIFTERS IN NEUTRAL INDICATOR (REAR) (GREEN) 4 - 116 K11 RELAY FRONT AXLE REED SWITCH
A*** 4 - 104 DS48 LIGHT FRONT PARK BRAKE "ON" INDICATOR (REAR)(RED) 4 - 119 K12 RELAY REAR AXLE REED SWITCH
6 - 177 AL1 ALARM CAB RAISE/LOWER 4 - 107 DS49 LIGHT REAR PARK BRAKE "ON" INDICATOR (REAR)(RED) N/S K13 RELAY RESERVED
7 - 181 AL2 ALARM BACK-UP 4 - 102 DS50 LIGHT PARK BRAKE APPLIED INDICATOR (REAR) (RED) 5 - 145 K14 RELAY COORD STEERING, REAR CONTROL
2 - 33 AL3 ALARM ENGINE/TRANSMISSION TROUBLE WARNING 5 - 149 DS51 LIGHT AXLE CENTER INDICATOR (REAR) ,12V (AMBER) 5 - 141 K15 RELAY CRAB STEERING, REAR CONTROL
AL*** 4 - 120 DS52 LIGHT FRONT CAB SELECT INDICATOR (REAR) N/S K16 RELAY RESERVED
1 - 8 B1 MOTOR STARTER 4 - 114 DS53 LIGHT REAR CAB SELECT INDICATOR (REAR) N/S K17 RELAY RESERVED
6 - 168 B2 MOTOR WINDSHIELD WASHER PUMP 5 - 144 DS54 LIGHT COORD STEERING MODE INDICATOR (REAR) N/S K18 RELAY RESERVED
6 - 165 B3 MOTOR WINDSHIELD WIPER, RIGHT HAND 5 - 138 DS55 LIGHT TRACK STEERING MODE INDICATOR (REAR) 1- 3 K19 RELAY EMERGENCY STEERING PUMP MOTOR, 12V
6 - 163 B4 MOTOR WINDSHIELD WIPER, LEFT HAND 5 - 139 DS56 LIGHT CRAB STEERING MODE INDICATOR (REAR) 1 - 21 K20 RELAY PARK BRAKE ON - STARTER ENABLE, 12V
1 - 3 B5 MOTOR EMERGENCY STEERING PUMP 8 - 216 DS57 LIGHT TURN, REAR, RIGHT HAND 3 - 67 K21 RELAY SHIFTER IN NEUTRAL, 12V
6 - 160 B6 MOTOR CAB DEFROSTER/COOLING, RIGHT HAND 8 - 220 DS58 LIGHT BRAKE, RIGHT HAND, 12V 6 - 154 K22 RELAY HORN, 12V
6 - 161 B7 MOTOR CAB DEFROSTER/COOLING, LEFT HAND 7 - 203 DS59 LIGHT TAIL, RIGHT HAND 4 - 92 K23 RELAY TRANSMISSION NOT IN N-, PARK BRAKE APPLIED, 12V
6 - 167 B8 MOTOR CAB ROOF WIPER 7 - 183 DS60 LIGHT BACK-UP, RIGHT HAND 7 - 181 K24 RELAY SHIFTER, BACK-UP, 12V
B*** 7 - 182 DS61 LIGHT BACK-UP, LEFT HAND 3 - 67 K25 RELAY LOCK-UP UNIT (DOWNSHIFT), 12V
1- 1 BT1 BATTERY 12VDC 7 - 200 DS62 LIGHT TAIL, LEFT HAND 7 - 187 K26 RELAY LIGHTS TRANSFER, 12V
1- 2 BT2 BATTERY 12VDC 8 - 219 DS63 LIGHT BRAKE, LEFT HAND, 12V 7 - 200 K27 RELAY PARKING LIGHTS TRANSFER, 12V
BT*** 8 - 212 DS64 LIGHT TURN, REAR, LEFT HAND 7 - 195 K28 RELAY REAR SHIFTER BACK-UP, 12V
1 - 14 CB1 CIRCUIT B. GLOW PLUG, 120A 7 - 187 DS65 LIGHT REAR LEFT HEAD 3 - 64 K29 RELAY UPSHIFT INHIBITOR TRANSFER, 12V
1- 8 CB2 CIRCUIT B. MAIN, 120A 7 - 188 DS66 LIGHT REAR RIGHT HEAD 1 - 23 K30 RELAY IGNITION (MASTER), 30A
CB*** 7 - 185 DS67 LIGHT DASH (REAR) 1 - 17 K31 RELAY STARTER SOLENOID AUXILIARY, 12V
SH.5 CR1-4 RECTIFIER BLOCKING, STEERING 7 - 190 DS68 LIGHT REAR HITCH ,12V N/S K32-34 RELAY RESERVED
SH.5 CR5-8 RECTIFIER BLOCKING, STEERING 7 - 204 DS69 LIGHT PARK, FRONT, RIGHT HAND 8 - 237 K35 RELAY RUN SOLENOID DISCONNECT
N/S CR9 RECTIFIER RESERVED 7 - 201 DS70 LIGHT PARK, FRONT, LEFT HAND 8 - 233 K36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
4 - 91 CR10 RECTIFIER BLOCKING, PARKING BRAKE 8 - 222 DS71 LIGHT BEACON, ROTATING K***
6 - 175 CR11 RECTIFIER BLOCKING, CAB LIFT DS*** 3 - 76 L1-5 SOLENOID TRANSMISSION VALVE BODY, ZF/Y1-Y5
6 - 177 CR12 RECTIFIER BLOCKING, CAB LIFT 1 - 23 E1 STUD FUSE BOX POWER 2 - 31 L6 SOLENOID ENGINE RUN VALVE
7 - 192 CR13 RECTIFIER BLOCKING, HITCH LIGHT 1 - 7 E2 STUD ENGINE POWER 1 - 29 L7 SOLENOID EXCESS START FUEL ALLOWANCE
4 - 99 CR14 RECTIFIER BLOCKING, NEUTRAL LIGHT, 600V 1 - 7 E3 STUD BATTERY POWER 4 - 118 L8 SOLENOID CAB ORBITAL SELECT VALVE
7 - 190 CR15 RECTIFIER BLOCKING, HITCH LIGHT 1 - 13 E4 STUD GLOW PLUG POWER 4 - 116 L9 SOLENOID CAB ORBITAL SELECT VALVE
7 - 204 CR16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A E*** 4 - 94 L10 SOLENOID PARKING BRAKE SET VALVE
N/S CR17-19 RECTIFIER RESERVED 2 - 31 F1 FUSE ENGINE, 10A 4 - 96 L11 SOLENOID PARKING BRAKE RELEASE VALVE
3 - 60 CR20 RECTIFIER BLOCKING, DOWNSHIFT LOCK 3 - 69 F2 FUSE TRANSMISSION, 10A 4 - 113 L12 SOLENOID ACCELERATOR TRANSFER VALVE
3 - 60 CR21 RECTIFIER BLOCKING, DOWNSHIFT LOCK 5 - 123 F3 FUSE STEERING, 10A 5 - 131 L13 SOLENOID COORD SELECT VALVE, SV2-A (OR 1)
2 - 33 CR22 RECTIFIER ENGINE WARNING ALARM, OIL PRESSURE LT. 8 - 234 F4 FUSE REAR WINDOW DEFROSTER, 20A 5 - 133 L14 SOLENOID CRAB SELECT VALVE, SV2-B (OR 1)
2 - 33 CR23 RECTIFIER ENGINE WARNING ALARM, COOLANT TEMP. LT. 4 - 94 F5 FUSE PARKING BRAKE, 10A 5 - 142 L15 SOLENOID COORD SELECT VALVE, REAR MODE, SV3-A
2 - 32 CR24 RECTIFIER ENGINE WARNING ALARM, COOLANT LEVEL LT. 6 - 171 F6 FUSE CAB RAISE/LOWER, 10A 5 - 141 L16 SOLENOID CRAB SELECT VALVE, REAR MODE, SV3-B
2 - 32 CR25 RECTIFIER ENGINE WARNING ALARM, TRANSMISSION TEMP. 4 - 100 F7 FUSE CAB SELECT, 10A 1 - 10 L17 SOLENOID ENGINE STARTER
CR*** N/S F8 FUSE RESERVED 6 - 171 L18 SOLENOID CAB RAISE VALVE
8 - 211 DS1 LIGHT LEFT TURN INDICATOR 8 - 217 F9 FUSE TURN/BRAKE/BACK-UP LIGHTS, 15A 6 - 174 L19 SOLENOID CAB LOWER VALVE
2 - 39 DS2 LIGHT LOW OIL PRESSURE INDICATOR 6 - 158 F10 FUSE HEATER - COOL FAN, 20A L***
1 - 11 DS3 LIGHT GLOW PLUG INDICATOR 6 - 154 F11 FUSE HORN, 20A
2 - 47 DS4 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR 1 - 23 F12 FUSE INSTRUMENT PANEL, 20A
7 - 199 DS5 LIGHT HIGH BEAM INDICATOR 8 - 225 F13 FUSE EMERGENCY STEERING, BEACON AND FRONT HITCH, 15A
8 - 215 DS6 LIGHT RIGHT TURN INDICATOR 7 - 189 F14 FUSE HEADLIGHTS, 20A
2 - 45 DS7 LIGHT LOW COOLANT LEVEL INDICATOR 6 - 165 F15 FUSE WINDSHIELD WIPER, 30A
2 - 43 DS8 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR N/S F16 FUSE RESERVED
N/S DS9,10 LIGHT RESERVED 1 - 16 F17 FUSE STARTER, 20A
4 - 92 DS11 LIGHT PARK BRAKE APPLIED INDICATOR N/S F18-20 FUSE RESERVED
2 - 35 DS12 LIGHT GENERATOR NO CHARGE INDICATOR 1- 3 F21 FUSE EMERGENCY STEERING PUMP, 225A
2 - 50 DS13 LIGHT FRONT DASH PANEL, LEFT HAND 1 - 23 F22 FUSE GAUGES, 5A
2 - 51 DS14 LIGHT FRONT DASH PANEL, RIGHT HAND F***
2 - 41 DS15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE 8 - 216 FL1 FLASHER TURN SIGNAL LIGHTS, 12VDC
2 - 37 DS16 LIGHT ENGINE OIL PRESSURE GAUGE 8 - 222 FL2 FLASHER BEACON LIGHT (FLASHING BEACON)
2 - 58 DS17 LIGHT TRANSMISSION OIL TEMPERATURE GAUGE FL***
2 - 50 DS18 LIGHT VOLTMETER 1- 7 G1 GENERATOR 12 VDC, 95A
2 - 52 DS19 LIGHT TACHOMETER, 12V G***
2 - 54 DS20 LIGHT SPEEDOMETER 2 - 56 GA1 GAUGE FUEL LEVEL, W/ 1/8 WARNING
5 - 130 DS21 LIGHT COORD STEERING MODE INDICATOR 2 - 41 GA2 GAUGE ENGINE COOLANT TEMPERATURE
5 - 136 DS22 LIGHT TRACK STEERING MODE INDICATOR 2 - 37 GA3 GAUGE ENGINE OIL PRESSURE
5 - 134 DS23 LIGHT CRAB STEERING MODE INDICATOR 2 - 58 GA4 GAUGE TRANSMISSION OIL TEMPERATURE
4 - 100 DS24 LIGHT REAR SHIFTER NOT IN NEUTRAL INDICATOR (RED) 2 - 50 GA5 GAUGE VOLTMETER
4 - 110 DS25 LIGHT SHIFTERS IN NEUTRAL INDICATOR (GREEN) 2 - 52 GA6 GAUGE TACHOMETER
4 - 119 DS26 LIGHT FRONT CAB SELECTED INDICATOR 2 - 54 GA7 GAUGE SPEEDOMETER
4 - 115 DS27 LIGHT REAR CAB SELECTED INDICATOR GA***
4 - 103 DS28 LIGHT FRONT PARK BRAKE "ON" INDICATOR (RED) 1 - 14 GP1-6 RESISTOR GLOW PLUG
4 - 106 DS29 LIGHT REAR PARK BRAKE "ON" INDICATOR (RED) GP***
4 - 101 DS30 LIGHT PARK BRAKE APPLIED INDICATOR (RED) 6 - 156 H1 HORN VEHICLE, FRONT, 12VDC
5 - 126 DS31 LIGHT AXLE CENTER INDICATOR, 12V (AMBER) 6 - 155 H2 HORN VEHICLE, FRONT, LEFT HAND
5 - 126 DS32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB) 6 - 155 H3 HORN VEHICLE, FRONT, RIGHT HAND
2 - 56 DS33 LIGHT FUEL LEVEL GAUGE H***
7 - 195 DS34 LIGHT HEAD, LEFT HAND
7 - 197 DS35 LIGHT HEAD, RIGHT HAND Figure 2-6. Schematic, Front & Rear Cab (Station)
8 - 214 DS36 LIGHT TURN, FRONT, LEFT HAND
Sheet 9 of 10
2-2-56 CD276
Rev 13
Chapter 2
LEGEND LEGEND
SH.NO.-GRID ITEM DESCRIPTION SH.NO.-GRID ITEM DESCRIPTION
VAR P1 CONNECTOR SHIFTER (TRANSMISSION) FRONT CAB (ZF) 4 - 96 P103 CONNECTOR PARK BRAKE RELEASE VALVE
VAR P2 CONNECTOR SHIFTER (CAB) FRONT CAB (ZF) 6 - 174 P104 CONNECTOR CAB LOWER SOLENOID VALVE
N/S P3 CONNECTOR RESERVED 6 - 171 P105 CONNECTOR CAB RAISE SOLENOID VALVE
VAR P4 CONNECTOR FUSE BOX N/S P106,107 CONNECTOR RESERVED
VAR P5 CONNECTOR SHIFTER (TRANSMISSION) REAR CAB 5 - 146 P108 CONNECTOR REAR AXLE REED SWITCH
VAR P6 CONNECTOR SHIFTER (CAB) REAR CAB 5 - 123 P109 CONNECTOR FRONT AXLE REED SWITCH
VAR P7 CONNECTOR REAR CAB INTERFACE P***
VAR P8 CONNECTOR MAIN HARNESS INTERFACE 2 - 45 R1 SENSOR ENGINE COOLANT LEVEL
VAR P9 CONNECTOR STEERING INTERFACE 3 - 62 R2 SENSOR TURBINE SPEED (ZF)
VAR P10 CONNECTOR CONTROL BOX 2 - 58 R3 SENSOR TRANSMISSION TEMPERATURE
N/S P11 CONNECTOR RESERVED 2 - 42 R4 SENSOR ENGINE HIGH COOLANT TEMPERATURE SWITCH - SENDER
VAR P12 CONNECTOR CONTROL BOX CAB SELECT 2 - 56 R5 SENSOR FUEL LEVEL
VAR P13 CONNECTOR STEERING BOX (STANDARD) 2 - 54 R6 SENSOR SPEED (ZF)
VAR P14 CONNECTOR STEERING BOX (OPTIONAL) 2 - 39 R7 SENSOR ENGINE LOW OIL SWITCH - SENDER
3 - 78 P15 CONNECTOR TRANSMISSION SOLENOID VALVES R***
2 - 54 P16 CONNECTOR VEHICLE SPEED SENSOR (ZF) 6 - 161 S1 SWITCH WIPER
VAR P17 CONNECTOR ENGINE PLUG 6 - 169 S2 SWITCH WINDSHIELD WASHER
VAR P18 CONNECTOR ENGINE PLUG (YELLOW) N/S S3 SWITCH RESERVED
VAR P19 CONNECTOR INSTRUMENT GAUGES 6 - 158 S4 SWITCH BLOWER FAN
VAR P20 CONNECTOR CEILING INTERFACE N/S S5 SWITCH RESERVED
VAR P21 CONNECTOR FRONT LIGHTS 7 - 195 S6 SWITCH PARK LIGHT
VAR P22 CONNECTOR REAR LIGHTS 7 - 196 S7 SWITCH HIGH-LOW BEAM
3 - 62 P23 CONNECTOR TURBINE SPEED SENSOR (ZF) 8 - 232 S8 SWITCH REAR WINDOW DEFROSTER, TOUCH PAD
VAR P24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK-UP N/S S9 SWITCH RESERVED
N/S P25 CONNECTOR RESERVED 8 - 228 S10 SWITCH EMERGENCY STEERING
SH.5 P26 CONNECTOR DIODE MODULE, STEERING, CR1-CR4 8 - 232 S11 SWITCH FRONT HITCH LIGHT
SH.5 P27 CONNECTOR DIODE MODULE, STEERING, CR5-CR8 7 - 194 S12 SWITCH REAR HITCH LIGHT
VAR P28 CONNECTOR IGNITION/LIGHT SWITCH 8 - 223 S13 SWITCH BEACON
SH.5 P29 CONNECTOR STEERING MODE INDICATOR LIGHTS 5 - 125 S14 SWITCH STEERING MODE SELECT
6 - 163 P30 CONNECTOR WINDSHIELD WIPER MOTOR, LEFT HAND 6 - 172 S15 SWITCH CAB LIFT
6 - 165 P31 CONNECTOR WINDSHIELD WIPER MOTOR, RIGHT HAND N/S S16-18 SWITCH RESERVED
VAR P32 CONNECTOR RIGHT HAND HEADLIGHT 4 - 116 S19 SWITCH CAB SELECT
VAR P33 CONNECTOR LEFT HAND HEADLIGHT 7 - 203 S20 SWITCH DASH LIGHT, TOGGLE TYPE
8 - 230 P34 CONNECTOR FRONT HITCH LIGHT 2 - 31 S21 SWITCH EMERGENCY ENGINE STOP, PUSH/PULL
VAR P35 CONNECTOR CAB SELECT LIGHTS (REAR) 1 - 23 S22 SWITCH STOP, RUN, START
VAR P36 CONNECTOR STEERING MODE INDICATOR LIGHTS (REAR) 6 - 153 S23 SWITCH HORN
VAR P37 CONNECTOR CAB SELECT LIGHTS 3 - 90 S24 SWITCH PARK BRAKE (REAR)
1 - 17 P38 CONNECTOR STARTER SOLENOID AUXILIARY RELAY 5 - 123 S25 SWITCH FRONT AXLE REED
VAR P39 CONNECTOR LEFT HAND REAR LIGHTS 8 - 216 S26 SWITCH TURN SIGNAL
VAR P40 CONNECTOR RIGHT HAND REAR LIGHTS 1 - 20 S27 SWITCH PARK BRAKE
1 - 14 P41 CONNECTOR ECU GLOW PLUG 4 - 92 S28 SWITCH PARKING BRAKE PRESSURE,
VAR P42 CONNECTOR REAR CAB STEERING INTERFACE OPENS AT 1800 psi ON FALLING PRESSURE
8 - 216 P43 CONNECTOR TURN SIGNAL 5 - 146 S29 SWITCH REAR AXLE REED
6 - 158 P44 CONNECTOR HEATER - FAN, CAB 2 - 32 S30 SWITCH EMERGENCY ENGINE STOP (REAR) PUSH/PULL
VAR P45 CONNECTOR REAR HEADLIGHT, RIGHT HAND 7 - 187 S31 SWITCH REAR HEADLIGHTS (REAR)
VAR P46 CONNECTOR REAR HEADLIGHT, LEFT HAND 7 - 190 S32 SWITCH REAR HITCH LIGHT (REAR)
N/S P47 CONNECTOR RESERVED N/S S33 SWITCH RESERVED (REAR)
2 - 45 P48 CONNECTOR ENGINE COOLANT LEVEL SENSOR 5 - 148 S34 SWITCH STEERING MODE SELECT (REAR)
N/S P49 CONNECTOR RESERVED 8 - 225 S35 SWITCH EMERGENCY STEERING (REAR)
4 - 113 P50 CONNECTOR ACCELERATOR TRANSFER SOLENOID VALVE 4 - 118 S36 SWITCH CAB SELECT (REAR)
VAR P51 CONNECTOR DIODE MODULE, CR9-CR12 6 - 154 S37 SWITCH HORN (REAR)
3 - 62 P52 CONNECTOR FRONT SHIFTER UPSHIFT INTERLOCK 6 - 170 S38 SWITCH CAB WAND, RIGHT HAND
3 - 88 P53 CONNECTOR REAR SHIFTER UPSHIFT INTERLOCK 6 - 170 S39 SWITCH CAB WAND, CENTER
5 - 131 P54 CONNECTOR COORD/CRAB SELECT VALVE, FRONT MODE 6 - 170 S40 SWITCH CAB WAND, LEFT HAND
5 - 141 P55 CONNECTOR COORD/CRAB SELECT VALVE, REAR MODE 8 - 228 S41 SWITCH EMERGENCY STEERING PRESSURE,
4 - 116 P56 CONNECTOR FRONT/REAR CAB ORBITAL SELECT VALVE OPENS AT 1800 psi ON FALLING PRESSURE
VAR P57 CONNECTOR DIODE MODULE, TRANSMISSION SHIFTER, CR18-CR21 2 - 48 S42 SWITCH TRANSMISSION HIGH TEMPERATURE
8 - 233 P58 CONNECTOR REAR WINDOW DEFROSTER 8 - 220 S43 SWITCH BRAKE PRESSURE (BRAKE LIGHTS)
N/S P59 CONNECTOR RESERVED CLOSES AT 50 psi
8 - 235 P60 CONNECTOR K35 RELAY (RUN SOLENOID DISCONNECT) S***
8 - 240 P61 CONNECTOR 120 VAC OR 240 VAC POWER SUPPLY
6 - 156 P62 CONNECTOR HORN
N/S P63 CONNECTOR RESERVED
2 - 34 P64 CONNECTOR DIODE MODULE, ENGINE WARNING ALARM, CR22-CR25 MASTER LEGEND Figure 2-6. Schematic, Front & Rear Cab (Station)
4 - 94 P100 CONNECTOR PARK BRAKE SET VALVE
N/S P101,102 CONNECTOR RESERVED Sheet 10 of 10
CD276 2-2-57
Rev 13
Chapter 2
E1
CB2 12V BATTERY (BREAKER)

E3
12V IGNITION SWITCH
F12 LEGEND
E2
BT1 BT2
CB1 P4
P28
P7
S22
F17
P7 S27
P28
P4
A8 K20
P41 P8
K31
P8 P38
P17 NOTES:
P17
K30
REFERENCE S&S TUG DRAWINGS:

P18 E4
K19
L17
M
DS3
G1
EMERG STEERING ALTERNATOR START MOTOR COLD START (GLOW PLUG) CONTROL CIRCUIT MASTER IGNITION RELAY
PUMP START
Figure 2-7. Schematic, Single Cab (Station)

Sheet 1 of 8
2-2-58 CD276
Rev 13
Chapter 2

12V IGNITION SWITCH
12V PARK SWITCH
LEGEND
F1
P8 P7
P4
P28 GA7
GA3 GA2 GA5 GA6 GA1 GA4
S21 DS7 DS4
P18 DS2
P28
P19 P19
P8 P19
P7
P42
L7
P8 P8
P42
P17
R7 R4 R1 S42 DS13 DS14 R6 R5 R3

L6 P48 P16
ACCESS RUN GENERATOR OIL COOLANT COOLANT TRANSM. VOLT TACHO SPEEDO FUEL TRANSM.
VOLUME SOLENOID NO CHARGE PRESSURE TEMP LEVEL TEMP. METERS GAUGE TEMP.
SOLENOID DASH LIGHTS GAUGE

Sheet 2 of 8
CD276 2-2-59
Rev 13
Chapter 2

F2
LEGEND
P7 P7 P4
P52
A1
P1 P2
P2
P7
P1
P2
P7 K25
K21
P7
P24
A4
P8
P24
R2
P23
A3
P15
FRONT CAB CONTROL VALVE BODY

TRANSMISSION

Sheet 3 of 8
2-2-60 CD276
Rev 13
Chapter 2

F5 F7
P4 P7 LEGEND
P4
P7
S27
DS11 P7
P51
P7 P7
P7
K23
P9
P8
L10 L11
S28 P100 P103
PARKING BRAKE
RESERVED FOR REAR CAB (STATION)

Sheet 4 of 8
CD276 2-2-61
Rev 13
Chapter 2

LEGEND
F3
S14 P9 P13
P4
P9 DS32 K11 K12
P9
P13
P42 P26/CR4
P13
S25
P109
P26/CR3
P42
P26/CR1
P26/CR2
P13 S29 SEE SHEET 1 FOR NOTES
P108
K9 K10
P42 P42
P13
P9 P9
DS21 DS23 DS22

P29 P29 P29
L13 L14
P54 P54
FRONT AXLE CENTER FRONT CONTROL REAR AXLE CENTER

STEERING

Sheet 5 of 8
2-2-62 CD276
Rev 13
Chapter 2

LEGEND
12V PARK SW
F11 F10 F15 F6
P4 P4 P4 P4
S15
K22 S1
S2
P20
P20 P20 H1 P20 S39
S4
H2
S40 CR12
P20 P51
H3 CR11
P7 S38 P51
P20
B2
DS38 S23 A6 B6 B7 B4 B3 B8 L18 L19 AL1
P44 P30 P31 P105 P104

CAB

Sheet 6 of 8
CD276 2-2-63
Rev 13
Chapter 2
LEGEND
12V PARK SW.
F14
P4
P28
P7 P7
S20
P28
S6
S7
S12
CR16
P7
P7

P8
P7
K24
P8
P8 P7
P22 P21
P21
P22
DS61 DS60 DS68 DS34 DS35 DS5 DS62 DS70 DS59 DS69
AL2 P39 P40 P47 P33 P32 P39 P33 P40 P32
BACK-UP REAR HEADLIGHT PARK

LIGHT HITCH
EXTERIOR LIGHTS
Sheet 7 of 8
2-2-64 CD276
Rev 13
Chapter 2

12V PARK SW. P61
F9 F13 F4
P4 P4
P4
P8
FL1 S13
S11
P7
K36
S26
P43 K35
S43 S10
FL2
P22 P58

P8 P8
P20 P8 P21 S8
P22 P21 P22 P21 P60
A10 M
DS1 DS64 DS36 DS6 DS57 DS37 DS63 DS58 *DS71 S41 DS39
P39 P33 P40 P32 P39 P40 P34
A11
TURN SIGNALS
LIGHT
EXTERIOR LIGHTS

Sheet 8 of 8
CD276 2-2-65
Rev 13
Chapter 2
CB2 E1
6 BLK 6 BLK 12V BATTERY (BREAKER) B(+)
LEGEND
E3 120A 128 ITEM DESCRIPTION
2/0 BLK 6 BLK
B(+)
BUS BAR
125 12V IGNITION SWITCH A 7 ASSEMBLY STARTER MOTOR (SOLENOID & MOTOR)
TO F11 A 8 ASSEMBLY ECU GLOW PLUG
2/0 BLK
F12 B 1 MOTOR STARTER
20A B 5 MOTOR EMERGENCY STEERING PUMP
BT1 BT2 E2 10 WHT BT 1 BATTERY BATTERY, 12 VOLTS
65 112 BT 2 BATTERY BATTERY, 12 VOLTS
+ + CB 1 CIRCUIT B. GLOW PLUG, 120A
CB1 P4 CB 2 CIRCUIT B. MAIN, 120A
170 1
120A DS 3 LIGHT GLOW PLUG INDICATOR
− − 112 E 1 STUD FUSE BOX POWER
1/0 BLK

P28
6 BLK
(−) C B E 3 STUD BATTERY POWER
P7 121 121 112 E 4 STUD GLOW PLUG POWER
2/0 BLK
1 F 12 FUSE INSTRUMENT PANEL, 20A

B S22 10 F 17 FUSE STARTER, 20A
29 F17 3
WELDMENT 32 JPR ST F 21 FUSE EMERGENCY STEERING PUMP, 225A
F21
6 BLK
20A NO 127
225A 61 IGN F 22 FUSE GAUGES, 5A
4 G 1 GENERATOR 12 VDC, 95A
127 101 2 ACC
P7 S27 GP 1−6 RESISTOR GLOW PLUG
159 125 K 19 RELAY EMERGENCY STEERING PUMP MOTOR
173 122 D P18 K 20 RELAY PARK BRAKE ON−STARTER ENABLE
126
P28 2 K 30 RELAY IGNITION (MASTER)
4 3 F22
5 5A K 31 RELAY STARTER SOLENOID AUXILIARY
125 L 7 SOLENOID EXCESS START FUEL ALLOWANCE
8 125
30 86 L 17 SOLENOID ENGINE STARTER
2
1/0 BLK
P4 P 4 CONNECTOR FUSE BOX

A8 178
25 K20 127
9 P41 P8
C A D B(+) P 17 CONNECTOR ENGINE PLUG
1 125
36 52 P 18 CONNECTOR ENGINE PLUG (YELLOW)
178 P 28 CONNECTOR IGN/LIGHT SWITCH
129 136 K31 P 38 CONNECTOR STARTER SOLENOID AUX. RELAY
P8 P38 P 41 CONNECTOR ECU GLOW PLUG
6 BLK
2 E F S 22 SWITCH STOP, RUN, START
228 P17 P17 86 30 L7 S 27 SWITCH PARK BRAKE
1 127
2 B
199 127 85 87 NOTES:
K30 1. ALL RELAYS AND SWITCHES SHOWN DE−ENERGIZED (DE−ACTUATED).
2. INDICATES VENDOR WIRING
159 128 3. INDICATES OPTIONAL WIRING
P18 E4 4. * INDICATES OPTIONAL COMPONENTS
1
D+ B+ W REFERENCE S&S TUG DRAWINGS:
FIGURE 5.1.12 REFERENCE DESIGNATORS/PART
K19 + NUMBERS/LOCATION INDEX
L17
G FIGURE 5.1.14 ELECTRICAL EQUIPMENT LOCATION

M JP1
− DS3
SEE SHEETS 9-10 FOR MASTER LEGEND
G1
EMERG STEERING ALTERNATOR START MOTOR COLD START (GLOW PLUG) CONTROL CIRCUIT MASTER IGNITION RELAY EXCESS
PUMP START VOLUME
SOLENOID
ENGINE

Sheet 1 of 10
2-2-66 CD276
Rev 13
Chapter 2
125 12V IGNITION SWITCH 125

LEGEND
224 12V PARK SWITCH 224
ITEM DESCRIPTION
BUS BAR AL 3 ALARM ENGINE TRANSMISSION TROUBLE WARNING
FROM F3 101 101
CR22−25 RECTIFIER ENGINE WARNING ALARM
DS 2 LIGHT LOW OIL PRESSURE INDICATOR
F1 DS 4 LIGHT TRANSMISSION HI OIL TEMP INDICATOR
10A P8 P7 DS 7 LIGHT LOW COOLANT LEVEL INDICATOR
4 24 DS 8 LIGHT ENGINE HI COOLANT TEMP INDICATOR
101 DS12 LIGHT GENERATOR NO CHARGE INDICATOR
101 101 125 101 125 101 101 101 224 224 224 224 224 DS13 LIGHT FRONT DASH PANEL, LEFT HAND
AL3 125 125 125 125 125 DS14 LIGHT FRONT DASH PANEL, RIGHT HAND
P4 DS15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE
3
13 + DS16 LIGHT ENGINE OIL PRESS GAUGE
−
101 224 224 DS17 LIGHT TRANS OIL TEMP GAUGE
224
101 DS 18 LIGHT VOLTMETER
269 DS 19 LIGHT TACHOMETER
P28 GA7
GA3 GA2 GA5 GA6 GA1 GA4 DS 20 LIGHT SPEEDOMETER
RED
RED
A
BLK
BLK
P64 DS 33 LIGHT FUEL LEVEL GAUGE
101 S21 F 1 FUSE ENGINE, 10A
E F G H DS7 DS4 I I
GA 1 GAUGE FUEL LEVEL
GA 2 GAUGE ENGINE COOLANT TEMPERATURE
GA 3 GAUGE ENGINE OIL PRESSURE
D C B A DS2 GA 4 GAUGE TRANS OIL TEMPERATURE
123 P64 GA 5 GAUGE VOLTMETER
136
CR24
CR23
CR22
CR25
130 132 135 139

E 137 138 GA 6 GAUGE TACHOMETER
P28 4 5 7 11 12 6 8 3 GA 7 GAUGE SPEEDOMETER
129 P19 P19 P19
123 L 6 SOLENOID ENGINE RUN VALVE
6 7 8 9 5
P8 P7 P 4 CONNECTOR FUSE BOX
3 P 7 CONNECTOR REAR CAB INTERFACE
134
133
131
140
123 224 P 8 CONNECTOR MAIN HARNESS INTERFACE

P42 P 16 CONNECTOR SPEED SENSOR (ZF)
E P 17 CONNECTOR ENGINE PLUG
P 19 CONNECTOR INSTRUMENT GAUGES
SEE GRID P 28 CONNECTOR IGN/LIGHT SWITCH
237 FOR P 42 CONNECTOR REAR CAB STEERING INTERFACE
136 137 138 135 139 156 P 48 CONNECTOR ENGINE COOLANT LEVEL SENSOR
JPR JPR REMOVAL 129 130 131 132 133 134 140
P 64 CONNECTOR DIODE MODULE, ENG.WARNING
ALARM, CR22−25
R 1 SENSOR ENGINE COOLANT LEVEL
F P8 P8 R 4 SENSOR ENGINE HI COOLANT TEMP. SW − SENDER
P42 1 5 6 7 8 9 10 11 12 17 18 19
CLOSES AT 239°F
129 137 138 R 5 SENSOR FUEL LEVEL
124 130 131 132 133 134 140
R 6 SENSOR SPEED (ZF)
224
4 R 7 SENSOR ENGINE LOW OIL SW − SENDER
P17 P17 AT 5.8 PSIG ON FALLING PRESSURE
7 5 6 3 4 S 21 SWITCH EMERGENCY ENGINE STOP
135 139
12 TWISTS PER FOOT,

3
1 G WK 1 2 224
TWISTED PAIR,
137 138
P
136 SEE SHEET 1 FOR NOTES AND SHEETS
9-10 FOR MASTER LEGEND
MIN
2 6
R7 R4 R1 2 S42 DS13 DS14 R6 R5 R3
L6
P48 P16
RUN GENERATOR OIL COOLANT COOLANT TRANSM. VOLT TACHO SPEEDO FUEL TRANSM.
SOLENOID NO CHARGE PRESSURE TEMP LEVEL TEMP. METERS GAUGE TEMP.
DASH LIGHTS GAUGE

Sheet 2 of 10
CD276 2-2-67
Rev 13
Chapter 2
BUS BAR
FROM F3
LEGEND
F2
10A ITEM DESCRIPTION
A 1 ASSEMBLY ZF FRONT CAB SHIFTER
A 3 ASSEMBLY TRANSMISSION VALVE BODY
102
A 4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK−UP
F 2 FUSE TRANSMISSION, 10A
P4 K 21 RELAY SHIFTER IN NEUTRAL
P7 JPR P7 102 5 K 25 RELAY LOCK−UP UNIT (DOWNSHIFT)
149 L 1−5 SOLENOID TRANSMISSION VALVE BODY, ZF/Y1−Y5
S27 P52 7 141 141 P 1 CONNECTOR ZF SHIFTER (TRANSMISSION), FRONT CAB
1 P 2 CONNECTOR ZF SHIFTER (CAB), FRONT CAB
1
273 1 8 142 142 P 4 CONNECTOR FUSE BOX
21, P 7 CONNECTOR REAR CAB INTERFACE
NC
274 7 4 143 143

93 2 P 8 CONNECTOR MAIN HARNESS INTERFACE
2 A1 3 144 144 P 15 CONNECTOR TRANSMISSION SOLENOID VALVES
P 23 CONNECTOR TURBINE SPEED SENSOR (ZF)
P2 2 145 145 P 24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK−UP
P 52 CONNECTOR FRONT SHIFTER UPSHIFT INTERLOCK
3 P1 P2 R 2 SENSOR TURBINE SPEED (ZF)
P2 102
5A 5
246
P7
27 JPR
P1 6 4 142
6 P2 SHIFTER OUTPUT SIGNAL
MARKED
SHIFTER
148 FORWARD REVERSE NEUTRAL
POINT
102 102
GEAR 1 2 3 4 1 2 3 NF NF NR N
AD1
10
P7 86 30 K25 86 30 AD2
AD3
87 AD4
147 85 87 85
K21 AD5
182 AD6
170
177 177
19
92 P7 26
P24
A4
141
145
144
143
142
245 5 6 161
1 3
150
P8 2 3 102 A E D C B
4 6
21 150 2
P24
R2
1
F SEE SHEET 1 FOR NOTES AND SHEETS
P23 9-10 FOR MASTER LEGEND
A3
P15

TRANSMISSION

Sheet 3 of 10
2-2-68 CD276
Rev 13
Chapter 2
BUS BAR BUS BAR 128

FROM F7 TO F6, F5
F5 F7
10A 10A
LEGEND
105 ITEM DESCRIPTION
107
P4 107
P7 TO REAR CAB
P4 CONTROLS
6 P7 7 22 WHEN EQUIPPED CR10 RECTIFIER BLOCKING, PARKING BRAKE
105 DS11 LIGHT PARK BRAKE APPLIED INDICATOR
3
S27 F 5 FUSE PARKING BRAKE, 10A
F 7 FUSE RESERVED
3 1
K 23 RELAY TRANSM NOT IN N−, PARK BRAKE APPL.
NC
NO
61 L 10 SOLENOID PARKING BRAKE SET VALVE
4 2 L 11 SOLENOID PARKING BRAKE RELEASE VALVE
DS11 P7 P 9 CONNECTOR STEERING INTERFACE
4 P 51 CONNECTOR DIODE MODULE
P 100 CONNECTOR PARK BRAKE SET VALVE
P 103 CONNECTOR PARK BRAKE RELEASE VALVE
66
177 S 28 SWITCH PARKING BRAKE PRESSURE
P51 B
153
181 171 182 193

SEE SHEET 1 FOR NOTES AND SHEET
THIS SPACE INTENTIONALLY LEFT BLANK
19 9-10 FOR MASTER LEGEND
P7 P7
20
171
JPR
30 85
21
P7
87 86
K23
196
182
P9
P8 M
20 196
182
B B
L10 L11
P100 A A
P103
S28
PARKING BRAKE

Sheet 4 of 10
CD276 2-2-69
Rev 13
Chapter 2
128
BUS BAR
TO F2, F1 LEGEND
F3 COORD ITEM DESCRIPTION
10A
TRACK CR1−4 RECTIFIER BLOCKING, STEERING
103 CRAB DS21 LIGHT COORD STEER MODE INDICATOR
S14 P9 P13 DS22 LIGHT TRACK STEER MODE INDICATOR
P4 8 E 198 E DS23 LIGHT CRAB STEER MODE INDICATOR
11 DS32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB)
103 3 6 C 206 C 206
F 3 FUSE STEERING, 10A
2 G 202 G K 9 RELAY COORD STEERING, FRONT CONTROL
148 K 10 RELAY CRAB STEERING, FRONT CONTROL
10 9
188 198 K 11 RELAY FRONT AXLE REED SWITCH
206 215 K 12 RELAY REAR AXLE REED SWITCH
202 K11 K12
P9 215 DS32 L 13 SOLENOID COORD SELECT VALVE, SV2−A (OR 1)
B 14 10 9 11 14
L 14 SOLENOID CRAB SELECT VALVE, SV2−B (OR 1)
11 12 12 9 10 P 4 CONNECTOR FUSE BOX
103 P9 P 9 CONNECTOR STEERING INTERFACE
H
B 2 1 7 3 8 4 4 8 3 1 5 2 6 P 13 CONNECTOR STEERING BOX (STD)
6 5 7
103 215 P13 13 13 P 26 CONNECTOR DIODE MODULE, STEERING, CR1−CR4
P 29 CONNECTOR STEER MODE INDICATOR LIGHTS
P42 210 211 P26/CR4
237
213 P 42 CONNECTOR REAR CAB STEER INTERFACE
A B 150
R H P 54 CONNECTOR COORD/CRAB SELECT VALVE, FRONT MODE
P13 P 108 CONNECTOR REAR AXLE REED SWITCH
JPR S25 BLK 188 201 237
P109 A
129 215 S 14 SWITCH STEER MODE SELECT
B WHT C 211 213 P26/CR3 S 25 SWITCH FRONT AXLE REED
P42 210 S 29 SWITCH REAR AXLE REED
122
191 A
BLK
P26/CR1
P26/CR2
140
P13 S29 R B 103
L
201 P108
191 C WHT
213
191
201 211 191 210 168
6 10 11 1 11 10 6 1
188
RESET
RESET
SET
SET
3 2 9 8 4 5 9 8 2 3 4 5
215 215
K9 K10
166
203
P42 167 P42 D 125

C
D J K A F
P13
D 166 203 A F
P9 P9
166 GRN WHT 203 168
A C B
DS21 D COM F DS23 E DS22

P29 COORD BLK CRAB P29 P29
L13 L14 SEE SHEETS 9−10 FOR MASTER LEGEND
P54 P54
COORD CRAB CRAB

FRONT AXLE CENTER FRONT CONTROL REAR AXLE CENTER
STEERING

Sheet 5 of 10
2-2-70 CD276
Rev 13
Chapter 2

229 LEGEND
B(+)
BUS BAR 128
ITEM DESCRIPTION
FROM F12 224 12V PARK SW 224
*A 6 ASSEMBLY CAB, HEATER − FAN
60 193
BUS BAR * AL 1 ALARM CAB RAISE/LOWER
FROM F7 *B 2 MOTOR WINDSHIELD WASHER PUMP
F11 F10 F15 F6 *B 3 MOTOR WINDSHIELD WIPER, RIGHT HAND
*B 4 MOTOR WINDSHIELD WIPER, LEFT HAND
20A 20A 30A 10A
*B 6 MOTOR CAB DEFROSTER/COOLING, R.H.
*B 7 MOTOR CAB DEFROSTER/COOLING, L.H.
111 110 224 115 224 106 *B 8 MOTOR CAB ROOF WIPER
P4 P4 P4 P4 CR 11 RECTIFIER BLOCKING, CAB LIFT
13 8 10 15 CR 12 RECTIFIER BLOCKING, CAB LIFT
* DS 38 LIGHT CAB DOME
115 224 106 F 6 FUSE CAB RAISE/LOWER, 10A
110 F 10 FUSE HEATER/COOL FAN, 20A
111 F 11 FUSE HORN, 20A
115 * S15 F 15 FUSE WINDSHIELD WIPER, 30A
10 3 H 1 HORN VEHICLE, FRONT
*H 2 HORN VEHICLE, FRONT, LEFT HAND
85 30 10 3 4 5 10 *H 3 HORN VEHICLE, FRONT, RIGHT HAND
K 22 RELAY HORN
9 7 1 R L
7 8 * L 18 SOLENOID CAB RAISE VALVE
87a HI LO * L 19 SOLENOID CAB LOWER VALVE
86 87 * S1 9 1 5 2 6 1 9 * S2 106 106 P 4 CONNECTOR FUSE BOX
K22 19 P 7 CONNECTOR REAR CAB INTERFACE
15 * P 20 CONNECTOR CEILING INTERFACE
G * P 21 CONNECTOR FRONT LIGHTS
P20 * * P 30 CONNECTOR WINDSHIELD WIPER MTR., LEFT HAND
15 5 6 7 8 9
111 181 24 P21 24 * P 31 CONNECTOR WINDSHIELD WIPER MTR., RIGHT HAND
* P 44 CONNECTOR HEATER − FAN, CAB
118 119 160 177 19 262 P 51 CONNECTOR DIODE MODULE
B 110
P 62 CONNECTOR HORN
* P20 * P20 P62 224 110 * P20 * S39 * P 104 CONNECTOR CAB LOWER SOLENOID VALVE
1 2 12 * P 105 CONNECTOR CAB RAISE SOLENOID VALVE
16 262
A H1 118 119 *S 1 SWITCH WIPER
*S 2 SWITCH WINDSHIELD WASHER
181 24 10 3
S4 *
*S 4 SWITCH BLOWER FAN
19 * S 15 SWITCH CAB LIFT
91 16 170 S 23 SWITCH HORN
* S 38 SWITCH CAB WAND, RIGHT HAND
H2 * 9 1 5
HI LO 115 * S 39 SWITCH CAB WAND, CENTER
15
262 * S 40 SWITCH CAB WAND, LEFT HAND
E
2 * S40 CR12
24 * P20 17
19 P51
4
243 222 D
181 SEE SHEET 1 FOR NOTES AND
H3 *
SHEETS 9−10 FOR MASTER LEGEND
262 CR11
JPR
A B
118
119
115 115 160 * S38 P51
20 P7 ORN RED 19
23 18
244
10 F C
* P20 19
18
+
* * B2
BLK * * *
DS38 S23 A6 * B6 B7 B4 * B3 * B8
F L18 * L19 *
P44 *
P30 * P31 * AL1 *
P105 * P104 *
DOME LIGHT−HORN HEATER COOLING FAN WINDSHIELD WIPER/WASHER CAB LIFT

CAB

Sheet 6 of 10
CD276 2-2-71
Rev 13
Chapter 2
BUS BAR
B(+) 224 12V PARK SW. 224
LEGEND
174 219
TO F13 ITEM DESCRIPTION
223
* AL 2 ALARM BACK−UP
F14 CR 16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A
20A DS 5 LIGHT HI−BEAM INDICATOR
DS 34 LIGHT HEADLAMP, LEFT HAND
114 DS 35 LIGHT HEADLAMP, RIGHT HAND
223 DS 59 LIGHT TAIL, RIGHT HAND
P4 DS 60 LIGHT BACK−UP, RIGHT HAND
14 P28 G DS 61 LIGHT BACK−UP, LEFT HAND
F
114
P7 P7 223 223 5 1 226 DS 62 LIGHT TAIL, LEFT HAND
223 * DS 68 LIGHT REAR HITCH
16 15 DS 69 LIGHT PARK, FRONT, RIGHT HAND
224 10 9
DS 70 LIGHT PARK, FRONT, LEFT HAND
S20 F 14 FUSE HEADLIGHTS, 20A
224 P28 3 1 6 K 24 RELAY SHIFTER, BACK−UP
S6 ON P 4 CONNECTOR FUSE BOX
5 10 H NORMAL
4 P 7 CONNECTOR REAR CAB INTERFACE
226 OFF P 8 CONNECTOR MAIN HARNESS INTERFACE
S7 3 10 2 5
P 21 CONNECTOR FRONT LIGHTS
1 9
P 22 CONNECTOR REAR LIGHTS
* S12 P 28 CONNECTOR IGN/LIGHT SWITCH
P 32 CONNECTOR R.H. HEADLIGHT
62 219 LO HI 5 1 9 CR16 224 P 33 CONNECTOR L.H. HEADLIGHT
P7 18
P 39 CONNECTOR L.H. REAR LIGHTS
109 P 40 CONNECTOR R.H. REAR LIGHTS
147
225 230 *P 47 CONNECTOR REAR HITCH LIGHT
S 6 SWITCH PARK LIGHT
P7 S 7 SWITCH HIGH−LO BEAM
13 *S 12 SWITCH REAR HITCH LIGHT
S 20 SWITCH DASH LIGHT
JPR
P8 235
86 87a 14
17
85 30 225 JPR P7
K24
P8
227 13 221
14
P8 P7 221
16
227 231 235
P22 P21 SEE SHEET 1 FOR NOTES AND
P21 D A
P22 231 C D SHEETS 9−10 FOR MASTER LEGEND
B
235
227 227 225 221 221 221 221
231 235 235
227 B A B A
B B
BLK BLK BLK GRN GRN RED BRN D YEL
D
BRN
D
YEL
D
RED
+
DS61 DS60 DS68 * DS34 DS35 DS5 DS62 DS70 DS59 DS69
* AL2 P39 P40 P47 * P33 P32 P39 P33 P40 P32
BACK−UP REAR HEADLIGHT PARK

LIGHT HITCH
EXTERIOR LIGHTS

Sheet 7 of 10
2-2-72 CD276
Rev 13
Chapter 2
128 12V IGNITION (MASTER RELAY)

175
BUS BAR
FROM F14
B(+)
224 12V PARK SW. * P61 LEGEND
207
ITEM DESCRIPTION
* A 10 ASSEMBLY CAB, REAR WINDOW DEFROSTER
F9 F13 * F4
15A 15A * A 11 ASSEMBLY ENG.COOLANT, TANK HEATER, 120VAC
OR 240VAC
183 DS 1 LIGHT LEFT TURN INDICATOR
109 113 DS 6 LIGHT RIGHT TURN INDICATOR
DS 36 LIGHT TURN, FRONT, LEFT HAND
P4 109 224 P4 DS 37 LIGHT TURN, FRONT, RIGHT HAND
16 12
113 * DS 39 LIGHT FRONT, HITCH
DS 57 LIGHT TURN, REAR, RIGHT HAND
109 113 P4 DS 58 LIGHT BRAKE, RIGHT HAND
DS 63 LIGHT BRAKE, LEFT HAND
DS 64 LIGHT TURN REAR, LEFT HAND
* DS 71 LIGHT BEACON, ROTATING
10 5 5 10 *F 4 FUSE REAR WINDOW DEFROSTER, 20A
P8 TRACTOR F 9 FUSE TURN/BRAKE/BACK−UP LIGHTS, 15A
23 FRAME F 13 FUSE EMERG. STEERING, BEACON & FRT. HITCH,15A
FL 1 FLASHER TURN SIGNAL LIGHTS
9 1
* S13
1 9 * S11
* FL 2 FLASHER BEACON LIGHT (FLASHING)
FL1 BLK * K 35 RELAY RUN SOLENOID DISCONNECT
109
P7 WHT * K 36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
BLU * K36 P 7 CONNECTOR REAR CAB INTERFACE
YEL 30
P 8 CONNECTOR REAR HARNESS INTERFACE
* P 20 CONNECTOR CEILING INTERFACE
242 P 21 CONNECTOR FRONT LIGHTS
S26 P 22 CONNECTOR REAR LIGHTS
BLK
P43 85 87 P 32 CONNECTOR R.H. HEADLIGHT
P 33 CONNECTOR L.H. HEADLIGHT
10 (+) 14
S10 12 9 P 34 CONNECTOR FRONT HITCH LIGHT
6 5 S43 P 39 CONNECTOR L.H. REAR LIGHTS
10 5 BLK
JUMPER ACROSS 6 4 8 1 5 P 40 CONNECTOR R.H. REAR LIGHTS
WHEN ROTATING 2 (−) 13 P 43 CONNECTOR TURN SIGNAL
BEACON IS * P 58 CONNECTOR REAR WINDOW DEFROSTER
229 234 232 * 9 1 4 WIRE * K35 WHT RELAY
* P 60 CONNECTOR K35 RELAY (RUN SOLENOID DISCONNECT)
FURNISHED PANEL
FL2 CORD (REF) WHT * P 61 CONNECTOR 120 OR 240 VAC POWER SUPPLY
*S 8 SWITCH REAR WINDOW DEFROSTER, TOUCH PAD
234 P22 * P58 S 10 SWITCH EMERGENCY STEERING
A 238 169
* S 11 SWITCH FRONT HITCH LIGHT
* S 13 SWITCH BEACON
264
P8 22 P8 24
S 26 SWITCH TURN SIGNAL
S 41 SWITCH EMERGENCY STEERING PRESSURE
229 234 * S 43 SWITCH BRAKE PRESSURE (BRAKE LIGHTS)
* P20 P8 P21 S8
P22 P21 P22 P21 11 15 F * P60
C B E E
232 232
229 229 229 234 234 234 238 SEE SHEET 1 FOR NOTES AND
264 WHT
BLK SHEETS 9−10 FOR MASTER LEGEND
C C C C A A
GRN YEL 32
BLU BLU RED RED
*
REMOVE JPR
*
A10 M BETWEEN P42 −E AND −F.
CONNECT 124A TO P42−E,
DS1 DS64 DS36 DS6 DS57 DS37 DS63 DS58 DS71 S41 DS39 * AND 124B TO P42−F,
P39 P33 P40 P32 P39 P40 P34 WHEN ENGINE COOLANT
199 BLK
HEATER IS FURNISHED
* A11
2
TURN SIGNALS
LIGHT
EXTERIOR LIGHTS

Sheet 8 of 10
CD276 2-2-73
Rev 13
Chapter 2

SH.NO.−GRID ITEM DESCRIPTION SH.NO.−GRID ITEM DESCRIPTION SH.NO.−GRID ITEM DESCRIPTION
1 − 16 F17 FUSE STARTER, 20A
3 − 64 A1 ASSEMBLY ZF FRONT CAB SHIFTER 5 − 136 DS22 LIGHT TRACK STEERING MODE INDICATOR N/S F18−20 FUSE RESERVED
N/S A2 ASSEMBLY RESERVED 5 − 134 DS23 LIGHT CRAB STEERING MODE INDICATOR 1− 3 F21 FUSE EMERGENCY STEERING PUMP, 225A
3 − 78 A3 ASSEMBLY TRANSMISSION VALVE BODY N/S DS24−31 LIGHT RESERVED 1 − 23 F22 FUSE GAUGES, 5A
3 − 65 A4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK−UP 5 − 126 DS32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB) F***
N/S A5 ASSEMBLY RESERVED 2 − 56 DS33 LIGHT FUEL LEVEL GAUGE 8 − 216 FL1 FLASHER TURN SIGNAL LIGHTS, 12VDC
6 − 158 A6 ASSEMBLY CAB, HEATER − FAN 7 − 195 DS34 LIGHT HEAD, LEFT HAND 8 − 222 FL2 FLASHER BEACON LIGHT (FLASHING BEACON)
1 − 10 A7 ASSEMBLY STARTER MOTOR (SOLENOID AND MOTOR) 7 − 197 DS35 LIGHT HEAD, RIGHT HAND FL***
1 − 14 A8 ASSEMBLY ECU GLOW PLUG 8 − 214 DS36 LIGHT TURN, FRONT, LEFT HAND 1− 7 G1 GENERATOR 12 VDC, 95A
N/S A9 ASSEMBLY RESERVED 8 − 217 DS37 LIGHT TURN, FRONT, RIGHT HAND G***
8 − 233 A10 ASSEMBLY CAB, REAR WINDOW DEFROSTER 6 − 152 DS38 LIGHT CAB DOME 2 − 56 GA1 GAUGE FUEL LEVEL, W/ 1/8 WARNING
8 − 240 A11 ASSEMBLY ENGINE COOLANT, TANK HEATER 8 − 230 DS39 LIGHT FRONT, HITCH, 12V 2 − 41 GA2 GAUGE ENGINE COOLANT TEMPERATURE
A*** 2 − 36 DS40 LIGHT GENERATOR NO CHARGE INDICATOR (REAR) 2 − 37 GA3 GAUGE ENGINE OIL PRESSURE
6 − 177 AL1 ALARM CAB RAISE/LOWER 2 − 40 DS41 LIGHT LOW OIL PRESSURE INDICATOR (REAR) 2 − 58 GA4 GAUGE TRANSMISSION OIL TEMPERATURE
7 − 181 AL2 ALARM BACK−UP 2 − 49 DS42 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR (REAR) 2 − 50 GA5 GAUGE VOLTMETER
2 − 33 AL3 ALARM ENGINE/TRANSMISSION TROUBLE WARNING 2 − 47 DS43 LIGHT LOW COOLANT LEVEL INDICATOR (REAR) 2 − 52 GA6 GAUGE TACHOMETER
AL*** 2 − 44 DS44 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR (REAR) 2 − 54 GA7 GAUGE SPEEDOMETER
1 − 8 B1 MOTOR STARTER N/S DS45 LIGHT RESERVED (REAR) GA***
6 − 168 B2 MOTOR WINDSHIELD WASHER PUMP 4 − 112 DS46 LIGHT FRONT SHIFTER NOT IN NEUTRAL INDICATOR (REAR) (RED) 1 − 14 GP1−6 RESISTOR GLOW PLUG
6 − 165 B3 MOTOR WINDSHIELD WIPER, RIGHT HAND 4 − 111 DS47 LIGHT SHIFTERS IN NEUTRAL INDICATOR (REAR) (GREEN) GP***
6 − 163 B4 MOTOR WINDSHIELD WIPER, LEFT HAND 4 − 104 DS48 LIGHT FRONT PARK BRAKE "ON" INDICATOR (REAR)(RED) 6 − 156 H1 HORN VEHICLE, FRONT, 12VDC
1 − 3 B5 MOTOR EMERGENCY STEERING PUMP 4 − 107 DS49 LIGHT REAR PARK BRAKE "ON" INDICATOR (REAR)(RED) 6 − 155 H2 HORN VEHICLE, FRONT, LEFT HAND
6 − 160 B6 MOTOR CAB DEFROSTER/COOLING, RIGHT HAND 4 − 102 DS50 LIGHT PARK BRAKE APPLIED INDICATOR (REAR) (RED) 6 − 155 H3 HORN VEHICLE, FRONT, RIGHT HAND
6 − 161 B7 MOTOR CAB DEFROSTER/COOLING, LEFT HAND 5 − 149 DS51 LIGHT AXLE CENTER INDICATOR (REAR) ,12V (AMBER) H***
6 − 167 B8 MOTOR CAB ROOF WIPER 4 − 120 DS52 LIGHT FRONT CAB SELECT INDICATOR (REAR) N/S K1−8 RELAY RESERVED
B*** 4 − 114 DS53 LIGHT REAR CAB SELECT INDICATOR (REAR) 5 − 129 K9 RELAY COORD STEERING, FRONT CONTROL
1− 1 BT1 BATTERY 12VDC 5 − 144 DS54 LIGHT COORD STEERING MODE INDICATOR (REAR) 5 − 135 K10 RELAY CRAB STEERING, FRONT CONTROL
1− 2 BT2 BATTERY 12VDC 5 − 138 DS55 LIGHT TRACK STEERING MODE INDICATOR (REAR) 5 − 131 K11 RELAY FRONT AXLE REED SWITCH
BT*** 5 − 139 DS56 LIGHT CRAB STEERING MODE INDICATOR (REAR) 5 − 142 K12 RELAY REAR AXLE REED SWITCH
1 − 14 CB1 CIRCUIT B. GLOW PLUG, 120A 8 − 216 DS57 LIGHT TURN, REAR, RIGHT HAND N/S K13−18 RELAY RESERVED
1− 8 CB2 CIRCUIT B. MAIN, 120A 8 − 220 DS58 LIGHT BRAKE, RIGHT HAND, 12V 1− 3 K19 RELAY EMERGENCY STEERING PUMP MOTOR, 12V
CB*** 7 − 203 DS59 LIGHT TAIL, RIGHT HAND 1 − 21 K20 RELAY PARK BRAKE ON − STARTER ENABLE, 12V
SH.5 CR1−4 RECTIFIER BLOCKING, STEERING 7 − 183 DS60 LIGHT BACK−UP, RIGHT HAND 3 − 67 K21 RELAY SHIFTER IN NEUTRAL, 12V
N/S CR5−9 RECTIFIER RESERVED 7 − 182 DS61 LIGHT BACK−UP, LEFT HAND 6 − 154 K22 RELAY HORN, 12V
4 − 91 CR10 RECTIFIER BLOCKING, PARKING BRAKE 7 − 200 DS62 LIGHT TAIL, LEFT HAND 4 − 92 K23 RELAY TRANSMISSION NOT IN N−, PARK BRAKE APPLIED,12V
6 − 175 CR11 RECTIFIER BLOCKING, CAB LIFT 8 − 219 DS63 LIGHT BRAKE, LEFT HAND, 12V 7 − 181 K24 RELAY SHIFTER, BACK−UP, 12V
6 − 177 CR12 RECTIFIER BLOCKING, CAB LIFT 8 − 212 DS64 LIGHT TURN, REAR, LEFT HAND 3 − 67 K25 RELAY LOCK−UP UNIT (DOWNSHIFT), 12V
N/S CR13−15 RECTIFIER RESERVED 7 − 187 DS65 LIGHT REAR LEFT HEAD N/S K26−29 RELAY RESERVED
7 − 204 CR16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A 7 − 188 DS66 LIGHT REAR RIGHT HEAD 1 − 23 K30 RELAY IGNITION (MASTER), 30A
N/S CR17−21 RECTIFIER RESERVED 7 − 185 DS67 LIGHT DASH (REAR) 1 − 17 K31 RELAY STARTER SOLENOID AUXILIARY, 12V
2 − 33 CR22 RECTIFIER ENGINE WARNING ALARM, OIL PRESSURE LT. 7 − 190 DS68 LIGHT REAR HITCH ,12V N/S K32−34 RELAY RESERVED
2 − 33 CR23 RECTIFIER ENGINE WARNING ALARM, COOLANT TEMP. LT. 7 − 204 DS69 LIGHT PARK, FRONT, RIGHT HAND 8 − 237 K35 RELAY RUN SOLENOID DISCONNECT
2 − 32 CR24 RECTIFIER ENGINE WARNING ALARM, COOLANT LEVEL LT. 7 − 201 DS70 LIGHT PARK, FRONT, LEFT HAND 8 − 233 K36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
2 − 32 CR25 RECTIFIER ENGINE WARNING ALARM, TRANSMISSION TEMP. 8 − 222 DS71 LIGHT BEACON, ROTATING K***
CR*** DS*** 3 − 76 L1−5 SOLENOID TRANSMISSION VALVE BODY, ZF/Y1−Y5
8 − 211 DS1 LIGHT LEFT TURN INDICATOR 1 − 23 E1 STUD FUSE BOX POWER 2 − 31 L6 SOLENOID ENGINE RUN VALVE
2 − 39 DS2 LIGHT LOW OIL PRESSURE INDICATOR 1 − 7 E2 STUD ENGINE POWER 1 − 29 L7 SOLENOID EXCESS START FUEL ALLOWANCE
1 − 11 DS3 LIGHT GLOW PLUG INDICATOR 1 − 7 E3 STUD BATTERY POWER N/S L8,9 SOLENOID RESERVED
2 − 47 DS4 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR 1 − 13 E4 STUD GLOW PLUG POWER 4 − 94 L10 SOLENOID PARKING BRAKE SET VALVE
7 − 199 DS5 LIGHT HIGH BEAM INDICATOR E*** 4 − 96 L11 SOLENOID PARKING BRAKE RELEASE VALVE
8 − 215 DS6 LIGHT RIGHT TURN INDICATOR 2 − 31 F1 FUSE ENGINE, 10A N/S L12 SOLENOID RESERVED
2 − 45 DS7 LIGHT LOW COOLANT LEVEL INDICATOR 3 − 69 F2 FUSE TRANSMISSION, 10A 5 − 131 L13 SOLENOID COORD SELECT VALVE, SV2−A (OR 1)
2 − 43 DS8 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR 5 − 123 F3 FUSE STEERING, 10A 5 − 133 L14 SOLENOID CRAB SELECT VALVE, SV2−B (OR 1)
N/S DS9,10 LIGHT RESERVED 8 − 234 F4 FUSE REAR WINDOW DEFROSTER, 20A N/S L15,16 SOLENOID RESERVED
4 − 92 DS11 LIGHT PARK BRAKE APPLIED INDICATOR 4 − 94 F5 FUSE PARKING BRAKE, 10A 1 − 10 L17 SOLENOID ENGINE STARTER
2 − 35 DS12 LIGHT GENERATOR NO CHARGE INDICATOR 6 − 171 F6 FUSE CAB RAISE/LOWER, 10A 6 − 171 L18 SOLENOID CAB RAISE VALVE
2 − 50 DS13 LIGHT FRONT DASH PANEL, LEFT HAND 4 − 100 F7 FUSE CAB SELECT, 10A 6 − 174 L19 SOLENOID CAB LOWER VALVE
2 − 51 DS14 LIGHT FRONT DASH PANEL, RIGHT HAND N/S F8 FUSE RESERVED L***
2 − 41 DS15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE 8 − 217 F9 FUSE TURN/BRAKE/BACK−UP LIGHTS, 15A
2 − 37 DS16 LIGHT ENGINE OIL PRESSURE GAUGE 6 − 158 F10 FUSE HEATER − COOL FAN, 20A MASTER LEGEND
2 − 58 DS17 LIGHT TRANSMISSION OIL TEMPERATURE GAUGE 6 − 154 F11 FUSE HORN, 20A
2 − 50 DS18 LIGHT VOLTMETER 1 − 23 F12 FUSE INSTRUMENT PANEL, 20A
2 − 52 DS19 LIGHT TACHOMETER, 12V 8 − 225 F13 FUSE EMERGENCY STEERING, BEACON AND FRONT HITCH, 15A
2 − 54 DS20 LIGHT SPEEDOMETER 7 − 189 F14 FUSE HEADLIGHTS, 20A
5 − 130 DS21 LIGHT COORD STEERING MODE INDICATOR 6 − 165 F15 FUSE WINDSHIELD WIPER, 30A
N/S F16 FUSE RESERVED

Sheet 9 of 10
2-2-74 CD276
Rev 13
Chapter 2
LEGEND LEGEND
SH.NO.−GRID ITEM DESCRIPTION SH.NO.−GRID ITEM DESCRIPTION
VAR P1 CONNECTOR SHIFTER (TRANSMISSION) FRONT CAB (ZF) 4 − 94 P100 CONNECTOR PARK BRAKE SET VALVE
VAR P2 CONNECTOR SHIFTER (CAB) FRONT CAB (ZF) N/S P101,102 CONNECTOR RESERVED
N/S P3 CONNECTOR RESERVED 4 − 96 P103 CONNECTOR PARK BRAKE RELEASE VALVE
VAR P4 CONNECTOR FUSE BOX 6 − 174 P104 CONNECTOR CAB LOWER SOLENOID VALVE
VAR P5 CONNECTOR SHIFTER (TRANSMISSION) REAR CAB 6 − 171 P105 CONNECTOR CAB RAISE SOLENOID VALVE
VAR P6 CONNECTOR SHIFTER (CAB) REAR CAB N/S P106,107 CONNECTOR RESERVED
VAR P7 CONNECTOR REAR CAB INTERFACE 5 − 146 P108 CONNECTOR REAR AXLE REED SWITCH
VAR P8 CONNECTOR MAIN HARNESS INTERFACE 5 − 123 P109 CONNECTOR FRONT AXLE REED SWITCH
VAR P9 CONNECTOR STEERING INTERFACE P***
VAR P10 CONNECTOR CONTROL BOX 2 − 45 R1 SENSOR ENGINE COOLANT LEVEL
N/S P11 CONNECTOR RESERVED 3 − 62 R2 SENSOR TURBINE SPEED (ZF)
VAR P12 CONNECTOR CONTROL BOX CAB SELECT 2 − 58 R3 SENSOR TRANSMISSION TEMPERATURE
VAR P13 CONNECTOR STEERING BOX (STANDARD) 2 − 42 R4 SENSOR ENGINE HIGH COOLANT TEMPERATURE SWITCH − SENDER
VAR P14 CONNECTOR STEERING BOX (OPTIONAL) 2 − 56 R5 SENSOR FUEL LEVEL
3 − 78 P15 CONNECTOR TRANSMISSION SOLENOID VALVES 2 − 54 R6 SENSOR SPEED (ZF)
2 − 54 P16 CONNECTOR VEHICLE SPEED SENSOR (ZF) 2 − 39 R7 SENSOR ENGINE LOW OIL SWITCH − SENDER
VAR P17 CONNECTOR ENGINE PLUG R***
VAR P18 CONNECTOR ENGINE PLUG (YELLOW) 6 − 161 S1 SWITCH WIPER
VAR P19 CONNECTOR INSTRUMENT GAUGES 6 − 169 S2 SWITCH WINDSHIELD WASHER
VAR P20 CONNECTOR CEILING INTERFACE N/S S3 SWITCH RESERVED
VAR P21 CONNECTOR FRONT LIGHTS 6 − 158 S4 SWITCH BLOWER FAN
VAR P22 CONNECTOR REAR LIGHTS N/S S5 SWITCH RESERVED
3 − 62 P23 CONNECTOR TURBINE SPEED SENSOR (ZF) 7 − 195 S6 SWITCH PARK LIGHT
VAR P24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK−UP 7 − 196 S7 SWITCH HIGH−LOW BEAM
N/S P25 CONNECTOR RESERVED 8 − 232 S8 SWITCH REAR WINDOW DEFROSTER, TOUCH PAD
SH.5 P26 CONNECTOR DIODE MODULE, STEERING, CR1−CR4 N/S S9 SWITCH RESERVED
SH.5 P27 CONNECTOR DIODE MODULE, STEERING, CR5−CR8 8 − 228 S10 SWITCH EMERGENCY STEERING
VAR P28 CONNECTOR IGNITION/LIGHT SWITCH 8 − 232 S11 SWITCH FRONT HITCH LIGHT
SH.5 P29 CONNECTOR STEERING MODE INDICATOR LIGHTS 7 − 194 S12 SWITCH REAR HITCH LIGHT
6 − 163 P30 CONNECTOR WINDSHIELD WIPER MOTOR, LEFT HAND 8 − 223 S13 SWITCH BEACON
6 − 165 P31 CONNECTOR WINDSHIELD WIPER MOTOR, RIGHT HAND 5 − 125 S14 SWITCH STEERING MODE SELECT
VAR P32 CONNECTOR RIGHT HAND HEADLIGHT 6 − 172 S15 SWITCH CAB LIFT
VAR P33 CONNECTOR LEFT HAND HEADLIGHT N/S S16−19 SWITCH RESERVED
8 − 230 P34 CONNECTOR FRONT HITCH LIGHT 7 − 203 S20 SWITCH DASH LIGHT, TOGGLE TYPE
VAR P35 CONNECTOR CAB SELECT LIGHTS (REAR) 2 − 31 S21 SWITCH EMERGENCY ENGINE STOP, PUSH/PULL
VAR P36 CONNECTOR STEERING MODE INDICATOR LIGHTS (REAR) 1 − 23 S22 SWITCH STOP, RUN, START
VAR P37 CONNECTOR CAB SELECT LIGHTS 6 − 153 S23 SWITCH HORN
1 − 17 P38 CONNECTOR STARTER SOLENOID AUXILIARY RELAY N/S S24 SWITCH RESERVED
VAR P39 CONNECTOR LEFT HAND REAR LIGHTS 5 − 123 S25 SWITCH FRONT AXLE REED
VAR P40 CONNECTOR RIGHT HAND REAR LIGHTS 8 − 216 S26 SWITCH TURN SIGNAL
1 − 14 P41 CONNECTOR ECU GLOW PLUG 1 − 20 S27 SWITCH PARK BRAKE
VAR P42 CONNECTOR REAR CAB STEERING INTERFACE 4 − 92 S28 SWITCH PARKING BRAKE PRESSURE,
8 − 216 P43 CONNECTOR TURN SIGNAL OPENS AT 1800 psi ON FALLING PRESSURE
6 − 158 P44 CONNECTOR HEATER − FAN, CAB 5 − 146 S29 SWITCH REAR AXLE REED
VAR P45 CONNECTOR REAR HEADLIGHT, RIGHT HAND N/S S30−34 SWITCH RESERVED (REAR)
VAR P46 CONNECTOR REAR HEADLIGHT, LEFT HAND 8 − 225 S35 SWITCH EMERGENCY STEERING (REAR)
7 − 190 P47 CONNECTOR REAR HITCH LIGHT N/S S36,37 SWITCH RESERVED (REAR)
2 − 45 P48 CONNECTOR ENGINE COOLANT LEVEL SENSOR 6 − 170 S38 SWITCH CAB WAND, RIGHT HAND
N/S P49,50 CONNECTOR RESERVED 6 − 170 S39 SWITCH CAB WAND, CENTER
VAR P51 CONNECTOR DIODE MODULE, CR9−CR12 6 − 170 S40 SWITCH CAB WAND, LEFT HAND
3 − 62 P52 CONNECTOR FRONT SHIFTER UPSHIFT INTERLOCK 8 − 228 S41 SWITCH EMERGENCY STEERING PRESSURE,
N/S P53 CONNECTOR RESERVED OPENS AT 1800 psi ON FALLING PRESSURE
5 − 131 P54 CONNECTOR COORD/CRAB SELECT VALVE, FRONT MODE 2 − 48 S42 SWITCH TRANSMISSION HIGH TEMPERATURE
N/S P55,56 CONNECTOR RESERVED 8 − 220 S43 SWITCH BRAKE PRESSURE (BRAKE LIGHTS)
VAR P57 CONNECTOR DIODE MODULE, TRANSMISSION SHIFTER, CR18−CR21 CLOSES AT 50 psi
8 − 233 P58 CONNECTOR REAR WINDOW DEFROSTER S***
N/S P59 CONNECTOR RESERVED MASTER LEGEND
8 − 235 P60 CONNECTOR K35 RELAY (RUN SOLENOID DISCONNECT)
8 − 240 P61 CONNECTOR 120 VAC OR 240 VAC POWER SUPPLY
6 − 156 P62 CONNECTOR HORN Figure 2-8. Schematic, Single Cab (Station)
N/S P63 CONNECTOR RESERVED
2 − 34 P64 CONNECTOR DIODE MODULE, ENGINE WARNING ALARM, CR22−CR25 Sheet 10 of 10
CD276 2-2-75
Rev 13
Chapter 2
RIGHT SIDE
DS35
HEADLIGHT
RIGHT SIDE A10/P58 LEFT SIDE

DS38 B8
DS37
TURN LIGHT H3 H2
DS69
PARK LIGHT
BLU − TURN
YEL − PARK
WHT − GND
GRN − LO
RED − HI
S38 B6 B7 S40
DS71
A E S39
(P)
P20
R.H.
P32 A B C D E HEADLIGHT P21
CONNECTOR
(S)
GND1 /GND1
SPARE P32 P33 H1/P62
235 /P21 D
231 /P21 C
234 /P21 E
221 /P21 A
(UNDER LAMP ASM.)
DS35,DS37,DS69 DS34,DS36,DS70
SP2 /P21
DS39/P34
REFERENCE LOCATIONS FOR SHEET 1
RIGHT SIDE
S38
14 GA
2 1 1 − 17 /S40 2
2 − 18 /P20 10
14 GA 3 − 19 /SPL19
4 3 4 − 262/SPL262
SPL221 221 /P33 D
X
CAB WAND
SWITCH, R.H.
SPLGND1 GND1 /P33 E
X
GND1 /P62 A 14 GA.
20 /P20 1
2 /SPL2
B(−)/SPLB(−)
24 /H2 SPL24
X
P/N 12951654 HARNESS H3
14 GA.
(P) WHT
FRONT OF TRACTOR
D E 24 /P20 2
BLK B6 B(−) /B6 SPLB(-)
X
C F B(−) /GND2
RED BLK B(−) /H2
14 GA B G 14 GA. M−
+ B(−) /B7
SP2 /P32 A H VEHICLE 14 GA.
(P) (S) CAB HORN CAB DEFROSTER/
SP3 /P33 COOLING FAN TO GND2, SH. 4,
R.H. B(−) /H3
P21 MOTOR, R.H. GRID 118
221 /P32 D A
P34 14 GA 229 /P33 C B P20
231 /P33 B C LIGHT MTG
169 /P21 F 231 /P32 B SEE SH. 3, GRID 68 S39 1 20 /DS38
235 /P33 A DS38 DS71 24 /H3
D FOR MATING CONNECTOR BLK 2
FRONT HITCH CL 235 /P32 A 1 − 15 /P20 5 CAB BEACON
MATING CONNECTOR
2 1 3
LIGHT CONNECTOR 234 /P32 C E 2 − 16 /SPL16 DOME LIGHT, 14 GA. 4 115 /B8
CONSOLE 3 − 19 /P20 6 ROTATING RED
169 /P34 F LIGHT 5 15 /S39 1
GRID 84 FOR
BLK HOLE 4 3
4 − 262 /P20 8
SEE SH. 3,
24 /P62 B G 264 /P20 11 6 19 /S39 3
DS39 H 7 19 /S40 3
FRONT HITCH CAB WAND 115 /P20 4 8 262 /S39 4
FRONT LIGHTS SWITCH, 262 /S40 4
LIGHT CONNECTOR B8 9
CENTER 10 18 /S38 2
19 /S38 3 SPL19
X
GND1 /P32 E TO GND1, SH. 2, GRID 62 M 11 264 /DS71
2 /B7 (+)
GND1 /SPLGND1
12
CAB ROOF 14 GA.
WIPER MOTOR CEILING
262 /S38 4 SPL262
X
14 GA H2 INTERFACE
24 /P21 G
CONNECTOR
WHT
GND1 /SPLGND1
24 /SPL24 16 /S39 2 SPL16
X
B7
BLK 16 /S40 1 3 2 1
B(−)/SPLB(−) RED BLK
221 /SPL221
SP3 /P21
M−
235 /P21 D
231 /P21 C
229 /P21 B
+
14 GA. 6 5 4
A B P62 VEHICLE CAB DEFROSTER/
CAB HORN COOLING FAN (P) 9 8 7
H1 L.H. MOTOR, L.H. 2 /B6 (+)
B(−)/SPLB(−)
SPL2
X
SPARE
2 /P20 12
12 11 10
VEHICLE HORN/
CONNECTOR (S)
FRONT, UNDER P33 A B C D E L.H.
HEADLIGHT ASM. HEADLIGHT FURNISHED WITH CAB
CONNECTOR 14 GA.
WHT − GND
GRN − LO
BLU − TURN
YEL − PARK
(P)
RED − HI
E A (P)
247 /P58
BLK/RED P58
LEFT SIDE
S40
SEE SH. 3,
247 /A10 GRID 82 FOR
2 1 1 − 16 /SPL16 A10 MATING CONNECTOR
2 − 17 /S38 1 14 GA. REAR WINDOW
4 3 3 − 19 /P20 7 CAB, REAR TO GND2, SH. 4, DEFROSTER
4 − 262 /P20 9 WINDOW B(−) /GND2
DS34 GRID 118 CONNECTOR
DEFROSTER BLK
LEFT SIDE
HEADLIGHT CAB WAND CAB WIRING

SWITCH, L.H. ASSEMBLY
CAB FRONT
DS36
TURN LIGHT 18 19 20 21 22 23 24 25 26 27 28 29 30 31
DS70
PARK LIGHT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Figure 2-9. Wiring Diagram, Single Cab (Station)

Sheet 1 of 16
2-2-76 CD276
Rev 13
Chapter 2
SEE DETAIL A FOR SWITCH + − DASH PANEL SEE DETAIL B FOR

− DASH PANEL
+
CONTACT ARRANGEMENT LIGHT, R.H. LAMP CONTACT LIGHT, L.H.
(S1−7,& S9−S15) ARRANGEMENT FRONT CAB CONTROL PANEL
DS14 (DS1−12) DS13
S2 14 GA. S1 14 GA.
+ 224 /DS20 RED - REAR VIEW - + 224 /DS33 BLK
1 160 /B2 1 118 /P30 H − GND1/GA7 (−) − GND1/GA1 G
5 115 /P31 P 2 118 /P31 H
S3 115 /S1 3 3 115 /P30 P
RESERVED 9 GND2 /S13 9 115 /S2 5 DS2 DS1
DS6 DS5 14 GA. DS4 GA5/DS18 GA2/DS15 DS3 S21
GND2 /S6 9 5 119 /P30 L VOLTMETER/LIGHT ENG.COOLANT TEMP EMERGENCY
10 224 /S12 10 6 119 /P31 L + 234 /P21 E + 235 /S7 1 + 101 /DS2 (+) GAUGE/LIGHT
+ 159 /P8 2 + 101 /DS4 (+) + 229 /P21 B GA1/DS33 ENGINE STOP
224 /S6 10 9 GND2 /S11 9 234 /P43 5 101 /DS12(+) DS18 101 /DS8 (+) 229 /P43 6 FUEL LEVEL
− − − SWITCH
GND2 /S12 9 − GND2/DS5 (−) − GND2/DS6 (−) − 140 /P8 10 BLK DS15
+ − GND2/DS5 (−) 131 /P8 6 GND2/S4 9 GAUGE/LIGHT
WINDSHIELD 10 224 /S11 10 GND2/S11 9 GND2/DS3 (−) 140 /P64 D GND2/DS1 (−) 131 /P64 A GND2/DS3 (−)
WASHER 224 /S4 10 − BLK DS33 101 /P28 A
SWITCH RIGHT TURN HI−BEAM TRANSMISSION G S GLOW PLUG LOW OIL LEFT TURN
WIPER INDICATOR INDICATOR HIGH OIL TEMP. INDICATOR PRESSURE INDICATOR 123 /P28 E
SWITCH LIGHT LIGHT INDICATOR I + LIGHT INDICATOR LIGHT G
LIGHT GA5 GA2 LIGHT I S
GND1 /P19 1 S8
S7 14 GA. S6 14 GA. S5 G GND1/DS16 (−) S 132 /P19 5 S4 14 GA. S20
RESERVED + 125 /GA4 (+) REAR WINDOW
DS12 DS11 DS10 GND1 /GA7 (−) DS9 DS8 DS7
1 235 /P21 D 1 226 /S7 3 125 /GA4 (+) 125 /GA6 (+) G GND1 /GA6 (−) 1 243 /P44 A DEFROSTER 1
I
235 /DS5 (+) 226 /P28 H + 101 /DS4 (+) + 105 /S27 NO3 RESERVED 125 /GA3 (+) − GND1/GA3 (−) RESERVED + 101 /DS2 (+) + 101 /DS8 (+) GND1/DS13 (−) 3 110 /P4 8 TOUCH PAD SW. 2
3 226 /S6 1 5 223 /P28 F 101 /P4 3 105 /P7 3 GND1/DS15 (−) 101 /DS7 (+) 101 /P28 A I 125 /GA6 (+) 5 222 /P44 B 3 226 /P28 H
226 /P7 18 223 /S12 5 − 129 /P8 1 − 182 /K23 86 − 133 /P8 8 − 134 /P8 9 125 /F22 9 GND2 /S10 9 4
5 230 /P7 13 9 GND2/S2 9 129 /P7 6 224 /DS20 RED DS15
133 /P64 B 134 /P64 C S 135 /P19 6 GND2/DS1 (−) 5 224 /P28 G
9 GND2/S13 9 GND2/S12 9 224 /DS16 (+) + 224 /DS17 (+) 10 224 /S10 10 CR16 6 223 /P28 F
GND2/S14 9 10 224 /S2 10 PARK BRAKE 224 /DS16 (+) ENGINE HIGH LOW COOLANT 224 /DS13 (+) 224 /S1 10
GENERATOR 224 /DS19 RED PARK DASH LIGHT
10 224 /S13 10 224 /S11 10 NO CHARGE APPLIED − GND1/GA2 (−) COOLANT TEMP LEVEL BLOWER FAN LIGHT
224 /S15 10 INDICATOR INDICATOR GND1/DS17 (−) INDICATOR INDICATOR SWITCH
SWITCH BLOCKING
LIGHT LIGHT LIGHT LIGHT RECITFIER
HIGH−LOW PARK LIGHT P/N 12941832 HARNESS
BEAM SWITCH SWITCH
CL STEERING WHEEL P/N 12941830 HARNESS

(REF) F22
DS16 DS17
RED RED GAUGES
+ − + −
FUSE,5A
14 GA. 14 GA. 14 GA. DS20 DS19 S22
S14/DS32 S13 S12 S11 BLK − BLK S10 14 GA. 125 /GA1 I
2 202 /P9 G 1 242 /FL2 X 1 225 /P8 14 1 169 /P21 F S S 1 238 /P8 15 IGN
GA6 125 /P28 D
3 103 /P9 B 5 113 /S11 5 5 223 /S6 5 5 113 /S10 5 GA7 + + 5 113 /P7 25
103 /P4 11 113 /P4 12 223 /P7 15 113 /S13 5 + S - 113 /S11 5 ST 121 /P28 C
-
6 206 /P9 C 9 GND2 /S7 9 9 GND2 /S6 9 9 GND2 /S1 9 + S S 9 GND2 /S4 9 BAT 112 /P28 B
8 198 /P9 E GND2 /S2 9 GND2 /S1 9 GND2/DS6 (−) GA3/DS16 GA4/DS17 10 224 /S4 10 GND
ENG. OIL PRESS. 14 GA.
9 GND2/S15 9 10 224 /S7 10 10 224 /S2 10 10 224 /S1 10 TRANS.OIL TEMP. 224 /P28 G ACC
GND2/S7 9 224 /S12 10 224 /S13 10 224 /S6 10 GAUGE/LIGHT
10 215 /P9 H P19 GA7/DS20 GA3 GA4 GAUGE/LIGHT GA6/DS19 EMERGENCY STOP, RUN, ACC
SEE SPEEDOMETER/LIGHT S 139 /P19 8 TACHOMETER/LIGHT STEERING START ST
BEACON REAR HITCH FRONT HITCH GND1/GA5 G 1 GND1 /GND1 S 130 /P19 4 SWITCH
DETAIL AXLE CENTER SWITCH LIGHT SWITCH LIGHT SWITCH GA7 + 125 /GA5 I + 125 /GA2 (+) SWITCH
C FOR IND. LIGHT, 2 125 /GA5 I S 136 /P19 7
224 /DS20 RED 3 224 /S15 10 S 138 /P19 12 125 /GA7 (+) + 125 /GA2 (+) IGN BAT
WIRING STEERING MODE
130 /GA3 S 130 /P8 5 S 137 /P19 11 − GND1/GA2 (−) − GND1 /GA6 (−)
SEL. SWITCH 4
GND1 /DS17 (−) 125 /GA1 I GND
132 /GA2 S 5 132 /P8 7 + 125 /GA3 (+) GND1/DS16 (−) − GND1 /GA4 (−)
135 /GA1 S 6 135 /P8 18 − GND1 /GA5 G DS16 DS17 GND1 /GA1 G 4 WIRE
P29 136 /GA6 S 7 136 /P8 11 GND1/DS14 (−) + 224 /DS18 BLK + 224 /DS15 (+) CORD (REF)
139 /GA4 S 139 /P8 19 224 /DS33 BLK
8 224 /DS14 (+) 224 /DS15 (+) 224 /DS19 RED 224 /DS17 (+)
9 − GND1/GA3 (−) − GND1 /DS15 (−)
224 /P19 3
10 224 /DS18 BLK GND1/GA5 G GND1 /GA4 (−) P/N 12941687 HARNESS
137 /GA7 S 11 137 /P8 12
138 /GA7 S 12 138 /P8 17
INSTRUMENT GAUGES CONNECTOR
(P) (S)
D E E D
3 2 1 P19 1 2 3 (P) (S) C F F C
X B G
(P) (S) G B
6 5 4 4 5 6 A H
S15 S
H A
1 19 /P20 6 7 8 9 P P28
19 /P104 B 9 8 7
ZF FRONT CAB P2
3 106 /P4 15 H 101 /S21 A 101 /DS7 (+)
SHIFTER ASSEMBLY
7 15 /P20 5 12 11 10 10 11 12 1 273 /S27 NC1 B4 P30 L 112 /S22 BAT B 112 /P4 1
15 /P51 E A1 2 246 /P7 27 X 121 /S22 ST C 121 /S27 NO3
9 GND2/P29 F 3 147 /K24 86 S 125 /S22 IGN D 125 /P4 2
GND2/S14 9 FOR WIRING 4 148 /K21 86 123 /S21 E 123 /P8 3
10 224 /S7 10 5 102 /P24 3 P 115 /S1 3 223 /S20 6 F 223 /S6 5
SEE ZF
224 /P19 3 DRAWING 6 GND1/P24 1 M H 118 /S1 1 224 /S20 5 G 224 /S10 10
CAB LIFT S27 7 274 /S27 NC2 L 119 /S1 5 226 /S20 3 H 226 /S6 1
SWITCH
8
14 GA. 14 GA. IGN/LIGHT 14 GA.
(S) NC1 273 /P2 1 ZF FRONT CAB
1 2 NC NC2 274 /P2 7 WINDSHIELD WIPER SWITCH
SHIFTER CONNECTOR MOTOR/CONNECTOR, CONNECTOR
CONTROL PANEL CAB LIFT NC1 105 /P4 6 (CAB) 4 WIRE
105 /S27 NO3 LEFT HAND CORD (REF)
OPTION PANEL A4 1 2 NC
P24 NC2 193 /P7 20 P52
NO3 121 /P28 C TURN SIGNAL
2 1 GND1 /P2 6 3 4 NO
NO4 122 /K20 86 1 149 /P7 11 K36
NOTE: GND1 /GND1 P43 SWITCH/CONNECTOR
SPL234 A4 & P24 NO3 105 /S27 NC1 30 104 /P4 18
4 150 /P8 21 3 4 NO
X
2 105 /DS11(+) FRONT SHIFTER UPSHIFT 1 GRN/BLK 87

PIN NUMBERS 6 3 102 /P2 5 INTERLOCK CONNECTOR 2 1 30
85 GND1/GND1
234 /P8 24 DO NOT NO4 192 /P7 4 (S) 3 GRY
AL3 102 /SPL102
CORRESPOND 1 5 245 /P7 10
4 BLK S26 87 247 /P58
+ 101 /SPL101 3 6 161 /K25 87a
PARK BRAKE (S) (P) 234 /DS6 (+) 5 RED
85 14 GA.
− SWITCH 229 /DS1 (+) 6 GRN
269 /P64 H 14 GA. TO P15, SEE BLU TIMER (11 MIN) REAR WINDOW
CONTROL UNIT (DOWNSHIFT)
P1 SH. 6, GRID 177
YEL DEFROSTER RELAY
ENGINE/TRANSMISSION 193 /P7 20 FOR CONTINUATION (S) (P)
TROUBLE WARNING LOCK−UP ASSEMBLY/ 273 /P2 1 1
ALARM CONNECTOR JUMPER 2 145 /P15 A TO GND3, SEE
3 144 /P15 E SH. 5, GRID 136 FRONT CAB GND1
1 4 7 10
4 143 /P15 D FOR CONTINUATION L.H. GND1/P24 1
5 GROUND STUD GND1/K36 85
274 /P2 7 2 5 8 11 105 /P4 6 6 GND3 /GND3 14 GA. GND1/P19 1
7 141 /P15 B P.N. 12950253
8 142 /K25 86 HARNESS 228 /FL1 L
3 6 9 12 192 /P7 4 142 /P15 C
SEE SH. 1,
GND1/P32 E GRID 11 FOR
105 /DS11(+) S23 14 GA. CONTINUATION
121 /P28 C S27 ZF FRONT CAB NOT USED WITH DUAL
SHIFTER CONNECTOR 181 /K22 86
SEE SH.3, 122 /K20 86 (MAINTAINED) CAB OPTION. SEE SH. 10
(TRANSMISSION) GRID 271 FOR DUAL CAB
GRID 65 FOR
CONTINUATION ALTERNATE PARK BRAKE SWITCH MATING CONNECTOR HORN
SWITCH CONTROL PANELS AND CAB WIRING
WIRING (TOGGLE TYPE)
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
DETAIL A DETAIL B DETAIL C CONT. ON
STEERING MODE GRID 32
IND. LIGHTS / CONNECTOR
RED A 166 /P9 D A F
C D COORD
(+) B 168 /P9 F
BLK C 203 /P9 A
D GND2/K25 85 B E
(−) B E RED
TRACK GND2
10 9
BLK E C D
A F GND2
CONTACT ARRANGEMENT CONTACT ARRANGEMENT RED F
FOR LAMPS (DS1−DS12) CRAB
FOR SWITCH SOCKETS GND2/S15 9
(S1−S7 & S9−S15) BLK Figure 2-9. Wiring Diagram, Single Cab (Station)
Sheet 2 of 16
CD276 2-2-77
Rev 13
Chapter 2
SEE SH. 2,
GRID 34 FOR SP9 (B2) DETAIL C
CONTINUATION TAPED BACK CONTACT ARRANGEMENT FOR
108 /SP10 AND SEALED
116 /SP10 WITH HEAT RELAY SOCKETS (K20−K25)
SP9 /SP10 SHRINK
14 GA. 85
(S) P8
87
FRONT CAB CONSOLE
87a 30
86
P7 (S) P7 P8
1 −170 /K21 87 1 −129 /DS12(−) WIRE ENTRANCE
NOT USED WITH 2 −173 /K20 30 2 −159 /DS3 (+)
DUAL CAB OPTION 3 −105 /DS11(+) 3 −123 /P28 E
SEE SH. 10, 4 −192 /S27 NO4 4 −101 /SPL101
GRID 280 FOR 5 −140 /P64 D 5 −130 /P19 4
DUAL CAB MATING 6 −129 /DS12(−) 6 −131 /DS2 (−) (S)
CONNECTOR 7 −131 /P64 A 7 −132 /P19 5
8 −133 /P64 B 8 −133 /DS8 (−)

14 GA. 9 −134 /P64 C 9 −134 /DS7 (−)
10 −245 /P24 5 10 −140 /DS4 (−)
SEE SH. 5, GRID 129

11 −149 /P52 1 11 −136 /P19 7
12 −102 /K25 30 12 −137 /P19 11
13 −230 /S7 5 13 −221 /SPL221
14 −231 /P21 C 14 −225 /S12 1
SPL229 −223 /S12 5 −238 /S10 1 FL1
X
15 15
229 /P8 22 16 −114 /P4 14 16 −227 /K24 30 P20 L 228 /S26 YEL
17 −221 /P21 A 17 −138 /P19 12 1 111 /K22 85 109 /K24 87
18 −226 /S7 3 18 −135 /P19 6 24 /K22 87 X 109 /P4 16
2
19 −171 /K23 85 −139 /P19 8
MATING CONNECTOR
19 3
SPL102 −193 /S27 NC2 TURN SIGNAL
X
20 20 −182 /K23 86 4 115 /SPL115

21 −196 /P9 M −150 /P24 2 LIGHTS FLASHER 14 GA.
GRID 29 FOR
102 /P24 3 21 5 15 /S15 7
SEE SH. 1,
22 −107 /P4 7 22 −229 /SPL229 6 19 /S15 1
JPR 23 −181 /K23 30 23 −109 /K24 87 7 19 /SPL19 242 /S13 1
24 −101 /SPL101 24 −234 /SPL234
MATING CONNECTOR
8 106 /SPL106
SPL221 25 −113 /S10 5 25 −178 /K20 87 (S) 106 /SPL106 FL2
X
9
26 −177 /K21 87a 26 18 /P105 B
GRID 28 FOR
14 GA. 10
221 /P8 13 −246 /P2 2 BLK
SEE SH. 1,
27 27 P58 264 /FL2 L BLK
11 264 /P20 11
14 GA. 28 14 GA. 28 247 /K36 87 12 110 /SPL110
REAR CAB MAIN HARNESS REAR WINDOW
DEFROSTER CEILING 14 GA. BEACON LIGHT
INTERFACE INTERFACE SEE DETAIL C FOR INTERFACE (FLASHING)
CONNECTOR CONNECTOR RELAY CONTACT CONNECTOR 14 GA.
CONNECTOR FLASHER
P9 ARRANGEMENT
A 203 /P29 C
(K20−K25)
B 103 /S14 3
SEE SH. 5, GRID 129
C 206 /S14 6 14 GA. SPL115 SEE SH. 4,

SEE SH. 1, GRID 10
D 166 /P29 A P21 K25 K24 K23 K22 K21 K20 X

GRID 112 FOR
E 198 /S14 8 A 221 /P7 17 87a 161 /P24 6 30 227 /P8 16 30 181 /P7 23 30 111 /P4 13 30 102 /K25 30 30 173 /P7 2 CONTINUATION
F 168 /P29 B B 229 /DS1 (+) 30 102 /P7 12 85 GND2/K21 85 181 /K22 86 111 102 /P4 5 85 GND2/GND2 SPL19 115 /P20 4
G 202 /S14 2 C 231 /P7 14 102 /K21 30 GND2/K25 85 85 171 /P51 B 85 85 GND2/K24 85 85 GND2/K21 85 19 /P51 F
X
H 215 /S14 10 D 235 /S7 1 85 GND2/P29 D 86 147 /P2 3 171 /P7 19 111 /P20 1 GND2/K20 85 86 122 /S27 NO4 14 GA.
E 234 /DS6 (+) GND2/K24 85 87 109 /P8 23 86 182 /DS11(−) 86 181 /K23 30 86 148 /P2 4 87 178 /P8 25 19 /P20 7
J
K F 169 /S11 1 86 142 /P1 8 109 /FL1 X 182 /P8 20 181 /S23 87 170 /P7 1 87a
L G 24 /K22 87 164 /SPL164 87a 87 GND2/GND2 87 24 /P20 2 87a 177 /P51 G
M 196 /P7 21 H 87 14 GA. 87a 24 /P21 G 177 /P7 26 PARK BRAKE
BACK−UP 87a ON − STARTER
N LOCK−UP UNIT
FRONT LIGHTS SHIFTER TRANSM NOT SHIFTER IN ENABLE RELAY
STEERING (S) CONNECTOR E D
DOWNSHIFT RELAY RELAY IN N−, PARK HORN NEUTRAL
INTERFACE P TO SH. 11, GRID BRAKE APPLIED RELAY RELAY
CONNECTORE N (S) F C
298 DUAL CAB ONLY RELAY SPL110
110 /P20 12
X
D G B NOTE: WIRE 164 NOT USED
F M
A C H A ON SINGLE CAB UNITS. 14 GA.
WIRE 142 NOT USED
G B L ON DUAL CAB UNITS
(TAPED BACK)
SPL106
H K 106 /P20 8
X
J 106 /P20 9
SPL101 X
P/N 12941830 HARNESS 101 /P8 4 101 /P7 24
101 /AL3 (+) P64 P51 CR9-CR12
CR22-CR25 A 131 /P7 7 A A DIODE
131 /DS2 (−) 171 /K23 85 B B BOARD
DIODE A B 133 /P7 8 JPR C C INSIDE
BOARD B
133 /DS8 (−) D P51
INSIDE C
C 134 /P7 9 244 /AL1(+) D
12 11 10 9
P64 D
22 23 24 25 134 /DS7 (−) 15 /S15 7 E E
D 140 /P7 5 19 /SPL19 F F
E 140 /DS4 (−) 177 /K21 87a G G
F E 269 H H
G
H
F 269 DIODE MODULE BLOCKING
G 269 CONNECTOR RECTIFIER
(S) H 269 /AL3 (−) (S) P51 CR9 RESERVED
P64 CR10 PARKING BRAKE SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES
DIODE MODULE, CR11 CAB LIFT
SEE SH. 4, GRID 100 ENGINE WARNING ALARM CR12 CAB LIFT
FOR CONTINUATION RECTIFIER/CONNECTOR
CR22 OIL PRESSURE LT. FRONT CAB CONSOLE WIRING
CR23 COOLANT TEMP LT.
CR24 COOLANT LEVEL LT.
CR25 TRANSM. TEMP. LT.
64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93

Sheet 3 of 16
2-2-78 CD276
Rev 13
Chapter 2
GND4
L18/P104
L19/P105
K20-K25
FUSE BOX/P4 FRONT CAB CONSOLE

(SEE SH. 8)
SEE SH. 3 FOR BELOW FRONT DASH
CONSOLE WIRING RIGHT SIDE
GND2 (P)
REMOVABLE SEAT
19 8 9
B2 18 7 2 10
B3/P31
17 6 1 3 11
A6/P44
16 5 4 12
FL1,FL2
AL1 CONSOLE 15 14 13
P20,P21 (P) (S) X P4

P9 S 1 112 /P28 B
SEE SH. 1, 2 125 /P28 D
C D A F
CR9-12/P51 P GRIDS 24 & 29 3 101 /DS12(+)
P8 H
FOR CONTINUATION 4 GND2 /GND2
CR22-25/P64 B E B E L 5 102 /K21 30
P7 L 14 GA. 6 105 /S27 NC1
H
A F C D CLOSED CAB 7 107 /P7 22
CONTROL PANEL P UNITS ONLY 8 110 /S4 3
B(−) /A10
B(−) /H3
9
CAB LIFT OPTION/S15 P44 B3 P31 S
10 115 /P31 P
(SEE SH. 2) ORN X 103 /S14 3
A 243 /S4 1 X 11
RED
S 12 113 /S13 5
P29 P58/A10 M B 222 /S4 5 115 /S2 5 GND2/K23 87 13 111 /K22 30
(UNDER PANEL) P
115 /P4 10 14 114 /P7 16
C 14 GA. GND2/P4 4
H 118 /S1 2 GND2/K20 85 15 106 /S15 3
P19,P28 M
GND2/P44 F 16 109 /FL1 X
(UNDER PANEL)
A6 D L 119 /S1 6 FUSE BOX, 17 NO CONN.THIS SIDE
SEE SH. 8 FOR
E 14 GA.
18 104 /K36 30
B4/P30 BLK
GND2 BOX WIRING 19
F GND2/GND2 WINDSHIELD WIPER FRONT CAB, AND P4 MATING
CONNECTOR
14 GA.
MOTOR/CONNECTOR, R.H.
FRONT CAB CONTROL PANEL CAB HEATER − FAN RIGHT HAND GROUND STUD
(SEE SH. 2) ASSEMBLY/CONNECTOR
(UNDER PANEL)− K36 SEE SH. 3,

GND1 GRID 91 FOR
CONTINUATION
14 GA. SP10 (P7)
S23, S26/P43 TAPED BACK
108 /SP9
160 /S2 1
AND SEALED
A4/P24, AL3 116 /SP9 WITH HEAT
(UNDER CONSOLE PANEL) SP9 /SP9 SHRINK
A1
P1,P2,P52 14 GA.
(UNDER CONSOLE PANEL) S27
M B2
WINDSHIELD WASHER
PUMP MOTOR
SEE SH. 3, GRID 68

FOR CONTINUATION
FRONT
BULKHEAD
GND4 /P104 A
GND4 /P105 A GND4
LIFT CAB VALVES
GROUND STUD
P/N 12941830 HARNESS (S) (P)
P104 L19 RED CAB LOWER

GND4/GND4 A
RED
SOLENOID VALVE/
19 /S15 1 B CONNECTOR
UNIT WELDMENT
AL1 P105 L18 RED CAB RAISE
244 /P51 D + GND4/GND4 A
RED
SOLENOID VALVE/
18 /P20 10 B CONNECTOR
(S) (P)
CAB
RAISE/LOWER
ALARM CAB/WELDMENT WIRING
98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

Sheet 4 of 16
CD276 2-2-79
Rev 13
Chapter 2
P
DUAL CAB UNITS ONLY E N (S)
P.N. 12941699 HARNESS D
F M
A C
GND3 /P1 6 SEE SH. 10, GRID 274 G
B
L 1/0 BLK
GND3 /P10 B SEE SH. 10, GRID 288 H K
GND3 /P15 F SEE SH. 11, GRID 306 J P13 TO F21, SH. 7,
GND3 /K29 85 SEE SH. 11, GRID 295 F21
GRID 187
203 /P9 A A
14 GA. 188 /P109 A B 199 /S41 NC K19
206 /P9 C C
GND3 /P13 M 166 /P9 D D EMERGENCY STEERING
GND3 GND3 /P109 C 198 /P9 E E PUMP MOTOR/RELAY
STEERING GND3 /P38 F 168 /P9 F F
GND3 /P48 2 2/0 GA
BOX GROUND 202 /P9 G G B5
STUD GND3 /P15 F 215 /SPL215 H BLK
GND3 /P1 6 166 /P54 A J
203 /P54 B K ENGINE BAY
FRONT AXLE 191 /P42 B L R.H. WELDMENT
FRONT CONSOLE FRONT WELDMENT GND3 /GND3 M
N STEERING BOX
P.N. 12950253 HARNESS P SEE SH. 8 FOR
DUAL CAB UNITS ONLY NOT USED WITH BOX & P13
P.N. 12941699 HARNESS DUAL CAB UNITS MATING CONNECTOR
ALTERNATE P8 SP6 /SP3
SP4
X
WIRING OF PIN SEE SH.11,
14 225 /A9−AC TO P1, SH. 2, GRID 49 14 GA.
14 FOR DUAL GRID 317 FOR TO P15, SH. 6, GRID 174 (S) (P)
CAB UNITS CONTINUATION
6 5 4 3 2 1
P.N. 12941831 HARNESS P100 L10 PARKING BRAKE
(P) GND6 /GND6 A
RED SET SOLENOID
12 11 10 9 8 7 A F F A RED
GREEN 196 /P9 M VALVE/CONNECTOR
P8 16 15 14 13 A8 B
C
D
A
B
F
E
D
C
B
A
F
ECU GLOW
MAIN HARNESS 22 21 20 19 18 17
(S) PLUG ASSEMBLY/CONNECTOR P103
INTERFACE 28 27 26 25 24 23
(P) P42 RED L11 PARKING BRAKE
CONNECTOR (REAR) A 103 /SPL103 6 GA.
GND6 /SPLGND6 A
RED RELEASE SOLENOID
JPR
B 191 /P13 L ECU P41 196 /SPL196 B VALVE/CONNECTOR
1 129 /P17 2 188 /SPL188 TO CB1, SH. 7,
2 159 /P41 5 C BLK /CB1
215 /P13 H D 215 /SPL215 GRID 189 1 GND6 /GND6
X
3 123 /P42 E E 123 /P8 3 8 (S) (P)

4 101 /P41 3 SPL215 JPR
F 124 /P17 7
2
DUAL CAB UNITS ONLY
5 130 /P17 5 9 3 101 /P8 4 P.N. 12941699 HARNESS
6 131 /P17 6 REAR CAB 4 127 /P18 2 S28
7 132 /P17 3 NOT USED WITH DUAL STEERING 182 /P12 5
8 133 /P17 4 CAB OR HEATER OPTIONS. INTERFACE TO E4, SH. 6,
BLK /E4
5 159 /P8 2 182 /P8 20 C
9 134 /P48 3 SEE SH. 10, GRID 290 CONNECTOR GRID 173 SEE SH. 10,
10 140 /S42 FOR DUAL CAB UNITS AND GND6 /GND6 NC GRID 288 FOR
SEE SH. 3, GRID 73
11 136 /P17 1 14 GA. SH. 9, GRID 244 FOR CONNECTION

12 137 /P16 HEATER/SINGLE CAB PARKING BRAKE
13 221 /P22 D MATING CONNECTOR
C B A
PRESSURE SWITCH
14 225 /P47
15 238 /S41 C SPLGND6
16 227 /P22 B COIL NC
17 138 /P16 GND6 /P103 A
X
18 135 /R5
K31
S25 COM
19 139 /R3
12 TWISTS/FT MIN.
20 182 /S28 C CONNECTOR (P)
WHT
RED COIL NO
BLK
150 /P23 REED SWITCH/

TWISTED PAIR
21 (P) (S)
22 229 /P22 C FRONT AXLE
23 109 /S43 C P109 A B C (S) STARTER SOLENOID
CBA
24 234 /P22 E CBA
AUX. RELAY/CONNECTOR L13 COORD
25 178 /P38 D
GND3 /GND3
P38
103/SPL103
26 A C D E F
P54
188 /P13 B
27
SP6 /SP4
GND3 /GND3
28 215 /P42 D GRN
SP3 SP7 /SP5 A 166 /P13 J
126 /F17 A
178 /P8 25
127 /P18 1
COM
SP8 /SP5 103 /P42 A A WHT
B 203 /P13 K
P9 14 GA. SPL188 BLK
C GND6 /GND6
X X X
STEERING SELECT VALVE
INTERFACE SPL103 SPL215 B
SOLENOID/
CONNECTOR 188 /P42 C L14 CRAB CONNECTOR,
A 203 /P13 A FRONT MODE
103 /P108 B
B 10 GA.
C 206 /P13 C SPL196 SEE SH. 7,
SEE SH. 3, GRID 65
D 166 /P13 D X X GRID 185 FOR

E 198 /P13 E 196 /P103 B P.N. 12941831 HARNESS CONTINUATION
F 168 /P13 F SPL103
G 202 /P13 G SEE SH. 6, SEE SH. 6, SEE SH. 6,
H 215 /P108 A
J GRID 167 FOR GRID 171 FOR WELDMENT WIRING GRID 180 FOR
K CONTINUATION CONTINUATION CONTINUATION
L
M 196 /P100 B P (P)
N E
N D
P M F
C A SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES
L G
B
K
J
H
AND SHEET 6 FOR REFERENCE LOCATIONS 141 142 143 144 145 146 147 148 149 150 151 152 153 154
128 129 130 131 132 133 134 135 136 137 138 139 140

Sheet 5 of 16
2-2-80 CD276
Rev 13
Chapter 2
SEE SH. 5, SEE SH. 5,

P9 GRID 139 FOR GRID 143 FOR
CONTINUATION CONTINUATION
P8
FUSE BOX/P4
P.N. 12941831 HARNESS SEE SH. 5,
(SEE SH.8)
GRID 152 FOR
CONTINUATION
14 GA.
SPL127 127 /P18 2 TO A8, SEE
X
SH. 5, GRID 142 P.N.
12941831
HARNESS
BLK /A8 9
ENGINE TRANSMISSION
P18 10 GA.
REMOVABLE SEAT A7 1 127 /P38 E
14 GA.
GP1−6
127 /SPL127
WIRING FOR INTERNAL WIRING

L7 2
127 /P41 4
3 6 GA.
OF A7, B1, G1, GP1−6, L6, L7,

P42
REFER TO DEUTZ ENGINE
L17, P17, P18, R4, AND R7.

4
HYD.STEERING 5 E4 139 /P8 19
CONTROL BOX/P13 6 GLOW PLUG R3
GND3 (SEE SH.8) 7 POWER STUD TRANSM.
8 TEMP.
S25/P109 (P) ENGINE PLUG SENSOR
(S)
CONNECTOR G1
(YELLOW) P23/R2 GND6 /GND6
TURBINE SPEED
P17 B+ (ZF) SENSOR/ 150 /P8 21
R1/P48 G1 CONNECTOR
G1 W 1 136 /P8 11 TWISTED
GP1-6 G1 D+ 2 129 /P8 1 GENERATOR, PAIR
R7 R4 1 3 132 /P8 7 12VDC, 95A P16/R6 137 /P8 12 12 TWISTS
P17/E4, P18 (YEL) R4 2 4 133 /P8 8 SPEED PER FOOT,
R7 G 130 /P8 5 BLK 138 /P8 17 MIN.
K31/P38 5 (ZF) SENSOR/
P18 1
R7 WK 6 131 /P8 6 CONNECTOR
L6 1 7 124 /P42 F 6 GA. 140 /P8 10
A7/B1/L17 8 S42
(INSIDE ENGINE) B5/K19 TRANSM.
ENGINE PLUG (S) HIGH TEMP
CONNECTOR B1 A7 SWITCH
L6 (P)
E2 A8/P41 A3
L17
S28 P48 R1
A3 (L1-5) P15 (L1-5) REFER TO ZF
R6/P16 L7/R4 1 M TRANSM.FOR INTERNAL
S42, R3 L10/P100/L11/P103 GND3 /GND3 2 E2 WIRING OF L1−5 & P15.
(LOWER 134 /P8 9 3
ENGINE TRANSM. VALVE BODY
EDGE) R2/P23 STARTER
F17, F21 ENGINE (S) POWER ASSEMBLY/CONNECTOR
S41 FLYWHEEL STUD MOTOR ASM. P15
S43 ENG.COOLANT LEVEL (SOL./MOTOR) A B C D E F
L13/L14/P54 HOUSING SENSOR/CONNECTOR
CB1/CB2/E3 2/0 GA. BLK
GND6
BT1, BT2 TO E3, SH. 7,
2/0 GA. BLK GRID 188
GND3 /GND3
GND7 S29/P108 (S)
145 /P1 2
141 /P1 7
142 /P1 8
143 /P1 4
144 /P1 3
GND8
R5
ENGINE BAY
P40 P22 R.H. WELDMENT
P39
TO GND3, P.N. 12950253 HARNESS
SH. 5, GRID 136
DS64 DS57
DS61 DS68/P47 DS60 NOT USED WITH DUAL
DS62/DS63 DS59/DS58 TO P1, SEE CAB OPTION. SEE
AL2 SH. 2, GRID 49 SH. 11, GRID 305 FOR
DS65/P46 DS66/P45 FOR CONTINUATION DUAL CAB UNIT WIRING.
(BUMPER) (BUMPER)
LEFT SIDE RIGHT SIDE SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES WELDMENT WIRING
166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182
156 157 158 159 160 161 162 163 164 165

Sheet 6 of 16
CD276 2-2-81
Rev 13
Chapter 2
DUAL CAB UNITS ONLY

SEE SH. 11,
GRID 316 FOR GND8 /P5 6
CONTINUATION WELDMENT ON REAR
L.H. SIDE CAB RAISER
REAR (SINGLE (DUAL CAB
14 GA
CAB UNITS) UNITS ONLY)
GND8 /P39 E GND8
232 /P40 A GND8 /P46 A REAR CAB/REAR
X
SPL232 LIGHTS GROUND STUD
SEE SH. 12, 233 /P45 B
X
GRID 327 DUAL CAB UNITS ONLY 14 GA SPL233
P.N. 12941699 HARNESS AL2
238 /S35 1
227 /P40 B BACK−UP
X
SPL227 ALARM
221 /P40 D
X
S41 DUAL CAB UNITS ONLY
SPL221
14 GA. GND6 227
STEERING VALVES P.N. 12941699 HARNESS P.N. 12941701 HARNESS
238 /P8 15 C P40 RED LIGHTS
199 /K19 NC GND6 /P100 A GROUND STUD GND6 /P50 A SEE SH. 11, 14 GA P22
GND6 /P108 C GND6 /P55 C GRID 301 FOR 232 /SPL232 A BRAKE DS58
EMERG.STEERING GND6 /P54 C GND6 /P56 C CONTINUATION 232 /S43 NC A 232 /P39 A 227 /SPL227 BLK
GND6 /R5 B BACK−UP DS60
PRESSURE SWITCH 227 /P8 16 B 227 /P39 B YEL
GND6 /S28 NC 234 /P22 E C TURN DS57
GND6 /P41 1 229 /P8 22 C 229 /P39 C BRN
GND6 /P23 221 /P8 13 221 /SPL221 D TAIL
SP5 SP8 /SP3
SP7 /SP3
D 221 /P39 D
WHT
DS59
ENGINE BAY 234 /P8 24 E 234 /P40 C GND8 /SPLGND8 E GROUND
R.H. 14 GA. 233 /S34 10 F 233 /P46 B
WELDMENT 14 GA R.H. REAR
REAR LIGHTS A A 14 GA (S)LIGHTS CONNECTOR (P)
SEE SH. 5, A
REAR OF TRACTOR
GRID 154 FOR B CONNECTOR B B
P.N. 12941831 HARNESS C C C
C
E
E
B
A
CONTINUATION
F17 D D D
STARTER E E E E A A E
135 /P8 18
S43 BRAKE PRESS. F (S) (P) F F
FUSE, 20A
C NC SWITCH (BRAKE R5 14 GA P45 DS66 DUAL CAB
LIGHTS) FUEL LEVEL GND8 /SPLGND8 A BLK UNITS ONLY
SEE SH. 12,
TO A8, SH. 5, 14 GA. SENSOR GRID 325 FOR BLK
233 /SPL233 B
GRID 142 232 /P22 A CONTINUATION
6 GA. RIGHT REAR
GND6 /GND6
109 /P8 23 DUAL CAB UNITS ONLY HEADLIGHT A (P)
A B
(S)
215 /P9 H
103 /P9 B
P.N. 12941699 HARNESS CONNECTOR B
10 GA.
GND6 /GND6 P39 LIGHTS
126 /P38 A 232 /P22 A A BRAKE
RED
DS63
BLK /A8 8
EMERGENCY STEERING PUMP DUAL CAB UNITS ONLY BLK

FUSE, 225A 227 /P22 B B BACK−UP DS61
P108 MOVE TO A9. REFER TO GRN
C
A
B
SEE SH. 8, CBA
SH. 11, GRID 317 229 /P22 C C TURN DS64
BLK /E1 GRID 233 FOR BRN
REAR AXLE
WHT
FOR DETAILS.
RED
221 /P22 D D TAIL
BLK
CONTINUATION (S) DS62
6 GA.BLK
REED SWITCH/ WHT
F21 CONNECTOR 14 GA. GND8 /GND8 E GROUND
(P) P47
BLK 14 GA L.H. REAR
CB1 CB2 225 /P8 14
MAIN CIRCUIT
(S)LIGHTS CONNECTOR (P)
1/0 BLK GLOW PLUG S29 SPLGND8
CIRCUIT BREAKER, 120A REAR HITCH DS68
TO K19, SH. 5, LIGHT/CONNECTOR
C
E
E
B
A
K19 BREAKER, 120A WHT /F17 GND8 /P40 E
X
GRID 149 A E
GND8 /P45 A E A
1/0 BLK 10 GA.
(P) 14 GA
6 GA. BLK (S) 14 GA P46 DS65
E3 BLK DUAL CAB
GND8 /GND8 A UNITS ONLY
BATTERY POWER STUD BLK
233 /P22 F B
2/0 GA. BLK LEFT REAR
A
A B
HEADLIGHT
(S)
CONNECTOR B (P)
GND7
TO E2, SH. 6, + − + − BATTERY
GRID 173 E2
BT1 BT2 GROUND STUD
BATTERY, BATTERY, WELDMENT AND SHEET 6 FOR REFERENCE LOCATIONS
12 VOLTS 12 VOLTS
2/0 GA. BLK
WELDMENT WIRING
198 199 200 201 202 203 204 205 206 207 208 209 210 211
185 186 187 188 189 190 191 192 193 194 195 196 197

Sheet 7 of 16
2-2-82 CD276
Rev 13
Chapter 2
CAVITY ARRANGEMENT
CONNECTOR FOR K30
86
85
FUSEHOLDER(S) K30 10 GA.
(FUSES) 30 B(+) /E1
LOOKING AT BACK B(+) /E1 (S)
OF CONNECTOR 85 GND2 /P4 4
(WIRE ENTRANCE) 86 125 /P4 2 P4
128 /F4 B FUSE BOX
87 128 /F7 B CONNECTOR
12 GA. 12 GA. 12 GA. 128 /F3 B
B F16 A B(+) /E1 B F12 A 112 /P4 1 B(+) /E1 B F8 A 108 /P4 17 128 /K30 87 B F4 A 104 /P4 18 128 /F10 B 1 112 /F12 A
12 GA. R 20A R 20A IGNITION 12 GA. 2 125 /K30 86
128 /K30 87 128 /K30 87 3 101 /F1 A
B(+) /E1 B F15 A 115 /P4 10 B F11 A 111 /P4 13 B F7 A 107 /P4 7 B F3 A 103 /P4 11 (MASTER) RELAY
4 GND2/K30 85
MATING CONNECTOR
30A 20A 10A 10A 102 /F2 A
SEE SH. 4, GRID 122

5
B(+) /E1 F14 128 /K30 87 F10 110 /P4 8 F6 106 /P4 15 F2 102 /P4 5 6 105 /F5 A 14 GA.
B
20A
A 114 /P4 14 B
20A
A B
10A
A B
10A
A
7 107 /F7 A
8 110 /F10 A
B F13
15A
A 113 /P4 12 B(+) /E1 B F9
15A
A 109 /P4 16 B F5
10A
A 105 /P4 6 B F1
10A
A 101 /P4 3 9
115 /F15 A
14 GA. 12 GA. 14 GA. 10
11 103 /F3 A
12 113 /F13 A
13 111 /F11 A
FUSES FUSES FUSES FUSES 14 114 /F14 A
F16 - RESERVED F12 - INSTRUMENT PANEL, 20A F8 - RESERVED F4 - REAR WINDOW DEFROSTER, 20A
15 106 /F6 A
F15 - WINDSHIELD WIPER, 30A F11 - HORN, 20A F7 - CAB SELECT, 10A F3 - STEERING, 10A
16 109 /F9 A
F14 - HEADLIGHTS, 20A F10 - HEATER/COOL FAN, 20A F6 - CAB RAISE/LOWER, 10A F2 - TRANSMISSION, 10A
17 108 /F8 A
F13 - EMERG.STEERING, BEACON, F9 - TURN/BRAKE/BACK-UP F5 - PARKING BRAKE, 10A F1 - ENGINE, 10A
18 104 /F4 A
19
AND FRONT HITCH, 15A LIGHTS, 15A
12 GA.

10 GA.
B(+) /K30 30
E1 B(+) /K30 30
B(+) /F12 B
B(+) /F15 B
B(+) /F9 B
FUSE BOX B(+) /F14 B
POWER STUD B(+) /F8 B
FUSE BOX WIRING 12 GA.
SEE SH. 7,
B(+) /CB2 GRID 192 FOR
CONTINUATION
6 GA.BLK
HYD. STEERING CONTROL BOX WIRING - SINGLE CAB CONTROLS

(REFER TO SH. 14 FOR DUAL CAB CONTROL CIRCUIT)
(P) P26 (S)

DIODE BOARD
P INSIDE P26
N E 8 7 6 5
D K9 K10 K11 K12 4 3 2 1
M F
P13 1 191 /K9 11 1 168 /P13 F 5 211 /K9 10 7 237 /P26 F CR1-CR4 3 2 1 11 10 9
C A
A 203 /K10 9 191 /K10 11 2 GND3/K9 2 6 210 /K10 10 237 /P26 E
GND3/K10 2 198 /P13 E A S

L G B 188 /K11 14 2 GND3 9 11 206 /P13 C P26
B
206 /K12 11 GND3 202 /P13 G GND3/K11 13 201 /K9 6 R
SEE SH. 5, GRID 141
10 A
C 3 GND3/K11 13 13 B 14 13
D 166 /K9 9 GND3/P13 M 13 GND3/K10 3 215 /P13 H B 213 /K10 6
K
J
H
198 /K11 9
3 5 167 /K9 5 GND3/K12 13
14 C C 201 /K9 6 12 11 10 9
E
167 /K10 5 213 /P26 B 188 /P13 B 213 /K10 6 4 5 6 7 8
F 168 /K10 1 5
201 /P26 A
6
213 /P26 D
14 5
SEE SH. 14, D D
G 202 /K11 10 6
7
6 E 237 /K12 7 RELAYS K9 & K10 RELAYS K11 & K12
215 /K12 14 201 /P26 C 9 203 /P13 A 8 GRID 382 FOR 1 2 3 4 F 237 /K12 7
H
166 /P13 D 203 /P13 K SEE SH. 14, CONNECTIONS, CONTACT ARRANGEMENT CONTACT ARRANGEMENT
166 /K9 9 9 8
9
G 211 /K9 10
J 166 /P13 J 10 210 /P26 H 11
GRID 379 FOR 10 DUAL CAB H 210 /K10 10
K 203 /K10 9 10 211 /P26 G 210 /K11 6 12
CONNECTIONS, 13 UNITS ONLY E
L 191 /K9 11 211 /K11 5 191 /K9 1
DUAL CAB
UNITS ONLY
12
F
STEERING
M GND3 /K9 3 11
191 /K9 1 11 DIODE MODULE
ASSEMBLY/
CONTROL BOXES
N 191 /P13 L G
CONNECTOR
P
COORD STEERING, CRAB STEERING, FRONT AXLE REAR AXLE H SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES
STEERING BOX FRONT CONTROL FRONT CONTROL REED SWITCH REED SWITCH
RELAY RELAY RELAY RELAY STEERING BLOCKING AND SHEET 6 FOR REFERENCE LOCATIONS
CONNECTOR
RECTIFIERS

232 233 234 235 236 237 238
212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231

Sheet 8 of 16
CD276 2-2-83
Rev 13
Chapter 2

Sheet 9 of 16
R.H. REAR
CONNECTOR BOX MOUNTED
P17 LIGHT ASM.
MARKED WITH * ENGINE HARNESS
FUSE BOX P4 * (TYP.2 PLCS) HARNESS
HARNESS
P18
P40
P9
R.H. REAR MAIN P22 REAR
HEADLIGHT ASM.
CAB CEILING PLG HARNESS LIGHTS
HARNESS HARNESS
HARNESS
P8
P39
STEERING
* P13 BOX
HARNESS
PLG
P42
L.H. REAR
LIGHT ASM.
FRONT P21 CAB MAIN
HARNESS
LIGHTS HARNESS
HARNESS TRANSMISSION
P7 SOLENOID TRANSMISSION
HARNESS VALVE
P33
P15 BODY
P1
L.H.
CONTROL P19 P2 FRONT
PANEL GAUGES SHIFTER
HEADLIGHT ASM.
HARNESS HARNESS
HARNESS
CONTROL P28 HARNESS

PANEL SWITCH INTERCONNECTING DIAGRAM
HARNESS
SINGLE CAB
CONTROL
STEERING MODE P29 PANEL
IND.LIGHTS FRONT CAB
HARNESS
3 CONDUCTOR 12 GA WHT
MIN.SIZE CABLE
NOT USED WITH SINGLE HEATER;
GR W
CONNECT WHT & BLK WIRES FROM A11 & GRN
WHT
P61 DIRECTLY TO RELAY SOCKET
K35 BLK P61

BLK RUN SOLENOID BLK BLK WHT GRN 120 VAC OR 24 VAC
DISCONNECT RELAY POWER SUPPLY CONNECTOR
10 12 9 (+) 14 TB1 BLK NOTE: CUSTOMER TO PROVIDE
1 TRACTOR
TO FRAME ADEQUATE OVERCURRENT/
WHT SHORT CIRCUIT PROTECTION.
2 BATTERY
(−) 13 GRN HEATER
2 6 4 8 1 5 TERMINAL
WHT BOARD WHT BLK
12 GA. ENGINE COOLANT HEATER BOX

GRN
RELAY
(P) PANEL
BLK WHT
A B P60 A B
K35 RELAY (S)
CONNECTOR BLK COLD WEATHER START ASSISTANCE
A B
(RUN SOLENOID
124A /P42 E
(OPTIONAL)
124B /P42 F
DISCONNECT) WHT
124B /P42 F
124A /P42 E
GRN
A (P) F
P42 A11
C
D
A
B
E
F
A ENG.COOLANT
B TANK HEATER
C SEE SH. 5, ASSEMBLY, SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES
D GRID 136 FOR 120VAC OR 240VAC
TO SH. 10, GRID 289 AND SHEET 13 FOR REFERENCE LOCATION
DUAL CAB UNITS
E 123 MATING CONNECTOR
ONLY
F 124
REAR CAB STEERING
INTERFACE CONNECTOR
SINGLE CAB ONLY
253 254
255 256 257 258 259 260 261 262 263 264 265
239 240 241 242 243 244 245 246 247 248 249 250 251 252
2-2-84 CD276
Rev 13
Chapter 2
P10 14 GA.
A 155 /P5 2 TO GND3, SEE
B GND3/GND3 SH. 5, GRID 137
C
D
CONTROL BOX CONNECTOR

E (S)
F 153 /P5 4 J
H
X
G
K W
(S)
H 154 /P5 3 B G
J 151 /P5 7 L V
(P) K 152 /P5 8
INDICATOR LIGHTS L 158 /P6 4 C A F
RED M 145 /P15 A M U
RED
N 162 /P15 E D E
P 163 /P15 D N T
R 165 /P15 B P S
FRONT CAB
DS26 SELECTED S 164 /P15 C R
RED BLK DS25 SHIFTERS (P)
CONTROL BOX
T 141 /P1 7
YEL P37 P7 U 142 /P1 8
YEL G IN NEUTRAL SEE SH. 13 143 /P1 4
G 190 /K26 86 6 5 4 3 2 1 1 170 /P12 27 V
2 173 /P12 15 FOR BOX WIRING W 144 /P1 3
DS27 REAR CAB H 191 /SPL191 12 11 10 9 8 7 3 105 /S24 NC1 AND P10 & P12 X 145 /P1 2
RED SELECTED BLK
DS28 FRONT PARK A 172 /P12 17 RED 4 192 /P12 25 MATING
YEL R BRAKE SW ONYEL
18 14 12 13 5 140 /DS42 (−) CONNECTOR
C 176 /P12 10 6 129 /DS40 (−) P12
B 175 /P12 12
22 23 22 21 20 19 7 131 /DS41 (−) 1 193 /P7 20
GROUND SCREW IN PANEL PLATE GND 8 133 /DS44 (−) 2 196 /P7 21
E 179 /P12 8 28 27 26 25 24 23 9 134 /DS43 (−) 3 194 /S24 NC2
10 245 /P57 E 4 195 /S24 NO3
S19 DS29 REAR PARK F 188 /P42 C 11 149 /K29 87a 182 /S28 C TO S28, SEE

5
CONTROL BOX CAB SELECT CONNECTOR

1 184 /S19 10 R BRAKE SW ONYEL D 180 /P12 7 12 102 /K29 30 6 171 /P7 19 SH. 5, GRID 153
230 /K28 87a
SEE SH. 3, GRID 68

184 /P14 B 13 7 180 /P37 D
2 GND /S19 9 CAB SELECT 14 231 /K28 30 8 179 /P37 E (S)
3 186 /P12 21 LIGHTS 15 223 /K26 87a 9 179 /P35 E
8 189 /DS29
YEL CONNECTOR 16 114 /K26 30 10 176 /P37 C
9 GND /S19 2
17 221 /K27 30 14 GA. 11 176 /P35 C
GND/ GND
P.N. 12941868 HARNESS 18 226 /K27 87a 12 175 /P37 B
10 9 10 184 /S19 1 DS30 19 171 /P12 6 13 175 /P35 B
PARK BRAKE 20 193 /P12 1 14 183 /P14 A
YEL R APPLIED YEL 196 /P12 2
CAB SELECT 21 15 173 /P7 2
SWITCH 22 107 /P12 16 16 107 /P7 22
23 181 /S37 17 172 /P37 A
YEL 24 101 /DS42 (+) 18 172 /P35 A
DS24 REAR SHIFTER DS31 AXLE CENTER 25 113 /S35 5 19 187 /S36 1
NOT IN NEUTRAL YEL A INDICATOR YEL 26 177 /P35 D 20 190 /P14 D
R 27 246 /P57 C 21 186 /S19 3
28 22 190 /S34 3 REAR CAB
REAR CAB 23 191 /P42 B STEER INTERFACE
YEL YEL INTERFACE TAPED BACK 24 191 /P35 H A
(P) F CONNECTOR
CONNECTOR & SEALED WITH 25 192 /P7 4
CR18-CR21P57 HEATSHRINK 26 P42
A 27 170 /P7 1 A
B
A
SP1 28 190 /K29 86 191 /P12 23 B
B 188 /P37 F
SP5 /SP2
CONTROL PANEL REAR CAB SELECT OPTION PANEL 29 C
SP4 /SP2
C C 246 /P7 27 30 215 /P35 F D
SEE SH. 5, GRID 136
FOR MATING
D D 146 /P6 2 31 123 /S30 E CONNECTOR
21
20
19
18
E 245 /P7 10 124 /S30 F
DIODE BOARD
INSIDE P57 E F JPR ALTERNATE
F G WIRING OF
G H 14 GA. 124B/P60 B F PIN F
SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES H FOR HEATER
DIODE MODULE
DOWNSHIFT LOCK CONNECTOR SEE SH. 9
AND SHEET 13 FOR REFERENCE LOCATION GRID 239 FOR
BLOCKING RECTIFIER (S)
(P) CONTINUATION
P14 124A/P60 A SPLICE
A 183 /P12 14 124 /S30
P1 HYD.STEERING B 184 /S19 1
CONTROL BOX (OPT) C 185 /S36 3 MOVE FROM

1 SEE SH. 14 190 /P12 20 P42 F
SEE SH. 2, GRID 46
D
2 145 /P10 X FOR BOX WIRING E 214 /P36 A
3 144 /P10 W AND P14 MATING F 220 /P36 C (P)
4 143 /P10 V CONNECTOR G 220 /P55 A N
P
E
5 219 /P55 B
TO GND3, SH. 5, H
6 GND3 /GND3 GRID 137 J 219 /P36 B M D F
7 141/ P10 T K 218 /S34 8 C A
8 142 /P10 U L 216 /S34 6 L B G
M 212 /S34 2
ZF FRONT CAB N K H
J
SHIFTER P
CONNECTOR
(TRANSMISSION)
SEE SH. 11, GRID 293
FOR CONTINUATION
DUAL CAB ONLY, WELDMENT WIRING
266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292

Sheet 10 of 16
CD276 2-2-85
Rev 13
Chapter 2
SEE SH. 12,

GRID 341 FOR
CONTINUATION
S37
HORN
SWITCH
181 /P7 23
SEE GND6 SH. 7, GRID 198
SEE SH.5, GRID 137

SEE SH. 3, GRID 72 164 K25 86
SPL191 SPL190 SPL191 SPL190 P.N. 12941699 HARNESS
SEE SH. 10,
GRID 290 FOR X X X X X
CONTINUATION SPL164 SEE SH. 5,
GRID 129
GND3 /GND3
190 /P50 B
191 /P56 A
190 /P56 B
191 /P37 H
145 /P10 M
165 /P10 R
162 /P10 N
164 /P10 S
163 /P10 P
GND8/S31 9
241 /S32 1
225 /P8 14
240 /S31 5
(P) (S)
ZF REAR
CAB SHIFTER
ASSEMBLY P6
A2 1 276 /S24 NC1
2 146 /P57 D
3 157 /K28 86 AC AC
P15 A B C D E F (S) FOR WIRING
GND6 /GND6
GND6 /GND6
GND6 /GND6
158 /P10 L
190 /SPL190
191 /SPL191
190 /SPL190
4
220 /P14 G
SEE ZF
219 /P14 H
CONNECTS TO TRANSM. 5 102 /K29 30
VALVE BODY CONNECTOR DRAWING
6 GND8/S36 9
ON SH. 6, GRID 178 GND8/P5 6
7 277 /S24 NC2 DASH
SEE GND3, SH. 5, LIGHT,
GRID 137 (S) 8
(S) (S) DIODE MODULE REAR
ZF REAR CAB
CBA
CBA ASSEMBLY
SHIFTER CONNECTOR (CR13 & CR15)
K29 K28 14 GA. K27 K26 14 GA. (CAB) HITCH LIGHT
231 /P7 14 221 /P7 17 114 /P7 16 P50 A B A B C P56 A B C P55 BLOCKING
30 102 /P7 12 30 30 30 BLK
102 /P6 5 CAB P53 RECTIFIER
WHT
WHT
GRN
GRN
BLK
BLK
RED
ORBITAL SELECT COORD/CRAB SELECT
RED
85 GND3 /GND3 85 GND3/K29 85 85 GND3/K28 85 85 GND3/K27 85 1 156 /K29 87
GND3/K28 85 GND3/K27 85 GND3/K26 85 SOLENOID VALVE/ SOLENOID VALVE/
157 /P6 3 190 /K29 86 190 /K27 86 CONNECTOR CONNECTOR,
86 190 /K27 86 86 86 86
CBA
REAR SHIFTER UPSHIFT
190 /P12 28 190 /K26 86 190 /P37 G REAR MODE 2 1
CBA
(P) (P) INTERLOCK CONNECTOR

87 156 /P53 1 87 240 /K26 87 87 233 /S32 10 87 240 /K28 87 (P) (S) REAR
240 /S32 5 HITCH
(S) (P) LIGHT
87a 149 /P7 11 87a 230 /P7 13 87a 226 /P7 18 87a 223 /P7 15
UPSHIFT INHIBITOR REAR SHIFTER PARKING LIGHTS LIGHTS 14 GA. A B A B
TRANSFER RELAY BACK−UP RELAY TRANSFER RELAY TRANSFER P5
COORD
14 GA. RELAY L12 FRONT 1
REAR
CRAB
COM COM 2 155 /P10 A
3 154 /P10 H
ACCELERATOR L8 L9 L16 L15 4 153 /P10 F
CONTACT ARRANGEMENT FOR TRANSFER 5
RELAY SOCKET (K29−K26) SOLENOID 6 GND8 /P6 6
VALVE/CONNECTOR GND8 /GND8 SEE SH. 7, GRID 204
87 151 /P10 J
86 7
8 152 /P10 K
85 87a
30 ZF REAR CAB
SHIFTER CONNECTOR DUAL CAB ONLY, WELDMENT WIRING
SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES (TRANSMISSION)
AND SHEET 13 FOR REFERENCE LOCATION
293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319

Sheet 11 of 16
2-2-86 CD276
Rev 13
Chapter 2
GEN NO LOW OIL TRANS.HI REAR STATION PANEL REAR STATION

CHARGE PRESSURE OIL TEMP TAPED BACK EMERGENCY STOP
INDICATOR INDICATOR INDICATOR AND SEALED
(FRONT VIEW) SWITCH PANEL
LIGHT LIGHT LIGHT WITH HEAT
DS40 DS41 DS42 SHRINK
SP2
SP4 /SP1
SP5 /SP1
101 /DS44(+)
101 /DS43(+)
101 /DS44(+)
277 /P6 7 194 /P12 3
101 /P7 24
140 /P7 5
129 /P7 6
131 /P7 7
1 2 NC JUMPER
1 2 NC
1 4 7 10
101
14 GA.
3 4 NO
S24
2 5 8 11
NC1 105 /S24 NO4
101 /DS41(+)
101 /DS41(+)
101 /DS42(+)
105 /P7 3
NC2 194 /P12 3 3 6 9 12 195 /P12 4
134 /P7 9
133 /P7 8
NO3 195 /P12 4
NO4 105 /S24 NC1
276 /P6 1 105 /P7 3
NC1 276 /P6 1 S24
NC2 277 /P6 7
10 9 (MAINTAINED)
CONTACT ARRANGEMENT PARK BRAKE ALTERNATE PARK
FOR SWITCH SOCKETS SWITCH BRAKE SWITCH WIRING
(S31−34) (TOGGLE TYPE)
DS43 DS44
LOW COOLANT ENG HI
LEVEL IND. COOLANT TEMP
LIGHT IND.LIGHT
RED
S31 FRONT SHIFTER

14 GA. YEL NOT IN NEUTRAL YEL
1 233 /S32 10 1 241 /A9 AC R
233 /S31 10 5 240 /K28 87
5 240 /S32 5 240 /S31 5
240 /DS67(+) 9 GND8/S35 9
GND8/S34 9 GND8/S34 9
123 /P42 E
9
124 /P42 F
GND8/DS67(−) 10 233 /K27 87 GROUND SCREW SHIFTERS
10 233 /S35 10 233 /S31 1 IN PLATE YEL IN NEUTRAL YEL
233 /S31 1 G
REAR HITCH H 191 /P12 24
REAR HEADLIGHTS LIGHT SWITCH
SWITCH FRONT CAB
D 177 /P7 26
SELECTED FRONT PARK A 172 /P12 18
RED BLK
P.N. 12941825 HARNESS YEL BRAKE SW ON YEL
R C 176 /P12 11
BLK BLK
B 175 /P12 13
YEL
E 179 /P12 9
RED BLK REAR PARK
YEL BRAKE SW ON F 215 /P42 D
R
STEERING MODE G 190 /S34 3
SEE SH. 7,
INDICATOR LIGHTS REAR CAB
GRID 189 CAB SELECT
SELECTED EMERGENCY ENGINE
COORD LIGHTS
PARK BRAKE CONNECTOR STOP SWITCH
YEL APPLIED YEL
TRACK BLK R P.N. 12941825
2 212 /P14 M 1 238 /S41 C 1 187 /P12 19 HARNESS
3 190 /P12 22 5 113 /P7 25 2 GND8/S35 9
CRAB BLK 190 /P35 G 9 GND8/S36 2 GND8/S36 9
6 216 /P14 L GND8/S32 9 3 185 /P14 C
8 218 /P14 K 10 233 /S34 10 185 /S36 10 YEL AXLE CENTER YEL
A
9 GND8/S32 9 233 /S31 10 8 197 /DS48
GND8/S31 9 9 GND8/S36 2
10 233 /S35 10 EMERG. STEERING GND8/P6 6
233 /P22 F SWITCH 10 185 /S36 3
STEERING MODE CAB
SELECTOR SWITCH SELECT SWITCH
RED
RED
RED
RED
SEE SH. 7, GRID 201
A B C D E F
REAR STEERING MODE

IND.LIGHTS CONNECTOR SEE SH. 11, GRID 317
214 /P14 E
220 /P14 F
219 /P14 J
FOR CONTINUATION
SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES DUAL CAB ONLY, WELDMENT WIRING
AND SHEET 13 FOR REFERENCE LOCATION REAR STATION PANEL
320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346

Sheet 12 of 16
CD276 2-2-87
Rev 13
Chapter 2
(P) 8 5
H
X J
W K
4 1
3 2 1 11 10 9 P57/CR18-CR21
G B
V L S
F A C
R
U M
E D 14− 13+
T N
12 9 4 5 6 7 8
S P
R
RELAYS K1−4 RELAYS K6−8
P10 171 /P12 6 CONTACT ARRANGEMENT CONTACT ARRANGEMENT
K26-K29
14 GA. CONTROL PANEL
CR14
A 155 /K7 4 NEUTRAL LIGHT
REAR CAB SELECT
B GND3/K1 13 OPTION PANEL, P37 P7
BLOCKING RECTIFIER
C (SEE SH. 10)
D P1 REMOVABLE SEAT
E K1 K2 K3 K4
F 153 /K7 4
1 1 1 1
G 180 P42
4 4 4
H 154 /K6 9 4 180 /P12 7 5 172 /P12 18 5 174 /K4 5 5 174 /K3 5
J 151 /K6 4 5 172 /K2 5 172 /K1 5 8 176 /P12 10 8 179 /P12 8
K 152 /K7 9 172 /P12 17 8 175 /P12 13 176 /P12 11 179 /P12 9 HYD.STEERING
L 158 /K1 14 8 175 /P12 12 9 173 /K2 9 9 183 /P12 14 CONTROL BOX, CONTROL BOX,
M 145 /P10 X 170 /P12 27 9 173 /K3 9 107 /K2 12 107 /K3 12 P10, P12
N 162 /K6 11
9 12 12 P14(SEE SH. 14)
12 107 /P12 16 173 /P12 15 107 /K4 12 107 /K4 14
P 163 /K6 1 107 /K2 12 12 107 /K3 12 13 GND3/K2 13 13 182 /P12 5
R 165 /K7 1 13 GND3/P10 B 107 /K1 12 GND3/K6 3 14 107 /K4 12
S 164 /K7 11 GND3 /K2 13 13 GND3/K1 13 14 192 /P12 25 107 /K8 11
T 141 /K7 5 14 158 /P10 L GND3/K3 13
U 142 /K7 8 14 195 /P12 4
V 143 /K6 5 14 GA.
W 144 /K6 8 REAR SHIFTER REAR PARKING FRONT PARKING PARK BRAKE
X 145 /P10 M NEUTRAL BRAKE SWITCH BRAKE SWITCH APPLIED
RELAY "ON" RELAY "ON" RELAY RELAY
CONTROL BOX A11
CONNECTOR
P12 K6 K7 K8
1 193 /K8 5 1 163 /P10 P 1 165 /P10 R 1 196 /P12 2
2 196 /K8 1 2 GND3/K7 3 2 GND3 /K8 3 2 GND3 ENG. HEATER
3 194 /K8 4 GND3 GND3 COOLANT BOX
4 195 /K2 14 3 GND3 /K7 2 P15 K35/P60/TB1
5 182 /K4 13 3 GND3/K3 13 3 GND3 /K6 2 4 194 /P12 3
6 171 /CR14 4 151 /P10 J 4 153 /P10 F 5 193 /P12 1
7 180 /K1 4 5 143 /P10 V 155 /P10 A 6 187 /P12 19 L8/L9/P56
8 179 /K4 8 6 191 /P12 23 5 141 /P10 T 7
9 179 /K4 8 191 /K7 6 6 191 /K8 8 8 191 /P12 24 L12/P50
10 176 /K3 8 7 191 /K6 6 191 /K7 6

11 176 /K3 8 8 144 /P10 W 7 190 /P12 22 L15/L16/P55

12 175 /K2 8 9 154 /P10 H 8 142 /P10 U 9 190 /P12 28
13 175 /K2 8 10 190 /P12 20 9 152 /P10 K 190 /K7 10
14 183 /K4 9 190 /K7 10 10 190 /K6 10 10 186 /P12 21
15 173 /K2 9 11 162 /P10 N 190 /K8 9 11 107 /K4 14
16 107 /K1 12 11 164 /P10 S
17 172 /K1 5 SHIFTER CHANGE CAB SELECT
18 172 /K2 5 OVER CONTROL SHIFTER CHANGE RELAY
19 187 /K8 6 RELAY OVER CONTROL
20 190 /K6 10 RELAY
21 186 /K8 10
22 190 /K8 9
23 191 /K6 6
24 191 /K8 8 DUAL CAB S37
25 192 /K3 14
26 EMERG.STOP
27 170 /K1 9 SW. PANEL
28 190 /K8 9 (S24,S30)
29
30 (P)
31 REAR STATION PANEL
31 20 CONTROL BOX WIRING GND8
(WITH REAR CAB ONLY) DS67
P35,P36
CONTROL BOX 30 8 21
CAB SELECT 19 9 A9, CR13/CR15
CONNECTOR
18 2 10
DUAL CAB (STATIONS) ONLY DS68 A2/P5/P6/P53
29 7 3 22
17 1 11 LEFT SIDE RIGHT SIDE
28 6 4 23
16 5 12 REFERENCE LOCATION FOR SHEETS 9 - 14
15 13
27 14 25
26 24 SEE SHEETS 15 & 16 FOR MASTER LEGEND AND NOTES
DUAL CAB UNIT
348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373

Sheet 13 of 16
2-2-88 CD276
Rev 13
Chapter 2

Sheet 14 of 16
DIODE BOARD
INSIDE P27
CR5-CR8
STEERING BLOCKING RECTIFIER
P27 (S)
5
TO K11 RELAY, TO K12 RELAY,
(S) SH. 8, GRID 222 SH. 8, GRID 224 6
P FOR CONNECTIONS FOR CONNECTIONS
E N 7
D K11 K12 8
F M
A C
7 204 /P27 E 5 208 /K14 10
204 /P27 F 6 209 /K15 10 H G F E D C B A
G
B
L 8 184 /P14 B 8 185 /P14 C DIODE MODULE,
11 216 /P14 L 9 218 /P14 K
12 183 /K12 12 10 212 /P14 M P27 STEERING
C
E
B
A
F
H K ASSEMBLY/
J
183 /P14 A 12 183 /K11 12
13 GND3/K14 2 CONNECTOR
209 /K15 10
208 /K14 10
204 /K11 7
204 /K11 7
205 /K14 6
207 /K15 6
207 /K15 6
205 /K14 6
FRONT AXLE
P14 REED SWITCH REAR AXLE
183 /K11 12 RELAY REED SWITCH
A
184 /K11 8 RELAY HYD. STEERING CONTROL BOX ADDITIONAL WIRING
B
C 185 /K12 8
DUAL CAB (STATIONS) ONLY

D 190 /K14 11
E 214 /K15 1 (REFER TO SH. 8 FOR SINGLE CAB CONTROL CIRCUIT)
F 220 /K15 9
G 220 /K15 9
H 219 /K14 9 K14 K15
J 219 /K14 9 P.N. 12941890 HARNESS
K 218 /K12 9 1 190 /K15 11 1 214 /P14 E
L 216 /K11 11 190 /K14 11 2 GND3/K14 3
M 212 /K12 10 2 GND3/K12 13 GND3
N GND3 3 8 7 6 5
P 3 5 217 /K14 5
GND3/K15 2 6 207 /P27 B 4 3 2 1
HYD. STEERING 5 217 /K15 5 207 /P27 C
CONTROL BOX (OPT) 3 2 1 11 10 9
6 205 /P27 A 9 220 /P14 G
CONNECTOR
205 /P27 D 220 /P14 F
9 219 /P14 H 10 209 /K12 6 S
219 /P14 J 209 /P27 H R
10 208 /K12 5 11 190 /K14 1 14 13
208 /P27 G
11 190 /P14 D CRAB STEERING 12 11 10 9
190 /K14 1 REAR CONTROL 4 5 6 7 8
RELAY
COORD STEERING RELAYS K11, K12 RELAYS K14, K15
REAR CONTROL CONTACT ARRANGEMENT CONTACT ARRANGEMENT
RELAY
CONNECTOR BOX MOUNTED

MARKED WITH * R.H. REAR
(TYP.5 PLCS) P17 LIGHT ASM.
ENGINE HARNESS
P18 HARNESS
FUSE BOX P4 *
HARNESS
P40
P9
HARNESS INTERCONNECTING DIAGRAM
REAR MAIN P22 REAR DUAL CAB (STATIONS)
R.H. P8 HARNESS LIGHTS
HEADLIGHT ASM. P20
CAB CEILING HARNESS
HARNESS
HARNESS
* P13
STEERING
P39
BOX
HARNESS
LEGEND
P32 * P14 1. PLUG EXAMPLE: PLUG DESIGNATOR
* P12 L.H. REAR
P42 CAB SELECT
CONTROL BOX
LIGHT ASM.
HARNESS
P#
FRONT P21 CAB MAIN
HARNESS(ES)
LIGHTS HARNESS
HARNESS
* P10
PIN SOCKET
CONTROL PANEL P37 P7 REAR CAB P15 TRANSMISSION

P33 REAR CAB INTERFACE VALVE
SEL.OPT.PANEL HARNESS BODY
P35
STEERING MODE P29 CONTROL
L.H. IND.LIGHTS PANEL
HEADLIGHT ASM. HARNESS P1
P2 FRONT REAR CAB
HARNESS P36
SHIFTER P6
HARNESS DUAL CAB UNIT
CONTROL P19
PANEL GAUGES P5
HARNESS
CONTROL P28 CONTROL REAR

PANEL SWITCH PANEL SHIFTER
HARNESS FRONT CAB HARNESS
388 389 390 391 392 393 394 395 396 397 398 399
374 375 376 377 378 379 380 381 382 383 384 385 386 387
CD276 2-2-89
Rev 13
Chapter 2
LEGEND LEGEND
SH.− GRID ITEM DESCRIPTION SH.− GRID ITEM DESCRIPTION LEGEND
2 − 42 DS 11 LIGHT PARK BRAKE APPLIED INDICATOR
LEGEND
2 − 44 A 1 ASSEMBLY ZF FRONT CAB SHIFTER
SH.− GRID ITEM DESCRIPTION SH.− GRID ITEM DESCRIPTION
11 − 312 A 2 ASSEMBLY ZF REAR CAB SHIFTER 2 − 40 DS 12 LIGHT GENERATOR NO CHARGE INDICATOR
6 − 178 A 3 ASSEMBLY TRANSMISSION VALVE BODY 2 − 55 DS 13 LIGHT FRONT DASH PANEL, LEFT HAND − DS ##
2 − 37 A 4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK−UP 2 − 40 DS 14 LIGHT FRONT DASH PANEL, RIGHT HAND 8 − 230 E 1 STUD FUSE BOX POWER
N/S A 5 ASSEMBLY RESERVED 2 − 49 DS 15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE 6 − 172 E 2 STUD ENGINE POWER 13 − 352 K 1 RELAY REAR SHIFTER NEUTRAL
4 − 112 A 6 ASSEMBLY CAB HEATER − FAN 2 − 47 DS 16 LIGHT ENGINE OIL PRESSURE GAUGE 7 − 189 E 3 STUD BATTERY POWER 13 − 355 K 2 RELAY REAR PARKING BRAKE SWITCH "ON"
6 − 174 A 7 ASSEMBLY STARTER MOTOR (SOLENOID AND MOTOR) 2 − 49 DS 17 LIGHT TRANSMISSION OIL TEMPERATURE GAUGE 6 − 173 E 4 STUD GLOW PLUG POWER 13 − 358 K 3 RELAY FRONT PARKING BRAKE SWITCH "ON"
5 − 144 A 8 ASSEMBLY ECU GLOW PLUG 2 − 47 DS 18 LIGHT VOLTMETER − E ## 13 − 361 K 4 RELAY PARK BRAKE APPLIED
11 − 318 A 9 ASSEMBLY DIODE MODULE (DIODES CR13 AND CR15) 2 − 53 DS 19 LIGHT TACHOMETER 8 − 228 F 1 FUSE ENGINE, 10A N/S K 5 RELAY RESERVED
1 − 21 A 10 ASSEMBLY CAB, REAR WINDOW DEFROSTER 2 − 45 DS 20 LIGHT SPEEDOMETER 8 − 228 F 2 FUSE TRANSMISSION, 10A 13 − 355 K 6 RELAY SHIFTER CHANGE OVER CONTROL
9 − 250 A 11 ASSEMBLY ENGINE COOLANT, TANK HEATER 2 − 38 DS 21 LIGHT COORD STEERING MODE INDICATOR 8 − 228 F 3 FUSE STEERING, 10A 13 − 358 K 7 RELAY SHIFTER CHANGE OVER CONTROL
− A ## 2 − 28 DS 22 LIGHT TRACK STEERING MODE INDICATOR 8 − 228 F 4 FUSE REAR WINDOW DEFROSTER, 20A 13 − 361 K 8 RELAY CAB SELECT
4 − 110 AL 1 ALARM CAB RAISE/LOWER 2 − 28 DS 23 LIGHT CRAB STEERING MODE INDICATOR 8 − 223 F 5 FUSE PARKING BRAKE, 10A 8 − 217 K 9 RELAY COORD STEERING, FRONT CONTROL
7 − 208 AL 2 ALARM BACK−UP 10 − 267 DS 24 LIGHT REAR SHIFTER NOT IN NEUTRAL INDICATOR 8 − 223 F 6 FUSE CAB RAISE/LOWER, 10A 8 − 219 K 10 RELAY CRAB STEERING, FRONT CONTROL
2 − 34 AL 3 ALARM ENGINE/TRANSMISSION TROUBLE WARNING 10 − 270 DS 25 LIGHT SHIFTERS IN NEUTRAL INDICATOR 8 − 223 F 7 FUSE CAB SELECT, 10A 8 − 222 K 11 RELAY FRONT AXLE REED SWITCH
− AL ## 10 − 267 DS 26 LIGHT FRONT CAB SELECTED INDICATOR 8 − 223 F 8 FUSE RESERVED 8 − 224 K 12 RELAY REAR AXLE REED SWITCH
6 − 173 B 1 MOTOR STARTER 10 − 267 DS 27 LIGHT REAR CAB SELECTED INDICATOR 8 − 218 F 9 FUSE TURN/BRAKE/BACK−UP LIGHTS, 15A N/S K 13 RELAY RESERVED
4 − 120 B 2 MOTOR WINDSHIELD WASHER PUMP 10 − 270 DS 28 LIGHT FRONT PARK BRAKE SWITCH "ON" INDICATOR 8 − 218 F 10 FUSE HEATER − COOL FAN, 20A 14 − 379 K 14 RELAY COORD STEERING, REAR CONTROL
4 − 115 B 3 MOTOR WINDSHIELD WIPER, RIGHT HAND 10 − 270 DS 29 LIGHT REAR PARK BRAKE SWITCH "ON" INDICATOR 8 − 218 F 11 FUSE HORN, 20A 14 − 382 K 15 RELAY CRAB STEERING, REAR CONTROL
2 − 51 B 4 MOTOR WINDSHIELD WIPER, LEFT HAND 10 − 270 DS 30 LIGHT PARK BRAKE APPLIED INDICATOR 8 − 218 F 12 FUSE INSTRUMENT PANEL, 20A N/S K 16 RELAY RESERVED
5 − 150 B 5 MOTOR EMERGENCY STEERING PUMP 10 − 270 DS 31 LIGHT AXLE CENTER INDICATOR 8 − 213 F 13 FUSE EMERGENCY STEERING, BEACON AND FRONT HITCH, 15A N/S K 17 RELAY RESERVED
1 − 23 B 6 MOTOR CAB DEFROSTER/COOLING, RIGHT HAND 2 − 33 DS 32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB) 8 − 213 F 14 FUSE HEADLIGHTS, 20A N/S K 18 RELAY RESERVED
1 − 23 B 7 MOTOR CAB DEFROSTER/COOLING, LEFT HAND 2 − 56 DS 33 LIGHT FUEL LEVEL GAUGE 8 − 213 F 15 FUSE WINDSHIELD WIPER, 30A 5 − 150 K 19 RELAY EMERGENCY STEERING PUMP MOTOR
1 − 21 B 8 MOTOR CAB ROOF WIPER 1−3 DS 34 LIGHT HEAD, LEFT HAND 8 − 213 F 16 FUSE RESERVED 3 − 82 K 20 RELAY PARK BRAKE ON − STARTER ENABLE
− B ## 1−3 DS 35 LIGHT HEAD, RIGHT HAND 7 − 194 F 17 FUSE STARTER, 20A 3 − 79 K 21 RELAY SHIFTER IN NEUTRAL
7 − 191 BT 1 BATTERY 12V 1−3 DS 36 LIGHT TURN, FRONT, LEFT HAND N/S F 18 FUSE RESERVED 3 − 77 K 22 RELAY HORN
7 − 192 BT 2 BATTERY 12V 1−3 DS 37 LIGHT TURN, FRONT, RIGHT HAND N/S F 19 FUSE RESERVED 3 − 75 K 23 RELAY TRANSMISSION NOT IN N−, PARK BRAKE APPLIED
− BT ## 1 − 20 DS 38 LIGHT CAB DOME N/S F 20 FUSE RESERVED 3 − 73 K 24 RELAY SHIFTER, BACK−UP
7 − 189 CB 1 CIRCUIT B. GLOW PLUG, 120A 1−3 DS 39 LIGHT FRONT HITCH 7 − 188 F 21 FUSE EMERGENCY STEERING PUMP, 225A 3 − 71 K 25 RELAY LOCK−UP UNIT (DOWNSHIFT)
7 − 191 CB 2 CIRCUIT B. MAIN, 120A 12 − 324 DS 40 LIGHT GENERATOR NO CHARGE INDICATOR (REAR) 2 − 61 F 22 FUSE GAUGES, 5A 11 − 299 K 26 RELAY LIGHTS TRANSFER
− CB ## 12 − 325 DS 41 LIGHT LOW OIL PRESSURE INDICATOR (REAR) − F ## 11 − 297 K 27 RELAY PARKING LIGHTS TRANSFER
8 − 227 CR 1−4 RECTIFIER BLOCKING, STEERING 12 − 327 DS 42 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR (REAR) 3 − 87 FL 1 FLASHER TURN SIGNAL LIGHTS 11 − 295 K 28 RELAY REAR SHIFTER BACK−UP
14 − 386 CR 5−8 RECTIFIER BLOCKING, STEERING 12 − 324 DS 43 LIGHT LOW COOLANT LEVEL INDICATOR (REAR) 3 − 87 FL 2 FLASHER BEACON LIGHT (FLASHING BEACON) 11 − 293 K 29 RELAY UPSHIFT INHIBITOR TRANSFER
3 − 80 CR 9 RECTIFIER RESERVED 12 − 325 DS 44 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR (REAR) − FL ## 8 − 231 K 30 RELAY IGNITION (MASTER)
3 − 80 CR 10 RECTIFIER BLOCKING, PARKING BRAKE N/S DS 45 LIGHT RESERVED (REAR) 6 − 172 G 1 GENERATOR 12 VDC, 95A 5 − 144 K 31 RELAY STARTER SOLENOID AUXILIARY
3 − 80 CR 11 RECTIFIER BLOCKING, CAB LIFT 12 − 332 DS 46 LIGHT FRONT SHIFTER NOT IN NEUTRAL INDICATOR (REAR) − G ## N/S K 32 RELAY RESERVED
3 − 80 CR 12 RECTIFIER BLOCKING, CAB LIFT 12 − 332 DS 47 LIGHT SHIFTERS IN NEUTRAL INDICATOR (REAR) 2 − 56 GA 1 GAUGE FUEL LEVEL, W/ 1/8 WARNING N/S K 33 RELAY RESERVED
11 − 318 CR 13 RECTIFIER BLOCKING, HITCH LIGHT 12 − 332 DS 48 LIGHT FRONT PARK BRAKE SWITCH "ON" INDICATOR (REAR) 2 − 48 GA 2 GAUGE ENGINE COOLANT TEMPERATURE N/S K 34 RELAY RESERVED
13 − 352 CR 14 RECTIFIER BLOCKING, NEUTRAL LIGHT 12 − 332 DS 49 LIGHT REAR PARK BRAKE SWITCH "ON" INDICATOR (REAR) 2 − 46 GA 3 GAUGE ENGINE OIL PRESSURE 9 − 242 K 35 RELAY RUN SOLENOID DISCONNECT
11 − 317 CR 15 RECTIFIER BLOCKING, HITCH LIGHT 12 − 332 DS 50 LIGHT PARK BRAKE APPLIED INDICATOR (REAR) 2 − 48 GA 4 GAUGE TRANSMISSION OIL TEMPERATURE 2 − 58 K 36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
2 − 61 CR 16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A 12 − 332 DS 51 LIGHT AXLE CENTER INDICATOR (REAR) 2 − 46 GA 5 GAUGE VOLTMETER − K ##
N/S CR 17 RECTIFIER RESERVED 12 − 329 DS 52 LIGHT FRONT CAB SELECTED INDICATOR (REAR) 2 − 52 GA 6 GAUGE TACHOMETER 6 − 177 L 1−5 SOLENOID TRANSMISSION VALVE BODY, ZF/ Y1−Y5
10 − 278 CR 18 RECTIFIER RESERVED 12 − 329 DS 53 LIGHT REAR CAB SELECTED INDICATOR (REAR) 2 − 44 GA 7 GAUGE SPEEDOMETER 6 − 166 L 6 SOLENOID ENGINE RUN VALVE
10 − 278 CR 19 RECTIFIER RESERVED 12 − 322 DS 54 LIGHT COORD STEERING MODE INDICATOR (REAR) − GA ## 6 − 166 L 7 SOLENOID EXCESS START FUEL ALLOWANCE
10 − 278 CR 20 RECTIFIER BLOCKING, DOWNSHIFT LOCK 12 − 322 DS 55 LIGHT TRACK STEERING MODE INDICATOR (REAR) 10 − 26 GND GROUND CH CONTROL PANEL REAR CAB SELECT OPTION PANEL 11 − 304 L 8 SOLENOID FRONT CAB ORBITAL SELECT VALVE
10 − 278 CR 21 RECTIFIER BLOCKING, DOWNSHIFT LOCK 12 − 322 DS 56 LIGHT CRAB STEERING MODE INDICATOR (REAR) 2 − 60 GND1 GROUND CH FRONT CAB, LEFT HAND 11 − 305 L 9 SOLENOID REAR CAB ORBITAL SELECT VALVE
3 − 73 CR 22 RECTIFIER ENGINE WARNING ALARM, OIL PRESSURE LT. 7 − 210 DS 57 LIGHT TURN, REAR, RIGHT HAND 4 − 118 GND2 GROUND CH FRONT CAB, RIGHT HAND 5 − 151 L 10 SOLENOID PARKING BRAKE SET VALVE
3 − 73 CR 23 RECTIFIER ENGINE WARNING ALARM, COOLANT TEMP. LT. 7 − 210 DS 58 LIGHT BRAKE, RIGHT HAND 5 − 134 GND3 GROUND CH STEERING BOX 5 − 151 L 11 SOLENOID PARKING BRAKE RELEASE VALVE
3 − 73 CR 24 RECTIFIER ENGINE WARNING ALARM, COOLANT LEVEL LT. 7 − 210 DS 59 LIGHT TAIL, RIGHT HAND 4 − 125 GND4 GROUND CH LIFT CAB VALVES 11 − 302 L 12 SOLENOID ACCELERATOR TRANSFER VALVE
3 − 73 CR 25 RECTIFIER ENGINE WARNING ALARM, TRANSM. TEMP. LT. 7 − 210 DS 60 LIGHT BACK−UP, RIGHT HAND N/S GND5 GROUND CH RESERVED 5 − 148 L 13 SOLENOID COORD SELECT VALVE, SV2−A (OR 1)
− CR ## 7 − 210 DS 61 LIGHT BACK−UP, LEFT HAND 7 − 195 GND6 GROUND CH STEERING VALVES 5 − 148 L 14 SOLENOID CRAB SELECT VALVE, SV2−B (OR 1)
2 − 53 DS 1 LIGHT LEFT TURN INDICATOR 7 − 210 DS 62 LIGHT TAIL, LEFT HAND 7 − 195 GND7 GROUND CH BATTERY 11 − 309 L 15 SOLENOID COORD SELECT VALVE, REAR MODE, SV3−A
2 − 52 DS 2 LIGHT LOW OIL PRESSURE INDICATOR 7 − 210 DS 63 LIGHT BRAKE, LEFT HAND 7 − 208 GND8 GROUND CH REAR CAB 11 − 308 L 16 SOLENOID CRAB SELECT VALVE, REAR MODE, SV3−B
2 − 50 DS 3 LIGHT GLOW PLUG INDICATOR 7 − 210 DS 64 LIGHT TURN, REAR, LEFT HAND − GND ## 6 − 174 L 17 SOLENOID ENGINE STARTER
2 − 44 DS 4 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR 7 − 209 DS 65 LIGHT REAR LEFT HEAD 6 − 166 GP 1−6 RESISTOR GLOW PLUG 4 − 124 L 18 SOLENOID CAB RAISE VALVE
2 − 42 DS 5 LIGHT HIGH BEAM INDICATOR 7 − 209 DS 66 LIGHT REAR RIGHT HEAD − GP ## 4 − 124 L 19 SOLENOID CAB LOWER VALVE
2 − 40 DS 6 LIGHT RIGHT TURN INDICATOR 11 − 319 DS 67 LIGHT DASH (REAR) 1−4 H 1 HORN VEHICLE, FRONT − L ##
2 − 53 DS 7 LIGHT LOW COOLANT LEVEL INDICATOR 7 − 202 DS 68 LIGHT REAR HITCH 1 − 17 H 2 HORN VEHICLE CAB, FRONT, LEFT HAND
2 − 52 DS 8 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR 1−3 DS 69 LIGHT PARK, FRONT, RIGHT HAND 1 − 17 H 3 HORN VEHICLE CAB, FRONT, RIGHT HAND
2 − 50 DS 9 LIGHT RESERVED 1−3 DS 70 LIGHT PARK, FRONT, LEFT HAND − H ##
MASTER LEGEND AND NOTES
2 − 44 DS 10 LIGHT RESERVED 1 − 22 DS 71 LIGHT BEACON, ROTATING

Sheet 15 of 16
2-2-90 CD276
Rev 13
Chapter 2
LEGEND LEGEND
SH.− GRID ITEM DESCRIPTION SH.− GRID ITEM DESCRIPTION
2 − 46 P 1 CONNECTOR SHIFTER (TRANSMISSION) FRONT CAB (ZF) N/S P 101 CONNECTOR RESERVED
2 − 46 P 2 CONNECTOR SHIFTER (CAB) FRONT CAB (ZF) N/S P 102 CONNECTOR RESERVED
5 − 150 P 103 CONNECTOR PARK BRAKE RELEASE VALVE NOTES:
N/S P 3 CONNECTOR RESERVED
4 − 123 P 104 CONNECTOR CAB LOWER SOLENOID VALVE 1. ALL S&S WIRING IS 16 GA. SXL WIRE, UNLESS OTHERWISE NOTED.
4 − 122 P 4 CONNECTOR FUSE BOX
4 − 123 P 105 CONNECTOR CAB RAISE SOLENOID VALVE 2. ALL CONNECTORS SHOWN FROM MATING END VIEW, UNLESS OTHERWISE INDICATED.
11 − 314 P 5 CONNECTOR SHIFTER (TRANSMISSION) REAR CAB
N/S P 106 CONNECTOR RESERVED 3. VENDOR WIRING
11 − 314 P 6 CONNECTOR SHIFTER (CAB) REAR CAB
3 − 68 P 7 CONNECTOR REAR CAB INTERFACE 4. S&S WIRING
7 − 196 P 108 CONNECTOR REAR AXLE REED SWITCH
3 − 73 P 8 CONNECTOR MAIN HARNESS INTERFACE 5. (S) FOR CONNECTOR SOCKET
5 − 137 P 109 CONNECTOR FRONT AXLE REED SWITCH
3 − 65 P 9 CONNECTOR STEERING INTERFACE
− P ## 6. (P) FOR CONNECTOR PIN
10 − 286 P 10 CONNECTOR CONTROL BOX
6 − 171 R 1 SENSOR ENGINE COOLANT LEVEL 7. THIS WIRING DIAGRAM HAS BEEN DRAWN TO SHOW THE STANDARD TRACTOR PLUS
6 − 177 R 2 SENSOR TURBINE SPEED (ZF) REGULAR OPTIONS INCLUDING DUAL CAB (DUAL STATION). IT MAY HAVE TO BE
10 − 286 P 12 CONNECTOR CONTROL BOX CAB SELECT COMPLEMENTED WITH SEPARATE WIRING DIAGRAMS FOR TRACTORS WITH MORE
6 − 177 R 3 SENSOR TRANSMISSION TEMPERATURE
5 − 142 P 13 CONNECTOR STEERING BOX (STANDARD) COMPONENTS THAN SHOWN. FOR SINGLE CAB (STATION) TRACTORS USE SHEETS
6 − 166 R 4 SENSOR ENGINE HIGH COOLANT TEMPERATURE SWITCH − SENDER
10 − 286 P 14 CONNECTOR STEERING BOX (OPTIONAL) 1 TO 9, 15 & 16.
7 − 197 R 5 SENSOR FUEL LEVEL 8. SPL(WIRE NO.) INDICATES POINT WHERE WIRES WITH SAME WIRE NUMBER ARE
6 − 178 P 15 CONNECTOR TRANSMISSION SOLENOID VALVES
6 − 177 R 6 SENSOR SPEED (ZF) SPLICED TOGETHER.
6 − 177 P 16 CONNECTOR SPEED SENSOR (ZF)
6 − 166 R 7 SENSOR ENGINE LOW OIL SWITCH − SENDER
6 − 169 P 17 CONNECTOR ENGINE PLUG
− R ##
6 − 169 P 18 CONNECTOR ENGINE PLUG (YELLOW)
2 − 38 S 1 SWITCH WIPER REFERENCE S&S DRAWINGS:
2 − 42 P 19 CONNECTOR INSTRUMENT GAUGES
2 − 36 S 2 SWITCH WINDSHIELD WASHER
1 − 29 P 20 CONNECTOR CEILING INTERFACE FIGURE 5.1.12 (PAGE 5−1−55 − 5−1−63) REFERENCE DESIGNATORS/PART NUMBERS/LOCATION INDEX
2 − 34 S 3 SWITCH RESERVED
1 − 10 P 21 CONNECTOR FRONT LIGHTS FIGURE 5.1.10 (PAGE 5−1−35 − 5−1−44) FRONT & REAR CAB (STATIONS) SCHEMATIC
2 − 58 S 4 SWITCH BLOWER FAN FIGURE 5.1.11 (PAGE 5−1−45 − 5−1−54) SINGLE CAB (STATION) SCHEMATIC
7 − 202 P 22 CONNECTOR REAR LIGHTS
2 − 38 S 5 SWITCH RESERVED FIGURE 5.1.13 (PAGE 5−1−64−−5−1−79) WIRING DIAGRAM (SEE NOTE 7)
6 − 177 P 23 CONNECTOR TURBINE SPEED SENSOR (ZF)
2 − 36 S 6 SWITCH PARK LIGHT SH. 1 − CAB WIRING / REFERENCE LOCATIONS
2 − 38 P 24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK−UP
2 − 34 S 7 SWITCH HIGH−LOW BEAM SH. 2 − FRONT CAB CONTROL PANEL/LEFT SIDE UNDER DASH
N/S P 25 CONNECTOR RESERVED SH. 3 − FRONT CAB CONSOLE
2 − 60 S 8 SWITCH REAR WINDOW DEFROSTER, TOUCH PAD
8 − 228 P 26 CONNECTOR DIODE MODULE, STEERING, CR1−CR4 SH. 4 − RIGHT SIDE UNDER PANEL/WELDMENT / REFERENCE LOCATIONS
N/S S 9 SWITCH RESERVED SH. 5 − WELDMENT WIRING
14 − 385 P 27 CONNECTOR DIODE MODULE, STEERING, CR5−CR8
2 − 58 S 10 SWITCH EMERGENCY STEERING SH. 6 − WELDMENT WIRING / REFERENCE LOCATIONS
2 − 59 P 28 CONNECTOR IGNITION/LIGHT SWITCH
2 − 38 S 11 SWITCH FRONT HITCH LIGHT SH. 7 − WELDMENT WIRING
2 − 40 P 29 CONNECTOR STEERING MODE INDICATOR LIGHTS
2 − 36 S 12 SWITCH REAR HITCH LIGHT SH. 8 − CONTROL BOXES
2 − 52 P 30 CONNECTOR WINDSHIELD WIPER MOTOR, LEFT HAND SH. 9 − COLD WEATHER START ASSISTANCE / SINGLE CAB INTERCONNECTING DIAGRAM
2 − 34 S 13 SWITCH BEACON
4 − 116 P 31 CONNECTOR WINDSHIELD WIPER MOTOR, RIGHT HAND SH.10 − DUAL CAB ONLY, WELDMENT WIRING
2 − 33 S 15 SWITCH CAB LIFT
1−6 P 32 CONNECTOR RIGHT HAND HEADLIGHT 2 − 33 S 14 SWITCH STEERING MODE SELECT SH.11 − DUAL CAB ONLY, WELDMENT WIRING
1−6 P 33 CONNECTOR LEFT HAND HEADLIGHT N/S S 16 SWITCH RESERVED SH.12 − DUAL CAB ONLY, REAR STATION PANEL
SH.13 − DUAL CAB UNIT, CONTROL BOX WIRING / REFERENCE LOCATIONS
1−4 P 34 CONNECTOR FRONT HITCH LIGHT N/S S 17 SWITCH RESERVED
SH.14 − DUAL CAB UNIT, HYD. STEERING BOX / DUAL CAB INTERCONNECTING DIAGRAM
12 − 335 P 35 CONNECTOR CAB SELECT LIGHTS (REAR) N/S S 18 SWITCH RESERVED SHTS. 15 & 16 − MASTER LEGEND AND NOTES
12 − 320 P 36 CONNECTOR STEERING MODE INDICATOR LIGHTS (REAR) 10 − 266 S 19 SWITCH CAB SELECT FIGURE 5.1.14 (PAGE 5−1−80 − 5−1−90) ELECTRICAL EQUIPMENT LOCATION DRAWING
10 − 274 P 37 CONNECTOR CAB SELECT LIGHTS 2 − 61 S 20 SWITCH DASH LIGHT
5 − 143 P 38 CONNECTOR STARTER SOLENOID AUXILIARY RELAY 2 − 59 S 21 SWITCH EMERGENCY ENGINE STOP
7 − 207 P 39 CONNECTOR LEFT HAND REAR LIGHTS 2 − 61 S 22 SWITCH STOP, RUN, START
7 − 207 P 40 CONNECTOR RIGHT HAND REAR LIGHTS 2 − 55 S 23 SWITCH HORN
5 − 145 P 41 CONNECTOR ECU GLOW PLUG 12 − 338 S 24 SWITCH PARK BRAKE (REAR) WIRE IDENTIFICATION
5 − 136 P 42 CONNECTOR REAR CAB STEERING INTERFACE 5 − 137 S 25 SWITCH FRONT AXLE REED 243 / P44 A
2 − 53 P 43 CONNECTOR TURN SIGNAL 12 − 344 S 24 SWITCH PARK BRAKE (REAR) (LOCATION WIRE NUMBER GOES TO
4 − 113 P 44 CONNECTOR HEATER − FAN, CAB 2 − 55 S 26 SWITCH TURN SIGNAL
7 − 207 P 45 CONNECTOR REAR HEADLIGHT, RIGHT HAND 2 − 41 S 27 SWITCH PARK BRAKE
7 − 207 P 46 CONNECTOR REAR HEADLIGHT, LEFT HAND 5 − 150 S 28 SWITCH PARKING BRAKE PRESSURE, OPENS AT
7 − 201 P 47 CONNECTOR REAR HITCH LIGHT 1800 psi ON FALLING PRESSURE
6 − 170 P 48 CONNECTOR ENGINE COOLANT LEVEL SENSOR 7 − 196 S 29 SWITCH REAR AXLE REED MASTER LEGEND AND NOTES
N/S P 49 CONNECTOR RESERVED 12 − 339 S 30 SWITCH EMERGENCY ENGINE STOP (REAR)
11 − 302 P 50 CONNECTOR ACCELERATOR TRANSFER SOLENOID VALVE 12 − 321 S 31 SWITCH REAR HEADLIGHTS (REAR)
3 − 79 P 51 CONNECTOR DIODE MODULE, CR9−CR12 12 − 324 S 32 SWITCH REAR HITCH LIGHT (REAR)
2 − 46 P 52 CONNECTOR FRONT SHIFTER UPSHIFT INTERLOCK N/S S 33 SWITCH RESERVED (REAR)
11 − 314 P 53 CONNECTOR REAR SHIFTER UP−SHIFT INTERLOCK 12 − 324 S 34 SWITCH STEERING MODE SELECTOR (REAR)
5 − 150 P 54 CONNECTOR COORD/CRAB SELECT VALVE, FRONT MODE 12 − 326 S 35 SWITCH EMERGENCY STEERING (REAR)
11 − 309 P 55 CONNECTOR COORD/CRAB SELECT VALVE, REAR MODE 12 − 328 S 36 SWITCH CAB SELECT (REAR)
11 − 305 P 56 CONNECTOR FRONT/REAR CAB ORBITAL SELECT VALVE 11 − 318 S 37 SWITCH HORN (REAR)
10 − 279 P 57 CONNECTOR DIODE MODULE, TRANSMISSION SHIFTER, CR18−CR21 1 − 17 S 38 SWITCH CAB WAND, RIGHT HAND
1 − 28 P 58 CONNECTOR REAR WINDOW DEFROSTER 1 − 14 S 39 SWITCH CAB WAND, CENTER
N/S P 59 CONNECTOR RESERVED 1 − 17 S 40 SWITCH CAB WAND, LEFT HAND
9 − 241 P 60 CONNECTOR K35 RELAY (RUN SOLENOID DISCONNECT) 7 − 191 S 41 SWITCH EMERGENCY STEERING PRESSURE, OPENS
9 − 251 P 61 CONNECTOR 120 VAC OR 240 VAC POWER SUPPLY AT 1800 psi ON FALLING PRESSURE
1−4 P 62 CONNECTOR HORN 6 − 177 S 42 SWITCH TRANSMISSION HIGH TEMPERATURE
7 − 191 S 43 SWITCH BRAKE PRESSURE (BRAKE LIGHTS)
CLOSES AT 239°F
3 − 74 P 64 CONNECTOR DIODE MODULE, ENGINE WARNING ALARM, CR22−CR25 − S ##
5 − 150 P 100 CONNECTOR PARK BRAKE SET VALVE 9 − 245 TB 1 TERMINAL BOARD
Sheet 16 of 16
CD276 2-2-91
Rev 13
Chapter 2
CB2 E1
E3
12V IGNITION SWITCH
F12
LEGEND
BT1 BT2
P4
P28
P7
S22
S54
F21
P7 S27
P28
F22
F17 K31 P4
K20
P17 P17
K30
NOTES:
P4
L17
K19
P8
G1 M
SEE SHEET 9 FOR MASTER LEGEND
B1
B5
A7
EMERG STEERING ALTERNATOR START MOTOR CONTROL CIRCUIT MASTER IGNITION RELAY
PUMP START
Figure 2-10. Schematic, Single Cab (Station) w/Cat Engine

Sheet 1 of 9
2-2-92 CD276
Rev 13
Chapter 2

12V IGNITION SWITCH
LEGEND
P64
CR24
CR23
CR22
CR25
RUN GENERATOR OIL COOLANT COOLANT TRANSM. VOLT TACHO SPEEDO FUEL TRANSM. SEE SHEET 1 FOR NOTES/SHEET 9 FOR MASTER LEGEND
SOLENOID NO CHARGE PRESSURE TEMP LEVEL TEMP. METERS GAUGE TEMP.
GAUGES/WARNING LIGHTS DASH LIGHTS GAUGE

w/Cat Engine Sheet 2 of 9
CD276 2-2-93
Rev 13
Chapter 2

F2 LEGEND
P7 P7 P4
S27 P52
A1
P2
P1 P2
P2
P7
P1 P2
P7 K25
K21
P7
P24
A4
P8 L4
L3
L2
L5
L1
P24
R2
P23 SEE SHEET 1 FOR NOTES/SHEET 9 FOR MASTER LEGEND
A3
P15

TRANSMISSION

2-2-94 CD276
Rev 13
Chapter 2

F5 F7
P4 P7
P4
P7
LEGEND
S27
DS11 P7
P51
THIS SPACE INTENTIONALLY LEFT BLANK

P7 P7
P7
K23 SEE SHEET 1 FOR NOTES/SHEET 9 FOR MASTER LEGEND
P8 P9
L10 L11
S28 P100 P103
PARKING BRAKE

CD276 2-2-95
Rev 13
Chapter 2
12V IGNITION
F3
P4
P9 P9
S14
P42
DS32
P42 P9
P13
P13
P11 KA
P73 P72
K9 K9 S53 S52 K11
S29 S25 S49 L.T. R.T.
P108 P109 P74
P73 P72
K11
P11
K10
KB
K10
P25/
CR31
P42 P42
K11 K12
P13 P11 P13
CR32
P26/ P26/
P25/ P25/ P9 P9 CR4 CR3
CR28 CR29 P25/ P26/ P26/
CR30 CR2 CR1
DS22 DS21 DS23

P29 P29 L13 L14 P29 SEE SHEET 1 FOR NOTES/SHEET 9 FOR MASTER LEGEND
K12 KB K11 KB P54 P54 KA K9 K10 K9 K10
REAR FRONT AXLE FRONT AXLE TRACK COORD CRAB RELAY LOGIC
AXLE RT. OF CENTER LEFT OF CENTER SOLENOID CONTROL
REED SWITCH
STEERING - SINGLE CAB

2-2-96 CD276
Rev 13
Chapter 2

12V PARK SW
F11 F10 F15 F6
P4 P4 P4 P4
S15
K22 S1 S2
P20
P21
P20 P20 P62 P20 S39

H1
S4
H2
S40 CR12
P20 P51
SEE SHEET 1 FOR NOTES AND
H3 SHEET 9 FOR MASTER LEGEND
CR11
P7 S38 P51
P20
DS38 S23 A6 B6 B2 L18 L19

B7 B4 B3 B8 AL1
P44 P30 P31 P105 P104
DOME LIGHT-HORN HEATER WINDSHIELD WIPER/WASHER CAB LIFT

COOLING FAN
CAB

CD276 2-2-97
Rev 13
Chapter 2
LEGEND
12V PARK SW.
F14
P4
P28
P7 P7
S20
P28
S6
S7
S12
CR16
P7 P7
P8
P7 P7
K24
P8
P8
P22 P21 SEE SHEET 1 FOR NOTES/SHEET 9 FOR MASTER LEGEND
P22 P21
DS61 DS60 DS68 DS34 DS35 DS5 DS62 DS70 DS59 DS69
AL2 P39 P40
P47 P33 P32 P39 P33 P40 P32
BACK-UP REAR HEADLIGHT PARK

LIGHT HITCH
EXTERIOR LIGHTS

2-2-98 CD276
Rev 13
Chapter 2

12V PARK SW.

LEGEND
F9 F13 F4
P4 P4
P4
P8
S13 S11
FL1
P7
K36
S26
P43
S43 S10
FL2
P22 P58
P8 P8 P8
P20
P22 P21 P22 P21 P21 S8
SEE SHEET 1 FOR NOTES/SHEET 9 FOR MASTER LEGEND

A10 M
DS1 DS64 DS36 DS6 DS57 DS37 DS63 DS58 DS71 S41 DS39
P39 P33 P40 P32 P39 P40 P34
LEFT HAND RIGHT HAND SERVICE BEACON FRONT DEFROSTER

BRAKE EMERG STEERING HITCH REAR WINDOW
TURN SIGNALS LIGHT
EXTERIOR LIGHTS
CD276 2-2-99
Rev 13
Chapter 2
LEGEND LEGEND
GRID ITEM DESCRIPTION GRID ITEM DESCRIPTION LEGEND
LEGEND GRID ITEM DESCRIPTION
GRID ITEM DESCRIPTION
MASTER LEGEND - SEE SHEET 1 FOR NOTES

2-2-100 CD276
Rev 13
Chapter 2
S16
LEGEND
S15
S7 S16
P8
WIRE ROUTING
P8
S16
P22
NOTES:
P8
P45 DS78
P22
(S) (P) (S) (P)
DS78 DS79
P45 P46 P46 DS79
(S) (P)
SCHEMATIC WIRING DIAGRAM
Figure 2-11. Wiring Diagram, Rear Driving

Lights/Single Cab
CD276 2-2-101
Rev 13
Chapter 2
REFERENCE CONNECTOR DESCRIPTION TERMINAL

DESIGNATOR
227 LEGEND AL1 --- --- 607923-2

GND --- --- 607923-4
AL2 ALARM BACK-UP
DS60 LIGHT BACK-UP, RIGHT HAND
P8 CONNECTOR REAR HARNESS INTERFACE
P22 CONNECTOR REAR LIGHTS
P8 P40 CONNECTOR REAR LIGHTS, RIGHT HAND
16
WIRE HARNESS
EXISTING WIRING
ADDED WIRING WIRE NO. GA. COLOR FROM TO LENGTH
227
P22
B 227 16 WHT SPL227 AL2 40.0
PIN GND 16 BLK AL2 GND 48.0
SPL227 SOCKET
227 227 NOTES:

1. ALL WIRING TO BE 16 GA. GXL.
2. SPLICES:
B -ONLY WHERE INDICATED.
BLK -MUST SURVIVE A PULL TEST OF 25 POUNDS.
-ENCLOSED IN A HEAT SHRINK WRAP "REM TECH" DWP-125 OR ANY
EQUIVALENT WITH DUAL WALL EPOXY ENCAPSULATING POLYOLEFIN.
3. LENGTH IS APPROXIMATE.
DS60 AL2
P40
GND
Figure 2-12. Wiring Diagram, Back Up Alarm
2-2-102 CD276
Rev 13
Chapter 2
WIRE ROUTING
F8
F9
P4 P7 P4
FL1
S26 LEGEND
P43
P22 K27
P7
P8
P22 P20
P22
P40 P33
DS64 DS57 DS82 DS83 DS80 DS81 DS75 DS74 DS76 DS77 DS72 DS73
NOTES:
Figure 2-13. Wiring Diagram, Marker Clearance Light

Sheet 1 of 2
CD276 2-2-103
Rev 13
Chapter 2
Figure 2-13. Wiring Diagram, Marker Clearance Light

Sheet 2 of 2
2-2-104 CD276
Rev 13
Chapter 2
Figure 2-14. Electrical Equipment Location

Sheet 1 of 7
CD276 2-2-105
Rev 13
Chapter 2
P19

Sheet 2 of 7
2-2-106 CD276
Rev 13
Chapter 2

Sheet 3 of 7
CD276 2-2-107
Rev 13
Chapter 2
GPU
LEFT SIDE RIGHT SIDE
GPU
GND8
AC CABLE
DS68/P47
A2/P5/P6/P53
A9, CR13/CR15
STANDARD REAR LIGHTS STANDARD REAR LIGHTS DS67
INTERCOM JACK
INTERCOM JACK
REAR STATION PANEL

S37
DS65/P46 DS66/P45 S24 S30
REAR VIEW WITH REAR STATION AND GPU
TOP VIEW WITH REAR STATION AND GPU

CAMERA EYE OPTIONAL EQUIPMENT
DS68/P47 SEE SHEET 7 FOR LEGEND
DS78
DS79 AL2
A9
REFLECTOR
GND8
INTERCOM JACK
REAR VIEW WITHOUT REAR STATION

Sheet 4 of 7
2-2-108 CD276
Rev 13
Chapter 2
S1 S2
DS9
S4
S8 S9
S11 S12 S13
NOTE: S15

S16 SEE SH.3, ZONE F3
DS26
DS25
DS28
DS27
P37
DS29
S19
DS30
REAR CAB OPTION PANEL
DS31 SEE SH.3, ZONE F3
DS24

Sheet 5 of 7
CD276 2-2-109
Rev 13
Chapter 2

Sheet 6 of 7
2-2-110 CD276
Rev 13
Chapter 2

Sheet 7 of 7
CD276 2-2-111
Rev 13
Chapter 2
S25/P109 B5
K19 K20
HYD. STEERING
CONTROL BOX/P13 K21
(SEE SH. 4 FOR LAYOUT) S28 K22
K23
L10/P100, L11/P103 K24
K20-K25 L13/L14/P54
(SEE DETAIL A) K25
R2/P23
RIGHT SIDE
(SEE NOTE 1)
FUSE BOX/P4 S41

(SEE SH. 4 FOR LAYOUT)
S29/P108
GND6 P9
DS37, DS69 DS57

DS35/P32 INTERCOM JACK
REMOVABLE SEAT
DS60 (UNDER LIGHT ASM.)

DS59/DS58 DETAIL A
GND2 P40 BEHIND LIGHTS
INTERCOM JACK
2
FL1 P22 NOTE:
P21 SEE SHEET 2 FOR
P9 CAT ENGINE COMPONENTS. 1. REFER TO ENGINE MANUAL FOR EXACT LOCATION.
CR9-CR12/P51
P8 SEE SHEET 3 FOR
CR22-CR25/P64
P7 DEUTZ ENGINE COMPONENTS R5
REFERENCE S&S DRAWINGS:
GND8 FIGURE 5.1.12 (PAGE 5−1−55 − 5−1−63) REFERENCE DESIGNATORS/PART NUMBERS INDEX
S23 FIGURE 5.1.10 (PAGE 5−1−35 − 5−1−44) FRONT & REAR CAB (STATIONS) SCHEMATIC
S26/P43 P39 BEHIND LIGHTS FIGURE 5.1.11 (PAGE 5−1−45 5−1−54) SINGLE CAB (STATION) SCHEMATIC WITH DEUTZ ENGINE
DS34/P33 DS62/DS63 FIGURE 5.1.17 (PAGE 5−1−98 − 5−1−106) SINGLE CAB (STATION) SCHEMATIC, WITH CAT ENGINE
DS36, DS70 DS61/ FIGURE 5.1.13 (PAGE 5−1−64 − 5−1−79) WIRING DIAGRAM WITH DEUTZ ENGINE
H1/P62
DS64 FIGURE 5.1.18 (PAGE 5−1−107 − 5−1−117) WIRING DIAGRAM WITH CAT ENGINE
UNDER HEADLIGHT ASM.
FIGURE 5.1.14 (PAGE 5−1−80 − 5−1−90) ELECTRICAL EQUIPMENT LOCATION:
LEFT SIDE
SHEET 1 − STANDARD EQUIPMENT, TRACTOR WITHOUT ENGINE
GND7 SHEET 2 − STANDARD EQUIPMENT, TRACTOR WITH CAT ENGINE
FRONT DASH PANEL BT1, BT2 SHEET 3 − STANDARD EQUIPMENT, TRACTOR WITH DEUTZ ENGINE
SHEET 4 − STANDARD EQUIPMENT, PANEL AND CONTROL BOXES
GND1 P42 GND3 SHEET 5 − OPTIONAL EQUIPMENT, TRACTOR
S43
SHEET 6 − OPTIONAL EQUIPMENT, TRACTOR, REAR VIEWS
F21 SHEET 7 − OPTIONAL EQUIPMENT, FRONT DASH PANELS
A4/P24
R6/P16 SHEET 8 − OPTIONAL EQUIPMENT, REAR PANEL AND CONTROL BOXES
HYD. PRESS GAUGE A3 (L1-5) P15 SHTS.9−11 − LEGEND
(SEE NOTE 1)
A1/P1,P2,P52
S27
INTERCOM JACK S43 F21 L13,L14/P54
A3 (L1-5) P15 DS57-DS60 HYD. STG CONTROL BOX
BT1, BT2 P40 S41
GND8 GND6
GND7
GND3
R5
DS61-DS64 DS35,DS37,DS69
S23 P42
P32
F E D C B A
P39
S26/P43
A1
DS34,DS36,
DS70/P33
GND1 S27
H1/P62 FUSE BOX/P4
P1/P2/P52 K19
R6/P16 L11/P103 S28 B5
A4/P24 (R6 LOCATED IN TRANSMISSION) S29/P108 S25/P109
LEFT SIDE S42 (SEE NOTE 1)
L10/P100
RIGHT SIDE STANDARD EQUIPMENT - WITHOUT ENGINE
SEE SHEETS 9-11 FOR LEGEND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Figure 2-15. Electrical Equipment Location Cat & Deutz Engines

Sheet 1 of 11
2-2-112 CD276
Rev 13
Chapter 2

Cat & Deutz Engines, Sheet 2 of 11
GND P17/P18
K31
A7,B1,L17,F17
S55, R7
G1
R3
RIGHT SIDE
R4
R11
S54
REMOVABLE SEAT
B C A
D E A B C
LEFT SIDE
CB2
L6 F21 E3
S56 S55 R4
R7 L6
G1
S56 S54 F21 CB2

E3 GND
F E D C B A
A B C D E
A B C
P17, P18 CAT ENGINE EQUIPMENT

R11 K31
R3 SEE SHEETS 9 -11 FOR LEGEND
LEFT SIDE K19
A7,B1,L17,F17
RIGHT SIDE
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
CD276 2-2-113
Rev 13
Chapter 2

P17, E4
P18 (YEL) Cat & Deutz Engines, Sheet 3 of 11
R7 (SEE NOTE 1)
A8/P41
GP1-GP6 L7
(SEE NOTE 1) K31/P38 R4 (SEE NOTE 1)
RIGHT SIDE
L6
G1
REMOVABLE SEAT
14089
9 36
C
E
A
D F
NOTE:
1. REFER TO ENGINE MANUAL FOR EXACT LOCATION.
LEFT SIDE
R1/P48
E2 CB1
CB2
A7/B1/L17 E3
(INSIDE ENGINE) F17
(SEE NOTE 1)
L6 A8/P41
P17
GP1-6 P18 (YEL)
L7 E4
F17 (SEE NOTE 1)
CB1 R7
CB2 K31/P38 -(ON WELDMENT)
R4 G1
E2 E3
F E D C B A
R3 DEUTZ ENGINE EQUIPMENT

R1/P48 A7/B1/L17
(INSIDE ENGINE) RIGHT SIDE SEE SHEETS 9-11 FOR LEGEND
(SEE NOTE 1) LEFT SIDE
56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
2-2-114 CD276
Rev 13
Chapter 2

EMERGENCY DS2
ENGINE STOP
DS1 DS3 DS4 DS5 DS6
GA1/DS33 DS13 SEE VIEW ’A’ FOR
DEUTZ ENGINE GA2/DS15 GA5/DS18 DS14
ARRANGEMENT. BLANK BLANK BLANK
FOR
FOR FOR
S21 FUTURE FUTURE FUTURE
USE
SEE VIEW ’B’ FOR BLANK P
− + USE USE
E LOW F CAT ENGINE

ARRANGEMENT. − +
DS7 DS8 DS11 DS12

BEHIND S20
S20 BLOWER FAN
S6 S7
SWITCH CR16 DASH LIGHT LOW − HI
ON
BLANK
BLANK FOR
FUTURE
NORMAL FOR
FUTURE USE
USE
LOW
OFF HIGH
RUN STEERING HITCH HITCH
STOP START GA4/DS17 GA3/DS16
DS21 P29
COORD
BLANK BLANK GA6/DS19 GA7/DS20 BLANK BLANK BLANK DS22
FOR FOR FOR FOR FOR
FUTURE FUTURE FUTURE FUTURE FUTURE TRACK
USE USE USE USE USE STEER
MODE
DS23
CRAB
S22
S10 S14/DS32 12941721
FRONT DASH PANEL
F22 (SEE SH. 1 FOR UNIT LOCATION)
P19
P28 F16 F13
HYDRAULIC STEERING CONTROL BOX F12 F9
(SEE SH. 1, FOR UNIT LOCATION)
30
20
15
14
16
15
13
20
20
20
15
10
12
11
9
VIEW A - DEUTZ ENG VIEW B - CAT ENG
10
10
10
8 7 6 5 8 7 6 5 USE FOR DEUTZ ENGINE PANEL USE FOR CAT ENGINE PANEL
ONLY, REF. P.N. 12941720. ONLY, REF. P.N. 12980022.
5
3 2 1 11 10 9 3 2 1 11 10 9 4 3 2 1 4 3 2 1
20
10
10
10
DS1 DS2 DS3 DS1 DS2 DS3
1
F8 F5
4 5 6 7 8 4 5 6 7 8 14 13 14 13
F4 F1
12 11 10 9 12 11 10 9 BLANK
P26 (CR1-4)
K9 K10 K11 K12 LOW BLANK BLANK BLANK

K30 COOL
E1 DS7 DS8 DS9 DS7 DS8 DS9

P13
BOX COVER NOT SHOWN.

STANDARD EQUIPMENT
BOX COVER NOT SHOWN.
FUSE BOX
(SEE SH. 1 FOR UNIT LOCATION)
P4
82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108
CD276 2-2-115
Rev 13
Chapter 2

ENGINE COOLANT HEATER BOX/P60
L18/P104 HYD.STEERING L12/P50

A11
L19/P105 CONTROL BOX/P14 L8/L9/P56
GND4 (SEE SH. 8 FOR LAYOUT)
K26-K29
RIGHT SIDE
L13/L14/P54 (RELOCATED)
R9 S38 SEE DETAIL B
L15/L16/P55
REMOVABLE SEAT
AC CABLE B2
B3/P31
DETAIL B
A6/P44
DS39/P34
FL2
AL1 CENTER K29
P20 CONSOLE K28
H3 P59
SEE SH.6 K27
S39
FOR OPTIONAL K26
TRACTOR REAR P57/CR18-CR21
DS71 LAYOUTS
H2 FRESH AIR SWITCH
AL3
B4/P30
OPTION PANELS
LEFT SIDE
R8
CONTROL BOX/P10,P12
(SEE SH. 8 FOR LAYOUT) K36
S40 B8 A10/P58
(INSIDE CAB) (INSIDE CAB)
CAB INTERIOR
HYD. STG. CONTROL BOX/P14

L19/P105, L18/P104
L13/L14/P54
DS38 CONTROL BOX/P10,P12 DS71
DS71 ETHER AID T'STAT L15/L16/P55 L8/L9/P56 GND4 H3
B8 S38
A10/P58 L12/P50
S39
(MIDDLE OF CAB)
B6/B7
P59 ETHER AID T'STAT
DS39/P34
AL1
DS81
K36 AL3 DS80 (OPPOS. SIDE)
CAB INTERIOR - LEFT DOOR REMOVED CAT ENGINE ONLY OPTION

A11 RIGHT SIDE OPTIONAL EQUIPMENT
109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135
2-2-116 CD276
Rev 13
Chapter 2

OPTIONAL HITCH
GPU
GPU
GND8
AC CABLE
DS68/P47
(RELOCATED) A2/P5/P6/P53
A9, CR13/CR15
STANDARD REAR LIGHTS STANDARD REAR LIGHTS DS67
(RELOCATED) (RELOCATED)
INTERCOM JACK
INTERCOM JACK
REAR STATION PANEL/P35,P36

DS65/P46 DS66/P45 (SEE SH. 8 FOR LAYOUT) S37
S24 S30
REAR VIEW WITH REAR STATION AND GPU
TOP VIEW WITH REAR STATION AND GPU
DS68/P47 CAMERA EYE
DS79 AL2 DS78
A9
CR13/CR15
REFLECTOR GND8
INTERCOM JACK
OPTIONAL EQUIPMENT
REAR STATION SIDE VIEW SEE SHEETS 9-11 FOR LEGEND
REAR VIEW WITHOUT REAR STATION
136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160
CD276 2-2-117
Rev 13
Chapter 2

EMERGENCY
S1 S2 Cat & Deutz Engines, Sheet 7 of 11
ENGINE STOP
BLANK
FOR
FUTURE
LOW - + USE
BLANK P
COOL
E LOW F
- +
S4 DS9
BLOWER FAN
DASH LIGHT LOW - HI
ON BLANK
FOR
FUTURE
NORMAL USE
LOW
OFF HIGH
RUN S8 S9 STEERING HITCH HITCH
STOP START
COORD
TRACK
STEER
MODE CRAB
S11 S12 S13 12941721

CAB LIFT
RAISE
NOTE:
S15
INDICATES STANDARD PANEL COMPONENTS,
SEE SH. 1 FOR UNIT LOCATION
LOWER

S16 SEE SH. 5 FOR LOCATION
BLANK
FOR
BLANK
FOR USE BLANK PLATE
FUTURE FUTURE P.N. 12941837
USE USE IF UNIT IS NOT
LIFT CAB TYPE
12941722
DS26
FRONT DS25
CAB SHIFTERS G
SELECTED IN NEUTRAL
REAR DS28
DS27 FRONT PARK R
BRAKE SW ON P37
FRONT DASH PANELS DS29
REAR PARK R
OPTIONAL EQUIPMENT CAB
S19 BRAKE SW ON
SEL.
DS30
SEE SHEETS 9-11 FOR LEGEND PARK BRAKE R
APPLIED
REAR
DS31 REAR CAB OPTION PANEL
R AXLE CENTER A
SEE SH. 5 FOR LOCATION
DS24 INDICATOR USE BLANK PLATE
REAR SHIFTER P.N. 12941836
NOT IN NEUTRAL IF REAR CAB OPTION
12941723 IS NOT FURNISHED
163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189
2-2-118 CD276
Rev 13
Chapter 2

P14 K35
P27 (CR5-8)
TB1
K14 K15
P60
COOLANT HEATER BOX
HYDRAULIC STEERING CONTROL BOX
DS40 DS41 DS42

DS46
CR14
DS52
S32 DS43 DS47
DS44
P10 S31 DS48
P35
DS49
K1 K2 K3 K4
DS50
DS54
DS55 DS51
P12 DS56
S34 S35 S36 DS53

REAR STATION (CAB) PANEL
K6 K7 K8
OPTIONAL EQUIPMENT
CONTROL BOX P36
CD276 2-2-119
Rev 13
Chapter 2

SH. NO. - GRID LOCATION ITEM DESCRIPTION SH. NO. - GRID LOCATION ITEM DESCRIPTION SH. NO. - GRID LOCATION ITEM DESCRIPTION
CAT DEUTZ BOTH CAT DEUTZ BOTH
CAT DEUTZ BOTH
− − 1−2 A1 ASSEMBLY ZF FRONT CAB SHIFTER − − 1−1 CR 2 RECTIFIER ENGINE WARNING ALARM, COOLANT LEVEL LT.
− − 8−208 DS 46 LIGHT FRONT SHIFTER NOT IN NEUTRAL INDICATOR (REAR)
− − 6−150 A2 ASSEMBLY ZF REAR CAB SHIFTER − − 1−1 CR 25 RECTIFIER ENGINE WARNING ALARM, TRANSMISSION TEMP. LT.
− − 8−208 DS 47 LIGHT SHIFTERS IN NEUTRAL INDICATOR (REAR)
− − 1−8 A3 ASSEMBLY TRANSMISSION VALVE BODY − − − CR ##
− − 8−208 DS 48 LIGHT FRONT PARK BRAKE "ON" INDICATOR (REAR)
− − 1−2 A4 ASSEMBLY CONTROL UNIT (DOWNSHIFT) LOCK−UP − − 4−89 DS 1 LIGHT LEFT TURN INDICATOR
− − 8−208 DS 49 LIGHT REAR PARK BRAKE "ON" INDICATOR (REAR)
− − N/S A5 ASSEMBLY RESERVED − − 4−89 DS 2 LIGHT LOW OIL PRESSURE INDICATOR
− − 8−208 DS 50 LIGHT PARK BRAKE APPLIED INDICATOR (REAR)
− − 5−126 A6 ASSEMBLY CAB, HEATER − FAN − 4−90 − DS 3 LIGHT GLOW PLUG INDICATOR
− − 8−208 DS 51 LIGHT AXLE CENTER INDICATOR (REAR)
2−36 3−62 − A7 ASSEMBLY STARTER MOTOR (SOLENOID AND MOTOR) − − 4−95 DS 4 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR
− − 8−209 DS 52 LIGHT FRONT CAB SELECT INDICATOR (REAR)
− 3−63 − A8 ASSEMBLY ECU GLOW PLUG − − 4−95 DS 5 LIGHT HIGH BEAM INDICATOR
− − 8−208 DS 53 LIGHT REAR CAB SELECT INDICATOR (REAR)
− − 6−151 A9 ASSEMBLY DIODE MODULE (DIODES CR13 AND CR15) − − 4−96 DS 6 LIGHT RIGHT TURN INDICATOR
− − 8−205 DS 54 LIGHT COORD STEERING MODE INDICATOR (REAR)
− − 5−112 A 10 ASSEMBLY CAB, REAR WINDOW DEFROSTER − 4−89 − DS 7 LIGHT LOW COOLANT LEVEL INDICATOR
− − 8−205 DS 55 LIGHT TRACK STEERING MODE INDICATOR (REAR)
− − 5−115 A 11 ASSEMBLY ENGINE COOLANT, TANK HEATER − − 4−89 DS 8 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR
− − 8−205 DS 56 LIGHT CRAB STEERING MODE INDICATOR (REAR)
− − − A ## − − 7−171 DS 9 LIGHT HEATED MIRROR "ON" INDICATOR
− − 1−14 DS 57 LIGHT TURN, REAR, RIGHT HAND
− − 5−109 AL 1 ALARM CAB RAISE/LOWER − − N/S DS 10 LIGHT RESERVED
− − 1−14 DS 58 LIGHT BRAKE, RIGHT HAND
− − 6−143 AL 2 ALARM BACK−UP − − 4−95 DS 11 LIGHT PARK BRAKE APPLIED INDICATOR
− − 1−14 DS 59 LIGHT TAIL, RIGHT HAND
− − 5−126 AL 3 ALARM ENGINE/TRANSMISSION TROUBLE WARNING − − 4−96 DS 12 LIGHT GENERATOR NO CHARGE INDICATOR
− − 1−14 DS 60 LIGHT BACK−UP, RIGHT HAND
− − − AL # − − 4−88 DS 13 LIGHT FRONT DASH PANEL, LEFT HAND
− − 1−14 DS 61 LIGHT BACK−UP, LEFT HAND
2−36 3−62 − B1 MOTOR STARTER − − 4−97 DS 14 LIGHT FRONT DASH PANEL, RIGHT HAND
− − 1−14 DS 62 LIGHT TAIL, LEFT HAND
− − 5−126 B2 MOTOR WINDSHIELD WASHER PUMP − − 4−92 DS 15 LIGHT ENGINE COOLANT TEMPERATURE GAUGE
− − 1−14 DS 63 LIGHT BRAKE, LEFT HAND
− − 5−126 B3 MOTOR WINDSHIELD WIPER, RIGHT HAND − − 4−94 DS 16 LIGHT ENGINE OIL PRESSURE GAUGE
− − 1−14 DS 64 LIGHT TURN, REAR, LEFT HAND
− − 5−126 B4 MOTOR WINDSHIELD WIPER, LEFT HAND − − 4−92 DS 17 LIGHT TRANSMISSION OIL TEMPERATURE GAUGE
− − 6−139 DS 65 LIGHT REAR LEFT HEAD
− − 1−8 B5 MOTOR EMERGENCY STEERING PUMP − − 4−94 DS 18 LIGHT VOLTMETER
− − 6−144 DS 66 LIGHT REAR RIGHT HEAD
− − 5−109 B6 MOTOR CAB DEFROSTER/COOLING, RIGHT HAND − − 4−90 DS 19 LIGHT TACHOMETER
− − 6−151 DS 67 LIGHT DASH (REAR)
− − 5−109 B7 MOTOR CAB DEFROSTER/COOLING, LEFT HAND − − 4−96 DS 20 LIGHT SPEEDOMETER
− − 6−140 DS 68 LIGHT REAR HITCH
− − 5−111 B8 MOTOR CAB ROOF WIPER − − 4−103 DS 21 LIGHT COORD STEERING MODE INDICATOR
− − 1−1 DS 69 LIGHT PARK, FRONT, RIGHT HAND
− − − B ## − − 4−103 DS 22 LIGHT TRACK STEERING MODE INDICATOR
− − 1−1 DS 70 LIGHT PARK, FRONT, LEFT HAND
− − 1−10 BT 1 BATTERY 12V − − 4−103 DS 23 LIGHT CRAB STEERING MODE INDICATOR
− − 5−109 DS 71 LIGHT BEACON, ROTATING
− − 1−11 BT 2 BATTERY 12V − − 7−184 DS 24 LIGHT REAR SHIFTER NOT IN NEUTRAL INDICATOR
− − 6−144 DS 78 LIGHT REAR DRIVING, RIGHT HAND
− − − BT ## − − 7−185 DS 25 LIGHT SHIFTERS IN NEUTRAL INDICATOR
− − 6−140 DS 79 LIGHT REAR DRIVING, LEFT HAND
− 3−64 − CB 1 CIRCUIT B. GLOW PLUG, 120A − − 7−184 DS 26 LIGHT FRONT CAB SELECTED INDICATOR
− − 5−134 DS 80 LIGHT TURN, FRONT SIDE, LEFT HAND
2−37 3−64 − CB 2 CIRCUIT B. MAIN, 120A − − 7−184 DS 27 LIGHT REAR CAB SELECTED INDICATOR
− − 5−134 DS 81 LIGHT TURN, FRONT SIDE, RIGHT HAND
− − − CB ## − − 7−185 DS 28 LIGHT FRONT PARK BRAKE "ON" INDICATOR
− − − DS #
− − 4−91 CR 1−4 RECTIFIER BLOCKING, STEERING − − 7−185 DS 29 LIGHT REAR PARK BRAKE "ON" INDICATOR
− − 4−95 E1 STUD FUSE BOX POWER
− − 8−195 CR 5−8 RECTIFIER BLOCKING, STEERING − − 7−185 DS 30 LIGHT PARK BRAKE APPLIED INDICATOR
− 3−62 − E2 STUD ENGINE POWER
− − 1−1 CR 9 RECTIFIER RESERVED − − 7−185 DS 31 LIGHT AXLE CENTER INDICATOR
2−37 3−64 − E3 STUD BATTERY POWER
− − 1−1 CR 10 RECTIFIER BLOCKING, PARKING BRAKE − − 4−102 DS 32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB)
− 3−61 − E4 STUD GLOW PLUG POWER
− − 1−1 CR 11 RECTIFIER BLOCKING, CAB LIFT − − 4−87 DS 33 LIGHT FUEL LEVEL GAUGE
− − − E ##
− − 1−1 CR 12 RECTIFIER BLOCKING, CAB LIFT − − 1−1 DS 34 LIGHT HEAD, LEFT HAND
− − 6−150 CR 13 RECTIFIER BLOCKING, HITCH LIGHT − − 1−1 DS 35 LIGHT HEAD, RIGHT HAND
− − 8−193 CR 14 RECTIFIER BLOCKING, NEUTRAL LIGHT − − 1−1 DS 36 LIGHT TURN, FRONT, LEFT HAND
− − 6−151 CR 15 RECTIFIER BLOCKING, HITCH LIGHT − − 1−1 DS 37 LIGHT TURN, FRONT, RIGHT HAND
LEGEND
− − 4−84 CR 16 RECTIFIER BLOCKING, PARKING LIGHTS, 6A − − 5−112 DS 38 LIGHT CAB DOME
− − N/S CR 17 RECTIFIER RESERVED − − 5−109 DS 39 LIGHT FRONT, HITCH
− − 5−126 CR 18 RECTIFIER RESERVED − − 8−206 DS 40 LIGHT GENERATOR NO CHARGE INDICATOR (REAR)
− − 5−126 CR 19 RECTIFIER RESERVED − − 8−207 DS 41 LIGHT LOW OIL PRESSURE INDICATOR (REAR)
− − 5−126 CR 20 RECTIFIER BLOCKING, DOWNSHIFT LOCK − − 8−207 DS 42 LIGHT TRANSMISSION HIGH OIL TEMPERATURE INDICATOR (REAR)
− − 5−126 CR 21 RECTIFIER BLOCKING, DOWNSHIFT LOCK − − 8−206 DS 43 LIGHT LOW COOLANT LEVEL INDICATOR (REAR)
− − 1−1 CR 22 RECTIFIER ENGINE WARNING ALARM, OIL PRESSURE LT. − − 8−207 DS 44 LIGHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR (REAR)
− − 1−1 CR 23 RECTIFIER ENGINE WARNING ALARM, COOLANT TEMP.LT. − − N/S DS 45 LIGHT RESERVED (REAR)

2-2-120 CD276
Rev 13
Chapter 2
LEGEND LEGEND
LEGEND
SH. NO. - GRID LOCATION ITEM DESCRIPTION SH. NO. - GRID LOCATION ITEM DESCRIPTION SH. NO. - GRID LOCATION ITEM DESCRIPTION
CAT DEUTZ BOTH CAT DEUTZ BOTH
CAT DEUTZ BOTH
− − 4−97 F1 FUSE ENGINE, 10A − − 1−8 L 1−5 SOLENOID TRANSMISSION VALVE BODY, ZF/Y1−Y5
− − 6−151 GND8 GROUND CH REAR CAB
− − 4−97 F2 FUSE TRANSMISSION, 10A 2−35 3−62 − L6 SOLENOID ENGINE RUN VALVE
− − 1−14 GND8 GROUND CH REAR LIGHTS
− − 4−96 F3 FUSE STEERING, 10A − 3−63 − L7 SOLENOID EXCESS START FUEL ALLOWANCE
2−34 − − GND GROUND CH ENGINE/WELDMENT
− − 4−96 F4 FUSE REAR WINDOW DEFROSTER, 20A − − 5−117 L8 SOLENOID CAB ORBITAL SELECT VALVE
− − − GND ##
− − 4−97 F5 FUSE PARKING BRAKE, 10A − − 5−117 L9 SOLENOID CAB ORBITAL SELECT VALVE
− 3−60 − GP 1−6 RESISTOR GLOW PLUG
− − 4−97 F6 FUSE CAB RAISE/LOWER, 10A − − 1−10 L 10 SOLENOID PARKING BRAKE SET VALVE
− − − GP ##
− − 4−96 F7 FUSE CAB SELECT, 10A − − 1−11 L 11 SOLENOID PARKING BRAKE RELEASE VALVE
− − 1−1 H1 HORN VEHICLE, FRONT
− − 4−96 F8 FUSE RESERVED − − 5−117 L 12 SOLENOID ACCELERATOR TRANSFER VALVE
− − 5−109 H2 HORN VEHICLE, FRONT, LEFT HAND
− − 4−97 F9 FUSE TURN/BRAKE/BACK−UP LIGHTS, 15A − − 1−12 L 13 SOLENOID COORD SELECT VALVE, SV2−A (OR 1)
− − 5−109 H3 HORN VEHICLE, FRONT, RIGHT HAND
− − 4−97 F 10 FUSE HEATER − COOL FAN, 20A − − 5−118 L 13 SOLENOID COORD SELECT VALVE, SV2−A (OR 1)
− − − H ##
− − 4−96 F 11 FUSE HORN, 20A − − 1−12 L 14 SOLENOID CRAB SELECT VALVE, SV2−B (OR 1)
− − 8−193 K1 RELAY REAR SHIFTER NEUTRAL
− − 4−96 F 12 FUSE INSTRUMENT PANEL, 20A − − 5−118 L 14 SOLENOID CRAB SELECT VALVE, SV2−B (OR 1)
− − 8−193 K2 RELAY REAR PARKING BRAKE SWITCH "ON"
− − 4−97 F 13 FUSE EMERGENCY STEERING, BEACON AND FRONT HITCH,15A − − 5−118 L 15 SOLENOID COORD SELECT VALVE, REAR MODE, SV3−A
− − 8−194 K3 RELAY FRONT PARKING BRAKE SWITCH "ON"
− − 4−97 F 14 FUSE HEADLIGHTS, 20A − − 5−118 L 16 SOLENOID CRAB SELECT VALVE, REAR MODE, SV3−B
− − 8−194 K4 RELAY PARK BRAKE APPLIED
− − 4−96 F 15 FUSE WINDSHIELD WIPER, 30A 2−36 3−62 − L 17 SOLENOID ENGINE STARTER
− − N/S K5 RELAY RESERVED
− − 4−96 F 16 FUSE RESERVED − − 5−111 L 18 SOLENOID CAB RAISE VALVE
− − 8−193 K6 RELAY SHIFTER CHANGE OVER CONTROL
2−37 − − F 17 FUSIBLE LINK, 14 GA. − − 5−111 L 19 SOLENOID CAB LOWER VALVE
− − 8−194 K7 RELAY SHIFTER CHANGE OVER CONTROL
− 3−63 − F 17 FUSE STARTER, 20A − − − L ##
− − 8−195 K8 RELAY CAB SELECT
− − N/S F 18 FUSE RESERVED − − 1−2 P1 CONNECTOR SHIFTER (TRANSMISSION) FRONT CAB (ZF)
− − 4−86 K9 RELAY COORD STEERING, FRONT CONTROL
− − N/S F 19 FUSE RESERVED − − 1−2 P2 CONNECTOR SHIFTER (CAB) FRONT CAB (ZF)
− − 4−88 K 10 RELAY CRAB STEERING, FRONT CONTROL
− − N/S F 20 FUSE RESERVED − − N/S P3 CONNECTOR RESERVED
− − 4−89 K 11 RELAY FRONT AXLE REED SWITCH
− − 1−10 F 21 FUSE EMERGENCY PUMP, 225A − − 4−97 P4 CONNECTOR FUSE BOX
− − 4−90 K 12 RELAY REAR AXLE REED SWITCH
− − 4−82 F 22 FUSE GAUGES, 5A − − 6−150 P5 CONNECTOR SHIFTER (TRANSMISSION) REAR CAB
− − N/S K 13 RELAY RESERVED
− − − F ## − − 6−150 P6 CONNECTOR SHIFTER (CAB) REAR CAB
− − 8−194 K 14 RELAY COORD STEERING, REAR CONTROL
− − 1−1 FL 1 FLASHER TURN SIGNAL LIGHTS − − 1−1 P7 CONNECTOR REAR CAB INTERFACE
− − 8−195 K 15 RELAY CRAB STEERING, REAR CONTROL
− − 5−126 FL 2 FLASHER BEACON LIGHT (FLASHING BEACON) − − 1−1 P8 CONNECTOR MAIN HARNESS INTERFACE
− − − FL ## − − 1−1 P9 CONNECTOR STEERING INTERFACE
2−34 3−60 − G1 GENERATOR 12 VDC, 95A − − 8−191 P 10 CONNECTOR CONTROL BOX
− − − G ## − − N/S P 11 CONNECTOR RESERVED
− − 1−8 K 19 RELAY EMERGENCY STEERING PUMP MOTOR
− − 4−87 GA 1 GAUGE FUEL LEVEL, W/ 1/8 WARNING − − 8−191 P 12 CONNECTOR CONTROL BOX CAB SELECT
− − 1−2 K 20 RELAY PARK BRAKE ON − STARTER ENABLE
− − 4−91 GA 2 GAUGE ENGINE COOLANT TEMPERATURE − − 4−82 P 13 CONNECTOR STEERING BOX (STANDARD)
− − 1−2 K 21 RELAY SHIFTER IN NEUTRAL
− − 4−93 GA 3 GAUGE ENGINE OIL PRESSURE − − 8−191 P 14 CONNECTOR STEERING BOX (OPTIONAL)
− − 1−2 K 22 RELAY HORN
− − 4−91 GA 4 GAUGE TRANSMISSION OIL TEMPERATURE − − 1−8 P 15 CONNECTOR TRANSMISSION SOLENOID VALVES
− − 1−2 K 23 RELAY TRANSMISSION NOT IN N−, PARK BRAKE APPLIED
− − 4−93 GA 5 GAUGE VOLTMETER − − 1−10 P 16 CONNECTOR SPEED SENSOR (ZF)
− − 1−2 K 24 RELAY SHIFTER, BACK−UP
− − 4−89 GA 6 GAUGE TACHOMETER 2−35 3−61 − P 17 CONNECTOR ENGINE PLUG
− − 1−2 K 25 RELAY LOCK−UP UNIT (DOWNSHIFT)
− − 4−95 GA 7 GAUGE SPEEDOMETER 2−35 3−61 − P 18 CONNECTOR ENGINE PLUG (YELLOW ON DEUTZ)
− − 5−128 K 26 RELAY LIGHTS TRANSFER
− − − GA ## − − 4−91 P 19 CONNECTOR INSTRUMENT GAUGES
− − 5−128 K 27 RELAY PARKING LIGHTS TRANSFER
− − 1−2 GND1 GROUND CH FRONT CAB, LEFT HAND − − 5−126 P 20 CONNECTOR CEILING INTERFACE
− − 5−128 K 28 RELAY REAR SHIFTER BACK−UP
− − 1−1 GND2 GROUND CH FRONT CAB, RIGHT HAND − − 1−1 P 21 CONNECTOR FRONT LIGHTS
− − 5−128 K 29 RELAY UPSHIFT INHIBITOR TRANSFER
− − 1−5 GND3 GROUND CH STEERING BOX − − 1−14 P 22 CONNECTOR REAR LIGHTS
− − 4−98 K 30 RELAY IGNITION (MASTER)
− − 5−111 GND4 GROUND CH LIFT CAB VALVES − − 1−10 P 23 CONNECTOR TURBINE SPEED SENSOR (ZF)
2−35 3−62 − K 31 RELAY STARTER SOLENOID AUXILIARY
− − N/S GND5 GROUND CH RESERVED − − 1−3 P 24 CONNECTOR CONTROL UNIT (DOWNSHIFT) LOCK−UP
− − 8−200 K 35 RELAY RUN SOLENOID DISCONNECT
− − 1−11 GND6 GROUND CH STEERING VALVES − − N/S P 25 CONNECTOR RESERVED
− − 5−128 K 36 RELAY TIMER (11 MIN) REAR WINDOW DEFROSTER
− − 1−11 GND7 GROUND CH BATTERY
− − − K ##
LEGEND

CD276 2-2-121
Rev 13
Chapter 2
LEGEND LEGEND
SH. NO. - GRID LOCATION ITEM DESCRIPTION SH. NO. - GRID LOCATION ITEM DESCRIPTION
LEGEND Figure 2-15. Electrical Equipment Location

2-2-122 CD276
Rev 13
Chapter 2
128 128 128

128
10A 121
103 215
H
11
103 103
B 215 ITEM DESCRIPTION
103 * CR1-4 RECTIFIER BLOCKING, STEERING
3 4 10 CR28-31 RECTIFIER BLOCKING, STEERING
A CR32 RECTIFIER BLOCKING, STEERING
* DS21 LIGHT COORD STEER MODE INDICATOR
8 1 * DS22 LIGHT TRACK STEER MODE INDICATOR
JPR 6 2 5 7 9 * DS23 LIGHT CRAB STEER MODE INDICATOR
COORD TRACK CRAB
198 206 202 * DS32 LIGHT AXLE CENTER INDICATOR (SINGLE CAB)
B * F 3 FUSE STEERING, 10A
E C G K A RELAY STEERING MODE "ON" INTERLOCK
K B RELAY FRONT AXLE OFF CENTER
103 103 103 191 * K 9 RELAY COORD STEERING FRONT CONTROL
E C G *
280 9 5 198 K 10 RELAY CRAB STEERING FRONT CONTROL
202 * K 11 RELAY FRONT AXLE REED SWITCH
L * K 12 RELAY REAR AXLE REED SWITCH
1 * L 13 SOLENOID COORD SELECT VALVE, SV2-A (OR 1)
280 A 206 * L 14 SOLENOID CRAB SELECT VALVE, SV2-B (OR 1)
191 280 * P 4 CONNECTOR FUSE BOX
* P 9 CONNECTOR STEERING INTERFACE
B B 198 P 11 CONNECTOR PASSIVE CENTERING
B B B *
RED RED RED 1 C C 9 P 13 CONNECTOR STEERING BOX (STD)
P 25 CONNECTOR DIODE MODULE, STEERING (CR28-CR31)
WHT WHT WHT NC NO NC NO
1 * P 26 CONNECTOR DIODE MODULE, STEERING (CR1-CR4)
C C C 4 5 5 * P 29 CONNECTOR STEER MODE INDICATOR LIGHTS
C A C A 202 *
BLK BLK BLK
P 42 CONNECTOR REAR CAB STEER INTERFACE
149 A A A 281 282 * P 54 CONNECTOR COORD /CRAB SELECT VALVE, FRONT MODE
B C 10 P 72 CONNECTOR RIGHT TURN SWITCH
167 191
P 73 CONNECTOR LEFT TURN SWITCH
215 2 P 74 CONNECTOR FRONT AXLE OFF CENTER SWITCH
281 282 6
4 11 11 * P 108 CONNECTOR REAR AXLE REED SWITCH
5 9 * P 109 CONNECTOR FRONT AXLE REED SWITCH
12 211 210
* S 14 SWITCH STEER MODE SELECT
215 188 286 1 9 8 9 8 1 5 4 8 * S 25 SWITCH FRONT AXLE REED
283 * S 29 SWITCH REAR AXLE REED
P25/ S 49 SWITCH FRONT AXLE OFF CENTER
168 166 203 S 52 SWITCH RIGHT TURN
283 11 3 284 E D 206
D C 11 S 53 SWITCH LEFT TURN
F D J K A
140 211 7
H B D 7 3
285 166 203 237
188 F D A P26/ P26/ 1. ALL RELAYS AND SWITCHES SHOWN DE-ACTUATED (DE-ENERGIZED).
215 P25/ P25/ 285 2. / * INDICATES EXISTING WIRING/COMPONENTS.
E F
168 166 GRN WHT 203 3. INDICATES NEW/ADDED WIRING.
H A B G
125
P25/ P26/ D P26/
C
215 B A C F 211 B H
C G A
285 286 SHEET 2 FOR WIRING DIAGRAM.
280 211 213 201 210 SHEET 3 FOR EQUIPMENT LOCATION AND HYDRAULIC
COM
14 14 14 E D 14 10 6 6 10 STEERING CONTROL BOX.
COORD BLK CRAB F S R R S
13 13 13 13 2 3 3 2
STEERING

Passive Centering Kit, Single Cab
Sheet 1 of 3
CD276 2-2-123
Rev 13
Chapter 2
(P) (S)
P11
K11
K12
P13
SP1
P25 (S)
KA KB
CR28-CR31
(P) (S)
SA P74 CR32 P25
SPL280
(P) (S) (S) (P) SPL103
S53 P73 P72 S52
HYD. STEERING CONTROL BOX
NOTES:
KB
KA
(S)
(P)
WIRE IDENTIFICATION
RELAY CONTACT ARRANGEMENT

Sheet 2 of 3
2-2-124 CD276
Rev 13
Chapter 2
(REF) S25/P109
(SEE VIEW B)
HYD.STEERING
CONTROL BOX
(SEE BELOW) S49/P74
AIR
CLEANER
S52/P72
S53/P73
FRONT DASH
PANEL (REF)
NOTES:
1. NUT & LOCKWASHER TO MOUNT RECEPTACLE TO PANEL
PANEL (REF) HYD.STEERING CONTROL BOX,
REFER TO ZONE H8 FOR ARE PART OF PLUG KIT.
LOCATION ON UNIT - REMOVE HOLE COVER AND USE EXISTING HOLE IN BOX TO MOUNT P11.
2. CABLE ROUTING NOT SHOWN. SECURE HARNESS TO EXISTING
BOX PLATE USING INSULATED CLAMPS.
3. RELAYS ARE NOT SHOWN.
4. MOUNTING:
- DRILL & TAP 2 MOUNTING HOLES (FOR #8 SCREWS) IN
EXISTING BOX PLATE.
FLAT (TYP)
- USE #8 X 3/8" SCREW (2), #8 FLAT WASHER FOR MOUNTING
ITEM 1 TO PLATE.
PART OF HARNESS
LEGEND
INDICATES EXISTING COMPONENTS.
INDICATES ADDED COMPONENTS.
SEE NOTES 1 & 2

Sheet 3 of 3
CD276 2-2-125
Rev 13
Chapter 2
FACEPLATE (REF)
EMERGENCY
ENGINE STOP S1 S2
FINISHED SIDE
BLANK
FOR
FUTURE
LOW - + USE
BLANK P
COOL
E LOW F
- +
S4
BLOWER FAN
DASH LIGHT LOW - HI
ON
BLANK
FOR
NORMAL FUTURE
USE
OFF

RUN
START
S8 S9 STEERING HITCH HITCH
STOP
COORD
TRACK
STEER
MODE CRAB
S11 S12 S13

NOTES:
1. REFERENCE DESIGNATORS ARE FOR REFERENCE ONLY
SEE NOTE 1 (TYP)
AND ARE NOT PART OF FACEPLATE.
2. SEE SEPARATE BILL OF MATERIAL.
Figure 2-17. Layout, Optional Components,

Front Cab Control Panel
2-2-126 CD276
Rev 13
Chapter 2
E1
12V BATTERY (BREAKER) 12V BATTERY (BREAKER)
F14
F12 12V PARK SW.
P4 P4
P28
P7 P7
P28
S20
S22 P28
S6
S7
S12
CR16
P28 P7
F22
P4 P7
P8
LEGEND
P7
P7
K30 K48 K49
MASTER IGNITION RELAY HEADLIGHT PARK

START EXTERIOR LIGHTS
NOTES:
Figure 2-18. Schematic, Lights through Ignition

Sheet 1 of 2
CD276 2-2-127
Rev 13
Chapter 2
F13 F8
P4
K49
P4
S13
S10
P20
P8
S41
DS38
Figure 2-18. Schematic, Lights through Ignition

BEACON EMERG STEERING DOME LIGHT Sheet 2 of 2
2-2-128 CD276
Rev 13
Chapter 2
Figure 2-19. Wiring Schematic for Starting, Alternator, Ignition Switch

Sheet 1 of 11
S27
E1
CB2 12V BATTERY (BREAKER)
E3
12V IGNITION SWITCH
F12
BT1 BT2
CB1 P4
P28 LEGEND
P7
S22
F17
F21
P7 S27
P18
P28
F22
A8
P41
P4
K20
P8
K31
P8 P17a P38
K30
P17 10 L7
P17
P17a
P17
7
P18 E4
SEN
K19
NOTES:
L17
M P17 GP1
DS3 8
B5 B1 A7
G1
REFERENCE S&S DRAWINGS:
EMERG STEERING ALTERNATOR START MOTOR COLD START HEATER CONTROL CIRCUIT MASTER IGNITION RELAY EXCESS
PUMP START VOLUME
SOLENOID
ENGINE
CD276 2-2-129
Rev 13
Chapter 2

K32, K33
12V IGNITION SWITCH
12V PARK SWITCH
F1 P8
P8 P7
AL3
P4 AL3
P8 K32
P7
AL3
P28 GA3 GA2
S21 P64 BRAKE
FAILURE
LIGHT DS4
K33
DS2
P64
CR24
CR23
CR22
CR25
P28
P19 P19
WIRING DIAGRAM
P7
K33 P8
P42
P8 LEGEND
P42
K32
P17 P17
NOTES:
NC NO
R7 R4 S42
L6
BRAKE
AUTOMATIC RUN OIL COOLANT FAILURE TRANSM.
ENGINE SHUTDOWN SOLENOID PRESSURE TEMP SWITCH TEMP.
ENGINE
SCHEMATIC DIAGRAM Figure 2-19. Wiring Schematic for Starting, Alternator, Ignition Switch
Sheet 2 of 11
2-2-130 CD276
Rev 13
Chapter 2
S27

F2
P7 P7 P4
LEGEND
S27 P52
A1
P2
P1 P2
P2
P7
P1
P2
P7 K25
K21
P7
P24
A4
P8
P24
R2
P23
A3
P15

TRANSMISSION

Sheet 3 of 11
CD276 2-2-131
Rev 13
Chapter 2
S27 P7 Figure 2-19. Wiring Schematic for Starting, Alternator, Ignition Switch
Sheet 4 of 11

F5 F7
P4 P7
P4
P7
S27
LEGEND
DS11 P7
P51
P7 P7
P7
K23
P9
P8
L10 L11
P100 P103
S28
PARKING BRAKE
2-2-132 CD276
Rev 13
Chapter 2
F13 F8
P4
K49
P4
S13
S10
P20
P8
S41
DS38

BEACON EMERG STEERING DOME LIGHT Sheet 5 of 11
CD276 2-2-133
Rev 13
Chapter 2
E1
12V BATTERY (BREAKER) 12V BATTERY (BREAKER)
F14
F12 12V PARK SW.
P4 P4
P28
P7 P7
P28
S20
S22 P28
S6
S7
S12
CR16
P28 P7
F22
P4 P7
P8
LEGEND
P7
P7
K30 K48 K49

Sheet 6 of 11
MASTER IGNITION RELAY HEADLIGHT PARK

START EXTERIOR LIGHTS
2-2-134 CD276
Rev 13
Chapter 2

12V PARK SW
F11 F10 F15 F6 LEGEND
P4 P4 P4 P4
S15
S1 S2
K22
P20
P21
P20 P20 P62 P20 S39

H1
S4
H2
S40 CR12
P20 P51
H3
CR11
P7 S38 P51
P20
B2
DS38 S23 A6 B6 B7 B4 B3 B8 L18 L19
P44 P30 P31 AL1
P105 P104

CAB

Sheet 7 of 11
CD276 2-2-135
Rev 13
Chapter 2

12V PARK SW. P61
F9 F13 F4
LEGEND
P4 P4
P4
P8
S13 S11
FL1
P7
K36
S26
P43
S10
S43
K35
FL2
P22 P58
P8 P8
P20 P8 P21 S8
P22 P21 P22 P21 P60
A10 M
DS1 DS64 DS36 DS6 DS57 DS37 DS63 DS58 DS71 S41 DS39
P39 P33 P40 P32 P39 P40 P34
A11
TURN SIGNALS
LIGHT
EXTERIOR LIGHTS

Sheet 8 of 11
2-2-136 CD276
Rev 13
Chapter 2
12V IGNITION
F3
P4
P9 P9
LEGEND
S14
P42
P42 P9
P13
P13
P11 KA
P73 P72
K9 S33 S32 K11
S29 S25 S49 L.T. R.T.
P108 P109 P74
P73 P72
K11
P11
K9 K10
KB
K10
P25/
CR31
P42 P42
K11 K12
P13 P11 P13
CR32 NOTES:
P9 P26/ P26/
P25/ P25/ P9 CR4 CR3
CR28 CR29
P25/ P26/ P26/
CR30 CR2 CR1
REFER TO:
DS22 DS21 DS23
P29 P29 L13 L14 P29
K12 KB K11 KB KA K9 K10 K9 K10
P54 P54
REAR FRONT AXLE TRACK COORD CRAB RELAY LOGIC

REED SWITCH SOLENOID CONTROL
STEERING

Sheet 9 of 11
CD276 2-2-137
Rev 13
Chapter 2
P11
CR32
P25
KB (CR28-CR31)
KA
NOTES:

Sheet 10 of 11
2-2-138 CD276
Rev 13
Chapter 2
S25/P109
HYD.STEERING
CONTROL BOX
S49/P74 FRONT AXLE REED SWITCH OPERATION
RIGHT SIDE
S52/P72
S53/P73
FRONT MODE AXLE REED SWITCH(ES) ARRANGEMENT
LEFT SIDE
VIEW B
FRONT DASH PANEL
NOTES:
P11
K9 K10 K11 K12
CR32
P25
KB (CR28-CR31)
P13 KA
LEGEND

Sheet 11 of 11
CD276 2-2-139
Rev 13
Chapter 2
2-2-140 CD276
Rev 13
Chapter 3
CHAPTER THREE: OVERHAUL

TABLE OF CONTENTS
SECTION 1: OVERHAUL DATA................................................................................................. 3-1-1

A. Model GT-110 Tow Tractor Overhaul .................................................................... 3-1-1
B. Engine .................................................................................................................. 3-1-1
C. Transmission ........................................................................................................ 3-1-1
D. Axles ..................................................................................................................... 3-1-2
SECTION 2: REMOVAL AND INSTALLATION ........................................................................... 3-2-1

A. Engine and Transmission Assembly Removal ...................................................... 3-2-1
B. Engine And Transmission Assembly Installation .................................................. 3-2-3
C. Axle Removal Procedures .................................................................................... 3-2-4
D. Axle Installation Procedures ................................................................................. 3-2-5
CD276 3-TOC-i
Rev 13
Chapter 3
3-TOC-ii CD276
Rev 13
Chapter 3
SECTION 1: OVERHAUL DATA
A. MODEL GT-110 TOW TRACTOR OVERHAUL
(1) The Model GT-110 Tow Tractor has many components which must be maintained by a
flexible program of preventive maintenance, repair, and overhaul. Overhaul is normally
conducted on a periodic basis or during unscheduled down time. Proper servicing,
maintenance, manufacturer's recommendations, and record keeping are important in
establishing overhaul periods.
(2) Tug Technologies Corporation provides preventive maintenance recommendations (Chapter 2,

Section 1). Maintenance instructions are provided in Chapter 2 for performing maintenance on
specific components or for performing specific maintenance tasks. Troubleshooting tables
(Chapter 2, Section 2), specific to this equipment, have also been provided to assist the
operator and maintenance personnel in quickly isolating and correcting most common
malfunctions. Removal and installation instructions (Chapter 3, Section 2), are provided for the
removal and installation of the engine and transmission as an assembly.
B. ENGINE
For engine maintenance and overhaul procedures, refer to the Deutz Engine Manual, located in
Chapter 5 of this manual.
C. TRANSMISSION
A transmission overhaul manual is not included in this publication. A Workshop Manual for ZF
Transmission Models WG180/200 is available from ZF or through Tug Technologies Corporation.
CD276 3-1-1
Rev 13
Chapter 3
D. AXLES
An axle overhaul manual is not included in this publication. An axle overhaul manual can be obtained
directly from Rockwell International Corporation or from Tug Technologies Corporation.
NOTE: Overhaul information, for each component, may be obtained

Note directly from the component manufacturer or by contacting:

815 Allgood Road
Marietta, GA 30062-3305
Domestic 1-800-989-8499
International + 1-770-422-8021
Parts Fax: 770-422-8730
Warranty Fax: 770-428-7315
Parts: tugparts@tugtech.com
Warranty: warranty@tugtech.com
3-1-2 CD276
Rev 13
Chapter 3
SECTION 2: REMOVAL AND INSTALLATION
A. ENGINE AND TRANSMISSION ASSEMBLY REMOVAL
1. The engine and transmission should be removed from the tractor as an assembly. Removing
the engine and transmission assembly from the Model GT-110 tow tractor is a relatively easy
task, because the unit has been designed for efficient maintenance. In the following
procedures, steps (15) through (18) require working under the vehicle; the remaining steps are
all accomplished from above the engine with the access doors opened or removed. Clearance
between the chassis and the ground is 10 in (25.4 cm) when the tires are inflated to normal
110 psi (758 kPa). Driving the tractor up onto blocks, over a pit, or acting in some other way
to increase ground clearance is optional. (See Warning on next page.)
2. No special tools are required for engine and transmission assembly removal. Recommended
tools are limited to those normally available to a mechanic.
3. The sling for hoisting the engine and transmission assembly is to be made up of equal length,
three-part, falls. Two brackets to accommodate hooks or shackles are located near the two
rocker arm covers, while a third bracket is located on the top and rear of the transmission.
Adjust the sling so that the engine and transmission assembly can be lifted from the
compartment in a level attitude.

(a) The following procedures must be accomplished before the engine and transmission
assembly can be removed:
(1) Remove the radiator air intake louver and the engine compartment access
doors.
(2) Disconnect the negative cable from batteries. Disconnect the battery cables
from the starting motor and from the engine ground.
(3) Remove the elbow manifold, the hose clamp, the hoses, the tube breather, and
the air inlet tube to the air filter.
(4) Disconnect the exhaust tube to the muffler by removing the seal clamps.
Disconnect muffler seal clamp and remove the muffler. Disconnect the
exhaust tube to the engine blower.
CD276 3-2-1
Rev 13
Chapter 3
(5) Disconnect all engine electrical connections. Cover both ends of the
electrical plugs with a tape wrapping to prevent contamination.
(6) Disconnect the fuel hose from the engine to the Racor fuel/water separator.
(7) Remove the Racor fuel/water separator. Then, remove the hose from the
fuel/water separator to the fuel tank. Remove the fuel return line running
from the rear of the engine to the fuel tank. Protect open fuel lines from
contamination by plugging open ends.
(8) Drain the hydraulic reservoir.
(9) Loosen, drain, and remove inlet and outlet hoses for transmission oil cooler.
(10) Remove all hoses from the hydraulic pump on top of the transmission.
(11) Remove the transmission oil filter.
(12) Remove the hoses to and from the hydraulic filter. Remove the filter by
removing the Allen head cap screws holding it to its bracket. Do the same
for the screws holding the bracket to the tractor frame.
(13) Remove the lines attached to the parking brake valve, the dual check/
distribution valves, and the hydraulic return manifold. Then, remove the
parking brake valve, the dual check/distribution valve, and the return manifold.
Plug all lines and hoses to prevent them from becoming contaminated.
(14) Mark the engine throttle linkages as necessary to facilitate their reinstallation.
Then, disconnect them.
WARNING: WHEN SCREWS ARE REMOVED, THE DRIVE SHAFT

WILL DROP UNTIL IT HITS WHATEVER IS BELOW. KEEP YOUR
HEAD CLEAR AND DO NOT GRASP ANY FRAME MEMBERS
DIRECTLY BENEATH A DRIVE SHAFT.
(15) Disconnect both drive shafts. There are sixteen M-11 capscrews to be
removed per driveshaft.
(16) Compress drive shaft splines to move flange away from transmission.
(17) Remove the bolts securing the engine mount front trunnion.
3-2-2 CD276
Rev 13
Chapter 3
(18) Remove the rear engine mounting bolts. Examine the rear motor mount
resilient bushings between engine mount brackets and chassis for wear. Be
sure the bushings are kept for replacement. If bushings appear worn, replace
them.
(b) Attach a sling to the engine and transmission lifting brackets.

CAUTION: USE EXTREME CARE NOT TO DAMAGE THE ENGINE,

TRANSMISSION, OR CHASSIS WHEN REMOVING THE ENGINE/
TRANSMISSION ASSEMBLY.
(c) Using the sling, lift the engine and transmission assembly. Prevent rotation of the
assembly in order to avoid damage to the engine, transmission, or chassis and lift the
engine straight up.
B. ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION
1. Install the engine and transmission assembly by reversing steps in engine and transmission
removal procedure.
2. Check all the fluid levels and service as needed. Start and leak check the tractor. Bleed
hydraulic, steering, and fuel systems as required. See the engine and transmission manuals in
Chapter 5 and the appropriate Maintenance Instructions in Chapter 2.
CD276 3-2-3
Rev 13
Chapter 3
C. AXLE REMOVAL PROCEDURES
1. The rear axle is mounted on a pivoting bolster to accommodate minor bumps and dips during
operation. The front axle is bolted solidly to the tractor chassis.
2. The following procedures are to be followed for removal of the axle assemblies.

(a) Hoist the tractor and place stands beneath its chassis to provide at least 24 in (61 cm)
of clearance underneath it.
(b) Remove the wheel and tire assemblies.
WARNING: WEAR PROTECTIVE GOGGLES OR OTHER

APPROPRIATE EYE PROTECTION WHEN LOOSENING BRAKE
SYSTEM OR HYDRAULIC SYSTEM FITTINGS, AS RESIDUAL
PRESSURE MAY BE PRESENT IN THESE SYSTEMS.
(c) Disconnect and cap the brake lines attached to the axle wheel cylinders.
(d) Disconnect the hydraulic system hoses from the steering cylinders on the rear axle.
Cap the hose fittings and plug the cylinder ports to prevent system contamination.
(e) Disconnect the drive shaft from the axle pinion shaft.
(f) Support the axle assembly with a hoist or heavy-duty transmission jack so that the
axle cannot suddenly pivot about the bolster shaft.
WARNING: FOR THE SAFETY OF MAINTENANCE PERSONNEL,

REAR AXLE BOLSTER MOVEMENT MUST BE PREVENTED
DURING AXLE INSTALLATION OR REMOVAL.
(g) Remove the nuts, bolts, and washers that attach the rear axle assembly to the bolster;
then carefully lower the axle from its mounted position and remove it from beneath
the tractor chassis.
(h) Remove cotter pins, washers, and clevis pins that retain the hydraulic steering
cylinders on the axle assembly. Install the cylinders in the same locations on the
replacement axle assembly with new cotter pins and new clevis pins if the old pins
show significant wear.
3-2-4 CD276
Rev 13
Chapter 3
(i) Remove the front axle in the same manner as the rear axle, except the front axle is
mounted solidly to the chassis instead of to a pivoting bolster.
D. AXLE INSTALLATION PROCEDURES
1. Install axle assemblies by reversing steps of axle removal procedure, with the following
additional requirements:
(a) Torque axle mounting bolts at 1900 to 2000 ft/lbs (2582 to 2718 Nm).
(b) Bleed hydraulic lines and steering cylinders while tractor is on stands as follows:
WARNING: THIS PROCEDURE REQUIRES TWO MEN. ONE MAN

IS NEEDED TO START AND STOP UNIT AND TURN STEERING
WHEEL TO FORCE FLUID TO THE HYDRAULIC CYLINDERS.
ONE MAN IS NEEDED UNDER THE VEHICLE TO LOOSEN AND
TIGHTEN FITTINGS TO EXPEL AIR FROM THE SYSTEM.
EXERCISE EXTREME CAUTION WHEN PERFORMING
MAINTENANCE ON THE HYDRAULIC SYSTEM. FLUID ESCAPING
UNDER HIGH PRESSURE CAN CAUSE SERIOUS PERSONAL
INJURY. A FACE SHIELD AND PROTECTIVE CLOTHING MUST BE
WORN.
Note NOTE: Ensure both axles are in place and the steering selector is in
COORD. mode.
(1) Check the hydraulic reservoir. Ensure that its fluid is at the proper operating
level.
(2) Attach the hydraulic lines to the hydraulic cylinders. Snug the fittings hand
tight.
(3) Place a container under the fittings to catch any draining fluid. Place a rag
over the fittings to divert any spray.
(4) Ensure that the front wheels are positioned straight ahead (zero pitch).
(5) Start the engine. Allow it to idle.
(6) Slowly turn the steering wheel. Cycle the hydraulic cylinders to their ends to
expel any trapped air. Once all air has been expelled, tighten the applicable
hydraulic line fittings.
CD276 3-2-5
Rev 13
Chapter 3
(7) Repeat step (6) turning steering wheel in the opposite direction.
(8) Check the hydraulic reservoir level. Replenish it to the operating level.
(9) Prior to returning the unit to service, drive it to check the response of the
hydraulic steering system. Check the system for leaks.
(c) After the axles are installed, align the wheels as follows: (On tow tractors with four-
wheel steering option, the rear wheels also require alignment).
NOTE: Because the tractor operates at low speeds, minor variations in

Note wheel alignment measurements are tolerable.
(1) Check caster and camber measurements. If they do not remain at zero, they
indicate wear or failure of the pivot assembly bushing. It must be replaced.
(2) Check the toe-in and toe-out angles. If they do not remain at zero, they can
corrected by adjusting the ends of the tie rod assembly.
(d) Perform operational and leak checks on the tow tractor.
3-2-6 CD276
Rev 13
Chapter 4
CHAPTER FOUR: PARTS

TABLE OF CONTENTS
SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1

A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number .......................................................................... 4-1-2
2. Part Numbers and Vendor Codes ............................................................. 4-1-3
3. Description and Quantity .......................................................................... 4-1-4
4. Effectivity................................................................................................... 4-1-4
C. Ordering Spare Parts ............................................................................................ 4-1-4
D. Consumable Parts List (Deutz Engine) ................................................................ 4-1-5
E. Vendor Code Reference List ................................................................................. 4-1-6
SECTION 2: ILLUSTRATED PARTS LIST ................................................................................ 4-2-1

Figure 4-1. Arrangement Drawing - Doors and Covers ....................................... 4-2-2
Figure 4-2. Engine Access Door Decals ............................................................. 4-2-4
Figure 4-4. Cab Arrangements ............................................................................ 4-2-7
Figure 4-5. Open Driver's Compartment with Suspension Seat ......................... 4-2-8
Figure 4-6. Rear Bumper Assembly .................................................................... 4-2-9
Figure 4-7. Standard Cab Exterior Assembly ..................................................... 4-2-10
Figure 4-8. Lift Cab Exterior Assembly .............................................................. 4-2-11
Figure 4-9. Cab Assembly (p/n 12941095) ........................................................ 4-2-12
Figure 4-10. Rear Operator's Compartment (ROC) Assembly ......................... 4-2-20
Figure 4-11. Arrangement Drawing - Rear Operator's Compartment (ROC) .... 4-2-22
Figure 4-12. Door Assembly .............................................................................. 4-2-24
Figure 4-13. Lift Carriage Assembly................................................................... 4-2-26
Figure 4-14. Internal Jacking System ................................................................. 4-2-28
Figure 4-15. Control Panel Assembly - Front Cab ............................................. 4-2-30
Figure 4-18. Console Decals ............................................................................. 4-2-36
Figure 4-19. Accelerator System ....................................................................... 4-2-38
Figure 4-20. Accelerator System (with ROC Option) ........................................ 4-2-40
CD276 4-TOC-i
Rev 13
Chapter 4
Figure 4-21. Brake Pedal Assembly................................................................... 4-2-43

Figure 4-22. Brake System ................................................................................ 4-2-44
Figure 4-23. Brake System (with ROC Option) ................................................. 4-2-46
Figure 4-24. Brake Actuator Assembly (p/n 12950599) ..................................... 4-2-48
Figure 4-25. Park Brake Assembly (Up to S/N 173) ........................................... 4-2-50
Figure 4-26. Park Brake Assembly (S/N 173 and Up) ........................................ 4-2-52
Figure 4-27. Drive Train (Sheet 1 of 2) ............................................................... 4-2-54
Figure 4-27. Drive Train (Sheet 2 of 2) ............................................................... 4-2-55
Figure 4-28. Bolt Torque Specification - Drive Train (Sheet 1 of 2) .................... 4-2-56
Figure 4-28. Bolt Torque Specification - Drive Train (Sheet 2 of 2) .................... 4-2-57
Figure 4-29. Drive Shaft Installation ................................................................... 4-2-58
Figure 4-30. Lubrication System ........................................................................ 4-2-60
Figure 4-31. Steering Column Assembly (Front) ................................................ 4-2-61
Figure 4-32. Steering Column Assembly (ROC Option) .................................... 4-2-62
Figure 4-33. Hydraulic Steering System ............................................................ 4-2-64
Figure 4-34. Hydraulic Steering System (w/ ROC Option) ................................ 4-2-66
Figure 4-35. Steering Control Box ...................................................................... 4-2-68
Figure 4-36. Hydraulic Tank Assembly ............................................................... 4-2-70
Figure 4-37. Hydraulic Control Board Assembly ................................................ 4-2-72
Figure 4-38. Hydraulic Control Board Assembly (with ROC Option) ................. 4-2-76
Figure 4-39. Hydraulic Pump Assembly ............................................................. 4-2-82
Figure 4-40. Emergency Hydraulic Pump Assembly ......................................... 4-2-83
Figure 4-41. Pump and Return Hydraulic System ............................................. 4-2-84
Figure 4-42. Cab Bulkhead Assembly ................................................................ 4-2-86
Figure 4-43. Lift Cab Hydraulic System ............................................................. 4-2-88
Figure 4-44. Engine Assembly (Side View) ........................................................ 4-2-90
Figure 4-44a. Engine Assembly (Front View) .................................................... 4-2-91
Figure 4-44b. Engine Assembly (Rear View) ..................................................... 4-2-92
Figure 4-44c. Engine and Engine Mounts .......................................................... 4-2-93
Figure 4-45. Engine Oil Pan Heater Pad ............................................................ 4-2-94
Figure 4-46. Transmission Installation ............................................................... 4-2-95
Figure 4-47. Transmission Oil System (Up to S/N 109)..................................... 4-2-96
Figure 4-48. Transmission Oil System (S/N 109 and Up) .................................. 4-2-98
Figure 4-49. Air Intake System ......................................................................... 4-2-100
Figure 4-50. Exhaust System .......................................................................... 4-2-101
Figure 4-51. Fuel System ................................................................................ 4-2-102
Figure 4-52. Radiator, Transmission Cooler Installation .................................. 4-2-104
Figure 4-53. Battery Installation ....................................................................... 4-2-106
Figure 4-54. Circuit Breaker and Fuse Installation ........................................... 4-2-107
4-TOC-ii CD276
Rev 13
Chapter 4
Figure 4-55. Relay Box Assembly .................................................................... 4-2-108

Figure 4-56. Fuse Box Assembly ..................................................................... 4-2-110
Figure 4-57. Rear View Camera Option and ESM Installation .......................... 4-2-111
SECTION 3: NUMERICAL INDEX .......................................................................................... 4-3-13
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
CD276 4-TOC-iii
Rev 13
Chapter 4
4-TOC-iv CD276
Rev 13
Chapter 4
SECTION 1: DESCRIPTION
A. INTRODUCTION
The Illustrated Parts List (IPL) contained in this manual furnishes spare parts and replacement parts
information as well as general part and assembly information necessary for maintenance of the TUG
Model GT-110 Aircraft Tow Tractor.
CD276 4-1-1
Rev 13
Chapter 4
B. USING THE ILLUSTRATED PARTS LIST
The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems which
comprise the M1A Low Profile Tow Tractor. Each IPL consists of a figure illustrating a group of
related parts and a corresponding list identifying the parts by part number(s) and description. The
quantity given in the list is for the particular assembly shown in the illustration and is not necessarily
the quantity for the entire unit.
1. Figure and Index Number

The figure and index number refers to the figure on which the part is depicted. The index
number refers to the individual part shown on the illustration. See the following example for
further explanation of the Figure and Index Number.
Refers to the figure number, and the Fig & Vendor Part Tug Part
Code Descriptio
item's number on that figure. Ind Number Number
89-1 372750 ------ TM1-4-8168 Spindle, R
No Index Number: This item is 89- 372750 ------ TM1-4-8166 Spindle, L/
related to the components or
89-2 ------ ------ TM1-1-8264 Pin, King,
system in the illustration, but is
89-3 373090 CB2430-16 TM1-1-8084 Bushing, S
not actually shown. In certain
89-4 372750 ------ TM1-2-8198 Cover, Du
cases, such items are shown in
89-5 403166 ------ MI-ND-813 Bearing, T
other figures in section 4-2.
89-6 403166 CR21208K T6-3001-60022 Seal, Grea
89-7 372739 ------ MI-ND-817 Bearing, H
Figure and index number blank: 89-8 373090 24720 T6-3001-60024 Race, Inne
This item is one of possibly many 89-9 ------ ------ TM1-ND-5287 Hub, Front
items designated by a single Figure 372750 ------ TM1-4-8196 Rotor, Cas
and Index Number. The first item in 89-10 450238 ------ T6-8015-103 Stud, Whe
such a group is assigned a 89-11 ------ ------ TM1-ND-5287 Hub, Front
number; the rest of these items are 89 12 373317 T6 3003 105 N t L ½
listed directly below. These items
are generally similar in function, but
have different applicabilities or
effectivities.
NOTE: Sample tables in this section are intended to illustrate table

Note structure and format, and should not be used for reference of actual data.
Refer to applicable figure for specific required part information.
4-1-2 CD276
Rev 13
Chapter 4
2. Part Numbers and Vendor Codes

Parts are identified by part numbers assigned by TUG or, in the case of fasteners and related
materials, by industry standard specification. When applicable, vendors’ part numbers are
also included and the individual vendor for each item identified. In a few instances, TUG
part numbers are not available and only the vendor numbers are indicated. These parts can be
ordered directly from TUG using the vendor part number in lieu of a TUG part number.
Vendor codes are provided for quick, easy reference to an individual vendor. The vendor can
be identified by referring to the Vendor Code Reference List in this section. Vendor codes
are not in any way related to the part number. They should not be used when ordering
replacement parts. They are for use as a reference only when using this manual. See the
following illustration for further explanation of Part Numbers and Vendor Codes.
Part number assigned by

TUG.
No vendor code or vendor
part number indicates that
the part is designed,
Fig & Vendor Part Tug Part
manufactured or modified Code Descriptio
Ind Number Number
by TUG.
89-1 372750 ------ TM1-4-8168 Spindle, R
89- 372750 ------ TM1-4-8166 Spindle, L/
89-2 ------ ------ TM1-1-8264 Pin, King,
89-3 373090 CB2430-16 TM1-1-8084 Bushing, S
89-4 372750 ------ TM1-2-8198 Cover, Du
89-5 403166 ------ MI-ND-813 Bearing, T
89-6 403166 CR21208K T6-3001-60022 Seal, Grea
89-7 372739 ------ MI-ND-817 Bearing, H
89-8 373090 24720 T6-3001-60024 Race, Inne
89-9 ------ ------ TM1-ND-5287 Hub, Front
372750 ------ TM1-4-8196 Rotor, Cas
89-10 450238 ------ T6-8015-103 Stud, Whe
89-11 ------ ------ TM1-ND-5287 Hub, Front
89-12 373317 ------ T6-3003-105 Nut, Lug ½
89-13 403166 15245 T6-3001-60026 Race, Out
89-14 403166 15123 T6-3001-60027 Bearing, O
89-15 261788 613108 T6-3001-60028 Washer, S
89-16 261788 ------ T6-3001-60030 Pin, Cotter
89-17 373059 ------ T6-3001-60029 Nut, Spind
89-18 261788 06-12016 T6-3001-60031 Cap, Grea
89-19 372739 EW244002 ------
TM1-1-3508 Washer, T
No TUG part number indicates that TUG has not assigned a part
number to the part, and that the part is inventoried and supplied
under the vendor part number.
CD276 4-1-3
Rev 13
Chapter 4
3. Description and Quantity

A description and quantity is provided for each part listed in the IPL. The quantity given for
subassemblies and subparts is the number of subassemblies/parts contained in the component
or system depicted by the associated illustration, not necessarily the entire vehicle.
4. Effectivity
The effectivity of each item in the parts list is given in part or in whole in the “Effective”
column of the IPL. Information concerning the effectivity of a particular part may also be
found in the description column, the figure title or in notes located at the bottom of the IPL
page. Effectivity is usually (but not always) associated with the serial number.
C. ORDERING SPARE PARTS
To ensure that proper spares and replacement parts are obtained, it is recommended that all major
components be procured directly from TUG. Use of parts not manufactured or supplied by TUG may
void the warranty on the vehicle. When replacing structural fasteners, use Grade 8 or higher material.
Spare parts can be ordered directly from TUG by telephoning TUG SHOP at
1-800-989-8499 (toll free in U.S. and Canada) or 770-422-8021 (outside U.S. or Canada). Ask for
TUG SHOP when calling. FAX messages can be sent to 770-422-8730 (U.S.).
When ordering parts, please be prepared with TUG part numbers (vendor part number and code if no
TUG part number is available), part description, figure and index number and the revision of the IPL
page (located in the footer of each page, directly under each page number).
TUG SHOP business hours are from 8:00 a.m. until 5:00 p.m. Eastern time, Monday through Friday.
Answering machines are ready to receive calls after regular business hours. All calls received after
hours will be returned during the next regular business day.
4-1-4 CD276
Rev 13
Chapter 4
D. CONSUMABLE PARTS LIST (DEUTZ ENGINE)
The Consumable Parts List is provided to help in locating consumable items that are required for routine
maintenance. All items below may be obtained form TUG.
CAUTION: FOR YOUR OWN PROTECTION, DO NOT SUBSTITUTE

PARTS WITHOUT THE PRIOR APPROVAL OF TUG.
Part No. MFG Nomenclature Qty
ENGINE AIR INTAKE SYSTEM

12233-8 FARR Element, Filter 1
ENGINE LUBE OIL SYSTEM

1174421 Deutz Element, Oil Filter 1
ENGINE FUEL OIL SYSTEM

1174423 Deutz Element, Fuel Filter 1
2020SM-OR Racor Element, Fuel Water Separator 1

(Optional)
TRANSMISSION
0750131053 ZF Element, Transmission 1
HYDRAULIC SYSTEM
9541007000 Parker Element, Hyd. System, Steering 1
TIRES
12891563 GoodYear Tire, Radial, Low Profile, 16x25x25, Tubeless Type 4
BRAKE SYSTEM
A15179X1-88 AxleTech Shoe and Lining (2 per Wheel) 2
A15179-59-1 AxleTech Pads, Brake, Park 4
BATTERIES
1150 GM / Delco Battery, 12 volt 2
HOSES & BELTS

419 8792 Deutz Thermostat 1
1179477 Deutz V-Belt, Set, Narrow, Blower 1
117 9648 Deutz V-Belt, Set, Narrow, Alternator 1
CD276 4-1-5
Rev 13
Chapter 4
E. VENDOR CODE REFERENCE LIST
Vendor Code Vendor Name Address City, State, Zip

200597 Coastal Rubber Co. Inc. P.O. Box 262392 Houston, TX 77207
203790 Racor Industries Corp. 3400 Finch Road Modesto, CA 95353
205409 Red Man Pipe & Supply 2333 Clinton Drive Galena Park, TX 77547
214264 Key Safety Restraint & Systems Inc. P.O. Box 95023 Lakeland, FL 33804
234190 Great Lakes Power Products 5727 Old Boonville Hwy Evansville, IN 47715
236040 Parker Hannifin 3400 Finch Road Modesto, CA 95353
238715 DW Industries Inc. 6326 Long Drive Houston, TX 77087
238730 Ladd Industries Inc. P.O. Box 802076 Chicago, IL 60680
238834 Titan Wheel Corporation 227 Allison Gap Road Saltville, VA 24370
239337 Juliana Company 4304 Boca Raton Drive The Colony, TX 75056
239359 Green Machine & Tool Inc 1007 Pennsylvania Avenue Houston, TX 77287
239440 Tug Technologies 815 Allgood Road Marietta, GA 30062
239446 Eaton Corp/Aeroquip Inc 14615 Lone Oak Road Eden Prairie, MN 55344
239450 Aeroquip Group/Eaton Corp P.O. Box 730455 Dallas, TX 75373
239602 Donaldson Co., Inc. 1400 West 94th Street Minneapolis, MN 55431
239848 The Protectoseal Company 225 West Foster Avenue Bensenville, IL 60106
239892 Southwest Electronics Energy Corp. P.O. Box 752072 Dallas, TX 75395
239893 Southwest Electronics Energy Corp. P.O. Box 4890 Houston, TX 77210
240035 Sealy Precision Machining Inc. P.O. Box 664 Sealy, TX 77474
240175 South Coast Supply Co. P.O. Box 55649 Houston, TX 77255
240454 City Awning & Tarpaulin Co. Inc. 7629 Harrisburg Blvd Houston, TX 77012
240617 Coastal Plastic Supply Inc 6002 W. 34th Street, Ste H Houston, TX 77092
240791 GHX Incorporated P.O. Box 952030 Dallas, TX 75395
240795 Houston Hydraulic Sales & Service P.O. Box 8586 Houston, TX 77249
240809 Sunsource Inc. 2301 Windsor Court Addison, IL 60101
240823 Jones Auto Trim Shop 6211 Harrisburg Blvd Houston, TX 77011
240909 MSI Equipment Centers Inc. P.O. Box 22548 Chattanooga, TN 37422
240950 Stasco Inc. 1140 Rothwell Houston, TX 77002
240986 Southwestern Controls Inc 6720 Sands Point, Ste 201 Houston, TX 77074
241766 Fastenal 1000 Cobb International Blvd. Marietta, GA 30152
241892 General Engineering Co. P.O. Box 549 Abingdon, VA 24212
241894 Maxima Technologies 1811 Rohrerstown Road Lancaster, PA 17601
241983 Power Systems Inc. 805 McFarland Pkwy Alpharetta, GA 30009
242225 Superior Manufacturing Co. 4102 Indiana Avenue Winston-Salem, NC 27105
242293 Lord Corporation P.O. Box 281707 Atlanta, GA 30384
242335 AKG of America Inc. P.O. Box 601121 Charlotte, NC 28260
242482 Lee Spring Company Inc. 1462 62nd Street Brooklyn, NY 11219
4-1-6 CD276
Rev 13
Chapter 4

242714 Delta Fastener Corp. P.O. Box 7652 Houston, TX 77270
242837 Zinga Industries Inc. 2400 Zinga Drive Reedsburg, WI 53959
242916 Kidron Inc. P.O. Box 651119 Charlotte, NC 28265
243474 Winzer Corporation 340 Harborway San Francisco, CA 94080
243655 Arctic Fox Inc. P.O. 1164 Minneapolis, MN 55480
244126 Bay City Machine & Supply 3113 Nichols Road Bay City, TX 77414
244159 Parker Hannifin Corp. 7899 Collection Center Drive Chicago, IL 60693
244293 Nappco Fastener Co. 11260 Hempstead Hwy Houston, TX 77255
245195 C&M Industries P.O. Box 2018 Dayton, TX 77535
247378 Sunwest Screen Graphics Ltd. 277 Cree Crescent Winnipeg MB R3J3X4*
247490 M&M Manufacturing Co. Inc. P.O. Box 3233 Fort Worth, TX 76113
248660 Siemens VDO Automotive Corp. 188 Brooke Road Winchester, VA 22604
248661 Siemens VDO Automotive Corp. Department CH 14239 Palatine, IL 60055
249487 Mico Incorporated 1911 Lee Blvd. N. Mankato, MN 56003
249874 Lenz Inc. P.O. Box 1044 Dayton, OH 45401
250697 Diamond Rubber Products Corp. 4000 50th Street SW Birmingham, AL 35221
251265 Fiamm Technologies Inc. 1550 Lesson Avenue Cadillac, MI 49601
253635 Lubriquip Inc. 18901 Cramwood Pkwy Cleveland, OH 44128
254934 McMaster Carr Supply Co. 6100 Fulton Indust. Blvd. Atlanta, GA 30336
255285 Thermal Dynamics Corp 4850 E. Airport Ontario, CA 91761
259908 ASEP Manufacturing Inc. P.O. Box 4346 Dept 643 Houston, TX 77210
260131 Truck Lite Company Inc. 310 East Elmwood Avenue Falconer, NY 14733
261104 Sigma-Netics Inc. 1 Washington Avenue Fairfield, NJ 07004
261331 AKG Thermal Systems P.O. Box 189 Mebane, NC 27302
262861 Grand Bending and Distributors, Inc. 1607 South Cobb Drive Marietta, GA 30060
263516 O’Neal Steel Inc. 4075 Blue Ridge Parkway Norcross, GA 30071
263540 Peerless Electronics 9600 W. Sample Rd., Ste. 506 Coral Springs, FL 33065
263594 Multi Wing America Burton 15030 Berkshire Industrial Pkwy Burton, OH 44021
263846 ZF Sales and Service North America P.O. Box 101260 Atlanta, GA 30392
263928 Ametek Dixon Inc. 287 27 Road Grand Junction, CO 81503
264038 Griffith Rubber Mills 2625 N.W. Industrial Way Portland, OR 97210
264269 Grote Industries Inc. 2600 Lanier Drive Madison, IN 47250
264285 Manitou North America Waco 6401 Imperial Drive Waco, TX 76712
* Canada
CD276 4-1-7
Rev 13
Chapter 4

264365 Fluid Line Products 38273 Western Pkwy Willoughby, OH 44094
264937 Deutz 3883 Steve Reynolds Blvd. Norcross, GA 30093
265288 Douglas Battery Inc. 500-T Battery Drive Winston-Salem, NC 27117
266111 Longhorn Steel Inc. 11921 FM 529 Rd. Houston, TX 77041
266142 National Hose & Accessory 1831 S. Richey Street Pasadena, TX 77502
266763 Hydradyne Hydraulics, LLC P.O. Box 974799 Dallas, TX 75397
267009 Goodyear Co - Atlanta P.O. Box 277808 Atlanta, GA 30384
281359 Deutz 3883 Steve Reynolds Blvd. Norcross, GA 30093
282311 MIT International Inc. P.O. Box 972531 Dallas, TX 75397
282851 Julian Electric Inc. 406 Plaza Drive Westmont, IL 60559
284181 Commerical Vehicle Group P.O. Box 643389 Cincinatti, OH 45264
288777 ZF Passau GMBH D94030 Passau Fed Republic of Germany
293892 Sunsource Technology Services 11928 W. Silver Springs Drive Milwaukee, WI 53225
293900 Camfill Farr, Inc. 4749 Pleasant Hill Road Memphis, TN 38118
293912 McMaster Carr Supply Co. 6100 Fulton Indust. Blvd. Atlanta, GA 30336
301146 Summers Electrical Supply 8042 Katy Freeway Ste 100 Houston, TX 77024
301664 Metalphoto of Cincinatti 1080 Skillman Dr. Cincinatti, OH 45215
329499 Cross Fluid Power P.O. Box 65486 Charlotte, NC 28265
349373 Tech Craft Inc. 462 Roswell Street NE Marietta, GA 30060
350000 Powers Machine & Tool Co. 1808 Lelia Street Austell, GA 30106
358417 Major Machining Inc. 3240 Heritage Drive Kennesaw, GA 30144
359036 ASV Plastics, Inc. 23620 Cooper Drive Elkhart, IN 46514
368977 Lavanture Products Company Inc. P.O. Box 2088 Elkhart, IN 46515
369142 Harlan Corp. 27 Stanley Rd. Kansas City, KS 66115
369175 Pioneer Rubber P.O. Box 1015 Tucker, GA 30085
369677 Grote Industries Inc. 2600 Lanier Drive Madison, IN 47250
369996 Attwood Corporation 1016 N. Monroe Street Lowell, MI 49331
372209 Graphic Applications, Inc. P.O. Box 1115 Kennesaw, GA 30144
372298 Diesel Injection & Electric 231 Main Street Forrest Park, GA
372736 BSA Machine Shop (Ameritech) 2771 Winston Indust. Pkwy Winston, GA 30187
372739 Motion Industries 8145 Troon Circle Austell, GA 30001
372750 Tech Craft Inc. 462 Roswell Street NE Marietta, GA 30060
373082 Austin & Thomas Hardware 1520 Broadmoor Blvd. Buford, GA 30518
373085 Roytec Industries, Inc. 306-A Bell Park Drive Woodstock, GA 30188
373089 Laserform & Machine Inc. 10010 Farrow Road Columbia, SC 29203
373317 Fastenal 1000 Cobb International Blvd. Marietta, GA 30152
4-1-8 CD276
Rev 13
Chapter 4

373383 Cliff’s Fire Extinguisher 311 Bell Park Dr. Woodstock, GA 30188
373386 Certified Power Inc. 390 Koopman Lane Elkhorn, WI 53121
373387 Williams Detroit Diesel/Allison Inc. 25 North Dr. SE Acworth, GA 30102
373488 Threads for the South, Inc. 1076 King Indust. Drive NE Marietta, GA 30062
395898 Textile Indust. Welding 109 Lillian Drive Dalton, GA 30720
397689 Mike’s Trophies & Awards 3073 Cherokee Street Kennesaw, GA 30144
402881 Seats Inc. P.O. Box 601121 Reedsburg, WI 53959
477279 The Home Depot Supply 6515 McDonough Drive Norcross, GA 30093
606035 O’Neal Steel Inc. P.O. Box 11407, Drawer 1255 Birmingham, AL 35246
666859 Axletech International 2756 Paysphere Circle Chicago, IL 60674
1173904 Camcode P.O. Box 73702-N Cleveland, OH 44193
1177411 Industrial Service Corp. 1731 N. Roosevelt Ave., Ste 1 Burlington, IA 52601
1178936 Industrial Diesal Products, Inc. 7850 Tranmere Drive Mississauga ON L5S1L9*
* Canada
CD276 4-1-9
Rev 13
Chapter 4
4-1-10 CD276
Rev 13
Chapter 4
SECTION 2: ILLUSTRATED PARTS LIST
CD276 4-2-1
Rev 13
Chapter 4
3 4
17
5 16 10
7
9
1
2 8
13
11 14 15
22 22
21 25 21
20 24 20
18 23 26
19
27
27 11
28 29 30
Figure 4-1. Arrangement Drawing - Doors and Covers
4-2-2 CD276
Rev 13
Chapter 4
Table 4-1. Arrangement Drawing - Doors and Covers

Code Description Qty Effective
Ind Number Number
1-1 372750 ------ 12941855 Box, Headlight 1 1 & Up

1-2 440230 ------ G1-10067 Cover, Hydraulic and Surge Tank 1 "
1-3 373089 ------ 12950512 Plate, Access - Air Filter Cover 1 "
1-4 259908 ------ 12950511 Plate, Cover - Top Air Filter 1 "
1-5 373089 ------ 12950513 Plate, Cover - Top Front 1 "
1-6 440230 ------ G1-10049 Cover, Louver Radiator Intake 1 "
1-7 373089 ------ 12950515 Door, Access - Engine Compartment 1 "
1-8 440230 ------ 12950517 Support, Access Door 1 "
1-9 373089 ------ 12950524 Door, Access - Battery-Valves 1 "
1-10 373089 ------ 12950530 Panel, Access - Rear Top 1 "
1-11 373089 ------ 12950443 Panel, Side - Ballast Cover 2 "
1-12 240909 ------ 12950514 Door, Access - Air Filter 1 "
1-13 440230 ------ 12950095 Cover, Tail Lights 2 "
1-14 358417 ------ 12961276 Cover, Tail Light Harness - L/S 1 "
1-15 259908 ------ 12961274 Cover, Tail Light Harness - R/S 1 "
1-16 373082 AH5867ZN 5867 Hinge, 5" Stamped Steel 4 "
1-17 244293 ------ 68-80-302-10 Latch, Ball Handle, Series 80 2 "
1-18 373089 ------ 12940586 Bracket, Mounting - Hood Lift 2 "
1-19 369996 ------ 78383 Cylinder, Gas Assist 4 "
1-20 369996 SL84 A9002 Clip (For 78383) 8 "
1-21 369996 SL69BS A9008 Stud (For 78383) 8 "
1-22 293912 90079A245 17-13-106-11 Screw, Captive - Knurled 1 "
1-23 244293 ------ 17-10017-11 Receptacle, Fastener, Clip-On 1 "
1-24 244293 ------ 17-10014-26 Retainer, Captive Screw 1 "
1-25 440230 ------ 12950858 Bracket, Mounting - Hood Lift 2 "
1-26 369142 029GT110 G1-10087 Frame Weldment, Tier II Deutz 1 "
263516 ------ G1-10017 Frame Weldment, Air Force 1 "
1-27 372750 ------ 12010139 Hitch Assembly 2 "
372750 ------ G1-10083 Hitch, Two Tier 2 "
1-28 372750 ------ G1-10085 Plate, Hitch Adapter 2 "
1-29 254934 ------ 98412A132 Pin, Hitch - 5/8" Dia. x 4 " Grip 4 "
1-30 254934 ------ 98296A185 Pin, Roll - 1/8" Dia. x 1.25" Long 4 "
1-31 242482 LC-055K-7S LC-055K-7 Spring - 8.45" OD x 0.055" Wire 4 "
1-32 358417 ------ G1-10050 Support, Top Cover Louver 1 "
CD276 4-2-3
Rev 13
Chapter 4
Table 4-2. Engine Access Door Decals

1 Ind
Code
Number Number
Description Qty Effective
2 2-1 373089 ------ 12950515 Door, Access - Engine Compartment 1 1 & Up

2-2 301664 ------ G1-10033 Plate, Data - Hydraulic Schematic 1 "
3 2-3 247378 ------ SW600 Decal, "Warning: To prevent burning…" 1 "
2-4 247378 ------ 12970880 Decal, "Service Information" 1 "
4 2-5
2-6
247378
247378
------
------
SW2
12990777
Decal, "Caution: To Avoid Injury"
Decal, "Danger: Explosion"
1
1
"
"
2-7 242845 ------ 9410000125 Decal, "Warning" 1 "
5 2-8 247378 ------ 12990611 Decal, "Moving Parts Hazard" 1 "
2-9 242845 ------ 9410000124 Decal, "Caution: Hot Surface" 1 "
6
!
9
7
Figure 4-2. Engine Access Door Decals
4-2-4 CD276
Rev 13
Chapter 4
Table 4-3. Ballast Schedule

Ind Number Number
3-1 373317 ------ 12880756 Bolt, Hex Ø 5/8-11NC x 2¾" Long 4 1 & Up
3-2 373317 ------ 99297 Washer, Lock 5/8" ID 4 "
3-3 373317 ------ 85936 Washer, Flat 5/8" ID 4 "
3-4 239359 ------ 12951637 Angle, Ballast Keeper 4 "
3-5 248083 ------ G1-10037 D-Ring, 46K with Strap 20 "
3-6 606035 ------ G1-10087 Frame Weldment - Tier II Deutz 1 289 & Up
606035 ------ G1-10018 Frame Weldment - Rear Cab 1 As Req'd
1 606035 ------ G1-10108 Frame Weldment - Tier II Deutz, 1 "
5 2 LOCATION 'B' 7 2 Front/Rear Hitches
3-7 373082 ------ 1-585809 Step, Folding Malleable 4 1 & Up
3 3-8 373317 ------ 5/16-18 Bolt, Flange Ø 5/16-18 8 "
3-9 373317 ------ 12970503 Bolt, Eye 4 "
5 LOCATION 'C' 3-10 373317 ------ ------ Washer, Flat 2" ID 4 "
9
REAR
BUMPER
10
9
10
6
9 5
10
5 5
4
5
LOCATION 'A'
7
8
Figure 4-3. Ballast Schedule (Sheet 1 of 2)
CD276 4-2-5
Rev 13
Chapter 4
BALLAST SCHEDULE
Figure 4-3. Ballast Schedule (Sheet 2 of 2)
4-2-6 CD276
Rev 13
Chapter 4
Table 4-4. Cab Arrangements
Figure A

Ind Number Number
4A-1 242916 ------ 12941095 Cab, Front - Full Length 1 1 & Up

1 4A-2 ------ ------ 12941385 Lift Frame Assembly 1 "
Figure B
1
Ind Number Number
4B-1 242916 ------ 12941095 Cab, Front - Full Length 1 1 & Up
2 3 4B-2 264285 12941386/1387 K8303 G1-10001 Carriage & Rail Assembly - 1 "
4 Lift Cab
4B-3 402724 2.5CSB2HLT27AX28.00 12893470 Cylinder, Cab Lift (28") 1 "
4B-4 240454 ------ 12951457 Cover, Sock for Hoses - Lift Cab 1 "
2
Figure C
ELEVATING-CAB-FLUSH MOUNTED ELEVATING-CAB-FLUSH MOUNTED Code Description Qty Effective
DOWN POSITION UP POSITION Ind Number Number
FIG A FIG B
4C-1 242916 ------ 12941095 Cab, Front - Full Length 1 1 & Up
4C-2 350000 ------ 12950078 Platform, Raised Cab 2 "
1 4C-3 250697 ------ 12951190 Pad, Isolator - Fixed Cab 2 "
9 4C-4 358417 ------ 12950791 Plate, Cover - Cab Front 1 "
10
8
7 Figure D
1
4 4 6 Fig & Vendor Part Tug Part
3 3 5 Ind Number Number
4D-1 242916 ------ 12941667 Driver's Compartment, Open 1 1 & Up
4D-2 350000 ------ 12950078 Platform, Raised Cab 2 "
4D-3 250697 ------ 12951190 Pad, Isolator - Fixed Cab 2 "
2 2
4D-4 358417 ------ 12950791 Plate, Cover - Cab Front 1 "
81.50 FIXED CAB, RAISED PLATFORM OPEN COMPARTMENT, RAISED PLATFORM 4D-5 264948 ------ C15394 Riser 2 "
FIG C FIG D
4D-6 266758 132172PS A15332 Mount, Seat, Mechanical 1 "
4D-7 266758 137846ZN81 A3588X5 Seat, Bucket 1 "
4D-8 242225 ------ 12950597 Seat, Bench w/ Storage Box - 1 "
Bolt-In
4D-9 247490 ------ 12951435 Support, Plexiglass Cover - 1 "
Open Compartment
4D-10 240617 ------ 12951436 Cover, Plexiglass - 1 "
Open Compartment
Figure 4-4. Cab Arrangements
CD276 4-2-7
Rev 13
Chapter 4
Table 4-5. Open Driver's Compartment with Suspension Seat

Ind Number Number
5-1 266758 137846ZN81 A3588X5 Seat, Bucket 2 1 & Up
5-2 368977 E2834101-01 660-6-0581-25 Belt, Safety (Non Retract) 2 "
5-3 266758 132172PS A15332 Mount, Seat, Mechanical 2 "
5-4 264948 ------ C15394 Riser 4 "
Figure 4-5. Open Driver's Compartment with Suspension Seat
4-2-8 CD276
Rev 13
Chapter 4
Table 4-6. Rear Bumper Assembly
Fig & Tug Part

Code Vendor Part Number Description Qty Effective
Ind Number
6-1 402530 9192 660-1-2640 Holder, Tag 1 1 & Up

6-2 373082 83-116DB 12-24VDC 697066 Alarm, Back-Up - Self-Adjusting 1 "
6-3 239892 99998550 12950102 Lamp Assembly, Rear Left 1 "
6-4 440230 ------ 12950095 Cover, Tail Lights 2 "
6-5 358417 ------ 12961276 Cover, Tail Light Harness - Left 1 "
6-6 260131 7513 60-50001 Mirror Assembly, Black Finish 1 "
4 8 9 6-7 373317 ------ ------ Bolt, Flange Ø 10/32" 9 "
10 15 6-8 259908 ------ 12961274 Cover, Tail Light Harness - Right 1 "
7 6-9 239892 99998510 12950101 Lamp Assembly, Rear Right 1 "
11 6-10 373383 ------ 30937 Bracket, Fire Extinguisher 1 "
6 6-11 373317 ------ ------ Bolt, Flange Ø 5/16" 4 "
6-12 373383 ------ SY024 Extinguisher, Fire 1 "
17 16 6-13 369677 GR64101 64-101 Lamp, Sealed Beam, 12V 1 "
5 4 6-14 373317 ------ ------ Bolt, Phillips Head Ø 10/32" 2 "
6-15 284181 ------ 595502 Frame, Mounting - Sprague 2 "
3 6-16 402645 ------ 511003 Switch, Rocker, 2 Pos. (Rear Hitch Light) 1 "
6-17 284181 ------ 594767 Lens w/ Rear Hitch Light Symbol 1 "
12 6-18 372750 ------ 12010139 Hitch Assembly 1 As Req'd
2 6-19 606035 ------ G1-10108-5 Spacer, Mounting - Hitch Plate (Opt.) 1 "
13 6-20 606035 ------ G1-10109 Spacer, Lower - Hitch (Opt.) 1 "
6-21 606035 ------ G1-10087-4 Bumper, Rear 1 "
14
1
21
19
20
21 18
Figure 4-6. Rear Bumper Assembly
CD276 4-2-9
Rev 13
Chapter 4
Table 4-7. Standard Cab Exterior Assembly

Ind Number Number
7-1 242916 ------ 12941095 Cab, Front - Full Length 1 1 & Up

7-2 293912 9600K19 391772R2 Grommet, Rubber 2 "
3 2 1 7-3 251265 7549014 75490H Horn, Electric, 12VDC, Air Tone 2 "
7-4 369677 ------ 013744 Mirror, Split Focus 2 "
7-5 264269 64281 G35-10003 Headlight, Front, R/H 1 "
4 7-6 372750 ------ 12010139 Hitch Assembly 1 "
7-7 372750 ------ 12941855 Box, Headlight 1 "
7-8 264269 64271 G35-10004 Headlight, Front, L/H 1 "
7-9 ------ ------ G1-10111 Mounting Weldment, 1 As Req'd
Additional Front Hitch Option
7-10 606035 ------ G1-10112 Extension, Front Bumper - Opt. 1 "
7-11 606035 ------ G1-10108-5 Plate, Hitch Mounting Spacer - Opt. 1 "
5 7-12 ------ ------ G1-10087-13 Bumper, Front 1 "
12
6
10
11
9
12
13
Figure 4-7. Standard Cab Exterior Assembly
4-2-10 CD276
Rev 13
Chapter 4
Table 4-8. Lift Cab Exterior Assembly

Ind Number Number
8-1 260131 ------ 312A Beacon, Rotating Amber, 12V 1 1 & Up
8-2 251265 7549014 75490H Horn, Electric, 12VDC, Air Tone 2 "
8-3 260131 7513 60-50001 Mirror Assembly, Black Finish 1 "
8-4 242916 ------ 12941095 Cab, Front - Full Length 1 "
8-5 369677 ------ 013744 Mirror, Split Focus 2 "
8-6 369175 ------ G1-10091 Curtain, Rubber 1 "
8-7 369677 GR64101 64-101 Lamp, Sealed Beam, 12V 1 "
1
8-8 247378 ------ 12970448 Decal, "Danger: Cab Pinch Point" 2 "
3 2 15
14 8-9 264269 64281 G35-10003 Headlight, Front, R/H 1 "
16 8-10 372750 ------ 12010139 Hitch Assembly 1 "
4
5 18 17 COORD
8-11 372750 ------ 12941855 Box, Headlight 1 "
STEER
MODE
TRACK
CRAB
8-12 264269 64271 G35-10004 Headlight, Front, L/H 1 "
8-13 373089 ------ 12951628 Bracket, Rubber Curtain 1 "
2019 23 24
8-14 402645 LSJ3K-7M 940393C91 Switch, Micro 3 "
22 21 25 8-15 293912 9600K19 391772R2 Grommet, Rubber 2 "
8-17 402645 ------ 511003 Switch, Rocker, 2 Pos. (Front Hitch Light) 1 "
8-18 284181 ------ 59L.430 Lens w/ Front Hitch Light Symbol 1 "
6 5 8-19 402645 ------ 511003 Switch, Rocker, 2 Pos. (Rear Hitch Light) 1 "
8-20 284181 ------ 594767 Lens w/ Rear Hitch Light Symbol 1 "
7 8-21 402645 ------ 511003 Switch, Rocker, 2 Pos. (Beacon Light) 1 "
13 8-22 284181 ------ 596628 Lens w/ Beacon Light Symbol 1 "
8-23 402645 ------ 511066 Switch, Cab Lift 1 "
8
8-24 284181 ------ 59L.494 Lens w/ Cab Lift Symbol 1 "
8-25 301664 ------ 12941722 Faceplate, Control Panel Cab 1 "
9
10
11
12
Figure 4-8. Lift Cab Exterior Assembly
CD276 4-2-11
Rev 13
Chapter 4
Figure 4-9. Cab Assembly (p/n 12941095)
4-2-12 CD276
Rev 13
Chapter 4
CD276 4-2-13
Rev 13
Chapter 4
4-2-14 CD276
Rev 13
Chapter 4
CD276 4-2-15
Rev 13
Chapter 4
4-2-16 CD276
Rev 13
Chapter 4
CD276 4-2-17
Rev 13
Chapter 4
4-2-18 CD276
Rev 13
Chapter 4
CD276 4-2-19
Rev 13
Chapter 4
ON
OFF
Figure 4-10. Rear Operator's Compartment (ROC) Assembly
4-2-20 CD276
Rev 13
Chapter 4
Table 4-10. Rear Operator's Compartment (ROC) Assembly

Ind Number Number
10-1 240823 ------ 892565C1 Cushion, Seat - ROC 1 1 & Up
10-2 244126 ------ 12940583 Bracket, Pivot - L/S Seat 1 "
10-3 244126 ------ 12940584 Bracket, Pivot - R/S Seat 1 "
10-4 358417 ------ 12950880 Cover, Orbitrol Valve - ROC Rear 1 "
10-5 373089 ------ 12941704 Mount, Orbitrol Valve 1 "
10-6 373089 ------ 12950926 Panel, Cover - Rear 1 "
10-7 240617 ------ 12950925 Cover, Plexiglass Rear 1 "
10-8 288777 6006022224 12950891 Shifter, Electric 1 "
10-9 ------ ------ 12950208 Platform, Rear Operator (Wldmt) 1 "
350000 ------ 12960291 Platform, Rear Mounted Generator Set 1 "
266111 ------ G1-10018 Frame Weldment - Rear Cab 1 "
10-10 373317 ------ 74030 Nut, Hex 1"-8 NC - Steel, Gr. 5 5 "
10-11 373317 ------ 12902827 Washer, Flat 1" SAE 10 "
10-12 373317 ------ 73796 Washer, Lock 1" - Spring, Steel 5 "
10-13 373317 ------ 73858 Bolt Ø 1"-8 NC x 5" Long 5 "
10-14 373317 ------ 81008 Bolt Ø ¾-10 NC x 2½" Long 8 "
10-15 373317 ------ 73793 Washer, Lock ¾" - Steel 8 "
10-16 301664 ------ 12000175 Plate, Face - Park Brake Switch 1 "
10-17 350000 ------ 12960978 Enclosure, Rear Operator Comp. 1 "
10-18 606035 ------ G1-10090 Plate, Cover 1 "
Bolt Torque Specifications
Bolt Size Torque

1"-8 NC Hex Bolt, Grade 5 575-590 ft-lb (782-802 N-m)
¾-10 NC Hex Bolt, Grade 5 200-225 ft-lb (272-306 N-m)
CD276 4-2-21
Rev 13
Chapter 4
GENERATOR SET IN STORED POSITION
ROLLOUT
ASSY.
GENERATOR SET IN ROLLED OUT

POSITION FOR MAINTENANCE ACCESS
Figure 4-11. Arrangement Drawing - Rear Operator's Compartment (ROC)
4-2-22 CD276
Rev 13
Chapter 4
CD276 4-2-23
Rev 13
Chapter 4
1.000'
2.325'
6 1
30.780'
2
22.400'
22
8 252
2
50.630'
4
CLIPS & RETAINERS NOT SHOWN TOP VIEWS
23
2
5
7
19.375' 2 21.000'
21
4
20
4 17 13 5
9 REF
3
GT110-DA100 - LH SHOWN
11 1012 GT110-DA200 - RH OPPOSITE
6 6
18
24
19 2
23
2
24
2
23
2
15
14
POSITION LOCKED AND CLOSED 19 GT110-DA100 - LH SHOWN

GT110-DA200 - RH OPPOSITE
4 POSITION UNLOCKED AND OPEN
REF
Figure 4-12. Door Assembly
4-2-24 CD276
Rev 13
Chapter 4
Table 4-12a. Left Hand Door Assembly Table 4-12b. Right Hand Door Assembly
Fig & Vendor Part Tug Part Fig & Vendor Part Tug Part
Code Description Qty Effective Code Description Qty Effective
Ind Number Number Ind Number Number
12a-1 242225 GT110-DA100 ------ Door Weldment - L/H 1 1 & Up 12b-1 242225 GT110-DA200 ------ Door Weldment - R/H 1 1 & Up
12a-2 242225 0121313-C ------ Window Assembly - L/H 1 " 12b-2 242225 0121312-C ------ Window Assembly - R/H 1 "
12a-3 242225 A278 ------ Latch, Rotary 1 " 12b-3 242225 A282 ------ Latch, Rotary 1 "
12a-4 242225 A263 ------ Handle, Outside Paddle 1 " 12b-4 242225 A264 ------ Handle, Outside Paddle 1 "
12a-5 242225 A411 ------ Latch, Inside Release Package - L/H 1 " 12b-5 242225 A422 ------ Latch, Inside Release Package - R/H 1 "
12a-6 242225 A127 ------ Seal, Windshield - 8' Ref. " 12b-6 242225 A127 ------ Seal, Windshield - 8' Ref. "
12a-7 242225 A170 ------ Plug, Hole - 0.438 Dia. 2 " 12b-7 242225 A170 ------ Plug, Hole - 0.438 Dia. 2 "
12a-8 242225 A750 ------ Handle, Eberhart 1 " 12b-8 242225 A750 ------ Handle, Eberhart 1 "
12a-9 242225 GT110-DA105 ------ Foam, Door - L/H 1 " 12b-9 242225 GT110-DA205 ------ Foam, Door - R/H 1 "
12a-10 242225 GT110-DA101 ------ Cover, Latch Box 1 " 12b-10 242225 GT110-DA101 ------ Cover, Latch Box 1 "
12a-11 242225 A567 ------ Screw, Phillips Pan Head 10-32 x ½" Long 6 " 12b-11 242225 A567 ------ Screw, Phillips Pan Head 10-32 x ½" Long 6 "
12a-12 242225 A602-C ------ Insert, AK 10-32 6 " 12b-12 242225 A602-C ------ Insert, AK 10-32 6 "
12a-13 242225 GT110-DA102 ------ Rod, Inside Handle - 7/32" Dia. Latch 1 " 12b-13 242225 GT110-DA202 ------ Rod, Inside Handle - 7/32" Dia. Latch 1 "
12a-14 242225 GT110-DA103 ------ Rod, Outside Handle - 3/16" Dia. Latch 1 " 12b-14 242225 GT110-DA203 ------ Rod, Outside Handle - 3/16" Dia. Latch 1 "
12a-15 242225 GT110-DA104 ------ Rod, Outside Handle - 5/32" Dia. Lockplate 1 " 12b-15 242225 GT110-DA204 ------ Rod, Outside Handle - 5/32" Dia. Lockplate 1 "
12a-17 242225 A254 ------ Clip, Rod 7/32" - L/H 1 " 12b-16 242225 A255 ------ Clip, Rod 7/32" - R/H 1 "
12a-18 242225 A283 ------ Retainer, Push-On 3/16" 1 " 12b-17 242225 A283 ------ Retainer, Push-On 3/16" 1 "
12a-19 242225 A257 ------ Clip, Rod 5/32" - R/H 2 " 12b-18 242225 A256 ------ Clip, Rod 5/32" - L/H 2 "
12a-20 242225 A513 ------ Screw, Hex Head Ø ¼-20 x 1¼" Long 4 " 12b-19 242225 A513 ------ Screw, Hex Head Ø ¼-20 x 1¼" Long 4 "
12a-21 242225 A534 ------ Washer, Flat ¼" 4 " 12b-20 242225 A534 ------ Washer, Flat ¼" 4 "
12a-22 242225 A852 ------ Screw, Phillips Head Ø ¼-20 x ¾" Long 2 " 12b-21 242225 A852 ------ Screw, Phillips Head Ø ¼-20 x ¾" Long 2 "
12a-23 242225 A857 ------ Screw, Phillips PA YZ 8-32 x ½" Long 6 " 12b-22 242225 A857 ------ Screw, Phillips PA YZ 8-32 x ½" Long 6 "
12a-24 242225 A611 ------ Washer, Lock #10 Split 4 " 12b-23 242225 A611 ------ Washer, Lock #10 Split 4 "
12a-25 242225 A750-A ------ Spacer 2 " 12b-24 242225 A750-A ------ Spacer 2 "
CD276 4-2-25
Rev 13
Chapter 4
Figure 4-13. Lift Carriage Assembly
4-2-26 CD276
Rev 13
Chapter 4
Table 4-13. Lift Carriage Assembly

Ind Number Number
13-1 264285 12941386/1387 K8303 G1-10001 Carriage & Rail Assembly - Lift Cab 1 1 & Up
13-2 402724 2.5CSB2HLT27AX28.00 12893470 Cylinder, Cab Lift (28") 1 "
13-3 ------ ------ R23282 Bracket 1 "
13-4 ------ ------ R23281 Bracket 1 "
13-5 ------ ------ K20472 Bolt, Hex 10 "
13-6 ------ ------ K34809 Washer, Lock 10 "
13-7 ------ ------ K33942 Nut, Hex Jam 10 "
13-8 264285 ------ R4095 Roller 2 "
13-9 264285 ------ R6428 Shaft, Roller 2 "
13-10 ------ ------ K302210 Bolt, Socket Head 4 "
13-11 ------ ------ K34806 Washer, Lock 4 "
13-12 264285 ------ R3564 Bolt, Hex 2 "
13-13 264285 ------ R3561 Shaft, Roller 2 "
13-14 264285 ------ R3563 Roller 2 "
13-15 264285 ------ K97535 Ring, Snap - External 2 "
13-16 ------ ------ R5974 Roller 4 "
13-17 ------ ------ R206 Shim A/R "
13-18 246960 83948 12884736 Mount, Cylinder 1 "
13-19 266763 ------ 12884735 Pin, Cylinder 2 "
13-20 244159 ------ 12884734 Rod Eye, Cylinder 1 "
CD276 4-2-27
Rev 13
Chapter 4
22 29 29 22
21
LEFT LEFT
24
25
20 20
26
27
31
DUAL CHECK
23 DIST. VALVE
REAR FRONT
29 22
22 29
18
14 15
21 19 28 17
16 28
11
28 12
13 30 20
20 28 11
10
RIGHT RIGHT
2
7 28 9
1
RETURN MANIFOLD
6
28 8 5
3 4
Figure 4-14. Internal Jacking System
4-2-28 CD276
Rev 13
Chapter 4
Table 4-14. Internal Jacking System

Ind Number Number
14-1 266763 34A003300 12884732 Valve, Control, Lift - Jack 1 1 & Up

14-2 358417 ------ 12950546 Bracket, R/H, Valve, Internal 1 "
14-3 247378 ------ 12970878 Decal, Jack Location 1 "
14-4 358417 ------ 12951434 Bracket, Jack Location Decal 1 "
14-5 397689 ------ 12950625 Nameplate, Jacking Instructions 1 "
14-6 301664 ------ 12950628 Nameplate, Jack Shutoff Valve 1 "
14-7 426744 ------ 12951367 Hose Assembly, Jack Valve Outlet to Return Manifold 1 "
14-8 426744 8MJ-8MB90 76953 Elbow, 90° #8 SAE O-Ring Boss, 37° Flare 1 "
14-9 426744 ------ 202713-8-8S Fitting, 8MJ-8MBL 8 "
14-10 358417 ------ 12950547 Bracket, L/H, Valve, Internal 1 "
14-11 426744 ------ 76927 Fitting, O-Ring/37° Flare - 8MJ-10MB 5 "
14-12 426744 ------ 2266-8-8S Adapter, SAE 8MLE, JIC 8FML 1 "
14-13 246960 ------ 76928 Adapter, SAE O-Ring/37° Flare - 5/8" Tube OD 1 "
14-14 426744 ------ 12951364 Hose Assembly, Jack Valve to Front Left Cylinder 2 "
14-15 426744 ------ 12951364 Hose Assembly, Jack Valve to Front Right Cylinder 2 "
14-16 266763 ------ N-820S Valve, Flow Control 1 "
14-17 426744 ------ 76923 Adapter, SAE O-Ring/37° Flare - 8MJ-8MB 1 "
14-18 426744 ------ 12951365 Hose Assembly, Jack Valve to Rear Left Cylinder 2 "
14-19 426744 ------ 12951366 Hose Assembly, Jack Valve to Rear Right Cylinder 2 "
14-20 241892 G2028 013030X1 Cylinder, Hydraulic Lift Jack 4 "
14-21 426744 ------ 2071-8-8S Elbow, 90° Swivel 8MJ-8FJX90 4 "
14-22 426744 ------ 08-06-070120 Fitting, Straight 8MJ-6MB 8 "
14-23 426744 ------ 12951363 Hose Assembly, Pressure Jack Valve Inlet to Ball Valve 1 "
14-24 426744 ------ 77006 Elbow, 90° 8MJ-12MP90 1 "
14-25 477279 ------ HP22GT Valve, Ball - ¾", 3000# 1 "
14-26 426744 ------ 78904 Fitting, 12MJ-12MP 1 "
14-27 200597 ------ 2266-12-12S Adapter, ¾" O-Ring/37° Flare Swivel - 12FJX-12MP 1 "
14-28 426744 ------ 22617-8 Fitting, #8 O-Ring (Service Item) 12 "
CD276 4-2-29
Rev 13
Chapter 4
9 11 9 12 13 17 16 9 20 7 22 28 27
9 8 15 14 9 19 9 21 26 25 29 30
10
5 4 7 6 10 30 33 34
18 30
CAUTION
DO NOT CRANK ENGINE
35 36
3 UNTIL GLOW PLUG LIGHT
GOES OUT
P/N 12990780
P
37 38
23 9 42
2 39 40 41
24 9
10 43 44 46 47 48 49
1 32 31
30
18 45
9 64 50 51
30
52
69 70 67 68 65 66 62 63 60 61 58 59 56 57 54 55
30
29
53
NOTICE
Steer mode selection can
71 only be made when the
axle center indicator light
is on.
TUG TECHNOLOGIES
9-410000143
Figure 4-15. Control Panel Assembly - Front Cab
4-2-30 CD276
Rev 13
Chapter 4
Table 4-15. Control Panel Assembly - Front Cab
15- 239892 99999012 12941720 Control Panel Assembly - Front Cab REF 1 & Up 15-36 284181 ------ 594767 Lens w/ Rear Hitch Light Symbol 1 1 & Up
15-1 402645 956-3124 956-3124 Switch, Starter 1 " 15-37 402645 ------ 511003 Switch, Rocker, 2 Pos. (Beacon Light) 1 "
15-2 402645 2TL1-12 012481 Switch, Toggle (Dash Light) 1 " 15-38 284181 ------ 596628 Lens w/ Beacon Light Symbol 1 "
15-3 402645 E34GBC251 014045 Switch, Push/Pull (Emergency Stop) 1 " 15-39 ------ ------ 12960969 Switch, Steering Mode Select (3 Pos.) 1 "
15-4 241894 102750 12941883 Gauge, Fuel Level, 1/8 Tank 1 " 15-40 402645 10250T-2 10250T-2 Block, Contact - 2NO (For Switch) 1 "
15-5 ------ ------ 53 Light, Fuel Level Gauge 1 " 15-41 402645 ------ 10250T-3 Block, Contact - 2NC (For Switch) 1 "
15-6 402645 900200 014050 Light, Dash Panel L/H 1 " 15-42 282851 ------ 12941687 Harness, Wire - Control Panel 1 "
15-7 402645 1815 604279-03 Bulb, Indicator Light 2 " 15-43 402645 1090D1-12V A11427X4 Light, Coord Steering Mode Indicator 1 "
15-8 284181 ------ 594461 Lens Insert, Left Turn 1 " 15-44 402645 ------ A11427X2 Light, Track Steering Mode Indicator 1 "
15-9 284181 ------ 511500 Lamp Assembly, Pilot - 12V 10 " 15-45 402645 ------ 1090D3-12 Light, Crab Steering Mode Indicator 1 "
15-10 402645 ------ 511502 Frame, Pilot Lamp, Sprague 6 " 15-46 ------ ------ ------ Connector, Steering Mode Indicator Lights 1 "
15-11 284181 ------ 596142 Lens, Low Oil Pressure 1 " 15-47 243474 ------ 12015345 Connector Body - Pin Contact 1 "
15-12 ------ ------ 596120 Lens Insert, Glow Plug 1 " 15-48 243474 12020782-L 12020782 Terminal, Male MP280 1 "
15-13 247378 ------ 12990780 Decal, "Caution" 1 " 15-49 373387 ------ 12015344 Connector Body - Socket Contact 1 "
15-14 248660 310936 310504 Gauge, Temperature, 150-300 Deg. 1 " 15-50 402645 511.066 511066 Switch, Rocker, 3 Pos. Momentary 1 "
15-15 ------ ------ 600802 Light, Temperature Gauge 1 " (Cab Lift)
15-16 241894 ------ 06863-38 Voltmeter, 12V, Black Bezel 1 " 15-51 284181 ------ 59L.494 Lens w/ Cab Lift Symbol 1 "
15-17 ------ ------ 53 Light, Voltmeter 1 " 15-52 301664 ------ 12941722 Faceplate, Control Panel Cab 1 "
15-18 284181 ------ 595105 Lens (Clearance Lamp) 3 " 15-53 373089 ------ 12941836 Plate, Control Panel Blanking 1 "
15-19 284181 ------ 596141 Lens, Red Transmission Temp. 1 " 301664 ------ 12941723 Nameplate, Control Panel - Rear Cab Opt. 1 "
15-20 284181 ------ 596169 Lens Insert, High Beam Blue 1 " 15-54 402645 ------ 511003 Switch, Rocker, 2 Pos. (Front Hitch Light) 1 "
15-21 284181 ------ 594460 Lens Insert, Right Turn 1 " 15-55 284181 ------ 59L.430 Lens w/ Front Hitch Light Symbol 1 "
15-22 402645 900200 014050 Light, Dash Panel R/H 1 " 15-56 263928 530B2-49544 12950105 Speedometer with Odometer 1 "
15-23 284181 ------ 596153 Lens, Battery, Sprague 1 " 15-57 ------ ------ 1816 Light, Speedometer 1 "
15-24 284181 130-0099-001 596173 Lens Insert, Park Brake, Red 1 " 15-58 248661 350.516 350516 Gauge, Oil Pressure, 0-80 psi, 12V 1 "
15-25 402645 511.229 511229 Switch, Rocker, Select 3 (Wiper) 1 " 15-59 ------ ------ 600802 Light, Engine Oil Pressure Gauge 1 "
15-26 284181 ------ 596625 Lens w/ Wiper Symbol 1 " 15-60 248660 ------ 310514 Gauge, Transmission Oil Temp. 1 "
15-27 402645 511.010 511010 Switch, Rocker, 2 Pos. Off 1 " 15-61 ------ ------ 600802 Light, Transmission Oil Temp. Gauge 1 "
(Windshield Washer) 15-62 263928 530A1-49538 12950106 Tachometer with Hourmeter 1 "
15-28 284181 ------ 596627 Lens w/ Windshield Washer Symbol 1 " 15-63 ------ ------ 1816 Light, Tachometer 1 "
15-29 284181 ------ 596273 Cover, Black 5 " 15-64 284181 ------ 59L.506 Lens Insert, Temperature Red 1 "
15-30 284181 ------ 595502 Frame, Mounting - Sprague 7 " 15-65 402645 511.029.0225 511029 Switch, Rocker, 3 Pos. (Blower Fan) 1 "
15-31 402645 ------ 511003 Switch, Rocker, 2 Pos. (Park Light) 1 " 15-66 268466 ------ 596195 Lens w/ Blower Fan Symbol 1 "
15-32 ------ ------ ------ Lens w/ Park Light Symbol 1 " 15-67 402645 511.010 511010 Switch, Rocker, 2 Pos. OFF-ON 1 "
15-33 402645 511.029.0225 511029 Switch, Rocker, 3 Pos. (High/Low Beam) 1 " (Emerg. Steering)
15-34 284181 ------ 596169 Lens Insert, High Beam Blue 1 " 15-68 284181 ------ 59L.105 Lens Insert, Aux. Hyd. Pump - Green 1 "
15-35 402645 ------ 511003 Switch, Rocker, 2 Pos. (Rear Hitch Light) 1 " 15-69 402645 511-056 G1-10081 Switch, Momentary 1 "
15-70 402645 130-0047-000 G1-10082 Lens, Defroster 1 "
15-71 ------ ------ G1-10088 Alarm, Vehicle Speed - Opt. 1 "
CD276 4-2-31
Rev 13
Chapter 4
Table 4-16. Control Panel Assembly - Rear Cab

Ind Number Number
16-1 301664 ------ 12941826 Nameplate, Rear Station Panel 1 1 & Up

16-2 284181 ------ 596273 Cover, Black 2 "
16-3 284181 ------ 511500 Lamp Assembly, Pilot - 12V 1 "
16-4 402645 ------ 511502 Frame, Pilot Lamp, Sprague 2 "
13 11
16-6 239893 80400200 12941828 Lens Insert, Yellow Low Cool 1 "
6 9 10
5 4 4 3
16-7 ------ ------ 12941884 Lens Insert, Steer Mode Yellow 1 "
16-8 397689 ------ 12941885 Lens Insert, Cab Select Yellow 1 "
16-9 284181 ------ 59L.506 Lens Insert, Temperature Red 1 "
16-10 284181 ------ 596141 Lens, Red Transmission Temp. 1 "
DS40 DS41 DS42 DS46
16-11 284181 ------ 596142 Lens, Low Oil Pressure 1 "
- + FRONT SHIFTER
R
16-12 284181 ------ 59L.105 Lens Insert, Aux. Hyd. Pump - Green 1 "
NOT IN NEUTRAL
16-13 284181 ------ 596153 Lens, Battery, Sprague 1 "
LOW
COOL
18
X4
16-14 284181 ------ 596169 Lens Insert, High Beam Blue 1 "
DS47
16-15 402645 10F7459 014051 Light, Green Indicator 5 "
19 14 5 2 DS43 DS44
X2 SHIFTERS
G 16-16 402645 ------ 1090D3-12 Light, Amber Indicator 1 "
HITCH IN NEUTRAL
CAB 17 16-17 402645 ------ A11427X2 Light, Green Indicator 1 "
SELECTED
DS52 DS48 16-18 402645 1090D1-12V A11427X4 Light, Red Indicator 4 "
FRONT
BLANK
FRONT PARK R
GROUND SCREW (BEHIND PANEL) 16-19 402645 ------ 511003 Switch, Rocker, 2 Pos. (Rear Headlights) 1 "
BRAKE SW ON
FOR 16-20 402645 511.229 511229 Switch, Rocker, 3 Pos. (Steer Mode Select - Rear) 1 "
FUTURE
USE DS53 23 24 25 16-21 284181 ------ 511265 Switch, Rocker, 3 Pos. (Cab Select - Rear) 1 "
DS49
REAR PARK R P35
S31 S12 BRAKE SW ON 16-22 402645 511.010 511010 Switch, Rocker, 2 Pos. Off (Emerg. Steering - Rear) 1 "
REAR
DS50
16-23 243474 ------ 12066195 Connector, 8-Way, MP280, Male 1 "
DS54 PARK BRAKE
R SEE SHT.2 FOR WIRING
16-24 243474 12020782-L 12020782 Terminal, Male MP280 11 "
APPLIED
COORD 16-25 243474 ------ 12065141 Lock, Secondary 1 "
DS55
TRACK
CAB DS51 16-26 243474 ------ 12015345 Connector, 6-Way, MP280, Male 1 "
SEL. AXLE CENTER
A
DS56 INDICATOR
STEER
CRAB MODE S36
16
S34 S35 FRONT
15 X5 7 12 8
20 22 21 1
P36
24
SEE SHT.2 FOR WIRING
26
Figure 4-16. Control Panel Assembly - Rear Cab (Sheet 1 of 2)
4-2-32 CD276
Rev 13
Chapter 4
RED
DS46 CONNECTOR DESCRIPTION PART NO. SEC LOCK TERMINAL

FRONT SHIFTER
YEL NOT IN NEUTRAL YEL
R P35 PACKARD, MP280, 12066195 12065141 12020782
8 WAY, MALE
P36 PACKARD, MP280, 12015345 12020782
6 WAY, MALE
GROUND SCREW IN PLATE
DS47 SHIFTERS
#6 X 1" LG, IN NEUTRAL P35 1 TERMINAL 3−520107−2
YEL YEL
ZINC PLATED G
H
DS52 D
FRONT CAB DS48 A
SELECTED FRONT PARK
YEL BRAKE SW ON YEL
RED BLK R C
BLK
B
NOTES:
DS49 E
1.− ALL WIRES SHOWN ARE VENDOR WIRES.
RED BLK REAR PARK
YEL BRAKE SW ON YEL F 2.− CRIMP ALL WIRES AND TERMINALS IN ACCORDANCE TO THE
R CONNECTOR MANUFACTURER’S SPECIFICATIONS.
REAR CAB G
SELECTED 3.− SPLICES:
− ONLY IF WIRES ARE TOO SHORT.
COORD DS54 DS53 DS50 − MUST SURVIVE A PULL TEST OF 15 POUNDS.
PARK BRAKE
YEL APPLIED YEL − ENCLOSED IN A HEAT SHRINK WRAP "REM" TECH DWP−125 OR ANY
R EQUIVALENT WITH DUAL WALL EPOXY ENCAPSULATING POLYOLEFIN.
TRACK DS55 BLK
4.− GROUND STUD:
USE RING TERMINALS FOR #6 STUD 22−16 AWG PIDG OR EQUIVALENT.
CRAB DS56 BLK STACK WIRES IN SETS OF FOUR OR LESS USING A NUT AND INTERNAL
DS51 AXLE CENTER TOOTH WASHER BETWEEN WIRE GROUPS. SEE ILLUSTRATION.
YEL INDICATOR YEL
A
RED
RED
RED
RED
12015345 CONNECTOR
12020782 TERMINAL (3)
P36 F E D B A C
NUT (3) WASHER (5)
WIRE LUG
WIRE GROUNDING
FACEPLATE
Figure 4-16. Control Panel Assembly - Rear Cab (Sheet 2 of 2)
CD276 4-2-33
Rev 13
Chapter 4
Table 4-17. Control Panel Assembly - Cab Selection

Ind Number Number
17-1 301664 ------ 12941723 Nameplate, Cab Control Panel 1 1 & Up
17-2 397689 ------ 12941885 Lens Insert, Cab Select Yellow 1 "
17-3 402645 ------ 1090D3-12 Light, Amber Indicator 1 "
17-4 402645 ------ A11427X2 Light, Green Indicator 1 "
17-5 402645 1090D1-12V A11427X4 Light, Red Indicator 4 "
17-6 284181 ------ 511265 Switch, Rocker, 3 Pos. (Cab Select) 1 "
17-7 402645 10F7459 014051 Light, Green Indicator 2 "
17-8 243474 ------ 12066195 Connector, 8-Way, MP280, Male 1 "
17-9 243474 12020782-L 12020782 Terminal, Male MP280 8 "
17-10 243474 ------ 12065141 Lock, Secondary 1 "
17-11 ------ ------ ------ Screw, Ground 1 "
17-12 ------ ------ ------ Washer, Flat 5 "
17-13 ------ ------ ------ Nut 3 "
G 17-14 ------ ------ ------ Washer, Star 1 "
17-15 ------ ------ ------ Bolt, Flange 4 "
R A
Figure 4-17. Control Panel Assembly - Cab Selection (Sheet 1 of 2)
4-2-34 CD276
Rev 13
Chapter 4
Figure 4-17. Control Panel Assembly - Cab Selection (Sheet 2 of 2)
CD276 4-2-35
Rev 13
Chapter 4
24
23
22
21
20
19
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.
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110-37
4
16
15
1
2 14
3 4 5 6 13
7
8
11 12
9 25
10
26
27
Figure 4-18. Console Decals
4-2-36 CD276
Rev 13
Chapter 4
Table 4-18. Console Decals

Ind Number Number
18-1 247378 ------ 12970342 Decal, Warning "Tow Aircraft on Low Gear" 1 1 & Up
18-2 288777 6006022224 12950891 Shifter, Electric 1 "
18-3 372209 ------ G1-10099 Decal, "Park Brake Engaged" 1 "
18-4 247378 ------ 12970444 Decal, "Do Not Drive with Park Brake Applied" 1 "
18-5 402645 4TL13 LE000307 Switch, Toggle, 4PDT, Maintained (Park Brake) 1 "
18-6 301664 ------ 12000237 Nameplate, Park Brake 1 "
18-7 247378 ------ 12970860 Decal, "Phone Jack" 1 "
18-8 402645 SWCL12B A14664 Jack, Phone 1 "
18-9 402645 515 A14663 Cover, Phone Jack Spring Loaded 1 "
18-10 240617 ------ 12941692 Mount, Phone Jack 1 "
18-11 249874 AFC-3M-25RC-FF 12881907 Gauge, Pressure, 0-3000 psi, 2.5" 1 "
18-12 247378 ------ 12970862 Decal, "Main Circuit" 1 "
18-13 1173904 ------ G1-10098 Plate, UID - Opt. 1 "
18-14 247378 ------ 12970851 Decal, "Do Not Shift Transmission" 1 "
18-15 242845 ------ 9410000146 Decal, "Notice: This Tractor…" 1 "
18-16 301664 43338 12930133 Plate, Data, Identification 1 "
301664 ------ G1-10031 Plate, Data, Contract 1 As Req'd
18-17 247378 ------ 12970872 Decal, "Towing Instructions" 1 1 & Up
18-18 247378 ------ 12990777 Decal, "Danger, Explosion Hazard" 1 "
18-19 247378 ------ 12970882 Decal, "GT-110 Towing Instructions" 1 "
18-20 247378 ------ 12970961 Decal, "Caution: Failure to Use Proper Gear" 1 "
18-21 247378 ------ 12970518 Decal, "Read the Manual" 1 "
18-22 247378 ------ 12970508 Decal, "Trained Personal" 1 "
18-23 247378 ------ 12970879 Decal, "Turn for Fresh Air" 1 "
18-24 ------ ------ ------ Switch, Mechanical (part of kit K994720) 1 "
18-25 426744 ------ 78890 Connector, Adapter, Male ¼" Tube 1 "
18-26 426744 ------ 3500X4 Elbow, 90° 4MJ-4FP90 1 "
18-27 426744 ------ 12941031 Hose, Cab Bulkhead to Pressure Gauge 1 "
CD276 4-2-37
Rev 13
Chapter 4
12 11 5
8 4 20 3
9
19 13
5 18 14
8 23 5 2
7 15 3
24 22 10 16
20 16
21
1
17
17
Figure 4-19. Accelerator System
4-2-38 CD276
Rev 13
Chapter 4
Table 4-19. Accelerator System

Ind Number Number
19-1 426744 ------ 12951012 Hose Assembly (Front Bulkhead to Slave) 1 1 & Up
19-2 426744 ------ 12951023 Hose Assembly (Reservoir to Front Blkhd) 1 "
19-3 426744 ------ 12970705 Hose Assembly (Bulkhead to Pedal) 2 "
19-4 373317 ------ 99844 Nut, Hex, 5/16-24 NF 1 "
19-5 373317 ------ 75470 Washer, Flat 5/16" ID 3 "
19-6 426744 ------ 12951024 Hose Assembly (Cab Blkhd to Front Blkhd) 2 "
19-7 373317 ------ 62847 Nut, Hex Lock, 1/4-20 NC 1 "
19-8 373317 ------ 99657 Washer, Flat, 1/4 2 "
19-9 373387 05120472 5120472 Bearing, End, 5/16 1 "
19-10 249487 12-460-186 12-460-126 Pedal, Accelerator 1 "
19-11 249487 ------ 12-120-010 Cylinder, Clutch Slave 1 "
19-12 373317 ------ 12881802 Bolt, Hex Head Ø ¼-20 x 1¾" Long 1 "
19-13 249487 ------ 20-920-009 Reservoir 1 "
19-14 426744 ------ 78886 Adapter, Connector, Male ¼ Tube 1 "
19-15 373317 ------ 60574 Nut, Top Lock Hex 5/16-18 2 "
19-16 426744 ------ 85759 Elbow, Bulkhead, Union, 1/4 Tube 90° 2 "
19-17 426744 4MJ-BLKHEAD-UN-KIT 77197 Bulkhead, Union, 37°, 1/4 Tube 2 "
19-18 373317 ------ 12871600 Bolt, Hex Head Ø 5/16-18 x 1¾" Long 1 "
19-19 373317 ------ 92275 Screw, Metric, Sockethead, 6 x 12mm 2 "
19-20 426744 ------ 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 2 "
19-21 385417 ------ G1-10048 Bracket, Mounting - Accelerator Cyl 1 "
19-22 373387 ------ 5169253 Spring, Lever Return 1 "
19-23 358417 ------ 12950587 Bracket, Engine Governor 1 "
19-24 426744 ------ 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 1 "
CD276 4-2-39
Rev 13
Chapter 4
22 2
23 24 25 26
31 9
21
26 10
30
29
20 28 26
11 3 3
32
18 27 1 4 4
2
19
17
2
16
8
12 5
15
14 6
10
13
7 6
5
Figure 4-20. Accelerator System (with ROC Option)
4-2-40 CD276
Rev 13
Chapter 4
Table 4-20. Accelerator System (with ROC Option)

Ind Number Number
20-1 249487 12-460-186 12-460-126 Pedal, Accelerator 1 1 & Up

20-2 426744 ------ 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 3 "
20-3 426744 ------ 12970705 Hose Assembly (Bulkhead to Pedal) 2 "
20-4 426744 ------ 85759 Elbow, Bulkhead, Union, 1/4 Tube 90° 2 "
20-5 426744 ------ 12951024 Hose Assembly (Cab Blkhd to Front Blkhd) 2 "
20-6 426744 4MJ-BLKHEAD-UN-KIT 77197 Bulkhead, Union, 37°, 1/4 Tube 2 "
20-7 251747 ------ 12951026 Hose Assembly (Front Blkhd to Solenoid) 1 "
20-8 426744 ------ 12951023 Hose Assembly (Reservoir to Front Blkhd) 1 "
20-9 249487 ------ 20-920-009 Reservoir 1 "
20-10 426744 ------ 78886 Adapter, Connector, Male ¼ Tube 3 "
20-11 426744 4MJ-4FJX-4MJ 12872931 Tee, ¼JIC with Swivel 1 "
20-12 426744 ------ 12951027 Hose Assembly (Reservoir to Rear Accel Pedal) 1 "
20-13 249487 ------ 12-460-124 Pedal, Accelerator - Rear Cab 1 "
20-14 249487 ------ 12951028 Hose Assembly (Rear Accel Pedal to Solenoid) 1 "
20-15 426744 ------ 76916 Adapter, Connector 2 "
20-16 240986 ------ 8-5-6T-A-12VDC Valve, Solenoid - 3-Way, 6 Port 1 "
20-17 426744 ------ 76948 Elbow, 90° ¼ Tube 1 "
20-18 426744 ------ 12951029 Hose Assembly (Solenoid Valve to Slave Cyl.) 1 "
20-19 385417 ------ G1-10048 Bracket, Mounting - Accelerator Cyl 1 "
20-20 373317 ------ 62847 Nut, Hex Lock, 1/4-20 NC 1 "
20-21 373317 ------ 99657 Washer, Flat, 1/4 2 "
20-22 373317 ------ 12881802 Bolt, Hex Head Ø ¼-20 x 1¾" Long 1 "
20-23 249487 ------ 12-120-010 Cylinder, Clutch Slave 1 "
20-24 373317 ------ 99844 Nut, Hex, 5/16-24 NF 1 "
20-25 373387 05120472 5120472 Bearing, End, 5/16 1 "
20-26 373317 ------ 75470 Washer, Flat 5/16" ID 3 "
20-27 373387 ------ 5169253 Spring, Lever Return 1 "
20-28 373317 ------ 60574 Nut, Top Lock Hex 5/16-18 2 "
20-29 358417 ------ 12950587 Bracket, Engine Governor 1 "
20-30 373317 ------ 12871600 Bolt, Hex Head Ø 5/16-18 x 1¾" Long 1 "
20-31 373317 ------ 92275 Screw, Metric, Sockethead, 6 x 12mm 2 "
20-32 426744 ------ 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 1 "
CD276 4-2-41
Rev 13
Chapter 4
4-2-42 CD276
Rev 13
Chapter 4
Table 4-21. Brake Pedal Assembly

Ind Number Number
21-1 372750 ------ 015149 Brake Pedal Weldment 1 1 & Up

21-2 249487 20-080-077 013521-1 Actuator 1 "
23 21-3 249487 30-290-006 013521-2 Adapter, Actuator 1 "
21-4 373317 A8003-074 3/8-16 x 4¼ Bolt, Hex Head Ø 3/8-16 x 4¼" Long 1 "
21-5 242714 ------ 9864004016 Screw, Flat Head 2 "
21-6 373089 ------ 015213 Spacer, Brake 1 "
24
21-7 249487 20-080-077 013521-1 Actuator 1 "
21-8 373317 73798 3/8 Washer, Flat 3/8" 1 "
22 21-9 373317 81586 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
21-10 249487 30-290-006 013521-2 Adapter, Actuator 1 "
21 21-11 426744 ------ 12931417 Tube Assembly 1 "
21-12 426744 ------ 203101-4-4S Tee, 37° Flare, Swivel 1 "
20 21-13 239446 2024-2-4S 76988 Elbow, 1/8" Pipe to ¼" JIC, 90, 4MJ-2MP90 4 "
21-14 373317 15003 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 2 "
19 21-15 426744 4MJ-4FJX-4MJ 12872931 Tee, ¼" JIC, Swivel 1 "
18 21-16 426744 ------ 12931418 Tube Assembly (Between Rear Actuator Elbows) 1 "
17 21-17 239359 ------ 12970493 Pad, Brake 1 "
372750 ------ G1-10105 Pad, Brake - High Angle with Grip 1 As Req'd
21-18 426744 ------ 12931419 Tube Assembly (Actuator Rear Elbow to Reservoir) 1 1 & Up
13
17 21-19 426744 ------ 78890 Fitting, ¼" Pipe to ¼' JIC Straight 1 "
21-20 373089 ------ 12961130 Guard, Brake Reservoir 1 "
16 21-21 426744 ------ 12941017 Tube Assembly (Front Axle to Front Brake Actuator) 1 "
12
21-22 249487 20-920-509 014589 Reservoir, Brake Fluid 1 "
15
11 21-23 372750 ------ 12931423 Cover, Brake Pedal 1 "
21-24 373317 19653 5/16-18 x ¾ Bolt, Flange 5/16-18 x ¾" Long 3 "
10 13
14
9
8
7 2
6 3
1
5
4
Figure 4-21. Brake Pedal Assembly
CD276 4-2-43
Rev 13
Chapter 4
AIR 55
17 CLEANER 42 22
50 51 21
21 22
50 52 20
20 47
17
23
23 48 49 38
54 40 55 46 37
45 40 54 39
11 36
44
13 43 42 41 26 27 28 32 35
6
11
15 16 29 34
17 18
12 14 24 6 31 53
30 53
9 10 11
1
19 25 53 30 33 17 18
2 19
4 22 20 20
3 22
21 21
6 4 17
5 17
8
7
Figure 4-22. Brake System
4-2-44 CD276
Rev 13
Chapter 4
Table 4-22. Brake System
22-1 372750 ------ 015149 Pedal Assembly, Brake 1 1 & Up 22-29 426744 ------ 12951460 Tube Assembly 1 1 & Up
22-2 249487 03-120-039 014242 Cylinder, Slave 1 " (Brake Actuator Valve to Pressure Switch)
22-3 426744 ------ 12931417 Tube Assembly (Between Top Actuators) 1 " 22-30 239446 202702-6-4S 76916 Fitting, Straight #6 O-Ring to 1/4 JIC 2 "
22-4 239446 2024-2-4S 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 4 " 22-31 426744 ------ 76948 Elbow, 90° #6 O-Ring to 1/4 JIC 2 "
22-5 426744 ------ 203101-4-4S Tee, 37° Flare Swivel 1 " 22-32 426744 ------ 12951461 Tube Assembly (Brake Actuator Return) 1 "
22-6 239446 2021-4-4S 78890 Fitting, Straight ¼ Pipe to ¼ JIC 3 " 22-33 249487 ------ 03-466-204 Brake Actuator, Modulating, 1 "
22-7 373089 ------ 12961130 Guard, Brake Reservoir 1 " 2-Stage, Tandem Section
22-8 249487 20-920-509 014589 Reservoir, Brake Fluid 1 " 22-34 426744 ------ 12951015 Hose Assembly 1 "
22-9 426744 ------ 12931419 Tube Assembly 1 " (Actuator Valve "A" to Rear Axle Tee)
(Right Actuator Rear Elbow to Reservoir) 22-35 240791 ------ 12950997 Hose Assembly 1 "
22-10 426744 ------ 12931418 Tube Assembly 1 " (Dual Check Relief Valve "B" to Brake Actuator)
(Between Rear Actuator Ports) 22-36 426744 ------ 12951013 Hose Assembly 1 "
22-11 426744 4MJ-4FJX-4MJ 12872931 Tee, ¼ JIC Swivel 3 " (Return Manifold to Actuator Valve Tee)
22-12 251747 ------ 12941017 Hose Assembly 1 " 22-37 426744 4MJ-8MB 76920 Connector, #8 SAE O-Ring/37° Straight 1 "
(Front Brake Actuator to Cab Bulkhead) 22-38 241983 90-0102 012496 Manifold, Return 1 "
22-13 239450 2043-4-4S 85759 Elbow, 90° Bulkhead ¼ JIC 1 " 22-39 239446 202702-8-8S 76923 Connector, Adapter, ½" Tube OD 1 "
22-14 426744 ------ 12951011 Hose Assembly 1 " 22-40 239446 2062-12-12S 76960 Elbow, 90° #12 O-Ring To 3/4 JIC 2 "
(Cab Bulkhead to Front Bulkhead) 22-41 240791 ------ 12950988 Hose Assembly 1 "
22-15 426744 4MJ-BLKHD-UN-KIT 77197 Fitting, Straight ¼ JIC to ¼ JIC, Bulkhead 1 " (Return Manifold to Relief Valve "T")
22-16 426744 ------ 12951012 Hose Assembly 1 " 22-42 426744 8MJ-8MB90 76953 Elbow, 90° #8 SAE O-Ring Boss, 37° Flare 3 "
(Front Bulkhead to Slave Cylinder) 22-43 240791 ------ 12950998 Hose Assembly 1 "
22-17 426744 4MJ-BLKHEAD-TEE 203002-4-4S Tee, Bulkhead, 37º Flare, #4 JIC Swivel 6 " (Relief Valve "A" to Bottom Port Brake Actuator)
22-18 372750 ------ 12950549 Bracket, Bulkhead Tee 2 " 22-44 426744 ------ 12950989 Hose Assembly 1 "
22-19 426744 ------ 12951018 Hose Assembly (Brake Tee to Left Side) 2 " (Distribution Valve to Relief Valve)
22-20 349373 ------ 012374 Bracket, Brake Line Mounting 4 " 22-45 426744 8FJ-4MJ 221501-8-4S Fitting, Reducer, 37° Flare Swivel 2 "
22-21 426744 ------ 015803X1 Tube Assembly, Brake 4 " 22-46 426744 8MJ-8FJX-8MJ 203102-8-8S Tee, #8 SAE, O-Ring Boss 37° Flare 2 "
22-22 426744 ------ 015803 Tube Assembly, Brake 4 " 22-47 241983 ------ 012483X4 Valve, Dual Check Relief 1 "
22-23 426744 ------ 12951017 Hose Assembly (Brake Tee to Right Side) 2 " 22-48 426744 ------ 12950991 Hose Assembly 1 "
22-24 426744 ------ 12951014 Hose Assembly 1 " (Relief Valve "B" to Accumulator Inside)
(Actuator Valve "A" to Tee Front Axle) 22-49 241983 ------ 012483X3 Valve, Dual Check Distribution 1 "
22-25 249487 03-120-039 014242 Cylinder, Slave 1 " 22-50 241983 4.5AL-8-8 9517001000 Accumulator, Hydraulic 2 "
22-26 240950 ------ 81358 Tee, ¼ Pipe, 4FP-Tee, Brass 1 " 22-51 241983 ------ 014248 Bracket, Accumulator 4 "
22-27 261104 744.22-S03F-50N 011714 Switch, Pressure, 50 psi 1 " 22-52 426744 ------ 12950990 Hose Assembly 1 "
22-28 238715 2404-4-4 76991 Elbow, 90°, ¼ Pipe to ¼ JIC 1 " (Relief Valve "A" to Accumulator Outside)
22-53 426744 ------ 22617-6 O-Ring, #6 Fitting (Service Item) 6 "
CD276 4-2-45
Rev 13
Chapter 4
REAR OPERATOR'S
COMPARTMENT
62 63 62 64
57
AIR 55
17 CLEANER 61
42 22 65
50 51 21 60
21 22
50 52 20 66
20 47 59
17
23
23 48 49 38
68 67
54 40 55 46 37
45 40 54 39
11 36
44
13 43 42 41 26 27 28 32 35
6
29 11
6
15 16 30 53 34
17 18 25 58
12 14 24 31 53
11
9 10
1
19 56 53 30 33 17 18
2
4 22 20 19 20
3 22
57
21 21
6 4 17
5 17
8
7
Figure 4-23. Brake System (with ROC Option)
4-2-46 CD276
Rev 13
Chapter 4
Table 4-23. Brake System (with ROC Option)
23-1 372750 ------ 015149 Pedal Assembly, Brake 1 1 & Up 23-35 240791 ------ 12950997 Hose Assembly 1 1 & Up
23-2 249487 03-120-039 014242 Cylinder, Slave 1 " (Dual Check Relief Valve "B" to Brake Actuator)
23-3 426744 ------ 12931417 Tube Assembly (Between Top Actuators) 1 " 23-36 426744 ------ 12951013 Hose Assembly 1 "
23-4 239446 2024-2-4S 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 4 " (Return Manifold to Actuator Valve Tee)
23-5 426744 ------ 203101-4-4S Tee, 37° Flare Swivel 1 " 23-37 426744 4MJ-8MB 76920 Connector, #8 SAE O-Ring/37° Straight 1 "
23-6 239446 2021-4-4S 78890 Fitting, Straight ¼ Pipe to ¼ JIC 3 " 23-38 241983 90-0102 012496 Manifold, Return 1 "
23-39 239446 202702-8-8S 76923 Connector, Adapter, ½" Tube OD 1 "
23-7 373089 ------ 12961130 Guard, Brake Reservoir 1 "
23-40 239446 2062-12-12S 76960 Elbow, 90° #12 O-Ring To 3/4 JIC 2 "
23-8 249487 20-920-509 014589 Reservoir, Brake Fluid 1 "
23-41 240791 ------ 12950988 Hose Assembly 1 "
23-9 426744 ------ 12931419 Tube Assembly 1 "
(Return Manifold to Relief Valve "T")
(Right Actuator Rear Elbow to Reservoir)
23-10 426744 ------ 12931418 Tube Assembly 1 "
23-43 240791 ------ 12950998 Hose Assembly 1 "
(Between Rear Actuator Ports) (Relief Valve "A" to Bottom Port Brake Actuator)
23-11 426744 4MJ-4FJX-4MJ 12872931 Tee, ¼ JIC Swivel 3 " 23-44 426744 ------ 12950989 Hose Assembly 1 "
23-12 251747 ------ 12941017 Hose Assembly 1 " (Distribution Valve to Relief Valve)
(Front Brake Actuator to Cab Bulkhead) 23-45 426744 8FJ-4MJ 221501-8-4S Fitting, Reducer, 37° Flare Swivel 2 "
23-13 239450 2043-4-4S 85759 Elbow, 90° Bulkhead ¼ JIC 1 " 23-46 426744 8MJ-8FJX-8MJ 203102-8-8S Tee, #8 SAE, O-Ring Boss 37° Flare 2 "
23-14 426744 ------ 12951011 Hose Assembly 1 " 23-47 241983 ------ 012483X4 Valve, Dual Check Relief 1 "
(Cab Bulkhead to Front Bulkhead) 23-48 426744 ------ 12950991 Hose Assembly 1 "
23-15 426744 4MJ-BLKHD-UN-KIT 77197 Fitting, Straight ¼ JIC to ¼ JIC, Bulkhead 1 " (Relief Valve "B" to Accumulator Inside)
23-16 426744 ------ 12951012 Hose Assembly 1 " 23-49 241983 ------ 012483X3 Valve, Dual Check Distribution 1 "
(Front Bulkhead to Slave Cylinder) 23-50 241983 4.5AL-8-8 9517001000 Accumulator, Hydraulic 2 "
23-17 426744 4MJ-BLKHEAD-TEE 203002-4-4S Tee, Bulkhead, 37º Flare, #4 JIC Swivel 6 " 23-51 241983 ------ 014248 Bracket, Accumulator 4 "
23-18 372750 ------ 12950549 Bracket, Bulkhead Tee 2 " 23-52 426744 ------ 12950990 Hose Assembly 1 "
23-19 426744 ------ 12951018 Hose Assembly (Brake Tee to Left Side) 2 " (Relief Valve "A" to Accumulator Outside)
23-20 349373 ------ 012374 Bracket, Brake Line Mounting 4 " 23-53 426744 ------ 22617-6 O-Ring, #6 Fitting (Service Item) 6 "
23-21 426744 ------ 015803X1 Tube Assembly, Brake 4 " 23-54 426744 ------ 22617-12 O-Ring, #12 Fitting (Service Item) 2 "
23-22 426744 ------ 015803 Tube Assembly, Brake 4 " 23-55 426744 ------ 22617-8 O-Ring, #8 Fitting (Service Item) 7 "
23-23 426744 ------ 12951017 Hose Assembly (Brake Tee to Right Side) 2 " 23-56 249487 03-120-039 014242 Cylinder, Slave - ROC 1 "
23-24 426744 ------ 12951014 Hose Assembly 1 " 23-57 426744 ------ 78890 Connector, ¼ Pipe to ¼ JIC, Straight 1 "
(Actuator Valve "A" to Tee Front Axle) 23-58 426744 ------ 12951016 Hose Assembly 1 "
(Rear Brake to Slave Cylinder) - ROC
23-25 249487 03-120-039 014242 Cylinder, Slave 1 "
23-59 372750 ------ 015149 Pedal, Brake (Wldmt) - ROC 1 "
23-26 240950 ------ 81358 Tee, ¼ Pipe, 4FP-Tee, Brass 1 "
23-60 249487 ------ 013521-1 Actuator, Brake - ROC 1 "
23-27 261104 744.22-S03F-50N 011714 Switch, Pressure, 50 psi 1 "
23-61 426744 ------ 12931417 Tube Assembly 1 "
23-28 238715 2404-4-4 76991 Elbow, 90°, ¼ Pipe to ¼ JIC 1 "
(Cylinder Crossover to Tee) - ROC
23-29 426744 ------ 12951460 Tube Assembly 1 " 23-62 426744 4MJ-2MP90 78988 Elbow, 90° 1/8 Pipe to ¼ JIC90 - ROC 4 "
(Brake Actuator Valve to Press. Switch) 23-63 426744 ------ 203101-4-4S Tee, 37° Flare, Swivel - ROC 1 "
23-30 239446 202702-6-4S 76916 Fitting, Straight #6 O-Ring to 1/4 JIC 2 " 23-64 426744 ------ 12931418 Tube Assembly 1 "
23-31 426744 ------ 76948 Elbow, 90° #6 O-Ring to 1/4 JIC 2 " (Between Rear Actuator Ports) - ROC
23-32 426744 ------ 12951461 Tube Assembly (Brake Actuator Return) 1 " 23-65 249487 20-920-509 014589 Reservoir, Brake Fluid - ROC 1 "
23-33 249487 ------ 03-466-204 Brake Actuator, Modulating, 1 " 23-66 373089 ------ 12961130 Guard, Brake Reservoir 1 "
2-Stage, Tandem Section 23-67 426744 ------ 12970110 Tube Assembly 1 "
23-34 426744 ------ 12951015 Hose Assembly 1 " (Actuators to Reservoir) - ROC
(Actuator Valve "A" to Rear Axle Tee) 23-68 426744 4MJ-4FJX-4MJ 12872931 Tee, ¼ JIC with Swivel 1 "
CD276 4-2-47
Rev 13
Chapter 4
1
2
10
11
17
14 18
7
13
6
5 7 19 20
12 6
8 5
9 4 16
15
3
3
Figure 4-24. Brake Actuator Assembly (p/n 12950599)
4-2-48 CD276
Rev 13
Chapter 4
Table 4-24. Brake Actuator Assembly (p/n 12950599)

Ind Number Number
24-1 373089 ------ 015790 Mount, Actuator, T700 Weld 1 1 & Up

24-2 358417 ------ 015791 Mount, Slave Cylinder, T700 Weld 1 "
24-3 249487 ------ 03-466-204 Brake Actuator, Modulating, 2-Stage 1 "
24-4 358417 ------ 015792 Pivot, Brake Actuator, Mount, T700 1 "
24-5 240035 ------ 015793 Clevis, T700 1 "
240035 ------ 015793 Clevis, T700 (w/ ROC Option) 2 "
24-6 373488 ------ 9128131062 Nut, Hex UNF2B 1 "
373488 ------ 9128131062 Nut, Hex UNF2B (w/ ROC Option) 2 "
24-7 249487 03-120-039 014242 Cylinder, Slave 1 "
249487 03-120-039 014242 Cylinder, Slave (w/ ROC Option) 2 "
24-8 373317 ------ 12871640 Bolt, Hex 5/16-18 UNC x 1" Long 3 "
24-9 373317 ------ 79578 Washer, Lock 5/16", Spring, Zerk 3 "
24-10 373317 ------ ------ Bolt, Flange 3/8-16 UNC x 1" Long 5 "
24-11 373317 33893 3/8 Washer, Lock 3/8" ID 4 "
24-12 373317 37264 3/8-16 Nut, Lock 3/8-16 1 "
24-13 373317 ------ ½-13 x 5¾ Bolt, Hex Head Ø ½-13 x 5¾" Long 1 "
24-14 373317 15107 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 2 "
24-15 373317 15117 3/8-16 x 3½ Bolt, Hex Head Ø 3/8-16 x 3½" Long 1 "
24-16 373317 33859 3/8 Washer, Flat 3/8" 4 "
24-17 373317 33861 ½ Washer, Flat ½" 1 "
24-18 373317 15111 3/8-16 x 2 Bolt, Hex Head Ø 3/8-16 x 2" Long 2 "
24-19 249487 ------ 06-400-152 Seal Repair Kit (Service Item Only) 1 "
24-20 249487 ------ 02-100-032 Seal Repair Kit (Service Item Only) 1 "
CD276 4-2-49
Rev 13
Chapter 4
3
AIR 21
CLEANER
16
20
18 28
14 26 15 27 19
9 17 4 27 17
27 17
7 1 19
2 28 18 5
6 12
26 9 22
29 10 26
8
9 26
24
11 13
23 6
18 25
28
HYDRAULIC
RESERVOIR
Figure 4-25. Park Brake Assembly (Up to S/N 173)
4-2-50 CD276
Rev 13
Chapter 4
Table 4-25. Park Brake Assembly (Up to S/N 173)

Ind Number Number
25-1 407341 ------ 12940551 Valve, Park Brake 1 Up to 173

25-2 241983 ------ 012483X3 Valve, Dual Check Distribution REF "
25-3 ------ ------ H1185 Pump, Hand 1 "
25-4 ------ ------ H1186 Valve, Shuttle (Hand Pump) REF "
25-5 241983 90-0102 012496 Manifold, Return 1 "
25-6 426744 ------ 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 2 "
25-7 205409 ------ 88197 Elbow, 90° ¼ Pipe Street, 3000# 1 "
25-8 261104 744.24-S01F-1800N 011714X1 Switch, Park Brake (1800 psi) 1 "
25-9 426744 4MJ-4MB90 76945 Elbow, 90° #4 SAE O-Ring/37° Flare 3 "
25-10 426744 ------ 76912 Connector, #4 SAE O-Ring/37° Flare 1 "
25-11 426744 ------ 2071-4-4S Elbow, 90° - 37° Flare Swivel/37° Flare 1 "
25-12 426744 ------ 12950982 Hose Assembly (Park Brake) 1 "
25-13 240791 ------ 12950983 Hose Assembly (Park Brake) 1 "
25-14 251747 ------ 12950979 Hose Assembly (Shuttle Valve C-Port) 1 "
25-15 251747 ------ 12950980 Hose Assembly (Hand Pump to "H" Port) 1 "
25-16 240791 ------ 12950981 Hose Assembly (Hand Pump to "T" Port) 1 "
25-17 240791 ------ 76948 Elbow, 90° #6 SAE O-Ring/37° Flare 3 "
25-18 426744 4MJ-8MB 76920 Connector, #8 SAE O-Ring/37° Straight 3 "
25-20 200597 2021-6-4S 78293 Connector, 3/8 Pipe to 37° Flare 1 "
25-21 426744 4MJ-8MP 78896 Connector, ½ Pipe to 37° Flare 2 "
25-22 251747 ------ 12951462 Tube Assembly (Shuttle Valve Bypass) 1 "
25-23 240791 ------ 12950946 Hose Assembly (Hand Pump "S" Port to Hyd. Resv.) 1 "
25-24 240791 ------ 12950947 Hose Assembly (Park Brake Valve "T") 1 "
25-25 240791 ------ 12950978 Hose Assembly (Shuttle Valve C-Port) 1 "
25-29 426744 ------ 76488 Plug, #4 O-Ring 1 "
CD276 4-2-51
Rev 13
Chapter 4
20 21 17 15
3
AIR
CLEANER 19
14 22
10 22 13
9
1 12
2 5
6 8
22 9
7 4
9
24
22 13
23 6
25
16
11
HYDRAULIC
RESERVOIR
Figure 4-26. Park Brake Assembly (S/N 173 and Up)
4-2-52 CD276
Rev 13
Chapter 4
Table 4-26. Park Brake Assembly (S/N 173 and Up)

Ind Number Number
26-1 241983 ------ 012483X4 Valve, Park Brake 1 173 & Up
26-3 241983 ------ HP-1S Pump, Hand w/ Integrated Shuttle 1 "
26-4 426744 ------ 76488 Plug, #4 O-Ring 1 "
26-5 241983 90-0102 012496 Manifold, Return 1 "
26-6 426744 ------ 76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 2 "
26-7 426744 ------ 86727 Elbow, 1/4 Pipe, 90°, Street, 3000# 1 "
26-8 261104 744.24-S01F-1800N 011714X1 Switch, Park Brake (1800 psi) 1 "
26-11 426744 ------ 76916 Adapter, Straight #6 O-Ring to #4 JIC 1 "
26-12 426744 ------ 12950982 Hose Assembly (Park Brake Valve "P" to Dist. Valve) 1 "
26-13 426744 ------ 12970746 Hose Assembly (Park Brake Valve to Hand Pump) 1 "
26-14 426744 ------ 12970745 Hose Assembly (Hand Pump to Front Axle) 1 "
26-17 240791 ------ 76948 Elbow, 90° #6 SAE O-Ring/37° Flare 1 "
26-20 426744 ------ 87880 Bushing, 1/2" Pipe to 1/4" JIC 1 "
26-21 426744 ------ 76991 Adapter, 1/4“ Pipe to #4 JIC 90 1 "
26-23 240791 ------ 12950946 Hose Assembly (Hand Pump "S" Port to Hyd. Resv.) 1 "
26-24 240791 ------ 12950947 Hose Assembly (Park Brake Valve "T" to Return Manifold) 1 "
26-25 426744 ------ 12970744 Hose Assembly (Hand Pump to Rear Axle) 1 "
CD276 4-2-53
Rev 13
Chapter 4
16
17 17 18
18 15 17
19
20 21 20 21
TYPICAL MOUNTING
FRONT AXLE
21 22 21 22
Table 4-27. Drive Train

Ind Number Number
11 27-1 358417 ------ G1-10040 Mount, Motor R/H - GT-110/U-30 1 1 & Up

FIG II 27-2 372750 ------ 12950819 Mount, Transmission 1 "
AXLE MOUNTING 27-3 242293 ------ SSB33-1000-4 Mount, Isolator 2 "
4
REAR AXLE SHOWN
27-4 241766 ------ A8002-187 Bolt, ¾-16 NF x 3½" Long 2 "
24 27-5 241766 ------ 73777 Nut, Locking, ¾-16 NF 3 "
27-6 373317 ------ 97897 Bolt, 20mm x 2.5 TP x 60mm Long 4 "
27-7 373317 ------ 93289 Washer, Lock 20mm 4 "
27-8 358417 ------ G1-10046 Mount, Motor L/H - GT-110/U-30 1 "
27-9 281359 ------ 12941853 Engine, Deutz, BF6M1013CP 1 Up to 289
264937 ------ G1-10012 Engine, Deutz, BF6M1013FC 1 289 & Up
27-10 288777 ------ 12950154 Transmission, ZF 1 Up to 109
288777 4644024122 12950500 Transmission, ZF 4WG200 1 109 & Up
3
27-11 666859 PSC-1485-HDB-232-617 12941407 Axle, Planetary Drive Steer 2 1 & Up
666859 PSC-1485-HDB-232-557 G1-10013 Axle, Drive Steer GT-110-AF 2 "
27-12 238834 90158-95 9432000006 Wheel Assembly 4 "
27-13 267009 125-509-420-0-0000 12891563 Tire, 1600 x 25HRRIB, Tubeless 4 "
1177411 ------ G1-10103 Tire/Wheel Assembly, GT-110 4 "
27-14 373317 ------ A13447 Nut, Lock - Cone Type 2, ¾" NC 88 "
27-15 350000 ------ 015366 Bearing Block Assembly 2 "
27-16 373317 ------ 12950215 Bolt, Hex Head Ø 1¼-7 NC x 6" Long 8 "
5 27-17 373317 ------ A8006-412C Washer, Flat 1¼ 16 "
27-18 373317 ------ A8006-030C Nut, Hex 1¼-7 NC 8 "
FIG I 27-19 239359 ------ 12941395 Bolster 1 "
ENGINE & TRANSMISSION MOUNTING 27-20 373317 ------ 12950216 Bolt, 1½-6 NC x 6" Lg. 16 "
27-21 373317 ------ 25985R1 Nut, 1½-6 NC 16 "
27-22 373317 ------ 12950673 Washer, Axle Mounting Bolt 32 "
27-23 373386 ------ 12950085 Driveline, Rear Axle 1 "
27-24 373317 33857 ¾ Washer, Flat ¾" ID 4 "
Figure 4-27. Drive Train (Sheet 1 of 2)
4-2-54 CD276
Rev 13
Chapter 4
14 13 14
AIR
13
12 CLEANER
SEE FIG I 12
20 3 2 19 20
21 9 10 21
22 15 22
23
15
SEE FIG II
20 16 17 18 16 17 18
21 6
22 7 3 4 5 20 21 22
4 5 24
11 8
12 11 12
HYDRAULIC TANK 14
13 14 13
Figure 4-27. Drive Train (Sheet 2 of 2)
CD276 4-2-55
Rev 13
Chapter 4
Figure 4-28. Bolt Torque Specification - Drive Train (Sheet 1 of 2)
4-2-56 CD276
Rev 13
Chapter 4
TRUNNION BEARING BLOCK D
TYPICAL MOUNTING C
C FRONT AXLE
FIG II
AXLE MOUNTING
FIG I
REAR AXLE SHOWN
ENGINE & TRANSMISSION MOUNTING
TYPICAL
DEUTZ ENGINE
C
L
CRANK SHAFT
E E E E
E F F
ROCKWELL FRONT AXLE ROCKWELL REAR AXLE
FIG III ZF TRANS.
DRIVE SHAFT INSTALLATION
Figure 4-28. Bolt Torque Specification - Drive Train (Sheet 2 of 2)
CD276 4-2-57
Rev 13
Chapter 4
C
L
CRANK SHAFT
4 5 6
ROCKWELL
ROCKWELL REAR AXLE
FRONT AXLE
1 3
2
4 5 6 8
8
9
CENTER BRG MOUNT HERE
ON EARLY MODEL FRAMES
Figure 4-29. Drive Shaft Installation
4-2-58 CD276
Rev 13
Chapter 4
Table 4-29. Drive Shaft Installation

Ind Number Number
29-1 373386 ------ 12950080 Driveline, Front Axle 1 1 & Up

29-2 373386 ------ 12950079 Driveline Assembly with Center Bearing Mount 1 "
29-3 373386 ------ 12950085 Driveline, Rear Axle 1 "
29-4 373317 ------ 97773 Bolt, M10-1.5 x 40mm Long, Gr 10.9 16 "
29-5 373317 ------ 94477 Nut, Hex M10-1.5, Gr 8 16 "
29-6 373317 ------ 99516 Washer, Lock, Metric, 10mm 16 "
29-8 666859 PSC-1485-HDB-232-617 12941407 Axle, Planetary Drive Steer 2 1 & Up
666859 PSC-1485-HDB-232-557 G1-10013 Axle, Drive Steer GT-110-AF 2 "
29-9 288777 ------ 12950154 Transmission, ZF 1 Up to 109
288777 4644024122 12950500 Transmission, ZF 4WG200 1 109 & Up
372750 ------ 12950819 Mount, Transmission, ZF 1 1 & Up
29-10 263846 ------ 4644311201 Gasket, ZF Transmission - PTO Group 2 "
CD276 4-2-59
Rev 13
Chapter 4
Table 4-30. Lubrication System

17
16
14
15 Fig &
Code
Vendor Part Tug Part
Ind Number Number
30- 253635 550-503-659 12990070 Lubrication System, Automatic 1 As Req'd

30- 234190 85942G2901 G1-10106 Lube System Kit 1 "
13
30-1 ------ ------ ------ Block, Front 1 "
18 30-2 ------ ------ ------ Hose, Orange to Bottom King Pin 1 "
12 30-3 ------ ------ ------ Hose, Black to Steer Cylinder 1 "
30-4 ------ ------ ------ Hose, Black to Steer Cylinder 1 "
30-5 ------ ------ ------ Hose, Blue to Tie Rod 1 "
6
30-6 ------ ------ ------ Hose, Orange to Top King Pin 1 "
11 5 30-7 ------ ------ ------ Hose, Orange to Bottom King Pin 1 "
10 4 30-9 ------ ------ ------ Hose, Black to Steer Cylinder 1 "
3 30-10 ------ ------ ------ Hose, Blue to Tie Rod 1 "
9 30-11 ------ ------ ------ Hose, Orange to Top King Pin 1 "
2 30-12 ------ ------ ------ Fitting 1 "
8
30-13 ------ ------ ------ Hose, Block Lube Front to Block Side 1 "
7 1 30-14 ------ ------ ------ Reservoir 1 "
30-15 ------ ------ ------ Plug 1 "
30-16 ------ ------ ------ Elbow 1 "
30-17 ------ ------ ------ Hose 1 "
30-18 ------ ------ ------ Timer, 12 to 32 VDC 1 "
30-19 ------ ------ ------ Block, Side 1 "
26 27 28 29 30-20 ------ ------ ------ Hose, Orange to Bottom King Pin 1 "
30
19 30-25 ------ ------ ------ Hose, Black to Axle Pivot 1 "
13 30-26 ------ ------ ------ Hose, Orange to Bottom King Pin 1 "
21
30-31 ------ ------ ------ Hose, Black to Axle Pivot 1 "
22 32
30-32 ------ ------ ------ Elbow, 90° 1 "
23 25
24
Figure 4-30. Lubrication System
4-2-60 CD276
Rev 13
Chapter 4
Table 4-31. Steering Column Assembly (Front)

2
1 Fig & Vendor Part Tug Part

Ind Number Number
31-1 403166 208-1013-001 77793 Horn Button Kit 1 1 & Up

31-2 373317 ------ 13/16-20 Nut, Hex 13/16-20 NEF (Steel) 1 "
3 31-3 214264 74049B1-171/2 7404900 Wheel, Steering - 3 spoke, 17" Dia. 1 "
31-5 373317 33893 3/8 Washer, Lock 3/8" ID 4 "
31-6 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
31-8 266763 ------ 204-1043 Column, Steering, 8" 1 "
4 31-9 260131 ------ T6-7007-101 Control, Turn Signal 1 "
31-10 372739 ------ 252-1003 Steering Unit, Orbitrol, 48 1 "
31-11 426744 8MJ-12MB 76932 Adapter, Straight 8MJ-12MB 4 "
5 7 31-12 426744 ------ 12941007 Hose Assembly (Front Orbitrol Valve (R) to Cab Blkhd) 1 "
31-13 240791 ------ 12951019 Hose Assembly (Front Orbitrol Valve (T) to Cab Blkhd) 1 "
6 31-14 426744 ------ 12941006 Hose Assembly (Front Orbitrol Valve (L) to Cab Blkhd) 1 "
31-15 240791 ------ 12951020 Hose Assembly (Front Orbitrol Valve (P) to Cab Blkhd) 1 "
31-16 373089 ------ 12951101 Cover, Front Orbitrol Valve 1 "
9
13 10
14
11 16
15
12
Figure 4-31. Steering Column Assembly (Front)
CD276 4-2-61
Rev 13
Chapter 4
Table 4-32. Steering Column Assembly (ROC Option)

2

Ind Number Number
32-1 403166 208-1013-001 77793 Horn Button Kit 1 1 & Up

32-2 373317 ------ 13/16-20 Nut, Hex 13/16-20 NEF (Steel) 1 "
3 32-3 214264 74049B1-171/2 7404900 Wheel, Steering - 3 spoke, 17" Dia. 1 "
32-5 373317 33893 3/8 Washer, Lock 3/8" ID 4 "
32-6 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
32-8 266763 ------ 204-1043 Column, Steering, 8" 1 "
4 32-9 260131 ------ T6-7007-101 Control, Turn Signal 1 "
32-10 372739 ------ 252-1003 Steering Unit, Orbitrol, 48 1 "
5 7 32-11 426744 8MJ-12MB 76932 Adapter, Straight 8MJ-12MB 4 "
32-12 426744 ------ 12951008 Hose Assembly (Rear Orbitrol Valve (R) to Cab Blkhd) 1 "
6 32-13 426744 ------ 12951007 Hose Assembly (Rear Orbitrol Valve (T) to Cab Blkhd) 1 "
32-14 426744 ------ 12951009 Hose Assembly (Rear Orbitrol Valve (L) to Cab Blkhd) 1 "
32-15 426744 ------ 12951008 Hose Assembly (Rear Orbitrol Valve (P) to Cab Blkhd) 1 "
32-16 358417 ------ 12950880 Cover, Orbitrol Valve - ROC 1 "
9
13 10
14
16
11
15
12
Figure 4-32. Steering Column Assembly (ROC Option)
4-2-62 CD276
Rev 13
Chapter 4
CD276 4-2-63
Rev 13
Chapter 4
AIR
CLEANER
18
35 18
34 19
17 35
36 20 21 17
26 2
33 16 32 16 33
C1
34
15 L 25 P B C1 C2
33 16 P T 15 16 33
28 C1
R T
10 14 A 25 C2
C2 14
8 19 22 31 35
9 11 34 30
R 35 23
7 19
L
4 P 21 27 35 14
24
34 29 15
T 33
9 12 14 L C2 16
3 8
16 33 C1
35 6
2 5 R
15 33 16 HYDRAULIC 16
P T RESERVOIR
17
33
13 17
R L
18 18
1
2
35
Figure 4-33. Hydraulic Steering System
4-2-64 CD276
Rev 13
Chapter 4
Table 4-33. Hydraulic Steering System

Ind Number Number
33-1 372739 ------ 252-1003 Steering Unit, Orbitrol, 48 1 1 & Up

33-3 240791 ------ 12951020 Hose Assembly (Front Orbitrol Valve (P) to Cab Blkhd) 1 "
33-4 426744 ------ 12941007 Hose Assembly (Front Orbitrol Valve (R) to Cab Blkhd) 1 "
33-5 426744 ------ 12941006 Hose Assembly (Front Orbitrol Valve (L) to Cab Blkhd) 1 "
33-6 240791 ------ 12951019 Hose Assembly (Front Orbitrol Valve (T) to Cab Blkhd) 1 "
33-7 426744 ------ 85762 Elbow, 90° Bulkhead Union, 8MJ-BLKHD90 4 "
33-8 240791 ------ 12951010 Hose Assembly (Front Cab Bulkhead to Front Bulkhead) 4 "
33-9 426744 ------ 77200 Fitting, ½" 37° Flare Bulkhead, 8MJ-BLKHD-UN w/ Nut 4 "
33-10 426744 ------ 12951000 Hose Assembly (Solenoid Valve (P) to Front Bulkhead (R)) 1 "
33-11 426744 ------ 12951445 Hose Assembly (Front Left Steer Cyl. (L) to Front Blkhd (L)) 1 "
33-12 240791 ------ 12950994 Hose Assembly (Distribution Valve (S) to Front Blkhd (P)) 1 "
33-13 240791 ------ 12950999 Hose Assembly (Return Manifold to Front Blkhd) 1 "
33-14 426744 8MJ-8FJX-8MJ 203102-8-8S Tee, #8 SAE, O-Ring Boss 37° Flare 8MJ-8FJX-9MJ 4 "
33-15 240791 ------ 12950987 Hose Assembly (Steering Cylinders) 4 "
33-17 403166 3X5025TX-7.25 12941452 Cylinder, Steering 4 "
33-18 379373 ------ 010937X1 Pin Assembly, Steering Cylinder 8 "
33-19 426744 ------ 76958 Elbow, #12 SAE, O-Ring Boss / 37° Flare 4 1 & Up
33-20 241983 ------ 012483X3 Valve, Dual Check Distribution 1 "
33-21 426744 ------ 76955 Elbow, 90° #10 SAE O-Ring Boss, 37° Flare 2 "
33-22 241983 NA01600 014631 Valve, Solenoid 1 "
33-23 241983 ------ 014632 Plate, Sub - Solenoid Valve 1 "
33-24 426744 ------ 12951001 Hose Assembly (Solenoid Valve to Front Cylinder Tee (R)) 1 "
33-25 426744 ------ 76927 Connector, ½" Tube OD, O-Ring / 37° Flare 2 "
33-26 426744 ------ 12951074 Tube Assembly (Select Valve to Pivot Valve) 1 "
33-27 266142 ------ 12951444 Hose Assembly (D.P. Check Valve (C2) to Solenoid) 1 "
33-28 241983 ------ A13048X2 Valve, Double Pilot Check Valve 1 "
33-29 426744 ------ 12951006 Hose Assembly (Bottom D.P. Check Valve (C2) to Rear Cyl. Tee (C2)) 1 "
33-30 426744 ------ 12951005 Hose Assembly (Top D.P. Check Valve (C1) to Rear Cyl. Tee (C1)) 1 "
33-32 241983 90-0102 012496 Manifold, Return 1 "
33-36 358417 ------ 12950548 Panel, Hydraulic Bulkhead 1 "
CD276 4-2-65
Rev 13
Chapter 4
52
51 53 2 56
47 50
P
AIR T P
CLEANER 43 T
45 46 1
18 50 L
42 L 54 R
18 59 40 2
R
60 27 28 51 56
17 58 26 58 29 41
20 17
57 16 21 39 16 57
16 57
55
15 P C2
L C2 B 38
57 16 P T T 15 16 57
22 30
10 14 R C1 A 35 C1
56 19 58 44 14
8 11 37
9 25 RR RC1
R RL RC2
48
31
7 36 FC1
L 56 FR
49
4 P 14
32 35 FL
FC2
T 15
12 14 16
9 L 58 24 33 C2
C2 23 L 57
3 8
6 16 57 (8 PLCS) 57 33 34 R
15 C1
56 C1
5 R
2 16 57 HYDRAULIC 16
P T RESERVOIR 17
57
13 17
18
R L
18
1
2
56
Figure 4-34. Hydraulic Steering System (w/ ROC Option)
4-2-66 CD276
Rev 13
Chapter 4
Table 4-34. Hydraulic Steering System (w/ ROC Option)
34-1 372739 ------ 252-1003 Steering Unit, Orbitrol, 48 2 1 & Up 34-31 426744 ------ 86080 Elbow, 45° 2 1 & Up
34-2 426744 8MJ-12MB 76932 Adapter, Straight 8MJ-12MB 8 " 34-32 266763 C1220S C1220 Valve, Check SAE #12 Ports 1 "
34-3 240791 ------ 12951020 Hose Assembly 1 " 34-33 426744 8MJ-8MB90 76953 Elbow, 90° #8 SAE O-Ring Boss, 37° Flare 8 "
(Front Orbitrol Valve (P) to Cab Blkhd) 34-34 241983 ------ 94-0238-10 Manifold, Valve 1 "
34-4 426744 ------ 12941007 Hose Assembly 1 " 34-35 426744 ------ 2242-2-4S Adapter, 1/8" Pipe to ¼" 2FP-4FJX 4 "
(Front Orbitrol Valve (R) to Cab Blkhd) 34-36 426744 8FJ-4MJ 221501-8-4S Adapter, 8FJ-4MJ 4 "
34-5 426744 ------ 12941006 Hose Assembly 1 " 34-37 261104 744.13-S33F-800N 12951213 Switch, Pressure 800 psi 4 "
(Front Orbitrol Valve (L) to Cab Blkhd) 34-38 426744 8MJ-8FJX-8MJ 203102-8-8S Tee, Swivel Flare 8MJ-8FJX-8MJ 1 "
34-6 240791 ------ 12951019 Hose Assembly 1 " 34-39 241983 90-0102 012496 Manifold, Return 1 "
(Front Orbitrol Valve (T) to Cab Blkhd) 34-40 426744 ------ 202702-24-16S Adapter, Connector, Aeroquip 2 "
34-41 200597 ------ 221501-16-12S Adapter, Connector 12MJ-16FX 1 "
34-8 240791 ------ 12951010 Hose Assembly 4 "
34-42 426744 ------ 12950996 Hose Assembly 1 "
(Front Cab Bulkhead to Front Bulkhead)
(Return Check Valve to Return Manifold)
34-9 426744 ------ 77200 Fitting, ½" 37° Flare Bulkhead, 4 "
34-43 426744 ------ 12950995 Hose Assembly 1 "
8MJ-BLKHD-UN w/ Nut
(Select Valve Sub-Plate (B) to Rear Blkhd (P))
34-10 426744 ------ 12951000 Hose Assembly 1 "
34-44 426744 8MJ-8FJX-8MJ 203102-8-8S Tee, Swivel Flare 8MJ-8FJX-8MJ 4 "
(Steer Manifold (FR) to Front Bulkhead (R))
34-11 426744 ------ 12951000 Hose Assembly 1 "
34-45 426744 ------ 12951004 Hose Assembly 1 "
(Steer Manifold (FL) to Front Bulkhead (L)) (Manifold Valve (RR) to Rear Blkhd (R))
34-12 240791 ------ 12950994 Hose Assembly 1 " 34-46 426744 ------ 12951004 Hose Assembly 1 "
(Solenoid Valve (A) to Front Blkhd (P)) (Manifold Valve (RL) to Rear Blkhd (L))
(Return Manifold (T) to Front Blkhd (T)) (Return Manifold (T) to Rear Blkhd (T))
34-14 426744 8MJ-8FJX-8MJ 203102-8-8S Tee, #8 SAE, O-Ring Boss 37° Flare 8MJ-8FJX-9MJ 4 " 34-48 426744 ------ 12951005 Hose Assembly 1 "
34-15 240791 ------ 12950987 Hose Assembly (Steering Cylinders) 4 " (Steer Manifold (RC1) to Rear Cyl. Tee (C1))
34-16 426744 8MJ-8MB90 76953 Elbow, 90° #8 SAE O-Ring Boss, 37° Flare 8 " 34-49 426744 ------ 12951006 Hose Assembly 1 "
34-17 403166 3X5025TX-7.25 12941452 Cylinder, Steering 4 " (Steer Manifold (RC2) to Rear Cyl. Tee (C2))
34-18 379373 ------ 010937X1 Pin Assembly, Steering Cylinder 8 " 34-50 426744 ------ 2071-8-8S Elbow, 90° Flare Swivel 4 "
34-19 426744 ------ 76958 Elbow, #12 SAE, O-Ring Boss / 37° Flare 1 " 34-51 426744 ------ 77200 Fitting, Union Bulkhead, 4 "
34-20 241983 ------ 012483X3 Valve, Dual Check Distribution 1 " 37° Flare 8MJ-BLKHD w/ Nut
(DCDV (GP1) to Solenoid Valve Plate (P)) (Rear Orbitrol Valve (P) to Cab Blkhd)
(Manifold (FC1) to Front Cylinder Tee (C1)) (Rear Orbitrol Valve (T) to Cab Blkhd)
(Manifold (FC2) to Front Cylinder Tee (C2)) (Rear Orbitrol Valve (L) to Cab Blkhd)
34-24 426744 ------ 76955 Elbow, 90° #10 SAE O-Ring Boss, 37° Flare 1 " 34-55 426744 ------ 12951008 Hose Assembly 1 "
34-25 426744 ------ 12950992 Hose Assembly 1 " (Rear Orbitrol Valve (R) to Cab Blkhd)
(Solenoid Valve (T) to Return Check Valve) 34-56 426744 ------ 22617-12 Fitting, #12 O-Ring (Service Item) 11 "
34-26 426744 ------ 76929 Adapter, Straight 12MJ-10MB 1 " 34-57 426744 ------ 22617-8 Fitting, #8 O-Ring (Service Item) 17 "
34-27 426744 ------ 76955 Elbow, 90° #10 SAE O-Ring Boss, 37° Flare 1 " 34-58 426744 ------ 22617-10 Fitting, #10 O-Ring (Service Item) 4 "
34-28 241983 ------ 015754 Valve, Cab Select 1 " 34-59 426744 ------ 22617-24 Fitting, #24 O-Ring (Service Item) 1 "
34-29 241983 ------ 014632 Plate, Sub - Cab Select Valve 1 " 34-60 358417 ------ 12950548 Panel, Hydraulic Bulkhead 1 "
CD276 4-2-67
Rev 13
Chapter 4
(REF) S25/P109
(SEE VIEW B)
S49/P74
1 2 2
(SEE VIEW A)
FRONT AXLE REED SWITCH OPERATION

APPROX.
0.12 DIRECTION
1& 2 1&2 1 1& OF
1
2
2
2 OFF ON ON ON 2 OFF
ASSEMBLY
MOTION
DIRECTION
OF 1& 2 1&2 1 1&
2 OFF ON ON ON 2 OFF
ASSEMBLY
MOTION
LED REF AIR CYLINDERS
REF.
1
2 31
3 4 FRONT MODE AXLE REED SWITCH(ES) ARRANGEMENT
27 28 30 1
29 VIEW B
26
24 25 5
NOTES:
P11 1. NUT & LOCKWASHER TO MOUNT RECEPTACLE TO PANEL

ARE PART OF PLUG KIT.
- REMOVE HOLE COVER AND USE EXISTING HOLE IN BOX TO MOUNT P11.
23 2. CABLE ROUTING NOT SHOWN. SECURE HARNESS TO EXISTING
BOX PLATE USING INSULATED CLAMPS.
3. RELAYS ARE NOT SHOWN.
4. MOUNTING:
- DRILL & TAP 2 MOUNTING HOLES (FOR #8 SCREWS) IN
K9 K10 K11 K12 EXISTING BOX PLATE.
- USE #8 X 3/8" SCREW (2), #8 FLAT WASHER FOR MOUNTING
CR32 ITEM 1 TO PLATE.
P25
12 13 14 P13 KA KB (CR28-CR31)
6 7 8
22
9 10 11
12 13 14
20 21
VIEWA
18 19 5 16 17 5 15
Figure 4-35. Steering Control Box
4-2-68 CD276
Rev 13
Chapter 4
Table 4-35. Steering Control Box

Ind Number Number
35-1 240035 ------ 12941843 Box, Modified Hydraulic Steer Control 1 1 & Up
35-2 239892 ------ 12940553 Reed Switch and Connector Assembly 3 "
35-3 373317 ------ 10-32 Screw, #10-32 4 "
35-4 373317 ------ 10-32 Washer, Flat 10-32 4 "
35-5 402645 IDEC: BNL-5 A14436 Clip, End 8 "
35-6 402645 RY4SUL-12VDC NP 014273 Relay, DPDT, 12V 2 "
35-7 402645 SY45-05 A13855X2 Socket, Relay 2 "
35-8 402645 ------ SFA-202 Spring, Hold Down F/Timer 4 "
35-9 243474 ------ 12015308 Housing, Diode Array 1 "
35-10 243474 ------ 12040502 Terminal, Female 8 "
35-11 243474 ------ 12020351 Diode Assembly, Circuit Board 1 "
35-12 402645 RR2KPUDC12V A13854 Relay, Latch 2 "
35-13 402645 ------ SH3B-05 Socket, Relay 3PDT 2 "
35-14 402645 ------ SR3P-06F3 Spring, Hold Down Relay 4 "
35-15 373085 ------ G1-10029 Harness, Relay, Centering, Assembly 1 "
35-16 402645 RH2LBUDC12V RH2LB-U-DC12 Relay, Latch - 12VDC, 10A 1 "
35-17 402645 ------ SH3B-05 Socket, Relay 3PDT 1 "
35-18 402645 ------ RY2S-L-DC12V Relay, DPDT w/ Indicator Light - 12VDC, 3A 1 "
35-19 402645 SY2S05 SY2S-05 Base, Plug-In Mounting 1 "
35-20 238730 ------ HD44-18-14PN Connector Body - Pin Contact 1 "
35-21 238730 ------ HD46-18-14SN Connector Body - Socket Contact 1 "
35-22 282851 ------ 12941889 Harness, Wire, Steer Box - Front Cab 1 "
35-23 ------ ------ 12941890 Harness, Wire, Steer Box - Rear Cab Opt. 1 "
35-24 238730 ------ HD44-18-14PN Connector Body - Pin Contact (Opt.) 1 "
35-25 238730 ------ HD46-18-14SN Connector Body - Socket Contact (Opt.) 1 "
35-26 244126 ------ 012780 Rail Channel 2 "
35-27 373317 ------ #8 Screw, #8 x 3/8" TAP 4 "
35-28 373317 ------ #8 Washer, Flat #8 4 "
35-29 301146 ------ 012494 Panel, Control Box - Hoffman 1 "
35-30 239892 99999011 12941696 Control Box Assembly, Hydraulic Steering 1 "
35-31 240809 RLC10A-DAP-AA90 12951347 Cylinder, Sensing 2 "
CD276 4-2-69
Rev 13
Chapter 4
Table 4-36. Hydraulic Tank Assembly

Ind Number Number
36-1 358417 ------ 12961263 Bracket, Hold Down, Hydraulic Tank 1 1 & Up
36-2 251747 ------ 12960437 Hose, Drain 1 "
36-3 426744 ------ 94259 Fitting, Hose, ¼" MNPT to 6ID 1 "
1 36-4 426744 ------ 6660 Valve, Drain - 90°, ¼ NPT 1 "
36-5 426744 3400X4 T6-9500-157 Elbow, 90° 1 "
2 36-6 426744 ------ 0502-8-4 Adapter, #8 SAE O-Ring to ¼ NPT 1 "
36-7 419408 ------ 12941657 Tank, Hydraulic 1 "
36-8 426744 ------ 202702-24-24S Adapter, Connector, Male, ½", 24MJ-24MB 1 "
3 36-9 426744 ------ 12951035 Hose Assembly (Hydraulic Tank to Hydraulic Pump) 1 "
20 36-10 240791 ------ 12950948 Hose Assembly (Emergency Pump to Hydraulic Tank) 1 "
4 36-11 240791 ------ 12950948 Hose Assembly (Hydraulic Tank to Emergency Pump) 1 "
36-12 426744 ------ 76923 Adapter, Connector, ½" Tube 8MJ-8MB 1 "
19 36-13 426744 4MJ-8MB 76920 Connector, #8 SAE O-Ring/37° Straight 1 "
36-14 426744 ------ 12951036 Hose Assembly, Pump Drain 1 "
36-15 405104 202702-8-5S 76921 Adapter, Connector, 5/16" Tube, 5MJ-8MB 1 "
18 36-16 426744 ------ 12950977 Hose Assembly (Tank to Filter) 1 "
36-17 426744 ------ 76942 Adapter, Connector, 1" Tube, 16MF-16MB 1 "
5 36-18 426744 ------ 86063 Plug, O-Ring Boss, ½" Tube, 8MB-Plug 1 "
17 36-19 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
36-20 373317 ------ 5/16-18 x 1 Bolt, Flange Ø 5/16-18 x 1" Long 2 "
6 16
7 15
13
12 14
11
10
8
9
Figure 4-36. Hydraulic Tank Assembly
4-2-70 CD276
Rev 13
Chapter 4
CD276 4-2-71
Rev 13
Chapter 4
1
2
3
4 83
6 5 81
6
80
7
16 71
17 8 9
20 11 82
21 10
22 18 78
23
24 77
25 12
26 76
27 19 14
28 75
15
29 79 71 74
30 73
72
31 51 13 12 71
70
27 52 69
32 53 68 67
66
57 65
33 50 56
34 33 55
34 58
54
35 46 84
64
36 44 63
37 61 62
38
60
2 59
39 48 49
47
40 45
41 43
38
42
Figure 4-37. Hydraulic Control Board Assembly
4-2-72 CD276
Rev 13
Chapter 4
Table 4-37. Hydraulic Control Board Assembly

Ind Number Number
37-1 244126 ------ 12950661 Control Board, Hydraulic 1 1 & Up
37-2 261104 744.24-S01F-1800N 011714X1 Switch, Brake (1800 psi) 2 "
37-3 329499 9310800 12951219 Gauge, Hydraulic Pressure (0-3000 psi) 1 "
37-4 358417 ------ 12910893 Bracket, Manifold - Gauges 1 "
37-5 373317 19653 5/16-18 x ¾ Bolt, Flange Ø 5/16-18 x ¾" Long 2 "
37-7 426744 ------ 12950985 Hose Assembly (Brake Switch to Hydraulic Press. Gauge) 1 "
37-9 426744 ------ 12951369 Hose Assembly (Cab Lift DCDV to Lift Canopy Valve) 1 "
37-11 426744 ------ 12951000 Hose Assembly (Solenoid Valve (P) to Front Bulkhead (R)) 1 "
37-12 426744 ------ 76955 Elbow, 90° #10 SAE O-Ring Boss, 37° Flare 2 "
37-14 426744 ------ 87909 Plug, Pipe - Allen Head, ½" NPT 1 "
37-15 240175 ------ 12870886 Plug, Pipe - Allen Head, ¼" NPT 1 "
37-16 426744 ------ 12950985 Hose Assembly (Press. Gauge Tee to Dist. Valve Tee (GP1)) 1 "
37-18 426744 ------ 2030-4-4S Tee, Adapter ¼" Tube OD, 4MJ-4MJ-4MP 1 "
37-19 426744 ------ 76958 Elbow, #12 SAE, O-Ring Boss / 37° Flare 1 "
37-20 239446 2062-12-12S 76960 Elbow, 90° #12 O-Ring to 3/4 JIC 1 "
37-21 426744 ------ 12940865 Hose Assembly (Bulkhead to DCDV Tee (GP1)) 1 "
37-22 240791 ------ 12950994 Hose Assembly (Distribution Valve (P) to Front Blkhd (P)) 1 "
37-23 373317 19931 3/8-16 x 1 Bolt, Flange Ø 3/8-16 x 1" Long 2 "
37-25 426744 ------ 12950982 Hose Assembly (Park Brake Valve "P" to DCDV "PB") 1 "
37-26 373317 ------ 86065 Plug, O-Ring Boss, ¾" Tube OD 1 "
37-28 426744 ------ 12950989 Hose Assembly (Distribution Valve to Relief Valve) 1 "
37-29 373317 33892 5/16 Washer, Lock 5/16" ID 2 "
37-30 241983 ------ 012483X4 Valve, Dual Check Relief 1 "
37-34 426744 8FJ-4MJ 221501-8-4S Adapter, 8FJ-4MJ 2 "
37-35 426744 ------ 12950990 Hose Assembly (DCRV "A" to Accumulator Outside) 1 "
37-36 240791 ------ 12950998 Hose Assembly (Relief Valve "A" to Brake Booster) 1 "
37-37 240791 ------ 12950988 Hose Assembly, Return Manifold to Relief Valve "T" 1 "
37-40 241983 ------ 012483X1 Valve, Park Brake 1 "
37-41 426744 ------ 76488 Plug, #4 O-Ring 1 "
CD276 4-2-73
Rev 13
Chapter 4
1
2
3
4 83
6 5 81
6
80
7
16 71
17 8 9
20 11 82
21 10
22 18 78
23
24 77
25 12
26 76
27 19 14
28 75
15
29 79 71 74
30 73
72
31 51 13 12 71
70
27 52 69
32 53 68 67
66
57 65
33 50 56
34 33 55
34 58
54
35 46 84
64
36 44 63
37 61 62
38
60
2 59
39 48 49
47
40 45
41 43
38
42
Figure 4-37. Hydraulic Control Board Assembly (Cont'd)
4-2-74 CD276
Rev 13
Chapter 4
Table 4-37. Hydraulic Control Board Assembly (Cont'd)

Ind Number Number
37-43 426744 ------ 12970746 Hose Assembly (Park Brake Valve to Hand Pump) 1 1 & Up
37-45 240791 ------ 12950976 Hose Assembly (Return Manifold to Hydraulic Filter) 1 "
37-46 240791 ------ 12950997 Hose Assembly (Dual Check Relief Valve "B" to Brake Booster) 1 "
37-48 426744 ------ 202702-24-16S Connector, Adapter AEROQUIP, 16MJ-24MB 1 "
37-49 426744 ------ 12951368 Hose Assembly (Bottom Return Manifold to Lift Valve) 1 "
37-50 426744 ------ 12950991 Hose Assembly (Relief Valve "B" to Accumulator Inside) 1 "
37-51 426744 ------ 76966 Elbow, Adapter, 90°, 16MJ-16MB-90 1 "
37-52 426744 ------ 12951001 Hose Assembly (Solenoid Valve to Front Cylinder Tee (R)) 1 "
37-54 240791 ------ 12951034 Hose Assembly ("PL" Distribution Valve to Hydraulic Pump) 1 "
37-55 426744 ------ 12950986 Hose Assembly (Bottom Dist. Valve to Emergency Steer Pump) 1 "
37-56 426744 ------ 221501-12-6S Connector, Adapter, Swivel 12FJ-6MJ 1 "
37-57 426744 12MJ-16MB90 76965 Elbow, Adapter, 90°, 12MJ-16MB-90 1 "
37-60 426744 ------ 86067 Plug, O-Ring Boss - 1" Tube OD 16MB-Plug 2 "
37-61 373317 ------ 86065 Plug, O-Ring Boss - ¾" Tube OD 12MP-Plug 1 "
37-62 240791 ------ 12950999 Hose Assembly (Return Manifold (T) to Front Blkhd (T)) 1 "
37-67 426744 ------ 12951013 Hose Assembly (Return Manifold to Brake Accumulator "T") 1 "
37-68 241983 90-0102 012496 Manifold, Return 1 "
37-70 426744 ------ 86069 Plug, O-Ring Boss - 1½" Tube OD 1 "
37-72 426744 ------ 12951006 Hose Assembly (Bottom DPCV (C2) to Rear Cyl. Tee (C2)) 1 "
37-73 266142 ------ 12951444 Hose Assembly (DPCV (C2) to Solenoid Valve Bottom) 1 "
37-76 373317 33893 3/8 Washer, Lock 3/8" ID 2 "
37-77 373317 33859 3/8 Washer, Flat 3/8" ID 2 "
37-78 241983 ------ A13048X2 Valve, Double Pilot Check Valve 1 "
37-79 373317 ------ 5/16-18 x 2 Bolt, Allen Head 5/16-18 x 2" Long 2 "
37-80 426744 ------ 12951074 Tube Assembly (Select Valve to Pivot Valve) 1 "
37-82 426744 ------ 12951005 Hose Assembly (Top DPCV (C1) to Rear Cyl. Tee (C1)) 1 "
37-83 358417 ------ 12951067 Spacer, Select Valve 1 "
37-84 ------ ------ 12980085 Cable Assembly, Steering Solenoid 1 "
CD276 4-2-75
Rev 13
Chapter 4
2
3 1 105
4 8 87
113
5
6 9
7
10 105
86
19 11 97 114
20 85 104
23 13
12
24 18 87 103
25 21 14
26 88
27 15
28 83
110 85
29 17
22 22 84
30 16 88
83 87
31
82 108
32 51 87 85
52 81 97 102
33 47 50
12 80 89 109
22 96 101
48 78 87 106
23 49 79 90
91
59 77 107
34 46 58
35 57 92 98
35 60 99
34 56
36 76 93 100
45
37 7
44 75 94
38 95
29 74
27 17REF
2 62 111 72
61 73
55 63 112
39 52 71
54 64
40 53
41 43 70
27 65
42 69
66 67 68
Figure 4-38. Hydraulic Control Board Assembly (with ROC Option)
4-2-76 CD276
Rev 13
Chapter 4
Table 4-38. Hydraulic Control Board Assembly (with ROC Option)

Ind Number Number
38-1 244126 ------ 12950661 Control Board, Hydraulic 1 1 & Up
38-2 261104 744.24-S01F-1800N 011714X1 Switch, Brake (1800 psi) 2 "
38-3 329499 9310800 12951219 Gauge, Hydraulic Pressure (0-3000 psi) 1 "
38-4 358417 ------ 12910893 Bracket, Manifold - Gauges 1 "
38-5 426744 ------ 76991 Elbow, 90° 4MJ-4MP90 1 "
38-8 373317 19653 5/16-18 x ¾ Bolt, Flange Ø 5/16-18 x ¾" Long 2 "
38-10 426744 ------ 12951369 Hose Assembly (Cab Lift DCDV to Lift Canopy Valve) 1 "
38-11 358417 ------ 12951067 Spacer, Select Valve 1 "
38-15 426744 ------ 12950995 Hose Assembly (Sub-Plate Select Valve "B" to Rear Blkhd "P") 1 "
38-17 426744 ------ 87909 Plug, Pipe - Allen Head, ½" NPT 1 "
38-21 426744 ------ 2030-4-4S Tee, Adapter ¼" Tube OD, 4MJ-4MJ-4MP 1 "
38-24 426744 ------ 12940865 Hose Assembly (Bulkhead to DCDV Tee (GP1)) 1 "
38-25 426744 ------ 12950993 Hose Assembly (DCDV "P" to Solenoid Valve Plate "P") 1 "
38-28 426744 ------ 12950982 Hose Assembly (Park Brake Valve "P" to DCDV "PB") 1 "
38-29 373317 ------ 86065 Plug, O-Ring Boss - ¾" Tube OD 12MP-Plug 2 "
426744 10MJ-8MB90 ------ Elbow, 90° 10MJ-8MB90 - Internal Jacking Opt. 1 "
38-30 426744 ------ 12950989 Hose Assembly (Distribution Valve to Relief Valve) 1 "
38-31 373317 33892 5/16 Washer, Lock 5/16" ID 2 "
38-32 241983 ------ 012483X4 Valve, Dual Check Relief 1 "
38-36 426744 ------ 12950990 Hose Assembly (DCRV "A" to Accumulator Outside) 1 "
38-37 240791 ------ 12950998 Hose Assembly (DCRV "A" to Brake Actuator Valve (Bottom)) 1 "
38-38 240791 ------ 12950988 Hose Assembly (Return Manifold to DCRV "T") 1 "
38-40 241983 ------ 012483X1 Valve, Park Brake 1 "
38-41 426744 ------ 76488 Plug, #4 O-Ring 1 "
CD276 4-2-77
Rev 13
Chapter 4
2
3 1 105
4 8 87
113
5
6 9
7
10 105
86
19 11 97 114
20 85 104
23 13
12
24 18 87 103
25 21 14
26 88
27 15
28 83
110 85
29 17
22 22 84
30 16 88
83 87
31
82 108
32 51 87 85
52 81 97 102
33 47 50
12 80 89 109
22 96 101
48 78 87 106
23 49 79 90
91
59 77 107
34 46 58
35 57 92 98
35 60 99
34 56
36 76 93 100
45
37 7
44 75 94
38 95
29 74
27 17REF
2 62 111 72
61 73
55 63 112
39 52 71
54 64
40 53
41 43 70
27 65
42 69
66 67 68
Figure 4-38. Hydraulic Control Board Assembly (with ROC Option) (Cont'd)
4-2-78 CD276
Rev 13
Chapter 4
Table 4-38. Hydraulic Control Board Assembly (with ROC Option) (Cont'd)

Ind Number Number
38-43 426744 ------ 12970746 Hose Assembly (Park Brake Valve to Hand Pump) 1 1 & Up
38-45 240791 ------ 12950997 Hose Assembly (DCRV "B" to Brake Actuator Valve) 1 "
38-46 426744 ------ 12950991 Hose Assembly (DCRV "B" to Accumulator Inside) 1 "
38-48 426744 ------ 12950992 Hose Assembly (Solenoid Valve (T) to Return Check Valve) 1 "
38-49 426744 ------ 76929 Adapter, Straight 12MJ-10MB 1 "
38-50 240791 ------ 12950994 Hose Assembly (Solenoid Valve (A) to Front Blkhd (P)) 1 "
38-51 373317 ------ 5/16-18 x 2 Bolt, Allen Head 5/16-18 x 2" Long 2 "
38-52 426744 ------ 202702-24-16S Connector, Adapter AEROQUIP, 16MJ-24MB 2 "
38-53 240791 ------ 12950976 Hose Assembly (Return Manifold to Hydraulic Filter) 1 "
38-56 240791 ------ 12951034 Hose Assembly (DCDV "PL" to Hydraulic Pump) 1 "
38-57 426744 ------ 12950986 Hose Assembly (Bottom DCDV to Emergency Steer Pump) 1 "
38-58 426744 ------ 221501-12-6S Connector, Adapter, Swivel 12FJ-6MJ 1 "
38-59 426744 12MJ-16MB90 76965 Elbow, Adapter, 90°, 12MJ-16MB-90 1 "
38-62 426744 ------ 86067 Plug, O-Ring Boss - 1" Tube OD 16MB-Plug 2 "
38-63 358417 ------ 12873365 Spacer, Solenoid Valve 1 "
38-64 426744 4MJ-6MB 76916 Adapter, Straight #6 O-Ring to #4 JIC 2 "
38-65 249487 ------ 12951028 Hose Assembly (Rear Accel Pedal to Solenoid) 1 "
38-66 251747 ------ 12951026 Hose Assembly (Front Blkhd to Solenoid) 1 "
38-67 240986 ------ 8-5-6T-A-12VDC Valve, Solenoid - 3-Way, 6 Port 1 "
38-69 373317 33892 5/16 Washer, Lock 5/16" ID 2 "
38-70 373317 33858 5/16 Washer, Lock 5/16" ID 2 "
38-71 426744 ------ 76948 Elbow, 90° ¼ Tube 1 "
38-72 426744 ------ 12951029 Hose Assembly (Solenoid Valve to Slave Cyl.) 1 "
38-74 240791 ------ 12950999 Hose Assembly (Return Manifold (T) to Front Blkhd (T)) 1 "
38-75 426744 ------ 12951003 Hose Assembly (Return Manifold to Rear Blkhd) 1 "
38-79 241983 90-0102 012496 Manifold, Return 1 "
38-80 200597 ------ 221501-16-12S Adapter, Connector 12MJ-16FX 1 "
38-81 373317 15051 5/16-18 x ½ Bolt, Hex Head Ø 5/16-18 x ½" Long 4 "
38-82 426744 ------ 12950996 Hose Assembly (Return Check Valve to Return Manifold) 1 "
38-83 426744 ------ 86080 Elbow, 45° 2 "
CD276 4-2-79
Rev 13
Chapter 4
2
3 1 105
4 8 87
113
5
6 9
7
10 105
86
19 11 97 114
20 85 104
23 13
12
24 18 87 103
25 21 14
26 88
27 15
28 83
110 85
29 17
22 22 84
30 16 88
83 87
31
82 108
32 51 87 85
52 81 97 102
33 47 50
12 80 89 109
22 96 101
48 78 87 106
23 49 79 90
91
59 77 107
34 46 58
35 57 92 98
35 60 99
34 56
36 76 93 100
45
37 7
44 75 94
38 95
29 74
27 17REF
2 62 111 72
61 73
55 63 112
39 52 71
54 64
40 53
41 43 70
27 65
42 69
66 67 68
Figure 4-38. Hydraulic Control Board Assembly (with ROC Option) (Cont'd)
4-2-80 CD276
Rev 13
Chapter 4
Table 4-38. Hydraulic Control Board Assembly (with ROC Option) (Cont'd)

Ind Number Number
38-84 266763 C1220S C1220 Valve, Check SAE #12 Ports 1 1 & Up
38-85 426744 ------ 76488 Plug, #4 O-Ring 6 "
38-86 241983 ------ 94-0238-10 Manifold, Valve 1 "
38-88 261104 744.13-S33F-800N 12951213 Switch, Pressure 800 psi 4 "
38-89 426744 ------ 12951000 Hose Assembly (Manifold to Front Bulkhead (R)) 1 "
38-90 426744 ------ 12951013 Hose Assembly (Return Manifold to Brake Actuator "T") 1 "
38-91 241983 ------ 015754 Valve, Cab Select 1 "
38-92 373317 33861 ½ Washer, Flat ½" ID 4 "
38-93 373317 33895 ½ Washer, Lock ½" ID 4 "
38-94 373317 15207 ½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 4 "
38-95 245195 ------ 12940587 Bracket, Mounting - Hyd. Valve 1 "
38-96 426744 ------ 12951000 Hose Assembly (Manifold to Front Bulkhead (L)) 1 "
38-98 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
38-99 373317 33893 3/8 Washer, Lock 3/8" ID 4 "
38-101 426744 ------ 12951004 Hose Assembly (Manifold to Rear Blkhd (R)) 1 "
38-102 426744 ------ 12951004 Hose Assembly (Manifold to Rear Blkhd (L)) 1 "
38-103 426744 ------ 2242-2-4S Adapter, 1/8" Pipe to ¼" 2FP-4FJX 4 "
38-106 426744 ------ 12951002 Hose Assembly (Steer Manifold to Front Steer Cylinder (C1)) 1 "
38-107 426744 ------ 12951001 Hose Assembly (Steer Manifold to Front Steer Cylinder (C2)) 1 "
38-108 426744 ------ 12951005 Hose Assembly (Rear Steer Manifold (C1) to Tee) 1 "
38-109 426744 ------ 12951006 Hose Assembly (Rear Steer Manifold (C2) to Tee) 1 "
38-110 372750 ------ 12961342 Bracket, Mounting - Check Valve 2 "
38-111 426744 ------ 12951367 Hose Assembly (Jack Valve Outlet to Return Manifold) - 1 "
Int. Jacking Opt.
38-112 200597 ------ 2266-12-12S Adapter, ¾" O-Ring/37° Flare Swivel - 12FJX-12MP 1 "
38-113 ------ ------ 12980085 Cable Assembly, Steering Solenoid 1 "
38-114 ------ ------ 12980085 Cable Assembly, Steering Solenoid (4 Wheel Steering Opt.) 1 As Req'd
CD276 4-2-81
Rev 13
Chapter 4
Table 4-39. Hydraulic Pump Assembly

Ind Number Number
39-1 240795 648-S-31-A-25 12871263 Pump Assembly, Hydraulic - 12V 1 1 & Up
39-2 373317 40226 M16 Washer, Flat 16mm 2 "
39-3 373317 39260 M16-2.0 x 45 Bolt, Hex Head Ø M16-2.0 x 45mm Long 2 "
39-4 426744 ------ 76971 Elbow, 90° 24MJ-24MB90 1 "
8 39-5
39-6
426744
373317
------
40256
12951035
M16
Hose Assembly (Hyd. Tank to Hyd. Pump)
Washer, Lock 16mm
1
2
"
"
7 39-8
39-9
373089
240791
------
------
12950541
12951034
Shim, Hydraulic Pump
Hose Assembly (Hydraulic Pump to Dist. Valve)
1
1
"
"
39-10 426744 ------ 76917 Adapter, ½" Tube 6MJ-6MB 1 "
39-11 426744 ------ 12951036 Hose Assembly, Pump Drain (to Hyd. Tank) 1 "
9
6
10
11
1 2 3 4
Figure 4-39. Hydraulic Pump Assembly
4-2-82 CD276
Rev 13
Chapter 4
Table 4-40. Emergency Hydraulic Pump Assembly

Ind Number Number
40-1 240795 648-S-31-A-25 12871263 Pump Assembly, Hydraulic - 12V 1 1 & Up
40-2 240791 ------ 12950948 Hose Assembly (Emergency Pump to Hydraulic Tank) 1 "
40-3 426744 ------ 12950986 Hose Assembly (Bottom Dist. Valve to Emergency Pump) 1 "
40-4 426744 ------ 76966 Elbow, 90° 6MJ-6MP90 1 "
NOTE: 40-6 ------ ------ ------ Cable, Emergency Pump Relay to Fuse, 225A 1 "
40-7 373317 ------ 5/16-18 Nut, Flange 5/16-18 4 "
2 1. TO REMOVE ELBOW (5), FIRST REMOVE
PLUG TO AVOID INTERFERENCE.
40-8
40-9
------
263540
------
70.902
------
12940344
Wire, Emerg. Pump Relay to Emerg. Steer Press. Switch
Solenoid, SPST, N/O, 12VDC - Relay Contactor
1
1
"
"
2. TO ASSEMBLE, FIRST INSTALL ELBOW (5) 40-10 ------ ------ 12950671 Cable Assembly, Emergency Pump - Ground 1 "
1 THEN INSTALL PLUG.
3 10
4
9
5 8
7
PLUG
6
Figure 4-40. Emergency Hydraulic Pump Assembly
CD276 4-2-83
Rev 13
Chapter 4
AIR
CLEANER
13 14 51 15 16
56
12 46 26
48
50 11 45 19 28 17 18 25
6 52
32 33
35 30
20
27 44 55
36 23 49 29 56 48 47 55 4
5
31 43 56
7 53
34 42 8
10 54 54 38 54
40 37 9
21 39 56
55 41
22
24
1 2
24 HYDRAULIC TANK
37 54 3
Figure 4-41. Pump and Return Hydraulic System
4-2-84 CD276
Rev 13
Chapter 4
Table 4-41. Pump and Return Hydraulic System
41-1 419408 ------ 12941657 Tank, Hydraulic Reservoir 1 1 & Up 41-29 426744 ------ 12950986 Hose Assembly 1 1 & Up
41-2 405104 ABB40NLT 210021 Breather & Fill Locking Cap 1 " (Bottom DCDV to Emergency Pump)
(Part of Item 1) 41-30 240791 ------ 12951034 Hose Assembly (Hydraulic Pump to DCDV) 1 "
41-3 263637 ------ 254005 Sight Gauge (Part of Item 1) 1 " 41-31 426744 ------ 3500X4 Elbow, 90°, ¼ NPT 4MJ-4FP90 1 "
41-4 266763 PAVC65BRP13 PAVC65BR Pump, Hydraulic, Main - 1 " 41-32 239450 2043-4-4S 85759 Elbow, 90° Bulkhead ¼ JIC 1 "
Variable Displacement 41-33 426744 ------ 12970953 Hose Assembly 1 "
41-5 373089 ------ 12950541 Shim, Hydraulic Pump 1 " (Bulkhead Panel to Pressure Gauge)
41-6 240795 648-S-31-A-25 12871263 Pump Assembly, Hydraulic - 12V 1 " 41-34 426744 4MJ-BLKHEAD-UN-KIT 77197 Fitting, Straight ¼ JIC to ¼ JIC, Bulkhead 1 "
41-7 240791 ------ 12950948 Hose Assembly, 1 " 41-35 426744 ------ 12940865 Hose Assembly 1 "
Emergency Pump Suction (Bulkhead Panel to DCDV Tee)
41-8 426744 ------ 12951035 Hose Assembly, Pump Suction 1 " 41-36 426744 ------ 12941031 Hose Assembly 1 "
41-9 426744 ------ 12951036 Hose Assembly, Pump Drain (to Tank) 1 " (Bulkhead Panel to Pressure Gauge)
41-10 426744 ------ 12950977 Hose Assembly (Tank to Filter) 1 " 41-37 426744 ------ 86063 Plug, O-Ring Boss, ½" Tube, 8MB-Plug 3 "
41-11 242837 CI-20 9541008000 Gauge, Filter Indicator 1 " 41-38 426744 ------ 76923 Adapter, Connector, ½" Tube 8MJ-8MB 1 "
41-12 358417 ------ 12931365 Bracket, Return Filter 1 " 41-39 426744 ------ 202702-24-24S Adapter, Connector, Male, ½", 24MJ-24MB 1 "
41-13 242837 SF-180-25-2 9541006000 Head, Filter (AA4678) 1 " 41-40 426744 ------ 76922 Adapter, Connector 6MJ-8MB 1 "
41-14 242837 LE-10 9541007000 Element, Filter 1 " 41-41 426744 ------ 76942 Adapter, Connector, 1" Tube, 16MF-16MB 1 "
41-15 329499 9310800 12951219 Gauge, Hydraulic Pressure (0-3000 psi) 1 " 41-42 426744 ------ 76922 Adapter, Connector 6MJ-8MB 1 "
41-16 261104 744.24-S01F-1800N 011714X1 Switch, Emergency Pump (1800 psi) 1 " 41-43 426744 ------ 76971 Elbow, 90° 24MJ-24MB90 1 "
41-17 358417 ------ 12910893 Bracket, Manifold - Gauges 1 " 41-44 426744 ------ 76966 Elbow, Adapter, 90°, 16MJ-16MB-90 1 "
41-18 247378 ------ 12970862 Decal, Main Circuit Hyd. Pressure 1 " 41-45 426744 ------ 221501-12-6S Connector, Adapter, Swivel 12FJ-6MJ 1 "
41-19 241983 ------ 012483X3 Valve, Dual Check Distribution 1 " 41-46 426744 4MJ-4MB90 76945 Elbow, 90° #4 SAE O-Ring/37° Flare 1 "
41-20 241983 90-0102 012496 Manifold, Return 1 " 41-47 426744 ------ 76966 Elbow, 90° 6MJ-6MP90 1 "
41-21 249874 AFC-3M-25RC-FF 12881907 Gauge, Pressure, 0-3000 psi, 2.5" 1 " 41-48 426744 ------ 202702-24-16S Connector, Adapter AEROQUIP, 16MJ-24MB 1 "
41-22 426744 ------ 78890 Connector, Adapter, Male ¼" Tube 1 " 41-49 426744 ------ 76996 Elbow, 90°, Pipe / 37° Flare 1 "
41-23 358417 ------ 12950548 Panel, Hydraulic Bulkhead 1 " 41-50 426744 8MJ-8MB90 76953 Elbow, 90° #8 SAE O-Ring Boss, 37° Flare 1 "
41-24 358417 ------ 12951068 Strap, Hold Down - Hydraulic Tank 2 " 41-51 426744 ------ 2030-4-4S Tee, Adapter ¼" Tube OD, 4MJ-4MJ-4MP 1 "
41-25 244126 ------ 12950661 Control Board, Hydraulic 1 " 41-52 426744 4MJ-4FJX-4MJ 12872931 Tee, ¼JIC with Swivel 1 "
41-26 240791 ------ 12950976 Hose Assembly 1 " 41-53 426744 ------ 22617-6 Fitting, #6 O-Ring (Service Item) 1 "
(Return Manifold to Hydraulic Filter) 41-54 426744 ------ 22617-8 Fitting, #8 O-Ring (Service Item) 5 "
41-27 426744 ------ 12950985 Hose Assembly, Pressure Switch 2 " 41-55 426744 ------ 22617-16 Fitting, #16 O-Ring (Service Item) 4 "
41-28 426744 ------ 78890 Connector, Adapter, Male ¼" Tube 2 " 41-56 426744 ------ 22617-24 Fitting, #24 O-Ring (Service Item) 3 "
CD276 4-2-85
Rev 13
Chapter 4
2 1
3
4
5
6
7 8
11 9
12 G
R B
P
10
13 L S
P 7
H T
H
15
14 16
23 H H 17
24 18
P T
P S
L 19
R
20
25 26 27 G
21
B
28 22
Figure 4-42. Cab Bulkhead Assembly
4-2-86 CD276
Rev 13
Chapter 4
Table 4-42. Cab Bulkhead Assembly

Ind Number Number
42-1 426744 ------ 12970705 Hose Assembly (Bulkhead "S" to Accelerator Pedal "S") 1 1 & Up
42-2 426744 ------ 12970705 Hose Assembly (Bulkhead "P" to Accelerator Pedal "P") 1 "
42-3 251747 ------ 12941017 Hose Assembly (Cab Bulkhead "B" to Brake Actuator) 1 "
42-4 426744 ------ 12941006 Hose Assembly (Orbitrol Valve "L" to Steer Valve "L") 1 "
42-5 239450 2043-4-4S 85759 Elbow, 90° Bulkhead ¼ JIC 4 "
42-6 426744 ------ 12941007 Hose Assembly (Orbitrol Valve "R" to Steer Valve "R") 1 "
42-8 426744 ------ 12941031 Hose Assembly (Bulkhead "G" to Pressure Gauge) 1 "
42-9 240791 ------ 12951020 Hose Assembly (Orbitrol Valve "P" to Steer Valve "P") 1 "
42-10 240791 ------ 12951019 Hose Assembly (Orbitrol Valve "T" to Steer Valve "T") 1 "
42-11 426744 10MJ-BLKHD90 w/Nut 85763 Elbow, Bulkhead Union 10MJ-BLKHD90° 2 "
42-12 373317 ------ ------ Clamp, Hose #8 2 "
42-13 426744 ------ 12960094 Hose (Heater to Cab Bulkhead) 2 "
42-15 426744 ------ 12960095 Hose Assembly (Heater "H" to Front Bulkhead) 2 "
42-16 240791 ------ 12951010 Hose Assembly (Cab Bulkhead "P" to Front Bulkhead "P") 1 "
42-17 240791 ------ 12951010 Hose Assembly (Cab Bulkhead "T" to Front Bulkhead "T") 1 "
42-18 426744 ------ 12951024 Hose Assembly (Cab Bulkhead "S" to Front Bulkhead "S") 1 "
42-19 426744 ------ 12951024 Hose Assembly (Cab Bulkhead "P" to Front Bulkhead "P") 1 "
42-20 240791 ------ 12951010 Hose Assembly (Cab Bulkhead "L" to Front Bulkhead "L") 1 "
42-21 240791 ------ 12951010 Hose Assembly (Cab Bulkhead "R" to Front Bulkhead "R") 1 "
42-22 251747 ------ 12951011 Hose Assembly (Cab Bulkhead "B" to Front Bulkhead "B") 1 "
42-23 264269 ------ 73040 Alarm, Lift Cab 1 "
42-24 373317 ------ ------ Bolt, Flange Ø 10-32 x ½" Long 2 "
42-25 261104 744.13-S33F-800N 12951213 Switch, Pressure 800 psi 2 "
42-26 426744 ------ 2242-2-4S Adapter, 1/8" Pipe to ¼" 2FP-4FJX 2 "
42-28 426744 ------ 12970953 Hose Assembly (Cab Bulkhead "G" to Front Bulkhead "G") 1 "
CD276 4-2-87
Rev 13
Chapter 4
AIR
CLEANER
18 9
1 11 18
2 5
19
17 10 18
14 3 13 18
12 12
7
10 18 8 4
15 16 17 6
HYDRAULIC
RESERVOIR
Figure 4-43. Lift Cab Hydraulic System
4-2-88 CD276
Rev 13
Chapter 4
Table 4-43. Lift Cab Hydraulic System

Ind Number Number
43-1 241983 89-1004-04 012483X5 Valve, Cab Lift/Lower 1 1 & Up
43-3 426744 ------ 12951369 Hose Assembly (Cab Lift DCDV to Lift Valve) 1 "
43-5 241983 90-0102 012496 Manifold, Return REF "
43-6 426744 ------ 12950589 Tube Assembly, Lift Assembly 1 "
43-7 402724 2.5CSB2HLT27AX28.00 12893470 Cylinder, Cab Lift (28") REF "
43-8 266763 ------ N-820S Valve, Flow Control 1 "
43-9 426744 ------ 76922 Adapter, Connector 6MJ-8MB 1 "
43-12 426744 ------ 2266-8-8S Adapter, SAE 8MLE, JIC 8FML 2 "
43-15 293892 ------ 012285 Breather, Air 1 "
43-16 372750 ------ 12951649 Adapter, Breather 1 "
CD276 4-2-89
Rev 13
Chapter 4
Table 4-44. Engine Assembly (Side View)
5 4 3 2 Ind
Code
Number Number

44-2 264937 ------ ------ Turbo, Air Intake (Modified) (Incl. w/ Engine) 1 1 & Up
6 1 44-3 264937 ------ ------ Glow Plug (Modified) 1 "
44-4 264937 ------ ------ Thermostat (Modified) 1 "
44-5 281359 ------ 1178607 Alternator, Deutz 1 "
7 44-6 281359 429-7565 G1-10094 Pulley, Air Conditioner 1 "
44-7 281359 420-9556 G1-10095 Hub, Fan - Air Conditioner 1 "
44-8 264937 ------ ------ Pulley, Tensioner (Included w/ Engine) 1 "
44-9 402530 ------ 9430 Belt, ½" W x 43" L (MFR: Gates) 2 "
Figure 4-44. Engine Assembly (Side View)
4-2-90 CD276
Rev 13
Chapter 4
Table 4-44a. Engine Assembly (Front View)

Ind Number Number
44a-1 281359 ------ 12941853 Engine, Deutz, BF6M1013CP 1 Up to 289

44a-2 264937 ------ ------ Turbo, Air Intake (Modified) (Incl. w/ Engine) 1 1 & Up
1 44a-3 263594
44a-4 281359
24-9-4ZL-PAG-35B
429-7565
G1-10038
G1-10094
Fan, 24"
Pulley, Air Conditioner
1
1
"
"
44a-5 281359 420-9556 G1-10095 Hub, Fan - Air Conditioner 1 "
2 44a-6 402530
44a-7 264937
------
0425-6159
9430
------
Belt, ½" W x 43" L (MFR: Gates)
Pulley, Tensioner
1
1
"
"
44a-8 281359 0117-8607 1178607 Alternator, Deutz 1 "
44a-9 264937 0118-0597 118-0597 Filter, Fuel - Spin-On 1 "
44a-10 264937 0420-5701 ------ Pan, Oil 1 "
44a-11 264937 0211-2862 ------ Injector, Fuel 6 "
3
11
4
5
10
9 6
8
7
Figure 4-44a. Engine Assembly (Front View)
CD276 4-2-91
Rev 13
Chapter 4
Table 4-44b. Engine Assembly (Rear View)

Ind Number Number
44b-1 281359 ------ 12941853 Engine, Deutz, BF6M1013CP 1 Up to 289

1 44b-2 264937 0224-4117 ------ Flywheel 1 1 & Up
44a-3 264937 0118-0928 ------ Starter 1 "
44a-4 372736 ----- G1-10116 Bracket, Oil Accumulator Mounting 2 "
44a-5 1178936 TEP3000-S G1-10113 Accumulator, Turbo Safe - Opt. 1 "
44a-6 426744 14mm-6MJ ------ Fitting, 14mm-6MJ 1 "
44a-7 264937 0425-9469 ------ Line, Oil Lubricant (Modified for Opt.) 1 "
44a-8 264937 0425-9313 ------ Turbocharger 1 "
8
2
7
6
4 3
Figure 4-44b. Engine Assembly (Rear View)
4-2-92 CD276
Rev 13
Chapter 4
5 Table 4-44c. Engine and Engine Mounts
4
Ind Number Number
2
44c-1 281359 ------ 12941853 Engine, Deutz, BF6M1013CP 1 Up to 289
6 44c-2 242293 ------ SSB33-1000-4 Mount, 3-Piece, 1125 lbs @ .03 in 2 1 & Up
16 44c-3 358417 ------ G1-10040 Mount, Motor, R/H 1 "
44c-4 373317 33857 ¾ Washer, Flat ¾" ID 4 "
44c-5 373317 18997 ¾-16 x 3¾ Bolt, Hex Head Ø ¾-16 x 3¾" Long 2 "
2 44c-6 426744 ------ 12951221 Adapter, Heater, Deutz M26-1.5 2 "
7 44c-7 373317 33861 ½ Washer, Flat ½" ID 6 "
1 44c-8 373317 15210 ½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾" Long 6 "
8 44c-9 358417 ------ G1-10046 Mount, Motor, L/H 1 "
44c-10 426744 ------ 900599-8S Plug, Swivel #8 1 "
44c-11 373317 37314 ¾-16 Nut, Top Lock Hex ¾-16 2 "
44c-12 426744 ------ 12960980 Hose Assembly, Oil Drain 1 "
9 44c-13 426744 ------ ------ Elbow, 90° 18mmx8MJ90° 1 "
44c-14 373317 37268 ½-13 Nut, Top Lock Hex ½-13 6 "
44c-15 281359 ------ 118-0928 Starter 1 "
2 44c-16 358417 ------ G1-10039 Bracket, Front Motor Mount (Wldmt) 2 "
44c-17 264937 0419-4170 DEU4194170 Circuit, Manifold Heater (Kit) 1 "
10
14
16
11
2 12 13 15
17
Figure 4-44c. Engine and Engine Mounts
CD276 4-2-93
Rev 13
Chapter 4
Table 4-45. Engine Oil Pan Heater Pad

Ind Number Number

1 45-2 243655 ------ EH-2802 Pad, Heater - 250 Watts, 120V 1 1 & Up
Figure 4-45. Engine Oil Pan Heater Pad
4-2-94 CD276
Rev 13
Chapter 4
Table 4-46. Transmission Installation

Ind Number Number
1 46-1 288777 4644024122 12950500 Transmission, ZF 4WG200 1 109 & Up
2 46-2 263846 0750131053 0750131060 Filter, Transmission Oil 1 1 & Up
5 46-3 282851 ------ 12941830 Harness, Wire - Main 1 "
3
46-4 372750 ------ 12950819 Mount, Transmission 1 "
6
46-5 373317 ------ 93289 Washer, Lock 20mm 4 "
46-6 373317 ------ 12950446 Screw, Hex Head Ø M20-2.5 x 65mm Long 4 "
7 46-7 373317 ------ A8002-188 Screw, Hex Head Ø ¾-16 x 3¾" Long 2 "
46-8 373317 33857 ¾ Washer, Flat ¾" ID 4 "
46-9 242293 ------ SSB33-1000-4 Mount, 3-Piece, 1125 lbs @ .03 in 2 "
8 46-10 241766 ------ 73777 Nut, Locking, ¾-16 NF 2 "
46-11 282851 ------ 12950253 Harness, Wire - Trans. Solenoid Control 1 "
46-12 263846 ------ 4644311201 Gasket, ZF Transmission - PTO Group 1 "
10
11
12
Figure 4-46. Transmission Installation
CD276 4-2-95
Rev 13
Chapter 4
5
4 7
3
2
7 9 8
Figure 4-47. Transmission Oil System (Up to S/N 109)
4-2-96 CD276
Rev 13
Chapter 4
Table 4-47. Transmission Oil System (Up to S/N 109)

Ind Number Number
47-1 255285 ------ DB-2292 Heat Exchanger, Transmission 1 Up to 109

47-2 358417 ------ 12950581 Bracket, Bottom Transmission Cooler 1 "
47-3 372750 ------ 12950582 Bracket, Top Transmission Cooler 1 "
47-4 426744 ------ 77011 Elbow, 90° 2 "
47-5 240791 ------ 12950975 Hose Assembly (Oil Cooler to Transmission "IN") 1 "
47-6 251747 ------ 12950949 Hose Assembly (Transmission "OUT" to Oil Cooler) 1 "
47-7 239440 ------ 12871335 Adapter, Transmission 2 "
47-8 263846 0750131053 0750131060 Filter, Transmission Oil 1 "
47-9 ------ ------ 94051 Washer, Sealing - 26mm 2 "
CD276 4-2-97
Rev 13
Chapter 4
3
2 4
5
4
Figure 4-48. Transmission Oil System (S/N 109 and Up)
4-2-98 CD276
Rev 13
Chapter 4
Table 4-48. Transmission Oil System (S/N 109 and Up)

Ind Number Number
48-1 261331 C-48 X9600-216 Cooler, Oil 1 109 & Up

48-2 426744 16MJ-20MB90 76968 Elbow, 90° 2 "
48-3 426744 ------ G1-10047 Hose Assembly (Transmission to Oil Cooler) 2 "
48-4 264365 ------ 9210214 Adapter, Transmission 2 "
48-5 263846 0750131053 0750131060 Filter, Transmission Oil 1 "
CD276 4-2-99
Rev 13
Chapter 4
Table 4-49. Air Intake System

6 7

Ind Number Number
5 49-1 262861 ------ G1-10057 Tube, Filter Box to Turbo 1 1 & Up
49-2 358417 ------ 12970111 Plug, Air Intake 1 "
236040 ------ 39135-001 Indicator, Service - Opt. 1 "
49-3 264038 ------ 97065 Hose, Hump - 5" to 4" Reducing 1 "
49-4 373317 3I63188 78603 Clamp, Hose 2 3/8" 2 "
4 49-5 372750 ------ 12950591 Air Cleaner Assembly 1 "
3 49-6 203790 ------ 604364-03 Filter, Air 1 "
49-7 293900 ------ 12233-8 Element, Air Filter (Service Item) 1 "
Figure 4-49. Air Intake System
4-2-100 CD276
Rev 13
Chapter 4
Table 4-50. Exhaust System

5

2 Code Description Qty Effective
8 Ind Number Number
3
4 50-1 282311 ------ 12951114 Blanket, Turbocharger 1 1 & Up
6
50-2 264937 ------ ------ Turbo, Exhaust (Part of Engine) 1 "
7 50-3 244126 ------ 12950595 Stub, Flange, Exhaust Turbo 1 "
11 50-4 281359 ------ 03470246 Bolt, Hex, Turbo 4 "
50-5 281359 04209203 ------ Gasket, Turbocharger Flange (Service Item) 1 "
50-6 402530 7335794 12931611 Clamp, U, Open End Saddle, 3" Size 1 "
50-7 262861 ------ G1-10065 Tube, Exhaust Turbo to Flex 1 "
9 50-8 282311 ------ 12951112 Blanket, Elbow Cover 1 "
50-9 239602 ------ 17060 Clamp, Seal 4" Size 2 "
50-10 262861 ------ 231-0240 Connector, Flex 4" Size x 18" Long 1 "
10 50-11 282311 ------ 12951351 Blanket, Exhaust, Flex Tube 1 "
50-12 262861 ------ G1-10066 Muffler, Spark Arresting 1 "
50-13 373317 ------ ------ Bolt, Flange Ø 3/8-16 x 1¼" Long 4 "
50-14 239602 X004484 17061 Clamp, Seal 5" Size 2 "
50-15 282861 ------ G1-10011 Tube, Exhaust 1 "
12 13
14
15
14
FRAME
Figure 4-50. Exhaust System
CD276 4-2-101
Rev 13
Chapter 4
9
5
5 6
3 4
4 13 14 15
10 16
2
1 8
7 17
11
18
12
19
20
Figure 4-51. Fuel System
4-2-102 CD276
Rev 13
Chapter 4
Table 4-51. Fuel System

Ind Number Number
51-1 264937 ------ ------ Pump, Fuel (Included w/ Engine) 1 1 & Up
51-2 410026 ------ 252X8 Fitting, Straight 1 "
51-3 426744 ------ 12951032 Hose, Fuel (Racor Filter to Fuel Pump) 1 "
51-4 426744 ------ 202X8X8 Adapter, Male-Female 2 "
51-5 426744 ------ 911-010-F8 Adapter, Straight, SAE O-Ring 2 "
51-6 236040 ------ 1000FH30 Filter/Water Separator, FG, Fuel 1 "
51-7 372298 ------ 2020PM-OR Element, Primary Fuel Filter 1 "
51-8 281359 ------ 117-4423 Filter, Fuel 1 "
51-9 426744 ------ 12951031 Hose, Fuel (Racor Filter to Tank (Check Valve)) 1 "
51-10 426744 ------ 12951033 Hose, Fuel, Return 1 "
51-11 426744 ------ 79382 Clamp, Hose, Worm, 3/8" 1 "
51-12 419408 ------ 12941850 Tank, Fuel, 65 Gallon 1 "
51-13 239848 ------ 76563 Cap, Filler, Vent, Cone Filter 1 "
51-14 426744 ------ 80221 Coupling, Pipe, Steel 2½" NPT 1 "
51-15 426744 ------ 79488 Nipple, Pipe, 2½" Close 1 "
51-16 426744 6MP-6MP90 87652 Elbow, 90° 6MP-6MP90 1 "
51-17 402748 2650 87046 Valve, Check, In-Line, 3/8" NPT 1 "
51-18 410026 ------ 252X8 Fitting, Straight 1 "
51-19 426744 ------ 649F0606 Elbow, 90° 1 "
51-20 419408 ------ 810143 Sender Assembly - Fuel Tank 1 "
CD276 4-2-103
Rev 13
Chapter 4
2
8
4 9 11
12 10
19 17
5 31 32
2
1
13
13
6
14
1
12
13 9
18
10
7 20
15
33 13
20
29
30 16
22 21
23
24 27
28
23 25
25
26
Figure 4-52. Radiator, Transmission Cooler Installation
4-2-104 CD276
Rev 13
Chapter 4
Table 4-52. Radiator, Transmission Cooler Installation

Ind Number Number
52-1 426744 ------ G1-10047 Hose, Transmission / Cooler 2 1 & Up

52-2 426744 16MJ-20MB90 76968 Elbow, 90° 2 "
52-3 261331 C-48 X9600-216 Cooler, Transmission Oil 1 "
52-4 372750 ------ G1-10042 Mount, Upper Transmission Cooler 1 "
52-5 242335 ------ G1-10034 Radiator, Charge Air Cooler 1 "
52-6 372750 ------ T6-4043-105 Bracket, L- Exhaust 2 "
52-7 373089 ------ G1-10041 Bracket, Radiator/Cooler Support 1 "
52-8 426744 ------ ------ Hose Ø 5/16", 250 psi (Surge Tank to Radiator) 1 "
52-9 426744 ------ G1-10062 Hose, Coupler 2½" ID, 6" Long 2 "
52-10 373317 ------ ------ Clamp, Hose 2" ID 4 "
52-11 262861 ------ G1-10059 Tube, Cooler to Engine 1 "
52-12 373317 ------ ------ Clamp, Hose 2½" ID 4 "
52-13 426744 ------ G1-10070 Hose, Coupler 2 x 6 4 "
52-14 262861 ------ G1-10058 Tube, Turbo to Cooler 1 "
52-15 262861 ------ G1-10060 Tube, Radiator Top 1 "
52-16 262861 ------ G1-10061 Tube, Radiator Bottom 1 "
52-17 372750 ------ G1-10043 Shroud, Upper Radiator 1 "
52-18 263594 24-9-4ZL-PAG-35B G1-10038 Fan, 24" 1 "
52-19 426744 ------ G1-10064 Hose, Coupler 3 x 4 1 "
52-20 373317 ------ ------ Clamp, Hose 3 3/8" ID 6 "
52-21 372750 111 G1-10044 Shroud, Lower Radiator 1 "
52-22 359036 ------ T6-4055-109 Bottle, Radiator Overflow w/ Bracket 1 "
52-23 426744 ------ HN16X4X4 Barb, Hose ¼" x 90° 2 "
52-24 242335 ------ G1-10035 Tank, Surge - Radiator 1 "
52-25 358417 ------ G1-10051 Bracket, Surge Tank 2 "
52-26 426744 ------ HN16SX16X12 Barb, Hose 1" x 90° 1 "
52-27 426744 ------ ------ Hose Ø 5/16", 250 psi (Surge Tank to Engine Fill) 2 "
52-28 426744 ------ ------ Hose Ø 1" (Surge Tank to Engine) 1 "
52-29 358417 ------ G1-10069 Support, Lower, Radiator Pipe 1 "
52-30 426530 733-5413 TM1-0-0809 Clamp, 2¼" Exhaust 1 "
52-31 358417 ------ G1-10068 Support, Upper Turbo Pipe 1 "
52-32 426530 733-5335 T6-1005-119 Clamp, 2" Exhaust 1 "
52-33 426744 ------ G1-10063 Hose, Coupler 3 x 6 1 "
52- 426744 ------ G1-10079 Hose Kit, Turbo 1 "
CD276 4-2-105
Rev 13
Chapter 4
Table 4-53. Battery Installation

Ind Number Number
53-1 373089 ------ 12950649 Battery Rack 1 1 & Up

53-2 265288 31-950T T6-9011-235 Battery, Group 31c w/ Studs 2 "
53-3 407341 ------ 12950424 Cable, Battery (+) to Compt Stud 1 "
6 5 53-4 282851 T68142 2MJ7 Cable, Jumper, 7" 2/0 Sealed 2 "
53-5 395898 ------ 12950655 Cover, Battery Rack 1 "
53-6 373317 10251-01425 7802 DBL, Type "U" BOP 4 "
53-7 ------ ------ ------ Cable, Battery Ground, 2/0, 12" Long 1 "
7 53-8 242714 ------ 12911567 Bolt, Battery Hold 4 "
4
4 3
1
8
Figure 4-53. Battery Installation
4-2-106 CD276
Rev 13
Chapter 4
Table 4-54. Circuit Breaker and Fuse Installation

Ind Number Number
54-1 373089 ------ 12950421 Bracket, Circuit Breaker Support 1 1 & Up

54-2 402645 ------ SDLM-120 Circuit Breaker, 120A, Manual 2 "
54-3 407341 ------ 12950670 Cable Assembly (CB1 to Compt Stud) 1 "
54-4 ------ ------ ------ Cable, 6 Gauge, 11'11" Long (CB1 to Glow Plug ECU) 1 "
54-5 402645 ------ C1933 Stud, Junction Block Ø ½-13 1 "
54-6 407341 ------ 12950424 Cable, Battery (+) to Compt Stud 1 "
54-7 ------ ------ ------ Cable Assembly (Compt Stud to Starter) 1 "
54-8 ------ ------ 12980408 Cable Assembly (Stud to 225A Fuse (F21)) 1 "
54-9 407341 ------ 12950670 Cable Assembly (CB2 to Compt Stud) 1 "
54-10 ------ ------ ------ Wire, 10 Gauge, White, 25" (to Auto Lube) 1 "
1 54-11 373317 ------ 10-32 x ¾ Screw, Flange Ø 10-32 x ¾" Long 8 "
54-12 ------ ------ ------ Cable, 6 Gauge, 33'6" Long (CB2 to Fuse Box) 1 "
11 54-13
54-14
------
------
------
------
------
------
Wire, 10 Gauge (to 20V Fuse)
Cable (ANL225A Fuse (F1) to Emerg. Pump Motor Relay)
1
1
"
"
54-15 402645 ------ ANL225 Fuse, 225 Amps, 23 Volts (F1) 1 "
2 18 54-16
54-17
373317
373317
------
------
10-32
½-20 x ½
Nut, Lock 10-32
Screw, Flange Ø ½-20 x ½" Long
4
2
"
"
3 54-18 402645 ------ 4164 Holder, Fuse (For ANL225) 1 "
4 17
5
16
6
7 10
8 11 12 15
9 13 14
Figure 4-54. Circuit Breaker and Fuse Installation
CD276 4-2-107
Rev 13
Chapter 4
23
1 7
3
24
4
2 8
6
5 K33
10
P7
12
P7 K23a K24
13
19 P8
P8 14
P7 K32
K25 K22
15
K20
K23
P9 K21 16
21
P8
P9 11
9 20
2 22 18
17
Figure 4-55. Relay Box Assembly
4-2-108 CD276
Rev 13
Chapter 4
Table 4-55. Relay Box Assembly

Ind Number Number
55-1 282851 ------ 12941683 Connector Plug Assembly (Rear Cab Opt.) 1 1 & Up
55-2 ------ ------ 100574 Connector Body - Pin Contact (Rear Cab Opt.) 1 "
55-3 ------ ------ 100572 Connector Body - Socket Contact (Rear Cab Opt.) 1 "
55-4 282851 ------ 12941683 Connector Plug Assembly 1 "
55-5 ------ ------ 100574 Connector Body - Pin Contact (Part of 12941683) 1 "
55-6 ------ ------ 100572 Connector Body - Socket Contact (Part of 12941683) 1 "
55-7 282851 ------ 12941830 Harness, Wire - Main 1 "
55-10 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Park Brake Engine Shutdown Opt.) 1 "
55-11 239337 ------ 3-334-485-008 Socket, Relay (Park Brake Engine Shutdown Opt.) 1 "
55-12 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Shifter, Back-Up) 1 "
55-13 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Lock-Up Unit) 1 "
55-14 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Horn) 1 "
55-15 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Park Brake ON) 1 "
55-16 239337 ------ 3-334-485-008 Socket, Relay 6 "
55-17 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Shifter in NEUTRAL) 1 "
55-18 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Trans. not in NEUTRAL, Park Brake Applied) 1 "
55-19 402645 MSM130W6 MSM130W6 Timer, Solid State, 12VDC, 30Sec - Opt. 1 "
55-20 239337 ------ 3-334-485-008 Socket, Relay (Engine Shutdown Opt.) 1 "
55-21 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Engine Shutdown Opt.) 1 "
55-22 282851 ------ 12941831 Harness, Wire - Main Chassis 1 "
55-23 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Downshift and Inhibitor) 1 "
55-24 239337 ------ 3-334-485-008 Socket, Relay 1 "
CD276 4-2-109
Rev 13
Chapter 4
Table 4-56. Fuse Box Assembly

Ind Number Number
56-1 239892 99999013 12941839 Box, Fuse Assembly 1 1 & Up
8 56-2 402645 ATC20BK A3188X22 Fuse, 20 Amp 5 "
56-3 402645 ------ A3188X23 Fuse, 30 Amp 1 "
6 7 56-4 402645 ------ JB3816-2 Stud, Fuse Box Power 1 "
56-5 282851 ------ 12941893 Harness, Wire - Fuse Box 1 "
56-8 282851 ------ 12941830 Harness, Wire - Main 1 "
56-9 239337 ------ 0-332-002-150 Relay, Ignition 1 "
56-10 402645 ATC10 A3188X20 Fuse, 10 Amp 6 "
56-11 402645 ATC15 A3188X21 Fuse, 15 Amp 2 "
56-12 243474 12004943 012489 Holder, Fuse 5 "
56-13 373089 ------ 12950813 Bracket, Fuse Box Support 2 "
9
4
2
10
11
3
12
2
13
1
Figure 4-56. Fuse Box Assembly
4-2-110 CD276
Rev 13
Chapter 4
Table 4-57. Rear View Camera Option and ESM Installation

Ind Number Number
57-1 1179022 STM5600 G1-10107 Monitor 1 As Req'd

4 57-2 1179022 STM5600 G1-10107 Camera, Rear View 1 "
1 57-3 350000 ------ G1-10114 Guard, Rear View Camera 1 "
5 57-4 239337 ------ 0-332-204-151 Relay, SPDT, 12V, 20-30 AMP/NO 1 "
57-5 239337 ------ 3-334-485-008 Socket, 0-332 Relay 1 "
6 57-6 288777 ------ 6041232452 Module, Electronic Speed (ESM) 1 "
Figure 4-57. Rear View Camera Option and ESM Installation
CD276 4-2-111
Rev 13
Chapter 4
4-2-112 CD276
Rev 13
Chapter 4
SECTION 3: NUMERICAL INDEX
Tug Part Number Description Fig & Ind#
——— Block, Front 30-1

——— Block, Side 30-19
——— Bolt, Flange 17-15
——— Bolt, Flange 3/8-16 UNC x 1" Long 24-10
——— Bolt, Flange Ø 10/32" 6-7
——— Bolt, Flange Ø 10-32 x ½” Long 42-24
——— Bolt, Flange Ø 3/8-16 x 1¼” Long 50-13
——— Bolt, Flange Ø 5/16" 6-11
——— Bolt, Phillips Head Ø 10/32" 6-14
——— Cable (ANL225A Fuse (F1) to Emerg. Pump Motor Relay) 54-14
——— Cable Assembly (Compt Stud to Starter) 54-7
——— Cable, 6 Gauge, 11’11" Long (CB1 to Glow Plug ECU) 54-4
——— Cable, 6 Gauge, 33’6" Long (CB2 to Fuse Box) 54-12
——— Cable, Battery Ground, 2/0, 12" Long 53-7
——— Cable, Emergency Pump Relay to Fuse, 225A 40-6
——— Clamp, Hose #8 42-12
——— Clamp, Hose 2" ID 52-10
——— Clamp, Hose 2½” ID 52-12
——— Clamp, Hose 3 3/8" ID 52-20
——— Clip, Rod 5/32" - L/H 12b-18
——— Clip, Rod 5/32" - R/H 12a-19
——— Clip, Rod 7/32" - L/H 12a-17
——— Clip, Rod 7/32" - R/H 12b-16
——— Connector, Steering Mode Indicator Lights 15-46
——— Cover, Latch Box 12a-10
——— Cover, Latch Box 12b-10
——— Door Weldment - L/H 12a-1
——— Door Weldment - R/H 12b-1
——— Elbow 30-16
——— Elbow, 90° 30-32
——— Elbow, 90° 10MJ-8MB90 - Internal Jacking Opt. 38-29
——— Elbow, 90° 18mmx8MJ90° 44c-13
——— Fitting 30-12
——— Fitting, 14mm-6MJ 44a-6
CD276 4-3-1
Rev 13
Chapter 4
——— Flywheel 44b-2

——— Foam, Door - L/H 12a-9
——— Foam, Door - R/H 12b-9
——— Gasket, Turbocharger Flange (Service Item) 50-5
——— Glow Plug (Modified) 44-3
——— Handle, Eberhart 12a-8
——— Handle, Eberhart 12b-8
——— Handle, Outside Paddle 12a-4
——— Handle, Outside Paddle 12b-4
——— Hose 30-17
——— Hose Ø 1" (Surge Tank to Engine) 52-28
——— Hose Ø 5/16", 250 psi (Surge Tank to Engine Fill) 52-27
——— Hose Ø 5/16", 250 psi (Surge Tank to Radiator) 52-8
——— Hose, Black to Axle Pivot 30-25
——— Hose, Black to Steer Cylinder 30-22
——— Hose, Block Lube Front to Block Side 30-13
——— Hose, Blue to Tie Rod 30-10
——— Hose, Orange to Bottom King Pin 30-2
——— Hose, Orange to Top King Pin 30-11
——— Injector, Fuel 44a-11
4-3-2 CD276
Rev 13
Chapter 4
——— Insert, AK 10-32 12a-12

——— Insert, AK 10-32 12b-12
——— Latch, Inside Release Package - L/H 12a-5
——— Latch, Inside Release Package - R/H 12b-5
——— Latch, Rotary 12a-3
——— Latch, Rotary 12b-3
——— Lens w/ Park Light Symbol 15-32
——— Line, Oil Lubricant (Modified for Opt.) 44a-7
——— Nut 17-13
——— Pan, Oil 44a-10
——— Plug 30-15
——— Plug, Hole - 0.438 Dia. 12a-7
——— Plug, Hole - 0.438 Dia. 12b-7
——— Pulley, Tensioner 44a-7
——— Pulley, Tensioner (Included w/ Engine) 44-8
——— Pump, Fuel (Included w/ Engine) 51-1
——— Reservoir 30-14
——— Retainer, Push-On 3/16" 12a-18
——— Retainer, Push-On 3/16" 12b-17
——— Rod, Inside Handle - 7/32" Dia. Latch 12a-13
——— Rod, Inside Handle - 7/32" Dia. Latch 12b-13
——— Rod, Outside Handle - 3/16" Dia. Latch 12a-14
——— Rod, Outside Handle - 3/16" Dia. Latch 12b-14
——— Rod, Outside Handle - 5/32" Dia. Lockplate 12a-15
——— Rod, Outside Handle - 5/32" Dia. Lockplate 12b-15
——— Screw, Ground 17-11
——— Screw, Hex Head Ø ¼-20 x 1¼” Long 12a-20
——— Screw, Hex Head Ø ¼-20 x 1¼” Long 12b-19
——— Screw, Phillips Head Ø ¼-20 x ¾” Long 12a-22
——— Screw, Phillips Head Ø ¼-20 x ¾” Long 12b-21
——— Screw, Phillips PA YZ 8-32 x ½” Long 12a-23
——— Screw, Phillips PA YZ 8-32 x ½” Long 12b-22
——— Screw, Phillips Pan Head 10-32 x ½” Long 12a-11
——— Screw, Phillips Pan Head 10-32 x ½” Long 12b-11
——— Seal, Windshield - 8' 12a-6
——— Seal, Windshield - 8' 12b-6
——— Spacer 12a-25
CD276 4-3-3
Rev 13
Chapter 4
——— Spacer 12b-24

——— Starter 44a-3
——— Switch, Mechanical (part of kit K994720) 18-24
——— Thermostat (Modified) 44-4
——— Timer, 12 to 32 VDC 30-18
——— Turbo, Air Intake (Modified) (Incl. w/ Engine) 44-2
——— Turbo, Air Intake (Modified) (Incl. w/ Engine) 44a-2
——— Turbo, Exhaust (Part of Engine) 50-2
——— Turbocharger 44a-8
——— Washer, Flat 17-12
——— Washer, Flat ¼” 12a-21
——— Washer, Flat ¼” 12b-20
——— Washer, Flat 2" ID 3-10
——— Washer, Lock #10 Split 12a-24
——— Washer, Lock #10 Split 12b-23
——— Washer, Star 17-14
——— Window Assembly - L/H 12a-2
——— Window Assembly - R/H 12b-2
——— Wire, 10 Gauge (to 20V Fuse) 54-13
——— Wire, 10 Gauge, White, 25" (to Auto Lube) 54-10
——— Wire, Emerg. Pump Relay to Emerg. Steer Press. Switch 40-8
8-5-6T-A-12VDC Valve, Solenoid - 3-Way, 6 Port 20-16
#8 Screw, #8 x 3/8" TAP 35-27
#8 Washer, Flat #8 35-28
010937X1 Pin Assembly, Steering Cylinder 33-18
011714 Switch, Pressure, 50 psi 22-27
011714X1 Switch, Brake (1800 psi) 37-2
011714X1 Switch, Emergency Pump (1800 psi) 41-16
011714X1 Switch, Park Brake (1800 psi) 25-8
012285 Breather, Air 43-15
012374 Bracket, Brake Line Mounting 22-20
4-3-4 CD276
Rev 13
Chapter 4
012481 Switch, Toggle (Dash Light) 15-2

012483X1 Valve, Park Brake 37-40
012483X3 Valve, Dual Check Distribution 22-49
012483X4 Valve, Dual Check Relief 22-47
012483X5 Valve, Cab Lift/Lower 43-1
012489 Holder, Fuse 56-12
012494 Panel, Control Box - Hoffman 35-29
012496 Manifold, Return 22-38
012780 Rail Channel 35-26
013030X1 Cylinder, Hydraulic Lift Jack 14-20
013521-1 Actuator 21-2
013521-1 Actuator 21-7
013521-1 Actuator, Brake - ROC 23-60
013521-2 Adapter, Actuator 21-10
CD276 4-3-5
Rev 13
Chapter 4

013744 Mirror, Split Focus 7-4
014045 Switch, Push/Pull (Emergency Stop) 15-3
014050 Light, Dash Panel L/H 15-6
014050 Light, Dash Panel R/H 15-22
014051 Light, Green Indicator 16-15
014242 Cylinder, Slave 22-2
014242 Cylinder, Slave - ROC 23-56
014242 Cylinder, Slave (w/ ROC Option) 24-7
014248 Bracket, Accumulator 22-51
014273 Relay, DPDT, 12V 35-6
014589 Reservoir, Brake Fluid 21-22
014589 Reservoir, Brake Fluid - ROC 23-65
014631 Valve, Solenoid 33-22
014632 Plate, Sub - Cab Select Valve 34-29
014632 Plate, Sub - Solenoid Valve 33-23
015149 Brake Pedal Weldment 21-1
015149 Pedal Assembly, Brake 22-1
015149 Pedal, Brake (Wldmt) - ROC 23-59
015213 Spacer, Brake 21-6
015366 Bearing Block Assembly 27-15
015754 Valve, Cab Select 34-28
4-3-6 CD276
Rev 13
Chapter 4
015790 Mount, Actuator, T700 Weld 24-1

015791 Mount, Slave Cylinder, T700 Weld 24-2
015792 Pivot, Brake Actuator, Mount, T700 24-4
015793 Clevis, T700 24-5
015793 Clevis, T700 (w/ ROC Option) 24-5
015803 Tube Assembly, Brake 22-22
015803X1 Tube Assembly, Brake 22-21
02-100-032 Seal Repair Kit (Service Item Only) 24-20
0-332-002-150 Relay, Ignition 56-9
0-332-204-151 Relay, SPDT, 12V, 20-30 AMP/NO 57-4
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Downshift and Inhibitor) 55-23
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Engine Shutdown Opt.) 55-21
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Horn) 55-14
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Lock-Up Unit) 55-13
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO
(Park Brake Engine Shutdown Opt.) 55-10
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Park Brake ON) 55-15
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Shifter in NEUTRAL) 55-17
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Shifter, Back-Up) 55-12
(Trans. not in NEUTRAL, Park Brake Applied) 55-18
03-466-204 Brake Actuator, Modulating, 2-Stage 24-3
03-466-204 Brake Actuator, Modulating, 2-Stage, Tandem Section 22-33
03470246 Bolt, Hex, Turbo 50-4
0502-8-4 Adapter, #8 SAE O-Ring to ¼ NPT 36-6
06863-38 Voltmeter, 12V, Black Bezel 15-16
0750131060 Filter, Transmission Oil 46-2
08-06-070120 Fitting, Straight 8MJ-6MB 14-22
¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾” Long 21-14
½ Washer, Flat ½” 24-17
½ Washer, Flat ½” ID 38-92
CD276 4-3-7
Rev 13
Chapter 4
½ Washer, Flat ½” ID 44c-7

½ Washer, Lock ½” ID 38-93
½-13 Nut, Top Lock Hex ½-13 44c-14
½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼” Long 38-94
½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾” Long 44c-8
½-13 x 5¾ Bolt, Hex Head Ø ½-13 x 5¾” Long 24-13
½-20 x ½ Screw, Flange Ø ½-20 x ½” Long 54-17
¾ Washer, Flat ¾” ID 27-24
¾ Washer, Flat ¾” ID 44c-4
¾-16 Nut, Top Lock Hex ¾-16 44c-11
¾-16 x 3¾ Bolt, Hex Head Ø ¾-16 x 3¾” Long 44c-5
1000FH30 Filter/Water Separator, FG, Fuel 51-6
100572 Connector Body - Socket Contact (Part of 12941683) 55-6
100572 Connector Body - Socket Contact (Rear Cab Opt.) 55-3
100574 Connector Body - Pin Contact (Part of 12941683) 55-5
100574 Connector Body - Pin Contact (Rear Cab Opt.) 55-2
10250T-2 Block, Contact - 2NO (For Switch) 15-40
10250T-3 Block, Contact - 2NC (For Switch) 15-41
10-32 Nut, Lock 10-32 54-16
10-32 Screw, #10-32 35-3
10-32 Washer, Flat 10-32 35-4
10-32 x ¾ Screw, Flange Ø 10-32 x ¾” Long 54-11
1090D3-12 Light, Amber Indicator 16-16
1090D3-12 Light, Crab Steering Mode Indicator 15-45
117-4423 Filter, Fuel 51-8
1178607 Alternator, Deutz 44-5
1178607 Alternator, Deutz 44a-8
118-0597 Filter, Fuel - Spin-On 44a-9
118-0928 Starter 44c-15
12000175 Plate, Face - Park Brake Switch 10-16
12000237 Nameplate, Park Brake 18-6
12010139 Hitch Assembly 1-27
4-3-8 CD276
Rev 13
Chapter 4
12015308 Housing, Diode Array 35-9

12015344 Connector Body - Socket Contact 15-49
12015345 Connector Body - Pin Contact 15-47
12015345 Connector, 6-Way, MP280, Male 16-26
12020351 Diode Assembly, Circuit Board 35-11
12020782 Terminal, Male MP280 15-48
12040502 Terminal, Female 35-10
12065141 Lock, Secondary 16-25
12-120-010 Cylinder, Clutch Slave 19-11
12233-8 Element, Air Filter (Service Item) 49-7
12-460-124 Pedal, Accelerator - Rear Cab 20-13
12-460-126 Pedal, Accelerator 19-10
12870886 Plug, Pipe - Allen Head, ¼” NPT 37-15
12871263 Pump Assembly, Hydraulic - 12V 39-1
12871335 Adapter, Transmission 47-7
12871600 Bolt, Hex Head Ø 5/16-18 x 1¾” Long 19-18
12871640 Bolt, Hex 5/16-18 UNC x 1" Long 24-8
12872931 Tee, ¼ JIC with Swivel 23-68
12872931 Tee, ¼ JIC Swivel 22-11
12872931 Tee, ¼ JIC Swivel 23-11
12872931 Tee, ¼” JIC, Swivel 21-15
12872931 Tee, ¼JIC with Swivel 20-11
CD276 4-3-9
Rev 13
Chapter 4

12873365 Spacer, Solenoid Valve 38-63
12880756 Bolt, Hex Ø 5/8-11NC x 2¾” Long 3-1
12881802 Bolt, Hex Head Ø ¼-20 x 1¾” Long 19-12
12881907 Gauge, Pressure, 0-3000 psi, 2.5" 18-11
12884732 Valve, Control, Lift - Jack 14-1
12884734 Rod Eye, Cylinder 13-20
12884735 Pin, Cylinder 13-19
12884736 Mount, Cylinder 13-18
12891563 Tire, 1600 x 25HRRIB, Tubeless 27-13
12893470 Cylinder, Cab Lift (28") 13-2
12893470 Cylinder, Cab Lift (28") 4B-3
12902827 Washer, Flat 1" SAE 10-11
12910893 Bracket, Manifold - Gauges 37-4
12911567 Bolt, Battery Hold 53-8
12930133 Plate, Data, Identification 18-16
12931365 Bracket, Return Filter 41-12
12931417 Tube Assembly 21-11
12931417 Tube Assembly (Between Top Actuators) 22-3
12931417 Tube Assembly (Cylinder Crossover to Tee) - ROC 23-61
12931418 Tube Assembly (Between Rear Actuator Elbows) 21-16
12931418 Tube Assembly (Between Rear Actuator Ports) 22-10
12931418 Tube Assembly (Between Rear Actuator Ports) - ROC 23-64
12931419 Tube Assembly (Actuator Rear Elbow to Reservoir) 21-18
12931419 Tube Assembly (Right Actuator Rear Elbow to Reservoir) 22-9
12931423 Cover, Brake Pedal 21-23
12931611 Clamp, U, Open End Saddle, 3" Size 50-6
4-3-10 CD276
Rev 13
Chapter 4
12940344 Solenoid, SPST, N/O, 12VDC - Relay Contactor 40-9

12940551 Valve, Park Brake 25-1
12940553 Reed Switch and Connector Assembly 35-2
12940583 Bracket, Pivot - L/S Seat 10-2
12940584 Bracket, Pivot - R/S Seat 10-3
12940586 Bracket, Mounting - Hood Lift 1-18
12940587 Bracket, Mounting - Hyd. Valve 38-95
12940865 Hose Assembly (Bulkhead Panel to DCDV Tee) 41-35
12940865 Hose Assembly (Bulkhead to DCDV Tee (GP1)) 37-21
12941006 Hose Assembly (Front Orbitrol Valve (L) to Cab Blkhd) 31-14
12941006 Hose Assembly (Orbitrol Valve “L” to Steer Valve “L”) 42-4
12941007 Hose Assembly (Front Orbitrol Valve (R) to Cab Blkhd) 31-12
12941007 Hose Assembly (Orbitrol Valve “R” to Steer Valve “R”) 42-6
12941017 Hose Assembly (Cab Bulkhead “B” to Brake Actuator) 42-3
12941017 Hose Assembly (Front Brake Actuator to Cab Bulkhead) 22-12
12941017 Tube Assembly (Front Axle to Front Brake Actuator) 21-21
12941031 Hose Assembly (Bulkhead “G” to Pressure Gauge) 42-8
12941031 Hose Assembly (Bulkhead Panel to Pressure Gauge) 41-36
12941031 Hose, Cab Bulkhead to Pressure Gauge 18-27
12941095 Cab, Front - Full Length 4A-1
12941095 Cab, Front - Full Length 4B-1
12941095 Cab, Front - Full Length 4C-1
12941095 Cab, Front - Full Length 7-1
12941385 Lift Frame Assembly 4A-2
12941395 Bolster 27-19
12941407 Axle, Planetary Drive Steer 27-11
12941452 Cylinder, Steering 33-17
12941657 Tank, Hydraulic 36-7
CD276 4-3-11
Rev 13
Chapter 4
12941657 Tank, Hydraulic Reservoir 41-1

12941667 Driver’s Compartment, Open 4D-1
12941683 Connector Plug Assembly 55-4
12941683 Connector Plug Assembly (Rear Cab Opt.) 55-1
12941687 Harness, Wire - Control Panel 15-42
12941692 Mount, Phone Jack 18-10
12941696 Control Box Assembly, Hydraulic Steering 35-30
12941704 Mount, Orbitrol Valve 10-5
12941720 Control Panel Assembly - Front Cab 15-
12941722 Faceplate, Control Panel Cab 15-52
12941723 Nameplate, Cab Control Panel 17-1
12941723 Nameplate, Control Panel - Rear Cab Opt. 15-53
12941826 Nameplate, Rear Station Panel 16-1
12941828 Lens Insert, Yellow Low Cool 16-6
12941830 Harness, Wire - Main 46-3
12941831 Harness, Wire - Main Chassis 55-22
12941836 Plate, Control Panel Blanking 15-53
12941839 Box, Fuse Assembly 56-1
12941843 Box, Modified Hydraulic Steer Control 35-1
12941850 Tank, Fuel, 65 Gallon 51-12
12941853 Engine, Deutz, BF6M1013CP 27-9
12941853 Engine, Deutz, BF6M1013CP 44a-1
12941853 Engine, Deutz, BF6M1013CP 44b-1
12941853 Engine, Deutz, BF6M1013CP 44c-1
12941855 Box, Headlight 1-1
12941883 Gauge, Fuel Level, 1/8 Tank 15-4
12941884 Lens Insert, Steer Mode Yellow 16-7
4-3-12 CD276
Rev 13
Chapter 4
12941885 Lens Insert, Cab Select Yellow 16-8

12941889 Harness, Wire, Steer Box - Front Cab 35-22
12941890 Harness, Wire, Steer Box - Rear Cab Opt. 35-23
12941893 Harness, Wire - Fuse Box 56-5
12950078 Platform, Raised Cab 4C-2
12950078 Platform, Raised Cab 4D-2
12950079 Driveline Assembly with Center Bearing Mount 29-2
12950080 Driveline, Front Axle 29-1
12950085 Driveline, Rear Axle 27-23
12950095 Cover, Tail Lights 1-13
12950101 Lamp Assembly, Rear Right 6-9
12950102 Lamp Assembly, Rear Left 6-3
12950105 Speedometer with Odometer 15-56
12950106 Tachometer with Hourmeter 15-62
12950154 Transmission, ZF 27-10
12950208 Platform, Rear Operator (Wldmt) 10-9
12950215 Bolt, Hex Head Ø 1¼-7 NC x 6" Long 27-16
12950216 Bolt, 1½-6 NC x 6" Lg. 27-20
12950253 Harness, Wire - Trans. Solenoid Control 46-11
12950421 Bracket, Circuit Breaker Support 54-1
12950424 Cable, Battery (+) to Compt Stud 53-3
12950443 Panel, Side - Ballast Cover 1-11
12950446 Screw, Hex Head Ø M20-2.5 x 65mm Long 46-6
12950500 Transmission, ZF 4WG200 27-10
12950511 Plate, Cover - Top Air Filter 1-4
12950512 Plate, Access - Air Filter Cover 1-3
12950513 Plate, Cover - Top Front 1-5
12950514 Door, Access - Air Filter 1-12
12950515 Door, Access - Engine Compartment 1-7
CD276 4-3-13
Rev 13
Chapter 4
12950517 Support, Access Door 1-8

12950524 Door, Access - Battery-Valves 1-9
12950530 Panel, Access - Rear Top 1-10
12950541 Shim, Hydraulic Pump 39-8
12950546 Bracket, R/H, Valve, Internal 14-2
12950547 Bracket, L/H, Valve, Internal 14-10
12950548 Panel, Hydraulic Bulkhead 33-36
12950549 Bracket, Bulkhead Tee 22-18
12950581 Bracket, Bottom Transmission Cooler 47-2
12950582 Bracket, Top Transmission Cooler 47-3
12950587 Bracket, Engine Governor 19-23
12950589 Tube Assembly, Lift Assembly 43-6
12950591 Air Cleaner Assembly 49-5
12950595 Stub, Flange, Exhaust Turbo 50-3
12950597 Seat, Bench w/ Storage Box - Bolt-In 4D-8
12950625 Nameplate, Jacking Instructions 14-5
12950628 Nameplate, Jack Shutoff Valve 14-6
12950649 Battery Rack 53-1
12950655 Cover, Battery Rack 53-5
12950661 Control Board, Hydraulic 37-1
12950670 Cable Assembly (CB1 to Compt Stud) 54-3
12950671 Cable Assembly, Emergency Pump - Ground 40-10
12950673 Washer, Axle Mounting Bolt 27-22
12950791 Plate, Cover - Cab Front 4C-4
12950791 Plate, Cover - Cab Front 4D-4
12950813 Bracket, Fuse Box Support 56-13
12950819 Mount, Transmission 27-2
12950819 Mount, Transmission, ZF 29-9
4-3-14 CD276
Rev 13
Chapter 4

12950880 Cover, Orbitrol Valve - ROC 32-16
12950880 Cover, Orbitrol Valve - ROC Rear 10-4
12950891 Shifter, Electric 10-8
12950925 Cover, Plexiglass Rear 10-7
12950926 Panel, Cover - Rear 10-6
12950946 Hose Assembly (Hand Pump “S” Port to Hyd. Resv.) 25-23
12950947 Hose Assembly (Park Brake Valve “T” to Return Manifold) 26-24
12950947 Hose Assembly (Park Brake Valve “T”) 25-24
12950948 Hose Assembly (Emergency Pump to Hydraulic Tank) 36-10
12950948 Hose Assembly (Hydraulic Tank to Emergency Pump) 36-11
12950948 Hose Assembly, Emergency Pump Suction 41-7
12950949 Hose Assembly (Transmission “OUT” to Oil Cooler) 47-6
12950975 Hose Assembly (Oil Cooler to Transmission “IN”) 47-5
12950976 Hose Assembly (Return Manifold to Hydraulic Filter) 37-45
12950977 Hose Assembly (Tank to Filter) 36-16
12950978 Hose Assembly (Shuttle Valve C-Port) 25-25
12950980 Hose Assembly (Hand Pump to “H” Port) 25-15
12950981 Hose Assembly (Hand Pump to “T” Port) 25-16
12950982 Hose Assembly (Park Brake Valve “P” to DCDV “PB”) 37-25
12950982 Hose Assembly (Park Brake Valve “P” to Dist. Valve) 26-12
12950982 Hose Assembly (Park Brake) 25-12
12950985 Hose Assembly (Brake Switch to Hydraulic Press. Gauge) 37-7
12950985 Hose Assembly (Press. Gauge Tee to Dist. Valve Tee (GP1)) 37-16
CD276 4-3-15
Rev 13
Chapter 4
12950985 Hose Assembly, Pressure Switch 41-27

12950986 Hose Assembly (Bottom DCDV to Emergency Pump) 41-29
12950986 Hose Assembly (Bottom DCDV to Emergency Steer Pump) 38-57
12950986 Hose Assembly (Bottom Dist. Valve to Emergency Pump) 40-3
12950986 Hose Assembly (Bottom Dist. Valve to Emergency Steer Pump) 37-55
12950987 Hose Assembly (Steering Cylinders) 33-15
12950988 Hose Assembly (Return Manifold to DCRV “T”) 38-38
12950988 Hose Assembly, Return Manifold to Relief Valve “T” 22-41
12950989 Hose Assembly (Distribution Valve to Relief Valve) 22-44
12950990 Hose Assembly (DCRV “A” to Accumulator Outside) 37-35
12950990 Hose Assembly (Relief Valve “A” to Accumulator Outside) 22-52
12950991 Hose Assembly (DCRV “B” to Accumulator Inside) 38-46
12950991 Hose Assembly (Relief Valve “B” to Accumulator Inside) 22-48
12950992 Hose Assembly (Solenoid Valve (T) to Return Check Valve) 34-25
12950993 Hose Assembly (DCDV “P” to Solenoid Valve Plate “P”) 38-25
12950993 Hose Assembly (DCDV (GP1) to Solenoid Valve Plate (P)) 34-21
12950994 Hose Assembly (Distribution Valve (P) to Front Blkhd (P)) 37-22
12950994 Hose Assembly (Distribution Valve (S) to Front Blkhd (P)) 33-12
12950994 Hose Assembly (Solenoid Valve (A) to Front Blkhd (P)) 34-12
12950995 Hose Assembly (Select Valve Sub-Plate (B) to Rear Blkhd (P)) 34-43
12950995 Hose Assembly (Sub-Plate Select Valve “B” to Rear Blkhd “P”) 38-15
12950996 Hose Assembly (Return Check Valve to Return Manifold) 34-42
12950997 Hose Assembly (DCRV “B” to Brake Actuator Valve) 38-45
12950997 Hose Assembly (Dual Check Relief Valve “B” to Brake Actuator) 22-35
4-3-16 CD276
Rev 13
Chapter 4
12950997 Hose Assembly (Dual Check Relief Valve “B” to Brake Booster) 37-46
12950998 Hose Assembly (DCRV “A” to Brake Actuator Valve (Bottom)) 38-37
12950998 Hose Assembly (Relief Valve “A” to Bottom Port Brake Actuator) 22-43
12950998 Hose Assembly (Relief Valve “A” to Brake Booster) 37-36
12950999 Hose Assembly (Return Manifold (T) to Front Blkhd (T)) 34-13
12950999 Hose Assembly (Return Manifold to Front Blkhd) 33-13
12951000 Hose Assembly (Manifold to Front Bulkhead (L)) 38-96
12951000 Hose Assembly (Manifold to Front Bulkhead (R)) 38-89
12951000 Hose Assembly (Solenoid Valve (P) to Front Bulkhead (R)) 33-10
12951000 Hose Assembly (Steer Manifold (FL) to Front Bulkhead (L)) 34-11
12951000 Hose Assembly (Steer Manifold (FR) to Front Bulkhead (R)) 34-10
12951001 Hose Assembly (Manifold (FC2) to Front Cylinder Tee (C2)) 34-23
12951001 Hose Assembly (Solenoid Valve to Front Cylinder Tee (R)) 33-24
12951001 Hose Assembly (Steer Manifold to Front Steer Cylinder (C2)) 38-107
12951003 Hose Assembly (Return Manifold (T) to Rear Blkhd (T)) 34-47
12951003 Hose Assembly (Return Manifold to Rear Blkhd) 38-75
12951004 Hose Assembly (Manifold to Rear Blkhd (L)) 38-102
12951004 Hose Assembly (Manifold to Rear Blkhd (R)) 38-101
12951004 Hose Assembly (Manifold Valve (RL) to Rear Blkhd (L)) 34-46
12951004 Hose Assembly (Manifold Valve (RR) to Rear Blkhd (R)) 34-45
12951005 Hose Assembly (Rear Steer Manifold (C1) to Tee) 38-108
12951005 Hose Assembly (Steer Manifold (RC1) to Rear Cyl. Tee (C1)) 34-48
12951005 Hose Assembly
(Top D.P. Check Valve (C1) to Rear Cyl. Tee (C1)) 33-30
12951005 Hose Assembly (Top DPCV (C1) to Rear Cyl. Tee (C1)) 37-82
(Bottom D.P. Check Valve (C2) to Rear Cyl. Tee (C2)) 33-29
12951006 Hose Assembly (Bottom DPCV (C2) to Rear Cyl. Tee (C2)) 37-72
CD276 4-3-17
Rev 13
Chapter 4
12951007 Hose Assembly (Rear Orbitrol Valve (T) to Cab Blkhd) 32-13
12951008 Hose Assembly (Rear Orbitrol Valve (P) to Cab Blkhd) 32-15
12951008 Hose Assembly (Rear Orbitrol Valve (R) to Cab Blkhd) 32-12
12951009 Hose Assembly (Rear Orbitrol Valve (L) to Cab Blkhd) 32-14
12951010 Hose Assembly (Cab Bulkhead “L” to Front Bulkhead “L”) 42-20
12951010 Hose Assembly (Cab Bulkhead “P” to Front Bulkhead “P”) 42-16
12951010 Hose Assembly (Cab Bulkhead “R” to Front Bulkhead “R”) 42-21
12951010 Hose Assembly (Cab Bulkhead “T” to Front Bulkhead “T”) 42-17
12951010 Hose Assembly (Front Cab Bulkhead to Front Bulkhead) 33-8
12951011 Hose Assembly (Cab Bulkhead “B” to Front Bulkhead “B”) 42-22
12951011 Hose Assembly (Cab Bulkhead to Front Bulkhead) 22-14
12951012 Hose Assembly (Front Bulkhead to Slave Cylinder) 22-16
12951012 Hose Assembly (Front Bulkhead to Slave) 19-1
12951013 Hose Assembly (Return Manifold to Actuator Valve Tee) 22-36
12951013 Hose Assembly (Return Manifold to Brake Accumulator “T”) 37-67
12951013 Hose Assembly (Return Manifold to Brake Actuator “T”) 38-90
12951014 Hose Assembly (Actuator Valve “A” to Tee Front Axle) 22-24
12951015 Hose Assembly (Actuator Valve “A” to Rear Axle Tee) 22-34
12951016 Hose Assembly (Rear Brake to Slave Cylinder) - ROC 23-58
12951017 Hose Assembly (Brake Tee to Right Side) 22-23
12951018 Hose Assembly (Brake Tee to Left Side) 22-19
12951019 Hose Assembly (Front Orbitrol Valve (T) to Cab Blkhd) 31-13
4-3-18 CD276
Rev 13
Chapter 4
12951019 Hose Assembly (Orbitrol Valve “T” to Steer Valve “T”) 42-10
12951020 Hose Assembly (Front Orbitrol Valve (P) to Cab Blkhd) 31-15
12951020 Hose Assembly (Orbitrol Valve “P” to Steer Valve “P”) 42-9
12951023 Hose Assembly (Reservoir to Front Blkhd) 19-2
12951024 Hose Assembly (Cab Blkhd to Front Blkhd) 19-6
12951024 Hose Assembly (Cab Bulkhead “S” to Front Bulkhead “S”) 42-18
12951026 Hose Assembly (Front Blkhd to Solenoid) 20-7
12951027 Hose Assembly (Reservoir to Rear Accel Pedal) 20-12
12951028 Hose Assembly (Rear Accel Pedal to Solenoid) 20-14
12951029 Hose Assembly (Solenoid Valve to Slave Cyl.) 20-18
12951031 Hose, Fuel (Racor Filter to Tank (Check Valve)) 51-9
12951032 Hose, Fuel (Racor Filter to Fuel Pump) 51-3
12951033 Hose, Fuel, Return 51-10
12951034 Hose Assembly (“PL” Distribution Valve to Hydraulic Pump) 37-54
12951034 Hose Assembly (DCDV “PL” to Hydraulic Pump) 38-56
12951034 Hose Assembly (Hydraulic Pump to DCDV) 41-30
12951034 Hose Assembly (Hydraulic Pump to Dist. Valve) 39-9
12951035 Hose Assembly (Hyd. Tank to Hyd. Pump) 39-5
12951035 Hose Assembly (Hydraulic Tank to Hydraulic Pump) 36-9
12951035 Hose Assembly, Pump Suction 41-8
12951036 Hose Assembly, Pump Drain 36-14
12951036 Hose Assembly, Pump Drain (to Hyd. Tank) 39-11
12951036 Hose Assembly, Pump Drain (to Tank) 41-9
12951067 Spacer, Select Valve 37-83
12951068 Strap, Hold Down - Hydraulic Tank 41-24
12951074 Tube Assembly (Select Valve to Pivot Valve) 33-26
12951101 Cover, Front Orbitrol Valve 31-16
CD276 4-3-19
Rev 13
Chapter 4
12951112 Blanket, Elbow Cover 50-8

12951114 Blanket, Turbocharger 50-1
12951190 Pad, Isolator - Fixed Cab 4C-3
12951190 Pad, Isolator - Fixed Cab 4D-3
12951213 Switch, Pressure 800 psi 34-37
12951219 Gauge, Hydraulic Pressure (0-3000 psi) 37-3
12951221 Adapter, Heater, Deutz M26-1.5 44c-6
12951347 Cylinder, Sensing 35-31
12951351 Blanket, Exhaust, Flex Tube 50-11
12951363 Hose Assembly, Pressure Jack Valve Inlet to Ball Valve 14-23
12951364 Hose Assembly, Jack Valve to Front Left Cylinder 14-14
12951364 Hose Assembly, Jack Valve to Front Right Cylinder 14-15
12951365 Hose Assembly, Jack Valve to Rear Left Cylinder 14-18
12951366 Hose Assembly, Jack Valve to Rear Right Cylinder 14-19
12951367 Hose Assembly (Jack Valve Outlet to Return Manifold) -
Int. Jacking Opt. 38-111
12951367 Hose Assembly, Jack Valve Outlet to Return Manifold 14-7
12951368 Hose Assembly (Bottom Return Manifold to Lift Valve) 37-49
12951369 Hose Assembly (Cab Lift DCDV to Lift Canopy Valve) 37-9
12951369 Hose Assembly (Cab Lift DCDV to Lift Valve) 43-3
12951434 Bracket, Jack Location Decal 14-4
12951435 Support, Plexiglass Cover - Open Compartment 4D-9
12951436 Cover, Plexiglass - Open Compartment 4D-10
12951444 Hose Assembly (D.P. Check Valve (C2) to Solenoid) 33-27
12951444 Hose Assembly (DPCV (C2) to Solenoid Valve Bottom) 37-73
12951445 Hose Assembly (Front Left Steer Cyl. (L) to Front Blkhd (L)) 33-11
12951457 Cover, Sock for Hoses - Lift Cab 4B-4
12951460 Tube Assembly (Brake Actuator Valve to Press. Switch) 23-29
12951460 Tube Assembly (Brake Actuator Valve to Pressure Switch) 22-29
12951461 Tube Assembly (Brake Actuator Return) 22-32
4-3-20 CD276
Rev 13
Chapter 4

12951462 Tube Assembly (Shuttle Valve Bypass) 25-22
12951628 Bracket, Rubber Curtain 8-13
12951637 Angle, Ballast Keeper 3-4
12951649 Adapter, Breather 43-16
12960094 Hose (Heater to Cab Bulkhead) 42-13
12960095 Hose Assembly (Heater “H” to Front Bulkhead) 42-15
12960291 Platform, Rear Mounted Generator Set 10-9
12960437 Hose, Drain 36-2
12960969 Switch, Steering Mode Select (3 Pos.) 15-39
12960978 Enclosure, Rear Operator Comp. 10-17
12960980 Hose Assembly, Oil Drain 44c-12
12961130 Guard, Brake Reservoir 21-20
12961263 Bracket, Hold Down, Hydraulic Tank 36-1
12961274 Cover, Tail Light Harness - R/S 1-15
12961274 Cover, Tail Light Harness - Right 6-8
12961276 Cover, Tail Light Harness - L/S 1-14
12961276 Cover, Tail Light Harness - Left 6-5
12961342 Bracket, Mounting - Check Valve 38-110
12970110 Tube Assembly (Actuators to Reservoir) - ROC 23-67
12970111 Plug, Air Intake 49-2
12970342 Decal, Warning “Tow Aircraft on Low Gear” 18-1
12970444 Decal, “Do Not Drive with Park Brake Applied” 18-4
12970448 Decal, “Danger: Cab Pinch Point” 8-8
12970493 Pad, Brake 21-17
12970503 Bolt, Eye 3-9
12970508 Decal, “Trained Personal” 18-22
12970518 Decal, “Read the Manual” 18-21
12970705 Hose Assembly (Bulkhead “P” to Accelerator Pedal “P”) 42-2
12970705 Hose Assembly (Bulkhead “S” to Accelerator Pedal “S”) 42-1
12970705 Hose Assembly (Bulkhead to Pedal) 19-3
12970744 Hose Assembly (Hand Pump to Rear Axle) 26-25
12970745 Hose Assembly (Hand Pump to Front Axle) 26-14
CD276 4-3-21
Rev 13
Chapter 4
12970746 Hose Assembly (Park Brake Valve to Hand Pump) 26-13

12970851 Decal, “Do Not Shift Transmission” 18-14
12970860 Decal, “Phone Jack” 18-7
12970862 Decal, “Main Circuit” 18-12
12970862 Decal, Main Circuit Hyd. Pressure 41-18
12970872 Decal, “Towing Instructions” 18-17
12970878 Decal, Jack Location 14-3
12970879 Decal, “Turn for Fresh Air” 18-23
12970880 Decal, “Service Information” 2-4
12970882 Decal, “GT-110 Towing Instructions” 18-19
12970953 Hose Assembly (Cab Bulkhead “G” to Front Bulkhead “G”) 42-28
12970961 Decal, “Caution: Failure to Use Proper Gear” 18-20
12980085 Cable Assembly, Steering Solenoid 37-84
12980085 Cable Assembly, Steering Solenoid (4 Wheel Steering Opt.) 38-114
12980408 Cable Assembly (Stud to 225A Fuse (F21)) 54-8
12990070 Lubrication System, Automatic 30-
12990611 Decal, “Moving Parts Hazard” 2-8
12990777 Decal, “Danger, Explosion Hazard” 18-18
12990777 Decal, “Danger: Explosion” 2-6
12990780 Decal, “Caution” 15-13
13/16-20 Nut, Hex 13/16-20 NEF (Steel) 31-2
13/16-20 Nut, Hex 13/16-20 NEF (Steel) 32-2
1-585809 Step, Folding Malleable 3-7
17060 Clamp, Seal 4" Size 50-9
17-10014-26 Retainer, Captive Screw 1-24
17-10017-11 Receptacle, Fastener, Clip-On 1-23
17-13-106-11 Screw, Captive - Knurled 1-22
1816 Light, Speedometer 15-57
1816 Light, Tachometer 15-63
2020PM-OR Element, Primary Fuel Filter 51-7
202702-24-16S Adapter, Connector, Aeroquip 34-40
202702-24-16S Connector, Adapter AEROQUIP, 16MJ-24MB 37-48
4-3-22 CD276
Rev 13
Chapter 4

202702-24-24S Adapter, Connector, Male, ½”, 24MJ-24MB 36-8
202713-8-8S Fitting, 8MJ-8MBL 14-9
202X8X8 Adapter, Male-Female 51-4
203002-4-4S Tee, Bulkhead, 37º Flare, #4 JIC Swivel 22-17
2030-4-4S Tee, Adapter ¼” Tube OD, 4MJ-4MJ-4MP 37-18
203101-4-4S Tee, 37° Flare Swivel 22-5
203101-4-4S Tee, 37° Flare, Swivel 21-12
203101-4-4S Tee, 37° Flare, Swivel - ROC 23-63
203102-8-8S Tee, #8 SAE, O-Ring Boss 37° Flare 8MJ-8FJX-9MJ 22-46
203102-8-8S Tee, Swivel Flare 8MJ-8FJX-8MJ 34-38
204-1043 Column, Steering, 8" 31-8
2071-4-4S Elbow, 90° - 37° Flare Swivel/37° Flare 25-11
2071-8-8S Elbow, 90° Flare Swivel 34-50
2071-8-8S Elbow, 90° Swivel 8MJ-8FJX90 14-21
20-920-009 Reservoir 19-13
20-920-009 Reservoir 20-9
210021 Breather & Fill Locking Cap (Part of Item 1) 41-2
221501-12-6S Connector, Adapter, Swivel 12FJ-6MJ 37-56
CD276 4-3-23
Rev 13
Chapter 4
221501-16-12S Adapter, Connector 12MJ-16FX 34-41

221501-8-4S Adapter, 8FJ-4MJ 34-36
221501-8-4S Adapter, 8FJ-4MJ 37-34
221501-8-4S Adapter, 8FJ-4MJ 38-104
221501-8-4S Adapter, 8FJ-4MJ 38-35
221501-8-4S Adapter, 8FJ-4MJ 42-27
221501-8-4S Fitting, Reducer, 37° Flare Swivel 22-45
2242-2-4S Adapter, 1/8" Pipe to ¼” 2FP-4FJX 34-35
22617-10 Fitting, #10 O-Ring (Service Item) 14-30
22617-12 O-Ring, #12 Fitting (Service Item) 22-54
4-3-24 CD276
Rev 13
Chapter 4

2266-12-12S Adapter, ¾” O-Ring/37° Flare Swivel - 12FJX-12MP 14-27
2266-8-8S Adapter, SAE 8MLE, JIC 8FML 14-12
231-0240 Connector, Flex 4" Size x 18" Long 50-10
252-1003 Steering Unit, Orbitrol, 48 31-10
252X8 Fitting, Straight 51-18
254005 Sight Gauge (Part of Item 1) 41-3
25985R1 Nut, 1½-6 NC 27-21
2MJ7 Cable, Jumper, 7" 2/0 Sealed 53-4
3/8 Washer, Flat 3/8" 21-8
3/8 Washer, Flat 3/8" 24-16
3/8 Washer, Flat 3/8" ID 31-6
3/8 Washer, Lock 3/8" ID 24-11
3/8-16 Nut, Lock 3/8-16 24-12
3/8-16 Nut, Top Lock Hex 3/8-16 21-9
3/8-16 x 1 Bolt, Flange Ø 3/8-16 x 1" Long 37-23
3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 37-69
3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼” Long 24-14
CD276 4-3-25
Rev 13
Chapter 4
3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½” Long 31-4

30937 Bracket, Fire Extinguisher 6-10
310504 Gauge, Temperature, 150-300 Deg. 15-14
310514 Gauge, Transmission Oil Temp. 15-60
312A Beacon, Rotating Amber, 12V 8-1
3-334-485-008 Socket, 0-332 Relay 57-5
3-334-485-008 Socket, Relay 55-16
3-334-485-008 Socket, Relay 55-24
3-334-485-008 Socket, Relay (Engine Shutdown Opt.) 55-20
3-334-485-008 Socket, Relay (Park Brake Engine Shutdown Opt.) 55-11
3500X4 Elbow, 90° 4MJ-4FP90 18-26
3500X4 Elbow, 90°, ¼ NPT 4MJ-4FP90 41-31
350516 Gauge, Oil Pressure, 0-80 psi, 12V 15-58
39135-001 Indicator, Service - Opt. 49-2
391772R2 Grommet, Rubber 7-2
4164 Holder, Fuse (For ANL225) 54-18
4644311201 Gasket, ZF Transmission - PTO Group 29-10
5/16 Washer, Lock 5/16" ID 37-29
5/16 Washer, Lock 5/16" ID 38-31
5/16 Washer, Lock 5/16" ID 38-69
5/16 Washer, Lock 5/16" ID 38-70
5/16-18 Bolt, Flange Ø 5/16-18 3-8
5/16-18 Nut, Flange 5/16-18 40-7
5/16-18 Nut, Top Lock Hex 5/16-18 36-19
5/16-18 x ½ Bolt, Hex Head Ø 5/16-18 x ½” Long 38-81
5/16-18 x ¾ Bolt, Flange 5/16-18 x ¾” Long 21-24
5/16-18 x ¾ Bolt, Flange Ø 5/16-18 x ¾” Long 37-5
4-3-26 CD276
Rev 13
Chapter 4

5/16-18 x 2 Bolt, Allen Head 5/16-18 x 2" Long 37-79
511003 Switch, Rocker, 2 Pos. (Beacon Light) 15-37
511003 Switch, Rocker, 2 Pos. (Front Hitch Light) 15-54
511003 Switch, Rocker, 2 Pos. (Park Light) 15-31
511003 Switch, Rocker, 2 Pos. (Rear Headlights) 16-19
511003 Switch, Rocker, 2 Pos. (Rear Hitch Light) 15-35
511010 Switch, Rocker, 2 Pos. Off (Emerg. Steering - Rear) 16-22
511010 Switch, Rocker, 2 Pos. Off (Windshield Washer) 15-27
511010 Switch, Rocker, 2 Pos. OFF-ON (Emerg. Steering) 15-67
511029 Switch, Rocker, 3 Pos. (Blower Fan) 15-65
511029 Switch, Rocker, 3 Pos. (High/Low Beam) 15-33
511066 Switch, Cab Lift 8-23
511066 Switch, Rocker, 3 Pos. Momentary (Cab Lift) 15-50
511229 Switch, Rocker, 3 Pos. (Steer Mode Select - Rear) 16-20
511229 Switch, Rocker, Select 3 (Wiper) 15-25
511265 Switch, Rocker, 3 Pos. (Cab Select - Rear) 16-21
511265 Switch, Rocker, 3 Pos. (Cab Select) 17-6
511500 Lamp Assembly, Pilot - 12V 15-9
511502 Frame, Pilot Lamp, Sprague 15-10
5120472 Bearing, End, 5/16 19-9
5120472 Bearing, End, 5/16 20-25
5169253 Spring, Lever Return 19-22
53 Light, Fuel Level Gauge 15-5
53 Light, Voltmeter 15-17
5867 Hinge, 5" Stamped Steel 1-16
CD276 4-3-27
Rev 13
Chapter 4
594460 Lens Insert, Right Turn 15-21

594461 Lens Insert, Left Turn 15-8
594767 Lens w/ Rear Hitch Light Symbol 15-36
595105 Lens (Clearance Lamp) 15-18
595502 Frame, Mounting - Sprague 15-30
596120 Lens Insert, Glow Plug 15-12
596141 Lens, Red Transmission Temp. 15-19
596142 Lens, Low Oil Pressure 15-11
596153 Lens, Battery, Sprague 15-23
596169 Lens Insert, High Beam Blue 15-20
596173 Lens Insert, Park Brake, Red 15-24
596195 Lens w/ Blower Fan Symbol 15-66
596273 Cover, Black 15-29
596625 Lens w/ Wiper Symbol 15-26
596627 Lens w/ Windshield Washer Symbol 15-28
596628 Lens w/ Beacon Light Symbol 15-38
59L.105 Lens Insert, Aux. Hyd. Pump - Green 15-68
59L.430 Lens w/ Front Hitch Light Symbol 15-55
59L.494 Lens w/ Cab Lift Symbol 15-51
59L.506 Lens Insert, Temperature Red 15-64
600802 Light, Engine Oil Pressure Gauge 15-59
4-3-28 CD276
Rev 13
Chapter 4
600802 Light, Temperature Gauge 15-15

600802 Light, Transmission Oil Temp. Gauge 15-61
6041232452 Module, Electronic Speed (ESM) 57-6
604279-03 Bulb, Indicator Light 15-7
604364-03 Filter, Air 49-6
60-50001 Mirror Assembly, Black Finish 6-6
60574 Nut, Top Lock Hex 5/16-18 19-15
60574 Nut, Top Lock Hex 5/16-18 20-28
62847 Nut, Hex Lock, 1/4-20 NC 19-7
62847 Nut, Hex Lock, 1/4-20 NC 20-20
64-101 Lamp, Sealed Beam, 12V 6-13
649F0606 Elbow, 90° 51-19
660-1-2640 Holder, Tag 6-1
660-6-0581-25 Belt, Safety (Non Retract) 5-2
6660 Valve, Drain - 90°, ¼ NPT 36-4
68-80-302-10 Latch, Ball Handle, Series 80 1-17
697066 Alarm, Back-Up - Self-Adjusting 6-2
73040 Alarm, Lift Cab 42-23
73777 Nut, Locking, ¾-16 NF 27-5
73777 Nut, Locking, ¾-16 NF 46-10
73793 Washer, Lock ¾” - Steel 10-15
73796 Washer, Lock 1" - Spring, Steel 10-12
73858 Bolt Ø 1"-8 NC x 5" Long 10-13
74030 Nut, Hex 1"-8 NC - Steel, Gr. 5 10-10
7404900 Wheel, Steering - 3 spoke, 17" Dia. 31-3
75470 Washer, Flat 5/16" ID 19-5
75470 Washer, Flat 5/16" ID 20-26
75490H Horn, Electric, 12VDC, Air Tone 7-3
76488 Plug, #4 O-Ring 25-29
76488 Plug, #4 O-Ring 26-4
76488 Plug, #4 O-Ring 37-41
76488 Plug, #4 O-Ring 38-41
76488 Plug, #4 O-Ring 38-85
CD276 4-3-29
Rev 13
Chapter 4
76563 Cap, Filler, Vent, Cone Filter 51-13

76912 Connector, #4 SAE O-Ring/37° Flare 25-10
76916 Adapter, Connector 20-15
76916 Adapter, Straight #6 O-Ring to #4 JIC 26-11
76916 Fitting, Straight #6 O-Ring to 1/4 JIC 22-30
76917 Adapter, ½” Tube 6MJ-6MB 39-10
76920 Connector, #8 SAE O-Ring/37° Straight 22-37
76921 Adapter, Connector, 5/16" Tube, 5MJ-8MB 36-15
76922 Adapter, Connector 6MJ-8MB 41-40
76923 Adapter, Connector, ½” Tube 8MJ-8MB 36-12
76923 Adapter, SAE O-Ring/37° Flare - 8MJ-8MB 14-17
76923 Connector, Adapter, ½” Tube OD 22-39
76927 Connector, ½” Tube OD, O-Ring / 37° Flare 33-25
4-3-30 CD276
Rev 13
Chapter 4

76927 Fitting, O-Ring/37° Flare - 8MJ-10MB 14-11
76928 Adapter, SAE O-Ring/37° Flare - 5/8" Tube OD 14-13
76929 Adapter, Straight 12MJ-10MB 34-26
76942 Adapter, Connector, 1" Tube, 16MF-16MB 36-17
76945 Elbow, 90° #4 SAE O-Ring/37° Flare 25-9
76948 Elbow, 90° #6 O-Ring to 1/4 JIC 22-31
76948 Elbow, 90° ¼ Tube 20-17
76948 Elbow, 90° ¼ Tube 38-71
76953 Elbow, 90° #8 SAE O-Ring Boss, 37° Flare 14-8
CD276 4-3-31
Rev 13
Chapter 4

76958 Elbow, #12 SAE, O-Ring Boss / 37° Flare 33-19
76965 Elbow, Adapter, 90°, 12MJ-16MB-90 37-57
76966 Elbow, 90° 6MJ-6MP90 40-4
76966 Elbow, 90° 6MJ-6MP90 41-47
76968 Elbow, 90° 48-2
76968 Elbow, 90° 52-2
76971 Elbow, 90° 24MJ-24MB90 39-4
76971 Elbow, 90° 24MJ-24MB90 41-43
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 19-20
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 19-24
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 20-2
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 20-32
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 22-4
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 23-4
4-3-32 CD276
Rev 13
Chapter 4
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 25-6

76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 26-6
76988 Elbow, 1/8" Pipe to ¼” JIC, 90, 4MJ-2MP90 21-13
76991 Adapter, 1/4“ Pipe to #4 JIC 90 26-21
76991 Elbow, 90° 4MJ-4MP90 38-5
76991 Elbow, 90°, ¼ Pipe to ¼ JIC 22-28
76991 Elbow, 90°, ¼ Pipe to ¼ JIC 23-28
76996 Elbow, 90°, Pipe / 37° Flare 41-49
77006 Elbow, 90° 8MJ-12MP90 14-24
77011 Elbow, 90° 47-4
77197 Bulkhead, Union, 37°, 1/4 Tube 19-17
77197 Fitting, Straight ¼ JIC to ¼ JIC, Bulkhead 22-15
77200 Fitting, ½” 37° Flare Bulkhead, 8MJ-BLKHD-UN w/ Nut 33-9
77200 Fitting, Union Bulkhead, 37° Flare 8MJ-BLKHD w/ Nut 34-51
77793 Horn Button Kit 31-1
7802 DBL, Type “U” BOP 53-6
78293 Connector, 3/8 Pipe to 37° Flare 25-20
78383 Cylinder, Gas Assist 1-19
78603 Clamp, Hose 2 3/8" 49-4
78886 Adapter, Connector, Male ¼ Tube 19-14
78890 Connector, ¼ Pipe to ¼ JIC, Straight 23-57
78890 Connector, Adapter, Male ¼” Tube 18-25
78890 Fitting, ¼” Pipe to ¼’ JIC Straight 21-19
78890 Fitting, Straight ¼ Pipe to ¼ JIC 22-6
78896 Connector, ½ Pipe to 37° Flare 25-21
78904 Fitting, 12MJ-12MP 14-26
CD276 4-3-33
Rev 13
Chapter 4
78988 Elbow, 90° 1/8 Pipe to ¼ JIC90 - ROC 23-62

79382 Clamp, Hose, Worm, 3/8" 51-11
79488 Nipple, Pipe, 2½” Close 51-15
79578 Washer, Lock 5/16", Spring, Zerk 24-9
80221 Coupling, Pipe, Steel 2½” NPT 51-14
81008 Bolt Ø ¾-10 NC x 2½” Long 10-14
810143 Sender Assembly - Fuel Tank 51-20
81358 Tee, ¼ Pipe, 4FP-Tee, Brass 22-26
85759 Elbow, 90° Bulkhead ¼ JIC 22-13
85759 Elbow, Bulkhead, Union, 1/4 Tube 90° 19-16
85762 Elbow, 90° Bulkhead Union, 8MJ-BLKHD90 33-7
85763 Elbow, Bulkhead Union 10MJ-BLKHD90° 42-11
85936 Washer, Flat 5/8" ID 3-3
86063 Plug, O-Ring Boss, ½” Tube, 8MB-Plug 36-18
86065 Plug, O-Ring Boss - ¾” Tube OD 12MP-Plug 37-61
86065 Plug, O-Ring Boss, ¾” Tube OD 37-26
86067 Plug, O-Ring Boss - 1" Tube OD 16MB-Plug 37-60
86069 Plug, O-Ring Boss - 1½” Tube OD 37-70
86080 Elbow, 45° 34-31
86080 Elbow, 45° 38-83
86727 Elbow, 1/4 Pipe, 90°, Street, 3000# 26-7
87046 Valve, Check, In-Line, 3/8" NPT 51-17
87652 Elbow, 90° 6MP-6MP90 51-16
87880 Bushing, 1/2" Pipe to 1/4" JIC 26-20
87909 Plug, Pipe - Allen Head, ½” NPT 37-14
4-3-34 CD276
Rev 13
Chapter 4

88197 Elbow, 90° ¼ Pipe Street, 3000# 25-7
892565C1 Cushion, Seat - ROC 10-1
900599-8S Plug, Swivel #8 44c-10
911-010-F8 Adapter, Straight, SAE O-Ring 51-5
9128131062 Nut, Hex UNF2B 24-6
9128131062 Nut, Hex UNF2B (w/ ROC Option) 24-6
92275 Screw, Metric, Sockethead, 6 x 12mm 19-19
93289 Washer, Lock 20mm 27-7
94-0238-10 Manifold, Valve 34-34
940393C91 Switch, Micro 8-14
94051 Washer, Sealing - 26mm 47-9
9410000124 Decal, “Caution: Hot Surface” 2-9
9410000125 Decal, “Warning” 2-7
9410000146 Decal, “Notice: This Tractor…” 18-15
94259 Fitting, Hose, ¼” MNPT to 6ID 36-3
9430 Belt, ½” W x 43" L (MFR: Gates) 44-9
9430 Belt, ½” W x 43" L (MFR: Gates) 44a-6
9432000006 Wheel Assembly 27-12
94477 Nut, Hex M10-1.5, Gr 8 29-5
9517001000 Accumulator, Hydraulic 22-50
9541006000 Head, Filter (AA4678) 41-13
9541007000 Element, Filter 41-14
9541008000 Gauge, Filter Indicator 41-11
956-3124 Switch, Starter 15-1
97065 Hose, Hump - 5" to 4" Reducing 49-3
97773 Bolt, M10-1.5 x 40mm Long, Gr 10.9 29-4
97897 Bolt, 20mm x 2.5 TP x 60mm Long 27-6
98296A185 Pin, Roll - 1/8" Dia. x 1.25" Long 1-30
98412A132 Pin, Hitch - 5/8" Dia. x 4 “ Grip 1-29
9864004016 Screw, Flat Head 21-5
99297 Washer, Lock 5/8" ID 3-2
CD276 4-3-35
Rev 13
Chapter 4
99516 Washer, Lock, Metric, 10mm 29-6

99657 Washer, Flat, 1/4 19-8
99657 Washer, Flat, 1/4 20-21
99844 Nut, Hex, 5/16-24 NF 19-4
99844 Nut, Hex, 5/16-24 NF 20-24
A11427X2 Light, Green Indicator 16-17
A11427X2 Light, Track Steering Mode Indicator 15-44
A11427X4 Light, Coord Steering Mode Indicator 15-43
A11427X4 Light, Red Indicator 16-18
A13048X2 Valve, Double Pilot Check Valve 33-28
A13447 Nut, Lock - Cone Type 2, ¾” NC 27-14
A13854 Relay, Latch 35-12
A13855X2 Socket, Relay 35-7
A14436 Clip, End 35-5
A14663 Cover, Phone Jack Spring Loaded 18-9
A14664 Jack, Phone 18-8
A15332 Mount, Seat, Mechanical 4D-6
A15332 Mount, Seat, Mechanical 5-3
A3188X20 Fuse, 10 Amp 56-10
A3188X21 Fuse, 15 Amp 56-11
A3188X22 Fuse, 20 Amp 56-2
A3188X23 Fuse, 30 Amp 56-3
A3588X5 Seat, Bucket 4D-7
A3588X5 Seat, Bucket 5-1
A8002-187 Bolt, ¾-16 NF x 3½” Long 27-4
A8002-188 Screw, Hex Head Ø ¾-16 x 3¾” Long 46-7
A8006-030C Nut, Hex 1¼-7 NC 27-18
A8006-412C Washer, Flat 1¼ 27-17
A9002 Clip (For 78383) 1-20
A9008 Stud (For 78383) 1-21
ANL225 Fuse, 225 Amps, 23 Volts (F1) 54-15
C1220 Valve, Check SAE #12 Ports 34-32
C15394 Riser 4D-5
4-3-36 CD276
Rev 13
Chapter 4
C15394 Riser 5-4

C1933 Stud, Junction Block Ø ½-13 54-5
DB-2292 Heat Exchanger, Transmission 47-1
DEU4194170 Circuit, Manifold Heater (Kit) 44c-17
EH-2802 Pad, Heater - 250 Watts, 120V 45-2
G1-10001 Carriage & Rail Assembly - Lift Cab 13-1
G1-10001 Carriage & Rail Assembly - Lift Cab 4B-2
G1-10011 Tube, Exhaust 50-15
G1-10012 Engine, Deutz, BF6M1013FC 27-9
G1-10012 Engine, Deutz, BF6M1013FC 44a-1
G1-10012 Engine, Deutz, BF6M1013FC 44b-1
G1-10012 Engine, Deutz, BF6M1013FC 44c-1
G1-10013 Axle, Drive Steer GT-110-AF 27-11
G1-10017 Frame Weldment, Air Force 1-26
G1-10018 Frame Weldment - Rear Cab 10-9
G1-10029 Harness, Relay, Centering, Assembly 35-15
G1-10031 Plate, Data, Contract 18-16
G1-10033 Plate, Data - Hydraulic Schematic 2-2
G1-10034 Radiator, Charge Air Cooler 52-5
G1-10035 Tank, Surge - Radiator 52-24
G1-10037 D-Ring, 46K with Strap 3-5
G1-10038 Fan, 24" 44a-3
G1-10038 Fan, 24" 52-18
G1-10039 Bracket, Front Motor Mount (Wldmt) 44c-16
G1-10040 Mount, Motor R/H - GT-110/U-30 27-1
G1-10040 Mount, Motor, R/H 44c-3
G1-10041 Bracket, Radiator/Cooler Support 52-7
G1-10042 Mount, Upper Transmission Cooler 52-4
G1-10043 Shroud, Upper Radiator 52-17
G1-10044 Shroud, Lower Radiator 52-21
G1-10046 Mount, Motor L/H - GT-110/U-30 27-8
G1-10046 Mount, Motor, L/H 44c-9
CD276 4-3-37
Rev 13
Chapter 4
G1-10047 Hose Assembly (Transmission to Oil Cooler) 48-3

G1-10047 Hose, Transmission / Cooler 52-1
G1-10048 Bracket, Mounting - Accelerator Cyl 19-21
G1-10049 Cover, Louver Radiator Intake 1-6
G1-10050 Support, Top Cover Louver 1-32
G1-10051 Bracket, Surge Tank 52-25
G1-10057 Tube, Filter Box to Turbo 49-1
G1-10058 Tube, Turbo to Cooler 52-14
G1-10059 Tube, Cooler to Engine 52-11
G1-10060 Tube, Radiator Top 52-15
G1-10061 Tube, Radiator Bottom 52-16
G1-10062 Hose, Coupler 2½” ID, 6" Long 52-9
G1-10063 Hose, Coupler 3 x 6 52-33
G1-10064 Hose, Coupler 3 x 4 52-19
G1-10065 Tube, Exhaust Turbo to Flex 50-7
G1-10066 Muffler, Spark Arresting 50-12
G1-10067 Cover, Hydraulic and Surge Tank 1-2
G1-10068 Support, Upper Turbo Pipe 52-31
G1-10069 Support, Lower, Radiator Pipe 52-29
G1-10070 Hose, Coupler 2 x 6 52-13
G1-10079 Hose Kit, Turbo 52-
G1-10081 Switch, Momentary 15-69
G1-10082 Lens, Defroster 15-70
G1-10083 Hitch, Two Tier 1-27
G1-10085 Plate, Hitch Adapter 1-28
G1-10087 Frame Weldment - Tier II Deutz 3-6
G1-10087 Frame Weldment, Tier II Deutz 1-26
G1-10087-13 Bumper, Front 7-12
G1-10087-4 Bumper, Rear 6-21
G1-10088 Alarm, Vehicle Speed - Opt. 15-71
G1-10090 Plate, Cover 10-18
G1-10091 Curtain, Rubber 8-6
G1-10094 Pulley, Air Conditioner 44-6
G1-10094 Pulley, Air Conditioner 44a-4
G1-10095 Hub, Fan - Air Conditioner 44-7
G1-10095 Hub, Fan - Air Conditioner 44a-5
4-3-38 CD276
Rev 13
Chapter 4
G1-10098 Plate, UID - Opt. 18-13

G1-10099 Decal, “Park Brake Engaged” 18-3
G1-10103 Tire/Wheel Assembly, GT-110 27-13
G1-10105 Pad, Brake - High Angle with Grip 21-17
G1-10106 Lube System Kit 30-
G1-10107 Camera, Rear View 57-2
G1-10107 Monitor 57-1
G1-10108 Frame Weldment - Tier II Deutz, 2 Front/Rear Hitches 3-6
G1-10108-5 Plate, Hitch Mounting Spacer - Opt. 7-11
G1-10108-5 Spacer, Mounting - Hitch Plate (Opt.) 6-19
G1-10109 Spacer, Lower - Hitch (Opt.) 6-20
G1-10111 Mounting Weldment, Additional Front Hitch Option 7-9
G1-10112 Extension, Front Bumper - Opt. 7-10
G1-10113 Accumulator, Turbo Safe - Opt. 44a-5
G1-10114 Guard, Rear View Camera 57-3
G1-10116 Bracket, Oil Accumulator Mounting 44a-4
G35-10003 Headlight, Front, R/H 7-5
G35-10004 Headlight, Front, L/H 7-8
H1185 Pump, Hand 25-3
H1186 Valve, Shuttle (Hand Pump) 25-4
HD44-18-14PN Connector Body - Pin Contact 35-20
HD44-18-14PN Connector Body - Pin Contact (Opt.) 35-24
HD44-24-19SN Connector Body - Socket Contact 56-7
HD46-18-14SN Connector Body - Socket Contact (Opt.) 35-25
HN16SX16X12 Barb, Hose 1" x 90° 52-26
HN16X4X4 Barb, Hose ¼” x 90° 52-23
HP-1S Pump, Hand w/ Integrated Shuttle 26-3
HP22GT Valve, Ball - ¾”, 3000# 14-25
JB3816-2 Stud, Fuse Box Power 56-4
K20472 Bolt, Hex 13-5
K302210 Bolt, Socket Head 13-10
CD276 4-3-39
Rev 13
Chapter 4
K33942 Nut, Hex Jam 13-7

K34806 Washer, Lock 13-11
K97535 Ring, Snap - External 13-15
LC-055K-7 Spring - 8.45" OD x 0.055" Wire 1-31
LE000307 Switch, Toggle, 4PDT, Maintained (Park Brake) 18-5
M16 Washer, Flat 16mm 39-2
M16 Washer, Lock 16mm 39-6
M16-2.0 x 45 Bolt, Hex Head Ø M16-2.0 x 45mm Long 39-3
MSM130W6 Timer, Solid State, 12VDC, 30Sec - Opt. 55-19
N-820S Valve, Flow Control 14-16
PAVC65BR Pump, Hydraulic, Main - Variable Displacement 41-4
R206 Shim 13-17
R23281 Bracket 13-4
R23282 Bracket 13-3
R3561 Shaft, Roller 13-13
R3563 Roller 13-14
R3564 Bolt, Hex 13-12
R4095 Roller 13-8
R5974 Roller 13-16
RH2LB-U-DC12 Relay, Latch - 12VDC, 10A 35-16
RY2S-L-DC12V Relay, DPDT w/ Indicator Light - 12VDC, 3A 35-18
SDLM-120 Circuit Breaker, 120A, Manual 54-2
SFA-202 Spring, Hold Down F/Timer 35-8
SH3B-05 Socket, Relay 3PDT 35-13
SR3P-06F3 Spring, Hold Down Relay 35-14
SSB33-1000-4 Mount, 3-Piece, 1125 lbs @ .03 in 44c-2
SSB33-1000-4 Mount, 3-Piece, 1125 lbs @ .03 in 46-9
SSB33-1000-4 Mount, Isolator 27-3
SW2 Decal, “Caution: To Avoid Injury” 2-5
SW600 Decal, “Warning: To prevent burning…” 2-3
SY024 Extinguisher, Fire 6-12
SY2S-05 Base, Plug-In Mounting 35-19
T6-1005-119 Clamp, 2" Exhaust 52-32
4-3-40 CD276
Rev 13
Chapter 4
T6-4043-105 Bracket, L- Exhaust 52-6

T6-4055-109 Bottle, Radiator Overflow w/ Bracket 52-22
T6-7007-101 Control, Turn Signal 31-9
T6-9011-235 Battery, Group 31c w/ Studs 53-2
T6-9500-157 Elbow, 90° 36-5
TM1-0-0809 Clamp, 2¼” Exhaust 52-30
X9600-216 Cooler, Transmission Oil 48-1
CD276 4-3-41
Rev 13
Chapter 4
4-3-42 CD276
Rev 13
Chapter 4
SECTION 4: ALPHABETICAL INDEX

G1-10113 Accumulator, Turbo Safe - Opt. 44a-5
013521-1 Actuator 21-2
013521-1 Actuator 21-7
013521-1 Actuator, Brake - ROC 23-60
0502-8-4 Adapter, #8 SAE O-Ring to ¼ NPT 36-6
76917 Adapter, ½” Tube 6MJ-6MB 39-10
76991 Adapter, 1/4“ Pipe to #4 JIC 90 26-21
221501-8-4S Adapter, 8FJ-4MJ 34-36
221501-8-4S Adapter, 8FJ-4MJ 37-34
221501-8-4S Adapter, 8FJ-4MJ 38-104
221501-8-4S Adapter, 8FJ-4MJ 38-35
221501-8-4S Adapter, 8FJ-4MJ 42-27
12951649 Adapter, Breather 43-16
76916 Adapter, Connector 20-15
CD276 4-4-1
Rev 13
Chapter 4

76921 Adapter, Connector, 5/16" Tube, 5MJ-8MB 36-15
202702-24-16S Adapter, Connector, Aeroquip 34-40
12951221 Adapter, Heater, Deutz M26-1.5 44c-6
202X8X8 Adapter, Male-Female 51-4
76928 Adapter, SAE O-Ring/37° Flare - 5/8" Tube OD 14-13
76923 Adapter, SAE O-Ring/37° Flare - 8MJ-8MB 14-17
911-010-F8 Adapter, Straight, SAE O-Ring 51-5
12950591 Air Cleaner Assembly 49-5
697066 Alarm, Back-Up - Self-Adjusting 6-2
73040 Alarm, Lift Cab 42-23
G1-10088 Alarm, Vehicle Speed - Opt. 15-71
1178607 Alternator, Deutz 44-5
1178607 Alternator, Deutz 44a-8
12951637 Angle, Ballast Keeper 3-4
HN16X4X4 Barb, Hose ¼” x 90° 52-23
4-4-2 CD276
Rev 13
Chapter 4
HN16SX16X12 Barb, Hose 1" x 90° 52-26

SY2S-05 Base, Plug-In Mounting 35-19
12950649 Battery Rack 53-1
T6-9011-235 Battery, Group 31c w/ Studs 53-2
312A Beacon, Rotating Amber, 12V 8-1
015366 Bearing Block Assembly 27-15
5120472 Bearing, End, 5/16 19-9
5120472 Bearing, End, 5/16 20-25
9430 Belt, ½” W x 43" L (MFR: Gates) 44-9
9430 Belt, ½” W x 43" L (MFR: Gates) 44a-6
660-6-0581-25 Belt, Safety (Non Retract) 5-2
12951112 Blanket, Elbow Cover 50-8
12951351 Blanket, Exhaust, Flex Tube 50-11
12951114 Blanket, Turbocharger 50-1
10250T-3 Block, Contact - 2NC (For Switch) 15-41
10250T-2 Block, Contact - 2NO (For Switch) 15-40
——— Block, Front 30-1
——— Block, Side 30-19
12941395 Bolster 27-19
81008 Bolt Ø ¾-10 NC x 2½” Long 10-14
73858 Bolt Ø 1"-8 NC x 5" Long 10-13
A8002-187 Bolt, ¾-16 NF x 3½” Long 27-4
12950216 Bolt, 1½-6 NC x 6" Lg. 27-20
97897 Bolt, 20mm x 2.5 TP x 60mm Long 27-6
12911567 Bolt, Battery Hold 53-8
12970503 Bolt, Eye 3-9
——— Bolt, Flange 17-15
——— Bolt, Flange 3/8-16 UNC x 1" Long 24-10
5/16-18 x ¾ Bolt, Flange 5/16-18 x ¾” Long 21-24
——— Bolt, Flange Ø 10/32" 6-7
——— Bolt, Flange Ø 10-32 x ½” Long 42-24
——— Bolt, Flange Ø 3/8-16 x 1¼” Long 50-13
——— Bolt, Flange Ø 5/16" 6-11
CD276 4-4-3
Rev 13
Chapter 4
5/16-18 Bolt, Flange Ø 5/16-18 3-8

K20472 Bolt, Hex 13-5
R3564 Bolt, Hex 13-12
12871640 Bolt, Hex 5/16-18 UNC x 1" Long 24-8
¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾” Long 21-14
½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼” Long 38-94
½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾” Long 44c-8
½-13 x 5¾ Bolt, Hex Head Ø ½-13 x 5¾” Long 24-13
¾-16 x 3¾ Bolt, Hex Head Ø ¾-16 x 3¾” Long 44c-5
12950215 Bolt, Hex Head Ø 1¼-7 NC x 6" Long 27-16
5/16-18 x ½ Bolt, Hex Head Ø 5/16-18 x ½” Long 38-81
M16-2.0 x 45 Bolt, Hex Head Ø M16-2.0 x 45mm Long 39-3
12880756 Bolt, Hex Ø 5/8-11NC x 2¾” Long 3-1
03470246 Bolt, Hex, Turbo 50-4
97773 Bolt, M10-1.5 x 40mm Long, Gr 10.9 29-4
4-4-4 CD276
Rev 13
Chapter 4
——— Bolt, Phillips Head Ø 10/32" 6-14

K302210 Bolt, Socket Head 13-10
T6-4055-109 Bottle, Radiator Overflow w/ Bracket 52-22
12941839 Box, Fuse Assembly 56-1
12941843 Box, Modified Hydraulic Steer Control 35-1
R23281 Bracket 13-4
R23282 Bracket 13-3
12950581 Bracket, Bottom Transmission Cooler 47-2
12950421 Bracket, Circuit Breaker Support 54-1
30937 Bracket, Fire Extinguisher 6-10
G1-10039 Bracket, Front Motor Mount (Wldmt) 44c-16
12950813 Bracket, Fuse Box Support 56-13
12961263 Bracket, Hold Down, Hydraulic Tank 36-1
12951434 Bracket, Jack Location Decal 14-4
T6-4043-105 Bracket, L- Exhaust 52-6
12950547 Bracket, L/H, Valve, Internal 14-10
12961342 Bracket, Mounting - Check Valve 38-110
12940587 Bracket, Mounting - Hyd. Valve 38-95
G1-10116 Bracket, Oil Accumulator Mounting 44a-4
CD276 4-4-5
Rev 13
Chapter 4
12940583 Bracket, Pivot - L/S Seat 10-2

12940584 Bracket, Pivot - R/S Seat 10-3
12950546 Bracket, R/H, Valve, Internal 14-2
G1-10041 Bracket, Radiator/Cooler Support 52-7
12931365 Bracket, Return Filter 41-12
12951628 Bracket, Rubber Curtain 8-13
G1-10051 Bracket, Surge Tank 52-25
12950582 Bracket, Top Transmission Cooler 47-3
03-466-204 Brake Actuator, Modulating, 2-Stage 24-3
015149 Brake Pedal Weldment 21-1
210021 Breather & Fill Locking Cap (Part of Item 1) 41-2
012285 Breather, Air 43-15
604279-03 Bulb, Indicator Light 15-7
G1-10087-13 Bumper, Front 7-12
G1-10087-4 Bumper, Rear 6-21
87880 Bushing, 1/2" Pipe to 1/4" JIC 26-20
12941095 Cab, Front - Full Length 4A-1
12941095 Cab, Front - Full Length 4B-1
12941095 Cab, Front - Full Length 4C-1
——— Cable (ANL225A Fuse (F1) to Emerg. Pump Motor Relay) 54-14
——— Cable Assembly (Compt Stud to Starter) 54-7
12980408 Cable Assembly (Stud to 225A Fuse (F21)) 54-8
12950671 Cable Assembly, Emergency Pump - Ground 40-10
12980085 Cable Assembly, Steering Solenoid (4 Wheel Steering Opt.) 38-114
——— Cable, 6 Gauge, 11’11" Long (CB1 to Glow Plug ECU) 54-4
——— Cable, 6 Gauge, 33’6" Long (CB2 to Fuse Box) 54-12
4-4-6 CD276
Rev 13
Chapter 4

——— Cable, Battery Ground, 2/0, 12" Long 53-7
——— Cable, Emergency Pump Relay to Fuse, 225A 40-6
2MJ7 Cable, Jumper, 7" 2/0 Sealed 53-4
G1-10107 Camera, Rear View 57-2
76563 Cap, Filler, Vent, Cone Filter 51-13
G1-10001 Carriage & Rail Assembly - Lift Cab 13-1
G1-10001 Carriage & Rail Assembly - Lift Cab 4B-2
SDLM-120 Circuit Breaker, 120A, Manual 54-2
DEU4194170 Circuit, Manifold Heater (Kit) 44c-17
T6-1005-119 Clamp, 2" Exhaust 52-32
TM1-0-0809 Clamp, 2¼” Exhaust 52-30
——— Clamp, Hose #8 42-12
78603 Clamp, Hose 2 3/8" 49-4
——— Clamp, Hose 2" ID 52-10
——— Clamp, Hose 2½” ID 52-12
——— Clamp, Hose 3 3/8" ID 52-20
79382 Clamp, Hose, Worm, 3/8" 51-11
12931611 Clamp, U, Open End Saddle, 3" Size 50-6
015793 Clevis, T700 24-5
015793 Clevis, T700 (w/ ROC Option) 24-5
A9002 Clip (For 78383) 1-20
A14436 Clip, End 35-5
——— Clip, Rod 5/32" - L/H 12b-18
——— Clip, Rod 5/32" - R/H 12a-19
——— Clip, Rod 7/32" - L/H 12a-17
——— Clip, Rod 7/32" - R/H 12b-16
12015345 Connector Body - Pin Contact 15-47
HD44-18-14PN Connector Body - Pin Contact (Opt.) 35-24
100574 Connector Body - Pin Contact (Part of 12941683) 55-5
CD276 4-4-7
Rev 13
Chapter 4
100574 Connector Body - Pin Contact (Rear Cab Opt.) 55-2

12015344 Connector Body - Socket Contact 15-49
HD46-18-14SN Connector Body - Socket Contact (Opt.) 35-25
100572 Connector Body - Socket Contact (Part of 12941683) 55-6
100572 Connector Body - Socket Contact (Rear Cab Opt.) 55-3
12941683 Connector Plug Assembly 55-4
12941683 Connector Plug Assembly (Rear Cab Opt.) 55-1
78890 Connector, ¼ Pipe to ¼ JIC, Straight 23-57
78896 Connector, ½ Pipe to 37° Flare 25-21
78293 Connector, 3/8 Pipe to 37° Flare 25-20
4-4-8 CD276
Rev 13
Chapter 4

231-0240 Connector, Flex 4" Size x 18" Long 50-10
——— Connector, Steering Mode Indicator Lights 15-46
12941696 Control Box Assembly, Hydraulic Steering 35-30
12941720 Control Panel Assembly - Front Cab 15-
80221 Coupling, Pipe, Steel 2½” NPT 51-14
12950655 Cover, Battery Rack 53-5
12931423 Cover, Brake Pedal 21-23
12951101 Cover, Front Orbitrol Valve 31-16
G1-10067 Cover, Hydraulic and Surge Tank 1-2
——— Cover, Latch Box 12a-10
——— Cover, Latch Box 12b-10
G1-10049 Cover, Louver Radiator Intake 1-6
12950880 Cover, Orbitrol Valve - ROC 32-16
12950880 Cover, Orbitrol Valve - ROC Rear 10-4
A14663 Cover, Phone Jack Spring Loaded 18-9
12951436 Cover, Plexiglass - Open Compartment 4D-10
CD276 4-4-9
Rev 13
Chapter 4
12950925 Cover, Plexiglass Rear 10-7

12951457 Cover, Sock for Hoses - Lift Cab 4B-4
12961276 Cover, Tail Light Harness - L/S 1-14
12961276 Cover, Tail Light Harness - Left 6-5
12961274 Cover, Tail Light Harness - R/S 1-15
12961274 Cover, Tail Light Harness - Right 6-8
G1-10091 Curtain, Rubber 8-6
892565C1 Cushion, Seat - ROC 10-1
12893470 Cylinder, Cab Lift (28") 4B-3
78383 Cylinder, Gas Assist 1-19
013030X1 Cylinder, Hydraulic Lift Jack 14-20
12951347 Cylinder, Sensing 35-31
014242 Cylinder, Slave - ROC 23-56
014242 Cylinder, Slave (w/ ROC Option) 24-7
7802 DBL, Type “U” BOP 53-6
12990780 Decal, “Caution” 15-13
12970961 Decal, “Caution: Failure to Use Proper Gear” 18-20
9410000124 Decal, “Caution: Hot Surface” 2-9
SW2 Decal, “Caution: To Avoid Injury” 2-5
12990777 Decal, “Danger, Explosion Hazard” 18-18
12970448 Decal, “Danger: Cab Pinch Point” 8-8
12990777 Decal, “Danger: Explosion” 2-6
12970444 Decal, “Do Not Drive with Park Brake Applied” 18-4
12970851 Decal, “Do Not Shift Transmission” 18-14
4-4-10 CD276
Rev 13
Chapter 4
12970882 Decal, “GT-110 Towing Instructions” 18-19

12970862 Decal, “Main Circuit” 18-12
12990611 Decal, “Moving Parts Hazard” 2-8
9410000146 Decal, “Notice: This Tractor…” 18-15
G1-10099 Decal, “Park Brake Engaged” 18-3
12970860 Decal, “Phone Jack” 18-7
12970518 Decal, “Read the Manual” 18-21
12970880 Decal, “Service Information” 2-4
12970872 Decal, “Towing Instructions” 18-17
12970508 Decal, “Trained Personal” 18-22
12970879 Decal, “Turn for Fresh Air” 18-23
9410000125 Decal, “Warning” 2-7
SW600 Decal, “Warning: To prevent burning…” 2-3
12970878 Decal, Jack Location 14-3
12970862 Decal, Main Circuit Hyd. Pressure 41-18
12970342 Decal, Warning “Tow Aircraft on Low Gear” 18-1
12020351 Diode Assembly, Circuit Board 35-11
——— Door Weldment - L/H 12a-1
——— Door Weldment - R/H 12b-1
12950514 Door, Access - Air Filter 1-12
12950524 Door, Access - Battery-Valves 1-9
G1-10037 D-Ring, 46K with Strap 3-5
12950079 Driveline Assembly with Center Bearing Mount 29-2
12950080 Driveline, Front Axle 29-1
12941667 Driver’s Compartment, Open 4D-1
——— Elbow 30-16
CD276 4-4-11
Rev 13
Chapter 4

76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 19-20
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 19-24
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 20-2
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 20-32
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 22-4
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 23-4
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 25-6
76988 Elbow, 1/8 Pipe to 1/4 JIC 90° 26-6
76988 Elbow, 1/8" Pipe to ¼” JIC, 90, 4MJ-2MP90 21-13
86080 Elbow, 45° 34-31
86080 Elbow, 45° 38-83
——— Elbow, 90° 30-32
649F0606 Elbow, 90° 51-19
76968 Elbow, 90° 48-2
76968 Elbow, 90° 52-2
77011 Elbow, 90° 47-4
T6-9500-157 Elbow, 90° 36-5
2071-4-4S Elbow, 90° - 37° Flare Swivel/37° Flare 25-11
4-4-12 CD276
Rev 13
Chapter 4

88197 Elbow, 90° ¼ Pipe Street, 3000# 25-7
76948 Elbow, 90° ¼ Tube 20-17
76948 Elbow, 90° ¼ Tube 38-71
78988 Elbow, 90° 1/8 Pipe to ¼ JIC90 - ROC 23-62
——— Elbow, 90° 10MJ-8MB90 - Internal Jacking Opt. 38-29
——— Elbow, 90° 18mmx8MJ90° 44c-13
76971 Elbow, 90° 24MJ-24MB90 39-4
76971 Elbow, 90° 24MJ-24MB90 41-43
3500X4 Elbow, 90° 4MJ-4FP90 18-26
76991 Elbow, 90° 4MJ-4MP90 38-5
76966 Elbow, 90° 6MJ-6MP90 40-4
76966 Elbow, 90° 6MJ-6MP90 41-47
87652 Elbow, 90° 6MP-6MP90 51-16
77006 Elbow, 90° 8MJ-12MP90 14-24
CD276 4-4-13
Rev 13
Chapter 4

2071-8-8S Elbow, 90° Flare Swivel 34-50
2071-8-8S Elbow, 90° Swivel 8MJ-8FJX90 14-21
3500X4 Elbow, 90°, ¼ NPT 4MJ-4FP90 41-31
76991 Elbow, 90°, ¼ Pipe to ¼ JIC 22-28
76991 Elbow, 90°, ¼ Pipe to ¼ JIC 23-28
76996 Elbow, 90°, Pipe / 37° Flare 41-49
85763 Elbow, Bulkhead Union 10MJ-BLKHD90° 42-11
12233-8 Element, Air Filter (Service Item) 49-7
9541007000 Element, Filter 41-14
2020PM-OR Element, Primary Fuel Filter 51-7
12960978 Enclosure, Rear Operator Comp. 10-17
12941853 Engine, Deutz, BF6M1013CP 44a-1
12941853 Engine, Deutz, BF6M1013CP 44b-1
12941853 Engine, Deutz, BF6M1013CP 44c-1
G1-10012 Engine, Deutz, BF6M1013FC 44a-1
G1-10012 Engine, Deutz, BF6M1013FC 44b-1
G1-10012 Engine, Deutz, BF6M1013FC 44c-1
G1-10112 Extension, Front Bumper - Opt. 7-10
SY024 Extinguisher, Fire 6-12
4-4-14 CD276
Rev 13
Chapter 4

G1-10038 Fan, 24" 44a-3
G1-10038 Fan, 24" 52-18
604364-03 Filter, Air 49-6
117-4423 Filter, Fuel 51-8
118-0597 Filter, Fuel - Spin-On 44a-9
1000FH30 Filter/Water Separator, FG, Fuel 51-6
——— Fitting 30-12
78890 Fitting, ¼” Pipe to ¼’ JIC Straight 21-19
CD276 4-4-15
Rev 13
Chapter 4

78904 Fitting, 12MJ-12MP 14-26
——— Fitting, 14mm-6MJ 44a-6
202713-8-8S Fitting, 8MJ-8MBL 14-9
94259 Fitting, Hose, ¼” MNPT to 6ID 36-3
76927 Fitting, O-Ring/37° Flare - 8MJ-10MB 14-11
08-06-070120 Fitting, Straight 8MJ-6MB 14-22
77200 Fitting, Union Bulkhead, 37° Flare 8MJ-BLKHD w/ Nut 34-51
——— Flywheel 44b-2
——— Foam, Door - L/H 12a-9
——— Foam, Door - R/H 12b-9
G1-10087 Frame Weldment - Tier II Deutz 3-6
G1-10108 Frame Weldment - Tier II Deutz, 2 Front/Rear Hitches 3-6
G1-10017 Frame Weldment, Air Force 1-26
G1-10087 Frame Weldment, Tier II Deutz 1-26
A3188X20 Fuse, 10 Amp 56-10
A3188X21 Fuse, 15 Amp 56-11
A3188X22 Fuse, 20 Amp 56-2
4-4-16 CD276
Rev 13
Chapter 4
ANL225 Fuse, 225 Amps, 23 Volts (F1) 54-15

A3188X23 Fuse, 30 Amp 56-3
——— Gasket, Turbocharger Flange (Service Item) 50-5
9541008000 Gauge, Filter Indicator 41-11
12941883 Gauge, Fuel Level, 1/8 Tank 15-4
350516 Gauge, Oil Pressure, 0-80 psi, 12V 15-58
310504 Gauge, Temperature, 150-300 Deg. 15-14
310514 Gauge, Transmission Oil Temp. 15-60
——— Glow Plug (Modified) 44-3
G1-10114 Guard, Rear View Camera 57-3
——— Handle, Eberhart 12a-8
——— Handle, Eberhart 12b-8
——— Handle, Outside Paddle 12a-4
——— Handle, Outside Paddle 12b-4
G1-10029 Harness, Relay, Centering, Assembly 35-15
12941687 Harness, Wire - Control Panel 15-42
12941893 Harness, Wire - Fuse Box 56-5
12941831 Harness, Wire - Main Chassis 55-22
12950253 Harness, Wire - Trans. Solenoid Control 46-11
12941889 Harness, Wire, Steer Box - Front Cab 35-22
12941890 Harness, Wire, Steer Box - Rear Cab Opt. 35-23
CD276 4-4-17
Rev 13
Chapter 4
9541006000 Head, Filter (AA4678) 41-13

DB-2292 Heat Exchanger, Transmission 47-1
5867 Hinge, 5" Stamped Steel 1-16
G1-10083 Hitch, Two Tier 1-27
012489 Holder, Fuse 56-12
4164 Holder, Fuse (For ANL225) 54-18
660-1-2640 Holder, Tag 6-1
——— Hose 30-17
12960094 Hose (Heater to Cab Bulkhead) 42-13
12951034 Hose Assembly (“PL” Distribution Valve to Hydraulic Pump) 37-54
12951006 Hose Assembly (Bottom D.P. Check Valve
(C2) to Rear Cyl. Tee (C2)) 33-29
12950986 Hose Assembly (Bottom DCDV to Emergency Pump) 41-29
12950986 Hose Assembly (Bottom DCDV to Emergency Steer Pump) 38-57
12950986 Hose Assembly (Bottom Dist. Valve to Emergency Pump) 40-3
12950986 Hose Assembly (Bottom Dist. Valve to Emergency Steer Pump) 37-55
12951006 Hose Assembly (Bottom DPCV (C2) to Rear Cyl. Tee (C2)) 37-72
4-4-18 CD276
Rev 13
Chapter 4

12941031 Hose Assembly (Bulkhead “G” to Pressure Gauge) 42-8
12970705 Hose Assembly (Bulkhead “P” to Accelerator Pedal “P”) 42-2
12970705 Hose Assembly (Bulkhead “S” to Accelerator Pedal “S”) 42-1
12940865 Hose Assembly (Bulkhead Panel to DCDV Tee) 41-35
12941017 Hose Assembly (Cab Bulkhead “B” to Brake Actuator) 42-3
12951011 Hose Assembly (Cab Bulkhead “B” to Front Bulkhead “B”) 42-22
12970953 Hose Assembly (Cab Bulkhead “G” to Front Bulkhead “G”) 42-28
12951010 Hose Assembly (Cab Bulkhead “L” to Front Bulkhead “L”) 42-20
12951010 Hose Assembly (Cab Bulkhead “R” to Front Bulkhead “R”) 42-21
12951024 Hose Assembly (Cab Bulkhead “S” to Front Bulkhead “S”) 42-18
12951010 Hose Assembly (Cab Bulkhead “T” to Front Bulkhead “T”) 42-17
12951369 Hose Assembly (Cab Lift DCDV to Lift Valve) 43-3
12951444 Hose Assembly (D.P. Check Valve (C2) to Solenoid) 33-27
12950993 Hose Assembly (DCDV “P” to Solenoid Valve Plate “P”) 38-25
12951034 Hose Assembly (DCDV “PL” to Hydraulic Pump) 38-56
12950993 Hose Assembly (DCDV (GP1) to Solenoid Valve Plate (P)) 34-21
CD276 4-4-19
Rev 13
Chapter 4

12950998 Hose Assembly (DCRV “A” to Brake Actuator Valve (Bottom)) 38-37
12950991 Hose Assembly (DCRV “B” to Accumulator Inside) 38-46
12950997 Hose Assembly (DCRV “B” to Brake Actuator Valve) 38-45
12950994 Hose Assembly (Distribution Valve (P) to Front Blkhd (P)) 37-22
12950994 Hose Assembly (Distribution Valve (S) to Front Blkhd (P)) 33-12
12951444 Hose Assembly (DPCV (C2) to Solenoid Valve Bottom) 37-73
12950997 Hose Assembly (Dual Check Relief Valve “B” to Brake Booster) 37-46
12951012 Hose Assembly (Front Bulkhead to Slave) 19-1
12951445 Hose Assembly (Front Left Steer Cyl. (L) to Front Blkhd (L)) 33-11
4-4-20 CD276
Rev 13
Chapter 4
12950980 Hose Assembly (Hand Pump to “H” Port) 25-15
12950981 Hose Assembly (Hand Pump to “T” Port) 25-16
12970745 Hose Assembly (Hand Pump to Front Axle) 26-14
12970744 Hose Assembly (Hand Pump to Rear Axle) 26-25
12960095 Hose Assembly (Heater “H” to Front Bulkhead) 42-15
12951035 Hose Assembly (Hyd. Tank to Hyd. Pump) 39-5
12951034 Hose Assembly (Hydraulic Pump to DCDV) 41-30
12951034 Hose Assembly (Hydraulic Pump to Dist. Valve) 39-9
12950948 Hose Assembly (Hydraulic Tank to Emergency Pump) 36-11
12951035 Hose Assembly (Hydraulic Tank to Hydraulic Pump) 36-9
(Jack Valve Outlet to Return Manifold) - Int. Jacking Opt. 38-111
12951000 Hose Assembly (Manifold to Front Bulkhead (L)) 38-96
12951000 Hose Assembly (Manifold to Front Bulkhead (R)) 38-89
12951004 Hose Assembly (Manifold to Rear Blkhd (L)) 38-102
12951004 Hose Assembly (Manifold to Rear Blkhd (R)) 38-101
12951004 Hose Assembly (Manifold Valve (RL) to Rear Blkhd (L)) 34-46
12951004 Hose Assembly (Manifold Valve (RR) to Rear Blkhd (R)) 34-45
12950975 Hose Assembly (Oil Cooler to Transmission “IN”) 47-5
12941006 Hose Assembly (Orbitrol Valve “L” to Steer Valve “L”) 42-4
12951020 Hose Assembly (Orbitrol Valve “P” to Steer Valve “P”) 42-9
12941007 Hose Assembly (Orbitrol Valve “R” to Steer Valve “R”) 42-6
12951019 Hose Assembly (Orbitrol Valve “T” to Steer Valve “T”) 42-10
12950982 Hose Assembly (Park Brake Valve “P” to Dist. Valve) 26-12
12950947 Hose Assembly (Park Brake Valve “T”) 25-24
CD276 4-4-21
Rev 13
Chapter 4

12950985 Hose Assembly (Press. Gauge Tee to Dist. Valve Tee (GP1)) 37-16
12951016 Hose Assembly (Rear Brake to Slave Cylinder) - ROC 23-58
12950998 Hose Assembly (Relief Valve “A” to Brake Booster) 37-36
12951027 Hose Assembly (Reservoir to Rear Accel Pedal) 20-12
12951003 Hose Assembly (Return Manifold (T) to Rear Blkhd (T)) 34-47
12951013 Hose Assembly (Return Manifold to Brake Accumulator “T”) 37-67
4-4-22 CD276
Rev 13
Chapter 4
12951013 Hose Assembly (Return Manifold to Brake Actuator “T”) 38-90

12950988 Hose Assembly (Return Manifold to DCRV “T”) 38-38
12950999 Hose Assembly (Return Manifold to Front Blkhd) 33-13
12951003 Hose Assembly (Return Manifold to Rear Blkhd) 38-75
12950995 Hose Assembly (Select Valve Sub-Plate (B) to Rear Blkhd (P)) 34-43
12951000 Hose Assembly (Steer Manifold (FL) to Front Bulkhead (L)) 34-11
12951000 Hose Assembly (Steer Manifold (FR) to Front Bulkhead (R)) 34-10
12950995 Hose Assembly (Sub-Plate Select Valve “B” to Rear Blkhd “P”) 38-15
12951005 Hose Assembly (Top D.P. Check Valve (C1) to Rear Cyl. Tee (C1)) 33-30
12951005 Hose Assembly (Top DPCV (C1) to Rear Cyl. Tee (C1)) 37-82
12950949 Hose Assembly (Transmission “OUT” to Oil Cooler) 47-6
G1-10047 Hose Assembly (Transmission to Oil Cooler) 48-3
12950948 Hose Assembly, Emergency Pump Suction 41-7
12951367 Hose Assembly, Jack Valve Outlet to Return Manifold 14-7
CD276 4-4-23
Rev 13
Chapter 4
12951364 Hose Assembly, Jack Valve to Front Left Cylinder 14-14

12951364 Hose Assembly, Jack Valve to Front Right Cylinder 14-15
12951365 Hose Assembly, Jack Valve to Rear Left Cylinder 14-18
12951366 Hose Assembly, Jack Valve to Rear Right Cylinder 14-19
12960980 Hose Assembly, Oil Drain 44c-12
12951363 Hose Assembly, Pressure Jack Valve Inlet to Ball Valve 14-23
12950985 Hose Assembly, Pressure Switch 41-27
12951036 Hose Assembly, Pump Drain 36-14
12951036 Hose Assembly, Pump Drain (to Hyd. Tank) 39-11
12951036 Hose Assembly, Pump Drain (to Tank) 41-9
12951035 Hose Assembly, Pump Suction 41-8
G1-10079 Hose Kit, Turbo 52-
——— Hose Ø 1" (Surge Tank to Engine) 52-28
——— Hose Ø 5/16", 250 psi (Surge Tank to Engine Fill) 52-27
——— Hose Ø 5/16", 250 psi (Surge Tank to Radiator) 52-8
——— Hose, Block Lube Front to Block Side 30-13
12941031 Hose, Cab Bulkhead to Pressure Gauge 18-27
G1-10070 Hose, Coupler 2 x 6 52-13
G1-10062 Hose, Coupler 2½” ID, 6" Long 52-9
G1-10064 Hose, Coupler 3 x 4 52-19
4-4-24 CD276
Rev 13
Chapter 4
G1-10063 Hose, Coupler 3 x 6 52-33

12960437 Hose, Drain 36-2
12951032 Hose, Fuel (Racor Filter to Fuel Pump) 51-3
12951031 Hose, Fuel (Racor Filter to Tank (Check Valve)) 51-9
12951033 Hose, Fuel, Return 51-10
97065 Hose, Hump - 5" to 4" Reducing 49-3
G1-10047 Hose, Transmission / Cooler 52-1
12015308 Housing, Diode Array 35-9
G1-10095 Hub, Fan - Air Conditioner 44-7
G1-10095 Hub, Fan - Air Conditioner 44a-5
39135-001 Indicator, Service - Opt. 49-2
——— Injector, Fuel 44a-11
——— Insert, AK 10-32 12a-12
——— Insert, AK 10-32 12b-12
A14664 Jack, Phone 18-8
12950102 Lamp Assembly, Rear Left 6-3
12950101 Lamp Assembly, Rear Right 6-9
68-80-302-10 Latch, Ball Handle, Series 80 1-17
——— Latch, Inside Release Package - L/H 12a-5
——— Latch, Inside Release Package - R/H 12b-5
——— Latch, Rotary 12a-3
——— Latch, Rotary 12b-3
595105 Lens (Clearance Lamp) 15-18
CD276 4-4-25
Rev 13
Chapter 4

596120 Lens Insert, Glow Plug 15-12
594461 Lens Insert, Left Turn 15-8
596173 Lens Insert, Park Brake, Red 15-24
594460 Lens Insert, Right Turn 15-21
12941884 Lens Insert, Steer Mode Yellow 16-7
12941828 Lens Insert, Yellow Low Cool 16-6
596195 Lens w/ Blower Fan Symbol 15-66
——— Lens w/ Park Light Symbol 15-32
596627 Lens w/ Windshield Washer Symbol 15-28
596625 Lens w/ Wiper Symbol 15-26
G1-10082 Lens, Defroster 15-70
12941385 Lift Frame Assembly 4A-2
A11427X4 Light, Coord Steering Mode Indicator 15-43
4-4-26 CD276
Rev 13
Chapter 4
1090D3-12 Light, Crab Steering Mode Indicator 15-45

014050 Light, Dash Panel L/H 15-6
014050 Light, Dash Panel R/H 15-22
600802 Light, Engine Oil Pressure Gauge 15-59
53 Light, Fuel Level Gauge 15-5
1816 Light, Speedometer 15-57
1816 Light, Tachometer 15-63
600802 Light, Temperature Gauge 15-15
A11427X2 Light, Track Steering Mode Indicator 15-44
600802 Light, Transmission Oil Temp. Gauge 15-61
53 Light, Voltmeter 15-17
——— Line, Oil Lubricant (Modified for Opt.) 44a-7
G1-10106 Lube System Kit 30-
12990070 Lubrication System, Automatic 30-
CD276 4-4-27
Rev 13
Chapter 4

6041232452 Module, Electronic Speed (ESM) 57-6
G1-10107 Monitor 57-1
SSB33-1000-4 Mount, 3-Piece, 1125 lbs @ .03 in 44c-2
SSB33-1000-4 Mount, 3-Piece, 1125 lbs @ .03 in 46-9
015790 Mount, Actuator, T700 Weld 24-1
12884736 Mount, Cylinder 13-18
SSB33-1000-4 Mount, Isolator 27-3
G1-10046 Mount, Motor L/H - GT-110/U-30 27-8
G1-10040 Mount, Motor R/H - GT-110/U-30 27-1
G1-10046 Mount, Motor, L/H 44c-9
G1-10040 Mount, Motor, R/H 44c-3
12941692 Mount, Phone Jack 18-10
A15332 Mount, Seat, Mechanical 4D-6
A15332 Mount, Seat, Mechanical 5-3
015791 Mount, Slave Cylinder, T700 Weld 24-2
12950819 Mount, Transmission, ZF 29-9
G1-10042 Mount, Upper Transmission Cooler 52-4
G1-10111 Mounting Weldment, Additional Front Hitch Option 7-9
G1-10066 Muffler, Spark Arresting 50-12
12941723 Nameplate, Cab Control Panel 17-1
12941723 Nameplate, Control Panel - Rear Cab Opt. 15-53
12950628 Nameplate, Jack Shutoff Valve 14-6
12950625 Nameplate, Jacking Instructions 14-5
12000237 Nameplate, Park Brake 18-6
12941826 Nameplate, Rear Station Panel 16-1
79488 Nipple, Pipe, 2½” Close 51-15
——— Nut 17-13
25985R1 Nut, 1½-6 NC 27-21
5/16-18 Nut, Flange 5/16-18 40-7
74030 Nut, Hex 1"-8 NC - Steel, Gr. 5 10-10
A8006-030C Nut, Hex 1¼-7 NC 27-18
4-4-28 CD276
Rev 13
Chapter 4
13/16-20 Nut, Hex 13/16-20 NEF (Steel) 31-2

13/16-20 Nut, Hex 13/16-20 NEF (Steel) 32-2
K33942 Nut, Hex Jam 13-7
62847 Nut, Hex Lock, 1/4-20 NC 19-7
62847 Nut, Hex Lock, 1/4-20 NC 20-20
94477 Nut, Hex M10-1.5, Gr 8 29-5
9128131062 Nut, Hex UNF2B 24-6
9128131062 Nut, Hex UNF2B (w/ ROC Option) 24-6
99844 Nut, Hex, 5/16-24 NF 19-4
99844 Nut, Hex, 5/16-24 NF 20-24
A13447 Nut, Lock - Cone Type 2, ¾” NC 27-14
10-32 Nut, Lock 10-32 54-16
3/8-16 Nut, Lock 3/8-16 24-12
73777 Nut, Locking, ¾-16 NF 27-5
73777 Nut, Locking, ¾-16 NF 46-10
½-13 Nut, Top Lock Hex ½-13 44c-14
¾-16 Nut, Top Lock Hex ¾-16 44c-11
3/8-16 Nut, Top Lock Hex 3/8-16 21-9
5/16-18 Nut, Top Lock Hex 5/16-18 36-19
60574 Nut, Top Lock Hex 5/16-18 19-15
60574 Nut, Top Lock Hex 5/16-18 20-28
12970493 Pad, Brake 21-17
G1-10105 Pad, Brake - High Angle with Grip 21-17
EH-2802 Pad, Heater - 250 Watts, 120V 45-2
12951190 Pad, Isolator - Fixed Cab 4C-3
12951190 Pad, Isolator - Fixed Cab 4D-3
——— Pan, Oil 44a-10
12950530 Panel, Access - Rear Top 1-10
012494 Panel, Control Box - Hoffman 35-29
12950926 Panel, Cover - Rear 10-6
CD276 4-4-29
Rev 13
Chapter 4

12950443 Panel, Side - Ballast Cover 1-11
12-460-124 Pedal, Accelerator - Rear Cab 20-13
015149 Pedal, Brake (Wldmt) - ROC 23-59
12884735 Pin, Cylinder 13-19
98412A132 Pin, Hitch - 5/8" Dia. x 4 “ Grip 1-29
98296A185 Pin, Roll - 1/8" Dia. x 1.25" Long 1-30
015792 Pivot, Brake Actuator, Mount, T700 24-4
12950512 Plate, Access - Air Filter Cover 1-3
12941836 Plate, Control Panel Blanking 15-53
G1-10090 Plate, Cover 10-18
12950791 Plate, Cover - Cab Front 4C-4
12950791 Plate, Cover - Cab Front 4D-4
12950511 Plate, Cover - Top Air Filter 1-4
12950513 Plate, Cover - Top Front 1-5
G1-10033 Plate, Data - Hydraulic Schematic 2-2
G1-10031 Plate, Data, Contract 18-16
12930133 Plate, Data, Identification 18-16
12000175 Plate, Face - Park Brake Switch 10-16
G1-10085 Plate, Hitch Adapter 1-28
G1-10108-5 Plate, Hitch Mounting Spacer - Opt. 7-11
014632 Plate, Sub - Cab Select Valve 34-29
G1-10098 Plate, UID - Opt. 18-13
12950078 Platform, Raised Cab 4C-2
12950078 Platform, Raised Cab 4D-2
12960291 Platform, Rear Mounted Generator Set 10-9
12950208 Platform, Rear Operator (Wldmt) 10-9
4-4-30 CD276
Rev 13
Chapter 4
——— Plug 30-15

76488 Plug, #4 O-Ring 25-29
76488 Plug, #4 O-Ring 26-4
76488 Plug, #4 O-Ring 37-41
76488 Plug, #4 O-Ring 38-41
76488 Plug, #4 O-Ring 38-85
12970111 Plug, Air Intake 49-2
——— Plug, Hole - 0.438 Dia. 12a-7
——— Plug, Hole - 0.438 Dia. 12b-7
86069 Plug, O-Ring Boss - 1½” Tube OD 37-70
86065 Plug, O-Ring Boss, ¾” Tube OD 37-26
900599-8S Plug, Swivel #8 44c-10
G1-10094 Pulley, Air Conditioner 44-6
G1-10094 Pulley, Air Conditioner 44a-4
——— Pulley, Tensioner 44a-7
——— Pulley, Tensioner (Included w/ Engine) 44-8
——— Pump, Fuel (Included w/ Engine) 51-1
H1185 Pump, Hand 25-3
HP-1S Pump, Hand w/ Integrated Shuttle 26-3
PAVC65BR Pump, Hydraulic, Main - Variable Displacement 41-4
G1-10034 Radiator, Charge Air Cooler 52-5
012780 Rail Channel 35-26
17-10017-11 Receptacle, Fastener, Clip-On 1-23
CD276 4-4-31
Rev 13
Chapter 4
12940553 Reed Switch and Connector Assembly 35-2

RY2S-L-DC12V Relay, DPDT w/ Indicator Light - 12VDC, 3A 35-18
014273 Relay, DPDT, 12V 35-6
0-332-002-150 Relay, Ignition 56-9
A13854 Relay, Latch 35-12
RH2LB-U-DC12 Relay, Latch - 12VDC, 10A 35-16
0-332-204-151 Relay, SPDT, 12V, 20-30 AMP/NO 57-4
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Downshift and Inhibitor) 55-23
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Engine Shutdown Opt.) 55-21
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Horn) 55-14
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Lock-Up Unit) 55-13
(Park Brake Engine Shutdown Opt.) 55-10
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Park Brake ON) 55-15
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Shifter in NEUTRAL) 55-17
0-332-204-151 Relay, SPDT, 12VDC, 20-30Amp/NO (Shifter, Back-Up) 55-12
(Trans. not in NEUTRAL, Park Brake Applied) 55-18
——— Reservoir 30-14
20-920-009 Reservoir 19-13
20-920-009 Reservoir 20-9
014589 Reservoir, Brake Fluid - ROC 23-65
17-10014-26 Retainer, Captive Screw 1-24
——— Retainer, Push-On 3/16" 12a-18
——— Retainer, Push-On 3/16" 12b-17
K97535 Ring, Snap - External 13-15
C15394 Riser 4D-5
C15394 Riser 5-4
12884734 Rod Eye, Cylinder 13-20
——— Rod, Inside Handle - 7/32" Dia. Latch 12a-13
——— Rod, Inside Handle - 7/32" Dia. Latch 12b-13
——— Rod, Outside Handle - 3/16" Dia. Latch 12a-14
——— Rod, Outside Handle - 3/16" Dia. Latch 12b-14
——— Rod, Outside Handle - 5/32" Dia. Lockplate 12a-15
4-4-32 CD276
Rev 13
Chapter 4
——— Rod, Outside Handle - 5/32" Dia. Lockplate 12b-15

R3563 Roller 13-14
R4095 Roller 13-8
R5974 Roller 13-16
10-32 Screw, #10-32 35-3
#8 Screw, #8 x 3/8" TAP 35-27
17-13-106-11 Screw, Captive - Knurled 1-22
½-20 x ½ Screw, Flange Ø ½-20 x ½” Long 54-17
10-32 x ¾ Screw, Flange Ø 10-32 x ¾” Long 54-11
9864004016 Screw, Flat Head 21-5
——— Screw, Ground 17-11
——— Screw, Hex Head Ø ¼-20 x 1¼” Long 12a-20
——— Screw, Hex Head Ø ¼-20 x 1¼” Long 12b-19
A8002-188 Screw, Hex Head Ø ¾-16 x 3¾” Long 46-7
12950446 Screw, Hex Head Ø M20-2.5 x 65mm Long 46-6
——— Screw, Phillips Head Ø ¼-20 x ¾” Long 12a-22
——— Screw, Phillips Head Ø ¼-20 x ¾” Long 12b-21
——— Screw, Phillips PA YZ 8-32 x ½” Long 12a-23
——— Screw, Phillips PA YZ 8-32 x ½” Long 12b-22
——— Screw, Phillips Pan Head 10-32 x ½” Long 12a-11
——— Screw, Phillips Pan Head 10-32 x ½” Long 12b-11
——— Seal, Windshield - 8' 12a-6
——— Seal, Windshield - 8' 12b-6
12950597 Seat, Bench w/ Storage Box - Bolt-In 4D-8
A3588X5 Seat, Bucket 4D-7
A3588X5 Seat, Bucket 5-1
810143 Sender Assembly - Fuel Tank 51-20
R206 Shim 13-17
CD276 4-4-33
Rev 13
Chapter 4

G1-10044 Shroud, Lower Radiator 52-21
G1-10043 Shroud, Upper Radiator 52-17
254005 Sight Gauge (Part of Item 1) 41-3
3-334-485-008 Socket, 0-332 Relay 57-5
3-334-485-008 Socket, Relay 55-16
3-334-485-008 Socket, Relay 55-24
A13855X2 Socket, Relay 35-7
3-334-485-008 Socket, Relay (Engine Shutdown Opt.) 55-20
3-334-485-008 Socket, Relay (Park Brake Engine Shutdown Opt.) 55-11
12940344 Solenoid, SPST, N/O, 12VDC - Relay Contactor 40-9
——— Spacer 12a-25
——— Spacer 12b-24
015213 Spacer, Brake 21-6
G1-10109 Spacer, Lower - Hitch (Opt.) 6-20
G1-10108-5 Spacer, Mounting - Hitch Plate (Opt.) 6-19
12873365 Spacer, Solenoid Valve 38-63
12950105 Speedometer with Odometer 15-56
LC-055K-7 Spring - 8.45" OD x 0.055" Wire 1-31
SFA-202 Spring, Hold Down F/Timer 35-8
SR3P-06F3 Spring, Hold Down Relay 35-14
——— Starter 44a-3
118-0928 Starter 44c-15
1-585809 Step, Folding Malleable 3-7
12951068 Strap, Hold Down - Hydraulic Tank 41-24
12950595 Stub, Flange, Exhaust Turbo 50-3
A9008 Stud (For 78383) 1-21
4-4-34 CD276
Rev 13
Chapter 4
JB3816-2 Stud, Fuse Box Power 56-4

C1933 Stud, Junction Block Ø ½-13 54-5
12950517 Support, Access Door 1-8
G1-10069 Support, Lower, Radiator Pipe 52-29
12951435 Support, Plexiglass Cover - Open Compartment 4D-9
G1-10050 Support, Top Cover Louver 1-32
G1-10068 Support, Upper Turbo Pipe 52-31
511066 Switch, Cab Lift 8-23
011714X1 Switch, Emergency Pump (1800 psi) 41-16
——— Switch, Mechanical (part of kit K994720) 18-24
940393C91 Switch, Micro 8-14
G1-10081 Switch, Momentary 15-69
014045 Switch, Push/Pull (Emergency Stop) 15-3
511003 Switch, Rocker, 2 Pos. (Park Light) 15-31
511003 Switch, Rocker, 2 Pos. (Rear Headlights) 16-19
511010 Switch, Rocker, 2 Pos. Off (Emerg. Steering - Rear) 16-22
511010 Switch, Rocker, 2 Pos. Off (Windshield Washer) 15-27
511010 Switch, Rocker, 2 Pos. OFF-ON (Emerg. Steering) 15-67
511029 Switch, Rocker, 3 Pos. (Blower Fan) 15-65
511265 Switch, Rocker, 3 Pos. (Cab Select - Rear) 16-21
511265 Switch, Rocker, 3 Pos. (Cab Select) 17-6
CD276 4-4-35
Rev 13
Chapter 4
511029 Switch, Rocker, 3 Pos. (High/Low Beam) 15-33

511229 Switch, Rocker, 3 Pos. (Steer Mode Select - Rear) 16-20
511066 Switch, Rocker, 3 Pos. Momentary (Cab Lift) 15-50
511229 Switch, Rocker, Select 3 (Wiper) 15-25
956-3124 Switch, Starter 15-1
12960969 Switch, Steering Mode Select (3 Pos.) 15-39
012481 Switch, Toggle (Dash Light) 15-2
LE000307 Switch, Toggle, 4PDT, Maintained (Park Brake) 18-5
12950106 Tachometer with Hourmeter 15-62
12941850 Tank, Fuel, 65 Gallon 51-12
12941657 Tank, Hydraulic 36-7
12941657 Tank, Hydraulic Reservoir 41-1
G1-10035 Tank, Surge - Radiator 52-24
12872931 Tee, ¼ JIC with Swivel 23-68
12872931 Tee, ¼ JIC Swivel 22-11
12872931 Tee, ¼ JIC Swivel 23-11
12872931 Tee, ¼” JIC, Swivel 21-15
4-4-36 CD276
Rev 13
Chapter 4
203101-4-4S Tee, 37° Flare, Swivel 21-12

203101-4-4S Tee, 37° Flare, Swivel - ROC 23-63
12040502 Terminal, Female 35-10
——— Thermostat (Modified) 44-4
——— Timer, 12 to 32 VDC 30-18
MSM130W6 Timer, Solid State, 12VDC, 30Sec - Opt. 55-19
12891563 Tire, 1600 x 25HRRIB, Tubeless 27-13
G1-10103 Tire/Wheel Assembly, GT-110 27-13
12931417 Tube Assembly 21-11
12931419 Tube Assembly (Actuator Rear Elbow to Reservoir) 21-18
12970110 Tube Assembly (Actuators to Reservoir) - ROC 23-67
12931418 Tube Assembly (Between Rear Actuator Elbows) 21-16
12931418 Tube Assembly (Between Rear Actuator Ports) - ROC 23-64
12951460 Tube Assembly (Brake Actuator Valve to Press. Switch) 23-29
12951460 Tube Assembly (Brake Actuator Valve to Pressure Switch) 22-29
12931417 Tube Assembly (Cylinder Crossover to Tee) - ROC 23-61
CD276 4-4-37
Rev 13
Chapter 4
12941017 Tube Assembly (Front Axle to Front Brake Actuator) 21-21

12951462 Tube Assembly (Shuttle Valve Bypass) 25-22
12950589 Tube Assembly, Lift Assembly 43-6
G1-10059 Tube, Cooler to Engine 52-11
G1-10011 Tube, Exhaust 50-15
G1-10065 Tube, Exhaust Turbo to Flex 50-7
G1-10057 Tube, Filter Box to Turbo 49-1
G1-10061 Tube, Radiator Bottom 52-16
G1-10060 Tube, Radiator Top 52-15
G1-10058 Tube, Turbo to Cooler 52-14
——— Turbo, Air Intake (Modified) (Incl. w/ Engine) 44-2
——— Turbo, Air Intake (Modified) (Incl. w/ Engine) 44a-2
——— Turbo, Exhaust (Part of Engine) 50-2
——— Turbocharger 44a-8
HP22GT Valve, Ball - ¾”, 3000# 14-25
012483X5 Valve, Cab Lift/Lower 43-1
87046 Valve, Check, In-Line, 3/8" NPT 51-17
12884732 Valve, Control, Lift - Jack 14-1
6660 Valve, Drain - 90°, ¼ NPT 36-4
4-4-38 CD276
Rev 13
Chapter 4

12940551 Valve, Park Brake 25-1
H1186 Valve, Shuttle (Hand Pump) 25-4
06863-38 Voltmeter, 12V, Black Bezel 15-16
12950673 Washer, Axle Mounting Bolt 27-22
——— Washer, Flat 17-12
#8 Washer, Flat #8 35-28
——— Washer, Flat ¼” 12a-21
——— Washer, Flat ¼” 12b-20
½ Washer, Flat ½” 24-17
½ Washer, Flat ½” ID 38-92
½ Washer, Flat ½” ID 44c-7
¾ Washer, Flat ¾” ID 44c-4
12902827 Washer, Flat 1" SAE 10-11
10-32 Washer, Flat 10-32 35-4
A8006-412C Washer, Flat 1¼ 27-17
CD276 4-4-39
Rev 13
Chapter 4
M16 Washer, Flat 16mm 39-2

——— Washer, Flat 2" ID 3-10
3/8 Washer, Flat 3/8" 21-8
3/8 Washer, Flat 3/8" 24-16
75470 Washer, Flat 5/16" ID 19-5
75470 Washer, Flat 5/16" ID 20-26
85936 Washer, Flat 5/8" ID 3-3
99657 Washer, Flat, 1/4 19-8
99657 Washer, Flat, 1/4 20-21
——— Washer, Lock #10 Split 12a-24
——— Washer, Lock #10 Split 12b-23
½ Washer, Lock ½” ID 38-93
73793 Washer, Lock ¾” - Steel 10-15
73796 Washer, Lock 1" - Spring, Steel 10-12
M16 Washer, Lock 16mm 39-6
5/16 Washer, Lock 5/16" ID 37-29
5/16 Washer, Lock 5/16" ID 38-31
5/16 Washer, Lock 5/16" ID 38-69
5/16 Washer, Lock 5/16" ID 38-70
79578 Washer, Lock 5/16", Spring, Zerk 24-9
99297 Washer, Lock 5/8" ID 3-2
99516 Washer, Lock, Metric, 10mm 29-6
94051 Washer, Sealing - 26mm 47-9
——— Washer, Star 17-14
4-4-40 CD276
Rev 13
Chapter 4
9432000006 Wheel Assembly 27-12

——— Window Assembly - L/H 12a-2
——— Window Assembly - R/H 12b-2
——— Wire, 10 Gauge (to 20V Fuse) 54-13
——— Wire, 10 Gauge, White, 25" (to Auto Lube) 54-10
——— Wire, Emerg. Pump Relay to Emerg. Steer Press. Switch 40-8
CD276 4-4-41
Rev 13
Chapter 4
4-4-42 CD276
Rev 13
MODEL GT-110
TOW TRACTOR
OPERATION, MAINTENANCE,
& PARTS MANUAL
VOLUME 2 OF 2
ORIGINALLY ISSUED SEPTEMBER 1995
Chapter 5
CHAPTER 5: APPENDICES
TABLE OF CONTENTS
SECTION 1: PERIODIC MAINTENANCE CHECKLIST ............................................................. 5-1-1
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS ................................................ 5-2-1

A. Description ............................................................................................................ 5-2-1
CD276 5-TOC-i
Rev 13
Chapter 5
5-TOC-ii CD276
Rev 13
Chapter 5
SECTION 1: PERIODIC MAINTENANCE CHECKLIST
GT-110 Tow Tractor

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 100 200 400 600 1200

Check units exterior for cleanliness and damage.
Check that all controls are in good working order.
Check fire extinguishers are in place and fully charged.
Check fuel system for leaks, include hoses, lines, fittings and
linkage.
Check fuel level, add fuel as required.
Check engines oil system for leaks around filters and gaskets.
Check engine oil level, add oil as required.
Check engines cooling system for leaks and cleanliness.
Check engine coolant level, add coolant as required.
Check exhaust system for integrity.
Check transmission for leaks, include hoses and fittings.
Check transmission oil level, add oil as required.
Check hydraulic system for leaks, include hoses and fittings
to the remote hydraulic fluid cooler.
Check hydraulic fluid level, add oil as required.
Check restriction indicator, replace as required.
Check the front/rear axle differential cases and planetary hubs
for oil leaks.
Check tire pressure.
Check wiring for loose connectors, brittle insulation, or heat
induced cracks.
Check the operation of all lights.
Check horn.
Check that the drive, steering and brake systems are in good
working order.
Check windshield wiper fluid level.
Check brake acutuator fluid levels.
Check brake fluid in master cylinder.
CD276 5-1-1
Rev 13
Chapter 5
GT-110 Tow Tractor

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 100 200 400 600 1200

Check oil level, axle differential and planetary wheel ends.
Drain fuel/water seperator.
Drain water condensate from hydraulic oil tank.
Change engine oil and filters.
Change transmission oil and filter.
Grease drive shafts and universal joints.
Check torque on wheel lug nuts.
Check drive belts condition and tension.
Check electrical system lights, switches and gauges for proper
operation.
Check generator.
Check battery electrolyte level.
Check radiator and heater core hoses and fittings.
Check hydraulic system tubing, hoses and fittings.
Check electrical harnesses, cables, wires and connections.
Lubricate steering knuckles zerk fittings.
Change engine fuel filters.
Change engine air filters.
Check engine air intake system.
Check engine exhaust system.
Check brake accumulator pressures.
Check service brake actuator circuit, bleed air if necessary.
Change hydraulic oil return filter.
Change transmission oil and filter.
Check brake pads and calipers.
Check brake assembly.
Change hydraulic oil.
Change axle differential and planetary wheel end oil.
Drain, flush and refill engine cooling system.
5-1-2 CD276
Rev 13
Chapter 5
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS
A. DESCRIPTION
This section contains additional information relevant to the operation and service of the GT-110 Tow
Tractor. The following is a list of component manufacturer’s service literature included in this chapter.
TAB DESCRIPTION
A. Grease Jockey Centralized On-Board Chassis Lubrication System

- Schematics and Maintenance Instructions
B. Pamic Series Air Cleaners Installation, Bulletin No. C-1500-65B
C. Rockwell Axle Exploded Drawings and Parts List for Model PSC-1485-HDB-211
Maintenance Manual 1, Lubrication
Maintenance and Overhaul Manual for Caliper SCL 59 (Service Brake)
Maintenance Manual No. 4AA, PD 1591 Series Dry Disc Calipers (Parking Brake)
Maintenance Manual 5, Single Reduction Differential Carriers
Maintenance Manual 9G, Planetary Axle Wheel Ends
D. Deutz Engine 1012/1013 Operators Manual

Deutz Engine 1012/1013 Workshop Manual
Deutz Engine 1013 Spare Parts Catalogue
E. Operations and Maintenance Manual for ZF 200 Hydromedia Transmissions,

ZF Part No. 5872 174 002
Spare Parts List 200
CD276 5-2-1
Rev 13
Chapter 5
5-2-2 CD276
Rev 13
LUBRIQUIP INC., 18901 CRANWOOD PARKWAY, CLEVELAND, OH 44128, TEL. 216-581-2000
Centralized On-Board
Chassis Lubrication System Specifically
Designed for
TUG Technologies Corp.
Schematics & Maintenance

Instructions
November 6, 2000
TABLE OF CONTENTS
TOPICS PAGE
SYSTEM OVERVIEW ...................................... ………………………… .... 1

Grease Jockey 2 - Tri Lube Pump .................... ................................. ...... 2
Relief Valve . ..................................................... ..... ........................... ...... 3
Output Adjustment . .................... .................................................... 3
System Timer ............................. .................................................... 4
Settings ...................................... .................................................... 5
Wiring ......................................... .................................................... 5
Installation . .................. ................................................................... 5
System Schematic .......................................................................... 6
Grease Point Chart. ......................................................................... 7
Service Parts List .................................................................................... .. 8
Purging the System of Air . ...................................................................... .. 9
TROUBLESHOOTING ...................................................................................... ... 11

Divider Valve Modular Assembly ..................................................... 12
Types of Blockage ........................................................................... 13
Locating System Blockage ....... ...................................................... 13
Basic PM and Troubleshooting Chart ............................................. 14
TUG TECHNOLOGIES CORPORATION AIRCRAFT
GROUND SUPPORT EQUIPMENT OUTFITTED WITH LUBRIQUIP
AUTO LUBE SYSTEMS
SYSTEM OVERVIEW
The Grease Jockey system is specifically designed for the TUG Technologies
Corporation aircraft ground support equipment on which they have been installed.
The design utilizes components selected for their dependability and efficiency with
over seventy years of successful application in the manufacturing and mobile
industries worldwide.
Figure 1 - Model GT 110 Auto Lube System
IT IS VERY IMPORTANT THAT ALL COMPONENTS REQUIRING GREASE BE FILLED

WITH GREASE BEFORE THE ZERKS ARE REMOVED AND THE GREASE JOCKEY
SYSTEM IS INSTALLED. IF THEY ARE NOT ...THE SYSTEM COULD FAIL.
1
"MSP" series progressive divider valve assemblies are used to meter precise amounts
of lubricant to each point. Divider valve assemblies are designed to provide a consistent
discharge pattern. The pattern is a result of internal porting and a multi-landed piston
within each valve section. Each point receives lubricant, in turn, when grease is pumped
into the divider valve assembly. Valve pistons stop when input flow ceases. Flow
resumes in the next pump cycle where it stopped in the preseding cycle. The designed
movement of the piston provides a precise amount of grease to every point. A flow
restriction occurs when a piston does not complete its designed movement in the series
progression. This will cause a rise in pressure indicating a need to inspect the system
for a blocked lube point, air trapped inside a divider valve, or contaminants in the
lubricant and reservoir.
Grease Jockey 2 -Tri-Lube Pump
Figure 2 - Tri-Lube 12VDC Electric Pump
A twelve-volt DC electric pump is used in this application (see Figure 2). The TriLube
pump is a rugged, single piston pump designed for use with grease up to and including
NLGI #2. For optimal results "0" or "00" grease its recommended.
Adjustments
The pump has an adjustable relief valve to protect the system from over pressure.
The relief valve setting can be adjusted by loosening the locking nut (see 1 in Figure
3, page 3) and turning the setscrew clockwise to increase the relief pressure, and
counterclockwise to decrease the relief pressure.
2
The pump's normal delivery rate is adjustable. Loosen the locking nut (see 1 in Figure
4) and rotate the adjustment screw (2) clockwise to reduce delivery or counterclockwise
to increase delivery of the lubricant, Various outputs that are obtained by varying the
distance of the adjustment screw (see column A in Table 1).
Figure 4 - Pump Output Adjustment
A Flow Rate Cycle Output

In (mm) Cubic Inch(CC) %
0.94 (24.0) 0.010 (0.16) 100
0.89 (22.5) 0.007 (0.12) 75
0.83 (21.0) 0.005 (0.08) 50
0.77 (19.5) 0.002 (0.04) 25
0.73 (18.5) 0.0006 (0.01) 6
0.69 (17.5) 0 (0) 0
Table 1 - Output Adjustment
3
The System Timer
The timer is a compact solid state device in a high impact resistant plastic enclosure. It
has seven lube cycle interval settings from 1/2 to 6 hours, plus a test position and a
manual run button.
Figure 5 - System Timer
The timer operates the system only when the vehicle's ignition switch is turned on. A
memory function keeps track of elapsed-cycle-time even if the ignition switch is
turned off. When the predetermined cycle time has elapsed, the timer signals the
pump to initiate a lubrication cycle. If the vehicle's ignition is turned off before the
interval is complete, the timer's memory "holds" the time count. When the vehicle is
restarted it starts the pumping activity where it left off.
When the cycle-time dial is switched from one range to another, the manual run
button must be pressed to cancel the old setting and apply the new cycle time setting
(otherwise, the new time is added to any time that remains from the previous lube
cycle).
When repeated rapid cycles are needed, such as when testing the system, set the
cycle-time dial to the "test” position and press the manual run button. In this mode the
timer signals the pump to cycle approximately once every minute (45 seconds on and
15 seconds off). This rapid cycling continues as long as the timer remains in the "test"
position. Always reset the timer dial to it's proper setting, when finished with
repeated rapid cycling, and before returning the equipment to duty.
See Table 1 on page 5 for suggested timer settings.
4
Timer Setting Driving Conditions
1/2 or 1 hour Off highway
1.5 or 2 hours Start and stop city, heavy salt, snow

and ice, rough pavement, wet climate,
Heavy loads, dust roads
3 hours Normal city or highway driving, normal
moderate loads
Table 1 - Timer Settings
The wiring schematic for the pump timer is shown in figure 6. It is very important
that the orange memory lead be attached to a constant hot source so the
memory function of the timer can operate properly. The pump and timer kit
contains a detailed wiring drawing with splicing directions.
Figure 6 - Pump Timer Wiring Schematic
An overview of the GT 110 auto-lube installation is shown in Figure 7 on page 6.

It is important that the integrity of the application be maintained by insuring the
correct valve divider block (i.e., 40T, 30T, 20T, 10T, etc.) is connected to the
designated grease point on the vehicle. Mistakenly connecting a 10T line, for
example, to a grease point designated for a 20T, 30T or 40T will severely under
lubricate that area of the equipment and cause a failure.
5
Figure 7 - GT 110 Auto Lube Schematic
Color-coded tube lines in sets of two and three assist in the installation and
servicing of the system. Fitting designations are beneficial for determining the
correct service part number on the parts list.
Table 2, on page 7, provides information on grease points and corresponding

colored tube supply tubes and fittings.
6
LUBRICATION POINTS IDENTIFICATION LIST
AUTO LUBE LAYOUT WITH GREASE JOCKEY 2 PUMP
FOR AIRCRAFT PUSHER TRACTOR S&S MODEL GT110
CUSTOMER NAME: TUG TECHNOLOGIES CORPORATION LOCATION: MARIETTA, GA

VEHICLE #: TYPE: AIRCRAFT PUSHER TRACTOR TUG
MODEL GT110 MILEAGE:
KIT #; 550-503-370 TUG Part # 12990070 DATE: 10/26/00
MASTER MODULE MSP 7: 106-200-066

POINT # DESCRIPTION INJ # COLOR BUNDLE FITTING
1 PLUG
2 PLUG
3 KING PIN TOP FRONT LEFT SIDE 30T BLUE } 1/8 ELBOW
4 KING PIN BOTTOM FRONT LEFT SIDE 30T ORANGE } 15 FT 1/8 ELBOW
5 HYD. STEERING CYL. O/BOARD FRONT LH 10T BLACK } 1/8 ELBOW
6 HYD. STEERING CYL INBOARD FRONT LH 10T BLACK } 15FT 1/8 ELBOW
7 BALL JOINT FRONT LEFT SIDE 20T ORANGE } 1/8 ELBOW
8 PLUG
9 HOSE TO SECONDARY MSP 6
10 KING PIN TOP FRONT RIGHT SIDE 30T BLUE } 1/8 ELBOW
11 KING PIN BOTTOM FRONT RIGHT SIDE 30T ORANGE } 15 FT 1/8 ELBOW
12 HYD. STEERING CYL. O/BOARD FRONT RH 10T BLACK } 1/8 ELBOW
13 HYD. STEERING CYL. I/BOARD FRONT RH 10T BLACK } 15 FT 1/8 ELBOW
14 BALL JOINT FRONT RIGHT SIDE 20T ORANGE } 1/8 ELBOW
SECONDARY MODULE MSP 6: 106-200-067
1 KING PIN TOP REAR RIGHT SIDE 30T BLUE } 1/8 ELBOW
2 KING PIN BOTTOM REAR RIGHT SIDE 30T ORANGE } 15 FT 1/8 ELBOW
3 HYD. STEERING CYL. O/BOARD REAR RH 10T BLACK } 1/8 ELBOW
4 HYD. STEERING CYL. I/BOARD REAR RH 10T BLACK } 15 FT 1/8 ELBOW
5 BALL JOINT REAR RIGHT SIDE 20T ORANGE } 1/8 ELBOW
6 BOLSTER AFT 40T BLACK SINGLE 1/8 ELBOW
7 KING PIN TAP REAR LEFT SIDE 30T BLUE } 1/8 ELBOW
8 KING PIN BOTTOM REAR LEFT SIDE 30T ORANGE } 15 FT 1/8 ELBOW
9 HYD. STEERING CYL. O/BOARD REAR LH 10T BLACK } 1/8 ELBOW
10 HYD. STEERING CYL. I/BOARD REAR LH 10T BLACK } 15 FT 1/8 ELBOW
11 BALL JOINT REAR LEFT SIDE 020T ORANGE } 1/8 ELBOW
12 BOLSTER FORWARD 40T BLACK SINGLE 1/8 ELBOW
1/8 ELBOW= 435-440-030 1/4 SAE ELBOW= 550-400-800 + 435-460-030

1/8 CONN= 435-460-030 1/4 SAE CONN= 550-402-370
1/8 EXTENTION= 509-027-000
Table 2 - Grease Point Chart
7
Table 3 provides the various service part numbers and quantities used in this application.
Service parts can be obtained from TUG Technologies Corporation.
Service Part breakdown for lit 550-503-370

(22 Point System)
Part
Quantity Number Description
1 529-900-070 GJ2 12 VDC 15 RPM ADJ PUMP 4.4LB RES N/LEVEL
1 529-905-030 GJ2 TIMER
1 550-250-140 HARNESS PUMP TO TIMER
1 550-250-120 TIMER WIRING HARNESS
3 441-070-030 STRAIGHT MALE CONN 1/4 NPT TO 1/4 ID HOSE 37
DEG*
1 441-070-020 STRAIGHT MALE CONN 1/8 NPT TO 1/4 ID HOSE 37
DEG
3 441-080-030 ELBOW MALE CONN 1/4 NPT TO 1/4 ID HOSE 37
DEG
1 443-700-023 HOSE ASSEMBLY 33 INCH
1 443-700-024 HOSE ASSEMBLY 25 FEET
4 443-180-020 HOSE END FITTINGS 1/4 NUT 37 DEG FIT OD
1 106-200-067 MSP-6-30T-30T-10T-10T-20T-40T
1 106-200-066 MSP-7-40SCR-405-30T-30T-10T-10T-20T
22 435-d40-030 ELBOW MALE 3/16 TUBE TO 1/8 NPT
4 1/8 NPT FEMALE BY 1/8 NPT MALE ADAPTOR
22 435-460-030 CONN. MALE 3/16 TUBE TO 1/8 NPT"'""
6 550-400-800 STREET ELBOW 1/4 X 28 SAE
2 435-460-030 CONNECTOR MALE 3/16 TUBE TO 1/8 NPT
4 550-450-950 3 TUBE BUNDLE 3/16 OD 15 FEET LONG
4 550-450-930 2 TUBE BUNDLE 3/16 OD 15 FEET LONG
2 550-450-210 3/16 OD TUBE BLACK 10 FEET LONG
5 435-440-030 ELBOW MALE 3/16 TUBE TO 1/8 NPT"
5 435-460-030 CONIC MALE 3/16 TUBE TO 1/8 NPT"
" These parts are provided for installation flexibility.
"" These are part of the 106-000-000 valve divider black assemblies end can be ordered separately.
Table 3 - GT 110 Auto Lube Service Parts List
IMPORTANT: Failure to bleed the entire system of air after installation and any subsequent
component service replacement will result in a malfunction of the system! This includes
insuring the pump lubricant reservoir is filled, the main hose leading from the pump to the
master divider valve module is filled, and the main hose leading from the master module to
the secondary divider valve module is filled.
8
Purging the Divider Valve
Divider valve assemblies have been individually tested but need to be filled with grease at start-up. Air
entrapped in a valve assembly can in certain situations cause the system to go out of "sync". This condition could
cause a blockage of the series progressive pattern of piston movements. The fault indication would be the same as
a blocked distribution point. Pressure will build because flow can not continue through a valve.
Use of a hand operated grease gun is recommended for purging of air and to test the divider valves. Fill
the grease gun with the same type of grease as is in the system. Connect the grease gun to the inlet port of each
divider valve assembly. Apply only moderate pressure to each divider valve assembly and observe if there is a
build up of pressure and/or if the cycle pin indicator has movement. The pin indicator is typically located on either
side of the first divider valve in the assembly. The pin should move in and out as you pump lubricant into the
assembly. Each movement of the pin (in and out) indicates that one cycle of all the valves in the assembly has
occurred. This does NOT indicate one complete lubrication cycle. Movement of the pin would indicate the divider
valves are operating correctly.
If the indicator pin remains stationary and/or pressure builds at the inlet. Loosen one alternate/indicator port
at a time and check for flow of lubricant to be free of any air. Begin at the bottom end ( the end opposite the inlet)
and work up the assembly one side at a time. Retighten each port as you proceed and note that o-ring plugs need
only to be snug, not overly tight.
ALL hose lines must be full and free of any air before connecting them to the divider valve assemblies.
9
Tubing and Grease
Always use approved Grease Jockey heavy wall nylon tubing in, a lubrication system. Non-approved nylon
tubing (or air brake hose) should NOT be used. The pressure ratings of other hose and tubing are typically not
adequate for lubrication system use.
When installing the tubing and hoses route the 3/16" distribution tubes where they can be secured with
nylon tie straps or tube clamps. Try to run these distribution lines with other hoses or tubing and secure them
together. The lines should never rub against objects around them. Allow ample clearance for any movement of the
lubrication point.
Hoses from the pump to the (master) divider valve and from divider valve to divider valve assemblies should
be fastened securely to protect from damage. All hoses must be filled with grease before connecting to the
lubrication system.
The 3/16" distribution tubing from Grease-Jockey, in standard 10' to 15' lengths, come prefilled with a
quality NLGI "00" grease. All hoses or other tubing need to be purged with grease.
Grease; Use a semi-fluid grease of NLGI grade "0" or "00" with a lithium base and "EP" additive for standard
systems ("E" pumps). Lubriquip # .550-400-020 fluid grease is available in a 35# pail from your Grease Jockey
component supplier.
Purging the Pump
The final step in purging the system of air is to loosen the feeder hose from the pump to the first divider
valve module assembly. Run the pump to insure the feeder line is bled and full of lubricant and the pump
is not air locked. The pump may develop an air lock in the bottom during initial filling, or if the pump
reservoir has been allowed to run dry before refilling. If an air lock has occurred, it can be easily bled by
loosening the relief valve on the pump outlet until lubricant issues from it and the end of the feeder hose.
After bleeding, return the relief valve screw to its original position and tighten the nut.
10
The system is now ready for operation.
TROUBLESHOOTING THE SYSTEM
The free flow of lubricant from the pump through the transmission lines and
valve divider block assemblies is necessary. If any portion of the transmission
system (a divider valve, line fitting or any bearing) does not freely accept and
pass its portion of the lubricant, a blockage has occurred. The blockage will
cause a higher than normal pumping pressure by the pump. The blockage and
resulting high pump pressure will cause a complete loss of lubricant flow into the
total system and none of the bearings will receive lubricant.
WARNING
Never block a tube outlet by removing a lubrication line and replacing it with
a plug or otherwise disabling it from discharging lubricant to the designated
grease point.
A blocked flow is first indicated with a higher than normal system pressure
developed by the pump as it attempts to overcome the blockage. Visual
inspection of the bearings at each grease point must occur regularly at
planned service intervals to insure the system is functioning.
Locating Blockage
Blockage of the system is caused by one of the following reasons:
1. Crushed transmission line (tube) in the system.
2. Blocked bearing (grease point) in the system.
3. Improperly drilled fitting (fittings not of OEM origination) in the system.
4. Blocked divider valve (plugged outlet or otherwise disabled) in the system.
Figure 11 and Table 4 on page 12 provides a clear view of the components

that make up a valve divider modular assembly.
11
Figure 11 - MSP Divider Valve Modular Assembly
Part Description Part Description

Key Key
u
1 Outlet Block 9 Tie Rod Nut

2 Sub Plate 10 Valve Block Mounting Screws
3 Inlet Block 11 Piston Enclosure
4 End Section 12 Piston Enclosure "0" Ring
5 Cross port Plate 1 3 Indicator Port Plug
6 Singling Plate 14 Indicator Port .Plug "O" Ring
7 Bypass Block 15 MSP "O" Rings
8 Tie Rod & Nut Assembly 16 Valve Block Mounting Screw
Table 4 - MSP Divider Valve Modular Assembly Parts Key
12
Torque Specifications MP Divider Valve
Ft. Lbs Ft. Lbs
Tie Rod Nut 5 to 8 Valve Block Mounting Screw 8 to 9
Piston Enclosure Plug 12 to 15 Inlet Bleed Screw 1 to 2
Indicator Port plug 8 to 9
Table 5 -- MSP Divider Valve Module Torque Values
Contamination Blockage
If dirt, foreign material or any other form of contamination is found in a divider valve,
cleaning the divider valve will only temporarily solve the contamination blockage
problem. The source of the contamination must be eliminated for satisfactory service.
The reservoir must be inspected and cleaned if necessary. The reservoir filling method
must be reviewed to eliminate any chance of foreign material entering the reservoir
during filling. All lubricating systems require clean lubricant
Use clean lubricant only.
Note: Dirt and foreign material are the worst enemies of any lubricating system
Separation Blockage
If a hard wax or soap like material is found in the intermediate section, grease
separation is occurring. This means that the oil is being squeezed from the grease at
normal system operating pressure and the grease thickener is being deposited in the
divider valve. This is more likely to happen with #2 grease and is why it is
recommended that "0" or “00" grease be used instead.
Consult your lubricant supplier for recommendations on alternate lubricants and the
OEM to verify compatibility with centralized lubricating systems.
All servicing and disassembling should be carried out under the cleanest
conditions possible. The system can be confirmed for blockage by installing a
pressure gauge at the pump outlet, by the emission of lubricant at the pump relief valve,
or by inspecting the bearing grease points for the presence of lubricant. It is important to
note that, since this is a progressive system, when one valve divider section becomes
dysfunctional the whole system is dysfunctional. Before proceeding with the inspection
to locate the blockage, make a visual inspection of the system. Check for crushed lines
or improper divider valve installation. Verify that each divider valve outlet required to
discharge lubricant can do so and that no pipe plugs have been installed in an outlet
designed to serve a bearing or another divider valve.
13
BASIC PM AND TROUBLESHOOTING
IF ............................................................................THEN
...the lubricant volume to all ... refill reservoir to proper level.

points is adequate ....
...the lubricant volume to all ... adjust the pump output

points is too high.- ....................................................volume lower (see page 3) and
..................................................................................refill reservoir to proper level.
...lubricant volume to all points ...check the level of grease in

is not enough ............................................................the reservoir, then:
1. If level is very low, air may have entered the system and an air purge
procedure is necessary for all system components (see pages 9-10).
2. If some grease is present, cycle the pump several times in the test setting to
see if it is working. If the pump pressure is unusually high, look for a system
blockage.
3. If some grease is present and neither 1 nor 2 are the problem, adjust the pump
output volume higher (see page 3 for pump adjustment).
Refill reservoir to proper level.

...the lubricant volume to one or Check for broken or damaged
more points is not enough.........................................tubing or hose and repair as
..................................................................................needed (purge all air from any
..................................................................................repaired or replaced lines before
..................................................................................reinstallation.
..................................................................................Refill reservoir to proper level.
14
Lubriquip, Inc.
A Unit of IDEX Corporation
18901 Cranwood Parkway
Cleveland, Ohio 44128
(216) 581-2000 Toll Free: 800-US

Fax:(216)581-8945
E-mail: Iubriquip@lubriquip.com
Internet: www.lubriquip.com
Revised 02-01
$2.50
Lubrication
Maintenance Manual 1
• Q PlusTM Cam Brake • Tandem Axle with • Automatic Slack • ZF Meritor Ten-Speed
Pump, Filter System Adjuster Transmission
and Driver-Controlled
Differential Lock
(DCDL)
Service Notes
Before
Service Notes
You Begin How to Obtain Additional
This manual provides maintenance intervals and Maintenance and Service
procedures, lubricant specifications, and product Information for Components
capacities for Meritor and ZF Meritor components. Included in This Manual
1. Understand all procedures and instructions.
2. Follow your company’s maintenance and Contact Our Customer Service Center
service, installation, and diagnostics Call ArvinMeritor’s Customer Service Center at
guidelines. 800-535-5560 to order maintenance and service
3. Use special tools when required to avoid information for components included in this
serious personal injury and damage to manual, as well as the following items.
components. O Drivetrain PlusTM by ArvinMeritor Technical
Electronic Library CD features product and
Safety Alerts, Torque Symbol service information on most Meritor, ZF Meritor
and Meritor WABCO components. $20. Order
and Notes TP-9853.
O Lubrication video. $20. Order T-9398V.
A Warning alerts you to an
WARNING instruction or procedure
that you must follow Access Product and Service Information
exactly to avoid serious from the Technical Library on
personal injury and ArvinMeritor’s Web Site
damage to components.
Visit the Technical Library section of our web site
A Caution alerts you to an at www.arvinmeritor.com, which contains product
CAUTION instruction or procedure and service information for ArvinMeritor’s
that you must follow commercial vehicle systems lineup.
exactly to avoid damage to
components and possible To access information on the site, click Products
serious injury. & Services/Tech Library Icon/HVS Publications.
The screen will display an index of publications
A torque symbol alerts you by type.
to tighten fasteners to a
specified torque value.
NOTE A Note provides
information or suggestions
that help you correctly
service a component.
Table of Contents
Section 1: Introduction
How to Obtain Additional Maintenance and Service Information for Components Included in This Manual . . . . 1
Introduction
Regularly-Scheduled Maintenance is Important
Oil Lubricants
Viscosity
Oil Change Schedules
Recommended Oil Drain Conditions Based on Used-Oil Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Differential Oils (Hypoid Gear Oils)
Manual Transmission Oils
Grease Lubricants
National Lubricating Grease Institute (NLGI) Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Extreme Pressure (EP) Lubricants
Section 2: Clutches
Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bell Housing
Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 3: Drivelines
Driveline Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RPL Series PermalubeTM Driveline Universal Joint, Slip Yoke and Splines
Standard/Conventional Driveline Universal Joint
Standard/Conventional Driveline Slip Yoke and Splines
92N Permalube Driveline Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
92N Greaseable Driveline Universal Joint
92N Permalube and Greaseable Driveline Slip Yoke and Splines
Section 4: Front Driving Axles
Front Driving Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Magnets and Magnetic Drain Plugs
Breather
Seals
Temperature Indicators
Oil Level
Drain and Replace Oil
Wheel Bearings and Wheel-Ends
Knuckle King Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft Retainer Bushing and Cam Bushing
Drive Axle Shaft Universal Joint
Axle Shaft Spline and Thrust Washer
Cross Tube End Assembly
Knuckle Bushing
Section 5: Front Non-Driving Axles
King Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conventional Front Axles
Sealed and Easy SteerTM Front Axles
Easy Steer PlusTM Front Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ball Studs on the Steering Arm, Tie Rod Arm Ends and Drag Link
Conventional Front Axles, Easy Steer Front Axles, Easy Steer Plus Front Axles
Conventional Front Axles, Easy Steer Front Axles, Easy Steer Plus Front Axles
Section 6: On-Highway Brakes
Q PlusTM LX500 Cam Brake Package with the Extended Lube Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Available for On-Highway Linehaul and All Other Applications
Q PlusTM MX500 Extended Maintenance Package Option
Available for On-Highway Linehaul Applications Only
Identifying Q PlusTM LX500 and MX500 Cam Brakes
Lubricating the Q PlusTM LX500 and MX500 Cam Brakes and Automatic Slack Adjusters
After Specified Mileage or Time Intervals
Camshaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Q PlusTM, Cast PlusTM, Q Series, P Series and T Series Cam Brakes
Table of Contents
Section 7: Planetary Drive Axles

Magnets and Magnetic Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Breather
Seals
Check and Adjust the Oil Level
Drain and Replace the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Section 8: Rear Drive Axles
Magnets and Magnetic Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Breather
Seals
Temperature Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Advanced Lube Axles
For Meritor R-170 Axles Equipped With Traction Equalizer®
When to Use Limited Slip Friction Modifiers
Specifications
Oil Level
Check and Adjust the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drain and Replace the Oil
Inter-Axle Assemblies With Separate Housings
Section 9: Trailer Axles
TB Series Trailer Axles With Unitized Hub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Comparing a Unitized Wheel-End to a Conventional Wheel-End
Identifying a Trailer Axle With Unitized Wheel-Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Camshaft Bushings
Conventional and TB Series
Section 10: Transfer Cases
Operating Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Breather
Seals
Temperature Indicator
Check and Adjust Oil Level
Drain and Replace the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 11: Transmissions
Recommended Oil Drain Conditions Based on Used-Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Transmission Oil Coolers
Oil Level
Before You Check the Oil Level
Check and Adjust the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Service the Transmission if Necessary
Additional Specifications, Ratios and Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Section 12: Wheel Bearings and Wheel-Ends
Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Grease the Bearings
Check the Oil Level
Drive Axle Hubs Without Fill Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Section 13: List of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Section 1
Introduction
How to Obtain Additional

Section 1
Introduction
Viscosity
Maintenance and Service
Information for Components CAUTION
Included in This Manual Use correct viscosity lubricants recommended by
Refer to the Service Notes page on the inside Meritor. Do not lower the viscosity of specified
front cover of this manual. lubricants by adding thinning agents, such as
kerosene, gasoline or other dilutents. Damage to
components will result.
Introduction
This manual provides Meritor’s grease and oil Select the correct viscosity oil for a specific
lubricant specifications, procedures, service Meritor component from the charts in each section
intervals and product capacities. Following these of this manual. When more than one lubricant is
guidelines will enable you to correctly lubricate listed, choose an oil viscosity that is suitable for
and maintain Meritor components, and help to the expected outside temperature.
ensure maximum component life. Oil viscosity grades and classifications are
O Always use the specified oil or grease lubricant provided by the SAE (Society of Automotive
from a manufacturer that provides quality Engineers) and the API (American Petroleum
products and complete application instructions. Institute).
O Always follow recommended lubrication O Use multigrade oils when vehicles operate in
intervals and procedures. both cold and warm weather between oil
changes.
Regularly-Scheduled Maintenance O Use low viscosity single grade oils only in

cold climates. Single grade 75W oils are not
is Important approved for use in drive axles where ambient
Internal components can shed fine metal wear (outside) temperatures exceed 40°F (4°C).
particles at a steady rate, especially during the O Use multigrade oil for drive axles only. The
break in period. If wear particles, moisture and hypoid gearing requires a GL-5 oil with Extreme
other contaminants are allowed to circulate in the Pressure (EP) additives to provide adequate
lubricant, the components will wear at a faster rate lubricant film protection that prevents gear
than normal. failure.
Regularly-scheduled maintenance using the
specified lubricants will help to ensure maximum Oil Change Schedules
component performance and life.
To determine an oil change schedule, take an
oil sample at a specified interval or mileage
Oil Lubricants recommendation. Analyze the sample to establish
There are three types of oil lubricants: petroleum a schedule.
oil, full synthetic oil and semi-synthetic oil. Both Often, however, service duty will dictate when
full synthetic and semi-synthetic oils retain their to change the oil, regardless of mileage or a
lubrication properties longer than petroleum oil. previously-established schedule.
O Petroleum oil is derived from crude oil. Crude
petroleum oil also yields combustible fuels and
a wide range of petroleum chemicals.
O Full synthetic oil uses a man-made-base oil with
predictable physical properties. Full synthetic
oil contains no refined petroleum-based fluids.
O Semi-synthetic oil contains a mixture of
petroleum-based and synthetic fluids that can
help extend service intervals, improve cold
weather properties and reduce volatility.
1
Section 1
Introduction
Recommended Oil Drain Conditions Grease Lubricants

Based on Used-Oil Analyses O Grease lubricants contain three substances: oil,
a thickener base and additives.
Differential Oils (Hypoid Gear Oils) O The oil lubricates. The thickener (base) holds the
Drain and replace used differential oil that does oil in place and releases it to provide the
not meet with the following used-oil analyses. necessary lubrication. The additives enhance the
Replace the drained oil with Meritor-specified characteristics of the oil and thickener. Extreme
oil for hypoid drive axle use. Pressure (EP) additives help prevent scoring,
galling and welding of moving parts.
Used-Oil Analyses (ppm=parts per million) O The thickener may be a simple or complex soap
(lithium, calcium, aluminum, etc.), organic
Iron (Fe) If level is between 1000 ppm and (polyurea) or inorganic (clay).
1500 ppm, resample the oil. If
resampling indicates that iron level is O Do not mix different types of greases. The
above 1000 ppm, drain and replace possibility of incompatible greases may reduce
the oil. the lubricating ability of the greases.
If level is above 1500 ppm, drain and
replace the oil. O An important property of a grease is its dropping
point, the temperature where grease changes
Silicon (Si) If level is greater than 100 ppm, drain from a semi-solid state to a liquid state.
and replace the oil. However, the operating temperature of a specific
Water (H2O) If level is greater than 0.3%, drain and grease is not determined solely by the dropping
replace the oil. point.
Phosphorus (P) If level is less than 900 ppm, it is Other properties such as resistance to change in
possible that the oil is not a GL-5 gear consistency and chemical deterioration at high
oil. Contact the lubricant manufacturer temperatures must be considered.
or Meritor Materials Engineering to
determine the expected phosphorus
level of a new oil sample. Only GL-5
type gear oils are approved for use in
Meritor differentials.
Toluene If level is greater than 0.100 wt.%, drain

Insolubles and replace the oil.

If used transmission oil analyses indicate that
any one of these criteria is not met, drain the
used oil and replace it with an oil that is
recommended for manual transmissions.
Used-Oil Analyses (ppm = parts per million)

Iron (Fe) If level is greater than 500 ppm, drain
and replace the oil.
Silicon (Si) If level is greater than 100 ppm, drain

and replace the oil.
Water (H2O) If level is greater than 0.3%, drain and

replace the oil.
2
Section 1
Introduction
National Lubricating Grease

Institute (NLGI) Standards
The National Lubricating Grease Institute (NLGI)
classifies and grades grease lubricants according
to a grease’s consistency and the application for
which it is used.
The NLGI also issues licensed labels that identify
approved grease lubricant applications.
Extreme Pressure (EP) Lubricants
CAUTION
Do not use multi-viscosity or Extreme Pressure
(EP) GL-5 gear oils in a manual transmission.
Damage to the transmission will result.
Extreme Pressure lubricants are often identified

by the abbreviation “EP.” Extreme Pressure
lubricants contain additives that provide extra
anti-wear protection to heavily-loaded parts.
Meritor requires either EP greases or EP oils in
various applications.
Approved hypoid gear oils contain EP additives
that protect against tooth scoring and surface
fatigue.
Labels licensed by the

NLGI identify approved
grease applications.
3
Section 2
Clutches
Section 2
Clutches
Figure 2.1
WARNING
RELEASE BEARING LURICATION POINTS
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
maintenance or service.
Release Bearing
CAUTION
Make sure the inspection cover on the clutch GREASE
housing is used. If an inspection cover is not used, FITTING
dirt and contaminants enter the clutch housing
and damage the clutch.
Bell Housing
1. Remove the inspection cover on the clutch 1. Clean all grease fittings prior to lubrication.
housing.
2. Grease the release fork cross shaft by applying
2. Clean all grease fittings prior to lubrication. grease to each fitting on the bell housing until
3. Correctly lubricate the release bearing. Apply a small amount of grease purges out. Use the
grease to the grease fitting on the release specified lubricant at the recommended
bearing until you can see a small amount of interval. Refer to the lubricant specifications
grease coming out of the bearing housing. and maintenance intervals of the vehicle
Do not overgrease. manufacturer. Figure 2.2.
4. Apply grease to the release yoke tips where
they contact the bearing housing. Also apply Figure 2.2
grease to the exposed transmission input shaft
between the bearing housing and the
transmission input bearing retainer to BELL HOUSING GREASE
lubricate the release sleeve bushing. FITTINGS — BOTH SIDES
5. If the release bearing is equipped with a lube

tube, be sure that you can see grease coming
out of the bearing housing, which ensures that
lubricant is reaching the bearing. Be sure that
the lube tube is secured and not damaged.
6. Use the same procedure for extended
maintenance clutches.
7. Install the inspection cover. Meritor
recommends using a high temperature,
multi-purpose wheel bearing grease (Meritor
Specification O-661), but use the lubricant
recommended by the manufacturer of the
vehicle. Figure 2.1.
4
Section 2
Clutches
Clutch Linkage
NOTE: Some vehicle manufacturers may use
“lubed-for-life” ball joints in the clutch linkage.
Refer to the vehicle manufacturer’s instructions.
You must lubricate each pivot point on the

linkage according to the vehicle manufacturer’s
procedure. Figure 2.3. Use the specified lubricant
at the recommended interval. Refer to the
lubricant specifications and maintenance intervals
in the tables below.
Figure 2.3
Lubricate every pivot point
in the clutch linkage.
LUBRICATE
LUBRICATE
Greasing Interval and Specifications
Greasing Meritor NLGI Grease Outside

Component Interval Grease Specification Grade Description Temperature
Release Bearing a High Temperature O-661 3 Lithium Down to –40°F
Multi-Purpose Complex (–40°C)
Wheel Bearing
Grease
Bell Housing a b — — — —
Clutch Linkage a b — — — —
a Use the interval specified by the vehicle manufacturer or the fleet, but make sure the release bearing is greased once per month.
b Use the grease specified by the vehicle manufacturer.
Approved Lubricants
Lubricant Recommendation
Clutch Bearing Grease Exxon Unirex N Grade 3
(NLGI Grade No. 3, Lithium
Complex)
5
Section 3
Drivelines
Section 3
Drivelines
Standard/Conventional Driveline Slip
WARNING Yoke and Splines (Figure 3.2)
To prevent serious eye injury, always wear safe 1. Check the driveline for looseness. If loose,
eye protection when you perform vehicle service the driveline as necessary.
2. Cover the vent hole in the welch plug with
a finger.
Driveline Styles
3. Apply the specified grease at the grease fitting
Industry Name/ Lubrication on the slip yoke until the grease purges from
Description Series Type Requirements the dust seal.
Standard or 16N Full Round Splines and
Conventional 17N Universal Joints
Driveline 176N Figure 3.1
18N
16T Easy Service
17T (1/2 Round) RPL SERIES PERMALUBE
176T
18T
Wing Style 92N Wing Style
Greaseable
END
Wing Style 92N Wing Style Splines Only CAPSCREWS
YOKE
Permalube WELD
RPL Series RPL 25 Combination None YOKE SLIP YOKE
(Meritor RPL 20 Wing and Full
Permalube) Round U-JOINT
CROSS
TUBING
TM
RPL Series Permalube Driveline
Universal Joint, Slip Yoke and Splines
The universal joint, slip yoke and splines are
permanently lubricated and sealed and do not Figure 3.2
require regular lubrication. Figure 3.1.
COMBINATION FULL-ROUND/EASY SERVICETM
Standard/Conventional Driveline
FULL ROUND
Universal Joint (Figure 3.2) BEARING CUPS
END
1. Check the driveline for looseness. If loose, YOKE
service the driveline as necessary.
SLIP YOKE
2. Clean all grease fittings prior to lubrication.
WELD YOKE
3. Apply the specified grease at the grease fitting YOKE SADDLE
on the universal joint. Apply grease until new
grease purges from all four seals. BEARING
EASY-SERVICE STRAP
U-JOINT
O If new grease does not purge at all the BEARING CROSS CAPSCREWS
seals: Loosen the problem bearing cap bolts CUPS
and regrease until all four cups purge.
O If new grease still does not purge: Replace
the universal joint.
6
Section 3
Drivelines
92N Permalube Driveline Universal Joint

The universal joint is permanently lubricated and
does not require regular maintenance. Figure 3.3.
Figure 3.3
92N PERMALUBE
CAPSCREWS
END
YOKE
WELD YOKE
U-JOINT GREASE TO
CROSS PURGE AT SEAL
SLIP
YOKE
92N Greaseable Driveline Universal Joint

1. Check the driveline for looseness. If loose,
grease purges from all four seals.
O If new grease does not purge at all the
seals: Loosen the problem bearing cap bolts
and regrease until all four cups purge.
O If new grease still does not purge: Replace
the universal joint.
92N Permalube and Greaseable Driveline

Slip Yoke and Splines
WARNING
1. Check the driveline for looseness. If loose,

3. Cover the vent hole in the welch plug with
a finger.
on the slip yoke until grease purges from the
dust seal.
7
Section 3
Drivelines
Greasing Intervals and Specifications for Standard/Conventional Drivelines

Component Application Interval Grease Specification Grade Description Temperature
Universal Joint, Line Haul 50,000 miles Universal O-634-B 2 Lithium b
Slip Yoke and (80 000 km) Joint 12-Hydroxy
Splines Grease Stearate with
Highway 16,000 miles Molybdenum
(25 000 km) Disulfide
City 6,500 miles
(10 000 km)
Construction a
a The greasing interval depends on the individual operating conditions, speed and loads. To determine the interval, inspect for
the presence of grease at all positions until an interval can be determined. Grease the assembly as necessary.
b Refer to the grease manufacturer’s specifications for the temperature service limits.
Approved Lubricants
Universal Joint Must meet Meritor Specification O-634-B
Grease (NLGI Grade No. 2, Lithium 12-Hydroxy Stearate
with Molybdenum Disulfide)
Amalie All Purpose Grease with Moly-L1-2M
Exxon 5160
Shell Super Duty Special FF
Marathon Maralube Molycode 529
Phillips Petroleum Philube MW-EP2 Grease
Shell Moly Poly Grease
Kendall L424 Grease
Amoco Super Chassis Grease
Ford Specification M1C-75B or part number
PN-C1AZ 19590
8
Section 4
Front Driving Axles
Section
Front Driving
4 Axles
WARNING
To prevent serious eye injury, always wear safe CAUTION
maintenance or service. Meritor axles can operate above 190°F (88°C)
without damage. However, if the oil temperature
reaches 250°F (121°C), stop the vehicle
Front Driving Axles immediately and check for the cause of
overheating. Damage to components can result.
Many Meritor axles have a tapped hole in the
Meritor front driving axles are equipped with housing for the installation of a lubricant
magnetic drain plugs that have a minimum temperature indicator that will help reduce the
pick-up capacity of 1.5 pounds (0.7 kilograms) failure of axle parts from overheated oil.
of low carbon steel.
The magnetic drain plug can be reused if, after Oil Level
cleaning, the plug has a minimum pick-up capacity
of 1.5 pounds (0.7 kilograms) of low carbon steel. Check and Adjust Oil
Meritor recommends replacing the magnetic drain 1. Make sure the vehicle is parked on a level
plug each time the oil is changed. Use the correct surface.
part. Pipe plugs will leak if used as a drain plug. 2. Remove the fill plug from the axle.
3. The oil level must be even with the bottom of
Breather the fill plug hole.
O If oil flows from the hole when the plug is
CAUTION loosened, the oil level is high. Let the oil
Cover the breather when steam cleaning the drain to the correct level.
housing to prevent water from entering the O If the oil level is below the bottom of the fill
housing and contaminating the oil. Damage to plug hole, add the specified oil.
components can result.
4. Install and tighten the fill plug to 35-50 lb-ft
Baffle-type breathers help keep Meritor axles free (48-67 N•m). T
from external moisture and dirt, which can cause
premature oil and component failure. Drain and Replace Oil
1. Make sure the vehicle is parked on a level
Seals surface. Put a large container under the axle.
2. Remove the drain plug from the bottom of the
CAUTION axle. Drain and discard the oil properly.
Always use the correct tools and procedures 3. Clean, install and tighten the drain plug to
when replacing seals to ensure correct 35-50 lb-ft (48-67 N•m). T
installation and help prevent seals from leaking.
4. Remove the fill plug from the axle.
Seals keep lubricant in and dirt out of a 5. Fill the axle to the bottom of the fill plug hole
component. When they are worn or damaged, with the specified oil. Allow enough time for
seals leak and produce low lubricant levels which oil to circulate through the axle assembly.
may damage components.
Durable triple lip seals, standard in Meritor axles, (48-67 N•m). T
protect the quality and levels of the lubricant and
provide superior performance.
Refer to Section 12 for lubrication information on
oil- and grease-lubricated wheel bearings and
wheel-ends.
9
Section 4
Front Driving Axles
Knuckle King Pins Cross Tube End Assembly

With the vehicle weight on the wheel-end, pump 1. Check the cross tube for looseness of more
grease through the grease (zerk) fittings located than 0.060-inch (1.52 mm). Figure 4.2. If loose,
on the upper cap or steering arm and lower cap service as necessary.
assemblies. Grease should purge through the
seals and thrust bearing.
on the cross tube. Apply grease until new
grease purges from all the seals.
Camshaft Retainer Bushing and
Cam Bushing 3. If new grease does not purge at the seals,
move the cross tube while applying grease at
Pump grease until it purges through the seals. the fittings until new grease purges from all
the seals. If new grease still does not purge,
Drive Axle Shaft Universal Joint disassemble the cross tube. Inspect the grease
and the components. Service as necessary.
1. Permanently-lubricated (PermalubeTM) joints
do not have a grease fitting provided. Periodic
greasing is not required for these parts. For Figure 4.2
serviceable universal joints (with grease KNUCKLE BUSHING
fittings) follow Steps 2 and 3. GREASE FITTING

grease purges from all the seals.
4. If new grease does not purge at every seal,
move the driveline while applying grease at
the fittings until new grease purges at every CROSS TUBE DRIVE FLANGE
seal. If new grease still does not purge, GREASE FITTING GREASE FITTING
disassemble the universal joint. Inspect the
grease and the components. Service as
necessary. Knuckle Bushing
Axle Shaft Spline and Thrust Washer 1. Check the knuckle for looseness. The correct
end play is 0.005-0.015-inch (0.127-0.381 mm).
On axles with greaseable drive flanges, pump Figure 4.2. If loose, service as necessary.
grease through the grease (zerk) fitting until it
purges at the axle shaft seal. Figure 4.1. 2. Clean all grease fittings prior to lubrication.
on the knuckle. Apply grease until new grease
Figure 4.1
purges from all the seals. Grease the lower pin
cap with the vehicle weight on the wheel-end
to ensure that the thrust bearing is completely
GREASE
(ZERK)
greased.
FITTING SEAL 4. If new grease does not purge at the seals,
move the knuckle while applying grease at the
fittings until new grease purges at the seals.
If new grease still does not purge, disassemble
the knuckle. Inspect the grease and the
components. Service as necessary.
10
Section 4
Front Driving Axles
Front Driving Axle Oil Change Intervals and Specifications*

Operation On-Highway Off-Highway
Initial Oil Change 3,000 miles (4800 km) 3,000 miles (4800 km)
Check Oil Level 3,000 miles (4800 km) or 200 operating 3,000 miles (4800 km)
hours (whichever comes first)
Petroleum Oil Change 30,000 miles (48 000 km) or 2,000 30,000 miles (48 000 km) or 2,000
operating hours (whichever comes first) operating hours (whichever comes first)
Synthetic Oil Change — —
Outside Temperature
F° C°
Meritor Specification
Specifications Approval Oil Description Min. Max. Min. Max.
O-76A Gear Oil MIL-PRF-2105-E GL-5, SAE 85W/140 –10 None –12 None
and
O-76D Gear Oil GL-5, SAE 80W/90 –15 None –26 None
SAE J2360
O-76E Gear Oil GL-5, SAE 75W/90 –40 None –40 None
O-76J Gear Oil GL-5, SAE 75W –40 35 –40 2
O-76L Gear Oil GL-5, SAE 75W/140 –40 None –40 None
* If the front drive axle is the only axle on the vehicle, change the oil every 15,000 miles (24 000 km) or 1,000 hours
of operation, whichever comes first.
Front Driving Axle Greasing Intervals and Specifications

Meritor NLGI Grease Outside
Component Greasing Intervals Grease Specification Grade Description Temperature
Cross Tube End 3,000 miles (4800 km) Multi- O-617-A 1 or 2 Lithium Refer to the
Assemblies, or 200 hours of Purpose or O-617-B 12-Hydroxy grease
Knuckle operation, whichever Grease Stearate or manufacturer’s
Bushings and comes first. Lithium Complex specifications
Drive Flange for the
temperature
U-Joints U-Joint O-634-B 2 Lithium
service limits.
Grease 12-Hydroxy
Stearate with
Molybdenum
Disulfide
11
Section 4
Front Driving Axles
Front Driving Axle Oil Capacities

Oil Capacity
Axle Model Pints Liters
FDS-75 13.0 6.2
FDS-78 13.0 6.2
FDS-85 13.0 6.2
FDS-90 13.0 6.2
FDS-93 13.0 6.2
FDS-750 13.9 6.5
FDS-1600 21.0 9.9
FDS-1800 28.0 13.2
FDS-1805 28.0 13.2
FDS-1807 28.0 13.2
FDS-1808 28.0 13.2
FDS-2100 28.0 13.2
FDS-2101 28.0 13.2
FDS-2102 43.0 20.3
FDS-2107 43.0 20.3
FDS-2110 43.0 20.3
FDS-2111 43.0 20.3
FDS-2117 43.0 20.3
RF-7-106* 14.0 6.6
RF-9-106* 14.0 6.6
RF-12-125* 15.3 7.2
RF-16-145* 36.4 17.2
RF-21-155* 27.9 13.2
RF-21-156* 27.9 13.2
RF-21-160* 43.7 20.7
RF-21-355* 28.0 13.2
RF-23-180* 39.3 18.6
* Oil capacities are for standard track axles that have been
measured at various common drive pinion angles. The
quantities listed include enough oil for both wheel-ends.
These oil capacities will change if the track or the drive
pinion angle is different.
12
Section 5
Front Non-Driving Axles
Section
Front Non-Driving
5 Axles
Figure 5.1
WARNING
GREASE FITTING
King Pins
Conventional Front Axles
Lube must purge
NOTE: This procedure applies to 901, 903, 910, from here. GREASE FITTING
935 and 970 front conventional axles. Refer to the
identification tag on the front of the axle beam.
On conventional front axles, the grease fittings Sealed and Easy SteerTM Front Axles
are on the side of the knuckle.
NOTE: This procedure applies to 911, 921, 931,
932, 933, 934, 941, 942, 943, 944, 951, 952, 961,
WARNING 963, 971 and 975 Series sealed front axles. Refer
Park the vehicle on a level surface. Block the to the identification tag on the front of the axle
wheels to prevent the vehicle from moving. beam.
Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks. On sealed and Easy Steer front axles, the grease
Jacks can slip or fall over and cause serious fittings are on the top and bottom king pin caps of
personal injury. the knuckle.
1. Make sure the tires touch the ground. Do not
1. Lift the vehicle so that the tires are off the elevate the vehicle.
ground. The tires should always be off the
ground when the king pins are lubricated. 2. Clean all grease fittings prior to lubrication.
Support the vehicle with safety stands. Put 3. Lubricate the king pins through the grease
blocks in front and in back of the rear wheels fittings on the top and bottom of the knuckle.
to keep the vehicle from moving. Figure 5.2.
2. Clean all grease fittings prior to lubrication. 4. Apply lubricant until new lubricant purges
3. Lubricate the king pins through the top and from the thrust bearing seal and the upper
the bottom grease fittings on the side of the shim pack.
knuckle. Figure 5.1.
4. Apply lubricant to the top fitting until new Figure 5.2
lubricant purges from between the upper shim
GREASE FITTING Lube must
pack and thrust bearing seal.
purge from
5. Lower the vehicle so that the wheels touch here.
the ground.
6. Apply lubricant to the bottom fitting until new
lubricant purges and fills the thrust bearing.
13
Section 5
Easy Steer PlusTM Front Axles Ball Studs on the Steering Arm,
Tie Rod Arm Ends and Drag Link
NOTE: Removal of the long-life bearings, seals
and lubricant from the hub assembly will void Conventional Front Axles, Easy Steer
the warranty.
Front Axles, Easy Steer Plus Front Axles
Meritor’s Easy Steer Plus front axle features a 1. The tires must touch the ground. Do not raise
permanently-sealed and lubricated truck hub unit the vehicle.
designed to help reduce wheel-end maintenance.
Refer to Maintenance Manual MM-99120 for 2. Clean and remove oil grease fittings prior to
service procedures. lubrication.
3. Apply lubricant at each grease fitting until
CAUTION new lubricant flows from the boot. Figures 5.4
and 5.5.
A unitized hub is permanently sealed and
lubricated as an assembly. Do not attempt to
remove the hub bearings, seals and lubricant. You Figure 5.4
cannot service or reinstall these components into
a unitized hub assembly. Damage to components
can result.
CONVENTIONAL
NOTE: On Easy Steer Plus front axles, the grease

fittings are located on the top and bottom king
pin caps.
1. Be certain that the tires touch the ground.

SIDE GREASE Lube must purge
Do not raise the vehicle. FITTING from here.
3. Lubricate the king pins through the grease
fittings on the top and bottom of the knuckle.
Figure 5.3. Figure 5.5
4. Force lubricant into upper and lower king pin EASY STEER PLUS
grease fitting caps until new lubricant flows
from between the following two areas:
O Upper axle beam end and the knuckle.
Figure 5.3.
O Lower axle beam end and the knuckle. Lube must
Figure 5.3. purge from
here.
GREASE FITTING
Figure 5.3
GREASE
Lube must purge
FITTING
from here.
Conventional Front Axles, Easy Steer
Front Axles, Easy Steer Plus Front Axles
Refer to Section 12 for oil and grease lubrication
information.
GREASE
FITTING
14
Section 5
Conventional Front Non-Driving Axle Greasing Intervals and Specifications

Applies to all FF and FD Series axle models used in linehaul and city delivery vocations and
including FD-931, FD-933 and FD-961 applications.

Component Intervals Grease Specification Grade Description Temperature
King Pins and 100,000 miles Multi-Purpose O-617-A 1 Lithium Refer to the grease
Bushings (160 000 km) or Grease 12-Hydroxy manufacturer’s
once a year, Stearate or specifications for the
whichever Lithium temperature service
comes first. Complex limits.
Ball Studs on O-617-B 2
Steering Arm,
Tie Rod Arm Ends
and Drag Link*
* Applies to ball studs on conventional and Easy Steer front axles. For sealed axles, inspect the boot on the ball stud every
96,000 miles (154 000 km) for wear and damage. Service as necessary.
Conventional Front Non-Driving Axle Greasing Intervals and Specifications

Applies to all FF Series axle model used in other vocations (not linehaul) and including all FC-901,
FC-903, FC-921, FC-941, FD-901, FE-970, FG-931, FG-933, FG-941, FG-943, FL-931, FL-941, FL-951,
FU-910 and FU-935 applications.

Component Intervals Grease Specification Grade Description Temperature
King Pins and 50,000 miles Multi-Purpose O-617-A 1 Lithium Refer to the grease
Bushings (80 000 km) or Grease 12-Hydroxy manufacturer’s
once a year, Stearate or specifications for the
whichever Lithium temperature service
comes first. Complex limits.
Steering Arm, Tie
Rod Arm Ends and
Drag Link*
* Applies to ball studs on conventional and Easy Steer axles. For sealed axles, inspect the boot on the ball stud every
96,000 miles (154 000 km) for wear and damage. Service as necessary.
Easy Steer Plus Front Non-Driving Axle Greasing Intervals and Specifications
Applies to FF 981, FF 982, FF 983, FF 984 and FF 985 front non-driving steering axles
in all vocations.
Greasing Meritor NLGI Grease

Component Intervals Grease Specification Grade Description
King Pins and 100,000 miles Multi-Purpose O-617-A 1 Lithium
Bushings (160 000 km) or Grease 12-Hydroxy
once a year, Stearate or
whichever Lithium
Steering Arm, Tie
comes first. Complex
Rod Arm Ends and
Drag Link*
Truck Hub Unit No Lube to Hub Unit sealed for life of component NONE DO NOT
LUBRICATE
* Applies to ball studs on conventional and Easy Steer axles. For sealed axles, inspect the boot on the
ball stud every 96,000 miles (154 000 km) for wear and damage. Service as necessary.
15
Section 6
On-Highway Brakes
TM
Q Plus LX500 Cam Brake Package
Section 6
On-Highway Brakes
Identifying Q PlusTM LX500 and
with the Extended Lube Feature MX500 Cam Brakes
Available for On-Highway Linehaul and NOTE: Do not remove the identification tag from
All Other Applications the camshaft bracket during the extended
maintenance period.
NOTE: You must continue to observe all other
brake preventive maintenance schedules and You can identify Q Plus LX500 and MX500 cam
procedures for Q Plus LX500 and MX500 cam brakes by checking the identification tags affixed
brakes with factory-installed Meritor automatic to the brake.
slack adjusters. Refer to Maintenance Manual 1. A brake shoe tag identifies the brakes as
MM-96173, Q Plus LX500 Cam Brakes, and Q Plus brakes.
Maintenance Manual 4B, Automatic Slack
Adjuster. 2. An additional identification tag imprinted with
“SEE MERITOR MAINTENANCE MANUAL
Meritor’s new Q Plus LX500 cam brake package MM-96173 FOR LUBE INFO,” which is affixed
with the Extended Lube feature is available for to the brake chamber bracket over the top of
on-highway linehaul and all other applications the plugged grease hole, identifies the brake
and includes: as a Q Plus LX500 or MX500 brake.
O Q Plus LX500 cam brakes. 3. Q Plus LX500 and MX500 brakes and
automatic slack adjusters do not have
O Meritor factory-installed automatic slack grease fittings.
adjusters.
O Extended Lube Feature: For on-highway Lubricating the Q PlusTM LX500 and
linehaul applications, the Q Plus LX500 MX500 Cam Brakes and Automatic
camshaft and slack adjusters do not require
lubrication and reline for 3 years or Slack Adjusters After Specified
500,000 miles (800 000 km), whichever comes Mileage or Time Intervals
first. For all other applications, the lubrication
interval is one year, regardless of mileage. 1. Remove the identification tag from the
chamber bracket housing.
Q PlusTM MX500 Extended 2. Remove grease plugs from both the chamber
bracket and the automatic slack adjuster.
Maintenance Package Option
3. Install grease fittings and lubricate the brake
Available for On-Highway Linehaul assembly through the grease fitting in the
bracket with Meritor-approved synthetic
Applications Only grease O-695 until new grease flows from
Meritor’s new Q Plus MX500 cam brake is the inboard seal.
available for on-highway linehaul applications 4. Lubricate the automatic slack adjuster through
only and includes: the grease fitting until new grease flows out of
O Extended Maintenance Package: Proprietary the pull pawl or camshaft seal.
friction material on 5-inch wider shoes for 5. Replace the fittings with new grease plugs
front axles and 8-inch wider shoes for rear and cover the bracket plug with a new
axles for more wearable volume than Q Plus identification tag.
LX500 brakes.
O Extended Lube Feature: The Q Plus MX500
camshaft and slack adjusters do not require
lubrication and reline for 3 years or
500,000 miles (800 000 km), whichever
comes first.
O Meritor factory-installed automatic slack
adjusters.
16
Section 6
On-Highway Brakes
Camshaft Bushings
WARNING
CAUTION
When grease flows from the seal near the cam
head, replace the seal. Remove any grease from
the cam head, rollers and linings. Grease on the
linings can increase stopping distances.
If grease flows from the seal near the cam head,

replace the seal. Remove any grease or oil from
the cam head, rollers and linings. Always replace
contaminated linings. Grease on the linings can
increase stopping distances. Serious personal
injury and damage to components can result.
Q PlusTM, Cast PlusTM, Q Series, P Series

and T Series Cam Brakes
Meritor cam brakes are air-actuated, cam-operated,
two-shoe brakes with each shoe mounted on a
separate anchor pin. The brakes are available with
automatic or manual slack adjusters and can be
assembled with spring brakes.
Wedge Brake Grease Specifications

Meritor
Component Specification NLGI Grade Grease Description Outside Temperature
All Actuating Components, O-616-A 1 Clay Base Down to –40°F (–40°C)
All Areas Where Shoes Contact
Spider, Anchor Plungers,
Adjusting Bolts or Retainer O-645 2 Synthetic Oil, Clay Base Down to –65°F (–54°C)
Hardware
Conventional Automatic Slack Adjuster Grease Specifications

Meritor
Automatic Slack Adjuster O-616-A 1 Clay Base Down to –40°F (–40°C)
O-692 1 and 2 Lithium Base Down to –40°F (–40°C)
O-645 2 Synthetic Oil, Clay Base Down to –65°F (–54°C)
Clevis Pins Any of Above Refer to Refer to Above Refer to Above
Above
O-637* 1-1/2 Calcium Base Refer to the grease
manufacturer’s specifications
O-641 — Anti-Seize for the temperature service
limits.
* Do not mix O-637 calcium-base, corrosion-control grease with other greases.
17
Section 6
On-Highway Brakes
Manual Slack Adjuster Grease Specifications

Meritor NLGI
Component Specification Grade Grease Description Outside Temperature
Manual Slack Adjuster O-616-A 1 Clay Base Down to –40°F (–40°C)
O-617-A 1 Lithium 12-Hydroxy Refer to the grease manufacturer’s
or Stearate or specifications for the temperature
2
O-617-B Lithium Complex service limits.
Clevis Pins Any of Above Refer to Refer to Above Refer to Above
Above
O-637* 1-1/2 Calcium Base Refer to the grease manufacturer’s
specifications for the temperature
O-641 — Anti-Seize service limits.
Cam Brake Grease Specifications

Meritor NLGI
Components Specification Grade Grease Description Outside Temperature
Retainer Clips O-616-A 1 Clay Base Down to –40°F (–40°C)
Anchor Pins
Roller (Journals Only) O-617-A 1 Lithium 12-Hydroxy Refer to the grease
Camshaft Bushings or Stearate or Lithium manufacturer’s
2
O-617-B Complex specifications for the
When the brake is disassembled, or
temperature service limits.
when necessary, lubricate the anchor
pins and rollers where they touch the O-645 2 Synthetic Oil, Down to –65°F (–54°C)
brake shoes. Clay Base
Do not allow grease to come in
contact with the part of the cam
roller that touches the cam head. O-692 1 and 2 Lithium Base Down to –40°F (–40°C)
Camshaft Splines Any of Above Refer to Refer to Above Refer to Above

Above
O-637* 1-1/2 Calcium Base Refer to the grease
manufacturer’s
O-641 — Anti-Seize specifications for the
temperature service limits.
Air Disc Brake (1540, 1560, 1760) Grease Specifications

Meritor
Caliper a O-616-A 1 Clay Base Down to –40°F (–40°C)
Slide Pin Retainers O-637 b 1-1/2 Calcium Base Refer to the grease manufacturer’s
specifications for the temperature
O-641 — Anti-Seize service limits.
Powershaft Splines Any of Above Refer to Above Refer to Above Refer to Above
a The grease used inside the caliper must be non-melting and also allow proper brake function at the cold temperatures listed.
b Do not mix O-637 calcium-base, corrosion-control grease with other greases.
18
Section 6
On-Highway Brakes
Q Plus LX500 and MX500 Greasing Service Intervals and Specifications
On-Highway Linehaul Applications 3 years or 50,000 miles (80 000 km), whichever comes first
All Other Applications One year, regardless of mileage
Meritor
Camshaft Splines and Clevis Pins O-695 2 Synthetic Polyurea –40°F (–40°C)
Anchor Pins O-617-A 1 Lithium 12-Hydroxy Refer to the grease
Stearate or Lithium manufacturer’s
When the brake is disassembled, or Complex specifications for the
or when necessary, lubricate the
O-617-B 2 temperature service
anchor pins where they touch the limits.
brake shoes.
Shoe Rollers O-617-A 1 Lithium 12-Hydroxy Refer to the grease
Stearate or Lithium manufacturer’s
When the brake is disassembled, or Complex specifications for the
or when necessary, lubricate the
O-617-B 2 temperature service
rollers where they touch the limits.
brake shoes. DO NOT get grease
on the part of the roller that
touches the cam head.
Automatic Slack Adjusters O-695 2 Synthetic Polyurea –40°F (–40°C)
Approved Greases
O-616-A Shell Darina Grease No. 1
Texaco Thermatex EP-1
Texaco Hytherm EP-1
Aralub 3837
O-617-A Multi-Purpose Lithium Chassis Grease
O-617-B
O-637* Witco Chemical Corp. SA-824946
O-641 Never-Seez Anti-Seize
O-645 Mobilgrease 28 (Military)
Mobiltemp SHC 32 (Industrial)
Aerospace Lubricants Inc. Tribolube 12-Grade 1
O-692 Amoco Super Permalube #2
Citgo Premium Lithium EP-2 #2
Exxon Ronex MP-2 #2
Kendall L-427 Super Blu #2
Mobilith AW-1 #1
Sohio Factran EP-2 #2
O-695 EVO-LUBE TEK-615
* Do not mix O-637 calcium-base, corrosion-control grease

with other greases.
19
Section 7
Planetary Drive Axles
Section 7 Drive Axles

Planetary
WARNING
maintenance or service. Meritor axles can operate above 190°F (88°C)
without damage. However, if the oil temperature
Refer to Section 1 for recommended oil drain reaches 250°F (121°C), stop the vehicle
conditions based on used axle oil analysis. immediately and check for the cause of
overheating to prevent damage to components.
Check and Adjust the Oil Level
Planetary axles are equipped with magnetic drain
plugs that have a minimum pick-up capacity of For complete fill procedures for wet disc brakes,
20 ounces (0.57 kilograms) of low carbon steel. refer to Maintenance Manual 4L, Wet Disc Brakes.
The drain plug must be checked for metal particles
at every oil change interval. NOTE: Fill and drain plugs are located in the axle
housing bowl and the wheel ends. Most axles
Meritor recommends replacing the magnetic drain have a common oil level. All steering axles and
plug each time the oil is changed. Use the correct some rigid axles have separate oil levels in each
part. Pipe plugs will leak if used as a drain plug. wheel end and the axle housing bowl.
The magnetic drain plug can be reused if, after
cleaning, the plug has a minimum pick-up capacity 1. The vehicle must be on a level surface.
of 20 ounces (0.57 kilograms) of low carbon steel. 2. For an axle with a common oil level that has
drain and fill plugs only in the axle assembly,
Breather proceed to Step 4.
3. Rotate the wheels so that the oil level lines on
CAUTION the wheel ends are parallel to the ground.
Cover the breather when steam cleaning the 4. Clean the areas around the fill/level plugs.
housing. If the breather is not covered, water Remove the plugs from the wheel end and the
can enter the housing and contaminate the oil. axle housing bowl. Figure 7.1. The oil level
Damage to components will result. must be even with the bottom of the fill/level
plug.
Breathers release pressure and vacuum O If oil flows from the hole when you loosen
condensation to help maximize oil and the plug: The oil level is high. Drain the oil
component life. to the correct level.
O If the oil level is below the bottom of
Seals fill/level plug hole: Add the specified oil
according to one of the following
CAUTION procedures:
Always use the correct tools and procedures A. For axles with separate oil levels in the
when replacing seals to prevent incorrect wheel ends and the axle housing
installation and leaking seals. bowl: Fill each area with specified oil
to the bottom of the fill plug holes.
Seals keep lubricant in and dirt out of a B. For axles with a common oil level:
component. When they are worn or damaged, Fill the axle with specified oil at each
seals leak and produce damaging low lubricant wheel end and axle housing bowl to
levels that will damage components. the bottom of the fill plug holes. Wait
and allow the oil to flow through the
axle. Check the oil level again and fill
to the correct level, if necessary.
20
Section 7
5. Install and tighten the fill/level plugs to the 7. Clean the area around the fill/level plug.
correct torque specification. Remove the fill/level plug from the wheel ends
and the axle housing bowl.
Figure 7.1 8. Add the specified oil until the oil level is even
with the bottom of the fill/level hole.
O For axles with separate oil levels in the
wheel ends and the axle housing bowl:
Fill each area with specified oil to the
bottom of the fill plug holes.
O For axles with a common oil level: Fill the
axle with specified oil at each wheel end
FILL/LEVEL and axle housing bowl to the bottom of the
PLUG fill plug holes. Wait and allow the oil to flow
through the axle. Check the oil level again
and fill to the correct level, if necessary.
9. Install and tighten the fill/level plugs to the
Drain and Replace the Oil correct torque specification.
NOTE: Fill and drain plugs are located in the axle

housing bowl and the wheel ends. Most axles
have a common oil level. All steering axles and
some rigid axles have separate oil levels in each
wheel end and the axle housing bowl.
WARNING
Park the vehicle on a level surface. Block the
wheels to prevent the vehicle from moving.
work under a vehicle supported only by jacks.
Jacks can slip and fall over. Serious personal
injury can result.
1. Make sure the vehicle is on a level surface.

Put large containers under the axle and
wheel ends.
2. Raise the vehicle so that the wheels are off
the ground. Support the vehicle with safety
stands.
3. Rotate the wheels so that the “fill/level” plugs
in the wheel ends are toward the ground.
4. Remove the drain plugs from the wheel ends.
Drain the oil. Follow correct procedures to
discard the oil. Clean the drain plug.
5. Install and tighten the drain plug in the axle
housing bowl and the wheel ends to 35-50 lb-ft
(48-67 N•m). T
6. Rotate the wheels so that the “oil level lines”
on the wheel ends are parallel to the ground.
Lower the vehicle.
21
Section 7
Planetary Drive Axle Oil Change Intervals and Specifications
Operation On-Highway* Off-Highway*

Initial Oil Change 2,500 miles (4000 km) 100 operating hours*
Check Oil Level 5,000 miles (8000 km) 250 operating hours*
Petroleum Oil 25,000 miles (40 000 km) or once a year 1,500 operating hours or twice a year
Change (whichever comes first) (whichever comes first)*
Synthetic Oil or Refer to Technical Publication TP-9303 3,000 operating hours or once a year
Semi-Synthetic (whichever comes first)
Oil Change
Outside Temperature
°F °C
Meritor Specification
Specifications Approval Oil Description Min. Max. Min. Max.
and
SAE J2360
O-76L Gear Oil GL-5, SAE 75W/140 –40 None –40 None
O-76M Gear Oil GL-5, SAE 75W/140 –40 None –40 None
O-76N Gear Oil GL-5, SAE 75W/140 –40 None –40 None
* The interval depends on the individual operating conditions, speeds and loads. Severe operating conditions may
require more frequent intervals.
Planetary Drive Axle Oil Capacities

Axle Housing Wheel Ends Axle Housing Wheel Ends
Approximate Approximate Approximate Approximate
Oil Capacity* Oil Capacity* Oil Capacity* Oil Capacity*
Axle Model Pints Liters Pints Liters Axle Model Pints Liters Pints Liters
PR-53 33.0 15.6 3.0 1.4 PR-253 39.0 18.5 13.0 6.20
PR-60 27.0 12.8 3.0 1.4 PR-256 44.0 20.8 18.0 8.50
PR-100 22.0 10.4 3.5 1.6 PR-270 44.0 20.8 18.0 8.50
PR-108 29.0 13.7 7.0 3.3 PR-350 28.0 13.2 14.0 16.60
PR-111 27.0 12.8 4.6 2.2 PR-400 32.0 15.1 16.0 7.60
PR-112 44.0 20.8 6.0 2.8 PR-500 56.0 26.5 28.0 13.20
PR-145 32.0 15.1 5.0 2.4 PR-501 64.0 30.3 28.0 13.20
PR-150 29.0 13.7 5.0 2.0 PR-502 62.0 29.3 31.0 14.70
PR-151 30.0 14.2 8.0 3.8 PR-700 64.0 30.3 30.0 14.19
PR-153 31.0 14.7 7.5 3.6 PRC-184 32.0 15.1 4.0 1.80
PR-200 40.0 18.9 6.0 2.8 PRC-264 16.0 7.5 4.0 1.80
PR-205 46.0 21.8 7.0 3.3 PRC-755 32.0 15.1 10.0 4.70
PR-207 45.0 21.3 6.0 2.8 PRC-864 30.0 14.1 6.0 2.80
PR-208 43.0 20.3 8.0 3.8 PRC-867 48.0 22.7 10.0 4.70
PR-209 56.0 26.4 5.0 2.4 PRC-1925 32.0 15.1 16.0 7.57
PR-251 42.0 19.9 12.0 5.7 PRC-3795 28.0 13.2 14.0 6.62
* Due to varied planetary drive axle specifications, these fill quantities are for reference only.
22
Section 7
Planetary Drive Axle Oil Capacities
Axle Housing Wheel Ends Axle Housing Wheel Ends

Approximate Approximate Approximate Approximate
Oil Capacity* Oil Capacity* Oil Capacity* Oil Capacity*
Axle Model Pints Liters Pints Liters Axle Model Pints Liters Pints Liters
PRC-3796 48.0 22.7 28.0 13.20 PSC-1875 56.0 26.4 20.0 9.40
PRC-3805 58.0 27.4 22.0 10.40 PSC-4564 58.0 27.4 29.0 13.72
PRC-4805 60.0 28.3 31.0 14.60 PSM-826 42.0 19.9 6.0 2.80
PRC-5324 80.0 37.8 24.0 11.30 PSM-1044 44.0 20.8 6.0 2.80
PRC-5334 80.0 37.8 24.0 11.30 PSM-1045 44.0 20.8 6.0 2.80
PRC-7314 72.0 34.0 24.0 11.30 PSM-1614 44.0 20.8 8.0 3.70
PRLC-344 44.0 20.8 6.0 2.84 PSTM-824 28.0 13.2 6.0 2.80
PRLC-614 29.0 13.7 7.0 3.31 EPRC-1356
Forward 32.0 15.1 14.0 6.60
PRLC-675 56.0 26.5 5.0 2.37
Middle 32.0 15.1 14.0 6.60
PRLC-823 44.0 20.8 18.0 8.51 Rear 32.0 15.1 14.0 6.60
PRLC-1756 39.0 18.5 13.0 6.15 SPRC-1356
85" Track 32.0 15.1 14.0 6.60
PRLC-1757 39.0 18.5 13.0 6.15
90" Track 33.5 15.9 14.0 6.60
PRLC-1925 72.0 34.0 12.0 5.60 100" Track 36.0 17.0 14.0 6.60
PRLM-855 28.0 13.2 8.0 3.70 SPRC-1357
Forward 36.0 17.0 14.0 6.60
PRM-672 29.0 13.7 5.0 2.37
Rear 36.0 17.0 14.0 6.60
PRM-673 29.0 13.7 5.0 2.37
SPRC-1357
PRM-676 46.0 21.8 7.0 3.31 85" Track 32.0 15.1 14.0 6.60
90" Track 33.5 15.9 14.0 6.60
PRM-677 46.0 21.8 7.0 3.31
100" Track 36.0 17.0 14.0 6.60
PRM-1314 44.0 20.8 18.0 8.51
SPRC-1735
PRM-1315 44.0 20.8 18.0 8.51 85" Track 32.0 15.1 15.0 7.10
90" Track 33.5 15.9 15.0 7.10
PRM-1615 44.0 20.8 18.0 8.51
100" Track 36.0 17.0 15.0 7.10
PRM-1756 43.0 20.3 13.0 6.15
SPRC-1736
PRM-1757 43.0 20.3 13.0 6.15 Forward 36.0 17.0 15.0 7.10
Rear 36.0 17.0 15.0 7.10
PRTA-134 14.0 6.6 4.0 1.80
SPRC-1736
PRTC-203 19.0 8.9 6.0 2.80
85" Track 32.0 15.1 15.0 7.10
PRS-16 27.0 12.8 3.0 1.42 90" Track 33.5 15.9 15.0 7.10
100" Track 36.0 17.0 15.0 7.10
PS-100 20.0 9.5 3.5 1.66
SPRC-1926 32.0 15.1 16.0 7.60
PS-150 22.0 10.4 5.0 2.37
SPRC-4806 64.0-72.0 31.0-34.0 32.0 15.10
PS-200 38.0 18.0 6.0 2.84
PS-260 44.0 20.8 8.0 3.25
PS-270 44.0 20.8 8.0 3.78
PS-310 36.0 17.0 14.0 6.62
PS-500 58.0 27.4 29.0 13.72
PSC-204 29.0 13.7 6.0 2.80
PSC-593 28.0 13.0 4.0 1.89
PSC-594 28.0 13.2 4.0 1.89
PSC-1615 40.0 18.9 8.0 3.78
PSC-1617 40.0 18.9 8.0 3.78
* Due to varied planetary drive axle specifications, these fill quantities are for reference only.
23
Section 8
Rear Drive Axles
Section
Rear Drive
8 Axles Check the drain plug for metal particles every
WARNING 100,000 miles (160 000 kilometers). You can reuse
a magnetic drain plug if the plug has a minimum
pick-up capacity of 1.5 pounds (0.7 kilograms) of
low carbon steel after cleaning.
Breather
CAUTION
You must fill Meritor axles with Meritor-specified CAUTION
lubricants only. Do not fill an axle with
non-approved lubricants, which will void Meritor’s Cover the breather when steam cleaning the
warranty. Damage to axle components also housing. If the breather is not covered, water
can result. enters the housing and contaminates the oil.
Damage to components can result.
To avoid axle component damage, fill Meritor
axles with approved lubricants only. Using Baffle-type breathers release pressure and
non-approved lubricants also will void Meritor’s vacuum condensation to minimize premature
warranty. oil and component failure.
NOTE: For information on lubricant suppliers, Seals

call ArvinMeritor’s Customer Service Center at
800-535-5560 and order technical bulletin TP-9539.
This bulletin is also available from the Technical CAUTION
Library section on ArvinMeritor’s web site at Always use the correct tools and procedures
www.arvinmeritor.com. Click Products & Services/ when replacing seals to prevent incorrect
Tech Library Icon/HVS Publications/Technical installation, leaking seals and damage to
Bulletins/Axles. components.
NOTE: Refer to Section 12 for information on Seals keep lubricant in and dirt out of a
wheel bearings and wheel-ends. component. When they are worn or damaged,
seals leak and produce damaging low lubricant
Magnets and Magnetic Drain Plugs levels.
Durable triple-lip pinion seals, standard in Meritor
NOTE: Meritor recommends replacing the axles, protect the quality and levels of the
magnetic drain plug each time the oil is changed. lubricant and provide superior performance.
Use the correct part. Pipe plugs will leak if used as
a drain plug. Meritor Advanced Lube axles have triple-lip seals
designed to work with current and future
Although Meritor axles are normally equipped lubricants.
with magnetic plugs having a minimum pick-up
capacity of 1.5 pounds (0.7 kilograms) of low
carbon steel, Meritor Advanced Lube axles have
stronger magnetic “cleansing” features.
These axles are equipped with strong five-pound
(2.2 kilograms) pull magnets, and high grade
magnetic fill and drain plugs that collect damaging
particles at the bottom of the axle housing.
Tandem axles have four magnets in each housing
and high grade magnetic fill and drain plugs.
Single axles have six magnets in each housing
and high grade magnetic drain and fill plugs.
24
Section 8
Rear Drive Axles
Temperature Indicators NOTE: Limited slip friction modifiers usually

deteriorate more quickly than extreme pressure
(EP) additives. Shorten the lubricant change
CAUTION schedule if you add a friction modifier.
Meritor axles can operate above 190°F (88°C)
without damage. However, if oil the O At the initial lubricant change interval for an
temperature reaches 250°F (121°C), stop the R-170 equipped with Traction Equalizer:
vehicle immediately and check for the cause Replace the factory-installed lubricant with an
of overheating. Damage to components can approved lubricant and one of the additives
result. specified in the table below.
O After the initial change interval: Change the
Some Meritor axles may have a tapped hole in lubricant and the additive at or before
the housing to install a temperature indicator. 50,000 miles (80 000 km).
A temperature indicator monitors oil temperature
and helps to maximize component life, which can Specifications
be shortened by high oil temperatures that result
from severe operating conditions, or unequally For all GL-5 oils (petroleum oil or synthetic), add
inflated and mismatched tires. one of the following limited slip friction modifiers
specified in the table below.
Advanced Lube Axles
Manufacturer Specification
Advanced Lube axles require different drain
intervals than other axles. Refer to the Oil Change DSL-178 Guardsman Products
Intervals and Axle Oil Specifications tables in Equa-Torque #2411 and #2414 Sta-Lube Corporation
this section. Lubrizol # 6178 Lubrizol Corporation
The vehicle manufacturer may attach a tag at the
axle fill hole or on the inside of the door to identify Quantities for R-170 Axles With and
an Advanced Lube axle. The tag specifies that the Without Traction Equalizer
axle is filled with semi-synthetic or full-synthetic
gear oil.
WITH WITHOUT
Traction Equalizer Traction Equalizer
For Meritor R-170 Axles Equipped 40 pints oil (18.9 liters) 43 pints oil (20.3 liters)
With Traction Equalizer® + 3 Pints additive (1.4 liters)
Meritor’s R-170 axles with Traction Equalizer

normally operate with either standard petroleum, Oil Level
semi-synthetic or full-synthetic oils.
Fill Plug Locations
When to Use Limited Slip 1. If the fill plug is only in the axle-housing bowl,
Friction Modifiers use that fill plug. Do not use the temperature
sending unit hole. Figure 8.1.
Occasionally the Traction Equalizer will “slip” or
“stick.” When this happens, you will hear intervals 2. If the drive pin angle is seven degrees or less,
of shrill noises when the vehicle operates at low use the fill plug in the differential carrier.
speed or when the vehicle makes sharp turns. You Figures 8.2 and 8.7.
can correct this condition by adding limited slip
friction modifiers. 3. If the drive pin angle is more than seven
degrees, use the fill plug in the axle-housing
bowl. Figures 8.4 through 8.8.
25
Section 8
Rear Drive Axles
Check and Adjust the Oil 3. Install the drain plug. Tighten the plug to
35-50 lb-ft (48-67 N•m). T
WARNING O If an oil pump is used: Remove and replace
the oil filters.
Check the oil level when the axle is at room
temperature. When hot, the oil temperature may O For Advanced Lube axles: Replace the oil
be 190°F (88°C) or more and can cause burns. filter every 100,000 miles (160 000 km).
Also, a correct level is not obtained when the axle
is warm or hot. Serious personal injury and 4. Clean the area around the fill plug. Remove
damage to components can result. the fill plug from the differential carrier of the
axle-housing bowl (depending on the axle).
Do not remove the temperature indicator plug.
1. Park the vehicle on a level surface. The axle
must be cold or near room temperature. 5. Add the specified oil until the oil is even with
the bottom of the fill plug hole. Wait to allow
2. Clean the area around the fill plug. Remove
the oil to flow through the axle.
the fill plug from the differential carrier or the
axle-housing bowl (depending on the axle). O If the inter-axle differential has a top fill
Do not remove the temperature indicator plug. plug hole: Add an additional two pints
Figures 8.2 through 8.8. (0.946 liters) of the same oil into the
inter-axle differential housing.
3. Check the oil level. The level must be even
with the bottom of the fill plug hole. 6. Check oil level again. If necessary, continue to
Figure 8.1. add oil until it is even with the bottom of the
fill plug hole.
4. Install the fill plug. Tighten the plug to
35-50 lb-ft (48-67 N•m). T 7. Install the fill plug. Tighten the plug to
35-50 lb-ft (48-67 N•m). T
Figure 8.1
Oil level must be
Inter-Axle Assemblies With
even with bottom Separate Housings
of fill plug hole.
Meritor’s SLHD, SQHD, STDD and SFDD
forward-rear tandem axle carrier models include
separate housings for inter-axle differential
assemblies.
The baffles and dams used in these housings hold
FILL PLUG a reservoir of oil that can also trap wear particles
TEMPERATURE INDICATOR and debris. Always purge the oil from these
PLUG — DO NOT REMOVE reservoirs when you change axle oil.
These carriers have separate drain and fill holes in
either the inter-axle differential cover or housing.
NOTE: Drain the oil when it is warm. Remove and Figure 8.2
replace the oil filters each time you drain the oil. FILL PLUG LOCATION IN BACK OF
AXLE HOUSING BOWL
1. Refer to Fill Plug Locations in this section. FILL PLUG
2. Park the vehicle on a level surface. Put a large
container under the axle.
TEMPERATURE INDICATOR
PLUG — DO NOT REMOVE
26
Section 8
Rear Drive Axles
Figure 8.3 Figure 8.6

FRONT MOUNTED SINGLE REDUCTION AXLES FRONT MOUNTED SINGLE
REDUCTION TANDEM AXLES
CARRIER FILL PLUG (NOT SHOWN)
FILL PLUG
DRIVE PINION ANGLE
7° OR LESS USE HYPOID GEARING
CARRIER FILL PLUG WITH INTER-AXLE
DIFFERENTIAL AND PUMP
FORCED LUBRICATION
DRAIN PLUG DRAIN PLUG

FRONT MOUNTED DOUBLE
FRONT MOUNTED SINGLE REDUCTION AXLES REDUCTION AND TWO-SPEED AXLES
DRIVE PINION ANGLE
HOUSING MORE THAN 7° USE AXLE
FILL PLUG HOUSING FILL PLUG FILL HOLE
IN CARRIER
FILL PLUG
DRAIN PLUG DRAIN PLUG

FRONT MOUNTED SINGLE REDUCTION TANDEM AXLES FRONT MOUNTED DOUBLE
REDUCTION AND TWO-SPEED AXLES
FILL PLUG
HYPOID GEARING
WITH INTER-AXLE FILL HOLE IN
DIFFERENTIAL AXLE HOUSING
DRAIN PLUG
FILL PLUG (NOT SHOWN)
FILL PLUG
DRAIN PLUG
DRAIN PLUG
27
Section 8
Rear Drive Axles
Oil Change Intervals and Specifications for All Rear Drive Axlesa
Vocation or Linehaul City Delivery Construction

Vehicle Operation Motorhome School Bus Transit Bus
Intercity Coach Fire Truck Refuse
Yard Tractor
Logging
Heavy Haul
Mining
Oil Field
Rescue
Initial Oil Change No longer required as of January 1, 1993
Check Oil Level Every 25,000 miles Every 10,000 miles Every 5,000 miles
(40 000 km), or the fleet (16 000 km), once a month, (8000 km), once a month,
maintenance interval or the fleet maintenance or the fleet maintenance
(whichever comes first) interval (whichever comes interval (whichever comes
first) first) b
Petroleum Based Oil Change on Every 100,000 miles Every 50,000 miles Every 25,000 miles
Axle with or without Pump and (160 000 km) or annually, (80 000 km) or annually, (40 000 km) or annually,
Filter System whichever comes first whichever comes first whichever comes first
Synthetic Oil Change on Axle Every 250,000 miles Every 100,000 miles Every 50,000 miles
without Pump and Filter System (400 000 km) or annually, (160 000 km) or annually, (80 000 km) or annually,
c whichever comes first whichever comes first whichever comes first
Synthetic Oil Change on Axle with Every 500,000 miles Every 250,000 miles Every 100,000 miles
Pump and Filter System c (800 000 km) (400 000 km) (160 000 km)
Filter Change on Axle with Pump Every 100,000 miles Every 100,000 miles Every 100,000 miles
and Filter System (160 000 km) (160 000 km) (160 000 km)
a If a No-Spin differential is installed, change the oil (petroleum or synthetic) at minimum interval or 40,000 miles (64 000 km) or a
maximum interval or 50,000 miles (80 000 km).
b For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km). Add the correct type and amount of oil
as required.
c This interval applies to approved semi-synthetic and fully synthetic oils only. For list of approved extended-drain axle oils, refer
to TP-9539, Approved Rear Drive Axle Lubricants. To order this publication, call ArvinMeritor’s Customer Service Center
at 800-535-5560.
Axle Oil Specifications
A.P.I. SAE Meritor Military/SAE Outside

Gear Oil Type Specification Grade Specification Specification Temperature
Petroleum with GL-5 85W/140 O-76A MIL-PRF-2105E Above +10°F (–12°C)
EP Additives and
Non-Extended Drain
SAE J2360
Petroleum with 80W/90 O-76D Above –15°F (–26°C)
Lubricants
EP Additives
Petroleum with 75W/90 O-76E Above –40°F (–40°C)
EP Additives
Petroleum with 75W O-76J From –40°F (–40°C)
EP Additives to 35°F (2°C)
Petroleum with 75W/140 O-76L Above –40°F (–40°C)
EP Additives
Extended Drain
Petroleum with GL-5 80W/90 — MIL-PRF-2105E Above –15°F (–26°C)

Extended Drain and
Lubricants
Additives SAE J2360

Semi-Synthetic 80W/90 — Above –15°F (–26°C)
Full Synthetic 75W/140 O-76M Above –40°F (–40°C)
Full Synthetic 75W/90 O-76N Above –40°F (–40°C)
28
Section 8
Rear Drive Axles
Single Rear Drive Axle Oil Capacities*
Oil Capacity* Oil Capacity* Oil Capacity*

Axle Model Pints Liters Axle Model Pints Liters Axle Model Pints Liters
A-150 5.5 2.6 R-160 28.0 13.3 W-170 43.0 20.3
B-100 10.0 4.7 R-163 34.0 16.1 W-270 55.0 26.0
B-140 12.0 5.7 R-170 43.0 20.3 59722 30.5 14.4
B-150 3.5 1.7 R-270 55.0 26.0 59723 30.5 14.4
C-100 12.5 5.9 RL-170 48.0 22.7 59732 30.5 14.4
D-100 12.5 5.9 RC-22-145 32.3 15.3 59733 30.5 14.4
D-140 12.5 5.9 RC-23-160 41.0 19.4 59843 30.5 14.4
E-100 15.0 7.1 RC-25-160 39.5 18.7 61142 42.0 19.8
E-105 12.5 5.9 RS-13-120 18.4 8.7 61143 41.0 19.3
E-150 9.0 4.3 RS-15-120 18.4 8.7
F-100 13.0 6.2 RS-15-210 14.3 6.8
F-106 13.0 6.2 RS-17-140 28.6 13.5
F-120 15.0 7.1 RS-17-145 33.6 15.9
F-121 15.0 7.1 RS-17-220 30.7 14.5
F-140 14.0 6.6 RS-19-145 33.2 15.7
G-161 21.0 9.9 RS-21-145 32.3 15.3
H-100 20.0 9.5 RS-21-230 38.9 18.4
H-140 21.0 9.9 RS-23-160 39.5 18.7
H-150 11.0 5.2 RS-23-161 37.2 17.6
H-162 20.0 9.5 RS-23-180 47.3 22.4
H-170 27.0 12.8 RS-23-186 47.3 22.4
H-172 27.0 12.8 RS-23-240 37.4 17.7
L-100 23.0 10.9 RS-23-380 63.6 30.1
L-140 24.0 11.4 RS-26-160 47.5 22.5
L-155 24.0 11.4 RS-26-180 46.6 22.0
L-172 27.0 12.8 RS-26-380 58.2 27.5
M-172 27.0 12.8 RS-30-180 46.6 22.0
Q-100 31.0 14.7 RS-30-380 58.2 27.5
Q-145 24.0 11.4 RS-38-380 53.1 25.1
QT-140 24.0 11.4 S-170 43.0 20.3
R-100 30.0 14.2 U-140 24.0 11.4
R-140 28.0 13.3 U-170 43.0 20.3
R-155 28.0 13.3 U-270 55.0 26.0
* Oil capacities are for standard track axles that have been measured at various common drive pinion angles. The quantities listed include
enough oil for both wheel ends. These oil capacities will change if the track or the drive pinion angle is different.
29
Section 8
Rear Drive Axles
Tandem Rear Drive Axle Oil Capacities
Oil Capacity a Oil Capacity a
Axle Model Carrier Pints Liters Axle Model Carrier Pints Liters
RT-34-140 Forward 26.0 12.3 RT-58-180 b Forward 56.1 26.5
Rear 35.0 16.6 Rear 36.1 17.1
RT-34-145 Forward 29.6 14.0 RT-58-185 Forward 56.1 26.5
Rear 25.4 12.0 Rear 36.1 17.1
RT-34-145P Forward 25.7 12.1 RT-58-380 b Forward 56.1 26.5
Rear 23.4 11.1 Rear 58.2 27.5
RT-40-140 Forward 30.2 14.3 RT-70-380 b Forward 54.4 25.7
Rear 22.8 10.8 Rear 53.1 25.1
RT-40-145 Forward 30.2 14.3 SFHD Forward 17.0 8.0
Rear 25.8 12.2 Rear 16.5 7.8
RT-40-160 Forward 39.1 18.5 SL-100 Forward 39.6 18.7
Rear 39.4 16.3 Rear 37.7 17.8
RT-44-145 Forward 29.3 13.9 SLHD Forward 32.5 15.3
Rear 25.1 11.9 Rear 32.0 15.1
RT-44-145P Forward 25.2 12.0 SQ-100 Forward 39.6 18.7
Rear 22.9 11.0 Rear 37.7 17.8
RT-46-160 Forward 39.1 18.5 SQ-100A Forward 39.3 18.6
Rear 34.4 16.3 Rear 37.6 17.8
RT-46-160P Forward 39.3 18.6 SQHD Forward 34.0 16.0
Rear 34.7 16.4 Rear 31.0 14.7
RT-46-164 Forward 39.1 18.5 SR-170 Forward 55.0 26.0
Rear 39.4 16.3 Rear 43.0 20.3
RT-48-180 b Forward 61.1 28.9 SRHD Forward 39.0 18.5
Rear 36.8 17.4 Rear 36.0 17.0
RT-48-380 b Forward 61.1 28.9 SSHD Forward 34.0 16.0
Rear 63.6 30.1 Rear 28.0 13.2
RT-52-160 Forward 44.1 20.9 ST-170 Forward 55.0 26.0
Rear 41.2 19.5 Rear 43.0 20.3
RT-52-160P Forward 44.1 20.9 STHD Forward 34.0 16.0
Rear 41.2 19.5 Rear 28.0 13.2
RT-52-180 b Forward 56.1 26.5 SU-170 Forward 55.0 26.0
Rear 36.1 17.1 Rear 43.0 20.3
RT-52-185 Forward 56.1 26.5 SUHD Forward 34.0 16.0
Rear 36.1 17.1 Rear 28.0 13.2
RT-52-380 b Forward 56.1 26.5 SW-170 Forward 55.0 26.0
Rear 58.2 27.5 Rear 43.0 20.3
a Oil capacities are for standard track axles that have been measured at various common drive pinion angles. The quantities listed include
enough oil for both wheel ends. These oil capacities will change if the track or the drive pinion angle is different.
b Forward carrier with oil pump system.
30
Section 9
Trailer Axles
SectionAxles
Trailer 9
Figure 9.1
WARNING
AXLE SPINDLE
TB Series Trailer Axles With

Unitized Hub Assemblies
CAUTION UNITIZED HUB ASSEMBLY

Meritor TB Series trailer axles with unitized
hub assemblies use conventional brakes and
automatic slack adjusters, as well as conventional
tire-wheel assemblies. Service these components Figure 9.2
as you would under normal operation conditions INNER
to avoid damage to components. BEARING CUP LUBRICANT
OUTER
BEARING CUP INNER
A unitized hub is permanently sealed and BEARING CONE
lubricated as an assembly. Do not attempt to
remove the hub bearings, seals and lubricant.
You cannot service or reinstall these components
into a unitized hub assembly. Damage to
OUTER OIL
BEARING CONE HUB SEAL AXLE
NOTE: Removal of the long-life bearings, seals
SPINDLE
and lubricant from the hub assembly will void
the warranty.
Meritor’s TB series trailer axle features a

permanently sealed and lubricated unitized hub
assembly designed to help reduce wheel-end
maintenance.
The unitized hub is designed to remain in place
on the axle for a minimum of five years or
500,000 miles (800 000 km).
For TB series unitized hub service procedures,
refer to technical bulletin TP-96175, Servicing
Meritor’s TB Series Trailer Axles with Unitized Hub
Assemblies. Call ArvinMeritor’s Customer Service
Center at 800-535-5560.
Comparing a Unitized Wheel-End to a

Conventional Wheel-End
On a unitized wheel-end, you install the hub, seal,
lubricant and bearings onto the axle spindle as an
assembly. Figure 9.1.
On a conventional wheel-end, you install the hub,
seal, lubricant and bearings onto the axle spindle
as separate components. Figure 9.2.
31
Section 9
Trailer Axles
Identifying a Trailer Axle With Unitized Figure 9.3

Wheel-Ends
GREASE
O The model number designation for the FITTING
TB series is prefixed with TB; for example,
TB-4670 or TB-8670.
O The axle spindles are shorter with a single
journal.
O The hubs contain non-serviceable bearings,
seals and lubricant.
O The hubcaps screw onto the axle spindle and
have no provisions for adding lubricant.
O The axle spindle retention hardware features
a thicker inner nut and a bendable tab
lockwasher.
O Warranty information is stamped on each
unitized hub:
Important:
Removal of long-life bearings, seals or
lubricant from the Meritor TB series
trailer axle hub will void the warranty.
Refer to Technical Bulletin TP-96175 or
call 800-535-5560 for information.
TP-9700

Refer to Section 12 for oil and grease lubrication
information.
Camshaft Bushings
Conventional and TB Series
Apply the specified grease at the grease fitting on
the spider. Apply grease until new grease purges
from all the seals. Figure 9.3.
32
Section 9
Trailer Axles
Conventional and TB Series Camshaft Bushing Greasing Intervals and Specifications

Greasing Interval* Grease Specification Grade Description Temperature
Use the schedule below that Multi-Purpose O-617-A 1 Lithium 12-Hydroxy Refer to the grease
gives the most frequent Grease or or Stearate or Lithium manufacturer’s
lubrication: O-617-B 2 Complex specifications for the
temperature service
O The lubrication schedule of
limits.
the fleet.
O The lubrication schedule of
the vehicle manufacturer.
O A minimum of four times
during the life of the brake
linings.
* Applies to standard-duty on-highway service. Lubricate more frequently for heavy-duty applications. Determine intervals by
inspecting lubricant every two weeks for a four month period. Look for hard, contaminated or missing grease. Choose an interval
based on the inspection.
Conventional Trailer Axle Wheel-End Oil Change Intervals and Specifications
Outside Temperature
°F °C
Check Meritor Specification Oil
Oil Level Oil Change * Specification Approval Description Min. Max. Min. Max.
1,000 miles General Service: Change O-76A Gear Oil MIL-PRF-2105-E GL-5 –10 None –12 None
(1600 km) oil if the wheel-end is and SAE 85W/140
disturbed during wheel SAE J2360
or hub removal or if the O-76D Gear Oil GL-5 –15 None –26 None
oil is contaminated. SAE 80W/90
Standard-Duty Service:
For 100,000 miles O-76E Gear Oil GL-5 –40 None –40 None
(160 000 km) or more a SAE 75W/90
year, change the oil
every 100,000 miles O-76J Gear Oil GL-5 –40 35 –40 2
(160 000 km). For less SAE 75W
than 100,000 miles
(160 000 km) a year, O-76L Gear Oil GL-5 –40 None –40 None
change the oil once a SAE 75W/140
year.
Heavy-Duty Service: For O-76M GL-5 –40 None –40 None
60,000 miles (96 000 km) Full Synthetic SAE 75W/140
or more a year, change Gear Oil
oil every 30,000 miles O-76N GL-5 –40 None –40 None
(48 000 km). For less Full Synthetic SAE 75W/90
than 60,000 miles Gear Oil
(96 000 km) a year,
change the oil every O-81 Full SAE 50 –40 None –40 None
6 months. Synthetic Oil
* The recommended oil change interval is based on operating conditions, speeds and loads. Limited service applications may allow the
recommended interval to be increased. Severe service applications may require the recommended interval to be reduced. For more
information, contact ArvinMeritor’s Customer Service Center at 800-535-5560.
33
Section 9
Trailer Axles
Conventional Trailer Axle Greasing Intervals and Specifications

Greasing Interval * Grease Specification Grade Description Temperature
General Service: Grease the Multi-Purpose O-617-A 1 Lithium 12-Hydroxy Refer to the grease
bearings if the wheel-end is Grease or or Stearate or Lithium manufacturer’s
disturbed during wheel or hub O-617-B 2 Complex specifications for
removal or if the grease is the temperature
contaminated. service limits.
Standard-Duty Service: For
100,000 miles (160 000 km)
or more a year, grease the
bearings every 100,000 miles
(160 000 km). For less than
100,000 miles (160 000 km) a
year, grease the bearings once Trailer Axle O-647 00 Lithium Complex
a year. Bearing
Heavy-Duty Service: For
60,000 miles (96 000 km) or
more a year, grease the
bearings every 30,000 miles
(48 000 km). For less than
60,000 miles (96 000 km) a
year, grease the bearings
every 6 months.
* The recommended greasing interval is based on operating conditions, speeds and loads. Limited service applications may allow the
recommended interval to be increased. Severe service applications may require the recommended interval to be reduced. For more
information, contact an ArvinMeritor service representative.
34
Section 10
Transfer Cases
Section 10
Transfer Cases
WARNING
maintenance or service. Meritor transfer cases may operate above
190°F (88°C) without damage. However, if the oil
temperature reaches 250°F (121°C), stop the
Operating Information vehicle immediately and check for the cause of
overheating. Maximum continuous running oil
Magnets and Magnetic Drain Plugs temperature should not exceed 225°F (107°C).
Damage to components can result.
Most Meritor transfer cases are equipped with
magnetic plugs having a minimum pick-up Check and Adjust Oil Level
capacity of 20 ounces (0.57 kilograms) of low
carbon steel.
CAUTION
NOTE: Meritor recommends replacing the Use only SAE Grade 50W full synthetic oil,
magnetic drain plug each time the oil is changed. Meritor specification O-81, in the transfer case.
Use the correct part. Pipe plugs will leak if used as Petroleum base oils and synthetic base oils can
a drain plug. react against sealing materials. Damage to
cleaning, the plug has a minimum pick-up capacity Only use new lubricant when you change or adjust
of 20 ounces (0.57 kilograms) of low carbon steel. the oil in the transfer case. Do not reuse lubricant,
which can contain metallic particles and other
contaminants. Damage to components can result.
Breather
1. Park the vehicle on a level surface.
CAUTION 2. Clean the area around the fill plug/fill cap.
Cover the breather when steam cleaning the Remove the fill plug/fill cap from the transfer
housing. If the breather is not covered, water case. Figure 10.1. The oil level must be even
enters the housing and contaminates the oil. with the bottom of the fill plug hole or the top
of the stand pipe.
Breathers release pressure that builds up inside O If oil flows from the hole when you loosen
the transfer case during vehicle operation. the plug: The oil level is high. Drain the oil
to the bottom of the fill hole.
Seals O If the oil level is below the bottom of
fill/level plug hole or stand pipe: Add the
CAUTION specified oil until oil is even with the bottom
of the fill hole.
Always use the correct tools and procedures
when you replace a seal to ensure that you 3. Install and tighten the fill plug to 35-50 lb-ft
correctly install the seal. A seal that is not (47-68 N•m). T
correctly installed can leak. Damage to
components can result. Figure 10.1
DRAIN PLUG T-2111 SHOWN
Seals keep lubricant in and dirt out of a (TYPICAL)
component. When they are worn or damaged,
seals leak and produce low lubricant levels which
may damage components.
FILL FILL
PLUG/CAP STAND PIPE
35
Section 10
Transfer Cases

1. Park the vehicle on a level surface. Put a large
container under the transfer case.
2. Remove the drain plug from the bottom of the
transfer case. Drain and discard the oil correctly.
Clean the plug. Figure 10.1.
3. Install and tighten the drain plug to 35-50 lb-ft
(47-68 N•m). T
4. Clean the area around the fill plug. Remove the
fill plug from the transfer case.
5. Add the specified oil until the oil level is even
with the bottom of the fill plug hole.
(47-68 N•m). T
7. Run the vehicle for 1/4 mile (0.4 km), then top
off the oil level by adding oil to the fill opening.
8. Reinstall and tighten the fill plug to 35-50 lb-ft
(47-68 N•m). T
Transfer Case Oil Change Intervals

Check Oil Level 2,000 miles 40 operating
(3200 km) hours
Initial Oil 2,500 miles 40-100 operating
Change (4000 km) hours
Scheduled Oil 12,000-25,000 miles 200-300 operating
Change (19 000-40 000 km) hours
Transfer Case Oil Specifications a d e
Meritor A.P.I. Military SAE Outside

Oil Description Specification Specification Specification Grade Temperature
Petroleum GL-1 Oil with — A.P.I. GL-1 — 90W Above 10°F (–12°C)
Rust and Oxidation 80W Above –15°F (–26°C)
Inhibitor b
Heavy Duty Engine Oil b A.P.I.-CD, CE, 50W Above 10°F (–12°C)
SF or SG f 40W Above 10°F (–12°C)
30W Above –12°F (–26°C)
Full Synthetic Oil c O81 — — 50W Above –40°F (–40°C)
A.P.I. GL-5 (Axle Lube) a DO NOT USE IN TRANSFER CASES
a Do Not use multi-viscosity (I.E. 80/90W) GL-5 Gear Oil (axle lube).
b 90W GL-1 or 50W motor oil is same viscosity and commonly used above 10°F (–12°C).
c Meritor approved full synthetic oil for manual ZF Meritor transmissions is also approved for Meritor transfer cases. Use
synthetic oil only if the transfer case was initially filled with synthetic oil.
d Do not mix or switch oil types. Use the same oil that initially filled the transfer case.
e Do not use multi-viscosity oils.
f Current designations are acceptable.
36
Section 10
Transfer Cases
Transfer Case Oil Capacities
Oil Capacity
Transfer Case
Model Pints* Liters*
T-32 2.0 0.95
T-136 14.0 6.62
T-215 3.0 1.42
T-221 4.0 1.89
T-223 5.0 2.37
T-226 6.5 3.07
T-228 21.0 9.93
T-232 6.2 2.93
T-1138 13.5 6.38
T-2111 3.0 1.42
T-2111-HD 5.0 2.37
T-2111-HT 5.0 2.37
T-2111-PD 10.0 4.73
T-2111-SD 5.0 2.37
T-2120 4.0 1.89
T-2120-RS 6.5 3.10
T-600 6.2 2.93
* Due to the varied transfer case

configurations, these fill quantities are
for reference only. The fill procedure for
all transfer cases is as follows:
1. Fill to the top of the stand pipe or
fill hole.
2. Run the vehicle for 1/4 mile (0.4 km).
3. Top off the oil level.
4. Check that the sump temperature
does not exceed 225°F (107°C).
37
Section 11
Transmissions
Section 11
Transmissions
Transmission Oil Coolers
WARNING
To prevent serious eye injury, always wear safe Required
eye protection when you perform vehicle O An engine has a rating of 399 HP or above.
O The transmission operating temperature is
NOTE: For a list of synthetic oil suppliers, always above 225°F (107°C) at continuous
call ArvinMeritor’s Customer Service Center at operation or reaches 275°F (135°C) during
800-535-5560 and order TP-2053. This bulletin is intermittent operation.
also available from the Technical Library section
on ArvinMeritor’s web site at arvinmeritor.com. Recommended
Click Products & Services/Tech Library Icon/HVS O An engine has a rating of 350 to 398 HP.
Publications/Technical Bulletins/Transmissions.
O Some aerodynamic vehicles that have engine
ratings below 399 HP because of the amount
Recommended Oil Drain Conditions of air that flows over the transmission to
Based on Used-Oil Analysis dissipate heat.
Manual Transmission Oils Temperature Indicator

If used transmission oil analyses indicate that any The temperature indicator is optional on
one of these criteria is not met, drain the used oil ZF Meritor transmissions. The temperature
and replace it with an oil that is recommended for sending unit is on the bottom right side of the
manual transmissions. main case. The normal operating temperature
range is less than 225°F (107°C).
Used-Oil Analyses (ppm = parts per million) Use the temperature indicator gauge to check
transmission operation. For example:
Iron (Fe) If level is greater than 500 ppm, drain
and replace the oil. O If the temperature suddenly rises to 275°F
Silicon (Si) If level is greater than 100 ppm, drain (135°C) or more, check the transmission for the
and replace the oil. cause of the increase.
Water (H2O) If level is greater than 0.3%, drain and O When operating a vehicle on a mountain grade,
replace the oil.
if the temperature increases 50-75°F but returns
to the normal operating temperature, this
indicates a normal operating condition. If the
Magnets and Magnetic Drain Plugs temperature does not return to the normal
All ZF Meritor transmissions have four magnets range, check the transmission.
in the bottom of the main case. The magnets and
magnetic plugs have a minimum pick-up capacity Oil Level
of 1.5 pounds (0.7 kilograms) of low carbon steel.
NOTE: ZF Meritor recommends replacing the

Before You Check the Oil Level
magnetic drain plug each time the oil is changed. 1. The oil must be at room temperature.
Use the correct part. Pipe plugs will leak if used
as a drain plug. 2. The vehicle must be parked for at least
10 minutes.
cleaning, the plug has a minimum pick-up capacity
of 1.5 pounds (0.7 kilograms) of low carbon steel.
38
Section 11
Transmissions
Check and Adjust the Oil Level Drain and Replace the Oil
NOTE: Drain the oil when the transmission is hot.
NOTE: If foam appears when you remove the fill
plug, the oil is too hot to check. Install the oil plug 1. Park the vehicle on a level surface. Place a
and allow the oil to cool. If oil flows from the fill large container under the transmission. Place
plug hole when you remove the plug, the oil level a screen on top of the container.
is too high. Drain the oil to the correct level. 2. Remove the drain plugs from the bottom of
the transmission. Drain the oil. Follow United
2. Clean the area by the fill plug. Remove the fill States Environmental Protection Agency (EPA)
plug from the side of the transmission. guidelines to recycle used oil.
3. Check for oil leaks. If a transmission oil leak 3. Inspect the screen on top of the container for
is evident, refer to the Troubleshooting section metal particles and damaged parts.
of Maintenance Manual 26A, 9-, 10- and
13-Speed Transmissions, for procedures. Service the Transmission if Necessary
To order a copy of this manual, call
ArvinMeritor’s Customer Service Center at 1. If the transmission is disassembled or
800-535-5560. replaced and a transmission oil cooler is used,
remove the cooler.
4. Check the transmission oil level. Verify that it
is EVEN WITH the bottom of the fill plug. If the 2. Remove the oil from the oil cooler and the oil
oil level is BELOW the bottom of the oil fill lines. Follow United States Environmental
plug, add the specified oil. Figure 11.1. Protection Agency (EPA) guidelines to recycle
used oil.
3. Install the oil cooler and the oil lines. Tighten
Figure 11.1 the fittings to the vehicle manufacturer’s
Oil level must be specifications.
EVEN WITH bottom
of fill plug hole. 4. Install the drain plug and tighten it to
35-50 lb-ft (48-67 N•m). T
5. Clean the air by the fill plug. Remove the fill
plug from the side of the transmission.
CAUTION
FILL PLUG Only use the specified oil. Do not use
DRAIN PLUG multi-viscosity engine oils or Extreme Pressure
(EP) GL-5 gear oils. Damage to components can
result. The use of multi-viscosity or EP oils will
5. Install the oil fill plug and tighten it to void ZF Meritor’s warranty.
35-50 lb-ft (48-67 N•m). T
6. Operate the vehicle for 5 minutes. Check for 6. Add the specified transmission oil through the
transmission oil leaks and correct operation. fill plug hole. Add the oil until the oil level is
EVEN WITH the bottom of the fill plug hole.
(48-67 N•m). T
8. Operate the vehicle for 5 minutes. Check for
correct operation.
39
Section 11
Transmissions
Oil Change Intervals

Manual Transmissions
Engine Synchro ShiftTM (ESSTM)
SureShiftTM
Approved
Petroleum Approved
Check Lubricant Oil Synthetic Oil
Oil Level Change Change
10,000 miles 50,000 miles 500,000 miles
(16 000 km) (80 000 km) (800 000 km) a
Oil Change Specifications

Manual Transmissions b
Engine Synchro ShiftTM (ESSTM)
SureShiftTM
Military
Meritor A.P.I. Specification SAE Outside
Oil Description Specification Specification Approval Grade Temperature
Heavy-Duty Engine Oil — A.P.I. -CD, -CE, MIL-L-2104 E 50 Above 10°F (–12°C)
-SG, -SH or SJ or F c
40 Above 10°F (–12°C)
c
30 Above –15°F (–26°C)
Petroleum GL-1 Oil with — A.P.I. - GL-1 — 90 Above 10°F (–12°C)
Rust and Oxidation
80 Above –15°F (–26°C)
Inhibitor
Full-Synthetic Oil O-81 — — 50 Above –40°F (–40°C)
a This interval is for linehaul applications.

b Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX OILS IN THE TRANSMISSION.
c Current designations are acceptable.
FreedomLineTM Transmission Oil Specification

Military
ZF Meritor A.P.I. Specification SAE Outside
Oil Description Specification Specification Approval Grade Temperature
Full-Synthetic Oil Exxon Mobil — — 50 Above –60°F (–51°C)
SHC 50
40
Section 11
Transmissions
Manual Transmissions
9-SPEED 10-SPEED 13-SPEED
9-Speed Manual
Torque
Transmission Model Rating Overall Rev. Rev.
Description Number lb-ft Ratio L H Ratio and Percent Step
FWD. REV. L % 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8
9-Speed Direct Drive, M-11G9A-M11 1,150
A Ratio M-12G9A-M12 1,250
M-13G9A-M13 1,350 13.41 13.17 13.17 3.73 13.41 48 9.05 39 6.51 37 4.74 34 3.53 38 2.56 39 1.84 37 1.34 34 1.00
M-14G9A-M14 1,450
M-15G9A-M15 1,550
9-Speed Overdrive, MO-12G9A-M12 1,250
A Ratio MO-13G9A-M13 1,350 13.41 13.17 9.81 2.78 9.99 48 6.74 39 4.85 37 3.53 34 2.63 38 1.91 39 1.37 37 1.00 34 0.74
MO-14G9A-M14 1,450
9-Speed Overdrive, MO-11G9B-M11 1,150
B Ratio MO-12G9B-M12 1,250
MO-13G9B-M13 1,350 17.74 17.42 12.60 3.24 12.83 67 7.69 40 5.48 41 3.89 38 2.81 42 1.98 40 1.41 41 1.00 38 0.72
MO-14G9B-M14 1,450
MO-15G9B-M15 1,550
9-Speed Manual — Additional Specifications

Optional Internal Oil Capacity Length Weight PTO Speed
Model Oil Pump (pints) (inches) (lbs.*) (% of engine)
M-11G9A-M11 20.5 29.5 605 75.8
M-12G9A-M12 20.5 29.5 605 75.8
M-13G9A-M13 20.5 29.5 605 75.8
M-14G9A-M14 20.5 29.5 605 75.8
M-15G9A-M15 STD. 20.5 29.5 608 75.8
MO-12G9A-M12 20.5 29.5 605 101.7
MO-13G9A-M13 20.5 29.5 605 101.7
MO-14G9A-M14 20.5 29.5 605 101.7
MO-11G9B-M11 20.5 28.9 605 87.1
MO-12G9B-M12 20.5 28.9 605 87.1
MO-13G9B-M13 20.5 29.5 605 87.1
MO-14G9B-M14 20.5 29.5 605 87.1
MO-15G9B-M15 STD. 20.5 29.5 608 87.1
*Weights are approximate, less clutch housing, shift controls, output yoke and lubricant.
13-Speed Manual
Torque
FWD. REV. L % 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10 % 11 % 12
13-Speed Overdrive, RM013-145A 1,450 15.43 15.15 13.15 3.73 13.39 48 9.03 39 6.50 37 4.74 34 3.53 38 2.56 15 2.22 21 1.84 15 1.60 19 1.34 15 1.17 17 1.00 15 0.87
A Ratio

RMO13-145A 22 32.4 666 75.8
41
Section 11
Transmissions
10-Speed Manual
Torque
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10
10-Speed Direct Drive, M-11G10A-M11 1,150

A Ratio M-12G10A-M12 1,250
M-13G10A-M13 1,350 15.02 16.71 16.71 3.73 15.02 35 11.14 35 8.26 37 6.02 34 4.48 34 3.35 35 2.48 35 1.84 37 1.34 34 1.00
M-14G10A-M14 1,450
M-15G10A-M15 1,550
M-14G10A-M161 1,450
10-Speed Overdrive, MO-11G10A-M11 1,150
A Ratio MO-12G10A-M12 1,250
MO-13G10A-M13 1,350
MO-14G10A-M14 1,450
15.02 16.71 12.45 2.78 11.19 35 8.30 35 6.15 37 4.48 34 3.34 34 2.50 35 1.85 35 1.37 37 1.00 34 0.74
MO-15G10A-M15 1,550
MO-14G10A-M161 1,450
MO-16G10A-M16 1,650
MO-16G10A-M181 1,650
10-Speed Overdrive, MO-11G10C-M11 1,150
C Ratio MO-12G10C-M12 1,250
MO-13G10C-M13 1,350
MO-14G10C-M14 1,450
MO-15G10C-M15 1,550
MO-16G10C-M16 1,650
17.53 19.49 14.15 2.88 12.72 38 9.23 37 6.75 37 4.92 38 3.57 38 2.58 38 1.88 37 1.37 37 1.00 38 0.73
MO-14G10C-M161 1,450
MO-16G10C-M18 1,650
MO-17G10C-M17 1,750
MO-17G10C-M19 1,750
MO-18G10C-M18 1,850
MO-18G10C-M201 1,850
1 Available with Torq-2 with either a 100 lb-ft or 200 lb-ft increase in the top two gears in CAT/Cummins engines.
Other Torq-2 combinations are available, call your OEM representative for details.

M-11G10A-M11 20.5 29.5 605 75.8
M-12G10A-M12 20.5 29.5 605 75.8
M-13G10A-M13 20.5 29.5 605 75.8
M-14G10A-M14 20.5 29.5 605 75.8
M-15G10A-M15 STD. 20.5 29.5 608 75.8
M-14G10A-M16 STD. 20.5 29.5 608 75.8
MO-11G10A-M11 20.5 29.5 605 75.8
MO-12G10A-M12 20.5 29.5 605 75.8
MO-13G10A-M13 20.5 29.5 605 101.7
MO-14G10A-M14 20.5 29.5 605 101.7
MO-15G10A-M15 STD. 20.5 29.5 608 101.7
MO-14G10A-M16 STD. 20.5 29.5 608 101.7
MO-16G10A-M16 STD. 20.5 29.5 608 101.7
MO-16G10A-M18 STD. 20.5 29.5 608 101.7
MO-11G10C-M11 20.5 29.5 605 98.2
MO-12G10C-M12 20.5 29.5 605 98.2
MO-13G10C-M13 20.5 29.5 605 98.2
MO-14G10C-M14 20.5 29.5 605 98.2
MO-15G10C-M15 STD. 20.5 29.5 608 98.2
MO-16G10C-M16 STD. 20.5 29.5 608 98.2
MO-14G10C-M16 STD. 20.5 29.5 608 98.2
MO-16G10C-M18 STD. 20.5 29.5 608 98.2
MO-17G10C-M17 STD. 20.5 29.5 608 98.2
MO-17G10C-M19 STD. 20.5 29.5 608 98.2
MO-18G10C-M18 STD. 20.5 29.5 608 98.2
MO-18G10C-M20 STD. 20.5 29.5 608 98.2
42
Section 11
Transmissions
ESS System Automated Transmissions

9-SPEED 10-SPEED
9-Speed ESS
Torque
FWD. REV. L % 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8
9-Speed Direct Drive, M-11G9A-X11 1,150
A Ratio M-12G9A-X12 1,250
M-13G9A-X13 1,350 13.41 13.17 13.17 3.73 13.41 48 9.05 39 6.51 37 4.74 34 3.53 38 2.56 39 1.84 37 1.34 34 1.00
M-14G9A-X14 1,450
M-15G9A-X15 1,550
9-Speed Overdrive, MO-12G9A-X12 1,250
A Ratio MO-13G9A-X13 1,350 13.41 13.17 9.81 2.78 9.99 48 6.74 39 4.85 37 3.53 34 2.63 38 1.91 39 1.37 37 1.00 34 0.74
MO-14G9A-X14 1,450
9-Speed Overdrive, MO-11G9B-X11 1,150
B Ratio MO-12G9B-X12 1,250
MO-13G9B-X13 1,350 17.74 17.42 12.60 3.24 12.83 67 7.69 40 5.48 41 3.89 38 2.81 42 1.98 40 1.41 41 1.00 38 0.72
MO-14G9B-X14 1,450
MO-15G9B-X15 1,550
FOR ENGINE TYPE:

X = Add “D” for Detroit Diesel or “E” for CAT/Cummins engine.
9-Speed ESS — Additional Specifications

M-11G9A-X11 20.5 29.5 605 75.8
M-12G9A-X12 20.5 29.5 605 75.8
M-13G9A-X13 20.5 29.5 605 75.8
M-14G9A-X14 20.5 29.5 605 75.8
M-15G9A-X15 STD. 20.5 29.5 608 75.8
MO-12G9A-X12 20.5 29.5 605 101.7
MO-13G9A-X13 20.5 29.5 605 101.7
MO-14G9A-X14 20.5 29.5 605 101.7
MO-11G9B-X11 20.5 29.5 605 87.1
MO-12G9B-X12 20.5 29.5 605 87.1
MO-13G9B-X13 20.5 29.5 605 87.1
MO-14G9B-X14 20.5 29.5 605 87.1
MO-15G9B-X15 STD. 20.5 29.5 608 87.1
43
Section 11
Transmissions
10-Speed ESS
Torque
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10
10-Speed Direct Drive, M-11G10A-X11 1,150

A Ratio M-12G10A-X12 1,250
M-13G10A-X13 1,350 15.02 16.71 16.71 3.73 15.02 35 11.14 35 8.26 37 6.02 34 4.48 34 3.35 35 2.48 35 1.84 37 1.34 34 1.00
M-14G10A-X14 1,450
M-15G10A-X15 1,550
M-14G10A-E16 1,450
10-Speed Overdrive, MO-11G10A-X11 1,150
A Ratio MO-12G10A-X12 1,250
MO-13G10A-X13 1,350
MO-14G10A-X14 1,450
15.02 16.71 12.45 2.78 11.19 35 8.30 35 6.15 37 4.48 34 3.34 34 2.50 35 1.85 35 1.37 37 1.00 34 0.74
MO-15G10A-X15 1,550
MO-14G10A-E161 1,450
MO-16G10A-X16 1,650
MO-16G10A-E18 1,650
10-Speed Overdrive, MO-11G10C-X11 1,150
C Ratio MO-12G10C-X12 1,250
MO-13G10C-X13 1,350
MO-14G10C-X14 1,450
MO-15G10C-X15 1,550
MO-16G10C-X16 1,650 17.53 19.49 14.15 2.88 12.72 38 9.23 37 6.75 37 4.92 38 3.57 38 2.58 38 1.88 37 1.37 37 1.00 38 0.73
MO-14G10C-E161 1,450
MO-16G10C-E181 1,650
MO-17G10C-X17 1,750
MO-17G10C-E19 1,750
MO-18G10C-X18 1,850
MO-18G10C-E201 1,850
FOR ENGINE TYPE: X = Add “D” for Detroit Diesel or “E” for CAT/Cummins engine. E = Available in CAT/Cummins engine only.
1 Available with Torq-2 with either a 100 lb-ft or 200 lb-ft increase in the top two gears. Other Torq-2 combinations are available, call your OEM representative for details.
10-Speed ESS — Additional Specifications

M-11G10A-X11 20.5 29.5 605 75.8
M-12G10A-X12 20.5 29.5 605 75.8
M-13G10A-X13 20.5 29.5 605 75.8
M-14G10A-X14 20.5 29.5 605 75.8
M-15G10A-X15 STD. 20.5 29.5 608 75.8
M-14G10A-E16 STD. 20.5 29.5 608 75.8
MO-11G10A-X11 20.5 29.5 605 75.8
MO-12G10A-X12 20.5 29.5 605 75.8
MO-13G10A-X13 20.5 29.5 605 101.7
MO-14G10A-X14 20.5 29.5 605 101.7
MO-15G10A-X15 STD. 20.5 29.5 608 101.7
MO-14G10A-E16 STD. 20.5 29.5 608 101.7
MO-16G10A-X16 STD. 20.5 29.5 608 101.7
MO-16G10A-E18 STD. 20.5 29.5 608 101.7
MO-11G10C-X11 20.5 29.5 605 98.2
MO-12G10C-X12 20.5 29.5 605 98.2
MO-13G10C-X13 20.5 29.5 605 98.2
MO-14G10C-X14 20.5 29.5 605 98.2
MO-15G10C-X15 STD. 20.5 29.5 608 98.2
MO-16G10C-X16 STD. 20.5 29.5 608 98.2
MO-14G10C-X16 STD. 20.5 29.5 608 98.2
MO-16G10C-X18 STD. 20.5 29.5 608 98.2
MO-17G10C-E17 STD. 20.5 29.5 608 98.2
MO-17G10C-E19 STD. 20.5 29.5 608 98.2
MO-18G10C-E18 STD. 20.5 29.5 608 98.2
MO-18G10C-X20 STD. 20.5 29.5 608 98.2
44
Section 11
Transmissions
SureShift™ Automated Transmissions (All J1939 Engines)

9-Speed SureShift
Torque
FWD. REV. L % 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8
9-Speed Direct Drive, M-11G9A-S11 1,150
A Ratio M-12G9A-S12 1,250
M-13G9A-S13 1,350 13.41 13.17 13.17 3.73 13.41 48 9.05 39 6.51 37 4.74 34 3.53 38 2.56 39 1.84 37 1.34 34 1.00
M-14G9A-S14 1,450
M-15G9A-S15 1,550
9-Speed Overdrive, MO-12G9A-S12 1,250
A Ratio MO-13G9A-S13 1,350 13.41 13.17 9.81 2.78 9.99 48 6.74 39 4.85 37 3.53 34 2.63 38 1.91 39 1.37 37 1.00 34 0.74
MO-14G9A-S14 1,450
9-Speed Overdrive, MO-11G9B-S11 1,150
B Ratio MO-12G9B-S12 1,250
MO-13G9B-S13 1,350 17.74 17.42 12.60 3.24 12.83 67 7.69 40 5.48 41 3.89 38 2.81 42 1.98 40 1.41 41 1.00 38 0.72
MO-14G9B-S14 1,450
MO-15G9B-S15 1,550
9-Speed SureShift — Additional Specifications

M-11G9A-S11 20.5 29.5 605 75.8
M-12G9A-S12 20.5 29.5 605 75.8
M-13G9A-S13 20.5 29.5 605 75.8
M-14G9A-S14 20.5 29.5 605 75.8
M-15G9A-S15 STD. 20.5 29.5 608 75.8
MO-12G9A-S12 20.5 29.5 605 101.7
MO-13G9A-S13 20.5 29.5 605 101.7
MO-14G9A-S14 20.5 29.5 605 101.7
MO-11G9B-S11 20.5 29.5 605 87.1
MO-12G9B-S12 20.5 29.5 605 87.1
MO-13G9B-S13 20.5 29.5 605 87.1
MO-14G9B-S14 20.5 29.5 605 87.1
MO-15G9B-S15 STD. 20.5 29.5 608 87.1
45
Section 11
Transmissions
10-Speed SureShift
Torque
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10
10-Speed Direct Drive, M-11G10A-S11 1,150

A Ratio M-12G10A-S12 1,250
M-13G10A-S13 1,350 15.02 16.71 16.71 3.73 15.02 35 11.14 35 8.26 37 6.02 34 4.48 34 3.35 35 2.48 35 1.84 37 1.34 34 1.00
M-14G10A-S14 1,450
M-15G10A-S15 1,550
M-14G10A-S161 1,450
10-Speed Overdrive, MO-11G10A-S11 1,150
A Ratio MO-12G10A-S12 1,250
MO-13G10A-S13 1,350
MO-14G10A-S14 1,450
15.02 16.71 12.45 2.78 11.19 35 8.30 35 6.15 37 4.48 34 3.34 34 2.50 35 1.85 35 1.37 37 1.00 34 0.74
MO-15G10A-S15 1,550
MO-14G10A-S161 1,450
MO-16G10A-S16 1,650
MO-16G10A-S181 1,650
10-Speed Overdrive, MO-11G10C-S11 1,150
C Ratio MO-12G10C-S12 1,250
MO-13G10C-S13 1,350
MO-14G10C-S14 1,450
MO-15G10C-S15 1,550 17.53 19.49 14.15 2.88 12.72 38 9.23 37 6.75 37 4.92 38 3.57 38 2.58 38 1.88 37 1.37 37 1.00 38 0.73
MO-16G10C-S16 1,650
MO-14G10C-S161 1,450
MO-16G10C-S181 1,650
MO-17G10C-S17 1,750
MO-17G10C-S19 1,750
MO-18G10C-S18 1,850
MO-18G10C-S201 1,850
1 Available with Torq-2 with either a 100 lb-ft or 200 lb-ft increase in the top two gears with CAT/Cummins engines.
Other Torq-2 combinations are available, call your OEM representative for details.
10-Speed SureShift — Additional Specifications

M-11G10A-S11 20.5 29.9 605 75.8
M-12G10A-S12 20.5 29.9 605 75.8
M-13G10A-S13 20.5 29.5 605 75.8
M-14G10A-S14 20.5 29.5 605 75.8
M-15G10A-S15 STD. 20.5 29.5 608 75.8
M-14G10A-S16 STD. 20.5 29.5 608 75.8
MO-11G10A-S11 20.5 29.9 605 75.8
MO-12G10A-S12 20.5 29.9 605 75.8
MO-13G10A-S13 20.5 29.5 605 101.7
MO-14G10A-S14 20.5 29.5 605 101.7
MO-15G10A-S15 STD. 20.5 29.5 608 101.7
MO-14G10A-S16 STD. 20.5 29.5 608 101.7
MO-16G10A-S16 STD. 20.5 29.5 608 101.7
MO-16G10A-S18 STD. 20.5 29.5 608 101.7
MO-11G10C-S11 20.5 29.5 605 98.2
MO-12G10C-S12 20.5 29.5 605 98.2
MO-13G10C-S13 20.5 29.5 605 98.2
MO-14G10C-S14 20.5 29.5 605 98.2
MO-15G10C-S15 STD. 20.5 29.5 608 98.2
MO-16G10C-S16 STD. 20.5 29.5 608 98.2
MO-14G10C-S16 STD. 20.5 29.5 608 98.2
MO-16G10C-S18 STD. 20.5 29.5 608 98.2
MO-17G10C-S17 STD. 20.5 29.5 608 98.2
MO-17G10C-S19 STD. 20.5 29.5 608 98.2
MO-18G10C-S18 STD. 20.5 29.5 608 98.2
MO-18G10C-S20 STD. 20.5 29.5 608 98.2
46
Section 11
Transmissions
FreedomLine™ Automated Transmissions

12-Speed FreedomLine
Torque
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10 % 11 % 12
12-Speed Direct Drive M-13Z12A-A13 1,350 15.86 14.68 14.68 11.41 15.86 29 12.33 29 9.57 29 7.44 27 5.87 28 4.57 32 3.47 28 2.70 29 2.10 29 1.63 26 1.29 29 1.00
M-14Z12A-A14 1,450
12-Speed Overdrive MO-13Z12A-A13 1,350

MO-14Z12A-A14 1,450 15.81 14.62 11.41 8.88 12.33 29 9.59 29 7.44 29 5.78 26 4.57 29 3.55 31 2.70 29 2.10 29 1.63 28 1.27 27 1.00 28 .78
MO-15Z12A-A15 1,550
MO-16Z12A-A16 1,650
12-Speed FreedomLine — Additional Specifications

Optional Internal Oil Capacity Length Weight
Model Oil Pump (pints) (inches) (lbs.*) PTO
M-13Z12A-A13 STD. 23.25 31.7 565 Available
M0-14Z12A-A14 STD. 23.25 31.7 565 Available
*Weights are approximate, less shift controls, output yoke and lubricant.
16-Speed FreedomLine
Torque
FWD. REV. 1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10 % 11 % 12 % 13 % 14 % 15 % 16
16-Speed Direct Drive M-13Z16A-A13 1,350
M-14Z16A-A14 1,450 17.03 15.77 15.77 13.07 17.03 21 14.12 23 11.50 21 9.54 21 7.86 21 6.52 18 5.51 21 4.57 23 3.73 21 3.09 23 2.52 21 2.09 22 1.72 21 1.43 18 1.21 21 1.00
M-14Z16A-A15 1,550
M-16Z16A-A16 1,650
16-Speed Overdrive MO-13Z16A-A13 1,350

MO-14Z16A-A14 1,450 17.01 15.75 13.07 10.81 14.12 21 11.68 22 9.54 21 7.89 21 6.52 21 5.39 18 4.57 21 3.78 22 3.09 21 2.56 22 2.09 21 1.73 21 1.43 21 1.18 18 1.00 20 0.83
MO-15Z16A-A15 1,550
MO-16Z16A-A16 1,650
16-Speed FreedomLine — Additional Specifications

Optional Internal Oil Capacity Length Weight
Model Oil Pump (pints) (inches) (lbs.*) PTO
MO-14Z16A-A14 STD. 25.0 33.4 604 Available
*Weights are approximate, less shift controls, output yoke and lubricant.
47
Section 11
Transmissions
Platform “F” Manual Transmission Oil Capacities a
Oil PTO Oil PTO

Capacity Length Weight (% of Capacity Length Weight (% of
Model (Pints) (In.) (Lbs.) Engine) Model (Pints) (In.) (Lbs.) Engine)
RM9-115A c 20.0 28.9 588 75.8 RM10-125A c 20.0 28.9 588 75.8
RM9-125A c 20.0 28.9 588 75.8 RM10-135A c 20.5 29.5 605 75.8
RM9-135A c 20.5 29.5 605 75.8 RM10-145A c 20.5 29.5 605 75.8
RM9-145A c 20.5 29.5 605 75.8 M-14F10A-M16 c 20.5 29.5 605 75.8
RM9-155A c 20.5 29.5 608 75.8 RM10-155A c 20.5 29.5 608 75.8
RMO9-125A 20.0 28.9 588 101.7 RD10-145A 20.5 29.5 605 75.8
RMO9-135A 20.5 29.5 605 101.7 RMX10-115A c 20.0 28.9 588 101.7
RMO9-145A 20.5 29.5 605 101.7 RMX10-125A c 20.0 28.9 588 101.7
RMX9-125A c 20.0 28.9 588 101.7 RMX10-135A c 20.5 29.5 605 101.7
RMX9-135A c 20.5 29.5 605 101.7 RMX10-145A c 20.5 29.5 605 101.7
RMX9-145A c 20.5 29.5 605 101.7 MO-14F10A-M16 20.5 29.5 605 101.7
RMO9-115B 20.0 28.9 588 87.1 c
RMO9-125B 20.0 28.9 588 87.1 RMX10-155A c 20.5 29.5 608 101.7
RMO9-135B 20.5 29.5 605 87.1 RMX10-165A c 20.5 29.5 608 101.7
RMO9-145B 20.5 29.5 605 87.1 RMX10-115C c 20.5 29.5 605 98.2
RMX9-115B c 20.0 28.9 588 87.1 RMX10-125C c 20.5 29.5 605 98.2
RMX9-125B c 20.0 28.9 588 87.1 RMX10-135C c 20.5 29.5 605 98.2
RMX9-135B c 20.5 29.5 605 87.1 RMX10-145C c 20.5 29.5 605 98.2
RMX9-145B c 20.5 29.5 605 87.1 MO-14F10C-M16 20.5 29.5 605 98.2
c
RMX9-155B c 20.5 29.5 608 87.1
RMX10-155C c 20.5 29.5 608 98.2
RMX9-115R c 20.0 28.9 588 101.7
RMX10-165C c 20.5 29.5 608 98.2
RMX9-125R c 20.0 28.9 588 101.7
MO-16F10C-M18 20.5 29.5 608 98.2
RMX9-135R c 20.5 29.5 605 101.7 c
RMX9-145R c 20.5 29.5 605 75.8 RMO13-145A c 22.0 32.4 666 75.8
RM10-115A c 20.0 28.9 588 75.8
a Oil capacities are approximate. Fill the transmission to the bottom of the fill plug hole. On transmissions equipped with an oil pump
and/or oil cooler, operate the engine for five minutes after the initial fill and check the oil level again.
b Weights are approximate, less clutch housing, shift controls, output yoke and lubricant.
c Available with Meritor’s Engine Synchro ShiftTM (ESSTM) System. For ESS transmission models, replace the “M” in the above model
numbers with an “S”.
48
Section 12
SectionBearings
Wheel 12 and Wheel-Ends
Figure 12.1
WARNING
TYPICAL GREASE-LUBRICTED WHEEL BEARINGS
To prevent serious eye injury, always wear safe LUBE
Wheel Bearings
Grease the Bearings
WARNING
Support the vehicle with safety stands. Do not Check the Oil Level
work under a vehicle only supported by jacks.
Jacks can slip or fall over and cause serious NOTE: If you cannot observe the oil level because
personal injury. the sightglass is stained, remove the fill plug,
check the oil level with your finger and follow the
1. Raise the vehicle so that the wheels are off the procedures for Step 2, below. Replace the stained
ground. Support the vehicle with safety sightglass as soon as possible.
stands.
2. Remove the tire and wheel assembly. Remove 1. Check the oil level on the cap.
and dissemble the hub. 2. If the oil level is more than 1/4-inch (6 mm)
3. Use the correct cleaning solvent to remove the below the specified level on the cap, remove
old grease from all parts. Discard the seals. the fill plug.
Inspect the wheel bearings for wear or 3. Add the specified oil to the specified level.
damage. Replace worn or damaged bearings. Figure 12.2.
4. Before installing the wheel bearings, lubricate 4. Install the fill plug.
the bearing journals on the spindle with the
grease that is used for the bearings.
Figure 12.1. Figure 12.2
TYPICAL OIL-LUBRICATED WHEEL BEARINGS
5. Use a pressure packer to force the specified
grease from the large end of the cones into the
cavities between the rollers and cage. Pack the
hub between the bearing cups with grease to
the level of the smallest diameter of the cups.
O If a pressure packer is not available: Grease
the bearings by hand.
LUBE
6. Install the inner and outer bearing cones into
the cups in the hubs. The bearing cups must
be pressed tight against the shoulder in the
hubs.
7. Install new wheel seals in the hubs.
8. Install the hub and the wheel and tire
assembly. Install the outer wheel bearing cone
in the hub. Install the adjusting nut.
9. Adjust the wheel bearings.
49
Section 12
Drive Axle Hubs Without Fill Holes

1. Add the specified amount of lubricant through
the carrier or housing bowl oil fill hole.
2. Tilt the axle to the right and to the left to let the
oil flow into the hub cavities. Keep the axle
tilted for one minute in each position.
3. With the axle in the level position, add the
specified oil so that the level is even with the
bottom of the fill plug hole.
4. Install and tighten the fill plug.
Wheel-End Axle Greasing Intervals and Specifications

Greasing Interval Grease Specification Grade Description Temperature
Whichever comes first: Multi-Purpose O-617-A 1 Lithium 12-Hydroxy Refer to the grease
Grease (preferred) or Stearate or Lithium manufacturer’s
Replacing Seals or 2 Complex specifications for the
Relining Brakes O-617-B temperature service
(acceptable) limits.
On-Highway: 30,000 miles
(48 000 km)
On/Off Highway and
Off-Highway: Twice a year
Wheel-End Oil Change Intervals and Specifications

Check Oil Level 1,000 miles (1600 km) 1,000 miles (1600 km)
Petroleum Oil Whichever comes first. Seals replaced. Whichever comes first. Seals replaced.
Change Brakes relined. 100,000 miles Brakes relined. Once a year.
(160 000 km). Once a year.
Synthetic Oil — —
Change
Outside Temperature
°F °C
Meritor Military/SAE
Specifications Specifications Oil Description Min. Max. Min. Max.
and
SAE J2360
O-76J Gear Oil GL-5, SAE 75 –40 35 –40 2
Heavy-Duty MIL-L-2104 E A.P.I. -CD, -CE, -SG, –10 None –12 None
Engine Oil or F -SH or -SJ
SAE 40 or 50 a
Heavy-Duty MIL-L-210 E A.P.I. -CD, -CE, -SG, –15 None –26 None
Engine Oil or F -SH or -SJ
SAE 30 b
a Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 40 or 50.
b Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 30.
50
Section 13
List of Lubricants
Grease Lubricants a
Section
List of Lubricants
13
Meritor NLGI Outside

Specification Grease Typical Application Grade Grease Description Temperature
O-616 Brake Grease Cam Brake Anchor Pins, 2 Clay Base b
Mechanical Brake Anchor
Pins
O-616-A Brake Grease Air Disc Brake Caliper, 1 Clay Base Down to –40°F
Automatic Slack Adjuster, (–40°C)
Wedge Brake Components
O-617-A Multi-Purpose Cam Brake Chamber 1 Lithium 12-Hydroxy b
or Grease Brackets, Cam Brake Hold or Stearate or Lithium
O-617-B Down Clips, Cross Tube Ends, 2 Complex
Drag Link, Wheel Bearings,
King Pins and Bushings,
Knuckle Bushings, Manual
Slack Adjuster, Steering Arm,
Ball Studs, Tie Rod End Ball
Studs, Trailer Axle Wheel
Bearings, Wedge Brake
Hold-Down Clips, Wedge
Brake Shoe Contacts at
Anchors.
O-634-B Universal Joint Driveshaft Slip Yokes, 2 Lithium 12-Hydroxy b
Grease Driveshaft Splines, Driveshaft Stearate with
Universal Joints Molybdenum Disulfide
O-637 c Special Air Disc Brake Slide Pin, 1-1/2 Calcium b
Rust-Preventing Splines and Clevis Pins, Cam
Brake Grease Brake Camshaft Splines
O-645 Low-Temperature Air Disc Brake Caliper, 2 Synthetic Down to –65°F
Brake Grease Automatic Slack Adjuster, (–54°C)
Wedge Brake Components
O-647 Trailer Axle Bearing Trailer Axle Wheel Bearings 00 Synthetic b
Grease
O-661 High-Temperature Clutch Release Bearing 3 Lithium Complex b
Multi-Purpose Wheel
Bearing Grease
O-692 Automatic Slack Automatic Slack Adjuster 1&2 Lithium Base Down to –40°F
Adjuster Grease (–40°C)
a Grease recommendations are based on commercial products that have given satisfactory results in normal operation. However, there are
many proprietary grease products on the market which will perform satisfactorily and may be preferable because of supply problems,
common usage for other truck components, etc. When such products are recommended by reputable suppliers for the specific lubrication
of our components, Meritor has no objections, provided that these substitute products are equal to or better than Meritor
recommendations in lubrication properties, water resistance, corrosion protection, high and low temperature characteristics, oxidation
stability, shear stability, etc. All substitute products are subject to Meritor approval. For more information, contact an ArvinMeritor service
representative.
b Refer to the manufacturer’s specifications for the temperature service limits.
c Do not mix O-637 calcium-base, corrosion-control grease with other greases.
51
Section 13
List of Lubricants
Oil Lubricants
Outside Temperature
Meritor Military/SAE Oil °F °C

Specification Oil Typical Application Specifications Description Min. Max. Min. Max.
O-62 Petroleum Transfer Case — SAE 90 –10 None –12 None
Oil
O-63 Petroleum Transfer Case — SAE 140 –40 None – 4 None
Oil
O-76A Gear Oil Front Driving Axle, Front Driving MIL-PRF-2105-E GL-5 –10 None –12 None
Axle Wheel Bearings, Non-Driving and SAE 85W/140
Axle Wheel Bearings, Planetary SAE J2360
Axle, Rear Driving Axle, Trailer
Axle Wheel Bearings
O-76D Gear Oil Front Driving Axle, Front Driving GL-5 –15 None –26 None
Axle Wheel Bearings, Non-Driving SAE 80W/90
Axle Wheel Bearings, Planetary
Axle Wheel Bearings
O76E Gear Oil Front Driving Axle, Front Driving GL-5 –40 None –40 None
Axle Wheel Bearings
O-76J Gear Oil Front Driving Axle, Front Driving GL-5 –40 35 –40 2
Axle Wheel Bearings, Non-Driving SAE 75W
Axle Wheel Bearings
O-76L Gear Oil Front Driving Axle, Front Driving GL-5 –40 None –40 None
Axle Wheel Bearings
O-76M Full Rear Driving Axle, Trailer Axle GL-5 –40 None –40 None
Synthetic Wheel Bearings SAE 75W/140
Oil
O-76N Full Rear Driving Axle, Trailer Axle GL-5 –40 None –40 None
Synthetic Wheel Bearings SAE 75W/90
Oil
O-81 Full Transmission — SAE 50 –40 None –40 None
Synthetic
Oil
— Heavy Transmission MIL-L-2104 A.P.I. -CD, –10 None –12 None
Duty -E or -F* -CE, -SG,
Engine Oil -SH or -SJ;
SAE 50*
— Heavy Transmission A.P.I. -CD, –10 None –12 None
Duty -CE, -SG,
SAE 40*
— Heavy Transmission A.P.I. -CD, –15 10 –26 –12
Duty -CE, -SG,
SAE 30*
— Petroleum Transmission A.P.I.-GL-1; –10 None –12 None
Gear SAE 90
— Petroleum Transmission A.P.I.-GL-1; –15 None –26 None
Gear SAE 80
* Current designations are acceptable.
52
Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is
2135 West Maple Road subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise
Troy, MI 48084 USA the information presented or discontinue the production of parts described at any time.
800-535-5560
www.arvinmeritor.com Copyright 2001 Maintenance Manual 1
ArvinMeritor, Inc. Revised 02-01
All Rights Reserved Printed in the USA 16579/24240
1386D MM 4AA PD-1591 Maint Man 9/1/00 10:19 AM Page 1
Issued 8-95
$2.50
PD 1591 Series
Dry Disc Brake Calipers
Maintenance Manual No. 4AA
SERVICE NOTES
This Maintenance Manual describes the correct service and repair procedures for Meritor PD 1591 Series Dry
Disc Brake Calipers.
The information contained in this manual was current at the time of printing and is subject to change without
notice or liability.
You must follow your company safety procedures when you service or repair equipment. Be sure you understand
all the procedures and instructions before you begin work on the unit.
Meritor uses the following types of notes to give warning of possible safety problems and to give information that
will prevent damage to equipment.
! WARNING
A warning indicates procedures that must be followed exactly. Serious personal injury can occur if the
procedure is not followed.
! CAUTION
A caution indicates procedures that must be followed exactly. If the procedure is not followed, damage to
equipment or components can occur. Serious personal injury can also occur in addition to damaged or
malfunctioning equipment or components.
T TORQUE
This symbol is used to indicate fasteners that must be tightened to a specific torque value.
NOTE:
A note indicates an operation, procedure or instruction that is important for correct service. A note can
also give information that will make service quicker and easier.
Some procedures require the use of special tools for safe and correct service. Failure to use these special tools
when required, can cause injury to service personnel or damage to vehicle components.
! ASBESTOS AND NON-ASBESTOS FIBER WARNING
Current Meritor PD 1591 Series Dry Disc Brake Caliper linings do not use asbestos fibers. Some aftermarket
brake linings contain asbestos fiber, a cancer and lung disease hazard. Some brake linings contain non-
asbestos fibers whose long term effects are unknown.
Caution should be exercised in handling both asbestos and non-asbestos materials as described on page 2.
Base Model: PD 1591

ITEM DESCRIPTION QTY. *SEQUENCE NUMBERS
1 Housing 1 00100
**2 Plug As req’d. 00260
3 Brake Lining 2 00130
****4 Screw 2 00115
****5 Snap Fastener 2 00120
6 Back-Up Ring 1 00170
7 O-Ring Seal 1 00180
8 Piston 1 00110
11 Flat Washer 2 00200
12 Spring 8 00210
13 Spring Cap 1 00190
14 Washer 1 00220
15 Stud 1 00140
16 Nut 1 00230
1 2 17 Cotter Pin 1 00240
***18 Bleeder Screw As req’d. 00270
* Sequence numbers as they appear in the Bill of Material available from the
equipment manufacturer.
** 1/8-27 NPTE threaded inlet fitting and pipe plug bleeder.
*** .4374-20-UNF threaded inlet fitting and bleeder screw.
**** Lining retainers.
6
7
8
18 9
10
4
5
Lining
Retainers:
5 11
3
12
One Piece
Snap
4 13
17
14
Set Screw 15
& Adhesive
4 16
13
2.474" (62.84 mm)
DIAMETER
INNER & OUTER
PADS
Two Screws 0.438"

(11.13 mm)
Table of Contents
SUBJECT PAGE
! Asbestos and Non-Asbestos Fiber Warnings ....................................................................................2
1. Introduction
Description ......................................................................................................................................................3
Hydraulic Fluid.................................................................................................................................................3
Identification ....................................................................................................................................................4
2. Troubleshooting ............................................................................................................................................5
3. Removal and Installation

Release Brake Manually .................................................................................................................................6
With Caging Stud and Nut ............................................................................................................................6
Without Caging Stud and Nut .......................................................................................................................6
Remove Caliper...............................................................................................................................................7
Install Caliper...................................................................................................................................................7
Adjust Brake ....................................................................................................................................................7
With Caging Stud and Nut ............................................................................................................................8
Without Caging Stud and Nut .......................................................................................................................8
Bleed Brakes ...................................................................................................................................................9
4. Disassembly and Assembly

Disassemble Caliper .....................................................................................................................................10
Assemble Caliper ..........................................................................................................................................10
5. Inspecting, Cleaning and Testing

Periodic On-Vehicle Inspections ...................................................................................................................12
Inspect Linings ..............................................................................................................................................12
Inspect for Caliper Leaks...............................................................................................................................12
Inspect Disc...................................................................................................................................................12
Inspect Caliper Parts .....................................................................................................................................13
Cleaning ........................................................................................................................................................13
Corrosion Protection......................................................................................................................................13
Test Caliper ...................................................................................................................................................14
Adjusting Caliper off Vehicle .........................................................................................................................14
6. Specifications
Torque Chart .................................................................................................................................................16
Wear Dimensions ..........................................................................................................................................16
Total Lining-to-Disc Clearance ......................................................................................................................16
Hydraulic Fluid...............................................................................................................................................16
Page 1
Asbestos and Non-Asbestos Fibers
! ASBESTOS FIBER WARNING ! NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce The following procedures for servicing brakes are recommended to reduce
exposure to asbestos fiber dust, a cancer and lung disease hazard. Material exposure to non-asbestos fiber dust, a potential cancer and lung disease
Safety Data Sheets are available from Meritor. hazard. Material Safety Data Sheets are available from Meritor.
Hazard Summary Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. Exposure linings may contain one or more of a variety of ingredients, including glass fibers, mineral
to airborne asbestos dust can cause serious and possibly fatal diseases, including wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.
asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma Scientists disagree on the extent of the risks from exposure to these substances.
(a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
of lung cancer among persons who smoke and who are exposed to asbestos is much Silicosis gradually reduces lung capacity and efficiency and can result in serious
greater than the risk for non-smokers. Symptoms of these diseases may not become breathing difficulty. Some scientists believe other types of non-asbestos fibers, when
apparent for 15, 20 or more years after the first exposure to asbestos. inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber
Accordingly, workers must use caution to avoid creating and breathing dust when dust are known to the State of California to cause lung cancer. U.S. and international
servicing brakes. Specific recommended work practices for reducing exposure to agencies have also determined that dust from mineral wool, ceramic fibers and silica are
asbestos dust follow. Consult your employer for more details. potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to non-
asbestos dust follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons. OSHA has set a maximum
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average Recommended Work Practices
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
extent adherence to the maximum allowable exposure levels will eliminate the risk of from other operations to reduce risks to unprotected persons.
disease that can result from inhaling asbestos dust. OSHA requires that the following sign
be posted at the entrance to areas where exposures exceed either of the maximum 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
allowable levels: silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-
asbestos brake linings recommend that exposures to other ingredients found in non-
DANGER: ASBESTOS asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
CANCER AND LUNG DISEASE HAZARD Scientists disagree, however, to what extent adherence to these maximum allowable
AUTHORIZED PERSONNEL ONLY exposure levels will eliminate the risk of disease that can result from inhaling non-
RESPIRATORS AND PROTECTIVE CLOTHING asbestos dust.
ARE REQUIRED IN THIS AREA Therefore, wear respiratory protection at all times during brake servicing, beginning with
the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, manufacturer’s recommended maximum levels. Even when exposures are expected to
beginning with the removal of the wheels. be within the maximum allowable levels, wearing such a respirator at all times during
3. Procedures for Servicing Brakes. brake servicing will help minimize exposure.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. should be equipped with a HEPA vacuum and worker arm sleeves. With the
b. As an alternative procedure, use a catch basin with water and a biodegradable, non- enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the
phosphate, water-based detergent to wash the brake drum or rotor and other brake brake parts.
parts. The solution should be applied with low pressure to prevent dust from becoming b. As an alternative procedure, use a catch basin with water and a biodegradable, non-
airborne. Allow the solution to flow between the brake drum and the brake support or phosphate, water-based detergent to wash the brake drum or rotor and other brake
the brake rotor and caliper. The wheel hub and brake assembly components should be parts. The solution should be applied with low pressure to prevent dust from becoming
thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. airborne. Allow the solution to flow between the brake drum and the brake support or
Wipe the brake parts clean with a cloth. the brake rotor and caliper. The wheel hub and brake assembly components should be
c. If an enclosed vacuum system or brake washing equipment is not available, employers thoroughly wetted to suppress dust before the brake shoes or brake pads are
may adopt their own written procedures for servicing brakes, provided that the removed. Wipe the brake parts clean with a cloth.
exposure levels associated with the employer’s procedures do not exceed the levels c. If an enclosed vacuum system or brake washing equipment is not available, carefully
associated with the enclosed vacuum system or brake washing equipment. Consult clean the brake parts in the open air. Wet the parts with a solution applied with a
OSHA regulations for more details. pump-spray bottle that creates a fine mist. Use a solution containing water, and, if
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use available, a biodegradable, non-phosphate, water-based detergent. The wheel hub
with asbestos when grinding or machining brake linings. In addition, do such work in an and brake assembly components should be thoroughly wetted to suppress dust before
area with a local exhaust ventilation system equipped with a HEPA filter. the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic grinding or machining brake linings. In addition, do such work in an area with a local
solvents, flammable solvents, or solvents that can damage brake components as exhaust ventilation system equipped with a HEPA filter.
wetting agents. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you solvents, flammable solvents, or solvents that can damage brake components as
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA wetting agents.
filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
wet the filter with a fine mist of water and dispose of the used filter with care. or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or When you empty vacuum cleaners and handle used rags, wear a respirator equipped
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter
shake or use compressed air to remove dust from work clothes. with care.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
waste disposal. with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
Do not shake or use compressed air to remove dust from work clothes.
Regulatory Guidance 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations
States, are made to provide further guidance to employers and workers employed within on waste disposal.
the United States. Employers and workers employed outside of the United States should
consult the regulations that apply to them for further guidance. Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers employed
within the United States. Employers and workers employed outside of the United States
Page 2 should consult the regulations that apply to them for further guidance.
Section 1
Introduction
Description
The PD 1591 Series dry disc brake calipers are
! CAUTION
Application of the PD 1591 in a service situation
intended primarily for parking use on hydraulic brake where the disc is moving can damage the linings.
systems. All calipers are free floating and are Replace damaged linings.
mounted at the 10 o’clock through 2 o’clock position
over the brake disc. Figure 1.
Hydraulic Fluid
Figure 1
! WARNING
• Use only the type of hydraulic fluid specified by
the equipment manufacturer. Do not use or mix
different types of hydraulic fluid. The wrong
type of hydraulic fluid will damage the rubber
parts of the caliper and cause damage, loss of
braking and serious personal injury.
• Do not reuse hydraulic fluid. Used fluid can be

contaminated and can cause loss of braking
which could result in serious personal injury.
The brake system uses one of two types of fluid:
• Petroleum Base Hydraulic Fluid

Example: Meets MIL-H-5606 specifications.
• Non-Petroleum Base Hydraulic Fluid (Automotive

Brake Fluid)
Example: Glycol DOT 3, meets SAE J-1703
specifications.
For the type of fluid and specifications, see the

recommendations of the equipment manufacturer.
Hydraulic pressure keeps the PD 1591 brake
released while the vehicle is moving. After the vehicle
is stopped with service brakes, the PD 1591 parking
brake can be applied to keep the vehicle from
moving. When hydraulic pressure is released, the
springs inside the brake expand to force the piston
and linings against the disc. To release the brake,
hydraulic pressure must be applied to compress the
springs.
• A loss of hydraulic pressure to the brake will cause

it to automatically apply.
• The brake can be released manually if hydraulic

pressure is not available.
Page 3
Section 1
Introduction
IDENTIFICATION
Figure 2 Identification
Older assemblies can be identified by a seven-digit
assembly number marked on the side of the caliper.
More recent assemblies are identified by an
identification tag located on the outside of the caliper
housing. Figure 2.
! WARNING
Use only the specified components when you
assemble the caliper. Do not mix components
from other calipers. If you install the wrong
components, the caliper will not operate correctly
and may cause damage to the equipment. Use of
non-Meritor parts can cause damage and loss of
braking which could result in serious personal
injury.
Page 4
Section 2
Troubleshooting
CONDITION POSSIBLE CAUSES CORRECTION

Brake does 1. Damaged springs. 1. Replace springs.
not apply. 2. Piston cocked in bore. 2. Replace piston if large end diameter is worn to less
than 3.995 inches (101.47 mm) or small end diameter
is worn to less than 2.495 inches (63.37 mm).
Replace housing if large end of bore exceeds
4.003 inches (101.68 mm) or small end of bore
exceeds 2.505 inches (63.63 mm).
3. Caliper locked in released position. 3. Move stud nut to end of stud.
Brake does 1. Brake under-adjusted. 1. Adjust brake.
not hold. 2. Linings or disc excessively worn 2. Replace linings when thickness is less than
0.125 inch (3 mm) from piston or housing.
Replace disc when wear exceeds maximum of
0.06 inch (1.524 mm) per side.
3. Grease or oil on linings 3. Replace linings.
4. Damaged springs 4. Replace springs.
Brake does 1. Piston cocked in bore. 1. Replace piston if large end diameter is worn to less
not release. than 3.995 inches (101.47 mm) or small end diameter
exceeds 2.505 inches (63.63 mm).
2. Lack of hydraulic pressure. 2. Check for low fluid level, air in system, clogged
lines, fluid leaks,damaged seals or seals installed
backwards.
Damaged 1. Wrong type of fluid used in brake. 1. Drain, flush, refill with correct fluid. Replace O-rings
seals and back-up rings.
2. Spring cap turned while hydraulic 2. Replace O-rings and back-up rings.
pressure was applied to the brake.
Damaged 1. Brake under-adjusted. Springs 1. Replace springs. Adjust brake.
springs fatigued.
2. Lack of lubricant. 2. Replace springs. Apply anti-seize compound
to springs.
Damaged 1. Brake over-adjusted. Linings 1. Adjust brake. Replace parts as needed.
linings or dragging.
disc.
2. Caliper seized on slide pins. 2. Clean, repair or replace pins or caliper. Replace
linings.
3. Brake used for service or 3. Replace linings.
emergency.
4. Piston cocked in bore. 4. Replace piston if large end diameter is worn to less
than 3.995 inches (101.47 mm) or small end diameter
exceeds 2.505 inches (63.63 mm). Replace linings.
Page 5
Section 3
Removal and Installation
Release Brake Manually Hydraulic pressure not available:
! WARNING 2. Put blocks under the wheels not being serviced to

To prevent serious eye injury, always wear keep the vehicle from moving.
safe eye protection when doing maintenance
or service. 3. Remove the cotter pin from the stud nut. Tighten
the nut against the spring cap and continue
tightening to manually retract the piston and lining
! WARNING
from the disc. Stop tightening when the spring cap
starts to turn.
If it is necessary to raise the vehicle to service
the parking brake, support the vehicle with safety
stands. Do not work under a vehicle supported Release Brake Without Caging
only by jacks. Jacks can slip or fall over and
cause serious personal injury.
Stud and Nut
! WARNING 2. Put blocks under the wheels not being serviced to

keep the vehicle from moving.
Never try to turn or remove the spring cap while
hydraulic pressure is applied to the brake.
Turning the cap while pressure is applied can 3. Release the hydraulic pressure to the brake.
damage the O-ring seals and the spring cap
threads. Removing the cap can cause serious 4. Use an Allen-head wrench to loosen the spring
personal injury by the sudden release of cap until all spring pressure is released and the
hydraulic pressure. Make sure the nut is at the disc rotates freely.
end of the stud before you put the vehicle in
service. If the nut is tightened against the spring NOTE:
cap, the brake cannot be applied and serious Loosening the spring cap does not retract the
personal injury can result. piston and lining. It only releases the spring
pressure against the piston and lining.
Release Brake with Caging
Stud and Nut
Hydraulic pressure available:
2. Put blocks under the wheels not being serviced to

keep the vehicle from moving.
3. Apply hydraulic pressure to release the brake.
4. To lock the brake in the released position, remove

the cotter pin from the stud nut and tighten the nut
until it touches the spring cap
NOTE:
The manual release stud and nut have left-hand
threads.
5. Release the hydraulic pressure.
Page 6
Section 3
Remove Caliper Adjust Brake

1. Manually release the brake using the procedures Adjust the brake to provide the lining to disc
described earlier in this section. clearance specified by Meritor or by the equipment
manufacturer.
2. Disconnect the brake line from the caliper inlet.
Put plugs in the brake line and the inlet to prevent Total lining to disc clearance recommended
contamination of the system. by Meritor:
3. Remove the centering device if one is assembled Maximum: 0.100 inch (2.54mm)
on the end of the caliper. Minimum: 0.020 inch (0.5mm)
4. Remove the caliper slide pin fasteners. Remove • If the brake has too little clearance, it may not
slide pins. Remove the caliper from the disc. release properly. This will cause the lining to drag
and damage both the linings and the disc.
Install Caliper
• If there is too much clearance, the clamping force
NOTE: applied to the disc will be reduced. This can cause
Make sure the caliper has been tested before you the brake to slip after it is applied. Too much
do the following steps. See “Testing the Caliper” clearance also puts extra stress on the springs in
in Section 5. Make sure all the steps listed below the caliper. This can cause premature spring wear
have been done. and damage.
1. Check the slide pins and the caliper holes for The brake must have less than 0.100 inch (2.54mm)
nicks, burrs or other damage that could keep the total lining to disc clearance when the brake is
caliper from sliding along the pins. Repair or released. Check and adjust the brake until the correct
replace components as necessary. clearance is achieved.
2. Apply a graphite base anti-seize compound to

slide pin O.D. ! WARNING
Never try to turn or remove the spring cap while
3. If necessary, remove the plugs from the brake line hydraulic pressure is applied to the brake.
and the caliper inlet and connect the line to the Turning the cap while pressure is applied can
inlet. damage the O-ring seals and the spring cap
threads. Removing the cap can cause serious
4. Remove all air from the brake hydraulic system. personal injury by the sudden release of
See “Bleed Brakes” on page 9. hydraulic pressure.
5. Apply hydraulic pressure to retract the piston and

provide clearance to install the caliper over the
disc. Install the pins and fasteners to hold the
caliper to the mounting bracket. Tighten the
fasteners to the torque specified by the vehicle
manufacturer.
T
6. Check for the correct lining clearance while the
brake is released. If necessary, adjust the brake
using the procedure later in this section.
7. Make sure the brake slides easily on the slide pins.
8. Reinstall the centering device if one was removed

from the end of the caliper.
Page 7
Section 3
Adjust Brake with Caging Stud 6. Loosen the nut, move it to the end of the stud and
install the cotter pin to hold the nut in place.
and Nut
7. Make sure the brake slides easily on the slide pins.
1. Apply hydraulic pressure to release the brake. 8. Reinstall the centering device if one was removed
from the end of the caliper during disassembly.
2. To lock the brake in the released position, remove
the cotter pin from the stud nut and tighten the nut
until it touches the spring cap.
Adjust Brake without Caging
Stud and Nut
NOTE:
The manual release stud and nut have left- 1. Apply hydraulic pressure to release the brake.
hand threads.
2. Measure the clearance between the linings and
3. Release the hydraulic pressure. the disc. The clearance must be within the
manufacturer's specification.
4. Use a spanner wrench to turn the spring cap to
provide the lining to disc clearance that is NOTE:
specified by the equipment manufacturer. A If equipment manufacturer specifications are not
quarter turn of the spring cap in either direction available, Meritor recommends 0.080 inch
changes the total clearance by 0.016 inch (2.0 mm) total lining to disc clearance (1-1/4 turns
(0.4 mm). Figure 3. back off) on Meritor axles.
Figure 3 3. To adjust the clearance:
3.5 inches A. Release the hydraulic pressure to the brake.

(88.9 mm)
B. Use an Allen wrench to tighten or loosen the
spring cap to adjust the clearance. A quarter
turn of the spring cap in either direction
changes the total clearance by 0.016 inch
0.3 inch (7.62 mm) Diameter (0.4 mm).
SPANNER WRENCH 4. Repeat steps 1-3 until the clearance is correct.
NOTE:
If equipment manufacturer specifications are not
available, Meritor recommends 0.080 inch
(2.0 mm) total lining to disc clearance (1-1/4 turns
back off) on Meritor axles.
5. Apply hydraulic pressure to the brake to

overcome the spring pressure.
! WARNING
Make sure the nut is at the end of the stud before
you put the vehicle in service. If the nut is
tightened against the spring cap, the brake
cannot be applied and serious personal injury
could result.
Page 8
Section 3
Bleed Brakes For full hydraulic systems:
Slowly apply low hydraulic pressure to the brake.

! WARNING Loosen the bleeder screw. Continue to apply
pressure until no air bubbles appear in the
When you loosen any brake system hydraulic
connection, you must bleed the brakes to remove container of fluid. Tighten the bleeder screw 15-
all air from the system. Air can prevent hydraulic 20 lb-ft (20-27 N.m), then release the pressure to
pressure from applying the brakes properly the brake.
which could increase stopping distances and
T
result in serious personal injury.
For air/hydraulic or mechanical actuator
systems:
NOTE:
The PD 1591 Series Dry Disc Brake Calipers are Apply the brake pedal, then loosen the bleeder
designed to bleed properly when installed at the screw.Tighten the bleeder screw 15-20 lb-ft (20-
10 o’clock through 2 o’clock position. 27 N.m) before you release the brake pedal so
that air is not pulled back into the system. Repeat
Always start at the point in the system that is farthest this procedure until no air bubbles appear in the
from the master cylinder and work back toward the container of fluid when you apply the brake
master cylinder. Bleed every bleeder screw on every pedal.
caliper at every brake position. When you complete a
bleeder screw, go to the next closest bleeder screw
T
on the same caliper. When you complete a caliper, 4. Check for fluid leaks.
go to the next closest caliper at the same position.
When you complete a position, go to the furthest
bleeder screw on the next closest position.
1. Make sure that the master cylinder is filled to the

specified level with the type of hydraulic fluid
specified by the equipment manufacturer. Keep
the master cylinder filled during bleeding so that
you do not pull air into the system through the
master cylinder. Make sure the master cylinder is
filled when you are done bleeding the system.
2. Put a clear tube on the bleeder screw. Submerge

the other end of the tube in a clear container of
the specified fluid.
3. Bleed brakes.
Page 9
Section 4
Disassembly and Assembly
Disassemble Caliper
! CAUTION
Use a wooden tool and a vise with soft jaws in
! WARNING steps 9 and 10 so that you do not damage the
housing or piston.
To prevent serious eye injury, always wear
or service. 9. Remove and discard the O-rings and back-up
rings from the piston and housing.
! WARNING
10. If necessary, hold the piston in a vise with soft
jaws and remove the stud from the piston.
If it is necessary to raise the vehicle to service
the parking brake, support the vehicle with safety NOTE:
stands. Do not work under a vehicle supported The piston has right-hand threads.
only by jacks. Jacks can slip or fall over and
1. Remove the inlet fitting and O-ring from the Assemble Caliper
housing. Drain and discard the fluid. Put a plug in
the inlet to prevent contamination of the housing. ! WARNING
2. Linings are fastened with either screws, set Use only the specified components when you
screws with adhesive, or snaps. Remove assemble the caliper. Do not mix components
fastener. Then remove linings by using a pry bar from the other calipers. If you install the wrong
between the lining and the piston or housing. components, the caliper will not operate correctly
and can cause damage to the equipment. Use of
3. Use isopropyl alcohol to clean the outside of the non-Meritor parts can cause damage and loss of
housing. Dry the housing with a clean cloth. braking which could result in serious personal
injury.
4. If necessary, remove the pin and nut from the
manual release stud. Do not remove the washer
from around the stud unless the washer is loose ! CAUTION
or damaged. Use a vise with soft jaws in step 1 so that you do
not damage the piston.
NOTE:
The manual release stud and nut have left-
hand threads. ! WARNING
5. Use a spanner wrench or Allen-head wrench as To avoid serious personal injury, be careful when
required to remove the spring cap. using Loctite. Follow the manufacturer’s
instructions for safe use to prevent irritation to
6. Remove the washers and springs from inside the eyes and skin. Wash after contact. If Loctite gets
housing. in the eyes , flush the eyes with water for 15
minutes. Have eyes checked by a doctor.
7. Remove the piston through the hole for the spring
cap. 1. If necessary, install the stud in the piston. Hold
the piston in a vise with soft jaws. Apply Loctite
8. If necessary, remove the set screws or snaps if 277 or equivalent to the threads in the piston.
either hold the linings in place on the piston and
housing. 2. Lubricate the following components with silicone
grease like Dow Corning DC4 or with the type of
hydraulic fluid used in the system:
• Piston outer diameter and ring groove

• Housing bore and ring groove
• New O-rings and back-up rings
Page 10
Section 4
Disassembly and Assembly
3. Install a new O-ring and a new back-up ring in Linings fastened with screws:
both the piston groove and the housing groove so
that the curved side, if applicable, of the back-up A. Apply Loctite 271, or equivalent, to the threads of
ring is against each O-ring. On the piston, the the screws.
O-ring goes closest to the disc. In the housing,
the O-ring goes closest to the spring cap. Figure 4. B. Attach linings to the piston and housing. Torque
screws to 45-55 lb-in (5-6 N•m).
Figure 4 O-Ring Backup Ring T
O-Ring
Backup Ring ! WARNING
Replace brake linings when contaminated with
grease or hydraulic fluid. Brake linings
contaminated with grease or hydraulic fluid can
cause loss of braking and serious personal
Spring injury.
Retaining
Cap 5. Install the piston and lining through the hole for
the spring cap. Push pistons through seals with a
steady force. Do not get grease or hydraulic fluid
Piston on linings.
Housing
6. Apply a graphite-base anti-seize compound to all
Stud Nut surfaces of the springs and to the housing threads
for the spring cap.
7. Install the washers and springs on the spring cap

4. Install the linings: as shown in Figure 5.
Linings fastened with adhesive and set screws:

Figure 5
Flat Washer
A. Apply Loctite 271, or equivalent, to the threads of
the set screws.
2 Springs, Cup Up
B. Install the set screws in the piston and the housing. 2 Springs, Cup Down
The tops of the screws must be 0.12 inch (3 mm)
from the surfaces of the piston and housing. 2 Springs, Cup Up
SPRING 2 Springs, Cup Down
C. Apply 3M Super 77 Spray Adhesive, or equivalent, CAP
to the linings where they touch the piston and the
housing. Follow the manufacturer's instructions for Flat Washer
use of the adhesive.
D. Install the linings on the piston and the housing. 8. Install the spring cap, washers and springs into
the housing. Tighten the spring cap until the top of
Linings fastened with one piece snaps: the spring cap is even with the top of the housing.
A. Apply Loctite 271, or equivalent, to the threads of 9. If necessary, install the washer around the stud.
the snap fastener screws. Attach the washer to the spring cap with 3M
Super 77 Spray Adhesive, or equivalent. Follow
B. Screw the snap onto the piston and the housing. the manufacturer's instructions for use of the
Torque to 45-55 lb-in (5-6 N•m). adhesive.
T
C. Align the lining pins with the 10. If necessary, install the stud nut at the end of the
holes and engage the snaps in the linings with the stud and fasten it in place with the pin. Figure 4.
snaps on the piston and the housing.
Page 11
Section 5
Inspecting, Cleaning and Testing
Periodic On-Vehicle Inspections • Bleeder Screw. If fluid leaks at the bleeder screw,
tighten the bleeder screw. If the leak continues,
replace the bleeder screw.
! WARNING • Inlet Fitting. If fluid leaks at the inlet fitting, tighten
To prevent serious eye injury, always wear the fitting. If the leak continues, replace the O-ring.
or service.
Inspect Disc
Inspect the caliper, linings and disc as specified by
If the disc is worn beyond the wear limits, replace the
the maintenance schedule of the equipment
disc. Figure 6. See the specifications of the
manufacturer.
equipment manufacturer for wear limits that may be
different from those shown below.
Inspect Linings
Inspect the linings for: Figure 6 MINIMUM DISC
THICKNESS
• Lining Wear. Replace the linings when the
thickness of the lining is less than 0.125 inch
(3 mm) from the piston or housing. MAXIMUM MAXIMUM DISC
DISC WEAR WEAR
• Lining Wear Not Even. Replace the linings if the
thickness of the two linings is different. Check the ORIGINAL
piston for correct operation. Replace the piston DISC THICKNESS
and/or housing if the piston is cocked in the bore.
Refer to “Troubleshooting” for piston and TYPICAL SECTION THROUGH DISC SHOWING
housing wear limits. Check that the disc surface RECOMMENDED MAXIMUM WEAR LIMITS
is flat and parallel to the linings. Check that the
brake slides easily on the slide pins. ORIGINAL DISC MAXIMUM MIN. DISC
THICKNESS DISC WEAR THICKNESS
• Oil or Grease on Linings. Replace the linings. (EACH SIDE)
0.5 inch 0.06 inch 0.38 inch

• Cracks on Linings. Replace linings that have
(12.7 mm) (1.5 mm) (9.7 mm)
larger or deeper cracks than the small, tight cracks
on the surface of the lining which are normal when 0.79 inch 0.06 inch 0.67 inch
the caliper is used under high temperature (20.0 mm) (1.5 mm) (17.0 mm)
conditions. These cracks are referred to as “Heat
Check Cracks”.
! CAUTION
Always replace both linings. If only one lining is
replaced, possible disc damage can occur.
Inspect for Caliper Leaks

Inspect the following areas for fluid leaks:
• Piston or Spring Cap. If fluid leaks at either the

piston or the spring cap, disassemble the caliper.
Inspect the piston, the bore, the O-rings and the
back-up rings. Service as necessary.
Page 12
Section 5
Inspect Caliper Parts

1. Inspect the piston, housing bore and O-ring
! CAUTION
Use only solvent cleaners to clean ground or
grooves for scratches or corrosion. Remove small polished metal parts. Hot solution tanks or water
scratches or corrosion with fine emery cloth. and alkaline solutions will damage these parts.
Replace the component if there are large Isopropyl alcohol, kerosene or diesel fuel can be
scratches or large amounts of corrosion. used for this purpose.
2. Measure the diameter of the piston at the large
end and the small end. Replace the piston if the
• Use solvent cleaners to clean all metal parts that
have ground or polished surfaces. Examples of
large end is worn to less than 3.995 inches ground or polished parts are the piston and the
(101.47 mm) or the small end is worn to less than piston bore in the caliper.
2.495 inches (63.37 mm).
3. Measure the diameter of the housing bore at both

• Metal parts with rough surfaces can be cleaned with
solvent cleaners or with alkaline solutions.
ends. Replace the housing if the large end
exceeds 4.003 inch (101.68 mm) or the small end
exceeds 2.505 inch (63.63 mm).
• Use a wire brush to clean the threads of fasteners
and fittings.
4. Inspect the springs for wear and damage.
Replace worn or damaged springs as a set.
• Use soap and water to clean parts that are not made
of metal.
5. Inspect the linings as described earlier in this
section. • Scrape away build-ups of mud and dirt on the
linings. Replace all linings contaminated with oil
or grease.
6. Inspect the threads of the spring cap and the
housing for damage. If the damage cannot be
repaired, replace the cap or housing. • Immediately after cleaning, dry all parts with clean
paper or rags.
7. If equipped, inspect the threads on the stud in the
piston. Replace damaged studs. Corrosion Protection
8. If equipped, inspect the lining snap fasteners for Apply brake system fluid to the cleaned and dried
wear or damage. Replace worn or damaged parts that are not damaged and are to be
fasteners. immediately assembled. Do NOT apply fluid to the
brake linings or the disc.
Cleaning If parts are to be stored, apply a special material that

prevents corrosion to all surfaces. Do NOT apply the
material to the brake linings or the disc. Store the
! WARNING parts inside special paper or other material that
prevents corrosion.
If you use cleaning solvents, hot solution tanks
or alkaline solutions incorrectly, serious personal
injury can occur. To prevent serious personal
injury, follow the instructions supplied by the
manufacturer of these products. Do NOT use
gasoline to clean parts. Gasoline can explode
and cause serious personal injury.
Page 13
Section 5
Test Caliper Adjusting Caliper off Vehicle

NOTE: 1. Loosen the spring cap to give enough clearance
The caliper should always be tested after it is and then install the caliper onto the disc or
assembled and before it is put into service. The spacer. The chart below shows the specified
tests can be done on a bench or on the vehicle thickness for a new disc for each brake model.
while you install the caliper. To avoid extra work
while installing the caliper: 2. Tighten the spring cap until both linings just
contact the disc or spacer.
• Do the tests on the vehicle while you install the
caliper, if possible. NOTE:
If you use a spacer of the wrong thickness, you will
• If you bench test, use a spacer the same have to adjust the lining clearance after you install
thickness as the disc where the caliper will be the caliper.
installed.
• If caliper is already adjusted, proceed to

step 4.
Caliper Spec. No. New Disc/Spacer *No. of Turns **Brake Release Pressure
PD1591-9 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-10 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-11 0.50 in. (12.7 mm) 5.50 2100 psi (145 bar))
PD1591-12 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-13 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-13-3 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD1591-13-4 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-13-5 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD1591-14-1 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD1591-15-1 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-15-2 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-15-3 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-15-4 0.50 in. (12.7 mm) 5.50 2100 psi (145 bar)
PD1591-15-5 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-15-6 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-15-7 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-16-1 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
PD1591-17-1 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD1591-17-2 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD1591-18-1 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD1591-19-1 0.79 in. (20.1 mm) 5.75 1500 psi (104 bar)
PD 1591-20-1 0.50 in. (12.7 mm) 5.75 1500 psi (104 bar)
* On Meritor axles, or the number of turns specified by the equipment manufacturer.
** Or the pressure specified by the equipment manufacturer.
Page 14
Section 5
3. Remove the caliper from the disc or spacer and
then tighten the spring cap the additional number
of turns specified in the chart. Doing this
determines three important, interrelated items:
• The spring tension that will produce the correct

clamp force on the disc when the brake is
applied.
• The hydraulic pressure that will be needed to

release the brake.
• The lining clearance when the brake is

released.
! WARNING
• Use only the type of hydraulic fluid specified by
different types of hydraulic fluid. The wrong
hydraulic fluid will damage the rubber parts of
the caliper and cause damage, loss of braking
and serious personal injury.
• Do not reuse hydraulic fluid. Used fluid that is

removed can be contaminated and can cause
loss of braking which could result in serious
personal injury.
4. Connect the hydraulic line to the caliper and bleed

all air from the caliper. Refer to page 9.
NOTE:
If you disconnect the hydraulic line after bleeding
the caliper, you must bleed the caliper again
when you install it.
5. After bleeding, apply hydraulic pressure as

specified in chart, to make sure that the brake will
release when required. If the piston does not
retract into the housing at the specified pressure,
readjust the brake. Refer to section 3.
6. Release the hydraulic pressure and make sure

the springs expand and force the piston out to
apply the brake. If not, disassemble the caliper,
find and correct the cause of the problem.
7. To check for leaks, apply and release the

hydraulic pressure three times. If there are any
leaks, disassemble and repair or replace
components as necessary.
8. To complete installation of the caliper, refer to

page 7.
Page 15
Section 6
Specifications
Torque Chart
Lining snap fastener screws..................................................45-55 lb-in (5-6 N•m)
Caliper mounting bracket fasteners ......................................Vehicle manufacturer’s
specification
Bleeder screws......................................................................100-120 lb-in (11.3-13.6 N•m)
Wear Dimensions*
Replace Disc:
– Wear exceeds maximum of 0.06 in. (1.524 mm) per side
Replace Housing:
– Large end of bore diameter exceeds 4.003 in. (101.68 mm)
– Small end of bore diameter exceeds 2.505 in. (63.63 mm)
Replace Linings:
– Thickness is less than 0.125 in. (3 mm) from piston or housing
Replace Piston:
– Large end diameter worn to less than 3.995 in. (101.47 mm)
– Small end diameter worn to less than 2.495 in. (63.37 mm)
*See specifications of vehicle manufacturer for wear limits that may be different from those shown above.
Total Lining-to-Disc Clearance

Maximum: 0.100 inch (2.54 mm)
Minimum: 0.020 inch (0.5 mm)
Hydraulic Fluid*
– Petroleum Base Hydraulic Fluid (Mineral Oil). Example: Meets MIL-H-5606 specifications.
– Non-Petroleum Base Hydraulic Fluid (Automotive Brake Fluid). Example: Glycol DOT 3,
meets SAE J-1703 specifications.
*See fluid and specification recommendations of equipment manufacturer.
Page 16
NOTES
Page 17
NOTES
Page 18
NOTE:
For more information on parts and kits, see Meritor publication PB-9201, Hydraulic Dry Disc Brake
Parts. This catalog is available from:
Meritor Literature Distribution Center

c/o Vispac, Inc.
35000 Industrial Road
Livonia, MI 48150
Or call (800) 535-5560

1386D MM 4AA PD-1591 Maint Man 9/1/00 10:19 AM Page a
Information contained in this publication was in effect at the time the publication was approved for printing and is
subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
information presented or discontinue the production of parts described at any time.
Meritor Heavy Vehicle Systems, LLC Meritor do Brasil Ltda. Meritor Heavy Vehicle Systems Saint-Etienne S.A.
2135 West Maple Road Av. João Batista, 824 4, Rue Jean Servanton
Troy, MI 48084 U.S.A. 06097-900 Osasco-SP Boite Postale 656
248-435-1085 BRAZIL 42042 Saint Etienne Cedex 1 Maintenance Manual No. 4AA
800-535-5560 (North America only) (55-11) 7084-6510 FRANCE Issued 8-95
www.meritorauto.com Fax: (55-11) 7084-6600 (33) 477.92.88.00 Fax: (33) 477.92.88.93 47865/24240
© Copyright 1995 Meritor Automotive, Inc. All Rights Reserved Printed in the U.S.A.
1386D MM 4AA PD-1591 Maint Man 9/1/00 10:19 AM Page b
MM4AA-95195
Issued 9-95
Update For Maintenance

Manual No. 4AA
“PD 1591 Series Dry Disc
Brake Calipers” Issued 8/95
This Maintenance Manual No. 4AA Update corrects 2. Observe the following warning before Step 1 of
two of the sequence numbers listed in the parts Bleeding Brakes, page 9:
callout chart for the exploded view of Base Model
PD 1591, first page of manual. ! WARNING
The Update also supplies warning information and
corrects the bleeder screw torque value on page 9. • Use only the type of hydraulic fluid specified by
different types of hydraulic fluid. The wrong type
of hydraulic fluid will damage the rubber parts of
1. Observe the following changes in Base Model the caliper and cause damage, loss of braking
PD 1591 sequence numbers, first page: and serious personal injury.
ITEM DESCRIPTION QTY. *SEQUENCE NUMBERS
1 Housing 1 00100 • Do not reuse hydraulic fluid. Used fluid can be
**2 Plug As req’d. 00270 contaminated and can cause loss of braking
3 Brake Lining 2 00130 which could result in serious personal injury.
****4 Screw 2 00115
****5 Snap Fastener 2 00120 3. Observe the following torque value changes in
6 Back-Up Ring 1 00170 Step 3, page 9:
8 Piston 1 00110 For full hydraulic systems:
Slowly apply low hydraulic pressure to the brake.
Loosen bleeder screw. Continue to apply pressure
11 Flat Washer 2 00200
until no air bubbles appear in the container of fluid.
12 Spring 8 00210
Tighten the bleeder screw 100-120 lb-in (11.3-13.6
13 Spring Cap 1 00190
N.m), then release the pressure to the brake.
14
15
Washer
Stud
1
1
00220
00140
T
16 Nut 1 00230
For air/hydraulic or mechanical actuator systems:
17 Cotter Pin 1 00240
***18 Bleeder Screw As req’d. 00250 Apply the brake pedal, then loosen the bleeder
* Sequence numbers as they appear in the Bill of Material available from the screw. Tighten the bleeder screw 100-120 lb-in
equipment manufacturer.
** 1/8-27 NPTE threaded inlet lifting and pipe plug bleeder. (11.3-13.6 N.m) before you release the brake
*** .4374-20-UNF threaded inlet lifting and bleeder screw. pedal so that air is not pulled back into the system.
**** Lining retainers.
Repeat this procedure until no air bubbles appear
Arrows denote change in the container of fluid when you apply the brake
pedal.
T
Automotive
MM 4AA-95195 Issued 9/95 Page 1

Printed in U.S.A. © Copyright 1995 Rockwell International, Inc.
Revised 10-00
$2.50
Single Reduction
Differential Carriers
Maintenance Manual 5
Standard Carriers Excluding RS and

Including: Single Axles, RT Series (Rear Only),
Rear of Tandem Axles, Single Reduction Axles
Front Drive Steering and RF Series Front
Axles Drive Axles
Service Notes
Before You Begin Access Information on

This manual provides instructions for Meritor’s ArvinMeritor’s Web Site
early production non-RF, -RS or -RT Series axles. Additional maintenance and service information
Before you begin procedures: for ArvinMeritor’s commercial vehicle systems
1. Read and understand all instructions an component lineup is also available at
procedures before you begin to service www.arvinmeritor.com.
components. To access information, click on Products &
2. Read and observe all Caution and Warning Services/Tech Library Icon/HVS Publications.
safety alerts that precede instructions or The screen will display an index of publications
procedures you will perform. These alerts help by type.
to avoid damage to components, serious
personal injury, or both. Additional Information
3. Follow your company’s maintenance and For complete maintenance and service procedures
service, installation, and diagnostics for all single reduction differential carriers, call
guidelines. ArvinMeritor’s Customer Service Center at
4. Use special tools when required to help avoid 800-535-5560 to order the following publications.
serious personal injury and damage to r Traction Controls package contains two videos —
components. Splitting the Difference T-87127V and
Driver-Controlled Full Locking Main Differential
Safety Alerts, Torque Symbol T-9007V. $50. Order T-95125V for this package or
and Notes each video is available individually as well.
r Technical Electronic Library on CD. Features
product and service information on most
A Warning alerts you to an
instruction or procedure ArvinMeritor, ZF Meritor and Meritor WABCO
WARNING components. $20. Order TP-9853.
that you must follow
exactly to avoid serious
personal injury and
damage to components.
A Caution alerts you to an
CAUTION instruction or procedure
exactly to avoid damage to
components and possible
serious injury.
A torque symbol alerts you
T to tighten fasteners to a
specified torque value.
NOTE A Note provides
information or suggestions
that help you correctly
service a component.
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Standard Single Reduction Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Axle Models Covered in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 2: Disassembly
Remove Differential Carrier from Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Brass Drift Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air Hammer Vibration Method
Carrier Removal from Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Remove the Differential and Ring Gear from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Disassemble the Differential and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Remove the Drive Pinion and Bearing Cage from Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Disassemble the Drive Pinion and Bearing Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Section 3: Preparing the Parts for Assembly
Cleaning Ground and Polished Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Cleaning Rough Parts
Cleaning Axle Assemblies
Drying Parts After Cleaning
Preventing Corrosion on Cleaned Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Inspecting Parts
Repair or Replacement of Parts, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Repair Axle by Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Bending or Straightening Drive Axle Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Removing Dri-Loc Fasteners
Section 4: General Information
Installing Fasteners with Pre-Applied Adhesive, Meritor Liquid Adhesive 2297-C-7049,
Loctite 680 Liquid Adhesive or Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Installing New Fasteners with Pre-applied Adhesive Patches
Installing Original or Used Fasteners Using Meritor Liquid Adhesive 2297-C-7049 or
Loctite 680 or Equivalent
Application of Meritor Adhesive 2297-T-4180 in Bearing Bores for the Differential
Application of Three Bond 1216 or Equivalent Silicone Gasket Material . . . . . . . . . . . . . . . . . . . . . . . .27
Installing Tight Fit Yokes and POSE™ Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
General Yoke and U-Joint Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Gear Set Information (Drive Pinion and Ring Gear Marks)
Section 5: Assembly
Assemble the Drive Pinion, Bearings and Bearing Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Adjusting Preload of Pinion Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Adjusting Shim Pack Thickness for the Pinion Cage (Depth of Pinion) . . . . . . . . . . . . . . . . . . . . . . . . . .41
Installing the Drive Pinion, Bearing Cage and Shim Pack into the Carrier . . . . . . . . . . . . . . . . . . . . . . .43
Installing Tight Fit Yokes and POSE™ Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Assemble the Main Differential and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Inspecting the Rotating Resistance of the Differential Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Install the Differential and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Adjust Preload of Differential Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Method 1
Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Inspect Runout of Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Ring Gear Backlash Adjustment
Inspect Tooth Contact Patterns of the Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Install and Adjust the Thrust Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Install Differential Carrier into Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Straight Holes, Nuts and Hardened Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Tapered Dowel, Hardened Washer and Hardened Nut
Table of Contents
Section 6: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Axle Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Section 7: Fastener Torque Information
Torque Values for Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
General Information
American Standard Fasteners
Metric Fasteners
Section 8: Adjustments and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Section 9: Vehicle Towing Instructions (Non-DCDL)
Before Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
After Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Exploded View
Exploded View — Legend
1 Nut — Drive Pinion 26 Washers* — Lock Plate

2 Washer — Drive Pinion* 27 Capscrews* — Lock Plate*
3 Input Yoke* or Flange* 28 Adjusting Ring — R.H.
4 Deflector 29 Plug* — Oil Fill Hole (carrier)
5 Oil Seal 30 Washer* — Capscrew/Plug*
6 Capscrew — Bearing Cage 31 Capscrew/Plug — Sensor Hole
7 Washer 32 Thrust Block*
8 Bearing Cone — Pinion Outer 33 Washers* — Differential Case
9 Bearing Cup — Pinion Outer 34 Nuts* — Differential Case
10 Bearing Cage — Drive Pinion 35 Bearing Cup — Differential L.H.
11 Shims 36 Bearing Cone — Differential L.H.

37 Nuts* — Ring Gear and Case Half
12 Spacer— Pinion Bearing
38 Case Half — Flange
13 Bearing Cup — Pinion Inner
39 Ring Gear
14 Bearing Cone — Pinion Inner
40 Bolts* or Rivets* — Ring Gear and
15 Drive Pinion
Case Half
16 Spigot Bearing
41 Side Gears —Differential
16A Snap Ring
42 Thrust Washers — Differential Pinion
17 Carrier
43 Pinions — Differential
18 Thrust Screw*
44 Spider — Differential
19 Jam Nut* — Thrust Screw*
45 Thrust Washers — Differential Side
20 Adjusting Ring — L.H. Gear
21 Cotter* or Pin* 46 Capscrews — Differential Case
22 Caps — Differential Bearing 47 Bolts* — Differential Case
23 Washers 48 Bearing Cup — Differential R.H.
24 Capscrews — Differential Bearing Cap 49 Bearing Cone — Differential R.H.
25 Lock Plate* — Adjusting Ring 50 Case Half — Plain
* Some Meritor carriers do not have these described parts.
NoSPIN® is a registered trademark of Tractech, a division of Dyneer Corp.
1
Exploded View
Single Reduction Differential Carrier
2
Exploded View
3
Section 1
Introduction
Standard Single The single reduction carrier models are front

Section 1Introduction
mounted into the axle housing. These carriers

Reduction Carriers have a hypoid drive pinion and ring gear set and
bevel gears in the differential assembly.
NOTE: For carriers with a differential lock, refer A straight roller bearing (spigot) is mounted on the
to Maintenance Manual 5A. head of the drive pinion. All other bearings in the
carrier are tapered roller bearings.
Meritor single reduction standard carriers,
Figure 1.1, are used in most Meritor single axles, When the carrier operates, there is normal
rear of tandem axles and front drive steering axles. differential action between the wheels all the time.
Figure 1.1
1 TAPERED ROLLER BEARINGS 5 BEVEL DIFFERENTIAL GEARS

2 CARRIER 6 HOUSING
3 STRAIGHT ROLLER BEARING 7 TAPERED ROLLER BEARING
4 TAPERED ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEAR
4
Section 1
Introduction
Axle Models Covered in This Manual

The following table lists all axle models covered in
this manual.
Single Drive Axles:

A-150 E-100 F-140 H-172 Q-100 R-163
B-100 E-105 G-161 L-100 Q-145 R-170
B-140 E-150 H-100 L-140 RL-170 S-170
For All RS & RT
B-150 F-100 H-140 L-155 R-100 U-140
Single Reduction
C-100 F-106 H-150 L-172 R-140 W-170 Axle Model Series,
Refer to
D-100 F-120 H-162 M-172 R-155
Maintenance
D-140 F-121 H-170 QT-140 R-160 Manual 5A.
Rear Axle of Tandem Axles:
SDHD SL-100 SQHD SSHD SU-170

SFHD SLHD SR-170 ST-170 SUHD
SHHD SQ-100 SRHD STHD SW-170
Front Drive Steering Axles:
FDS-75 FDS-85 FDS-93 FDS-1807 FDS-2100 FDS-2107 FDS-2111

FDS-78 FDS-90 FDS-1600 FDS-1808 FDS-2101 FDS-2110 FDS-2117
5
Section 2
Disassembly
Remove Differential Carrier

Section 2Disassembly
from Axle Housing
WARNING
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance
or service.
1. Raise the end of vehicle where the axle is
mounted. Use a jack or other lifting tool, and
place safety stands under each side of the axle.
Figure 2.1.
WARNING
work under a vehicle supported only by jacks.
Jacks can slip or fall over. Serious personal injury
can result.
2. Place jack stands under each spring seat of the
axle to hold vehicle in the raised position.
Figure 2.1.
Figure 2.1
1 SAFETY STANDS
6
Section 2
Disassembly
3. Remove the plug from bottom of axle housing 6. Loosen the tapered dowels* if applicable, in
and drain lubricant from the assembly. the axle flanges of both axle shafts using either
the Brass Drift or the Air Hammer Vibration
4. Disconnect the driveline universal joint from method.
the pinion input yoke or flange on the carrier.
Figure 2.2.
5. Remove the capscrews* and washers or stud
nuts* and washers from the flanges of both *Some Meritor carriers do not have these
axle shafts.* described parts.
Figure 2.2
1 FULL ROUND BEARING CUPS 10 CAPSCREWS 18 SLIP YOKE

2 END YOKE 11 END YOKE 19 U-JOINT CROSS
3 YOKE SADDLE 12 WELD YOKE 20 CAPSCREWS
4 WELD YOKE 13 SLIP YOKE 21 END YOKE
5 BEARING STRAP 14 U-JOINT CROSS 22 SLIP YOKE
6 CAPSCREWS 15 CAPSCREWS 23 TUBING
7 EASY-SERVICE BEARING CUPS 16 END YOKE 24 U-JOINT CROSS
8 U-JOINT CROSS 17 WELD YOKE 25 WELD YOKE
9 SLIP YOKE
7
Section 2
Disassembly
Brass Drift Method Figure 2.4
WARNING
or service.
Do not strike the round driving lugs on the flange
of an axle shaft. Pieces can break off and cause
serious personal injury.
1. Hold a 1-1/2 inch diameter brass drift against
the center of the axle shaft, inside the round
driving lugs. Figure 2.3.
Figure 2.3
1 STUD NUT
2 WASHER
3 TAPERED DOWEL
4 GASKET
5 STUD
6 SHAFT HUB AXLE
7 AXLE SHAFT (FLANGE)
8 WASHER
9 CAPSCREW
5. Install a cover over the open end of each axle

assembly hub where an axle shaft was
removed.
Air Hammer Vibration Method
WARNING
Wear safe eye protection when using an air
hammer. When using power tools, axle
1 BRASS HAMMER
components can loosen and break off causing
2 DRIVING LUGS serious personal injury.
NOTE: A 1-1/2 inch diameter brass hammer can be

CAUTION
used as a drift. Do not use a chisel or wedge to loosen the axle
shaft and tapered dowels. Using a chisel or wedge
2. Strike the end of the drift with a large hammer can result in damage to the axle shaft, the gasket
(five to six pounds) and the axle shaft and and seal, and/or the axle hub.
tapered dowels will loosen.
1. Use a round hammer bit and an air hammer
3. Mark to identify each axle shaft before it is such as Chicago Pneumatic CP-4181-PULER,
removed from the axle assembly. or equivalent, to loosen tapered dowels and
4. Remove the tapered dowels and separate the axle shaft.
axle shafts from the main axle hub assembly. 2. Place the round hammer bit against the axle
Figure 2.4. shaft (flange) between the hub studs. Operate
the air hammer at alternate locations between
the studs to loosen the tapered dowels and
axle shaft from the hub. Figure 2.5.
8
Section 2
Disassembly
1 WOOD BLOCK
1 ROUND HAMMER BIT BETWEEN HUB STUDS 2 ROLLER JACK
3. Mark to identify each axle shaft before it is

removed from the axle assembly. CAUTION
4. Remove the tapered dowels and separate the When using a pry bar be careful not to damage
axle shaft from the main axle hub assembly. the carrier or housing flange. Damage to these
Figure 2.4. surfaces will cause oil leaks.
5. Install a cover over the open end of each axle 6. Carefully remove the carrier from the axle
assembly hub where an axle shaft was housing using the hydraulic roller jack. Use a
removed. pry bar that has a round end to help remove
the carrier from the housing.
CAUTION 7. Lift the differential carrier by the input yoke or

flange and place the assembly in a repair
Do not use a chisel or wedge to loosen the axle stand. Figure 2.7. Use a lifting tool for this
shaft and tapered dowels. Using a chisel or wedge procedure. Do not lift by hand. A carrier stand
can result in damage to the axle shaft, the gasket can be built by referring to Figure 2.8.
and seal, and/or the axle hub.
Carrier Removal from Axle Figure 2.7
1. Place a hydraulic roller jack under the

differential carrier to support the assembly.
Figure 2.6.
2. Remove all but the top two carrier to housing
capscrews or stud nuts and washers.
3. Loosen the top two carrier-to-housing
fasteners and leave attached to the assembly.
The fasteners will hold the carrier in the
housing.
4. Loosen the differential carrier in the axle
housing. Use a leather mallet to hit the
mounting flange of carrier at several points.
5. After the carrier is loosened, remove the top
two fasteners.
1 DIFFERENTIAL CARRIER
2 REPAIR STAND
9
Section 2
Disassembly
A carrier stand, part number J 3409-D is available
from Kent-Moore, Heavy-Duty Division, 28635
Mound Road, Warren, MI 48092.
Figure 2.8
1 PLATES 8' LONG x 3/4" THICK x 1-1/4" WIDE WITH A 7 23-1/2" CENTER TO CENTER OF PIPE
TONGUE TO FIT SLOT IN BAR WELD PLATES TO BAR 8 CHAMFER END OF PIPE FOR WELDING
2 HANDLE 7" LONG WITH SLOT IN ONE END TO FIT CLAMP 9 4” DIAMETER PIPE
SCREW 10 PLUG 4" DIAMETER x 7" LONG WITH ONE END TURNED
3 BAR 2" DIAMETER x 9" LONG WITH ONE END SLOTTED 3" LONG TO FIT PIPE. DRILL 2" HOLE AND MILL 3/16"
TO FIT PLATE WIDE SLOT 2" FROM TOP
4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE 11 SCREW 3-1/2" LONG x 5/8" DIAMETER WITH FLATS ON
5 WELD END TO FIT HANDLE AND 2-1/2" LENGTH OF THREAD
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER ON OTHER END
12 DRILL 3/8" HOLE THROUGH HANDLE AND SCREW
CARRIER STAND
10
Section 2
Disassembly
Remove the Differential and 2. Remove the thrust screw* and jam nut* from
the differential carrier. Figure 2.11.
Ring Gear from the Carrier 3. Rotate the differential carrier in the repair stand
NOTE: Before working on the differential carrier, until the ring gear is at the top of the assembly.
inspect the hypoid gear set for damage. If
4. Mark one carrier leg and bearing cap to
inspection shows no damage, the same gear set
correctly match the parts during carrier
can be used again. Measure the backlash of the assembly. Mark the parts using a center punch
gear set and make a record of the dimension.
and hammer. Figure 2.12.
Figure 2.9. (Refer to “Ring Gear Backlash
Adjustment” in Section 5, Steps 1-5.) During
differential reassembly, adjust the backlash to the Figure 2.11
original recorded dimension when the gear set is
installed into the carrier.
1. Loosen the jam nut* on the thrust screw*.
Figure 2.10.
Figure 2.9
1 THRUST SCREW AND JAM NUT
Figure 2.12
1 DIAL INDICATOR
Figure 2.10
1 BEARING CAP
2 CARRIER LEG
3 MATCH MARKS
*Some Meritor carriers do not have these

described parts.
11
Section 2
Disassembly
5. Remove the cotter keys*, pins* or lock plates*
Figure 2.14
that hold the two bearing adjusting rings in
position. Use a small drift and hammer to
remove pins. Each lock plate is held in position
by two capscrews. Figure 2.13.
6. Remove the capscrews and washers that hold
the two bearing caps on the carrier. Each cap is
held in position by two capscrews and
washers. Figure 2.14.
7. Remove the bearing caps and bearing
adjusting rings from the carrier. Figure 2.15.
8. Safely lift the main differential and ring gear
assembly from the carrier. Place the assembly
on a work bench. Figure 2.16.
Figure 2.13 1 BEARING CAP
Figure 2.15
1 BEARING CAP
2 BEARING ADJUSTING RING
Figure 2.16
1 REMOVING COTTER KEY

2 REMOVING LOCK PLATE

described parts.
12
Section 2
Disassembly
Disassemble the Differential 5. If the ring gear needs to be replaced, remove

the bolts*, nuts*, and washers* that hold the
and Ring Gear Assembly gear to the flange case half.
1. If the matching marks on the case halves of the
differential assembly are not visible, mark each Figure 2.18
case half with a center punch and hammer. The
purpose of the marks is to match the plain half
and flange half correctly when you assemble
the carrier. Figure 2.17.
Figure 2.17
1 THRUST WASHER
2 SIDE GEAR
3 SPIDER, PINIONS AND THRUST WASHERS
WARNING
1 MATCH MARKS Observe all warnings and cautions provided by the
2 MATCH MARKS press manufacturer to avoid damage to
components and serious personal injury.
2. Remove the capscrews* and washers* or

bolts*, nuts* and washers that hold the case CAUTION
halves together. Do not remove the rivets or rivet heads with a
chisel and hammer. Using a flat edge tool can
cause damage to the flange case.
WARNING
Use a brass or leather mallet for assembly and 6. If rivets* hold the ring gear to the flange case
disassembly procedures. Do not hit steel parts half, remove the rivets as follows:
with a steel hammer. Pieces of a part can break off 7. Carefully center punch each rivet head in the
and cause serious personal injury. center, on the ring gear side of the assembly.
3. Separate the case halves. If necessary, use a
brass, plastic or leather mallet to loosen the
parts.
4. Remove the differential spider (cross), four
pinion gears, two side gears and six thrust
washers from inside the case halves.
Figure 2.18. *Some Meritor carriers do not have these
described parts.
13
Section 2
Disassembly
8. Drill each rivet head on the ring gear side of the
Figure 2.20
assembly to a depth equal to the thickness of
one rivet head. Use a drill bit that is 1/32 of an
inch smaller than the body diameter of the
rivets. Figure 2.19.
Figure 2.19
DRILLING RIVET FROM HEAD
1 CASE HALF
2 PRESS
3 PLATE
4 SUPPORTS
1003001b 11. If the differential bearings need to be replaced,

remove the bearing cones from the case
9. Press the rivets through holes in the ring gear halves. Use a bearing puller or press.
and flange case half. Press from the drilled Figure 2.21.
rivet head.
Figure 2.21
WARNING
Observe all warnings and cautions provided by the
press manufacturer to avoid damage to
10. Separate the case half and ring gear using a
press. Support the assembly under the ring
gear with metal or wood blocks and press the
case half through the gear. Figure 2.20.
14
Section 2
Disassembly
Remove the Drive Pinion and Figure 2.23

Bearing Cage from Carrier
1. Fasten a flange bar to the input yoke or flange.
When the nut is removed, the bar will hold the
drive pinion in position. Figure 2.22.
Figure 2.22
Figure 2.24
1 FLANGE BAR
2 YOKE BAR
2. Remove the nut and washer* from the drive

pinion. Figure 2.22.
3. Remove the yoke or flange bar.
CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mallet
can damage the parts and cause driveline runout,
or driveline imbalance problems after carrier to
driveline assembly. 1 BEARING CAGE
2 CARRIER
4. Remove the yoke or flange from the drive
pinion. If the yoke or flange is tight on the
pinion, use a puller for removal. Figure 2.23.
5. Remove the capscrews and washers that hold
the bearing cage in the carrier. Figure 2.24.

described parts.
15
Section 2
Disassembly
Disassemble the Drive Pinion

WARNING
Use a brass or leather mallet for assembly and
and Bearing Cage
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break off
Figure 2.26
CAUTION
Do not use a pry bar to remove the bearing cage
from the carrier. A pry bar can damage the bearing
cage, shims and carrier.
6. Remove the drive pinion, bearing cage and
shims from the carrier. If the bearing cage is
tight in the carrier, hit the bearing cage at
several points around the flange area with a
leather, plastic or rubber mallet. Figure 2.25.
Figure 2.25
1 DRIVE PINION
2 OIL SEAL
3 OUTER BEARING (CUP AND CONE)
4 INNER BEARING (CUP AND CONE)
5 SPIGOT BEARING
6 SNAP RING
7 BEARING SPACER
WARNING
1 DRIVE PINION AND BEARING CAGE
2 SHIMS 1. Place the drive pinion and bearing cage in a
press. The pinion shaft must be toward the top
of the assembly. Figure 2.27.
7. If the shims are in good condition, keep the
shims together for use later when the carrier is
assembled.
8. If shims are to be discarded because of
damage, first measure the total thickness of
the pack. Make a note of the dimension. The
dimension will be needed to calculate the
depth of the drive pinion in the carrier when
the gear set is installed.
16
Section 2
Disassembly
1 OIL SEAL
1 PRESS WARNING
2 DRIVE PINION Observe all warnings and cautions provided by the
3 OIL SEAL press manufacturer to avoid damage to
4 BEARING CAGE
5 SUPPORT components and serious personal injury.
6 SPIGOT BEARING
7 SUPPORT
6. If the pinion bearings need to be replaced,
remove the inner and outer bearing cups from
the inside of cage. Use a press and sleeve,
2. Support the bearing cage under the flange area bearing puller, bearing driver or a small drift
with metal or wood blocks. Figure 2.27. hammer. The type of tool used depends on the
design of the bearing cage. Figure 2.29.
3. Press the drive pinion through the bearing
cage. Figure 2.27. When a press is used, support the bearing cage
under the flange area with metal or wood blocks.
WARNING
Use a brass or leather mallet for assembly and Figure 2.29
NOTE: The inner bearing cone and bearing spacer
will remain on the pinion shaft.
4. If a press is not available, use a leather, plastic
or rubber mallet to drive the pinion through
the bearing cage.
CAUTION
Be careful when removing the seal. Do not
damage the wall of bore. Damage to the bore wall
can result in oil leaks.
NOTE: When the oil seal has been removed,
always replace it with a new triple-lip (main) seal
during component reassembly.
5. If the pinion oil seal is mounted directly in the
outer bore of the bearing cage, remove the
seal at this time.
Be careful that you do not damage the
mounting surfaces of the bearing cage.
Figure 2.28.
17
Section 2
Disassembly
7. If the pinion bearings need to be replaced,
Figure 2.31
remove the inner bearing cone from the drive
pinion with a press or bearing puller. The
puller MUST fit under the inner race of the
cone to remove the cone correctly without
damage. Figure 2.30.
Figure 2.30
1 SPIGOT BEARING
2 SNAP RING
Figure 2.32
1 PRESS
2 DRIVE PINION
3 BEARING PULLER
4 SUPPORTS
5 INNER BEARING CONE
8. If the spigot bearing needs to be replaced,

place the drive pinion in a vise. Install a soft
metal cover over each vise jaw to protect the
drive pinion.
9. Remove the snap ring* from the end of drive
pinion with snap ring pliers that expand.
Figure 2.31. 1 PEENING POINTS
NOTE: Some spigot bearings are fastened to

the drive pinion with a special peening tool.
Figure 2.32.

described parts.
18
Section 2
Disassembly
10. Remove the spigot bearing from the drive
pinion with a bearing puller. Figure 2.33.
NOTE: Some spigot bearings are a two-piece
assembly. Remove the inner race from the pinion
with a bearing puller. Remove the outer race/roller
assembly from carrier with a drift or a press.
Figure 2.34.
Figure 2.33
1 BEARING PULLER
2 SPIGOT BEARING
Figure 2.34
1 REMOVE OUTER RACE AND ROLLER ASSEMBLY FROM

CARRIER
2 REMOVE INNER RACE FROM PINION
19
Section 3
Preparing the Parts for Assembly
Cleaning Ground and Cleaning Rough Parts

Section 3Preparing the Parts for Assembly
Polished Parts
WARNING
WARNING Solvent cleaners can be flammable, poisonous and
cause burns. Examples of solvent cleaners are
To prevent serious eye injury, always wear safe eye carbon tetrachloride, emulsion-type cleaners and
protection when you perform vehicle maintenance petroleum-based cleaners. To avoid serious
or service. personal injury when you use solvent cleaners,
Solvent cleaners can be flammable, poisonous and you must carefully follow the manufacturer's
cause burns. Examples of solvent cleaners are product instructions and these procedures:
carbon tetrachloride, emulsion-type cleaners and r Wear safe eye protection.
petroleum-based cleaners. To avoid serious
personal injury when you use solvent cleaners, r Wear clothing that protects you skin.
you must carefully follow the manufacturer's r Work in a well-ventilated area.
product instructions and these procedures:
r Do not use gasoline, or solvents that contain
r Wear safe eye protection. gasoline. Gasoline can explode.
r Wear clothing that protects you skin. r You must use hot solution tanks or alkaline
r Work in a well-ventilated area. solutions correctly. Follow the manufacturer's
instructions carefully.
gasoline. Gasoline can explode. 1. Clean rough parts with the same method as
cleaning ground and polished parts.
r You must use hot solution tanks or alkaline
solutions correctly. Follow the manufacturer's 2. Rough parts can be cleaned in hot solution
instructions carefully. tanks with a weak or diluted alkaline solution.
3. Parts must remain in hot solution tanks until
CAUTION heated and completely cleaned.
Use only solvent cleaners to clean ground or 4. Parts must be washed with water until all
polished metal parts. Hot solution tanks or water traces of the alkaline solution are removed.
and alkaline solutions will damage parts. Isopropyl
alcohol, kerosene or diesel fuel can be used for this
purpose. If required, use a sharp knife to remove
Cleaning Axle Assemblies
gasket material from parts. Be careful not to 1. A complete axle assembly can be steam
damage the ground or polished surfaces. cleaned on the outside to remove dirt.
1. Use a cleaning solvent to clean ground or 2. Before the axle is steam cleaned, close or place
polished parts or surfaces. Kerosene or diesel a cover over all openings in the axle assembly.
fuel oil can be used for this purpose. Do not Examples of openings are breathers or vents in
use gasoline. air chambers.
2. Use a tool with a flat blade, if required, to
remove sealant material from parts. Be careful Drying Parts After Cleaning
not to damage the polished or smooth
surfaces.
CAUTION
3. Do not clean ground or polished parts with
Damage to bearings can result when they are
water or steam. Do not immerse ground or
rotated and dried with compressed air.
polished parts in a hot solution tank or use
strong alkaline solutions for cleaning, or the 1. Parts must be dried immediately after cleaning
smooth sealing surface may be damaged. and washing.
2. Dry the parts using soft, clean paper or cloth
rags.
3. Except for bearings, parts can be dried with
compressed air.
20
Section 3
Preventing Corrosion on Figure 3.1

Cleaned Parts 1
1. Apply axle lubricant to cleaned and dried parts

that are not damaged and are to be assembled.
2. To store parts, apply a special material that
prevents corrosion to all surfaces. Wrap
cleaned parts in a special paper that will
protect the parts from moisture and prevent
corrosion during storage.
Inspecting Parts
It is very important to inspect all parts carefully and 2
completely before the axle or carrier is assembled. 1 WORN RADIUS
Inspect all parts for wear and replace damaged 2 WORN SURFACE
parts. Replacement of damaged or worn parts now,
will prevent failure of the assembly later.
1. Inspecting Tapered Roller Bearings:
Figure 3.2
Inspect the cup, cone, rollers and cage of all
tapered roller bearings in the assembly. If any
of the following conditions exist, the bearing
MUST be replaced:
a. The center of large-diameter end of rollers
2
worn level with or below the outer surface. 1
Figure 3.1.
b. The radius at large-diameter end of rollers
worn to a sharp edge. Figure 3.1.
c. A visible roller groove in the cup or cone
inner race surfaces. The groove can be
seen at the small- or large-diameter end of
both parts. Figure 3.2.
d. Deep cracks or breaks in the cup, cone
inner race or roller surfaces. Figure 3.2.
1 CRACK
e. Bright wear marks on the outer surface of 2 WEAR GROOVE
the roller cage. Figure 3.3.
Figure 3.3
1 WEAR MARKS
21
Section 3
f. Damage on rollers and on surfaces of the
cup and cone inner race that touch the CAUTION
rollers. Figure 3.4. Always replace thrust washers, differential side
g. Damage on the cup and cone inner race gears and pinion gears in full matched sets. A
surfaces that touch the rollers. Figure 3.5. higher stress on original parts and early failure of
the entire assembly will result if a new part is used
in combination with parts that are older or worn.
Figure 3.4
3. Inspect the Main Differential Assembly:
1
Inspect the following parts for wear or stress.
Parts that are damaged MUST be replaced.
Figure 3.6.
Figure 3.6
1003020a
1 ETCHING AND PITTING
Figure 3.5
1 SPALLING AND FLAKING
CAUTION
Hypoid drive pinions and ring gears are machined in
matched sets. When a drive pinion or ring gear of a
hypoid set needs to be replaced, both drive gear 1 INSPECT INSIDE SURFACES 5 INSPECT
2 PINION AND THRUST WASHER 6 SPIDER (CROSS)
and pinion must be replaced at the same time. 3 SIDE GEAR AND THRUST 7 INSPECT
WASHER
2. Inspect hypoid pinions and gears for wear or 4 INSPECT
damage. Gears that are worn or damaged
MUST be replaced.
22
Section 3
a. Inside surfaces of both case halves. 5. Remove nicks, mars and burrs from parts with
machined or ground surfaces. Use a fine file,
b. Both surfaces of all thrust washers.
india stone, emery cloth or crocus cloth for this
c. The four trunnion ends of the spider purpose.
(cross).
d. Teeth and splines of both differential side CAUTION
gears. Threads must be without damage and clean so
e. Teeth and bore of all differential pinions. that accurate adjustments and correct torque
values can be applied to fasteners and parts.
4. Inspect Axle Shafts:
6. Clean and repair threads of fasteners and
a. Inspect axle shafts for wear and cracks at holes. Use a die or tap of the correct size or a
the flange, shaft and splines. fine file for this purpose.
b. Replace axle shafts, if required. 7. T ighten all fasteners to the correct torque
values. Refer to Table J for torque values of
Repair or Replacement of fasteners. Figure 3.8.
Parts, General
Figure 3.8
Replace worn or damaged parts of an axle
assembly. The following are some examples in
inspecting for part replacement or repair.
1. Replace any fastener if corners of the head
are worn.
2. Replace washers if damaged.
3. Replace gaskets, oil seals or grease seals at the
time of axle or carrier repair.
4. Clean parts and apply new silicone gasket
material where required when axle or carrier is
assembled. Figure 3.7.
1 ALWAYS USE TORQUE WRENCHES

Figure 3.7
8. DO NOT repair rear axle housings by bending

or straightening.
WARNING
Repair of axle housings by bending or
straightening will cause poor or unsafe vehicle
operation and early failure of the axle.
1 REMOVE SILICONE GASKET FROM PARTS
23
Section 3
Repair Axle by Welding d. Clean the damaged area inside and outside
the housing. Cleaning solvent can be used.
1. ArvinMeritor Commercial Vehicle Systems will
e. Grind the damaged weld to the base metal.
permit repairing drive axle housing assemblies
by welding ONLY in the following areas: f. Warm the complete axle housing to a
a. Snorkel welds. temperature of 70°F−80°F (21°C−27°C) or
higher.
b. Housing seam welds between the
suspension attaching brackets. g. Before you start welding, heat the damaged
c. Bracket welding to drive axle housing. area to be repaired to approximately 300°F
Refer to TP-9421. (149°C).
d. Refer to Meritor Maintenance Manual 8 h. Use a 70,000 psi tensile weld material and
for approved axle welding procedures. the correct voltage and amperage for the
e. Contact your Meritor representative for diameter weld rod used. Examples of weld
further or specific recommendations. rods that can be used are E-7018 or ER-70S-3.
WARNING CAUTION
Using wrong welding procedures or welding at If the E-7018 weld rod is used, the rod must be kept
locations other than the three areas permitted by dry. Electrodes that are not stored in the correct
ArvinMeritor will make the heat-treated sealed containers must be heated at 700°°F (371°° C)
component weak. A weak component will cause for one hour before welding. Wet electrodes must
poor or unsafe operation of the vehicle and early be dried at 180°° F (82°° C) for one to two hours and
axle failure. The following procedure must be used. then heated at 700°°F (371°° C) for one hour before
welding.
CAUTION i. Fill in the weld gap as follows:
Welding can be used when the crack or damaged 1. The opening in cover welds MUST be
area is within the old weld material. Replace the
filled level with the old weld.
axle housing if the crack extends into the metal
next to the old weld. A repaired housing must be 2. The opening in seam welds MUST be
used only in correct specified vehicle load ground out to 70% of the wall thickness.
applications. The wall thickness can be measured at the
2. Welding Procedure carrier opening of housing.
a. Drain the lubricant from the axle assembly. 3. Clean the new weld area. Carefully
b. Remove hub, drum, wheel bearing and remove all the rough weld material.
brake air chambers. 4. Install the differential carrier and axle
c. Remove the axle shafts and differential shafts.
carrier from the axle housing.
5. Fill the axle assembly with the correct
amount of lubricant. Refer to Maintenance
WARNING Manual 1, Lubrication, for information on
Solvent cleaners can be flammable, poisonous and lubricants.
carbon tetrachloride, emulsion-type cleaners and CAUTION
Do not connect the ground cable at any point on
personal injury when you use solvent cleaners, you
must carefully follow the manufacturer's product the axle assembly that will place a bearing
instructions and these procedures: between the ground cable and weld area. If a
bearing is between the ground cable and weld, the
r Wear safe eye protection. bearing will be damaged because of electrical
r Wear clothing that protects you skin. arcing in the bearing and bearing track areas.
r Work in a well-ventilated area. A good location to connect the ground cable is the
r Do not use gasoline, or solvents that contain spring mounting pad of the housing.
gasoline. Gasoline can explode.
NOTE: Before welding brackets or other
r You must use hot solution tanks or alkaline components to the axle housing, contact
solutions correctly. Follow the manufacturer's ArvinMeritor for proper welding procedures.
24
Section 3
Bending or Straightening
Drive Axle Housings
ArvinMeritor Commercial Vehicle Systems
strongly recommends against any attempt to
correct or modify drive axle housings by bending
or straightening. All damaged drive axle housings
should be replaced.
WARNING
Do not bend or straighten damaged drive axle
housings. Any bending or straightening process
may result in misalignment or weakening of the
axle housing and cause component damage and
result in serious personal injury.
Removing Dri-Loc Fasteners

If it is difficult to remove fasteners from
components, the strength of Dri-Loc, Meritor
adhesive or Loctite 277 can be decreased by
heating. Use the following procedure:
1. Heat the fastener for three to five seconds
ONLY and try to loosen the fastener with a
wrench. DO NOT use an impact wrench to
loosen the fastener or hit the fastener with a
hammer.
CAUTION
Do not exceed 350°°F (177°°C) maximum. Heating
must be done slowly to prevent thermal stresses
in the other components.
2. Repeat Step 1 until the fastener can be
removed.
25
Section 4
General Information
Installing Fasteners with

Section 4General Information
Figure 4.1
Pre-Applied Adhesive, Meritor
Liquid Adhesive 2297-C-7049,
Loctite 680 Liquid Adhesive
or Equivalent
Installing New Fasteners with
Pre-applied Adhesive Patches
WARNING
or service.
1. Clean the oil and dirt from threaded holes.
Use a wire brush. There is no other special 1 4 TO 5 DROPS ON BORE THREADS
cleaning required.
CAUTION 3. T ighten the fasteners to the required torque

value for that size fastener.
Do not apply adhesives or sealants on new
fasteners with pre-applied adhesive patches or NOTE: There is no drying time required for
inside closed threaded holes. If other adhesives or Meritor Liquid Adhesive 2297-C-7049, Loctite 680
sealants are used, the new adhesive will not or equivalent.
function correctly.
2. Assemble parts using the new pre-applied Application of Meritor Adhesive
adhesive fasteners.
2297-T-4180 in Bearing Bores for
NOTE: There is no drying time required for
fasteners with pre-applied adhesive. the Differential
3. T ighten the fasteners to the required torque Use adhesive 2297-T-4180 for all axles.
value for that size fastener. 1. Clean the oil and dirt from outer diameters of
bearing cups and bearing bores in the carrier
Installing Original or Used Fasteners and bearing caps. There is no special cleaning
required.
Using Meritor Liquid Adhesive
2297-C-7049 or Loctite 680 2. Apply axle lubricant to the bearing cones and
the inner diameters of the bearing cups of the
or Equivalent main differential. DO NOT get oil on the outer
1. Clean the oil, dirt and old adhesive from all diameter of the bearing cup and DO NOT
threads and threaded holes. Use a wire brush. permit oil to drip on the bearing bores.
CAUTION
Do not apply adhesive directly to the fastener
threads. Air pressure in a closed hole will push the
adhesive out and away from mating surfaces as
the fastener is installed.
2. Apply four or five drops of Meritor Liquid
Adhesive, Loctite 680 or equivalent inside
each threaded hole or bore ONLY. Make sure
the adhesive is applied inside to the bore
threads. Figure 4.1.
26
Section 4
General Information
3. Apply a single continuous bead of the
adhesive to the bearing bores in the carrier and
Application of Three Bond
bearing caps. Apply the adhesive 360° around 1216 or Equivalent Silicone
the smooth, ground surfaces only. DO NOT
place adhesive on threaded areas. Figure 4.2.
Gasket Material
WARNING
Figure 4.2
Take care when you use silicone gasket materials
to avoid serious personal injury. Follow the
manufacturer’s instructions to prevent irritation
to the eyes and skin.
NOTE: The following silicone gasket products or
equivalent are available in 3 oz (85 gram) tubes
and can be used for Meritor components:
r Three Bond RTV No. TB 1216 (Grey) — Meritor
Part Number 2297-Z-7098
r Loctite Ultra Grey Adhesive/Sealant #18581 —
Meritor Part Number 2297-A-7021
Also available in 120 oz (3.4 kg) cartridges:
r Three Bond RTV1216 (Grey) — Meritor Part
Number 2297-A-7051
1 ADHESIVE
2 BEARING CAP
1. Remove all old gasket material from both
3 CARRIER LEG surfaces. Figure 4.3.
2. Clean the surfaces where silicone gasket
material will be applied. Remove all oil, grease,
NOTE: Meritor adhesive 2297-T-4180 will become dirt and moisture without damaging the
hard (dry) in approximately two hours. The mating surfaces. Figure 4.3.
following two steps of the procedure must be
done in two hours from the time the adhesive
was applied. If two hours have passed since Figure 4.3
application, clean the adhesive from the parts
again and apply new adhesive.
4. Install the main differential assembly, bearing
cups and bearing caps into the carrier. Use the
normal procedure, refer to “Install the
Differential and Ring Gear Assembly” in
Section 5.
5. Adjust preload of the differential bearings,
backlash and tooth contact patterns of the gear
set as required using the normal procedures.
Refer to “Adjust Preload of Differential
Bearings” in Section 5.
1 REMOVE OLD SEALANT MATERIAL
HOUSING AND CARRIER SHOWN
27
Section 4
General Information
3. Dry both surfaces. Installing Tight Fit Yokes and
POSE™ Seal
CAUTION
The amount of silicone gasket material applied
must not exceed 0.125-inch (3 mm) diameter bead. Figure 4.5
Too much gasket material can block lubrication
passages and result in damage to the
components.
4. Apply 0.125-inch (3 mm) diameter continuous
bead of the silicone gasket material around
one surface. Also apply the gasket material
around the edge of all fastener holes on that
surface. Figure 4.4.
5. Assemble the components immediately to
permit the silicone gasket material to
compress evenly between the parts. T ighten
1 LUBRICATE TRIPLE-LIP (MAIN) SEAL
fasteners to the required torque value for that 2 INPUT SHAFT (PINION)
size fastener. There is no special procedure or 3 POSE™ SEAL 0.25"–0.50" (6.4 MM–12.7 MM) ONTO
additional torque value required. Refer to HUB
Table J. T 4 INSPECT YOKE HUB
6. Wait 20 minutes before filling the assembly

with lubricant. 1. Apply the same lubricant used in the axle
housing to the hub of the yoke or flange.
Figure 4.4 2. Inspect and make sure the lips of the POSE™
seal and the outer retainer of the triple-lip
(main) seal are clean and free from dirt and
particles that may cause lubricant leakage
between the seals.
3. Install the POSE™ seal on the hub of the yoke
or flange by hand. The lips of the seal must
face toward the end of the hub (opposite
shoulder). Slide the POSE™ seal on the hub
until the lips are from 0.25-inch to 0.50-inch
(6.4 mm-12.7 mm) from the end of the hub.
Do not install the POSE™ seal against the
shoulder. Figure 4.6.
Figure 4.6
1 0.125” (3 MM) DIAMETER SILICONE GASKET BEAD
1 0.25”–0.50” (6.4 MM–12.7 MM)

2 YOKE HUB
3 FACE SEAL ASSEMBLY (POSE™ SEAL ELEMENT)
28
Section 4
General Information
NOTE: The POSE™ seal will position itself 1. Part Number
correctly as the yoke or flange is pressed on
a. Examples of gear set part numbers:
the shaft.
4. Before you install the yoke or flange on the r Conventional ring gear, 36786.
shaft, apply the same lubricant used in the r Conventional drive pinion, 36787.
axle housing to the hub.
r Generoid ring gear, 36786 K or 36786 K2.
5. Install the yoke or flange using the correct
procedure. r Generoid drive pinion, 36787 K or
36787 K2.
NOTE: The yoke must be completely seated before
tightening pinion nut to the input shaft. NOTE: The last digit in part numbers for Generoid
gears is a letter or letter and number.
General Yoke and b. Location on Drive Pinion: End at threads.
U-Joint Reassembly c. Location on Ring Gear: Front face or outer
diameter.
Install the end yoke hub capscrews by hand after
seating the U-joint. Tighten the capscrews 2. Tooth Combination Number
according to manufacturer's torque specifications.
a. Example of a tooth combination number:
5-37.
Gear Set Information (Drive NOTE: A 5-37 gear set has a 5-tooth drive pinion
Pinion and Ring Gear Marks) and a 37-tooth ring gear.
NOTE: Read the following information before b. Location on Drive Pinion: End at threads.
installing a new gear set in the carrier. Always c. Location on Ring Gear: Front face or outer
inspect the gear set for correct marks to make sure diameter.
the gears are a matched set.
The locations of the marks are shown in Figure 4.7. 3. Gear Set Match Number
Meritor drive pinions and ring gears are
available only as matched sets. Both gears of
Figure 4.7 a set have a match number.
a. Example of a gear set match number: M29.
NOTE: A gear set match number has any
combination of a number or letter and number.
b. Location on Drive Pinion: End of gear head.
c. Location on Ring Gear: Front face or outer
diameter.
1 ALTERNATE LOCATIONS: PART NO.,

TOOTH COMBINATION NO.,
GEAR SET MATCH NO.,
PINION CONE VARIATION NO.
2 PART NO., TOOTH COMBINATION NO.
3 GEAR SET MATCH NO., PINION CONE VARIATION NO.
4 PART NO., TOOTH COMBINATION NO., GEAR SET
MATCH NO.
5 PART NO., TOOTH COMBINATION NO., GEAR SET
MATCH NO., PINION CONE VARIATION NO.
29
Section 4
General Information
NOTE: The pinion cone variation number is not
used when inspecting for a matched gear set. The
number is used when you adjust the depth of the
pinion in the carrier. Refer to the procedure for
adjusting the shim pack thickness under the pinion
cage heading.
4. Pinion Cone Variation Number
a. Examples — refer to Figure 4.8.
Pinion cone variation numbers:
r PC+3
r PC–5
r +2
r –1
r +0.01 mm
r –0.02 mm
b. Location on Gear Set: End of pinion gear
head or outer diameter of ring gear.
Figure 4.8
1 PINION CONE VARIATION NUMBER
30
Section 5
Assembly
Assemble the Drive Pinion, 4. Place the drive pinion in a press, gear head
Section 5Assembly
(teeth) toward the bottom. Figure 5.2.

Bearings and Bearing Cage
Figure 5.2
WARNING
or service.
Observe all warnings and cautions provided by
the press manufacturer to avoid damage to
1. Place the bearing cage in a press. Figure 5.1.
Figure 5.1
1 SLEEVE
2 INNER BEARING CONE
5. Press the inner bearing cone on the shaft of the

drive pinion until the cone is flat against the
gear head. Use a sleeve of the correct size
against the bearing inner race.
NOTE: Spigot bearings are usually fastened to the
drive pinion with a snap ring. Some are fastened
with a peening tool, and some are a two-piece
1 PRESS bearing assembly with the inner race pressed on
2 SLEEVE the nose of the pinion and the outer race pressed
3 BEARING CUP into its bore in the carrier. Use the following
4 CAGE
5 SUPPORTS
procedure to install the spigot bearing, then
continue with Steps 9-12 under “Staking the
One-Piece Spigot Bearing on the Drive Pinion
2. Support the bearing cage with metal or wood (Without Snap Ring).”
blocks.
3. Press the bearing cup into the bore of bearing
cage until cup is flat against bottom of bore.
Use a sleeve of the correct size to install
bearing cup. Figure 5.1.
NOTE: Use the same procedure for both bearing
cups.
31
Section 5
Assembly
6. Installing the One-Piece Spigot Bearing on the c. Install the snap ring* into groove in end
Drive Pinion with Snap Ring: of drive pinion with snap ring pliers.
Figure 5.4.
NOTE: This step applies to all axles except:
r Some 160 Series single axles may use
Figure 5.4
snap rings.
r Some 160 and 180 Series rear rear
tandem axles may use snap rings.
a. Place the drive pinion in a press, gear head
(teeth) toward the top. Figure 5.3.
b. Press the spigot bearing on the end of
drive pinion until the bearing is flat against
the gear head. Use a sleeve of the correct
size against the bearing inner race.
Figure 5.3.
Figure 5.3
1 SNAP RING
2 SPIGOT BEARING
7. Staking the One-Piece Spigot Bearing on the

Drive Pinion (Without Snap Ring):
NOTE: This procedure applies to some 180 Series
rear rear tandem axles with existing snap ring
components.
Specification
r Apply 6,614 lb. (3,000 kg) force on a 0.375-inch
(10 mm) ball.
r Stake the end of drive pinion at a minimum of
1 PRESS five points. Figure 5.5.
2 SLEEVE
3 SPIGOT BEARING
When using a staking tool and press, Figure 5.6,
calculate the force required on the tool as follows.
6,614 lb. (3,000 kg) x amount of balls in tool =
pounds or kilograms

described parts.
32
Section 5
Assembly
Example
Figure 5.7
6,614 lb. x 3 balls = 19,842 pounds
For information about the staking tool, contact

your local Meritor representative. Figure 5.6.
a. Place the drive pinion and the tube of the
staking tool in a press, spigot bearing
toward the top. Figure 5.7.
b. Calculate the amount of force that will be
required on the staking tool. Refer to
specification and example calculation.
c. Place the punch of the staking tool over the
end of the pinion and spigot bearing. Apply
the required amount of force on the punch.
Figure 5.7.
Figure 5.5
1 PRESS
2 INSTALL AND CENTER THE PUNCH ON THE END OF
PINION.
3 SPIGOT BEARING
4 PUT THE SHAFT OF PINION INTO TUBE.
CAUTION
Do not align new points with grooves in end of
drive pinion or in old points. If the new staked
points are placed in the wrong areas, the spigot
bearing will not be held correctly on the pinion
shaft.
1 STAKING POINTS d. Rotate the punch as many times as
required for a minimum of five points.
Repeat Step c for each point.
Figure 5.6 NOTE: If a three-ball stake tool is used, rotate the

tool 180° (degrees).
8. Installing and Staking the Two-Piece Spigot

Bearing on the Drive Pinion:
NOTE: This procedure applies to some 160 Series
single rear axles and rear rear tandem axles. These
axles may also use a one-piece spigot bearing with
a snap ring retainer.
The inner race of two-piece spigot bearings may
need to be staked in place on some R-160 series
rear axles. Before you stake the pinion, you must
heat the pinion stem to soften it.
1 PUNCH
2 TUBE
Kent-Moore Kit J-39039 includes the staking tool,
temperature indicating liquid, heating shield and
plastigage needed for this job.
33
Section 5
Assembly
a. Apply two stripes of temperature
Figure 5.9
indicating liquid on the pinion stem from
the top to the bottom. Figure 5.8. Apply a
green stripe to indicate 400°F (205°C) and a
blue stripe to indicate 500°F (260°C).
Figure 5.8
c. Light and adjust the torch until the white

part of the flame is approximately 1/4-inch
long. Keep the white part of the flame
approximately 1/8-inch from the top of the
stem. Figure 5.10. Move the flame around
the outer diameter of the top of the pinion
1 TEMPERATURE INDICATING LIQUID APPLICATION stem. The green temperature indicating
liquid will turn black before the blue liquid
does. Heat the stem until the blue liquid
turns black at a point in the middle of the
WARNING window.
Always wear safe clothing, gloves and eye
protection when working with a torch for heating Figure 5.10
parts to prevent serious personal injury during
assembly.
CAUTION
Do not heat the pinion stem without the heat
shield in place. Also, do not overheat the pinion
stem or you will weaken the metal which can
cause early failure. Correct heating will take
approximately 25-35 seconds, depending on how
hot the torch is.
b. Place the heating shield over the pinion
stem so that you can see the temperature
indicating liquid through the hole in the
shield. Figure 5.9.
1 TORCH
2 WHITE PART OF FLAME
3 1/4"
4 1/8”
5 PINION
6 HEATING SHIELD
34
Section 5
Assembly
d. Remove the flame and the heat shield
Figure 5.11
from the pinion. Let the pinion air cool for
10 minutes. Use a razor blade to remove
the temperature indicating liquid.
WARNING
CAUTION
Do not press or directly strike the new inner race
in Step e or damage to the bearing will result.
e. Use a press, if available, or a brass
hammer to install the new inner race. Use
the old inner race as a sleeve. The face is
completely seated when you cannot fit a
0.002-inch feeler gauge between the race
and the pinion shoulder.
NOTE: To hold the races in place, use a staking
tool, instead of the old race, to start the new race
on the stem. The old race can be used to
completely seat the new race. 1 PUNCH
2 PLASTIGAGE
In Step f, you do not need to use the plastigage for 3 STAKING TOOL
4 BEARING INNER RACE
every stake. Use the plastigage until you are sure 5 STAKES
you are hitting the punch with the correct amount
of force.
f. Place the staking tool over the bearing h. With a press or a soft mallet and sleeve,
race. Cut a one inch piece from the green install the outer race and roller assembly
plastigage strip and place in between the into its bore in the carrier. Use a sleeve that
punch and the staking tool. Figure 5.11 — is the same size as the outer race and press
View A. the bearing until it is squarely against the
shoulder in the bottom of its bore.
g. Strike the punch with a two-three pound
brass hammer to upset the end of the 9. Apply axle lubricant to the bearing cups and to
pinion stem. Then, remove the strip and the bearing cones in the cage.
measure its thickness against the gauge on 10. Install the drive pinion into the bearing cage.
the wrapper that the strip came in. The
strip must not be less than 0.003-inch thick. 11. Install the bearing spacer or spacers on pinion
This thickness indicates that you are using shaft against the inner bearing cone.
enough force when you hit the punch. If the Figure 5.12.
strip is too thin, then you must hit the
punch harder so the stake will hold the race
in place. Rotate the tool and repeat this
procedure until there are six evenly
spaced stake marks around the stem.
Figure 5.11 — View B.
35
Section 5
Assembly
Figure 5.12 Adjusting Preload of

Pinion Bearings
Specifications
r New pinion bearings — torque
— 5 to 45 lb-in (0.56-5.08 N•m) T
r Used pinion bearing in good condition —
torque
— 10 to 30 lb-in (1.13-3.39 N•m) T
Press Method
NOTE: If a press is not available, or the press does
not have a pressure gauge, use the yoke or flange
method to adjust pinion bearing preload. Refer to
“Yoke or Flange Method” in this section.
1. Place the drive pinion and cage assembly in a

press, gear head (teeth) toward the bottom.
2. Install a sleeve of the correct size against the
1 OUTER BEARING CONE inner race of the outer bearing. Figure 5.13.
2 BEARING SPACER
3 BEARING CAGE 3. Apply and hold the correct amount pressure
4 INNER BEARING CONE to the pinion bearings. Refer to Table A. As
5 DRIVE PINION pressure is applied rotate the bearing cage
several times so that bearings make normal
contact.
NOTE: The spacer or spacers control the preload
adjustment of the drive pinion bearings.
12. Install the outer bearing cone on pinion shaft
against the spacer. Figure 5.12.
NOTE: DO NOT install pinion seal in bearing cage.
Continue with adjusting preload of pinion
bearings.
Table A: Pinion Bearing Preload Adjustment Values

Press Pressure Needed on Bearings for T Torque Value Needed on Pinion Nut
Correct Preload. for Correct Bearing Preload.
Thread Size of
Pinion Shaft pounds/tons (kg/metric tons) lb-ft (N•m)
7/8"-20 22,000/1 (9979/10) 200-275 (271-373)
1"-20 30,000/15 (13608/13.6) 300-400 (407-542)
1 1/4"-12 54,000/27 (24494/24.5) 700-900 (949-1220)
1 1/4"-18 54,000/27 (24494/24.5) 700-900 (949-1220)
1 1/2"-12 54,000/27 (24494/24.5) 800-1100 (1085-1491)
1 1/2"-18 54,000/27 (24494/24.5) 800-1100 (1085-1491)
1 3/4"-12 50,000/25 (22680/22.7) 900-1200 (1220-1627)
2"-12 50,000/25 (22680/22.7) 1200-1500 (1627-2034)
36
Section 5
Assembly
4. While pressure is held against the assembly,
Figure 5.14
wind a cord around the bearing cage several
times.
Figure 5.13
1 MEASURE DIAMETER OF CAGE.
1 PRESS 9. Use the following procedure to calculate the

2 SLEEVE bearing preload (torque).
r Pounds Pulled x Radius (inches) =
lb-in Preload
5. Attach a spring scale to the end of the cord.
— Preload x 0.113 = N•m Preload
6. Pull the cord with scale on a horizontal line.
As the bearing cage rotates, read the value r Kilograms Pulled x Radius (cm) =
indicated on scale. Write down and record the kg-cm Preload
reading. Figure 5.13. — Preload x 0.098 = N•m Preload
NOTE: Do not read starting torque. Read only
or
the torque value after the cage starts to rotate.
Starting torque will give a false reading. Examples
7. Measure the diameter of bearing cage where r Reading from spring scale = 7.5 pounds
the cord was wound. Measure in inches or (3.4 kg)
centimeters. Figure 5.14.
r Diameter of bearing cage = 6.62 inches
8. Divide the dimension in half to get the radius. (16.80 cm)
Write down and record the radius dimension.
r Radius of bearing cage = 3.31 inches
(8.40 cm)
7.50 lb. x 3.31 in. = 24.80 in-lb Preload
Preload x 0.113 = 2.800 N•m Preload
or
3.4 kg x 8.4 cm = 28.6 kg-cm Preload
Preload x 0.098 = 2.800 N•m Preload
37
Section 5
Assembly
10. If the preload (torque) of pinion bearings is
not within specifications, do the following CAUTION
procedure then repeat Steps a through i. Do not install tight fit yokes or flanges on shafts
To increase preload, install a thinner bearing using a hammer or mallet. A hammer or mallet
spacer. To decrease preload, install a thicker will damage the yoke or flange.
bearing spacer. 2. Temporarily install the drive pinion and cage
11. Inspect the bearing preload with the drive assembly in the carrier. Do not install shims
pinion and cage assembly installed in the under the bearing cage. Figure 5.16.
carrier. Follow the procedures to adjust preload
of pinion bearings, yoke or flange method.
Figure 5.16
Yoke or Flange Method
WARNING
1. Install the input yoke or flange, nut and
washer* on the drive pinion. The yoke or
flange MUST be seated against the outer
bearing.
NOTE: Use a press to install the yoke or flange.
Figure 5.15.
Figure 5.15
3. Install the bearing cage to carrier capscrews.
Washers are not required at this time. T ighten
the capscrews by hand until snug.
4. Fasten a yoke or flange bar to the input yoke or
flange. The bar will hold the drive pinion in
position when the nut is tightened. Figure 5.17.
Figure 5.17
1 PRESS
2 INPUT FLANGE SHOWN
1 USE FLANGE OR YOKE BAR.
*Some Meritor carriers do not have these 5. T ighten the nut on drive pinion to the correct
described parts. torque value. Figure 5.17. Refer to Table A.
38
Section 5
Assembly
6. Remove the yoke or flange bar.
Figure 5.19
7. Attach a torque wrench on the drive pinion nut.
Rotate the drive pinion and read the value
indicated on torque wrench. Figure 5.18.
Figure 5.18
1 APPLY GREASE.
2 TRIPLE-LIP (MAIN) SEAL
1 READ TORQUE VALUE. 3 APPLY LUBRICANT TO SEAL BORE.
4 BEARING CAGE
5 DRIVE PINION
8. If the preload (torque) of pinion bearings is not
within specifications, remove the pinion and
cage assembly from carrier. Do the following
procedure, then repeat Steps a through g. CAUTION
Make sure that the seal lips are clean and free
r To INCREASE preload, install a thinner
from dirt and particles that will cause a leak
bearing spacer.
between the yoke and the seal.
r To DECREASE preload, install a thicker
b. Place the drive pinion and cage assembly
bearing spacer.
in a press, seal bore toward the top.
9. After adjusting preload of pinion bearings,
remove the drive pinion and bearing cage from
carrier. Follow Steps 1-5 under “Remove the
Drive Pinion and Bearing Cage from Carrier.”
10. Install a new triple-lip seal as follows.
a. Apply the same lubricant used in the axle
housing to the outer surface of the seal
and the seal bore in the bearing cage.
Figure 5.19.
39
Section 5
Assembly
c. Press the seal into bearing cage until
Figure 5.21
flange of seal is flat against the top of
bearing cage. Use a sleeve or seal driver of
the correct size that fits against the metal
flange of seal. The diameter of the sleeve
or drive MUST be larger than the diameter
of the flange. Figure 5.20.
Figure 5.20
1 SEAL DRIVER
d. After the triple-lip seal is installed, a gap

of approximately 0.015- to 0.030-inch
(0.38-0.76 mm) between the flange and
bearing cage is normal. Figure 5.22.
Inspect the gap with a feeler gauge at
several points around the seal. The gap
must be within 0.015- to 0.030-inch
(0.38-0.76 mm). The difference between the
largest and smallest gap measurement
MUST NOT exceed 0.010-inch (0.254 mm).
Figure 5.22
1 PRESS
2 SLEEVE
3 SUPPORTS
4 SLEEVE
5 SEAL
6 BEARING CAGE
7 DRIVE PINION
NOTE: If a press is not available, use a mallet and 1 0.015-0.030” (0.38-0.76 MM)
the sleeve or driver to install the seal. Figure 5.21.
SHOWN WITHOUT BEARINGS AND PINION
40
Section 5
Assembly
Figure 5.24
WARNING
Adjusting Shim Pack Thickness for

the Pinion Cage (Depth of Pinion)
NOTE: Use this procedure if a new drive pinion
and ring gear set is installed, or if the depth of the
drive pinion has to be adjusted. Figure 5.23.
Figure 5.23
2. Look at the pinion cone (PC) variation number

on the old drive pinion that is being replaced.
Refer to “Gear Set Information,” Step 4, in
Section 4 for examples and location of the
number. Record the number for later use. If
(PC) variation number cannot be located,
assemble gear set with shim pack thickness
found in Step 1 under “Adjusting Shim Pack
Thickness for the Pinion Cage (Depth of
Pinion).” Figure 5.25.
Figure 5.25
1 SHIM PACK CONTROLS DEPTH OF PINION.

2 BEARING CAGE
3 CARRIER
1. Measure the thickness of the old shim pack that

was removed from under the pinion cage with
a micrometer. Record the measurement for use
later. Figure 5.24.
1 PINION CONE VARIATION NUMBER
41
Section 5
Assembly
NOTE: The pinion cone number can be either NOTE: The value calculated in Step 3 or 4 is the
100ths of a millimeter or 1,000ths of an inch. Refer thickness of the standard shim pack, without a
to the following examples. variation.
PC +3, PC−3, +3 or −3 = 0.003 inch 5. Look at the pinion cone (PC) variation number
on the new drive pinion that will be installed.
PC +.03, PC−0.03 mm, +0.03 mm
Record the number for later use.
or −0.03 = 0.03 mm
6. If the new pinion cone number is a plus (+)
To change millimeters to inches — millimeters
number, add the number to the standard shim
x 0.039
pack thickness that was calculated in Step 3
To change inches to millimeters — or 4.
inches x 25.40
7. If the new pinion cone number is a minus (−)
3. If the old pinion cone number is a plus (+) number, subtract the number from the standard
number, subtract the number from the old shim shim pack thickness that was calculated in
pack thickness that was measured in Step 3 or 4.
Step 2.
NOTE: The value calculated in Step 6 or 7 is the
4. If the old pinion cone number is a minus (−) thickness of the new shim pack that will be
number, add the number to the old shim pack installed. Refer to the following examples, Table B.
thickness that was measured in Step 2.
8. Install the drive pinion, bearing cage and new
shim pack into the carrier.
Table B: Shim Pack Thickness Calculations
Examples: Inches mm
1. Old Shim Pack Thickness 0.030 – 0.002 = 0.028 0.760 – 0.050 = 0.710
Old PC Number, PC +2 inches (+0.05 mm) + 0.005 = 0.033 + 0.130 = 0.840
Standard Shim Pack Thickness
New PC Number, PC +5 inches (+0.13 mm)
New Shim Pack Thickness
2. Old Shim Pack Thickness 0.030 + 0.002 = 0.032 0.760 + 0.050 = 0.810
Old PC Number, PC –2 inches (–0.05 mm) + 0.005 = 0.037 + 0.130 = 0.940
New PC Number, PC +5 inches (+0.13 mm)
3. Old Shim Pack Thickness 0.030 – 0.002 = 0.028 0.760 – 0.050 = 0.710
Old PC Number, PC +2 inches (+0.05 mm) – 0.005 = 0.023 – 0.130 = 0.580
New PC Number, PC –5 inches (–0.13 mm)
4. Old Shim Pack Thickness 0.030 + 0.002 = 0.032 0.760 + 0.050 = 0.810
Old PC Number, PC –2 inches (–0.05 mm) – 0.005 = 0.027 – 0.130 = 0.608
New PC Number, PC –5 inches (–0.13 mm)
NOTE: Drive pinions and ring gears MUST be

replaced as fully matched sets.
42
Section 5
Assembly
Installing the Drive Pinion,

WARNING
Bearing Cage and Shim Pack Use a brass or leather mallet for assembly and
into the Carrier disassembly procedures. Do not hit steel parts
NOTE: If a new drive pinion and ring gear set is and cause serious personal injury.
installed, or if the depth of the drive pinion has to
be adjusted, calculate the thickness of the shim 5. Install the drive pinion and bearing cage into
pack. Refer to “Adjusting Shim Pack Thickness for the carrier. If necessary, use a rubber, plastic or
the Pinion Cage (Depth of Pinion)” in this section. leather mallet to hit the assembly into position.
Figure 5.27.
1. Select the correct shim pack between the
bearing cage and carrier. Figure 5.26.
Figure 5.27
2. Apply Loctite 518 Gasket Eliminator to face
of carrier.
3. Align the oil slots in the shims with oil slots in
the bearing cage and carrier. The use of guide
studs will help align the shims. Figure 5.26.
Figure 5.26
1 DRIVE PINION AND BEARING CAGE

2 SHIMS
3 CARRIER
6. If used, install the cover* and seal assembly

and gasket* over the bearing cage. Figure 5.28.
Figure 5.28
1 GUIDE STUDS
2 THREE SHIMS MINIMUM
3 CARRIER
NOTE: If the pack is made from different thickness

shims, install the thinnest shims on both sides of
the pack for maximum sealing.
4. Apply Loctite 518 Gasket Eliminator to top of
shim pack.
1 GASKET
2 BEARING CAGE
3 COVER AND SEAL ASSEMBLY

described parts.
43
Section 5
Assembly
7. Align the oil slots in the cover* and gasket*
with oil slot in the bearing cage. CAUTION
8. Install the bearing cage to carrier capscrews Make sure that the seal lips are clean and free from
and washers. T ighten capscrews to correct dirt and particles that can cause a leak between
torque value. Refer to Table J. Figure 5.29. the yoke and the POSE™ seal.
b. Partially install the POSE™ seal onto the
Figure 5.29 yoke to 1/4-inch – 1/2-inch as shown in
Figure 5.30.
Figure 5.30
Installing Tight Fit Yokes and 1 LUBRICATE TRIPLE-LIP (MAIN) SEAL.

POSE™ Seal 2
3
INPUT SHAFT (PINION)
POSE™ SEAL 0.25”–0.50” (6.4 MM–12.7 MM) ONTO
HUB
4 INSPECT YOKE HUB.
CAUTION
Make sure that the seal lips are clean and free from
dirt and particles that will cause a leak between NOTE: DO NOT install POSE™ seal all the way
the yoke and the seal. against the yoke shoulder. This seal is designed to
position itself as yoke is installed.
Do not install tight fit yokes on shafts using a
hammer or mallet. Using a hammer or mallet can c. Before installing the yoke onto the drive
damage the yoke. pinion, lubricate the yoke again with the
same lubricant used in the axle housing.
1. Apply axle lubricant on the yoke seal.
3. Slide the yoke over the input shaft pinion.
2. Inspect all surfaces of the yoke hub for Align the yoke splines with the shaft splines.
damage.
If carrier uses a POSE™ seal element, install a CAUTION
new POSE™ seal as follows:
Do not use a hammer or mallet to install the yoke
a. Lightly lubricate yoke journal with same to the input pinion shaft. Using a hammer or
lubricant used in the axle housing. mallet can damage the yoke or flange.
4. Install the input yoke flange onto the drive
pinion shaft. The yoke or flange must be fully
seated against the outer differential bearing
BEFORE the nut is torqued to specifications.

described parts.
44
Section 5
Assembly
5. Install the drive pinion nut on the input pinion 5. If rivets* were used to hold the ring gear to the
shaft and against the yoke collar. T ighten the flange case half, replace them with bolts, nuts
nut against yoke collar to torque specifications. and washers.
Figure 5.31. Refer to Table J. T
6. Install the bolts*, nuts* and washers* that hold
the ring gear to the flange case half. Install the
Figure 5.31 bolts from the gear side of the assembly. The
bolt heads MUST be against the ring gear.
Figure 5.32.
Figure 5.32
1 USE FLANGE OR YOKE BAR.
1 FLANGE CASE HALF

Assemble the Main Differential 2
3
RING GEAR
BOLT HEAD AGAINST GEAR
and Ring Gear Assembly
7. T ighten the bolts* and nuts* to the correct
CAUTION torque value. Refer to Table J. T
Do not press a cold ring gear on the flange case 8. Inspect for gaps between the back surface of
half. A cold ring gear will damage the case half the ring gear and the case flange after the bolts
because of the tight fit. Metal particles between are installed. Use an 0.003-inch (0.080 mm)
the parts will cause gear runout that exceeds the feeler gauge and inspect at four points around
Meritor specification of 0.008-inch (0.200 mm). the assembly. Figure 5.33.
1. Expand the ring gear by heating the gear in a
tank of water to a temperature of 160°F to
180°F (71°C-82°C) for 10 to 15 minutes. Figure 5.33
WARNING
Wear safe clothing and gloves for protection from
injury when working with the hot ring gear.
2. Safely lift the ring gear from the tank of water
using a lifting tool.
3. Install the ring gear on the flange case half
immediately after the gear is heated. If the ring
gear does not fit easily on the case half, heat
the gear again. Repeat Step 1.
4. Align fastener holes of the ring gear and flange
1 CHECK FOR 0.003” GAP AT FOUR LOCATIONS.
case half. Rotate the ring gear as needed.

described parts.
45
Section 5
Assembly
9. Inspect the flange case half and ring gear for
Figure 5.35
the problem that causes the gap. Repair or
replace parts that do not meet specifications.
10. Assemble the repaired or replaced ring gear on
the flange case half. Repeat the Main
Differential and Ring Gear Assembly
procedure.
11. Install the bearing cones on both of the case
halves. Use a press and sleeve of the correct
size. Figure 5.34.
Figure 5.34
1 SIDE GEAR
2 THRUST WASHER
3 FLANGE CASE HALF
CAUTION
The side gears in some carrier models have hubs
of different lengths. Install the correct length side
gear into the flange case half.
15. Install the spider (cross), differential pinions
and thrust washers into the flange case half.
1 PRESS Figure 5.36.
2 SLEEVE
3 BEARING CONE
4 SUPPORT Figure 5.36
5 SUPPORT
6 CASE HALF
12. Apply axle lubricant on the inside surfaces of

both case halves, spider (cross), thrust
washers, side gears and differential pinions.
13. Place the flange case half on a bench, ring gear
teeth toward top.
14. Install one thrust washer and side gear into the
flange case half. Figure 5.35.
1 SPIDER, PINION AND THRUST WASHERS
46
Section 5
Assembly
16. Install the second side gear and thrust washer 18. Install Dri-Loc fasteners into the case halves.
over spider and differential pinions. Refer to “Application of Three Bond 1216 or
Figure 5.37. Equivalent Silicone Gasket Material” in
Section 4 and the following Steps a and b.
Figure 5.37 a. Install four capscrews* and washers* or

bolts*, nuts* and washers* into the case
halves. The distance between the fasteners
MUST be equal. T ighten the fasteners to
the correct torque value in a progressive
criss-cross pattern opposite each other.
Refer to Figure 5.39 and to Table J. T
Figure 5.39
10 6
2
4
15
13
12
8
1 THRUST WASHER
2 SIDE GEAR
3 PLAIN CASE HALF
11 7
17. Place the plain half of the differential case over 14
the flange half and gears. Rotate the plain half 1
as needed to align the match marks. Figure 5.37 3
and Figure 5.38. 16
5 9
Figure 5.38
b. Install the other fasteners into the case
halves. T ighten the fasteners to the correct
torque value. Refer to Table J. T
19. Inspect the rotating resistance of the
differential gears. Use the following procedure.
1 PLAIN CASE HALF

2 MATCH MARKS

described parts.
47
Section 5
Assembly
Inspecting the Rotating Resistance Figure 5.41

of the Differential Gears
Specification
r 50 lb-ft (67.8 N•m) maximum torque applied to
one side gear. T
NOTE: Make a tool for inspecting the rotating
resistance of the differential gears. The tool can
be made from an axle shaft that matches the
spline size of the differential side gear. Refer to
Figure 5.40 and Figure 5.41.
Figure 5.40
1 TOOL FOR CHECKING RESISTANCE

2 SOFT METAL COVER
Figure 5.42
1 APPROXIMATELY 12-INCHES (304.8 MM)

2 SIDE VIEW
3 WELD NUT TO END OF SHAFT.
4 END VIEW
1. Install soft metal covers over vise jaws to

protect the ring gear. Figure 5.41.
2. Place the differential and ring gear assembly in
the vise and close the vise jaws.
1 READ TORQUE VALUE.
3. Install the tool into the differential until the
splines of the tool and one side gear are
engaged. Figure 5.41. 5. If the torque value exceeds the specification,
disassemble the differential gears from the
4. Engage a torque wrench to the nut of the tool case halves.
and rotate the differential gears. As the
differential gears rotate, read the value 6. Inspect the case halves, spider, gears and
indicated on the torque wrench. Figure 5.42. thrust washers for the problem that causes the
torque value to exceed the specification. Repair
or replace parts.
7. After all the differential assembly parts are
repaired or replaced, assemble the parts and
repeat Steps 1 through 7.
48
Section 5
Assembly
Install the Differential and Figure 5.44

Ring Gear Assembly
1. Clean and dry the bearing cups and bores of
the carrier legs and bearing caps.
2. Apply axle lubricant on the inner diameter of
the bearing cups and on both bearing cones
that are assembled on the case halves.
3. Apply Meritor Adhesive into the bearing bores
of the carrier legs and bearing caps. Make
certain not to allow adhesive to contact
adjusting ring threads. Refer to “Application of
Three Bond 1216 or Equivalent Silicone Gasket
Material” in Section 4. Figure 5.43.
Figure 5.43
1 BEARING CUP
2 BEARING CUP
3 LEG BORE
6. Install both of the bearing adjusting rings into

position between the carrier legs. Turn each
adjusting ring hand-tight against the bearing
cup. Figure 5.45.
Figure 5.45
1 ADHESIVE
2 BEARING CAP
3 CARRIER LEG
4. Install the bearing cups over the bearing

cones that are assembled on the case halves.
Figure 5.44.
5. Safely lift the differential and ring gear
assembly and install into the carrier. The
bearing cups MUST be flat against the bores
between the carrier legs. Figure 5.44.
1 ADJUSTING RING
2 LEG
49
Section 5
Assembly
7. Install the bearing caps over the bearings and 10. Install the capscrews and washers that hold
adjusting rings in the correct location as bearing caps to the carrier. T ighten the
marked before removal. Figure 5.46. capscrews by hand four to six turns, then
tighten the capscrews to the correct torque
value. Refer to Table J. T
Figure 5.46
NOTE: Do not install the cotter keys*, pins* or lock
plates* that hold the bearing adjusting rings in
position. Continue by adjusting the preload of
differential bearings, adjust backlash of the hypoid
gear and inspect tooth contact patterns.
* Some Meritor carriers do not have these

described parts.
Adjust Preload of
Differential Bearings
Specifications
r Preload of differential bearings
(all carrier models)
— 15 to 35 lb-in (1.7-3.9 N•m) torque. T
r Expansion between bearing caps (leg spread)
1 BEARING CAP — R-140, R-155 and R-160 carrier models:
2 MATCH MARKS 0.002- to 0.009-inch (0.050-0.229 mm)
— R, S, U and W 120 series and most (check
latest specifications) other carrier models:
WARNING 0.00- to 0.013-inch (0.150-0.330 mm)
disassembly procedures. Do not hit steel parts Method 1
with a steel hammer. Pieces of a part can break off 1. Attach a dial indicator on the mounting flange
and cause serious personal injury. of the carrier.
8. Seat each bearing cap with a light leather, 2. Adjust the dial indicator so that the plunger or
plastic or rubber mallet. The caps MUST fit pointer is against the back surface of the ring
easily against the bearings, adjusting rings and gear. Figure 5.47.
carrier. Do not force the bearing caps into
position.
Figure 5.47
CAUTION
If bearing caps are not installed in the correct
original locations, the bores and threads in caps
will not match the carrier. Assembling
mismatched caps into the carrier can result in
carrier damage after reassembly to axle and
during vehicle operation. Do not force the bearing
caps into unmatched bore locations in the carrier.
9. If bearing caps do not correctly fit into position,
inspect the alignment of match marks between
caps and carrier. Remove the caps and repeat
Steps 6-8.
1 DIAL INDICATOR
50
Section 5
Assembly
Figure 5.49
CAUTION
When you turn the adjusting rings, always use a
tool that engages two or more opposite notches in
the ring. A “T” bar wrench can be used for this
purpose. If the tool does not correctly fit into
the notches, damage to the lugs will occur.
Figure 5.48.
3. Loosen the bearing adjusting ring that is
opposite the ring gear so that a small amount
of end play shows on the dial indicator.
Figure 5.48. Move the differential and ring gear
to the left and right with pry bars while you
read the dial indicator. Use the following Step
a or b.
Figure 5.48
1 BARS MUST NOT TOUCH BEARINGS.
Figure 5.50
1 “T” BAR WRENCH

2 ADJUSTING RING OPPOSITE RING GEAR
a. Use two pry bars that fit between the

bearing adjusting rings and ends of the
differential case. The pry bars MUST NOT
touch the differential bearings. Figure 5.49.
b. Use two pry bars between the differential
case or ring gear and the carrier at
locations other than described in Step a.
The pry bars MUST NOT touch the 1 BARS MUST NOT TOUCH BEARINGS.
differential bearings. Figure 5.50.
51
Section 5
Assembly
4. T ighten the same bearing adjusting ring so
Figure 5.52
that no end play shows on the dial indicator.
Move the differential and ring gear to the left
and right as needed. Repeat Step a or b.
5. T ighten each bearing adjusting ring one notch
from the zero end play measured in Step 4.
6. Continue by checking runout of the ring gear.
Method 2
A second method of inspecting preload is to
measure the expansion between the bearing caps
(leg spread) after the adjusting rings are tightened.
Use the following procedure.
1. Turn both adjusting rings hand tight against
the differential bearings.
2. Measure the distance X or Y between opposite
surfaces of the bearing caps. Use a large 1 MICROMETER
micrometer of the correct size. Figure 5.51 and
Figure 5.52. Record the measurement.
3. T ighten each bearing adjusting ring one notch.
Figure 5.51 4. Measure the distance X or Y again. Compare
the dimension with the distance X or Y
measured in Step 2. The difference between
the two dimensions is the amount the bearing
caps have expanded.
Example
r Measurements of R-155 carrier
r Distance X or Y
— before tightening adjusting rings =
13.927-inch (353.740 mm)
r Distance X or Y
— after tightening adjusting rings =
13.936-inch (353.970 mm)
r 13.936-inch − 13.927-inch =
0.009-inch (0.230 mm) difference
If the dimension is within specifications, continue
by checking runout of the ring gear. If the
dimension is less than specifications, repeat
Steps 3 and 4 as needed.
52
Section 5
Assembly
Inspect Runout of Ring Gear Ring Gear Backlash Adjustment

Runout Specification Specifications
r 0.008-inch (0.200 mm) r Ring gears that have a pitch diameter of less
than 17-inches (431.8 mm)
1. Attach a dial indicator on the mounting flange
of the carrier. Figure 5.53. — Range of backlash setting:
0.008- to 0.018-inch (0.200-0.460 mm).
— Backlash setting for new gear sets:
Figure 5.53
0.012-inch (0.300 mm)
r Ring gears that have a pitch diameter greater
than 17-inches (431.8 mm)
— Range of backlash setting:
0.010- to 0.020-inch (0.250-0.510 mm)
— Backlash setting for new gear sets:
0.015-inch (0.380 mm)
NOTE: Measure the outer diameter of ring gear for
approximate pitch diameter. Figure 5.54.
Figure 5.54
1 ROTATE RING GEAR.

2 DIAL INDICATOR
2. Adjust the dial indicator so that the plunger or

pointer is against the back surface of the ring
gear.
3. Set the dial indicator to zero (0).
4. Rotate the differential and ring gear and read
the dial indicator. The runout of the ring gear
1 MEASURE OUTER DIAMETER FOR APPROXIMATE.
must not exceed 0.008-inch (0.200 mm). PITCH DIAMETER
Figure 5.53.
If runout of the ring gear exceeds
specifications, remove the differential and ring If the old gear set is installed, adjust the backlash
gear assembly from the carrier. Refer to to the setting that was measured before the carrier
“Remove the Differential and Ring Gear from was disassembled.
the Carrier” in Section 2 and the following If a new gear set is installed, adjust the backlash to
Steps 5 and 6. the correct specification for new gear sets.
5. Inspect the differential parts including the After inspection of the tooth contact patterns, the
carrier for the problem that causes the runout backlash can be adjusted within specification
of gear to exceed specifications. Repair or limits, if needed. To change the location of the
replace parts. pattern use the following procedures.
6. After the parts are repaired or replaced, install
the differential and ring gear into the carrier.
Refer to “Install the Differential and Ring Gear
Assembly” in this section.
7. Repeat preload adjustment of differential
bearings.
53
Section 5
Assembly
1. Attach a dial indicator on the mounting flange 6. Loosen one bearing adjusting ring one notch
of the carrier. Figure 5.55. then tighten the opposite ring the same
amount. Refer to Figure 5.56 and Figure 5.57.
Figure 5.55
Figure 5.56
1 TIGHTEN ADJUSTING RING THIS SIDE.

2 INCREASE BACKLASH.
3 LOOSEN ADJUSTING RING THIS SIDE.
Figure 5.57
2. Adjust the dial indicator so that the plunger

or pointer is against the tooth surface.
Figure 5.55.
3. Adjust the indicator dial to zero (0).
4. Hold the drive pinion in position.
5. After reading the dial indicator, rotate the
differential and ring gear a small amount in 1 LOOSEN ADJUSTING RING THIS SIDE.
2 DECREASE BACKLASH.
both directions, against the drive pinion teeth. 3 TIGHTEN ADJUSTING RING THIS SIDE.
If the backlash reading is within specification,
continue inspecting tooth contact patterns. If
the backlash reading is not within NOTE: When you adjust backlash, move the ring
specifications, adjust backlash as needed. gear ONLY. DO NOT move the drive pinion.
Continue following Steps 6 and 7.
7. Repeat Steps 2-6 until the backlash is within
NOTE: Backlash is increased by moving the ring specifications.
gear away from the drive pinion. Figure 5.56.
Backlash is decreased by moving the ring gear
toward the drive pinion. Figure 5.57.
54
Section 5
Assembly
Inspect Tooth Contact Patterns of In the following procedures, movement of the

contact pattern in the length of the tooth is
the Gear Set indicated as, toward the “heel” or “toe” of the ring
gear. Figure 5.59.
General Information
Meritor carriers can have a conventional HYPOID Figure 5.59
gear set or a GENEROID hypoid gear set. The
tooth contact patterns for each type of gear set
are different. Look at the part numbers to see
what type of gear set is in the carrier. Refer to
Figure 5.58 for the location of part numbers.
Figure 5.58
1 HEEL
2 TOE
Always inspect tooth contact patterns on the drive

1 PART NO.
side of the gear teeth. Figure 5.60.
2 PART NO.
3 PART NO. OPTION
Figure 5.60
Examples of part numbers for conventional

HYPOID gear sets.
r 36786 for the ring gear.
r 36787 for the drive pinion.
Examples of part numbers for GENEROID gear sets.
r 36786-K or 36786-K2 for the ring gear.
r 36787-K or 36787-K2 for the drive pinion.
1 DRIVE SIDE (CONVEX)
55
Section 5
Assembly
Tooth Contact Patterns of Conventional The location of a good hand-rolled contact
Hypoid and Generoid Hypoid Gear Sets pattern for an old gear set MUST match the
wear pattern in the ring gear. The contact
1. Adjust the backlash of a new gear set to pattern will be smaller in area than the wear
either 0.012-inch (0.305 mm) or 0.015-inch pattern.
(0.380 mm) depending on the size of the ring
gear. Adjust the backlash of an old gear set to If the contact patterns require adjustment,
the setting that was measured before the continue by following Step 5 to move the
carrier was disassembled. Refer to ”Ring Gear contact patterns between the top and bottom
Backlash Adjustment” in this section. of the gear teeth. If the contact patterns are in
the center of the gear teeth, continue by
2. Apply a marking compound to approximately following Step 6.
12 gear teeth of the ring gear. Rotate the ring
gear so that the 12 gear teeth are next to the
drive pinion. Figure 5.61. Figure 5.62
Figure 5.61
Good Hand-Rolled Pattern/Conventional Gears
Figure 5.63
3. Rotate ring gear forward and backward so that
the 12 gear teeth go past the drive pinion six
times to get the contact patterns. Repeat if
needed to get a more clear pattern.
4. Look at the contact patterns on the ring gear
teeth. Compare the patterns to Figure 5.62 or
Figure 5.65, Figure 5.63 or Figure 5.66, and
Figure 5.64 or Figure 5.67.
The Location of Good Hand-Rolled Contact
Patterns.
New Conventional and Generoid Gear Sets —
toward the toe of the gear tooth and in the
center between the top and bottom of the
tooth. Refer to Figure 5.62 and Figure 5.65.
When the carrier is being operated, a good High Pattern/Conventional Gears
pattern will extend approximately the full
length of the gear tooth. The top of the pattern
will be near the top of the gear tooth. Refer to
Figure 5.68 or Figure 5.69.
56
Section 5
Assembly
Low Pattern/Conventional Gears Low Pattern/Generoid Gears
Good Hand-Rolled Pattern/Generoid Gears Good Pattern in Operation Conventional Gears
High Pattern/Generoid Gears Good Pattern in Operation Generoid Gears
57
Section 5
Assembly
5. Change the thickness of the shim pack under
Figure 5.71
bearing cage to move the contact patterns
between the top and bottom of the gear teeth.
Use the following procedure.
a. Remove the drive pinion and bearing cage
from the carrier. Refer to “Remove the
Drive Pinion and Bearing Cage from
Carrier” in Section 2.
NOTE: A high contact pattern indicates that the
drive pinion was not installed deep enough into
the carrier. A low contact pattern indicates that the
drive pinion was installed too deep in the carrier.
b. To correct a high contact pattern,
Figure 5.63, decrease the thickness of the
shim pack under the bearing cage. When
decreasing the thickness of the shim pack,
the drive pinion will move toward the ring
1 INCREASE SHIM PACK.
gear. Figure 5.70.
To correct a low contact pattern,
Figure 5.71, increase the thickness of shim c. Install the drive pinion, bearing cage and
pack under the bearing cage. When shims into the carrier. Refer to “Adjusting
increasing the thickness of the shim pack, Shim Pack Thickness for the Pinion Cage
the drive pinion will move away from the (Depth of Pinion)” in this section.
ring gear. Figure 5.71. d. Repeat Steps 2-5 until the contact patterns
are in the center between the top and
bottom of the gear teeth.
Figure 5.70
6. Adjust backlash of the ring gear within
specification range to move the contact
patterns to the correct location in the length of
the gear teeth. Refer to “Ring Gear Backlash
Adjustment” in this section.
a. Decrease backlash to move the contact
patterns toward the toe of the ring gear
teeth. Figure 5.72.
Figure 5.72
1 DECREASE SHIM PACK.
1 MOVE PATTERN TOWARD TOE, LOOSEN ADJUSTING

RING THIS SIDE.
3 TIGHTEN ADJUSTING RING.
58
Section 5
Assembly
b. Increase backlash to move the contact c. Lock Plates* — Install lock plate on bearing
patterns toward the heel of the ring gear cap so that the tab is between lugs of the
teeth. Figure 5.73. adjusting ring. Install the two capscrews
that hold the lock plate to the bearing cap.
c. Repeat Steps 2-4 and 6 until the contact
T ighten the capscrews to correct torque
patterns are at the correct location in the
value. Refer to Table J. Figure 5.74. T
length of the gear teeth.
Figure 5.74
Figure 5.73
1 MOVE PATTERN TOWARD TOE, LOOSEN ADJUSTING

RING THIS SIDE.
3 LOOSEN ADJUSTING RING.
1 COTTER KEY
2 PIN
CAUTION 3 LOCK PLATE
4 THREADED HOLES IN CAP WHEN LOCK PLATE IS
If the carrier has cotter keys, lock the adjusting USED
rings only with cotter keys. If your carrier has roll
pins, reuse the roll pins or lock the adjusting rings SHOWN WITH COTTER KEY INSTALLED
with cotter keys. Do not force a roll pin into a
cotter key hole.
7. Install cotter keys*, pins*, or lock plates* that
hold the two bearing adjusting rings in
position. Use the following procedures.
a. Cotter Keys* — Install cotter keys between
lugs of the adjusting ring and through the
boss of the bearing cap. Bend the two
ends of the cotter key around the boss.
Figure 5.74.
b. Pins* — Install pin through boss of the
bearing cap until the pin is between lugs of
the adjusting ring. Use a drift and hammer
to install the pin. Figure 5.74.

described parts.
59
Section 5
Assembly
Install and Adjust the Figure 5.76

Thrust Screw*
Specification
r Clearance between thrust screw and ring gear
— 0.025- to 0.045-inch (0.650-1.140 mm).
r Loosen the thrust screw 1/2 turn or 180°.
If the carrier does not have a thrust block*, start
at Step 4.
1. Rotate the carrier in the repair stand until the
back surface of ring gear is toward the top.
Figure 5.75.
2. Place the thrust block* on the back surface of
the ring gear. The thrust block* MUST be in the
center between the outer diameter of gear and 1 THRUST SCREW AND JAM NUT
differential case.
3. Rotate the ring gear until the thrust block* and
hole for thrust screw, in carrier, are aligned. Figure 5.77
Figure 5.75.
4. Install the jam nut* on the thrust screw*, one
half the distance between both ends.
5. Install the thrust screw* into the carrier until
the screw stops against the ring gear or thrust
block*. Figure 5.76.
6. Loosen the thrust screw* 1/2 turn, 180°.
Figure 5.77.
Figure 5.75
1 LOOSEN THRUST SCREW 1/2 TURN.
1 HOLE FOR THRUST SCREW

2 THRUST BLOCK

described parts.
60
Section 5
Assembly
7. T ighten the jam nut* to the correct torque 1. Clean the inside of axle housing and the
value against the carrier. Refer to Table J. mounting surface where the carrier fastens.
Figure 5.78. T Use a cleaning solvent and rags to remove dirt.
Blow dry the cleaned areas with air. Also refer
to “Cleaning Axle Assemblies” in Section 3.
Figure 5.78
2. Inspect the axle housing for damage. Repair or
replace the axle housing. Refer to “Repair or
Replacement of Parts, General” in Section 3.
3. Inspect for loose studs* in the mounting
surface of the housing where the carrier
fastens. Remove and clean the studs* that are
loose.
4. Apply liquid adhesive to the threaded holes
and install the studs* into axle housing.
Refer to “Application of Meritor Adhesive
2297-T-4180 in Bearing Bores for the
Differential” in Section 4. T ighten studs* to
correct torque value. Refer to Table J. T
5. Apply silicone gasket material to the mounting
surface of the housing where the carrier
fastens. Refer to “Application of Three Bond
1216 or Equivalent Silicone Gasket Material” in
Section 4. Figure 5.79.
Figure 5.79
1 TIGHTEN JAM NUT TO CORRECT TORQUE VALUE.
2 HOLD THRUST SCREW IN POSITION.
Install Differential Carrier into

Axle Housing
WARNING
Solvent cleaners can be flammable, poisonous and
carbon tetrachloride, emulsion-type cleaners and
personal injury when you use solvent cleaners,
you must carefully follow the manufacturer's
1 1/8” (3.2 MM) DIAMETER SILICONE GASKET BEAD
r Wear safe eye protection.
r Wear clothing that protects you skin.
r Work in a well-ventilated area.
r You must use hot solution tanks or alkaline
solutions correctly. Follow the manufacturer's

described parts.
61
Section 5
Assembly
6. Install the carrier into the axle housing. Use a 12. Install the gaskets and axle shafts into the axle
hydraulic roller jack or a lifting tool. housing and carrier. The gasket and flange of
the axle shafts MUST fit flat against the wheel
hub. Figure 5.81.
CAUTION
Do not use a hammer or a mallet to install the
carrier. A hammer or a mallet will damage the Figure 5.81
mounting flange of the carrier and cause oil leaks.
7. Install the nuts* and the washers or the
capscrews and washers in the four corner
locations around the carrier and the axle
housing. T ighten the fasteners by hand. Do not
tighten to the specified torque. Figure 5.80.
8. Carefully push the carrier into position.
T ighten the four fasteners two or three turns
each in a pattern opposite each other. Refer to
Figure 5.80.
Figure 5.80
1 TAPERED DOWEL 7 SHAFT HUB AXLE

RETENTION 8 AXLE SHAFT (FLANGE)
2 STUD NUT 9 WASHER
3 WASHER 10 CAPSCREW
4 TAPERED DOWEL 11 NON-TAPERED DOWEL
5 GASKET RETENTION
6 STUD
9. Repeat Step 9 until the four fasteners are

tightened to the correct torque value. T
r Fasteners with standard flat washers:
T ighten fasteners to 150-230 lb-ft
(203-312 N•m).
10. Install the remaining fasteners and washers
that hold the carrier in the axle housing.
T ighten fasteners to the correct torque value.
Refer to Table J. T
11. Connect the driveline universal joint to the
pinion input yoke or flange on the carrier.

described parts.
62
Section 5
Assembly
Straight Holes, Nuts and Tapered Dowel, Hardened Washer

Hardened Washers and Hardened Nut
1. Clean the mating surfaces of the axle shaft and 1. Clean the mating surfaces of the axle shaft and
the wheel hub. the wheel hub.
2. If silicone gasket material is used, apply a 2. If silicone gasket material is used, apply a
1/8-inch diameter bead of the gasket material 1/8-inch diameter bead of the gasket material
around the mating surface of the hub and around the mating surface of the hub and
around the edge of each fastener hole in around the edge of each fastener hole in
that surface. that surface.
3. Install the gasket and the axle shaft into the 3. Install the gasket and the axle shaft into the
housing. The gasket and the flange of the axle housing. The gasket and the flange of the axle
shaft MUST fit flat against the wheel hub. Refer shaft MUST fit flat against the wheel hub. Refer
to Figure 5.81. to Figure 5.81.
4. Install the Grade 8 nuts and hardened washers 4. Install solid tapered dowels over each stud and
on the stud. (Lock washers are an acceptable into the flange of the axle shaft. Use a punch or
alternative.) T ighten the stud nuts to the torque a drift and hammer, if necessary.
specified in Table C. 5. Install the Grade 8 nuts and hardened washers
on the stud. (Lock washers are an acceptable
alternative.) T ighten the stud nuts to the torque
specified in Table D.
Table C: Shaft-to-Hub Torque Fastener — Non-tapered Dowel Applications

Torque Value — Grade 8 Nuts lb-ft (N•m) T
Fastener Thread Size Plain Nut Lock Nut
Stud Nut .62-18 150-230 (203-312) 130-190 (176-258)
(Axle Shaft) .75-16 310-400 (420-542) 270-350 (366-475)
Studs All Install the course thread end of stud into hub and tighten
to last thread.
Table D: Shaft-to-Hub Torque Fastener — Tapered Dowel Applications

Torque Value — Grade 8 Nuts lb-ft (N•m) T
Fastener Thread Size Plain Nut Lock Nut
Stud Nut .44-20 50-75 (81-102) 40-65 (67-88)
(Axle Shaft) .50-20 75-115 (115-156) 65-100 (102-136)
.56-18 110-165 (176-224) 100-145 (149-197)
.62-18 150-230 (203-312) 130-190 (176-258)
Studs All Install the course thread end of stud into hub and tighten
to last thread.
63
Section 6
Lubrication
NOTE: For complete information on lubricating
Section 6Lubrication
drive axles and carriers, refer to Maintenance

Manual 1, Lubrication.
Refer to Table E, Table F and Table I for standard
information on lubricants, schedules and
capacities.
Table E: Lubricant Cross Reference (Viscosity) and Temperature

Meritor Lubricant Minimum Outside Maximum Outside
Specification Description Cross Reference Temperature Temperature
O-76-A Hypoid Gear Oil GL-5, S.A.E. 85W/140 +10°F (–12.2°C) - - -**
O-76-B Hypoid Gear Oil GL-5, S.A.E. 80W/140 –15°F (–26.1°C) - - -**
O-76-D Hypoid Gear Oil GL-5, S.A.E. 80W/90 –15°F (–26.1°C) - - -**
O-76-E Hypoid Gear Oil GL-5, S.A.E. 75W/90 –40°F (–40°C) - - -**
O-76-J Hypoid Gear Oil GL-5, S.A.E. 75W –40°F (–40°C) + 35°F (+ 1.6°C)
O-76-L Hypoid Gear Oil GL-5, S.A.E. 75W/140 –40°F (–40°C) - - -**
**There is no upper limit on these outside temperatures, but the axle sump temperature must never exceed 250-F (+ 121-C).
Table F: Rear Drive Axle Oil Change Intervals and Specifications a

APPLIES TO ALL REAR AXLES EXCEPT THE “ADVANCED LUBE” REAR AXLES.
On-Highway Operation Intervals Off-Highway Operation Intervals b Outside Temperature

Initial Synthetic Petroleum Synthetic Meritor F° C°
Oil Inspect Oil Petroleum
Change Level Oil Change
Oil
Change
Initial Oil Inspect
Change Oil Level
Oil
Change c Oil
Change
Specifications
(Military)
Oil
Description Min. Max. Min. Max.
3,000 3,000 miles If annual 250,000 1,000 1,000 If annual 50,000 O-76A, Gear Oil GL-5, SAE 10 None –12 None
miles (4,800 km), mileage is miles miles miles mileage is miles (MIL-L-2105D or 85W/140
(4,800 once a less than (400,000 (1,600 (1,600 less than (80,000 MIL-PRF-2105E)
km) month or 100,000 km) km) km) 60,000 km)
the fleet miles miles O-76D, Gear Oil GL-5, SAE –15 None –26 None
maint- (160,000 km) (96,000 km) (MIL-L-2105D or 80W/90
enance change oil change oil MIL-PRF-2105E)
interval once a year. twice a
(whichever year. O-76E, Gear Oil GL-5, SAE –40 None –40 None
comes (MIL-L-2105D or 75W/90
first) MIL-PRF-2105E)
O-76J, Gear Oil GL-5, SAE –40 35 –40 2
(MIL-L-2105D or 75W
MIL-PRF-2105E)
O-76L, Gear Oil GL-5, SAE –40 None –40 None
(MIL-L-2105D or 75W/140
MIL-PRF-2105E)
O-76M, Full GL-5, SAE –40 None –40 None
Synthetic 75W/140
Gear Oil
(MIL-L-2105D or
MIL-PRF-2105E)
If annual If annual O-76N, Full GL-5, SAE –40 None –40 None
mileage is mileage is Synthetic 75W/90
more than more than Gear Oil
100,000 60,000 (MIL-L-2105D or
miles miles MIL-PRF-2105E)
(160,000 km), (96,000
change oil km),
every change oil
100,000 every
miles 30,000
(160,000 km). miles
(48,000
km).
NOTES
a If oil pump and filter is used, change filter every 100,000 miles (160,000 km). Inspect oil level. Add correct oil as required.
b Includes heavy-duty on-highway and on/off-highway applications.
c For continuous heavy-duty operation, inspect oil level every 1,000 miles (1,600 kilometers).
64
Section 6
Lubrication
Table G: “Advanced Lube” Rear Drive Axle without Oil Pump and
Filter Oil Change Intervals and Specifications a
APPLIES TO TANDEM REAR AXLES MANUFACTURED AFTER JANUARY 1, 1993 EQUIPPED WITH
“MEMBRANE” TYPE BREATHERS AND ADVANCED MATERIAL TRIPLE-LIP SEALS.
On-Highway Operation Intervals On-/Off-Highway Operation Intervals b Outside Temperature
Meritor F° C°
Inspect
Oil Level
Petroleum
Oil Change c Change d Levele
Synthetic Oil Inspect Oil Petroleum
Oil Change c Change d
Synthetic Oil Specifications
(Military)
Oil
3,000 miles 100,000 250,000 3,000 miles 40,000 miles 80,000 miles O-76A, Gear Oil GL-5, SAE 10 None –12 None
(4,800 km), miles miles (4,800 km) or (64,000 km) (128,000 km) (MIL-PRF-2105E) 85W/140
once a (160,000 km) (400,000 km) 200 hours of
month or the operation O-76D, Gear Oil GL-5, SAE –15 None –26 None
fleet (MIL-PRF-2105E) 80W/90
maintenance
interval O-76E, Gear Oil GL-5, SAE –40 None –40 None
(whichever (MIL-PRF-2105E) 75W/90
comes first) O-76J, Gear Oil GL-5, SAE –40 35 –40 2
(MIL-PRF-2105E) 75W
(MIL-PRF-2105E) 75W/140
Synthetic Gear Oil 75W/140
(MIL-PRF-2105E)
O-76N, Full GL-5, SAE –40 None –40 None
Synthetic Gear Oil 75W/90
(MIL-PRF-2105E)
NOTES
a IforaaNo-Spin differential is installed, oil (petroleum or synthetic) must be changed at minimum interval of 64,000 km (40,000 miles)
maximum interval of 50,000 miles (80,000 km).
b Also applies to heavy-duty on-highway applications. Does not apply to off-highway applications.
c For petroleum oil with extended drain additives, use the “Synthetic Oil Change” interval.
d Applies to semi-synthetic oils and full-synthetic oils. For a list of approved synthetic oils, refer to Maintenance Manual 1, Lubrication.
e For continuous heavy-duty operation, inspect the oil level every 1,000 miles (1,600 km). Add the correct oil as required.
Table H: Tandem “Advanced Lube” Rear Drive Axle with Oil Pump and
Filter Oil Change Intervals and Specifications ab
APPLIES TO TANDEM REAR AXLES MANUFACTURED AFTER JANUARY 1, 1993 EQUIPPED WITH
“MEMBRANE” TYPE BREATHERS AND ADVANCED MATERIAL TRIPLE-LIP SEALS.
On-Highway Operation Intervals On-/Off-Highway Operation Intervals c Outside Temperature
Meritor F° C°
Inspect Oil
Level
Petroleum
Oil Change d Change e Level f
Synthetic Oil Inspect Oil Petroleum
Oil Change d Change e
Synthetic Oil Specifications
(Military)
Oil
3,000 miles 100,000 500,000 miles 3,000 miles 50,000 miles 100,000 O-76A, Gear Oil GL-5, SAE 10 None –12 None
(4,800 km), miles (800,000 km) (4,800 km) or (80,000 km) miles (MIL-PRF-2105E) 85W/140
once a (160,000 km) 200 hours of (160,000 km)
month or the operation O-76D, Gear Oil GL-5, SAE –15 None –26 None
fleet (MIL-PRF-2105E) 80W/90
maintenance
interval O-76E, Gear Oil GL-5, SAE –40 None –40 None
(whichever (MIL-PRF-2105E) 75W/90
comes first) O-76J, Gear Oil GL-5, SAE –40 35 –40 2
(MIL-PRF-2105E) 75W
(MIL-PRF-2105E) 75W/140
Synthetic 75W/140
Gear Oil
(MIL-PRF-2105E)
O-76N, Full GL-5, SAE –40 None –40 None
Synthetic 75W/90
Gear Oil
(MIL-PRF-2105E)
NOTES
a Replace oil filter every 100,000 miles (160,000 km). Inspect oil level. Add specified oil as required.
b If No-Spin differential is installed, oil (petroleum or synthetic) must be changed at minimum interval of 40,000 miles (64,000 km) or
a maximum interval of 50,000 miles (80,000 km).
c Applies to heavy-duty on-highway applications and to on/off highway applications. Does not apply to off-highway applications.
d For petroleum oil with extended drain additives, use the “Synthetic Oil Change” interval.
e Applies to semi-synthetic oils. For a list of approved synthetic oils, refer to Maintenance Manual 1, Lubrication.
f For continuous heavy-duty operation, inspect the oil level every 1,000 miles (1,600 km). Add the correct oil as required.
65
Section 6
Lubrication
Axle Lubricant Capacities

Use the following lubricant capacities as a guide only. The capacities are measured with the drive pinion in the
horizontal position. When the angle of the drive pinion changes, the lubricant capacity of the axle will change.
Table I: Axle Lubricant Capacities

Capacity Capacity
Axle Model U.S. Pints Liters Axle Model U.S. Pints Liters
Single Drive Axles Single Drive Axles (Continued)
A-150 5.5 2.6 L-172 27 12.8
B-100 10 4.7 M-172 27 12.8
B-140 12 5.7 QT-140 24 11.4
B-150 3.5 1.7 Q-100 31 14.7
C-100 12.5 5.9 Q-145 24 11.4
D-100 12.5 5.9 RL-170 48 22.7
D-140 12.5 5.9 R-100 30 14.2
E-100 15 7.1 R-140 28 13.2
E-105 12.5 5.9 R-155 28 13.2
E-150 9 4.3 R-160 28 13.2
F-100 13 6.2 R-163 34 16.1
F-106 13 6.2 R-170 43 20.3
F-120 15 7.1 S-170 43 20.3
F-121 15 7.1 U-140 24 11.4
F-140 14 6.6 U-170 43 20.3
FDS-75 14 6.6 W-170 43 20.3
FDS-78 14 6.6 * Includes 1 pint (0.97 liter) for each wheel end and
FDS-85 15 7.1 with drive pinion angle at 3°.
FDS-90 14 6.6
FDS-93 14 6.6
FDS-750 7 3.3 Capacity
FDS-1600 23 10.9 Axle Model U.S. Pints Liters
FDS-1800 35 16.6 Rear Axle of Tandems
FDS-1805 35 16.6
SDHD (DHR rear) 16 7.6
FDS-1807 27 13.2
SFHD (FHR rear) 16.5 7.8
FDS-1808 27.9 13.2
SHHD (HHR rear) 26 12.3
FDS-2100 27.9 13.2
SL-100 (LR-100 rear) 37 17.5
FDS-2101 27.9 13.2
SLHD (LHR rear) 32 15.1
FDS-2107 43 20.3
SQ-100 (QR-100 rear) 33 15.7
FDS-2110 43 20.3
SQHD (QHR rear) 31 14.7
FDS-2111 43 20.3
SQHP (QAR rear) 36 17
FDS-2117 43 20.3
SR-170 (RR-170 rear) 43 20.3
G-161 21 9.9
SRHD (RHR rear) 36 17
H-100 20 9.5
SSHD (SHR rear) 28 13.2
H-140 21 9.9
ST-170 (TR-170 rear) 43 20.3
H-150 11 5.2
STHD (THR rear) 28 13.2
H-162 20 9.5
SU-170 (UR-170 rear) 43 20.3
H-170 27* 12.8
SUHD (UHR rear) 28 13.2
H-172 27 12.8
SW-170 (WR-170 rear) 43 20.3
L-100 23 10.9
L-140 24 11.4
L-155 24 11.4
66
Section 7
Fastener Torque Information
Torque Values for Fasteners

Section 7Fastener Torque Information
Figure 7.1
General Information
1. The torque values in Table J are for fasteners
that have a light application of oil on the
threads.
2. If the fasteners are dry, increase the torque
values by ten percent (10%).
3. If the fasteners have a heavy application of oil
on the threads, decrease the torque values by
ten percent (10%).
4. If you do not know the size of the fastener that
is being installed, measure the fastener. Use 1 AMOUNT OF THREADS IN ONE INCH
2 1”
the following procedure. 3 X
American Standard Fasteners X DIMENSION = (EXAMPLE 1/2")
a. Measure the diameter of the threads in

inches, dimension X. Figure 7.1.
Figure 7.2
b. Count the amount of threads there are in
one inch (1.0 inch). Figure 7.1.
Example
r American Standard size fastener is .50-13.
— 0.50 is the diameter of the fastener in inches
or dimension X.
— 13 is the amount of threads in one inch
(1.0 inch).
Metric Fasteners
a. Measure the diameter of the threads in
millimeters (mm), dimension X. Figure 7.2.
b. Measure the distance of ten (10) threads,
point to point in millimeters (mm),
dimension Y. Make a note of dimension Y.
Figure 7.2.
1 PITCH
c. Divide dimension Y by ten (10). The result 2 X
will be the distance between two threads 3 Y
or pitch.
X DIMENSION = (EXAMPLE M8 OR 8 MM)
Example Y DIMENSION = DISTANCE OF 10 THREADS
r Metric size fastener is M8 x 1.25.
— M8 is the diameter of the fastener in
millimeters (mm) or dimension X.
— 1.25 is the distance between two threads or
pitch.
— Compare the size of fastener measured in
Step 4 to the list of fasteners in Table J to find
the correct torque value.
67
Section 7
Figure 7.3
5
4
1
14
6
12
7
16
17
15
11 10
13
10
9
1003115c
Table J: Fastener Torque Information

Fastener Thread Size Torque Value lb-ft (N•m) T
1. *Capscrew, Axle Shaft .31-24 18-24 (24-33)
.50-13 85-115 (115-156)
2. *Nut, Axle Shaft Stud Plain Nut
.44-20 50-75 (68-102)
.50-20 75-115 (102-156)
.56-18 110-165 (149-224)
.62-18 150-230 (203-312)
Lock Nut
.44-20 40-65 (54-88)3
.50-20 65-100 (88-136)
.56-18 100-145 (136-197)
.62-18 130-190 (176-258)
68
Section 7

3. Breather .38-18 20 minimum (27 minimum)
4. *Plug, Oil Fill (Housing) .75-14 35 minimum (47.5 minimum)
5. *Plug, Heat Indicator .50-14 25 minimum (34 minimum)
6. Plug, Oil Drain .50-14 25 minimum (34 minimum)
7. Capscrew, Differential Case .38-16 35-50 (48-68)
.44-14 60-75 (81-102)
.50-13 85-115 (115-156)
.56-12 130-165 (176-224)
.62-11 180-230 (244-312)
Grade 10.9 Flange Head M12 x 1.75 85-103 (115-140)
Grade 10.9 Standard Hex Head M12 x 1.75 74-96 (100-130)
Grade 12.9 Standard Hex Head M12 x 1.75 105-125 (143-169)
Grade 12.9 Flange Head M16 x 2 203-251 (275-340)
Grade 12.9 Standard Head M16 x 2 220-310 (300-420)
8. *Nut, Differential Case Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 x 1.75 74-96 (100-130)
M16 x 2 220-310 (300-420)
9. *Nut, Ring Gear Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 x 1.25 66-81 (90-110)
M12 x 1.75 77-85 (104-115)
Flange Head M16 x 1.5 192-214 (260-190)
Standard Hex Head M16 x 1.5 196-262 (265-355)
10. Capscrew, Bearing Cap .56-12 110-145 (149-197)
.62-11 150-190 (203-258)
.75-10 270-350 (366-475)
.88-14 360-470 (488-637)
.88-9 425-550 (576-746)
M16 x 2 181-221 (245-300)
M20 x 2.5 347-431 (470-585)
M22 x 2.5 479-597 (650-810)
11. Nut, Housing to Carrier Stud .44-20 50-75 (68-102)
.50-20 75-115 (102-156)
.56-18 110-165 (149-224)
.62-18 150-230 (203-312)
12. Capscrew, Carrier to Housing .44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
.75-10 270-400 (366-542)
M12 x 1.75 74-89 (100-120)
M16 x 2 181-221 (245-300)
69
Section 7

13. *Jam Nut, Thrust Screw 1.75-16 150-190 (203-258)
1.88-14 150-300 (203-407)
1.12-16 150-190 (203-258)
M22 x 1.5 148-210 (200-285)
M30 x 1.5 236-295 (320-400)
14. Nut, Drive Pinion 1.88-20 200-275 (271-373)
1.00-20 300-400 (407-542)
1.25-12 700-900 (949-1220)
1.25-18 700-900 (949-1220)
1.50-12 800-1100 (1085-1491)
1.50-18 800-1100 (1085-1491)
1.75-12 900-1200 (1220-1627)
M32 x 1.5 738-918 (1000-1245)
M39 x 1.5 922-1132 (1250-1535)
M45 x 1.5 996-1232 (1350-1670)
15. Capscrew, Bearing Cage .38-16 30-50 (41-68)
.44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
M12 x 1.75 70-110 (90-150)
16. *Plug, Oil Fill (Carrier) 1.75-14 25 minimum (34 minimum)
1.5-11.5 120 minimum (163 minimum)
M24 x 1.5 35 minimum (47 minimum)
17. *Capscrew, Lock Plate .31-18 20-30 (27-41)
M8 x 1.25 21-26 (28-35)
70
Section 8
Adjustments and Specifications
Drive Pinion Bearings — Preload (Refer to Section 5)
Section 8Adjustments and Specifications
Specification New bearings

— 5 to 45 lb-in (0.56-5.08 N•m) torque T
Used bearings
— 10 to 30 lb-in (1.13-3.39 N•m) torque T
Adjustment Preload is controlled by the thickness of the spacer between bearings.
— To increase preload install a thinner spacer
— To decrease preload install a thicker spacer
Drive Pinion — Depth in Carrier (Refer to Section 5)

Specification Install the correct amount of shims between the bearing cage and carrier. To
calculate, use old shim pack thickness and new and old pinion cone numbers.
Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.
Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled) (Refer to Section 5)
Specification Conventional gear set
— Toward the toe of the gear tooth and in the center between the top and bottom
of the tooth
Generoid gear set
— Between the center and toe of the tooth and in the center between the top and
bottom of the tooth
Adjustment Tooth contact patterns are controlled by the thickness of the shim pack between the
pinion bearing cage and carrier and by ring gear backlash
— To move the contact pattern lower, decrease the thickness of the shim pack
under the pinion bearing cage
— To move the contact pattern higher, increase the thickness of the shim pack
under the pinion bearing cage
— To move the contact pattern toward the toe of the tooth, decrease backlash of
the ring gear
— To move the contact pattern toward the heel of the tooth, increase backlash of
the ring gear.
Main Differential Bearings — Preload (Refer to Section 5)
Specification 15 to 35 lb-in (1.7-3.9 N•m) torque T

or
Expansion between bearing caps
— R-140, R-155 and R-160 carrier models — 0.002 to 0.009 inch (0.050-0.229 mm)
— All other carrier models — 0.006 to 0.013 inch (0.150-0.330 mm)
Adjustment Preload is controlled by tightening both adjusting rings after zero end play is reached
71
Section 8
Adjustments and Specifications
Main Differential Gears — Rotating Resistance (Refer to Section 5)
Specification 50 lb-ft (68 N•m) torque applied to one side gear T
Ring Gear — Backlash (Refer to Section 5)

Specification Ring gears that have a pitch diameter of less than 17 inches (431.8 mm)
— Range: 0.008 to 0.018 inch (0.200-0.460 mm)
0.012 inch (0.300 mm) for a new gear set
Ring gears that have a pitch diameter of 17 inches (431.8 mm) or greater
— Range: 0.010 to 0.020 inch (0.250-0.510 mm)
0.015 inch (0.380 mm) for a new gear set
Adjustment Backlash is controlled by the position of the ring gear. Change backlash within
specifications to get a good tooth contact pattern.
— To increase backlash, move the ring gear away from the drive pinion
— To decrease backlash, move the ring gear toward the drive pinion
Ring Gear — Runout (Refer to Section 5)

Specification 0.008 inch (0.200 mm) maximum
Spigot Bearing — Peening on the Drive Pinion (Refer to Section 5)

Specification Apply 6,614 lb (3,000 kg) load on a 0.375 inch or 10 mm ball.
Peen the end of the drive pinion at a minimum of five points.
Softening of the pinion stem end by heating may be required.
72
Section 9
Vehicle Towing Instructions (Non-DCDL)
SINGLE AXLE without Driver Controlled Main
Section 9Vehicle Towing Instructions (Non-DCDL)
Differential Lock (DCDL) CAUTION

TANDEM AXLE without Driver Controlled Main Do not use a chisel or wedge to loosen the axle
Differential Lock (DCDL), with Inter-Axle shaft and tapered dowels. Using a chisel or wedge
Differential (IAD) can result in damage to the axle shaft, the gasket
and seal, and/or the axle hub.
These instructions are for vehicles equipped with
Meritor single or tandem rear drive axles. 6. Loosen the tapered dowels, if used, in the
flange of the axle shaft using one of the two
The instructions supersede all other instructions following methods. Figure 9.1.
for the purpose of transporting vehicles for service
or new vehicle drive-away dated before April 1995,
including those contained in Meritor Maintenance Figure 9.1
Manuals.
When transporting a vehicle with the wheels of
one or both drive axles on the road, it is possible to
damage the axles if the wrong procedure is used
before transporting begins. Meritor recommends
that you use the following procedure.
Before Towing or Drive-Away

WARNING
or service.
Engage the parking brake to prevent the vehicle
from moving before you begin maintenance or
service procedures that require you to be under
the vehicle. Serious personal injury can result.
1 TAPERED DOWEL RETENTION
1. Apply the vehicle parking brakes using the 2 STUD NUT
switch inside the cab of the vehicle. 3 WASHER
4 TAPERED DOWEL
NOTE: Single Axle continue with Step 5. Tandem 5 GASKET
Axle continue with Step 2. 6 STUD
7 SHAFT HUB AXLE
2. Shift the transmission into neutral and start the 8 AXLE SHAFT (FLANGE)
vehicle's engine. 9 WASHER
10 CAPSCREW
3. Shift the IAD to the unlocked (disengaged) 11 NON-TAPERED DOWEL RETENTION
position using the switch inside the cab of the
vehicle. The indicator light in the cab will go
off.
4. Stop the engine.
NOTE: Remove both axle shafts from the axle(s)
that will remain on the road when the vehicle is
transported. Continue with Step 5 for both axle
shafts.
5. Remove the stud nuts or capscrews and the
washers from the flange of the axle shaft.
Figure 9.1.
73
Section 9
7. Brass Drift Method:
WARNING
WARNING Wear safe eye protection when using an air
hammer. Power tools and components can loosen
Do not strike the round driving lugs on the flange and break and cause serious personal injury.
of an axle shaft. Pieces can break off and cause
serious personal injury. 8. Air Hammer Vibration Method:
NOTE: A 1.5-inch (38.1 mm) diameter brass a. Use an air hammer, such as Chicago
hammer can be used as a drift. Pneumatic CP-4181-PULER, or equivalent,
with a round hammer bit to loosen the axle
a. Hold a 1.5-inch (38.1 mm) diameter brass shaft and dowels.
drift against the center of the axle shaft
flange, inside the round driving lugs. b. Place the round hammer bit against the
Figure 9.2. axle shaft flange between the studs, at
different points around the flange. Operate
the air hammer at each location and loosen
Figure 9.2 the axle shaft and tapered dowels from the
hub. Figure 9.3.
Figure 9.3
1 BRASS HAMMER INSIDE LUGS

2 ROUND DRIVING LUG 1 BIT PLACED BETWEEN STUDS
2 AIR HAMMER AND BIT
b. Hit the end of the drift with a large hammer

(5 to 6 lbs, 2 to 3 kg) to loosen the axle 9. Identify each axle shaft that is removed from
shaft and tapered dowels from the hub. the axle assembly so they can be installed in
Figure 9.2. the same location after transporting or repair is
completed. (Example: Match mark a mating
axle shaft and hub.)
10. Remove the tapered dowels, gasket (if used)
and the axle shaft from the axle assembly.
Figure 9.1.
11. Install a cover over the open end of each hub
where an axle shaft was removed. This will
prevent dirt from entering the bearing cavity
and loss of lubricant.
74
Section 9
NOTE: If an air supply will be used for the brake 3. Disconnect the auxiliary air supply, if used,
system of the transported vehicle, continue with from the brake system of the vehicle that was
Steps 12 and 13, otherwise continue with Step 14. transported. Connect the vehicle's air supply to
the brake system.
12. Connect an auxiliary air supply to the brake
system of the vehicle that is being transported. 4. Remove the covers from the hubs.
Before moving the vehicle, charge the brake
system with the correct amount of air pressure NOTE: Continue with Steps 5 through 7 to install
all axle shafts.
to operate the brakes. Refer to the instructions
supplied by the manufacturer of the vehicle for 5. Install the gasket, if used, and axle shaft into
procedures and specifications. If an auxiliary the axle housing and carrier in the same
air supply is not used, continue with Step 14. location it was removed from. The gasket and
flange of the axle shaft must be flat against the
13. When the correct amount of air pressure is in
the brake system, release the parking brakes of hub. Rotate the axle shaft and/or the driveline
the vehicle that is being transported. Step 14 is as necessary to align the splines and the holes
in the flange with the studs in the hub.
not required.
Figure 9.1.
WARNING 6. Install the dowels, if used, over each stud and

into the tapered holes of the flange.
When you work on a spring chamber, carefully
follow the service instructions of the chamber 7. Install the washers and capscrews or stud nuts.
manufacturer. Sudden release of a compressed Determine the size of the fasteners and tighten
spring can cause serious personal injury. the capscrews or nuts to the corresponding
torque value shown in Table K.
14. If there are spring (parking) brakes on the axle(s)
that will remain on the road when the vehicle is
transported, and they cannot be released by air Table K
pressure, manually compress and lock each
Torque Value
spring so that the brakes are released. Refer to
Fasteners Thread Size lb-ft (N•m) T
the manufacturer's instructions.
Capscrews: 0.31"-24 18-24 (24-33)
0.50"-13 85-115 (115-156)
After Towing or Drive-Away Stud Nuts:
(plain nuts) 0.44"-20 50-75 (68-102)
WARNING 0.50"-20 75-115 (102-156)
To prevent serious eye injury, always wear safe eye 0.56"-18 110-165 (149-224)
protection when you perform vehicle maintenance 0.62"-18 150-230 (203-312)
or service. 0.75"-16 310-400 (420-542)
Engage the parking brake to prevent the vehicle (lock nut) 0.44"-20 40-65 (54-88)
from moving before you begin maintenance or 0.50"-20 65-100 (88-136)
service procedures that require you to be under 0.56"-18 100-145 (136-197)
the vehicle. Serious personal injury can result. 0.62"-18 130-190 (176-258)
0.75"-16 270-350 (366-475)
1. If an auxiliary air supply was used, apply the
vehicle parking brakes using the switch inside
8. Inspect the lubricant level in the axles and
the cab of the vehicle. If an auxiliary air supply
hubs where the axle shafts were removed. Add
was not used, begin with Step 2.
the correct type and amount of lubricant if
necessary. For information about lubrication,
WARNING refer to Maintenance Manual MM 1,
When you work on a spring chamber, carefully Lubrication, or refer to the Lubrication Section
follow the service instructions of the chamber of the Maintenance Manual for the axle model
manufacturer. Sudden release of a compressed you are working with.
spring can cause serious personal injury.
2. Apply the vehicle spring (parking) brakes by
manually releasing each spring that was
compressed before transporting started. Refer
to manufacturer's instructions.
75
Notes
Notes
Notes
Section 9
79
ArvinMeritor, Inc. Information contained in this publication was in effect at the time the publication was approved for printing and is
Commercial Vehicle Systems subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise
2135 West Maple Road the information presented or discontinue the production of parts described at any time.
Troy, MI 48084 USA Copyright 2000 Maintenance Manual 5
800-535-5560 ArvinMeritor, Inc. Revised 10-00
www.arvinmeritor.com All Rights Reserved Printed in the USA 16579/24240
0000D MM9G 2/26/02 9:33 AM Page 2
Revised 02-02
$2.50
Planetary Axle Wheel Ends

Coverless Planetary Spider Design
Maintenance Manual 9G
0000D MM9G 2/26/02 9:33 AM Page 3
Service Notes
Before You Begin Access Product and Service

This manual provides maintenance and service Information in the DriveTrain Plus™
procedures for Meritor coverless planetary spider by ArvinMeritor Tech Library on
design wheel end assemblies. Before you begin
procedures:
our Web Site
Enter the following address in your browser’s
1. Read and understand all instructions and
address box. The screen will display an index of
procedures before you begin to service
publications by category. Bookmark this screen
components.
for quick access to the Tech Library.
2. Read and observe all Caution and Warning
www.arvinmeritor.com/tech_library/home.asp
safety alerts that precede instructions or
procedures you will perform. These alerts help
to avoid damage to components, serious To Order Information by Phone
personal injury, or both.
Call ArvinMeritor’s Customer Service Center at
3. Follow your company’s maintenance and 800-535-5560 to order the following publications.
service, installation, and diagnostics guidelines.
• Cam Brakes
4. Use special tools when required to help avoid (Maintenance Manual 4)
serious personal injury and damage to
components. • Wet Disc Brakes
(Maintenance Manual 4L)
Safety Alerts, Torque Symbol • Off-Highway Heavy-Duty Brakes
(Maintenance Manual 4P)
and Notes
• SCL 2 Series Dry Disc Brake Calipers
(Maintenance Manual 4S)
! WARNING A Warning alerts you to an • SCL 35, 46, 53 Dry Disc Brake Calipers
instruction or procedure (Maintenance Manual 4Y)
exactly to avoid serious • Drivetrain Plus™ by ArvinMeritor Technical
personal injury and Electronic Library on CD. Features product
damage to components. and service information on most Meritor,
ZF Meritor and Meritor WABCO products. $20.
! CAUTION A Caution alerts you to an
Order TP-9853.
instruction or procedure
exactly to avoid damage
to components and
possible serious personal
injury can also occur.
T The torque symbol alerts

you to tighten fasteners to
a specified torque value.
NOTE: A Note provides

information or
suggestions that help you
correctly service a
component.
0000D MM9G 2/26/02 9:33 AM Page 4
Table of Contents
! Asbestos and Non-Asbestos Fibers Warnings .......................................................................iii
Section 1: Exploded View

Coverless Planetary Wheel-End ...................................................................................................................1
Drum Brake and Disc Brake Assemblies ....................................................................................................2
Description .....................................................................................................................................................3
Identification
Section 3: Disassembly
Remove and Disassemble the Planetary Wheel Ends................................................................................5
Remove the Tires and Rims
Remove the Planetary Spider Assembly ....................................................................................................6
Disassemble the Planetary Spider Assembly ............................................................................................7
Remove the Ring Gear and Axle Shaft
Prepare to Remove the Wheel Hub..............................................................................................................8
Prepare to Remove the Ring Gear Hub and Wheel Hub
Remove the Ring Gear Hub and Wheel Hub ..............................................................................................9
Remove the Hub Oil Seal and Bearings ....................................................................................................10
Remove the Brake Drum or Disc Brake Rotor
Remove the Brake Shoes
Remove the Spindle
Section 4: Prepare Parts for Assembly

Clean Ground or Polished Parts ................................................................................................................13
Clean Parts With Rough Finishes
Clean Axle Assemblies
Dry Cleaned Parts
Prevent Corrosion
Inspect Parts
Inspect Tapered Roller Bearings ................................................................................................................14
Inspect Planetary Wheel End Components ..............................................................................................15
Repair or Replace Parts
Repair Welding
Remove Capscrews Fastened with Liquid Adhesive
Cleaning ......................................................................................................................................................16
Using Dri-Loc Fasteners and Meritor Liquid Adhesive
Reusing Dri-Loc Fasteners and Loctite® No. 277
Applying Silicone Gasket Material ............................................................................................................17
Flush Lube From the Axle
47865/Meritor Copyright 2001 Revised 02-02
Printed in the USA ArvinMeritor, Inc. Page i
0000D MM9G 2/26/02 9:33 AM Page 5
Table of Contents
Section 5: Assembly
Install the Spindle ......................................................................................................................................19
Install the Axle Shaft in Rigid Axle Models ..............................................................................................22
Assemble the Ring Gear Hub Assembly
Assemble the Hub, Bearings, Oil Seal and Drum or Rotor
Install the Wheel Hub ..................................................................................................................................23
Adjust the Wheel Bearing Preload
Install the Planetary Ring Gear and Sun Gear ..........................................................................................25
Assemble the Planetary Spider
Install the Planetary Spider Assembly ......................................................................................................27
Adjust the Brakes ........................................................................................................................................28
Install the Tires and Rims
Fill the Wheel Ends With Lubricant
Measure and Adjust the Toe Setting
Tire Matching for Tandem and Tridem Axles ..........................................................................................29
Section 6: Lubrication
Lubrication Schedule ..................................................................................................................................31
Lubricant Specifications
Section 7: Specifications
Rigid Axle Wet Disc Brake ..........................................................................................................................33
Rigid Axle Drum Brake
Rigid Axle Dry Disc Brake ..........................................................................................................................34
Steering Axle Dry Disc Brake
Planetary Axle Wheel End Torque Specifications ....................................................................................35
Revised 02-02 Copyright 2001 47865/Meritor
Page ii ArvinMeritor, Inc. Printed in the USA
0000D MM9G 2/26/02 9:33 AM Page 6
Asbestos and Non-Asbestos Fibers
! ASBESTOS FIBERS WARNING ! NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce The following procedures for servicing brakes are recommended to reduce
exposure to asbestos fiber dust, a cancer and lung disease hazard. Material exposure to non-asbestos fiber dust, a potential cancer and lung disease
Safety Data Sheets are available from Meritor. hazard. Material Safety Data Sheets are available from Meritor.
Hazard Summary Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. Exposure linings may contain one or more of a variety of ingredients, including glass fibers, mineral
to airborne asbestos dust can cause serious and possibly fatal diseases, including wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.
asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma Scientists disagree on the extent of the risks from exposure to these substances.
(a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
of lung cancer among persons who smoke and who are exposed to asbestos is much Silicosis gradually reduces lung capacity and efficiency and can result in serious
greater than the risk for non-smokers. Symptoms of these diseases may not become breathing difficulty. Some scientists believe other types of non-asbestos fibers, when
apparent for 15, 20 or more years after the first exposure to asbestos. inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber
Accordingly, workers must use caution to avoid creating and breathing dust when dust are known to the State of California to cause lung cancer. U.S. and international
servicing brakes. Specific recommended work practices for reducing exposure to agencies have also determined that dust from mineral wool, ceramic fibers and silica are
asbestos dust follow. Consult your employer for more details. potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to non-
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away asbestos dust follow. Consult your employer for more details.
from other operations to reduce risks to unprotected persons. OSHA has set a maximum
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average Recommended Work Practices
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
extent adherence to the maximum allowable exposure levels will eliminate the risk of from other operations to reduce risks to unprotected persons.
disease that can result from inhaling asbestos dust. OSHA requires that the following sign
be posted at the entrance to areas where exposures exceed either of the maximum 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
allowable levels: silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-
asbestos brake linings recommend that exposures to other ingredients found in non-
DANGER: ASBESTOS asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
CANCER AND LUNG DISEASE HAZARD Scientists disagree, however, to what extent adherence to these maximum allowable
AUTHORIZED PERSONNEL ONLY exposure levels will eliminate the risk of disease that can result from inhaling non-
RESPIRATORS AND PROTECTIVE CLOTHING asbestos dust.
ARE REQUIRED IN THIS AREA
Therefore, wear respiratory protection at all times during brake servicing, beginning with
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or
beginning with the removal of the wheels. manufacturer’s recommended maximum levels. Even when exposures are expected to
3. Procedures for Servicing Brakes. be within the maximum allowable levels, wearing such a respirator at all times during
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure brake servicing will help minimize exposure.
should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure 3. Procedures for Servicing Brakes.
in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
b. As an alternative procedure, use a catch basin with water and a biodegradable, non- should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure
phosphate, water-based detergent to wash the brake drum or rotor and other brake in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.
parts. The solution should be applied with low pressure to prevent dust from becoming b. As an alternative procedure, use a catch basin with water and a biodegradable, non-
airborne. Allow the solution to flow between the brake drum and the brake support or phosphate, water-based detergent to wash the brake drum or rotor and other brake
the brake rotor and caliper. The wheel hub and brake assembly components should be parts. The solution should be applied with low pressure to prevent dust from becoming
thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. airborne. Allow the solution to flow between the brake drum and the brake support or
Wipe the brake parts clean with a cloth. the brake rotor and caliper. The wheel hub and brake assembly components should be
c. If an enclosed vacuum system or brake washing equipment is not available, employers thoroughly wetted to suppress dust before the brake shoes or brake pads are
may adopt their own written procedures for servicing brakes, provided that the removed. Wipe the brake parts clean with a cloth.
exposure levels associated with the employer’s procedures do not exceed the levels c. If an enclosed vacuum system or brake washing equipment is not available, carefully
associated with the enclosed vacuum system or brake washing equipment. Consult clean the brake parts in the open air. Wet the parts with a solution applied with a
OSHA regulations for more details. pump-spray bottle that creates a fine mist. Use a solution containing water, and, if
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use available, a biodegradable, non-phosphate, water-based detergent. The wheel hub
with asbestos when grinding or machining brake linings. In addition, do such work in an and brake assembly components should be thoroughly wetted to suppress dust before
area with a local exhaust ventilation system equipped with a HEPA filter. the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic grinding or machining brake linings. In addition, do such work in an area with a local
solvents, flammable solvents, or solvents that can damage brake components as exhaust ventilation system equipped with a HEPA filter.
wetting agents. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents,
by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you flammable solvents, or solvents that can damage brake components as wetting agents.
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or
filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you
wet the filter with a fine mist of water and dispose of the used filter with care. empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or filter approved by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter,
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with wet the filter with a fine mist of water and dispose of the used filter with care.
a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
shake or use compressed air to remove dust from work clothes. smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on Do not shake or use compressed air to remove dust from work clothes.
waste disposal. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
Regulatory Guidance care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations
on waste disposal.
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United
States, are made to provide further guidance to employers and workers employed within Regulatory Guidance
the United States. Employers and workers employed outside of the United States should
consult the regulations that apply to them for further guidance. References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers employed
within the United States. Employers and workers employed outside of the United States
should consult the regulations that apply to them for further guidance.
Printed in the USA ArvinMeritor, Inc. Page iii
0000D MM9G 2/26/02 9:33 AM Page 7
Notes
0000D MM9G 2/26/02 9:33 AM Page 8
Section 1
Exploded View
Coverless Planetary Wheel-End

15
14
13B 13
16A
12
17B 17A 11
10
13A
9
10A
22
19
18
7
6
5 8
23
7
20
4
21
20
6
2 3
1
Item Description Item Description

1 Planetary Spider to Hub Capscrew 13/13A Wheel Bearing Adjusting Nut
2 Planetary Spider to Hub Washer 13B Wheel Bearing Adjusting Nut
3 Shaft Planet Pinion Setscrew 14 Planetary Ring Gear
4 Ring Gear Thrust Button 15 Planetary Ring Gear Hub
5 Planet Pinion Shaft 16A Hub Nut Lock
6 Planet Pinion Outer Thrust Washer 17A Capscrew
7 Planetary Drive Pinion 17B Capscrew
8 Planet Pinion Inner Thrust Washer 18 Axle Shaft Thrust Button
9 Planetary Sun Gear 19 Oil Drain Plug
10 Sun Gear Thrust Washer 20 Needle Roller Bearing
10A Sun Gear Thrust Washer 21 Needle Roller Bearing Spacer
11 Wheel Bearing Adjusting Jam Nut 22 Spider
12 Wheel Bearing Adjusting Washer 23 O-Ring
Printed in the USA ArvinMeritor, Inc. Page 1
0000D MM9G 2/26/02 9:33 AM Page 9
Section 1
Exploded View
Drum Brake and Disc Brake Assemblies
13
12
11
10
8
5 9
6
4 7
3 21
19 20
2 18
1 16
17
7 9
6 22
4 23
24
2
15
25
3
14
STEERING
AXLE
SHAFT
RIGID
AXLE
SHAFT
Item Description Item Description

1 Outer Wheel Bearing Cone 14 Oil Drain Plug
2 Outer Wheel Bearing Cup 15 Axle Shaft Snap Ring
3 Wheel Stud Nut 16 Brake Disc
4 Wheel Hub 17 Disc Mounting Nut (If Applicable)
5 Wheel Stud 18 Disc Mounting Washer
6 Inner Wheel Bearing Cup 19 Disc Mounting Capscrew
7 Inner Wheel Bearing Cone 20 Spindle
8 Spacer 21 Caliper Mounting Adapter
9 Hub Inner Bearing Oil Seal 22 Spindle to Housing Nut (If Applicable)
10 Oil Slinger 23 Spindle to Housing Washer
11 Brake Drum 24 Spindle to Housing Capscrew
12 Drum Mounting Washer 25 Axle Shaft
13 Drum Mounting Capscrew
Page 2 ArvinMeritor, Inc. Printed in the USA
0000D MM9G 2/26/02 9:33 AM Page 10
Section 2
Introduction
Description Identification
Meritor coverless spider design planetary axles To determine the exact axle model specification,
incorporate a single or double reduction carrier refer to the identification tag located on the axle.
with hypoid gearing mounted in the axle center. Figures 2.1, 2.2 and 2.3.
Final gearing reduction occurs in the wheel hubs
by planetary design spur gears.
Figure 2.1 Axle Identification Tag Location
Meritor planetary axles permit the carrier hypoid
gearing and axle shafts to carry only nominal
torsional loads. At the same time, the planetary
axles also provide the highest practical numerical
gear reduction at the wheels.
• Power is transmitted by the hypoid gear set in
the carrier to the axle shafts and the sun gear
of the final reduction, through the revolving
planetary gears and into the planetary spider
which drives the wheel hub.
• The floating sun gear teeth mesh with teeth of
the planetary spur gears.
• The planetary gears rotate on planetary shafts
mounted on the spider. The planetary gear
teeth, in turn, mesh with the fixed or floating
ring gear teeth.
Axle Models Covered in This Manual Model No.PRC-1756-W2H-200

.................
Customer No. . . . . . . . . . . . . . .
Rigid Axles
PRC 594 PRC 866 PRLC 755 PRLC 1736 Serial No. . . . . . . . Plant . . . . . .
PRC 671 PRC 867 PRLC 756 PRLC 1756 ..
PRC 673 PRC 1314 PRLC 824 PRLC 1752 Ratio . . . . . . . . . . Date . . . . . . .
PRC 674 PRC 1756 PRLC 874 PRLC 1757
PRC 727 PRLC 616 PRLC 1735 PRLC 1794
PRLS 614
Steering Axles
PSC 594 PSC 1044 PSC 1794
PSC 822 PSC 1485 PSTC 824
PSC 824 PSC 1614
PSC 825 PSC 1615
PSC 826 PSC 1617
Tandem Axles
SPRC 673
SPRC 1356
SPRC 1735
SPRC 1756
Tridem Axles
EPRC 1356
EPRC 1735
0000D MM9G 2/26/02 9:33 AM Page 11
Section 2
Introduction
Figure 2.2 Single Planetary Axles

Steering P S C 1 6 1 7 P 100
Example
Rigid P R C 1 7 3 5 W4H 200

Example
Last Digit – Carrier

Designation for
Base Model Number Exact
Specification
First Two Digits Wheel
End Designation
(Basic Model Number)
Housing Type Designation

C = Integral Cast
Brake Type:
Only If Applicable: DLH — 17 in. (432 mm) Hydraulic Drum – (Dual
T = Transmission on Carrier Leading Hydraulic)
O= Oscillating or Pin Mount H — Hydraulic Drum
L = Mounting Other Than Pad
HDB — Hydraulic Dry Disc
With Drilling
M — Mechanical Drum
R = Rigid N — None
S = Steering NR — With Rotor Less Calipers
P = Planetary P — “P” Series Cam
N = Non-Drive RDA — Wedge (Dual Air Chamber)
RDH — Wedge (Dual Hydraulic Cylinders)
RSA — Wedge Single Air Chamber
RSH — Wedge (Single Hydraulic Cylinders)
W2H — Dura-Disc® 9" (224) Wet Disc
W3H — Dura-Disc® 13" (330) Wet Disc
W4H — Dura-Disc® 17 in. (432 mm) Wet Disc
W4M — Dura-Disc® 17 in. (432 mm) Wet Disc
Spring Applied Hydraulic Release
Figure 2.3 Tandem and Tridem Axles

P R C – 1 7 5 6
P = Planetary R = Rigid Housing Type First Two or Last Digit –

N = No S = Steering Designation Three Digits Carrier
Planetary C = Integral Wheel End Designation for
Gears Cast Designation Base Model
(Basic Model Number
Number)
0000D MM9G 2/26/02 9:33 AM Page 12
Section 3
Disassembly
Remove and Disassemble the Figure 3.1 FLANGE STYLE HUB

Planetary Wheel Ends
! WARNING
! WARNING
Block the wheels to prevent the vehicle from
moving. Support the vehicle with safety stands.
Do not work under a vehicle that is supported
only by jacks. Jacks can slip or fall over and cause DUAL DEMOUNTABLE HUB
serious personal injury.
2. Block the wheels that will not be raised to
prevent the vehicle from moving.
3. Raise the vehicle, so that the area you will
service is off of the ground. Support the
vehicle with safety stands. Refer to the vehicle
manufacturer’s maintenance manual for
instructions on raising the vehicle.
Remove the Tires and Rims

Planetary axles can come equipped with dual
demountable hubs or flange style hubs.
Figure 3.1. You can service the planetary gearing
on flange style hubs without removing the tire
from the wheel end.
1. For axles with dual demountable hubs: Refer
to the vehicle manufacturer’s removal
instructions.
2. If the axle is equipped with an oil drain plug
in the planetary spider, rotate the hub until
the plug is at the bottom.
3. Remove the drain plug.
4. Drain and discard the lubricant.
0000D MM9G 2/26/02 9:33 AM Page 13
Section 3
Disassembly
Remove the Planetary Spider Figure 3.3

Assembly
1. Match mark the spider and wheel hub for
correct alignment when you reassemble the
unit. Figure 3.2.
Figure 3.2 FLANGE STYLE HUB
MATCH MARK BOTH

SPIDER AND HUB
! WARNING
Take care when you use lifting devices. When
you use a lifting strap, inspect the strap for
damage before you use it. Do not use a lifting
strap to shock load or drop load a component.
Serious personal injury and damage to
4. Use a lifting device to remove the planetary
DUAL DEMOUNTABLE HUB spider assembly from the wheel hub
assembly. Figure 3.4.
MATCH MARK
SPIDER AND HUB
Figure 3.4
2. Insert a pry bar into the assembly notches

and separate the planetary spider assembly
from the wheel hub assembly. Figure 3.3. Do
not remove the spider assembly at this time.
• For axles without assembly notches: Hit the
spider with a plastic or rubber mallet to
separate the planetary assembly from the
wheel hub assembly. Do not remove the
spider assembly at this time.
0000D MM9G 2/26/02 9:33 AM Page 14
Section 3
Disassembly
Disassemble the Planetary Spider Figure 3.6 Planetary pinion shaft with
Assembly nylon coating
SPIDER
! WARNING
Observe all WARNINGS and CAUTIONS provided INNER THRUST
by the press manufacturer concerning press WASHER
operation to avoid serious personal injury and (SMALL BORE)
possible damage to components during assembly
PLANETARY
and installation procedures. GEAR
SETSCREW
NOTE: During disassembly, mark or tag the OUTER THRUST
WASHER PINION
planetary spider parts you do not plan to replace. SHAFT
Marking and tagging these parts, will aid correct
installation during assembly.
1. Remove the setscrew from each pinion shaft. 6. Remove the planetary gears and thrust
washers from the planetary spider.
2. Place the spider assembly in a press with the
flange side DOWN. 7. For planetary pinion shafts with needle roller
bearings: Remove the needle roller bearings
• If a press is not available: Use a brass drift and spacer from the bore of the planetary gear.
and mallet to remove the pinion shafts.
3. Support the spider assembly as required. Remove the Ring Gear
4. Place a container of cushioning material and Axle Shaft
under the press to catch the planetary pinion
shafts as you press them out of the spider 1. Remove the floating ring gear. If necessary,
and planetary pinion gears. use a lifting device to remove the ring gear.
Figure 3.7.
5. Press each pinion shaft out of the spider and
planetary gear. Figure 3.5 and Figure 3.6. 2. Remove the snap ring from the end of the
axle shaft.
3. Remove the sun gear. Figure 3.7.
Figure 3.5 Planetary pinion shaft with
INNER needle roller bearings
THRUST
WASHER
Figure 3.7 WHEEL BEARING
ADJUSTING NUT
NEEDLE THRUST
ROLLERS WASHER
SPACER
ADJUSTING NUT
PLANETARY LOCK PLATE
GEAR
SETSCREW
NEEDLE
ROLLERS
PINION
OUTER SHAFT
THRUST
WASHER ADJUSTING
NUT LOCK TO FLAT TO CORNER
PLATE OF NUT OF NUT
0000D MM9G 2/26/02 9:33 AM Page 15
Section 3
Disassembly
4. Remove the sun gear thrust washer Axles With Hydraulic or

assembly. Figure 3.8. Mechanical Brakes
Figure 3.8 For hydraulic or mechanical brake removal and

service instructions refer to Maintenance Manual
4S, SCL 2 Series Dry Disc Brake Calipers and
Maintenance Manual 4Y, SCL 35, 46 and 53 Dry
Disc Brake Calipers. To order these manuals, call
Meritor’s Customer Service Center at
800-535-5560.
THRUST Axles With P Series or RSA Drum Brakes

WASHER
AXLE
! WARNING
SHAFT When you work on a spring chamber, carefully
follow the service instructions of the chamber
manufacturer. Sudden release of a compressed
5. Remove the axle shaft. spring can cause serious personal injury.
• To remove the axle shaft from a steering 1. If the brake has spring chambers, manually
axle: Remove the wheel hub and spindle compress and lock the springs to release the
before you remove the axle shaft. brakes.
Prepare to Remove the Wheel Hub 2. Turn the slack adjuster manual adjusting nut
until the brake shoes fully retract and the
Axles With Dry Disc Brakes drum clears the lining. If Meritor automatic
slack adjusters are used, refer to Meritor
Remove the brake caliper and adapter assembly. Maintenance Manual 4B, Automatic Slack
Refer to Maintenance Manuals 4S, SCL 2 Series Adjuster for the correct adjustment procedure.
Dry Disc Brake Calipers and Maintenance Manual To order this publication, call Meritor’s
4Y, SCL 35, 46, 53 Dry Disc Brake Calipers. To Customer Service Center at 800-535-5560.
order these publications, call Meritor’s Customer
Service Center at 800-535-5560. Prepare to Remove the
Axles With Wet Disc Brakes Ring Gear Hub and Wheel Hub
Refer to Maintenance Manual 4L, Wet Disc Wheel Bearings With Single Adjusting
Brakes, for instructions on removing and Nut and Lockplates
servicing the wheel hub, brake driver, hub oil 1. Remove the capscrews from the adjusting nut
seal, wheel bearings and spindle. To order this lock. The adjusting nut features one of the
manual, call Meritor’s Customer Service Center at following designs.
800-535-5560.
• A ring that secures all corners of the nut
• One or two “bow ties” that secure one or
two corners of the adjusting nut or the flat
of the nut
2. Remove the wheel bearing adjusting nut lock
and wheel bearing nut.
0000D MM9G 2/26/02 9:33 AM Page 16
Section 3
Disassembly
Wheel Bearings With Figure 3.9

Scalloped Flange Adjusting Nut PULLER
SCREW
NOTE: To aid in capscrew removal, it may be HOLES
necessary to use a torch to apply heat to the
capscrew to loosen it. Follow the torch
manufacturer’s instructions.
1. Remove the locking capscrew located in the

scallop of the nut. Check the capscrew for
wear. Replace a worn or damaged capscrew.
2. Remove the wheel bearing nut. PULLER SCREW HOLES
Wheel Bearings With Double Adjusting 2. Remove the outer wheel bearing from the
Nuts ring gear hub.
Remove the wheel bearing jam nut, washer and NOTE: Some ring gear hub assemblies include a
wheel bearing adjusting nut. hub and ring sleeve insert. You can not service
these components separately.
Remove the Ring Gear Hub 3. Use a chain fall or similar device to lift the
and Wheel Hub hub and drum slightly to relieve the hub
weight and drum-to-brake shoe drag.
Figure 3.10 and Figure 3.11.
! CAUTION
4. Remove the assembly from the hub spindle.
Support the wheel hub, as shown in Figure 3.10,
before you remove the ring gear and the ring
gear hub assembly. Do not remove the ring gear Figure 3.10
and the ring gear hub assembly without
supporting the wheel hub. Serious personal
injury and damage to components can result.
1. Remove the ring gear hub by pulling it
straight out of the wheel hub and off of the
spindle. To avoid dropping and possibly
damaging the outer wheel bearing cone,
ensure that the outer wheel bearing cone
remains in place as you remove the ring gear
hub. Figure 3.9.
• If you cannot remove the ring gear hub by
hand: Install capscrews into the puller
screw holes in the ring gear hub flange.
Figure 3.11
Tighten each capscrew the same amount
to separate the ring gear hub assembly
from the spindle and the wheel hub.
0000D MM9G 2/26/02 9:33 AM Page 17
Section 3
Disassembly
Remove the Hub Oil Seal Remove the Brake Shoes

and Bearings
To remove the brake shoes, refer to the correct
1. Position the wheel hub with the brake end maintenance manual.
UPWARD. • For P series brakes: Refer to Maintenance
2. Some axle model designs with dry disc Manual 4, Cam Brakes.
brakes provide enough clearance to remove • For RSA drum brakes: Refer to Maintenance
the hub oil seal, bearing cone and bearing Manual 4P, Off-Highway Heavy-Duty Brakes.
cups without removing the rotor.
• For SCL 2 series dry disc brakes: Refer to
• If you can remove the hub oil seal, bearing Maintenance Manual 4S, SCL 2 Series Dry Disc
cone and bearing cups from the axle Brake Calipers.
without removing the rotor: Proceed to
Step 4. • For SCL 35, 46 or 53 series dry disc brakes:
Refer to Maintenance Manual 4Y, SCL 35, 46,
• If you must remove the rotor from the 53 Dry Disc Brake Calipers.
wheel hub to remove the hub oil seal,
bearing cone and bearing cups: Proceed to To order these publications, call Meritor’s
Step 3. Customer Service Center at 800-535-5560.
3. Remove the rotor mounting capscrews and

washers. Remove the rotor. Remove the Spindle
4. Remove the hub oil seal with a suitable puller. Axles With Dry Disc Brakes
Do not scratch the hub seal bore surface.
5. Remove the inner bearing cone. 1. Match mark the spindle and housing flange.
6. Remove the bearing cups with a suitable 2. Use straps and a lifting device to support the
puller. spindle.
3. Remove the spindle mounting capscrews and
Remove the Brake Drum or Disc washers.
Brake Rotor 4. Remove the spindle from the axle housing or
steer knuckle.
1. Match mark the drum and hub.
2. Remove the capscrews and washers from the Steering Axles With RSA Drum Brakes
brake drum or rotor joint.
1. Remove all air from the air system.
! WARNING 2. Remove the air lines from the air chamber.
Tag the lines and ports to aid reassembly.
Take care when you use lifting devices. When you
use a lifting strap, inspect the strap for damage
before you use it. Do not use a lifting strap to ! WARNING
shock load or drop load a component. Serious When you work on a spring chamber, carefully
personal injury and damage to components can follow the service instructions of the chamber
result. manufacturer. Sudden release of a compressed
3. Remove the brake drum or rotor from the spring can cause serious personal injury.
wheel hub. If necessary, use a lifting device to 3. If the brake has spring chambers, manually
remove the brake drum or rotor. compress and lock the springs to release the
brakes.
0000D MM9G 2/26/02 9:33 AM Page 18
Section 3
Disassembly
4. Match mark the air chamber housing tube Steering Axles With RSH Drum Brakes
and the brake spider plunger housing to aid
reassembly. 1. Remove the hydraulic lines from the hydraulic
5. Remove the set-screw that retains the air chamber. Tag the lines to aid reassembly.
chamber assembly in the spider plunger 2. Match mark the hydraulic chamber housing
housing. tube and the brake spider plunger housing to
6. If there is a collet nut on the threads of the aid reassembly.
chamber housing tube: Use a hammer and a 3. Remove the set screw that retains the fluid
brass drift to loosen the collet nut. within the spider plunger housing.
7. Remove the air chamber assembly from the 4. If there is a collet nut on the threads of the
plunger housing. If necessary, use a strap chamber housing tube: Use a hammer and a
wrench to remove the air chamber assembly. brass drift to loosen the collet nut.
8. Remove the brake shoe return springs. 5. Remove the hydraulic chamber assembly
9. Rotate the brake shoes to allow access to the from the plunger housing. If necessary, use a
spindle/brake spider mounting capscrews. strap wrench to remove the hydraulic
chamber assembly.
10. Match mark the brake spider and steering
knuckle to aid correct installation at assembly. 6. Remove the brake shoe return springs.
11. Remove the two capscrews and washers that 7. Rotate the brake shoes to allow access to the
mount the brake spider and spindle to the spindle/brake spider mounting screws.
steering knuckle at the 11 and 1 o’clock 8. Match mark the brake spider and steering
positions. knuckle to aid reassembly.
12. To aid spindle removal, install two 4- 6-inch 9. Remove the two capscrews and washers that
(10.16-15.24 cm) long studs with 0.875-14 UNF mount the brake spider and spindle to the
threads on the end that engage the steering steering knuckle at the 11- and 1-o’clock
knuckle. positions.
13. Support the spindle and brake spider 10. To aid spindle removal, install two 4- 6-inch
assembly. (10.16-15.24 cm) long studs with 0.875-14 UNF
14. Remove the remaining capscrews and threads on the end that engage the steering
washers. knuckle.
15. Remove the brake spider and brake shoe 11. Support the spindle and brake spider assembly.
assembly. 12. Remove the remaining capscrews and
washers.
! CAUTION 13. Remove the brake spider and brake shoe
Avoid damaging the oil seal in the spindle when assembly.
you remove the spindle. Lubricant loss and
damage to components can result. ! CAUTION
16. Carefully remove the spindle from the Avoid damaging the oil seal in the spindle when
steering knuckle by sliding the spindle over you remove the spindle. Lubricant loss and
the outer end of the axle shaft and universal damage to components can result.
joint.
14. Carefully remove the spindle from the steering
17. Remove the axle shaft and universal joint knuckle by sliding the spindle over the outer end
assembly. of the axle shaft and universal joint.
15. Remove the axle shaft and universal joint
assembly.
0000D MM9G 2/26/02 9:33 AM Page 19
Section 3
Disassembly
Steering Axles With P Series 7. Remove the brake camshaft from the spindle.
Cam Brakes Separate the washers you removed from the
face of the spindle boss. Prevent the washers
from mixing with the washers you previously
1. Remove the brake shoe return springs. removed.
2. Rotate the brake shoes until enough clearance
exists to remove the spindle mounting nuts ! WARNING
and washers with a wrench. Take care when you use lifting devices. When you
3. Remove the spindle mounting nuts and use a lifting strap, inspect the strap for damage
washers. before you use it. Do not use a lifting strap to
shock load or drop load a component. Serious
! CAUTION
personal injury and damage to components can
result.
Avoid damaging the oil seal in the spindle when
you remove the spindle. Lubricant loss and 8. Use straps and a lifting device to support the
damage to components can result. spindle and brake shoe assembly.
4. Carefully remove the spindle from the 9. Match mark the housing and spindle flange.
steering knuckle by sliding the spindle over 10. Remove the mounting capscrews and
the outer end of the axle shaft assembly. washers.
5. Remove the axle shaft and universal joint 11. Remove the spindle from the axle housing.
assembly.
Rigid Axles With P Series Cam Brakes

Some rigid axles feature a two-piece camshaft
and coupling which allows you to remove the
camshaft without removing the slack adjuster.
When servicing an axle with a two-piece camshaft
and coupling, proceed to Step 6.
1. Remove the brake shoe return springs.
2. Rotate the brake shoes to allow access to the
brake camshaft and the spindle mounting
capscrews.
3. Remove the slack adjuster clevis pin that
connects the air chamber push rod.
4. Remove the snap ring and washers that
connect the slack adjuster to the brake
camshaft. Stack the washers and separate
them from other parts.
5. Remove the slack adjuster and washers.
Separate the washers from other parts and
prevent them from mixing with the washers
you previously removed.
6. Remove the snap rings that retain the
camshaft in the spindle support boss.
0000D MM9G 2/26/02 9:33 AM Page 20
Section 4
Prepare Parts for Assembly
Clean Ground or Polished Parts Clean Axle Assemblies

• A complete axle assembly can be steam
! WARNING cleaned on the outside to remove dirt.
To prevent serious eye injury, always wear safe • Before the axle is steam cleaned, close or put a
eye protection when you perform vehicle cover over all openings in the axle assembly.
maintenance or service. Examples of openings are breathers or vents
in air chambers.
Solvent cleaners can be flammable, poisonous
and cause burns. Examples of solvent cleaners
are carbon tetrachloride, emulsion-type cleaners Dry Cleaned Parts
and petroleum-based cleaners. To avoid serious
personal injury when you use solvent cleaners, • Dry the parts immediately after cleaning and
you must carefully follow the manufacturer’s washing.
• Dry the parts with soft clean paper or rags.
• Wear safe eye protection.
• Wear clothing that protects your skin.
• Work in a well-ventilated area. ! CAUTION
Damage to bearings can be caused if dried by
• Do not use gasoline or solvents that contain
rotating with compressed air.
• You must use hot solution tanks or alkaline • Except for bearings, parts can be dried with
compressed air.
solutions correctly. Follow the manufacturer’s
Prevent Corrosion
• Use a cleaning solvent to clean ground or
polished parts or surfaces. Kerosene or diesel • Apply a light lubricant to cleaned and dried
fuel oil can be used for this purpose. NEVER parts that are not damaged and are to be
USE GASOLINE. assembled.
• Remove gasket material from parts. Be careful • Apply a special material that prevents
not to damage ground surfaces. corrosion to all surfaces. If parts are to be
stored, wrap the parts in special paper that
• DO NOT clean ground or polished parts in a prevents corrosion.
hot solution tank, water, steam or alkaline
solution.
Inspect Parts
Clean Parts With Rough Finishes
It is very important to inspect all parts carefully
• Parts with a rough finish can be cleaned with and completely before the axle or carrier is
cleaning solvent or in a hot solution tank with assembled. Check all parts for wear and replace
a weak alkaline solution. damaged parts. Replacement of damaged or
worn parts will prevent breakdown of assembly
• Parts must remain in hot solution tanks until later.
completely cleaned and heated.
• Parts must be washed with water until the
alkaline solution is removed.
0000D MM9G 2/26/02 9:33 AM Page 21
Section 4
Inspect Tapered Roller Bearings • Deep cracks or breaks in the cup, cone inner
race or roller surfaces.
Inspect the cup, cone, rollers and cage of all
tapered roller bearings in the assembly. If any of
• Bright wear marks on the outer surface of the
roller cage. Figure 4.3.
the following conditions exist, the bearing must
be replaced:
• The center of the large diameter end of the Figure 4.3
rollers are worn level with, or below the surface.
• The center of the large diameter end of the
rollers are worn to a sharp edge. Figure 4.1.
Figure 4.1 WORN RADIUS
WEAR MARKS
• Damage on rollers and on surfaces of the cup

and cone inner race that touch the rollers.
Figure 4.4.
WORN SURFACE
Figure 4.4
• A visible roller groove in the cup or cone inner
race surfaces. The groove can be seen at the ETCHING & PITTING
small or large diameter end of both parts.
Figure 4.2.
Figure 4.2
CRACK WEAR GROOVES
0000D MM9G 2/26/02 9:33 AM Page 22
Section 4
• Damage on the cup and cone inner race • Remove nicks, marks and burrs from parts
surfaces that touch the rollers. Figure 4.5. having machined or ground surfaces. Use a
fine file, India stone, emery cloth or crocus
cloth for this purpose.
Figure 4.5
SPALLING & FLAKING • Clean and repair threads of fasteners and
holes. Use a die or tap of the correct size or a
fine file for this purpose.
! CAUTION
Threads must be without damage and clean so
that accurate adjustment and correct torque
values can be applied to fasteners and parts.
• Tighten all fasteners to correct torque values.
! WARNING
Do not repair axle housings by bending or
straightening. Repair of axle housings by bending
or straightening can cause poor performance and
possible unsafe operation of the axle. This can
Repair Welding
Do not repair weld drive axle assemblies. Repair
Inspect Planetary Wheel End welding can detract from the structural integrity of
Components a component, particularly to heat treated parts
where the benefit of heat treatment can be
nullified by welding.
Inspect the planetary reduction, planetary gears,
sun gear and ring gear assembly for wear or
damage. Replace gears, shafts or thrust washers Remove Capscrews Fastened With
that are scored, pitted, ridged, chipped or worn. Liquid Adhesive
Repair or Replace Parts ! CAUTION
Do not use impact wrenches or strike components
Replace worn or damaged parts of an axle with a hammer.
assembly. The following are some examples to
check for repair and possible replacement: To remove capscrews fastened with liquid
adhesive, use the regular mechanical disassembly
• Replace any fastener if corners of the head are procedure.
worn.
If the removal of a capscrew, for example,
• Replace washers if damaged. becomes difficult due to a worn head or unusually
• Replace gaskets, oil seals or grease seals at the high breakaway torque, the locking strength can
time of axle repair. be reduced by heating the threaded area to
approximately 300°F (150°C). Heat slowly to avoid
• Clean parts and apply new liquid gasket thermal stresses in components.
material where required when axle is
assembled.
0000D MM9G 2/26/02 9:33 AM Page 23
Section 4
Cleaning NOTE: Do not apply liquid adhesive to the

fastener. Trapped air in the threaded hole will
create back pressure and “blow out” the
! WARNING adhesive as the fastener advances.
To avoid serious personal injury, trichloroethylene 2. Apply Loctite® No. 277 adhesive to the
must not come in contact with your skin. Do not threaded holes only. Before threading in the
smoke and avoid breathing vapors in closed fasteners, visually check to make sure that
rooms without ventilation. Do not use the adhesive contacts the threads. Figure 4.6.
trichloroethylene near flames, welding operations
or hot surfaces exceeding 900°F (482°C).
Figure 4.6
Clean the capscrew, nut or bolt tapped hole and
fastener thread carefully. Use a cleaning solvent
such as trichloroethylene or equivalent to remove
dirt, oil, grease or moisture.
Using Dri-Loc Fasteners and

Meritor Liquid Adhesive
NOTE: Do not apply Meritor liquid adhesive or
any other type of fastener retainer material,
sealant or adhesive on Dri-Loc fasteners or in the
threaded holes.
NOTE: No cure time is required for Dri-Loc 3. Tighten the fasteners to the specific torque
fasteners before rebuilding the axle and returning value recommended for the fastener. Loctite®
it to service. No. 277 will not alter the torque requirement.
NOTE: No cure time is required for Loctite® No.
1. Wipe excess oil residue from the threaded 277 before rebuilding the axle and returning it to
holes of all components that use Dri-Loc service.
fasteners.
4. When servicing drive units assembled with
2. Assemble the components that use Dri-Loc Dri-Loc fasteners or with Loctite® No. 277 in
fasteners. threaded holes where the fasteners do not
3. Tighten the Dri-Loc fasteners to the specified require removal: Check each fastener for
torque value. tightness by tightening the fastener to the
minimum specified torque.
Reusing Dri-Loc Fasteners and • If the fastener does not rotate, the fastener
Loctite® No. 277 is tightened to the correct torque.
• If the fastener rotates to any degree,
! WARNING remove it from the component and apply
liquid adhesive to the threaded hole.
Take care when you use Loctite® to avoid serious
personal injury. Follow the manufacturer’s
instructions to prevent irritation to the eyes and
skin.
1. Wipe excess oil residue from the Dri-Loc

fasteners and threaded holes.
0000D MM9G 2/26/02 9:33 AM Page 24
Section 4
Applying Silicone Gasket Material 5. Assemble the components quickly to permit the
gasket material to compress evenly between
Meritor recommends the following liquid gasket parts.
materials: 6. Tighten the fasteners with the required torque.
• ThreeBond 1216
Flush Lube From the Axle
• Loctite® 5699
The rigid axle wheel end and housing bowl share
! WARNING
the same oil. Lubricant contamination of the wheel
end or housing bowl can spread to all areas of the
Take care when you use silicone gasket materials axle.
to avoid serious personal injury. Follow the
manufacturer’s instructions to prevent irritation 1. If the housing bowl has magnets, remove all
to the eyes and skin. metallic debris from the magnets.
2. Flush lubricant from the entire axle, including
! CAUTION the wheel ends and housing bowl, before you
assemble the axle.
The amount of liquid gasket material applied must
not exceed a 0.125 in. (3.18 mm) diameter bead.
Too much gasket material can block lubrication
passages and result in damage to components.
1. Remove all old gasket material from both
surfaces.
2. Clean the surfaces where liquid gasket material
will be applied. Remove all oil, grease, dirt and
moisture.
3. Thoroughly dry both surfaces.
4. Apply approximately a 0.125 inch (3.18 mm)
diameter continuous bead of liquid gasket
material around one surface.
Also apply gasket material around the edge of all
fastener holes on that surface. Figure 4.7.
Figure 4.7
0.125" (3.18 MM)
DIAMETER
SILICONE GASKET
MATERIAL BEAD
0000D MM9G 2/26/02 9:33 AM Page 25
Notes
0000D MM9G 2/26/02 9:33 AM Page 26
Section 5
Assembly
Install the Spindle Figure 5.2
Install the Spindle on Rigid Axles With P

Series Cam Brakes
! WARNING
maintenance or service. GASKET
MATERIAL
1. Install two 4-inch (10.14 cm) long temporary
studs into the axle housing flange at the 1-
and 11- o’clock positions. Figure 5.1.
4. Install and hand tighten the spindle mounting
capscrews and washers. Remove the
Figure 5.1 temporary studs and replace them with
capscrews and washers.
5. Tighten the capscrews according to the
torque specifications shown in Table A. T
Table A: Spindle Mounting Capscrew Torque
Specifications
Torque
Size lb-ft N•m
1/2"-12 85-115 115-156
9/16"-18 130-165 176-224
5/8"-11, - 18 210-230 284-311
2. Apply a 0.125-inch (3.18 mm) diameter 3/4"-10 310-400 420-542
continuous bead of liquid gasket material 7/8"-9, - 14 575-650 779-880
around the flange mounting face of the axle
1"-12, - 14 850-1100 1152-1491
housing.
6. Replace the brake camshaft bushings and
! WARNING grease seals in the spindle boss and camshaft
brackets. Refer to Maintenance Manual 4,
Take care when you use lifting devices. When you Cam Brakes. To order this publication,
use a lifting strap, inspect the strap for damage call Meritor’s Customer Service Center at
before you use it. Do not use a lifting strap to 800-535-5560.
shock load or drop load a component. Serious
personal injury and damage to components can 7. Install the cam head thrust washer onto the
result. camshaft. Apply O-617-A or -B chassis grease
to the camshaft bushings and journals.
3. Align the spindle and axle housing match
marks. Install the spindle on the axle housing. 8. Install the camshaft through the spindle
If necessary, use an overhead crane to lift and bushings. Install the washers and slide the
support large spindles. Figure 5.2. camshaft through the air chamber support
bracket.
• For two-piece camshaft designs: Engage
the coupling when you install the
camshafts.
0000D MM9G 2/26/02 9:33 AM Page 27
Section 5
Assembly
9. Install the slack adjuster, washers, and snap Install the Spindle on Steering Axles
ring. Connect the slack adjuster to the air With P Series Cam Brakes
chamber push rod yoke. Check that the snap
ring is installed to the camshaft at the inner 1. Install the differential carrier assembly and
face of the spindle boss. the steering knuckles on the steering axles.
Install the Spindle on Rigid Axles With 2. Apply a thin coat of NLGI grade 1 or 2 grease
to the following areas:
Dry Disc Brakes
• Oil seal lips and bushing bore in the end of
1. For axle models that use capscrews to mount the axle housing
the spindle: Install two 4-inch (10.14 cm) long
temporary studs into the axle housing flange at
• Axle shaft assembly seal and bushing
journals
the 1-and 11-o’clock positions. Figure 5.1.
2. For axle models that use a “bow-tie” caliper
configuration: Use one bolt to guide the
! CAUTION
spindle onto the axle. Avoid damaging the housing oil seal when you
install the shaft assembly. Lubricant loss and
3. Apply a 0.125-inch (3.18 mm) diameter damage to components can result.
continuous bead of liquid gasket material
around the flange mounting face of the axle 3. Carefully install the axle shaft assembly through
housing. the steering knuckle and axle housing until the
shaft engages the differential assembly side
4. Align the spindle with the axle housing gear. Figure 5.3.
match marks to correctly position the brake
caliper mounting bosses. Install the spindle 4. If the original shaft support bushing in the bore
on the axle housing. of the spindle is worn or damaged: Remove the
oil seal and bushing and install a new bushing.
5. Install and hand tighten the spindle mounting
capscrews and washers. Remove the
temporary studs and replace them with Figure 5.3
capscrews and washers.
• For models with studs in the axle
housing: Install washers and locknuts.
5. Tighten the capscrews or locknuts according
to the torque specifications shown in Table B. T
Table B:Spindle Mounting Capscrew and Locknut
Torque Specifications
Torque
Size lb-ft N•m
1/2"-12 85-115 115-156
9/16"-18 130-165 176-224 5. Install a new oil seal in the spindle bore. Apply a
5/8"-11, - 18 210-230 284-311
thin coat of NLGI grade 1 or 2 grease to the seal
lips and bushing bore.
3/4"-10 310-400 420-542
7/8"-9, - 14 575-650 779-880
1"-12, - 14 850-1100 1152-1491
0000D MM9G 2/26/02 9:33 AM Page 28
Section 5
Assembly
! CAUTION ! CAUTION
Avoid damaging the oil seal in the spindle when you Avoid damaging the oil seal in the spindle when
install the spindle. Lubricant loss and damage to you install the spindle. Lubricant loss and damage
components can result. to components can result.
6. Carefully install the spindle on the steering 6. Use a lifting device to install the spindle onto the
knuckle by carefully sliding it over the outer end steering knuckle. Carefully slide the spindle over
of the axle shaft assembly. the outer end of the axle shaft assembly and
engage the two temporary guide studs.
7. Install the spindle mounting washers and nuts.
Hand tighten the nuts. 7. Align the brake spider and brake shoe
assembly with the spindle match marks.
8. Tighten the 3/4-inch-19 nuts or capscrews to
Install the brake spider and brake shoe
310-400 lb-ft (420-542 N•m). T
assembly on the spindle. Refer to
9. If you removed the brake shoes or camshaft: Maintenance Manual 4P, Off-Highway Heavy-
Install the brake shoes or camshaft. Refer to Duty Brakes.
Maintenance Manual 4, Cam Brakes. To order
8. Install the spindle and brake spider mounting
this publication, call Meritor’s Customer Service
capscrews and washers. Remove the two
Center at 800-535-5560.
temporary studs you installed during
disassembly. Replace the temporary studs
Install the Spindle on Steering Axles with capscrews and washers.
With RSA Drum Brakes
9. Tighten the capscrews according to the
1. Install the differential carrier assembly and torque specifications shown in Table C. T
the steering knuckles on the steering axle.
2. Apply a thin coat of NLGI grade 1 or 2 grease Table C: Spindle Mounting Capscrew and
to the following areas: Locknut Torque Specifications
• Oil seal lips and bushing bore in the end of Torque

the axle housing Size lb-ft N•m
1/2"-12 85-115 115-156
• Axle shaft assembly seal and bushing
journals 9/16"-18 130-165 176-224
5/8"-11, - 18 210-230 284-311
3/4"-10 310-400 420-542
! CAUTION 7/8"-9, - 14 575-650 779-880
Avoid damaging the housing oil seal when you 1"-12, - 14 850-1100 1152-1491
install the axle shaft assembly. Lubricant loss and
damage to components can result. 10. Install the air chamber assembly into the
3. Carefully install the axle shaft assembly brake spider. Refer to Maintenance Manual
through the steering knuckle and axle 4P, Off-Highway Heavy-Duty Brakes.
housing until the shaft engages the 11. Install the brake shoe return spring.
differential assembly side gear.
12. Connect the air lines to the correct ports in
4. If the original shaft support bushing in the the air chamber assembly. Release the spring
bore of the spindle is worn or damaged: chamber after you adjust the wheel hub.
Remove the oil seal and bushing and install a
new bushing.
5. Install a new oil seal in the spindle bore.
Apply a thin coat of NLGI grade 1 or 2 grease
to the seal lips and bushing bore.
0000D MM9G 2/26/02 9:33 AM Page 29
Section 5
Assembly
Install the Axle Shaft in

Rigid Axle Models
! CAUTION
Use extreme care to avoid nicking the oil seal
Install the axle shaft through the spindle bore and wear sleeve end when you install the oil seal
housing until it engages the differential side gear. wear sleeve. A nicked oil seal wear sleeve end
The shaft end with the snap ring groove must can damage the seal lip when you install the
extend beyond the outer end of the spindle. wheel hub. Lubricant loss and damage to
Assemble the Ring Gear 5. If a sleeve is used, carefully install a new oil
Hub Assembly seal wear sleeve on the spindle.
6. Lubricate the seals in the following areas
NOTE: Install the ring gear immediately before only.
you assemble the planetary spider.
• Conventional seals: Lubricate the oil seal
1. Install the outer wheel bearing cone on the lips.
ring gear hub journal squarely against the
hub shoulder. • Unitized seals: Lubricate the inside
diameter of the seal.
2. Apply the same lubricant used in the wheel
ends to the rollers. • Face seals: Lubricate the contact surfaces
of the metal rings. Do not apply lubricant
3. Slip fit the bearing cone over the ring gear to any other part of the face seal.
hub journal. Do not install the ring gear hub
assembly on the spindle at this time. 7. Apply a thin coat of lubricant to the oil seal
journal surface of the spindle.
Assemble the Hub, Bearings, Oil 8. Install the brake rotor or drum and oil slinger.
Seal and Drum or Rotor • If the slinger fits loosely between the hub
and drum: Apply a bead of liquid gasket
1. If the hub bearing cups need to be replaced, material to prevent rattling.
install the new cups with a suitable driver.
9. Install the drum or rotor mounting capscrews
NOTE: Most models require installation of the and washers.
inner bearing cone prior to installation of the • For dual tire models: Align the air valve
wheel hub oil seal into the bore of the wheel hub. stem clearance notch in the drum outside
2. Apply lubricant to the inner bearing cone diameter with the wheel hub notch.
rollers. Install the bearing cone into the 10. Tighten the capscrews according to the
wheel hub. torque specifications shown in Table D.
T
3. If used, install the oil seal guard washer.
Table D: Brake Rotor Mounting Capscrew Torque
4. Position the new wheel hub oil seal so that Specifications
the spring lip of the seal faces the wheel
bearing. Use a suitable seal driver to drive the Torque
seal into the same location as the original Size lb-ft N•m
wheel hub oil seal. Refer to the following list 1/2"-12 85-115 115-156
for three possible seal installation locations: 9/16"-18 130-165 176-224
• Bottom of the hub bore 5/8"-11, - 18 210-230 284-311
• Pushed-in until it contacts the guard 3/4"-10 310-400 420-542
washer
7/8"-9, - 14 575-650 779-880
• Flush with the end face of the hub
1"-12, - 14 850-1100 1152-1491
0000D MM9G 2/26/02 9:33 AM Page 30
Section 5
Assembly
Install the Wheel Hub 2. Install the ring gear hub assembly, which
includes the outer bearing cone, on the
spindle.
! WARNING
Take care when you use lifting devices. When you 3. Install the wheel bearing adjusting nut on
use a lifting strap, inspect the strap for damage the spindle.
before you use it. Do not use a lifting strap to • If you temporarily attached the planetary
shock load or drop load a component. Serious ring gear hub assembly to the wheel hub
personal injury and damage to components can in Step 1: Remove the temporary
result. capscrews from the ring gear hub.
1. Use a lifting device to carefully lift and slide the
wheel hub assembly over the spindle. Keep the Adjust the Wheel Bearing Preload
wheel hub assembly aligned with the spindle to
avoid oil seal damage. Figure 5.5 and Figure 5.6. For wheel bearing adjustment procedures for
axles equipped with wet disc brakes, refer to
• For axle models with three threaded holes Meritor Maintenance Manual 4L, Wet Disc Brakes.
(5/8 inch-11 UNC) in the boss area near To order this publication, call Meritor's Customer
the outer wheel bearing: You can Service Center at 800-535-5560.
temporarily attach the planetary ring gear
hub assembly to the wheel hub prior to Single Nut Design with Lockplates
installation on the spindle.
1. Tighten the wheel bearing adjusting nut to
the initial seating torque listed in Table E,
Figure 5.5
while rotating the wheel hub. T
2. Continue to rotate the hub a minimum of one
full revolution in both directions.
3. Tighten the wheel bearing adjusting nut
again to the initial seating torque listed in
Table E, while rotating the wheel hub in both
directions.
T
4. Repeat Steps 1 and 2 until the adjusting nut
will not advance with the application of the
initial seating nut torque.
T
5. Loosen the adjusting nut 1/8 – 1/4 turn
6. Tighten the adjusting nut to the final
Figure 5.6 adjustment nut torque listed in Table E while
rotating the wheel hub.
T
0000D MM9G 2/26/02 9:33 AM Page 31
Section 5
Assembly
Table E: Single Wheel Bearing Adjustment

Rigid Steering Adjusting Nut Torque
Axle Axle Initial Seating Final Adjustment
Models Models lb-ft N•m lb-ft N•m
PRC594-PRC727 PSC594-PSC825 400 542 200 271
PRC1757 PSC826-PSC1617 400 542 350 474
PRLC824-PRLC1794 PSC1794 500 678 400 542
! CAUTION ! WARNING
Do not loosen the adjusting nut when you install Take care when you use Loctite® to avoid serious
the adjusting nut lockplate. Loosening the personal injury. Follow the manufacturer’s
adjusting nut from the setting in Step 6 can result instructions to prevent irritation to the eyes
in an incorrect bearing preload and damage to and skin.
components.
9. Install new lockplate capscrews with
7. Use one of the following procedures to install pre-applied locking agent on the threads. If
the adjusting nut lockplate: you use the original capscrews, apply 2 or 3
drops of Loctite 277 or equivalent to the
• Place the flat side of the lockplate against a internal threads of the ring gear hub. Tighten
flat surface of the nut. the capscrews 60-75 lb-ft (81-102 N•m). T
• Place the lockplate notch over a corner of
the adjusting nut. Figure 5.7. Scalloped Flange Single Nut Design
1. Tighten the wheel bearing adjusting nut to

Figure 5.7 WHEEL BEARING the initial seating torque listed in Table E,
ADJUSTING NUT while rotating the wheel hub.
THRUST
T
WASHER 2. Continue to rotate the hub a minimum of one
full revolution in both directions.
ADJUSTING NUT 3. Tighten the wheel bearing adjusting nut again
LOCK PLATE to the initial seating torque listed in Table E,
while rotating the wheel hub in both
directions. T
4. Repeat Steps 1 and 2 until the adjusting nut
will not advance with the application of the
initial seating nut torque.
ADJUSTING T
NUT LOCK TO FLAT TO CORNER 5. Loosen the adjusting nut 1/8 – 1/4 turn
PLATE OF NUTT OF NUT
6. Tighten the adjusting nut to the final
adjustment nut torque listed in Table E while
8. If necessary, tighten the adjusting nut to align rotating the wheel hub. T
the lockplate holes with the threaded holes in
the ring gear hub. Do not loosen the adjusting
nut. ! CAUTION
Do not loosen the adjusting nut when you install
the capscrew. Loosening the adjusting nut from
the setting in Step 6 can result in an incorrect
bearing preload and damage to components.
7. If necessary, tighten the adjusting nut to align
a scallop with a threaded hole in the ring gear
hub. Do not loosen the adjusting nut.
0000D MM9G 2/26/02 9:33 AM Page 32
Section 5
Assembly
Install the Planetary Ring Gear

! WARNING and Sun Gear
Take care when you use Loctite® to avoid serious
personal injury. Follow the manufacturer’s 1. Apply grease to the inner face of the sun gear
instructions to prevent irritation to the eyes thrust washer (the side with tangs or dowel
and skin. pins). Install the thrust washer so that the
tangs or dowels engage the slots or holes in
8. Install the capscrew. Apply 2 or 3 drops of the wheel bearing adjusting nut.
Loctite 242 or equivalent to the internal
2. Install the sun gear on the axle shaft and
threads of the ring gear hub. Tighten the
against the thrust washer. Figure 5.7.
capscrew 20-30 lb-ft (27-40 N•m). Figure 5.8. T
3. Install the snap ring into the axle shaft groove.
Figure 5.8 4. Install the planetary ring gear onto the ring
CAPSCREW SUN GEAR
gear hub.
Assemble the Planetary Spider

Meritor coverless spider planetary wheel ends come
equipped with two different planetary designs.
• Planetary pinion shaft with needle roller bearings
• Nylon coated planetary pinion shafts
Refer to the correct assembly procedure for the
type of planetary design you are servicing.
WHEEL BEARING Planetary Pinion Shaft With

ADJUSTING NUT
Needle Roller Bearings
Double Nut Design NOTE: For maximum planetary gear life, replace
the pinion shafts and needle roller bearings on
1. Install the wheel bearing adjusting nut so that both wheel ends at the same time.
the nut lock faces OUTWARD. Installing the 1. Separate the inner thrust washers from the
wheel bearing adjusting nut will seat the outer thrust washers.
bearings and related components.
• To differentiate between the thrust
2. Tighten the nut to 400 lb-ft (542 N•m) while washers: Compare the washers’ inner
you rotate the hub in both directions. T diameters. Outer thrust washers feature a
3. Tap the hub several times with a brass or larger inner diameter than inner thrust
plastic hammer. washers.
4. Tighten the nut to 400 lb-ft (542 N•m). 2. Apply approved O-617-A or -B, NLGI grade 1
T or 2 grease to the side of the inner thrust
5. Loosen the adjusting nut to 0 lb-ft (0 N•m) to washer opposite the tang.
relieve the preload on the bearings.
3. Place the greased side of the inner thrust
6. Tighten the adjusting nut to 25 lb-ft (34 N•m).
T washer toward the planetary gear. The thrust
7. Install the nut lock ring washer. Ensure that washer tangs fit into the spider grooves.
the washer tang fits into the slot on the spindle 4. Place the inner thrust washer on the end of
and that the adjusting nut engages a washer the new planetary gear.
hole.
5. Apply approved O-617-A or -B, NLGI grade 1
8. Install the jam nut. Tighten the jam nut to or 2 grease to the planetary gear bore.
600-800 lb-ft (813-1085 N•m).
T
0000D MM9G 2/26/02 9:33 AM Page 33
Section 5
Assembly
6. Install the needle roller bearings. Install new 12. Repeat Steps 1-11 to install the second and
needle roller bearings if you replace the third sets of pinion shafts, gears, needle roller
pinion shafts. bearings and thrust washers.
• To install the needle roller bearings: Install 13. Check the alignment of the pinion shafts.
a row of needle roller bearings around the
pinion bore and against the inner thrust • Place the spider cover over the shaft ends.
washer. Install as many needle roller When necessary, rotate the shafts so that
bearings as will fit. The number of needle spider cover fits over the flats. After you
roller bearings installed in the pinion bore align the shafts, remove the cover.
differs among axle models.
! WARNING
7. Place the spacer into the bore of the gear on Observe all WARNINGS and CAUTIONS provided
top of the needle rollers. Install another row of by the press manufacturer concerning press
needle rollers on top of the spacer. operation to avoid serious personal injury and
8. Apply approved O-617-A or -B, NLGI grade 1 possible damage to components during assembly
or 2 grease to the side of the outer thrust and installation procedures.
washer opposite the tang. 14. Install each pinion shaft into the spider gear
9. Place the outer thrust washer on the end of assembly by hand.
the planetary gear. The tang must align with • If you cannot install a pinion shaft into the
the tang of the opposite washer. spider gear assembly by hand: Use a press
10. Set the planetary spider on a level surface to install the pinion shaft into the spider
with the flange side facing UP. Carefully slide assembly until the shoulder of the shaft
the loaded planetary gear assembly into the bottoms against the inner (bottom) thrust
planetary spider. Ensure that the following washer. When a press is not available, use a
conditions exist before you proceed to Step 11: brass drift and mallet to install the pinion shafts.
• The outer thrust washer (large bore) must Nylon Coated Planetary Pinion Shaft
be on top of the gear assembly.
• The washer tangs must fit in the planetary 1. Inspect the large bore chamfers. The
spider grooves. chamfers must be smooth to prevent damage
to the nylon coating on the planetary pinion
• The needle roller bearings must be in place. shaft during installation.
11. Install the pinion shaft through the spider, the • If the large bore chamfers are not smooth:
planetary gear and the thrust washers. Allow Use an emery cloth to clean the chamfer
the pinion shaft to extend out from spider. Do surface.
not press the pinion shaft into the spider at
this time. Figure 5.9. 2. Install a new O-ring into the O-ring groove on
the pinion shaft.
Figure 5.9 PINION O-RINGS 3. Inspect the planetary gear bores. Do not use
OUTER THRUST SHAFT planetary gears with rough bore surfaces.
WASHER
NEEDLE ROLLERS
! WARNING
SPACER
Observe all WARNINGS and CAUTIONS provided
PLANETARY GEAR by the press manufacturer concerning press
operation to avoid serious personal injury and
NEEDLE ROLLERS possible damage to components during assembly
SETSCREW
and installation procedures.
INNER
THRUST WASHER 4. Place the spider in a press with the flange
side UP. Support the spider as required.
0000D MM9G 2/26/02 9:33 AM Page 34
Section 5
Assembly
5. Install the inner thrust washer (small bore). Install the Planetary
Place the washer tab into the spider indent
and align the washer bore with the spider
Spider Assembly
bore.
6. Apply a thin coat of the same gear lubricant ! WARNING
used in the wheel end to the planetary Take care when you use silicone gasket materials
gear bore. to avoid serious personal injury. Follow the
7. Slide the planetary gear and the outer thrust manufacturer’s instructions to prevent irritation
washer into the spider. Align the bores of the to the eyes and skin.
parts and place the outer thrust washer tab
into the spider indent. ! CAUTION
8. Apply a thin coat of gear lube to the nylon Use only the correct gasket material. Do not use
coating on the pinion shaft. non-approved gasket material. Lubricant loss and
9. Install the planetary pinion shaft in the spider damage to components can result.
and through the planetary gear and thrust 1. Apply silicone (RTV) gasket material to the
washer. Figure 5.10. spider flange at the hub mounting face. Refer
to “Applying Silicone Gasket Material” in
Section 4.
Figure 5.10 SPIDER
PINION 2. Install the spider and pinion assembly in the
SHAFT wheel hub. Align the planetary gear teeth with
the sun gear and ring gear teeth. Align the
O-RINGS spider flange and wheel hub match marks you
previously marked at disassembly. Figure 5.11.
OUTER THRUST
WASHER Figure 5.11
PLANETARY
GEAR
INNER THRUST
WASHER
SETSCREW
(SMALL BORE)
10. Repeat Steps 1-9 to install the second and

third sets of planetary pinion shafts, gears
and washers.
11. Install the set screw into the spider to secure 3. Correctly align the spider mounting holes
the pinion shaft. with the wheel hub holes or studs. Push the
spider assembly against the hub.
4. Install the nuts and washers or capscrews and
washers.
• To install studs with integral hex and
washers: Use a 3.25-inch internal depth,
extra deep socket.
0000D MM9G 2/26/02 9:33 AM Page 35
Section 5
Assembly
5. Tighten the wheel studs, capscrews or nuts NOTE: The rigid axle wheel end and housing
according to the torque specifications shown bowl share the same oil and oil level.
in Table F.
T 4. Fill each wheel-end and the axle housing
bowl to the bottom of the fill/level plug hole
Table F: Planetary Spider Mounting Capscrew and with the specified oil. Do not fill oil through
Stud Torque Specifications the bowl only.
Torque 5. Wait for the oil to evenly flow through the axle.
Size lb-ft N•m 6. Check the oil level. Add oil if necessary.
1/2"-13 85-115 115-156
7. Replace and securely tighten all plugs.
9/16"-12 130-165 176-224
5/8"-11, – 14 210-230 284-311
Measure and Adjust the
3/4"-10 310-400 420-542
Toe Setting
7/8"-14 575-750 780-1017
Toe is the difference in distance between the
Adjust the Brakes front of the front tires and the rear of the front
tires. Figure 5.12.
Adjust the brakes for axles with P series and RSA
drum brakes only.
Figure 5.12
• For P series brakes: Refer to Maintenance FORWARD
Manual 4, Cam Brakes. X
• For RSA brakes: Refer to Maintenance Manual
4P, Off-Highway Heavy Duty Brakes.
To order these publications, call Meritor’s
Customer Service Center at 800-535-5560.
Install the Tires and Rims
1. Install the tires and rims. Secure them with Y

TOP VIEW
wheel rim clamps, nuts and washers.
2. Tighten the wheel nuts according to the Y MINUS X EQUALS TOE-IN
vehicle manufacturer's specifications.
Check and adjust the toe setting after you install

Fill the Wheel Ends With Lubricant any of the following components:
1. Rotate the wheel end until the oil fill line and • a front steering axle
oil level line are parallel to the ground. • a new steering knuckle
2. Lower the vehicle to the ground. • a tie rod component
3. Remove the oil fill plug from the cover. Clean Meritor performs the toe adjustment with the
all magnetic plugs and install the oil drain axle in an unloaded condition.
plug in the spider prior to filling the wheel
end with lubricant. The toe specification for Meritor off-highway
steering axles is 1/16-inch (1.60 mm) toe-in
[± 1/16-inch (1.60 mm)]. This specification is
based on a 24-inch (60.96 cm) radius (theoretical
tire with a 48-inch (121.92 cm) outside diameter).
0000D MM9G 2/26/02 9:33 AM Page 36
Section 5
Assembly
Tire Matching for Tandem 6. Test run the vehicle to gather accurate rear
axle lubricant temperature readings on the
and Tridem Axles two axle lubricant temperature gauges.
7. Vary tire air pressure within the tire
! CAUTION manufacturer's recommended range so the
Unmatched tires on both tandem drive units and lubricant temperature of both axles is within
tridem drive units will cause tire wear and 30°F (-1°C) of each other and not in excess of
scuffing and possible damage to the drive units. 200°F (93°C). This will usually result in
Meritor recommends that the tires be matched to uniform tire loading and good tire life.
within 1/8-inch (3.18 mm) of the same rolling
radius, 3/4-inch (19.05 mm) of the same rolling Tridem Axles
circumference.
When three driving axles are “hooked” together
Tandem Axles in a tridem series, unmatched tires will compound
the problems described in the preceding
The four largest tires should never be installed on paragraphs. Meritor recommends matching, as
one driving axle or the four smallest tires on the nearly as possible, the total tire circumference of
other driving axle. Such tire mounting will cause each of the three driving axles.
an interaxle “fight,” unusually high axle lubricant To match tires on tridem units, follow the same
temperatures that result in premature lubricant procedure used for tandem units.
breakdown and possible costly axle service.
Arrange the tires in order of size:
In addition to matching individual tire rolling radii
or rolling circumference, Meritor recommends • The two largest and two smallest go on one
matching, as nearly as possible, the total tire axle.
circumference of one driving axle to the total tire • The next two largest and smallest go on the
circumference of the other driving axle. This will second axle.
usually result in satisfactory tandem axle lubricant
temperatures that lengthen drive unit service with • The remaining four tires go on the third axle.
higher tire mileage.
Park the vehicle on a level surface. The vehicle
must carry a correctly distributed rated capacity
load. All the tires must be the same size.
Measure new tires to verify that they will be
correctly matched.
1. Inflate all tires to the same pressure.
2. Carefully measure the rolling circumference
of each tire with a steel tape.
3. Mark the size on each tire with chalk and
arrange the tires in order of size, largest to
smallest.
4. Mount the two largest tires on one side of one
axle and mount the two smallest on the
opposite side of the same axle.
5. Mount the four other tires on the other axle in
the same manner.
0000D MM9G 2/26/02 9:33 AM Page 37
Notes
0000D MM9G 2/26/02 9:33 AM Page 38
Section 6
Lubrication
Lubrication Schedule
Operation Off-Highway➀
Initial Oil Change 100 operating hours➀
Check Oil Level 250 operating hours➀
Petroleum Oil 1,500 operating hours or twice a year

Change (whichever comes first)➀
Synthetic Oil or 3,000 operating hours or once a year

Semi-Synthetic Oil (whichever comes first)
Change
➀ The interval depends on the individual operating conditions, speeds and loads. Severe operating conditions may
require more frequent intervals.
Lubricant Specifications
Outside Temperature
Military °F °C
Meritor Specification Oil
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil MIL-L-2105D GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil or GL-5, SAE 75W/90 -40 None -40 None
O-76L, Gear Oil MIL-PRF-2105-E GL-5, SAE 75W/140 -40 None -40 None
O-76M, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
O-76N, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
0000D MM9G 2/26/02 9:33 AM Page 39
Notes
0000D MM9G 2/26/02 9:33 AM Page 40
Section 7
Specifications
8
Rigid Axle Wet Disc Brake 3
10
Rigid Axle Drum Brake
8
3
4
10
6
13
0000D MM9G 2/26/02 9:33 AM Page 41
Section 7
Specifications
Rigid Axle Dry Disc Brake

8 7
12
10
11
Steering Axle Dry Disc Brake
9 7
10
0000D MM9G 2/26/02 9:33 AM Page 42
Section 7
Specifications
Planetary Axle Wheel End Torque Specifications

Torque
Item Fastener Description Size lb-ft N•m
1 Planetary Spider Mounting Capscrew 1/2"-13 85-115 115-156
9/16"-12 130-165 176-224
5/8"-11, -14 210-230 284-311
3/4"-10 310-400 420-542
7/8"-14 575-750 780-1017
2 Wheel Stud Nut 3/4"-10 310-400 420-542
7/8"-14 575-750 780-1017
3 Lockplate Capscrew 3/8"-16 30-45 41-61
4 Wheel Bearing Adjusting Nut Refer to “Adjusting the Wheel Bearing Preload”
in Section 5.
5 Wet Brake Driver Mounting Capscrew 7/8"-14 575-750 780-1017
1"-12 850-1100 1152-1491
6 Brake Drum Mounting Capscrew 5/8"-11, -18 210-230 284-311
9/16"-18 130-165 172-224
3/4"-10 310-400 420-542
7/8"-14 575-750 780-1017
7 Brake Rotor Mounting Capscrew 1/2"-12 85-115 115-156
9/16"-18 130-165 176-224
5/8"-11, -18 210-230 284-311
3/4"-10 310-400 420-542
7/8"-9, -14 575-650 779-880
1"-12, -14 850-1100 1152-1491
8 Spindle Mounting Capscrew 1/2"-12 85-115 115-156
9/16"-18 130-165 176-224
5/8"-11, -18 210-230 284-311
3/4"-10 310-400 420-542
7/8"-9, -14 575-650 779-880
(Nut on Stud) 1"-12, -14 850-1100 1152-1491
9 Spindle to Steer Knuckle Capscrew 1/2"-13 85-115 115-156
5/8"-11 210-230 284-311
9/16"-12 130-165 176-224
7/8"-14 575-750 780-1017
10 Pinion Shaft Locknut 3/8"-16 30-45 41-61
11 Caliper Adapter to Spindle Bolt 7/8"-9 440-580 597-786
12 Caliper to Adapter Capscrew 3/4"-10 310-400 420-542
M20 369-479 500-650
13 Wheel Rim Clamp Nut Refer to OEM specifications
Oil Level/Drain Plug (Not Shown) 3/4"-14 35 47
Planetary Ring Gear Lock Capscrew 3/8"-16 35-50 47-68
(Not Shown) 7/16"-14 60-75 81-102
0000D MM9G 2/26/02 9:33 AM Page 1
Information contained in this publication was in effect at the time the publication was approved for printing and is
subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
information presented or discontinue the production of parts described at any time.
Meritor Heavy Vehicle Systems, LLC Meritor do Brasil Ltda. Meritor Heavy Vehicle Systems Saint-Etienne S.A.
2135 West Maple Road Av. João Batista, 824 4, Rue Jean Servanton
Troy, MI 48084 U.S.A. 06097-900 Osasco-SP Boite Postale 656
248-435-1085 BRAZIL 42042 Saint Etienne Cedex 1 Maintenance Manual 9G
800-535-5560 (North America only) (55-11) 7084-6510 FRANCE Revised 02-02
www.arvinmeritor.com Fax: (55-11) 7084-6600 (33) 477.92.88.00 Fax: (33) 477.92.88.93 47865/Meritor
© Copyright 2001 Meritor Automotive, Inc. All Rights Reserved Printed in the U.S.A.
Operation Manual
1012
1013
ENGLISCH • Kapitel 00 • Seite 1

● Please read and observe the information given
in this Operation Manual. This will enable you
to avoid accidents, preserve the manufacturer’s
warranty and maintain the engine in peak
operating condition.
● This engine has been built exclusively for the
application specified in the scope of supply – as
described by the equipment manufacturer –
and is to be used only for the intended purpose.
Any use exceeding that scope is considered to
be contrary to the intended purpose. The
manufacturer will not assume responsibility for
any damage resulting therefrom. The risks
involved are to be borne solely by the user.
● Use in accordance with the intended purpose
also implies compliance with the conditions
laid down by the manufacturer for operation,
maintenance and servicing. The engine should
only be operated by personnel trained in its use
and the hazards involved.
● The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be
observed.
● Unauthorized engine modifications will
invalidate any liability claims against the manu-
facturer for resultant damage. Manipulations of
the injection and regulating system may also
influence the performance of the engine, and its
emissions. Adherence to legislation on
pollution cannot be guaranteed under such
conditions.
● Do not alter, modify or adapt the cooling air
intake area to the fan. The manufacturer will not
assume responsibility for any damage resulting
therefrom.

Operation Manual
1012
1013
0297 9682 en
Engine
serial number:
Please enter the engine serial number here. This

number should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see Section
2.1).
All rights reserved. Technical modifications required to

improve our engines are reserved with regard to
specification data and other technical information
contained in this Operation Manual. No part of this
Manual may be reproduced in any form or by any
means without our written approval.

Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed

for a large number of applications.
Consequently, a wide range of variants are
offered to meet the requirements of specific
cases.
Your engine is appropriately equipped for
the installation concerned, which means that
not all of the components described in this
Operation Manual are necessarily mounted
to your engine.
We have endeavored to highlight any
differences so that you will be able to locate
the operating and maintenance instructions
relevant to your engine quickly and easily.
Please read this Manual before starting your
engine, and always observe the operating
and maintenance instructions.
We are available to help with any additional
inquiries.
Sincerely,
DEUTZ AG

Table of contents
1. General 2.4 Fuel System 4. Operating Media

2.4.1 Fuel System Schematic 4.1 Lube Oil
2.5 Cooling System 4.1.1 Quality Grade
2. Engine Description
2.5.1 Cooling System Schematic 1012 4.1.2 Viscosity
2.1 Model
2.5.2 Cooling System Schematic 1012 E 4.2 Fuel
2.1.1 Rating Plate
2.5.3 Cooling System Schematic 1013 4.2.1 Quality Grade
2.1.2 Rating Plate Location
2.5.4 Cooling System Schematic 1013 E 4.2.2 Winter Grade Fuel
2.1.3 Engine Serial Number
2.1.4 Cylinder Numbering 4.3 Coolant
2.2 Engine Illustrations 3. Engine Operation 4.3.1 Water Quality for Coolant Preparation
2.2.1 Service Side 1012 3.1 Commissioning 4.3.2 Coolant Preparation
2.2.2 Starter Side 1012 3.1.1 Adding Engine Oil 4.3.3 Antifreeze/Chemical Corrosion Inhibitors
2.2.3 Service Side 1012 E 3.1.2 Filling Oil Bath Air Cleaner
3.1.3 Adding Fuel 5. Routine Maintenance
2.2.4 Starter Side 1012 E
3.1.4 Filling/Venting the Cooling System
2.2.5 Service Side 1013 3.1.5 Other Preparations 5.1 Maintenance Schedule
2.2.6 Starter Side 1013 3.1.6 Other Preparations 5.2 Maintenance Chart
2.2.7 Service Side 1013 E 3.2 Starting 5.3 Maintenance Record
2.2.8 Starter Side 1013 E 3.2.1 Electric Starting
2.2.9 Starter Side
3.3 Monitoring Systems
Unit Engine BF4M 1013 EC
2.2.10 Service Side 3.3.1 Engine Oil Pressure
Unit Engine BF4M 1013 EC 3.3.2 Coolant Temperature
2.2.11 Starter Side 3.3.3 Coolant Level/Level Gauge
Unit Engine BF6M 1013 EC 3.4 Stopping
2.2.12 Service Side 3.4.1 Engines with Mechanical Shutdown
3.4.2 Engines with Electrical Shutdown
2.3 Lube Oil Circuit
3.5 Operating Conditions
2.3.1 Lube Oil Circuit Schematic 1012/1012 E
3.5.1 Winter Operation
2.3.2 Lube Oil Circuit Schematic 1013/1013 E
3.5.2 High Ambient Temperature, High Altitude

Table of contents
6. Service and Maintenance 6.5 Belt Drives 6.7.1.3 Checking Specific Gravity of Electrolyte
6.1 Lubrication System 6.5.1 Checking V-Belts 6.7.2 Three-Phase Alternator
6.1.1 Oil Change Intervals 6.5.2 Tensioning Fan / Alternator Belts 1012 6.7.3 Lifting Tackle
6.1.2 Changing Engine Oil, Checking Oil Level 6.5.3 Changing Fan / Alternator Belts 1012
6.1.3 Changing Oil Filter 6.5.4 Tensioning Coolant / Fuel Pump Belts 7. Troubleshooting
6.1.4 Cleaning/Changing Oil Filter (Cup) 1012 7.1 Diagnosis Chart
6.2 Fuel System 6.5.5 Changing Coolant / Fuel Pump Belts
1012
6.2.1 Changing Fuel Filter 8. Engine Preservation
6.5.6 Tensioning Coolant / Fuel Pump Belts
6.2.2 Cleaning / Changing Fuel Pre-Filter 1012 E 8.1 Preservation
Element 6.5.7 Changing Coolant / Fuel Pump Belts
6.2.3 Venting the Fuel System 1012 E
with Preliminary Fuel Filter 9. Technical Specifications
6.5.8 Tensioning Alternator Belt 1012 E 9.1 Engine Specifications and Settings
6.2.4 Venting the Fuel System
w/o Preliminary Fuel Filter 6.5.9 Changing Alternator Belt 1012 E 9.2 Torque Wrench Settings
6.2.5 Changing Fuel Leakage Pipes 6.5.10 Tensioning / Changing Compressor / 9.3 Tools
Alternator Belts 1013
6.3 Cooling System
6.5.11 Tensioning Coolant / Fuel Pump Belts
6.3.1 Cleaning Intervals 1013 10. Service
6.3.2 Cleaning Cooling System 6.5.12 Changing Coolant / Fuel Pump Belts
6.3.3 Draining Cooling System 1012 / 1013 1013
6.3.4 Filling / Venting Cooling System 6.5.13 Tensioning / Changing Alternator Belt
1012 / 1013 1013
6.3.5 Draining the Cooling System 6.5.14 Tensioning Coolant / Fuel Pump Belts
1012 E / 1013 E 1013 E
6.3.6 Filling/Venting the Cooling System
1012 E / 1013 E 6.5.15 Changing Coolant / Fuel Pump Belts
6.3.7 Draining the Cooling System 1013 E
Unit Engine 6.5.16 Tensioning / Changing Compressor Belt
6.3.8 Filling/Venting the Cooling System 6.6 Adjustments
Unit Engine 6.6.1 Checking / Adjusting Valve Clearances
6.3.9 Draining the Charge Air Cooler 6.6.1.1 Valve Clearance Adjustment Schematic
6.4 Combustion Air Cleaner 6.7 Accessories
6.4.1 Cleaning Intervals 6.7.1 Battery
6.4.2 Emptying Cyclone-Type Precleaner 6.7.1.1 Checking the Battery and Cable
6.4.3 Cleaning Oil Bath Air Cleaner Connections
6.4.4 Dry Type Air Cleaner 6.7.1.2 Checking Electrolyte Level

General
DEUTZ Diesel Engines Care and Maintenance Service

1
are the product of many years of research and Sound care and maintenance practices will ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or for
with stringent quality standards, guarantee their placed on it. Recommended service intervals must spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance work carry out repairs quickly and professionally, using
consumption. carried out conscientiously. only genuine spare parts.
It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced
meet the highest standards for environmental demanding operating conditions. in accordance with state-of-the-art technology.
protection. Please turn to the end of this manual for further
service information.
Beware of Running Engine Safety

California
Proposition 65 Warning
Shut the engine down before carrying out mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
DEUTZ original parts are asbestos-

free.
7 Gerade
9689en_K01_neu 7 30.09.1999, 15:45 Uhr
1
8
9689en_K01_neu 8 30.09.1999, 15:45 Uhr
Engine Description
2.1␣ Model
2.2␣ Engine Illustrations
2.3␣ Lube Oil Circuit
2.4␣ Fuel System
2.5␣ Cooling System

7380en_k02_pdf 1 01.10.1999, 16:20 Uhr
Engine Description 2.1␣ Model
2.1.1 Rating Plate 2.1.2 Rating Plate Location 2.1.3 Engine Serial Number
2
26 332 0 26231 1 26232 1
The model A, the engine serial number B and the The rating plate C is attached to the crankcase. The engine serial number is also stamped on the
performance data are stamped on the rating plate. crankcase itself (arrow).
The model and engine serial number must be
given when ordering spare parts.

7380en_k02_pdf 2 01.10.1999, 16:20 Uhr
2.1␣ Model Engine Description
2.1.4 Cylinder Numbering

2
26233 0
Cylinders are numbered consecutively, beginning

at the flywheel end.

7380en_k02_pdf 3 01.10.1999, 16:20 Uhr
Engine Description 2.2 Engine Illustrations
2 2.2.1 Service Side 1012
1Oil filler (option: between filters)

2Coolant filler
3Cooling fan
4Coolant pump
5Belt pulley
6Fuel pump
7Engine mount
8Fuel filter
␣␣9Lube oil filter
10 Oil pan
11 Dipstick
12 Lube oil cooler
13 Mounting facility for hydraulic pumps
14 Alternator
15 Back leak fuel pipe with pressure-regulating
valve
16 Cylinder head
26234 1

7380en_k02_pdf 4 01.10.1999, 16:20 Uhr
2.2␣ Engine Illustrations Engine Description
2.2.2 Starter Side 1012

2
17 Lifting points
18 Exhaust turbocharger
19 Speed governor
20 SAE housing
21 Flywheel
22 Starter motor
23 Hydraulic oil cooler
24 Coolant heat exchanger
25 Coolant level gauge
26 Bleeder valve
26235 1

7380en_k02_pdf 5 01.10.1999, 16:20 Uhr
Engine Description 2.2␣ Engine Illustrations
2 2.2.3 Service Side 1012 E
1 Oil filler (option: between filters)

2 Coolant inlet
3 Coolant pump
4 Alternator
5 Belt pulley
6 Engine mount
7 Fuel pump
8 Fuel filter
9 Lube oil filter
10 Oil pan
11 Dipstick
12 Lube oil cooler
13 Mounting facility for hydraulic pump
valve
15 Cylinder head
26236 0

7380en_k02_pdf 6 01.10.1999, 16:21 Uhr
2.2.4 Starter Side 1012 E

2
16 Lifting points
18 Speed governor
19 SAE housing
20 Flywheel
21 Starter motor
22 Coolant outlet to heat exchanger
23 Exhaust manifold
24 Air intake manifold
26237 0

7380en_k02_pdf 7 01.10.1999, 16:21 Uhr
2 2.2.5 Service Side 1013
1 Oil filler (option: between filters)

2 Alternator
3 Coolant pump
4 Fan
5 Belt Pulley
6 Vibration damper
7 Fuel pump
8 Engine mount
9 Fuel filter
10 Lube oil filter
11 Oil pan
12 Dipstick
13 Lube oil cooler
14 Hydraulic pumps (or compressor)
15 Fuel pipe
16 Solenoid
17 Lube oil line to turbocharger
18 Cylinder head
26 333 0

7380en_k02_pdf 8 01.10.1999, 16:21 Uhr
2.2.6 Starter Side 1013

2
19 Lifting points
21 Speed governor
22 SAE housing
23 Flywheel
24 Starter motor
25 Coolant level gauge
26 Bleeder valve
27 Coolant filler cap
26 334 0

7380en_k02_pdf 9 01.10.1999, 16:21 Uhr
2 2.2.7 Service Side 1013 E
1 Oil filler
2 Coolant pump
3 Fuel pump
4 Vibration damper
5 Lube oil filter
6 Engine mount
7 Fuel filter
8 Oil pan
9 Dipstick
10 Lube oil cooler
11 Mounting facility for hydraulic pump
valve
13 Cylinder head
A Coolant inlet
26 336 0

7380en_k02_pdf 10 01.10.1999, 16:21 Uhr
2.2.8 Starter Side 1013 E 2

14 Lifting points
15 Crankcase breather valve
16 Speed governor
17 SAE housing
18 Flywheel
19 Starter motor
21 Fan
22 Exhaust manifold
26 337 0

7380en_k02_pdf 11 01.10.1999, 16:21 Uhr
2 2.2.9 Starter Side

1 Coolant filler neck with cap

2 Expansion tank
3 Vent line from cylinder head to expansion tank
1 2 3 4 5 6 7 4 Coolant line from engine crankcase to engine
fluid radiator
5 Expansion line from expansion tank to radiator
6 Charge air line from exhaust turbocharger to
charge-air cooler
7 Dry air filter
8 Induction air line between dry air filter and
8 exhaust turbocharger
10 Coolant line from crankcase to engine fluid
radiator
9 11 Charge-air cooler
12 Engine fluid radiator
13 Coolant line from engine fluid radiator to engine
thermostat
10
12
13 11
26
30 088
336 0

7380en_k02_pdf 12 01.10.1999, 16:21 Uhr
2.2.10 Service Side

2
3 Ventilation line from cylinder head to expansion
tank
13 13 Charge-air line from charge-air cooler to engine
14 Protective guard
14
30
26 089
337 0

7380en_k02_pdf 13 01.10.1999, 16:21 Uhr
2.2.11 Starter Side

2 Unit Engine BF6M 1013 EC
1 Filler neck with cap

2 Expansion tank
3 Vent line from cylinder head to expansion tank
4 Expansion line from expansion tank to coolant
1 2 3 4 5 6 7 pump
5 Coolant line from crankcase to engine fluid
radiator
6 Charge-air line from charge-air cooler to engine
7 Charge-air line from exhaust turbocharger to
charge-air cooler
8 Coolant line from engine fluid radiator to engine
thermostat
8
30 087 0

7380en_k02_pdf 14 01.10.1999, 16:21 Uhr
2.2.12 Service Side

2
9 Engine fluid radiator
10 Charge-air cooler
11 Protective guard
11 10
30 086 0

7380en_k02_pdf 15 01.10.1999, 16:21 Uhr
Engine Description 2.3␣ Lube Oil Circuit
2.3.1 Lube Oil Circuit Schematic

2 1012 / 1012 E
1 Oil pan
3 Lube oil pump
3a Back leak fuel valve
3b Pressure-relief valve
4 Lube oil cooler
5 Lube oil filter
6 Main oil gallery
7 Crankshaft bearing
8 Conrod bearing
9 Camshaft bearing
10 Line to spray nozzle
11 Spray nozzle for piston cooling
12 Tappet w/ control bore for pulse lubrication
of rocker arms
13 Pushrod (designed for lube oil supply of
rocker arms)
14 Rocker arm
15 Return line to oil pan
16 Oil sensor
17 Oil line to exhaust turbocharger
19 Oil line to compressor or hydraulic pump
20 Compressor
21 Hydraulic pump
22 Return line to compressor or hydraulic pump
23 Line to mass balancing gear (2x)
24 Counterbalancing shafts
25 Exhaust turbocharger return to crankcase
26238 1

7380en_k02_pdf 16 01.10.1999, 16:22 Uhr
2.3␣ Lube Oil Circuit Engine Description
2.3.2 Lube Oil Circuit Schematic
1013 / 1013 E 2
1 Oil pan
3 Lube oil pump
3a Back leak fuel valve
3b Pressure-relief valve
4 Lube oil cooler
5 Lube oil filter
6 Main oil gallery
7 Crankshaft bearing
8 Conrod bearing
9 Camshaft bearing
10 Spray nozzle line
11 Spray nozzle for piston cooling
12 Tappet w/ control bore for pulse lubrication
of rocker arms
13 Pushrod (designed for lube oil supply of
rocker arms)
14 Rocker arm
15 Return line to oil pan
16 Oil sensor
17 Oil line to exhaust turbocharger
19 Oil line to compressor or hydraulic pump
20 Compressor
21 Hydraulic pump
22 Return line to compressor or hydraulic pump
23 Return to oil pan
24 Exhaust turbocharger return to crankcase
26 335 0

7380en_k02_pdf 17 01.10.1999, 16:22 Uhr
Engine Description 2.4 Fuel System
2 2.4.1 Fuel System Schematic
1 Fuel tank
2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
5 Fuel filter
6 Line to injection pumps
7 Injection pump
8 Line to injector
9 Injector
10 Back leak fuel pipe
11 Banjo bolt with pressure-regulating valve
12 Return line to fuel tank
13 Keep this spacing as wide as possible
26239 1

7380en_k02_pdf 18 01.10.1999, 16:22 Uhr
2.5 Cooling System Engine Description
2.5.1 Cooling System Schematic

1012
2
1 Coolant filler
2 Thermostat housing
3 Coolant pump
4 Lube oil cooler
5 Cylinder cooling
6 Cylinder head cooling
7 Heat exchanger
8 Return from thermostat to coolant pump
housing
9 Ventilation line from cylinder head to heat
exchanger (expansion tank)
26240 2

7380en_k02_pdf 19 01.10.1999, 16:22 Uhr
Engine Description 2.5 Cooling System

2 1012 E
entrance regulation
2 Coolant pump
3 Lube oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Ventilation line expansion tank - coolant
pump
8 Line from engine to heat exchanger
9 Ventilation line from cylinder head to
expansion tank
10 Expansion tank
11 Line from heat exchanger to thermostat
26241 4

7380en_k02_pdf 20 01.10.1999, 16:22 Uhr
1012 E 2
escape regulation
2 Cooling fluid pump
3 Lubricating oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Compensation setting of compensation tank t
o cooling fluid pump
8 Line (Crankcase) from thermostat to heat
exchanger
compensation tank
10 Compensation tank
11 Line from heat exchanger to cooling fluid pump
30 816 0

7380en_k02_pdf 21 01.10.1999, 16:22 Uhr

2 1013
1 Coolant filler
3 Coolant pump
4 Lube oil cooler
5 Cylinder cooling
7 Heat exchanger
8 Expansion line coolant pump/expansion
tank
heat exchanger (expansion tank)
26 338 1

7380en_k02_pdf 22 01.10.1999, 16:22 Uhr

1013 E 2
entrance regulation
2 Coolant pump
3 Lube oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Ventilation line expansion tank - coolant
pump
8 Line from engine to heat exchanger
expansion tank
10 Expansion tank
11 Line from heat exchanger to thermostat
26 339 1

7380en_k02_pdf 23 01.10.1999, 16:22 Uhr
2 1013 E
escape regulation
2 Cooling fluid pump
3 Lubricating oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Compensation setting of compensation tank t
o cooling fluid pump
8 Line (Crankcase) from thermostat to heat
exchanger
compensation tank
10 Compensation tank
11 Line from heat exchanger to cooling fluid pump
30 817 0

7380en_k02_pdf 24 01.10.1999, 16:22 Uhr
Engine Operation
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 Operating Conditions

Engine Operation 3.1 Commissioning
3 3.1.1 Adding Engine Oil 3.1.2 Filling Oil Bath Air Cleaner 3.1.3 Adding Fuel
26243 0 24980 2 26244 0
As a rule, engines are delivered empty of oil. Fill oil cup 1 of the oil bath air cleaner (if fitted) Use only commercial-grade diesel fuel. For fuel
Pour lube oil into the oil filler neck (arrow). with oil up to the arrow. grade, see 4.2.
For oil quantities, see 9.1. For oil grade and viscosity, see 4.1. If required use a preliminary fuel filter.
For oil grade and viscosity, see 4.1. If in doubt, please ask your service representative.
Use summer or winter-grade fuel, depending on
the ambient temperature.
Do not fill the precleaner dust Never fill the fuel tank while the
collector (if fitted) with oil. engine is running. Keep the filler
cap area clean and do not spill fuel.

3.1 Commissioning Engine Operation
3.1.4 Filling/Venting the Cooling

System
3.1.5 Other Preparations
3
● 1012/1013 ● Check battery and cable connections, see 6.7.1.
See section 6.3.4
● Trial run
● 1012 E/1013 E - After the engine has been prepared, let it run
See section 6.3.6 for about 10 minutes without load.
● Unit engine (with frontal radiator) During and after trial run
See section 6.3.8. - Check the engine for leaks.
After the engine has been turned off

- Check the oil level and top up if necessary, see
6.1.2.
- Tighten the V-belt, see 6.5.
● Breaking-in
During the break-in phase - about 200 operat-
ing hours - check the oil level twice a day.
After the engine is broken in, checking once a
day will be sufficient.
● Commissioning conserved engines

Remove conservation materials as outlined in
section 8.1

Engine Operation 3.2 Starting
3 3.2.1 Electric Starting
Starting without Cold-Start Aid

Before starting, make sure that
nobody is standing in the imme-
! diate vicinity of the engine or driven
machine.
After repair work:
Check that all guards have been replaced and that
all tools have been removed from the engine.
When starting with glow plugs, do not use any
other starter substance (e.g. injection with start
pilot). Doing so could result in an accident.
Important:
Never start the engine with speed governor
removed. Disconnect battery.
26245 0 25745 0
● Disengage the clutch to separate the engine ● Insert key.

from the driven equipment. – Position 0 = no operating voltage.
● Move speed control lever 1 in direction of ● Turn key clockwise.

arrow at least to middle speed position. – Position 1 = operating voltage.
– Pilot lights 1 and 2 come on.
● Move shutdown lever 2 to operating position
(in opposite direction of arrow). ● Push the key in and turn it further clockwise
against spring pressure.
– Position 2 = no function
– Position 3 = start
Do not actuate the starter for more than 20
seconds. If the engine does not catch, wait a ● Release key as soon as engine fires.
minute then try again. – Pilot lights go out.
If the engine does not catch after two attempts,
refer to the Diagnosis Chart (see 7.1).

3.2 Starting Engine Operation
3
Starting with Heater Plugs
25746 1
● Insert key.
– Position 0 = no operating voltage.
● Turn key clockwise.

– Position 1 = operating voltage.
– Pilot lights come on. Leave to preheat until
pilot lights go out.
● Push key in and turn further clockwise against

spring pressure.
– Position 2 = no function.
– Position 3 = start.
● Release key as soon as engine fires.

– Pilot lights go out.

Engine Operation 3.3 Monitoring Systems
3 3.3.1 Engine Oil Pressure
Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge
25752 1 25753 0 25754 0
● The oil pressure pilot light comes on with ● The pointer must remain in the green sector ● The pointer must indicate the minimum oil
operating voltage on and engine off. over the entire operating range. pressure (see 9.1).
● The oil pressure pilot light should go out when

the engine is running.

3.3 Monitoring Systems Engine Operation
3.3.2 Coolant Temperature 3.3.3 Coolant Level /

Coolant Level Gauge
3
26246 0 26247 0
● The coolant temperature gauge pointer should ● When the engine is cold, coolant level 1 should ● If a level switch is fitted, the engine is shut
remain in the green sector most of the time. It be above the KALT-COLD mark. down automatically when the level falls below
should rarely enter the yellow-green sector. If the MIN marking.
the pointer enters the orange sector, the engine ● Top up with coolant if the level falls below the
is overheating. Turn it off and establish the MIN mark on the sight glass, or if the coolant
cause from the Diagnosis Chart (see 7.1). warning switch comes on.
– Unscrew the filler cap.
– Top up with coolant up to the upper edge of
the filler neck.
– Tighten the filler cap
● If it is not possible to carry out a check at the

inspection opening, if required carry out a
check at the filler neck:
If you cannot see any fluid:
- topping up is required.

Engine Operation 3.4 Stopping
3 3.4.1 Engines with Mechanical

Shutdown
3.4.2 Engines with Electrical
Shutdown
26266 0 25746 2
● Move speed control lever 1 to low idle. ● Turn key counterclockwise (to Position 0) and
remove. The pilot lights will go out.
● Operate shutdown lever 2 until the engine
comes to a stop. The charge pilot light and the
oil pressure pilot light will come on when the
engine stops.
● Turn key counterclockwise (to Position 0) and

remove. The pilot lights will go out.
Where possible, do not switch the engine off from

full load. Leave running in idle for approx. 2
minutes.

3.5 Operating Conditions Engine Operation
3.5.1 Winter Operation

3
● Lube Oil Viscosity ● Battery
– Select the oil viscosity (SAE grade) – Efficient cold starting requires a healthy
according to the ambient temperature when battery (see 6.7.1).
the engine is started (see 4.1.2). – The starting limit temperature can be
– Increase oil change frequency when operat- lowered by 4-5°C by heating the battery up to
ing below –10°C, see 6.1.1. about +20°C. To do so, remove the battery
and store in a warm place.
● Diesel Fuel
– Use winter-grade diesel fuel for operation
below 0°C, see 4.2.2.
● Coolant
– Set the water/antifreeze mix to suit the lowest
likely temperature (max. –35°C), see 4.3.1.
● Additional Maintenance Work

26248 0
– Drain the sludge from the fuel tank once a
week by undoing the drain plug.
– Adjust the oil level in the oil bath air cleaner
(if fitted) to suit the ambient temperature.
– At temperatures below –20°C, lubricate the
flywheel ring gear from time to time with
low-temperature grease, such as Bosch FT 1
V 31. To do so, remove the starter and
introduce the grease through the pinion hole.
● Cold-Start Aids
– At temperatures near or below freezing point,
use glow plugs if necessary (see 3.2.1).
This not only lowers the starting limit
temperature, but provides easier starting at
temperatures normally not requiring a
starting aid.

Engine Operation 3.5 Operating Conditions
3.5.2 High Ambient Temperature,

3 High Altitude
● As the altitude and ambient temperature rise,

the density of the air tends to decrease, which
affects the maximum power output of the
engine, the exhaust gas quality and, in extreme
cases, the starting behavior. Under transient
C F
conditions, the engine can be used at altitudes
up to 1000 meters / 3400 feet and tempera-
tures up to 30°C.
If the engine is to operate under more severe
conditions (at higher altitudes or tempe-
ratures), it will be necessary to reduce the
0 32
injected fuel quantity and, thus, engine power.
● If you have any doubts about engine operation

under these or similar conditions, ask your
engine or equipment supplier whether the
engine has been derated in the interests of 25901 1
reliability, service life and exhaust gas quality
(smoke). Otherwise, contact the nearest
service representative.

Operating Media
4.1 Lube Oil

4.2 Fuel
4.3 Coolant

Operating Media 4.1 Lube Oil
4 4.1.1 Quality Grade 4.1.2 Viscosity
Lube oils are differentiated according to their As the viscosity of lube oil is dependent on
performance and quality class. In common use temperature, the choice of SAE grade should be
are specifications named after the API (American governed by the ambient temperature prevailing
Petroleum Institute) and ACEA (European Oil at the engine operating site.
Sequences). Optimum operating behaviour will be attained if
you take the accompanying oil viscosity diagram
Approved API Oils: as a guide.
Turbocharged engines: CF-4 CG-4 CH-4 Should the temperature fall temporarily below the
limits of the SAE grade selected, cold starting may
Approved ACEA Oils: be affected but the engine will not be damaged.
Turbocharged engines: E1-E3/96 + E4-98 In order to keep wear to a minimum, do not ex-
ceed application limits for extended periods of
time.
If in doubt, contact your service representative Oil changes dictated by the seasons can be
avoided by using multi-grade lube oils. Multi-
grade oils - particularly low-friction oils - also re-
duce fuel consumption.
Only with preheating 30 298 1

4.2 Fuel Operating Media
4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel 4

Use commercially available diesel fuel with less Waxing may occur at low temperatures, clogging
than 0.5% sulphur content. If the sulfur content is +32 0
the fuel system and reducing engine efficiency. If I
higher than 0.5%, oil change intervals should be the ambient temperature is less than 0 °C, winter-
reduced (see 6.1.1). +23 -5
grade fuel (suitable down to -20 °C) should be used.
This fuel is usually available from filling stations
The following fuel specifications/standards are +14 - 10
well in advance of the cold months.
approved:
+ 5 - 15
● At temperatures below -20°C/, kerosene should
● EN 590 be added to the diesel fuel. The relevant
percentages are given in the diagram at the right - 4 - 20
● BS 2869: A1 and A2 ● Special diesel fuels can be used for climatic
zones down to - 44 °C. - 13 - 25
● ASTM D975-96: 1-D and 2-D II
If summer-grade diesel fuel must be used at - 22 - 30
● NATO Code F-34/F-35, F44, F-54 and F-63 temperatures below 0°C, up to 60% kerosene can 0 10 20 30 40 50 60 %
be added (see diagram). °F °C B
A
26441
25 790 11
In most cases, adequate resistance to cold can be
obtained by adding a flow improver (additive). Legend:
Please contact your DEUTZ partner.
I Summer diesel fuel
II Winter diesel fuel
A Outside temperature
B Percentage of kerosene to be added
Mix in tank only. Fill with the

appropriate amount of kerosene
! first, then add the diesel fuel.

----
Operating Media 4.3 Coolant
4.3.1 Water Quality for Coolant 4.3.2 Coolant Preparation 4.3.3 Cooling System Protective
4 Preparation Liquid
The values given below must not be exceeded. The preparation and monitoring of coolant in li- DEUTZ cooling system protective agents can be
A test kit (order number 1213 0382) can be quid-cooled engines is especially important obtained under order number 01011490 (5 litres)
obtained from DEUTZ Service to check the quality because corrosion, cavitation and freezing can or 1221 1500 (210 litres). These are nitrite-,
of the water available. lead to engine damage. amine- and phosphate-free and provide effective
The coolant is prepared by admixing a cooling protection against corrosion, cavitation and
system protective liquid with the cooling water. freezing.
Water quality min. max. The cooling system must be monitored regularly If the above-mentioned cooling system agents are
(see 5.1). The water level and the cooling system not available, the following products can be used
pH-value at 20°C /68° F 6.5 8.5 in exceptional cases.
protective liquid concentration should both be
checked. Manufacturer Product description
Chloride ion content [mg/dm3] – 100
The cooling system protective liquid concent- AVIA AVIA Antifreeze Extra
Sulfate ion content [mg/dm3] – 100 ration can be checked with a commercially BASF Glysantin G 48
available tester (e.g. gefo glycomat® ). DEA DEA radiator antifreeze
Total hardness [°dGH] 3 20 SHELL SHELL GlycoShell
The concentration of the cooling system protec-
tive liquid in the coolant may not fall below/exceed
the following limits:
Cooling system protective liquid Water
max. 45 Vol.% 55%
min. 35 Vol.% 65%
For the quantity, see table overpage and infor-
mation in section 9.1.
Other cooling system protective liquids, e.g.
chemical corrosion inhibitors, can, in exceptional
circumstances, be used in the coolant, in consult-
ation with DEUTZ Service. Order the cooling
system protective liquid from: DEUTZ Service
When nitrite-based cooling system Cooling system protective liquids

protective liquids are mixed with must be disposed of in accordance
! amine-based liquids, harmful nitro-
samines are formed.
! with environmental regulations.

4.3 Coolant Operating Media
4
Cooling System Protection
Cooling system capacity *)
[Liters]
Cooling system Cooling protection
protective agent [°C] 18 20 22 25 27 30 32 35
[Vol %]
Cooling system protective liquid
[Liters]
35 –22 2.8 7.0 7.7 8.75 9.5 10.5 11.2 12.3
40 –28 7.2 8.0 8.8 10.0 10.8 12.0 12.8 14.0
45 –35 8.1 9.0 9.9 11.3 12.2 13.5 14.4 15.8
50 –45 9.0 10.0 11.0 12.5 13.5 15.0 16.0 17.5
*) For quantity of coolant in your engine, see Section 9.1.

Note: For figures in gray field, refer back to head-office.

Routine Maintenance
5.1 Maintenance Schedule

5.2 Maintenance Chart
5.3 Maintenance Record

Routine Maintenance 5.1 Maintenance Schedule
check
5 once Every In running hours (h)1)
clean Section
after 10 h every
2) or renew
50-150 daily 125 250 500 1000 1500 2000 3000
Job
● ● Oil level 2) 9) 6.1.2/ 3.1.6
● ● Engine for leakages
● ● Oil bath 3)- and dry type air cleaners 4) 6.4
● ● Battery and lead connections 6.7.1
● ● ● ● ● ● Cooling system (dep. on engine use) 3) 8) 6.3.1/ 6.3.2
● ● ● Engine oil (dep. on engine use) 5) 6.1.1/ 6.1.2
● ● ● Oil filter cartridge 6.1.3
● ● ● Fuel filter cartridge 6.2.1
● ● ● Fuel prefilter 6.2 / 6.3
● ● 7) ● ● Fuel leakage lines 6.2.5
● ● ● Valve clearance (readjust if nec.) 6.6.1
● ● ● Engine mounts (retighten if necessary) 9.2
● ● ● V-belts (retension if nec.) 6.5
● ● Alarm system, engine mounts 3.3/ 9.3
● ● ● Radiator bearing rubber/locking elements
● ● Glow plugs
● 7) ● Coolant 6) 6.3.3/ 6.3.4
● ● Coolant , additive-concentration 4.3.2/ 4.3.3
● ● Coolant level 3.3.3
● ● Hose connections / clamps on air intake side, CAC 10) 6.3.3/9-6.2.5
The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please observe the operating instructions of
the equipment manufacturer.
1) recommended maximum 5) oil grade API-CD or ACEA E1-E3-96+E4-98 for turbocharged 8) system cleaning
2) commissioning new and reconditioned engines engines, for oil change intervals, see 6.1.1 9) check twice a day during the run-in phase
3) clean if needed 6) check antifreeze or if necessary chemical concentration every 10) drain off any lube oil/condensation water that has collected
4) change if required. If fitted, service according to maint- 500 OH in the charge-air cooler, see section 6 .3.9
enance indicator 7) or change at least every 2 years

5.2 Maintenance Chart Routine Maintenance
in. 0,3 mm
0.012 in.
h
Std.
OIL
5
a ex. 0,5 mm
0.020 in.
in. 500
ex. 1500
The maintenance chart shown here is supplied as R
WATE
self-adhesive label with each engine. It should be
AIR 10
affixed where it can be seen clearly on the engine 10
or driven equipment.
ca. 15 mm
0.6 in.
Check that this is the case. 500

125-
2000
If necessary, ask your engine or equipment supp-
lier for a fresh supply of labels. FU
1000 EL
Routine work should be carried out according to OIL

max.
10
the schedule in 5.1.
500
OIL
1013
0297 7782 0
a
h OIL
in.
Std.
1500
ex. 0,3 mm 500
in. 0.012 in.
ex. 0,5 mm
0.020 in.
R
WATE
AIR
10
10
ca. 15 mm
0.6 in.
125- 500
2000
FU
1000 EL
OIL 10
Stop the engine before carrying out max.
! any maintenance work. 500
OIL
BF4/6M 1012/E/C
0297 7783 0

Routine Maintenance 5.2 Maintenance Chart
5
The service diagram for series 1012/1013 (filling
the cooling system, venting, bleeding) featured on
this page is stuck on the engine as a servicing aid.
Check that this is the case!
If the sticker is not on the engine, ask for a

replacement from your engine or vehicle supplier.
For a full description regarding servicing, see

Sections 3.1.4, 6.3.3 and 6.3.4.
0297 4979 1
BFM 1012
BFM 1013

5.2 Maintenance Chart Routine Maintenance
5
The service diagram for series 1012/1013 (filling the cooling system, venting, bleeding) featured on this page is stuck on the engine as a servicing aid.
Check that this is the case!
If the sticker is not on the engine, ask for a replacement from your engine or vehicle supplier.
For a full description regarding servicing, see Sections 3.1.4, 6.3.3 and 6.3.4.
0297 4985 1
0297 4987 1
BFM 1012E
BFM 1013E BFM 1013E

Routine Maintenance 5.3 Completed Maintenance Jobs
Hours. Date Signaure / Stamp Hours Date Signaure / Stamp

5
50-150* -
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
* Commissioning new and overhauled engines
The maintenance jobs duly completed can be recorded in the above table.
Quelle:48 /MUS_Kap_5.3 en/W12# BA Seite

5.3 Completed Maintenance Jobs Routine Maintenance
Hours Date Signaure / Stamp Hours Date Signaure / Stamp

5
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
Quelle:49 /MUS_Kap5.3 en/W12# BA Seite

Routine Maintenance 5.3 Completed Maintenance Jobs

5
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750

Hours Date Signaure / Stamp Hours Date Signaure / Stamp
5
8875 9000
9125 9250
9375 9500
9625 9750
9875 10000
10125 10250
10375 10500
10625 10750
10825 11000
11125 11250
11375 11500
11625 11750
Quelle:51 /MUS_Kap5.3 en/W12# BA Seite

5

Service and Maintenance
6.1 Lubrication System

6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air Cleaner
6.5 Belt Drives
6.6 Adjustments
6.7 Accessories

Service and Maintenance 6.1 Lubrication System
6.1.1 Oil Change Intervals

6
● The oil change intervals are dependent on the
engine application and the quality of the lube Oil Grade Turbocharged engine
oil.
API Classification CF-4
● If the engine runs fewer hours during the year CG-4
than stated in the table, the oil should be CH-4
changed at least once a year.
ACEA Classification E1– E3/96 + E4-98
● The table refers to the following conditions:
– For diesel fuel: sulfur content max. 0.5 % by
weight.
– Continuous ambient temperatures down to
-10 °C / +14°F Oil Change Intervals Service Group Average Speed [km] [OH] [km]
● For fuels
– with sulfur content is > 0.5 to 1 % Equipment Engines – – 500 –
or
– continuous ambient temperature below Automotive Engines I 25 – 10 000
-10 °C/+14°F II 40 – 20 000
– with bio-diesel fuels in accordance with DIN III 60 – 30 000
51606-FAME the intervals between oil
changes should be halved.
● In the case of fuels containing more than 1 %

sulfur, contact your service representative.
Change the oil with the engine off but still warm
(lube oil temperature approx. 80 °C).

6.1 Lubrication System Service and Maintenance
6.1.2 Checking Oil Level /

Changing Engine Oil
6
6.1.2.1 Checking Oil Level 6.1.2.2 Changing Engine Oil
25 729 0 26 022 0 26 023 0
● Ensure that the engine or vehicle is on a level ● Run the engine warm ● Place an oil tray beneath the engine
surface. ● Ensure that the engine or vehicle is on a level ● Unscrew drain plug.
● – Warm engine surface ● Drain oil.
● Switch off engine, wait 5 minutes and check the – Lube oil temperature approx. 80°C. ● Fit oil drain plug with new gasket and tighten
oil level ● Switch off the engine. firmly (for torque, see 9.2).
● – Cold engine ● Fill with lube oil
Check the oil level – For grade/viscosity, see 4.1.
● Remove the dipstick – For quantity, see 9.1.
● Wipe off with a non-fibrous, clean cloth. ● Check oil level, see 6.1.2.1
● Insert up to the stop and pull out again.
● Check oil level, if required top up to the
“MAX” level
– If the oil level is just above the “MIN” mark,
it should be topped up. Be careful when draining hot oil - danger
! of scalds! Do not let used oil run into
the soil but catch it in a container ready
The oil level must not drop below the “MIN” mark.
for proper disposal.

Service and Maintenance 6.1 Lubrication System
6 6.1.3 Changing Oil Filter
25880 0 25881 0 25882 0
● With fitted torsion lock: ● Clean any dirt from the filter carrier rim. ● Check that the cartridge is correctly seated
Loosen screws and slide clamps downwards. against the gasket and tighten with a final half-
● Lightly oil the rubber gasket of the new oil filter turn.
● Undo the filter cartridge with commercial tool cartridge.
and spin off. ● If a torsion lock is fitted:
● Screw in the new cartridge finger tight against Slide clamps up into position and tighten
● Catch any dripping oil. the gasket. screws.
● Check oil level (see 6.1.2).
● Check oil pressure (see 3.3.1).
Beware of burns from hot oil. ● Check cartridge seal.

6.1 Lubrication System Service and Maintenance
6.1.4 Cleaning/Changing Oil filter 6

(Cup)
4
300 74 0
● Switch off the engine. ● Carefully insert the new paper filter cartridge 3 in
● Loosen the lube oil filter cap 1 and unscrew in guide 4.
an anticlockwise direction. ● Tighten lube oil filter cover 1 in the clockwise
● Carefully lift the paper filter cartridge 3 out of direction (25 Nm).
guide 4. ● Start the engine.
● Catch any dripping oil. ● Check the oil level, see 6.1.2.
● Change the paper filter cartridge 3. ● Check the oil pressure, see 3.3.1.
● Clean any dirt from the filter carrier rim and the ● Check lube oil filter fitting for leaks.
lube oil filter cover 1 and guide 4.
● Replace rubber seal 2 and apply a small amount
of grease
Caution: hot oil!
Risk of scalding!
!

Service and Maintenance 6.2 Fuel System
6.2.1 Changing Fuel Filter

6
25880 0 25881 0 25882 0
● Close fuel stopcock. ● Clean any dirt from the filter carrier rim. ● Check that the cartridge is seated correctly
against the gasket and tighten with a final half-
● Undo fuel filter cartridge with commercial tool ● Apply light film of oil or diesel fuel to the rubber turn.
and spin off. gasket of the new fuel filter cartridge.
● Open fuel stopcock.
● Catch any fuel. ● Screw in the new cartridge finger tight against
the gasket. ● Check for leaks.
Keep naked flames away when The fuel system does not need to be bled.
working on the fuel system. Do not
! smoke!

6.2 Fuel System Service and Maintenance
6.2.2 Cleaning/Changing Fuel 6.2.3 Venting the Fuel System

Pre-Filter Element with Preliminary Fuel Filter 6
Bleeding:
● Place the fuel pan beneath the preliminary fuel
8 1 filter.
● Loosen drain plug 4 and observe the draining
fluid. When fuel instead of water starts to flow,
retighten drain plug 4.
7 2 ● Check for leaks after the engine has been started.
6 3 Venting:
● During initial commissioning, after maintenance
work or if the tank is run empty it is essential to
vent the fuel system.
5 4 ● Set engine controller to stop position
● Place fuel collecting trough under the filter
25 801 0
30 084 0
housing (5) / pressure control valve (9).
● Open fuel stopcock, pressure control valve (9),
vent screw (8)
Cleaning: ● Press filter housing 5 with filter insert 3 and ● Turn engine with starter (max. 20 sec.) until fuel
● Close fuel stopcock. sealing ring 6 against the filter console 7 and with no air bubbles escapes from vent screw (8)
● Place the fuel pan beneath the preliminary fuel screw into place with clamping screw 1 and pressure holding valve (9).
filter. (tightening torque 25 Nm). ● Tighten vent screw 8 (tightening torque 15 Nm)
● Remove drain plug 4 and drain off fuel. Note: it must be possible to push the upper seal and pressure control valve 9.
● Unscrew clamping screw 1, remove filter housing 2 on filter insert 3 over the guide bracket on filter ● Set engine controller to start position and start
5 with filter insert 3. console 7. ● When the engine has started check for leaks
● Clean sealing surface of the filter bracket 7 and ● Tighten drain plug 4.
filter insert housing 5 of any dirt. ● Open fuel stopcock.
● Insert new sealing ring 6 and filter insert 3 ● Check for leaks after the engine has been started.
(change as necessary).
– Push the filter insert up to approx. 3 cm over Changing: Avoid naked flames when working
the edge of the housing onto the guide in the ● Replace defective filter insert 3.
on the fuel system. Do not smoke.
filter housing 5.
! Dispose of waste fuel in an en-
vironmentally-friendly way

Service and Maintenance 6.2 Fuel System
6 6.2.4 Changing Fuel Leakage Line 6.2.5 Changing Fuel Leakage

Pipes
30 084 0 30 034 0
● Set engine controller to stop position ● Close fuel stopcock

● Open fuel stopcock ● Dismantle valve cap cover
● Loosen pressure holding valve (9) ● Remove rubber hoses (3) from the injection
Catch any fuel which escapes and dispose of in valves
an environmentally-friendly way ● Dismantle rubber hoses (1), (3) and (4) and
● Turn engine with starter (max. 20 sec.) until fuel connection piece (2) and dispose of in an
with no air bubbles escapes from pressure environmentally-friendly way
holding valve (9). ● Fit new rubber hoses (1), (3) and (4) and
● Tighten up pressure holding valve (9). connection piece (2)
● Set engine controller to start position and start ● Connect rubber hoses (3) to injection valves
● When the engine has started check for leaks ● Remount valve cap cover
● Open fuel stopcock
Avoid naked flames when working ● When the engine has started check for leaks
on the fuel system. Do not smoke.
! Dispose of waste fuel in an en–
vironmentally-friendly way

6.3 Cooling System Service and Maintenance
6.3.1 Cleaning Intervals 6.3.2 Cleaning Cooling System

6
● The amount of contamination in the cooling Cold Cleansing Agent
system depends on the engine application. – Spray the heat exchanger with a commercial
cold cleansing agent and let stand for about
● Spilled oil or fuel on the engine increases the 10 minutes.
risk of contamination. Be especially careful if – First spray clean with a water jet from
the engine is used in dusty environments. position 3 then from position 1 (do not spray
● Serious contamination can occur, for example: sensitive engine components directly with a
– on construction sites where there is a high water jet, eg generator, cables, electronic
level of air-borne dust. components, fan drive).
– in harvesting application where there are Cleaning with steam or with hot water
high concentrations of chaff and chopped – Remove oil and grease residues with the jet
straw in the vicinity of the machine. set at a gentle setting.
● Because applications vary, cleaning intervals ● Refit service flap.

have to be determined from case to case. The ● Run the engine up to normal operating temp-
cleaning intervals given in the table below can erature to evaporate any remaining water.
26252 0
be used as a guide.
Checking / Cleaning Intervals Series 1012/1013 Series 1012E/1013E

Suggested OH Application ● Place a cleaning bath under the heat exchanger ● If an external cooling system is fitted, follow
(it. 2). the manufacturer’s instructions.
2000 Ships, gensets in enclosed
spaces, pumps ● Remove the service flap on the heat exchanger Unit engine
(see insert). ● Clean as described under series 1012/1013.
1000 Vehicles on paved roads
The cleaning jet must be positioned parallel to
500 Tractors, forklift trucks, mobile Compressed Air the cooling-air ducts.
gensets – Blow out heat exchanger with compressed
air (first from it. 3, then from it. 1).
250 Vehicles on construction sites Be careful not to damage the cooling fins.
and unpaved roads, construction – Wash out loosened dirt with a hose.
equipment, compressors,under-
ground mining equipment
125 Agricultural machinery, harvester
tractors Hose pressure: max. 100 bar

Service and Maintenance 6.3 Cooling System
6 6.3.3 Draining Cooling System 6.3.4 Filling / Venting

Cooling System
1012 / 1013 1012 / 1013
2 2
1 4 ca. 5 m 1 4
m
ca.
10
3 mm 3
30 082 0 26260 2
● Place container under drain plug 3. ● Unscrew cap 1

● Unscrew cap 1. ● Loosen sealing plug 2
● Unscrew drain plug 3 fully. ● Unscrew vent plug 4.
● Drain coolant. ● Unscrew sealing plug 3 (10 mm) up to the first
● Drain the remaining fluid from the engine oil notch.
cooler (coolant duct). ● Add coolant up to the max. marking or fill-up
● Screw in the sealing plug 3 up to the first notch limit (heater valve – if fitted – of the unit must
and screw in the sealing plug on the oil cooler be opened).
(arrow). ● Tighten sealing plug 2 (tightening torque 18 Nm)
Fill/vent the cooling system: see section 6.3.4 If a heater is connected to the ● Tighten vent plug 4 (tightening torque 40 Nm)
cooling system, all heater valves ● Tighten sealing plug 3.
Be careful when draining hot
coolant – danger of scalds! Collect ! must be opened during filling.
Depending on the water content
● Close cap 1.
● Start engine and warm up until thermostat
! drained coolant and dispose of
according to environmental
and the installation position of the
heater, it may be required to repeat the last point
opens.
● Switch off engine.
regulat-ions. several times to vent the heater system. ● Check coolant level (see section 3.3.3) and top
up as required.

6.3.6 Filling/Venting the Cooling

6.3.5 Draining the Cooling System
1012 E / 1013 E System 1012 E/1013 E 6
Standard engine
Venting
● The cooling systems, which are built in line
1 with our installation guidelines, are vented
automatically after they have been filled.
● With external cooling systems in accordance
with the specifications of the manufacturer.
0297 4987 1
26 341 0 BFM 1012E
BFM 1013E
● Place a container under sealing plug 1. ● Open radiator cap position 1.

● Remove sealing plug 1 from the crankcase. ● Loosen vent plug position 2.
● Drain off the coolant. ● Add coolant up to the maximum marking or
● Tighten sealing plug 1 again. filler limit (heater valve of the system must be
● If sealing plug 1 is not accessible, the system opened – if fitted).
can be drained at the engine oil cooler (coolant ● Tighten vent plug position 2 + sealing plug
duct). position 3.
Filling/venting the cooling system: ● Close radiator cap position 1.
See section 6.3.6. ● Start engine and warm up until thermostat
opens.
Be careful when draining hot ● Check coolant level when the engine is cold and
coolant – danger of scalds! Collect top up as required.
! drained coolant and dispose of
according to environmental
● Close the radiator sealing plug position 1.
regulat-ions.

Service and Maintenance 6.3 Cooling System
6.3.7 Draining the Cooling System

6 1013 E Unit Engine (4 Cylinders)
Short engine
Venting
● The cooling systems, which are built in line 1
with our installation guidelines, are vented
automatically after they have been filled.
● With external cooling systems in accordance
with the specifications of the manufacturer.
● Start the engine and warm up until the
thermostat opens.
0297 4985 1
2
30 299 0
BFM 1013E
● Loosen vent plug position 2 and sealing plug ● Open the cap 1 of the expansion tank.
position 3. ● Place a container beneath knurled screw 2.
● Add coolant up to the maximum marking or ● Unscrew the knurled screw 2 in an anti-
filler limit (heater valve of the system must be clockwise direction until coolant is emitted.
opened – if fitted). ● Drain off coolant.
● Tighten vent plug position 2 + sealing plug ● In case of clogging, rinse the radiator through
position 3. with clear water.
● Close radiator cap position 1. ● Tighten knurled screw 2.
● Start engine and warm up until thermostat Filling/venting the cooling system:
opens. see section 6.3.8
● Check coolant level when the engine is cold and
top up as required.
● Close the radiator sealing plug position 1.

6.3.8 Filling/Venting the Cooling 6.3.9 Draining the Charge-Air Cooler

Unit engine (6 cylinders) System 6
Unit Engine
1 1
2 2 1
30 277 0 30 277 0 30 191 0
● Open the cap 1 of the expansion tank. ● Open the cap 1 of the expansion tank. ● Loosen the drain plug 1 on the end of the
● Place a container beneath sealing plug 2. ● Slowly add coolant up to the max. marking or charge-air cooler.
● Unscrew the sealing plug 2. filler limit. ● Drain off any oil residues that may be
● Drain off coolant. ● Close the cap. remaining.
● In case of clogging, rinse the radiator through ● Start the engine and warm up until the thermostat ● Close the drain plug 1.
with clear water. opens, the upper coolant line warms up tangibly.
● Tighten sealing plug 2. ● Briefly run the engine at nominal output (fixed
Filling/venting the cooling system: setting), this rinses out any pockets.
see section 6.3.8 ● Switch off the engine and leave to cool down.
● Open cap 1, add coolant up to the max. marking
or filler limit and close the cap 1.
● Once the engine has been run once, check the
Be careful when draining hot coolant coolant level when the engine is cold.
- danger of scalds! Collect drained
! coolant and dispose of according to
environmental regulations.
If a heater is connected to the cooling system,
the heater valves must be opened when cool-
ant is added. Depending on the coolant cont-
ents and the installation location of the heater, it may be
necessary to repeat the procedure several times.

Service and Maintenance 6.4 Combustion Air Cleaner
6.4.1 Cleaning Intervals

6
● The amount of dirt in the air cleaner depends
on the amount of dust in the air and the size of
the air cleaner used. If a high level of dust is
anticipated, a cyclone-type precleaner can be
fitted to the air cleaner.
● Cleaning intervals will have to be determined

from case to case.
● If a dry type air cleaner is used, clean when

indicated by the service indicator or switch.
● Air cleaner servicing is needed when:

– Service Indicator
the red signal 1 is fully visible when the
engine is off. 25885 1
– Service Switch
the yellow pilot light comes on when the
engine is running.
● After carrying out service work, reset the signal

by pressing the button on the service indicator.

6.4 Combustion Air Cleaner Service and Maintenance
6.4.2 Emptying Cyclone Type 6.4.3 Cleaning Oil Bath Air Cleaner
Precleaner 6
25886 0 25887 0
● Undo wing nut 1 and remove cover 2. ● Turn engine off and wait about 10 minutes for ● Clean filter housing 1 if very dirty.
the oil to drain from filter housing 1.
● Remove collector bowl 3 from lower section 4 ● Inspect and replace rubber gaskets 5 and 6 if
and empty. Clean leaves, straw and other ● Release snap clips 2 and remove oil cup 3 necessary.
foreign matter from lower section of together with filter element 4. If necessary prize
precleaner. element out with a screwdriver, taking care not ● Fill oil cup with engine oil up to the mark
to damage the rubber gasket 5. (arrow) (for viscosity, see 4.1.2).
● Reposition collector bowl 3 onto lower section
4, fasten cover 2 in place by tightening wing ● Remove dirty oil and sludge. Clean oil cup. ● Refit oil cup and element to filter housing and
nut 1. secure with snap clips.
● Clean filter element 4 in diesel fuel and allow to
drip-dry. Never clean air cleaner with
gasoline. Dispose of old oil in
Never fill collector bowl with oil. Replace collector
bowl if damaged.
! accordance with environmental
regulations.

Service and Maintenance 6.4 Combustion Air Cleaner
6.4.4 Dry Type Air Cleaner

6
Dust Discharge Valve Filter Cartridge
25888 1 25889 0
● Empty dust discharge valve 1 by pressing apart ● Undo clip fasteners 1. ● After five air cleaner services or after two years
lips of discharge slot as indicated by arrows. at the latest, replace safety cartridge 4 (never
● Take off hood 2 and remove cartridge 3. clean).
● Clean discharge slot from time to time. ● Clean cartridge (replace at least once a year). To do so:
– Undo hex. nut 5 and remove cartridge 4.
● Remove any caked dirt by pressing together ● Clean cartridge 3: – Install new cartridge, insert and tighten hex.
the upper section of the valve. – Blow out from inside out with dry com- nut.
pressed air (max. 5 bar), or
– in difficult cases, tap out, taking care not to ● Install cartridge 3, replace hood 2 and do up
damage the cartridge, or clip fasteners.
– wash according to manufacturer’s instruc-
tions.
Never clean filter cartridge with
● Check paper filter (light showing through) and gasoline or hot fluids.
gaskets for damage. Replace if necessary. !

6.5 Belt Drives Service and Maintenance
6.5.1 Checking V-Belts
6
1012 1013
26 255 0 26 315 0 26 261 1
● Inspect entire V-belt for damage. ● Carefully remove the gauge without altering the
position of the indicator arm.
● Replace damaged V-belts. – Read off the value: Turn the gauge sideways to
see the exact spot where the top of the black
● After installing new belts, run engine for 15 mi- indicator arm 1 intersects scale 5 (arrow). For
nutes, then check belt tension. settings, see 9.1.
– If necessary, retension belt and measure again.
● Use a V-belt tension gauge (see 9.3) to check
belt tension.
– Place indicator arm 1 into gauge.
– Position gauge on V-belt 2, midway between
the pulleys, with flange 3 on bottom of gauge
against the edge of belt. Check, tension and change belts
– Push slowly on the black pad 4 at right angles only with the engine off. Refit belt
to belt 2 until the spring is heard or felt to
trigger.
! guard, if provided.

Service and Maintenance 6.5 Belt Drives
6.5.2 Tensioning Fan / 6.5.3 Changing Fan / 6.5.4 Tensioning Coolant /

6 Alternator Belts Alternator Belts Fuel Pump Belts
1012 1012 1012
5 1 5 1 1
4 4
A A B
2
2 2
B 3 B 3 3
A
26 449 0 26 449 0 26 450 0
● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1 and 2.
● Press alternator 5 in direction of arrow A until ● Press alternator in direction of arrow B. ● Push fuel pump 3 in direction of arrow (A) until
correct belt tension is achieved. correct belt tension is achieved.
● Remove and replace belt.
● Re-tighten bolts 1, 2 and 3. ● Re-tighten bolts 1 and 2.
● Tension belt in accordance with 6.5.3.
● Re-tighten bolts 1, 2 and 3.
Check, tension and change belts
! only with the engine off. Refit belt

guard, if provided.

6.5.5 Changing Coolant / 6.5.6 Tensioning Coolant / 6.5.7 Changing Coolant /
Fuel Pump Belts Fuel Pump Belts Fuel Pump Belts 6
1012 1012 E 1012 E
B
2
3
A
26 450 0 26 254 0 26 267 0
● Remove fan belt as described in 6.5.3. ● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2.
● Slacken off bolts 1 and 2. ● Push fuel pump 3 in direction of arrow.

● Push fuel pump 3 in direction of arrow until
● Push fuel pump 3 in direction of arrow (B). correct belt tension is achieved. ● Remove and replace belt.
● Remove and replace belt. ● Tighten bolts 1 and 2. ● Push fuel pump in opposite direction of arrow
until correct belt tension is achieved.
● Push fuel pump in direction of arrow (A) until
correct belt tension is achieved. ● Tighten bolts 1 and 2.
● Tighten bolts 1 and 2.

● Reinstall fan belt and tension as described in only with the engine off. Refit belt
6.5.2. ! guard, if provided.

6.5.8 Tensioning Alternator Belt 6.5.9 Changing Alternator Belt

6 1012 E 1012 E
26 250 0 26 251 0
● Slacken off bolts 1, 2 and 4. ● Remove fuel pump belt as described in 6.5.7.
● Move alternator 5 in direction of arrow by ● Slacken off bolts 1, 2 and 4.

turning bolt 3 until correct belt tension is
achieved. ● Adjust bolt 3 until the V-belt can be removed.
● Tighten bolts 1, 2 and 4. ● Fit new belt.
● Adjust bolt 3 until the correct belt tension is

achieved.
Check, tension and change belts ● Tighten bolts 1, 2 and 4.

only with the engine off. Refit belt
● Reinstall fuel pump belt and tension as
described in 6.5.6.

6.5.10 Tensioning / 6.5.11 Tensioning Coolant / 6.5.12 Changing Coolant /

Changing Fan Belt Fuel Pump belts Fuel Pump Belts 6
1013 1013 1013
1 1
B B
2 2
3 3
A A
26 345 0 26 450 0 26 450 0
● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2. ● Remove fan / alternator belt as described in
– Tensioning: 6.5.10 and 6.5.13.
Insert square wrench in square and pull in ● Push fuel pump 3 in direction (A) of arrow until
direction of arrow until correct belt tension is correct belt tension is achieved. ● Slacken off bolts 1 and 2.
achieved.
● Tighten bolts 1 and 2. ● Push fuel pump 3 in direction (B) of arrow.
– Changing:
Insert square wrench in square and loosen in ● Remove and replace belt.
opposite direction of arrow. Tension new belt
as described above. ● Push fuel pump in direction (A) of arrow until
correct belt tension is achieved.
only with the engine off. Refit belt ● Tighten bolts 1 and 2.
● Reinstall fan / alternator belt and retension as
described in 6.5.10 and 6.5.13.

6.5.13 Tensioning /Changing 6.5.14 Tensioning Coolant /Fuel 6.5.15 Changing Coolant /
6 Alternator Belt Pump Belts Fuel Pump Belts
1013 1013 E 1013 E
5 1
4
A
B 3
26 449 0 26 380 0 26 383 0
Tensioning: ● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2.

● Slacken off bolts 1, 2 and 3.
● Move alternator 5 in direction of arrow (A) until ● Push fuel pump 3 in direction of arrow until ● Push fuel pump 3 in direction of arrow.
correct belt tension is achieved. correct belt tension is achieved.
● Re-tighten bolts 1, 2 and 3. ● Remove and replace belt.
Changing: ● Push fuel pump 3 in opposite direction of
● Slacken off bolts 1, 2 and 3. arrow until correct belt tension is achieved.
● Move alternator 5 in direction of arrow (B) until
belt is exposed. ● Tighten bolts 1 and 2.
● Remove and replace belt, tension (see above).
● Re-tighten bolts 1, 2 and 3. Check, tension and change belts
only with the engine off. Refit belt

6.5.16 Tensioning /
Changing Compressor Belt 6
24598 1 24599 1
● Remove hex. bolts 1. ● To retension belt, remove one or more shims

3 – as may be required – from inside. Place
● Take off outer half-pulley 2. removed shim(s) outside on removed half-
pulley 2.
● Replace belt if necessary.
● Turn engine over while tightening bolts 1 to
prevent belt being pinched.

only with the engine off. Refit

Service and Maintenance 6.6 Adjustments
6 6.6.1 Checking /
Adjusting Valve Clearances
19691 2 26262 1
● Slacken off breather valve and swing to one ● Adjust valve clearance if necessary:
side. – Release locknut 4.
– Use screwdriver 7 to turn setscrew 5 so that
● Remove rocker cover. the correct clearance is attained after locknut
4 has been tightened.
● Position crankshaft as per schematic 6.6.1.1
● Check and adjust valve clearance on all
● Before adjusting valve clearance, allow engine remaining cylinders.
to cool down for at least 30 minutes. The oil
temperature should be below 80 °C / 176 °F. ● Replace rocker cover (use new gasket if
needed).
● Check valve clearance between rocker arm /
tappet contact face 2 and valve stem 3 with ● Swing breather valve back into position and
feeler gauge 6 (there should be only slight secure.
resistance when feeler blade is inserted).
For permissible valve clearance, see 9.1.

6.6 Adjustments Service and Maintenance
6.6.1.1 Valve Clearance

Adjustment Schematic
6
● Crankshaft Position 1:
Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet
valve about to open). Adjust clearance of valves
marked in black on schematic. Mark respec-
tive rocker arm with chalk to show that adjust-
ment has been done.
● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in black on
schematic.
26 263 2

Service and Maintenance 6.7 Accessories
6.7.1 Battery
6 6.7.1.1 Checking Battery and Cable 6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Specific Gravity of
Connectors Electrolyte
25895 0 24232 3 25896 0
● Keep battery clean and dry. ● Remove caps 1. ● Measure the specific gravity of individual cells
with a commercial hydrometer.
● Undo dirty clamps. ● If testers 2 are used, the electrolyte should
come up to their base. The hydrometer reading (see table on following
● Clean terminal posts (+ and –) and clamps of page) indicates the state of charge. During
the battery, and grease with acid-free and acid- ● If testers are not used, the electrolyte level measurement, the temperature of the electro-
resistant grease. should be 10-15 mm above the top of the lyte should preferably be 20°C / 68°F.
plates.
● When reassembling, ensure that clamps make
good contact. Do up clamp bolts finger tight. ● If necessary, top up with distilled water.
● Replace caps.

6.7 Accessories Service and Maintenance
Specific Gravity
in [kg/l] in °Bé [°Baumé]* State of Charge
Normal Tropics Normal Tropics
1.28 1.23 32 27 Fully charged
1.20 1.12 24 16 Half charged, recharge
1.12 1.08 16 11 Discharged, recharge immediately
* Measurement of specific gravity in °Bé is out of

date and rarely used today.
The gases emitted by the battery

are explosive. Keep sparks and
! naked flames away from the
battery.
Do not allow battery acid to come
into contact with skin or clothing.
Wear protective goggles.
Do not rest tools on the battery.

Service and Maintenance 6.7 Accessories
6 6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle
Notes on the three-phase system:
● Never disconnect the cables between battery,

alternator and regulator while the engine is
running.
● If, however, it is necessary to start and operate

the engine without the battery, disconnect the
regulator from the alternator before starting.
● Be sure not to confuse the battery terminals.
● Replace defective bulb of the charge pilot lamp

immediately.
● Cleaning the engine: Do not spray water/steam

26264 0 26265 0
directly onto the alternator. Run the engine up
to normal operating temperature to evaporate
any remaining water. ● Always use proper lifting tackle when
transporting the engine.
● The habit of touching a lead against the frame
to check whether it is live must under no
circumstances be used with three-phase
electrical systems.
● In the case of electric welding, connect the

ground terminal on the welder directly to the
piece being welded.
Use only the correct lifting tackle.

7.1 Diagnosis Chart Troubleshooting
7.1 Diagnosis Chart

Troubleshooting 7.1 Diagnosis Chart
7
● If engine problems occur, they frequently have
their cause in improper operation or engine
maintenance.
● If problems do occur, always check first that

the operating and maintenance instructions
have been followed.
● A diagnosis chart is given on the facing page.
● If you cannot identify the cause of the problem

or are unable to rectify it yourself, please
contact DEUTZ Service.
Before starting, make sure that

nobody is standing in the imme-
! diate vicinity of the engine or
driven machine.
Important: When carrying out
repair work, never start the engine
with speed governor removed.
Disconnect battery.

7.1 Diagnosis Chart Troubleshooting
Fault
Engine fails or is difficult to start
Remedy
Check P
7
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Not declutched (where possible) Operation P
● ● Below starting limit temperature P
● ● Engine shutdown lever in stop position (faulty solenoid) P
● ● Oil level too low A
● ● ● ● Oil level too high S
● ● ● Excessive inclination of engine P/E
● Speed control lever set to middle position P/E
● ● ● Dirty air cleaner/Faulty turbocharger Combustion air P/W
● ● ● Air cleaner service switch/indicator defective P
● ● LDA* defective (leaking line) P
● ● ● Charge air line leaking P/W
● Coolant pump defective Cooling system P/R
● ● Charge air cooler contaminated P/R
● Coolant heat exchanger dirty P/R
● ● ● ● ● Cooling fan defective, split or loose V-belt (belt-driven fuel pump) P/W
● ● Cooling air temperature rise/ hot air recirculation P
● Battery defective or discharged Electrics P
*LDA = Aneroid device Table 1 of 2

Troubleshooting 7.1 Diagnosis Chart
7 Fault
Engine fails or is difficult to start
Remedy
Check P
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Electrics cable connections to starter, electrical system loose or oxidized Electrics P
● Starter defective or pinion does not engage P
● ● ● ● ● Incorrect valve clearance Engine E
● ● ● ● Leaking injection line P
● Vent pipe blocked (coolant heat exchanger) P/R
● ● Glow plugs defective P
● ● ● ● ● ● ● Injector defective P/W
● ● ● ● Air in fuel system P/W
● ● ● ● Fuel filter/prefilter dirty P/ R /W
● Oil filter defective W
● ● ● Incorrect lube oil SAE class or quality Operating media W
● ● ● ● Fuel quality not as per Operation Manual P/ W
● Coolant level too low P/ A
Table 2 of 2

8.1 Preservation Engine Preservation
8.1 Preservation

Engine Preservation 8.1 Preservation
8 8.1 Preservation
If the engine is to remain idle for an extended

period of time, it is necessary to take protective
measures to prevent rust formation. The pre-
servative measures described here will protect the
engine for up to 6 months. The procedure will
have to be reversed before the engine is re-
commissioned.
● Anti-corrosion oils to specification:

– MIL-L-21260B
– TL 9150-037/2
– NATO code C 640/642
● Recommended cleansing agent to remove

preservatives when recommissioning engine:
– Petroleum benzine (hazardous materials
class A3) 26 268 1
Preserving Engine: ● Run engine for about 10 minutes. Removing Engine Preservatives:
● Clean engine (with cold cleansing agent if
● Turn engine off. ● Remove anti-corrosion agent from grooves in
preferred). See 6.3.2.
● Turn engine over manually several times. If V-belt pulleys 2.
● Run engine until warm, then turn off.
using starter, set shutdown lever to stop position.
● Drain engine oil (see 6.1.2) and fill with anti- ● Install V-belts 1. Retension after brief operation
corrosion oil. ● Remove V-belts 1 and store in wrapped condition. is necessary (see 6.5).
● Drain coolant (see 6.3.3/6.3.5). ● Spray grooves of V-belt pulleys 2 with anti- ● Remove covers from intake port 3 and exhaust
● Fill with anti-corrosion agent (see 4.3.3). corrosion agent. port 4.
● If necessary, clean oil bath air cleaner (see 6.4.3) ● Close off intake ports 3 and exhaust ports 4.
● Fill with coolant (see 6.3.4 / 6.3.5).
and fill with anti-corrosion oil.
● Lightly grease and replace coolant filler 5.
● Drain fuel tank. ● Start engine.
● Drain anti-corrosion agent (see 6.3.3 / 6.3.5).
● Make up a mixture of 90% diesel fuel and 10%
anti-corrosion oil, and refill fuel tank.

Technical Specifications
9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings
9.3 Tools

7380en_k09_pdf 1 04.10.1999, 12:01 Uhr
Technical Specifications 9.1 Engine Specifications and Settings
Model ——— BF4M 1012 ——— BF4M 1012 C ———— BF6M 1012 —— BF6M 1012 C ——
9 ——— BF4M 1012 E —— BF4M 1012 EC ———— BF6M 1012 E —— BF6M 1012 EC ——
Number of cylinders ————— 4 ——————— 4 ————————— 6 ——————— 6 ————

Cylinder arrangement ————————————————— vertical, in line ————————————————
Bore [mm] ——————————————————— 94 ——————————————————
Stroke [mm] ——————————————————— 115 ——————————————————
Total displacement [cm3] ————— 3192 —————— 3192 ——————— 4788 —————— 4788 ————
Compression ratio [ε]. ——————————————————— 17.5 ——————————————————
Working cycle/Combustion system ————————— 4-stroke diesel with turbocharging and direct injection ————————
Charge air cooler ————— w/o —————— w/ ———————— w/o —————— w/ ————
Direction of rotation ———————————————— counter-clockwise ———————————————
Weight 1012 / C incl. cooling system [kg approx.] ——————————————— contact company headquarters ————————————
Weight 1012 E / EC w/o cooling system
as per DIN 70020-A [kg approx.] ————— 330 —————— 332 ——————— 435 —————— 437 ————
Engine power [kW] ———————————————————— 1). ——————————————————

Speed [rpm] ———————————————————— 1). ——————————————————
Valve clearance with cold engine [mm] ——————————————— Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. —————————————
Injector opening pressure [bar] —————————————————— 250/275 —————————————————

Start of delivery [°crank angle bTDC] ———————————————————— 1). ——————————————————
Firing order of engine ———— 1-3-4-2 ————— 1-3-4-2 —————— 1-5-3-6-2-4 ——— 1-5-3-6-2-4 ——
V-belt tension: ——————————————— Pre-tension / re-tension 2). ——————————————
Generator fan [N] ————————————————— 450 / 300 ± 50. ————————————————

Fuel pump - coolant pump [N] ————————————————— 450 / 300 ± 50. ————————————————
Compressor [N] ————————————————— 550 / 450 ± 50. ————————————————
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1
2)
Retension 15 minutes after the engine has been driven under load

7380en_k09_pdf 2 04.10.1999, 12:01 Uhr
9.1 Engine Specifications and Settings Technical Specifications
Model BFM1012 / E ——— BF4M 1012 ——— BF4M 1012 C ———— BF6M 1012 —— BF6M 1012 C ——
Cooling system
——— BF4M 1012 E —— BF4M 1012 EC ———— BF6M 1012 E —— BF6M 1012 EC ——
——————————————— Liquid-cooled/Cooling system protection ————————
9
Coolant quantity
1012/C [litres approx.] ————— 9.3 —————— 10.0 ——————— 12.2 —————— 13.6 ————
1012 E/EC 5) [litres approx.] ————— 5.6 —————— 5.6 ————————— 7.3 —————— 7.3 ————
1012 unit engine (with frontal radiator) [litres approx.] ————— 15.9 —————— 18.1 ———————— — ——————— — ————
Permissible continuous coolant temperature
Engine outlet, with performance group I [°C] —————————————————— max.110 6) . —————————————————
Engine outlet, with performance group II-IV [°C] —————————————————— max.105 6) . —————————————————
Thermostat initial opening at [°C] ——————————————————— 83 7) . ——————————————————

Thermostat full open temperature [°C] ——————————————————— 95 8) . ——————————————————
Coolant prewarming ——————————————————— (4 . ——————————————————
Coolant pump
9)
Delivery pressure in [bar] ——————————————————— . ——————————————————
Delivery rate in [m3 /h] ——————————————————— 9)
. ——————————————————
9)
Power consumption in [kW] ——————————————————— . ——————————————————
Lubrication ——————————————— forced-feed lubrication ——————————————
Oil temperature in oil pan [°C] ——————————————————— 125 ——————————————————

Min. oil pressure with engine warm
(120°C and SAE oil 15 W 40) and low idle speed [bar] ——————————————————— 0.8 ——————————————————
Oil capacity (first fill-up) without filter [litres approx.] ———— 8.5 3) . ————— 8.5 3) . ——————— 12.5 3) . ————— 12.5 3) . ———
Oil capacity (first fill-up) with filter [litres approx.] ———— 10.0 3) . ————— 10.0 3). ——————— 14.0 3). ————— 14.0 3). ———
3)
Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum.
4)
Only during winter (see 3.5.1)
5)
Only engine capacity without radiator. Capacity of external cooling system dependent on cooling system design.
6)
Other performance groups have different values. Please contact company headquarters.
7)
With external cooling systems with outlet control, the temperature at which the thermostat opens is 87°C
8)
With external cooling systems with outlet control, the temperature at which the thermostat is fully opened is 102°C.
9)
Please contact company headquarters (varies depending on engine design)

7380en_k09_pdf 3 04.10.1999, 12:01 Uhr
Model —— BF4M 1013 — BF4M 1013 C — BF6M 1013 — BF6M 1013 C — BF6M 1013 CP —
9 —— BF4M 1013 E — BF4M 1013 EC — BF6M 1013 E — BF6M 1013 EC — BF6M 1013 ECP —
————
Number of cylinders ———— 4 —————— 4 ————— 6 —————— 6 ——————— 6 ————
Bore [mm] ——————————————————— 108 ——————————————————
Stroke [mm] ——————————————————— 130 ——————————————————
Total displacement [cm3] ——— 4764 ———— 4764 ————— 7146 ———— 7146 ————— 7146 ———
Working cycle/Combustion system ————————— 4-stroke diesel with turbocharging and direct injection —————————
Charge air cooler ———— w/o —————— w/ ————— w/o ————— w/ ————— w/ ————
Direction of rotation ———————————————— counter-clockwise ————————————————
Weight 1013 / CP incl. cooling system [kg approx.] ————————————— contact company headquarters —————————————
Weight 1013 E / EC / ECP w/o cooling system
as per DIN 70020-A [kg approx.] ———— 455 ————— 455 ————— 600 ———— 600 ————— 600 ———
Engine power [kW] ——————————————————— 1). ———————————————————

Speed [rpm] ——————————————————— 1). ———————————————————
Valve clearance with cold engine [mm] —————————————— Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. —————————————
Injector opening pressure [bar] —————————————————— 250/275 ——————————————————
Start of delivery [°crank angle bTDC] ——————————————————— 1). ———————————————————
Firing order of engine ——— 1-3-4-2 ———— 1-3-4-2 —— 1-5-3-6-2-4 —— 1-5-3-6-2-4 — 1-5-3-6-2-4 ——
V-belt tension: —————————————— Pre-tension / re-tension 2). ——————————————
Generator fan [N] ————————————————— 450 / 300 ± 50. —————————————————

Fuel pump - coolant pump [N] ————————————————— 450 / 300 ± 50. —————————————————
Compressor [N] ————————————————— 550 / 375 ± 50. —————————————————
1)
2)

7380en_k09_pdf 4 04.10.1999, 12:01 Uhr
Model 1013 /E — BF4M 1013 —— BF4M 1013 C — BF6M 1013 — BF6M 1013 C — BF6M 1013 CP —
Cooling system
— BF4M 1013 E —— BF4M 1013 EC — BF6M 1013 E — BF6M 1013 EC — BF6M 1013 ECP —
———————————— Liquid-cooled/Cooling system protection ———————————
9
Coolant quantity
1013 / C / CP [litres approx.] ——— 12.1 ————— 13.6 ————— 15 ————— 16.3 ————— 16.9 ———
1013 E / EC / ECP 5) [litres approx.] ——— 7.2 —————— 7.2 ————— 9.8 —————— 9.8 ————— 9.8 ———
1013 unit engine (with frontal radiator) [litres approx.] ——— 17.5 ————— 19.7 ————— 22 ————— 23.7 ————— 23.7 ———
Engine outlet, with performance group I [°C] ————————————————— max.110 6) . —————————————————
Engine outlet, with performance group II-IV [°C] ————————————————— max.105 6) . —————————————————
Thermostat initial opening at [°C] —————————————————— 83 7) . ——————————————————

Thermostat full open temperature [°C] —————————————————— 95 8) . ——————————————————
Coolant prewarming ——————————————————— (4 . ———————————————————
Coolant pump
9)
Delivery pressure in [bar] ——————————————————— . ———————————————————
. ———————————————————
9)
Power consumption in [kW] ——————————————————— . ———————————————————
Lubrication ——————————————— forced-feed lubrication ———————————————
Oil temperature in oil pan [°C] —————————————————— max. 125 —————————————————

(120°C and SAE oil 15 W 40) and low idle speed [bar] ——————————————————— 0.8 ———————————————————
Oil capacity (first fill-up) without filter [litres approx.] —— 13 3) . ————— 13 3) . ——— 20 3) . ———— 20 3) . ———— 20 3) . ———
Oil capacity (first fill-up) with filter [litres approx.] —— 14.0 3) . ————— 14.0 3) . ——— 21.0 3) . ———— 21.0 3). ——— 21.0 3). ———
3)
4)
5)
6)
7)
With external cooling systems with outlet control, the temperature at which the thermostat opens is 87°C
8)
With external cooling systems with outlet control, the temperature at which the thermostat is fully opened is 102°C.
9)

7380en_k09_pdf 5 04.10.1999, 12:01 Uhr
Model ————————— BF4M 1013 FC ———————— BF6M 1013 FC —————————

9 Number of cylinders ———————————— 4 ————————————— 6 ————————————
Bore [mm] ——————————————————— 108 ——————————————————
Stroke [mm] ——————————————————— 130 ——————————————————
Total displacement [cm3] ——————————— 4764 ———————————— 7146 ———————————
Working cycle/Combustion system ————————— 4-stroke diesel with turbocharging and direct injection —————————
Charge air cooler ——————————————————— with ——————————————————

Direction of rotation ———————————————— counter-clockwise ————————————————
Weight 1013 FC without cooling system ————————————— contact company headquarters —————————————
as per DIN 70020-A [kg approx.] ——————————— 455 ———————————— 600 ———————————
Engine power [kW] ——————————————————— 1). ———————————————————

Speed [rpm] ——————————————————— 1). ———————————————————
Valve clearance with cold engine [mm] —————————————— Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. —————————————
Injector opening pressure [bar] ——————————————————— 275 ——————————————————
Start of delivery [°crank angle bTDC] ——————————————————— 1). ———————————————————
Firing order of engine ——— 1-3-4-2 ———— 1-3-4-2 —— 1-5-3-6-2-4 —— 1-5-3-6-2-4 — 1-5-3-6-2-4 ——
V-belt tension: —————————————— Pre-tension / re-tension 2). ——————————————
Generator fan [N] ————————————————— 550 / 300 ± 50. —————————————————

Fuel pump - coolant pump [N] ————————————————— 550 / 300 ± 50. —————————————————
Compressor [N] ————————————————— 650 / 400 ± 50. —————————————————
1)
2)

7380en_k09_pdf 6 04.10.1999, 12:01 Uhr
Model 1013 FC ————————— BF4M 1013 FC ———————— BF6M 1013 FC —————————
Cooling system ———————————— Liquid-cooled/Cooling system protection ———————————

9
Coolant quantity
1013 FC 5) [litres approx.] ——————————— 7.2 ————————————— 9.8 ———————————
Engine outlet, with performance group I [°C] ——— with flap turbocharger max.110 6) ./ with feast turbocharger max.105 6) . ———————
Engine outlet, with performance group II-IV [°C] ————————————————— max.105 6). —————————————————
Thermostat initial opening at [°C] ——————————————————— 87 . ——————————————————
Thermostat full open temperature [°C] ——————————————————— 102 . ——————————————————
Coolant prewarming ——————————————————— (4 . ———————————————————
Coolant pump
7)
Delivery pressure in [bar] ——————————————————— . ———————————————————
. ———————————————————
7)
Power consumption in [kW] ——————————————————— . ———————————————————
Lubrication ——————————————— forced-feed lubrication ———————————————
Oil temperature in oil pan [°C] —————————————————— max. 125 —————————————————

(120°C and SAE oil 15 W 40) and low idle speed [bar] ——————————————————— 0.8 ———————————————————
Oil capacity (first fill-up) without filter [litres approx.] ——————————— 16 3) . ———————————— 28 3) . ——————————
Oil capacity (first fill-up) with filter [litres approx.] ——————————— 17 3) . ———————————— 29 3). ——————————
3)
4)
5)
6)
7)

7380en_k09_pdf 7 04.10.1999, 12:01 Uhr
Technical Specifications 9.2 Torque Wrench Settings
9 Preload [Nm] Torquing Load [Nm]

Location Total [Nm] Remarks
Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage 4
Rocker cover 8,5
Rocker arm setscrew 21

M16x40 8.8
Mount, flywheel side 187
A4C
M16x40 8.8
Mount, turbocharger side 187
A4C
Air intake manifold 8,5
Exhaust manifold 21
Oil drain plug 50
Injector mounting 16 Torx
Injection line mounting 30 M14x 1.5
Oil pan (cast iron) 29
Oil pan (sheet metal) 21

7380en_k09_pdf 8 04.10.1999, 12:01 Uhr
9.3 Tools Technical Specifications
TORX V-belt Tension Gauge

9
25899 0 26002 0
A TORX wrench set is used with engines in the The V-belt tension gauge can be obtained under
1012/1013 series. This system was chosen order number 91107 from:
because of the many advantages it offers:
WILBÄR
● Outstanding accessibility to bolts. Postfach 14 05 80
● High load transfer when loosening and tighten- D-42826 Remscheid
ing.
● Almost impossible for socket to slide off or
break.
TORX tools can be ordered from:
WILBÄR
Postfach 14 05 80
D-42826 Remscheid

7380en_k09_pdf 9 04.10.1999, 12:01 Uhr
Notes

7380en_k09_pdf 10 04.10.1999, 12:01 Uhr
Service
Knowing it’s DEUTZ Order-No.: 0297 7444 10

en DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manu-
facturer, we offer — worldwide — a com-
prehensive range of diesel and gas motors
spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job

reliably all over the world. We are determined to
preserve the high standard of performance and
dependability of our motors, thus keeping our
customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors

which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support Order-No.: 0297 7445 (CD-ROM)
to enhance your motor’s performance.
This index Sales & Service offers you an overview

of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the Obtainable from the local service Partner reponsible DEUTZ AG
range of services provided. But even when no direct for you or from: Deutz-Mülheimer Str. 147-149
product responsibility is mentioned, your DEUTZ D-51057 Köln
partner will be happy to help you with expert advice.
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. Telex: 8812-0 khd d
http://www.deutz.de
DEUTZ AG — at your service.
englisch
Werkstatthandbuch
Workshop Manual
Manuel d’Atelier
Manuale d’officina BFM 1012/1013
0297 9771
Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind

technische Änderungen, die zur Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeglicher Art, auch auszugsweise,
bedarf unserer schriftlichen Genehmigung.
In view of continuous design improvements or changes, the technical spe-

cifications and the illustrations shown in this Workshop Manual are subject to
alteration. Reprinting and reproduction, in part or in whole, are subject to our
written approval.
Sous réserve de modifications techniques nécessaires à l’amélioration des

moteurs présentés par des illustrations et des indications référencées dans ce
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soit la nature, interdites sans l’autorisation écrite de nos service.
Ci riserviamo il diritto di apportare sia ai dati tecnici che alle descrizioni

contenute nel presente manuale d’officina le modifiche che si sono eventual-
mente rese necessarie per migliorare i motori. Per ristamparlo o riprodurlo in
qualsiasi forma, anche parziale, è necessaria la nostra autorizzazione scritta.
© 05/00
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
Deutz-Mülheimer Straße 147-149
D - 51057 Köln
Telefon: 0221 - 822 - 0
Fax: 0221 - 822 - 5358
http://www.deutz.de
Printed in Germany
All rights reserved
1st Edition, © 05/2000
Knowing it’s DEUTZ. Best.-Nr. 0297 9771
VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.
In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparatur-

und Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, daß die
Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.
Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der
Inhalte zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den
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jeweils bei Neuauflage eingearbeitet.
Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.
Allgemeine Hinweise:
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vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten
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Einstellarbeiten Beteiligten zur Verfügung steht und daß der Inhalt verstanden wird.
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Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller
keine Haftung übernommen wird.
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anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzu-
halten.
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chen Ausrüstungen, Hand- und Spezialwerkzeuge sowie deren einwandfreier Zu-
stand.
- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei

Verwendung von Original Teilen der DEUTZ AG sichergestellt.
- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.
- Die Instandsetzung des Motors muß der bestimmungsgemäßen Verwendung -

definiert durch den Gerätehersteller - entsprechen. Bei Umbauten dürfen nur von der
DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt
werden.
© 05/00
FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work
on the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise
text passages are accompanied by pictographs to illustrate the relevant operation.
The Workshop Manual has been laid out to ensure quick comprehension of the contents, i. e
illustrations have been placed adjacent to the brief text passages to clearly show the working
operations.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next
issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.
General information:
- Please read carefully and observe the instructions given in this Workshop Manual
to avoid accidents and ensure that your engine always functions properly and
reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out
repairs or adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine
damage as well as personal injuries for which the manufacturer shall not accept any
liability.
- The accident prevention regulations and all other generally recognized regulations
on safety and occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special
tools are available and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be
ensured when genuine parts of DEUTZ AG are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not
handled with care.
- Engine repairs must be carried out in accordance with intended use as defined by
the equipment manufacturer. For conversions, only parts approved by DEUTZ AG
for a specific purpose should be used.
© 05/00
PRÉFACE
Un fonctionnement fiable du moteur suppose l’exécution en bonne et due forme des travaux de
réparation et de réglage.
Le présent Manuel d’atelier décrit la suite des travaux de réparation et de réglage à effectuer sur
le moteur et ses éléments. Cela suppose que les travaux sont réalisés par un personnel spécialisé
et qualifié.
En vue d’une compréhension rapide du contenu, le manuel d’atelier comporte, en plus des textes
brefs, des symboles visualisant l’opération à réaliser.
Le manuel d’atelier a été conçu de manière à assurer une rapide compréhension des textes concis
agrémentés d'illustrations et de symboles visualisant l’opération à effectuer.
Les indications relatives au service et à l’entretien figurent dans les instructions de service
correspondantes.
Pour la commande de pièces de rechange, il convient de se baser sur la liste des pièces de rechange
correspondante.
Le présent manuel d’atelier n’est soumis à aucun service de modifications. Les modifications
seront incorporées à chaque réédition du Manuel.
Pour les réparations, veuillez respecter les indications de nos circulaires techniques.
Remarques générales:
- Veuillez lire attentivement les informations du présent Manuel d’ Atelier et en tenir

compte. Vous éviterez ainsi des accidents et disposerez en même temps d’ un
moteur fonctionnel et en parfait état de marche.
- Assurez-vous que chaque personne chargée des travaux de réparation et de mise

au point dispose bien de ce Manuel d’ Atelier et en comprenne bien le contenu.
- Le non-respect de ces instructions de réparation peut entraîner des pannes, avaries

de moteur et accidents de personnes, pour lesquels le constructeur ne peut en aucun
cas assumer la responsabilité.
- Il convient de respecter les consignes générales de sécurité et de prévention des

accidents en vigueur.
- La condition préalable de la bonne exécution des réparations est la mise à disposition

de tous les équipements, outillages manuels et spéciaux requis, en parfait état de
fonctionnement.
- Seule l’utilisation de pièces de rechange d’origine DEUTZ AG garantit une rentabilité

et fiabilité optimales ainsi qu’une longue durée de vie.
- Les éléments du moteur notamment les ressorts, attaches, bagues élastiques etc.,
peuvent entraîner, en cas de non-respect des prescriptions, des blessures graves.
- La remise en état du moteur doit répondre à son utilisation propre, définie par le
constructeur de l’engin. En cas de modification, seules les pièces autorisées par
DEUTZ AG dans le cas de l’application concernée, peuvent être utilisées.
© 05/00
PREFAZIONE
La corretta esecuzione dei lavori di riparazione o di regolazione è un presupposto indispen-
sabile per un sicuro funzionamento del motore.
Nel presente manuale sono descritte le sequenze più convenienti per l’esecuzione di lavori
di riparazione o regolazione su motori o suoi componenti. L’impiego di personale qualificato è
il presupposto fondamentale per l’esecuzione di tali lavori.
Allo scopo di permettere una rapida comprensione del contenuto, oltre alle descrizioni
volutamente sintetiche, nel manuale sono state inserite dei simboli che chiariscono visiva-
mente le varie fasi di lavoro.
Per quanto riguarda l’esercizio e la manutenzione si rimanda al libretto di istruzioni.
Per le ordinazioni di parti di ricambio ci si deve basare sul relativo listino.
Per il presente manuale d’officina non sono previsti aggiornamenti. Le eventuali modifiche
verranno apportate alle edizioni successive.
Nel caso di riparazioni si devono consultare le nostre circolari tecniche.
Informazioni generali:
- Leggere attentamente ed osservare le istruzioni contenute nel presente manuale

d’officina. Si eviteranno pertanto incidenti e si disporrà di un motore funzionale
ed affidabile.
- Assicurarsi che questo manuale d’officina sia a disposizione di tutte le persone

che eseguono lavori di riparazione e messa a punto e ne abbiano ben compreso
il contenuto
- La non osservanza di queste istruzioni per le riparazioni può essere causa di

disfunzioni o guasti del motore, oppure di danni a persone o cose, per i quali il
costruttore non può essere chiamato a rispondere.
- Si devono osservare le prescrizioni in vigore per la prevenzione degli incidenti,

come pure le regole generali di sicurezza e medicina del lavoro.
- Presupposto fondamentale per una riparazione eseguita a regola d’arte è la

disponibilità di tutta l’attrezzatura necessaria, nonchè degli utensili speciali
perfettamente funzionanti.
- Soltanto l’impiego di parti originali della DEUTZ AG può assicurare la massima

economicità, affidabilità e durata di un motore.
- Piccoli componenti del motore, come molle, morsetti, anelli elastici di fissaggio,
ecc. possono costituire, se non usati in modo corretto, un elevato pericolo di
incidenti.
- La riparazione del motore deve corrispondere all’uso per cui è previsto, a sua
volta definito dal costruttore dell’attrezzo. Nel caso di modifiche possono venire
impiegate soltanto parti approvate dalla DEUTZ AG per quello specifico uso.
© 05/00
Inhalts-Verzeichnis
Table of Contents
Sommaire
Indice
Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols
Caractéristiques techniques / Légende des symbols
Dati tecnici / Spiegazione dei simboli
Prüfen und Einstellen

Checking and adjusting
Contrôle et réglage
Controlli e regolazioni
Bauteile instand setzen

Repair of components
Mise en état des composants
Riparazione di componenti
Demontage und Montage, Motor komplett

Disassembly and reassembly of complete engine
Démontage et montage moteur complet
Smontaggio e rimontaggio completo del motore
Werkzeuge
Tools
Outils
Attrezzi
© 05/00
5
Technische Daten
Specification data
Caractéristiques techniques
Dati tecnici BFM 1012/1013
Hinweis zum Gebrauch des Werkstatthandbuches

In diesem Werkstatthandbuch sind alle technischen Daten, Einstellwerte und
Anziehvorschriften den Stellen zugeordnet, wo sie bei Servicearbeiten, De- und
Montage am Motor benötigt werden.
Notes for the user of this Workshop Manual

In this Workshop Manual all specification data, adjustment values and
tightening specifications are allocated to those parts where they are needed for
service work, disassembly and reassembly on the engine.
Remarque quant à l’utilisazion du Manuel d’atelier

Dans le présent Manuel d’atelier, toutes les caractéristiques techniques, valeurs
de réglage et préconisations de serrage nécessaires se trouvent dans les
chapitres correspondant aux travaux de service après-vente et montage et
démontage du moteur.
Consigli per l’uso del manuale d’officina

Nel presente manuale d’officina tutti i dati tecnici, valori di regolazione e
prescrizioni di serraggio sono coordinati con quei punti in cui se ne avrà
bisogno per eseguire lavori di assistenza, smontaggio e rimontaggio del
motore.
© 05/00
Inhalts-Verzeichnis Technische Daten
Table of Contents Specification data
Sommaire Caractéristiques techniques
Indice Dati tecnici
Werkstatthandbuch BFM 1012/E, BFM 1013/E
Deutsch
1. Technische Daten Seite
Techn. Daten ________________________________________________________ 1.00.01 - 1.00.07

1
Ventilspieleinstellschema _______________________________________________ 1.00.09
Reihenfolge beim Anziehen der Zylinderkopfschrauben _______________________ 1.00.11
Ausgleichscheibendicke für Förderbeginn ermitteln
bei Bosch-Einspritzpumpe ______________________________________________ 1.00.13
Ausgleichscheibendicke für Förderbeginn ermitteln bei BFM 1012
Bosch-Einspritzpumpentausch im Servicefall. Grundmaß L0 = 109 mm ___________ 1.00.15
Bosch-Einspritzpumpentausch im Servicefall. Grundmaß L0 = 119 mm ___________ 1.00.15.1
Bosch-Einspritzpumpentausch im Servicefall. Grundmaß L0 = 143 mm ___________ 1.00.17
Korrigiertes Einbaumaß und EP-Code ermitteln bei Bosch Einspritzpumpe _________ 1.00.19
Bildzeichenerklärung __________________________________________________ 1.00.21
English
1. Specification data Page
Specification data ____________________________________________________ 1.00.01 - 1.00.07

Schematic for valve clearance adjustment __________________________________ 1.00.09
Tightening order for cylinder head bolts ___________________________________ 1.00.11
Shim thickness for determining commencement
of delivery with Bosch injection pump _____________________________________ 1.00.13
Shim thickness for determining commencement of delivery
with Bosch injection pump replacement on BFM 1012
in case of service.Standard dimensions L0 = 109 mm _________________________ 1.00.15
in case of service.Standard dimensions L0 = 119 mm _________________________ 1.00.15.1
in case of service. Standard dimensions L0 = 143 mm ________________________ 1.00.17
Determining corrected installation dimension
and EP code with Bosch injection pump ___________________________________ 1.00.19
Key to symbols ______________________________________________________ 1.00.21
© 05/00
Technische Daten Inhalts-Verzeichnis
Specification data Table of Contents
Caractéristiques techniques Sommaire
Dati tecnici Indice
Français
1. Caractéristiques techniques Page

1 Caractéristiques techniques _____________________________________________ 1.00.01 - 1.00.07
Schéma de réglage des soupapes ________________________________________ 1.00.09
Ordre à respecter lors du préserrage et serrage définitif des vis de culasse ________ 1.00.11
Calcul de l’épaisseur des rondelles de compensation
pour le début d’injection sur pompe d’injection Bosch ________________________ 1.00.13
Calcul de l’épaisseur des cales d’épaisseur utilisées pour remplacement
de la pompe d’injection Bosch BFM 1012 en cas d’intervention SAV.
Cote de base L0 = 109 mm _____________________________________________ 1.00.15
Cote de base L0 = 119 mm _____________________________________________ 1.00.15.1
Cote de base L0 = 143 mm _____________________________________________ 1.00.17
Calcul des cotes de montage corrigées et du code EP
pour pompe d’injection Bosch ___________________________________________ 1.00.19
Explication des légendes _______________________________________________ 1.00.21
Italiano
1. Dati tecnici Pagina
Dati tecnici __________________________________________________________ 1.00.01 - 1.00.07

Schema di registrazione del gioco delle valvole ______________________________ 1.00.09
Sequenza del serraggio delle viti delle teste dei cilindri ________________________ 1.00.11
Determinazione dello spessore delle rondelle per
l’inizio di mandata con pompa d’iniezione Bosch _____________________________ 1.00.13
Determinazione dello spessore delle rondelle per l’inizio di mandata
nel caso di sostituzione di una pompa di iniezione Bosch sul motore
BFM 1012. Misura base L0 = 109 mm _____________________________________ 1.00.15
BFM 1012. Misura base L0 = 119 mm _____________________________________ 1.00.15.1
BFM 1013. Misura base L0 = 143 mm _____________________________________ 1.00.17
Determinazione delle misure d’ingombro corrette e del codice EP
per le pompe di iniezione Bosch _________________________________________ 1.00.19
Spiegazione dei simboli ________________________________________________ 1.00.21
© 05/00
Technische Daten
Specification data
Dati tecnici
© 05/00
Technische Daten
Specification data
Dati tecnici
Deutsch English Français Italiano
Motorgewicht Engine weight Poids du moteur Peso del motore

nach DIN 70020 - A acc. to DIN 70020 - A selon DIN 70020 - A secondo DIN 70020 - A
1 ca. kg approx. kg approx. kg circa kg
Gesamthubvolumen Engine swept volume Cylindrée totale Cilindrata totale
cm3 cm3 cm3 cm3
Bohrung Bore Alésage Alesaggio
mm mm mm mm
Hub Stroke Course Corsa
mm mm mm mm
Drehrichtung Direction of rotation Sens de rotation Senso di rotazione
Nenndrehzahl Rated speed Régime nominal Regime nominale
max. 1/min max. rpm maxi tr/mn max. 1/min
niedrigste Minimum Ralenti extrême Regime minimo

Leerlaufdrehzahl idle speed a vuoto
1/min rpm tr/mn 1/min
Arbeitsweise Working cycle Principe de fonction- Ciclo di

nement funzionamento
© 05/00 1.00.02
Technische Daten
Specification data
Dati tecnici
BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E
inklusive Kühlsystem ohne Kühlsystem inklusive Kühlsystem ohne Kühlsystem

incl. cooling system without cooling system incl. cooling system without cooling system
y compris circuit de réfroid. sans circuit de réfroid. y compris circuit de réfroid. sans circuit de réfroid.
incluso sist.raffredd. senza sist. raffredd. incluso sist. raffredd. senza sist. raffredd.
1
380 BFM 1012 330 BFM 1012 E 490 BFM 1012 435 BFM 1012 E
480 BFM 1013 430 BFM 1013 E 625 BFM 1013 570 BFM 1013 E
3192 BFM 1012/ E 4788 BFM 1012/ E

4764 BFM 1013/ E 7146 BFM 1013/ E
94 BFM 1012/ E
108 BFM 1013/ E
115 BFM 1012/ E

130 BFM 1013/ E
auf Schwungrad gesehen links

When facing flywheel counter-clockwise
Vu sur volant à gauche
in senso anti-orario guardando il volano
2500 BFM 1012/ E

2300 BFM 1013/ E
650
Viertakt - Diesel
Four-stroke diesel
Diesel 4 temps
diesel a 4 tempi
1.00.03 © 05/00
Technische Daten
Specification data
Dati tecnici
Verbrennungs- Combustion Principe de Sistema di

verfahren system combustion combustione
1
Verdichtungs- Compression Taux de Rapporto di

verhältnis ratio compression compressione
Kompressionsdruck Compression pressure Compression Pressione di

compressione
bar bar bars bar
Zündfolge Fiing order Ordre d’allumage Ordine di

accensione
Abmessungen des Dimensions of Dimensions du Dimensioni motore

Motors mit engine incl. moteur avec carter compresa campana
Anschlußgehäuse standard adapter d’adaption standard di collegamento
(normal) housing (normale)
größte Länge Max. length Longueur HT Lunghezza massima
mm mm mm mm
größte Breite Max. width Largeur HT Larghezza massima
mm mm mm mm
größte Höhe Max. height Hauteur HT Altezza massima
mm mm mm mm
© 05/00 1.00.04
Technische Daten
Specification data
Dati tecnici
BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E
Direkteinspritzung
Direct injection
Injection directe 1
Iniezione diretta
17,5 BFM 1012/ E

17,6 BFM 1013/ E
28 - 33 BFM 1012/ E
30 - 38 BFM 1013/ E
1-3-4-2 1-5-3-6-2-4
874 BFM 1012 775 BFM 1012 E 1120 BFM 1012 1003 BFM 1012 E
945 BFM 1013 862 BFM 1013 E 1239 BFM 1013 1146 BFM 1013 E
678 BFM 1012 540 BFM 1012 E 678 BFM 1012 540 BFM 1012 E
685 BFM 1013 616 BFM 1013 E 760 BFM 1013 622 BFM 1013 E
743 BFM 1012 742 BFM 1012 E 834 BFM 1012 827 BFM 1012 E
818 BFM 1013 844 BFM 1013 E 868 BFM 1013 852 BFM 1013 E
1.00.05 © 05/00
Technische Daten
Specification data
Dati tecnici
Steuerzeiten ohne Valve timing without valve Calage distribution sans Fasatura senza
Stößel- und Ventilspiel clearance adjusted jeu aux culbuteurs gioco delle punterie
réglé e delle aste
1
Einlaß öffnet Inlet opens Admission ouvre Valvola aspirazione

vor OT before TDC avant PMH apre prima del PMS
Grad degrees degrés Gradi
Einlaß schließt Inlet closes Admission ferme Valvola aspirazione

nach UT after BDC après PMB chiude dopo il PMI
Auslaß öffnet Exhaust opens Echappement ouvre Valvola scarico

vor UT before BDC avant PMB apre prima del PMI
Auslaß schließt Exhaust closes Echappement ferme Valvola scarico

nach OT after TDC après PMH chiude dopo il PMS
Absteuerventil Pressurestat Clapet régulateur Valvola di regolazione

final pressione olio
bar bar bars bar
Schmieröldruck in Lube oil pressure at low Pression d’huile au bas Pressione olio con
niedrigem Leerlauf idling ralent motore al minimo,
Temperatur ca. 120 °C Temperature approx. température ca. 120 °C temp. olio circa 120 °C,
Öl SAE 15W/40 120 °C oil SAE 15W/40 huile SAE 15W/40 olio SAE 15W/40
Minimum bar min. bar mini bars minima bar
© 05/00 1.00.06
Technische Daten
Specification data
Dati tecnici
BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E
46 BFM 1012/ E
46,5 BFM 1013/ E
56 BFM 1012/ E
55,5 BFM 1013/ E
96 BFM 1012/ E
100,5 BFM 1013/ E
50 BFM 1012/ E
51,5 BFM 1013/ E
6 ± 0,75 10 ± 1
0,8
1.00.07 © 05/00
Technische Daten
Specification data
Dati tecnici
© 05/00
Ventilspieleinstellschema
Schematic for valve clearance adjustment
Schéma de réglage des soupapes
Schema di regolazione del gioco delle valvole
English Français Italiano
Crankshaft position 1 Position de l’arbre à cames 1 Posizione dell’albero 1

a gomiti
Kurbelwellenstellung 11 Kurbelwellenstellung 2 1 1
Turn engine until valves of cylinder Virer le moteur jusqu’au chevau- Virare il motore nel suo senso di
No. 1 overlap. chement des soupapes au cylindre 1. rotazione fino a portare le valvole
Motor um eine volle Umdrehung (360°) del cilindro nr. 1 nella posizione
Motor bis zum Erreichen der Ventilüber-
di sovrapposizione.
schneidung am Zyl. Nr. 1 durchdrehen. weiterdrehen.
Not ready for adjustment. non réglable La regolazione non è effettuabile.
nicht einstellbar einstellbar

Crankshaft position 2: Position de l’arbre à cames 2 Posizione dell’albero
a gomiti 2
Turn engine further by one complete Tourner le moteur d’un tour complet Virare il motore nel suo senso
revolution (360°). (360°) di rotazione di un giro completo,
cioè per ulteriori 360°.
Ready for adjustment. réglable La regolazione è effettuabile.
© 05/00 1.00.09 1.00.09 © 05/00

Ventilspieleinstellschema
Schematic for valve clearance adjustment
Schéma de réglage des soupapes
Schema di regolazione del gioco delle valvole
Crankshaft position 1 Position de l’arbre à cames 1 Posizione dell’albero 1

a gomiti
Kurbelwellenstellung 11 Kurbelwellenstellung 2 1 1
Turn engine until valves of cylinder Virer le moteur jusqu’au chevau- Virare il motore nel suo senso di
No. 1 overlap. chement des soupapes au cylindre 1. rotazione fino a portare le valvole
Motor um eine volle Umdrehung (360°) del cilindro nr. 1 nella posizione
Motor bis zum Erreichen der Ventilüber-
di sovrapposizione.
schneidung am Zyl. Nr. 1 durchdrehen. weiterdrehen.
Not ready for adjustment. non réglable La regolazione non è effettuabile.
nicht einstellbar einstellbar

Crankshaft position 2: Position de l’arbre à cames 2 Posizione dell’albero
a gomiti 2
Turn engine further by one complete Tourner le moteur d’un tour complet Virare il motore nel suo senso
revolution (360°). (360°) di rotazione di un giro completo,
cioè per ulteriori 360°.
Ready for adjustment. réglable La regolazione è effettuabile.
© 05/00 1.00.09 1.00.09 © 05/00

Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening order for cylinder head bolts
Ordre à respecter lors du serrage d’approche et définitif des vis de cul.
Sequenza di serraggio delle viti delle teste dei cilindri
1 1
Krümmerseite, Manifold side, Krümmerseite, Manifold side,
Coté coudes, Lato collettore Coté coudes, Lato collettore
14 6 4 12 14 6 4 12
18 10 2 8 16 18 10 2 8 16
4-Zylinder 4-Zylinder
4-cylinder 4-cylinder
4-cylindres 4-cylindres
4 cilindri 4 cilindri
17 9 1 7 15 17 9 1 7 15
13 5 3 11 13 5 3 11

22 14 6 4 12 20 22 14 6 4 12 20
26 18 10 2 8 16 24 26 18 10 2 8 16 24
25 17 9 1 7 15 23 25 17 9 1 7 15 23
21 13 5 3 11 19 21 13 5 3 11 19
© 05/00 1.00.11 1.00.11 © 05/00

Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening order for cylinder head bolts
Ordre à respecter lors du serrage d’approche et définitif des vis de cul.
Sequenza di serraggio delle viti delle teste dei cilindri
1 1
14 6 4 12 14 6 4 12
18 10 2 8 16 18 10 2 8 16
17 9 1 7 15 17 9 1 7 15
13 5 3 11 13 5 3 11

22 14 6 4 12 20 22 14 6 4 12 20
26 18 10 2 8 16 24 26 18 10 2 8 16 24
25 17 9 1 7 15 23 25 17 9 1 7 15 23
21 13 5 3 11 19 21 13 5 3 11 19
© 05/00 1.00.11 1.00.11 © 05/00

Förderbeginn ermitteln. Technische Daten
Setting commencement of delivery. Specification data
Calagne du début d’injection. Caractéristiques techniques
Determinazione dell’inizio di mandata. Dati tecnici
Mot. - Typ Code Mot. - Nr.
0122 3237
kW(G) red. EP K
kW(G) kW(S) 1/min )°

kW(S) red.
E 1
6 A
kW(W)
°C
DEUTZ AG MADE IN GERMANY
Hinweis:
Ab 07.1996 ist auf dem Schriftfeld für den Förderbeginn auch der Nockenwellentyp A, B oder C angegeben. Dies ist
bei der Grundeinstellung der Einspritzpumpen, siehe Tabelle 1, unbedingt zu berücksichtigen.
Note:
As of July 1996, camshaft type A, B or C will also be indicated in the inscription field for the commencement of
delivery. It is absolutely necessary to consider this when determining the standard dimension of the injection
pumps, see table 1.
Nota:
A compter de 07/1996 le cadre d’identification réservé au début d’injection indiquera également le type d’arbre à
cames A, B ou C. Prière de respecter impérativement cette indication lors du calagne des pompes d’injection, voir
tableau 1.
Nota:
A partire dal mese di luglio 1996, nel riquadro per l’inizio di mandata è riportato pure il tipo di albero a camme
(A,B o C). Di tale dato si deve assolutamente tener conto all’atto della messa a punto di base delle pompe di
iniezione, vedi tabella 1.
1.00.13 © 05/00
Technische Daten
Specification data
Dati tecnici
© 05/00
Ausgleichscheibendicke für Förderbeginn ermitteln.
Bosch Einspritzpumpe
Tabelle 1 Tabelle 2 Tabelle 1 Tabelle 2

Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich- Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich-
(FB) (Vh) Korrektur- E-Pumpe "TS" scheiben- "TS" scheiben- (FB) (Vh) Korrektur- E-Pumpe "TS" scheiben- "TS" scheiben-
Nenn./Tol. Typ Nennwert faktor (L0) dicke "SS" dicke "SS" Nenn./Tol. Typ Nennwert faktor (L0) dicke "SS" dicke "SS"
(° kW v. OT) (mm) (mm/° kW) (mm) (mm) (mm) (mm) (mm) (° kW v. OT) (mm) (mm/° kW) (mm) (mm) (mm) (mm) (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9 BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6 BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 BFM 1013 8 A 5,70 0,1 143
2,25 - 2,349 2,3 2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143
Berechnungsbeispiel: BFM 1012 BFM 1013 Berechnungsbeispiel: BFM 1012 BFM 1013
Zylinder Nr. 0 0 1 2 0 1 2 3 Zylinder Nr. 0 0 1 2 0 1 2 3
E - Pumpen Nr. xxx xxx xxx E - Pumpen Nr. xxx xxx xxx
FB Ist gemessen °kW 8 8 10 FB Ist gemessen °kW 8 8 10
FB Nenn aus Tabelle 1 °kW 9 9 10 FB Nenn aus Tabelle 1 °kW 9 9 10
Vh Korr.faktor aus Tab. 1 mm/°kW 0,1 0,1 0,1 Vh Korr.faktor aus Tab. 1 mm/°kW 0,1 0,1 0,1
Vh Nenn aus Tabelle 1 mm 4,63 4,63 5,31 Vh Nenn aus Tabelle 1 mm 4,63 4,63 5,31
L0 aus Tabelle 1 mm 109 119 143 L0 aus Tabelle 1 mm 109 119 143
A/100 von E.-Pumpe mm 0,53 0,22 1,33 A/100 von E.-Pumpe mm 0,53 0,22 1,33
L gemessen mm 116,26 126,57 152,22 L gemessen mm 116,26 126,57 152,22
E1 = FB Ist - FB Nenn °kW -1 -1 0 E1 = FB Ist - FB Nenn °kW -1 -1 0
E2 = E1 x Vh Korrekturfakor mm -0,1 -0,1 0 E2 = E1 x Vh Korrekturfakor mm -0,1 -0,1 0

E3 = E2 + Vh Nenn mm 4,53 4,53 5,31 E3 = E2 + Vh Nenn mm 4,53 4,53 5,31
E4 = E3 + L 0 mm 113,53 123,53 148,31 E4 = E3 + L 0 mm 113,53 123,53 148,31

E5 = E4 + A/100 mm 114,06 123,75 149,64 E5 = E4 + A/100 mm 114,06 123,75 149,64
TS = L - E5 mm 2,20 2,82 2,58 TS = L - E5 mm 2,20 2,82 2,58
"SS" aus Tabelle 2 mm 2,2 2,8 2,6 "SS" aus Tabelle 2 mm 2,2 2,8 2,6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Ausgleichscheibendicke für Förderbeginn ermitteln.
Bosch Einspritzpumpe
Tabelle 1 Tabelle 2 Tabelle 1 Tabelle 2

Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich- Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich-
(FB) (Vh) Korrektur- E-Pumpe "TS" scheiben- "TS" scheiben- (FB) (Vh) Korrektur- E-Pumpe "TS" scheiben- "TS" scheiben-
Nenn./Tol. Typ Nennwert faktor (L0) dicke "SS" dicke "SS" Nenn./Tol. Typ Nennwert faktor (L0) dicke "SS" dicke "SS"
(° kW v. OT) (mm) (mm/° kW) (mm) (mm) (mm) (mm) (mm) (° kW v. OT) (mm) (mm/° kW) (mm) (mm) (mm) (mm) (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9 BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6 BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 BFM 1013 8 A 5,70 0,1 143
2,25 - 2,349 2,3 2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143
E - Pumpen Nr. xxx xxx xxx E - Pumpen Nr. xxx xxx xxx
FB Ist gemessen °kW 8 8 10 FB Ist gemessen °kW 8 8 10
FB Nenn aus Tabelle 1 °kW 9 9 10 FB Nenn aus Tabelle 1 °kW 9 9 10
Vh Korr.faktor aus Tab. 1 mm/°kW 0,1 0,1 0,1 Vh Korr.faktor aus Tab. 1 mm/°kW 0,1 0,1 0,1
A/100 von E.-Pumpe mm 0,53 0,22 1,33 A/100 von E.-Pumpe mm 0,53 0,22 1,33
E1 = FB Ist - FB Nenn °kW -1 -1 0 E1 = FB Ist - FB Nenn °kW -1 -1 0

E4 = E3 + L 0 mm 113,53 123,53 148,31 E4 = E3 + L 0 mm 113,53 123,53 148,31

E5 = E4 + A/100 mm 114,06 123,75 149,64 E5 = E4 + A/100 mm 114,06 123,75 149,64
TS = L - E5 mm 2,20 2,82 2,58 TS = L - E5 mm 2,20 2,82 2,58
"SS" aus Tabelle 2 mm 2,2 2,8 2,6 "SS" aus Tabelle 2 mm 2,2 2,8 2,6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Determining shim thickness for commencement of delivery.
Bosch injection pump
Table 1 Table 2 Table 1 Table 2

Engine type Commencement Camshaft Pre-stroke Pre-stroke Standard Theor. thickness Shim- Theor. thickness Shim- Engine type Commencement Camshaft Pre-stroke Pre-stroke Standard Theor. thickness Shim- Theor. thickness Shim-
of delivery type (Vh) correction dimensions "TS" thickness "TS" thickness of delivery type (Vh) correction dimensions "TS" thickness "TS" thickness
(FB) Nom. value factor inj. pump "SS" "SS" (FB) Nom. value factor inj. pump "SS" "SS"
(° C/A BTDC) (mm) (mm/° C/A) (Lo) (mm) (mm) (mm) (mm) (mm) (° C/A BTDC) (mm) (mm/° C/A) (Lo) (mm) (mm) (mm) (mm) (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
1,35 - 1,449 1,4 2,85 - 2,949 2,9 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 10 C 4,47 0,1 109 / 119 BFM 1012/ C 10 C 4,47 0,1 109 / 119
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
2,05 - 2,149 2,1 3,55 - 3,649 3,6 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 1013 7 A 5,90 0,1 143 BFM 1013 7 A 5,90 0,1 143
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 2,25 - 2,349 2,3 BFM 1013 8 A 5,70 0,1 143 2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143
Calculation example: BFM 1012 BFM 1013 Calculation example: BFM 1012 BFM 1013
Cylinder No. 0 0 1 2 0 1 2 3 Cylinder No. 0 0 1 2 0 1 2 3

Injection pump No. xxx xxx xxx Injection pump No. xxx xxx xxx
FB measured °C/A 8 8 10 FB measured °C/A 8 8 10
FB nom. from table 1 °C/A 9 9 10 FB nom. from table 1 °C/A 9 9 10
Vh corr. factor from table 1 mm/°C/A 0.1 0.1 0.1 Vh corr. factor from table 1 mm/°C/A 0.1 0.1 0.1
Vh nom. from table 1 mm 4.63 4.63 5.31 Vh nom. from table 1 mm 4.63 4.63 5.31
L0 nom. from table 1 mm 109 119 143 L0 nom. from table 1 mm 109 119 143
A/100 of inj. pump mm 0.53 0.22 1.33 A/100 of inj. pump mm 0.53 0.22 1.33
L measured mm 116.26 126.57 152.22 L measured mm 116.26 126.57 152.22
E1 = FB act. - FB nom °C/A -1 -1 0 E1 = FB act. - FB nom °C/A -1 -1 0

E2 = E1 x Vh corr. factor mm -0.1 -0.1 0 E2 = E1 x Vh corr. factor mm -0.1 -0.1 0
E3 = E2 + Vh nom. mm 4.53 4.53 5.31 E3 = E2 + Vh nom. mm 4.53 4.53 5.31
E4 = E3 + L 0 mm 113.53 123.53 148.31 E4 = E3 + L 0 mm 113.53 123.53 148.31
E5 = E4 + A/100 mm 114.06 123.75 149.64 E5 = E4 + A/100 mm 114.06 123.75 149.64
TS = L - E5 mm 2.20 2.82 2.58 TS = L - E5 mm 2.20 2.82 2.58
"SS" from table 2 mm 2.2 2.8 2.6 "SS" from table 2 mm 2.2 2.8 2.6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Determining shim thickness for commencement of delivery.
Bosch injection pump
Table 1 Table 2 Table 1 Table 2

Engine type Commencement Camshaft Pre-stroke Pre-stroke Standard Theor. thickness Shim- Theor. thickness Shim- Engine type Commencement Camshaft Pre-stroke Pre-stroke Standard Theor. thickness Shim- Theor. thickness Shim-
of delivery type (Vh) correction dimensions "TS" thickness "TS" thickness of delivery type (Vh) correction dimensions "TS" thickness "TS" thickness
(FB) Nom. value factor inj. pump "SS" "SS" (FB) Nom. value factor inj. pump "SS" "SS"
(° C/A BTDC) (mm) (mm/° C/A) (Lo) (mm) (mm) (mm) (mm) (mm) (° C/A BTDC) (mm) (mm/° C/A) (Lo) (mm) (mm) (mm) (mm) (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
1,35 - 1,449 1,4 2,85 - 2,949 2,9 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 10 C 4,47 0,1 109 / 119 BFM 1012/ C 10 C 4,47 0,1 109 / 119
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
2,05 - 2,149 2,1 3,55 - 3,649 3,6 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 1013 7 A 5,90 0,1 143 BFM 1013 7 A 5,90 0,1 143
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 2,25 - 2,349 2,3 BFM 1013 8 A 5,70 0,1 143 2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143
Cylinder No. 0 0 1 2 0 1 2 3 Cylinder No. 0 0 1 2 0 1 2 3

Injection pump No. xxx xxx xxx Injection pump No. xxx xxx xxx
FB nom. from table 1 °C/A 9 9 10 FB nom. from table 1 °C/A 9 9 10
Vh corr. factor from table 1 mm/°C/A 0.1 0.1 0.1 Vh corr. factor from table 1 mm/°C/A 0.1 0.1 0.1
A/100 of inj. pump mm 0.53 0.22 1.33 A/100 of inj. pump mm 0.53 0.22 1.33
E1 = FB act. - FB nom °C/A -1 -1 0 E1 = FB act. - FB nom °C/A -1 -1 0

E2 = E1 x Vh corr. factor mm -0.1 -0.1 0 E2 = E1 x Vh corr. factor mm -0.1 -0.1 0
E4 = E3 + L 0 mm 113.53 123.53 148.31 E4 = E3 + L 0 mm 113.53 123.53 148.31
E5 = E4 + A/100 mm 114.06 123.75 149.64 E5 = E4 + A/100 mm 114.06 123.75 149.64
TS = L - E5 mm 2.20 2.82 2.58 TS = L - E5 mm 2.20 2.82 2.58
"SS" from table 2 mm 2.2 2.8 2.6 "SS" from table 2 mm 2.2 2.8 2.6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Calcul de l’épaisseur des rondelles d’épaisseur pour le début d’injection.
Pompe d’injection Bosch
Tableau 1 Tableau 2 Tableau 1 Tableau 2

Type de Début d’injection Arbre à cames Précourse Course à Cote de base Epaisseur Epaisseur Epaisseur Epaisseur Type de Début d’injection Arbre à cames Précourse Course à Cote de base Epaisseur Epaisseur Epaisseur Epaisseur
moteur (FB) type (Vh) Facteur de Ppe d’inject. théorique rondelles- théorique rondelles- moteur (FB) type (Vh) Facteur de Ppe d’inject. théorique rondelles- théorique rondelles-
nomin./tol. valeur nomin. correction (Lo) "TS" d’epaisseur "TS" d’epaisseur nomin./tol. valeur nomin. correction (Lo) "TS" d’epaisseur "TS" d’epaisseur
(° vil. av. PMH) (mm) (mm/° vil.) (mm) (mm) "SS" (mm) (mm) "SS" (mm) (° vil. av. PMH) (mm) (mm/° vil.) (mm) (mm) "SS" (mm) (mm) "SS" (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
1,35 - 1,449 1,4 2,85 - 2,949 2,9 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 10 C 4,47 0,1 109 / 119 BFM 1012/ C 10 C 4,47 0,1 109 / 119
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
2,05 - 2,149 2,1 3,55 - 3,649 3,6 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 1013 7 A 5,90 0,1 143 BFM 1013 7 A 5,90 0,1 143
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 2,25 - 2,349 2,3 BFM 1013 8 A 5,70 0,1 143
2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143
Exemple de calcul: BFM 1012 BFM 1013 Exemple de calcul: BFM 1012 BFM 1013
Cylindre no. 0 0 1 2 0 1 2 3 Cylindre no. 0 0 1 2 0 1 2 3

Pompe no. xxx xxx xxx Pompe no. xxx xxx xxx
FB Début d’injection mesuré °vil 8 8 10 FB Début d’injection mesuré °vil 8 8 10
FB Début d’injection nominal tableau 1°vil 9 9 10 FB Début d’injection nominal tableau 1°vil 9 9 10
Facteur de correction Vh tableau 1 mm/°vil 0,1 0,1 0,1 Facteur de correction Vh tableau 1 mm/°vil 0,1 0,1 0,1
Vh nominal tableau 1 mm 4,63 4,63 5,31 Vh nominal tableau 1 mm 4,63 4,63 5,31
L0 tableau 1 mm 109 119 143 L0 tableau 1 mm 109 119 143
A/100 de pompe d’injection mm 0,53 0,22 1,33 A/100 de pompe d’injection mm 0,53 0,22 1,33
L mesuré mm 116,26 126,57 152,22 L mesuré mm 116,26 126,57 152,22
E1 = FB réel - FB nomin. °vil. -1 -1 0 E1 = FB réel - FB nomin. °vil. -1 -1 0

E2 = E1 x Vh facteur de correction mm -0,1 -0,1 0 E2 = E1 x Vh facteur de correction mm -0,1 -0,1 0
E3 = E2 + Vh nomin. mm 4,53 4,53 5,31 E3 = E2 + Vh nomin. mm 4,53 4,53 5,31
E4 = E3 + L 0 mm 113,53 123,53 148,31 E4 = E3 + L 0 mm 113,53 123,53 148,31
E5 = E4 + A/100 mm 114,06 123,75 149,64 E5 = E4 + A/100 mm 114,06 123,75 149,64
TS = L - E5 mm 2,20 2,82 2,58 TS = L - E5 mm 2,20 2,82 2,58
"SS" tableau 2 mm 2,2 2,8 2,6 "SS" tableau 2 mm 2,2 2,8 2,6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Calcul de l’épaisseur des rondelles d’épaisseur pour le début d’injection.
Pompe d’injection Bosch
Tableau 1 Tableau 2 Tableau 1 Tableau 2

Type de Début d’injection Arbre à cames Précourse Course à Cote de base Epaisseur Epaisseur Epaisseur Epaisseur Type de Début d’injection Arbre à cames Précourse Course à Cote de base Epaisseur Epaisseur Epaisseur Epaisseur
moteur (FB) type (Vh) Facteur de Ppe d’inject. théorique rondelles- théorique rondelles- moteur (FB) type (Vh) Facteur de Ppe d’inject. théorique rondelles- théorique rondelles-
nomin./tol. valeur nomin. correction (Lo) "TS" d’epaisseur "TS" d’epaisseur nomin./tol. valeur nomin. correction (Lo) "TS" d’epaisseur "TS" d’epaisseur
(° vil. av. PMH) (mm) (mm/° vil.) (mm) (mm) "SS" (mm) (mm) "SS" (mm) (° vil. av. PMH) (mm) (mm/° vil.) (mm) (mm) "SS" (mm) (mm) "SS" (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
1,35 - 1,449 1,4 2,85 - 2,949 2,9 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 10 C 4,47 0,1 109 / 119 BFM 1012/ C 10 C 4,47 0,1 109 / 119
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
2,05 - 2,149 2,1 3,55 - 3,649 3,6 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 1013 7 A 5,90 0,1 143 BFM 1013 7 A 5,90 0,1 143
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 2,25 - 2,349 2,3 BFM 1013 8 A 5,70 0,1 143
2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143

Pompe no. xxx xxx xxx Pompe no. xxx xxx xxx
FB Début d’injection mesuré °vil 8 8 10 FB Début d’injection mesuré °vil 8 8 10
FB Début d’injection nominal tableau 1°vil 9 9 10 FB Début d’injection nominal tableau 1°vil 9 9 10
Facteur de correction Vh tableau 1 mm/°vil 0,1 0,1 0,1 Facteur de correction Vh tableau 1 mm/°vil 0,1 0,1 0,1
Vh nominal tableau 1 mm 4,63 4,63 5,31 Vh nominal tableau 1 mm 4,63 4,63 5,31
A/100 de pompe d’injection mm 0,53 0,22 1,33 A/100 de pompe d’injection mm 0,53 0,22 1,33
E1 = FB réel - FB nomin. °vil. -1 -1 0 E1 = FB réel - FB nomin. °vil. -1 -1 0

E3 = E2 + Vh nomin. mm 4,53 4,53 5,31 E3 = E2 + Vh nomin. mm 4,53 4,53 5,31
E4 = E3 + L 0 mm 113,53 123,53 148,31 E4 = E3 + L 0 mm 113,53 123,53 148,31
E5 = E4 + A/100 mm 114,06 123,75 149,64 E5 = E4 + A/100 mm 114,06 123,75 149,64
TS = L - E5 mm 2,20 2,82 2,58 TS = L - E5 mm 2,20 2,82 2,58
"SS" tableau 2 mm 2,2 2,8 2,6 "SS" tableau 2 mm 2,2 2,8 2,6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Determinazione dello spessore delle rondelle per l’inizio di mandata.
Pompa d’iniezione Bosch
Tabella 1 Tabella 2 Tabella 1 Tabella 2

Tipo di Inizio mandata Albero Precorsa Precorsa Misura base Spessore Spessore Spessore Spessore Tipo di Inizio mandata Albero Precorsa Precorsa Misura base Spessore Spessore Spessore Spessore
motore (FB) a camme (Vh) Fattore di pompa iniez. teorico rondelle teorico rondelle motore (FB) a camme (Vh) Fattore di pompa iniez. teorico rondelle teorico rondelle
Nomin./Toller Tipo Valore nom. correzione (L0) “TS” “TS” “TS” “TS” Nomin./Toller Tipo Valore nom. correzione (L0) “TS” “TS” “TS” “TS”
(°alb. mot pr. PMS) (mm) (mm/°alb. mot) (mm) (mm) (mm) (mm) (mm) (°alb. mot pr. PMS) (mm) (mm/°alb. mot) (mm) (mm) (mm) (mm) (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9 BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6 BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 BFM 1013 8 A 5,70 0,1 143
2,25 - 2,349 2,3 2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143
Esempio di calcolo BFM 1012 BFM 1013 Esempio di calcolo BFM 1012 BFM 1013
Cilindro nr. 0 0 1 2 0 1 2 3 Cilindro nr. 0 0 1 2 0 1 2 3

Pompe di iniezione nr. xxx xxx xxx Pompe di iniezione nr. xxx xxx xxx
FB reale misurato °alb.mot. 8 8 10 FB reale misurato °alb.mot. 8 8 10
FB nom. da tab.1 °alb.mot. 9 9 10 FB nom. da tab.1 °alb.mot. 9 9 10
Fatt. corr. Vh da tab.1 mm/°alb.mot. 0,1 0,1 0,1 Fatt. corr. Vh da tab.1 mm/°alb.mot. 0,1 0,1 0,1
Vh nom. da tabella 1 mm 4,63 4,63 5,31 Vh nom. da tabella 1 mm 4,63 4,63 5,31
Lo da tabella 1 mm 109 119 143 Lo da tabella 1 mm 109 119 143
A/100 della pompa iniez. mm 0,53 0,22 1,33 A/100 della pompa iniez. mm 0,53 0,22 1,33
L misurata mm 116,26 126,57 152,22 L misurata mm 116,26 126,57 152,22
E1 = FB reale - FB nom °alb.mot. -1 -1 0 E1 = FB reale - FB nom °alb.mot. -1 -1 0

E2 = E1x fattore correz. Vh mm -0,1 -0,1 0 E2 = E1x fattore correz. Vh mm -0,1 -0,1 0
E3 = E2 + Vh Nominale mm 4,53 4,53 5,31 E3 = E2 + Vh Nominale mm 4,53 4,53 5,31
E4 = E3 + L 0 mm 113,53 123,53 148,31 E4 = E3 + L 0 mm 113,53 123,53 148,31
E5 = E4 + A/100 mm 114,06 123,75 149,64 E5 = E4 + A/100 mm 114,06 123,75 149,64
TS = L - E5 mm 2,20 2,82 2,58 TS = L - E5 mm 2,20 2,82 2,58
“Ss” da tabella 5 mm 2,2 2,8 2,6 “Ss” da tabella 5 mm 2,2 2,8 2,6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Determinazione dello spessore delle rondelle per l’inizio di mandata.
Pompa d’iniezione Bosch
Tabella 1 Tabella 2 Tabella 1 Tabella 2

Tipo di Inizio mandata Albero Precorsa Precorsa Misura base Spessore Spessore Spessore Spessore Tipo di Inizio mandata Albero Precorsa Precorsa Misura base Spessore Spessore Spessore Spessore
motore (FB) a camme (Vh) Fattore di pompa iniez. teorico rondelle teorico rondelle motore (FB) a camme (Vh) Fattore di pompa iniez. teorico rondelle teorico rondelle
Nomin./Toller Tipo Valore nom. correzione (L0) “TS” “TS” “TS” “TS” Nomin./Toller Tipo Valore nom. correzione (L0) “TS” “TS” “TS” “TS”
(°alb. mot pr. PMS) (mm) (mm/°alb. mot) (mm) (mm) (mm) (mm) (mm) (°alb. mot pr. PMS) (mm) (mm/°alb. mot) (mm) (mm) (mm) (mm) (mm)
BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5 BFM 1012 6 C 5,16 0,1 109 / 119 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6 BFM 1012 7 C 4,98 0,1 109 / 119 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7 BFM 1012 8 C 4,80 0,1 109 / 119 1,15 - 1,249 1,2 2,65 - 2,749 2,7
BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8 BFM 1012/ C 9 C 4,63 0,1 109 / 119 1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9 BFM 1012/ C 10 C 4,47 0,1 109 / 119 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
1 1 BFM 1012/ C 11 C 4,30 0,1 109 / 119
1,45 - 1,549
1,55 - 1,649
1,5
1,6
2,95 - 3,049
3,05 - 3,149
3,0
3,1
BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2 BFM 1012 12 C 4,14 0,1 109 / 119 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3 BFM 1012 13 C 4,00 0,1 109 / 119 1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4 BFM 1013 5 A 6,32 0,1 143 1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5 BFM 1013 6 A 6,11 0,1 143 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6 BFM 1013 7 A 5,90 0,1 143 2,05 - 2,149 2,1 3,55 - 3,649 3,6
2,15 - 2,249 2,2 3,65 - 3,749 3,7 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 1013 8 A 5,70 0,1 143 BFM 1013 8 A 5,70 0,1 143
2,25 - 2,349 2,3 2,25 - 2,349 2,3
BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4 BFM 1013/ C 9 A 5,50 0,1 143 2,35 - 2,449 2,4
BFM 1013 10 A 5,31 0,1 143 BFM 1013 10 A 5,31 0,1 143
BFM 1013 4 B 5,70 0,1 143 BFM 1013 4 B 5,70 0,1 143
BFM 1013 4,5 B 5,60 0,1 143 BFM 1013 4,5 B 5,60 0,1 143
BFM 1013 5 B 5,50 0,1 143 BFM 1013 5 B 5,50 0,1 143
BFM 1013 5,5 B 5,40 0,1 143 BFM 1013 5,5 B 5,40 0,1 143
BFM 1013 6 B 5,31 0,1 143 BFM 1013 6 B 5,31 0,1 143
BFM 1013 7 B 5,10 0,1 143 BFM 1013 7 B 5,10 0,1 143

Pompe di iniezione nr. xxx xxx xxx Pompe di iniezione nr. xxx xxx xxx
FB nom. da tab.1 °alb.mot. 9 9 10 FB nom. da tab.1 °alb.mot. 9 9 10
Lo da tabella 1 mm 109 119 143 Lo da tabella 1 mm 109 119 143
A/100 della pompa iniez. mm 0,53 0,22 1,33 A/100 della pompa iniez. mm 0,53 0,22 1,33
E1 = FB reale - FB nom °alb.mot. -1 -1 0 E1 = FB reale - FB nom °alb.mot. -1 -1 0

E2 = E1x fattore correz. Vh mm -0,1 -0,1 0 E2 = E1x fattore correz. Vh mm -0,1 -0,1 0
E3 = E2 + Vh Nominale mm 4,53 4,53 5,31 E3 = E2 + Vh Nominale mm 4,53 4,53 5,31
E4 = E3 + L 0 mm 113,53 123,53 148,31 E4 = E3 + L 0 mm 113,53 123,53 148,31
E5 = E4 + A/100 mm 114,06 123,75 149,64 E5 = E4 + A/100 mm 114,06 123,75 149,64
TS = L - E5 mm 2,20 2,82 2,58 TS = L - E5 mm 2,20 2,82 2,58
“Ss” da tabella 5 mm 2,2 2,8 2,6 “Ss” da tabella 5 mm 2,2 2,8 2,6
© 05/00 1.00.13.1 1.00.13.1 © 05/00

Bosch Einspritzpumpentausch im Servicefall. Grundmaß L0 = 109 mm
Die alte Einspritzpumpe und Ausgleichscheibe ist hierzu nicht erforderlich. Die alte Einspritzpumpe und Ausgleichscheibe ist hierzu nicht erforderlich.
Beispiel: An einem BF6M1012 ist die Einspritzpumpe von Zylinder 3 zu ersetzen. Beispiel: An einem BF6M1012 ist die Einspritzpumpe von Zylinder 3 zu ersetzen.
Vorgehensweise: Vorgehensweise:
Vom Firmenschild in der Rubrik "EP" den EP-Code für Zylinder 3 ablesen, z.B. 070. Vom Firmenschild in der Rubrik "EP" den EP-Code für Zylinder 3 ablesen, z.B. 070.
(Lesefolge: Zeile 1 = Zyl.1, Zeile 2 = Zyl.2, u.s.w.) (Lesefolge: Zeile 1 = Zyl.1, Zeile 2 = Zyl.2, u.s.w.)
Mot. - Typ Code Mot. - Nr. 1 1 Mot. - Typ Code Mot. - Nr.
0122 3237
0122 3237
kW(G) red. EP K kW(G) red. EP K

kW(S) red.
E kW(G) kW(S) 1/min )°
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
DEUTZ AG MADE IN GERMANY DEUTZ AG MADE IN GERMANY
Korrigiertes Einspritzpumpeneinbaumaß (EK) aus Tabelle 3 entsprechend dem EP-Code entnehmen, Korrigiertes Einspritzpumpeneinbaumaß (EK) aus Tabelle 3 entsprechend dem EP-Code entnehmen,
z.B.111,725 mm. z.B.111,725 mm.
Tabelle 3 Tabelle 3
EK EP- EK EP- EK EP- EK EP- EK EP- EK EP- EK EP- EK EP- EK EP- EK EP-
Code Code Code Code Code Code Code Code Code Code
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
110,0 110,6 111,2 049 111,8 073 112,4 097 110,0 110,6 111,2 049 111,8 073 112,4 097
110,025 110,625 111,225 050 111,825 074 112,425 098 110,025 110,625 111,225 050 111,825 074 112,425 098
110,05 110,65 111,25 051 111,85 075 112,45 099 110,05 110,65 111,25 051 111,85 075 112,45 099
110,075 110,675 111,275 052 111,875 076 112,475 100 110,075 110,675 111,275 052 111,875 076 112,475 100
110,1 110,7 111,3 053 111,9 077 112,5 101 110,1 110,7 111,3 053 111,9 077 112,5 101
110,125 110,725 111,325 054 111,925 078 112,525 102 110,125 110,725 111,325 054 111,925 078 112,525 102
110,15 110,75 031 111,35 055 111,95 079 112,55 103 110,15 110,75 031 111,35 055 111,95 079 112,55 103
110,175 110,775 032 111,375 056 111,975 080 112,575 104 110,175 110,775 032 111,375 056 111,975 080 112,575 104
110,2 110,8 033 111,4 057 112,0 081 112,6 105 110,2 110,8 033 111,4 057 112,0 081 112,6 105
110,225 110,825 034 111,425 058 112,025 082 112,625 106 110,225 110,825 034 111,425 058 112,025 082 112,625 106
110,25 110,85 035 111,45 059 112,05 083 112,65 110,25 110,85 035 111,45 059 112,05 083 112,65
110,275 110,875 036 111,475 060 112,075 084 112,675 110,275 110,875 036 111,475 060 112,075 084 112,675
110,3 110,9 037 111,5 061 112,1 085 112,7 110,3 110,9 037 111,5 061 112,1 085 112,7
110,325 110,925 038 111,525 062 112,125 086 112,725 110,325 110,925 038 111,525 062 112,125 086 112,725
110,35 110,95 039 111,55 063 112,15 087 112,75 110,35 110,95 039 111,55 063 112,15 087 112,75
110,375 110,975 040 111,575 064 112,175 088 112,775 110,375 110,975 040 111,575 064 112,175 088 112,775
110,4 111,0 041 111,6 065 112,2 089 112,8 110,4 111,0 041 111,6 065 112,2 089 112,8
110,425 111,025 042 111,625 066 112,225 090 112,825 110,425 111,025 042 111,625 066 112,225 090 112,825
110,45 111,05 043 111,65 067 112,25 091 112,85 110,45 111,05 043 111,65 067 112,25 091 112,85
110,475 111,075 044 111,675 068 112,275 092 112,875 110,475 111,075 044 111,675 068 112,275 092 112,875
110,5 111,1 045 111,7 069 112,3 093 112,9 110,5 111,1 045 111,7 069 112,3 093 112,9
110,525 111,125 046 111,725 070 112,325 094 112,925 110,525 111,125 046 111,725 070 112,325 094 112,925
110,55 111,15 047 111,75 071 112,35 095 112,95 110,55 111,15 047 111,75 071 112,35 095 112,95
110,575 111,175 048 111,775 072 112,375 096 112,975 110,575 111,175 048 111,775 072 112,375 096 112,975
Kennzahl für Einspritzpumpenlänge (A) von der neuen Einspritzpumpe ablesen, z.B. 53. Kennzahl für Einspritzpumpenlänge (A) von der neuen Einspritzpumpe ablesen, z.B. 53.
Grundmaß der Einspritzpumpe (LO) aus Tabelle 1 entnehmen, z.B. 109 mm. Grundmaß der Einspritzpumpe (LO) aus Tabelle 1 entnehmen, z.B. 109 mm.
Theoretische Ausgleichscheibendicke (TS) ermitteln. Theoretische Ausgleichscheibendicke (TS) ermitteln.

TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 111,725 mm - (109 mm + 53/100 mm) TS = 111,725 mm - (109 mm + 53/100 mm)
TS = 2,195 mm TS = 2,195 mm
Ausgleichscheibendicke (SS) nach Tabelle 2 auswählen. Ausgleichscheibendicke (SS) nach Tabelle 2 auswählen.
TS 2,195 mm = SS 2,2 mm TS 2,195 mm = SS 2,2 mm
© 05/00 1.00.15 1.00.15 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
z.B.111,725 mm. z.B.111,725 mm.
Tabelle 3 Tabelle 3
110,0 110,6 111,2 049 111,8 073 112,4 097 110,0 110,6 111,2 049 111,8 073 112,4 097
110,025 110,625 111,225 050 111,825 074 112,425 098 110,025 110,625 111,225 050 111,825 074 112,425 098
110,05 110,65 111,25 051 111,85 075 112,45 099 110,05 110,65 111,25 051 111,85 075 112,45 099
110,075 110,675 111,275 052 111,875 076 112,475 100 110,075 110,675 111,275 052 111,875 076 112,475 100
110,1 110,7 111,3 053 111,9 077 112,5 101 110,1 110,7 111,3 053 111,9 077 112,5 101
110,125 110,725 111,325 054 111,925 078 112,525 102 110,125 110,725 111,325 054 111,925 078 112,525 102
110,15 110,75 031 111,35 055 111,95 079 112,55 103 110,15 110,75 031 111,35 055 111,95 079 112,55 103
110,175 110,775 032 111,375 056 111,975 080 112,575 104 110,175 110,775 032 111,375 056 111,975 080 112,575 104
110,2 110,8 033 111,4 057 112,0 081 112,6 105 110,2 110,8 033 111,4 057 112,0 081 112,6 105
110,225 110,825 034 111,425 058 112,025 082 112,625 106 110,225 110,825 034 111,425 058 112,025 082 112,625 106
110,25 110,85 035 111,45 059 112,05 083 112,65 110,25 110,85 035 111,45 059 112,05 083 112,65
110,275 110,875 036 111,475 060 112,075 084 112,675 110,275 110,875 036 111,475 060 112,075 084 112,675
110,3 110,9 037 111,5 061 112,1 085 112,7 110,3 110,9 037 111,5 061 112,1 085 112,7
110,325 110,925 038 111,525 062 112,125 086 112,725 110,325 110,925 038 111,525 062 112,125 086 112,725
110,35 110,95 039 111,55 063 112,15 087 112,75 110,35 110,95 039 111,55 063 112,15 087 112,75
110,375 110,975 040 111,575 064 112,175 088 112,775 110,375 110,975 040 111,575 064 112,175 088 112,775
110,4 111,0 041 111,6 065 112,2 089 112,8 110,4 111,0 041 111,6 065 112,2 089 112,8
110,425 111,025 042 111,625 066 112,225 090 112,825 110,425 111,025 042 111,625 066 112,225 090 112,825
110,45 111,05 043 111,65 067 112,25 091 112,85 110,45 111,05 043 111,65 067 112,25 091 112,85
110,475 111,075 044 111,675 068 112,275 092 112,875 110,475 111,075 044 111,675 068 112,275 092 112,875
110,5 111,1 045 111,7 069 112,3 093 112,9 110,5 111,1 045 111,7 069 112,3 093 112,9
110,525 111,125 046 111,725 070 112,325 094 112,925 110,525 111,125 046 111,725 070 112,325 094 112,925
110,55 111,15 047 111,75 071 112,35 095 112,95 110,55 111,15 047 111,75 071 112,35 095 112,95
110,575 111,175 048 111,775 072 112,375 096 112,975 110,575 111,175 048 111,775 072 112,375 096 112,975

TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,195 mm TS = 2,195 mm
© 05/00 1.00.15 1.00.15 © 05/00

Determining shim thickness for Bosch injection pump replacement on BFM 1012
in case of service. Standard dimensions L0 = 109 mm
The old injection pump with shim is not required for such purpose. The old injection pump with shim is not required for such purpose.
Example: The injection pump of cylinder 3 is to be replaced on a BFM 1012 engine. Example: The injection pump of cylinder 3 is to be replaced on a BFM 1012 engine.
Procedure: Procedure:
Read off EP code for cylinder 3 from nameplate under column „EP“, e.g. 070. Read off EP code for cylinder 3 from nameplate under column „EP“, e.g. 070.
(Reading sequence: line 1=cyl.1, line 2 = cyl.2, etc. (Reading sequence: line 1=cyl.1, line 2 = cyl.2, etc.
0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
Take corrected injection pump installation dimension (EK) from table 3 according to EP code, Take corrected injection pump installation dimension (EK) from table 3 according to EP code,
e.g. 111.725 mm. e.g. 111.725 mm.
Tabelle 3 Tabelle 3
EK EP EK EP EK EP EK EP EK EP EK EP EK EP EK EP EK EP EK EP
code code code code code code code code code code
110.0 110.6 111.2 049 111.8 073 112.4 097 110.0 110.6 111.2 049 111.8 073 112.4 097
110.025 110.625 111.225 050 111.825 074 112.425 098 110.025 110.625 111.225 050 111.825 074 112.425 098
110.05 110.65 111.25 051 111.85 075 112.45 099 110.05 110.65 111.25 051 111.85 075 112.45 099
110.075 110.675 111.275 052 111.875 076 112.475 100 110.075 110.675 111.275 052 111.875 076 112.475 100
110.1 110.7 111.3 053 111.9 077 112.5 101 110.1 110.7 111.3 053 111.9 077 112.5 101
110.125 110.725 111.325 054 111.925 078 112.525 102 110.125 110.725 111.325 054 111.925 078 112.525 102
110.15 110.75 031 111.35 055 111.95 079 112.55 103 110.15 110.75 031 111.35 055 111.95 079 112.55 103
110.175 110.775 032 111.375 056 111.975 080 112.575 104 110.175 110.775 032 111.375 056 111.975 080 112.575 104
110.2 110.8 033 111.4 057 112.0 081 112.6 105 110.2 110.8 033 111.4 057 112.0 081 112.6 105
110.225 110.825 034 111.425 058 112.025 082 112.625 106 110.225 110.825 034 111.425 058 112.025 082 112.625 106
110.25 110.85 035 111.45 059 112.05 083 112.65 110.25 110.85 035 111.45 059 112.05 083 112.65
110.275 110.875 036 111.475 060 112.075 084 112.675 110.275 110.875 036 111.475 060 112.075 084 112.675
110.3 110.9 037 111.5 061 112.1 085 112.7 110.3 110.9 037 111.5 061 112.1 085 112.7
110.325 110.925 038 111.525 062 112.125 086 112.725 110.325 110.925 038 111.525 062 112.125 086 112.725
110.35 110.95 039 111.55 063 112.15 087 112.75 110.35 110.95 039 111.55 063 112.15 087 112.75
110.375 110.975 040 111.575 064 112.175 088 112.775 110.375 110.975 040 111.575 064 112.175 088 112.775
110.4 111.0 041 111.6 065 112.2 089 112.8 110.4 111.0 041 111.6 065 112.2 089 112.8
110.425 111.025 042 111.625 066 112.225 090 112.825 110.425 111.025 042 111.625 066 112.225 090 112.825
110.45 111.05 043 111.65 067 112.25 091 112.85 110.45 111.05 043 111.65 067 112.25 091 112.85
110.475 111.075 044 111.675 068 112.275 092 112.875 110.475 111.075 044 111.675 068 112.275 092 112.875
110.5 111.1 045 111.7 069 112.3 093 112.9 110.5 111.1 045 111.7 069 112.3 093 112.9
110.525 111.125 046 111.725 070 112.325 094 112.925 110.525 111.125 046 111.725 070 112.325 094 112.925
110.55 111.15 047 111.75 071 112.35 095 112.95 110.55 111.15 047 111.75 071 112.35 095 112.95
110.575 111.175 048 111.775 072 112.375 096 112.975 110.575 111.175 048 111.775 072 112.375 096 112.975
Take code for injection pump length (A) from new injection pump, e.g. 53. Take code for injection pump length (A) from new injection pump, e.g. 53.
Take standard dimension of injection pump (Lo) from table 1, e.g. 109 mm. Take standard dimension of injection pump (Lo) from table 1, e.g. 109 mm.
Determine theoretical shim thickness (Ts). Determine theoretical shim thickness (Ts).
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 111.725 mm - (109 mm + 53/100 mm) Ts = 111.725 mm - (109 mm + 53/100 mm)
Ts = 2.195 mm Ts = 2.195 mm
Select shim thickness (Ss) according to table 2. Select shim thickness (Ss) according to table 2.
Ts 2.195 mm = Ss 2.2 mm Ts 2.195 mm = Ss 2.2 mm
© 05/00 1.00.15 1.00.15 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
e.g. 111.725 mm. e.g. 111.725 mm.
Tabelle 3 Tabelle 3
110.0 110.6 111.2 049 111.8 073 112.4 097 110.0 110.6 111.2 049 111.8 073 112.4 097
110.025 110.625 111.225 050 111.825 074 112.425 098 110.025 110.625 111.225 050 111.825 074 112.425 098
110.05 110.65 111.25 051 111.85 075 112.45 099 110.05 110.65 111.25 051 111.85 075 112.45 099
110.075 110.675 111.275 052 111.875 076 112.475 100 110.075 110.675 111.275 052 111.875 076 112.475 100
110.1 110.7 111.3 053 111.9 077 112.5 101 110.1 110.7 111.3 053 111.9 077 112.5 101
110.125 110.725 111.325 054 111.925 078 112.525 102 110.125 110.725 111.325 054 111.925 078 112.525 102
110.15 110.75 031 111.35 055 111.95 079 112.55 103 110.15 110.75 031 111.35 055 111.95 079 112.55 103
110.175 110.775 032 111.375 056 111.975 080 112.575 104 110.175 110.775 032 111.375 056 111.975 080 112.575 104
110.2 110.8 033 111.4 057 112.0 081 112.6 105 110.2 110.8 033 111.4 057 112.0 081 112.6 105
110.225 110.825 034 111.425 058 112.025 082 112.625 106 110.225 110.825 034 111.425 058 112.025 082 112.625 106
110.25 110.85 035 111.45 059 112.05 083 112.65 110.25 110.85 035 111.45 059 112.05 083 112.65
110.275 110.875 036 111.475 060 112.075 084 112.675 110.275 110.875 036 111.475 060 112.075 084 112.675
110.3 110.9 037 111.5 061 112.1 085 112.7 110.3 110.9 037 111.5 061 112.1 085 112.7
110.325 110.925 038 111.525 062 112.125 086 112.725 110.325 110.925 038 111.525 062 112.125 086 112.725
110.35 110.95 039 111.55 063 112.15 087 112.75 110.35 110.95 039 111.55 063 112.15 087 112.75
110.375 110.975 040 111.575 064 112.175 088 112.775 110.375 110.975 040 111.575 064 112.175 088 112.775
110.4 111.0 041 111.6 065 112.2 089 112.8 110.4 111.0 041 111.6 065 112.2 089 112.8
110.425 111.025 042 111.625 066 112.225 090 112.825 110.425 111.025 042 111.625 066 112.225 090 112.825
110.45 111.05 043 111.65 067 112.25 091 112.85 110.45 111.05 043 111.65 067 112.25 091 112.85
110.475 111.075 044 111.675 068 112.275 092 112.875 110.475 111.075 044 111.675 068 112.275 092 112.875
110.5 111.1 045 111.7 069 112.3 093 112.9 110.5 111.1 045 111.7 069 112.3 093 112.9
110.525 111.125 046 111.725 070 112.325 094 112.925 110.525 111.125 046 111.725 070 112.325 094 112.925
110.55 111.15 047 111.75 071 112.35 095 112.95 110.55 111.15 047 111.75 071 112.35 095 112.95
110.575 111.175 048 111.775 072 112.375 096 112.975 110.575 111.175 048 111.775 072 112.375 096 112.975
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2.195 mm Ts = 2.195 mm
© 05/00 1.00.15 1.00.15 © 05/00

Calcul de l’épaisseur des rondelles d’épaisseur pour le début d’injection pour
remplacement de pompe d’injection Bosch BFM 1012 en intervention SAV.
Cote de base L0 = 109 mm
L’ancienne pompe d’injection et la rondelle d’épaisseur ne sont pas nécessaires pour cela. L’ancienne pompe d’injection et la rondelle d’épaisseur ne sont pas nécessaires pour cela.
Exemple : remplacement de la pompe d’injection du cylindre 3 sur le BF6M 1012. Exemple : remplacement de la pompe d’injection du cylindre 3 sur le BF6M 1012.
Procédure à suivre : Procédure à suivre :

Lire sur la plaque d’identification du constructeur à la rubrique „EP“ le code EP pour le cylindre 3, exemple : Lire sur la plaque d’identification du constructeur à la rubrique „EP“ le code EP pour le cylindre 3, exemple :
070, ensuite comme suit : ligne 1 = cyl. 1, ligne 2 = cyl. 2 etc. 070, ensuite comme suit : ligne 1 = cyl. 1, ligne 2 = cyl. 2 etc.
0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
Cote de montage corrigé de la pompe d’injection (Ek) relevée dans le tableau 3 correspondant au code EP. Cote de montage corrigé de la pompe d’injection (Ek) relevée dans le tableau 3 correspondant au code EP.
Exemple 111,725 mm Exemple 111,725 mm
Tableau 3 Tableau 3
EK Code EK Code EK Code EK Code EK Code EK Code EK Code EK Code EK Code EK Code
EP EP EP EP EP EP EP EP EP EP
110,0 110,6 111,2 049 111,8 073 112,4 097 110,0 110,6 111,2 049 111,8 073 112,4 097
110,025 110,625 111,225 050 111,825 074 112,425 098 110,025 110,625 111,225 050 111,825 074 112,425 098
110,05 110,65 111,25 051 111,85 075 112,45 099 110,05 110,65 111,25 051 111,85 075 112,45 099
110,075 110,675 111,275 052 111,875 076 112,475 100 110,075 110,675 111,275 052 111,875 076 112,475 100
110,1 110,7 111,3 053 111,9 077 112,5 101 110,1 110,7 111,3 053 111,9 077 112,5 101
110,125 110,725 111,325 054 111,925 078 112,525 102 110,125 110,725 111,325 054 111,925 078 112,525 102
110,15 110,75 031 111,35 055 111,95 079 112,55 103 110,15 110,75 031 111,35 055 111,95 079 112,55 103
110,175 110,775 032 111,375 056 111,975 080 112,575 104 110,175 110,775 032 111,375 056 111,975 080 112,575 104
110,2 110,8 033 111,4 057 112,0 081 112,6 105 110,2 110,8 033 111,4 057 112,0 081 112,6 105
110,225 110,825 034 111,425 058 112,025 082 112,625 106 110,225 110,825 034 111,425 058 112,025 082 112,625 106
110,25 110,85 035 111,45 059 112,05 083 112,65 110,25 110,85 035 111,45 059 112,05 083 112,65
110,275 110,875 036 111,475 060 112,075 084 112,675 110,275 110,875 036 111,475 060 112,075 084 112,675
110,3 110,9 037 111,5 061 112,1 085 112,7 110,3 110,9 037 111,5 061 112,1 085 112,7
110,325 110,925 038 111,525 062 112,125 086 112,725 110,325 110,925 038 111,525 062 112,125 086 112,725
110,35 110,95 039 111,55 063 112,15 087 112,75 110,35 110,95 039 111,55 063 112,15 087 112,75
110,375 110,975 040 111,575 064 112,175 088 112,775 110,375 110,975 040 111,575 064 112,175 088 112,775
110,4 111,0 041 111,6 065 112,2 089 112,8 110,4 111,0 041 111,6 065 112,2 089 112,8
110,425 111,025 042 111,625 066 112,225 090 112,825 110,425 111,025 042 111,625 066 112,225 090 112,825
110,45 111,05 043 111,65 067 112,25 091 112,85 110,45 111,05 043 111,65 067 112,25 091 112,85
110,475 111,075 044 111,675 068 112,275 092 112,875 110,475 111,075 044 111,675 068 112,275 092 112,875
110,5 111,1 045 111,7 069 112,3 093 112,9 110,5 111,1 045 111,7 069 112,3 093 112,9
110,525 111,125 046 111,725 070 112,325 094 112,925 110,525 111,125 046 111,725 070 112,325 094 112,925
110,55 111,15 047 111,75 071 112,35 095 112,95 110,55 111,15 047 111,75 071 112,35 095 112,95
110,575 111,175 048 111,775 072 112,375 096 112,975 110,575 111,175 048 111,775 072 112,375 096 112,975
Consulter le tableau indiquant l’indice de longueur de la pompe d’injection (A) (nouvelle pompe d’injection), Consulter le tableau indiquant l’indice de longueur de la pompe d’injection (A) (nouvelle pompe d’injection),
exemple 53. exemple 53.
La cote de base de la pompe d’injection (Lo) est indiquée dans le tableau 1, exemple 109 mm. La cote de base de la pompe d’injection (Lo) est indiquée dans le tableau 1, exemple 109 mm.
Calculer l’épaisseur théorique (Ts) des rondelles d’épaisseur Calculer l’épaisseur théorique (Ts) des rondelles d’épaisseur
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 111,725 mm - (109 mm + 53/100 mm) Ts = 111,725 mm - (109 mm + 53/100 mm)
Ts = 2,195 mm Ts = 2,195 mm
Choisir l’épaisseur des rondelles d’épaisseur (Ss) selon le tableau 2 Choisir l’épaisseur des rondelles d’épaisseur (Ss) selon le tableau 2
Ts 2,195 mm = SS 2,2 mm Ts 2,195 mm = SS 2,2 mm
© 05/00 1.00.15 1.00.15 © 05/00


0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
Tableau 3 Tableau 3
110,0 110,6 111,2 049 111,8 073 112,4 097 110,0 110,6 111,2 049 111,8 073 112,4 097
110,025 110,625 111,225 050 111,825 074 112,425 098 110,025 110,625 111,225 050 111,825 074 112,425 098
110,05 110,65 111,25 051 111,85 075 112,45 099 110,05 110,65 111,25 051 111,85 075 112,45 099
110,075 110,675 111,275 052 111,875 076 112,475 100 110,075 110,675 111,275 052 111,875 076 112,475 100
110,1 110,7 111,3 053 111,9 077 112,5 101 110,1 110,7 111,3 053 111,9 077 112,5 101
110,125 110,725 111,325 054 111,925 078 112,525 102 110,125 110,725 111,325 054 111,925 078 112,525 102
110,15 110,75 031 111,35 055 111,95 079 112,55 103 110,15 110,75 031 111,35 055 111,95 079 112,55 103
110,175 110,775 032 111,375 056 111,975 080 112,575 104 110,175 110,775 032 111,375 056 111,975 080 112,575 104
110,2 110,8 033 111,4 057 112,0 081 112,6 105 110,2 110,8 033 111,4 057 112,0 081 112,6 105
110,225 110,825 034 111,425 058 112,025 082 112,625 106 110,225 110,825 034 111,425 058 112,025 082 112,625 106
110,25 110,85 035 111,45 059 112,05 083 112,65 110,25 110,85 035 111,45 059 112,05 083 112,65
110,275 110,875 036 111,475 060 112,075 084 112,675 110,275 110,875 036 111,475 060 112,075 084 112,675
110,3 110,9 037 111,5 061 112,1 085 112,7 110,3 110,9 037 111,5 061 112,1 085 112,7
110,325 110,925 038 111,525 062 112,125 086 112,725 110,325 110,925 038 111,525 062 112,125 086 112,725
110,35 110,95 039 111,55 063 112,15 087 112,75 110,35 110,95 039 111,55 063 112,15 087 112,75
110,375 110,975 040 111,575 064 112,175 088 112,775 110,375 110,975 040 111,575 064 112,175 088 112,775
110,4 111,0 041 111,6 065 112,2 089 112,8 110,4 111,0 041 111,6 065 112,2 089 112,8
110,425 111,025 042 111,625 066 112,225 090 112,825 110,425 111,025 042 111,625 066 112,225 090 112,825
110,45 111,05 043 111,65 067 112,25 091 112,85 110,45 111,05 043 111,65 067 112,25 091 112,85
110,475 111,075 044 111,675 068 112,275 092 112,875 110,475 111,075 044 111,675 068 112,275 092 112,875
110,5 111,1 045 111,7 069 112,3 093 112,9 110,5 111,1 045 111,7 069 112,3 093 112,9
110,525 111,125 046 111,725 070 112,325 094 112,925 110,525 111,125 046 111,725 070 112,325 094 112,925
110,55 111,15 047 111,75 071 112,35 095 112,95 110,55 111,15 047 111,75 071 112,35 095 112,95
110,575 111,175 048 111,775 072 112,375 096 112,975 110,575 111,175 048 111,775 072 112,375 096 112,975
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2,195 mm Ts = 2,195 mm
© 05/00 1.00.15 1.00.15 © 05/00

Determinazione dello spessore delle rondelle per l’inizio di mandata nel BFM 1012
Sostituzione della pompa d’iniezione Bosch a cura del service.
Misura base L0 = 109 mm
In tale caso non è necessario disporre né della vecchia pompa d’iniezione né del vecchio spessore. In tale caso non è necessario disporre né della vecchia pompa d’iniezione né del vecchio spessore.
Esempio: su un motore BF6M 1012 è necessario sostituire la pompa d’iniezione del cilindro 3. Esempio: su un motore BF6M 1012 è necessario sostituire la pompa d’iniezione del cilindro 3.
Procedimento: Procedimento:
rilevare dalla targhetta motore nei riquadri “EP” il codice EP per il cilindro 3, per esempio 070. rilevare dalla targhetta motore nei riquadri “EP” il codice EP per il cilindro 3, per esempio 070.
(sistema di lettura: riquadro 1 = cilindro 1, riquadro 2 = cilindro 2, e così via) (sistema di lettura: riquadro 1 = cilindro 1, riquadro 2 = cilindro 2, e così via)
0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
Prendere nota dalla tabella 3 delle dimensioni d’ingombro corrette (EK) della pompa d’iniezione in Prendere nota dalla tabella 3 delle dimensioni d’ingombro corrette (EK) della pompa d’iniezione in
corrispondenza al codice EP, nel nostro caso 111,725 mm. corrispondenza al codice EP, nel nostro caso 111,725 mm.
Tabella 3 Tabella 3
EK Codice EK Codice EK Codice EK Codice EK Codice EK Codice EK Codice EK Codice EK Codice EK Codice
110,0 110,6 111,2 049 111,8 073 112,4 097 110,0 110,6 111,2 049 111,8 073 112,4 097
110,025 110,625 111,225 050 111,825 074 112,425 098 110,025 110,625 111,225 050 111,825 074 112,425 098
110,05 110,65 111,25 051 111,85 075 112,45 099 110,05 110,65 111,25 051 111,85 075 112,45 099
110,075 110,675 111,275 052 111,875 076 112,475 100 110,075 110,675 111,275 052 111,875 076 112,475 100
110,1 110,7 111,3 053 111,9 077 112,5 101 110,1 110,7 111,3 053 111,9 077 112,5 101
110,125 110,725 111,325 054 111,925 078 112,525 102 110,125 110,725 111,325 054 111,925 078 112,525 102
110,15 110,75 031 111,35 055 111,95 079 112,55 103 110,15 110,75 031 111,35 055 111,95 079 112,55 103
110,175 110,775 032 111,375 056 111,975 080 112,575 104 110,175 110,775 032 111,375 056 111,975 080 112,575 104
110,2 110,8 033 111,4 057 112,0 081 112,6 105 110,2 110,8 033 111,4 057 112,0 081 112,6 105
110,225 110,825 034 111,425 058 112,025 082 112,625 106 110,225 110,825 034 111,425 058 112,025 082 112,625 106
110,25 110,85 035 111,45 059 112,05 083 112,65 110,25 110,85 035 111,45 059 112,05 083 112,65
110,275 110,875 036 111,475 060 112,075 084 112,675 110,275 110,875 036 111,475 060 112,075 084 112,675
110,3 110,9 037 111,5 061 112,1 085 112,7 110,3 110,9 037 111,5 061 112,1 085 112,7
110,325 110,925 038 111,525 062 112,125 086 112,725 110,325 110,925 038 111,525 062 112,125 086 112,725
110,35 110,95 039 111,55 063 112,15 087 112,75 110,35 110,95 039 111,55 063 112,15 087 112,75
110,375 110,975 040 111,575 064 112,175 088 112,775 110,375 110,975 040 111,575 064 112,175 088 112,775
110,4 111,0 041 111,6 065 112,2 089 112,8 110,4 111,0 041 111,6 065 112,2 089 112,8
110,425 111,025 042 111,625 066 112,225 090 112,825 110,425 111,025 042 111,625 066 112,225 090 112,825
110,45 111,05 043 111,65 067 112,25 091 112,85 110,45 111,05 043 111,65 067 112,25 091 112,85
110,475 111,075 044 111,675 068 112,275 092 112,875 110,475 111,075 044 111,675 068 112,275 092 112,875
110,5 111,1 045 111,7 069 112,3 093 112,9 110,5 111,1 045 111,7 069 112,3 093 112,9
110,525 111,125 046 111,725 070 112,325 094 112,925 110,525 111,125 046 111,725 070 112,325 094 112,925
110,55 111,15 047 111,75 071 112,35 095 112,95 110,55 111,15 047 111,75 071 112,35 095 112,95
110,575 111,175 048 111,775 072 112,375 096 112,975 110,575 111,175 048 111,775 072 112,375 096 112,975
Identificare sulla nuova pompa d’iniezione il numero caratteristico per la lunghezza (A) della pompa Identificare sulla nuova pompa d’iniezione il numero caratteristico per la lunghezza (A) della pompa
d’iniezione, per esempio 53. d’iniezione, per esempio 53.
Prendere dalla tabella 1 la misura base (LO) della pompa di iniezione, per esempio 109 mm. Prendere dalla tabella 1 la misura base (LO) della pompa di iniezione, per esempio 109 mm.
Determinare lo spessore teorico (Ts) della rondella: Determinare lo spessore teorico (Ts) della rondella:
TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,195 mm TS = 2,195 mm
Ricavare dalla tabella 2 lo spessore effettivo della rondella (Ss): Ricavare dalla tabella 2 lo spessore effettivo della rondella (Ss):
© 05/00 1.00.15 1.00.15 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 070 kW(W) 070
°C °C
m m
Prendere nota dalla tabella 3 delle dimensioni d’ingombro corrette (EK) della pompa d’iniezione in Prendere nota dalla tabella 3 delle dimensioni d’ingombro corrette (EK) della pompa d’iniezione in
corrispondenza al codice EP, nel nostro caso 111,725 mm. corrispondenza al codice EP, nel nostro caso 111,725 mm.
Tabella 3 Tabella 3
110,0 110,6 111,2 049 111,8 073 112,4 097 110,0 110,6 111,2 049 111,8 073 112,4 097
110,025 110,625 111,225 050 111,825 074 112,425 098 110,025 110,625 111,225 050 111,825 074 112,425 098
110,05 110,65 111,25 051 111,85 075 112,45 099 110,05 110,65 111,25 051 111,85 075 112,45 099
110,075 110,675 111,275 052 111,875 076 112,475 100 110,075 110,675 111,275 052 111,875 076 112,475 100
110,1 110,7 111,3 053 111,9 077 112,5 101 110,1 110,7 111,3 053 111,9 077 112,5 101
110,125 110,725 111,325 054 111,925 078 112,525 102 110,125 110,725 111,325 054 111,925 078 112,525 102
110,15 110,75 031 111,35 055 111,95 079 112,55 103 110,15 110,75 031 111,35 055 111,95 079 112,55 103
110,175 110,775 032 111,375 056 111,975 080 112,575 104 110,175 110,775 032 111,375 056 111,975 080 112,575 104
110,2 110,8 033 111,4 057 112,0 081 112,6 105 110,2 110,8 033 111,4 057 112,0 081 112,6 105
110,225 110,825 034 111,425 058 112,025 082 112,625 106 110,225 110,825 034 111,425 058 112,025 082 112,625 106
110,25 110,85 035 111,45 059 112,05 083 112,65 110,25 110,85 035 111,45 059 112,05 083 112,65
110,275 110,875 036 111,475 060 112,075 084 112,675 110,275 110,875 036 111,475 060 112,075 084 112,675
110,3 110,9 037 111,5 061 112,1 085 112,7 110,3 110,9 037 111,5 061 112,1 085 112,7
110,325 110,925 038 111,525 062 112,125 086 112,725 110,325 110,925 038 111,525 062 112,125 086 112,725
110,35 110,95 039 111,55 063 112,15 087 112,75 110,35 110,95 039 111,55 063 112,15 087 112,75
110,375 110,975 040 111,575 064 112,175 088 112,775 110,375 110,975 040 111,575 064 112,175 088 112,775
110,4 111,0 041 111,6 065 112,2 089 112,8 110,4 111,0 041 111,6 065 112,2 089 112,8
110,425 111,025 042 111,625 066 112,225 090 112,825 110,425 111,025 042 111,625 066 112,225 090 112,825
110,45 111,05 043 111,65 067 112,25 091 112,85 110,45 111,05 043 111,65 067 112,25 091 112,85
110,475 111,075 044 111,675 068 112,275 092 112,875 110,475 111,075 044 111,675 068 112,275 092 112,875
110,5 111,1 045 111,7 069 112,3 093 112,9 110,5 111,1 045 111,7 069 112,3 093 112,9
110,525 111,125 046 111,725 070 112,325 094 112,925 110,525 111,125 046 111,725 070 112,325 094 112,925
110,55 111,15 047 111,75 071 112,35 095 112,95 110,55 111,15 047 111,75 071 112,35 095 112,95
110,575 111,175 048 111,775 072 112,375 096 112,975 110,575 111,175 048 111,775 072 112,375 096 112,975
Determinare lo spessore teorico (Ts) della rondella: Determinare lo spessore teorico (Ts) della rondella:
TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,195 mm TS = 2,195 mm
Ricavare dalla tabella 2 lo spessore effettivo della rondella (Ss): Ricavare dalla tabella 2 lo spessore effettivo della rondella (Ss):
© 05/00 1.00.15 1.00.15 © 05/00

Mot. - Typ Code Mot. - Nr. 1 1
0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
z.B.122,05 mm. z.B.122,05 mm.
Tabelle 4 Tabelle 4
120,0 120,6 121,2 149 121,8 173 122,4 197 120,0 120,6 121,2 149 121,8 173 122,4 197
120,025 120,625 121,225 150 121,825 174 122,425 198 120,025 120,625 121,225 150 121,825 174 122,425 198
120,05 120,65 121,25 151 121,85 175 122,45 199 120,05 120,65 121,25 151 121,85 175 122,45 199
120,075 120,675 121,275 152 121,875 176 122,475 200 120,075 120,675 121,275 152 121,875 176 122,475 200
120,1 120,7 121,3 153 121,9 177 122,5 201 120,1 120,7 121,3 153 121,9 177 122,5 201
120,125 120,725 121,325 154 121,925 178 122,525 202 120,125 120,725 121,325 154 121,925 178 122,525 202
120,15 120,75 131 121,35 155 121,95 179 122,55 203 120,15 120,75 131 121,35 155 121,95 179 122,55 203
120,175 120,775 132 121,375 156 121,975 180 122,575 204 120,175 120,775 132 121,375 156 121,975 180 122,575 204
120,2 120,8 133 121,4 157 122,0 181 122,6 205 120,2 120,8 133 121,4 157 122,0 181 122,6 205
120,225 120,825 134 121,425 158 122,025 182 122,625 206 120,225 120,825 134 121,425 158 122,025 182 122,625 206
120,25 120,85 135 121,45 159 122,05 183 122,65 207 120,25 120,85 135 121,45 159 122,05 183 122,65 207
120,275 120,875 136 121,475 160 122,075 184 122,675 208 120,275 120,875 136 121,475 160 122,075 184 122,675 208
120,3 120,9 137 121,5 161 122,1 185 122,7 209 120,3 120,9 137 121,5 161 122,1 185 122,7 209
120,325 120,925 138 121,525 162 122,125 186 122,725 210 120,325 120,925 138 121,525 162 122,125 186 122,725 210
120,35 120,95 139 121,55 163 122,15 187 122,75 211 120,35 120,95 139 121,55 163 122,15 187 122,75 211
120,375 120,975 140 121,575 164 122,175 188 122,775 212 120,375 120,975 140 121,575 164 122,175 188 122,775 212
120,4 121,0 141 121,6 165 122,2 189 122,8 213 120,4 121,0 141 121,6 165 122,2 189 122,8 213
120,425 121,025 142 121,625 166 122,225 190 122,825 214 120,425 121,025 142 121,625 166 122,225 190 122,825 214
120,45 121,05 143 121,65 167 122,25 191 122,85 215 120,45 121,05 143 121,65 167 122,25 191 122,85 215
120,475 121,075 144 121,675 168 122,275 192 122,875 120,475 121,075 144 121,675 168 122,275 192 122,875
120,5 121,1 145 121,7 169 122,3 193 122,9 120,5 121,1 145 121,7 169 122,3 193 122,9
120,525 121,125 146 121,725 170 122,325 194 122,925 120,525 121,125 146 121,725 170 122,325 194 122,925
120,55 121,15 147 121,75 171 122,35 195 122,95 120,55 121,15 147 121,75 171 122,35 195 122,95
120,575 121,175 148 121,775 172 122,375 196 122,975 120,575 121,175 148 121,775 172 122,375 196 122,975

TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,83 mm TS = 2,83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
z.B.122,05 mm. z.B.122,05 mm.
Tabelle 4 Tabelle 4
120,0 120,6 121,2 149 121,8 173 122,4 197 120,0 120,6 121,2 149 121,8 173 122,4 197
120,025 120,625 121,225 150 121,825 174 122,425 198 120,025 120,625 121,225 150 121,825 174 122,425 198
120,05 120,65 121,25 151 121,85 175 122,45 199 120,05 120,65 121,25 151 121,85 175 122,45 199
120,075 120,675 121,275 152 121,875 176 122,475 200 120,075 120,675 121,275 152 121,875 176 122,475 200
120,1 120,7 121,3 153 121,9 177 122,5 201 120,1 120,7 121,3 153 121,9 177 122,5 201
120,125 120,725 121,325 154 121,925 178 122,525 202 120,125 120,725 121,325 154 121,925 178 122,525 202
120,15 120,75 131 121,35 155 121,95 179 122,55 203 120,15 120,75 131 121,35 155 121,95 179 122,55 203
120,175 120,775 132 121,375 156 121,975 180 122,575 204 120,175 120,775 132 121,375 156 121,975 180 122,575 204
120,2 120,8 133 121,4 157 122,0 181 122,6 205 120,2 120,8 133 121,4 157 122,0 181 122,6 205
120,225 120,825 134 121,425 158 122,025 182 122,625 206 120,225 120,825 134 121,425 158 122,025 182 122,625 206
120,25 120,85 135 121,45 159 122,05 183 122,65 207 120,25 120,85 135 121,45 159 122,05 183 122,65 207
120,275 120,875 136 121,475 160 122,075 184 122,675 208 120,275 120,875 136 121,475 160 122,075 184 122,675 208
120,3 120,9 137 121,5 161 122,1 185 122,7 209 120,3 120,9 137 121,5 161 122,1 185 122,7 209
120,325 120,925 138 121,525 162 122,125 186 122,725 210 120,325 120,925 138 121,525 162 122,125 186 122,725 210
120,35 120,95 139 121,55 163 122,15 187 122,75 211 120,35 120,95 139 121,55 163 122,15 187 122,75 211
120,375 120,975 140 121,575 164 122,175 188 122,775 212 120,375 120,975 140 121,575 164 122,175 188 122,775 212
120,4 121,0 141 121,6 165 122,2 189 122,8 213 120,4 121,0 141 121,6 165 122,2 189 122,8 213
120,425 121,025 142 121,625 166 122,225 190 122,825 214 120,425 121,025 142 121,625 166 122,225 190 122,825 214
120,45 121,05 143 121,65 167 122,25 191 122,85 215 120,45 121,05 143 121,65 167 122,25 191 122,85 215
120,475 121,075 144 121,675 168 122,275 192 122,875 120,475 121,075 144 121,675 168 122,275 192 122,875
120,5 121,1 145 121,7 169 122,3 193 122,9 120,5 121,1 145 121,7 169 122,3 193 122,9
120,525 121,125 146 121,725 170 122,325 194 122,925 120,525 121,125 146 121,725 170 122,325 194 122,925
120,55 121,15 147 121,75 171 122,35 195 122,95 120,55 121,15 147 121,75 171 122,35 195 122,95
120,575 121,175 148 121,775 172 122,375 196 122,975 120,575 121,175 148 121,775 172 122,375 196 122,975

TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,83 mm TS = 2,83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
e.g. 122.05 mm. e.g. 122.05 mm.
Tabelle 4 Tabelle 4
120.0 120.6 121.2 149 121.8 173 122.4 197 120.0 120.6 121.2 149 121.8 173 122.4 197
120.025 120.625 121.225 150 121.825 174 122.425 198 120.025 120.625 121.225 150 121.825 174 122.425 198
120.05 120.65 121.25 151 121.85 175 122.45 199 120.05 120.65 121.25 151 121.85 175 122.45 199
120.075 120.675 121.275 152 121.875 176 122.475 200 120.075 120.675 121.275 152 121.875 176 122.475 200
120.1 120.7 121.3 153 121.9 177 122.5 201 120.1 120.7 121.3 153 121.9 177 122.5 201
120.125 120.725 121.325 154 121.925 178 122.525 202 120.125 120.725 121.325 154 121.925 178 122.525 202
120.15 120.75 131 121.35 155 121.95 179 122.55 203 120.15 120.75 131 121.35 155 121.95 179 122.55 203
120.175 120.775 132 121.375 156 121.975 180 122.575 204 120.175 120.775 132 121.375 156 121.975 180 122.575 204
120.2 120.8 133 121.4 157 122.0 181 122.6 205 120.2 120.8 133 121.4 157 122.0 181 122.6 205
120.225 120.825 134 121.425 158 122.025 182 122.625 206 120.225 120.825 134 121.425 158 122.025 182 122.625 206
120.25 120.85 135 121.45 159 122.05 183 122.65 207 120.25 120.85 135 121.45 159 122.05 183 122.65 207
120.275 120.875 136 121.475 160 122.075 184 122.675 208 120.275 120.875 136 121.475 160 122.075 184 122.675 208
120.3 120.9 137 121.5 161 122.1 185 122.7 209 120.3 120.9 137 121.5 161 122.1 185 122.7 209
120.325 120.925 138 121.525 162 122.125 186 122.725 210 120.325 120.925 138 121.525 162 122.125 186 122.725 210
120.35 120.95 139 121.55 163 122.15 187 122.75 211 120.35 120.95 139 121.55 163 122.15 187 122.75 211
120.375 120.975 140 121.575 164 122.175 188 122.775 212 120.375 120.975 140 121.575 164 122.175 188 122.775 212
120.4 121.0 141 121.6 165 122.2 189 122.8 213 120.4 121.0 141 121.6 165 122.2 189 122.8 213
120.425 121.025 142 121.625 166 122.225 190 122.825 214 120.425 121.025 142 121.625 166 122.225 190 122.825 214
120.45 121.05 143 121.65 167 122.25 191 122.85 215 120.45 121.05 143 121.65 167 122.25 191 122.85 215
120.475 121.075 144 121.675 168 122.275 192 122.875 120.475 121.075 144 121.675 168 122.275 192 122.875
120.5 121.1 145 121.7 169 122.3 193 122.9 120.5 121.1 145 121.7 169 122.3 193 122.9
120.525 121.125 146 121.725 170 122.325 194 122.925 120.525 121.125 146 121.725 170 122.325 194 122.925
120.55 121.15 147 121.75 171 122.35 195 122.95 120.55 121.15 147 121.75 171 122.35 195 122.95
120.575 121.175 148 121.775 172 122.375 196 112.975 120.575 121.175 148 121.775 172 122.375 196 112.975
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2.83 mm Ts = 2.83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
e.g. 122.05 mm. e.g. 122.05 mm.
Tabelle 4 Tabelle 4
120.0 120.6 121.2 149 121.8 173 122.4 197 120.0 120.6 121.2 149 121.8 173 122.4 197
120.025 120.625 121.225 150 121.825 174 122.425 198 120.025 120.625 121.225 150 121.825 174 122.425 198
120.05 120.65 121.25 151 121.85 175 122.45 199 120.05 120.65 121.25 151 121.85 175 122.45 199
120.075 120.675 121.275 152 121.875 176 122.475 200 120.075 120.675 121.275 152 121.875 176 122.475 200
120.1 120.7 121.3 153 121.9 177 122.5 201 120.1 120.7 121.3 153 121.9 177 122.5 201
120.125 120.725 121.325 154 121.925 178 122.525 202 120.125 120.725 121.325 154 121.925 178 122.525 202
120.15 120.75 131 121.35 155 121.95 179 122.55 203 120.15 120.75 131 121.35 155 121.95 179 122.55 203
120.175 120.775 132 121.375 156 121.975 180 122.575 204 120.175 120.775 132 121.375 156 121.975 180 122.575 204
120.2 120.8 133 121.4 157 122.0 181 122.6 205 120.2 120.8 133 121.4 157 122.0 181 122.6 205
120.225 120.825 134 121.425 158 122.025 182 122.625 206 120.225 120.825 134 121.425 158 122.025 182 122.625 206
120.25 120.85 135 121.45 159 122.05 183 122.65 207 120.25 120.85 135 121.45 159 122.05 183 122.65 207
120.275 120.875 136 121.475 160 122.075 184 122.675 208 120.275 120.875 136 121.475 160 122.075 184 122.675 208
120.3 120.9 137 121.5 161 122.1 185 122.7 209 120.3 120.9 137 121.5 161 122.1 185 122.7 209
120.325 120.925 138 121.525 162 122.125 186 122.725 210 120.325 120.925 138 121.525 162 122.125 186 122.725 210
120.35 120.95 139 121.55 163 122.15 187 122.75 211 120.35 120.95 139 121.55 163 122.15 187 122.75 211
120.375 120.975 140 121.575 164 122.175 188 122.775 212 120.375 120.975 140 121.575 164 122.175 188 122.775 212
120.4 121.0 141 121.6 165 122.2 189 122.8 213 120.4 121.0 141 121.6 165 122.2 189 122.8 213
120.425 121.025 142 121.625 166 122.225 190 122.825 214 120.425 121.025 142 121.625 166 122.225 190 122.825 214
120.45 121.05 143 121.65 167 122.25 191 122.85 215 120.45 121.05 143 121.65 167 122.25 191 122.85 215
120.475 121.075 144 121.675 168 122.275 192 122.875 120.475 121.075 144 121.675 168 122.275 192 122.875
120.5 121.1 145 121.7 169 122.3 193 122.9 120.5 121.1 145 121.7 169 122.3 193 122.9
120.525 121.125 146 121.725 170 122.325 194 122.925 120.525 121.125 146 121.725 170 122.325 194 122.925
120.55 121.15 147 121.75 171 122.35 195 122.95 120.55 121.15 147 121.75 171 122.35 195 122.95
120.575 121.175 148 121.775 172 122.375 196 112.975 120.575 121.175 148 121.775 172 122.375 196 112.975
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2.83 mm Ts = 2.83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00


0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
Tableau 4 Tableau 4
120,0 120,6 121,2 149 121,8 173 122,4 197 120,0 120,6 121,2 149 121,8 173 122,4 197
120,025 120,625 121,225 150 121,825 174 122,425 198 120,025 120,625 121,225 150 121,825 174 122,425 198
120,05 120,65 121,25 151 121,85 175 122,45 199 120,05 120,65 121,25 151 121,85 175 122,45 199
120,075 120,675 121,275 152 121,875 176 122,475 200 120,075 120,675 121,275 152 121,875 176 122,475 200
120,1 120,7 121,3 153 121,9 177 122,5 201 120,1 120,7 121,3 153 121,9 177 122,5 201
120,125 120,725 121,325 154 121,925 178 122,525 202 120,125 120,725 121,325 154 121,925 178 122,525 202
120,15 120,75 131 121,35 155 121,95 179 122,55 203 120,15 120,75 131 121,35 155 121,95 179 122,55 203
120,175 120,775 132 121,375 156 121,975 180 122,575 204 120,175 120,775 132 121,375 156 121,975 180 122,575 204
120,2 120,8 133 121,4 157 122,0 181 122,6 205 120,2 120,8 133 121,4 157 122,0 181 122,6 205
120,225 120,825 134 121,425 158 122,025 182 122,625 206 120,225 120,825 134 121,425 158 122,025 182 122,625 206
120,25 120,85 135 121,45 159 122,05 183 122,65 207 120,25 120,85 135 121,45 159 122,05 183 122,65 207
120,275 120,875 136 121,475 160 122,075 184 122,675 208 120,275 120,875 136 121,475 160 122,075 184 122,675 208
120,3 120,9 137 121,5 161 122,1 185 122,7 209 120,3 120,9 137 121,5 161 122,1 185 122,7 209
120,325 120,925 138 121,525 162 122,125 186 122,725 210 120,325 120,925 138 121,525 162 122,125 186 122,725 210
120,35 120,95 139 121,55 163 122,15 187 122,75 211 120,35 120,95 139 121,55 163 122,15 187 122,75 211
120,375 120,975 140 121,575 164 122,175 188 122,775 212 120,375 120,975 140 121,575 164 122,175 188 122,775 212
120,4 121,0 141 121,6 165 122,2 189 122,8 213 120,4 121,0 141 121,6 165 122,2 189 122,8 213
120,425 121,025 142 121,625 166 122,225 190 122,825 214 120,425 121,025 142 121,625 166 122,225 190 122,825 214
120,45 121,05 143 121,65 167 122,25 191 122,85 215 120,45 121,05 143 121,65 167 122,25 191 122,85 215
120,475 121,075 144 121,675 168 122,275 192 122,875 120,475 121,075 144 121,675 168 122,275 192 122,875
120,5 121,1 145 121,7 169 122,3 193 122,9 120,5 121,1 145 121,7 169 122,3 193 122,9
120,525 121,125 146 121,725 170 122,325 194 122,925 120,525 121,125 146 121,725 170 122,325 194 122,925
120,55 121,15 147 121,75 171 122,35 195 122,95 120,55 121,15 147 121,75 171 122,35 195 122,95
120,575 121,175 148 121,775 172 122,375 196 122,975 120,575 121,175 148 121,775 172 122,375 196 122,975
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2,83 mm Ts = 2,83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00


0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
Tableau 4 Tableau 4
120,0 120,6 121,2 149 121,8 173 122,4 197 120,0 120,6 121,2 149 121,8 173 122,4 197
120,025 120,625 121,225 150 121,825 174 122,425 198 120,025 120,625 121,225 150 121,825 174 122,425 198
120,05 120,65 121,25 151 121,85 175 122,45 199 120,05 120,65 121,25 151 121,85 175 122,45 199
120,075 120,675 121,275 152 121,875 176 122,475 200 120,075 120,675 121,275 152 121,875 176 122,475 200
120,1 120,7 121,3 153 121,9 177 122,5 201 120,1 120,7 121,3 153 121,9 177 122,5 201
120,125 120,725 121,325 154 121,925 178 122,525 202 120,125 120,725 121,325 154 121,925 178 122,525 202
120,15 120,75 131 121,35 155 121,95 179 122,55 203 120,15 120,75 131 121,35 155 121,95 179 122,55 203
120,175 120,775 132 121,375 156 121,975 180 122,575 204 120,175 120,775 132 121,375 156 121,975 180 122,575 204
120,2 120,8 133 121,4 157 122,0 181 122,6 205 120,2 120,8 133 121,4 157 122,0 181 122,6 205
120,225 120,825 134 121,425 158 122,025 182 122,625 206 120,225 120,825 134 121,425 158 122,025 182 122,625 206
120,25 120,85 135 121,45 159 122,05 183 122,65 207 120,25 120,85 135 121,45 159 122,05 183 122,65 207
120,275 120,875 136 121,475 160 122,075 184 122,675 208 120,275 120,875 136 121,475 160 122,075 184 122,675 208
120,3 120,9 137 121,5 161 122,1 185 122,7 209 120,3 120,9 137 121,5 161 122,1 185 122,7 209
120,325 120,925 138 121,525 162 122,125 186 122,725 210 120,325 120,925 138 121,525 162 122,125 186 122,725 210
120,35 120,95 139 121,55 163 122,15 187 122,75 211 120,35 120,95 139 121,55 163 122,15 187 122,75 211
120,375 120,975 140 121,575 164 122,175 188 122,775 212 120,375 120,975 140 121,575 164 122,175 188 122,775 212
120,4 121,0 141 121,6 165 122,2 189 122,8 213 120,4 121,0 141 121,6 165 122,2 189 122,8 213
120,425 121,025 142 121,625 166 122,225 190 122,825 214 120,425 121,025 142 121,625 166 122,225 190 122,825 214
120,45 121,05 143 121,65 167 122,25 191 122,85 215 120,45 121,05 143 121,65 167 122,25 191 122,85 215
120,475 121,075 144 121,675 168 122,275 192 122,875 120,475 121,075 144 121,675 168 122,275 192 122,875
120,5 121,1 145 121,7 169 122,3 193 122,9 120,5 121,1 145 121,7 169 122,3 193 122,9
120,525 121,125 146 121,725 170 122,325 194 122,925 120,525 121,125 146 121,725 170 122,325 194 122,925
120,55 121,15 147 121,75 171 122,35 195 122,95 120,55 121,15 147 121,75 171 122,35 195 122,95
120,575 121,175 148 121,775 172 122,375 196 122,975 120,575 121,175 148 121,775 172 122,375 196 122,975
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2,83 mm Ts = 2,83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00

Misura base L0= 119 mm
0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
Prendere nota dalla tabella 4 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza al Prendere nota dalla tabella 4 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza al
codice EP, nel nostro caso 122,05 mm. codice EP, nel nostro caso 122,05 mm.
Tabelle 4 Tabelle 4
120,0 120,6 121,2 149 121,8 173 122,4 197 120,0 120,6 121,2 149 121,8 173 122,4 197
120,025 120,625 121,225 150 121,825 174 122,425 198 120,025 120,625 121,225 150 121,825 174 122,425 198
120,05 120,65 121,25 151 121,85 175 122,45 199 120,05 120,65 121,25 151 121,85 175 122,45 199
120,075 120,675 121,275 152 121,875 176 122,475 200 120,075 120,675 121,275 152 121,875 176 122,475 200
120,1 120,7 121,3 153 121,9 177 122,5 201 120,1 120,7 121,3 153 121,9 177 122,5 201
120,125 120,725 121,325 154 121,925 178 122,525 202 120,125 120,725 121,325 154 121,925 178 122,525 202
120,15 120,75 131 121,35 155 121,95 179 122,55 203 120,15 120,75 131 121,35 155 121,95 179 122,55 203
120,175 120,775 132 121,375 156 121,975 180 122,575 204 120,175 120,775 132 121,375 156 121,975 180 122,575 204
120,2 120,8 133 121,4 157 122,0 181 122,6 205 120,2 120,8 133 121,4 157 122,0 181 122,6 205
120,225 120,825 134 121,425 158 122,025 182 122,625 206 120,225 120,825 134 121,425 158 122,025 182 122,625 206
120,25 120,85 135 121,45 159 122,05 183 122,65 207 120,25 120,85 135 121,45 159 122,05 183 122,65 207
120,275 120,875 136 121,475 160 122,075 184 122,675 208 120,275 120,875 136 121,475 160 122,075 184 122,675 208
120,3 120,9 137 121,5 161 122,1 185 122,7 209 120,3 120,9 137 121,5 161 122,1 185 122,7 209
120,325 120,925 138 121,525 162 122,125 186 122,725 210 120,325 120,925 138 121,525 162 122,125 186 122,725 210
120,35 120,95 139 121,55 163 122,15 187 122,75 211 120,35 120,95 139 121,55 163 122,15 187 122,75 211
120,375 120,975 140 121,575 164 122,175 188 122,775 212 120,375 120,975 140 121,575 164 122,175 188 122,775 212
120,4 121,0 141 121,6 165 122,2 189 122,8 213 120,4 121,0 141 121,6 165 122,2 189 122,8 213
120,425 121,025 142 121,625 166 122,225 190 122,825 214 120,425 121,025 142 121,625 166 122,225 190 122,825 214
120,45 121,05 143 121,65 167 122,25 191 122,85 215 120,45 121,05 143 121,65 167 122,25 191 122,85 215
120,475 121,075 144 121,675 168 122,275 192 122,875 120,475 121,075 144 121,675 168 122,275 192 122,875
120,5 121,1 145 121,7 169 122,3 193 122,9 120,5 121,1 145 121,7 169 122,3 193 122,9
120,525 121,125 146 121,725 170 122,325 194 122,925 120,525 121,125 146 121,725 170 122,325 194 122,925
120,55 121,15 147 121,75 171 122,35 195 122,95 120,55 121,15 147 121,75 171 122,35 195 122,95
120,575 121,175 148 121,775 172 122,375 196 122,975 120,575 121,175 148 121,775 172 122,375 196 122,975
Determinare lo spessore teorico (TS) della rondella: Determinare lo spessore teorico (TS) della rondella:
TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,83 mm TS = 2,83 mm
Ricavare dalla tabella 2 lo spessore effettivo della rondella (SS): Ricavare dalla tabella 2 lo spessore effettivo della rondella (SS):
© 05/00 1.00.15.1 1.00.15.1 © 05/00

Misura base L0= 119 mm
0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 183 kW(W) 183
°C °C
m m
Prendere nota dalla tabella 4 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza al Prendere nota dalla tabella 4 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza al
codice EP, nel nostro caso 122,05 mm. codice EP, nel nostro caso 122,05 mm.
Tabelle 4 Tabelle 4
120,0 120,6 121,2 149 121,8 173 122,4 197 120,0 120,6 121,2 149 121,8 173 122,4 197
120,025 120,625 121,225 150 121,825 174 122,425 198 120,025 120,625 121,225 150 121,825 174 122,425 198
120,05 120,65 121,25 151 121,85 175 122,45 199 120,05 120,65 121,25 151 121,85 175 122,45 199
120,075 120,675 121,275 152 121,875 176 122,475 200 120,075 120,675 121,275 152 121,875 176 122,475 200
120,1 120,7 121,3 153 121,9 177 122,5 201 120,1 120,7 121,3 153 121,9 177 122,5 201
120,125 120,725 121,325 154 121,925 178 122,525 202 120,125 120,725 121,325 154 121,925 178 122,525 202
120,15 120,75 131 121,35 155 121,95 179 122,55 203 120,15 120,75 131 121,35 155 121,95 179 122,55 203
120,175 120,775 132 121,375 156 121,975 180 122,575 204 120,175 120,775 132 121,375 156 121,975 180 122,575 204
120,2 120,8 133 121,4 157 122,0 181 122,6 205 120,2 120,8 133 121,4 157 122,0 181 122,6 205
120,225 120,825 134 121,425 158 122,025 182 122,625 206 120,225 120,825 134 121,425 158 122,025 182 122,625 206
120,25 120,85 135 121,45 159 122,05 183 122,65 207 120,25 120,85 135 121,45 159 122,05 183 122,65 207
120,275 120,875 136 121,475 160 122,075 184 122,675 208 120,275 120,875 136 121,475 160 122,075 184 122,675 208
120,3 120,9 137 121,5 161 122,1 185 122,7 209 120,3 120,9 137 121,5 161 122,1 185 122,7 209
120,325 120,925 138 121,525 162 122,125 186 122,725 210 120,325 120,925 138 121,525 162 122,125 186 122,725 210
120,35 120,95 139 121,55 163 122,15 187 122,75 211 120,35 120,95 139 121,55 163 122,15 187 122,75 211
120,375 120,975 140 121,575 164 122,175 188 122,775 212 120,375 120,975 140 121,575 164 122,175 188 122,775 212
120,4 121,0 141 121,6 165 122,2 189 122,8 213 120,4 121,0 141 121,6 165 122,2 189 122,8 213
120,425 121,025 142 121,625 166 122,225 190 122,825 214 120,425 121,025 142 121,625 166 122,225 190 122,825 214
120,45 121,05 143 121,65 167 122,25 191 122,85 215 120,45 121,05 143 121,65 167 122,25 191 122,85 215
120,475 121,075 144 121,675 168 122,275 192 122,875 120,475 121,075 144 121,675 168 122,275 192 122,875
120,5 121,1 145 121,7 169 122,3 193 122,9 120,5 121,1 145 121,7 169 122,3 193 122,9
120,525 121,125 146 121,725 170 122,325 194 122,925 120,525 121,125 146 121,725 170 122,325 194 122,925
120,55 121,15 147 121,75 171 122,35 195 122,95 120,55 121,15 147 121,75 171 122,35 195 122,95
120,575 121,175 148 121,775 172 122,375 196 122,975 120,575 121,175 148 121,775 172 122,375 196 122,975
TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,83 mm TS = 2,83 mm
© 05/00 1.00.15.1 1.00.15.1 © 05/00

0122 3237
0122 3237
kW(G) red. EP K
kW(G) red. EP K

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C
°C
m
m
z.B.146,9 mm. z.B.146,9 mm.
Tabelle 5 Tabelle 5
144,5 145,1 145,7 349 146,3 373 146,9 397 144,5 145,1 145,7 349 146,3 373 146,9 397
144,525 145,125 145,725 350 146,325 374 146,925 398 144,525 145,125 145,725 350 146,325 374 146,925 398
144,55 145,15 145,75 351 146,35 375 146,95 399 144,55 145,15 145,75 351 146,35 375 146,95 399
144,575 145,175 145,775 352 146,375 376 146,975 400 144,575 145,175 145,775 352 146,375 376 146,975 400
144,6 145,2 145,8 353 146,4 377 147,0 401 144,6 145,2 145,8 353 146,4 377 147,0 401
144,625 145,225 145,825 354 146,425 378 147,025 144,625 145,225 145,825 354 146,425 378 147,025
144,65 145,25 145,85 355 146,45 379 147,05 144,65 145,25 145,85 355 146,45 379 147,05
144,675 145,275 145,875 356 146,475 380 147,075 144,675 145,275 145,875 356 146,475 380 147,075
144,7 145,3 145,9 357 146,5 381 147,1 144,7 145,3 145,9 357 146,5 381 147,1
144,725 145,325 145,925 358 146,525 382 147,125 144,725 145,325 145,925 358 146,525 382 147,125
144,75 145,35 335 145,95 359 146,55 383 147,15 144,75 145,35 335 145,95 359 146,55 383 147,15
144,775 145,375 336 145,975 360 146,575 384 147,175 144,775 145,375 336 145,975 360 146,575 384 147,175
144,8 145,4 337 146,0 361 146,6 385 147,2 144,8 145,4 337 146,0 361 146,6 385 147,2
144,825 145,425 338 146,025 362 146,625 386 147,225 144,825 145,425 338 146,025 362 146,625 386 147,225
144,85 145,45 339 146,05 363 146,65 387 147,25 144,85 145,45 339 146,05 363 146,65 387 147,25
144,875 145,475 340 146,075 364 146,675 388 147,275 144,875 145,475 340 146,075 364 146,675 388 147,275
144,9 145,5 341 146,1 365 146,7 389 147,3 144,9 145,5 341 146,1 365 146,7 389 147,3
144,925 145,525 342 146,125 366 146,725 390 147,325 144,925 145,525 342 146,125 366 146,725 390 147,325
144,95 145,55 343 146,15 367 146,75 391 147,35 144,95 145,55 343 146,15 367 146,75 391 147,35
144,975 145,575 344 146,175 368 146,775 392 147,375 144,975 145,575 344 146,175 368 146,775 392 147,375
145,0 145,6 345 146,2 369 146,8 393 147,4 145,0 145,6 345 146,2 369 146,8 393 147,4
145,025 145,625 346 146,225 370 146,825 394 147,425 145,025 145,625 346 146,225 370 146,825 394 147,425
145,05 145,65 347 146,25 371 146,85 395 147,45 145,05 145,65 347 146,25 371 146,85 395 147,45
145,075 145,675 348 146,275 372 146,875 396 147,475 145,075 145,675 348 146,275 372 146,875 396 147,475

TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,57 mm TS = 2,57 mm
TS 2,57 mm = SS 2,6mm TS 2,57 mm = SS 2,6mm
© 05/00 1.00.17 1.00.17 © 05/00

0122 3237
0122 3237
kW(G) red. EP K
kW(G) red. EP K

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C
°C
m
m
z.B.146,9 mm. z.B.146,9 mm.
Tabelle 5 Tabelle 5
144,5 145,1 145,7 349 146,3 373 146,9 397 144,5 145,1 145,7 349 146,3 373 146,9 397
144,525 145,125 145,725 350 146,325 374 146,925 398 144,525 145,125 145,725 350 146,325 374 146,925 398
144,55 145,15 145,75 351 146,35 375 146,95 399 144,55 145,15 145,75 351 146,35 375 146,95 399
144,575 145,175 145,775 352 146,375 376 146,975 400 144,575 145,175 145,775 352 146,375 376 146,975 400
144,6 145,2 145,8 353 146,4 377 147,0 401 144,6 145,2 145,8 353 146,4 377 147,0 401
144,625 145,225 145,825 354 146,425 378 147,025 144,625 145,225 145,825 354 146,425 378 147,025
144,65 145,25 145,85 355 146,45 379 147,05 144,65 145,25 145,85 355 146,45 379 147,05
144,675 145,275 145,875 356 146,475 380 147,075 144,675 145,275 145,875 356 146,475 380 147,075
144,7 145,3 145,9 357 146,5 381 147,1 144,7 145,3 145,9 357 146,5 381 147,1
144,725 145,325 145,925 358 146,525 382 147,125 144,725 145,325 145,925 358 146,525 382 147,125
144,75 145,35 335 145,95 359 146,55 383 147,15 144,75 145,35 335 145,95 359 146,55 383 147,15
144,775 145,375 336 145,975 360 146,575 384 147,175 144,775 145,375 336 145,975 360 146,575 384 147,175
144,8 145,4 337 146,0 361 146,6 385 147,2 144,8 145,4 337 146,0 361 146,6 385 147,2
144,825 145,425 338 146,025 362 146,625 386 147,225 144,825 145,425 338 146,025 362 146,625 386 147,225
144,85 145,45 339 146,05 363 146,65 387 147,25 144,85 145,45 339 146,05 363 146,65 387 147,25
144,875 145,475 340 146,075 364 146,675 388 147,275 144,875 145,475 340 146,075 364 146,675 388 147,275
144,9 145,5 341 146,1 365 146,7 389 147,3 144,9 145,5 341 146,1 365 146,7 389 147,3
144,925 145,525 342 146,125 366 146,725 390 147,325 144,925 145,525 342 146,125 366 146,725 390 147,325
144,95 145,55 343 146,15 367 146,75 391 147,35 144,95 145,55 343 146,15 367 146,75 391 147,35
144,975 145,575 344 146,175 368 146,775 392 147,375 144,975 145,575 344 146,175 368 146,775 392 147,375
145,0 145,6 345 146,2 369 146,8 393 147,4 145,0 145,6 345 146,2 369 146,8 393 147,4
145,025 145,625 346 146,225 370 146,825 394 147,425 145,025 145,625 346 146,225 370 146,825 394 147,425
145,05 145,65 347 146,25 371 146,85 395 147,45 145,05 145,65 347 146,25 371 146,85 395 147,45
145,075 145,675 348 146,275 372 146,875 396 147,475 145,075 145,675 348 146,275 372 146,875 396 147,475

TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,57 mm TS = 2,57 mm
© 05/00 1.00.17 1.00.17 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C °C
m m
e.g. 146.9 mm. e.g. 146.9 mm.
Table 5 Table 5
144.5 145.1 145.7 349 146.3 373 146.9 397 144.5 145.1 145.7 349 146.3 373 146.9 397
144.525 145.125 145.725 350 146.325 374 146.925 398 144.525 145.125 145.725 350 146.325 374 146.925 398
144.55 145.15 145.75 351 146.35 375 146.95 399 144.55 145.15 145.75 351 146.35 375 146.95 399
144.575 145.175 145.775 352 146.375 376 146.975 400 144.575 145.175 145.775 352 146.375 376 146.975 400
144.6 145.2 145.8 353 146.4 377 147.0 401 144.6 145.2 145.8 353 146.4 377 147.0 401
144.625 145.225 145.825 354 146.425 378 147.025 144.625 145.225 145.825 354 146.425 378 147.025
144.65 145.25 145.85 355 146.45 379 147.05 144.65 145.25 145.85 355 146.45 379 147.05
144.675 145.275 145.875 356 146.475 380 147.075 144.675 145.275 145.875 356 146.475 380 147.075
144.7 145.3 145.9 357 146.5 381 147.1 144.7 145.3 145.9 357 146.5 381 147.1
144.725 145.325 145.925 358 146.525 382 147.125 144.725 145.325 145.925 358 146.525 382 147.125
144.75 145.35 335 145.95 359 146.55 383 147.15 144.75 145.35 335 145.95 359 146.55 383 147.15
144.775 145.375 336 145.975 360 146.575 384 147.175 144.775 145.375 336 145.975 360 146.575 384 147.175
144.8 145.4 337 146.0 361 146.6 385 147.2 144.8 145.4 337 146.0 361 146.6 385 147.2
144.825 145.425 338 146.025 362 146.625 386 147.225 144.825 145.425 338 146.025 362 146.625 386 147.225
144.85 145.45 339 146.05 363 146.65 387 147.25 144.85 145.45 339 146.05 363 146.65 387 147.25
144.875 145.475 340 146.075 364 146.675 388 147.275 144.875 145.475 340 146.075 364 146.675 388 147.275
144.9 145.5 341 146.1 365 146.7 389 147.3 144.9 145.5 341 146.1 365 146.7 389 147.3
144.925 145.525 342 146.125 366 146.725 390 147.325 144.925 145.525 342 146.125 366 146.725 390 147.325
144.95 145.55 343 146.15 367 146.75 391 147.35 144.95 145.55 343 146.15 367 146.75 391 147.35
144.975 145.575 344 146.175 368 146.775 392 147.375 144.975 145.575 344 146.175 368 146.775 392 147.375
145.0 145.6 345 146.2 369 146.8 393 147.4 145.0 145.6 345 146.2 369 146.8 393 147.4
145.025 145.625 346 146.225 370 146.825 394 147.425 145.025 145.625 346 146.225 370 146.825 394 147.425
145.05 145.65 347 146.25 371 146.85 395 147.45 145.05 145.65 347 146.25 371 146.85 395 147.45
145.075 145.675 348 146.275 372 146.875 396 147.475 145.075 145.675 348 146.275 372 146.875 396 147.475
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2.57 mm Ts = 2.57 mm
© 05/00 1.00.17 1.00.17 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C °C
m m
e.g. 146.9 mm. e.g. 146.9 mm.
Table 5 Table 5
144.5 145.1 145.7 349 146.3 373 146.9 397 144.5 145.1 145.7 349 146.3 373 146.9 397
144.525 145.125 145.725 350 146.325 374 146.925 398 144.525 145.125 145.725 350 146.325 374 146.925 398
144.55 145.15 145.75 351 146.35 375 146.95 399 144.55 145.15 145.75 351 146.35 375 146.95 399
144.575 145.175 145.775 352 146.375 376 146.975 400 144.575 145.175 145.775 352 146.375 376 146.975 400
144.6 145.2 145.8 353 146.4 377 147.0 401 144.6 145.2 145.8 353 146.4 377 147.0 401
144.625 145.225 145.825 354 146.425 378 147.025 144.625 145.225 145.825 354 146.425 378 147.025
144.65 145.25 145.85 355 146.45 379 147.05 144.65 145.25 145.85 355 146.45 379 147.05
144.675 145.275 145.875 356 146.475 380 147.075 144.675 145.275 145.875 356 146.475 380 147.075
144.7 145.3 145.9 357 146.5 381 147.1 144.7 145.3 145.9 357 146.5 381 147.1
144.725 145.325 145.925 358 146.525 382 147.125 144.725 145.325 145.925 358 146.525 382 147.125
144.75 145.35 335 145.95 359 146.55 383 147.15 144.75 145.35 335 145.95 359 146.55 383 147.15
144.775 145.375 336 145.975 360 146.575 384 147.175 144.775 145.375 336 145.975 360 146.575 384 147.175
144.8 145.4 337 146.0 361 146.6 385 147.2 144.8 145.4 337 146.0 361 146.6 385 147.2
144.825 145.425 338 146.025 362 146.625 386 147.225 144.825 145.425 338 146.025 362 146.625 386 147.225
144.85 145.45 339 146.05 363 146.65 387 147.25 144.85 145.45 339 146.05 363 146.65 387 147.25
144.875 145.475 340 146.075 364 146.675 388 147.275 144.875 145.475 340 146.075 364 146.675 388 147.275
144.9 145.5 341 146.1 365 146.7 389 147.3 144.9 145.5 341 146.1 365 146.7 389 147.3
144.925 145.525 342 146.125 366 146.725 390 147.325 144.925 145.525 342 146.125 366 146.725 390 147.325
144.95 145.55 343 146.15 367 146.75 391 147.35 144.95 145.55 343 146.15 367 146.75 391 147.35
144.975 145.575 344 146.175 368 146.775 392 147.375 144.975 145.575 344 146.175 368 146.775 392 147.375
145.0 145.6 345 146.2 369 146.8 393 147.4 145.0 145.6 345 146.2 369 146.8 393 147.4
145.025 145.625 346 146.225 370 146.825 394 147.425 145.025 145.625 346 146.225 370 146.825 394 147.425
145.05 145.65 347 146.25 371 146.85 395 147.45 145.05 145.65 347 146.25 371 146.85 395 147.45
145.075 145.675 348 146.275 372 146.875 396 147.475 145.075 145.675 348 146.275 372 146.875 396 147.475
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2.57 mm Ts = 2.57 mm
© 05/00 1.00.17 1.00.17 © 05/00


0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C °C
m m
Tableau 5 Tableau 5
144,5 145,1 145,7 349 146,3 373 146,9 397 144,5 145,1 145,7 349 146,3 373 146,9 397
144,525 145,125 145,725 350 146,325 374 146,925 398 144,525 145,125 145,725 350 146,325 374 146,925 398
144,55 145,15 145,75 351 146,35 375 146,95 399 144,55 145,15 145,75 351 146,35 375 146,95 399
144,575 145,175 145,775 352 146,375 376 146,975 400 144,575 145,175 145,775 352 146,375 376 146,975 400
144,6 145,2 145,8 353 146,4 377 147,0 401 144,6 145,2 145,8 353 146,4 377 147,0 401
144,625 145,225 145,825 354 146,425 378 147,025 144,625 145,225 145,825 354 146,425 378 147,025
144,65 145,25 145,85 355 146,45 379 147,05 144,65 145,25 145,85 355 146,45 379 147,05
144,675 145,275 145,875 356 146,475 380 147,075 144,675 145,275 145,875 356 146,475 380 147,075
144,7 145,3 145,9 357 146,5 381 147,1 144,7 145,3 145,9 357 146,5 381 147,1
144,725 145,325 145,925 358 146,525 382 147,125 144,725 145,325 145,925 358 146,525 382 147,125
144,75 145,35 335 145,95 359 146,55 383 147,15 144,75 145,35 335 145,95 359 146,55 383 147,15
144,775 145,375 336 145,975 360 146,575 384 147,175 144,775 145,375 336 145,975 360 146,575 384 147,175
144,8 145,4 337 146,0 361 146,6 385 147,2 144,8 145,4 337 146,0 361 146,6 385 147,2
144,825 145,425 338 146,025 362 146,625 386 147,225 144,825 145,425 338 146,025 362 146,625 386 147,225
144,85 145,45 339 146,05 363 146,65 387 147,25 144,85 145,45 339 146,05 363 146,65 387 147,25
144,875 145,475 340 146,075 364 146,675 388 147,275 144,875 145,475 340 146,075 364 146,675 388 147,275
144,9 145,5 341 146,1 365 146,7 389 147,3 144,9 145,5 341 146,1 365 146,7 389 147,3
144,925 145,525 342 146,125 366 146,725 390 147,325 144,925 145,525 342 146,125 366 146,725 390 147,325
144,95 145,55 343 146,15 367 146,75 391 147,35 144,95 145,55 343 146,15 367 146,75 391 147,35
144,975 145,575 344 146,175 368 146,775 392 147,375 144,975 145,575 344 146,175 368 146,775 392 147,375
145,0 145,6 345 146,2 369 146,8 393 147,4 145,0 145,6 345 146,2 369 146,8 393 147,4
145,025 145,625 346 146,225 370 146,825 394 147,425 145,025 145,625 346 146,225 370 146,825 394 147,425
145,05 145,65 347 146,25 371 146,85 395 147,45 145,05 145,65 347 146,25 371 146,85 395 147,45
145,075 145,675 348 146,275 372 146,875 396 147,475 145,075 145,675 348 146,275 372 146,875 396 147,475
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2,57mm Ts = 2,57mm
© 05/00 1.00.17 1.00.17 © 05/00


0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C °C
m m
Tableau 5 Tableau 5
144,5 145,1 145,7 349 146,3 373 146,9 397 144,5 145,1 145,7 349 146,3 373 146,9 397
144,525 145,125 145,725 350 146,325 374 146,925 398 144,525 145,125 145,725 350 146,325 374 146,925 398
144,55 145,15 145,75 351 146,35 375 146,95 399 144,55 145,15 145,75 351 146,35 375 146,95 399
144,575 145,175 145,775 352 146,375 376 146,975 400 144,575 145,175 145,775 352 146,375 376 146,975 400
144,6 145,2 145,8 353 146,4 377 147,0 401 144,6 145,2 145,8 353 146,4 377 147,0 401
144,625 145,225 145,825 354 146,425 378 147,025 144,625 145,225 145,825 354 146,425 378 147,025
144,65 145,25 145,85 355 146,45 379 147,05 144,65 145,25 145,85 355 146,45 379 147,05
144,675 145,275 145,875 356 146,475 380 147,075 144,675 145,275 145,875 356 146,475 380 147,075
144,7 145,3 145,9 357 146,5 381 147,1 144,7 145,3 145,9 357 146,5 381 147,1
144,725 145,325 145,925 358 146,525 382 147,125 144,725 145,325 145,925 358 146,525 382 147,125
144,75 145,35 335 145,95 359 146,55 383 147,15 144,75 145,35 335 145,95 359 146,55 383 147,15
144,775 145,375 336 145,975 360 146,575 384 147,175 144,775 145,375 336 145,975 360 146,575 384 147,175
144,8 145,4 337 146,0 361 146,6 385 147,2 144,8 145,4 337 146,0 361 146,6 385 147,2
144,825 145,425 338 146,025 362 146,625 386 147,225 144,825 145,425 338 146,025 362 146,625 386 147,225
144,85 145,45 339 146,05 363 146,65 387 147,25 144,85 145,45 339 146,05 363 146,65 387 147,25
144,875 145,475 340 146,075 364 146,675 388 147,275 144,875 145,475 340 146,075 364 146,675 388 147,275
144,9 145,5 341 146,1 365 146,7 389 147,3 144,9 145,5 341 146,1 365 146,7 389 147,3
144,925 145,525 342 146,125 366 146,725 390 147,325 144,925 145,525 342 146,125 366 146,725 390 147,325
144,95 145,55 343 146,15 367 146,75 391 147,35 144,95 145,55 343 146,15 367 146,75 391 147,35
144,975 145,575 344 146,175 368 146,775 392 147,375 144,975 145,575 344 146,175 368 146,775 392 147,375
145,0 145,6 345 146,2 369 146,8 393 147,4 145,0 145,6 345 146,2 369 146,8 393 147,4
145,025 145,625 346 146,225 370 146,825 394 147,425 145,025 145,625 346 146,225 370 146,825 394 147,425
145,05 145,65 347 146,25 371 146,85 395 147,45 145,05 145,65 347 146,25 371 146,85 395 147,45
145,075 145,675 348 146,275 372 146,875 396 147,475 145,075 145,675 348 146,275 372 146,875 396 147,475
Ts = EK - (Lo + A/100) Ts = EK - (Lo + A/100)
Ts = 2,57mm Ts = 2,57mm
© 05/00 1.00.17 1.00.17 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C °C
m m
(EK)Prendere nota dalla tabella 5 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza (EK)Prendere nota dalla tabella 5 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza
al codice EP, nel nostro caso 146,9 mm. al codice EP, nel nostro caso 146,9 mm.
Tabella 5 Tabella 5
144,5 145,1 145,7 349 146,3 373 146,9 397 144,5 145,1 145,7 349 146,3 373 146,9 397
144,525 145,125 145,725 350 146,325 374 146,925 398 144,525 145,125 145,725 350 146,325 374 146,925 398
144,55 145,15 145,75 351 146,35 375 146,95 399 144,55 145,15 145,75 351 146,35 375 146,95 399
144,575 145,175 145,775 352 146,375 376 146,975 400 144,575 145,175 145,775 352 146,375 376 146,975 400
144,6 145,2 145,8 353 146,4 377 147,0 401 144,6 145,2 145,8 353 146,4 377 147,0 401
144,625 145,225 145,825 354 146,425 378 147,025 144,625 145,225 145,825 354 146,425 378 147,025
144,65 145,25 145,85 355 146,45 379 147,05 144,65 145,25 145,85 355 146,45 379 147,05
144,675 145,275 145,875 356 146,475 380 147,075 144,675 145,275 145,875 356 146,475 380 147,075
144,7 145,3 145,9 357 146,5 381 147,1 144,7 145,3 145,9 357 146,5 381 147,1
144,725 145,325 145,925 358 146,525 382 147,125 144,725 145,325 145,925 358 146,525 382 147,125
144,75 145,35 335 145,95 359 146,55 383 147,15 144,75 145,35 335 145,95 359 146,55 383 147,15
144,775 145,375 336 145,975 360 146,575 384 147,175 144,775 145,375 336 145,975 360 146,575 384 147,175
144,8 145,4 337 146,0 361 146,6 385 147,2 144,8 145,4 337 146,0 361 146,6 385 147,2
144,825 145,425 338 146,025 362 146,625 386 147,225 144,825 145,425 338 146,025 362 146,625 386 147,225
144,85 145,45 339 146,05 363 146,65 387 147,25 144,85 145,45 339 146,05 363 146,65 387 147,25
144,875 145,475 340 146,075 364 146,675 388 147,275 144,875 145,475 340 146,075 364 146,675 388 147,275
144,9 145,5 341 146,1 365 146,7 389 147,3 144,9 145,5 341 146,1 365 146,7 389 147,3
144,925 145,525 342 146,125 366 146,725 390 147,325 144,925 145,525 342 146,125 366 146,725 390 147,325
144,95 145,55 343 146,15 367 146,75 391 147,35 144,95 145,55 343 146,15 367 146,75 391 147,35
144,975 145,575 344 146,175 368 146,775 392 147,375 144,975 145,575 344 146,175 368 146,775 392 147,375
145,0 145,6 345 146,2 369 146,8 393 147,4 145,0 145,6 345 146,2 369 146,8 393 147,4
145,025 145,625 346 146,225 370 146,825 394 147,425 145,025 145,625 346 146,225 370 146,825 394 147,425
145,05 145,65 347 146,25 371 146,85 395 147,45 145,05 145,65 347 146,25 371 146,85 395 147,45
145,075 145,675 348 146,275 372 146,875 396 147,475 145,075 145,675 348 146,275 372 146,875 396 147,475
TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,57 mm TS = 2,57 mm
© 05/00 1.00.17 1.00.17 © 05/00

0122 3237
0122 3237

kW(S) red.
kW(S) red.
E
kW(W) 397 kW(W) 397
°C °C
m m
(EK)Prendere nota dalla tabella 5 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza (EK)Prendere nota dalla tabella 5 delle dimensioni d’ingombro (EK) della pompa d’iniezione in corrispondenza
al codice EP, nel nostro caso 146,9 mm. al codice EP, nel nostro caso 146,9 mm.
Tabella 5 Tabella 5
144,5 145,1 145,7 349 146,3 373 146,9 397 144,5 145,1 145,7 349 146,3 373 146,9 397
144,525 145,125 145,725 350 146,325 374 146,925 398 144,525 145,125 145,725 350 146,325 374 146,925 398
144,55 145,15 145,75 351 146,35 375 146,95 399 144,55 145,15 145,75 351 146,35 375 146,95 399
144,575 145,175 145,775 352 146,375 376 146,975 400 144,575 145,175 145,775 352 146,375 376 146,975 400
144,6 145,2 145,8 353 146,4 377 147,0 401 144,6 145,2 145,8 353 146,4 377 147,0 401
144,625 145,225 145,825 354 146,425 378 147,025 144,625 145,225 145,825 354 146,425 378 147,025
144,65 145,25 145,85 355 146,45 379 147,05 144,65 145,25 145,85 355 146,45 379 147,05
144,675 145,275 145,875 356 146,475 380 147,075 144,675 145,275 145,875 356 146,475 380 147,075
144,7 145,3 145,9 357 146,5 381 147,1 144,7 145,3 145,9 357 146,5 381 147,1
144,725 145,325 145,925 358 146,525 382 147,125 144,725 145,325 145,925 358 146,525 382 147,125
144,75 145,35 335 145,95 359 146,55 383 147,15 144,75 145,35 335 145,95 359 146,55 383 147,15
144,775 145,375 336 145,975 360 146,575 384 147,175 144,775 145,375 336 145,975 360 146,575 384 147,175
144,8 145,4 337 146,0 361 146,6 385 147,2 144,8 145,4 337 146,0 361 146,6 385 147,2
144,825 145,425 338 146,025 362 146,625 386 147,225 144,825 145,425 338 146,025 362 146,625 386 147,225
144,85 145,45 339 146,05 363 146,65 387 147,25 144,85 145,45 339 146,05 363 146,65 387 147,25
144,875 145,475 340 146,075 364 146,675 388 147,275 144,875 145,475 340 146,075 364 146,675 388 147,275
144,9 145,5 341 146,1 365 146,7 389 147,3 144,9 145,5 341 146,1 365 146,7 389 147,3
144,925 145,525 342 146,125 366 146,725 390 147,325 144,925 145,525 342 146,125 366 146,725 390 147,325
144,95 145,55 343 146,15 367 146,75 391 147,35 144,95 145,55 343 146,15 367 146,75 391 147,35
144,975 145,575 344 146,175 368 146,775 392 147,375 144,975 145,575 344 146,175 368 146,775 392 147,375
145,0 145,6 345 146,2 369 146,8 393 147,4 145,0 145,6 345 146,2 369 146,8 393 147,4
145,025 145,625 346 146,225 370 146,825 394 147,425 145,025 145,625 346 146,225 370 146,825 394 147,425
145,05 145,65 347 146,25 371 146,85 395 147,45 145,05 145,65 347 146,25 371 146,85 395 147,45
145,075 145,675 348 146,275 372 146,875 396 147,475 145,075 145,675 348 146,275 372 146,875 396 147,475
TS = EK - (L0 + A/100) TS = EK - (L0 + A/100)
TS = 2,57 mm TS = 2,57 mm
© 05/00 1.00.17 1.00.17 © 05/00

Korrigiertes Einbaumaß (EK) und EP-Code ermitteln für Bosch Einspritzpumpe.
Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muß das korrigierte Einbaumaß (EK) neu ermittelt Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muß das korrigierte Einbaumaß (EK) neu ermittelt
und der dazugehörende EP-Code auf dem Firmenschild geändert werden. und der dazugehörende EP-Code auf dem Firmenschild geändert werden.
Tabellen siehe Seite 1.00.13 und 1.00.15 / 1.00.15.1 / 1.00.17 Tabellen siehe Seite 1.00.13 und 1.00.15 / 1.00.15.1 / 1.00.17
1 1

FB Ist gemessen °Kw 8 8 10 FB Ist gemessen °Kw 8 8 10
FB Nenn aus Tabelle 1 °Kw 9 9 10 FB Nenn aus Tabelle 1 °Kw 9 9 10
Vh Korr.faktor aus Tab.1 mm/°Kw 0,1 0,1 0,1 Vh Korr.faktor aus Tab.1 mm/°Kw 0,1 0,1 0,1
E1 = FB Ist - FB Nenn °Kw -1 -1 0 E1 = FB Ist - FB Nenn °Kw -1 -1 0

EK = L - E3 mm 111,73 122,04 146,91 EK = L - E3 mm 111,73 122,04 146,91
EK symmetrisch gerundet mm 111,725 122,05 146,9 EK symmetrisch gerundet mm 111,725 122,05 146,9
EP-Code aus Tabelle 3 070 EP-Code aus Tabelle 3 070
© 05/00 1.00.19 1.00.19 © 05/00

Korrigiertes Einbaumaß (EK) und EP-Code ermitteln für Bosch Einspritzpumpe.
Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muß das korrigierte Einbaumaß (EK) neu ermittelt Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muß das korrigierte Einbaumaß (EK) neu ermittelt
und der dazugehörende EP-Code auf dem Firmenschild geändert werden. und der dazugehörende EP-Code auf dem Firmenschild geändert werden.
Tabellen siehe Seite 1.00.13 und 1.00.15 / 1.00.15.1 / 1.00.17 Tabellen siehe Seite 1.00.13 und 1.00.15 / 1.00.15.1 / 1.00.17
1 1

FB Ist gemessen °Kw 8 8 10 FB Ist gemessen °Kw 8 8 10
FB Nenn aus Tabelle 1 °Kw 9 9 10 FB Nenn aus Tabelle 1 °Kw 9 9 10
Vh Korr.faktor aus Tab.1 mm/°Kw 0,1 0,1 0,1 Vh Korr.faktor aus Tab.1 mm/°Kw 0,1 0,1 0,1
E1 = FB Ist - FB Nenn °Kw -1 -1 0 E1 = FB Ist - FB Nenn °Kw -1 -1 0

EK = L - E3 mm 111,73 122,04 146,91 EK = L - E3 mm 111,73 122,04 146,91
EK symmetrisch gerundet mm 111,725 122,05 146,9 EK symmetrisch gerundet mm 111,725 122,05 146,9
© 05/00 1.00.19 1.00.19 © 05/00

Determining corrected installation dimension (EK) and EP code for Bosch
injection pump.
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be
determined once again and the relevant EP code on the nameplate must be changed. determined once again and the relevant EP code on the nameplate must be changed.
For tables see pages 1.00.13 and 1.00.15 / 1.00.15.1 / 1.00.17 For tables see pages 1.00.13 and 1.00.15 / 1.00.15.1 / 1.00.17
1 1
Cylnder No. 0 0 1 2 0 1 2 3 Cylnder No. 0 0 1 2 0 1 2 3

FB nom. from table °C/A 9 9 10 FB nom. from table °C/A 9 9 10
Vh corr.factor from tab.1 mm/°C/A 0.1 0,1 0.1 Vh corr.factor from tab.1 mm/°C/A 0.1 0,1 0.1
E1 = FB actual - FB nom °C/A -1 -1 0 E1 = FB actual - FB nom °C/A -1 -1 0

E2 = E1 x Vh corr.factor mm -0.1 -0. 1 0 E2 = E1 x Vh corr.factor mm -0.1 -0. 1 0
EK = L - E3 mm 111.73 122.04 146.91 EK = L - E3 mm 111.73 122.04 146.91
EK symm. rounded mm 111.725 122.05 146.9 EK symm. rounded mm 111.725 122.05 146.9
EP code from table 3 070 EP code from table 3 070
© 05/00 1.00.19 1.00.19 © 05/00

Determining corrected installation dimension (EK) and EP code for Bosch
injection pump.
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be
determined once again and the relevant EP code on the nameplate must be changed. determined once again and the relevant EP code on the nameplate must be changed.
For tables see pages 1.00.13 and 1.00.15 / 1.00.15.1 / 1.00.17 For tables see pages 1.00.13 and 1.00.15 / 1.00.15.1 / 1.00.17
1 1
Cylnder No. 0 0 1 2 0 1 2 3 Cylnder No. 0 0 1 2 0 1 2 3

FB nom. from table °C/A 9 9 10 FB nom. from table °C/A 9 9 10
Vh corr.factor from tab.1 mm/°C/A 0.1 0,1 0.1 Vh corr.factor from tab.1 mm/°C/A 0.1 0,1 0.1
E1 = FB actual - FB nom °C/A -1 -1 0 E1 = FB actual - FB nom °C/A -1 -1 0

E2 = E1 x Vh corr.factor mm -0.1 -0. 1 0 E2 = E1 x Vh corr.factor mm -0.1 -0. 1 0
EK = L - E3 mm 111.73 122.04 146.91 EK = L - E3 mm 111.73 122.04 146.91
EK symm. rounded mm 111.725 122.05 146.9 EK symm. rounded mm 111.725 122.05 146.9
© 05/00 1.00.19 1.00.19 © 05/00

Calculer la cote de montage corrigée (EK) et le code EP pour la pompe
d’injection Bosch
En cas de changement du carter moteur, de l’arbre à came ou du poussoir à galet recalculer à nouveau la cote de En cas de changement du carter moteur, de l’arbre à came ou du poussoir à galet recalculer à nouveau la cote de
montage corrigée (EK), le code EP se trouvant sur la plaque d’identification du constructeur doit être modifié. montage corrigée (EK), le code EP se trouvant sur la plaque d’identification du constructeur doit être modifié.
Tableau voir page 1.00.13 et 1.00.15 / 1.00.15.1 / 1.00.17 Tableau voir page 1.00.13 et 1.00.15 / 1.00.15.1 / 1.00.17
1 1

FB réel mesuré °vil. 8 8 10 FB réel mesuré °vil. 8 8 10
FB nominal indiqué dans le tableau 1 °vil. 9 9 10 FB nominal indiqué dans le tableau 1 °vil. 9 9 10
Vh facteur de correction indiqué Vh facteur de correction indiqué
dans le tableau 1 mm/°vil. 0,1 0,1 0,1 dans le tableau 1 mm/°vil. 0,1 0,1 0,1
Vh nominal indiqué dans le tableau 1 mm 4,63 4,63 5,31 Vh nominal indiqué dans le tableau 1 mm 4,63 4,63 5,31
E1 = FB réel - FB nominal °vil. -1 -1 0 E1 = FB réel - FB nominal °vil. -1 -1 0

E3 = E2 + Vh nominal mm 4,53 4,53 5,31 E3 = E2 + Vh nominal mm 4,53 4,53 5,31
EK = L - E3 mm 111,73 122,04 146,91 EK = L - E3 mm 111,73 122,04 146,91
EK arrondi symétrique mm 111,725 122,05 146,9 EK arrondi symétrique mm 111,725 122,05 146,9
Code EP tableau 3 070 Code EP tableau 3 070
© 05/00 1.00.19 1.00.19 © 05/00

Calculer la cote de montage corrigée (EK) et le code EP pour la pompe
d’injection Bosch
En cas de changement du carter moteur, de l’arbre à came ou du poussoir à galet recalculer à nouveau la cote de En cas de changement du carter moteur, de l’arbre à came ou du poussoir à galet recalculer à nouveau la cote de
montage corrigée (EK), le code EP se trouvant sur la plaque d’identification du constructeur doit être modifié. montage corrigée (EK), le code EP se trouvant sur la plaque d’identification du constructeur doit être modifié.
Tableau voir page 1.00.13 et 1.00.15 / 1.00.15.1 / 1.00.17 Tableau voir page 1.00.13 et 1.00.15 / 1.00.15.1 / 1.00.17
1 1

FB réel mesuré °vil. 8 8 10 FB réel mesuré °vil. 8 8 10
FB nominal indiqué dans le tableau 1 °vil. 9 9 10 FB nominal indiqué dans le tableau 1 °vil. 9 9 10
Vh facteur de correction indiqué Vh facteur de correction indiqué
dans le tableau 1 mm/°vil. 0,1 0,1 0,1 dans le tableau 1 mm/°vil. 0,1 0,1 0,1
Vh nominal indiqué dans le tableau 1 mm 4,63 4,63 5,31 Vh nominal indiqué dans le tableau 1 mm 4,63 4,63 5,31
E1 = FB réel - FB nominal °vil. -1 -1 0 E1 = FB réel - FB nominal °vil. -1 -1 0

E3 = E2 + Vh nominal mm 4,53 4,53 5,31 E3 = E2 + Vh nominal mm 4,53 4,53 5,31
EK = L - E3 mm 111,73 122,04 146,91 EK = L - E3 mm 111,73 122,04 146,91
EK arrondi symétrique mm 111,725 122,05 146,9 EK arrondi symétrique mm 111,725 122,05 146,9
© 05/00 1.00.19 1.00.19 © 05/00

Determinazione delle misure d’ingombro corrette (EK) e del Codice EP
per la pompa d’iniezione Bosch.
Nel caso di sostituzione dell’incastellatura motore, dell’albero a camme o della punteria a rullo, si deve procedere a Nel caso di sostituzione dell’incastellatura motore, dell’albero a camme o della punteria a rullo, si deve procedere a
calcolare nuovamente le misure d’ingombro corrette (EK), nonché a modificare il relativo codice EP sulla targhetta calcolare nuovamente le misure d’ingombro corrette (EK), nonché a modificare il relativo codice EP sulla targhetta
del motore. del motore.
Vedere le tabelle alle pagine 1.00.13 ed 1.00.15 / 1.00.15.1 / 1.00.17 Vedere le tabelle alle pagine 1.00.13 ed 1.00.15 / 1.00.15.1 / 1.00.17
1 1

L0 come da tabella 1 mm 109 119 143 L0 come da tabella 1 mm 109 119 143
FB Nenn aus Tabelle 1 °alb.mot. 9 9 10 FB Nenn aus Tabelle 1 °alb.mot. 9 9 10
E1 = FBreale - FBnom. °alb.mot. -1 -1 0 E1 = FBreale - FBnom. °alb.mot. -1 -1 0

E2 = E1 x fattore correzione Vh mm -0,1 -0,1 0 E2 = E1 x fattore correzione Vh mm -0,1 -0,1 0
E3 = E2 + Vh nominale mm 4,53 4,53 5,31 E3 = E2 + Vh nominale mm 4,53 4,53 5,31
EK = L - E3 mm 111,73 122,04 146,91 EK = L - E3 mm 111,73 122,04 146,91
EK arrotondato simmetricam mm 111,725 122,05 146,9 EK arrotondato simmetricam mm 111,725 122,05 146,9
Codice Ep come da tabella 3 070 Codice Ep come da tabella 3 070
© 05/00 1.00.19 1.00.19 © 05/00

Determinazione delle misure d’ingombro corrette (EK) e del Codice EP
per la pompa d’iniezione Bosch.
Nel caso di sostituzione dell’incastellatura motore, dell’albero a camme o della punteria a rullo, si deve procedere a Nel caso di sostituzione dell’incastellatura motore, dell’albero a camme o della punteria a rullo, si deve procedere a
calcolare nuovamente le misure d’ingombro corrette (EK), nonché a modificare il relativo codice EP sulla targhetta calcolare nuovamente le misure d’ingombro corrette (EK), nonché a modificare il relativo codice EP sulla targhetta
del motore. del motore.
Vedere le tabelle alle pagine 1.00.13 ed 1.00.15 / 1.00.15.1 / 1.00.17 Vedere le tabelle alle pagine 1.00.13 ed 1.00.15 / 1.00.15.1 / 1.00.17
1 1

L0 come da tabella 1 mm 109 119 143 L0 come da tabella 1 mm 109 119 143
FB Nenn aus Tabelle 1 °alb.mot. 9 9 10 FB Nenn aus Tabelle 1 °alb.mot. 9 9 10
E1 = FBreale - FBnom. °alb.mot. -1 -1 0 E1 = FBreale - FBnom. °alb.mot. -1 -1 0

E2 = E1 x fattore correzione Vh mm -0,1 -0,1 0 E2 = E1 x fattore correzione Vh mm -0,1 -0,1 0
E3 = E2 + Vh nominale mm 4,53 4,53 5,31 E3 = E2 + Vh nominale mm 4,53 4,53 5,31
EK = L - E3 mm 111,73 122,04 146,91 EK = L - E3 mm 111,73 122,04 146,91
EK arrotondato simmetricam mm 111,725 122,05 146,9 EK arrotondato simmetricam mm 111,725 122,05 146,9
© 05/00 1.00.19 1.00.19 © 05/00

Bildzeichenerklärung
Bildzeichenerklärung Bildzeichenerklärung
Zerlegen Personenschäden verhüten Zerlegen Personenschäden verhüten
von Baugruppen Hinweis auf Gefahrenstelle von Baugruppen Hinweis auf Gefahrenstelle
1 1
Zusammenbauen Materialschaden verhüten Zusammenbauen Materialschaden verhüten
zu einer Baugruppe Teilbeschädigung zu einer Baugruppe Teilbeschädigung
Abbauen - Ausbauen Unterbauen - Abstützen - Abbauen - Ausbauen Unterbauen - Abstützen -

Abfangen Abfangen
behindernder Teile behindernder Teile
Einbauen - Anbauen Einölen Einbauen - Anbauen Einölen
Teile, die beim Ab-/ Ausbau hinderten Teile, die beim Ab-/ Ausbau hinderten
Achtung, wichtiger Hinweis Einfetten Achtung, wichtiger Hinweis Einfetten
Prüfen - Einstellen Markieren Prüfen - Einstellen Markieren

vor dem Zerlegen, beachten beim vor dem Zerlegen, beachten beim
z. B. Drehmomente, Maße, Drücke usw. Zusammenbau z. B. Drehmomente, Maße, Drücke usw. Zusammenbau
Spezialwerkzeug Wuchten Spezialwerkzeug Wuchten
Ausgleichen von Unwuchten Ausgleichen von Unwuchten
Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen
z. B. Öl, Kühlwasser usw. z. B. Öl, Kühlwasser usw.
Kontrollieren - Prüfen Ablassen Kontrollieren - Prüfen Ablassen
Sichtprüfung z. B. Öl, Kühlwasser usw. Sichtprüfung z. B. Öl, Kühlwasser usw.
Bedingt wiederverwendbar Lösen Bedingt wiederverwendbar Lösen
Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung
Beim Zusammenbau immer Spannen Beim Zusammenbau immer Spannen

erneuern erneuern
z. B. Anziehen einer Spanneinrichtung z. B. Anziehen einer Spanneinrichtung
Entsichern - Sichern Entlüften Entsichern - Sichern Entlüften
z. B. Splint, Sicherungsblech usw. z. B. Splint, Sicherungsblech usw.
Sichern - Kleben Spanabhebende Bearbeitung Sichern - Kleben Spanabhebende Bearbeitung
z. B. Dichtmittel flüssig z. B. Dichtmittel flüssig
© 05/00 1.00.21 1.00.21 © 05/00

Bildzeichenerklärung
Bildzeichenerklärung Bildzeichenerklärung
Zerlegen Personenschäden verhüten Zerlegen Personenschäden verhüten
von Baugruppen Hinweis auf Gefahrenstelle von Baugruppen Hinweis auf Gefahrenstelle
1 1
Zusammenbauen Materialschaden verhüten Zusammenbauen Materialschaden verhüten
zu einer Baugruppe Teilbeschädigung zu einer Baugruppe Teilbeschädigung
Abbauen - Ausbauen Unterbauen - Abstützen - Abbauen - Ausbauen Unterbauen - Abstützen -

Abfangen Abfangen
behindernder Teile behindernder Teile
Einbauen - Anbauen Einölen Einbauen - Anbauen Einölen
Teile, die beim Ab-/ Ausbau hinderten Teile, die beim Ab-/ Ausbau hinderten
Achtung, wichtiger Hinweis Einfetten Achtung, wichtiger Hinweis Einfetten
Prüfen - Einstellen Markieren Prüfen - Einstellen Markieren

vor dem Zerlegen, beachten beim vor dem Zerlegen, beachten beim
z. B. Drehmomente, Maße, Drücke usw. Zusammenbau z. B. Drehmomente, Maße, Drücke usw. Zusammenbau
Spezialwerkzeug Wuchten Spezialwerkzeug Wuchten
Ausgleichen von Unwuchten Ausgleichen von Unwuchten
Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen
z. B. Öl, Kühlwasser usw. z. B. Öl, Kühlwasser usw.
Kontrollieren - Prüfen Ablassen Kontrollieren - Prüfen Ablassen
Sichtprüfung z. B. Öl, Kühlwasser usw. Sichtprüfung z. B. Öl, Kühlwasser usw.
Bedingt wiederverwendbar Lösen Bedingt wiederverwendbar Lösen
Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung
Beim Zusammenbau immer Spannen Beim Zusammenbau immer Spannen

erneuern erneuern
z. B. Anziehen einer Spanneinrichtung z. B. Anziehen einer Spanneinrichtung
Entsichern - Sichern Entlüften Entsichern - Sichern Entlüften
z. B. Splint, Sicherungsblech usw. z. B. Splint, Sicherungsblech usw.
Sichern - Kleben Spanabhebende Bearbeitung Sichern - Kleben Spanabhebende Bearbeitung
z. B. Dichtmittel flüssig z. B. Dichtmittel flüssig
© 05/00 1.00.21 1.00.21 © 05/00

Key to Symbols
Key to Symbols Key to Symbols

Disassembly Guard against personal injury Disassembly Guard against personal injury
of assembly groups Indication of hazard of assembly groups Indication of hazard

1 1
Reassembly Guard against material damage Reassembly Guard against material damage
to form assembly group Damage to parts to form assembly group Damage to parts
Remove Prop up - Support - Hold Remove Prop up - Support - Hold
obstructing parts obstructing parts
Reinstall - Remount Oil Reinstall - Remount Oil
parts which had obstructed disassembly parts which had obstructed disassembly
Attention! Impartant notice! Grease Attention! Impartant notice! Grease
Check - Adjust Mark Check - Adjust Mark

before disassembly, observe marks when before disassembly, observe marks when
e. g. torque dimensions, pressures, etc. reassembling e. g. torque dimensions, pressures, etc. reassembling
Special tool Balance Special tool Balance
Eliminate any imbalance Eliminate any imbalance
Note direction of installation Filling - Topping up - Refilling Note direction of installation Filling - Topping up - Refilling
e. g. oil, cooling water, etc. e. g. oil, cooling water, etc.
Visual inspection Drain off Visual inspection Drain off
Possibly still serviceable Loosen - Release Possibly still serviceable Loosen - Release
Renew if necessary e. g. loosening a clamping device Renew if necessary e. g. loosening a clamping device
Renew at each reassembly Tighten - Clamp Renew at each reassembly Tighten - Clamp
e. g. tightening a clamping device e. g. tightening a clamping device
Unlock - Lock Vent Unlock - Lock Vent
e. g. split pin, locking plate, etc. e. g. split pin, locking plate, etc.
Lock - Adhere Machining process Lock - Adhere Machining process
e. g. with liquid sealant e. g. with liquid sealant
© 05/00 1.00.21 1.00.21 © 05/00

Key to Symbols
Key to Symbols Key to Symbols

Disassembly Guard against personal injury Disassembly Guard against personal injury
of assembly groups Indication of hazard of assembly groups Indication of hazard

1 1
Reassembly Guard against material damage Reassembly Guard against material damage
to form assembly group Damage to parts to form assembly group Damage to parts
Remove Prop up - Support - Hold Remove Prop up - Support - Hold
obstructing parts obstructing parts
Reinstall - Remount Oil Reinstall - Remount Oil
parts which had obstructed disassembly parts which had obstructed disassembly
Attention! Impartant notice! Grease Attention! Impartant notice! Grease
Check - Adjust Mark Check - Adjust Mark

before disassembly, observe marks when before disassembly, observe marks when
e. g. torque dimensions, pressures, etc. reassembling e. g. torque dimensions, pressures, etc. reassembling
Special tool Balance Special tool Balance
Eliminate any imbalance Eliminate any imbalance
Note direction of installation Filling - Topping up - Refilling Note direction of installation Filling - Topping up - Refilling
Visual inspection Drain off Visual inspection Drain off
Possibly still serviceable Loosen - Release Possibly still serviceable Loosen - Release
Renew if necessary e. g. loosening a clamping device Renew if necessary e. g. loosening a clamping device
Renew at each reassembly Tighten - Clamp Renew at each reassembly Tighten - Clamp
e. g. tightening a clamping device e. g. tightening a clamping device
Unlock - Lock Vent Unlock - Lock Vent
e. g. split pin, locking plate, etc. e. g. split pin, locking plate, etc.
Lock - Adhere Machining process Lock - Adhere Machining process
e. g. with liquid sealant e. g. with liquid sealant
© 05/00 1.00.21 1.00.21 © 05/00

Légende des symboles
Légende des symboles Légende des symboles

Déassemblage Prévention aux accidents profession Déassemblage Prévention aux accidents profession
d’un ensemble constructif attirer l’attention sur un risque eventuel d’un ensemble constructif attirer l’attention sur un risque eventuel
d’ accident
1 1 d’ accident
Assemblage Prévention à la détérioration de Assemblage Prévention à la détérioration de

matériels matériels
des composants d’un ensemble constructif Risque d’endommager des piéces des composants d’un ensemble constructif Risque d’endommager des piéces
Démontage Monter sur tréteaux - freiner par Démontage Monter sur tréteaux - freiner par
sabots - immobiliser par un moyen sabots - immobiliser par un moyen
d’eléments entravant l’accés quelconque d’eléments entravant l’accés quelconque
Remontage - Remise en place Huiler Remontage - Remise en place Huiler
d’eléments qui entravaient l’accés d’eléments qui entravaient l’accés
Remarque importante! Graisser Remarque importante! Graisser
employer lubrificant plastique employer lubrificant plastique
Utilisation impérative Repérage en cours de démontage Utilisation impérative Repérage en cours de démontage
p. ex.: couple-moteur, cotes, pressions etc. permet un remontage correct! p. ex.: couple-moteur, cotes, pressions etc. permet un remontage correct!
Utilisation impérative Equilibrer Utilisation impérative Equilibrer
d’un outil specialise éliminer le balourd d’un outil specialise éliminer le balourd
Respecter l’ordre de montage Premier garnissage - remplissage - Respecter l’ordre de montage Premier garnissage - remplissage -
garnissage d’appoint garnissage d’appoint
p. ex.: Huile eau de refroidissement etc. p. ex.: Huile eau de refroidissement etc.
Vérification - Contrôle Vidanger - soutirer Vérification - Contrôle Vidanger - soutirer
à vue p. ex.: Huile eau de refroidissement etc. à vue p. ex.: Huile eau de refroidissement etc.
Réutilisation sous certaines Desserrer Réutilisation sous certaines Desserrer

conditions conditions
à remplacer,si besoin est p. ex.: desserrage d’un dispositiv à remplacer,si besoin est p. ex.: desserrage d’un dispositiv
A remplacer systématiquement Serrer A remplacer systématiquement Serrer
lors de remontage p. ex.: serrage entre un dispositif lors de remontage p. ex.: serrage entre un dispositif
Arracher la goupille - goupiller Faire la purge d’air Arracher la goupille - goupiller Faire la purge d’air
freiner par tôle-arrétoir freiner par tôle-arrétoir
Freiner - coller Usinage par enlèvement de copeaux Freiner - coller Usinage par enlèvement de copeaux
p. ex. avec páte hermétique, ou frein liquide p. ex. avec páte hermétique, ou frein liquide
© 05/00 1.00.21 1.00.21 © 05/00

Légende des symboles
Légende des symboles Légende des symboles

Déassemblage Prévention aux accidents profession Déassemblage Prévention aux accidents profession
d’un ensemble constructif attirer l’attention sur un risque eventuel d’un ensemble constructif attirer l’attention sur un risque eventuel
d’ accident
1 1 d’ accident
Assemblage Prévention à la détérioration de Assemblage Prévention à la détérioration de

matériels matériels
des composants d’un ensemble constructif Risque d’endommager des piéces des composants d’un ensemble constructif Risque d’endommager des piéces
Démontage Monter sur tréteaux - freiner par Démontage Monter sur tréteaux - freiner par
sabots - immobiliser par un moyen sabots - immobiliser par un moyen
d’eléments entravant l’accés quelconque d’eléments entravant l’accés quelconque
Remontage - Remise en place Huiler Remontage - Remise en place Huiler
d’eléments qui entravaient l’accés d’eléments qui entravaient l’accés
Remarque importante! Graisser Remarque importante! Graisser
employer lubrificant plastique employer lubrificant plastique
Utilisation impérative Repérage en cours de démontage Utilisation impérative Repérage en cours de démontage
p. ex.: couple-moteur, cotes, pressions etc. permet un remontage correct! p. ex.: couple-moteur, cotes, pressions etc. permet un remontage correct!
Utilisation impérative Equilibrer Utilisation impérative Equilibrer
d’un outil specialise éliminer le balourd d’un outil specialise éliminer le balourd
Respecter l’ordre de montage Premier garnissage - remplissage - Respecter l’ordre de montage Premier garnissage - remplissage -
garnissage d’appoint garnissage d’appoint
p. ex.: Huile eau de refroidissement etc. p. ex.: Huile eau de refroidissement etc.
Vérification - Contrôle Vidanger - soutirer Vérification - Contrôle Vidanger - soutirer
à vue p. ex.: Huile eau de refroidissement etc. à vue p. ex.: Huile eau de refroidissement etc.
Réutilisation sous certaines Desserrer Réutilisation sous certaines Desserrer

conditions conditions
à remplacer,si besoin est p. ex.: desserrage d’un dispositiv à remplacer,si besoin est p. ex.: desserrage d’un dispositiv
A remplacer systématiquement Serrer A remplacer systématiquement Serrer
lors de remontage p. ex.: serrage entre un dispositif lors de remontage p. ex.: serrage entre un dispositif
Arracher la goupille - goupiller Faire la purge d’air Arracher la goupille - goupiller Faire la purge d’air
freiner par tôle-arrétoir freiner par tôle-arrétoir
Freiner - coller Usinage par enlèvement de copeaux Freiner - coller Usinage par enlèvement de copeaux
p. ex. avec páte hermétique, ou frein liquide p. ex. avec páte hermétique, ou frein liquide
© 05/00 1.00.21 1.00.21 © 05/00

Spiegazioni dei simboli
Spiegazioni dei simboli Spiegazioni dei simboli

Scomporre Prevenire danni alle persone Scomporre Prevenire danni alle persone
gruppi di componenti Indicazione di pericolo gruppi di componenti Indicazione di pericolo

1 1
Riassemblare Evitare danni ai materiali Riassemblare Evitare danni ai materiali
i componenti di un gruppo Danneggiamento di particolari i componenti di un gruppo Danneggiamento di particolari
Smontare Puntellare - Supportare - Smontare Puntellare - Supportare -
le parti che erano di ostacolo le parti che erano di ostacolo
Rimontare Oliare Rimontare Oliare
le parti che sono di ostacolo le parti che sono di ostacolo
Attenzione, indicazione importante Ingrassare Attenzione, indicazione importante Ingrassare
Controllare – Regolare Contrassegnare Controllare – Regolare Contrassegnare

prima dello smontaggio prima dello smontaggio
per esempio coppie, misure, pressioni, ecc. per esempio coppie, misure, pressioni, ecc.
Attrezzo speciale Equilibrare Attrezzo speciale Equilibrare
Compensare gli squilibri Compensare gli squilibri
Prestare attenzione al senso Riempire – Rabboccare Prestare attenzione al senso Riempire – Rabboccare
di montaggio di montaggio
per esempio olio, liquido refrigerante, ecc. per esempio olio, liquido refrigerante, ecc.
Controllare – Provare Scaricare Controllare – Provare Scaricare
Controllo visivo per esempio olio, liquido refrigerante, ecc. Controllo visivo per esempio olio, liquido refrigerante, ecc.
Può venire riutilizzato Allentare - Slegare Può venire riutilizzato Allentare - Slegare
per esempio allentare un dispositivo per esempio allentare un dispositivo
Se necessario, sostituire di bloccaggio Se necessario, sostituire di bloccaggio
Sostituire in occasione di Tendere - Stringere Sostituire in occasione di Tendere - Stringere

ogni riassemblaggio per esempio serrare un dispositivo ogni riassemblaggio per esempio serrare un dispositivo
di bloccaggio di bloccaggio
Sbloccare – Bloccare Sfiatare - Ventilare Sbloccare – Bloccare Sfiatare - Ventilare
per esempio copiglia, rosetta di sicurezza, ecc. per esempio copiglia, rosetta di sicurezza, ecc.
Fissare, incollare Lavorazione con asportazione Fissare, incollare Lavorazione con asportazione
di trucioli di trucioli
per esempio ermetico liquido per esempio ermetico liquido
© 05/00 1.00.21 1.00.21 © 05/00

Spiegazioni dei simboli
Spiegazioni dei simboli Spiegazioni dei simboli

Scomporre Prevenire danni alle persone Scomporre Prevenire danni alle persone
gruppi di componenti Indicazione di pericolo gruppi di componenti Indicazione di pericolo

1 1
Riassemblare Evitare danni ai materiali Riassemblare Evitare danni ai materiali
i componenti di un gruppo Danneggiamento di particolari i componenti di un gruppo Danneggiamento di particolari
Smontare Puntellare - Supportare - Smontare Puntellare - Supportare -
le parti che erano di ostacolo le parti che erano di ostacolo
Rimontare Oliare Rimontare Oliare
le parti che sono di ostacolo le parti che sono di ostacolo
Attenzione, indicazione importante Ingrassare Attenzione, indicazione importante Ingrassare
Controllare – Regolare Contrassegnare Controllare – Regolare Contrassegnare

prima dello smontaggio prima dello smontaggio
per esempio coppie, misure, pressioni, ecc. per esempio coppie, misure, pressioni, ecc.
Attrezzo speciale Equilibrare Attrezzo speciale Equilibrare
Compensare gli squilibri Compensare gli squilibri
Prestare attenzione al senso Riempire – Rabboccare Prestare attenzione al senso Riempire – Rabboccare
di montaggio di montaggio
per esempio olio, liquido refrigerante, ecc. per esempio olio, liquido refrigerante, ecc.
Controllare – Provare Scaricare Controllare – Provare Scaricare
Controllo visivo per esempio olio, liquido refrigerante, ecc. Controllo visivo per esempio olio, liquido refrigerante, ecc.
Può venire riutilizzato Allentare - Slegare Può venire riutilizzato Allentare - Slegare
per esempio allentare un dispositivo per esempio allentare un dispositivo
Se necessario, sostituire di bloccaggio Se necessario, sostituire di bloccaggio
Sostituire in occasione di Tendere - Stringere Sostituire in occasione di Tendere - Stringere

ogni riassemblaggio per esempio serrare un dispositivo ogni riassemblaggio per esempio serrare un dispositivo
di bloccaggio di bloccaggio
Sbloccare – Bloccare Sfiatare - Ventilare Sbloccare – Bloccare Sfiatare - Ventilare
per esempio copiglia, rosetta di sicurezza, ecc. per esempio copiglia, rosetta di sicurezza, ecc.
Fissare, incollare Lavorazione con asportazione Fissare, incollare Lavorazione con asportazione
di trucioli di trucioli
per esempio ermetico liquido per esempio ermetico liquido
© 05/00 1.00.21 1.00.21 © 05/00

Controlli e regolazioni BFM 1012/1013
© 05/00
Inhalts-Verzeichnis Prüfen und Einstellen
Table of Contents Checking and adjusting
Sommaire Contrôle et réglage
Indice Controlli e regolazioni
Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E
2. Prüfen und Einstellen Seite
Ventilspiel _______________________________________ 2.00.01 - 2.00.02

Kompressionsdruck _______________________________________ 2.00.03 - 2.00.04
Einspritzventil _______________________________________ 2.00.05 - 2.00.07
English
2. Checking and adjusting Page
Valve clearance _______________________________________ 2.00.01 - 2.00.02

Compression pressure _______________________________________ 2.00.03 - 2.00.04 2
Injector _______________________________________ 2.00.05 - 2.00.07
Français
2. Contrôle et réglage Page
Jeu aux soupapes _______________________________________ 2.00.01 - 2.00.02

Taux de compression _______________________________________ 2.00.03 - 2.00.04
Soupape injectrice _______________________________________ 2.00.05 - 2.00.07
Italiano
2. Controlli e regolazioni Pagina
Gioco delle valvole _______________________________________ 2.00.01 - 2.00.02

Pressione di compressione _______________________________________ 2.00.03 - 2.00.04
Iniettore _______________________________________ 2.00.05 - 2.00.07
© 05/00
Prüfen und Einstellen Ventilspiel
Checking and adjusting Valve clearance
Contrôle et réglage Jeu de soupapes
Controlli e regolazioni Gioco delle valvole
Special tool required: Outillage usuel: Attrezzo speciale:
Turning gear 100 320 Dispositif vireur 100 320 Dispositivo di viraggio 100.320
Turning gear 100 330 Dispositif vireur 100 330 Dispositivo di viraggio 100.330
The standard valve clearance can be Le réglage standard du jeu aux E’ possibile eseguire la regolazione
adjusted: soupapes est possible: standard del gioco delle valvole:
with engine cold or warm after cooling Sur moteur froid ou chaud après une sia a motore freddo che a motore
down for at least 0.5 h. période de refroidissement d’au moins caldo dopo un tempo minimo do
Oil temperature ≤ 80°C. 30 minutes. Température de l’huile raffreddamento di 0,5 h.
≤ 80°C. Temperatura dell’olio ≤ 80°C.
Note: The valve clearance is to be Nota: à chaque changement du joint Nota: Dopo ogni sostituzione della
increased by 0.1 mm at every de culasse augmenter le jeu aux guarnizione della testa, il gioco
cylinder head gasket renewal. culbuteurs de 0,1 mm. delle valvole deve venire
The standard valve clearance is Après 50-150 heures de marche aumentato di 0,1 mm. Dopo
2 to be adjusted after completion procéder au réglage standard 50-150 h di funzionamento il
of 50-150 hours of operation. des culbuteurs. gioco delle valvole deve venire
riportato sul suo valore standard.
Cylinder head cover and crankcase Le cache-culbuteurs et l’évent de
breather have been removed carter ont été déposés. Il coperchio delle punterie e lo sfiato
del motore sono smontati.
1. Turn engine until valves of cyl. 1. Virer le moteur jusqu’à ce que les 1. Virare il motore fino a portare
No. 1 overlap. soupapes soient en bascule, le valvole del cilindro nr. 1 nella
cyl. no. 1. posizione di sovrapposizione.
See specification data for valve Schéma de réglage du jeu aux Schema di registrazione del gioco
clearance adjustment schematic. culbuteurs voir caractéristiques delle valvole: vedere la tabella dei
techniques. dati tecnici
1.1 If the engine is not freely accessible 1.1 Si la poulie à gorge du moteur 1.1 Nel caso in cui la puleggia della
at the V-belt pulley, turning gear n´est pas bien accessible, utiliser, cinghia trapezoidale non sia acces-
100 320 may be used with the après avoir déposé la pompe sibile, dopo aver smontato la
hydraulic pump removed. hydraulique, le dispositif vireur pompa idraulica si può utilizzare il
100 320. dispositivo di viraggio 100.320.
Note: Valves overlapping means: Nota: le chevauchement des Nota: Posizione di sovrapposizione
Exhaust valve about to close. soupapes signifie: significa che la valvola di scarico
Inlet valve about to open. soupaped’échappement n’est non è ancora chiusa, mentre la
Neither pushrod can be turned pas encore fermée et soupape valvola di aspirazione incomincia
in this position. d’admission commence à ad aprire. In questa posizione le
s’ouvrir. Les deux tiges de aste delle relative punterie non
culbuteurs ne peuvent plus possono venir fatte girare.
tourner.
© 05/00 2.00.01
Ventilspiel Prüfen und Einstellen
Valve clearance Checking and adjusting
Jeu de soupapes Contrôle et réglage
Gioco delle valvole Controlli e regolazioni
Spezialwerkzeug:
Durchdrehvorrichtung ____________ 100 320

Durchdrehvorrichtung ____________ 100 330
Die Standard-Ventilspieleinstellung ist möglich:
Am kalten- oder am warmen Motor nach einer

Abkühlzeit von mindestens 0,5 h.
Öltemperatur ≤ 80° C
Hinweis: Bei jedem Zylinderkopf-Dichtungs-

wechsel ist das Ventilspiel um 0,1 mm
zu erhöhen.
9
Nach 50-150 Bh ist das Standard-
Ventilspiel einzustellen. 7 Neues Bild 38-2-3
2
mit Durvchdreh-
Zylinderkopfhaube und vorrichtung
Kurbelgehäuseentlüftung ist abgebaut.
1. Motor durchdrehen bis zum Erreichen der

Ventilüberschneidung, Zyl. Nr. 1
Ventilspieleinstellschema siehe Techn. Daten 9

7 Änderung von 38-2-1
1.1 Ist der Motor an der Keilriemenscheibe nicht 100 320
frei zugänglich, kann bei abgebauter Hydrau-
likpumpe die Durchdrehvorrichtung 100 320
verwendet werden.
Hinweis: Ventilüberschneidung bedeutet:

Auslaßventil ist noch nicht geschlos-
sen, Einlaßventil beginnt zu öffnen.
9
Dabei sind beide Stoßstangen nicht
drehbar.
5
2.00.01 © 05/00
Prüfen und Einstellen Ventilspiel
Checking and adjusting Valve clearance
Contrôle et réglage Jeu de soupapes
Controlli e regolazioni Gioco delle valvole
Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch
2. Ventilspieleinstellung am entsprechenden
Neues Bild mit Schraubendreher 6 Zylinder mit Fühlerlehrenblatt einstellen.
Änderung von 28-2-4
5 Hinweis: Ventilspiel Einlaß: _______ 0,3 mm
Ventilspiel Außlaß: _______ 0,5 mm
3. Kontermutter mit einem Drehmoment von

20 ± 2 Nm festdrehen. Einstellung nochmals
mit Fühlerlehrenblatt überprüfen.
4. Dichtung aufsetzen.
2
2 0
5. Zylinderkopfhaube und Abdeckblech montie-

4 ren. Schrauben mit einem Drehmoment von
9 ± 1 Nm festdrehen.
6. Kurbelgehäuseentlüftung anbauen.
4 Schrauben mit einem Drehmoment von
9 ± 1 Nm festdrehen.
© 05/00 2.00.02
Ventilspiel Prüfen und Einstellen
Valve clearance Checking and adjusting
Jeu de soupapes Contrôle et réglage
Gioco delle valvole Controlli e regolazioni
2. Adjust valve clearance on respec- 2. Régler le jeu aux soupapes au 2. Facendo uso di uno spessimetro,
tive cylinder with feeler gauge. cylindre correspondant avec une effettuare la regolazione del
jauge d’épaisseur. gioco delle valvole del cilindro
corrispondente
Note: Inlet valve clearance: 0.3 mm Nota: Jeu soupape ADM: 0,3 mm Nota: gioco valvole:
Exhaust valve Jeu soupape ECH: 0,5 mm aspirazione: 0,3 mm
clearancee: 0.5 mm scarico: 0,5 mm
3. Tighten locknut with a torque of 3. Serrer le contre-écrou au couple de 3. Bloccare il controdado con una
20 ± 2 Nm. Recheck the adjust- 20 ± 2 Nm. Effectuer un nouveau coppia di serraggio di 20 ± 2 Nm.
ment with feeler gauge. contrôle du serrage avec une jauge Controllare ancora una volta con lo
d’épaisseur. spessimetro
4. Position gasket in place. 4. Mettre en place le joint. 4. Sistemare la guarnizione.
5. Fit cylinder head cover and cover 5. Monter le cache-culbuteurs et la 5. Montare il coperchio delle punterie
plate. Tighten bolts with a torque of tôle de recouvrement. Serrer e la lamiera di copertura. Bloccare
9 ± 1 Nm. les vis au couple de 9 ± 1 Nm. le viti con una coppia di serraggio
di 9 ± 1 Nm.
6. Fit crankcase breather. Tighten 6. Monter l’évent de carter. Serrer les 6. Rimontare lo sfiato del motore.
bolts with a torque of 9 ± 1 Nm. vis au couple de 9 ± 1 Nm. Bloccare le viti con una coppia
di serraggio di 9 ± 1 Nm.
2.00.02 © 05/00
Prüfen und Einstellen Kompressionsdruck
Checking and adjusting Compression pressure
Contrôle et réglage Taux de compression
Controlli e regolazioni Pressione di compressione
Commercial tools required: Outillage usuel: Attrezzi comuni:
Compression tester 8005 Compressiomètre 8005 Misuratore della pressione

Torx tool kit 8189 Jeu d’outils Torx 8189 di compressione 8005
Kit di attrezzi Torx 8189
Special tool required: Outil spécial: Attrezzi speciali:
Connector 100 110 Pièce de raccordement 100 110 Raccordo 100 110
Injectors have been removed, valve Les injecteurs ont été déposés et le Gli iniettori sono stati smontati ed il
clearance has been checked. jeu aux soupapes contrôlé. gioco delle valvole controllato
1. Insert connector with new special 1. Mettre en place la pièce de 1. Montare il raccordo munito della
2 seal. raccordement avec un joint spécial speciale guarnizione.
neuf.
2. Fit clamping pad. Tighten bolt. 2. Placer la griffe de serrage et serrer 2. Applicare la staffa di serraggio e
le boulon. serrare a fondo la vite.
3. If necessary, screw on adapter for 3. Si nécessaire mettre en place 3. Se necessario, avvitare l’adattatore
connector. l’adaptateur de la pièce de per il raccordo.
raccordement.
© 05/00 2.00.03
Kompressionsdruck Prüfen und Einstellen
Compression pressure Checking and adjusting
Taux de compression Contrôle et réglage
Pressione di compressione Controlli e regolazioni
Handelsübliche Werkzeuge:
Kompressionsdruckprüfer ____________ 8005

Torx-Werkzeugsatz _________________ 8189
Spezialwerkzeug:
Anschlußstück __________________ 100 110
Einspritzventile sind ausgebaut, Ventilspiel ist

kontrolliert
4
1. Anschlußstück mit Spezialdichtung
einsetzen 7 2
0
2. Spannpratze aufsetzen. Schraube fest-

drehen. 4
3. Falls notwendig Adapter für Anschlußstück

aufschrauben.
4
2.00.03 © 05/00
Prüfen und Einstellen Kompressionsdruck
Checking and adjusting Compression pressure
Contrôle et réglage Taux de compression
Controlli e regolazioni Pressione di compressione
4. Kompressionsdruckprüfer anschließen.
4 Motor mit Starter durchdrehen.
Kompressionsdruck: BFM 1012 28-33 bar
6 BFM 1013 30-38 bar
Der gemessene Kompressionsdruck ist

abhängig von der Anlaßdrehzahl während des
Meßvorganges und der Höhenlage des Motor-
aufstellortes.
9 Grenzwerte sind daher nicht genau festlegbar.
Empfohlen wird die Kompressionsdruck-
2 5 messung nur als Vergleichsmessung aller

Zylinder eines Motors untereinander anzusehen.
Sind mehr als 15% Abweichung ermittelt
worden, sollte durch die Demontage der
betroffenen Zylindereinheit die Ursache
ermittelt werden.
Hinweis: Einspritzventile mit neuen Spezial-

dichtungen einsetzen. Spannpratzen
aufsetzen und Schrauben lose ein-
schrauben.
Neue Einspritzleitungen anbauen.
Überwurfmuttern fingerfest auf-
schrauben.
Die Dichtkonen müssen exakt aufein-
andersitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitungen dürfen nicht
2x verwendet werden.
Schrauben der Spannpratzen mit
einem Drehmoment von 16 + 5 Nm
festdrehen. Überwurfmuttern der
Einspritzleitungen an den Einspritz-
pumpen und Einspritzventilen mit
einem Drehmoment von ca. 5 Nm
vorspannen. Danach die Überwurf-
muttern mit einem Drehmoment von
25 + 3,5 Nm festdrehen.
Leckölleitungen sind grundsätzlich
zu erneuern.
Zylinderkopfhaube mit einem Dreh-
moment von 9 ± 1 Nm festdrehen.
© 05/00 2.00.04
Kompressionsdruck Prüfen und Einstellen
Compression pressure Checking and adjusting
Taux de compression Contrôle et réglage
Pressione di compressione Controlli e regolazioni
4. Connect compression tester. Turn 4. Brancher le compressiomètre. 4. Collegare il misuratore della

engine with starter. pressione di compressione.
Far girare il motore per mezzo
del motorino d’avviamento.
Compression pressure: Pression de compression: Valore della pressione:

BFM 1012 28-33 bar BFM 1012 28-33 bars BFM 1012 28-33 bar
BFM 1013 30-38 bar BFM 1013 30-38 bars BFM 1013 30-38 bar
The measured compression pressure Le taux de compression mesuré Il valore della pressione di compres-
is dependent on the starting speed dépend de la vitesse de démarrage sione misurato dipende dalla velocità
during the measuring process and also pendant le relevé des mesures, et du d’avviamento durante la misurazione
on the altitude of the engine site. niveau du lieu d’implantation du e dall’altitudine del luogo in cui si
Therefore it is difficult to specify moteur. effettua il controllo.
precise limit values. It is recommended Des valeurs limites précises ne Per questa ragione non è possibile
to use the compression pressure peuvent donc pas être fixées. Il est fissare dei valori limite. Si consiglia
measurement only for comparison of conseillé de considérer la mesure du pertanto di considerare tale misura- 2
compression pressures of all cylinders taux de compression uniquement zione unicamente come un paragone
in one engine. If a difference in comme mesure comparative pour tous tra i singoli cilindri dello stesso
pressure in excess of 15% is les cylindres d’un moteur. En cas motore. Se però si riscontrano degli
determined, the cylinder unit d’écart supérieur à 15%, la cause scarti superiori al 15% se ne deve
concerned should be dismantled to pourra être déterminée en démontant stabilire la causa dopo avere smontato
establish the cause. l’unité cylindre concernée. l’unità cilindro interessata.
Note: Fit injectors with new special Nota: Utiliser des injecteurs avec de Nota: Montare gli iniettori munendoli
seals. Position clamping pads nouveaux joints spéciaux. Placer di nuove guarnizioni speciali.
and start bolts. les griffes de serrage et serrer Applicare le staffe di serraggio
Fit new injection lines. Screw on les vis sans serrer. ed avvitare le viti lasciandole
cap nuts fingertight. Monter des conduites d’injection lente. Montare nuove tubazioni
The sealing cones must match neuves. di iniezione. Avvitare a mano le
precisely. Serrer les écrous-raccords mo- viti a risvolto, lasciandole lente
Rebending is not permissible. dérément à la main. Le tenute coniche devono accop-
The injection lines may not be Les cônes d´étanchéité doivent piarsi esattamente tra di loro.
used twice. parfaitement correspondre. Non è ammesso modificare le
Tighten bolts of clamping pads Un recintrage n’est pas auto- curve esistenti od eseguirne
with a torque of 16 + 5 Nm. risé. Ne jamais utiliser deux di nuove. Le tubazioni di inie-
Preload cap nuts of injection fois les conduites d’injection. zione non possono venire
lines on injection pumps and Bloquer les vis des griffes de utilizzate più di una volta.
injectors with a torque of serrage au couple de 16 + 5 Nm. Bloccare le viti delle staffe di
approx. 5 Nm. Thereafter tighten Préserrer les écrous-raccords serraggio con una coppia di
cap nuts with a torque of 25 + des conduites d’injection et injec- 16 + 5 Nm. Precaricare i dadi
3.5 Nm. teurs au couple d’environ 5 Nm. a risvolto tra le tubazioni di
Leakage fuel lines must always Ensuite bloquer les écrous-rac- iniezione e le pompe di iniezione,
be renewed. cords au couple de 25 + 3,5 Nm. nonché gli iniettori con una
Tighten cylinder head cover with Toujours renouveller les con- coppia di circa 5 Nm. Serrare a
a torque of 9 ± 1 Nm. duites de retour des fuites. fondo quindi i dadi a risvolto
Bloquer le cache-culasse au con una coppia di 25+3,5 Nm.
couple de 9 ± 1 Nm. Le tubazioni di ricupero del
combustibile devono di norma
venire rinnovate.
Bloccare il coperchio delle punterie
con una coppia di 9 ± 1 Nm.
2.00.04 © 05/00
Prüfen und Einstellen Einspritzventil
Checking and adjusting Injector
Contrôle et réglage Soupape injectrice
Controlli e regolazioni Iniettore
Commercial tools required: Outillage usue: Attrezzi comuni:
Nozzle tester 8008 Banc d’essais d’injecteurs 8008 Banco prova iniettori 8008
Long socket a/flats 15 8012 Longue clé à douille de 15 8012 Chiave a bussola SW15 8012
Special tool required: Outillage spécial: Attrezzo speciale
Assembly tool 110 110 Dispositif de montage 110 110 Dispositivo di montaggio 110 110
Note: Utmost cleanliness must be Nota: Tous les travaux à effectuer sur Nota: Durante i lavori sul sistema di
ensured when working on the les injecteurs doivent être iniezione ci si deve preoccupare
injection equipment. For testing réalisés dans de parfaites di usare la massima pulizia. Per
the injector use only pure test conditions de propreté. Pour il controllo degli iniettori far uso
oil to ISO 4113 or clean diesel contrôler les injecteurs n’utiliser soltanto di puro olio di prova
fuel. que du gazole d’essai pur selon ISO 4113 oppure ci combustibile
ISO 4113 ou du combustible pulito.
2 diesel parfaitement propre.
Caution Attention Attenzione
Beware of injection nozzle fuel jet. The Tenir les mains à l’écart des jets de Tenere lontane le mani dal getto
fuel penetrates deeply into the skin gazole, la force de pénétration de ceux- dell’iniettore. Il combustibile penetra
tissue and may cause blood poisening. ci est telle qu’ils peuvent créer des profondamente nei tessuti e può
blessures graves et provoquer un provocare un avvelenamento del
empoisonnement du sang. sangue.
1. Connect injector to nozzle tester. 1. Monter l’injecteur sur la pompe 1. Montare l’iniettore sull’apparecchio
d’essais d’injecteurs. di prova per i polverizzatori.
2. Checking opening pressure 2. Contrôle de la pression 2. Controllo della pressione

d’ouverture di apertura.
With pressure gauge switched on, Le manomètre étant branché, appuyer Dopo avere collegato il manometro,
slowly press down lever of nozzle lentement sur le levier de la pompe spingere in basso lentamente la leva
tester. The pressure at which the d’essai d’injecteurs. La pression à dell’apparecchio di prova. La pressione
gauge pointer stops or suddenly laquelle l’aiguille s’arrête ou chute alla quale la lancetta si arresta oppure
drops, is the opening pressure. brusquement, est la pression maxi ou torna indietro improvvisamente
Opening pressure check value for pression d’ouverture. rappresenta la pressione di apertura..
possible reuse: Valeur de contrôle de pression
BFM 1012 250 + 8 bar d’ouverture pour réutilisation: Pressione d’apertura:
BFM 1013 275 + 8 bar. BFM 1012 250 + 8 bars BFM 1012 250 + 8 bar
BFM 1013 275 + 8 bars. BFM 1013 275 + 8 bar
© 05/00 2.00.05
Einspritzventil Prüfen und Einstellen
Injector Checking and adjusting
Soupape injectrice Contrôle et réglage
Iniettore Controlli e regolazioni
Handelsübliche Werkzeuge:
5
Düsenprüfgerät ____________________ 8008
Lange Stecknuß SW15 ______________ 8012
Spezialwerkzeug
Montagevorrichtung _____________ 110 110
Hinweis: Bei Arbeiten an der Einspritzaus-

rüstung auf größte Sauberkeit
achten. Zur Prüfung der Einspritz-
ventile nur reines Prüföl nach
ISO 4113 oder sauberen Diesel-
kraftstoff verwenden.
Achtung
Hände weg vom Düsenstrahl. Der Kraftstoff

e
dringt tief in das Fleisch ein und kann zur
Blutvergiftung führen. 4
1. Einspritzventil an das Düsenprüfgerät
anbauen.
2. Prüfung des Öffnungsdruckes
Hebel des Düsenprüfgerätes bei

zugeschaltetem Manometer langsam
6
niederdrücken. Der Druck bei dem der Zei-
ger stehen bleibt oder plötzlich abfällt, ist
der Öffungsdruck.
Öffnungsdruck: BFM 1012 250 + 8 bar
BFM 1013 275 + 8 bar
2.00.05 © 05/00
3. Einstellen des Öffnungsdruckes am

1 Einspritzventil
7 Überwurfmutter abschrauben, alle Teile

ausbauen.
Folge der Einzeldemontage

8 1. Überwurfmutter
2 r 2. Einspritzdüse
3. Zwischenstück
4. Druckbolzen
Neues Bild 10-2.16
5. Druckfeder
mit 1 Scheibe
6. Ausgleichscheibe
4. Durch Auswahl der erforderlichen Scheibe

6 Druck einstellen. Stärkere Scheibe ergibt
höheren Öffnungsdruck. Einspritzventil
zusammenbauen. Überwurfmutter mit
Neues Bild 38-2-6 einem Drehmoment von 40 - 50 Nm fest-
1 Scheibe entfernen drehen. Einspritzventil auf dem Düsen-
prüfgerät erneut prüfen.
5. Prüfung auf Dichtheit

6 Düse und Düsenhalter abtrocknen - mit Luft
trockenblasen. Handhebel des Prüfgerätes
langsam niederdrücken, bis ca. 20 bar
unterhalb des vorher abgelesenen
Öffnungsdruckes erreicht werden.
© 05/00 2.00.06
3. Adjusting the opening pressure on 3. Tarage de la pression d’ouverture 3. Regolazione della pressione
the injector sur injecteur d’apertura dell’iniettore
Unscrew cap nut and remove all Dévisser l’écrou-raccord et déposer Svitare il dado a risvolto e
parts. toutes les pièces. smontare tutti i componenti.
Sequence of parts disassembly Suite du démontage des pièces Sequenza di smontaggio dei
singoli componenti
1. Cap nut 1. Ecrou-raccord 1. Dado a risvolto

2. Injection nozzle 2. Injecteur 2. Polverizzatore 2
3. Adapter 3. Elément intermédiaire 3. Piattello intermedio
4. Thrust pin 4. Tige poussoir 4. Perno
5. Compression spring 5. Ressort 5. Molla di compressione
6. Shim 6. Rondelle d’épaisseur 6. Rondella di spessore
4. Adjust pressure by selecting 4. Régler la pression en prenant le 4. Regolare la pressione scegliendo

appropriate shim. A thicker shim nombre de rondelles nécessaires. le rondelle necessarie. Con una
increases the opening pressure. Des rondelles plus épaisses rondella di maggior spessore si
Tighten cap nut with a torque of entraînent une pression d’ouverture ottiene una pressione più alta.
40 - 50 Nm. Recheck injector on plus grande. Remonter l’injecteur. Riassemblare l’iniettore. Serrare
nozzle tester. Serrer l’écou-raccord au couple de a fondo il dado a risvolto con una
40 - 50 Nm. Contrôler l’injecteur à coppia di 40-50 Nm. Controllare
nouveau à l’aide de la pompe nuovamente l’iniettore al banco
d’essai d’injecteurs. prova.
5. Checking for tightness 5. Contrôle de l’étanchéité 5. Controllo della tenuta
Dry nozzle and nozzle holder - blow Sécher l’injecteur et le porte- Con un getto d’aria asciutta
out with compressed air. Press injecteur par jet d’air. Appuyer asciugare il polverizzatore ed il
down handlever of tester until a lentement sur le levier de la pompe porta-polverizzatore. Spingere
pressure of up to about 20 bar d’essai jusqu’à obtention d’environ lentamente in basso la leva
below the previous opening 20 bars en-dessous de la pression dell’apparecchio di prova fino
pressure reading is attained. d’ouverture lue auparavant. a raggiungere circa 20 bar al
di sotto della pressione di
apertura letta precedentemente.
2.00.06 © 05/00
6. Nozzle is tight if there is no drip- 6. L’injecteur est étanche lorsqu’il ne 6. Il polverizzatore deve ritenersi
ping within a period of 10 seconds. goutte plus durant 10 secondes. stagno se nel tempo di 10 secondi
non lascia cadere nessuna goccia.
7. In case of a drip, the injector must 7. Si l’injecteur goutte, le déposer et le 7. Se cade anche una sola goccia,
be dismantled and cleaned to nettoyer pour supprimer le manque dopo aver smontato completa-
remedy the leak. If this does not d’étanchéité. En cas d’échec, mente l’iniettore se ne devono
cure the leak, the injector must be remplacer l’injecteur. pulire accuratamente tutti i suoi
replaced. componenti. Se malgrado ciò il
polverizzatore continua a perdere
2 Reworking is not permissible. Ne jamais rectifier l’injecteur. sarà necessario sostituirlo.
Non è ammesso tentare

di rettificare i componenti
dell’iniettore.
8. Buzzing and spray pattern test 8. Contrôle du crissement 8. Controllo del getto e del rugghio
caractéristique de l’injecteur
Switch off pressure gauge of tester. Débrancher le manomètre de la Disinserire il manometro

pompe d’essai. dall’apparecchio di prova.
The buzzing test permits an audible Le contrôle du crissement permet La prova del rugghio consente un
check of the ease of movement of un contrôle audible de l’injecteur controllo acustico circa la facilità
the nozzle needle in the nozzle dont l’aiguille doit retomber d’elle- di movimento dell’ago del polveriz-
body. New injectors emit a different même dans son logement. Les zatore nella sua sede. Un iniettore
buzzing sound as compared to injecteurs neufs présentent par nuovo produce un rugghio diverso
used injectors. It deteriorates due rapport aux injecteurs usagés un da quello prodotto da un iniettore
to wear in the needle seat area. If crissement différent. L’usure se usato. Tale cambiamento è dovuto
an injection nozzle does not buzz produisant au niveau du siège de all’usura che ha luogo nella zona
despite cleaning, it must be l’aiguille entraîne une dégradation della sede dell’ago del polveriz-
renewed. du crissement. Si, après nettoyage, zatore. Se, dopo averne eseguita la
l’injecteur refuse de crisser, il faut pulizia, un polverizzatore continua
le remplacer. a non rugghiare sarà necessario
sostituirlo.
A used injector should buzz clearly Un injecteur usagé doit, après
during rapid actuation of the actionnement rapide du levier de Azionando velocemente la leva del
handlever, while exhibiting a well commande, émettre un crissement banco prova, un iniettore usato
atomized spray pattern. The spray audible et pulvériser de manière bien deve rugghiare in modo udibile ed
pattern may differ noticeably from homogène. La forme du jet peut emettere contemporaneamente un
that of a new injector. alors, à la différence d’un injecteur getto perfettamente nebulizzato.
neuf, être tout à fait différente. L’aspetto del getto può comunque
essere sensibilmente diverso da
quello di un iniettore nuovo.
© 05/00 2.00.07
6. Düse ist dicht, wenn innerhalb 10 Sekunden

kein Tropfen abfällt.
9
7. Fällt ein Tropfen ab, ist das Einspritzventil

zu zerlegen und die Undichtigkeit durch
Reinigen zu beseitigen. Ist das nicht
9
erfolgreich, muß die Einspritzdüse erneuert
werden. 2
Nacharbeit ist nicht zulässig.
8. Schnarr- und Strahlprüfung
Manometer des Prüfgerätes abschalten.

9
Die Schnarrprüfung ermöglicht eine
hörbare Prüfung der Leichtgängigkeit der
Düsennadel im Düsenkörper. Neue
Einspritzventile haben gegenüber gebrauch-
ten ein geändertes Schnarrverhalten.
Durch Verschleiß im Nadelsitzbereich
verschlechtert es sich. Schnarrt eine Ein-
spritzdüse trotz Reinigung nicht, muß sie
durch eine neue ersetzt werden.
Ein gebrauchtes Einspritzventil muß bei

schneller Hebeltätigkeit hörbar schnarren
und dabei gut zerstäubt abspritzen. Das
Strahlbild kann dabei gegenüber dem eines
neuen Einspritzventils deutlich unterschied-
lich sein.
2.00.07 © 05/00
Controlli e regolazioni
© 05/00
Bauteile instand setzen
Repair of components
Mise en état des composants

Riparazione di componenti BFM 1012/1013
© 05/00
06 07
19 11
08
38
27
10 39
83
01 38
15
17
05
83 05
33
01
72
01
© 05/00
Inhalts-Verzeichnis Bauteile instandsetzen
Table of Contents Repair of components
Sommaire Mise en état des composants
Indice Riparazione dei componenti
Deutsch
3. Bauteile instandsetzen
Baugruppe Benennung Seite

01 Zylinderkurbelgehäuse 3.01.01 - 3.01.11
01 Vorderer Deckel/Schmierölpumpe 3.01.15 - 3.01.17
01 Räderkasten 3.01.21 - 3.01.22
05 Kurbelwelle 3.05.25 - 3.05.28
05 Starterzahnkranz/Schwungrad

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MODEL GT-110

NOTE: The information contained in this publication is intended exclusively

NOTE: The information contained in this document is intended to be

City: State: Zip Code:

Date of original publication: September 1995

Revision Number Date Brief Description

Revision Number Date Brief Description

LIST OF EFFECTIVE PAGES

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

MANUAL TABLE OF CONTENTS

SAFETY ............................................................................................................................... SAFETY-i

Chapter 1: General Information and Operating Instructions

P. Electrical System ................................................................................................ 1-1-11

SECTION 2: OPERATION ........................................................................................................... 1-2-1

SECTION 3: SPECIFICATIONS AND CAPABILITIES ................................................................ 1-3-1

SECTION 4: SHIPPING ............................................................................................................... 1-4-1

E. Preparing Unit ....................................................................................................... 1-4-2

SECTION 5: STORAGE .............................................................................................................. 1-5-1

SECTION 2: TROUBLESHOOTING............................................................................................ 2-1-1

N. Wiring Diagrams ................................................................................................. 2-2-19

SECTION 2: REMOVAL AND INSTALLATION ........................................................................... 3-2-1

Chapter 4: Illustrated Parts List

SECTION 2: ILLUSTRATED PARTS LIST ................................................................................. 4-2-1

Figure 4-21. Brake Pedal Assembly .................................................................. 4-2-43

Figure 4-54. Circuit Breaker and Fuse Installation .......................................... 4-2-107

SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-13

SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1

SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS ................................................ 5-2-1

This manual is copyrighted as an unpublished work.

© Copyright 2007 by TUG Technologies Corporation. All rights reserved.

If applicable, enter your company identification number

TUG Technologies Corporation

TUG Technologies Corporation

AIRCRAFT GROUND SUPPORT EQUIPMENT

IN THE EVENT OF A FAILURE

TUG Technologies Corp.

HOW TO USE THIS MANUAL

SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

Note Relevant information for the reader, that is not hazard-related.

6. When operating in an enclosed area, pipe the exhaust fumes outside.

7. Follow the manufacturer’s recommendations to properly maintain equipment.

9. In case of accident, shut down the unit immediately.

(This page intentionally left blank.)

CHAPTER 1: GENERAL INFORMATION

SECTION 1: GENERAL DESCRIPTION ..................................................................................... 1-1-1

SECTION 2: OPERATION ........................................................................................................... 1-2-1

SECTION 3: SPECIFICATIONS AND CAPABILITIES ................................................................ 1-3-1

SECTION 4: SHIPPING ............................................................................................................... 1-4-1

SECTION 5: STORAGE .............................................................................................................. 1-5-1

SECTION 1: GENERAL DESCRIPTION

Figure 1-1. Model GT-110 Tow Tractor

G. AIR INTAKE SYSTEM

1. Main Hydraulic Pump

2. Emergency Steering Pump

5. Dual Check/Distribution Valve

(a) Single Cab Steering Subsystem