Service Manual MT855C PDF

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Challenger ®
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MT835C / MT845C / MT855C / MT865C / MT875C

Rubber Track Tractor
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SERVICE MANUAL
79033095 C Rev.
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Volume 1
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NOTE TO THE RECIPIENT - This packet is one component of two or more components required to
comprise a complete publication. The following items, shipped under separate part number, are
used with this publication:
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• Two expandable storage binders (Binder labels provided in printed material packets.)
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• Volume 1: Divisions 1-10 printed packet
© AGCO Corporation, 2013 All rights reserved.

Part Number 79033095 C Rev. (English)
Printed in U.S.A.
March, 2013
Printing Batch Number

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Challenger ®
SERVICE MANUAL
79033095 C Rev.
Volume 1
CONTENTS
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Volume 1
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INTRODUCTION.....................................................................................................................................................01
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ENGINE ..................................................................................................................................................................02
POWERTRAIN........................................................................................................................................................03
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FRAME ...................................................................................................................................................................04
STEERING AND BRAKE SYSTEM .......................................................................................................................05
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IMPLEMENT HYDRAULIC AND THREE-POINT HITCH SYSTEMS.....................................................................06

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ELECTRICAL SCHEMATICS.................................................................................................................................07
AIR SYSTEM ..........................................................................................................................................................08
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VIRTUAL TERMINAL .............................................................................................................................................09

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CAB ........................................................................................................................................................................10
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Volume 2
HEATING VENTILATION AND AIR CONDITIONING...................................................................................................... 11

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BALLASTING ..................................................................................................................................................................... 12
APPEARANCE GROUP..................................................................................................................................................... 13
ELECTRONICS................................................................................................................................................................... 14

Printed in U.S.A.
March, 2013
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Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
01 - Introduction
Contents
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INTRODUCTION
Service Manual ................................................................................................................................................ 1-1
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Divisions and Page Numbers .................................................................................................................... 1-1

Units of Measurement ...................................................................................................................................... 1-1
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Replacement Parts .......................................................................................................................................... 1-1

Important Safety Information ........................................................................................................................... 1-2
Safety Alert Symbol ......................................................................................................................................... 1-3
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Signal Words ................................................................................................................................................... 1-3

Informational Messages ................................................................................................................................... 1-4
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General Hazard Information ............................................................................................................................ 1-5

Protective Clothing .................................................................................................................................... 1-6
Mounting and Dismounting ........................................................................................................................ 1-7
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Crushing Prevention and Cutting Prevention ............................................................................................ 1-7

Exhaust Dangers ....................................................................................................................................... 1-8
Before Starting Engine .............................................................................................................................. 1-8
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Parking ...................................................................................................................................................... 1-8

Operation ................................................................................................................................................... 1-8
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Operator Station ........................................................................................................................................ 1-9

Engine Starting ........................................................................................................................................ 1-10
Seat Belts ................................................................................................................................................ 1-10
Shield Removal ....................................................................................................................................... 1-10
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Fluid Precautions ..................................................................................................................................... 1-11

Battery Disconnect .................................................................................................................................. 1-11
Rollover Protective Structure (ROPS) ..................................................................................................... 1-12
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Burn Hazards .......................................................................................................................................... 1-12

Coolant Precautions ................................................................................................................................ 1-12
Escaping Fluid Dangers .......................................................................................................................... 1-13
Batteries .................................................................................................................................................. 1-14
Lights, Reflector and Signs ..................................................................................................................... 1-14
Fire and Explosion Prevention ................................................................................................................ 1-15
Fire Extinguisher ..................................................................................................................................... 1-16
Auto-Guide Precautions .......................................................................................................................... 1-16
Asbestos Information ............................................................................................................................... 1-16
Electrical Storm Injury Prevention ........................................................................................................... 1-16
Machine Identification .................................................................................................................................... 1-17
Machine Identification Information ........................................................................................................... 1-17
Torque Specifications .................................................................................................................................... 1-19
Constant Torque Hose Clamps ............................................................................................................... 1-19
Fasteners Information .................................................................................................................................... 1-20
Metric Fasteners ...................................................................................................................................... 1-20
Inch Fasteners ......................................................................................................................................... 1-21
Tightening Straight Thread Fittings ................................................................................................................ 1-22
Metric Information .......................................................................................................................................... 1-23
79033095 C Rev. 01-i

Contents
Special Tooling .............................................................................................................................................. 1-24
INDEX ............................................................................................................................................................. 01-25
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01-ii 79033095 C Rev.

Introduction
INTRODUCTION
SERVICE MANUAL
This service manual has been prepared with the latest
service information available at publication. Read and
understand service manual carefully before doing any
service on machine.
Right-hand and left-hand, as used in this manual, is
determined by facing direction the machine travels when
in use.
Photos, illustrations and data used were current at time of
printing, due to possible production changes machine
may vary slightly. Manufacturer reserves right to redesign
and change machine as necessary without notification.
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WARNING: Some pictures in manual show

shields removed to allow a clearer view.
Never operate machine with any shields
removed.
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Divisions and Page Numbers

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Service manual is separated into divisions. Refer to

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Master Table of Contents.

Each division has an identifying part number with an
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alpha revision level indicator. Each division also has a

Table of Contents, Safety section and Index.
Each page is identified with division part number and
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revision level. Pages are in numeric order within each

division.
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UNITS OF MEASUREMENT
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Measurements are given in metric units followed by

equivalent in U.S. units. Hardware sizes are given in
millimeters for metric hardware and inches for U.S.
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hardware.
REPLACEMENT PARTS
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To receive prompt efficient service, always remember to

have correct part number and description along with
model and serial number of machine.
79033095 C Rev. 1-1

Introduction
IMPORTANT SAFETY INFORMATION
FIG. 1: Most personal injuries occurring during machine
operation, maintenance or repair are caused by failure to
observe basic safety rules and precautions. In most
cases, an injury can be avoided by recognizing hazardous
situations before an injury occurs.
Be alert to potential hazards and have the necessary
training, skills and tools to perform these functions
properly.
Improper operation, lubrication, maintenance or repair of
machine can be hazardous and could result in injury or
death.
Do not operate or perform any lubrication, maintenance N020903002
or repair on machine, until reading and understanding
operation, lubrication, maintenance and repair FIG. 1
information.
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Safety precautions and warnings are provided in manual

and on machine. If hazard warnings are not heeded,
bodily injury or death could occur to operator or
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bystanders.
Not every possible circumstance involving a potential
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hazard can be anticipated. Warnings in service manual

and on machine are, therefore, not all inclusive. If a tool,
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procedure, work method or operating technique not

specifically recommended by AGCO is used, ensure it is
safe for operator and others.
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Make sure machine will not be damaged or be made

unsafe by operation, lubrication, maintenance or repair
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procedures chosen. Information, specifications and

illustrations in publication are based on information
available at time of publication.
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Specifications, torques, pressures, measurements,

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adjustments, illustrations and other items can change at

any time. Changes can affect service given to machine.
Obtain complete and most current information from
dealer before starting any job.
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WARNING: When replacement parts are
required for machine, AGCO recommends
using AGCO replacement parts or parts
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with equivalent specifications including,

but not limited to, physical dimensions,
type, strength and material. Failure to heed
this warning can lead to premature failures,
machine damage, personal injury or death.
1-2 79033095 C Rev.

Introduction
SAFETY ALERT SYMBOL
FIG. 2: This is the safety alert symbol. It means
ATTENTION! BECOME ALERT! SAFETY IS INVOLVED!
Look for it, both in this manual and on safety decals on
machine. It directs operator attention to information
involving operator safety and safety of others.
Saf
FIG. 2
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SIGNAL WORDS
FIG. 3: Words DANGER, WARNING or CAUTION are
used with safety alert symbol. Learn to recognize safety
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alerts and follow recommended precautions and safe

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practices.
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DANGER: Indicates an imminently
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hazardous situation that, if not avoided, will

result in DEATH OR VERY SERIOUS
INJURY.
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WARNING: Indicates a potentially
hazardous situation that, if not avoided,
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could result in DEATH OR SERIOUS

INJURY.
N020903004
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CAUTION: Indicates a potentially FIG. 3
hazardous situation that, if not avoided,
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may result in MINOR INJURY.

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79033095 C Rev. 1-3

Introduction
INFORMATIONAL MESSAGES
FIG. 4: Do not operate or perform any lubrication,
maintenance or repair on machine until reading and
understanding operation, lubrication, maintenance and
repair information.
Read and understand this manual, operator’s manual and
attachment manuals before operation.
Learn how to operate machine and use controls properly.
Do not allow anyone to operate machine without
instruction and training.
For operator’s safety and safety of others, follow all safety
precautions and instruction found in manuals and on
decals affixed to machine and attachments. N020903002
Personal injury and death may result in precautions are FIG. 4

not followed.
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Words IMPORTANT and NOTE are not related to

personal safety, but are used to give additional
information and tips for operating or servicing machine.
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IMPORTANT: Identifies special instructions or

procedures that, if not strictly observed, could
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result in damage to, or destruction of machine,

attachments or environment.
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NOTE: Identifies points of particular interest for more

efficient and convenient operation or repair.
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Right-hand and left-hand, as used in this manual, are

determined by facing direction machine travels when in
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use.
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1-4 79033095 C Rev.

Introduction
GENERAL HAZARD INFORMATION
FIG. 5: When engine is running and steering wheel is
turned, machine will not turn with transmission control
lever in PARK position.
IMPORTANT: Ensure all personnel are a safe distance
from machine before turning steering wheel.
Do not start engine until area is free of personnel to avoid
personal injury due to unexpected machine movement.
Unless instructed otherwise, perform maintenance under
the following conditions:
• Machine is parked on level ground.
• Implements are lowered to ground. P111203001
• Transmission control lever is in PARK position. FIG. 5

• Engine is stopped.
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• Engine start switch is turned off and switch key is

removed.
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• Machine has cooled down.

• Steering cylinder lock is in place.
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WARNING: Do not start engine until area is
free of personnel to avoid personal injury
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due to unexpected machine movement.

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Know width of machine to maintain proper clearance

when operating machine near fences or boundary
obstacles.
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Wear a hard hat, protective glasses and other protective

equipment, as required.
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Wearing loose clothing or not using correct safety

equipment for job, injury can occur. Never wear clothing
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that will catch on objects. Extra safety equipment that can

be required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy gloves and
reflective clothing.
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Make sure all protective guards and covers are secured

on machine.
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Keep machine free from foreign material. Remove debris,

oil, tools and other items from deck, walkways and steps.
Secure lunch boxes, tools and other loose items not a
part of machine.
Know appropriate work site hand signals and personnel
authorized to give hand signals. Accept hand signals from
one person only.
Hydraulic oil or diesel fuel leaking under pressure can
penetrate skin and cause infection or other injury.
To prevent personal injury relieve all pressure before
disconnecting fluid lines. Before applying pressure, make
sure all connections are tight and components are in good
condition. Do not use hand to check for suspected leaks
under pressure. Use a piece of cardboard or wood for this
purpose. If injured by leaking fluid, see a doctor
immediately.
79033095 C Rev. 1-5

Introduction
Never put maintenance fluids into glass containers, drain
into a suitable container.
Discard any drained fluids and discard any filter elements
according to local regulations.
Use all cleaning solutions with care.
Report all necessary repairs.
Some components of machine are very heavy. Use
suitable lifting equipment or additional help.
Do not allow unauthorized personnel on machine.
Do not smoke when servicing an air conditioner. Do not
smoke if refrigerant gas may be present. Inhaling fumes
released from a flame that contacts air conditioner
refrigerant can cause bodily harm or death.
Inhaling gas from air conditioner refrigerant through a
lighted cigarette can cause bodily harm or death.
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FIG. 6: Be prepared for emergencies. Always carry one

or more suitable fire extinguishers - ABC rating, dry
chemical.
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Keep a first aid kit handy for treatment or minor cuts and
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scratches.
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N021603005
FIG. 6
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Protective Clothing
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FIG. 7: Wear a hard hat, protective glasses and other

protective equipment as required.
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N020903007
FIG. 7
1-6 79033095 C Rev.

Introduction
Mounting and Dismounting
FIG. 8: Mount and dismount machine only where there
are steps and/or hand holds. Face machine whenever
mounting or dismounting.
Maintain three-point contact with steps and hand holds.
Three-point contact is two feet and one hand or one foot
and two hands.
Never mount or dismount a moving machine. Never jump
off machine except in an emergency.
Do not carry tools or supplies when trying to mount or
dismount machine. Use a hand line to pull equipment
onto platform.
Do not use any controls as hand holds when entering or N020903008
exiting operator compartment. FIG. 8

IMPORTANT: Make sure steps are not adjusted too
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close to hood of machine.

Leave a minimum dimension of 75 mm between inside
hand hold and hood so there is enough room for
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operator's hand.
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Crushing Prevention and Cutting

Prevention
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Stay clear of center articulation joint area of machine

when engine is running. Connect articulation joint stop
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whenever servicing this area.

Support equipment properly when performing work under
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equipment. Do not depend on hydraulic cylinders to hold

equipment.
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WARNING: An implement can fall if a
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control lever is moved or if a hydraulic line

breaks.
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Never jump across starter solenoid terminals to start

machine. Unexpected machine movement could result.
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Never attempt adjustments while machine is moving or

while engine is running.
Whenever there are attachment control linkages,
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clearance in linkage area changes with movement of

attachment.
Stay clear of all rotating and moving parts. Keep objects
away from moving fan blades. Fan blades will throw and
cut objects.
Wear gloves to handle wire cable and do not use kinked
or frayed wire cable.
Retainer pins can fly when struck, ensure there are no
personnel in area before striking. Wear protective glasses
to protect eyes. When striking objects, chips or other
debris may fly off. Ensure there will be no injury prior to
striking any object.
79033095 C Rev. 1-7

Introduction
Exhaust Dangers
FIG. 9: Diesel engine exhaust contains products of
combustion, potentially harmful to health. Always run
engine in a well-ventilated area. Never operate engine in
a closed building unless exhaust is vented outside.
Before Starting Engine

Clear all personnel from machine and surrounding area.
Make sure all obstacles are cleared from machine’s path.
Operator must be familiar with hazards (wires, ditches,
fences, etc).
Be sure all windows are clean. Secure doors and
windows in open or closed position.
N020903009
Adjust rearview mirrors for best visibility close to machine.
FIG. 9
Make sure horn, backup alarm (if equipped) and all other
warning devices are working properly.
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Fasten seat belt securely, low around hips.
Parking
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Park on a level surface. If it is necessary to park on grade,

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chock belts.
Move transmission control lever to PARK and lower all
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implements to ground. Move implement controls to HOLD

position.
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Before stopping engine, move throttle control lever to

LOW IDLE position. Run engine at low idle speed for five
minutes allowing turbocharger to cool.
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Stop engine, turn engine start switch to OFF position and

remove engine start switch key.
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Turn battery disconnect switch to OFF position.

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Operation
Only operate machine while in operator's seat. Seat belt
must be fastened during operation. Only operate controls
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while engine is running.

Check for proper operation of all controls and protective
devices while operating machine slowly in an open area.
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Make sure that no one will be endangered before moving

machine.
Report any damage noted during operation and make
any necessary repairs.
Hold attachments approximately 40 cm (15 inches) above
ground level while driving machine. Do not drive near an
overhang, edge of a cliff or near an excavation.
If machine begins to sideslip on a grade, immediately
dispose of load and turn machine downhill.
Avoid any ground condition which could cause machine to
tip.
A rollover can occur when working on hills, banks or
slopes or when crossing ditches, ridges or other
unexpected obstacles.
1-8 79033095 C Rev.

Introduction
When possible, operate machine up and down slopes.
Avoid operating machine across slope, when possible.
Keep machine under control. Do not overload machine
beyond capacity.
Make sure towing devices are adequate for application.
Make sure components on three-point hitch are adequate
for application.
Connect trailing equipment only to a drawbar or hitch.
Never straddle a wire cable. Never allow other personnel
to straddle a wire cable.
When maneuvering to connect equipment, make sure no
personnel are between machine and trailing equipment.
Block up hitch of trailing equipment to align equipment
with drawbar.
Know maximum dimensions of machine.
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When operating on icy roads, reduce travel speed.

After operating in muddy conditions, allow sufficient time
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for belts to reject debris and moisture before making high

speed maneuvers. Belts that are wet and/or muddy may
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impede machine’s steering.

If stability of machine is noticeably reduced, reduce travel
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speed.
Select a gear that will control machine speed when
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descending a hill.
Downshift if braking is required to control machine speed.
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Never coast down a hill with transmission in NEUTRAL.

Do not steer machine when crossing ditches. Ditches that
are wide and/or deep may allow guide blocks to sag
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below midwheels, causing belt to come off.

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Operator Station
Any modifications to inside of operator station should not
project into operator space. The addition of a radio, fire
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extinguisher and other equipment must be installed so

defined operator space is maintained.
Any item brought into cab should not project into defined
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operator space. A lunch box or other loose items must be

secured. Objects must not pose an impact hazard in
rough terrain or a rollover.
79033095 C Rev. 1-9

Introduction
Engine Starting
FIG. 10: Only start engine from operator’s seat. Never
short across starter terminals or batteries.
Move all hydraulic controls to HOLD position and
transmission control lever to PARK before starting engine.
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WARNING: Machine will turn if steering
wheel is moved and engine is starting or
running.
Do not start engine until area is free of personnel to avoid

personal injury due to unexpected machine movement.
N020903010
FIG. 10
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Seat Belts
FIG. 11: Only operate machine from operator’s seat with
seat belt fastened. Only operate controls while engine is
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running.
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Any rider in instructor’s seat must fasten seat belt. Never

allow anyone on any part of machine or its attachments
except in operator5’s and instructor’s seat when engine is
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running.
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N020903011
FIG. 11
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Shield Removal
FIG. 12: Some photos in this manual may have been
taken with shields removed for clarity.
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WARNING: To provide a better view, certain
photographs and illustrations in manual
may show an assembly with shields
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removed. Do not operate machine unless all

shields are in good condition and are in
place. Replace shields immediately upon
completion of inspection, repairs, cleaning
or adjustments and before operating begins
or resumes.
N020903012
FIG. 12
1-10 79033095 C Rev.

Introduction
Fluid Precautions
FIG. 13: Drain all fluids into suitable container and never
put maintenance fluid into glass containers.
Discard drained fluids and fluid-saturated materials
according to local regulations. Use all cleaning solutions
with care.
N020903013
FIG. 13
FIG. 14: Do not smoke when servicing an air
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conditioner. Inhaling gas from air conditioner refrigerant

through a lit cigarette can cause bodily harm or death.
Keep machine free of foreign material (fuel, oil, some
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coolants, oily rags and debris).

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Do not weld on lines or tanks containing flammable fluids.

Use caution when refueling machine and do not smoke.
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Always stop engine before refueling. Fill fuel tank

outdoors.
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N020903014
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FIG. 14
Battery Disconnect
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FIG. 15: Always shut off engine, shift transmission to

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park, remove ignition key and set battery disconnect

switch to OFF before permitting inspection, cleaning,
lubrication, adjustment or repair of any part of machine or
attachments.
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P111203002
FIG. 15
79033095 C Rev. 1-11

Introduction
Rollover Protective Structure (ROPS)
Do not make any modifications to ROPS as this affects
protection provided. Do not alter structure by welding,
cutting, adding weight or drilling holes into structure.
Any alteration not specifically authorized by AGCO
invalidates AGCO certification for ROPS. Protection
offered by ROPS will be impaired if ROPS has structural
damage. Damage to structure can be caused by an
overturn or by falling objects.
Do not mount items (fire extinguishers, first aid kits, work
lights, etc.) by welding any brackets to ROPS or by drilling
holes in ROPS. See dealer for mounting guidelines.
Burn Hazards
FIG. 16: Do not touch any part of an operating engine.
Other components such as transmission, axles and oil
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reservoir may be hot. Allow engine to cool before any

maintenance is performed. Relieve all pressure in air, oil,
lubrication, fuel system or cooling system before any line,
fittings or related items are disconnected.
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N020903016
FIG. 16
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Coolant Precautions
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FIG. 17: When engine is at operating temperature,

engine coolant is hot and under pressure. Radiator and all
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lines to heaters or engine contain hot coolant.

Any contact with hot coolant or steam can cause severe
burns. Allow cooling system components to cool before
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cooling system is drained.

Check coolant level only after engine has been stopped.
Cooling system conditioner contains alkali that can cause
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personal injury.
Do not allow alkali to contact skin, eyes or mouth. Do not
remove radiator cap if engine is hot. Only remove cap
when it is cool enough to touch with bare hands. Loosen N020903017
cap slowly to first notch to relieve pressure, then remove FIG. 17

cap.
1-12 79033095 C Rev.

Introduction
Escaping Fluid Dangers
FIG. 18: Escaping fluid under high pressure can be
almost invisible but can penetrate skin causing serous
injury and possible death. A pinhole leak can cause
severe injury.
Consult a doctor immediately if an injury from escaping
fluids is sustained. Fluid injected into skin must be
surgically removed within a few hours or gangrene may
result.
Hot oil and hot components can cause personal injury.
N020903018
FIG. 18
FIG. 19: Use a piece of cardboard or wood to search for
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possible leaks, never use hands.

IMPORTANT: Ensure fluids are contained during
performance of inspection, maintenance, testing,
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adjusting and repair of machine. Be prepared to

collect fluid with suitable containers before
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opening any compartment or disassembling any

component containing fluids. Dispose of all fluids
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according to local regulations and mandates.

Do not bend or strike any high pressure line. Do not install
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bent or damaged lines.

Check lines, tubes and hoses carefully. Repair loose or N020903019
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damaged lines. Tighten all connections to recommended

torque. FIG. 19
Replace parts if any of the following conditions are
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present:
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End fittings are damaged or leaking.

Outer coverings are chafed or cut.
Wires are exposed.
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Outer covering is ballooning.

Flexible parts of hoses are kinked.
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Outer covers have embedded armoring.

End fittings are displaced.
79033095 C Rev. 1-13

Introduction
Batteries
FIG. 20: Electrolyte is an acid and can cause personal
injury. Do not allow electrolyte to contact skin or eyes.
Always wear protective glasses when servicing batteries.
Wash hands after touching batteries and connectors.
N020903020
FIG. 20
FIG. 21: Battery gases can explode. Keep any open
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flames or sparks away from top of battery. Do not smoke

in battery charging areas.
Never check battery charge by placing a metal object
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across terminal posts. Do not lay tools or other conductive

materials on battery. Use a voltmeter on a hydrometer.
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improper jumper cable connections can cause an

explosion resulting injury.
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Be careful when connecting booster cables to batteries.

Electrical component damage or battery explosion can
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result if booster cables are not installed correctly.

Do not charge a frozen battery as it may explode. Warm N020903021
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battery to 16 degrees C (60 degrees F) FIG. 21
Lights, Reflector and Signs

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FIG. 22: Ensure all machine lights, reflectors and slow

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moving vehicle (SMV) signs are installed, in good

condition and wiped clean.
Consult local law enforcement agency for local
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regulations regarding movement of equipment on public

roads.
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N020903022
FIG. 22
1-14 79033095 C Rev.

Introduction
Fire and Explosion Prevention
FIG. 23: All fuels, most lubricants and some coolant
mixtures are flammable.
Flammable fluids leaking or spilled onto hot surfaces or
electrical components can cause fire.
Fire may cause personal injury and property damage.
Remove all flammable materials such as fuel, oil and
debris from machine.
Store fuels and lubricants in properly marked containers
away from unauthorized persons. Store oily rags and any
flammable materials in protective containers.
Do not smoke in areas used for storing flammable N021603001
materials.
FIG. 23
Do not operate machine near any flame.
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Exhaust shields protect hot exhaust components from oil

or fuel spray in case of a break in a line, hose or seal.
Exhaust shields must be installed correctly.
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Do not weld or flame cut on lines or tanks containing

flammable fluids. Clean any such lines or tanks
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thoroughly with non-flammable solvent prior to welding or

flame cutting.
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Check all electrical wires daily. Repair any lose or frayed

wire before operating machine. Clean and tighten all
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electrical connections.
Dust generated from repairing non-metallic hoods or
fenders can be flammable and/or explosive. Repair such
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components in a well-ventilated area way from open

flames or sparks.
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Inspect all lines and hoses for wear or deterioration.

Hoses must be properly routed. Lines and hoses must
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have adequate support and secure clamps. Tighten all

connections to recommended torque.
FIG. 24: Use caution and do not smoke while refueling a
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machine. Do not refuel a machine near open flames or

sparks and always stop engine before refueling. Always
refuel outdoors.
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N021603002
FIG. 24
79033095 C Rev. 1-15

Introduction
Fire Extinguisher
FIG. 25: Ensure a fire extinguisher is available. Be
familiar with operation of fire extinguisher. Inspect and
service extinguisher regularly and obey instructions on
instruction plate.
A mounting bracket can be installed on right front frame
rail. Bracket is designed to hold a 4.5 kg (10 lb)
extinguisher.
Ensure all clamps, guards and shields are installed
correctly to prevent vibration, rubbing against other parts
and excessive heat.
N020903006
FIG. 25
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Auto-Guide Precautions
Auto-Guide can be momentarily disabled if satellite signal
is lost. it is imperative operator be alert to position and
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conditions in field at all times.

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Auto-Guide system is designed to aid operator with

machine steering. Operator attention is required at all
times.
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Asbestos Information
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AGCO equipment and replacement parts shipped from

AGCO are asbestos-free. AGCO recommends use of
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only genuine AGCO replacement parts.
Electrical Storm Injury Prevention

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When lightning is striking in vicinity of machine, do not

dismount or mount machine.
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If in operator's station during an electrical storm, remain

there. If on ground during an electrical storm, stay away
from machine.
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1-16 79033095 C Rev.

Introduction
MACHINE IDENTIFICATION
Machine Identification Information

Plate Locations
Machine identification number (PIN) is used to identify a
powered machine designed for an operator to ride.
Components such as engines, transmissions and major
attachments not designed for an operator to ride are
identified by serial numbers.
For quick reference, record identification numbers in
spaces provided below illustration.
FIG. 26: Machine PIN. Plate is located on left side of
frame rail.
Machine PIN: _________________________________

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j731185
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FIG. 26
FIG. 27: Engine Serial Number. Plate is located on

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engine.
Engine Serial Number: _________________________
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J701041
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FIG. 27
FIG. 28: Transmission Serial Number. Plate is located on
left front side of transmission above hardball.
Transmission Serial Number: _____________________
j731180
FIG. 28
79033095 C Rev. 1-17

Introduction
FIG. 29: Cab Serial Number. Plate is located on the
outside front cab left.
Cab Serial Number: ____________________________
P111103001
FIG. 29
FIG. 30: Operator’s Seat Serial Number. Tag (1) is
located on rear of operator’s seat.
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Seat Serial Number: ___________________________

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KA15322
FIG. 30
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FIG. 31: Serial Number for Differential and Axles. Plate

is located near base of filler tube for hydraulic system.
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Differential and Axles Serial Number: _______________

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P050911001
FIG. 31
1-18 79033095 C Rev.

Introduction
TORQUE SPECIFICATIONS
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WARNING: Mismatched or incorrect
fasteners can result in damage, malfunction
or personal injury. Avoid mixing metric
dimensioned fasteners and inch
dimensioned fasteners.
Prior to installation of any hardware, ensure components

are in near new condition. Bolts and threads must not be
worn or damaged. Threads must not have burrs or nicks.
Hardware must be free of rust and corrosion. Clean
hardware with a noncorrosive cleaner.
Do not lubricate fastener threads except for rust
preventive. Rust preventive should be applied by supplier
of component for purposes of shipping and storage. Other
applications for lubricating components may also be
specified in Service Manual.
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Constant Torque Hose Clamps

Due to extreme temperature changes, hoses heat set.
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Heat setting can cause hose clamps to loosen. Loose

hose clamps can result in leaks. There have been reports
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of component failures caused by loosened hose clamps.

Constant torque hose clamp help prevent these failures.
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FIG. 32: Constant torque hose clamps is installed

correctly under the following conditions:
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• Screw tip (1) extends 6.35 mm (.25 inch) (A) beyond A

housing.
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• Belleville washers are collapsed nearly flat after

screw (2) is tightened to a torque of 11 Nm (8.1 lbf ft).
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1 2
00735086
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FIG. 32
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79033095 C Rev. 1-19

Introduction
FASTENERS INFORMATION
Metric Fasteners
Assembly Torque for Metric Fasteners
Standard High Low

Thread Size Torque Torque Torque Torque Torque Torque
Pound Feet Newton Pound Feet Newton Pound Feet Newton
lbf ft Meters lbf ft Meters lbf ft Meters
Nm Nm Nm
M6 x 1 8 to 10 9 to 15 9 to 11 10 to 16 3.5 to 4.5 5 to 7
M8 x 1.25 19 to 23 21 to 35 20 to 24 23 to 37 10 to 12 12 to 18
M10 x 1.5 37 to 45 45 to 65 40 to 48 48 to 72 20 to 24 23 to 37
M12 x 1.75 67 to 83 80 to 120 72 to 88 85 to 125 31 to 39 40 to 60
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M14 x 2 108 to 132 130 to 190 120 to 140 145 to 205 55 to 65 65 to 95

M16 x 2 160 to 190 200 to 280 180 to 220 230 to 310 80 to 100 105 to 145
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M20 x 2.5 305 to 375 400 to 520 350 to 430 460 to 600 165 to 205 210 to 290
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M24 x 3 530 to 650 700 to 900 600 to 730 800 to 1000 285 to 345 375 to 475
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M30 x 3.5 1060 to 13000 1400 to 1800 1200 to 1460 1600 to 2000 565 to 685 750 to 950
M36 x 4 1800 to 2200 2400 to 3000 2055 to 2515 2750 to 3450 990 to 1210 1300 to 1700
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Standard Taperlock Studs

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Thread Size Torque Torque

lbf ft Nm
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M6 6 8
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M8 13 17
M10 26 35
M12 48 65
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M16 80 110
M20 125 170
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M24 300 400

M30 550 750
M36 880 1200
1-20 79033095 C Rev.

Introduction
Inch Fasteners
Assembly Torque for Inch Fasteners
Standard High Low

Thread Size Torque Torque Torque Torque Torque Torque
Pound Feet Newton Pound Feet Newton Pound Feet Newton
lbf ft Meters lbf ft Meters lbf ft Meters
Nm Nm Nm
1/4 - 20 8 to 10 9 to 15 9 to 11 10 to 16 3.5 to 4.5 5 to 7
5/16 - 18 16 to 20 19 to 31 18 to 22 21 to 35 9 to 11 10 to 16
3/8 - 16 31 to 39 38 to 56 36 to 44 40 to 60 16 to 20 19 to 31
7/16 - 14 45 to 55 55 to 85 54 to 66 65 to 95 27 to 33 32 to 48
1/2 - 13 67 to 83 85 to 125 81 to 99 100 to 140 40 to 50 48 to 72
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9/16 - 12 110 to 130 130 to 190 117 to 143 145 to 205 55 to 65 70 to 100
5/8 - 11 145 to 175 175 to 255 160 to 190 200 to 280 75 to 95 95 to 135
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3/4 - 10 245 to 305 320 to 420 290 to 350 370 to 490 135 to 165 160 to 240
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7/8 - 9 410 to 510 540 to 700 470 to 570 610 to 790 215 to 265 285 to 365
1-8 590 to 730 800 to 1000 700 to 850 900 to 2200 335 to 405 435 to 565
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1 1/8 - 7 860 to 1060 1150 to 1450 965 to 1175 1300 to 1600 465 to 565 610 to 790
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1 1/4 - 7 1190 to 1450 1600 to 2000 1395 to 1705 1850 to 2350 880 to 1070 875 to 1125
1 3/8 - 6 1600 to 1960 2100 to 2700 1790 to 2190 2400 to 3000 1185 to 1445 850 to 1150
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1 1/2 - 5 2050 to 2510 2750 to 3450 2385 to 2915 3200 to 40000 1515 to 1845 1500 to 1900
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Standard Taperlock Studs

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Thread Size Torque Torque

lbf ft Nm
1/4 6 8
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5/16 13 17
3/8 26 35
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7/16 33 45
1/2 48 65
5/8 80 110
3/4 125 170
7/8 190 260
1 300 400
1 1/8 390 525
1 1/4 550 750
1 3/8 700 950
1 1/2 880 1200
79033095 C Rev. 1-21

Introduction
TIGHTENING STRAIGHT THREAD
FITTINGS
Straight thread hydraulic fittings require precise
tightening. Overtightening of hydraulic fittings ruin sealing
surfaces and require replacement of damaged parts.
Proper initial tightening depends on mating parts to be
connected. Proceed as follows:
An adapter fitting (37 degree flare) connected to a double
flare tube assembly. Fitting must be tightened finger tight
and wrenched 1/2 turn (for single flare, 1/4 turn).
An adapter fitting (37 degree flare) connected to a hose.
Fitting must be tightened finger tight and wrenched 1/4
turn.
An o-ring adapter fitting connected to a solid port. Fitting
must be tightened so backup washer contacts face of
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boss after fitting has been properly positioned.

To retighten after initial tightening, as in service work, both
tube and hose connections should be tightened finger
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tight and wrenched 1/4 turn. O-ring fittings should be

tightened as for initial assembly.
in
JIC SWIVEL NUTS (37 degree SEAT). The following

values are maximum recommended torque values for JIC
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(37 degree seat) swivel nuts either swaged or brazed

type. Swivel nuts normally withstand this torque for a
minimum of 15 repeated assemblies.
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Torque required to seal swivel female fittings or hose

couplings to a male connector depend on many variables
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such as fluid medium, pressure, surface finish, etc. The

following values are intended only as a guide for
maximum values fittings may be subjected to.
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DASH SIZE TUBE O. D. TORQUE MAX

(REF.)
Nm lbf in lbf ft
-4 1/4 12 110 9
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-5 5/16 20 180 15
-6 3/8 27 240 20
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-8 1/2 40 360 30
-10 5/8 54 480 40
-12 3/4 95 840 70
-14 7/8 110 980 80
-16 1 120 1080 90
-20 1 1/4 160 1440 120
-24 1 1/2 180 1575 130
-32 2 400 3600 300
-40 2 1/2 540 4800 400
-48 3 680 6000 500
1-22 79033095 C Rev.

Introduction
METRIC INFORMATION
MULTIPLY: BY: To Get: MULTIPLY BY: To Get:

LINEAR inches x 25.4 = millimeters (mm) x 0.03937 = inches
feet x 0.3048 = meters (m) x 3.281 = feet
yards x 0.9144 = meters (m) x 1.0936 = yards
miles x 1.6093 = kilometers (km) x 0.6214 = miles
inches x 2.54 = centimeters (cm) x 0.3937 = inches
microinches x 0.0254 = micrometers (um) x 39.37 = microinches
AREA inches² x 645.16 = millimeters² (mm²) x 0.00155 = inches²

inches² x 6.4516 = centimeters² (cm²) x 0.155 = inches²
feet² x 0.0929 = meters² (m²) x 10.764 = feet²
yards² x 0.8361 = meters² (m²) x 1.196 = yards²
acres x 0.4047 = hectometers² (hm²) x 2.471 = acres
= hectares (ha)
VOLUME inches³ x 16387 = millimeters³ (mm³) x 0.000061 = inches³

inches³ x 16.387 = centimeters³ (cm³) x 0.06102 = inches³
inches³ x 0.01639 = liters x 61.024 = inches³
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quarts x 0.94635 = liters x 1.0567 = quarts

gallons x 3.7854 = liters x 0.2642 = gallons
feet³ x 28.317 = liters x 0.03531 = feet³
feet³ x 0.02832 = meters³ (m³) x 35.315 = feet³
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fluid oz. x 29.57 = milliliters (ml) x 0.03381 = fluid oz.

yards³ x 0.7646 = meters³ (m³) x 1.3080 = yards³
in
teaspoons x 4.929 = milliliters (ml) x 0.2029 = teaspoons

cups x 0.2366 = liters x 4.227 = cups
bushel x 35.239 = liters x 0.02838 = bushels
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bushel x 0.03524 = meters³ (m³) x 28.378 = bushels
MASS ounces (av) x 28.35 = grams (g) x 0.03527 = ounces (av)

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pounds (av) x 0.4536 = kilograms (kg) x 2.2046 = pounds (av)

tons (2000 Ibs) x 907.18 = kilograms (kg) x 0.001102 = tons (2000 Ibs)
tons (2000 lbs) x .90718 = metric tons(t) x 1.1023 = tons(2000 lbs)
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tons (long) x 1016.05 = kilograms (kg) x .000984 = tons (long)

(2240 Ibs) (2240 Ibs)
FORCE ounces - f (av) x 0.278 = newtons (N) x 3.597 = ounces - f (av)

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pounds - f (av) x 4.488 = newtons (N) x 0.2248 = pounds - f (av)

kilograms - f x 9.807 = newtons (N) x 0.10197 = kilograms - f
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PRESSURE pounds/sq.in. x 6.895 = kilopascals (kPa) x 0.145 = pounds/sq. in.

OR STRESS
pounds/sq.in. x 0.0689 = bar x 14.503 = pounds/sq. in.
on
POWER horsepower x 0.746 = kilowatts (kW) x 1.34 = horsepower

ft-lbf/min. x 0.0226 = watts (W) x 44.25 = ft - lbf/min.
TORQUE pound - inches x 0.11298 = newton-meters (N.m) x 8.851 = pound-inches

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pound - feet x 1.3558 = newton-meters (N.m) x 0.7376 = pound-feet
VELOCITY miles/hour x 1.6093 = kilometers/hour (km/h) x 0.6214 = miles/hour

feet/sec. x 0.3048 = meters/sec. (m/s) x 3.281 = feet/sec.
kilometers/hr. x 0.27778 = meters/sec. (m/s) x 3.600 = kilometers/hr.
miles/hours x 0.4470 = meters/sec. (m/s) x 2.237 = miles/hour
TEMPERATURE
MetConv.doc
METCONV
79033095 C Rev. 1-23

Introduction
SPECIAL TOOLING
Special tooling listed below may be required for removal,
installation, disassembly or assembly of components of
the machine.
These parts can be ordered from AGCO.
Part Number Description

516186D1 Hose AS. - Tensioner Charge
548008D1 Adapter GP - Communications
563181D1 Adapter GP (COM 3)
516201D1 Cable - Data Link
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1-24 79033095 C Rev.

Index
INDEX
A M
Asbestos Information ........................................... 1-16 Machine Identification ........................................... 1-17

Assembly Torque for Inch Fasteners ................... 1-21 Metric Fasteners ................................................... 1-20
Assembly Torque for Metric Fasteners ................ 1-20 Metric Information ................................................. 1-23
Auto-Guide Precautions ....................................... 1-16 Mounting and Dismounting ..................................... 1-7
B O
Batteries ............................................................... 1-14 Operation ................................................................ 1-8

Battery Disconnect ............................................... 1-11 Operator Station ..................................................... 1-9
Before Starting Engine ........................................... 1-8
Burn Hazards ....................................................... 1-12
P
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C Parking ................................................................... 1-8

Plate Locations ..................................................... 1-17
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Constant Torque Hose Clamps ............................ 1-19 Product Identification Information ......................... 1-17
Coolant Precautions ............................................. 1-12 Protective Clothing ................................................. 1-6
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Crushing Prevention and Cutting Prevention ......... 1-7
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Replacement Parts ................................................. 1-1
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Divisions and Page Numbers ................................. 1-1 Rollover Protective Structure (ROPS) .................. 1-12
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E S
Electrical Storm Injury Prevention ........................ 1-16 Safety Alert Symbol ................................................ 1-3
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Engine Starting .................................................... 1-10 Safety Information .................................................. 1-2

Escaping Fluid Dangers ....................................... 1-13 Safety Words And Symbols .................................... 1-3
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Exhaust Dangers ................................................... 1-8 Seat Belts ............................................................. 1-10

Service Manual ....................................................... 1-1
Shield Removal .................................................... 1-10
F Special Tooling ..................................................... 1-24
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Fasteners Information .......................................... 1-20

Fire and Explosion Prevention ............................. 1-15 T
Fire Extinguisher .................................................. 1-16
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Fluid Precautions ................................................. 1-11 Tightening Straight Thread Fittings ...................... 1-22
Torque Specifications ........................................... 1-19
G
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General Hazard Information ................................... 1-5
Units of Measurement ............................................ 1-1
Inch Fasteners ..................................................... 1-21

Informational Messages ......................................... 1-4
Lights, Reflector and Signs .................................. 1-14
79033095 C Rev. 01-25

Index
NOTES
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01-26 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
02 - Engine
Contents
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ENGINE COMPONENT
Introduction .................................................................................................................................................... 02-1
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Specifications and Standards Concerning Fuel, Oil and Coolant .................................................................. 02-1
Fuel Quality ............................................................................................................................................. 02-1
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Oil Quality ................................................................................................................................................ 02-1

Coolant Quality ........................................................................................................................................ 02-1
Serpentine Belt Replacement ........................................................................................................................ 02-2
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Serpentine Belt Removal ......................................................................................................................... 02-2

Serpentine Belt Installation ...................................................................................................................... 02-5
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Alternator - Removal and Installation ............................................................................................................. 02-8

Removal Procedure ................................................................................................................................. 02-8
Alternator Install .................................................................................................................................... 02-11
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Cooling Assembly - Removal and Installation ............................................................................................. 02-13

Cooling Assembly Removal Procedure ................................................................................................. 02-13
Cooling Assembly Installation Procedure .............................................................................................. 02-23
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Cooling Assembly - Radiator Removal and Installation ............................................................................... 02-30

Radiator Removal .................................................................................................................................. 02-30
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Radiator Installation ............................................................................................................................... 02-40

Cooling Assembly - transmission / Implement Cooler Removal and Installation ......................................... 02-49
Transmission / Implement Cooler Removal .......................................................................................... 02-49
Hydraulic/Transmission/Axle Cooler Installation ................................................................................... 02-59
on
Cooling Assembly - Charge Air Cooler Removal and Installation ................................................................ 02-68
Charge Air Cooler Removal .................................................................................................................. 02-68
Charge Air Cooler Installation ............................................................................................................... 02-73
Cooling Assembly - Air Conditioning Condenser Removal and Installation ................................................ 02-78
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Air Conditioning Condenser Removal ................................................................................................... 02-78

Air Conditioning Condenser Installation ................................................................................................ 02-82
Cooling Assembly - Fuel Cooler Removal and Installation .......................................................................... 02-85
Fuel Cooler Removal Procedure ........................................................................................................... 02-85
Fuel Cooler Installation Procedure ........................................................................................................ 02-88
Air Intake Assembly Removal and Installation ............................................................................................. 02-90
Air Intake Assembly Removal ............................................................................................................... 02-90
Air Intake Assembly Installation ............................................................................................................ 02-93
Air Cleaner Assembly Removal and Installation .......................................................................................... 02-96
Air Cleaner Assembly Removal ............................................................................................................. 02-96
Air Cleaner Installation .......................................................................................................................... 02-98
Air Cleaner Filter Removal and Installation ............................................................................................... 02-100
Air Cleaner Filter Removal .................................................................................................................. 02-100
Air Cleaner Filter Installation ............................................................................................................... 02-101
Dust Ejector Removal and Installation ....................................................................................................... 02-102
Dust Ejector Removal .......................................................................................................................... 02-102
Dust Ejector Installation ....................................................................................................................... 02-104
Exhaust System Removal and Installation ................................................................................................ 02-105
Exhaust System Removal ................................................................................................................... 02-105
79033095 C Rev. 02-i

Contents
Exhaust System Installation ................................................................................................................ 02-107
Muffler Removal and Installation ............................................................................................................... 02-109
Muffler Removal .................................................................................................................................. 02-109
Muffler Installation ............................................................................................................................... 02-111
Battery Removal and Installation ............................................................................................................... 02-113
Battery Removal .................................................................................................................................. 02-113
Battery Installation ............................................................................................................................... 02-115
Fan Removal and Installation .................................................................................................................... 02-117
Fan Removal ....................................................................................................................................... 02-117
Fan Installation .................................................................................................................................... 02-120
Fan Drive Removal and Installation ........................................................................................................... 02-123
Fan Drive Removal .............................................................................................................................. 02-123
Fan Drive Installation ........................................................................................................................... 02-126
Fan Drive Disassembly and Assembly ...................................................................................................... 02-129
Fan Drive Disassembly ....................................................................................................................... 02-129
Fan Drive Assembly ............................................................................................................................ 02-131
Air Conditioning Compressor Removal and Installation ............................................................................ 02-132
Air Conditioning Compressor Removal ............................................................................................... 02-132
Air Conditioning Compressor Installation ............................................................................................ 02-136
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Air Conditioning Accumulator Removal and Installation ............................................................................ 02-138

Air Conditioning Accumulator Removal ............................................................................................... 02-138
Air Conditioning Accumulator Installation ............................................................................................ 02-141
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Hood Removal and Installation .................................................................................................................. 02-142

Hood Removal ..................................................................................................................................... 02-142
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Hood Installation .................................................................................................................................. 02-146

Input Shaft and Input Coupling Removal and Installation .......................................................................... 02-149
Input Shaft and Input Coupling Removal ............................................................................................. 02-149
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Input Shaft and Input Coupling Installation .......................................................................................... 02-152

Air Compressor Removal and Installation ................................................................................................. 02-154
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Air Compressor Removal .................................................................................................................... 02-154

Air Compressor Installation ................................................................................................................. 02-159
Air Reservoir Removal and Installation ...................................................................................................... 02-163
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Air Reservoir Removal ........................................................................................................................ 02-163

Air Reservoir Installation ..................................................................................................................... 02-167
Engine Removal and Installation ............................................................................................................... 02-170
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Engine Removal .................................................................................................................................. 02-170

Engine Installation ............................................................................................................................... 02-191
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Primary Fuel Filter / Water Separator Removal and Installation ................................................................ 02-209
Primary Fuel Filter / Water Separator Removal .................................................................................. 02-209
Primary Fuel Filter / Water Separator Installation ............................................................................... 02-211
Secondary Fuel Filter Removal and Installation ........................................................................................ 02-212
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Secondary Fuel Filter Removal ........................................................................................................... 02-212

Secondary Fuel Filter Installation ........................................................................................................ 02-214
Fuel Priming Pump .................................................................................................................................... 02-215
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Fuel Priming Pump .............................................................................................................................. 02-215

Ether Start Removal and Installation ......................................................................................................... 02-216
Ether Start Removal ............................................................................................................................ 02-216
Ether Start Installation ......................................................................................................................... 02-218
INDEX ........................................................................................................................................................... 02-219
02-ii 79033095 C Rev.

Engine Component
ENGINE COMPONENT
INTRODUCTION
The machine utilizes a diesel engine manufactured by
CAT for AGCO.
Many of the components are mounted and operate
directly with the CAT engine. This section describes the
proper procedures to remove and install the components.
If an internal engine problem arises that warrants engine
removal from the frame of the machine this section will
describe the proper procedure for removal and
installation.
SPECIFICATIONS AND STANDARDS

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CONCERNING FUEL, OIL AND COOLANT

The engines fitted on the machine series comply with
standards concerning emissions imposed by the
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authorities. (EU97/68/EC and 2007 US EPA and

California Regulations for Large Non Road Compression
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Ignition Engines)
The quality of the fluids used in these engines, as well as
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the servicing schedule, must be respected in order to

keep pollution emission levels low and to maintain the
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machine’s performance throughout its life.
Fuel Quality
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The fuel must comply with standard DIN EN 590 and with
the following specifications:
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Density at 15 degrees C (59 degrees F): 0.82 to 0.84

kg/dm
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Viscosity at 40 degrees C (104 degrees F): 2 to 4.5

mm/sec
Cetane index: min 51
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Sulphur content: max 0.005p-%

Water content: max 200mg/kg
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Oil Quality
The oil used must comply with API CI-4 standard.
Coolant Quality
The coolant used must comply with the ASTM d 3306
standard. It must consist of pure water and
ethylene/propylene glycol type antifreeze in the following
proportions:
• 40-60% water
• 40-60% antifreeze
The ideal ratio is 50% water to 50% antifreeze.
79033095 C Rev. 02-1

Engine Component
SERPENTINE BELT REPLACEMENT
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WARNING: Hot engine components can
cause injury from burns. Before performing
maintenance on the engine, allow the
engine and the components to cool.
Serpentine Belt Removal

FIG. 1: Battery disconnect switch.
IMPORTANT: Park the machine on a hard, level surface.
Location of battery disconnect switch (1).
1
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P100506001
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FIG. 1
FIG. 2: Disconnect battery power at battery disconnect
in
switch.
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Rotate and remove key (1) to disconnect the battery

power.
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1
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N012206002
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FIG. 2
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02-2 79033095 C Rev.

Engine Component
FIG. 3: Remove right guard.
Remove bolts (1) and remove guard (2).
2
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N011906001
FIG. 3
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FIG. 4: Remove left guard.

NOTE: This guard does not need to be removed if
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replacing just the fan drive serpentine belt.

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N012606004
FIG. 4
79033095 C Rev. 02-3

Engine Component
FIG. 5: Fan drive serpentine belt removal.
Use a ratchet wrench in the square hole (1) on the belt
tensioner (2) and turn counter clockwise to relieve belt
tension. Remove serpentine belt (3). Slowly release the
belt tensioner to relax into a neutral position.
m
WARNING: Equipment or parts under 2 3
spring tension can cause bodily injury. Use
caution in releasing belt tension.
NOTE: Be sure to allow enough room for the swing of the

ratchet to allow belt tensioner to relax into a
neutral position.
1
N021606002
FIG. 5
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FIG. 6: Accessories serpentine belt removal.

NOTE: Fan drive serpentine belt must be removed to
replace accessories serpentine belt.
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tensioner (2) and turn clockwise to relieve belt tension. 1 2
in
Remove serpentine belt (3). Slowly release the belt

tensioner to relax into a neutral position.
3
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WARNING: Equipment or parts under
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caution in releasing belt tension.

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neutral position.
N021606002
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FIG. 6
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02-4 79033095 C Rev.

Engine Component
Serpentine Belt Installation
FIG. 7: Accessories serpentine belt install.
NOTE: Skip this step if the accessories serpentine belt
was not removed.
Install serpentine belt (3) over pulleys on front of engine,
leaving it off of alternator pulley. Ensure that belt ribs are 1 2
properly seated in pulley valleys.
Insert square drive of ratchet into square hole (1) on belt 3
tensioner (2) and rotate tensioner clockwise and hold.
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caution in applying pressure to belt
tensioner. 4
Carefully place belt onto alternator pulley (4) ensuring belt N021606002
ribs are properly seated in pulley valleys and slowly allow
Fo
FIG. 7
belt tensioner to release until it makes contact with belt.
FIG. 8: Fan drive serpentine belt install.
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leaving it off of fan drive. Ensure that belt ribs are properly
in
seated in pulley valleys.

Insert square drive of ratchet into square hole (1) on belt
4
3
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tensioner (2) and rotate tensioner counter clockwise and

hold. 2
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tensioner.
Carefully place belt onto fan drive pulley (4) ensuring belt
1
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belt tensioner to release until it makes contact with belt. N021606002
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FIG. 8
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79033095 C Rev. 02-5

Engine Component
FIG. 9: Install right guard.
Install guard (2) and install bolts and washers (1) and
tighten. Tighten to 55 Nm (40 lbf ft).
2
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N011906001
FIG. 9
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FIG. 10: Install left guard.

NOTE: This step can be skipped if the left guard was not
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removed.
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tighten. Tighten to 55 Nm (40 lbf ft). 1

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N012606004
FIG. 10
02-6 79033095 C Rev.

Engine Component
FIG. 11: Connect battery at battery disconnect switch.
Install key (1) and rotate to connect the battery power.
N012206002
FIG. 11
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79033095 C Rev. 02-7

Engine Component
ALTERNATOR - REMOVAL AND
INSTALLATION
Removal Procedure
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P100506001
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FIG. 12
FIG. 13: Disconnect battery at battery disconnect switch.
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power.
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N012206002
FIG. 13
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02-8 79033095 C Rev.

Engine Component
NOTE: This guard does not need to be removed if
replacing just the fan drive serpentine belt.
1
1
2
Fo
1
r in
te
rn
N012606004
FIG. 14
al
FIG. 15: Remove wiring:

Mark and remove wiring (1), (2), and (3) from alternator 4
(4).
u se
1 3
on
2
P100106057
ly
FIG. 15
79033095 C Rev. 02-9

Engine Component
FIG. 16: Serpentine belt removal.
tensioner (2) and turn clockwise to relieve belt tension.
1 2
m
caution in releasing belt tension. 3

neutral position.
N021606002
FIG. 16
Fo
FIG. 17: Remove alternator.

Remove the two top bolts (1) and bottom bolt (2). Remove 1
alternator (3). The weight of the alternator is
r
approximately 27 kg (60 lb).

in
te
2 3
rn
P100106058
al
FIG. 17
u se
on
ly
02-10 79033095 C Rev.

Engine Component
Alternator Install
FIG. 18: Install pulley.
Install pulley (1) onto alternator shaft (2) and tighten nut
(3) to 102 Nm ± 7 Nm (75 lbf ft ± 5 lbf.ft). 1
2 3
P100106058
FIG. 18
FIG. 19: Install alternator.
Fo
Place alternator (3) and install the two top bolts (1) and 1
bottom bolt (2). Tighten top two bolts to 71 N.m. (52 ft.lb.).
Tighten bottom bolt to 105 N.m. (77 lb.ft.). The weight of
the alternator is approximately 27 kg (60 lb).
r in
te
2 3
rn
P100106058
FIG. 19
al
FIG. 20: Belt install.

leaving it off of alternator pulley. Ensure that belt ribs are
u

se
Insert square drive of ratchet into square hole (1) on belt 1 2

m
WARNING: Equipment or parts under 3
on

tensioner.
ly
Carefully place belt onto alternator pulley (4) ensuring belt 4

N021606002
FIG. 20
79033095 C Rev. 02-11

Engine Component
FIG. 21: Install wiring.
Mark and remove wiring (1), (2) and (3) from alternator 4
(4).
Connect electrical wires (1), (2) and (3) to posts on back
of alternator (4).
Position protective boot over power terminal (2). 1 3
2
P100106057
FIG. 21
NOTE: This step can be skipped if the left guard was not
removed.
Fo
tighten. Tighten to 55 Nm (40 lbf ft). 1
1
r in
te
2
rn
al
u
1
se
on
N012606004
ly
FIG. 22
FIG. 23: Connect battery at battery disconnect switch.
Insert and rotate key (1) to connect the battery power.
N012206002
FIG. 23
02-12 79033095 C Rev.

Engine Component
COOLING ASSEMBLY - REMOVAL AND
INSTALLATION
Cooling Assembly Removal Procedure

NOTE: Put identification marks on all hoses, on all hose
assemblies, on all wires, and on all tube
assemblies for installation purposes. Any engine
openings such as turbo charger, intake manifold
ports and coolant ports should be plugged or
capped while their respective tubes, hoses and
any other connections are removed. This helps
to prevent fluid loss, and helps keep
contaminants from entering the system.
IMPORTANT: Care must be taken to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
machine. Be prepared to collect the fluid with
Fo
suitable containers before opening any

compartment or disassembling any component
containing fluids. Dispose of all fluids according
r
to local regulations and mandates.

Dispose of all fluids according to local regulations
in
and mandates.
NOTE: Cleanliness is an important factor. Before you
te
begin the disassembly procedure, the exterior of

the components should be thoroughly cleaned.
rn
This will help to prevent dirt from entering the

internal mechanism. Precision components can
be damaged by contaminants or by dirt. Perform
al
disassembly procedures on a clean work

surface. Keep components covered and
protected at all times.
u
m
se

on
ly
79033095 C Rev. 02-13

Engine Component
m
WARNING: Personal injury can result from
contact with refrigerant.
Contact with refrigerant can cause frost
bite. Keep face and hands away to help
prevent injury.
Protective goggles must always be worn
when refrigerant lines are opened, even if
the gauges indicate the system is empty of
refrigerant.
Always use precaution when a fitting is
removed. Slowly loosen the fitting. If the
system is still under pressure, release it
slowly in a well ventilated area.
Personal injury or death can result from
inhaling refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas
Fo
through a lit cigarette or other smoking

method or inhaling fumes released from a
flame contacting air conditioner refrigerant
gas, can cause bodily harm or death.
r
Do not smoke when servicing air

in
conditioners or wherever refrigerant gas

may be present.
te
Use a certified recovery and recycling cart

to properly remove the refrigerant from the
rn
air conditioning system.
IMPORTANT: Only a certified technician with certified

al
equipment should service the air conditioning

system.
IMPORTANT: Whenever the air conditioning system is
u
opened you must replace the air conditioning

accumulator. See air conditioning accumulator
se
removal and installation section.

FIG. 24: Battery disconnect switch
on

1
ly
P100506001
FIG. 24
02-14 79033095 C Rev.

Engine Component
power.
N012206002
FIG. 25
FIG. 26: Remove fanblast guard.
Remove four bolts (1) and remove fanblast guard (2). The
1
weight of the fanblast guard is approximately 58 kg (128 2
Fo
lb).
r in
1
te
P100506002
FIG. 26
rn
FIG. 27: Drain engine coolant.

al
Place approved container under drain line (1). Turn valve

(2) counter clockwise to open. Drain engine coolant into
an approved container for storage or disposal. When 2
coolant is finished draining turn valve (2) clockwise to
u
close.
se
1
on
N012606002
FIG. 27
ly
FIG. 28: Remove hood.

Remove hood (1). Refer to Removal and Installation -
Hood - Removal. 1
P100506003
FIG. 28
79033095 C Rev. 02-15

Engine Component
FIG. 29: Remove air intake.
Remove bolts (1).
3
Slide air intake (2) forward. Carefully pull it out of its seal
(3).
1 1
Fo
N012606006
FIG. 29
FIG. 30: Remove right side charge air tube.
r
Clean dirt off of charge air tube (1) and its connections to 1
2 2
in
prevent dirt entering the system.

Loosen nuts (2) on hose clamps.
te
Remove charge air tube (1).

IMPORTANT: Plug turbo hole and hole in the charge air
rn
cooler with clean cloth towels to prevent dirt

entering the system.
al
N012606007
u
FIG. 30
se
FIG. 31: Remove left side charge air tube.

Clean dirt off of charge air tube (1) and it connections to 2 1
on

IMPORTANT: Plug intake hole and hole in the charge air
ly

entering the system. 2
N020606001
FIG. 31
02-16 79033095 C Rev.

Engine Component
1
1
2
Fo
1
r in
te
rn
N012606004
FIG. 32
al

u
1
se
1
on
2
ly
N011906001
FIG. 33
79033095 C Rev. 02-17

Engine Component
FIG. 34: Fuel shut off.
At the primary fuel filter / water separator (1) on the left
side of the engine, turn shut off valve handle (2) 90
degrees clockwise. Shut off valve handle (2) should be
perpendicular to the valve. 2
1
N033006001
FIG. 34
FIG. 35: Remove fuel lines (1) from fuel cooler core (2).
Plug hoses to prevent fuel loss.
NOTE: Mark hoses to ensure that hoses are connected
Fo
to original location. 2
r
1
in
te
P100506004
FIG. 35
rn
FIG. 36: Remove cover plate.

al
Remove knobs (1) and remove cover plate (2). 1

u
2
se
1
on
N021606005
FIG. 36
ly
FIG. 37: Remove plastic cable straps (1) from fuel lines
(2) and fasten out of the way.
2
1
1
P100506005
FIG. 37
02-18 79033095 C Rev.

Engine Component
FIG. 38: Remove right side of fan shroud.
Remove bolts (1) and nuts from shroud that hold the two
halves together.
Remove bolts (2) from shroud that fasten it to the cooler
assembly. 2
Remove right half of shroud (3). 1
3
Fo
r
2
in
1
te
N011906002
FIG. 38
rn
FIG. 39: Remove left side of fan shroud.

Remove bolts (1) that fasten air conditioning line to the
al
shroud. Fasten air conditioning line out of the way.

2
u
assembly.
se
Remove left half of shroud (3).
1
on
3
ly
N012606005
FIG. 39
79033095 C Rev. 02-19

Engine Component
FIG. 40: Remove the upper radiator hoses.
Loosen hose clamps to disconnect radiator hose (1) and
top tank vent hose (2) from the top of the radiator. Plug
1
ends of hose to prevent fluid from escaping and dirt
2
N020606002
FIG. 40
FIG. 41: Remove the lower radiator hose.
Disconnect radiator hose by loosening hose clamp (1)
from the bottom of the radiator. Plug end of hoses and
Fo
cap oil cooler ports to prevent fluid from escaping and dirt
r
1
in
te
N020606003
FIG. 41
rn
FIG. 42: Remove oil cooler hoses.

al
Remove oil cooler hoses (1) and fasten out of the way.
Plug ends of hose to prevent fluid from escaping and dirt
u se
1
on
1
N020606005
FIG. 42
ly
FIG. 43: Remove air conditioning lines.

system. 1
IMPORTANT: Refer to Refrigerant section for proper
removal of hoses.
A certified technician must recover refrigerant and remove
air conditioning lines (1). Refer to Refrigerant section for
proper removal of hoses. Fasten air conditioning lines out
of the way.
N020606004
FIG. 43
02-20 79033095 C Rev.

Engine Component
FIG. 44: Remove the supports.
Remove bolts (1) on each side of cooler assembly.
1
N020706002
FIG. 44
FIG. 45: Connect lifting chains.
Attach proper lifting device to keyholes (1) on cooling
package. Use chains and a suitable lifting device to
Fo
support the cooling package.

1
r in
te
N020706001
FIG. 45
rn
FIG. 46: Remove the mounting hardware.

al
Remove four bolts (1) on the back of cooling assembly

(2).
u
2
se
1
on
1
N020906001
FIG. 46
ly
FIG. 47: Remove the mounting hardware.

Remove four bolts (1) on the front of cooling assembly (2).
1 1
N020706003
FIG. 47
79033095 C Rev. 02-21

Engine Component
FIG. 48: Remove cooling assembly.
Remove cooling package (1). The weight of the cooling
package is approximately 205 kg (450 lb).
N020706001
FIG. 48
Fo
r in
te
rn
al
u se
on
ly
02-22 79033095 C Rev.

Engine Component
Cooling Assembly Installation
Procedure
FIG. 49: Connect lifting chains.
Attach proper lifting device to keyholes (1) on cooling
package (2). Use chains and a suitable lifting device to
support the cooling package.
1
Install cooling package. The weight of the cooling 2
package is approximately 205 kg (450 lb).
NOTE: Route the coolant drain line through the hole in
the floor of the frame.
N020706001
FIG. 49
FIG. 50: Install the mounting hardware.
Fo
Install four bolts and washers (1) on the front of cooling

assembly (2). Tighten to 120 Nm (88 lbf ft).
r in
te
2
rn
1 1
N020706003
al
FIG. 50
FIG. 51: Install the mounting hardware.
u
Install four bolts and washers (1) on the back of cooling

assembly (2). Tighten to 120 Nm (88 lbf ft).
se
Remove lifting chains.

2
on
1
1
ly
N020906001
FIG. 51
FIG. 52: Install the supports.
Install two bolts and washers (1) on each side of cooler
assembly. Tighten to 55 Nm (40 lbf ft).
1
N020706002
FIG. 52
79033095 C Rev. 02-23

Engine Component
FIG. 53: Install air conditioning lines.
system. 1
installation of hoses.
A certified technician must install air conditioning lines (1)
and charge the air conditioning system. Refer to
Refrigerant section for proper installation of hoses.
N020606004
FIG. 53
FIG. 54: Install oil cooler hoses.
Install oil cooler hoses (1).
Fo
r
1
in
1
te
N020606005
FIG. 54
rn
FIG. 55: Install the lower radiator hose.

al
Remove all plugs from the ends of the hose that prevent 3
fluid from escaping and dirt entering the system. Install
radiator hose (2) onto the radiator (3) and tighten hose
clamp (1).
u se
1
2
on
N020606003
FIG. 55
ly
FIG. 56: Install the upper radiator hoses.

2
Remove all plugs from the ends of the hose that prevent
1
radiator hose (2) and top tank vent hose (3) onto the top 4
of the radiator (4) and tighten hose clamps (1).
Fill the cooling system. Refer to Operation and 1
3
Maintenance Manual, Lubrication and Maintenance,
Cooling System.
N020606002
FIG. 56
02-24 79033095 C Rev.

Engine Component
FIG. 57: Install left side of fan shroud.
Install left half of shroud (2).
IMPORTANT: Do not tighten the bolts at this time. After
the other side is installed, adjust the shroud to
provide symmetrical clearance with fan. 1
Install bolts and washers (1) that fasten air conditioning
line to the shroud.
2
Fo
1
r in
te
N012606005
FIG. 57
rn
FIG. 58: Install right side of fan shroud.

Install right half of shroud (3).
al
Install bolts and washers (2) that fasten it to the cooler

assembly.
u
Install bolts, nuts and washers (1) that hold the two halves 2
1
se
of the shroud together and tighten.

IMPORTANT: Do not tighten the bolts that attach the
shroud to the cooler assembly at this time. Adjust
the shroud to provide symmetrical clearance with
on
fan.
After the shroud has a symmetrical clearance to the fan,
tighten the bolts (2) on each side of the shroud. 3
ly
1
N011906002
FIG. 58
79033095 C Rev. 02-25

Engine Component
FIG. 59: Install fuel lines (2) and fasten to clips with cable
straps (1).
2
1
1
P100506005
FIG. 59
FIG. 60: Remove plugs from hoses. Install fuel lines (1)
onto fuel cooler core (2) in there original location.
Fo
2
r
1
in
te
P100506004
FIG. 60
rn
FIG. 61: Install cover plate.

al
Apply anti-seize to threaded studs before installing knobs. 1

Install cover plate (2) and install knobs (1).
u
2
se
1
on
N021606005
FIG. 61
ly
FIG. 62: Open fuel shut off.

degrees counter clockwise. Shut off valve handle (2)
should be parallel to the valve. 2
1
N033006001
FIG. 62
02-26 79033095 C Rev.

Engine Component
2
Fo
1
r in
N011906001
FIG. 63
te

rn

al
1
1
u se
2
on
ly
N012606004
FIG. 64
79033095 C Rev. 02-27

Engine Component
FIG. 65: Install left side charge air tube.
IMPORTANT: Make sure that there is no dirt or debris in 2 1
the charge air tube, charge air cooler or intake
manifold.
IMPORTANT: Remove all cloth plugs from the intake
hole and hole in the charge air cooler.
Install charge air tube (1) and tighten nuts (2) on hose
clamps. Tighten to 7 Nm (61 lbf in).
2
N020606001
FIG. 65
FIG. 66: Install right side charge air tube.
IMPORTANT: Make sure that there is no dirt or debris in 1
2 2
the charge air tube, charge air cooler or turbo.
Fo
IMPORTANT: Remove all the cloth that plugs the turbo

outlet and hole in the charge air cooler to prevent
dirt entering the system.
r
in

te
N012606007
FIG. 66
rn
FIG. 67: Install air intake.

al
Install air intake (2). Slide seal (3) back to its original
position. 3
Install bolts and washers (1).
u se
1 1
on
ly
N012606006
FIG. 67
02-28 79033095 C Rev.

Engine Component
Install fanblast guard (2) and install four bolts (1). The
1
lb). Tighten bolts to 100 Nm (74 lbf ft).
1
P100506002
FIG. 68
FIG. 69: Install hood.
Install hood (1). Refer to Removal and Installation - Hood
- Installation. 1
Fo
r in
te
P100506003
FIG. 69
rn
FIG. 70: Connect battery power at battery disconnect

switch.
al

Start engine and check all hoses and hose connections
u
for leaks.
se
1
on
N012206002
FIG. 70
ly
79033095 C Rev. 02-29

Engine Component
COOLING ASSEMBLY - RADIATOR
REMOVAL AND INSTALLATION
Radiator Removal
m

assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and helps keep
Fo

r

containing fluids.
in

and mandates.
te

rn

1
al
u se
P100506001
FIG. 71
on
FIG. 72: Disconnect battery power at battery disconnect

switch.
ly

power.
N012206002
FIG. 72
02-30 79033095 C Rev.

Engine Component
1
lb).
1
P100506002
FIG. 73
Fo

close.
r in
1
te
N012606002
FIG. 74
rn

al

Hood - Removal. 1
u se
on
P100506003
FIG. 75
ly
79033095 C Rev. 02-31

Engine Component
Remove bolts (1).
3
(3).
1 1
Fo
N012606006
FIG. 76
r
Clean dirt off of charge air tube (1) and its connections to 2 1
in

te

rn

al
N020606001
u
FIG. 77
se
on
ly
02-32 79033095 C Rev.

Engine Component
1
1
2
Fo
1
r in
te
rn
N012606004
FIG. 78
al

u
1
se
1
on
2
ly
N011906001
FIG. 79
79033095 C Rev. 02-33

Engine Component
halves together.
assembly. 2
3
Fo
r
2
in
1
te
N011906002
FIG. 80
rn

al

2
u
assembly.
se
1
on
3
ly
N012606005
FIG. 81
02-34 79033095 C Rev.

Engine Component
top tank vent hose (2) from the top of the radiator. Plug
1
ends of hose to prevent fluid from escaping and dirt
2
N020606002
FIG. 82
from the bottom of the radiator. Plug end of hose and
Fo
radiator to prevent fluid from escaping and dirt entering

the system.
r
1
in
te
N020606003
FIG. 83
rn
FIG. 84: Remove upper brackets.

al
Remove bolts (1) and remove brackets (2). 2

u se
1
1
on
N021306001
FIG. 84
ly
FIG. 85: Remove upper brace.

Remove four bolts (1) and remove upper brace (2).
1
2
N021406006
FIG. 85
79033095 C Rev. 02-35

Engine Component
FIG. 86: Unfasten lower bracket.
1
Remove bolts (1) and leave bracket (2) connected to
hydraulic lines (3).
3
N020606003
FIG. 86
FIG. 87: Remove lower brace.
Remove four bolts (1) and remove lower brace (2).
Fo
r in
1 2 1
te
N021406007
FIG. 87
rn

al
Remove knobs (1) and remove cover plate (2).

1
u se
2
on
1
ly
N021306002
FIG. 88
1
N033006001
FIG. 89
02-36 79033095 C Rev.

Engine Component
P100506004
FIG. 90
Fo
2
r in
1
te
N021606005
FIG. 91
rn
al
2
u
1
se
on
1
P100506005
FIG. 92
ly
FIG. 93: Remove the two bolts (1) from each side and
remove fuel cooler (2).
2
P100506006
FIG. 93
79033095 C Rev. 02-37

Engine Component
FIG. 94: Remove interior mounting bolts.
Remove four bolts (1), access from the top or through the
access holes (2).
1 2
N021406002
FIG. 94
Fo
FIG. 95: Remove rear mounting bolts.

Remove four bolts (1).
r
1
in
te
rn
al
1
u se
N021406003
FIG. 95
FIG. 96: Remove side mounting bolts.
on
Remove six bolts (1).

ly
N021406004
FIG. 96
02-38 79033095 C Rev.

Engine Component
FIG. 97: Remove radiator.
Connect proper lifting device to the two bolts (1) on the
front and to the two bolts on the rear of the radiator (2).
When installing the four bolts the maximum torque is 40
Nm (29 lbf ft). The weight of the radiator is approximately
43 kg (94 lb).
IMPORTANT: Radiator must lifted evenly on all four
corners.
2 1
1
N021406005
FIG. 97
FIG. 98: Remove radiator.
Lift the radiator (1) straight up and out of the cooling
assembly (2). The weight of the radiator is approximately
1
Fo
43 kg (94 lb).
r in
te
rn
2
al
N021606001
u
FIG. 98
se
on
ly
79033095 C Rev. 02-39

Engine Component
Radiator Installation
FIG. 99: Install radiator.
Connect proper lifting device to the two bolts (1) on the
front and to the two bolts on the rear of the radiator (2).
When installing the four bolts the maximum torque is 40
Nm (29 lbf ft). The weight of the radiator is approximately
43 kg (94 lb). 1
IMPORTANT: Radiator must lifted evenly on all four
corners.
1
2
Fo
N021606004
FIG. 99
FIG. 100: Install radiator.
r
Install radiator (1) into cooling assembly (2). Ensure

in
radiator remains straight up and down during installation.

1
te
rn
al
u se
2
on
N021606001
FIG. 100
ly
02-40 79033095 C Rev.

Engine Component
FIG. 101: Install side mounting bolts.
Lower radiator until bolt holes line up and install six bolts
and washers (1).
1
Fo
N021406004
FIG. 101
FIG. 102: Install rear mounting bolts.
r
Install four bolts and washers (1).

in
1
te
rn
al
u se
1
on
N021406003
FIG. 102
FIG. 103: Install interior mounting bolts.
ly
Install four bolts and washers (1), access from the top or
through the access holes (2).
Remove lifting device and tighten the four bolts to 40 Nm
(29 lbf ft).
1
1 2
N021406002
FIG. 103
79033095 C Rev. 02-41

Engine Component
FIG. 104: Install the fuel cooler (2). Install two washers
and two bolts (1) on each side and tighten.
2
P100506006
FIG. 104
FIG. 105: Install fuel lines (2) and fasten to clips with
cable straps (1).
Fo
2
1
r in
1
te
P100506005
FIG. 105
rn
al
2
u se
1
on
P100506004
FIG. 106
ly

N021606005
FIG. 107
02-42 79033095 C Rev.

Engine Component
1
N033006001
FIG. 108
Apply anti-seize to threaded studs before installing knobs.
Install cover plate (2) and install knobs (1). 1
Fo
r
2
in
te
1
rn
N021306002
FIG. 109
al
FIG. 110: Install upper brace.

Install upper brace (2) and install four bolts and washers
(1). Tighten the four bolts to 55 Nm (40 lbf ft).
u se
1
on
2
ly
N021406006
FIG. 110
FIG. 111: Install upper brackets.
Install brackets (2) and install bolts and washers (1). 2
Tighten the four bolts to 28 Nm (21 lbf ft).
1
1
N021306001
FIG. 111
79033095 C Rev. 02-43

Engine Component
FIG. 112: Install lower brace.
Install lower brace (2) and install four bolts and washers
1 2 1
N021406007
FIG. 112
FIG. 113: Fasten lower bracket.
1
Install bolts and washers (1) into bracket (2).
Fo
r
2
in
te
N020606003
FIG. 113
rn

al
Remove plugs in the end of hose and lower radiator outlet

that prevent fluid from escaping and dirt entering the
system. Install lower radiator hose and tighten hose
clamp (1).
u se
1
on
N020606003
FIG. 114
ly

Remove plugs in the end of hose and upper radiator inlet
that prevent fluid from escaping and dirt entering the
1
system. Install upper radiator hose (1) and top tank vent
hose (2) and tighten hose clamps.
Cooling System.
N020606002
FIG. 115
02-44 79033095 C Rev.

Engine Component
line to the shroud.
2
Fo
1
r in
te
N012606005
FIG. 116
rn

al

assembly.
u
1
se

on
fan.
ly
1
N011906002
FIG. 117
79033095 C Rev. 02-45

Engine Component
tighten. Tighten the four bolts to 55 Nm (40 lbf ft).
2
Fo
1
r in
N011906001
FIG. 118
te

rn

al
1
1
u se
2
on
ly
N012606004
FIG. 119
02-46 79033095 C Rev.

Engine Component
manifold.
IMPORTANT: Remove all the cloths that plug the intake
manifold and hole in the charge air cooler to
clamps. Tighten to 7 Nm (61 lbf in). 2
N020606001
FIG. 120
2 2
Fo
IMPORTANT: Remove all the cloths that plug the turbo

r
in

te
N012606007
FIG. 121
rn

al
position. 3
Install bolts and washers (1). Tighten the four bolts to 29
u
Nm (21 lbf ft).

se
1 1
on
ly
N012606006
FIG. 122
79033095 C Rev. 02-47

Engine Component
1
1
P100506002
FIG. 123
- Installation. 1
Fo
r in
te
P100506003
FIG. 124
rn

switch.
al

u
for leaks.
se
1
on
N012206002
FIG. 125
ly
02-48 79033095 C Rev.

Engine Component
COOLING ASSEMBLY -
TRANSMISSION / IMPLEMENT
COOLER REMOVAL AND
INSTALLATION
Transmission / Implement Cooler Removal
m

Fo

r

in

containing fluids.
te

and mandates.
rn

al

u

se

on

1
ly
P100506001
FIG. 126
79033095 C Rev. 02-49

Engine Component
FIG. 127: Disconnect battery power at battery
disconnect switch.
power.
N012206002
FIG. 127
1
Fo
lb).
r in
1
te
P100506002
FIG. 128
rn

al

Hood - Removal. 1
u se
on
P100506003
FIG. 129
ly
02-50 79033095 C Rev.

Engine Component
Remove bolts (1).
3
(3).
1 1
Fo
N012606006
FIG. 130
r
2 2
in

te

IMPORTANT: Plug turbo outlet and hole in the charge air
rn

al
N012606007
u
FIG. 131
se
on
ly
79033095 C Rev. 02-51

Engine Component
1
1
2
Fo
1
r in
te
rn
N012606004
FIG. 132
al

u
1
se
1
on
2
ly
N011906001
FIG. 133
02-52 79033095 C Rev.

Engine Component
halves together.
assembly. 2
3
Fo
r
2
in
1
te
N011906002
FIG. 134
rn

al

2
u
assembly.
se
1
on
3
ly
N012606005
FIG. 135
79033095 C Rev. 02-53

Engine Component
FIG. 136: Remove upper brackets.
Remove bolts (1) and remove brackets (2). 2
N021306001
FIG. 136
FIG. 137: Remove upper brace.
Remove four bolts (1) and remove upper brace (2).
Fo
1
r in
1
2
te
rn
N021406006
FIG. 137
al
FIG. 138: Unfasten lower bracket.

1
Remove bolts (1) and leave bracket (2) connected to
u
hydraulic lines (3).

se
2
on
3
ly
N020606003
FIG. 138
FIG. 139: Remove lower brace.
Remove four bolts (1) and remove lower brace (2).
1 2 1
N021406007
FIG. 139
02-54 79033095 C Rev.

Engine Component
FIG. 140: Remove rear mounting bolts.
1
Fo
N021406003
FIG. 140
r

in
te
2
rn
1
al
N021606005
u
FIG. 141
se

on

1
ly
N033006001
FIG. 142
79033095 C Rev. 02-55

Engine Component
P100506004
FIG. 143
Fo
2
r in
1
te
N021606005
FIG. 144
rn
al
2
u
1
se
on
1
P100506005
FIG. 145
ly
2
P100506006
FIG. 146
02-56 79033095 C Rev.

Engine Component
FIG. 147: Disconnect interior hydraulic lines.
Remove two bolts (1) from the P-clips and disconnect
hydraulic lines (2). Access from the top or through the
access holes (3). Plug ends of tubes to prevent fluid from
escaping and dirt entering the system.
1
3
N021606006
FIG. 147
Fo
FIG. 148: Remove oil cooler hoses.

Remove oil cooler hoses (1) and fasten out of the way.
Plug ends of hose to prevent fluid from escaping and dirt
r

in
te
1
rn
N020606005
al
FIG. 148
FIG. 149: Remove interior mounting bolts.
u
Remove four bolts (1), access from the top or through the
access holes (2).
se
1
on
2
ly
N021606007
FIG. 149
79033095 C Rev. 02-57

Engine Component
FIG. 150: Remove exterior mounting bolts.
N021906001
FIG. 150
Fo
FIG. 151: Remove hydraulic cooler.

Connect proper lifting device to the two eyelets (1) on the
hydraulic cooler (2). The weight of the hydraulic cooler is
r

in
te
1
2
rn
N021906002
al
FIG. 151
FIG. 152: Remove hydraulic cooler.
u
Lift hydraulic cooler (1) straight up and out of the cooling

assembly (2). The weight of the hydraulic cooler is
se
approximately 33 kg (73 lb). 1

on
ly
N021906003
FIG. 152
02-58 79033095 C Rev.

Engine Component
Hydraulic/Transmission/Axle Cooler
Installation
FIG. 153: Install hydraulic cooler.
Hydraulic cooler (2). The weight of the hydraulic cooler is
2
Fo
N021906004
FIG. 153
r
FIG. 154: Install hydraulic cooler.

in
Install hydraulic cooler (1) into cooling assembly (2).

Ensure hydraulic cooler remains straight up and down
te
during installation. 1
rn
al
2
u se
N021906003
FIG. 154
on
FIG. 155: Install exterior mounting bolts.

Install four bolts, washers and nuts (1).
ly
N021906001
FIG. 155
79033095 C Rev. 02-59

Engine Component
FIG. 156: Install interior mounting bolts.
Install four bolts and washers (1), access from the top or
through the access holes (2).
1
2
1
N021606007
FIG. 156
Fo
FIG. 157: Connect interior hydraulic lines.

Remove plugs in the end of lines that prevent fluid from
escaping and dirt entering the system. Connect hydraulic
r
lines (2). Install two bolts, washers and nuts (1) to the
P-clips. Access from the top or through the access holes
in
(3). 2
3
te
rn
1
al
N021606006
u
FIG. 157
se
FIG. 158: Install rear mounting bolts.

Install four bolts and washers (1).
on
1
ly
N021406003
FIG. 158
02-60 79033095 C Rev.

Engine Component
2
P100506006
FIG. 159
cable straps (1).
Fo
2
1
r in
1
te
P100506005
FIG. 160
rn
al
2
u se
1
on
P100506004
FIG. 161
ly

N021606005
FIG. 162
79033095 C Rev. 02-61

Engine Component
1
N033006001
FIG. 163
Fo
2
r in
1
te
N021606005
FIG. 164
rn
FIG. 165: Install upper brace.

al
Install upper brace (2) and install four bolts and washers
u
1
se
1
on
2
ly
N021406006
FIG. 165
FIG. 166: Install upper brackets.
Install brackets (2) and install bolts and washers (1). 2
Tighten the four bolts to 29 Nm (21 lbf ft).
N021306001
FIG. 166
02-62 79033095 C Rev.

Engine Component
FIG. 167: Install lower brace.
Install lower brace (2) and install four bolts and washers
1 2 1
N021406007
FIG. 167
FIG. 168: Fasten lower bracket.
1
Install bolts and washers (1) into bracket (2). Tighten the
four bolts to 29 Nm (21 lbf ft).
Fo
r
2
in
te
N020606003
FIG. 168
rn
FIG. 169: Install oil cooler hoses.

al
Remove plugs in the end of hose that prevent fluid from

escaping and dirt entering the system. Install hydraulic
line (1).
u se
1
on
N020606005
FIG. 169
ly
79033095 C Rev. 02-63

Engine Component
line to the shroud.
1
1
Fo
1
r in
te
N012606005
FIG. 170
rn

al

assembly.
u
1
se

on
fan.
ly
1
N011906002
FIG. 171
02-64 79033095 C Rev.

Engine Component
2
Fo
1
r in
N011906001
FIG. 172
te

rn

al
1
1
u se
2
on
ly
N012606004
FIG. 173
79033095 C Rev. 02-65

Engine Component
2 2
manifold.
Install charge air tube (1) and tighten bolts (2) on hose
N012606007
FIG. 174
position. 3
Fo

Nm (21 lbf ft).
2
r in
1 1
te
rn
al
N012606006
u
FIG. 175
se

1
on
ly
1
P100506002
FIG. 176
02-66 79033095 C Rev.

Engine Component
- Installation. 1
P100506003
FIG. 177
switch.
Fo
Refill system with approved hydraulic fluid.

for leaks.
r
1
in
te
N012206002
FIG. 178
rn
al
u se
on
ly
79033095 C Rev. 02-67

Engine Component
COOLING ASSEMBLY - CHARGE AIR
COOLER REMOVAL AND
INSTALLATION
Charge Air Cooler Removal
m

Fo

r

in
containing fluids.
te
and mandates.
rn

al

1
u se
on
P100506001
FIG. 179
ly
disconnect switch.
power.
N012206002
FIG. 180
02-68 79033095 C Rev.

Engine Component
Hood - Removal. 1
P100506003
FIG. 181
Remove bolts (1).
3
Fo
(3).
2
r in
1 1
te
rn
al
N012606006
u
FIG. 182
se

2 2
on

ly

N012606007
FIG. 183
79033095 C Rev. 02-69

Engine Component
IMPORTANT: Plug intake manifold and hole in the
charge air cooler with clean cloth towels to
prevent dirt entering the system. 2
N020606001
FIG. 184
Fo

1
r in
te
N033006001
FIG. 185
rn
al

u se
1
on
P100506004
FIG. 186
ly

N021606005
FIG. 187
02-70 79033095 C Rev.

Engine Component
2
1
1
P100506005
FIG. 188
2
Fo
r
1
in
te
P100506006
FIG. 189
rn
FIG. 190: Remove left side cover plate.

al
Remove knobs (1) and remove cover plate (2).

1
u se
2
on
1
ly
N021306002
FIG. 190
FIG. 191: Remove right side cover plate.
N022106001
FIG. 191
79033095 C Rev. 02-71

Engine Component
FIG. 192: Remove bottom fasteners on charge air
cooler.
Remove two bolts (1) on the bottom of the charge air
cooler (2).
2
1 1
N022106002
FIG. 192
FIG. 193: Connect lifting device.
charge air cooler (2). The weight of the charge air cooler
Fo
is approximately 34 kg (75 lb).

r in
1 1
te
2
N022106003
FIG. 193
rn
FIG. 194: Remove upper fasteners on charge air cooler.

al
Remove two bolts (1) on the charge air cooler (2).

u se
2
1 1
on
N022106004
FIG. 194
ly
FIG. 195: Remove charge air cooler.

Lift charge air cooler (1) straight up and forward, out of the
cooling assembly (2). The weight of the charge air cooler
2 1
P100506007
FIG. 195
02-72 79033095 C Rev.

Engine Component
Charge Air Cooler Installation
FIG. 196: Install charge air cooler.
charge air cooler (2). The weight of the charge air cooler
1 1
2
Fo
N022106006
FIG. 196
FIG. 197: Install charge air cooler.
r
Install charge air cooler (1) into cooling assembly (2).

in
te
2 1
rn
al
P100506007
u
FIG. 197
se
FIG. 198: Install upper fasteners on charge air cooler.

Install two bolts, spacers and washers (1) on the charge
air cooler (2).
on
ly
2
1 1
N022106004
FIG. 198
79033095 C Rev. 02-73

Engine Component
FIG. 199: Install bottom fasteners on charge air cooler.
Install two bolts, spacers and washers (1) on the bottom
of the charge air cooler (2).
2
1 1
N022106002
FIG. 199
FIG. 200: Install right side cover plate.
Install cover plate (2) and install knobs (1), hand tighten.
Fo
r
2
in
1
te
rn
N022106001
FIG. 200
al
FIG. 201: Install left side cover plate.

Apply anti-seize to threaded studs before installing knobs.
Install cover plate (2) and install knobs (1), hand tighten. 1
u se
2
on
1
ly
N021306002
FIG. 201
2
P100506006
FIG. 202
02-74 79033095 C Rev.

Engine Component
cable straps (1).
2
1
1
P100506005
FIG. 203
Fo
2
r
1
in
te
P100506004
FIG. 204
rn

al

u
2
se
1
on
N021606005
FIG. 205
ly

1
N033006001
FIG. 206
79033095 C Rev. 02-75

Engine Component
manifold.
N020606001
FIG. 207
2 2
Fo

r
in

te
N012606007
FIG. 208
rn

al
position. 3
u
Nm (21 lbf ft).

se
1 1
on
ly
N012606006
FIG. 209
02-76 79033095 C Rev.

Engine Component
- Installation. 1
P100506003
FIG. 210
switch.
Fo
r
1
in
te
N012206002
FIG. 211
rn
al
u se
on
ly
79033095 C Rev. 02-77

Engine Component
COOLING ASSEMBLY - AIR
CONDITIONING CONDENSER
Air Conditioning Condenser Removal
m

Fo

r

in
containing fluids.
te
and mandates.
m
rn

al

prevent injury.
u

se

refrigerant.
on

ly

may be present.
02-78 79033095 C Rev.

Engine Component
system.
1
Fo
P100506001
FIG. 212
r
FIG. 213: Disconnect battery at battery disconnect

in
switch.
te
power.
rn
1
al
u
N012206002
se
FIG. 213
FIG. 214: Disconnect battery cables.
1 1
m
WARNING: A lead acid battery will
on
generate flammable and explosive gases.

Keep sparks and flames away from the
battery.
ly
Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness if 2 2
splashed into eyes.
If acid contacts eyes, skin or clothing, flush
with water immediately. If acid contacts
N022006001
eyes get immediate medical help.
FIG. 214
On the negative cables (1), lift up terminal boots (2) and
loosen nuts on terminal clamps, remove negative cables.
79033095 C Rev. 02-79

Engine Component
m
Keep sparks and flames away from the 1 1
battery.
eat holes in clothing, and cause blindness if
splashed into eyes.
If acid contacts eyes, skin or clothing, flush 2 2
N022006001
FIG. 215
On the positive cable (1), lift up terminal boots (2) and
loosen nuts on terminal clamps, remove positive cable.
FIG. 216: Remove battery mount.
3
Fo
m
generate flammable and explosive gases. 2
battery.
r
3
in

te
splashed into eyes.

1 1 1
rn

N022006001
FIG. 216
al
Remove the five bolts (1) and remove the battery mount
(2). The bolts also fasten battery cables with P-clips (3).
When the bolts (1) are removed fasten the battery cables
u
out of the way.

Remove batteries and place on a dry and level surface.
se

on
system.
removal of hoses. 1
ly

of the way.
N022006002
FIG. 217
02-80 79033095 C Rev.

Engine Component
FIG. 218: Remove air conditioning condenser.
Remove the bolts (1) and remove the air conditioning
condenser. The weight of the air conditioning condenser
1 1
N022006003
FIG. 218
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-81

Engine Component
Air Conditioning Condenser
Installation
FIG. 219: Install air conditioning condenser.
Install the air conditioning condenser (1). The weight of
the air conditioning condenser is approximately 16 kg (35
lb).
1
N022206001
FIG. 219
FIG. 220: Install air conditioning condenser.
Fo
Install the air conditioning condenser and install the four

bolts and washers (1). Tighten the four bolts to 55 Nm (40
lbf ft).
r
1 1
in
te
rn
N022006003
al
FIG. 220
u

se
system.
installation of hoses. 1
on

ly
N022006002
FIG. 221
02-82 79033095 C Rev.

Engine Component
FIG. 222: Install batteries.
3
m
battery.
3
splashed into eyes.
1 1 1
N022006001
FIG. 222
Install batteries in the frame of the machine.
Install the battery mount (2). Fasten battery cables with
P-clips (3) using the bolts and washers (1) for the battery
mount (2). Tighten the five bolts and washer (1), tighten to
Fo
8Nm (71 lbf in).

FIG. 223: Connect battery cables.
r
Install positive cable (1) on the terminals and tighten nuts

on terminal clamps. Seat the terminal boots (2) on the
1
in
terminal clamps. 1
te
rn
2
al
2
N022006001
FIG. 223
u

se
1 1
Install negative cables (1) on the terminals and tighten
nuts on terminal clamps. Seat the terminal boots (2) on
the terminal clamps.
on
ly
2 2
N022006001
FIG. 224
79033095 C Rev. 02-83

Engine Component
switch.
N012206002
FIG. 225
Fo
r in
te
rn
al
u se
on
ly
02-84 79033095 C Rev.

Engine Component
COOLING ASSEMBLY - FUEL COOLER
Fuel Cooler Removal Procedure
m

Fo

r

containing fluids.
in

and mandates.
te

rn

1
al
u se
P100506001
FIG. 226
on

disconnect switch.
ly

power.
N012206002
FIG. 227
79033095 C Rev. 02-85

Engine Component
2 2
N012606007
FIG. 228
Fo

r

in

te
N020606001
FIG. 229
rn

al

u
1
se
on
N033006001
FIG. 230
ly
P100506004
FIG. 231
02-86 79033095 C Rev.

Engine Component
N021606005
FIG. 232
Fo
2
1
r in
1
te
P100506005
FIG. 233
rn
al
2
u se
1
on
P100506006
FIG. 234
ly
79033095 C Rev. 02-87

Engine Component
Fuel Cooler Installation Procedure
2
P100506006
FIG. 235
cable straps (1).
Fo
2
r
1
in
te
1
rn
P100506005
FIG. 236
al
u
2
se
1
on
ly
P100506004
FIG. 237
N021606005
FIG. 238
02-88 79033095 C Rev.

Engine Component
1
N033006001
FIG. 239
Fo
manifold.
IMPORTANT: Remove all cloth plugs from the intake
hole and hole in the charge air cooler.
r
in

2
te
N020606001
FIG. 240
rn

1
al

2
u

se
on
N012606007
FIG. 241
ly

switch.
N012206002
FIG. 242
79033095 C Rev. 02-89

Engine Component
AIR INTAKE ASSEMBLY REMOVAL
AND INSTALLATION
Air Intake Assembly Removal

1
P100506001
Fo
FIG. 243
disconnect switch.
r

in
power.
te
1
rn
al
N012206002
FIG. 244
u
FIG. 245: Remove air intake duct.

se
Remove two bolts (1).

3
(3).
on
2
ly
1 1
N012606006
FIG. 245
02-90 79033095 C Rev.

Engine Component
FIG. 246: Remove dust ejector
Loosen hose clamps (1) and remove dust ejector tube (2).
2
1
N022206002
FIG. 246
FIG. 247: Remove air inlet switch harness.
Disconnect the air inlet switch harness (1).
Fo
1
r in
te
N022206003
FIG. 247
rn
FIG. 248: Disconnect elbow.

al
Loosen hose clamp (1) and disconnect elbow (2).

2
u se
1
on
N022206003
FIG. 248
ly
FIG. 249: Remove inlet tube.

Loosen clamps (1) and remove elbow (2), inlet tube (3) 1
and 45 degree elbow (4). 2
Remove air compressor intake tube (5) if equipped. 3
5
4
1
1
N022606003
FIG. 249
79033095 C Rev. 02-91

Engine Component
FIG. 250: Remove air cleaner.
Remove four bolts (1) and remove air cleaner (2).
2
1
1
N022306001
FIG. 250
2 2
Fo

r

in

te
N012606007
FIG. 251
rn

1
al
Clean dirt off of charge air tube (1) and it connections to 2

u

se

on
N020606001
FIG. 252
ly
02-92 79033095 C Rev.

Engine Component
Air Intake Assembly Installation
manifold.
N020606001
FIG. 253
1
Fo

2
r

in
te
rn
N012606007
FIG. 254
al
FIG. 255: Install air cleaner.

Install air cleaner (2) and install four bolts and washers
u
2
se
1
1
on
ly
N022306001
FIG. 255
FIG. 256: Install inlet tube.
Install elbow (2), inlet tube (3) and 45 degree elbow (4). 1
Tighten clamps (1) and tighten to 6.2 Nm (55 lbf in). 2
Install air compressor intake tube (5) if equipped. 3
5
4
1
1
N022606003
FIG. 256
79033095 C Rev. 02-93

Engine Component
FIG. 257: Connect elbow.
Install elbow (2) and tighten hose clamp (1). Tighten to
6.2 Nm (55 lbf in). 2
N022206003
FIG. 257
FIG. 258: Install air inlet switch harness.
Install the air inlet switch harness (1).
Fo
1
r in
te
N022206003
FIG. 258
rn
FIG. 259: Install dust ejector.

al
Install dust ejector tube (2) and tighten hose clamps (1).
Tighten the four bolts to 11 Nm (96 lbf in).
u
2
se
1
on
N022206002
FIG. 259
ly
02-94 79033095 C Rev.

Engine Component
position. 3
Nm (21 lbf ft).
2
1 1
Fo
N012606006
FIG. 260
r
switch.
in

te
rn
1
al
N012206002
u
FIG. 261
se
on
ly
79033095 C Rev. 02-95

Engine Component
AIR CLEANER ASSEMBLY REMOVAL
AND INSTALLATION
m
Air Cleaner Assembly Removal

1
Fo
r
P100506001
FIG. 262
in

te
disconnect switch.
rn
power.
al
1
u se
N012206002
FIG. 263
FIG. 264: Remove air intake duct.
on

3
ly
(3).
1 1
N012606006
FIG. 264
02-96 79033095 C Rev.

Engine Component
FIG. 265: Remove dust ejector.
Loosen hose clamps (1) and remove dust ejector tube (2).
2
1
N022206002
FIG. 265
FIG. 266: Remove air inlet switch harness.
Disconnect the air inlet switch harness (1) and fasten it
out of the way.
Fo
1
r in
te
N022206003
FIG. 266
rn

al
Loosen hose clamp (1) and remove elbow (2).

2
u se
1
on
N022206003
FIG. 267
ly
FIG. 268: Remove air cleaner (2).

Remove four bolts (1) and remove air cleaner.
2
1
1
N022306001
FIG. 268
79033095 C Rev. 02-97

Engine Component
Air Cleaner Installation
FIG. 269: Install air cleaner.
Install air cleaner (2) and install four bolts and washers
2
1
1
N022306001
FIG. 269
Fo

6.2 Nm (55 lbf in). 2
r in
1
te
rn
N022206003
FIG. 270
al
FIG. 271: Install air inlet switch harness.

Install the air inlet switch harness (1).
u se
1
on
ly
N022206003
FIG. 271
FIG. 272: Install dust ejector.
Install dust ejector tube (2) and tighten hose clamps (1).
Tighten the four bolts to 11 Nm (96 lbf in).
2
1
N022206002
FIG. 272
02-98 79033095 C Rev.

Engine Component
position. 3
Install bolts and washers (1).
1 1
Fo
N012606006
FIG. 273
r
switch.
in

te
for leaks.
rn
1
al
N012206002
u
FIG. 274
se
on
ly
79033095 C Rev. 02-99

Engine Component
AIR CLEANER FILTER REMOVAL AND
INSTALLATION
Set parking brake and remove key from ignition
Air Cleaner Filter Removal

FIG. 275: Remove primary filter.
1
Clean the outside of the air cleaner (1) and cover plate.
Remove the wing nut (2) from cover plate (3). Use D-rings
(4) to pull primary filter/cover plate (3) straight out. 4
2
3
Fo
N022706001
FIG. 275
r
FIG. 276: Remove secondary air filter.

in
Remove the wing nut (1) from cover plate (2). Pull
secondary air filter/cover plate (2) straight out.
te
rn
al
1 2
u
N022706003
se
FIG. 276
FIG. 277: Clean air intake.
Clean the inside of the air cleaner (1) with a non-residue
on
cleaning solvent.
ly
N022706004
FIG. 277
02-100 79033095 C Rev.

Engine Component
Air Cleaner Filter Installation
FIG. 278: Clean air intake.
IMPORTANT: Ensure that the inside of the air cleaner is
free of all debris.
Clean the inside of the air cleaner (1) with a non-residue
cleaning solvent.
N022706004
FIG. 278
FIG. 279: Install secondary air filter.
3
Fo
Install secondary air filter/cover plate (2). Tighten wing nut

and washer (1). Ensure secondary air filter (3) fully
r
seated.
in
1 2
te
rn
N022706003
FIG. 279
al
FIG. 280: Install primary air filter.

1
Install primary air filter/cover plate (2). Tighten wing nut
and washer (1). Ensure primary air filter (3) fully seated.
u se
2
on
3
ly
N022706001
FIG. 280
79033095 C Rev. 02-101

Engine Component
DUST EJECTOR REMOVAL AND
INSTALLATION
Set parking brake and remove key from ignition
m
Dust Ejector Removal

FIG. 281: Remove P-clip.
Remove nut, bolt and washer (1). Remove P-clip (2) from
2
dust collection tube (3). Fasten the hoses (4) out of the
way.
Fo
1
4
r
3
in
N022806002
FIG. 281
te
FIG. 282: Remove P-clip.

rn
Remove nut (1) and remove P-clip (2). 2

al
u se
N022806003
on
FIG. 282
FIG. 283: Remove hose clamp.
ly
Loosen hose clamps (1) and hose (2). 1
P100506008
FIG. 283
02-102 79033095 C Rev.

Engine Component
Loosen hose clamps (1) and hose (2). Remove dust
collection tube (3). 2
3
1
N022206002
FIG. 284
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-103

Engine Component
Dust Ejector Installation
FIG. 285: Install hose clamp.
Install dust collection tube (3). Install hose (2) and loosely
install hose clamps (1), do not tighten at this time. 2
3
1
N022206002
FIG. 285
1
Fo
Install hose (2) and loosely install hose clamps (1).

Tighten all four hose clamps after tube is properly
positioned. Tighten to 11 Nm (97 lbf in).
r in
te
2
rn
P100506008
FIG. 286
al
FIG. 287: Install P-clip.

Install P-clip (2) and tighten nut and washer (1). Tighten to 2
55 Nm (40 lbf ft).
u se
on
1
ly
N022806003
FIG. 287
FIG. 288: Install P-clamps.
Install P-clamps (2) for the hoses (4) on the dust collection
2
tube (3) and tighten bolts (1). Tighten to 55 Nm (40 lbf ft).
1
4
3
N022806002
FIG. 288
02-104 79033095 C Rev.

Engine Component
EXHAUST SYSTEM REMOVAL AND
INSTALLATION
m
Exhaust System Removal

1
Fo
r
P100506001
FIG. 289
in

te
disconnect switch.
rn
power.
al
1
u se
N012206002
FIG. 290
FIG. 291: Remove exhaust stack.
on
Loosen clamp (1) and remove exhaust stack (2). 2
1
ly
P100506009
FIG. 291
79033095 C Rev. 02-105

Engine Component
FIG. 292: Connect lift device.
Connect proper lifting device to the two holes (1) on the
top of the muffler (2). The weight of the muffler is 1
P100506010
FIG. 292
FIG. 293: Remove muffler.
Loosen clamp (1) and remove flex exhaust tube (2).
Remove five bolts (3) from the bottom and remove muffler 4
Fo
(4).
2
r in
te
1 3 P100506011
FIG. 293
rn
FIG. 294: Remove flex exhaust tube.

al
2
u se
1
on
P100506012
FIG. 294
ly
02-106 79033095 C Rev.

Engine Component
Exhaust System Installation
FIG. 295: Install flex exhaust tube.
Install flex exhaust tube (2) to turbo (3) and tighten clamp 2 3
(1). Tighten to 8.5 NM (75 lbf in).
P100506012
FIG. 295
FIG. 296: Prepare surface for muffler installation.
Fo
Apply a bead of high temperature sealant (1) around and

outside of the hole prior to installing muffler. 1
Apply high temperature anti-seize on bearing surface (2)
r
before installing.
Ensure that drain hole (3) is open to allow fluid to drain out
in
of muffler.
te
3 2
rn
P100506013
FIG. 296
al

u

se
2
on
ly
P100506010
FIG. 297
FIG. 298: Install muffler.
Lower muffler (4) onto bearing surface (5). Apply high
temperature anti-seize to threads on the bolts (3). Tighten 4
five bolts and washers (3) and tighten to 55 Nm (41 lbf ft).
Install flex exhaust tube (2) onto the muffler (4). Tighten 2
clamp (1) to 70 Nm (52 lbf ft).
5
1 3 P100506011
FIG. 298
79033095 C Rev. 02-107

Engine Component
FIG. 299: Install exhaust stack.
Install exhaust stack (2) and tighten clamp (1) to 70 Nm 2
(52 lbf ft).
1
P100506009
FIG. 299
switch.
Fo
r
1
in
te
N012206002
FIG. 300
rn
al
u se
on
ly
02-108 79033095 C Rev.

Engine Component
MUFFLER REMOVAL AND
INSTALLATION
m
Muffler Removal
1
Fo
r
P100506001
FIG. 301
in

te
disconnect switch.
rn
power.
al
1
u se
N012206002
FIG. 302
FIG. 303: Remove exhaust stack.
on
Loosen clamp (1) and remove exhaust stack (2). 2
1
ly
P100506009
FIG. 303
79033095 C Rev. 02-109

Engine Component
P100506010
FIG. 304
FIG. 305: Remove muffler.
Remove five bolts (3) from the bottom and remove muffler 4
Fo
(4).
2
r in
te
1 3 P100506011
FIG. 305
rn
al
u se
on
ly
02-110 79033095 C Rev.

Engine Component
Muffler Installation
FIG. 306: Prepare surface for muffler installation.
Apply a bead of high temperature sealant (1) around and
outside of the hole prior to installing muffler. 1
Apply high temperature anti-seize on bearing surface (2)
before installing.
Ensure that drain hole (3) is open to allow fluid to drain out
of muffler.
3 2
P100506013
FIG. 306
Fo

r in
2
te
rn
P100506010
FIG. 307
al

u
2
se
Install flex exhaust tube (2) onto the muffler (4). Tighten
clamp (1) to 70 Nm (52 lbf ft).
on
5
1 3
ly
P100506011
FIG. 308
FIG. 309: Install exhaust stack.
Install exhaust stack (2) and tighten clamp (1) to 70 Nm 2
(52 lbf ft).
1
P100506009
FIG. 309
79033095 C Rev. 02-111

Engine Component
switch.
N012206002
FIG. 310
Fo
r in
te
rn
al
u se
on
ly
02-112 79033095 C Rev.

Engine Component
BATTERY REMOVAL AND
INSTALLATION
Battery Removal
m
battery.
Fo

splashed into eyes.
r

in

te

rn
1
al
u se
P100506001
FIG. 311
on
disconnect switch.
power.
ly
N012206002
FIG. 312
79033095 C Rev. 02-113

Engine Component
1 1
m
battery.
eat holes in clothing, and cause blindness if 2 2
splashed into eyes.
N022006001
FIG. 313
On the negative cables (1), lift up terminal boots (2) and
loosen nuts on terminal clamps, remove negative cables.
Fo
m
Keep sparks and flames away from the 1 1
battery.
r

in

te
splashed into eyes.

If acid contacts eyes, skin or clothing, flush 2 2
rn

N022006001
FIG. 314
al
On the positive cable (1), lift up terminal boots (2) and

loosen nuts on terminal clamps, remove positive cable.
FIG. 315: Remove battery mount.
u
m
se

battery.
3
on

splashed into eyes.
1
ly
1 1
N022006001
FIG. 315
Remove the five bolts (1) and remove the battery mount
(2). The bolts also fasten battery cables with P-clips (3).
When the bolts (1) are removed fasten the battery cables
out of the way.
Remove batteries and place on a dry and level surface.
The weight of each battery is approximately 27 kg (60 lb).
02-114 79033095 C Rev.

Engine Component
Battery Installation
FIG. 316: Install batteries.
3
m
battery.
3
splashed into eyes.
1 1 1
N022006001
FIG. 316
Install batteries in the frame of the machine. The weight of
a battery is approximately 27 kg (60 lb).
Fo
Install the battery mount (2). Fasten battery cables with

P-clips (3) using the bolts and washers (1) for the battery
mount (2). Tighten the five bolts and washer (1) to 8Nm
r
(71 lbf in).

in
Install positive cable (1) on the terminals and tighten nuts

on terminal clamps. Seat the terminal boots (2) on the
te
terminal clamps. 1 1
rn
al
2 2
u
N022006001
se
FIG. 317
1 1
Install negative cables (1) on the terminals and tighten
on
nuts on terminal clamps. Seat the terminal boots (2) on

the terminal clamps.
ly
2 2
N022006001
FIG. 318
79033095 C Rev. 02-115

Engine Component
switch.
N012206002
FIG. 319
Fo
r in
te
rn
al
u se
on
ly
02-116 79033095 C Rev.

Engine Component
FAN REMOVAL AND INSTALLATION
Fan Removal
1
P100506001
FIG. 320
Fo

disconnect switch.
r
power.
in
te
1
rn
al
N012206002
FIG. 321
u

se
1
on
1
ly
N011906001
FIG. 322
79033095 C Rev. 02-117

Engine Component
halves together.
assembly. 2
3
Fo
r
2
in
1
te
N011906002
FIG. 323
rn
FIG. 324: Remove fan.

Remove the eight bolts (1) and remove fan (2) out of the
al
right side of the machine. The weight of fan is 2

u se
1
on
P100506014
FIG. 324
ly
FIG. 325: Remove fan adapter.

Remove the six bolts (1) and remove fan adapter (2). The
weight of the fan adapter is approximately 7 kg (15 lb).
2
1
N030506002
FIG. 325
02-118 79033095 C Rev.

Engine Component
FIG. 326: Remove O-ring seal.
Remove O-ring seal (1).
N030706001
FIG. 326
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-119

Engine Component
Fan Installation
FIG. 327: Install O-ring seal.
Clean the surface (2) and install new O-ring seal (1).
N030706001
FIG. 327
FIG. 328: Install fan adapter.
Fo
Install fan adapter (2) and install six bolts and washers (1).
Tighten bolts to 47 Nm (35 lbf ft). The weight of the fan
adapter is approximately 7 kg (15 lb).
2
r
1
in
te
rn
N030506002
FIG. 328
al
FIG. 329: Install fan.

IMPORTANT: Ensure that fan blades are facing the
correct direction. The cupped surface should be 2
u
facing the engine.

se
Install fan (2) and install the eight bolts and washers (1).
Tighten bolts to 47 Nm (35 lbf ft). The weight of a fan is
on
ly
P100506014
FIG. 329
02-120 79033095 C Rev.

Engine Component
assembly.
of the shroud together and tighten. 1
fan.
Fo
r
2
in
1
te
N011906002
FIG. 330
rn

al
1
u se
1
on
2
ly
N011906001
FIG. 331
79033095 C Rev. 02-121

Engine Component
switch.
N012206002
FIG. 332
Fo
r in
te
rn
al
u se
on
ly
02-122 79033095 C Rev.

Engine Component
FAN DRIVE REMOVAL AND
INSTALLATION
Fan Drive Removal

1
P100506001
Fo
FIG. 333
disconnect switch.
r

in
power.
te
1
rn
al
N012206002
FIG. 334
u

se
1
on
1
ly
N011906001
FIG. 335
79033095 C Rev. 02-123

Engine Component
halves together.
assembly. 2
3
Fo
r
2
in
1
te
N011906002
FIG. 336
rn

al
right side of the machine. The weight of a fan is 2

u se
1
on
P100506014
FIG. 337
ly

2
1
N030506002
FIG. 338
02-124 79033095 C Rev.

Engine Component
N030706001
FIG. 339
Fo

m
r

in
2 1
te
neutral position. N030506003
FIG. 340
rn
FIG. 341: Remove fan drive.

al
Remove the four bolts (1) and remove the fan drive (2).
The weight of the fan drive is approximately 20 kg (45 lb). 1
u se
2
on
N030506004
FIG. 341
ly
79033095 C Rev. 02-125

Engine Component
Fan Drive Installation
FIG. 342: Install fan drive.
Install the fan drive (2) and install the four bolts and
washers (1). Tighten bolts to 100 Nm (74 lbf ft). The 1
weight of the fan drive is approximately 20 kg (45 lb).
N030506004
FIG. 342
FIG. 343: Serpentine belt installation.
Fo

4
r

in
hold.
3
m
te
spring tension can cause bodily injury. Use 2 1

tensioner.
rn
N030506003
Carefully place belt onto fan drive pulley (4) ensuring belt FIG. 343
al

u
se
Lightly coat O-ring with bearing lube.

1
on
2
ly
N030706001
FIG. 344
FIG. 345: Apply lubricant.
Lubricate cavity (1) in fan adapter (2) with 30 g (1.05 oz)
of bearing lube.
2
N030806001
FIG. 345
02-126 79033095 C Rev.

Engine Component
Install fan adapter (2) and install the six bolts and washers
(1). Tighten bolts to 47 Nm (35 lbf ft). The weight of the
fan adapter is approximately 7 kg (15 lb).
2
1
N030506002
FIG. 346
Fo
facing the engine.

1
r

in
te
P100506014
FIG. 347
rn

al

assembly.
u
se

on
fan.
tighten the bolts (2) on each side of the shroud.
ly
1
N011906002
FIG. 348
79033095 C Rev. 02-127

Engine Component
2
Fo
1
r in
N011906001
FIG. 349
te

switch.
rn

al
1
u se
N012206002
FIG. 350
on
ly
02-128 79033095 C Rev.

Engine Component
FAN DRIVE DISASSEMBLY AND
ASSEMBLY
Fan Drive Disassembly

FIG. 351: Fan drive disassembly.
Remove bolt (1), plate (2) and pin (3).
2 3
1
N030706002
Fo
FIG. 351
FIG. 352: Remove pulley.
r
Remove fan pulley (1).

in
te
rn
al
1
N030706003
FIG. 352
u
FIG. 353: Fan pulley bearing removal.

se
2 5
Remove tapered roller cone (1), tapered roller cup (2) and
spacer (3).
Remove seal (4), tapered roller cone (5) and tapered
on
roller cup (6).

ly
1 3 6 4
N030706004
FIG. 353
79033095 C Rev. 02-129

Engine Component
FIG. 354: Remove spacer.
Remove pulley spacer (1).
N030706005
FIG. 354
Fo
r in
te
rn
al
u se
on
ly
02-130 79033095 C Rev.

Engine Component
Fan Drive Assembly
FIG. 355: Install spacer.
Install pulley spacer (1).
N030706005
FIG. 355
FIG. 356: Fan pulley bearing assembly.
2 5
Fo
Lightly lube sealing lips with bearing lube. Lubricate cavity

between bearings where the spacer (3) is located with 10
g (.35 oz) of bearing lube.
r
Install tapered roller cup (6), tapered roller cone (5) and
install seal (4).
in
Install spacer (3), tapered roller cup (2) and install tapered
roller cone (1).
te
1 3 6 4
rn
N030706004
FIG. 356
al
FIG. 357: Install pulley.

Install fan pulley (1).
u se
on
1
ly
N030706003
FIG. 357
FIG. 358: Fan drive assembly.
Install pin (3) and plate (2). Apply loctite to threads on bolt
(1) and install bolt. Tighten to 115 Nm (85 lbf ft).
2 3
1
N030706002
FIG. 358
79033095 C Rev. 02-131

Engine Component
AIR CONDITIONING COMPRESSOR
Air Conditioning Compressor Removal

containing fluids.
Fo

and mandates.
m
r

in

te
m
rn

al
prevent injury.
u

refrigerant.
se

on

ly

may be present.
02-132 79033095 C Rev.

Engine Component
equipment to service the air conditioning system.
1
Fo
P100506001
FIG. 359
r

disconnect switch.
in

power.
te
Open hood.
rn
1
al
N012206002
u
FIG. 360
se
on
ly
79033095 C Rev. 02-133

Engine Component
1
1
2
Fo
1
r in
te
rn
N012606004
FIG. 361
al

u

1
se
m
on

neutral position.
ly
N021606002
FIG. 362
02-134 79033095 C Rev.

Engine Component
FIG. 363: Remove wiring.
Remove air conditioning clutch wire (1) and fasten out of
the way.
N030806003
FIG. 363
Fo
system.
IMPORTANT: Refer to Refrigerant Section for proper
removal of hoses. 1
r

in
air conditioning lines (1). Refer to Refrigerant Section for

of the way.
te
N030806003
FIG. 364
rn
FIG. 365: Remove air conditioning compressor.

al
Remove bolts (1) and compressor (2). The weight of the

air conditioning compressor is approximately 10 kg (22
lb). 2
u se
1
on
N030806004
FIG. 365
ly
79033095 C Rev. 02-135

Engine Component
Air Conditioning Compressor Installation
FIG. 366: Install air conditioning compressor.
Install compressor (2) and tighten bolts and washers (1).
Tighten to 28 Nm (20 lbf ft). The weight of the air
conditioning compressor is approximately 10 kg (22 lb). 2
N030806004
FIG. 366
Fo

1
r
Insert square drive of ratchet into square hole (1) on belt 2

in
m
te

tensioner.
rn
Carefully place belt onto air conditioning compressor 4

pulley (4) ensuring belt ribs are properly seated in pulley
al
valleys and slowly allow belt tensioner to release until it

makes contact with belt. N021606002
FIG. 367
u

se

system.
on
removal of hoses. 1
ly
N030806003
FIG. 368
02-136 79033095 C Rev.

Engine Component
Install wiring (1).
N030806003
FIG. 369
Fo
1
1
r in
te
2
rn
al
u
1
se
on
N012606004
ly
FIG. 370
switch.
N012206002
FIG. 371
79033095 C Rev. 02-137

Engine Component
AIR CONDITIONING ACCUMULATOR
Air Conditioning Accumulator Removal

containing fluids.
Fo

and mandates.
m
r

in

te
m
rn

al
prevent injury.
u

refrigerant.
se

on

ly

may be present.
02-138 79033095 C Rev.

Engine Component
equipment to service the air conditioning system.
1
P100506001
FIG. 372
Fo
disconnect switch.
power.
r
Open hood.
in
1
te
rn
N012206002
FIG. 373
al
FIG. 374: Air conditioning accumulator location.

The location of the air conditioning accumulator (1) is on
u
the left-hand side of the machine and behind the step (2).
The step is behind the left front fender in front of the cab.
se
2
on
1
ly
P100506015
FIG. 374
Remove air conditioning lines (1) and disconnect low 2
pressure switch (2) from air conditioning accumulator (3).
IMPORTANT: Only a certified technician with certified 1
system.
removal of hoses.
3
air conditioning lines (1). Refer to Refrigerant section for 1
proper removal of hoses. Fasten air conditioning lines out P100506016
of the way. FIG. 375
79033095 C Rev. 02-139

Engine Component
FIG. 376: Remove accumulator.
Remove bolt (1), two piece clamp (2) and accumulator
(3).
2
P100506017
FIG. 376
Fo
r in
te
rn
al
u se
on
ly
02-140 79033095 C Rev.

Engine Component
Air Conditioning Accumulator
Installation
FIG. 377: Install accumulator.
Install two piece clamp (2) around accumulator (3) and
install on bracket (4). Install bolt and washer (1) and
tighten.
4
3
2
P100506017
FIG. 377
Fo

system.
r
1
in
removal of hoses.
te
and charge the air conditioning system. Reconnect the

low pressure switch (2). Refer to Refrigerant section for
rn
proper installation of hoses. 1

P100506016
al
FIG. 378
switch.
u

se
on
1
ly
N012206002
FIG. 379
79033095 C Rev. 02-141

Engine Component
HOOD REMOVAL AND INSTALLATION
Hood Removal
1
P100506001
FIG. 380
Fo

disconnect switch.
r
power.
in
te
1
rn
al
N012206002
FIG. 381
FIG. 382: Open hood and attach lifting device.
u
Lift the hood and find a sturdy location at the front of the
se
hood to attach a lifting device.

Attach a suitable lifting device (1) to hood (2). The weight
of the hood is approximately 130 kg (285 lb).
on
2
ly
N031206001
FIG. 382
02-142 79033095 C Rev.

Engine Component
FIG. 383: Disconnect wiring.
Disconnect wire harness (1) on the left side of the hood at 1
the rear.
Fo
N031206002
FIG. 383
r
FIG. 384: Connect rear lifting device.

Raise the access door (1) and find a sturdy location to 1
in
attach the lifting device.

te
Attach a suitable lifting device to hood (2). The weight of

the hood is approximately 130 kg (285 lb). 2
rn
al
u se
on
N031206003
FIG. 384
ly
79033095 C Rev. 02-143

Engine Component
FIG. 385: Remove support shocks.
IMPORTANT: Support hood with proper lifting device
before removing support shocks.
Remove support shock (1) from the bottom bracket (2) on
both sides of machine and fasten out of the way.
2
1
Fo
N031306001
FIG. 385
FIG. 386: Disconnect hinges.
r
IMPORTANT: Lower hood before disconnecting hinges.

in
Remove bolts (1).

te
rn
1
al
1
u se
on
N031206004
FIG. 386
ly
02-144 79033095 C Rev.

Engine Component
Remove hood (1). The weight of the hood is
1
Fo
N031306002
FIG. 387
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-145

Engine Component
Hood Installation
Install hood (1). The weight of the hood is approximately
130 kg (285 lb).
Fo 1
N031306002
FIG. 388
r
FIG. 389: Connect hinges.

in
Install four bolts and washers (1). Tighten to 55 Nm (41 lbf

ft).
te
rn
al
1
u se
on
N031206004
FIG. 389
ly
02-146 79033095 C Rev.

Engine Component
FIG. 390: Install support shocks.
IMPORTANT: Support hood with proper lifting device
before installing support shocks.
Install support shock (1) onto the bottom bracket (2) on
both sides of machine. Tighten to 20 Nm (15 lbf ft).
2
1
Fo
N031306001
FIG. 390
FIG. 391: Disconnect rear lifting device.
r
Remove the lifting device from the hood (2). 1

in
Lower the access door (1) and fasten the latch (3).
te
2
3
rn
al
u se
N031206003
on
FIG. 391
ly
79033095 C Rev. 02-147

Engine Component
Connect wire harness (1) on the left side of the hood at 1
the rear.
Fo
N031206002
FIG. 392
r
FIG. 393: Disconnect lifting device.

Remove the suitable lifting device (1) from the hood (2).
in
te
rn
2
al
u
1
se
on
N031206001
FIG. 393
ly
switch.
N012206002
FIG. 394
02-148 79033095 C Rev.

Engine Component
INPUT SHAFT AND INPUT COUPLING
NOTE: This process will require a minimum of two
service technicians. One technician under the
machine and the other on top of the machine by
the engine / transmission.
Input Shaft and Input Coupling Removal

1
Fo
r
P100506001
FIG. 395
in

te
disconnect switch.
rn
power.
al
1
u se
N012206002
FIG. 396
FIG. 397: Remove heavy duty guard. (Special
on
applications machine only)

Remove the four bolts (1) and remove the plate (2). The
weight of the heavy duty guard is approximately 51 kg
ly
(112 lb).
1
2
P100506018
FIG. 397
79033095 C Rev. 02-149

Engine Component
FIG. 398: Remove two bolts (1) and remove bracket (2).
1
1
P100506019
FIG. 398
FIG. 399: Disconnect the input shaft.
Remove bolts (1) from the U-joint (2). Separate input shaft
from the transmission yoke (3) and slide yoke back into
Fo
transmission housing. 1
r in
3
2
te
P100506020
FIG. 399
rn

al
Remove bolts (1) and remove the input shaft (2).

u se
2
on
1
P100506021
FIG. 400
ly
FIG. 401: Remove flywheel cover.

Remove bolts (1) and remove the cover (2).
P100506022
FIG. 401
02-150 79033095 C Rev.

Engine Component
FIG. 402: Remove input coupling.
Remove bolts (1) and remove the input coupling (2). 1
P100506023
FIG. 402
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-151

Engine Component
Input Shaft and Input Coupling
Installation
FIG. 403: Install input coupling.
Install the input coupling (2) and install twelve bolts and 1
washers (1). Tighten to 70 Nm (52 lbf ft).
P100506023
FIG. 403
FIG. 404: Install flywheel cover
Fo
Install the cover (2) and install six bolts and washers (1).
Tighten to 70 Nm (52 lbf ft).
1
r in
te
2
rn
P100506022
al
FIG. 404
FIG. 405: Connect the input shaft.
NOTE: If the bolt pattern on the input shaft and the input 3
u
coupling do not line up, then refer to the CAT

se
engine manual on how to rotate the flywheel.

Connect the input shaft (2) to the input coupling (3) and
install bolts and washers (1). Tighten to 240 Nm or within
the range of 200 Nm to 280 Nm (177 lbf ft or within the
on
range of 147 lbf ft to 207 lbf ft).
2
ly
1
P100506021
FIG. 405
Position the U-joint (2) and input shaft (4) on the
transmission yoke (3). Install four bolts and washers (1).
Tighten to 150 Nm (111 lbf ft). 4 1
3
2
P100506020
FIG. 406
02-152 79033095 C Rev.

Engine Component
FIG. 407: Remove two bolts (1) and remove bracket (2).
Install bracket (2) and install two washers and bolts (1). 1
Tighten bolts to 100 Nm (74 lbf ft).
1
P100506019
FIG. 407
FIG. 408: Install heavy duty guard. (Special applications
machine only)
Install heavy duty guard (2) and install four bolts (1). The
Fo
weight of the heavy duty guard is approximately 51 kg

(112 lb). Tighten bolts to 100 Nm (74 lbf ft).
1
r in
2
te
P100506018
FIG. 408
rn

switch.
al
Install key and rotate to connect the battery (1).

u se
1
on
N012206002
FIG. 409
ly
79033095 C Rev. 02-153

Engine Component
AIR COMPRESSOR REMOVAL AND
INSTALLATION
containing fluids.
and mandates.
Fo
m
r

in
IMPORTANT: Drain all compressed air from the system

before servicing it.
te
Air Compressor Removal

rn

al

1
u se
on
P100506001
FIG. 410
ly

disconnect switch.
power.
N012206002
FIG. 411
02-154 79033095 C Rev.

Engine Component
1
lb).
1
P100506002
FIG. 412
FIG. 413: Remove guard.
Remove six bolts (1) and remove guard (2). The weight of
the guard is approximately 54 kg (120 lb).
2
Fo
1
r in
te
P100506024
FIG. 413
rn
FIG. 414: Drain air from air reservoir.

1
al
Location of air reservoir tank (1) is located in the right front

frame rail (2).
u se
2
on
P100506025
FIG. 414
ly

Pull pin (1) sideways on drain valve (2) and drain air from
system.
1
P100506026
FIG. 415
79033095 C Rev. 02-155

Engine Component
FIG. 416: Air compressor location.
The air compressor (1) is located on the left side of the
engine.
1
N032006001
FIG. 416
FIG. 417: Remove hose.
Remove oil hose (1) and fasten out of the way.
Fo
1
r in
te
N032006002
FIG. 417
rn

al
Remove hose (1) and fasten out of the way.
1
u se
on
N032006003
FIG. 418
ly
FIG. 419: Remove tube.

Remove air discharge tube (1).
N032006004
FIG. 419
02-156 79033095 C Rev.

Engine Component
close.
N012606002
FIG. 420
FIG. 421: Remove coolant tube.
Remove coolant tubes (1).
Fo
1
1
r in
te
N032006006
FIG. 421
rn
FIG. 422: Remove air inlet tube.

al
Remove air inlet tube (1).

1
u se
on
N032006007
FIG. 422
ly
FIG. 423: Remove support bracket.

Loosen bolt (2) and rotate bracket (3) out of the way.
1
2
N032006010
FIG. 423
79033095 C Rev. 02-157

Engine Component
FIG. 424: Remove air compressor.
Remove three nuts (1) and remove air compressor (2).
The weight of the air compressor is approximately 21 kg
(46 lb).
2
1
N032006008
FIG. 424
FIG. 425: Remove air governor.
Remove the two bolts (1) and remove air governor (2).
Fo
1
2
r in
te
N032106005
FIG. 425
rn
FIG. 426: Remove air governor adapter.

al
Remove two bolts (1) and remove air governor adapter

(2).
u
2
se
1
on
N032106006
FIG. 426
ly
02-158 79033095 C Rev.

Engine Component
Air Compressor Installation
FIG. 427: Install air governor adapter.
Install the gasket between the air governor adapter (2)
and the air compressor (3).
Install air governor adapter (2) and tighten two bolts (1).
2
1
3
N032106006
FIG. 427
FIG. 428: Install air governor.
Fo
Install the gasket between the air governor (2) and the air
governor adapter (3).
1
Install air governor (2) and install two bolts and washers
r
(1). Tighten bolts to 25 Nm (18 lbf ft).

2
in
3
te
rn
N032106005
FIG. 428
al
FIG. 429: Install air compressor.

Surfaces (1) must be free of primer, topcoat, cleaning
solutions and corrosion.
u

se
(46 lb).
1
on
1
ly
N032006009
FIG. 429
FIG. 430: Install air compressor.
Install air compressor (2) and install three nuts and
washers (1). Tighten bolts to 105 Nm (77 lbf ft).
2
1
N032006008
FIG. 430
79033095 C Rev. 02-159

Engine Component
FIG. 431: Install support bracket.
Rotate bracket (3) to the air compressor.
Install two bolts (1) into the air compressor. Tighten bolt to
55 Nm (40 lbf ft). 1
Tighten bolt (2) to 215 Nm (158 lbf ft).
3
2
N032006010
FIG. 431
FIG. 432: Install air inlet tube.
Install the connector (1). Tighten to 135 Nm (100 lbf ft).
Install air inlet tube (2). Tighten to 156 Nm (115 lbf ft).
Fo
2
r in
1
te
N032106001
FIG. 432
rn
FIG. 433: Install coolant tube.

al
Install 90 degree elbow (1). Tighten to 82 Nm (60 lbf ft).

Install coolant tubes (2). Tighten to 55 Nm (40 lbf ft). 1
u se
2
on
N032106002
FIG. 433
ly
FIG. 434: Install coolant tube.

2
Install coolant tubes (2). Tighten to 55 Nm (40 lbf ft).
Fill the cooling system. Refer to Operation and
Cooling System. 1
N032106003
FIG. 434
02-160 79033095 C Rev.

Engine Component
FIG. 435: Install tube.
Install air discharge tube (2). Tighten to 86 Nm (63 lbf ft).
1 2
N032006004
FIG. 435
FIG. 436: Install hose.
Install fitting and hose(1). Tighten to 16 Nm (11 lbf ft).
Fo
1
r in
te
N032006003
FIG. 436
rn
FIG. 437: Install oil hose.

al

Install oil hose (2). Tighten to 18 Nm (13 lbf ft).
u
1
se
2
on
N032006002
FIG. 437
ly
FIG. 438: Install oil hose.

Install oil hose (2). Tighten to 18 Nm (13 lbf ft). 1
N032106004
FIG. 438
79033095 C Rev. 02-161

Engine Component
FIG. 439: Install guard.
Install guard (2) and install six bolts (1). The weight of the
guard is approximately 54 kg (120 lb). Tighten bolts to
100 Nm (74 lbf ft). 2 1
P100506024
FIG. 439
1
Fo

r in
1
te
P100506002
FIG. 440
rn

switch.
al

u se
1
on
N012206002
FIG. 441
ly
02-162 79033095 C Rev.

Engine Component
AIR RESERVOIR REMOVAL AND
INSTALLATION
containing fluids.
and mandates.
Fo
m
r

in
IMPORTANT: Drain all compressed air from the system

before servicing it.
te
Air Reservoir Removal

rn

al

1
u se
on
P100506001
FIG. 442
ly

disconnect switch.
power.
N012206002
FIG. 443
79033095 C Rev. 02-163

Engine Component
1
lb).
1
P100506002
FIG. 444
2
Fo
1
r in
te
P100506024
FIG. 445
rn

1
al
Location of air reservoir tank (1) is located in the right front

frame rail (2).
u se
2
on
P100506025
FIG. 446
ly

system.
1
P100506026
FIG. 447
02-164 79033095 C Rev.

Engine Component
FIG. 448: Disconnect air coupler line.
Disconnect air coupler line (1) from air reservoir (2). 2
P100506027
FIG. 448
FIG. 449: Disconnect pressure sensor.
Disconnect pressure sensor (1) from air reservoir (2).
Fo
r
1
in
2
te
P100506028
FIG. 449
rn
FIG. 450: Remove air inlet hose.

Remove air inlet hose (1) from air reservoir (2).
al
1
u se
2
on
P100506029
FIG. 450
ly
FIG. 451: Remove air reservoir.

Remove bolts (1) and remove air reservoir (2) from straps
(3). The weight of the air compressor is approximately 31
kg (67 lb).
1 1
2 3 3
P100506030
FIG. 451
79033095 C Rev. 02-165

Engine Component
FIG. 452: Remove air reservoir straps.
Remove the two bolts (1) on each set of air reservoir
straps (2). Remove the air reservoir straps (2).
2 2
P100506031
FIG. 452
Fo
r in
te
rn
al
u se
on
ly
02-166 79033095 C Rev.

Engine Component
Air Reservoir Installation
FIG. 453: Install air reservoir straps.
Install the four bolts and washers (1) through the outside
of the frame (2).
2
P100506032
FIG. 453
FIG. 454: Install air reservoir straps.
Fo
Install the air reservoir straps (2) and install two washer
and two nuts (1) on each set of air reservoir straps (2).
Tighten bolts 55 Nm (41 lbf ft).
r
1
in
te
2 2
rn
P100506031
FIG. 454
al
FIG. 455: Install air reservoir.

Install the air reservoir (2) into straps (3). Install bolts (1)
and tighten. The weight of the air compressor is
u

se
1 1
on
2 3 3
ly
P100506030
FIG. 455
FIG. 456: Install air inlet hose.
4
Install tee (2) into air reservoir (3). Tighten to 100 Nm (74
lbf ft).
Install tube (1) onto tee (2). Screw on nut manually until
1
finger tight, then turn nut approximately 1 1/4 turns.
Install nut (4) onto tee and tighten to 75 Nm (55 lbf ft).
2
3
P100506029
FIG. 456
79033095 C Rev. 02-167

Engine Component
FIG. 457: Connect pressure sensor.
Install elbow (2) into air reservoir (3). Tighten to 100 Nm
(74 lbf ft). 4
Install pressure sensor (1) onto elbow (2) and tighten.
Connect pressure sensor wire (4).
1
3 2
P100506028
FIG. 457
FIG. 458: Connect air coupler line.
Install elbow (2) into air reservoir (3). Tighten to 100 Nm 3
(74 lbf ft).
Fo
Connect air coupler line (1) onto elbow (2). Screw on nut
manually until finger tight, then turn nut approximately 1
1/4 turns. Tighten to 30 Nm (22 lbf ft). 2
r in
1
te
P100506027
FIG. 458
rn

al
100 Nm (74 lbf ft). 2 1
u se
on
P100506024
FIG. 459
ly

1
1
P100506002
FIG. 460
02-168 79033095 C Rev.

Engine Component
switch.
N012206002
FIG. 461
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-169

Engine Component
ENGINE REMOVAL AND INSTALLATION
Engine Removal
containing fluids.
Fo
and mandates.
r

in

te

rn
m
al

u se
on
ly
02-170 79033095 C Rev.

Engine Component
m
prevent injury.
refrigerant.
Fo

r

in

may be present.
te

rn

al

system.
u

se

on

1
ly
P100506001
FIG. 462
79033095 C Rev. 02-171

Engine Component
disconnect switch.
power.
N012206002
FIG. 463
1
Fo
lb).
r in
1
te
P100506002
FIG. 464
rn

al
2 1
u se
on
P100506024
FIG. 465
ly

close.
N012606002
FIG. 466
02-172 79033095 C Rev.

Engine Component
Hood - Removal. 1
P100506003
FIG. 467
Remove bolts (1).
3
Slide air intake (2) forward. Carefully removing it from the
Fo
seal (3).
2
r in
1 1
te
rn
al
N012606006
u
FIG. 468
se

2 2
on

ly

N012606007
FIG. 469
79033095 C Rev. 02-173

Engine Component
Clean dirt off of charge air tube (1) and its connections to 2 1
N020606001
FIG. 470
Fo
1
1
r in
te
2
rn
al
u
1
se
on
N012606004
ly
FIG. 471
02-174 79033095 C Rev.

Engine Component
2
Fo
1
r in
N011906001
FIG. 472
te

1
rn
top tank vent hose (2) from the top of the radiator and
fasten out of the way. Plug ends of hose to prevent fluid
from escaping and dirt entering the system.
al
2
u se
N020606002
FIG. 473
on

ly
from the bottom of the radiator. Plug end of hose to

prevent fluid from escaping and dirt entering the system.
N020606003
FIG. 474
79033095 C Rev. 02-175

Engine Component
FIG. 475: Remove cab heater hoses.
The location of the cab heater hoses (2) are on the right 2
side of the engine at the rear. Loosen hose clamps (1)
1
and remove cab heater hoses (2).
1 2
N033106002
FIG. 475
halves together.
Fo

assembly. 2
r in
te
rn
3
al
u se
1
on
N011906002
FIG. 476
ly

right side of the machine. The weight of fan is 2
P100506014
FIG. 477
02-176 79033095 C Rev.

Engine Component
2
1
N030506002
FIG. 478
Fo
1
r in
te
N030706001
FIG. 479
rn

al

u
m
se

2 1
on

neutral position. N030506003
FIG. 480
ly
FIG. 481: Remove fan drive.

Remove the four bolts (1) and remove the fan drive (2).
The weight of the fan drive is approximately 20 kg (45 lb). 1
N030506004
FIG. 481
79033095 C Rev. 02-177

Engine Component
FIG. 482: Disconnect air inlet switch harness.
Disconnect the air inlet switch harness (1).
N022206003
FIG. 482
Loosen hose clamp (1) and remove elbow (2).
2
Fo
r
1
in
te
N022206003
FIG. 483
rn
FIG. 484: Remove inlet tube.

1
al
Loosen clamps (1) and remove elbow (2), inlet tube (3)
and 45 degree elbow (4).
2 3
If machine is equipped with air compressor option remove
u
air compressor inlet tube (5) from inlet tube (3). 5

se
4
1
on
1
N022606003
FIG. 484
ly

Loosen hose clamps (1) and hose (2). 1
P100506008
FIG. 485
02-178 79033095 C Rev.

Engine Component
FIG. 486: Remove muffler (3).
3
1 P100506011
FIG. 486
FIG. 487: Remove flex exhaust tube.
2
Fo
r in
1
te
N022606001
FIG. 487
rn
FIG. 488: Remove battery cable.

al
Remove positive battery cables (1) from starter (2) on left

side of machine.
u se
1
2
on
P100506033
FIG. 488
ly
FIG. 489: Remove cable.

Remove ground cable (1) from starter (2) on left side of
machine. Fasten out of the way.
1 2
P100506034
FIG. 489
79033095 C Rev. 02-179

Engine Component
FIG. 490: Remove solenoid wire.
Remove solenoid wire (1) from starter (2) on left side of
1 2
P100506035
FIG. 490
FIG. 491: Remove battery cable.
Remove positive battery cable (1) from starter (2) on right
side of machine.
Fo
Remove P-clip (3) and fasten positive battery cable out of

the way.
3
r
1
2
in
te
N031706003
FIG. 491
rn

2
al
Remove ground cable (1) from starter (2) on right side of

u se
1
on
N031706004
FIG. 492
ly
FIG. 493: Remove solenoid wire.

Remove solenoid wire (1) from starter (2) on right side of 1
N031706004
FIG. 493
02-180 79033095 C Rev.

Engine Component
Remove positive battery cable (1) from alternator (2). 2
Remove P-clip (3) and fasten positive cable out of the
way.
1
3
N031706005
FIG. 494
Remove ground cable (1) from alternator (2) and fasten
out of the way.
Fo
r
1
in
2
te
N031706006
FIG. 495
rn
FIG. 496: Remove terminal wire.

al
Remove terminal wire (1) from alternator (2).

u se
2
1
on
N031706006
FIG. 496
ly
FIG. 497: Remove chassis harness.

5
Remove air conditioning clutch and high pressure switch
wire (1).
Remove Alternator terminal wire (2). 3 7
Remove air intake restriction switch wire (3).
1
Remove ether start wire (4). 4
Remove front and rear washer pump wire (5).
Remove engine ECM wire (6). 2
Remove chassis harness (7) and neatly wrap all the wires 6 P100506036
up and fasten out of the way. FIG. 497
79033095 C Rev. 02-181

Engine Component
system.
removal of hoses. 1
of the way.
N030806003
FIG. 498
FIG. 499: Remove air conditioning line.
Remove P-clip (1) and fasten air conditioning line (2) out
of the way.
Fo
2
r
1
in
te
N031706009
FIG. 499
rn

al

u
1 2
m
se


on

neutral position.
ly
N021606002
FIG. 500
FIG. 501: Remove air conditioning compressor.
Remove bolts (1) and compressor (2). The weight of the
air conditioning compressor is approximately 10 kg (21
lb). 2
N030806004
FIG. 501
02-182 79033095 C Rev.

Engine Component
FIG. 502: Remove alternator.
Remove the two top bolts (1) and bottom bolt (2). Remove
alternator (3). The weight of the alternator is
N031706008
FIG. 502
Location of air reservoir tank (1) is located in the right front 1
frame rail (2).
Fo
r
2
in
te
P100506025
FIG. 503
rn

al
system.
u se
1
on
P100506026
FIG. 504
ly
FIG. 505: Air compressor location. (If equipped)

The air compressor (1) is located on the left side of the
engine.
1
N032006001
FIG. 505
79033095 C Rev. 02-183

Engine Component
FIG. 506: Remove hose. (If equipped)
Remove oil hose (1) and fasten out of the way.
N032006002
FIG. 506
FIG. 507: Remove hose. (If equipped)
Remove hose (1) and fasten out of the way.
Fo
1
r in
te
N032006003
FIG. 507
rn
FIG. 508: Remove tube. (If equipped)

al
Remove air discharge tube (1).

u
1
se
on
N032006004
FIG. 508
ly
FIG. 509: Remove coolant tube. (If equipped)

Remove coolant tubes (1).
1
1
N032006006
FIG. 509
02-184 79033095 C Rev.

Engine Component
FIG. 510: Remove air inlet tube. (If equipped)
Remove air inlet tube (1).
1
N032006007
FIG. 510
FIG. 511: Remove support bracket. (If equipped)
Loosen bolt (2) and rotate bracket (3) out of the way.
Fo
3
r in
2
te
N032006010
FIG. 511
rn
FIG. 512: Remove air compressor. (If equipped)

al
Remove three nuts (1) and remove air compressor (2).

(46 lb).
u
2
se
1
on
N032006008
FIG. 512
ly
FIG. 513: Remove air compressor hoses. (If equipped)

Disconnect hose (1) and remove P-clip (2).
Remove cable ties from hose (3). 1 3
2
N032606001
FIG. 513
79033095 C Rev. 02-185

Engine Component
FIG. 514: Remove air compressor hoses. (If equipped)
Disconnect tube (1), remove P-clip (2) and remove tube
(1).
2
2
2
1
P100506037
FIG. 514
FIG. 515: Air conditioning accumulator location.
The location of the air conditioning accumulator (1) is on
the left side of the machine and behind the step (2). The
Fo
step is behind the left front fender in front of the cab.

2
r in
1
te
P100506015
FIG. 515
rn

Remove air conditioning lines (1) and disconnect low 2
al
pressure switch (2) from air conditioning accumulator (3).

u

system.
se

removal of hoses.
3
on
air conditioning lines (1). Refer to Refrigerant section for 1

proper removal of hoses. Fasten air conditioning lines out P100506016
of the way. FIG. 516

ly
FIG. 517: Remove accumulator.

Remove bolt (1), two piece clamp (2) and accumulator
(3).
2
P100506017
FIG. 517
02-186 79033095 C Rev.

Engine Component
FIG. 518: Remove bolts and remove plate (1).
1
P100506038
FIG. 518
On the fuel tank (1) on the right side of the fuel tank, turn 1
shut off valve handles (2) 90 degrees clockwise. Shut off
Fo
valve handles (2) should be perpendicular to the valve.

2
r in
2
te
P100506039
FIG. 519
rn

al

u
1
se
on
N033006001
FIG. 520
ly
FIG. 521: Remove fuel line.

Remove supply fuel lines (1) and fasten out of the way.
1
1
P100506040
FIG. 521
79033095 C Rev. 02-187

Engine Component
FIG. 522: Remove window washer hoses.
Disconnect window washer hoses (1) from pump (2).
2
Remove P-clip (3) and cable straps (4) and fasten washer 1
hoses (1) out of the way.
3 4
N031906005
FIG. 522
FIG. 523: Remove ether start hose.
Remove ether start hose (1) and fasten out of the way.
Fo
r in
1
te
N031906006
FIG. 523
rn
FIG. 524: Remove engine coolant fill hose.

al
Loosen hose clamp (1) and remove hose (2).
2
u se
on
1
N031906007
FIG. 524
ly

Loosen hose clamp (1) and remove hose (2).
1
N031906008
FIG. 525
02-188 79033095 C Rev.

Engine Component
FIG. 526: Remove bracket.
Remove bolts (1) and remove bracket (2).
1
2
N032706003
FIG. 526
FIG. 527: Disconnect support.
Remove bolts (1) from bearing pad and cooling assembly
(2) on the right side of machine.
Fo
r
1
2
in
te
P100506041
FIG. 527
rn
FIG. 528: Disconnect support.

al
Remove bolts (1) from bearing pad and cooling assembly

(2) on the right side of machine.
Remove the component support (3) and the components
u
still fastened to it.

3
se
2
1
on
P100506042
FIG. 528
ly

Remove bolts (1) and remove the input shaft (2).
2
1
P100506021
FIG. 529
79033095 C Rev. 02-189

Engine Component
FIG. 530: Attach lifting device.
Attach approved lifting device to the lifting brackets (1) at
the front and rear of engine. The weight of the engine is
approximately 1332 kg (2930lb).
1
P100506043
FIG. 530
FIG. 531: Remove engine mounting hardware.
Remove two bolts (1) on each side of engine.
Fo
1
r in
1
te
P100506044
FIG. 531
rn
FIG. 532: Remove engine.

Remove the engine (1). The weight of the engine is
al

u se
1
on
P100506043
FIG. 532
ly
FIG. 533: Clean beneath engine mounting isolators.

Remove the four sets of mounting hardware (1). Clean
mounting surface to be free of rust and dirt.
1
1
P100506045
FIG. 533
02-190 79033095 C Rev.

Engine Component
Engine Installation
FIG. 534: Install engine mounting hardware.
Ensure mounting surfaces (1) are clean and free of rust.
Install washer (2), primary support pad (3) and sleeve (4) 4
on the four engine mounting points, two on each side.
3
1 2
P100506046
FIG. 534
FIG. 535: Install engine.
Fo
Install the engine (1). The weight of the engine is

approximately 1332 kg (2930lb).
r in
te
1
rn
P100506043
FIG. 535
al
FIG. 536: Install engine mounting hardware.

Install rebound pad (1), washer (2), washer (3) and bolt
(4) on the four engine mounting points, two on each side. 3 4
u

se
2
on
1
ly
P100506047
FIG. 536
NOTE: If the bolt pattern on the input shaft and the input 3
coupling do not line up, then refer to the CAT
engine manual on how to rotate the flywheel.
Connect the input shaft (2) to the input coupling (3) and
install bolts and washers (1). Tighten to 350 Nm (258 lbf
ft).
2
1
P100506021
FIG. 537
79033095 C Rev. 02-191

Engine Component
FIG. 538: Connect support.
Install the component support (3) and the components
still fastened to it. 5
Install bolts and washers (1) into bearing pad (2) on the
right side of machine. Tighten to 240 Nm (177 lbf ft).
Install bolts and washers (4) onto cooling assembly (5) on 3
the right side of machine. Tighten to 55 Nm (40 lbf ft). 4
1 2
P100506042
FIG. 538
FIG. 539: Connect support.
Install bolts and washers (1) into bearing pad (2) on the
right side of machine. Tighten to 240 Nm (177 lbf ft).
Fo
Install bolts and washers (3) onto cooling assembly (4) on

the right side of machine. Tighten to 55 Nm (40 lbf ft).
r
2
4
in
3
te
1 P100506041
FIG. 539
rn
FIG. 540: Install bracket.

al
Install bracket (2) and install four bolts and washers (1).
1
u se
1
2
on
N032706003
FIG. 540
ly

Install hose (2) and tighten hose clamp (1).
1
N031906008
FIG. 541
02-192 79033095 C Rev.

Engine Component
Install hose (2) and tighten hose clamp (1).
1
N031906007
FIG. 542
FIG. 543: Install ether start hose.
Install ether start hose (1).
Fo
r in
1
te
N031906006
FIG. 543
rn
FIG. 544: Install window washer hoses.

al
Install hose (1), P-clip (3) and cable straps (4).

2
Connect window washer hoses (1) to the pumps (2). 1
u
3 4
se
on
N031906005
FIG. 544
ly
FIG. 545: Install fuel line.

Install supply fuel lines (1). Tighten to 55 Nm (40 lbf ft).
1
1
P100506040
FIG. 545
79033095 C Rev. 02-193

Engine Component
FIG. 546: Turn on fuel shut off.
At the fuel filter (1) on the left side of the engine, turn shut
off valve handle (2) 90 degrees counter clockwise. Shut
off valve handle (2) should be parallel to the valve.
2
1
N033006001
FIG. 546
FIG. 547: Turn on fuel shut off.
On the fuel tank (1) turn shut off valve handle (2) 90 1
Fo
should be parallel to the valve.

2
r in
2
te
P100506039
FIG. 547
rn
FIG. 548: Remove bolts and remove plate (1). Install

plate (1). Install washers and bolts, tighten to 55 Nm (40
al
lbf ft).
u se
on
1
P100506038
FIG. 548
ly
FIG. 549: Install accumulator.

Install two piece clamp (2) around accumulator (3) and
install on bracket (4). Install bolt and washer (1) and
tighten.
4
3
2
P100506017
FIG. 549
02-194 79033095 C Rev.

Engine Component
system.
1
removal of hoses.
and charge the air conditioning system. Reconnect the
low pressure switch (2). Refer to Refrigerant section for
proper installation of hoses. 1
P100506016
FIG. 550
FIG. 551: Install air compressor hoses. (If equipped)
Connect tube (1) and tighten to 86 Nm (63 lbf ft). Install
P-clip (2) and tighten to 70 Nm (51 lbf ft).
Fo
2
2
r
2
in
1
te
P100506037
FIG. 551
rn
FIG. 552: Install air compressor hoses. (If equipped)

al
Connect tube (1) and tighten to 86 Nm (63 lbf ft). Install

P-clip (2). 1 3
Install hose (3) and install cable ties for hose (3).
u se
2
on
N032606001
FIG. 552
ly
FIG. 553: Install air compressor. (If equipped)

Surfaces (1) must be free of primer, topcoat, cleaning
solutions and corrosion.
(46 lb).
1
1
N032006009
FIG. 553
79033095 C Rev. 02-195

Engine Component
FIG. 554: Install air compressor. (If equipped)
Install air compressor (2) and install three nuts and
washers (1). Tighten bolts to 105 Nm (77 lbf ft).
2
1
N032006008
FIG. 554
FIG. 555: Install support bracket. (If equipped)
Rotate bracket (3) to the air compressor.
Install two bolts (1) into the air compressor. Tighten bolt to
Fo
55 Nm (40 lbf ft). 1

Tighten bolt (2) to 215 Nm (158 lbf ft).
3
r in
2
te
N032006010
FIG. 555
rn
FIG. 556: Install air inlet tube. (If equipped)

al

Install air inlet tube (2). Tighten to 156 Nm (115 lbf ft).
u
2
se
1
on
N032106001
FIG. 556
ly
FIG. 557: Install coolant tube. (If equipped)

Install 90 degree elbow (1). Tighten to 82 Nm (60 lbf ft).
1
N032106002
FIG. 557
02-196 79033095 C Rev.

Engine Component
FIG. 558: Install coolant tube. (If equipped)
2
N032106003
FIG. 558
FIG. 559: Install tube. (If equipped)
Install air discharge tube (2). Tighten to 86 Nm (63 lbf ft).
Fo
1 2
r in
te
N032006004
FIG. 559
rn
FIG. 560: Install hose. (If equipped)

al
Install fitting and hose(1). Tighten to 16 Nm (11 lbf ft).
1
u se
on
N032006003
FIG. 560
ly
FIG. 561: Install oil hose. (If equipped)

Install oil hose. Tighten to 18 Nm (13 lbf ft).
N032006002
FIG. 561
79033095 C Rev. 02-197

Engine Component
FIG. 562: Install oil hose. (If equipped)
Install oil hose (2). Tighten to 18 Nm (13 lbf ft). 1
N032106004
FIG. 562
FIG. 563: Install alternator.
Place alternator (3) and install the two top bolts (1) and
bottom bolt (2). Tighten top two bolts to 71 N.m. (52 ft.lb.).
Fo
Tighten bottom bolt to 105 N.m. (77 lb.ft.). The weight of 1

the alternator is approximately 27 kg (60 lb).
3
r in
2
te
N031706008
FIG. 563
rn
FIG. 564: Install air conditioning compressor

al
Install compressor (2) and tighten bolts and washers (1).

Tighten to 28 Nm (20 lbf ft). The weight of the air
conditioning compressor is approximately 10 kg (21 lb). 2
u se
1
on
N030806004
FIG. 564
ly

Insert square drive of ratchet into square hole (1) on belt 1 2
m
tensioner.
Carefully place belt onto air conditioning compressor 4

pulley (4) ensuring belt ribs are properly seated in pulley
valleys and slowly allow belt tensioner to release until it
makes contact with belt. N021606002
FIG. 565
02-198 79033095 C Rev.

Engine Component
system.
removal of hoses. 1
N030806003
FIG. 566
FIG. 567: Install air conditioning line.
Install P-clip (1) to fasten air conditioning line (2). Tighten
to 55 Nm (40 lbf ft).
Fo
2
r
1
in
te
N031706009
FIG. 567
rn
FIG. 568: Install chassis harness.

5
al
Install chassis harness (7) and fasten to original anchor

points.
Install air conditioning clutch and high pressure switch 3 7
u
wire (1).
1
se
Install Alternator terminal wire (2). 4

Install air intake restriction switch wire (3).
Install ether start wire (4).
on
2
Install front and rear washer pump wire (5). 6 P100506036
Install engine ECM wire (6). FIG. 568
ly

Mark and remove wiring (1), (2) and (3) from alternator 4
(4).
Connect electrical wires (1), (2) and (3) to posts on back
of alternator (4).
Position protective boot over power terminal (2). 1 3
2
P100106057
FIG. 569
79033095 C Rev. 02-199

Engine Component
FIG. 570: Install solenoid wire.
Install solenoid wire (1) onto starter (2) on right side of 1
machine.
N031706004
FIG. 570
FIG. 571: Install cable.
Install ground cable (1) onto starter (2) on right side of 2
machine.
Fo
r in
1
te
N031706004
FIG. 571
rn
FIG. 572: Install battery cable.

al
Install positive battery cables (1) onto starter (2) on right

side of machine.
Install P-clip (3) and tighten to 47 Nm (34 lbf ft).
u se
3
1
2
on
N031706003
FIG. 572
ly
FIG. 573: Install solenoid wire.

Install solenoid wire (1) onto starter (2) on left side of
machine.
1 2
P100506035
FIG. 573
02-200 79033095 C Rev.

Engine Component
FIG. 574: Install cable.
Install ground cable (1) onto starter (2) on left side of
machine.
1 2
P100506034
FIG. 574
FIG. 575: Install battery cable.
Install positive battery cables (1) onto starter (2) on left
side of machine.
Fo
r
1
in
2
te
P100506033
FIG. 575
rn
FIG. 576: Install flex exhaust tube.

al
Install flex exhaust tube (2) to turbo (3) and tighten clamp 2 3
(1). Tighten to 8.5 NM (75 lbf in).
u se
1
on
P100506012
FIG. 576
ly

2
Install flex exhaust tube (2) onto the muffler (4). Tighten
clamp (1) and tighten to 70 Nm (52 lbf ft).
5
1 3 P100506011
FIG. 577
79033095 C Rev. 02-201

Engine Component
Install hose (2) and loosely install hose clamps (1). 1
Tighten all four hose clamps after tube is properly
positioned. Tighten to 11 Nm (97 lbf in).
P100506008
FIG. 578
FIG. 579: Install inlet tube.
Install elbow (2), inlet tube (3) and 45 degree elbow (4). 1
Tighten clamps (1) and tighten to 6.2 Nm (55 lbf in). 2
Fo
Install air compressor intake tube (5) if equipped. 3

5
r
4
1
in
te
1
N022606003
FIG. 579
rn

al

6.2 Nm (55 lbf in). 2
u se
1
on
N022206003
FIG. 580
ly
FIG. 581: Connect air inlet switch harness.

Connect the air inlet switch harness (1).
N022206003
FIG. 581
02-202 79033095 C Rev.

Engine Component
FIG. 582: Install fan drive.
Install the fan drive (2) and install the four bolts and
washers (1). Tighten bolts to 100 Nm (74 lbf ft). The 1
weight of the fan drive is approximately 20 kg (45 lb).
N030506004
FIG. 582
FIG. 583: Serpentine belt installation.
Fo

4
r
hold.
3
m
in

spring tension can cause bodily injury. Use 2 1
te
tensioner.
N030506003
FIG. 583
rn
Carefully place belt onto fan drive pulley (4) ensuring belt
al

u
Lightly coat O-ring with bearing lube.

1
se
2
on
ly
N030706001
FIG. 584
FIG. 585: Apply lubricant.
Lubricate cavity (1) in fan adapter (2) with 30 g (1.05 oz)
of bearing lube.
2
N030806001
FIG. 585
79033095 C Rev. 02-203

Engine Component
Install fan adapter (2) and install the six bolts and washers
(1). Tighten bolts to 47 Nm (35 lbf ft). The weight of the
fan adapter is approximately 7 kg (15 lb).
2
1
N030506002
FIG. 586
Fo
facing the engine.

1
r

in
te
P100506014
FIG. 587
rn

al

assembly.
u
se

on
fan.
tighten the bolts (2) on each side of the shroud.
ly
1
N011906002
FIG. 588
02-204 79033095 C Rev.

Engine Component
FIG. 589: Install cab heater hoses.
Install cab heater hoses (2) and tighten hose clamps (1). 2
Tighten bolts to 7.5 Nm (66 lbf in).
1
1 2
N033106002
FIG. 589
Remove all plugs from the ends of the hose that prevent 3
Fo
radiator hose (2) onto the radiator (3) and tighten hose
clamp (1).
r
1
2
in
te
N020606003
FIG. 590
rn

2
al
Remove all plugs from the ends of the hose that prevent
1
radiator hose (2) and top tank vent hose (3) onto the top 4
of the radiator (4) and tighten hose clamps (1).
u

se
3
Cooling System.
on
N020606002
FIG. 591
ly
79033095 C Rev. 02-205

Engine Component
2
Fo
1
r in
N011906001
FIG. 592
te

rn

al
1
1
u se
2
on
ly
N012606004
FIG. 593
02-206 79033095 C Rev.

Engine Component
manifold.
IMPORTANT: Remove all the cloth that plugs the intake
N020606001
FIG. 594
2 2
Fo

r
in

te
N012606007
FIG. 595
rn

al
position. 3
Install bolts and washers (1). Tighten to 29 Nm (21 lbf ft).
u se
1 1
on
ly
N012606006
FIG. 596
79033095 C Rev. 02-207

Engine Component
100 Nm (74 lbf ft). 2 1
P100506024
FIG. 597
1
Fo

r in
1
te
P100506002
FIG. 598
rn

al

- Installation. 1
u se
on
P100506003
FIG. 599
ly

switch.
N012206002
FIG. 600
02-208 79033095 C Rev.

Engine Component
PRIMARY FUEL FILTER / WATER
SEPARATOR REMOVAL AND
INSTALLATION
Primary Fuel Filter / Water Separator

Removal
m
WARNING: Fuel leaked or spilled on hot
surfaces or electrical components can
cause a fire. To prevent possible injury, turn
start switch off when changing fuel filters or
water separator elements. Clean up fuel
spills immediately.
m
Fo

r

in

containing fluids.
te

and mandates.
rn
IMPORTANT: Do not allow dirt to enter fuel system.

Clean area around fuel system component
al
before disconnecting. Fit a suitable cover over

any disconnected fuel system components.
u

se

1
on
ly
P100506001
FIG. 601
79033095 C Rev. 02-209

Engine Component
disconnect switch.
power.
N012206002
FIG. 602
FIG. 603: Primary Fuel Filter / Water Separator removal.
1. Park vehicle on level ground. Ensure engine is cool
before servicing fuel filters.
Fo
2. Before removing the filter ensure all fuel will be

caught in approved container.
3. Open drain valve (1) to drain any fuel from filter case.
r
Close the drain valve.

in
4. Remove fuel filter bowl (2) and wash fuel filter bowl 2
with clean diesel fuel.
te
5. Remove filter element by turning counterclockwise. 1

N033006001
6. Clean surface of filter head where the filter element FIG. 603
rn
makes contact with filter head. Ensure old gasket is

completely removed.
al
u se
on
ly
02-210 79033095 C Rev.

Engine Component
Primary Fuel Filter / Water Separator
Installation
FIG. 604: Primary Fuel Filter / Water Separator
Installation
1. Apply clean diesel fuel on rubber gasket of new filter
element.
2. Install new filter on filter head. Turn filter element by
hand 1/2 to 3/4 turn after gasket makes contact with
the filter head. Do not overtighten.
3. Install clean fuel filter bowl (2) on new fuel filter.
Ensure drain valve (1) is closed. 2
4. Prime fuel system. 1
N033006001
NOTE: Do not prime system if the other fuel filters need
to be serviced at this time. FIG. 604
Fo

switch.
r
Start engine and check for leaks. Run engine for one
minute. Stop Engine and check engine for leaks again.
in
NOTE: If engine will not start, there could be air in fuel

system. Repeat fuel priming procedure.
te
1
rn
N012206002
al
FIG. 605
u se
on
ly
79033095 C Rev. 02-211

Engine Component
SECONDARY FUEL FILTER REMOVAL
AND INSTALLATION
Secondary Fuel Filter Removal
m
WARNING: Fuel leaked or spilled on hot
surfaces or electrical components can
cause a fire. To prevent possible injury, turn
start switch off when changing fuel filters or
water separator elements. Clean up fuel
spills immediately.
m

Fo

r

containing fluids.
in

and mandates.
te
IMPORTANT: Do not allow dirt to enter fuel system.

Clean area around fuel system component
rn
before disconnecting. Fit a suitable cover over

any disconnected fuel system components.
al

u

se
1
on
ly
P100506001
FIG. 606
disconnect switch.
power.
N012206002
FIG. 607
02-212 79033095 C Rev.

Engine Component
FIG. 608: Secondary fuel filter removal.
1. Park vehicle on level ground. Ensure engine is cool
before servicing the fuel filters.
2. Before removing the filter, ensure all fuel will be
caught in approved container.
3. Remove filter element (1) by turning 1
counterclockwise.
4. Clean surface of filter head where filter element
contacts filter head. Ensure old gasket is completely
removed.
N033006002
FIG. 608
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 02-213

Engine Component
Secondary Fuel Filter Installation
FIG. 609: Secondary fuel filter installation.
1. Apply clean diesel fuel on rubber gasket of new filter
element.
2. Install new filter (1) on filter head. Turn filter element
by hand 1/2 to 3/4 turn after gasket contacts filter
head. Do not overtighten.
1
3. Prime fuel system. Do not prime system if other fuel
filters need to be serviced at this time.
N033006002
FIG. 609
switch.
Fo

Start engine and check for leaks. Run engine for one
r
minute. Stop engine and check engine for leaks again.

in
system. Repeat fuel priming procedure. 1

te
rn
N012206002
FIG. 610
al
u se
on
ly
02-214 79033095 C Rev.

Engine Component
FUEL PRIMING PUMP
Fuel Priming Pump

FIG. 611: Fuel Priming Pump.
IMPORTANT: Do not loosen fuel lines at fuel manifold.
Fittings may be damaged and/or a loss of
priming pressure may occur when fuel lines are 2
loosened.
IMPORTANT: Do not crank engine continuously for more
than 30 seconds. Allow starting motor to cool for
two minutes before cranking engine again.
1. Loosen plug (2) to allow air to escape from the fuel
lines. Ensure that the plug is open enough or the
priming pump (1) will not work. 1
2. Open fuel priming pump (1) by turning counter Q021103001
Fo
clockwise. Operate until a strong pressure is felt and FIG. 611

fuel is leaking out of the plug (2). This procedure
requires considerable strokes.
r
3. Lock fuel priming pump (1) by pushing it fully in and

turn clockwise. Tighten plug (2).
in
4. Promptly start engine. If engine runs rough, continue

to operate engine at low idle, until engine operates
te
smoothly.
5. If engine does not start repeat the previous steps.
rn

system. Repeat fuel priming procedure.
al
u se
on
ly
79033095 C Rev. 02-215

Engine Component
ETHER START REMOVAL AND
INSTALLATION
Ether Start Removal

FIG. 612: Ether start location.
The location of the ether start (1) is on the left side of the
machine next to the air filter (2).
1
N033006004
Fo
FIG. 612
r
Remove ether start hose (1) from intake (2).

in
te
rn
1
2
al
N031906006
FIG. 613
u

se
Remove P-clip (1) and remove hose (2).

on
2
ly
N033006006
FIG. 614
02-216 79033095 C Rev.

Engine Component
FIG. 615: Remove valve.
Disconnect wire (1).
Remove bolts (2) and remove valve (3). 2
2
3
N033006007
FIG. 615
FIG. 616: Remove bracket.
Remove bolt (1) and remove mounting bracket (2).
1
Fo
2
r in
te
N033006008
FIG. 616
rn
al
u
se
on
ly
79033095 C Rev. 02-217

Engine Component
Ether Start Installation
FIG. 617: Install bracket.
Install mounting bracket (2) and install bolt and washer
1
(1). Tighten to 27 Nm (20 lbf ft).
N033006008
FIG. 617
FIG. 618: Install valve.
Fo
Install valve (3) and install bolts and washers (2). Tighten
to 27 Nm (20 lbf ft).
2
Connect wire (1). 2
r
1
in
te
3
rn
N033006007
FIG. 618
al

Install hose (2). Install P-clip (1) and tighten bolt to 55 Nm
(40 lbf ft).
u se
2
on
1
ly
N033006006
FIG. 619
FIG. 620: Install atomizer.
Install atomizer (1) and tighten bolt to 10 Nm (88 lbf in).
Hole in atomizer (1) must be aligned parallel with center
line of air flow, and must be oriented against the direction
of air flow. Use mark on hex head.
2
Install hose (2) onto the atomizer (1).
1
N033006009
FIG. 620
02-218 79033095 C Rev.

Index
INDEX
A Exhaust System Installation ............................. 02-107

Exhaust System Removal ................................ 02-105
Air Cleaner Assembly ........................................ 02-96
Air Cleaner Assembly Removal ......................... 02-96
Air Cleaner Filter .............................................. 02-100 F
Air Cleaner Filter Installation ............................ 02-101
Air Cleaner Filter Removal ............................... 02-100 Fan ................................................................... 02-117
Air Cleaner Installation ....................................... 02-98 Fan Drive ............................................. 02-123, 02-129
Air Compressor ................................................ 02-154 Fan Drive Assembly ......................................... 02-131
Air Compressor Installation .............................. 02-159 Fan Drive Disassembly .................................... 02-129
Air Compressor Removal ................................. 02-154 Fan Drive Installation ........................................ 02-126
Air Conditioning Accumulator .............. 02-138, 02-141 Fan Drive Removal ........................................... 02-123
Air Conditioning Compressor .............. 02-132, 02-136 Fan Installation ................................................. 02-120
Air Conditioning Condenser .................... 02-78, 02-82 Fan Removal .................................................... 02-117
Air Intake Assembly ........................................... 02-90 Fuel ...................................................................... 02-1
Fo
Air Intake Assembly Installation ......................... 02-93 Fuel Cooler ......................................................... 02-85
Air Intake Assembly Removal ............................ 02-90 Fuel Priming Pump ........................................... 02-215
Air Reservoir .................................................... 02-163 Fuel Quality .......................................................... 02-1
r
Air Reservoir Installation .................................. 02-167

Air Reservoir Removal ..................................... 02-163
in
Alternator .................................................. 02-8, 02-11 H

Removal Procedure .......................................... 02-8
Hood ................................................................. 02-142
te
Hood Installation ............................................... 02-146

B Hood Removal .................................................. 02-142
rn
Hydraulic Coooler Installation ............................. 02-59

Battery .............................................................. 02-113 Hydraulic Removal and Installation .................... 02-49
Battery Installation ........................................... 02-115
al
Battery Removal .............................................. 02-113

Belt Tensioner ............................. 02-4, 02-10, 02-125, I
.................................................02-134, 02-177, 02-182
u
Input Coupling .................................................. 02-149

Input Shaft ........................................................ 02-149
se
C Input Shaft and Input Coupling Installation ....... 02-152

Input Shaft and Input Coupling Removal .......... 02-149
Charge Air Cooler .............................................. 02-68
Charge Air Cooler Removal ............................... 02-68
on
Charge Air Installation ........................................ 02-73 M

Coolant ................................................................. 02-1
Coolant Quality .................................................... 02-1 Muffler .............................................................. 02-109
Cooling Assembly .................................. 02-13, 02-30, Muffler Installation ............................................ 02-111
ly
.......................................................02-49, 02-68, 02-78 Muffler Removal ............................................... 02-109
D O
Dust Ejector ..................................................... 02-102 Oil ......................................................................... 02-1

Dust Ejector Installation ................................... 02-104 Oil Quality ............................................................. 02-1
Dust Ejector Removal ...................................... 02-102
P
E
Primary Fuel Filter / Water Separator ............... 02-209
Engine .............................................................. 02-170 Primary Fuel Filter / Water
Engine Installation ............................................ 02-191 Separator Installation ................................. 02-211
Engine Removal ............................................... 02-170 Primary Fuel Filter / Water
Ether Start ........................................................ 02-216 Separator Removal .................................... 02-209
Ether Start Installation ...................................... 02-218 Primary Fuel Filter/Water Separator .... 02-210, 02-211
Ether Start Removal ......................................... 02-216
Exhaust System ............................................... 02-105
79033095 C Rev. 02-219

Index
R
Radiator Removal .............................................. 02-30
Secondary Fuel Filter ............. 02-212, 02-213, 02-214

Secondary Fuel Filter Installation ..................... 02-214
Secondary Fuel Filter Removal ........................ 02-212
Serpentine Belt ............................... 02-2, 02-5, 02-11,
................................... 02-126, 02-136, 02-198, 02-203
Serpentine Belt Installation .................................. 02-5
Specifications ....................................................... 02-1
Standards ............................................................. 02-1
Fo
r in
te
rn
al
u se
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02-220 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
03 - Powertrain
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POWERTRAIN SYSTEM OPERATIONS

Introduction .................................................................................................................................................... 03-1
General Information ................................................................................................................................. 03-1
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Transmission System .................................................................................................................................... 03-3

Introduction (Transmission) ..................................................................................................................... 03-3
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Location of Electronic Components for Transmission System ................................................................ 03-9

Location of Hydraulic Components for Transmission System ............................................................... 03-16
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Test Ports .............................................................................................................................................. 03-23

Features of Transmission System ......................................................................................................... 03-25
Input Components of Transmission System .......................................................................................... 03-28
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Control Settings for Transmission System ............................................................................................ 03-34

Electronic Control Modules for Transmission System ........................................................................... 03-35
Output Components of Transmission System ....................................................................................... 03-38
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Data Link for Transmission System ....................................................................................................... 03-39

Electrical Schematic for Transmission System ..................................................................................... 03-40
Common Sump ..................................................................................................................................... 03-42
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Hydraulic Oil Filter ................................................................................................................................. 03-46

Tandem Charge Pump .......................................................................................................................... 03-49
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Modulating Valve (Transmission) .......................................................................................................... 03-51

Relief Valve (Charge Pressure) ............................................................................................................. 03-60
Hydraulic Oil Cooler .............................................................................................................................. 03-62
Hydraulic System Schematic (Transmission) ........................................................................................ 03-64
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Transmission Clutches .......................................................................................................................... 03-66

Transmission Power Flow ..................................................................................................................... 03-78
Power Take-Off (PTO) System .................................................................................................................... 03-93
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Introduction (Power Take-Off System) .................................................................................................. 03-93

Power Take-Off (PTO) System ............................................................................................................. 03-94
Electrical Control System For Power Take-Off (PTO) ........................................................................... 03-96
Hydraulic System for Power Take-Off (PTO) ........................................................................................ 03-97
Location of Electronic Components for Power Take-Off System .......................................................... 03-98
Location of Hydraulic Components for Power Take-Off System ......................................................... 03-101
Electrical Schematic for Power Take-Off System ................................................................................ 03-106
Modulating Valve (Power Take-Off) .................................................................................................... 03-107
Hydraulic System Schematic (Power Take-Off) .................................................................................. 03-116
Power Take-Off (PTO) Clutch ............................................................................................................. 03-118
DISASSEMBLY AND ASSEMBLY

Relief Valve (Transmission Lubrication) - Remove and Install .................................................................. 03-123
Removal Procedure ............................................................................................................................. 03-123
Installation Procedure .......................................................................................................................... 03-123
Relief Valve (Charge Pressure) - Remove and Install ............................................................................... 03-124
Hydraulic Pump Drive Removal ................................................................................................................. 03-125
79033095 C Rev. 03-i

Contents
Hydraulic Pump Drive Disassembly ........................................................................................................... 03-127
Hydraulic Pump Drive Assembly ............................................................................................................... 03-130
Hydraulic Pump Drive Installation .............................................................................................................. 03-132
Engine Frame and Powertrain - Separate ................................................................................................. 03-135
Engine Frame and Powertrain - Connect .................................................................................................. 03-140
Transmission Removal .............................................................................................................................. 03-145
Transmission Disassembly ........................................................................................................................ 03-147
Reverse Shaft Disassembly ................................................................................................................ 03-155
Intermediate Shaft Disassembly .......................................................................................................... 03-158
Output Shaft Disassembly ................................................................................................................... 03-161
Input Shaft Disassembly ...................................................................................................................... 03-164
Transmission Assembly ............................................................................................................................. 03-168
Input Shaft Assembly .......................................................................................................................... 03-172
Output Shaft Assembly ........................................................................................................................ 03-174
Intermediate Shaft Assembly .............................................................................................................. 03-177
Reverse Shaft Assembly ..................................................................................................................... 03-179
Transmission Assembly ...................................................................................................................... 03-180
Transmission Installation ........................................................................................................................... 03-185
Modulating Valve (Power Take-Off) Removal and Installation .................................................................. 03-188
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Power Take-Off (PTO) Removal ................................................................................................................ 03-189
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Power Take-Off (PTO) Disassembly ......................................................................................................... 03-191

Power Take-Off (PTO) Assembly .............................................................................................................. 03-200
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Power Take-Off (PTO) Installation ............................................................................................................. 03-207

Service Brake Removal ............................................................................................................................. 03-209
Service Brake Installation .......................................................................................................................... 03-213
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Service Brake Cable Adjustment ............................................................................................................... 03-217

Parking Brake Disassembly ....................................................................................................................... 03-218
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Parking Brake Assembly ............................................................................................................................ 03-223

Park Brake Cable Adjustment Procedure .................................................................................................. 03-227
Final Drive Removal .................................................................................................................................. 03-228
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Left-Hand Final Drive Removal ........................................................................................................... 03-228

Right-Hand Final Drive Removal ......................................................................................................... 03-235
Final Drive Disassembly ............................................................................................................................ 03-239
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Final Drive Assembly ................................................................................................................................. 03-245

Final Drive Installation ............................................................................................................................... 03-250
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Right-Hand Final Drive Installation ...................................................................................................... 03-250

Left-Hand Final Drive Installation ........................................................................................................ 03-253
Steering Differential Removal .................................................................................................................... 03-258
Steering Differential Disassembly .............................................................................................................. 03-263
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Steering Differential Assembly ................................................................................................................... 03-278

Steering Differential Installation ................................................................................................................. 03-292
Differential Housing Removal .................................................................................................................... 03-296
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Differential Housing Disassembly .............................................................................................................. 03-298

Differential Housing Assembly ................................................................................................................... 03-299
Differential Housing Installation ................................................................................................................. 03-300
TESTING AND ADJUSTING

General Testing and Adjusting Information ............................................................................................... 03-303
Preparation of Machine ....................................................................................................................... 03-303
Procedure ............................................................................................................................................ 03-303
Troubleshooting Procedure ................................................................................................................. 03-305
Visual Inspection ........................................................................................................................................ 03-306
Relief Valve (Charge) - Test and Adjust .................................................................................................... 03-307
Pressure Test for Relief Valve (Charge Pressure) .............................................................................. 03-307
Adjust the Pressure Setting of Relief Valve (Charge Pressure) .......................................................... 03-309
Transmission Clutch Calibration ................................................................................................................ 03-312
Accessing Calibrations For Transmission Solenoid Valves ................................................................ 03-312
Transmission Clutch Pressure - Test ......................................................................................................... 03-315
Clutch Pressure Test ........................................................................................................................... 03-315
Pressure Test for Lubrication Oil ......................................................................................................... 03-320
Power Take-Off (PTO) Clutch Pressure - Test and Adjust ........................................................................ 03-323
03-ii 79033095 C Rev.

Contents
Pressure Test for Power Take-Off Clutch ........................................................................................... 03-323
Hydraulic Oil Cooler - Test ......................................................................................................................... 03-326
Pressure Test of Hydraulic Oil Cooler ................................................................................................. 03-326
INDEX ........................................................................................................................................................... 03-329
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79033095 C Rev. 03-iii

Contents
NOTES
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03-iv 79033095 C Rev.

Powertrain System Operations
POWERTRAIN SYSTEM OPERATIONS
INTRODUCTION
General Information
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P100305001
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FIG. 1
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FIG. 1: This systems operation section describes

features and operation of following systems:
• Transmission electrical system
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• Transmission hydraulic system

• PTO electrical system
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• PTO hydraulic system

The major electrical components and hydraulic
components are discussed.
79033095 C Rev. 03-1

Transmission System Power Take-Off (PTO) System
The transmission electrical system provides controls for The PTO electrical system provides controls for PTO
transmission hydraulic system. The transmission hydraulic system. The PTO electrical system includes
electrical system includes switches, sensors, and control switches and sensors. These electrical inputs are
levers. The inputs signals are processed by machine processed by machine electronic control module (ECM)
electronic control module (ECM) which then energizes which then energizes appropriate solenoid.
appropriate solenoid.
The PTO electrical system contains following
The transmission electrical system contains following components:
components:
• Machine ECM
• Machine ECM
• Armrest ECM
• Armrest ECM
• Virtual Terminal (VT)
• Dash panel cluster
• Dash Panel Cluster
• Control inputs
• Control Inputs
• Solenoid
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• Solenoids
The PTO hydraulic system provides a modulated flow of
The transmission hydraulic system provides a modulated pressurized oil to PTO clutch. The PTO hydraulic system
flow of pressurized oil to transmission. The transmission includes one modulating valve (power take-off) and one
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contains nine transmission clutches. The nine clutches PTO clutch.

are controlled by nine corresponding modulating valves
The modulating valve (power take-off) provides following
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(transmission). The transmission provides operator with

control functions:
16 forward and 4 reverse gears that are under 37 km/h
(23.0 mph) at rated engine speed and under 39.6 km/h • Proportional control of oil flow
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(24.6 mph) at 2300 RPM.

• Pressure compensation
The modulating valves (transmission) provide following
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control functions: • Modulating control
• Proportional control of oil flow • Pressure relief control

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• Modulating control
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• Pressure relief control

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03-2 79033095 C Rev.

TRANSMISSION SYSTEM
Introduction (Transmission) Tandem Charge Pump
The MT800C Series machine is equipped with a power The large section of tandem charge pump provides
shift transmission. This transmission provides 16 forward charge oil to transmission hydraulic system. The small
gears and four reverse gears. section provides lube flow to various components and
keeps EOR full. The oil flow from this pump is continuous
There are nine individual clutch packs on four and pressure is constant after engine is started. The
transmission shafts. Each clutch pack is controlled by a tandem charge pump is a simple gear pump.
corresponding modulating valve (transmission). The
machine electronic control module (ECM) controls Hydraulic Oil Filters
modulating valve. The modulating valve will modulate oil
pressure and flow to provide smooth shifting between The hydraulic oil filters protect transmission hydraulic
gears. system from damaging contamination. The hydraulic filter
will filter particles larger than 7.5 microns in charge oil.
The transmission hydraulic system has following main
components: Relief Valve (Charge Pressure)
• Elevated Oil Reservoir (EOR) The relief valve (charge pressure) controls oil pressure to
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• Hydraulic Oil Filter 2100 kPa (305 psi).
• Scavenge Pump Modulating Valves (Transmission)

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• Tandem Charge Pump The MT800C Series machine is equipped with nine
modulating valves. The modulating valves are controlled
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• Relief Valve (Charge Pressure)

by use of electronics. Nine modulating valves provide oil
• Modulating Valves (Transmission) to transmission clutches. There are nine corresponding
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transmission clutches.
• Electronic Controls
Electronic Controls
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Elevated Oil Reservoir (EOR)

The armrest ECM receives signals from input controls.
The elevated oil reservoir (EOR) provides lubrication oil to The armrest ECM then signals machine ECM as to what
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PTO clutch. functions are needed to be performed.

Scavenge Pump The machine ECM controls solenoids on modulating
valves (transmission). The Virtual Terminal (VT) and dash
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This pump will provide a consistent oil level in common cluster is used to view current gear and selected gear.
sump in all working conditions. Oil is pumped from
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transmission case and transferred to differential case.

The oil flow from this pump is continuous and pressure is
constant after engine is started. The scavenge pump is a
simple gear pump.
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79033095 C Rev. 03-3

Transmission System
NOTE: The following illustration shows electrical
components and hydraulic components of
transmission system on MT800C Series
machines.
1 7
6
2
14
3
8
4
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10 12
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9 13
5
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R020305001
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FIG. 2
FIG. 2: Block Diagram for Transmission System

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The operator can initiate a transmission hydraulic function

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by using one of the following controls:

(1) Shift Lever
(2) One Touch Switch
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(3) Inching Pedal Switch

(4) Inching Pedal Position Sensor
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(5) Common Sump

(6) Armrest ECM
(7) Virtual Terminal (VT)
(8) Machine ECM
(9) Tandem Charge Pump
(10) Hydraulic Oil Filter
(11) Relief Valve
(12) Oil Cooler
(13) Modulating Valves (Transmission)
(14) Transmission
03-4 79033095 C Rev.

The controls will send a signal to armrest electronic
control module (ECM) (6). The armrest ECM will then
process these signals with any parameters that were set
in virtual terminal (VT) (7).
The armrest ECM will then send a signal to machine ECM
(8) and machine ECM will energize modulating valves
(13) (transmission).
The common sump (5) supplies tandem charge pump (9)
with oil. The oil goes through hydraulic oil filter (10). The
oil is then delivered to relief valve (11) (charge pressure).
The relief valve controls oil pressure to 2100 kPa (305
psi). All excess oil is routed through hydraulic oil cooler
(12). The oil then goes to transmission to lubricate
clutches.
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79033095 C Rev. 03-5

Transmission Electrical Control System
16
1
2 17
15
3 18
4
19
5
20
6
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7 21
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8 14
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24
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11
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P111105002
FIG. 3
FIG. 3: Electrical Block Diagram for Transmission

System
03-6 79033095 C Rev.

The electrical system for transmission consists of The CAN data link (14) is a serial communication
following components: bus that is used to communicate with following
components:
• Engine ECM
• Machine ECM
(3) Transmission Input Speed Sensor
• Armrest ECM
(4) Transmission Output Speed Sensor
• VT (Virtual Terminal)
(5) Transmission Output Speed Sensor
(6) Temperature Sensor (Hydraulic Oil)
• Other Optional Electronic Control Modules
(7) Pressure Sensor (Charge)
The shift lever (9) sends a PWM signal to armrest ECM
(8) VT (Virtual Terminal)
(11). The armrest ECM processes signal to determine
(9) Shift Lever position of shift lever.
(10) One Touch Switch The lever has following four positions:
(11) Armrest ECM • Park
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(12) Dash Panel Cluster • Neutral

(13) To Service Connector and Optional ECMs • Forward
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(14) CAN Network • Reverse

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(15) Machine ECM When shift lever is located in park position, a parking
brake sensor signals armrest ECM.
(16) Modulating Valve (Transmission No.1 clutch C)
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The shift lever has three push button switches. The

(17) Modulating Valve (Transmission No. 2 clutch D) switches control upshift, downshift, and one touch mode.
The armrest ECM (11) receives signals from switches.
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(18) Modulating Valve (Transmission No. 3 clutch E)

The armrest ECM signals machine ECM which will then
(19) Modulating Valve (Transmission No. 4 clutch F) shift transmission according to request.
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(20) Modulating Valve (Transmission No. 5 clutch G) The speed sensors (3), (4) and (5), temperature sensor
(21) Modulating Valve (Transmission No. 6 clutch B) (6), and pressure sensor (7) send signals to machine
ECM. The machine ECM uses signals to monitor
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(22) Modulating Valve (Transmission No. 7 clutch H) conditions of transmission.

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(23) Modulating Valve (Transmission No. 8 clutch J) Dash panel cluster (12) and virtual terminal (8) is used
(24) Modulating Valve (Transmission No. 9 clutch A) view current gear and selected gear.
The armrest ECM (11) signals machine ECM desired

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function. The machine ECM (15) controls solenoid valves

(16) through (24) for transmission.
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79033095 C Rev. 03-7

Transmission Hydraulic System
4 7
6 8 9
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P111105003
FIG. 4
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FIG. 4: Block Diagram for Transmission Hydraulic Filtered oil is supplied to following valves:
System.
• Relief Valve (Charge Pressure)
(1) Common Sump
• Modulating Valves (Transmission)
on
(2) Suction Screen

When modulating valves are energized, oil flows to
(3) Tandem Charge Pump transmission clutches. When modulating valves are
de-energized, oil flows from clutch to common sump.
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The relief valve (charge pressure) regulates pressure in
(5) Relief Valve
transmission hydraulic system to a maximum pressure of
(6) Modulating Valves (Transmission) 2100 to 2135 kPa (305 to 310 psi).
(7) Transmission Excess oil flows from relief valve (5) (charge pressure) to
hydraulic oil cooler (9). The cooler bypass valve (8) will
(8) Cooler Bypass Valve open if a pressure of 520 kPa (75 psi) is felt at input side
(9) Oil Cooler of hydraulic oil cooler. Normally, cooler bypass valve will
remain closed unless there is a restriction in hydraulic oil
(10) Lube Relief Valve cooler or if oil is very cold.
Oil from common sump (1) is drawn through suction Oil from hydraulic oil cooler flows to transmission for
screen (2) by large section of tandem charge pump (3). lubrication of clutches. The transmission lubrication relief
The suction screen is rated at 200 micron. The hydraulic valve (10) regulates oil pressure for lubrication to a
oil filter (4) filters oil from large section of tandem charge maximum of 275 kPa (40 psi).
pump.
03-8 79033095 C Rev.

Location of Electronic Components for
Transmission System
The electronic system for transmission consists of
following components:
• Position Sensors (Shift Lever)
• Upshift Switch (Transmission)
• Downshift Switch (Transmission)
• Switch (One Touch)
• Power Management Switch (Transmission)
• Switch (Inching Pedal)
• Position Sensor (Inching Pedal)
• Speed Sensor (Transmission Input)
• Speed Sensors (Transmission Output) - Two
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• Temperature Sensor (Hydraulic Oil)

• Pressure Sensor (Charge)
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• CAN data link

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• Machine Electronic Control Module (ECM)

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• Armrest ECM
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• Modulating Valves (Transmission Clutch) (No. 1

through No. 9)
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Position Sensors (Shift Lever)

FIG. 5: Transmission Control Lever
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(1) Transmission Control Lever 1 2

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(2) Upshift Switch

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(3) Downshift Switch
4
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Transmission control lever (1) is located on armrest

The transmission control lever signals armrest ECM of
position of lever.
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The lever has following four positions:

• Park P020112002
• Neutral FIG. 5
• Forward
• Reverse
79033095 C Rev. 03-9

Switch (Upshift)
FIG. 6: Switches on Transmission Control Lever
(2) Upshift Switch
3
4
Upshift switch (2) is a momentary push button switch that
is located on left-hand side of transmission control lever
(1). The switch is top push button switch on lever.
The upshift switch signals armrest ECM that operator
wants to shift transmission to a higher gear.
P020112002
Switch (Downshift) FIG. 6

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(2) Upshift Switch
3
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4
Downshift switch (3) is a momentary push button switch
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that is located on left-hand side of transmission control

lever (1). The switch is middle push button switch on lever.
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The downshift switch signals armrest ECM that operator

wants to shift transmission to a lower gear.
P020112002
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Switch (One Touch) FIG. 7

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(2) Upshift Switch

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4
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The switch signals armrest ECM that operator wants to

perform multiple operations with a single command.
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P020112002
FIG. 8
03-10 79033095 C Rev.

Power Management Switch
FIG. 9: Power Management Switch
The power management switch (1) is a rocker switch that
is located in front of transmission control lever (2).
The power management switch signals armrest ECM that 1
operator wants to operate in power management mode.
P100605003
FIG. 9
Switch (Inching Pedal)

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FIG. 10: Inching Pedal Switch

NOTE: The inching pedal switch (1) is a limit switch that
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is actuated when inching pedal is fully

depressed. The inching pedal is left-hand foot
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pedal that is located in front of operator. The

switch is located on left-hand side of inching
pedal behind cover.
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The switch signals machine ECM that operator has fully 1

depressed inching pedal.
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P100805003
FIG. 10
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Position Sensor (Inching Pedal)

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FIG. 11: Inching Pedal Sensor

NOTE: The cover is removed in illustration.
The inching pedal sensor (1) is a position sensor that 1
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senses position of inching pedal. The inching pedal is

left-hand foot pedal that is located in front of operator. The
sensor is located on left-hand top side of inching pedal
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behind cover.
The position sensor signals machine ECM of position of
inching pedal.
P100805004
FIG. 11
79033095 C Rev. 03-11

Speed Sensor (Transmission Input)
FIG. 12: Speed Sensor for Input to Transmission
The speed sensor (1) is a sensor that senses input speed
to transmission. The sensor is located on left-hand side of
transmission towards top.
The speed sensor signals machine ECM of speed of input
shaft of transmission.
1
P111105004
FIG. 12
Speed Sensor (Transmission Output)

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FIG. 13: Speed Sensor for Output from Transmission

Speed sensors (1) are sensors that sense output speed
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of transmission. The sensors are located on front side of

transmission toward bottom.
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The speed sensors signal machine ECM of speed of

output shaft of transmission.
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P111105005
FIG. 13
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Temperature Sensor (Hydraulic Oil)

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FIG. 14: Temperature Sensor for Hydraulic Oil

The temperature sensor (1) is located on left-hand side of
machine on top side of transmission.
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The temperature sensor signals machine ECM of

hydraulic oil temperature.
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P111105006
FIG. 14
03-12 79033095 C Rev.

Pressure Sensor (Charge)
FIG. 15: Pressure Sensor for Transmission
The pressure sensor (1) is located on left-hand side of
machine on top side of transmission.
The pressure sensor signals machine ECM of hydraulic 1
oil pressure of transmission.
P111105007
FIG. 15
CAN Data Link

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FIG. 16: Connector for CAN Data Link

The CAN data link is located in wire harness. The
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connector (1) for CAN data link is located next to fuse

blocks on right-hand side of cab.
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The CAN data link is a serial communication bus that is

used to communicate with following components: 1
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• Engine ECM
• Machine ECM
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• Armrest ECM
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• Virtual Terminal
P090305001
• Auto-guide Receiver (if equipped)
FIG. 16
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AGCO Electronic Diagnostic Tool (EDT) Connector

FIG. 17: AGCO Electronic Diagnostic Tool (EDT)
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Connector
The EDT connector (1) is located in wire harness. The
connector for EDT is located next to fuse blocks on
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right-hand side of cab.

The connector gives ability for Electronic Diagnostic Tool
to access electronics of machine for troubleshooting
purposes. 1
P090305001
FIG. 17
79033095 C Rev. 03-13

Machine ECM
FIG. 18: Machine ECM
The machine ECM (1) is located on left-hand side of
machine beneath floor plate of cab in front of instructional
seat.
The machine ECM controls following components:
1
• Transmission
• Steering
• Parking Brake
• PTO
P100805005
FIG. 18
Armrest ECM
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FIG. 19: Armrest Electronic Control Module (ECM)

The armrest ECM (1) is located in armrest inside of cab.
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NOTE: The armrest is shown transparent to allow better

view of armrest ECM
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P100805006
FIG. 19
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Virtual Terminal
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FIG. 20: Virtual Terminal

The virtual terminal (1) is located on armrest in front of 1
hydraulic control levers.
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The virtual terminal allows operator to view following

items:
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• Current Gear of Transmission

• Selected Gear of Transmission
P012205003
FIG. 20
03-14 79033095 C Rev.

Modulating Valves (Transmission Clutch)
FIG. 21: Modulating Valves for Transmission Clutches
(A) Modulating valve (transmission clutch) (No. 9)
A
(B) Modulating valve (transmission clutch) (No. 6)
(C) Modulating valve (transmission clutch) (No. 1) B
(D) Modulating valve (transmission clutch) (No. 2)
C
(E) Modulating valve (transmission clutch) (No. 3)
(F) Modulating valve (transmission clutch) (No. 4) D
(G) Modulating valve (transmission clutch) (No. 5) 1
(H) Modulating valve (transmission clutch) (No. 7) E
(J) Modulating valve (transmission clutch) (No. 8)
The nine modulating valves (1) for transmission clutches
F
are located on left-hand side of transmission. Each valve
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has a designated letter, as shown. The letters have been G

cast into transmission housing. The designated letters are
used to correlate transmission control valve to H
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corresponding transmission clutch.

The modulating valves control hydraulic flow of oil to J
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clutches in transmission to engage different gear ratios.

P102105007
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FIG. 21
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79033095 C Rev. 03-15

Location of Hydraulic Components for
Transmission System
Common Sump
2
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P111105008
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FIG. 22
FIG. 22: Common Sump The common sump normally supplies oil to following
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components:
Common sump (1) supplies oil to all hydraulic systems on
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machine. • Transmission
THE COMMON SUMP IS LOCATED IN LOWER • Steering
PORTIONS OF FOLLOWING CASES:
• Elevated oil reservoir (EOR)
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• Transmission
• Parking brake
• Steering differential
• PTO
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• Final drive
03-16 79033095 C Rev.

Suction Screen (Tandem Charge Pump)
FIG. 23: Suction Screen for Tandem Charge Pump
Suction screen (1) for tandem charge pump is located on
left-hand side of machine behind hydraulic filters.
The suction screen filters all sump oil before oil is routed
to inlet side of tandem charge pump. The suction screen
will filter particles that are larger than 200 microns.
T040505001
FIG. 23
Suction Screen (Scavenge Pump)

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FIG. 24: Suction Screen for Scavenge Pump

Suction screen (1) for scavenger pump is located on
left-hand side of machine behind implement pump. The
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suction screen for scavenge pump will filter particles that

are larger than 540 microns. The suction screen filters all
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sump oil before oil is routed to inlet of scavenge pump.

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T040505002
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FIG. 24
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79033095 C Rev. 03-17

Tandem Charge Pump
FIG. 25: Tandem Charge Pump
Tandem charge pump (1) is located on left-hand side of
machine just behind implement pump.
The tandem charge pump is a two-section gear pump.
The large section of tandem charge pump supplies oil to
following hydraulic systems:
• Transmission
• Steering
• Parking brake 1
• PTO P111105011
The small section of tandem charge pump supplies oil to FIG. 25

following hydraulic systems that are not part of
transmission hydraulic system:
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• Implement
• Three-point hitch
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• Service brakes
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• Differential steer lubrication

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NOTE: The EOR supplies lubrication oil to PTO clutch.

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Hydraulic Oil Filter (Transmission)

FIG. 26: Hydraulic Oil Filter
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Hydraulic oil filter (1) is located on left-hand side of

machine just in front of hydraulic oil filter for implements.
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The hydraulic oil filter removes contaminants from oil that

is delivered by large section of tandem charge pump. The
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hydraulic oil filter is a 7.5 micron filter.

The hydraulic oil filter receives oil from large section of
tandem charge pump. The filtered oil then flows to 1
transmission system.
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P111105012
FIG. 26
03-18 79033095 C Rev.

Relief Valve (Charge Pressure)
FIG. 27: Relief Valve (Charge Pressure)
Relief valve (1) (charge pressure) is located on left-hand 1
side of machine near top of modulating valves
(transmission).
The relief valve receives oil flow directly from hydraulic oil
filter. The relief valve regulates oil pressure in
transmission hydraulic system at a nominal pressure of
2100 kPa (305 psi).
P111105013
FIG. 27
Relief Valve (Transmission Lube)

Fo
FIG. 28: Relief Valve (Transmission Lube)

Relief valve (1) is located in front transmission case above
1
r
reverse shaft for transmission.

The relief valve regulates hydraulic oil pressure to
in
transmission clutches at 275 kPa (40 psi). The oil flow to

relief valve comes from hydraulic oil cooler.
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rn
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P111105014
FIG. 28
u
Modulating Valves (Transmission)

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FIG. 29: Modulating Valves (Transmission)

The modulating valves (1) are located on left-hand side of
machine just behind hardbar.
on
There are nine individual modulating valves. Each

modulating valve modulates flow of oil to a specific clutch
in transmission.
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P111105015
FIG. 29
79033095 C Rev. 03-19

Transmission Clutches
FIG. 30: Transmission Cases
Nine transmission clutches are located in rear 2
transmission case (1) and front transmission case (2).
Each clutch pack and planetary clutch pack is controlled
by a corresponding modulating valve (transmission).
There are nine modulating valves for nine clutch
assemblies.
1
P111105016
FIG. 30
Fo
A
r in
11
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11
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B
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13
u
C
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11
on
12
P110605003
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FIG. 31
FIG. 31: Four Transmission Shafts

NOTE: Gear (A) never meshes with gear (B), only gear
(C). The configuration of four transmission shafts
is for illustrative purposes.
There are seven similar clutch packs (11) that are located
on four shafts. The seven clutch packs are located in
transmission cases.
There are two identical planetary clutch packs that fit to
planetary carriers (12) and (13). One planetary clutch
pack is located in front transmission case and one
planetary clutch pack is located in rear transmission case.
03-20 79033095 C Rev.

FIG. 32: Front Transmission Case
One planetary clutch pack (1) is located in front 2
transmission case (2). The planetary clutch pack fits to
planetary carrier.
1
Fo
P111205001
FIG. 32
FIG. 33: Rear Transmission Case
r
One planetary clutch pack (1) is located in rear

in
transmission case (2). The planetary clutch pack fits to

planetary carrier.
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rn
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1
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2
P111205002
on
FIG. 33
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79033095 C Rev. 03-21

Hydraulic Oil Cooler (Transmission)
FIG. 34: The transmission oil cooler (1) is mounted on
right-hand side of cooler package.
Fo
r in
P090405004
FIG. 34
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03-22 79033095 C Rev.

Test Ports
Test Port for Relief Valve (Charge Pressure)
FIG. 35: Test Port for Relief Valve (Charge Pressure)
The test port (1) is located above relief valve (charge
pressure).
This test port serves as a means of checking charge oil
pressure.
1
P111105013
Fo
FIG. 35
Test Ports for the Modulating Valves

(Transmission)
r
FIG. 36: Test Ports for Modulating Valves (Transmission)

in
The test ports (1) are located on modulating valve. There

is a test port for each individual modulating valve.
te
This test port serves as means for checking oil pressure

that is being delivered to each of the individual nine
rn
transmission clutches.
al
1
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on
P111105015
FIG. 36
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Test Port for Lube Pressure (Transmission)

FIG. 37: Test Port for Lube Pressure (Transmission)
The test port (1) for checking transmission lube pressure
is located on left-hand side of machine next to modulating
valves (transmission).
1
This port can be used to check pressure of hydraulic oil
that is lubricating transmission clutches.
P111105015
FIG. 37
79033095 C Rev. 03-23

Test Port for Hydraulic Oil Cooler
FIG. 38: Test Port for Hydraulic Oil Cooler
The test port (1) for hydraulic oil cooler is located on
left-hand side of machine above relief valve (charge
pressure).
This test port is used to check pressure of hydraulic oil
before entering hydraulic oil cooler.
1
P111105013
FIG. 38
Fo
r in
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03-24 79033095 C Rev.

Features of Transmission System
The transmission is a direct drive power shift transmission
which is controlled by an electronic control module
(ECM). The transmission has following gearing:
• 16 forward gears
• 4 reverse gears
The transmission utilizes following features:
• Sequential Shifts
• Shuttle Shifting
• Speed Matching
• Power Management
• One-Touch Mode
Sequential Shifting
Fo
FIG. 39: Use transmission control lever (1) to shift

transmission sequentially. The lever is used to select
forward travel or reverse travel. Also, use lever to engage 1 2
r
parking brake.
3
in
(1) Transmission Control Lever

(2) Upshift Switch
te
4
rn

The transmission control lever is also used to make gear
al
changes. Press upshift switch (2) to select a higher gear.

Press downshift switch (3) to select a lower gear. Pressing P020112002
and holding switches will allow you to advance through
gears. FIG. 39
u
The transmission can be shifted sequentially by using

se
following two methods:

• Preselect a gear before moving machine.
• Use power shift to change gears while machine is in
on
motion.
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79033095 C Rev. 03-25

Shuttle Shifting Power Management
The shuttle shift is to change direction of travel without Power management is used to maximize machine's
using inching clutch control. performance.
IMPORTANT: The use of inching clutch during shuttle Power management contains following three modes:
shifting can produce unwanted results.
• Constant engine speed
IMPORTANT: To prevent excessive transmission clutch
• Constant ground speed
wear, shuttle shifting is not recommended when
towing a heavy load at high speeds. In this • Maximum output
instance, bring machine to a stop before
changing direction by using inching pedal and Constant Engine Speed
service brakes. The constant engine speed allows operator to select an
m
WARNING: Do not move control lever to engine speed that will remain constant.
neutral when traveling at high speeds. Constant engine speed will downshift to pull through
Moving control lever to neutral could allow tough loads and then upshift when appropriate.
transmission to speed match and it may not
be possible to reselect original gear, Constant Ground Speed
particularly if traveling down a steep grade.
Fo
The constant ground speed allows operator to select a

This could cause loss of control and result ground speed that will remain constant.
in an accident and personal injury.
Maximum Output
r
Move transmission control lever fully in opposite direction The maximum output allows maximum performance for
to change direction of travel. Shuttle shifting can be done machine by automatically shifting transmission for varying
in
at any engine speed. Also, any gear may be selected. field conditions.
When you perform a forward to reverse shuttle or a
te
reverse to forward shuttle, electronic controls will

modulate transmission clutches to slow machine. Next,
rn
ECM will modulate engagement of corresponding gear

for opposite direction of travel.
NOTE: The gear changes will be displayed on VT at
al
actual gear.
Speed Matching
u
When you are roading at a ground speed of at least 16

se
km/h (10 mph), transmission can automatically select a

ratio to match engine speed to road speed. Speed
matching can be useful if you are pulling a heavy trailer.
on
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03-26 79033095 C Rev.

Switch (One Touch)
FIG. 40: One Touch Switch
The one touch switch (1) is located on transmission
control lever.
The switch signals armrest ECM that operator wants to
1
P020112002
FIG. 40
Fo
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79033095 C Rev. 03-27

Input Components of Transmission
System
Switches
Switch (Upshift)
FIG. 41: Upshift Switch on Transmission Control Lever
1
The upshift switch (1) signals armrest ECM that operator 1
wants to shift transmission to a higher gear.
The switch is part of shift lever for transmission control.
The switch is a momentary push button switch. The
switch contacts are a single pole double throw.
When switch is not actuated, 3.33 volts will travel from pin
8 of armrest ECM to normally closed pin 4 of upshift
switch. 3.33 volts will then travel from pin 2 of upshift
switch to pin 15 of armrest ECM.
Fo
When switch is actuated, 1.66 volts will travel from pin 10

of armrest ECM to normally open pin 3 of upshift switch.
1.66 volts will then travel from pin 2 of upshift switch to pin
r
15 of armrest ECM. The armrest ECM will recognize drop N021305008

in voltage and notify machine ECM. FIG. 41
in
Switch (Downshift)
FIG. 42: Downshift Switch (1) on Transmission Control
te
Lever 1
The downshift switch signals armrest ECM that operator 1
rn

al

u
8 of armrest ECM to normally closed pin 8 of downshift

se
switch. 3.33 volts will then travel from pin 6 of downshift

When switch is actuated, 1.66 volts will travel from pin 10
of armrest ECM to normally open pin 7 of downshift
on
switch. 1.66 volts will then travel from pin 6 of downshift N021305008
switch to pin 16 of armrest ECM. The armrest ECM will
FIG. 42
recognize drop in voltage and notify machine ECM.
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03-28 79033095 C Rev.

One Touch Switch
FIG. 43: One Touch Switch (1) on Transmission Control
Lever
The one touch switch signals armrest ECM that operator 1
8 of armrest ECM to normally closed pin 12 of one touch
switch. 3.33 volts will then travel from pin 10 of one touch
When switch is actuated, 1.66 volts will travel from pin 10 1
of armrest ECM to normally open pin 11 of one touch
switch. 1.66 volts will then travel from pin 10 of downshift N021305008
switch to pin 14 of armrest ECM. The armrest ECM will
Fo
FIG. 43
recognize drop in voltage and notify machine ECM.
Switch (Inching Pedal)
r
FIG. 44: Inching Pedal Switch

The inching pedal switch signals machine ECM that
in
operator has fully depressed inching pedal. The switch is

a limit switch. The switch contacts are a single pole
te
double throw.
When switch is not actuated, normally closed contact is
rn
connected to ground circuit through common contact. The

normally open contact is connected to battery voltage
through connector on machine ECM.
al
When switch is actuated, normally open contact is

connected to ground circuit through common contact. The
normally closed contact is connected to battery voltage
u
P100905001
through ECM.
FIG. 44
se
The ECM monitors switch circuit for incorrect signals. A

diagnostic code will be set by ECM.
on
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79033095 C Rev. 03-29

Power Management Switch
FIG. 45: Power Management Switch
The power management switch signals armrest ECM that
operator wants to operate in power management mode.
The switch is a three-position rocker switch. The forward
position and rearward position are momentary positions.
The switch has two sets of normally open contacts and
switch has two set of normally closed contacts.
When switch is not actuated, 3.33 volts enters at pin 4 of
switch and exits at pin 2. 3.33 volts then returns to pin 25
(PWR Management Cruise) of armrest ECM. 3.33 volts
also enters at pin 5 of switch and exits at pin 7. 3.33 volts
then returns to pin 24 (PWR Management Max) of
P100705002
armrest ECM.
FIG. 45
When switch is pressed forward 1.66 volts enters at pin 8
and exits at pin 7. 1.66 volts then returns to pin 24 (PWR
Fo
Management Max) of armrest ECM. This change in

voltage tells armrest ECM to operate in power
management max.
r
When switch is pressed rearward 1.66 volts enters at pin

1 and exits at pin 2. 1.66 volts then returns to pin 25
in
(PWR Management Cruise) of armrest ECM. This

change in voltage tells armrest ECM to operate in power
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management cruise.
rn
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on
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03-30 79033095 C Rev.

Sensors
Position Sensor (Shift Lever)
FIG. 46: Position Sensor for Transmission Shift Lever
(1) Power
(2) Ground
(3) Signal
(4) Blank
4 1
The sensor signals armrest ECM of position of lever.
The lever has four positions:
• Park
• Neutral 3 2 N021305010
• Forward
FIG. 46
Fo
• Reverse
The sensor sends a proportional signal to armrest ECM.
The signal is a pulse width modulated signal (PWM) that
r
is generated at a frequency of 500 Hz. The signal has a

duty cycle from 5 percent to 95 percent.
in
A duty cycle of 5 percent to 35 percent indicates a forward

position. A duty cycle of 40 percent to 60 percent
te
indicates a neutral position. A duty cycle of 65 percent to

95 percent indicates a reverse position.
rn
The ECM monitors sensor for abnormal frequencies or

abnormal pulse width signals. A diagnostic code will then
be set. The transmission control lever will not function and
al
transmission will be placed in neutral.

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on
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79033095 C Rev. 03-31

Position Sensor (Inching Pedal)
FIG. 47: Position Sensor (Inching Pedal)
(A) Power
(B) Ground
(C) Signal
The inching pedal signals machine ECM that operator
wants to manually modulate transmission clutches. The
inching pedal is used to aid in attachment of implements
or maneuvering machine in tight locations.
The inching pedal sends a PWM signal to ECM. The
signal is a pulse width modulated signal (PWM) that is
generated at a frequency of 500 Hz. The signal has a duty P100705004
cycle from 8 percent to 92 percent.
FIG. 47
When inching pedal is fully released, a maximum duty
cycle of 92 percent is seen by ECM.
Fo
When inching pedal is fully depressed, a minimum duty

cycle of 8 percent is seen by ECM.
r
If data is outside of these limits, a fault code will be

generated.
in
Power travels from fuse C02 in fuse block 2 to pin A of

inching pedal senor. Ground signal travels from pin 9 of
te
machine ECM J1 connector to pin B of inching pedal

sensor. A PWM signal will then travel from pin C of
inching pedal sensor to pin 3 of machine ECM J1
rn
connector. The ECM receives PWM signal and software

processes signal to determine position of inching pedal.
al
The ECM monitor inching pedal for abnormal frequencies

or abnormal pulse width signals. A diagnostic code will
then be set and inching pedal will not function. If inching
u
pedal is pressed all the way down (triggering inching

pedal switch), transmission will shift into neutral. The
se
operator can continue machine operation by shifting into

neutral and then back into gear without using inching
pedal.
NOTE: If both inching pedal sensor and switch fails,
on
machine will go into Default Mode (Limp-Home

Mode) where machine operation is limited.
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03-32 79033095 C Rev.

Speed Sensor (Transmission Input)
FIG. 48: Speed Sensor for Input Shaft of Transmission
The speed sensor signals machine ECM of input speed of
transmission.
The speed sensor sends an analog signal to ECM. The
signal generates a frequency that is proportional to input
speed of transmission.
The ECM receives analog signal and software processes
signal to calculate speed of machine.
The ECM monitors speed sensor for abnormal
frequencies or abnormal pulse width signals.
A diagnostic code will then be set and following g00772674
functions will be disabled: FIG. 48

Fo
• Overspeed Protection
• Speed Matching
Speed Sensor (Transmission Output)
r
FIG. 49: Speed Sensor for Output Shaft of Transmission

in
The speed sensor signals machine ECM of output speed

of transmission.
te
The speed sensor sends an analog signal to ECM. The

signal generates a frequency that is proportional to output
rn
speed of transmission.
The ECM receives analog signal and software processes
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signal to calculate speed of machine.

The ECM monitors speed sensor for abnormal
frequencies or abnormal pulse width signals.
u
A diagnostic code will then be set and following g00772674

se
functions will be disabled: FIG. 49

• Overspeed Protection
on
• Speed Matching
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79033095 C Rev. 03-33

Temperature Sensor (Hydraulic Oil)
FIG. 50: Temperature Sensor for Transmission
The temperature sensor signals machine ECM of
temperature of hydraulic oil in transmission.
The temperature sensor sends a proportional signal to
ECM. The signal is an analog signal that changes voltage
that is seen by ECM. As temperature of hydraulic oil
increase voltage will decrease.
The ECM receives signal and software processes signal
to calculate temperature of oil.
g00772749
Pressure Sensor (Charge) FIG. 50
FIG. 51: Pressure Sensor for Transmission

Fo
(A) Power A
B
(B) Ground
r
(C) Signal
The pressure sensor signals ECM of pressure of
in
hydraulic oil in transmission.

The pressure sensor sends a proportional signal to C
te
machine ECM. The signal is a pulse width modulated

signal (PWM) that is generated at a frequency of 500 Hz.
rn
The duty cycle is proportionate to hydraulic oil pressure.

N021305012
The ECM receives signal and software processes signal
al
to calculate pressure of oil system. FIG. 51

The ECM monitors pressure sensor for abnormal
frequencies or abnormal pulse width signals. A diagnostic
u
code will then be set and a warning will be displayed on

VT.
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Control Settings for Transmission System

The display for virtual terminal (VT) allows operator
on
to change following settings:

• The Desired Engine Speed for power management
(constant engine speed)
ly
• The Desired Ground Speed for power management

(constant ground speed)
• The Upshift Setting for shift mode of one touch
• The Downshift Setting for shift mode of one touch
03-34 79033095 C Rev.

Electronic Control Modules for
Transmission System
Machine Electronic Control Module (ECM) for
Transmission System
FIG. 52: Machine ECM
(1) J1 (connector) 1
(2) J2 (connector)
The machine ECM controls various systems for machine.
For transmission system, machine ECM controls
transmission solenoid valves (No. 1 through No. 9). The
transmission solenoid valves control shifting of
transmission.
The following components are inputs to machine ECM for
transmission system:
Fo
• Armrest Electronic Control Module (ECM)

• Switch (Inching Pedal) 2
r
• Position Sensor (Inching Pedal)

• Speed Sensor (Transmission Input)
in
N021305013
• Speed Sensor (Transmission Output) FIG. 52

te
• Temperature Sensor (Hydraulic Oil)

• Pressure Sensor (Charge)
rn
The following components are outputs from machine

ECM for transmission system:
al
• Modulating valves (transmission clutch) (No. 1

through No. 9)
u
• Creeper gear solenoid

The CAN data link is used to communicate between other
se
electronic control modules and Caterpillar ET.

Refer to table for contact description for connector
J1 (1) of machine ECM.
on
Refer to table for contact description for connector

J2 (2) of machine ECM.
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79033095 C Rev. 03-35

Contact Description for Machine ECM for Contact Description for Machine ECM for
Transmission System (Connector J1) Transmission System (Connector J2)
Contact Contact
Function Type Function Type
Number Number
3 Position sensor (inching PWM signal 1 +Battery Power

pedal)
2 Ground Ground
6 CAN Data Link - Input/Output
Modulating valve
7 CAT Data Link - Input/Output (Transmission) (No. 1) Driver
4
Output
8 CAT Data Link + Input/Output Clutch C
9 Sensor return (10 V) Ground Modulating valve

(Transmission) (No. 4) Driver
14
10 5 Volt supply Supply Output
Clutch F
12 Sensor return Ground
Modulating valve
Fo
13 10 Volt supply Supply (Transmission) (No. 5) Driver

15
Output
18 CAN Data Link + Input/Output Clutch G
r
Switch (inching pedal) Modulating valve

30 Input (Transmission) (No. 8) Driver
(NC) 17
Output
in
Clutch J
Switch (inching pedal)
31 Input
(NO) 36 Solenoid return Ground
te
Speed sensor 2 Modulating valve

32 Frequency
(transmission output SIG) (Transmission) (No. 6) Driver
48
rn
Output
33 Speed sensor 2 Frequency Clutch B
(transmission output RTN)
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49 Solenoid return Ground

40 Speed sensor 1 Frequency
(transmission output SIG) Modulating valve
51
u
41 Speed sensor 1 Frequency Output

(transmission output RTN) Clutch D
se
51 Pressure sensor (charge) Input 52 Solenoid return Ground
54 Transmission charge filter Input Modulating valve

bypass switch 58 Output
on
Clutch E
62 Temperature sensor Analog
(hydraulic oil) 59 Solenoid return Ground
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Speed sensor Modulating valve

67 Frequency
(transmission input RTN) (Transmission) (No. 7) Driver
61
Output
Speed sensor Clutch H
68 Frequency
(transmission input SIG)
Modulating valve
J1 is a 70-pin connector. The contacts that are not listed are not used or may be used in
other systems. 63 Output
Clutch A
J2 is a 70-pin connector. The contacts that are not listed are not used or may be used in
other systems.
03-36 79033095 C Rev.

Armrest Electronic Control Module (ECM) for
Transmission System
FIG. 53: Armrest ECM
The following components are inputs to machine ECM for
transmission system:
• Position Sensors (Transmission Control Lever)
• Upshift Switch (Transmission Control Lever)
• Downshift Switch (Transmission Control Lever)
• Power Management Switch
• Switch (One Touch)
P100905002
FIG. 53
Fo
Contact Description for Armrest ECM for Transmission

System
Contact Number Function
r
1 Power -
in
2 Power +12V
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3 ISO and Service CAN +

4 ISO and Service CAN -
rn
6 Powertrain CAN +
7 Powertrain CAN -
al
8 Sensor +3.33V
10 Sensor +1.66V
u
11 Machine CAN +
se
12 Machine CAN -
14 One Touch Switch
on
15 Upshift Switch
16 Downshift Switch
ly
18 FNR Position
22 Creeper Switch
24 Pwr Management SW - MAX
25 Pwr Management SW - Cruise
The contacts that are not listed are not used or may be used in other systems.
79033095 C Rev. 03-37

Output Components of Transmission
System
Solenoids
Modulating Valves (Transmission clutch)
FIG. 54: Solenoid Valves for Transmission
The machine ECM activates solenoid valves for
transmission to control shifting.
There are nine solenoid valves that control gear ratios for
transmission.
The solenoid valves are proportional valves. The valves
control amount of hydraulic oil that is sent to transmission
clutches.
The valves receive a proportional current from ECM. The
amount of current is determined by software to maintain
Fo
smooth shifting. The current may also be reduced by g00772954

using inching pedal.
FIG. 54
Refer to following table for energized valve for a
r
given gear.
in
Energized valve for transmission gear

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Gear Valve Valve

Fourth gear (reverse) No. 9 No. 8
rn
Third gear (reverse) No. 9 No. 7

Second gear (reverse) No. 9 No. 6
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First gear (reverse) No. 9 No. 5

Neutral No. 8 -
u
First gear No. 1 No. 5

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Second gear No. 2 No. 5

Third gear No. 3 No. 5
on
Fourth gear No. 4 No. 5

Fifth gear No. 1 No. 6
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Sixth gear No. 1 No. 7

Seventh gear No. 2 No. 6
Eighth gear No. 2 No. 7
Ninth gear No. 3 No. 6
Tenth gear No. 3 No. 7
Eleventh gear No. 4 No. 6
Twelfth gear No. 4 No. 7
Thirteenth gear No. 1 No. 8
Fourteenth gear No. 2 No. 8
Fifteenth gear No. 3 No. 8
Sixteenth gear No. 4 No. 8
03-38 79033095 C Rev.

The ECM monitors solenoid valves for fault detection. If a
fault is detected, the ECM will log corresponding
diagnostic code.
Data Link for Transmission System

FIG. 55: Block Diagram of Connections of Data Links
(1) CAN data link
(2) VT (Virtual Terminal) 2
(3) Dash Panel Cluster
(4) Machine ECM 1
(5) Engine ECM
3
(6) Armrest ECM
(7) To other ECMs and Service Connector
The CAN data link is a serial communication bus
Fo
7
that is used to communicate with following
components:
4
r

in
• Machine ECM
te
• Engine ECM 5
• Armrest ECM
rn
• Auto-Guide Receiver (if equipped)

• Other Optional Electronic Control Modules 6
al
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P102705001
FIG. 55
on
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79033095 C Rev. 03-39

Electrical Schematic for Transmission
System
1 J1 2
45 4
35
5
44
43
6
7
8
Fo
9
r
10
in
11
te
12
rn
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3
J2
u
13
se
14
on
15
16
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17
18
19
20
21
P080508001
FIG. 56
FIG. 56: Electrical schematic for transmission system
03-40 79033095 C Rev.

(1) Machine ECM
(2) J1 Connector
(3) J2 Connector
(6) Transmission Input Speed Sensor
(7) Transmission Output Speed Sensor 1
(8) Transmission Output Speed Sensor 2
(9) Transmission Charge Filter Switch
(10) Fuel Level Sender
(11) Transmission Oil Temperature Sender
(12) Implement/Steering Charge Filter Bypass Switch
Fo
(13) Transmission Clutch Solenoid Number 9

r

in

te

rn

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NOTE: The differential lock solenoid / creeper gear

solenoid is not used on 800 series.
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79033095 C Rev. 03-41

Common Sump
Common Sump
2
Fo
r in
te
1
rn
P111105008
FIG. 57
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FIG. 57: Common Sump and Elevated Oil Reservoir Common sump normally provides hydraulic oil to
(EOR) following systems:
u
Common sump (1) supplies oil to transmission hydraulic • Transmission

se
system.
• PTO
Common sump and elevated oil reservoir (2) has a refill
capacity of 250 L (66 gal).
• Parking brake
on
Common sump is located in lower portions of following

housings: • Steering
• Transmission Elevated oil reservoir provides lubrication oil to power
ly
take-off clutch.
• Final drives
03-42 79033095 C Rev.

FIG. 58: Magnet in Differential Case
There is one magnet (1) that is located in bottom of
differential case to attract any metallic contaminants.
1
Fo
P111205003
FIG. 58
FIG. 59: Magnet in Rear Transmission Case
r
There is one magnet (1) that is located in bottom of rear

in
transmission case to attract any metallic contaminants.

te
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1
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P111205004
on
FIG. 59

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FIG. 60: Suction Screen

The suction screen (1) from tandem charge pump is
located directly behind hydraulic filters.
The tandem charge pump will draw oil from common
sump through suction screen whenever engine is running.
The suction screen is rated at 200 microns. Oil is drawn
from outside of suction screen. The oil then flows through
suction screen before going to inlet side of tandem charge
pump.
1
P111105009
FIG. 60
79033095 C Rev. 03-43

The suction screen (1) for scavenge pump is located on
left-hand side of machine behind implement pump. The
suction screen will filter particles that are larger than 540
microns. The suction screen filters all sump oil before oil is
routed to inlet of scavenge pump.
1
P111105010
FIG. 61
Filler Cap
Fo
FIG. 62: Filler Cap

The filler cap (1) is located at rear of machine to left-hand
r
side of implement valve stack.

1
in
The filler cap allows hydraulic oil to be added to common

sump.
te
rn
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P111205005
FIG. 62
u
Breather (Common Sump)

se
FIG. 63: Breather (1) is located on left-hand side of

machine in front of cab. The breather will filter particles up 1
to 7 microns.
on
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P111205006
FIG. 63
03-44 79033095 C Rev.

Sight Gauge
FIG. 64: Sight Gauge for Inspecting Hydraulic Oil Level
The sight gauge (1) is located at rear of machine near
PTO.
The oil level in common sump may be visually inspected
by using sight gauge.
P111205007
FIG. 64
Fo
Hydraulic Oil Drain Plug

FIG. 65: Hydraulic Oil Drain Plugs for Common Sump
r
There are two hydraulic oil drain plugs for common sump.
in
One hydraulic oil drain plug (1) is located underneath

machine in rear transmission case. One hydraulic oil drain
1
te
plug (2) is located underneath machine in front

transmission case.
rn
The hydraulic oil can be drained from common sump by

removing drain plug. The common sump may also be
equipped with an ecology drain.
al
2
u
P111205008
FIG. 65
se
on
ly
79033095 C Rev. 03-45

Hydraulic Oil Filter
Transmission / Steering
FIG. 66: Hydraulic Oil Filter (Transmission / Steering)
Hydraulic oil filter (1) is located on left-hand side of
machine just in front of left final drive. The hydraulic oil
filter receives oil from large section of tandem charge
pump. The filtered oil then flows to relief valve (charge
pressure).
is delivered by large section of tandem charge pump. The 1
hydraulic oil filter is a 7.5 micron filter.
P111105012
Fo
FIG. 66
r in
te
rn
al
u se
on
ly
03-46 79033095 C Rev.

Oil Flow
7 8
6
9
1 3
Fo
4 2
p111204001
r
FIG. 67
in
FIG. 67: Schematic for Hydraulic Oil Filter

Hydraulic oil is drawn from common sump through line (2)
te
by large section of tandem charge pump (3). Oil flows to

hydraulic oil filter (1).
rn
Filtered oil can then flow to following components:

• Relief valve (charge pressure)
al
• Modulating valves (transmission)

• Modulating valve (power take-off)
u
If bypass valve (4) is closed, oil will flow through hydraulic

se
oil filter (1). When bypass valve is open, hydraulic oil will
bypass filter and flow directly to rest of hydraulic system.
See Bypass Valve for information about oil flow when
bypass valve is open.
on
ly
79033095 C Rev. 03-47

Bypass Valve
FIG. 68: Hydraulic Oil Filter Assembly
The filter base contains a bypass valve (1) and a bypass
switch (2). The bypass switch is a normally closed 12 volt 1
switch.
The bypass valve will open when a 469 kPa (68 psi)
pressure differential is felt between inlet pressure and
outlet pressure of hydraulic oil filter. If bypass valve opens,
unfiltered oil will flow throughout charge oil circuit.
IMPORTANT: Do not operate machine when hydraulic oil
2
filter is in bypass mode. Operating machine in
bypass mode may cause damage to internal
components of machine.
P111205009
When bypass switch (2) senses a pressure differential of FIG. 68
248 to 304 kPa (36 to 44 psi) between inlet pressure and
outlet pressure of hydraulic oil filter, bypass switch will
Fo
signal machine electronic control module (ECM). The

event will be shown on VT and dash cluster with a visual
and audible warning.
r
NOTE: The bypass switch will send a signal to machine

ECM before a pressure differential of 469 kPa
in
(68 psi) is felt by bypass valve.

te
Oil Sampling Valve

FIG. 69: Oil Sampling Valve
rn
The oil sampling valve (1) is located on top of left-hand

final drive.
al
Use oil sampling valve to obtain a sample of hydraulic oil 1

for analysis.
u se
on
P111205010
FIG. 69
ly
03-48 79033095 C Rev.

Tandem Charge Pump
The tandem charge pump (1) is located on left-hand side
of machine in front of left-hand final drive.
The large section of tandem charge pump provides oil to
• Transmission
• PTO
• Steering
• Parking brake 1
The small section of tandem charge pump supplies oil to P111105011
all of the following systems that are not part of
transmission hydraulic system: FIG. 70
• Implement
Fo
• Three-point Hitch
• Service Brake
r
• Differential Steer Lubrication

in
• Elevated Oil Reservoir

NOTE: The elevated oil reservoir (EOR) provides
te
lubrication oil to PTO clutch.

rn
Oil Flow
FIG. 71: Schematic for Tandem Charge Pump
al
The tandem charge pump is driven by a drive shaft (3)

which is splined to implement pump.
Oil from common sump is drawn by tandem charge pump 5
u
through an inlet line (4). The inlet line (4) feeds oil to both 2
se
sections of tandem charge pump.

on
ly
3
4
p111204002
FIG. 71
79033095 C Rev. 03-49

Sections of Tandem Charge Pump
The tandem charge pump is made up of a large gear
pump and a small gear pump.
Large Section
FIG. 72: Large Section of Tandem Charge Pump
The large section (1) is located near driven end of tandem 1
charge pump.
• Transmission
• PTO
• Steering
• Parking Brake
Fo
P102905005
FIG. 72
Small Section
r
FIG. 73: Small Section of Tandem Charge Pump

in
The small section (1) of tandem charge pump is located

at opposite end of drive shaft. 1
te
The small section of tandem charge pump supplies oil to

rn
• Implement
• Three-Point Hitch
al
• Differential Steer Lubrication

• Service Brake
u
• Elevated Oil Reservoir (EOR)

se
P102905006
NOTE: The elevated oil reservoir (EOR) supplies FIG. 73

lubrication oil to PTO clutch.
on
ly
03-50 79033095 C Rev.

Modulating Valve (Transmission)
Nine modulating valves (1) are located on left-hand side A
of machine just behind hardbar.
Each modulating valve has a designated letter, as shown.
B
The letters have been cast into transmission case. The
designated letters are used to correlate modulating valve C
to corresponding transmission clutch.
1
The modulating valve provides following control functions: D
• Proportional Control of Oil Flow E
• Pressure Compensation
F
• Modulating Control
• Pressure Relief Control G
Fo
H
J
r
P111105015
FIG. 74
in
te
rn
al
u se
on
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79033095 C Rev. 03-51

2
6
3
7
4
8
5 1
Fo
P102905007
FIG. 75
r
FIG. 75: Schematic for Modulating Valve (Transmission)

in
(1) Modulating valve (transmission)

(2) Test port
te
(3) Transmission clutch

rn
(4) Spring
(5) Line to common sump
al
(6) Spool orifice

(7) Charge pressure oil
u
(8) Solenoid
se
The modulating valve (1) is controlled by machine

electronic control module (ECM). The modulating valve is
used by machine ECM to directly modulate oil pressure
that is sent to each of the nine individual transmission
on
clutches.
When operator selects a direction or when operator
selects a speed, machine ECM sends a pulse width
ly
modulated current to solenoid (8).

The distance that is travelled by solenoid plunger is
proportional to electrical current that is sent to solenoid.
The position of solenoid plunger controls oil pressure that
is sent to transmission clutch (3).
When machine ECM sends maximum programmed
current to modulating valve, oil pressure in transmission
clutch will be at maximum desired pressure. When no
current is sent to modulating valve, oil pressure in
transmission clutch will be zero.
03-52 79033095 C Rev.

Valve Ports
FIG. 76: Bottom View of Modulating Valve
(Transmission)
3
(1) To Common Sump
(2) Charge Pressure Oil
(3) To Transmission Clutch
The bottom view shows porting for inlet and outlet flow of
hydraulic oil.
Valve Operation 1
There are three basic stages of controlled 2
operation of modulating valve: N021505003
• No signal current FIG. 76

• Less than maximum signal current
Fo
• Maximum signal current

The operation of modulating valve is not a simple on/off
cycle. The machine ECM varies strength of signal current
r
through a programmed cycle to control movement of

proportional solenoid valve spool.
in
te
rn
al
u se
on
ly
79033095 C Rev. 03-53

No Signal Current
2
9
1
6 12 4
Fo
10
8
11
r
13
7
in
5 3
14
te
g01336785
FIG. 77
rn
FIG. 77: Modulating Valve (Transmission)

al

(2) Test port
u
(3) To transmission clutch

se
(4) Spring
(5) To common sump
(6) Spool orifice
on

(8) Solenoid
ly
(9) Ball
(10) Pin
(11) Drain orifice
(12) Valve spool
(13) Charge Pressure
(14) Sump
The machine ECM controls rate of oil flow through
modulating valve (1) by changing strength of signal
current to solenoid (8). When signal current is not being
sent to solenoid, solenoid will be de-energized.
03-54 79033095 C Rev.

Oil Flow in a De-energized Valve
The spring (4) holds valve spool to left in valve body.
The valve spool opens passage between transmission
clutch (3) and common sump.
The valve spool blocks passage between transmission
clutch and charge pressure oil. Consequently,
pressurized oil flow is blocked to transmission clutch.
Charge pressure oil (7) flows from tandem charge pump
into valve body and around valve spool (12).
The oil flows through drilled passage that is in valve spool
and into spool orifice (6). The Spool orifice is on left-hand
side of valve spool. The oil then flows through drain orifice
(11).
Because there is no force on pin (10), to hold ball (9)
against drain orifice, oil flows through valve spool. The oil
Fo
flows through drain orifice, around ball and to common

sump (5).
Oil from transmission clutch will drain into common sump.
r
As a result, transmission clutch is not engaged.

in
te
rn
al
u se
on
ly
79033095 C Rev. 03-55

Less Than Maximum Signal Current
2
1
9 6 12
4
8 10
Fo
11
13 3
r
5
14
in
7
15
te
g01328854
FIG. 78
rn

al

(2) Test port
u

se
(4) Spring
(5) To common sump
(6) Spool orifice
on

(8) Solenoid
ly
(9) Ball
(10) Pin
(11) Drain orifice
(12) Valve spool
(14) Sump
(15) 1st Charge Pressure Reduction
The machine ECM controls signal current to modulate
flow of oil through modulating valve (1). When solenoid (8)
receives less than maximum programmed signal current,
oil flow is modulated.
03-56 79033095 C Rev.

Oil Flow in a Valve with Less Than Maximum Signal
Current
The engagement of transmission clutch (3) begins when
machine ECM initially sends signal current to energize
solenoid.
The signal current creates a magnetic field around pin
(10) which will cause pin to move to right against ball (9).
The force against ball will be in proportion to strength of
signal current from machine ECM.
The position of ball against drain orifice (11) restricts oil
flow to common sump (5). This partial restriction causes
pressure at left end of valve spool (12) to increase.
The oil pressure moves valve spool to right against spring
(4). The movement of valve spool starts to open a
passage on right end of valve spool. As a result, charge
pressure oil (7) will start to fill transmission clutch.
Fo
Oil also begins to fill chamber for spring on right end of

valve spool.
r
In initial stage for filling transmission clutch with oil,

machine ECM sends a high pulse of current to quickly
in
move valve spool.

During this short period of time, clutch piston will move to
te
remove clearances that are between clutch discs and

plates. This will minimize amount of time that is needed to
fill clutch.
rn
The machine ECM will then reduce signal current which

will also reduce pressure setting of modulating valve. The
al
change in signal current reduces flow of oil to

transmission clutch.
When plates and discs start to touch each other, this is
u
called touch-up point. Once touch-up point is obtained,

se
machine ECM begins a controlled increase of signal

current to start modulation cycle.
The increase in signal current causes ball and pin to
further restrict flow of oil through drain orifice and to
on
common sump. This causes a controlled movement of

valve spool to right.
This movement of valve spool allows pressure to
ly
transmission clutch (3) to increase.

The modulating valve uses variable signal current from
machine ECM to vary pressure output of valve.
The sequence of partial engagement is called desired
slippage. The clutches must slip a specific amount to
provide smooth shifting. The desired slippage is
controlled by application program that is stored in
machine ECM.
79033095 C Rev. 03-57

Maximum Programmed Signal Current
2
1
12 4
Fo 9 6
8 10 11
r
5
in
13 3
14 7
te
g00774323
FIG. 79
rn

al

(2) Test port
u

se
(4) Spring
(5) To common sump
(6) Spool orifice
on

(8) Solenoid
ly
(9) Ball
(10) Pin
(11) Drain orifice
(12) Valve spool
(14) Sump
When modulation cycle stops, machine ECM will send
maximum specified signal current to fully engage
transmission clutch (3).
03-58 79033095 C Rev.

Oil Flow in a Valve with Maximum Programmed
Current Signal
The constant signal current pushes the pin (10) firmly
against ball (9) in modulating valve (1).
The force against ball reduces amount of oil flow through
drain orifice (11). This restriction causes an increase in
pressure on left-hand side of valve spool (12).
The valve spool moves to right to allow charge oil to fully
engage transmission clutch.
In a short period of time, maximum pressure is felt at both
ends of valve spool. This pressure and additional force
that is produced by spring (4) causes valve spool to move
to left until forces on right end and left end of valve spool
are balanced.
The movement of valve spool to left balanced position
reduces flow of oil to engaged transmission clutch. The
Fo
machine ECM sends a constant maximum specified

signal current to solenoid (8) to maintain desired clutch
pressure.
r
Test Ports
in
FIG. 80: Test Ports

Test port (1) is located on top of each modulating valve.
te
The test port serves as a means of checking oil pressure

that is being delivered to each transmission clutch.
rn
1
al
u se
on
P111105015
ly
FIG. 80
79033095 C Rev. 03-59

The relief valve (1) (charge pressure) is located on 1
left-hand side of machine near top of modulating valves
(transmission) (2).
The relief valve limits maximum charge pressure to
adjusted setting.
The relief valve (charge pressure) regulates hydraulic oil
pressure in following systems:
• Transmission 2
• PTO
• Steering P111105013
• Parking brake FIG. 81

Fo
2
r
1 5
in
6
3
te
rn
4
7
al
p111204003
FIG. 82
u
FIG. 82: Schematic for Relief Valve (Charge Pressure)

se
If engine is running, tandem charge pump is pumping oil.

The large section of tandem charge pump provides
filtered oil to relief valve (charge pressure). The hydraulic
on
oil is regulated by relief valve at a nominal pressure of

2100 kPa (305 psi).
The charge oil is used in following components:
ly
• Modulating valves (transmission)

• Steering pump
• Parking brake valve
Excess flow from relief valve (charge pressure) will be
diverted to following components:
• Hydraulic oil cooler
• Oil cooler bypass valve
• Relief valve (transmission lube)
• Transmission clutches (lube oil)
• Common sump
03-60 79033095 C Rev.

Valve Operation
The relief valve (charge pressure) works as a pilot
operated/spring return valve. This valve works
independently from all electrical control systems.
12 14
15
13
Fo
8 16
10
r in
te
rn
11 17 9
g00886311
al
FIG. 83
FIG. 83: Relief Valve (Charge Pressure) The spool will open a passage for oil to flow from
u
chamber (8) to chamber (16). Oil flows through chamber

(8) Chamber
(16) to hydraulic oil cooler. As spool moves further to
se
(9) Orifice right, amount of oil that is diverted to hydraulic oil cooler
will increase.
(10) Ball
When pressure in chamber (12) equals pressure that is
(11) Spring
on
exerted by spring (14), movement of spool to right will

(12) Chamber stop.
(13) Spool The pressure in chamber (8) should be 2100 kPa (305
ly
psi).
(14) Spring
When tandem charge pump is stopped, or oil flow from
(15) Screw tandem charge pump is insufficient, spool will move to
(16) Chamber left. This movement will continue if flow and pressure is
not sufficient enough to maintain a pressure of 2100 kPa
(17) Orifice (305 psi) in chamber (8).
Hydraulic oil from tandem charge pump flows into relief When all flow and pressure is stopped, spring (14) will
valve (1) (charge pressure) at chamber (8). Charge oil push spool all the way to left-hand side of relief valve. The
enters orifice (9) and presses against ball (10). spring (11) will push ball (10) to right. This will keep pilot
The ball will push spring (11) as pressure increases. The oil from entering chamber (12).
ball will overcome spring pressure. This will allow oil to The orifice (17) will allow oil that is trapped in chamber
flow to chamber (12). (12) to be released. This will allow spring to push spool all
Oil pressure in chamber (12) will push spool (13) to right the way to left.
against spring (14). NOTE: Adjust screw (15) to obtain 2100 to 2135 kPa
(305 to 310 psi) pressure setting.
79033095 C Rev. 03-61

Test Port
FIG. 84: Test Port for Relief Valve (Charge Pressure)
The test port (18) is located above relief valve, as shown.
The test port serves as a means of checking charge oil
pressure.
1
P111105013
FIG. 84
Hydraulic Oil Cooler

Fo
FIG. 85: Hydraulic Oil Cooler

Hydraulic oil cooler (1) is located on right-hand side of
r
cooling package. The hydraulic oil cooler is behind

air-to-air aftercooler (2).
in
NOTE: The air-to-air aftercooler is shown as transparent

for clarity. 1
te
The hydraulic oil cooler (implement/transmission) is

smaller cooler.
rn
The hydraulic oil cooler circulates hydraulic oil in front of

engine fan to keep oil at correct operating temperature.
al
2
u
P111205011
se
FIG. 85
on
ly
03-62 79033095 C Rev.

3 6
7
1
5
8
Fo
p111204004
FIG. 86
r
FIG. 86: Schematic for Hydraulic Oil Cooler

in
Hydraulic oil flows from line (6) to relief valve (3) (charge
pressure). Charge pressure oil (7) flows to hydraulic oil
cooler (1).
te
FIGS. 87–88: Relief Valve (Charge Pressure) (3) and Oil

Cooler Bypass Valve (4).
rn
3
NOTE: The oil cooler bypass valve is located behind
relief valve (charge pressure).
al
If oil pressure in hydraulic oil cooler builds up to a

differential of 520 kPa (75 psi), oil cooler bypass valve (4)
will divert oil around hydraulic oil cooler.
u
The following conditions could cause oil cooler bypass

se
valve to divert oil around hydraulic oil cooler:

• Cold hydraulic oil
• Restriction in a hydraulic oil line to or from hydraulic
on
P111105013
cooler
FIG. 87
• Restriction in hydraulic oil cooler
ly
P111205012
FIG. 88
79033095 C Rev. 03-63

Hydraulic System Schematic
(Transmission)
5
6
Fo
r in
7
te
2
rn
al
u se
8 13
on
15 14
ly
9 19
16
10 17
11 18
12
p111204005
FIG. 89
03-64 79033095 C Rev.

FIG. 89: Hydraulic System schematic
(1) Test port
(2) Transmission clutch
(3) Relief valve (charge pressure)
(4) Cooler bypass valve
(5) Relief valve (lube oil)
(6) Hydraulic oil cooler
(8) Sampling valve
(9) Bypass valve
(10) Filler cap
(11) Suction screen (scavenge pump)
Fo
(12) Ecology drain valve

(13) Line to implement hydraulic oil cooler
(14) Line to steering pump
r
(15) Hydraulic oil filter

in
(16) Scavenge pump

te
(17) Breather (common sump)

(18) Suction screen (tandem charge pump)
rn
(19) Tandem charge pump (large section)

al
u
se
on
ly
79033095 C Rev. 03-65

Transmission Clutches
FIG. 90: Front and Rear Transmission Cases
Nine transmission clutches are located in rear 2
transmission case (1) and front transmission case (2).
1
P111105016
FIG. 90
Fo
r in
te
rn
al
u se
on
ly
03-66 79033095 C Rev.

B 3
5
Fo
r
3
in
4
P110605003
te
FIG. 91
rn

NOTE: Gear (A) never meshes with gear (B). The
al
configuration of four transmission shafts is only

for illustrative purposes.
There are seven similar clutch packs (3) that are located
u
on four shafts. There are two identical planetary clutch

se
packs that fit to planetary carriers (4) and (5). The

planetary clutch packs are fastened to front and rear
transmission cases.
on
ly
79033095 C Rev. 03-67

FIGS. 92–93: Front Transmission Case
One planetary clutch pack (6) is located in front 2
transmission case (2). This planetary clutch pack fits to
planetary carrier (4).
6
Fo
P111205001
FIG. 92
r in
te
rn
al
4
u se
on
P111205013
FIG. 93
ly
03-68 79033095 C Rev.

FIG. 95: Rear Transmission Case
One planetary clutch pack (7) is located in rear
transmission case (1). This planetary clutch pack fits to
planetary carrier (5).
Each clutch pack and planetary clutch pack is controlled
by a corresponding modulating valve (transmission).
There are nine modulating valves for nine clutch
assemblies.
1
Fo
P111205002
FIG. 94
r in
te
rn
al
u se
5
on
P111205014
FIG. 95
ly
79033095 C Rev. 03-69

9
Fo
r
10
in
P111205015
te
FIG. 96
rn
FIG. 96: Transmission Shafts

The following shafts contain clutch packs and planetary
al
clutch packs that control forward speeds:

• Input shaft (8)
• Intermediate shaft (9)
u
• Output shaft (10)

se
on
ly
03-70 79033095 C Rev.

A
8
11
9
Fo
10
r in
P110605003
te
FIG. 97
rn
FIG. 97: Transmission Shafts

NOTE: Gear (A) never meshes with gear (B). The
al

The following shafts contain clutch packs and planetary
u
clutch packs that control reverse speeds:

se
• Input shaft (8)

on
• Reverse shaft (11)

ly
79033095 C Rev. 03-71

Oil Flow and Rotational Power Flow
Regular Clutch Pack
15
14
21
22 13
23
Fo
12
r
16
18
in
te
rn
17
al
u
20
se
19
on
P110305011
FIG. 98
ly
FIG. 98: Clutch Pack in disengaged position. (18) Oil passage

(12) Oil passage (19) Cylinder
(13) Piston (20) Gear
(14) Clutch plates (21) Input Components
(15) Friction discs (22) Output Components
(16) Clutch lubrication passage (23) Clutch Components
(17) Spring
03-72 79033095 C Rev.

Oil flows from modulating valve through oil passage (12)
in transmission shaft. Oil fills chamber behind piston (13).
The piston (13) is used for following functions:
• The piston will compress clutch plates (14) against
friction discs (15).
• The piston will block lube flow to friction discs and
clutch plates.
• The piston will direct lube flow to friction discs and
clutch plates.
• The piston will direct lube flow to other side of piston.
The piston will block clutch lubrication passage (16) when
clutch is disengaged. Lubrication oil is always blocked
when clutch is disengaged. This will prevent viscous
friction between lubrication oil and rotating friction discs
and clutch plates. This friction could cause increased load
Fo
to engine.
Centrifugal pressure will build up in front of piston when
transmission shaft is turning and the clutch is disengaged.
r
This will cause piston to move toward friction discs and

clutch plates. This movement is sufficient enough to
in
slightly engage clutch. Consequently, it is necessary to

assist spring (17) by using lubrication oil to move piston
away from friction discs and clutch plates.
te
The piston contains oil holes to allow lubrication oil to flow

behind piston. The lubrication oil flows from oil passage
rn
(18) through holes in piston. This lubrication oil pressure

assists spring in retracting piston away from friction discs
and clutch plates. This passage is always open.
al
If piston is not properly retracted away from friction discs

and clutch plates, excess heat could build up in hydraulic
u
oil system. Also, unnecessary wear to friction discs and

clutch plates could occur.
se
As pressure builds up in front of piston, piston will start to

move toward friction discs and clutch plates. This will
eventually overcome spring and lubrication oil pressure
behind piston. At maximum pressure, piston will
on
completely compress the friction discs and clutch plates.

The clutch plates are engaged to cylinder (19) by use of
ly
spline teeth. Because cylinder is rotating with

transmission shaft, clutch plates will cause friction discs to
rotate.
Because friction discs are engaged to gear (20) by use of
spline teeth, gear will rotate. Consequently, rotational
power flow will be transferred through transmission shaft
to the gear.
79033095 C Rev. 03-73

Planetary Clutch Pack
FIG. 99: Clutch Housing for Planetary Clutch Pack
There are two oil passages (21) on each clutch housing
(22) so clutch housing can be used in either front 22
transmission case or rear transmission case. Only one oil
passage is used for each application.
21
P110305013
FIG. 99
Fo
r in
te
rn
al
u se
on
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03-74 79033095 C Rev.

23
24
5
4
Fo
P111205016
FIG. 100
r
FIG. 100: Intermediate Shaft and Output Shaft

in
There are two planetary clutch packs that control

planetary carriers (4) and (5).
te
Gear (23) drives gear (24) in explanation of operation of

planetary clutch pack. The operation of other planetary
rn
clutch pack is identical.

al
u se
on
ly
79033095 C Rev. 03-75

29
31
30
27
34
32
Fo
33
r
35
in
36
te
37
rn
38
39
al
28
25
u
26
se
P110305014
FIG. 101
on
FIG. 101: Planetary Clutch Pack (32) Drive tube

(25) Friction discs (33) Sun gear
(26) Clutch plates (34) Planetary gears
ly
(27) Oil holes (35) Input Components

(28) Piston (36) Ring Gear
(29) Spring (37) Planetary Gears
(30) Ring gear (38) Output Components
(31) Gear (39) Clutch Components
03-76 79033095 C Rev.

Unlike regular clutch pack, lubrication oil flows through
planetary clutch pack continuously. The lubrication oil
flows through an oil passage in shaft and through
planetary carrier. The oil flows from planetary carrier to
planet gear shafts and through them to lube planetary
gear bearings. This oil then goes through holes (27) in
ring gear. The oil is dispersed to friction discs (25) and
clutch plates (26) through oil holes (27).
Because friction discs and clutch plates do not rotate with
transmission shaft, viscous drag within clutch assembly is
not significant. Also, lubrication oil is better able to
disperse from planetary clutch pack.
Oil flows from modulating valve (transmission), through
transmission case, and to one of the oil passages in
clutch housing. Oil flows through clutch housing to front of
piston (28).
As pressure builds up in front of piston, the piston will start
Fo
to move toward friction discs and clutch plates. This will

eventually overcome six springs (29). At maximum
pressure, piston will completely compress friction discs
and clutch plates. At this point, clutch will be completely
r
engaged.
in
When clutch is engaged, friction discs will not rotate.

Because ring gear (30) is engaged to friction discs by use
te
of spline teeth, ring gear will not rotate.

Gear (31) turns drive tube (32). The drive tube turns sun
rn
gear (33). The sun gear turns planetary gears (34).

Because ring gear is held stationary by friction discs,
planetary gears are forced to travel around ring gear. The
al
planetary gears are pinned to planetary carrier. As a

result, planetary carrier will rotate.
u
The planetary carrier is splined to output shaft.

Consequently, planetary carrier will cause output shaft to
se
rotate.
on
ly
79033095 C Rev. 03-77

Transmission Power Flow
Transmission Clutches and Shafts
1
C D
5
2
A
Fo
10
3
r
E F
in
te
4
rn
G H J B
al
u se
P110605003
FIG. 102
on

NOTE: Gear (5) never meshes with gear (10). The
ly

The transmission contains following transmission shafts:
• Input shaft (1)
03-78 79033095 C Rev.

Input Shaft
7
8
C D
1 9
5 6
P110605004
FIG. 103
Fo
FIG. 103: Input Shaft

When clutch pack (C) is engaged, gear (5) is locked to
r
input shaft (1). When clutch pack (D) is engaged, gear (6)
is locked to input shaft. Otherwise, gears are free to
in
rotate.
Gears (7), (8), and (9) are permanently splined to input
te
shaft. These gears always rotate with input shaft.

Reverse Shaft
rn
al
2
u se
A
on
10 11
p110605005
ly
FIG. 104
FIG. 104: Reverse Shaft

When clutch pack (A) is engaged, gear (10) is locked to
reverse shaft (2). Otherwise, gear is free to rotate.
Gear (11) is permanently splined to reverse shaft (2).
79033095 C Rev. 03-79

Intermediate Shaft
12 16
14
E F
3
13
15
P110605006
FIG. 105
Fo
FIG. 105: Intermediate Shaft

When clutch pack (E) is engaged, gear (12) is locked to
r
intermediate shaft (3). Otherwise, gear is free to rotate.

When clutch pack (F) is engaged, gear (13) is locked to
in
intermediate shaft. Otherwise, gear is free to rotate.

te
Gears (14), (15), and (16) are permanently splined to

intermediate shaft. The gears always rotate with
intermediate shaft.
rn
al
u se
on
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03-80 79033095 C Rev.

Output Shaft
20 19
4
G H J B
17 18
p110605007
FIG. 106
Fo
FIG. 106: Output Shaft

NOTE: The planetary clutches are not shown in following
figure. These clutches are located in front and
r
rear transmission cases.

in
When planetary clutch pack (G) is engaged, planetary

carrier (17) will turn output shaft (4). Gear (18) turns sun
te
gear in planetary carrier.

When planetary clutch pack (B) is engaged, planetary
rn
carrier (19) will turn output shaft. Gear (20) turns sun gear
in planetary carrier.
al
When clutch pack (H) is engaged, gear (18) is locked to

output shaft. Otherwise, gear is free to rotate.
When clutch pack (J) is engaged, gear (20) is locked to
u
output shaft. Otherwise, gear is free to rotate.

se
on
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79033095 C Rev. 03-81

Transmission Clutch Engagement
Each modulating valve has a designated letter, as shown. A
The letters have been cast into transmission housing.
Each modulating valve controls an individual clutch. Each
B
letter is assigned to a corresponding modulating valve.
C
No more than two clutches are ever engaged at a time.
Also, no more than one clutch is ever engaged on a shaft.
D
E
G
Fo
H
J
r
P111105015
FIG. 107
in
te
rn
al
u se
on
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03-82 79033095 C Rev.

These letters used in following table show clutches that
are engaged for each gear.

Engine RPM at 2100
Reverse Input Intermediate Output Machine
Gear
Shaft Shaft Shaft Shaft Speed
14.31 km/h
Fourth gear (reverse) A - - J
(8.89 mph)
5.89 km/h
Third gear (reverse) A - - H
(3.66 mph)
5.23 km/h
Second gear (reverse) A - - B
(3.25 mph)
2.15 km/h
First gear (reverse) A - - G
(1.34 mph)
Fo
Neutral - - - J -
2.69 km/h
r
First gear - C - G
(1.67 mph)
in
3.42 km/h
Second gear - D - G
(2.12 mph)
te
Third gear - - E G 4.32 km/h

(2.69 mph)
rn
5.49 km/h
Fourth gear - - F G (3.41 mph)
al
6.54 km/h
Fifth gear - C - B
(4.06 mph)
7.36 km/h
Sixth gear - C H
u
(4.57 mph)
se
8.30 km/h
Seventh gear - D - B (5.16 mph)
9.35 km/h
Eighth gear - D - H (5.81 mph)
on
10.51 km/h
Ninth gear - - E B
(6.53 mph)
ly
11.83 km/h
Tenth gear - - E H
(7.35 mph)
13.34 km/h
Eleventh gear - - F B
(8.29 mph)
15.02 km/h
Twelfth gear - - F H
(9.33 mph)
17.89 km/h
Thirteenth gear - C - J
(11.11 mph)
22.72 km/h
Fourteenth gear - D - J (14.11 mph)
28.75 km/h
Fifteenth gear - - E J
(17.86 mph)
38.59 km/h
Sixteenth gear - - F J
(24.60 mph)
79033095 C Rev. 03-83

Power Flow for Reverse Gears
See Transmission Clutches and Shafts for additional
information about gears and clutches on transmission
shafts.
9
1
C D
5
2
A
10
Fo
15
16
3
r in
E F
te
14
rn
4
al
G H J B
u se
P110605003
FIG. 108
on
FIG. 108: Transmission Shafts for Reverse Gears

ly

Power flow for reverse gears only involves clutches on
following shafts:
For reverse gears, input shaft (1) is used only to transfer
power flow through gear (9). For reverse gears,
intermediate shaft (3) is used only to transfer power flow
through gears (14), (15), and (16). These gears are
permanently splined to shafts. The gears will always
rotate with shaft.
03-84 79033095 C Rev.

Input Shaft
7 6 8
1
C D
9
5
2
A
10
11
3
Fo
E F
r in
4
te
rn
G H J B
al
u
P110605003
se
FIG. 109

on

The engine turns input shaft (1) clockwise. As a result,
ly
gear (9) will rotate. This gear is permanently splined to

shaft so gear will always rotate with input shaft.
Gear (9) drives gear (11) that is on reverse shaft (2).
Clutch pack (C) and clutch pack (D) are not used to obtain
any reverse gears. Gears (5) and (6) are engaged by
clutch packs (C) and (D). As a result, these gears are not
used to obtain any of the reverse gears.
Gears (7) and (8) are permanently splined to shaft. These
gears do not drive any gears for reverse gears.
79033095 C Rev. 03-85

Reverse Shaft
9
1
C D
5 11
2
A
10
15
3
Fo
E F
r in
4
te
rn
G H J B
al
u
P110605003
se
FIG. 110

on

Gear (11) is driven by gear (9) that is on input shaft (1).
ly
Consequently, reverse shaft (2) will rotate

counterclockwise.
When clutch pack (A) is engaged, gear (10) will lock to
reverse shaft. The gear will rotate. Consequently, gear
(10) will drive gear (15) that is on intermediate shaft (3).
NOTE: Every reverse gear uses clutch pack (A) plus one
other clutch pack on output shaft (4).
03-86 79033095 C Rev.

Intermediate Shaft
1
C D
5
2
A
12
10
15
16
3
Fo
13
E F
r
14
in
4
te
rn
G H J B
al
18 20
u
P110605003
se
FIG. 111

on

Gears (14), (15), and (16) are permanently splined to
ly
intermediate shaft (3). These gears will always rotate with

intermediate shaft.
Gear (15) is driven by gear (10) that is on reverse shaft
(2). Consequently, intermediate shaft will rotate clockwise.
Gear (14) drives gear (18) that is on output shaft (4).
Gear (16) drives gear (20) that is on output shaft.
Clutch pack (E) and clutch pack (F) are not used to obtain
any reverse gears. Gears (12) and (13) are not used to
obtain any reverse gears.
79033095 C Rev. 03-87

Output Shaft
1
C D
5
2
A
10
16
3
Fo
E F
r
14
in
4
19
te
rn
G H J B
17
al
18 20
u
P110605003
FIG. 112
se
FIG. 112: Transmission Shafts for Reverse Gears Gear (20) turns sun gear in planetary carrier (19). When
planetary clutch pack (B) is engaged, planetary carrier
on
(19) will turn output shaft counterclockwise.

for illustrative purposes. When clutch pack (H) is engaged, gear (18) will lock to
output shaft. Gear (18) is driven by gear (14) that is on
NOTE: The planetary clutches are not shown. These
ly
intermediate shaft. Consequently, output shaft will rotate

clutches are located in front and rear counterclockwise.
transmission cases.
When clutch pack (J) is engaged, gear (20) will lock to
NOTE: For all clutch engagement on output shaft, gears output shaft. Gear (20) is driven by gear (16) that is on
(18) and (20) are driven by gears (14) and (16) intermediate shaft. Consequently, output shaft will rotate
that are on intermediate shaft (3).
counterclockwise.
Gear (18) turns sun gear in planetary carrier (17). When Transmission power flow is transferred through output
planetary clutch pack (G) is engaged, planetary carrier
shaft to differential.
(17) will turn output shaft (4) counterclockwise.
03-88 79033095 C Rev.

Power Flow for Forward Gears
See Transmission Clutches and Shafts for additional
information about gears and clutches on transmission
shafts.
C D
1
E F
Fo
3
r in
G H J B
te
4
rn
P111205017
al
FIG. 113
FIG. 113: Transmission Shafts for Forward Gears

u
The power flow for forward gears only involves clutches

se
on following shafts:
• Input shaft (1)
on

ly
Gear (9) is not used to obtain any forward gears.
79033095 C Rev. 03-89

Input Shaft
7 6
8
5
C D
1
12 9
E F
3 15 13
Fo
16
G H J B
r
4
in
te
P111205017
FIG. 114
rn

al
The engine turns input shaft (1) clockwise.

When clutch pack (C) is engaged, gear (5) will lock to
input shaft (1). The gear will rotate clockwise.
u
Consequently, gear (5) will drive gear (15). Intermediate

shaft (3) will rotate counterclockwise.
se
When clutch pack (D) is engaged, gear (6) will lock to

input shaft. The gear will rotate clockwise. Consequently,
gear (6) will drive gear (16). Intermediate shaft (3) will
on
rotate counterclockwise.
Gear (9) is permanently splined to input shaft. This gear
will always rotate with input shaft. This gear is not used for
ly
any forward gears.

Gears (7) and (8) are permanently splined to input shaft.
As a result, these gears always rotate with input shaft in a
clockwise direction. Gear (7) turns gear (12). Intermediate
shaft (3) will rotate counterclockwise. Gear (8) turns gear
(13). Intermediate shaft (3) will rotate counterclockwise.
NOTE: The output side of input shaft (1) is connected to
input shaft for PTO.
03-90 79033095 C Rev.

Intermediate Shaft
7
8
5
C D
1
14 12
E F
3 15 13
Fo
16
G H J B
r
4
in
te
P111205017
FIG. 115
rn

al
Gear (15) is permanently splined to intermediate shaft (3).

This gear will always rotate. This gear is driven by gear (5)
that is on input shaft (1). Consequently, intermediate shaft
u
will rotate counterclockwise.

When clutch pack (E) is engaged, gear (12) will lock to
se
intermediate shaft. This gear is driven by gear (7) that is

on input shaft. As a result, this gear will rotate.
Consequently, intermediate shaft will rotate
counterclockwise.
on
When clutch pack (F) is engaged, gear (13) will lock to

intermediate shaft. This gear is driven by gear (8) that is
on input shaft. As a result, this gear will rotate.
ly
Consequently, intermediate shaft will rotate

counterclockwise.
Gears (14) and (16) are permanently splined to
intermediate shaft. These gears always rotate with
intermediate shaft.
79033095 C Rev. 03-91

Output Shaft
C D
1
14
E F
3
18
Fo
16
G H J B
r
4
in
19
17 20
te
P111205017
FIG. 116
rn
FIG. 116: Transmission Shafts for Forward Gears When clutch pack (J) is engaged, gear (20) will lock to
output shaft. Gear (16) will turn gear (20). As a result,
al
Gear (18) is driven by gear (14) that is on intermediate gear (20) will rotate. Consequently, output shaft will rotate
shaft (3). Gear (18) turns sun gear in planetary carrier
clockwise.
(17). When planetary clutch pack (G) is engaged,
u
planetary carrier (17) will turn output shaft (4) clockwise. Transmission power flow is transferred through output
shaft to differential.
Gear (20) is driven by gear (16) that is on intermediate
se
shaft (3). Gear (20) turns sun gear in planetary carrier

(19). When planetary clutch pack (B) is engaged,
planetary carrier (19) will turn output shaft (4) clockwise.
on
When clutch pack (H) is engaged, gear (18) will lock to

output shaft. Gear (14) will turn gear (18). As a result,
gear (18) will rotate. Consequently, output shaft (4) will
rotate clockwise.
ly
03-92 79033095 C Rev.

POWER TAKE-OFF (PTO) SYSTEM
Introduction (Power Take-Off System)

Power Take-Off (PTO)
FIG. 117: The MT800C Series machine is equipped with
1000 RPM power take-off (PTO). The power take-off (1) is
driven by input shaft from transmission. The hydraulic oil
for PTO clutch is provided by tandem charge pump.
The modulating valve (power take-off) is electronically
modulated to provide smooth clutch engagement. The
modulation of modulating valve is permanently
programmed in machine electronic control module
(ECM).
For safety, PTO clutch will automatically disengage when
engine is stopped or when engine is stalled.
Fo
There is a brake in drive line for PTO. The brake

disengages when you engage the PTO. The brake is
automatically applied when PTO is not engaged and
r
engine is running. When you stop engine, brake engages.

NOTE: You can not use PTO while you are using
in
steerable hitch in a non-centered mode.

The machine is equipped with a 44.5 mm (1.75 inch) PTO
te
shaft. 1
rn
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P111205018
FIG. 117
u se
on
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79033095 C Rev. 03-93

Power Take-Off (PTO) System
NOTE: The electrical components and hydraulic
components for power take-off are shown below.
1
8 9 10
Fo
2
r
6
in
5
te
7
rn
3 4
al
11
u se
P110405004
on
FIG. 118
FIG. 118: The Block Diagram for PTO System shows (6) Relief Valve (Charge Pressure)
ly
electrical components and hydraulic components.

(7) Oil Cooler
(1) PTO Switch
(8) Armrest ECM
(9) Machine ECM
(3) Common Sump
(10) Modulating Valve (Power-Take-Off)
(11) PTO Clutch
03-94 79033095 C Rev.

The operator can initiate a hydraulic function by
using one of following controls:
• PTO switch
• One-touch switch
The controls will send a signal to armrest electronic
control module (ECM) (8). The armrest ECM will then
signal machine electronic control module (ECM) (9).
The machine ECM will energize modulating valve (10)
which will send oil to PTO clutch (11).
The common sump (3) supplies tandem charge pump (4)
with oil. The oil goes through hydraulic oil filter (5). The oil
is then delivered to relief valve (6) (charge pressure). The
relief valve controls oil pressure to 2100 to 2135 kPa (305
to 310 psi). All excess oil is routed through oil cooler (7).
Fo
r in
te
rn
al
u se
on
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79033095 C Rev. 03-95

Electrical Control System For Power
Take-Off (PTO)
5
6
4
7
Fo
r
2
in
8
te
1
3
rn
9
al
u
P101505012
FIG. 119
se
FIG. 119: Electrical Block Diagram for PTO System The PTO can be deactivated by PTO switch. The PTO
can also be deactivated by one-touch feature, and PTO
The electrical system for PTO consists of following
on
can also be deactivated by three-point hitch.

components:
The VT (8) is used to view RPM of PTO.
(1) Switch (power-take-off)
The CAN data link (4) is a serial communication
ly
(2) Switch (one-touch)

bus that is used to communicate with following
(3) Armrest ECM components:
(4) CAN Data Link • Engine ECM
(5) Machine ECM • Machine ECM
(6) PTO Solenoid • VT
(7) To ECMs and Service Connector • Dash panel cluster
(8) Virtual Terminal (VT) • Auto-Guide Receiver (if equipped)
(9) Dash panel cluster • Other electronic control modules (if equipped)
The machine ECM (5) controls solenoid for modulating
valve (6).
The PTO can be activated by PTO switch. The PTO can
also be activated by one-touch feature.
03-96 79033095 C Rev.

Hydraulic System for Power Take-Off
(PTO)
10
5
17
Fo
11
r
4
in
te
19
rn
12
3
al
u
P110405005
FIG. 120
se
FIG. 120: Hydraulic Block Diagram for PTO System • Modulating valves (transmission)
on
(3) Common Sump When modulating valve (10) is energized, oil flows to PTO
clutch (11). When modulating valve is de-energized, oil
(4) Tandem Charge Pump flows from clutch to common sump (3).
ly
The relief valve (6) (charge pressure) regulates pressure

(6) Relief Valve (Charge Pressure) in PTO hydraulic system to a nominal pressure of 2100 to
2135 kPa (305 to 310 psi).
(10) Modulating Valve (power-take-off)
Oil flows from relief valve (6) (charge pressure) to
(11) PTO Clutch hydraulic oil cooler. The cooler bypass valve will open if a
(12) PTO Assembly pressure differential of 275 kPa (40 psi) is felt at hydraulic
oil cooler. Normally, cooler bypass valve will remain
(17) Elevated Oil Reservoir closed unless there is a restriction in hydraulic oil cooler
(19) Suction Screen or if oil is very cold.
Oil from common sump (3) is drawn through suction NOTE: Lubrication oil for PTO clutches is not supplied by
screen (19) by large section of tandem charge pump (4). hydraulic system for power take-off (PTO) or
The hydraulic oil filter (5) filters oil from large section of transmission hydraulic system.
tandem charge pump (4). The lubrication oil for PTO clutches is supplied by
Filtered oil is supplied to following valves: elevated oil reservoir (17).

• Creeper valve
79033095 C Rev. 03-97

Power Take-Off System
The electronic system for power take-off (PTO)
consists of following components:
• Switch (PTO)
• Switch (one-touch)
• CAN Data Link
• Armrest Electronic Control Module (ECM)
• Machine Electronic Control Module (ECM)
• PTO Solenoid
PTO Switch
Fo
FIG. 121: PTO Switch

The PTO switch signals armrest ECM that operator wants
to either activate or deactivate PTO.
1
r in
te
rn
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P101605001
FIG. 121
u se
on
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03-98 79033095 C Rev.

Switch (One Touch)
FIG. 122: One Touch Switch
The one touch switch (1) signals armrest ECM that
operator wants to perform multiple operations with a
single command. This includes activation and
deactivation of PTO. The armrest ECM then relays this
information to machine ECM.
1
P020112002
FIG. 122
CAN Data Link

Fo
FIG. 123: Connector for CAN Data Link

The CAN data link is located in wire harness. The
r
connector (1) for CAN data link is located next to fuse

blocks on right-hand side of cab.
in
The CAN data link is a serial communication bus that is

used to communicate with following components: 1
te
• Engine ECM
rn
• Machine ECM
• Armrest ECM
al
• Virtual Terminal
P090305001
• Auto-guide Receiver (if equipped)
FIG. 123
u

se
Armrest ECM
FIG. 124: Armrest Electronic Control Module (ECM)
on
The armrest ECM (1) is located in armrest inside of cab.

NOTE: The armrest is shown transparent to allow better
ly
view of armrest ECM.
P100805006
FIG. 124
79033095 C Rev. 03-99

Machine ECM
FIG. 125: Machine Electronic Control Module (ECM)
The machine ECM (1) is located on left-hand side of
machine beneath floor plate of cab in front of instructional
seat.
P100805005
FIG. 125
Virtual Terminal
Fo
FIG. 126: Virtual Terminal

The virtual terminal (1) is located on armrest in front of 1
r

The virtual terminal allows operator to view whether or not
in
PTO is engaged.
te
rn
al
P012205003
FIG. 126
u
Modulating Valve (Power Take-Off)

se
FIG. 127: Modulating Valve (Power Take-Off)

The modulating valve (1) for PTO is located on rear of
machine on top side of differential case. The modulating
on
valve for PTO is in front of three-point hitch (if equipped).

The modulating valve controls flow of hydraulic oil to
power take-off for engaging or disengaging clutch pack.
1
ly
P111205019
FIG. 127
03-100 79033095 C Rev.

Power Take-Off System
Common Sump
2
Fo
r in
te
1
rn
P111105008
al
FIG. 128
FIG. 128: Common Sump and Elevated Oil Reservoir

u
The common sump (1) supplies oil to all hydraulic

se
systems on machine.
The common sump (1) is located in lower portions of
following cases:
on
• Transmission
• Final drive
ly
The common sump (1) supplies oil directly to following

systems:
• Transmission
• Steering
Elevated oil reservoir (2) supplies lubrication oil to power
take-off clutch.
79033095 C Rev. 03-101

FIG. 129: Suction Screen for Tandem Charge Pump
The suction screen (1) for tandem charge pump is located
behind hydraulic oil filters.
to inlet side of tandem charge pump. The suction screen
will filter particles that are larger than 200 microns.
P111105009
FIG. 129

Fo

The suction screen (1) for scavenge pump is located on
r
left-hand side of machine behind pump. The suction

screen will filter particles that are larger than 540 microns.
in
to inlet of scavenge pump.
te
rn
1
al
P111105010
FIG. 130
u se
on
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03-102 79033095 C Rev.

Tandem Charge Pump
The tandem charge pump (1) is located on left-hand side
of machine in front of left-hand final drive.
The tandem charge pump is a two-section gear pump.
all of the following hydraulic systems:
• Transmission
• PTO
• Steering 1
• Parking Brake P111105011
NOTE: The small section of tandem charge pump FIG. 131

supplies lubrication oil to PTO clutch.
Fo
The small section of tandem charge pump supplies oil to

all of the following hydraulic systems that are not part of
transmission hydraulic system:
r
• Implement
in
• Service brake
te

• EOR
rn
Hydraulic Oil Filter (Transmission/Steering)

al
FIG. 132: Hydraulic Oil Filter (Transmission/Steering)

The hydraulic oil filter (1) is located on left-hand side of
machine in front of left-hand final drive. The hydraulic oil
u
filter receives oil from large section of tandem charge

pump. The filtered oil then flows to relief valve (charge
se
pressure).
is delivered by large section of tandem charge pump. The 1
on
hydraulic oil filter will filter particles that are larger than 7.5
microns.
ly
P111105012
FIG. 132
79033095 C Rev. 03-103

Relief valve (1) (charge pressure) is located on left-hand
side of machine near top of modulating valves 1
(transmission).
The relief valve (charge pressure) receives oil flow directly
from hydraulic oil filter. This relief valve regulates oil
pressure in transmission hydraulic system at a maximum
pressure of 2100 kPa (305 psi).
P111105013
FIG. 133

Fo

The modulating valve (1) is located at rear of machine on
r
cover for PTO.

in
The modulating valve controls oil to PTO clutch.

The modulating valve provides following control functions: 1
te
• Proportional control of oil flow

rn
al

P111205019
FIG. 134
u se
on
ly
03-104 79033095 C Rev.

Power Take-Off Clutch
FIG. 135: Power Take-Off Clutch
The power take-off clutch (1) is located at rear of machine
in differential case.
The power take-off clutch transfers rotational power flow
from input shaft of transmission to power take-off shaft.
The PTO clutch is controlled by modulating valve (power
take-off).
1
Fo
P111305001
FIG. 135
r
Test Port
in
FIG. 136: Test Port

Test port (1) is located below modulating valve, as shown.
te

that is being delivered to PTO clutch.
rn
al
1
u se
on
P111305002
ly
FIG. 136
79033095 C Rev. 03-105

Electrical Schematic for Power Take-Off
System
J1
1
4
J2
Fo
5
r
2
in
3
te
rn
al
u
P082808003
FIG. 137
se
FIG. 137: Electrical schematic for PTO system

(1) Machine ECM
on
(2) Armrest ECM

(3) PTO Switch
ly
(4) PTO Fender Switch

(5) Modulating Valve (power take-off)
03-106 79033095 C Rev.

The modulating valve (1) is located at rear of machine
and on cover for power take-off.
The modulating valve provides oil to PTO clutch.
The modulating valve provides following control functions: 1
• Proportional control of oil flow
P111205019
FIG. 138
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79033095 C Rev. 03-107

3 2 7
5
4 8
1
6
Fo
P110505002
FIG. 139
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FIG. 139: Schematic for Modulating Valve (Power

in
Take-Off)
(1) Modulating valve (power-take-off)
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(2) Test port

(3) PTO clutch
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(4) Spring
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(5) Spool orifice

(6) Line to common sump
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(8) Solenoid
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The modulating valve (1) is controlled by machine

electronic control module (ECM). The modulating valve is
used by machine ECM to directly modulate oil pressure
on
that is sent to PTO clutch (3).

When modulating valve is energized, machine ECM
sends a pulse width modulated current to solenoid (8).
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NOTE: Unlike modulating valve (transmission),

modulation cycle for modulating valve (power
take-off) is programmed into machine ECM. This
program can not be calibrated or adjusted.
The distance that is travelled by solenoid plunger is
proportional to electrical current that is sent to solenoid.
The position of solenoid plunger controls oil pressure that
is sent to PTO clutch.
When machine ECM sends maximum programmed
current to modulating valve, oil pressure in PTO clutch will
be at maximum desired pressure. When no current is
sent to modulating valve, oil pressure in PTO clutch will be
zero.
03-108 79033095 C Rev.

Valve Ports
FIG. 140: Bottom View of Modulating Valve (Power
Take-Off)
3
(1) To Common Sump
(3) To PTO Clutch
The bottom view shows porting for inlet and outlet flow of
hydraulic oil.
1
2
N021505003
FIG. 140
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79033095 C Rev. 03-109

Valve Operation
There are three basic stages of controlled
operation of a proportional solenoid valve:
• No Signal Current
• Less Than Maximum Signal Current
• Maximum Signal Current
The operation of modulating valve is not a simple on/off
cycle. The machine ECM varies strength of signal current
through a programmed cycle to control movement of
valve spool.
No Signal Current
2
12
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9
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5 4
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11
8
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13 10
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7
6 3
14
g01336785
on
FIG. 141
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03-110 79033095 C Rev.

(1) Modulating valve (power-take-off) Oil Flow with No Signal Current
(2) Test port The spring (4) moves valve spool to left in valve body.
(3) To PTO clutch The valve spool opens passage between PTO clutch (3)
and common sump (6).
(4) Spring
The valve spool blocks passage between PTO clutch and
(5) Spool orifice
charge pressure oil. Consequently, pressurized oil flow is
(6) To common sump blocked to PTO clutch.
(7) Charge pressure oil Charge pressure oil (7) flows from tandem charge pump
into valve body and around valve spool (9).
(8) Solenoid
The oil flows through drilled passage that is in valve spool
(9) Valve spool and into spool orifice (5). The Spool orifice is on left-hand
(10) Drain orifice side of valve spool. The oil then flows through drain orifice
(10).
(11) Pin
Because there is no force on pin (11), to hold ball (12)
(12) Ball against drain orifice, oil flows through valve spool. The oil
Fo
(13) Charge Pressure flows through drain orifice, around ball and to common
sump (6).
(14) Sump
Oil from PTO clutch will drain into common sump. As a
The machine ECM controls rate of oil flow through
r
result, PTO clutch is not engaged.

modulating valve (1) by changing strength of signal
current to solenoid (8). When signal current is not being
in
sent to solenoid, solenoid will be de-energized.

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79033095 C Rev. 03-111

Less Than Maximum Signal Current
2
1
9
12 5 4
11
10
8
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13 6 3
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7
14
in
15
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P110505003
FIG. 142
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(1) Modulating Valve (Power Take-Off)

(2) Test port
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(3) To PTO Clutch

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(4) Spring
(5) Spool Orifice
(6) To Common Sump
on

(8) Solenoid
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(9) Valve Spool

(10) Drain Orifice
(11) Pin
(12) Ball
(14) Sump
(15) 1st Charge Pressure Reduction
The machine ECM controls signal current to modulate
flow of oil through modulating valve. When solenoid (8)
receives less than maximum programmed signal current,
oil flow is modulated.
03-112 79033095 C Rev.

Oil Flow in a Valve with Less Than Maximum Signal
Current
The engagement of PTO clutch (3) begins when machine
ECM initially sends signal current to energize solenoid.
The signal current creates a magnetic field around pin
(11) which will cause pin to move to right against ball (12).
The force against ball will be in proportion to strength of
signal current from machine ECM.
The position of ball against drain orifice (10) restricts oil
flow to common sump (6). This partial restriction causes
pressure at left end of valve spool (9) to increase.
The oil pressure moves valve spool to right against spring
(4). The movement of valve spool starts to open a
passage on right end of valve spool. As a result, charge
pressure oil (7) will start to fill PTO clutch.
Fo
Oil also begins to fill chamber for spring on right end of

valve spool.
In initial stage for filling PTO clutch with oil, machine ECM
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sends a high pulse of current to quickly move valve spool.

During this short period of time, clutch piston will move to
in
remove clearances that are between clutch discs and

plates. This will minimize amount of time that is needed to
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fill clutch.
The machine ECM will then reduce signal current which
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will also reduce pressure setting of modulating valve. The

change in signal current reduces flow of oil to PTO clutch.
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When plates and discs start to touch each other, this is

called touch-up point. Once touch-up point is obtained,
machine ECM begins a controlled increase of signal
current to start modulation cycle.
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The increase in signal current causes ball and pin to

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further restrict oil through drain orifice to common sump.

This causes a controlled movement of valve spool to right.
The spool movement allows pressure to PTO clutch to
on
increase.
The modulating valve uses variable signal current from
machine ECM to vary pressure output of valve.
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The sequence of partial engagement is called desired

slippage. The clutches must slip a specific amount to
provide smooth engagement. The desired slippage is
controlled by application program that is stored in
machine ECM.
79033095 C Rev. 03-113

Maximum Programmed Signal Current
2
1
9 4
Fo 12 5
8 11 10
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6
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13 3
14 7
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g00774323
FIG. 143
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(1) Modulating valve (power-take-off)

(2) Test port
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(3) To PTO clutch

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(4) Spring
(5) Spool orifice
(6) To common sump
on

(8) Solenoid
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(9) Valve spool

(10) Drain orifice
(11) Pin
(12) Ball
(14) Sump
When modulation cycle stops, machine ECM will send
maximum specified signal current to fully engage PTO
clutch (3).
03-114 79033095 C Rev.

Oil Flow in a Valve with Maximum Programmed
Current Signal
The constant signal current pushes pin (11) firmly against
ball (12) in modulating valve (1).
The force against ball restricts amount of oil that can flow
through drain orifice (10). This restriction causes an
increase in pressure on left-hand side of valve spool (9).
The valve spool moves to right to allow charge oil to fully
engage PTO clutch.
In a short period of time, maximum pressure is felt at both
ends of valve spool. This pressure and additional force
that is produced by spring (4) causes valve spool to move
to left until forces on right end and left end of valve spool
are balanced.
The movement of valve spool to left balanced position
reduces flow of oil to engaged PTO clutch. The machine
Fo
ECM sends a constant maximum specified signal current

to solenoid (8) to maintain desired clutch pressure.
Test Port
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FIG. 144: Test Port

in
The test port (1) is located below modulating valve, as

shown.
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that is being delivered to PTO clutch.
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P111305002
FIG. 144
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79033095 C Rev. 03-115

Hydraulic System Schematic (Power
Take-Off)
5
1
3
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6
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4
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7 17
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12
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13
8
14
15 18
9
10 16
11
p111204006
FIG. 145
03-116 79033095 C Rev.

FIG. 145: Hydraulic System Schematic (PTO)
The following components are as shown
(1) PTO clutch
(2) Test port
(3) Modulating valve (power take-off)
(4) Line from elevated oil reservoir (lube oil)
(5) Relief valve (charge pressure)
(6) Hydraulic oil cooler
(7) Sampling valve
(8) Bypass valve
(9) Filler cap
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(11) Ecology drain valve

(12) Line to steering pump
(13) Hydraulic oil filter
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(14) Scavenge pump

in

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(17) Line to implement hydraulic oil cooler
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(18) Tandem charge pump (large section)

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79033095 C Rev. 03-117

Power Take-Off (PTO) Clutch
FIG. 146: Power take-off clutch (1) is located in
differential case behind cover (2).
The power take-off clutch transfers rotational power flow
from input shaft of transmission to PTO shaft. The PTO
clutch is controlled by modulating valve (power take-off).
The hydraulic oil to PTO clutch is modulated by
modulating valve (power take-off). This will help provide
smooth clutch engagement. Also, modulating oil flow will
help protect whole power take-off assembly from
damage. The modulation of modulating valve (power 1
take-off) is permanently programmed in machine
electronic control module (ECM).
2
Fo
P111305001
FIG. 146
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03-118 79033095 C Rev.

Oil Flow and Rotational Power Flow
3 7 5
4
6
20
14
13 15
12 16
11
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18
24
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17 8
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p111204007
FIG. 147
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FIG. 147: Power Take-Off Group

NOTE: The PTO clutch is disengaged.
on
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79033095 C Rev. 03-119

Operation of the PTO Brake
When PTO clutch is disengaged, PTO brake is engaged.
This is a spring engaged/pressure released brake
system.
FIG. 148: Detail of area B from previous figure.
7 5
Engaged
19
The brake plate (19) is splined to plate (23). The plate (23)
is bolted to housing. As a result, plate (23) and clutch
plate (19) never rotate. 20
Three springs (22) will push plate (23) against brake plate
(19). The brake plate will press against friction disc (21). 6
21
Consequently, friction disc will stop rotating.
The friction disc is splined to gear (20). Therefore, when
friction disc stops rotating, gear (20) will stop rotating.
Because gear (20) is engaged with gear (24), and gear
Fo
(24) is permanently splined to PTO shaft, PTO shaft will

stop rotating.
23
Disengaged
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When modulating valve (5) is energized, oil will flow to 22

chamber (6) behind piston (7). The oil pressure will
in
overcome force of three springs (22). The contact 24

pressure between brake plate and friction disc will be p111204008
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relieved. As a result, brake will disengage and PTO shaft FIG. 148
can rotate.
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03-120 79033095 C Rev.

Operation of PTO Clutch
FIG. 149: Detail of area A from previous figure
14 15
Engaged 16
13
Shaft assembly (4) is driven by input shaft from
transmission. The coupler (3) connects two shafts. The
shaft assembly is always rotating when engine is running.
The cylinder (14) is always rotating when engine is
running. 12
When modulating valve (power take-off) is energized, oil
flows through oil passage (18) that is in shaft assembly
(4). Oil fills chamber (12) behind piston (13). 4
As pressure builds up in front of piston, piston will start to
move toward clutch plates (15) and friction discs (16).
The clutch plates have teeth that engage cylinder (14).
The cylinder is always rotating when engine is running. As 18
Fo
a result, clutch plates will always rotate with cylinder.

The piston will overcome pressure from spring (17).
Consequently, piston will completely compress clutch
r
plates against friction discs. When friction discs are

compressed against clutch plates, friction discs will rotate. 17
in
The friction discs have gear teeth that engage gear (20).
As a result, gear (20) will rotate.
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The gear (20) is engaged with gear (24). Because gear

(24) is permanently splined to PTO shaft, PTO shaft will
rotate.
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24
Disengaged p111204009
FIG. 149
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The modulating valve will de-energize and charge oil in oil

passage (18) will be free to flow to common sump.
The spring (17) will push piston (13) away from friction
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discs and clutch plates. The PTO brake will engage.

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At this point, PTO clutch will be completely disengaged.

Lubrication Oil Flow
When engine is running, lubrication oil is always flowing.
on
This oil is supplied by elevated oil reservoir (EOR).

Lubrication oil flows through shaft assembly (4) and into
chamber (11). As a result, PTO clutch is bathed in oil.
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The lubrication oil can then flow through tube (10) and
into chambers (8) and (9). Consequently, gear (24), PTO
shaft, and bearings are lubricated. The lubrication oil can
then overflow out of chamber (8) and flow to common
sump.
79033095 C Rev. 03-121

NOTES
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03-122 79033095 C Rev.

Disassembly and Assembly
DISASSEMBLY AND ASSEMBLY
RELIEF VALVE (TRANSMISSION

LUBRICATION) - REMOVE AND INSTALL
Removal Procedure
NOTE: Cleanliness is an important factor. Before
disassembly procedure, exterior of component
should be thoroughly cleaned. This will help to
prevent dirt from entering internal mechanism.
FIG. 150: Remove plug (4).
1
Remove O-ring (3), retaining ring (2), and relief valve (1).
3
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2
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4
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P111305003
FIG. 150
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Installation Procedure
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assembly, all parts should be thoroughly cleaned

in cleaning fluid. Allow parts to air dry. Wiping
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cloths or rags should not be used to dry parts.

Lint may be deposited on parts which may cause
later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for
on
replacement.
FIG. 151: Install relief valve (1), retaining ring (2), and
O-ring (3). 1
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Install plug (4). 3
P111305003
FIG. 151
79033095 C Rev. 03-123

RELIEF VALVE (CHARGE PRESSURE) -
REMOVE AND INSTALL
Removal Procedure
FIG. 152: Remove bolts with washers (1) and remove
relief valve (2).
2
Fo
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1
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P111305004
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FIG. 152
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replacement.
FIG. 153: Install relief valve (2) with bolts and washers
(1). Tighten bolts to 26 to 34 Nm (19 to 25 lbf ft).
on
2
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1
P111305004
FIG. 153
03-124 79033095 C Rev.

HYDRAULIC PUMP DRIVE REMOVAL
Required Tools
Tool Part Description Qty
A Hydraulic Jack 1
NOTE: Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting, and repair of
machine. Be prepared to collect fluid with
containing fluids.
and mandates.
Drain sump into a suitable container for storage or
Fo
disposal.
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in
FIG. 154: Remove steering pump (1).

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NOTE: Refer to Steering Pump Removal section for

more information.
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1
P111305005
FIG. 154
on
FIG. 155: Remove implement pump.

NOTE: Refer to Hydraulic Pump (Implement) Removal
section for more information. 1
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P111305006
FIG. 155
79033095 C Rev. 03-125

FIG. 156: Remove clamp (1) and tube assembly (2).
P111305007
FIG. 156
FIG. 157: Loosen and remove bolts (1) that secure hose
clamp (2). Position hoses out of the way.
Fo
1
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2
in
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P111305008
FIG. 157
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FIG. 158: Position hydraulic jack (A) under hydraulic

pump drive (1) and remove bolts (2).
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Use Tooling and remove hydraulic pump drive.

NOTE: The weight of hydraulic pump drive is
se

on
1
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2
A
g00906383
FIG. 158
03-126 79033095 C Rev.

HYDRAULIC PUMP DRIVE DISASSEMBLY
Required Tools
A Push-Puller Tool Gp 1
B Bearing Puller Gp 1
C Driver Gp 1
Remove hydraulic pump drive.

NOTE: Refer to Hydraulic Pump Drive - Removal section
for more information.
Fo

Dirt and contaminants can damage components.
All disassembly and assembly procedures must
be performed on a clean work surface. Clean all
r
interior components in clean solvent. Dry all

interior components with compressed air.
in
FIG. 159: Drive spring pin (1) into shaft (2) with a pin
1
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punch. Remove shaft. 2 3

Remove thrust disc (3) from each side of gear (4).
rn
Remove gear from pump drive housing (5).

Remove bearing (6) from gear.
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NOTE: Be careful not to drive pin (1) to far in or pin will

engage housing (5) on opposite side, making
shaft (2) removal difficult. 6
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IMPORTANT: The spring pin must have a plugged center

to prevent lube oil from escaping. Do not use old
se
spring pin. 4
on
5 3
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P110605014
FIG. 159
79033095 C Rev. 03-127

FIG. 160: Remove bolts (1). Remove end cover (2).
Remove O-ring seal (3). Remove filter (4). Remove O-ring 2
seal (5) from pump drive housing.
Remove old sealant (6) from pump drive housing. 1
3
6
4
Fo
5
r
P110605015
FIG. 160
in
FIG. 161: Remove bolts (3). Remove cover (1).

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NOTE: When cover (1) is removed, gear (2) can fall. 3

Remove O-ring seal (4). Tap gear (2) from cover with a 1
rn
soft mallet.
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4
on
P110605016
FIG. 161
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FIG. 162: Use Tooling (A), (B) and (C) to remove bearing
(1) from gear (2). A
B
1
2 C
N121015001
FIG. 162
03-128 79033095 C Rev.

FIG. 163: Remove bearings (1) from gear (2).
1
Fo
P110605017
FIG. 163
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79033095 C Rev. 03-129

HYDRAULIC PUMP DRIVE ASSEMBLY
NOTE: Check O-ring seals for wear or for damage.
Replace O-ring seals, if necessary.
replacement. Dirt and contaminants can damage
components. All disassembly and all assembly
procedures must be performed on a clean work
surface. Keep cleaned parts covered and
FIG. 164: Install two bearings (1) onto gear (2). Use a
suitable press to install bearings.
Fo
2
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P110605017
FIG. 164
FIG. 165: Install O-ring seal (1). Tap gear (2) and
bearing into cover (3) with a soft mallet.
on
4
NOTE: The Gear (2) can fall from cover (3).
3
Install cover with bolts (4). Tighten securely.
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1
P110605016
FIG. 165
03-130 79033095 C Rev.

FIG. 166: Install filter (1). Install O-ring seal (2).
IMPORTANT: Be sure filter (1) is installed into bore in 4
front of housing (3). The filter can be crushed
when bolts are tightened. 5
Install end cover (4) with bolts (5).
Install O-ring seal (6) to pump drive housing. 2
3
1
Fo
6
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P110605015
FIG. 166
in
FIG. 167: Install bearing (1) into gear (2).

6 5 4
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Install gear into pump drive housing (3). Install two discs
(4) onto gear.
rn
NOTE: The spring pin seals oil to bearings. Do not use

old spring pin (5). The spring pin has rubber
inside spring pin to prevent lube oil from
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escaping.
Install shaft (6). Drive spring pin into pump drive housing 1
with a pin punch.
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Install pump drive.

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NOTE: Refer to Hydraulic Pump Drive Installation 2

section for more information.
on
3 4
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P110605014
FIG. 167
79033095 C Rev. 03-131

HYDRAULIC PUMP DRIVE INSTALLATION
Required Tools
A Hydraulic Jack 1
Fo
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1
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d-9578
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FIG. 168
FIG. 168: Apply Gasket Sealant (1) to mating surface of

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hydraulic pump drive.

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1. Apply a continuous bead (2) of 2.5 to 3.5 mm (0.109

to 0.141 in).
2. Spread bead to a width of 9.0 mm (0.3125 in)
minimum with a roller.
on
3. Remove excess sealant (do not get sealant on O-ring

seal).
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replacement.
03-132 79033095 C Rev.

FIG. 169: Use hydraulic jack (A) to position hydraulic
pump drive (1). Install hydraulic pump drive.
NOTE: The weight of hydraulic pump drive is
Loosely install bolts (2) to mount pump drive to
transmission.
2
A
Fo
g00906383
FIG. 169
FIG. 170: Install hose clamp (1) with bolts (2). Securely
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tighten all bolts.

Remove hydraulic jack.
in
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P111305008
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FIG. 170
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FIG. 171: Install tube assembly (2) and clamp (1).

on
1
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P111305007
FIG. 171
79033095 C Rev. 03-133

FIG. 172: Install implement pump (1).
NOTE: Refer to Implement Pump Installation section for
more information. 1
P111305006
FIG. 172
FIG. 173: Install steering pump (1).
NOTE: Refer to Steering Pump Installation section for
Fo
more information.
r in
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1
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P111305005
FIG. 173
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03-134 79033095 C Rev.

ENGINE FRAME AND POWERTRAIN -
SEPARATE
a. Remove Undercarriage.
NOTE: Refer to Undercarriage Assembly Removal
b. Remove guards.
NOTE: Refer to Guard Removal section for more
information.
c. Remove fuel tanks.
NOTE: Refer to Fuel Tank Removal section for more
information.
d. Remove cab.
NOTE: Refer to Cab Removal section for more
information.
Fo
e. Remove air tanks (if equipped).

NOTE: Refer to Air Tank Removal section for more
r
information.
in
f. Remove driveshaft.
NOTE: Refer to Driveshaft Removal section for more
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information.
rn

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helps prevent fluid loss, and this helps to keep

contaminants from entering system.
FIG. 174: Disconnect hose assemblies (2). Disconnect
u
tube assemblies (1). 1

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2
g00905957
FIG. 174
79033095 C Rev. 03-135

FIG. 175: Remove plugs (1) from front support.
g00905960
FIG. 175
FIG. 176: Attach support bracket (A) to both sides of
machine. Install lifting device (B) and slightly raise
machine. Install support stands (C) to both sides of the
Fo
machine.
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C
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g00905961
FIG. 176
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FIG. 177: Install Rear Stand Group (E) on both sides of

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machine
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g00905962
FIG. 177
03-136 79033095 C Rev.

FIG. 178: Disconnect harness assemblies (1). Remove
clamps (2) and move hose assemblies out of the way. 2
1
g00905965
FIG. 178
Fo
FIG. 179: Attach a suitable lifting device to mounting

bracket (1). Remove bolts (2) from mounting bracket.
2
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Remove mounting bracket.

in
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g00905968
FIG. 179
FIG. 180: Install lifting eyebolts (D). Attach a suitable
on
lifting device to lifting eyebolts

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g00905971
FIG. 180
79033095 C Rev. 03-137

FIG. 181: Remove bolts (1) from both side of
transmission.
Fo 1
g00906001
FIG. 181
FIG. 182: Remove bolts (1) from both sides of
r
transmission.
in
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g00906003
FIG. 182
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03-138 79033095 C Rev.

FIG. 183: Pull powertrain (1) to rear.
1
g00906017
FIG. 183
Fo
FIG. 184: Use jack stands (B) to support front of

powertrain.
NOTE: It may be necessary to pry dowels out of the way.
r
Powertrain can now be removed. Use caution when

moving powertrain.
in
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B
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g00906019
FIG. 184
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79033095 C Rev. 03-139

ENGINE FRAME AND POWERTRAIN -
CONNECT
FIG. 185: Install lifting eyebolt (D). Attach a suitable
lifting device in lifting eyebolt.
D
Fo
g00905971
FIG. 185
FIG. 186: Use jack stands (B) to support front of
r
powertrain (1).
in
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B
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g00906019
FIG. 186
FIG. 187: Move powertrain (1) into position.
on
NOTE: Adjust stands, if necessary.

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1
g00906017
FIG. 187
03-140 79033095 C Rev.

FIG. 188: Install bolts (1) on both sides of transmission.
g00906003
FIG. 188
FIG. 189: Install bolts (1) on both sides of transmission.
Fo
r
1
in
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g00906001
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FIG. 189
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FIG. 190: Attach a suitable lifting device to mounting

bracket (1). Install mounting bracket. Install bolts (2) on 2
mounting bracket.
on
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g00905968
FIG. 190
79033095 C Rev. 03-141

FIG. 191: Connect harness assemblies (1). Position
hose assemblies to original location. Install clamps (2). 2
1
g00905965
Fo
FIG. 191
r in
te
rn
al
u se
on
ly
03-142 79033095 C Rev.

FIG. 192: Remove rear stand group (E) on both sides of
machine.
E
Fo
g00905962
FIG. 192
FIG. 193: Slightly raise machine using lifting device (C).
r
Remove support stands (B) from both sides of machine.

Lower machine and remove support bracket (A) from both
in
sides of machine.
te
rn
al
C
u
B
se
g00905961
FIG. 193
on
FIG. 194: Install plugs (1).

ly
g00905960
FIG. 194
79033095 C Rev. 03-143

FIG. 195: Connect hose assemblies (2). Connect tube
assemblies (1). 1
a. Install driveshaft.
NOTE: Refer to Driveshaft Installation section for more
information.
b. Install air tanks (if equipped).
NOTE: Refer to Air Tank Installation section for more
information.
c. Install cab.
NOTE: Refer to Cab Installation section for more
information.
d. Install fuel tanks.
NOTE: Refer to Fuel Tank Installation section for more 2
information.
g00905957
Fo
e. Install guards. FIG. 195

NOTE: Refer to Guard Installation section for more
information.
r
f. Install Undercarriage.
in
NOTE: Refer to Undercarriage Assembly Installation

te
rn
al
u se
on
ly
03-144 79033095 C Rev.

TRANSMISSION REMOVAL
a. Remove pump drive.
NOTE: Refer to Pump Drive Removal section for more
information.
b. Separate engine frame and transmission.
NOTE: Refer to Engine Frame and Powertrain -
Separate section for more information.
Fo

containing fluids.
r

and mandates.
in
Powertrain should be supported with stands under rear

axle and in front of differential.
te
Drain powertrain oil into a suitable container for storage or

disposal if not already done.
rn
FIG. 196: Position hydraulic jack (A) under bracket (2).

Remove three bolts (1) from both sides of bracket.
1
al
Remove bracket.
u se
on
2
ly
A
g00905646
FIG. 196
79033095 C Rev. 03-145

FIG. 197: Attach eye bolts (B) to a suitable lifting device,
as shown. B
g00905687
Fo
FIG. 197
FIG. 198: Remove tube assembly (1) from both sides of
machine.
r in
te
rn
al
u
1
se
g00905652
FIG. 198
FIG. 199: Remove transmission (1).
on
NOTE: The weight of the transmission and creeper is

ly
g00905691
FIG. 199
03-146 79033095 C Rev.

TRANSMISSION DISASSEMBLY
a. Remove steering pump.
NOTE: Refer to Steering Pump Removal section for
more information.
b. Remove implement pump.
NOTE: Refer to Implement Pump Removal section for
more information.
c. Remove transmission.
NOTE: Refer to Transmission Removal section for more
information.
helps prevent fluid loss, and this helps to keep
Fo

begin disassembly procedure, exterior of
r
components should be thoroughly cleaned. This

will help to prevent dirt from entering internal
in
mechanism. Precision components can be

damaged by contaminants or by dirt. Perform
te

rn
FIG. 200: Use suitable blocking to level transmission.

Remove bolts (1) and remove transmission control valve
al
(2). Repeat this procedure for removal of remaining

control valves. 2
u se
1
on
P111005002
ly
FIG. 200
79033095 C Rev. 03-147

FIG. 201: Remove bolts (1) and lip seal (3) from seal
ring housing (2). Use driver to remove seal ring housing. 4
Remove bolts (5) and remove cover (4). Remove bolts (7)
and remove cover (6). Remove bolts (9) and remove 5
cover (8).
6
7
8
9
1
2
Fo
3 g00908009
FIG. 201
FIG. 202: Remove O-ring seals (1) from seal ring
r
housing (2). 2 1
in
te
rn
al
u
P110704032
FIG. 202
se
FIG. 203: Attach link bracket (A) to pump drive (1).

Remove bolts (2) and remove pump drive. A
1
on
ly
g00907947
FIG. 203
03-148 79033095 C Rev.

FIG. 204: Remove bolts (6). Remove tube (7). Remove
O-ring seal (8) (not shown). 6
7
8
Fo
g00911113
FIG. 204
FIG. 205: Measure and record endplay of each shaft (1)
r
with dial indicator (K). K

in
te
rn
al
u se
1
g00888147
FIG. 205
on
FIG. 206: Attach link brackets (A) to rear transmission

case (1). Remove bolts (2) from front transmission case A
(3).
ly
1
Use forcing bolt (B) to separate front transmission case
and rear transmission case.
NOTE: The weight of rear transmission case is
B
2
g00907954
FIG. 206
79033095 C Rev. 03-149

FIG. 207: Place rear transmission case (1) on wood
blocks.
1
g00907955
Fo
FIG. 207
FIG. 208: Remove bolts (1). Remove bearing cage (2)
and shims (3). Remove lip seal (4) and bearing race (5). 4
r
Repeat this procedure for bearing cage (6), (7), and (8).
Mark the location of each bearing cage for installation 5 1
in
purposes.
2
te
3
6
rn
7 8
al
u se
g00907976
on
FIG. 208
FIG. 209: Rotate rear transmission case (1) by 180
degrees by installing eyebolts to lower bolt holes in 4 2
ly
transmission case. Use a wench or other suitable lifting 1

devise to rotate transmission. Remove bolts (2). Do not
remove bolts (3) at this time. Remove clutch (4). Use two
people to remove clutch.
NOTE: The weight of clutch is approximately 25 kg (55
lb).
3 g00907980
FIG. 209
03-150 79033095 C Rev.

FIG. 210: Clutch Disassembly
Remove O-ring seals (1) from clutch (2). 2 1
P110704024
FIG. 210
FIG. 211: Remove bolts (1). Remove reaction plate (2)
and ring gear (3).
Fo
1
r in
te
2
rn
3
al
u
P111005003
FIG. 211
se
on
ly
79033095 C Rev. 03-151

FIG. 212: Remove disc (1) and plates (2). Remove
dowels (3) and springs (4). Remove rods (5) from housing
(6). 1
m
WARNING: Personal injury can result from 2
being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective 4
equipment.
Follow recommended procedure and use all
recommended tooling to release spring 5
force. 3
6
Fo
r in
g00886001
FIG. 212
te
FIG. 213: Remove piston (1) from housing (2). Remove

rn
seals (3) and (4) from piston.

al
u
3
se
on
2
ly
g00911116
FIG. 213
03-152 79033095 C Rev.

FIG. 214: Remove yoke (1).
1
g00907981
Fo
FIG. 214
FIG. 215: Transmission Shaft Removal
C
Attach plate (C) to transmission shafts. Remove
r
intermediate shaft (1), reverse shaft (2), input shaft (3), 1

and output shaft (4).
in
NOTE: The weight of transmission shafts is

te
2
rn
3
al
4
u se
g00907984
FIG. 215
on
FIG. 216: Remove O-ring seals (1).
1
ly
g00907988
FIG. 216
79033095 C Rev. 03-153

FIG. 217: Place transmission shaft on table (D). Remove
plate (C).
C
g00886071
Fo
FIG. 217
r in
te
rn
al
u se
on
ly
03-154 79033095 C Rev.

Reverse Shaft Disassembly
FIG. 218: Install combination puller (E). Pull bearing (2)
from reverse shaft (1).
E
2
Fo
g00886077
FIG. 218
r
FIG. 219: Remove bearing (1), spacer (2), spacer (3),

gear (4), and spacer (5) from reverse shaft (6).
in
1
te
2
rn
3
al
5
u se
6
on
g00886113
FIG. 219
ly
79033095 C Rev. 03-155

FIG. 220: Rotate shaft by 180 degrees.
Use combination puller and step plate (E) to remove
bearing (1).
E
E 1
Fo
g00886118
FIG. 220
FIG. 221: Remove bearing (1) and spacer (2). Remove
r
thrust washer (3) and gear (4).

1
in
2
te
3
rn
4
al
u se
g00886121
FIG. 221
on
ly
03-156 79033095 C Rev.

FIG. 222: Remove bearings (1) and thrust washer (2).
Use flat screwdriver to remove retaining ring (3). Remove
clutch plate (4). Remove friction discs and plates (5) from 1
reverse shaft (6).
4
5
6
Fo
r
g00886123
FIG. 222
in
FIG. 223: Remove spring from shaft (1).
m
3
te

being struck by parts propelled by a G
rn
Make sure to wear all necessary protective

equipment. 2
al

recommended tooling to release spring
force.
u
Use a suitable press and shaft retainer (G) to compress

se
spring (2). Remove retaining ring (3).

1
g00886127
on
FIG. 223
FIG. 224: Remove spacer (1), seal assembly (2), and
spring (3) from reverse shaft (4).
ly
g00911118
FIG. 224
79033095 C Rev. 03-157

FIG. 225: Remove piston (1) from shaft (2). Remove
seals (3) from piston. Remove seal (4) from piston.
2
Fo
r in
g00886132
FIG. 225
te
Intermediate Shaft Disassembly

rn
FIG. 226: Use combination puller and step plate (E) to

remove bearing (2) from intermediate shaft (1).
E
al
2
u se
on
1
ly
g00886134
FIG. 226
03-158 79033095 C Rev.

thrust washer (4), and gear (5) from intermediate shaft.
Remove two bearing (6) and thrust washer (7) from shaft
(8).
1
NOTE: The procedure for disassembly of clutch packs
are identical. 2
3
5
6
Fo
8
7
r in
g00886137
FIG. 227
te
FIG. 228: Rotate intermediate shaft (1) by 180 degrees.

Use combination puller and step plate (E) to remove E
rn
bearing (2) from shaft.

2
al
1
u se
on
ly
g00886144
FIG. 228
79033095 C Rev. 03-159

and gear (4) from intermediate shaft (5).
1
2
5
Fo
r in
g00886147
FIG. 229
te
FIG. 230: Remove gear (1), spacer (2), thrust washer

(3), and gear (4). Remove bearings (5) and thrust washer
rn
(6) from intermediate shaft (7).

al
are identical. 1
2
u
3
se
4
on
5
ly
g00886149
FIG. 230
03-160 79033095 C Rev.

Output Shaft Disassembly
remove bearing (2) from output shaft (1).
E 1
Fo 2
g00911120
FIG. 231
FIG. 232: Remove bearing (1), spacer (2), and planetary
carrier (3) from output shaft (4).
r
1
in
2
te
4
rn
3
al
u se
g00911122
FIG. 232
on
FIG. 233: Drive spring pin (1) into shaft (2). Remove
shaft, thrust discs (3), gear (4), and bearings (6) from
carrier (6).
6
ly
3 1
Once shaft is removed, remove spring pin from shaft.
NOTE: Driving spring pin into shaft too far will result in 5
difficult removal. 2
4
5
3 g00886157
FIG. 233
79033095 C Rev. 03-161

FIG. 234: Remove thrust washer (1), sun gear (2), tube
(3), thrust washer (4), and gear (5). Remove bearings (6)
and thrust washer (7) from output shaft (8).
1
are identical.
2
3
4
6
8
Fo
7
r in
g00886166
FIG. 234
te
FIG. 235: Rotate output shaft by 180 degrees.

rn
Remove bolts (1), and rotor (2) from output shaft (3).
1
al
3
u se
on
g00886170
FIG. 235
ly

remove bearing (1) from output shaft (2).
g00886171
FIG. 236
03-162 79033095 C Rev.

FIG. 237: Remove bearing (1), spacer (2), and planetary
carrier (3) from output shaft (4).
NOTE: The procedure for disassembly of planetary 1
carriers are identical.
2
4
Fo
g00886174
FIG. 237
FIG. 238: Remove thrust washer (1), sun gear (2), tube
r
(3), thrust washer (4), and gear (5). Remove bearings (6),
1
in
spacer (7) and thrust washer (8) from output shaft.

2
te
are identical.
rn
3
al
4
u
5
se
6
7
on
8
ly
g00886180
FIG. 238
79033095 C Rev. 03-163

Input Shaft Disassembly
remove bearing (2) from input shaft (1).
1
Fo
r in
g00886188
FIG. 239
te

gear (4), and gear (5) from input shaft (6). 1
rn
2
al
3
u
4
se
5
on
ly
g00886190
FIG. 240
03-164 79033095 C Rev.

FIG. 241: Remove spacer (1), thrust washer (2) and
gear (3). Remove bearings (4) and thrust washer (5) from
input shaft (6)
1
are identical. 2
4 5
Fo
6
r in
g00886193
FIG. 241
te
FIG. 242: Rotate shaft by 180 degrees.

E
rn
Use combination puller and step plate (E) to remove

bearing (1) from shaft (2).
al
1
u se
on
2
ly
g00886196
FIG. 242
79033095 C Rev. 03-165

FIG. 243: Remove bearing (1), spacer (2), thrust washer
(3), and gear (4). Remove bearings (5) and thrust washer
(6) from shaft (7). 1
are identical. 2
5 6
Fo
7
r in
g00886197
FIG. 243
te
FIG. 244: Remove bolts (3) from clutch (2). Do not

remove bolts (1) at this time. Remove clutch. 1
rn

are identical.
al
2
u se
on
3
1
ly
g00908002
FIG. 244
03-166 79033095 C Rev.

FIG. 245: Use slide hammer puller (H) to remove
bearing races (1), (2), (3), and (4) from front of H
transmission case.
1
3
2
4
Fo
g00908005
FIG. 245
r in
te
rn
al
u se
on
ly
79033095 C Rev. 03-167

TRANSMISSION ASSEMBLY
replacement.
IMPORTANT: For all bearings that require heating
bearings should be heated to 107 degrees C
(250 degrees F). Use an oil bath heater or an
oven to heat bearing. Do not use a torch.
FIG. 246: Lower temperature of bearing races. Install
bearing races (1), (2), (3), and (4) in front of transmission 1
case.
3
Fo
4
r in
te
rn
g00908268
al
FIG. 246
FIG. 247: Install seals (1) and (2) on piston (3). Install
piston on housing.
u se
1
on
ly
g00886008
FIG. 247
03-168 79033095 C Rev.

FIG. 248: Clutch Assembly
m
WARNING: Personal injury can result from 5
released spring force. 6
equipment. 4
force. 1 3
2
Install rods (1) in housing (2). Install dowels (3) and
springs (4). Install disc (5) and plates (6).
Fo
g00886001
r
FIG. 248
in
FIG. 249: Install ring gear (1) and reaction plate (2).
Install bolts (3).
te
NOTE: Be sure that rods seat into bore of both reaction

plate and housing so they are not damaged.
rn
3
al
u
2
se
1
on
P111005003
ly
FIG. 249
FIG. 250: Install O-ring seals (1) on clutch (2).
2 1
P110704024
FIG. 250
79033095 C Rev. 03-169

FIG. 251: Use two people to install clutch (1).
1 2
NOTE: The weight of clutch is approximately 25 kg (55
lb). 4
Install clutch. Install bolts (2) and (3). Rotate rear
transmission case (4) by 180 degrees.
NOTE: The procedure for assembly of clutch packs are
identical.
3
Fo
g00907980
FIG. 251
FIG. 252: Clutch Pack Assembly
r
Install seals (3) onto piston (4). Install seal (5) onto shaft.
in
Install piston on input shaft (1). Install seals (2). 2
m
te

released spring force. 4
rn

equipment. 3
al

recommended tooling to release spring 5
force.
u se
1
on
ly
g00911181
FIG. 252
03-170 79033095 C Rev.

FIG. 253: Install spring (1), seal assembly (2), and
retainer ring (3) on input shaft (4).
g00911118
Fo
FIG. 253
FIG. 254: Use a suitable press and shaft retainer (G) to
compress spring (1). Install ring (2) to shaft (3).
r
2
G
in
te
1
rn
al
3
u se
g00886127
FIG. 254
on
ly
79033095 C Rev. 03-171

FIG. 255: Install friction discs and plates (1) on reverse
shaft (2). Install clutch plate (3). Use flat bladed
screwdriver to install retaining ring (4). Install thrust 6
washer (5) and bearings (6).
3
1
2
Fo
r
g00886123
in
FIG. 255
te
Input Shaft Assembly

FIG. 256: Install thrust washer (1), bearings (2), gear (3),
rn
thrust washer (4), and spacer (5) on input shaft (6). Raise
temperature of bearing (7) and install on input shaft. 7
al

identical. 5
u
4
se
3
on
ly
2 1
g00886197
FIG. 256
03-172 79033095 C Rev.

FIG. 257: Rotate input shaft 180 degrees.
Install thrust washer (1), bearings (2), gear (3), thrust disc
(4), and spacer (5) on input shaft (6). 5
identical. 4
2 1
Fo
6
r in
g00886193
FIG. 257
te
FIG. 258: Install gear (1), gear (2), spacer (3), and
spacer (4) on input shaft (5). Raise temperature of
rn
6
bearing (6) and install on input shaft.
4
al
3
u
2
se
1
on
ly
g00886190
FIG. 258
79033095 C Rev. 03-173

Output Shaft Assembly
FIG. 259: Install thrust washer (1), bearing (2), spacer
(3), bearing (2), gear (4), thrust washer (5), spacer (6),
sun gear (7), and thrust disc (8) on output shaft. 8
identical. 7
4
Fo
2
3
r
1
in
te
g00886180
FIG. 259
rn
FIG. 260: Install thrust washers (1), bearings (2), and

gear (3). Install shaft (4) in carrier (5). Drive spring pin (6)
into carrier and shaft. 5
al
1 4
NOTE: Do not use old spring pins.
NOTE: Spring pin must have a rubber plugged center. 2
u
This will prevent lubrication oil from escaping. 6

3
se
2
on
1
g00886157
FIG. 260
ly
03-174 79033095 C Rev.

FIG. 261: Install planetary carrier (1) and spacer (2) on
output shaft (3). Raise temperature of bearing (4) and
install on output shaft. 4
3
Fo
g00886174
FIG. 261
FIG. 262: Install rotor (1) and bolts (2) on output shaft
(3). Rotate output shaft.
r
2
in
1
te
3
rn
al
u
g00889331
se
FIG. 262
on
ly
79033095 C Rev. 03-175

FIG. 263: Rotate shaft 180 degrees.
Install bearings (1), gear (2), thrust washer (3), tube (4), 6
sun gear (5), and thrust washer (6) on output shaft (7).
NOTE: The procedure for assembly of clutch packs are 5
identical.
4
3
1
7
Fo
r in
g00886166
FIG. 263
te
FIG. 264: Install planetary carrier (1) and spacer (2), on

output shaft (3). Raise temperature of bearing (4) and
rn
install onto output shaft. 4

NOTE: The procedure for assembly of planetary carriers
2
al
are identical.
3
u se
1
on
ly
g00911122
FIG. 264
03-176 79033095 C Rev.

Intermediate Shaft Assembly
FIG. 265: Install thrust washer (1), bearings (2), gear (3),
thrust washer (4), spacer (5), and gear (6) on
intermediate shaft (7).
identical. 6
5
4
2
Fo
7
r
1
in
te
g00886149
FIG. 265
rn
FIG. 266: Install gear (1), spacer (2) and spacer (3), on
intermediate shaft (4). Raise temperature of bearing (5)
and install on intermediate shaft. 5
al
3
u
2
se
1
on
ly
g00886147
FIG. 266
79033095 C Rev. 03-177

FIG. 267: Rotate intermediate shaft (1) by 180 degrees.
Install thrust washer (2) and two bearing (3). Install gear
(4), thrust washer (5), spacer (6) and spacer (7), 8
intermediate shaft. Raise temperature of bearing (8) and
install on intermediate shaft.
7
identical. 6
4
3
1
Fo
2
r in
g00886137
FIG. 267
te
rn
al
u se
on
ly
03-178 79033095 C Rev.

Reverse Shaft Assembly
FIG. 268: Install gear (1) and thrust washer (2). Install
spacer (3). Raise temperature of bearing (4) and install on
reverse shaft.
4
3
2
1
Fo
g00886121
FIG. 268
r
FIG. 269: Rotate reverse shaft (1) by 180 degrees.

Install spacer (2), gear (3), spacer (4) and spacer (5) on
in
reverse shaft. Raise temperature of bearing (6) and install

on reverse shaft. 6
te
5
rn
4
al
3
2
u
1
se
g00886113
on
FIG. 269
ly
79033095 C Rev. 03-179

Transmission Assembly
FIG. 270: Transmission Shaft Installation
Install plate (C). Remove transmission shaft from table C
(D).
g00886071
Fo
FIG. 270
FIG. 271: Install transmission shafts (1), (2), (3), and (4).
C
r
NOTE: The weight of transmission shafts is 1

in
IMPORTANT: Seal carriers (5) must not be installed on

shafts during shaft installation. Damage to seal
te
carriers may result and be difficult to detect.

2
rn
3
al
4
u se
5
g00907984
FIG. 271
on
FIG. 272: Install O-ring seals (1).
1
ly
g00907988
FIG. 272
03-180 79033095 C Rev.

FIG. 273: Install bearing face (1) and lip seal (2) into
bearing cage (3). Install shims (4), bearing cage and bolts 2
(5). Repeat this procedure for bearing cage (6), (7), and
(8). 1 5
3
4
6
7 8
Fo
g00907976
FIG. 273
FIG. 274: Apply gasket sealant and install seal (not
r
shown) onto bottom of transmission (1).

NOTE: The weight of rear transmission case is
in
approximately 327 kg (720 lb). Place rear

transmission case on wood blocks.
te
NOTE: The mating surfaces must be free of oil. 1

rn
al
u se
g00885949
FIG. 274
on
FIG. 275: Attach link brackets (A) to rear transmission

case (1). Install coupler (not shown). Install bolts (2) on A
front transmission case (3). Remove link brackets.
ly
2
3
g00908281
FIG. 275
79033095 C Rev. 03-181

FIG. 276: Use shims (1) to adjust bearing clearance to
0.0508 to 0.1016 mm (0.00200 to 0.00400 inch) for input K
shaft. Use dial indicator (K) to measure bearing
clearance. Repeat this step for remaining shafts.
1
Fo
g00888147
FIG. 276
FIG. 277: Install O-ring seal (1) onto tube (2). Install tube
r
and bolts (3). 3

in
2
te
1
rn
al
u se
g00911113
FIG. 277
on
FIG. 278: Install transmission control valve (1) and install

bolts (2). Repeat this procedure for installation of
remaining control valves.
ly
P111005002
FIG. 278
03-182 79033095 C Rev.

FIG. 279: Install O-ring seal (1) on seal ring housing (2).
2 1
P110704032
FIG. 279
FIGS. 280–281: Seal Carrier Installation
Install seal ring housing (1). Install bolts (2).
Fo
Install O-ring seals (15) on the seal carriers.

Install seal carrier (3). Install bolts (4). Install cover (5), 3 4
seal (15), and bolts (6).
r
Install seal carrier (7). Install bolts (8). Install cover (9),
in
seal, and bolts (10). 8

7
Install seal carrier (11). Install bolts (12). Install cover (13),
te
seal, and bolts (14).

rn
11
al
15
12 g00908285
g00908285
u
FIG. 280
se
2
on
1
5
6
ly
15
9
10
14
14
g00908288
FIG. 281
79033095 C Rev. 03-183

FIG. 282: Yoke Installation
Install yoke (1). 1
a. Install transmission. Refer to Transmission Installation
b. Install pump drive. Refer to Pump Drive Installation
c. Install implement pump. Refer to Implement Pump
Installation section for more information.
d. Install steering pump. Refer to Steering Pump
g00907981
Fo
FIG. 282
r in
te
rn
al
u se
on
ly
03-184 79033095 C Rev.

TRANSMISSION INSTALLATION
replacement.
FIG. 283: Attach eyebolts (B) to a suitable lifting device,
as shown. Install transmission (1).
NOTE: The weight of transmission is approximately 1406 1
kg (3100 lb).
B
Fo
r in
te
rn
g00905691
FIG. 283
al
FIG. 284: Apply Gasket Sealant to only one mating

surface. Use jack stand (C) to support steering
differential. Install bolts (1) and tighten to 5230 to 5370
u
Nm (340 to 440 lbf ft).

se
1
on
C
ly
g00905689
FIG. 284
79033095 C Rev. 03-185

FIG. 285: Place jackstands (C) under front of
transmission.
C
g00905678
FIG. 285
Fo
FIG. 286: Install tube assembly (1).

r in
te
rn
al
u
1
se
g00905652
FIG. 286
FIG. 287: Remove hoist (B).
B
on
ly
g00905687
FIG. 287
03-186 79033095 C Rev.

FIG. 288: Position hydraulic jack (A) under bracket (2).
Install bracket. Install three bolts (1) on both sides of 1
bracket.
Fill transmission with powertrain oil.
a. Connect engine frame and transmission.
NOTE: Refer to Engine Frame and Transmission -
Connect section for more information.
b. Install pump drive.
NOTE: Refer to Pump Drive Installation section for more
information.
c. Install undercarriage to original width.
2
NOTE: Refer to Undercarriage Assembly section for
more information. A
d. Install guards. g00905646
Fo
FIG. 288
NOTE: Refer to Guards Installation section for more
information.
r in
te
rn
al
u se
on
ly
79033095 C Rev. 03-187

MODULATING VALVE (POWER TAKE-OFF)
Removal Procedure
FIG. 289: Remove bolts (1). Disconnect harness
assembly from coil (2) and remove modulating valve (3).
2
3
Fo
1
r in
te
P111305009
FIG. 289
rn
al

u

se

replacement.
on
FIG. 290: Install modulating valve (3). Install bolts (1).

Connect harness assembly to coil (2).
2
ly
P111305009
FIG. 290
03-188 79033095 C Rev.

POWER TAKE-OFF (PTO) REMOVAL
Remove three-point hitch (if equipped).
NOTE: Refer to Three-Point Hitch Removal section.
NOTE: Care must be taken to ensure that fluids are
contained during performance of inspection,
containing fluids.
and mandates.
NOTE: Keep all parts clean from contaminants.
Contamination of hydraulic system with foreign
material will reduce service life of hydraulic
system components.
Fo
To prevent contaminants from entering hydraulic

system, always plug or cap lines, fittings, or
hoses as they are disconnected. Cover any
r
disassembled components and clean them

properly before assembly.
in
Clean hydraulic system properly after any major

component exchange or especially after a
te
component failure, to remove any contamination.

Drain transmission into a suitable container for storage or
rn
disposal.
FIG. 291: Loosen and remove hydraulic lines (1).
al
u
1
se
1
on
ly
P111305010
FIG. 291
FIG. 292: Loosen and remove three bolts with washers
(1) that mount shield (2). Remove shield. 2
1
1
1
P111305011
FIG. 292
79033095 C Rev. 03-189

FIG. 293: Remove bolts (1) from PTO.
Fo
P111305012
FIG. 293
FIG. 294: Install M16 x 2 x 50mm guide bolts (1).
r
Remove remaining bolts (1) from PTO. Use M16 x 2 x 1

50mm forcing bolts (3) to separate PTO
in
te
rn
al
3
u se
2
on
P111305013
FIG. 294
FIG. 295: Install link brackets (1) to PTO (2). Remove
ly
PTO. 1
NOTE: The weight of PTO is approximately 160 kg (350
lb). 2
Remove coupling for PTO.
00904327
FIG. 295
03-190 79033095 C Rev.

POWER TAKE-OFF (PTO) DISASSEMBLY
Remove power take-off.
NOTE: Refer to Power Take-Off Removal section for
more information.
FIG. 296: Remove rock guard from PTO shaft and place
PTO assembly on two blocks. 1
Remove bolt (1) and tube assembly (2). If necessary,
remove ring (3).
2
3
Fo
T052905003
r
FIG. 296
in
FIG. 297: Remove bolts (1) and remove sight gauge (2)
from housing.
te
rn
2
al
1
u se
T052905004
FIG. 297
FIG. 298: Loosen and remove bolts (1). Remove bearing
carrier (2) from housing. 1
on
2
ly
T052905005
FIG. 298
79033095 C Rev. 03-191

FIG. 299: Remove bearing races (1) from bearing carrier
(2).
2
1
T052905006
FIG. 299
FIG. 300: Install bearing puller (1) on bearing cone (2).
Attach push-puller tool (3) to bearing puller. Remove
bearing cone from shaft (4). 3
Fo
2 4
r
1
in
te
rn
al
g00912655
FIG. 300
u
FIG. 301: Install eyebolt (1) in shaft. Remove clutch

assembly (2) from housing (3).
se
1
2
on
3
ly
g00912657
FIG. 301
03-192 79033095 C Rev.

FIG. 302: Remove shaft (1) and gear assembly (2) from
housing. 1
2
T052905007
FIG. 302
Fo
Attach push-puller tool (3) and driver (4) to bearing puller.

Remove bearing cone from gear assembly (5) and shaft.
3
r in
4
te
2
1
rn
5
al
g00912660
FIG. 303
FIG. 304: Rotate shaft and gear assembly (1) 180
u
degrees.
1
se
on
ly
T052905008
FIG. 304
79033095 C Rev. 03-193

Attach push-puller tool (3) to bearing puller. Remove
bearing cone from shaft.
3
2
1
g00912662
FIG. 305
FIG. 306: Exploded view of bearing cone (1), gear
assembly (2), shaft (3), and bearing cone (4).
1
Fo
2
r in
3
te
rn
4
al
T052905009
FIG. 306
FIG. 307: Loosen and remove bolts with washers (1)
u
that secure cage (2) to housing. 1

se
Remove plugs (3) from cage. 3

on
2
ly
T053005001
FIG. 307
FIG. 308: Install forcing bolts (1) into cage (2). Tighten
bolts evenly until cage is loose.
1
T053005002
FIG. 308
03-194 79033095 C Rev.

FIG. 309: Remove cage (1) and shims (2) from housing
(3).
1
2
T053005003
FIG. 309
Fo
FIG. 310: Remove rock guard (1) and seal assembly (2)
from cage (3).
1
2
r in
3
te
rn
T053005004
al
FIG. 310
FIG. 311: Rotate cage 180 degrees. Remove O-rings (1)
and bearing cup (2) from cage (3). 1
u se
3
on
ly
T053005005
FIG. 311
79033095 C Rev. 03-195

FIG. 312: Rotate shaft assembly (1). Rest shaft
assembly on a suitable device.
2
Remove seals (2) and (3) from shaft assembly.
3
1
T053005006
FIG. 312
FIG. 313: Install bearing puller (1) to shaft assembly (2).
Fo
Attach push-puller tool (3) and driver (4) to bearing puller.

Remove bearing (5). 3
1
r in
4
te
rn
2
5
al
u se
g00912669
FIG. 313
FIG. 314: Remove ring carrier (1), bearing (2), thrust
washer (3) and gear assembly (4) from shaft assembly
on
(5). 1
2
ly
FIG. 314
03-196 79033095 C Rev.

FIG. 315: Remove bearing (1), bearing (2), thrust disc
(3) and clutch plate (4) from shaft assembly (5). 1 2
3
4
T053005008
FIG. 315
FIG. 316: Remove retaining ring (1), friction disc (2) and
Fo
plates (3) from shaft assembly (4).

2 1
NOTE: There are 6 sets of discs and plates.
r in
3
te
rn
4
al
T053005009
u
FIG. 316
FIG. 317: Piston Removal
se
m
being struck by parts propelled by a 2
on

equipment. 3
1
ly

force.
Compress spring. Use compressor assembly (1).

Remove retainer ring (2) from shaft assembly (3).
g00912672
FIG. 317
79033095 C Rev. 03-197

FIG. 318: Remove retaining ring (1), spacer ring (2),
balance seal assembly (3), spring (4) and piston (5) from
shaft assembly (6). 1 2
3 4
5
6
T053005010
FIG. 318
FIG. 319: Remove seals (1) from piston (2).
Fo
1
2
r in
te
1
rn
T053105001
FIG. 319
al
FIG. 320: Remove retaining ring (1), plate (2), and

friction disc (3).
u
2 1
se
3
on
ly
T060105001
FIG. 320
FIG. 321: Remove bolts (1), washers (2), springs (3),
and spacers (4) from reaction plate (5). Remove reaction 1
plate from housing.
5 3
2
T060105002
FIG. 321
03-198 79033095 C Rev.

FIG. 322: Install slide hammer puller (1) to remove race
(2).
1
2
Fo
g00886886
FIG. 322
FIG. 323: Remove race (1) and three slugs (2) from
r
housing.
in
2
te
rn
1
al
T053105004
u
FIG. 323
se
on
ly
79033095 C Rev. 03-199

POWER TAKE-OFF (PTO) ASSEMBLY
FIG. 324: Rotate housing 180 degrees. Install slugs (1)
in housing.
Lower temperature of bearing race (2). Install race in
housing. 1
T053105004
FIG. 324
FIG. 325: Install reaction plate (1) to housing with spacer
(2), spring (3), washer (4) and bolt (5). 5
Fo
1 3
r
4
in
2
te
rn
T060105002
FIG. 325
al
FIG. 326: Install disc (1), plate (2), and retaining ring (3)
in housing.
2 3
u se
1
on
ly
T060105001
FIG. 326
FIG. 327: Install seals (1) on piston (2).
NOTE: Some models may only have two seals.
1
2
T053105001
FIG. 327
03-200 79033095 C Rev.

FIG. 328: Slide piston (1) over shaft assembly (2).
Position spring (3) and seal assembly (4) around shaft 5 4
and install spacer ring (5).
3 1
T060405001
FIG. 328
FIG. 329: Use compressor assembly (1). Install retaining
ring (2) on shaft assembly (3).
2
Fo
3
r
1
in
te
rn
al
g00912672
FIG. 329
u
FIG. 330: Install plates (1) and friction discs (2) to shaft
se
assembly (3). Install retaining ring (4).

2 4
NOTE: There are 6 sets of discs and plates.
on
1
ly
T053005009
FIG. 330
79033095 C Rev. 03-201

FIG. 331: Install thrust disc (1), bearings (2), bearing (3)
and end plate (4), on shaft assembly (5). 3 2
1
4
T053005008
FIG. 331
Fo
FIG. 332: Install gear assembly (1) and thrust washer (2)
to shaft assembly (3).
5
Raise temperature of bearing (4) to 107 degrees C (250
r
degrees F) with an oil bath heater or an oven. Do not use 4

a torch. Install bearing on shaft assembly. Install ring
2
in
carrier (5) after bearing cools.
1
te
rn
al
3
u
FIG. 332
se
FIG. 333: Install seals (1) and (2) on shaft assembly (3).
2
on
1
3
ly
T053005006
FIG. 333
03-202 79033095 C Rev.

FIG. 334: Install gear (1) on shaft (2).
Raise temperature of cones (3) and (4) to 107 degrees C 3
(250 degrees F) with a oil bath heater or an oven. Do not
use a torch. Install cones on shaft.
1
4
T052905009
FIG. 334
Fo
FIG. 335: Install gear (1) and shaft (2) into housing.
2
1
r in
te
rn
al
T052905007
u
FIG. 335
se
FIG. 336: Install eyebolt (1). Install clutch assembly (2) in

housing (3). Remove eyebolt.
1
2
on
ly
g00912657
FIG. 336
79033095 C Rev. 03-203

FIG. 337: Lower temperature and install bearing races
(1) in bearing carrier (2).
2
1
T052905006
FIG. 337
FIG. 338: Position bearing carrier (1) on housing, as
shown. 2
Secure bearing carrier to housing with bolts (2) and
Fo
washers. 1
r in
te
rn
T052905005
al
FIG. 338
FIG. 339: If necessary, install ring (1) in tube assembly
(2). Center tube assembly over hole. Secure tube
u
3
assembly with bolt (3).
se
2
on
1
ly
T052905003
FIG. 339
03-204 79033095 C Rev.

FIG. 340: Install cage (1), bolts (2), and plugs (3) without
seals.
2 2
T060505001
FIG. 340
FIG. 341: Bearing Clearance Adjustment
Position dial indicator (1) on shaft. Measure bearing
clearance. Bearing clearance should be -0.04 to 0.06 mm 1
Fo
(-0.0015 to 0.0025 inch). Use shims to adjust bearing

clearance.
r in
te
rn
al
00909035
FIG. 341
u
FIG. 342: Remove cage (1) from housing. Install seals

(2) and shims (3). Install cage in housing. Secure cage to
se
housing with bolts (4) and washers.

NOTE: Some models may only have one seal.
1
2
on
3
ly
T060505003
FIG. 342
79033095 C Rev. 03-205

FIG. 343: Install sight gauge (1) with bolts (2).
Install power take-off.
NOTE: Refer to Power Take-Off Installation section for 2
more information.
1
T060505004
FIG. 343
Fo
r in
te
rn
al
u se
on
ly
03-206 79033095 C Rev.

POWER TAKE-OFF (PTO) INSTALLATION
FIG. 344: Install link brackets (1) to PTO (2).
NOTE: The weight of PTO is approximately 160 kg (350 1
lb).
2
Fo
00904327
FIG. 344
r
FIG. 345: Install M16 x 2 50mm guide bolts (1) to guide

PTO into position. Install bolts (2) on PTO. Remove guide
in
bolts and install fastener bolts. Tighten all bolts.

te
1 2
rn
al
u se
T060505005
FIG. 345
FIG. 346: Install shield (1) with three bolts with washers
on
(2). 1
2
ly
2
2
P111305011
FIG. 346
79033095 C Rev. 03-207

FIG. 347: Install hydraulic lines (1).
Install three-point hitch (if equipped).
NOTE: Refer to Three-Point Hitch Installation section for
more information. 1
P111305010
FIG. 347
Fo
r in
te
rn
al
u se
on
ly
03-208 79033095 C Rev.

SERVICE BRAKE REMOVAL
Remove final drive.
NOTE: Refer to Final Drive Removal section for more
information.
Open brake purge valve to remove residual pressure for
service brakes.
FIG. 348: Install four M10 x 1.5mm forcing bolts (1) to
reaction plate (2).
2
Fo
1
r in
te
rn
T050205005
FIG. 348
al
FIG. 349: Mark differential housing (1) and service brake

reaction plate (2) for proper positioning during
reassembly.
u
1
2
se
on
T050205006
ly
FIG. 349
FIG. 350: Remove bolts (1) and use forcing bolts to force
reaction plate (2) off.
T050205004
FIG. 350
79033095 C Rev. 03-209

FIG. 351: Pull out reaction plate (1) using pusher bolts.
1
T050205007
FIG. 351
FIG. 352: Remove plug (1), coned spring (2), bushing
(3), and spring pin (4) from reaction plate (5).
Fo
r
4
3 2 1
in
5
te
T050205008
FIG. 352
rn
FIG. 353: Remove friction disc (1), plate (2), and friction
disc (3). 1
al
u se
3
on
2
T050305001
FIG. 353
ly
FIG. 354: Compress retaining ring (1) that secures brake

hub (2). 2
T050305002
FIG. 354
03-210 79033095 C Rev.

FIG. 355: Remove brake hub (1), retaining ring (2) and
thrust disc (3). 1
2
NOTE: Brake hub must be removed to remove service
brake housing.
3
T050305003
FIG. 355
FIG. 356: Install three M30 X 150mm guide studs (1).
Fo
r
1
in
te
rn
T050305004
al
FIG. 356
u se
on
ly
79033095 C Rev. 03-211

FIG. 357: Install three M36 X 150mm lifting bolts (1) into
holes.
T050305005
FIG. 357
FIG. 358: Remove bolt (1). Use two people or a suitable
Fo
lifting device to remove service brake housing (2).

NOTE: The weight of service brake housing is 2
r in
1
te
rn
T050305006
al
FIG. 358
FIG. 359: Separate piston (1) from service brake
housing (2). Remove seals (3). 1
u
Remove dowels (4), if necessary.

se
NOTE: O-ring seals, gaskets, and seals should always

be replaced. A used O-ring may not have same
sealing properties as a new O-ring seal. A
reconditioning procedure should not be 3
on
degraded because of a low cost component such

as an O-ring seal or a gasket. Use O-Ring 4
Assembly Compound during assembly
ly
procedure.
2
T050305007
FIG. 359
03-212 79033095 C Rev.

SERVICE BRAKE INSTALLATION
FIG. 360: Use O-Ring Assembly Compound to install
one O-ring seal (1) into service brake housing (2) and one 4
O-ring seal (3) onto piston (4). Install dowels (5). Install
piston. The piston must be installed squarely. This will
prevent cutting seals
3
NOTE: O-ring seals, gaskets, and seals should always
be replaced. A used O-ring may not have same
sealing properties as a new O-ring seal. A
reconditioning procedure should not be 5
degraded because of a low cost component such 1
as an O-ring seal or a gasket. Use O-Ring
Assembly Compound during assembly
procedure.
2
T050305007
Fo
FIG. 360
FIG. 361: Install M36 X 150mm guide bolts (1) to aid in
installation of service brake housing. Use two people or a
r
suitable lifting device to install service brake housing.

in
te
1
rn
al
u
T050305008
se
FIG. 361
FIG. 362: Install service brake housing (1) with bolt (2).
NOTE: The weight of service brake housing is
on

Tighten bolt to 107 Nm (79 lbf ft).
ly
T050305006
FIG. 362
79033095 C Rev. 03-213

FIG. 363: Remove three M36 X 150mm lifting bolts (1)
into holes.
T050305005
FIG. 363
FIG. 364: Install three M30 X 150mm guide studs (1).
Fo
r in
1
te
rn
al
T050305004
u
FIG. 364
se
FIG. 365: Install thrust disc (1). Install retaining ring (2)
onto carrier. Compress retaining ring and install brake hub 3
(3). 2
NOTE: Inspect engagement of retaining ring into brake
on
hub and planetary carrier.

ly
1
T050305003
FIG. 365
03-214 79033095 C Rev.

FIG. 366: Install friction disc (1), plate (2) and friction
disc (3). Remove installation guide pins. 3
NOTE: Use care to align brake hub with friction discs.
2
T050305001
FIG. 366
FIG. 367: If a new reaction plate is installed, install
spring pin (1), bushing (2), coned spring (3), and plug (4)
in reaction plate (5). Tighten plug to 100 to 140 Nm (74 to
104 lbf ft).
Fo
NOTE: The spring pin should be installed into bushing

first. The end of spring pin should be flush with
large end face of bushing.
r
1
2 3 4
in
5
te
T050205008
FIG. 367
rn
FIG. 368: Install reaction plate (1).

al
u se
1
on
T050205007
FIG. 368
ly
FIG. 369: Align mark on service brake reaction plate (1)

with mark on differential housing (2).
2
1
T050205006
FIG. 369
79033095 C Rev. 03-215

FIG. 370: Install reaction plate (1). The threaded holes
should align with dowel pins (not shown).
Tighten bolts (2) in an even pattern. Plate must fit evenly
on dowels. Tighten bolts to 460 to 600 Nm (340 to 444 lbf
ft).
Install final drives. 1
NOTE: Refer to Final Drive Installation section for more
information. 2
Connect brake tube assemblies.
Test service brakes after repair procedures are complete. T050205004
NOTE: Refer to Systems Operation/Testing and FIG. 370

Adjusting for Steering and Brakes for machine
that is being serviced.
Fo
r in
te
rn
al
u se
on
ly
03-216 79033095 C Rev.

SERVICE BRAKE CABLE ADJUSTMENT
1 2 6
3 7
4
5 8
Fo
r in
te
rn
L811003
al
FIG. 371
FIG. 371: Perform following procedure if brake pedal has 5. Check pedal in cab for free play. Adjust cable more if
u
too much play before resistance is felt. To get better necessary.

performance from service brake system, pedal should
se
6. Start machine and check service brake pressure. Be

have between 0 and 12.7 mm (0 and 0.5 in) of arc travel
sure that when releasing service brake pedal
before firm resistance is felt.
pressure in brake system returns to approximately 34
1. Loosen forward nut (1) on cable end. kPa (5 psi).
on
2. Loosen aft nut (2) to within a 6.35 mm (0.25 in) of Additional adjustments if necessary:
cable conduit end fitting (3) (conduit end fitting is not
If there is not enough adjustment available with conduit
threaded on last 6.35 mm (0.25 in).
ly
end nuts to create a firm pedal, further adjustments can

3. Pull forward on cable assembly to create force on be made in linkage. The cable yoke (6) may be threaded
brake valve through lever arm (4) and input stem (5). on to cable end fitting (7) further as long it is not causing
While in this position, thread aft nut (2) forward to interference with cable end fitting (7) and lever arm (4).
within 3.175 mm (0.125 in) of bracket face. The stem yoke (8) may also be adjusted by loosening it
out to be even with end of input stem (5).
4. Thread forward nut (1) up to forward face of bracket
and tighten nut to 34 Nm (25 lbf ft) max. This will take
slack out of cable.
79033095 C Rev. 03-217

PARKING BRAKE DISASSEMBLY
Remove steering differential.
NOTE: Refer to Steering Differential Removal section for
more information.
FIG. 372: Disconnect and remove tube assembly (1).
Remove bolts (2) evenly and remove end plate (3). 2
NOTE: The brake is spring applied.
m
Fo

equipment.
1
3
r
T052305001
in
FIG. 372
FIG. 373: Remove discs (1) and plates (2).

te
1 2
rn
al
u se
T052405001
FIG. 373
on
FIG. 374: Remove coupling (1) and clutch hub (2).
2
ly
T052405002
FIG. 374
03-218 79033095 C Rev.

FIG. 375: Remove retaining ring (1) and (2). Separate
coupling (3) from clutch hub (4). 3 4
2
1
T052405003
FIG. 375
FIG. 376: Remove bolts (1) and remove piston housing
(2). 1
Fo
r in
te
2
T052505001
FIG. 376
rn
FIG. 377: Remove Bellville springs (1).

al
u se
on
1 T052505003
FIG. 377
ly
FIG. 378: Cross section of Bellville springs.

Springs should contact each other at center (1) and 2
separated at outer diameter (2) of spring.
NOTE: Take special notice of the orientation of Bellville
spring as they must be installed as shown for
proper park brake operation. 1
T022705017
FIG. 378
79033095 C Rev. 03-219

FIG. 379: Remove O-ring (1) from rear of piston
housing.
T052905001
FIG. 379
FIG. 380: Remove dowels (1) from piston housing (2).
Remove piston (3) and remove seals (4).
1
Fo
2
r in
4
3
te
T052505002
FIG. 380
rn
FIG. 381: Measure and record pinion rolling torque.

al
Use special tooling part number 225-4125 to loosen and

remove locknut (1).
Disassemble Steering Differential. 1
u
NOTE: Refer to Steering Differential Disassembly for

se
more information.
on
T051405003
FIG. 381
ly
FIG. 382: Install two 12mm x 200mm T-bar bolts (1).
1
T051505004
FIG. 382
03-220 79033095 C Rev.

FIG. 383: Install T-bar (1) and apply pressure to pinion
shaft.
T051505005
FIG. 383
Fo
FIG. 384: Remove pinion (1) and bearing.

r
1
in
te
rn
T051405004
al
FIG. 384
FIG. 385: Remove two bolts (1). Install forcing bolts to
remove spring plate (2).
u se
2
on
1
ly
T051505006
FIG. 385
FIG. 386: Remove bearing (1) from spring plate (2).
2
T051505007
FIG. 386
79033095 C Rev. 03-221

FIG. 387: Remove bearing race (1) from spring plate (2).
1
2
T051505002
FIG. 387
Fo
r in
te
rn
al
u se
on
ly
03-222 79033095 C Rev.

PARKING BRAKE ASSEMBLY
replacement.
FIG. 388: Lower temperature of bearing race (1). Install
bearing race in spring plate (2).
1
Fo
2
r
T051505002
in
FIG. 388
FIG. 389: Install O-ring (1) to rear of spring plate (2).
te
rn
1
al
2
u se
T052905002
FIG. 389
on
FIG. 390: Install spring plate with two bolts (2). Tighten
bolts to 61 Nm (45 lbf ft).
ly
1
2
T051505015
FIG. 390
79033095 C Rev. 03-223

FIG. 391: Use two people to install pinion (1) with
bearing.
T051405004
FIG. 391
FIG. 392: Raise temperature of bearing (1) to 107
degrees C (250 degrees F) with a oil bath heater or an 1
oven. Do not use a torch.
Fo
r in
te
T051505017
FIG. 392
rn
FIG. 393: Install nut (1).

1
al
u se
on
T051505016
FIG. 393
ly
FIG. 394: Use special tooling part number 225-4125 (1)

to install nut. Tighten nut to a pinion rolling torque of 5.2 to 1
6.2 Nm (45 to 55 lbf in) (if both bearing are new).
NOTE: If bearings are used, set to recorded bearing
torque recorded during disassembly. Never mix
old bearings and new bearings.
T051605001
FIG. 394
03-224 79033095 C Rev.

FIG. 395: Install seals (1) to piston (2). Install dowels (3)
to piston housing (4) and install piston to piston housing.
3
NOTE: Install ball plug and small dowels.
1
2
T052505002
FIG. 395
FIG. 396: Install bellville spring (1) on spring plate (2)
cupped down. Install bellville spring (3) cupped up.
2
Fo
r in
te
3 1 T052505003
FIG. 396
rn
FIG. 397: Install O-ring (1) to rear of piston housing.

al
u
1
se
on
T052905001
FIG. 397
ly
FIG. 398: Install piston housing (1) with bolts (2). Tighten
bolts to 61 Nm (45 lbf ft). 2
1
T052505001
FIG. 398
79033095 C Rev. 03-225

FIG. 399: Connect coupling (1) on clutch hub (2). Install
retaining ring (3) and (4). 1 2
4
3
T052405003
FIG. 399
FIG. 400: Install coupling (1) and clutch hub (2).
2
Fo
1
r in
te
T052405002
FIG. 400
rn
FIG. 401: Inspect friction discs prior to installation. If any

friction disc fails to measure a minimum thickness of 6.90 1
al
mm (0.27 in) all friction discs must be replaced. Apply oil 2

to friction discs prior to installation.
Install discs (1) and plates (2).
u
NOTE: When installing clutch hub. Align tabs on clutch

se
hub.
on
T052405001
FIG. 401
ly
FIG. 402: Install end plate (1) and install bolts (2).
Tighten bolts evenly for spring applied brakes. Tighten 2
bolts to 61 Nm (45 lbf ft). Connect tube assembly (3).
Install steering differential.
NOTE: Refer to Steering Differential Installation section
3
1
T052305001
FIG. 402
03-226 79033095 C Rev.

PARK BRAKE CABLE ADJUSTMENT
PROCEDURE
FIG. 403: Parking brake (1) is located left of seat.
1
R012805005
FIG. 403
Fo
FIGS. 404–405: The park brake cable (1) will be adjusted

at park brake valve. The valve is bolted to powertrain 2
inside of left-hand side frame rail. 1
r
Adjust upper nut (2) and lower nut (3) to obtain clearance
in
of 0.2 to 0.8 mm (0.007873992 to 0.03149597 in) (A) 3

shown at tee handle.
te
rn
al
R021705001
FIG. 404
u se
on
ly
R012805004
FIG. 405
79033095 C Rev. 03-227

FINAL DRIVE REMOVAL
Drain powertrain oil into a suitable container for storage or
disposal.
Left-Hand Final Drive Removal

Remove left-hand side undercarriage.
FIG. 406: Remove powertrain guards (1).
NOTE: Refer to Powertrain Guard Removal section for
more information.
1
Fo
r
P082012003
in
FIG. 406
FIG. 407: Remove Hydraulic Filter Assembly
te
Hydraulic filter (1) is located on left-hand side of machine

and in front of drive axle.
rn
al
1
u se
P091012008
FIG. 407
on
FIG. 408: Disconnect hydraulic hose (1) from T4-port.

Disconnect hydraulic hose (2) from T5-port.
ly
1
3
2
P091112001
FIG. 408
03-228 79033095 C Rev.

Disconnect hydraulic hose (2) from T1-port. 3
4
Disconnect hydraulic hose (3) from H1-port.
1
P091112002
FIG. 409
Disconnect hydraulic hose (2) from C1-port.
Fo
4 3
r
2
in
1
te
P091112003
FIG. 410
rn
FIG. 411: Disconnect wiring harness (1) from pressure

sensors (2).
al
1
u
2
se
on
P091112004
FIG. 411
ly
FIG. 412: Disconnect vent hose (1).
P091112005
FIG. 412
79033095 C Rev. 03-229

FIG. 413: Remove three bolts (1) holding side guard (2)
to filter mount. Remove side guard.
2
1
P091112006
FIG. 413
FIG. 414: Remove four bolts (1) holding filter assembly
to mounting bracket (2). Remove filter assembly.
Fo
1 2
r in
te
P091112007
FIG. 414
rn

and disconnect hose support bracket (2) from bracket (3).
al
1
u
2
se
3
on
T050205002
FIG. 415
ly
FIG. 416: Loosen and remove four bolts with washers

(1) and remove bracket (2) from final drive assembly.
2
1
T050205001
FIG. 416
03-230 79033095 C Rev.

FIG. 417: Disconnect tube assembly (1) from final drive.
T040605003
FIG. 417
FIG. 418: Disconnect tube assembly (1) from top of final
drive.
Fo
1
r in
te
T040605005
FIG. 418
rn
FIG. 419: Loosen and remove two bolts (1) and install
two guide pins. Special tooling part number 7x-2578. 1
al
NOTE: If guide pins are not used as recommended,

internal component damage may occur.
u se
on
T040605004
FIG. 419
ly
FIG. 420: Remove plug and install lifting eye (1) to final
drive. Repeat procedure for opposite side of final drive
housing.
T040605006
FIG. 420
79033095 C Rev. 03-231

FIG. 421: Install an appropriate lifting device to lifting
eyes (1). Remove remaining retaining bolts (2).
1
NOTE: The approximately weight of final drive is 660 kg
(1455 lb).
Remove plugs (3) covering pusher bolt hole location.
3
2
T040605007
FIG. 421
FIG. 422: Install M12x1.75x140 pusher bolts (1) to both
sides of final drive housing.
Fo
1
r in
te
T040605008
FIG. 422
rn
FIG. 423: Tighten pusher bolts (1) evenly until final drive
is free from mating surface.
al
u se
1
on
T040605009
FIG. 423
ly
FIG. 424: Carefully remove final drive assembly (1).

IMPORTANT: Damage may occur if weight of final drive
is not allowed to rest on sun gear. 1
T040605010
FIG. 424
03-232 79033095 C Rev.

FIG. 425: Set final drive (1) aside at a safe and
appropriate location.
T040605011
FIG. 425
FIG. 426: Install two M12x1.75x140 pusher bolts (1) in
ring gear (2). Use an appropriate lifting device to support 1
ring gear. 2
Fo
NOTE: The approximately weight of ring gear is 90 kg

(199 lb).
r in
te
rn
1
T040605012
al
FIG. 426
FIG. 427: Tighten pusher bolts evenly until ring gear (1)
is free from mating surface.
u se
on
1
ly
T040605013
FIG. 427
79033095 C Rev. 03-233

FIG. 428: Remove ring gear (1) and set aside at a safe
location.
1
T040605014
FIG. 428
Fo
r in
te
rn
al
u se
on
ly
03-234 79033095 C Rev.

Right-Hand Final Drive Removal
Remove right-hand side undercarriage.
FIG. 429: Remove powertrain guards (1).
NOTE: Refer to Powertrain Guard Removal section for
more information.
1
Fo
T040605015
FIG. 429
FIG. 430: Remove tube assembly (1) from final drive
assembly (2).
r
2
in
1
te
rn
al
T040605016
FIG. 430
u
FIG. 431: Remove tube assembly (1) from top of final

se
drive assembly (2).

on
1 2
ly
T040605017
FIG. 431
79033095 C Rev. 03-235

FIG. 432: Remove fitting (1) from top of final drive
assembly.
T040605018
FIG. 432
FIG. 433: Loosen and remove two bolts (1) where guide
pins will be installed.
1
Fo
r in
te
T040605019
FIG. 433
rn
FIG. 434: Install guide pins (1) where bolts were

previously installed. Special tooling part number 7x-2578. 1
al
Remove plugs (2) and install M12x1.75x140 pusher bolts.

NOTE: If guide pins are not used as recommended,
u
internal component damage may occur.

se
2
on
T040605020
FIG. 434
ly
FIG. 435: Remove plug and install lifting eye (1) to final
drive. Repeat procedure for opposite side of final drive
housing.
Install an appropriate lifting device to lifting eyes and
remove remaining retaining bolts.
(1455 lb).
Tighten pushing bolts evenly until final drive is free from
mating surface. 1
T040605006
FIG. 435
03-236 79033095 C Rev.

FIG. 436: Carefully remove final drive assembly (1).
IMPORTANT: Damage may occur if weight of final drive 1
is not allowed to rest on sun gear (2).
2
T040605021
FIG. 436
FIG. 437: Set final drive (1) aside at a safe and
appropriate location.
Fo
r in
1
te
T040605022
FIG. 437
rn
FIG. 438: Install two M12x1.75x140 pusher bolts in

pusher bolt holes (1). Use an appropriate lifting device to 1
al
support ring gear (2).

(199 lb).
u
Tighten pusher bolts evenly until ring gear is free from

2
se
mating surface.
1
on
T040605023
FIG. 438
ly
FIG. 439: Remove ring gear (1) and set aside at a safe
location.
1
T050105003
FIG. 439
79033095 C Rev. 03-237

FIG. 440: Remove dowels (1).
T050105002
FIG. 440
Fo
r in
te
rn
al
u se
on
ly
03-238 79033095 C Rev.

FINAL DRIVE DISASSEMBLY
Remove final drive.
information.
begin disassembly procedure, exterior of
Fo

containing fluids.
r

in
and mandates.
FIG. 441: Attach link bracket (1) to axle housing (2). Use
te
bolt (3) and nut to secure link bracket.

rn
1
al
3
u se
2
on
T042605001
FIG. 441
FIG. 442: Bolt support stand (1) to a suitable area on
ly
floor.
2
NOTE: Support stand special tooling part number
FT2768.
Use link bracket, chains (2) and a suitable lifting device to
position final drive (3) in support stand as shown.
T042505001
FIG. 442
79033095 C Rev. 03-239

FIG. 443: Install axle rolling torque bracket (1).
1
NOTE: Axle rolling torque bracket special tooling
Caterpillar part number 224-8960.
NOTE: Support the weight of the axle housing, protect
seals and bearings.
Measure and record rolling torque. This torque is seal
drag torque plus used bearing torque.
g00907599
FIG. 443
FIG. 444: Loosen and remove bolt (1) with washer and
Fo
thrust washer (2).

1 2
r in
te
rn
T042605007
al
FIG. 444
FIG. 445: Remove snap ring (1) with snap ring pliers.
NOTE: Snap ring will stay in carrier.
u
1
se
on
ly
T042605002
FIG. 445
03-240 79033095 C Rev.

FIG. 446: Attach link brackets (1), chains, and a suitable
lifting device to planetary carrier (2). Remove planetary
carrier. 1
NOTE: The weight of planetary carrier is approximately 2
191 kg (420 lb).
g00907451
Fo
FIG. 446
FIG. 447: Install a 16 mm lifting eye to planetary shaft (1)
and attach an appropriate lifting device. 1
r
NOTE: Mark planetary shafts and carrier bores to ensure

that the shaft removed is reinstalled in it’s original
in
4
carrier bore.
3
te
Remove bolt (2) and retaining pin (3) from carrier (4). 2
Remove planetary shaft from carrier.
NOTE: Some models may have a bolt instead of a
rn
retaining pin. If a bolt is used the carrier should

be updated to the retaining pin design. Refer to
al
service bulletin AX0006 for more information.

T042605003
FIG. 447
u
FIG. 448: Remove thrust washers (1) and planet gear

(2) from planetary carrier (3). 1
se
Remove needle bearings (4) and thrust bearing race (5)

from planet gear. 4
NOTE: Needle bearings should be inspected for damage
5
on
and wear. If damage or wear is found needle

bearings should be replaced as a complete set.
Remove remaining planetary shafts and gears from 2
ly
carrier.
NOTE: Keep all components in matched sets. 4
1 3
T042605004
FIG. 448
79033095 C Rev. 03-241

FIG. 449: Remove snap ring (1) from carrier (2).
1
2
T042605005
FIG. 449
FIG. 450: Install spanner wrench assembly (1) and
loosen spanner nut.
NOTE: Spanner wrench assembly special tooling
Fo
Caterpillar part number 224-8958.

r
1
in
te
rn
T042605006
al
FIG. 450
FIG. 451: Remove spanner nut (1).
u
1
se
on
ly
T042605008
FIG. 451
03-242 79033095 C Rev.

FIG. 452: Attach link bracket (1), chains, and a suitable
lifting device to axle housing (2).
1
Remove axle housing from axle shaft (3). 2
NOTE: The weight of axle housing is approximately 204
kg (450 lb).
3
Fo
g00907459
r
FIG. 452
in
FIG. 453: Remove bearing (1) from housing (2).

te
1
2
rn
al
u se
T042605010
on
FIG. 453
FIG. 454: Attach slide hammer (1) to bearing cups (2).
ly
T042605011
FIG. 454
79033095 C Rev. 03-243

FIG. 455: Remove bearing cups (1) from axle housing
(2).
3
Remove dowels (3).
1
2
T042605012
FIG. 455
FIG. 456: Remove Duo Cone seals (1) from axle shaft
Fo
(2).
1
r
2
in
te
rn
al
T042605013
u
FIG. 456
FIG. 457: If bearing has damage or excessive wear
se
attach bearing puller (1) to bearing cone (2) and use 1

driver group (3) with bearing puller to remove bearing
cone and spacer (4) from axle shaft. The bearing cone
and spacer can be removed at same time.
on
ly
3
2
4 g00907543
FIG. 457
03-244 79033095 C Rev.

FINAL DRIVE ASSEMBLY
assembly, thoroughly clean all parts in cleaning
fluid. Allow parts to air dry. Do not use wiping
cloths or rags to dry parts. Lint may be deposited
on parts which may cause trouble. Inspect all
parts. If any parts are worn or damaged, use new
parts for replacement. Dirt and other
contaminants can damage precision component.
Perform assembly procedures on a clean work
NOTE: Check O-ring seals and shim pack for wear or for
damage. Replace components, if necessary.
Some models may not have shim pack.
FIG. 458: Bolt support stand to a suitable area on floor.
Position axle shaft (1) in support stand.
Fo
Raise temperature of spacer (2). Firmly seat spacer

against shoulder of axle shaft. Allow spacer to cool before 2
proceeding.
r in
1
te
rn
T043005001
FIG. 458
al
FIG. 459: Raise temperature of bearing cone (1) using

an oil bath heater or oven. Do Not use a torch. The
maximum allowable temperature is 150 degrees C (302 1
u
degrees F).
se
Position bearing cone on axle shaft (2).
2
on
ly
T043005002
FIG. 459
FIG. 460: Clean inner face of spacer. Install Duo Cone
seals (1) on spacer (2).
NOTE: Refer to Duo Cone Seals Installation section for 1
more information.
NOTE: Use a cleaner, such as isopropyl alcohol, that is
not a petroleum based cleaner.
2
T043005003
FIG. 460
79033095 C Rev. 03-245

FIG. 461: Install bearing cup (1) in axle housing (2).
Install hollow dowels (3). 3
1
2
T042605012
FIG. 461
Fo
FIG. 462: Attach link bracket (A), chains, and a suitable

lifting device to axle housing (1). A
1
NOTE: The weight of axle housing is approximately 204
kg (450 lb).
r
Clean inner face of housing.

in
NOTE: Use isopropyl alcohol cleaner.

te
Install Duo-cone seal to axle housing.

NOTE: Refer to Duo-Cone Seal installation section for
rn
more information.
Be sure not to contact seal or let seal contact anything.
al
Position axle housing over axle (2) and lower within 150
mm (6 inch). Coat bearing with powertrain oil and lower 2
axle housing.
u se
g00907459
FIG. 462
on
FIG. 463: Heat bearing cone (1) and install bearing cone
in axle housing (2).
1
ly
T043005004
FIG. 463
03-246 79033095 C Rev.

FIG. 464: Install spanner nut (1) and hand tighten.
NOTE: Support weight of axle housing and protect seals 1
and bearings.
T042605008
FIG. 464
FIG. 465: Install fixture (1) and torque wrench. Rotate
housing a minimum of five times to ensure bearings are 1
seated.
Fo
NOTE: Carrier is not installed as shown in photo.

Use torque wrench to measure rolling torque on housing.
Rotate housing at 3-4 rpm. This is seal drag torque. The
r
torque wrench should be measuring torque at center of

housing. Record seal drag torque “T”. This torque will be
in
in range of 0 to 54 Nm (0 to 40 lb ft).
Gradually tighten spanner nut until torque required to
te
rotate housing at 3-4 rpm equals seal drag torque “T” + 47

to 61 Nm (35 to 45 lbf ft) (if bearings are new) (if bearing
are old, use numbers recorded in disassembly) plus seal
rn
drag 0 to 54 Nm (0 to 40 lb ft). Rotate housing at least 5

revolutions before measuring rotating torque.
al
NOTE: Never mix old bearings and new bearings.

g00907599
FIG. 465
u
FIG. 466: Install snap ring (1) in carrier (2).

se
NOTE: Snap ring must be installed prior to planet gears. 1

2
on
ly
T042605005
FIG. 466
79033095 C Rev. 03-247

FIG. 467: Install needle bearings (1) and thrust bearing
race (2) in planet gear (3). 4
NOTE: Use lithium based grease to aid in needle bearing
installation. 1
Install thrust washers (4) and planet gear in planetary
carrier (5).
2
4 5
T042605004
FIG. 467
FIG. 468: Match the markings that were placed on the
Fo
planetary shaft with the markings that were placed on the 1

planetary shaft bore to make sure that the shaft is
installed to the bore that it was originally removed.
4
r
Install planetary shaft (1) to mount gear (2) in planetary

3
in
carrier (3). Install retaining pin (4) through hole in carrier

and planetary shaft. Apply a small amount of thread 2
locker to bolt (5) and install bolt to secure retaining pin.
te
Repeat procedure for remaining two planetary gears.

NOTE: Some models may have a bolt instead of a
rn
retaining pin. If a bolt is used the carrier should

T042605003
be updated to the retaining pin design. Refer to
FIG. 468
al
service bulletin AX0006 for more information.

FIG. 469: Attach link bracket (1), chains, and a suitable
lifting device to planetary carrier (2).
u
1
Align lock tab on carrier with flat on bearing nut and install
se
planetary carrier. 2
NOTE: The weight of planetary carrier is approximately
191 kg (420 lb).
on
ly
g00907451
FIG. 469
03-248 79033095 C Rev.

FIG. 470: Install snap ring (1) to secure carrier to axle
shaft (2).
1
T050105001
FIG. 470
FIG. 471: Install link bracket (1), chains and a suitable
lifting device to housing (2) and remove axle shaft (3) from
FT-2768 support stand (4), as shown. 1
2
Fo
Place final drive housing onto ground and remove bolt (5)
and nut. Remove link bracket from axle housing.
Install final drive.
r

information.
in
3
te
5
4
rn
al
u se
g00912896
FIG. 471
on
ly
79033095 C Rev. 03-249

FINAL DRIVE INSTALLATION
Right-Hand Final Drive Installation

FIG. 472: Clean mating surfaces of differential and ring
gear. Install dowels (1).
T050105002
FIG. 472
Fo
FIG. 473: Install two guide pins (1) to aid in ring gear and
final drive assembly installation.
NOTE: Guide pins special tooling part number 7x-2578. 1
r in
te
rn
al
T050105004
FIG. 473
FIG. 474: Apply gasket sealant and install ring gear (1)
u
to differential (2).
1
se

(199 lb).
on
2
ly
T050105003
FIG. 474
FIG. 475: Clean mating surfaces of ring gear (1) and
apply gasket sealant to ring gear. Install dowels (2).
2
1
T050105006
FIG. 475
03-250 79033095 C Rev.

FIG. 476: Install lifting eyes (1) to both sides of final drive
housing. Install an appropriate lifting device to lifting eyes.
(1455 lb).
1
T040605006
FIG. 476
FIG. 477: Carefully move final drive assembly (1) into
position on ring gear. 1
IMPORTANT: Damage may occur if weight of final drive
Fo
is not allowed to rest on sun gear (2).

r in
2
te
T040605021
FIG. 477
rn
FIG. 478: Install mounting hardware (1) and remove

guide pins (2).
al
2
u se
1
on
T050105007
FIG. 478
ly
FIG. 479: Tighten bolts (1) in a star shaped pattern to a

range of 800 to 1000 Nm (590 to 738 lbf ft) with a desired
tightness of 900 Nm (664 lbf ft).
1
T040605019
FIG. 479
79033095 C Rev. 03-251

FIG. 480: Install fitting (1) to top of final drive assembly.
T040605018
FIG. 480
FIG. 481: Install tube assembly (1) to top of final drive
assembly (2).
Fo
1 2
r in
te
T040605017
FIG. 481
rn
FIG. 482: Install tube assembly (1) to final drive

assembly (2).
al
2
u
1
se
on
T040605016
FIG. 482
ly
FIG. 483: Install powertrain guards (1).

NOTE: Refer to Powertrain Guard Installation section for
more information.
Install undercarriage.
NOTE: Refer to Undercarriage Assembly Installation
1
T040605015
FIG. 483
03-252 79033095 C Rev.

Left-Hand Final Drive Installation
FIG. 484: Clean mating surfaces of differential and ring
gear. Install dowels (1).
T050105008
FIG. 484
FIG. 485: Install two guide pins (1) to aid in ring gear and
final drive assembly installation.
Fo
NOTE: Guide pins special tooling part number 7x-2578. 1

r in
te
rn
T050105004
FIG. 485
al
FIG. 486: Apply gasket sealant and install ring gear (1)
to differential (2). 1
u
(199 lb).
se
2
on
ly
T050105009
FIG. 486
FIG. 487: Clean mating surfaces of ring gear (1) and
apply gasket sealant to ring gear. Install dowels (2).
1
T050105010
FIG. 487
79033095 C Rev. 03-253

FIG. 488: Install lifting eyes (1) to both sides of final drive
housing. Install an appropriate lifting device to lifting eyes.
(1455 lb).
1
T040605006
FIG. 488
FIG. 489: Carefully move final drive assembly (1) into
position on ring gear.
IMPORTANT: Damage may occur if weight of final drive 1
Fo
is not allowed to rest on sun gear.

r in
te
T040605010
FIG. 489
rn
FIG. 490: Install mounting hardware (1) and remove

guide pins (2).
al
2
u se
1
on
T050105007
FIG. 490
ly
FIG. 491: Tighten bolts (1) in a star shaped pattern to a

range of 800 to 1000 Nm (590 to 738 lbf ft) with a desired 1
tightness of 900 Nm (664 lbf ft).
T040605004
FIG. 491
03-254 79033095 C Rev.

FIG. 492: Install tube assembly (1) to top of final drive.
T040605005
FIG. 492
FIG. 493: Install tube assembly (1) to final drive.
Fo
1
r in
te
T040605003
FIG. 493
rn
FIG. 494: Install bracket (1) with four bolts with washers
(2).
al
u se
1
on
2
T050205001
FIG. 494
ly
FIG. 495: Install hose support bracket (1) with bolt and
washer (2) to bracket (3).
2
T050205002
FIG. 495
79033095 C Rev. 03-255

FIG. 496: Install filter assembly (1) to mounting bracket
(2) with four bolts with washers (3).
3 2
P091112007
FIG. 496
FIG. 497: Install side guard (1) with three bolts (2).
Fo
r in
1
2
te
P091112006
FIG. 497
rn
FIG. 498: Install vent hose (1) to side guard.

al
u se
1
on
P091112005
FIG. 498
ly
FIG. 499: Connect wiring harness (1) to pressure

sensors (2).
1
2
P091112004
FIG. 499
03-256 79033095 C Rev.

FIG. 500: Connect hydraulic hose (1) to T3-port.
Connect hydraulic hose (2) to C1-port.
Connect hydraulic hose (3) to C2-port. 3
4
Connect hydraulic hose (4) to H2-port.
P091112003
FIG. 500
Connect hydraulic hose (2) to T1-port. 3
4
Fo

1
r
2
in
te
P091112002
FIG. 501
rn

al
Connect hydraulic hose (2) to T5-port.

u
1
3
se
2
on
P091112001
FIG. 502
ly
FIG. 503: Install powertrain guards (1).

NOTE: Refer to Powertrain Guard Installation section for
more information.
1
P082012003
FIG. 503
79033095 C Rev. 03-257

STEERING DIFFERENTIAL REMOVAL
Remove fuel tanks.
NOTE: Refer to Fuel Tank Removal section for more
information.
Remove final drive.
information.
Remove drawbar.
NOTE: Refer to Drawbar Removal section for more
information.
Remove PTO.
NOTE: Refer to PTO Removal section for more
information.
Fo
Remove three-point hitch.

NOTE: Refer to Three-Point Hitch Removal section for
more information.
r
Remove differential housing.

in
NOTE: Refer to Differential Housing Removal section for

more information.
te
FIG. 504: Remove bolts (1) and clamps. Disconnect

harness assemblies (2) and (3).
rn
1
al
u se
2
on
3
ly
g00910930
FIG. 504
03-258 79033095 C Rev.

FIG. 505: Attach a suitable lifting device to bracket
assembly (1). Remove bolts (2) and remove bracket 2
assembly.
NOTE: The weight of bracket assembly is approximately
130 kg (287 lb).
g00910931
FIG. 505
Fo
FIG. 506: Remove bolts (1) and remove filler tube (2).
1
r in
te
rn
al
2
g00910932
FIG. 506
u
FIG. 507: Disconnect harness assembly (1). Attach a

se
suitable lifting device to bracket assembly (2). Remove

bolts (3) and remove bracket assembly. 1 2
77 kg (170 lb).
on
3
ly
g00910933
FIG. 507
79033095 C Rev. 03-259

FIG. 508: Install support stands (1) under engine and
transmission.
1 g00911437
Fo
FIG. 508
FIG. 509: Attach link brackets (1) and eyebolts (2) to
steering differential (3). 2
r
NOTE: The weight of steering differential is 3

in

1
te
rn
al
u se
T052205001
FIG. 509
on
FIG. 510: Remove EOR manifold block (1).

ly
1
T052205002
FIG. 510
03-260 79033095 C Rev.

FIG. 511: Loosen and remove nine twelve point bolts (1)
from the bottom of differential.
1
T052205003
FIG. 511
FIG. 512: Loosen and remove remaining bolts with
washers (1).
Fo
r
1
in
te
T052205004
FIG. 512
rn
FIG. 513: Install two M20 x 200 mm guide pins (1).

al
u se
1
on
T052205005
FIG. 513
ly
FIG. 514: Install a 14 mm pusher bolt (1) on the left-hand

side of the differential housing.
T052205006
FIG. 514
79033095 C Rev. 03-261

FIG. 515: Install a second 14 mm pusher bolt (1) on the
lower right-hand side of the differential housing.
T052205007
FIG. 515
FIG. 516: Separate the differential housing (1) from
transmission housing using pusher bolts (2).
1
Fo
r in
2
te
T052205009
FIG. 516
rn
FIG. 517: Continue separating until all internal shafts are

disengaged.
al
1
Remove differential housing (1) from transmission and set
securely on blocks.
u se
on
T052205010
FIG. 517
ly
03-262 79033095 C Rev.

STEERING DIFFERENTIAL DISASSEMBLY
Remove right-hand service brake and parking brake (if
necessary).
NOTE: Refer to Service Brake Removal and Parking
Brake Removal section for more information.
NOTE: The differential removal is not required unless
bevel pinion needs to be serviced.
containing fluids.
and mandates.
Fo

r

in
NOTE: Plug all lines, hoses, and tubes. This helps to

prevent fluid loss and helps to keep contaminants
from entering system.
te
NOTE: The service brakes prevents planetaries from

falling out. Keep service brake assembled to
rn
differential if the planetaries are installed.

The steering differential was positioned on a turntable.
al
Use engine stand and adapter plate to support differential

housing. This assembly can be done without engine
stand and adapter plate but with greater difficulty.
u
FIG. 518: Remove thrust disc (1).

se
1
on
ly
T050305009
FIG. 518
79033095 C Rev. 03-263

FIG. 519: Install eyebolt (1) to planetary carrier
assembly (2). Remove planetary carrier assembly from
differential housing (3).
1
Fo 3
g00910485
FIG. 519
FIG. 520: Remove ring gear (1) from planetary (2).
r
Remove lock ring (3) and remove ring gear (4).

in
1
te
2
rn
al
3
4
u se
T050405001
FIG. 520
FIG. 521: Expand retaining ring (1) that secures sun
gear.
on
1
ly
T050405002
FIG. 521
03-264 79033095 C Rev.

FIG. 522: Remove retaining ring (1) and remove sun
gear (2) from carrier (3).
1
T050405003
FIG. 522
Fo
shaft from planetary carrier (3). Remove thrust disc (4), 3
bearing (5), planetary gear (6), and thrust disc (7). 4 1 2
NOTE: Driving spring pin into shaft too far will result in
r
difficult removal.
in
5
te
rn
6
al
7
T050405004
u
FIG. 523
se
FIG. 524: Remove thrust disc (1) and thrust disc (2).
1
2
on
ly
T050405005
FIG. 524
79033095 C Rev. 03-265

gear (2).
1
2
T050405006
FIG. 525
FIG. 526: Remove sun gear (1). Install eyebolt (2).
Fo
Compress retaining ring (3) and remove planetary carrier 1

(4).
NOTE: The weight of planetary carrier is approximately 3
r
40 kg (90 lb). 4
in
te
2
rn
al
u se
g00910527
FIG. 526
8
on
shaft, thrust disc (3), bearing (4), planetary gear (5),

bearing (6), and thrust disc (7) from planetary carrier (8). 6
difficult removal.
ly
5
2
4 1
3
T050405007
FIG. 527
03-266 79033095 C Rev.

FIG. 528: Remove seals (1) and (2) from planetary
carrier (3).
1
3
T050405008
FIG. 528
Fo
FIG. 529: Install eyebolts (1) to gear (2) and remove

gear.
NOTE: Steering motor drive must be removed prior to 1
gear removal.
r in
te
rn
2
al
u se
on
g00910548
ly
FIG. 529
FIG. 530: Rotate housing.
Remove service brakes (1) on left-hand side of machine.
NOTE: Refer to Service Brake Removal section for more
information.
T050405009
FIG. 530
79033095 C Rev. 03-267

FIG. 531: Attach eyebolt (A) to planetary (2). Remove
planetary.
1
NOTE: The weight of planetary is approximately 43 kg
(95 lb).
2
Fo
g00910550
FIG. 531
FIG. 532: Expand retaining ring (1) that secures sun
r
gear.
in
1
te
rn
al
u se
T050405010
FIG. 532
gear (2) from carrier (3).
on
1
3
ly
T050405011
FIG. 533
03-268 79033095 C Rev.

shaft, thrust disc (3), bearing (4), planetary gear (5), 7
bearing (6), and thrust disc (7) from planetary carrier (8).
difficult removal.
8
4 2
1
3 T050405012
FIG. 534
Fo
FIG. 535: Remove seal (1) from planetary carrier (2).

r in
2
te
1
rn
T050705001
al
FIG. 535
FIG. 536: Remove thrust disc (1) and (2).
u
1
se
2
on
ly
T050705002
FIG. 536
79033095 C Rev. 03-269

FIG. 537: Attach eyebolt (1) to shaft (2). Remove shaft
and sun gear.
1 2
Fo
g00910562
FIG. 537
FIG. 538: Remove retaining ring (1), sun gear (2), and
retaining ring (3) from shaft (4).
r
2
in
te
1
rn
3
al
4
u se
T050705003
FIG. 538
FIG. 539: Check and record backlash of bevel gear to
pinion.
on
NOTE: Location of measuring device must be recorded

or marked for proper measurement upon
assembly.
ly
T050705006
FIG. 539
03-270 79033095 C Rev.

FIG. 540: Loosen and remove three allen head bolts (1).
Set bolts aside to be used later as pusher bolts for bevel
gear removal. 1
T050705004
FIG. 540
Fo
FIG. 541: Remove two hex head bolts (1) 180 degrees
apart. Use allen head bolts in hex head bolt location as
pusher bolts.
2
r
Tighten pusher bolts to free bevel gear (2).

1
in
te
rn
al
T050705005
u
FIG. 541
se
FIG. 542: Attach eyebolt (1) to bevel gear (2). Remove

bevel gear and shims (3). Record number of removed 1 2
shims.
on
3
ly
g00910571
FIG. 542
79033095 C Rev. 03-271

FIG. 543: Remove bolts (1), ring gear (2), shims (3) and
bearing (4) from housing (5). 1
T051605003
FIG. 543
FIG. 544: Attach eyebolt (1) to bevel gear (2). Remove
Fo
bevel gear from housing (3).

1
r
3
in
te
2
rn
al
u se
g00910590
FIG. 544
FIG. 545: Remove bearing cone (1) from bevel gear
on
shaft (2). Remove bolts (3) with washers and remove

bevel gear shaft from bevel gear (3). Remove bearing cup 1
(4) from bevel gear.
3
NOTE: If bevel gear shaft bolts do not contain washers
ly
the bevel gear shaft should be reworked per 2

service bulletin AX0011.
Refer to service bulletin AX0011 for more
information.
4
T050705009
FIG. 545
03-272 79033095 C Rev.

FIG. 546: Remove bearing cup (1) from housing (2).
Remove retaining ring (3) and remove bearing (4).
1
3
T050705010
FIG. 546
Fo
FIG. 547: Remove bolts (1) and remove plate (2).
2
r in
te
1
rn
al
T051405001
u
FIG. 547
se
FIG. 548: Remove bolt (1) and the clamp. Remove tube
assembly (2).
1
Clean Elevated Oil Reservoir (EOR).
on
ly
T051405002
FIG. 548
79033095 C Rev. 03-273

FIG. 549: Measure and record pinion rolling torque.
Use special tooling part number 225-4125 to loosen and
remove locknut (1).
1
T051405003
FIG. 549
FIG. 550: Install two 12mm x 200mm T-bar bolts (1).
Fo
r in
1
te
T051505004
FIG. 550
rn
FIG. 551: Install T-bar (1) and apply pressure to pinion

shaft.
al
1
u se
on
ly
T051505005
FIG. 551
FIG. 552: Remove pinion (1) and bearing.
T051405004
FIG. 552
03-274 79033095 C Rev.

FIG. 553: Remove bearing (1) from pinion (2).
T051505003
FIG. 553
FIG. 554: Remove two bolts (1). Install forcing bolts to
remove spring plate (2).
Fo
2
r
1
in
te
T051505006
FIG. 554
rn
FIG. 555: Remove bearing (1) from spring plate (2).

Remove O-rings (3) from spring plate. 3
al
1
u se
2
on
T051505007
FIG. 555
ly
FIG. 556: Remove bearing race (1) from spring plate (2).
1
2
T051505002
FIG. 556
79033095 C Rev. 03-275

FIG. 557: Remove retaining ring (1) and retainer plate
(2).
1
2
T051505008
FIG. 557
FIG. 558: Remove bearing cup (1) and shims (2).
2 1
Fo
r in
te
T051505009
FIG. 558
rn
FIG. 559: Check Valve Removal

2
m
al

3
u

equipment.
se
Follow recommended procedure and use all 4

force.
5
on
Remove bolts (1), plug (2), flange (3), spring (4), and
check valve (5). Remove O-ring from flange.
ly
T051505010
FIG. 559
FIG. 560: Remove bolts (1) and remove tube assembly
(2).
1
FIG. 560
03-276 79033095 C Rev.

FIG. 561: Remove bolts (1) and remove housing (2).
2
T051505012
FIG. 561
FIG. 562: Remove bolts (1), plug (2), cover (3), seal (4),
and screen (5) from housing (6). 1
2 3
Fo
4
r in
5
te
6
rn
T051505013
FIG. 562
al
u se
on
ly
79033095 C Rev. 03-277

STEERING DIFFERENTIAL ASSEMBLY
replacement.
The steering differential was positioned on a turntable.
Use an engine stand to support differential housing. This
assembly can be done without adapter plate but with
greater difficulty
FIG. 563: Install screen (1) into inner bore. Install seal
(2), cover (3), and bolts (4) in housing (5). Install plug (6). 4
6
Fo
2
r in
1
te
5
rn
T051505013
al
FIG. 563
FIG. 564: Install housing (1) and bolts (2).
u se
1
on
2
ly
T051505012
FIG. 564
FIG. 565: Install tube assembly (1) with bolts (2).
2
FIG. 565
03-278 79033095 C Rev.

FIG. 566: Check Valve Installation
5
m
3
equipment.
Follow recommended procedure and use all 2
force.
1
Install check valve (1), spring (2) and O-ring on flange (3).
Install flange with bolts (4). Install plug (5).
T051505010
FIG. 566
Fo
FIG. 567: Shim Installation

Use following formula to determine shim thickness (1):
1 2
• A - B - C - 257.111 mm = D
r
A - Stamped number inside differential housing

in
B - Combined height of cone and cup, with cone installed

on pinion
te
C - Stamped number on pinion

D - Thickness of shim
rn
NOTE: 257.111 mm is a predetermined constant. T051505009

al
Install shims. Lower temperature and install bearing cup FIG. 567
(2).
FIG. 568: Raise temperature of bearing cone (1) to 107
u
degrees C (250 degrees F) with a oil bath heater or an

oven.
se
NOTE: Do not use a torch.

1
on
ly
T051505014
FIG. 568
FIG. 569: Install bearing cone (1) on pinion (2).
T051505003
FIG. 569
79033095 C Rev. 03-279

FIG. 570: Install retainer plate (1) and retaining ring (2).
1
2
T051505008
FIG. 570
FIG. 571: Lower temperature of bearing race (1). Install
bearing race in spring plate (2).
1
Fo
r in
2
te
T051505002
FIG. 571
rn
FIG. 572: Install O-rings (1) to both sides of spring plate

(2). Install spring plate with two bolts (3). Tighten bolts to
al
61 Nm (45 lbf ft). 1

u se
2
3
on
T051505015
FIG. 572
ly
FIG. 573: Use two people to install pinion (1) with

bearing.
T051405004
FIG. 573
03-280 79033095 C Rev.

FIG. 574: Raise temperature of bearing (1) to 107
degrees C (250 degrees F) with a oil bath heater or an 1
oven. Do not use a torch.
T051505017
FIG. 574
FIG. 575: Install nut (1).
1
Fo
r in
te
T051505016
FIG. 575
rn
FIG. 576: Use special tooling part number 225-4125 (1)

to install nut. Tighten nut to a pinion rolling torque of 5.2 to 1
al
6.2 Nm (45 to 55 lbf in) (if both bearing are new).

NOTE: If bearings are used, set to recorded bearing
torque recorded during disassembly. Never mix
u
old bearings and new bearings.

se
on
T051605001
FIG. 576
ly
FIG. 577: Install tube assembly (1). Install bolt (2) and
clamp.
2
T051405002
FIG. 577
79033095 C Rev. 03-281

FIG. 578: Apply anaerobic sealant (1) at EOR cover
location.
T051605002
FIG. 578
FIG. 579: Install EOR cover (1) with mounting hardware
(2) and tighten to 61 Nm (45 lbf ft).
1
Fo
r
2
in
te
rn
T051405001
al
FIG. 579
u se
on
ly
03-282 79033095 C Rev.

FIG. 580: Lower temperature of bearing cup (1) and
install bearing cup on housing (2). Raise temperature of
bearing (3) and install bearing in housing. Install retaining 1
ring (4).
4
T050705010
FIG. 580
Fo
FIG. 581: Install bevel gear shaft (1) to bevel gear (2)
with washers and bolts (3). Tighten bolts to 519 Nm (383
lbf ft) in a 180 degree pattern. 5
r
Lower temperature of bearing cup (4) and install bearing 3

cup in bevel gear. Raise temperature of bearing cone (5)
1
in
and install bearing cone on bevel gear shaft.

NOTE: If bevel gear shaft bolts do not contain washers
te
the bevel gear shaft should be reworked per

service bulletin AX0011.
Refer to service bulletin AX0011 for more
rn
information. 2
al
4
T050705009
u
FIG. 581
se
FIG. 582: Attach eyebolt (1) to bevel gear (2) and install
bevel gear to housing (3).
1
on
3
ly
g00910590
FIG. 582
79033095 C Rev. 03-283

FIG. 583: Install bearing (1), shims (2) and ring gear (3)
to housing (4) with bolts (5). Tighten bolts to 107 Nm (79 5
lbf ft).
3
T051605003
FIG. 583
FIG. 584: Attach eyebolt (1) to bevel gear (2). Install
Fo
shims (3). Install bevel gear. 1 2

NOTE: Steering gear will need to be installed at this time,
if differential housing is not removed.
r in
3
te
rn
al
u se
on
g00910571
FIG. 584
ly
FIG. 585: Install allen head bolts (1). Tighten bolts to 107
Nm (79 lbf ft).
1
T050705004
FIG. 585
03-284 79033095 C Rev.

FIG. 586: Use dial indicator (1) to set backlash. Adjust
shims to a backlash of 0.3048 to 0.381 mm (0.012 to
0.015 inch). Check backlash in three locations. Remove
dial indicator. 1
NOTE: Location of measuring device must be in same
location for proper measurement upon assembly.
T050705006
FIG. 586
Fo
FIG. 587: Install sun gear (1), snap ring (2), and snap
ring (3) on shaft (4).
1
r in
2
te
3
rn
4
al
T050705003
u
FIG. 587
se
FIG. 588: Attach eyebolt (1) to shaft (2). Install shaft and
sun gear.
1 2
on
ly
g00910562
FIG. 588
79033095 C Rev. 03-285

FIG. 589: Install thrust disc (1) and (2).
2
T050705002
FIG. 589
FIG. 590: Install thrust disc (1), bearing (2), gear (3),
bearing (4) and thrust disc (5) into planetary carrier (6). 1
Install shaft (7). Drive spring pin (8) into shaft.
Fo
NOTE: Do not reuse spring pins if they have rubber in 2

them.
r
3
in
te
6
4 7
rn
8
5 T050405012
al
FIG. 590
FIG. 591: Install sun gear (1) to planetary carrier (2) with
retaining ring (3).
u
3
2
se
on
ly
T050405011
FIG. 591
03-286 79033095 C Rev.

FIG. 592: Install seal (1) to planetary carrier (2).
1
T051605004
FIG. 592
FIG. 593: Attach eyebolt (1) to planetary (2). Install
planetary. The weight of planetary is approximately 43 kg
(95 lb). 1
Fo
NOTE: Do not damage cast seal ring.

Install service brakes on left-hand side of machine.
2
r in
te
rn
al
g00910550
FIG. 593
u
FIG. 594: Rotate housing.

se
Install eyebolt (1) to gear (2). Install gear.

1
on
ly
g00910548
FIG. 594
79033095 C Rev. 03-287

FIG. 595: Install thrust disc (1), bearing (2), planetary
gear (3), bearing (4), and thrust disc (5) into planetary 6
carrier (6). Install shaft (7). Drive spring pin (8) into shaft. 2
NOTE: Do not reuse spring pins if they have rubber in 1
them.
3
7
4 8
5
T050405007
FIG. 595
FIG. 596: Install seals (1) and (2) from planetary carrier
Fo
(3).
1
r
3
in
te
rn
2
al
T051605005
u
FIG. 596
FIG. 597: Install retaining ring (1) on bevel gear shaft.
se
Squeeze retaining ring and install planetary carrier (2). 2

The weight of planetary gear is approximately 40 kg (90
lb).
on
NOTE: Do not damage cast seal rings.

ly
1
T051605006
FIG. 597
03-288 79033095 C Rev.

FIG. 598: Install sun gear (1).
1
T051605007
FIG. 598
FIG. 599: Install sun gear (1) with retaining ring (2).
2
Fo
1
r in
te
rn
T050405006
al
FIG. 599
FIG. 600: Install thrust disc (1) and thrust disc (2).
2
u
se
1
on
ly
T050405005
FIG. 600
79033095 C Rev. 03-289

FIG. 601: Install thrust disc (1), bearing (2), planetary
gear (3), and thrust disc (4) to planetary carrier (5). Install 5
shaft (6). Drive spring pin (7) into shaft. 1 7 6
NOTE: Do not reuse spring pins if they have rubber in
them.
3
4
T050405004
FIG. 601
Fo
FIG. 602: Install sun gear (1) into planetary gear (2).
Install retaining ring (3) on sun gear.
3
r in
te
2
rn
1
al
T050405003
u
FIG. 602
se
FIG. 603: Install ring gear (1), lock ring (2), planetary (3),
and ring gear (4).
4
on
3
ly
2
1
T050405001
FIG. 603
03-290 79033095 C Rev.

FIG. 604: Install eyebolt (1) to planetary carrier
assembly (2) and install planetary carrier assembly in
differential housing (3).
1
NOTE: The weight of planetary carrier assembly is
Fo 3
g00910485
FIG. 604
FIG. 605: Install thrust disc (1).
r
Install right-hand service brake.

in
NOTE: Refer to Service Brake Installation section for

more information. 1
te
rn
al
T050305009
FIG. 605
u se
on
ly
79033095 C Rev. 03-291

STEERING DIFFERENTIAL INSTALLATION
FIG. 606: Attach link brackets (1) and eyebolts (2) to
steering differential (3). Move differential into position on 2
transmission.
3
NOTE: The weight of steering differential is
Fo
T052205012
r
FIG. 606
FIG. 607: Slowly merge housing (1) onto alignment
in
guide pins (2).

1
te
rn
al
2
u
T052205011
se
FIG. 607
FIG. 608: Slowly merge housings together until all
splined transmission shafts (1) can be engaged into
on
differential.
1
ly
T052205013
FIG. 608
03-292 79033095 C Rev.

FIG. 609: Install mounting bolts with washers (1) and
remove guide pins.
Once all differential mounting bolts have been installed
tighten to 519 Nm (383 lbf ft).
T052205004
FIG. 609
FIG. 610: Install nine twelve point bolts (1) to mount the
bottom of differential.
Once all differential mounting bolts have been installed 1
Fo
tighten to 519 Nm (383 lbf ft).

r in
te
T052205003
FIG. 610
rn
FIG. 611: Install EOR manifold block (1).

al
u se
1
on
T052205002
FIG. 611
ly
79033095 C Rev. 03-293

assembly (1). Install bracket assembly and install bolts
(2). Connect harness assembly (3). 3 1
77 kg (170 lb).
2
g00910933
Fo
FIG. 612
FIG. 613: Install filler tube (1) with bolts (2).
2
r in
te
rn
al
1
g00910932
FIG. 613
u

se
assembly (1). Install bracket assembly with bolts (2).

2
130 kg (287 lb).
on
ly
g00910931
FIG. 614
03-294 79033095 C Rev.

FIG. 615: Connect harness assemblies (1) and (2).
Secure harness with bolts (3) and clamps.
Install differential housing. 3
NOTE: Refer to Differential Housing Installation section
Install three-point hitch.
NOTE: Refer to Three-Point Hitch Installation section for
more information.
Install PTO.
NOTE: Refer to PTO Installation section for more
information. 1
Install drawbar.
NOTE: Refer to Drawbar Installation section for more
information. 2
Fo
Install final drives.

information.
r
Install fuel tanks.

in
NOTE: Refer to Fuel Tank Installation section for more

information. g00910930
te
FIG. 615
rn
al
u se
on
ly
79033095 C Rev. 03-295

DIFFERENTIAL HOUSING REMOVAL
Remove steering motor.
NOTE: Refer to Steering Motor Removal section for
more information.
containing fluids.
Fo
and mandates.
Remove guards.
r
NOTE: Refer to Guards Removal section for more

information.
in
FIG. 616: Remove priority valve (1) from differential.

NOTE: Refer to Priority Valve Removal section for more
te
information. 1
rn
al
u se
T051805001
FIG. 616
FIG. 617: Disconnect steering case drain hose (1).
on
Disconnect implement case drain hose (2).

ly
T051705006
FIG. 617
03-296 79033095 C Rev.

FIG. 618: Remove bolts (1) and coupling (2) from
differential housing (3). 1
3
T051705005
FIG. 618
Fo
FIG. 619: Attach eyebolt (1) to differential housing.

Attach a suitable hoist and eyebolt. Remove differential
housing (2).
NOTE: The weight of differential housing is
r
1
in
te
rn
2
al
u
g00906933
FIG. 619
se
on
ly
79033095 C Rev. 03-297

DIFFERENTIAL HOUSING DISASSEMBLY
Remove differential housing.
NOTE: Refer to Differential Housing Removal section for
more information.
FIG. 620: Use pin punch set to drive spring pin (1) into
shaft (2) on steering drive housing (3). Use a soft brass 2 1
drift to drive shaft from gear (4). 5
NOTE: Be sure not to drive pin into other side of housing.
NOTE: Spring pin seals oil to bearings. 6
Drive spring pin from shaft.
Remove gear from steering drive housing. Remove thrust
disc (5), bearing (6), bearing (7) and thrust disc (8) from
cluster gear.
7
Fo
3
4
8
T051705001
r
FIG. 620
in
FIG. 621: Remove retaining ring (1) from steering drive

housing (2) with retaining ring pliers.
te
Remove gear (3) and bearings from steering drive 1

housing.
rn
3
al
2
u se
T051705002
on
FIG. 621
FIG. 622: Remove bearings (1) from gear (2).
2
ly
1
T051705003
FIG. 622
03-298 79033095 C Rev.

DIFFERENTIAL HOUSING ASSEMBLY
FIG. 623: Install bearings (1) on gear (2).
2
1
T051705003
FIG. 623
FIG. 624: Install gear (1) and bearings in steering drive
housing (2).
Fo
Install retaining ring (3) in steering drive housing with 3

retaining ring pliers.
r
1
in
te
2
rn
al
T051705002
FIG. 624
u
FIG. 625: Install bearing (1) and bearing (2) on each

side of cluster gear (3). 7 8
se
Install cluster gear in steering drive housing (4). 5

Install thrust disc (5) and thrust disc (6) on each side of
cluster gear. Install shaft (7) and align hole in shaft with 1
on
hole in steering drive housing.

Use pin punch set and push spring pin (8) into steering
ly
drive housing and shaft so spring pin is flush with steering

drive housing.
NOTE: Spring pin seals oil to bearings. 2
Do not reuse old spring pin. 4
3
Install differential housing. 6
NOTE: Refer to Differential Housing Installation section T051705001
for more information. FIG. 625
79033095 C Rev. 03-299

DIFFERENTIAL HOUSING INSTALLATION
replacement.
FIG. 626: Apply anaerobic sealant (1) to the differential
steer gear mating surface. 1
Fo
r
T051705004
in
FIG. 626
FIG. 627: Attach eyebolt (1) to differential housing.
te
Attach a suitable hoist to eyebolt. Move differential

housing (2) into position and remove eyebolt.
rn
NOTE: The weight of differential housing is 1

al
u se
2
on
g00906933
FIG. 627
ly
FIG. 628: Install differential housing (1) with bolts and

washers (2). Tighten bolts to 266 Nm (196 lbf ft). 2
Install coupling (3). 1
T051705005
FIG. 628
03-300 79033095 C Rev.

FIG. 629: Connect implement case drain hose (1).
Connect steering case drain hose (2).
T051705006
FIG. 629
FIG. 630: Install priority valve (1) to differential.
NOTE: Refer to Priority Valve Installation section for
more information. 1
Fo
Install steering motor.

NOTE: Refer to Steering Motor Installation section for
more information.
r in
te
T051805001
FIG. 630
rn
al
u
se
on
ly
79033095 C Rev. 03-301

NOTES
Fo
r in
te
rn
al
use
on
ly
03-302 79033095 C Rev.

Testing and Adjusting
GENERAL TESTING AND ADJUSTING

INFORMATION
Preparation of Machine Procedure
m
WARNING: Sudden movement of machine When you are defining a problem in any hydraulic
or release of oil under pressure can cause systems, following procedure should be followed:.
serious injury to persons on or near
Perform visual checks in Testing and Adjusting, Visual
machine.
Inspection. If you complete visual inspection and problem
To prevent possible injury, perform is not identified, perform mechanical system tests. If you
procedure that follows before testing and complete mechanical system tests and problem is not
adjusting hydraulic system. identified, perform electrical system tests.
For additional help in resolving a problem, refer to
1. Move machine to a smooth horizontal location.
Fo
Troubleshooting Manual, Electrical and Hydraulic

2. Lower all implements to ground and lower three-point Systems. The troubleshooting manual lists probable
hitch to ground. causes of a known problem.
r
3. Make sure that transmission control lever is in Park Since more than one cause may exist for a problem,
position. troubleshooting section may suggest specific inspections
in
or instrument tests. These inspections and tests will help

4. Warm oil to a minimum temperature of 60 degrees C identify most probable cause.
(140 degrees F), if necessary. See Warming
te
Hydraulic Oil for procedure to warm hydraulic oil.

5. Move all hydraulic control levers through Float
rn
position to relieve hydraulic pressure.

6. Stop engine and remove key.
al
7. Remove appropriate guards.

u se
on
ly
79033095 C Rev. 03-303

Test Equipment
Hydraulic test procedures may be performed using either
one of following test equipment:
• Dataview tool group
• Appropriate pressure gauges
Warming the Hydraulic Oil

FIGS. 631–632: If necessary, install Hose Assembly into
+ quick coupler and - quick coupler of any hydraulic
control valve. Place hydraulic control lever in Extend
Detent position. Adjust needle valve accordingly to heat
hydraulic oil.
NOTE: During a diagnosis in any hydraulic systems,
remember that correct oil flow and pressure are
necessary for correct operation. Oil pressure is
caused by resistance to flow of oil. Oil
Fo
temperature must be a minimum of 60 degrees C

(140 degrees F). The temperature of hydraulic oil
can be viewed on Summary screen of Virtual
Terminal (VT).
r
g00861169
FIG. 631
in
te
rn
al
u se
g00807309
FIG. 632
on
ly
03-304 79033095 C Rev.

Troubleshooting Procedure Verify Symptom
Use following six steps to begin troubleshooting Operate machine. When possible, repeat conditions
machine: which caused symptom. Check gauges inside cab. Notice
any unusual odors in air. Listen for unusual noises.
• Know machine.
• Understand symptom. Determine Probable Causes
• Verify symptom. Once information is gathered create a list of probable

causes. Determine subsystem that is cause of symptom.
• Determine probable causes. Use list of probable causes in Troubleshooting, Electrical
and Hydraulic Systems, as a guide.
• Reduce list of probable causes.
• Test system. Reduce List of Probable Causes
Use previous steps to troubleshoot machine. List probable causes in order of probability. Identify
probable causes that are easy to verify. When possible,
Know Machine eliminate probable causes that are easy to check.
Understand operation of machine. Know if symptom is Test System
characteristic of normal operation or if symptom is an
Fo
indication of component failure. Use operational tests to verify cause of symptom. Once
cause has been identified, repair suspect component.
Read systems operation information to understand Then, test system again.
systems of machine. You must understand interaction of
r
systems on machine.
in
Understand Symptom
te
Question operator about problem.

• Ask about performance of machine prior to symptom.
rn
• Determine time of first occurrence of symptoms.

• Determine operating conditions at time of symptom.
al
• Ask operator about sequence of events prior to

symptom. Determine order of occurrences.
u
• Ask operator about steps that have been taken to

troubleshoot machine.
se
• Ask history of repairs of machine.

• Ask about preventive maintenance of machine. Many
failures are due to poor maintenance.
on
Inspect machine. Look for problems. Notice any unusual

odors in air. Listen for unusual noises.
ly
79033095 C Rev. 03-305

VISUAL INSPECTION
m
WARNING: Do not check for leaks with
your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will
be invisible close to hose. This oil can
penetrate skin and cause personal injury.
Use cardboard or paper to locate pin hole
leaks.
m
WARNING: Sudden movement of machine
or release of oil under pressure can cause
machine.
To prevent possible injury, perform
procedure that follows before testing and
adjusting hydraulic system.
Fo
Use following procedure to perform a visual

inspection.
r
2. Lower all implements to ground and lower three-point

hitch to ground.
in
3. Make sure that transmission control lever is in Park

position.
te
4. Warm oil to a minimum temperature of 60 degrees C

(140 degreesF), if necessary.
rn

al

u
Perform following visual inspections.

se
1. Measure oil level.

2. Check for air in oil that is in sump. Check immediately
after stopping machine. Check sight gauge at rear of
on
machine next to PTO shaft. Check for air bubbles in

sight gauge.
3. Remove filter elements. Check for particles that are
ly
removed from oil by filter element. Use a magnet to

separate metallic particles from nonmetallic particles.
Bronze colored particles give an indication of a clutch
failure. Brass particles or shiny steel particles give
indication of a pump failure. Rubber particles give an
indication of a seal failure or hose failure.
4. Inspect all oil lines and connections for damage or
leaks.
5. Inspect control linkages for broken components or for
damaged components.
03-306 79033095 C Rev.

RELIEF VALVE (CHARGE) - TEST AND
ADJUST
Pressure Test for Relief Valve (Charge

Pressure)
Introduction
The following test procedure will verify whether oil
pressure that is controlled by relief valve (charge
pressure) is within specified limit. The relief valve limits
maximum charge pressure in hydraulic system to
adjusted setting.
The undercarriage has been removed for photographic
purposes in following procedure.
Required Tools
Fo
Hydraulic test procedures may be performed using

either one of following test equipment:
• Dataview tool gp
r

in
FIG. 633: Dataview Tool Gp

Table provides a list of required tools if a dataview tool gp
te
is used to perform following test procedure. A dataview

tool gp is not shown in following test procedure.
rn
Required Tools
al
Dataview Tool Gp
Part Number Description Qty
u
131-5051 DataView Tool Gp 1

se
Pressure Sensor g00787927

213-3275 1
0 to 6895 kPa (0 to 1000 psi)* FIG. 633
* This pressure sensor is not part of dataview tool gp.
on
FIG. 634: Tooling (A)

Use tools in Table to complete following test procedure. A2 A1
ly
Required Tools (Pressure Gauge) A4

Tool Item Part Description
Qty
Number
A3
A1 6V-3989 Fitting (Test) 1
A2 8T-0855 Pressure Gauge 1 A4
A
A3 177-7861 Hose As 1
A4 6V-4143 Coupler 2 P012512001
FIG. 634
79033095 C Rev. 03-307

Test Procedure
m
machine.

containing fluids.
Fo
and mandates.
A pressure gauge is used in following test
procedure:
r

hitch to ground.
in
2. Make sure transmission control lever is in Park

position.
te
3. Warm oil to a minimum temperature of 60 degreesC

(140 degreesF).
rn

al

u
FIG. 635: Connecting Tooling

se
7. ConnectTooling (A) to test port (1). 1

8. Start engine. Run engine at rated speed (2100 rpm).
9. Make sure that temperature of hydraulic oil is at least
on
A
60 degrees C (140 degrees F). Place transmission in
neutral, then record pressure setting of relief valve
(charge pressure). The pressure setting should be
ly
2065 to 2135 kPa (300 to 310 psi).

10. If pressure setting is not within specified limit, perform
procedure in, Adjust Pressure Setting of Relief Valve
(Charge Pressure).
P012912002
FIG. 635
03-308 79033095 C Rev.

Adjust the Pressure Setting of Relief Valve
(Charge Pressure)
Introduction
The following adjustment procedure will verify whether oil
pressure that is controlled by relief valve (charge
pressure) is within specified limit. The relief valve limits
maximum charge pressure in hydraulic system to
adjusted setting.
Required Tools
Fo

r

is used to perform following adjustment procedure. A
in
dataview tool gp is not shown in following adjustment

procedure.
te
Required Tools
rn
Dataview Tool Gp
al

g00787927
Pressure Sensor
u
213-3275 1 FIG. 636

0 to 6895 kPa (0 to 1000 psi)*
se

on
Use tools in Table to complete following adjustment A2 A1

procedure.
A4
ly
Required Tools (Pressure Gauge)

Qty A3
Number
A4
A2 8T-0855 Pressure Gauge 1
A
A3 177-7861 Hose As 1
P012512001
A4 6V-4143 Coupler 2 FIG. 637
79033095 C Rev. 03-309

Adjustment Procedure
m
machine.

containing fluids.
Fo
and mandates.
procedure:
r

hitch to ground.
in

position.
te
3. Warm oil to a minimum temperature of 60degrees C

(140 degrees F).
rn

al

u
FIG. 638: Removing Cap

se
7. Remove two bolts (2) from cap (3).
2
on
ly
3
P110705002
FIG. 638
03-310 79033095 C Rev.

FIGS. 639–640: Installing Tooling
8. Install Tooling (A) to test port (1). 1
9. Start engine. Run engine at rated speed (2100 rpm).
10. Make sure temperature of hydraulic oil is at least 60
degrees C (140 degrees F).
11. Turn adjusting screw (4) to adjust pressure setting.
Turn adjusting screw clockwise to increase pressure A
or turn adjusting screw counterclockwise to decrease
pressure setting.
12. If there is room to allow for machine movement, shift
machine into gear and then back to park. If there is P110705003
no room, push and hold down inching pedal and shift
FIG. 639
machine into gear. Without releasing inching pedal,
shift machine back into park. This will allow relief
valve to settle into appropriate pressure setting.
Fo
13. Adjust pressure setting until pressure on Tooling (A)

is 2065 to 2135 kPa (300 to 310 psi).
4
NOTE: The machine must be in neutral for this
specification. Adjust pressure in park, then check
r
pressure in neutral.
in
te
P012812002
rn
FIG. 640
FIG. 641: Removing Tooling
al
14. After obtaining correct pressure setting, remove

Tooling (A).
u se
A
on
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P110705003
FIG. 641
FIG. 642: Installing Cap
15. Install cap (3) by using two bolts (2).
16. Stop engine.
2
3
P110705002
FIG. 642
79033095 C Rev. 03-311

TRANSMISSION CLUTCH CALIBRATION
Accessing Calibrations For Transmission

Solenoid Valves
Introduction
Calibration is required when one of following
conditions occur:
• A component has been replaced.
• The ECM has been replaced.
• Normal wear on a component
• Physical alteration of component or linkage
Required Tools
Fo
Service Tools
Caterpillar Electronic Technician (ET)
r
The Caterpillar Electronic Technician service tool (ET) is

in
used to access calibration procedures. A message on ET

screen will give instructions that guide user through
calibration procedure. Refer to Manual that is provided
te
with ET for more information.

rn
Calibration Procedure
1. Connect ET to machine.
al
Once communication has been established, ET will

list electronic control modules that are on machine.
u se
on
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03-312 79033095 C Rev.

Fo
r in
te
rn
al
g00803086
FIG. 643
u
FIG. 643: ET Screen of Available Electronic Control

se
Modules (ECM)
2. Choose menu item Machine Control.
3. Select Service from menu bar.
on
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79033095 C Rev. 03-313

Fo
r in
te
rn
g00803143
al
FIG. 644
u
FIG. 644: ET Screen of Calibration Menu for Machine NOTE: To ensure proper heat-soak of transmission
ECM components prior to calibration, heat hydraulic oil
se
by using a load line (Reference: See System

4. Select Calibrations from drop-down menu (Service).
Operation/Testing and Adjusting, General
Another drop-down menu will appear. The menu will Testing and Adjusting Information, for information
list each available calibration. on warming oil). When transmission oil has
on
reached about 90 degrees F (32 degrees C),

5. Select Transmission Fill Calibration. operate machine in roading gears (13F to 16F)
6. Follow all instructions on ET to complete calibration with load-line on to heat hydraulic oil to near
calibration temperature. Then operate machine
ly
procedures.
in gears 2R to 16F multiple times to properly
NOTE: Calibration will require certain conditions to be set heat-soak transmission components. Continue
prior to start of calibration. For example, set shift shifting through gear range until hydraulic oil has
lever to PARK. The user must ensure that all reached calibration temperature. In cold weather
setup for conditions of calibration are satisfied. operation, to facilitate faster oil heating, restrict
air flow to hydraulic oil cooler (i.e. placing
cardboard over radiator).
Calibrate transmission as close to minimum
required temperature as possible (as outlined by
Caterpillar Electronic Technician). To prevent
temperature dropping too much during
calibration in cold climate, load line can be left on
to continuously heat hydraulic oil. If during
calibration temperature gets too hot or cold, load
line or air flow to the oil cooler can be adjusted to
maintain proper calibration temperature.
03-314 79033095 C Rev.

TRANSMISSION CLUTCH PRESSURE -
TEST
Clutch Pressure Test

Introduction
The following test procedure will check pressure of charge
oil that is being delivered from a modulating valve
(transmission) to a transmission clutch. There are nine
individual modulating valves that control nine
transmission clutches. The modulating valves
(transmission) are modulated. The modulation of these
valves is adjusted by transmission fill calibration.
Required Tools
Fo

r
in

te

rn
Required Tools
al
Dataview Tool Gp
u

se
Pressure Sensor* g00787927

213-3275 1
0 to 6895 kPa (0 to 1000 psi) FIG. 645
on
FIG. 646: Tooling (K)

ly
Use tools in Table to complete following test procedure. K2 K1
Required Tools (Pressure Gauges) K4

Qty
Number
K3
K1 6V-3989 Fitting (Test) 2
K2 8T-0855 Pressure Gauge 2 K4
K
K3 177-7861 Hose As 2
K4 6V-4143 Coupler 4 P012512001
FIG. 646
79033095 C Rev. 03-315

Test Procedure
m
machine.

containing fluids.
Fo
and mandates.
Pressure gauges are used in following test
procedure.
r
FIG. 647: Transmission Clutches

in
The designated letters are used to correlate a modulating

valve to corresponding transmission clutch, as shown. C D
te
rn
A
al
E F
u se
G H J B
on
P110605003
FIG. 647
ly
03-316 79033095 C Rev.

Each modulating valve has a designated letter, as shown.
The letters have been cast into transmission housing. A
Log clutch pressures in Table. There are always two
clutches that are engaged for each gear selection. Neutral B
position only uses one clutch. See Table to determine
clutches that are engaged for each gear selection. C
G
Fo
H
r
J
in
P102105007
FIG. 648
te
rn
al
u se
on
ly
79033095 C Rev. 03-317

Checklist for Transmission Clutch Pressures

Pressure Pressure
Gear Clutch or Valve Clutch or Valve
Measurement Measurement
Fourth gear (reverse) A J
Third gear (reverse) A H
Second gear
A B
(reverse)
First gear (reverse) A G
Neutral J - -
First gear C G
Second gear D G
Third gear E G
Fo
Fourth gear F G
Fifth gear C B
r
Sixth gear C H
in
Seventh gear D B
Eighth gear D H
te
Ninth gear E B
rn
Tenth gear E H
Eleventh gear F B
al
Twelfth gear F H
Thirteenth gear C J
u
Fourteenth gear D J
se
Fifteenth gear E J
Sixteenth gear F J
on
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03-318 79033095 C Rev.

hitch to ground.
position.
4. Warm oil to a minimum temperature of 60degrees C
(140 degrees F).
Third gear that uses clutches (E) and (G) is
shown in following test:
Fo
8. Connect one end of Tooling (K) to test port (1) on K

valve (E). Connect one end of Tooling (K) to test port 2 1
(2) on valve (G).
r
NOTE: The hoses are long enough to reach into cab.

Make sure that hoses are safely secured away
in
from belts.
9. Operate machine in third gear.
te
K
rn
P110705004
al
FIG. 649
FIG. 650: Reading Pressure
u
10. Observe pressure that is being delivered to

transmission clutches (E) and (G). You can use Table
se
to write down measurement.

11. Stop engine.
12. Repeat Steps for remaining reverse gears and
on
forward gears. Use Table to determine combination of

modulating valves that are being engaged for each
gear.
ly
13. Compare pressure measurements from all

transmission clutches. The pressure measurement g00795526
should be 2065 to 2135 kPa (300 to 310 psi).
FIG. 650
14. Remove Tooling (K).
15. Stop engine.
16. If pressure is not within specified limits, check
pressure that is being delivered by relief valve
(charge pressure).
NOTE: If pressure is not 2065 to 2135 kPa (300 to 310
psi), go to Systems Operation/Testing and
Adjusting, Relief Valve (Charge) - Test and
Adjust.
79033095 C Rev. 03-319

Pressure Test for Lubrication Oil
Introduction
The following test procedure will check pressure of
lubrication oil that is being delivered to transmission
clutches.
Required Parts
Fo

r
Required Tools
in
Dataview Tool Gp
te

rn
Pressure Sensor* g00787927

213-3274 1
0 to 689.5 kPa (0 to 100 psi)
al
FIG. 651
u
FIG. 652: Tooling (K)

K2
se
Use tools in Table to complete following test procedure. K1
Required Tools (Pressure Gauges) K4

on

Number Qty
K3
K1 6V-3989 Fitting (Test) 1
ly
K2 8T-0853 Pressure Gauge 1 K4

K
K3 177-7861 Hose As 1
K4 6V-4143 Coupler 2 P012512001
FIG. 652
03-320 79033095 C Rev.

Test Procedure
m
machine.

containing fluids.
Fo
and mandates.
procedure.
r

in

hitch to ground.
te

position.
rn

(140degrees F).
al

u
7. Remove all appropriate guards.

se
on
ly
79033095 C Rev. 03-321

FIG. 653: Installing Tooling
8. Connect Tooling (K) to test port (3), as shown.
9. Start engine. With machine in park, run engine at 3
high idle. Make sure temperature of hydraulic oil is at
least 60 degrees C (140 degrees F).
10. The pressure should read 158 to 228 kPa (22 to 34
psi).
11. Remove Tooling (K) from test port (3). K
12. Stop engine.
pressure that is being delivered by relief valve P110705005
(charge pressure). FIG. 653

Reference: If pressure is not 2065 to 2135 kPa (300
to 310 psi), go to Systems Operation/Testing and
Adjusting, Relief Valve (Charge) - Test and Adjust.
Fo
r in
te
rn
al
u se
on
ly
03-322 79033095 C Rev.

POWER TAKE-OFF (PTO) CLUTCH
PRESSURE - TEST AND ADJUST
Pressure Test for Power Take-Off Clutch

Introduction
The following test procedure will verify whether pressure
of oil that is delivered from modulating valve (power
take-off) to power take-off clutch is within specified limit.
There is only one test port on modulating valve. The oil
flow to power take-off clutch is modulated. The
modulation is not adjustable.
Required Tools
Fo
FIG. 654: Dataview Tool Group
r
NOTE: If a dataview tool gp is used to perform following

in
test procedure. A dataview tool gp is not shown

in following test procedure.
te
rn
al
u
g00787927
FIG. 654
se
FIG. 655: Pressure Gauge Assembly

Use these tools to complete following test procedure. 2 1
on
(1) Test Fitting

(2) Pressure Gauge
4
ly
(3) Hose Assembly

(4) Coupler 3
P012512001
FIG. 655
79033095 C Rev. 03-323

Test Procedure
m
machine.

containing fluids.
Fo
and mandates.
Pressure gauges are used in following test procedure.
r
hitch to ground.
in

position.
te

(140 degrees F).
rn

al

6. Remove all appropriate guards.
u se
on
ly
03-324 79033095 C Rev.

FIG. 656: Test port and Pressure gauge
A
7. Connect gauge (A) to test port (1), as shown.
NOTE: If machine is equipped with a three-point hitch,
you will need to remove upper link to access test
port (1).
8. Start engine. Run engine at high idle. Make sure that
temperature of hydraulic oil is at least 60 degrees C
(140 degrees F).
9. Engage PTO.
10. The pressure should read 2065 to 2135 kPa (300 to
310 psi). 1 g00861283
11. Remove Tooling (A) from test port. FIG. 656

12. Stop engine.
Fo
pressure that is being delivered by relief valve

(charge pressure).
If pressure is not 2050 to 2150 kPa (298 to 312 psi),
r
go to Systems Operation/Testing and Adjusting Relief

Valve (Charge) - Test and Adjust.
in
te
rn
al
u se
on
ly
79033095 C Rev. 03-325

HYDRAULIC OIL COOLER - TEST
Pressure Test of Hydraulic Oil Cooler

Introduction
The following test procedure will check pressure of oil that
returns from hydraulic oil cooler.
Required Tools
Fo
FIG. 657: Dataview Tool Group

Table provides a list of required tools if a dataview tool
group is used to perform following test procedure. A
r
dataview tool group is not shown in following test

procedure.
in
Required Tools
te
Dataview Tool Gp
rn

al
g00787927
Pressure Sensor*
213-3274 1 FIG. 657
0 to 689.5 kPa (0 to 100 psi)
u

se

Use tools in Table to complete following test procedure. A2 A1
on

Qty
ly
Number
A3
A2 8T-0853 Pressure Gauge 2 A4
A
A3 177-7861 Hose As 2
A4 6V-4143 Coupler 4 P012512001
FIG. 658
03-326 79033095 C Rev.

Test Procedure
m
machine.

containing fluids.
Fo
and mandates.
procedure:
r

in

hitch to ground.
te

position.
rn

(140 degrees F).
al

u

se
FIG. 659: Connecting Tooling

8. Connect Tooling (A) to test port (1).
1
9. Start engine. Run engine at 2100 engine rpm (rated
on
speed).
ly
60 degrees C (140 degrees F). Record pressure of

hydraulic oil that is coming from hydraulic oil cooler.
The pressure of oil that is returning from hydraulic oil
cooler should be 275 kPa (40 psi).
11. Remove Tooling (A) from test port (1). A
12. Stop engine. P110705011
FIG. 659
79033095 C Rev. 03-327

NOTES
Fo
r in
te
rn
al
use
on
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03-328 79033095 C Rev.

Index
INDEX
A F
AGCO Electronic Diagnostic Tool (EDT) Features of Transmission System ...................... 03-25
Connector .......................................................... 03-13 Power Management ........................................ 03-26
Armrest ECM .......................................... 03-14, 03-99 Sequential Shifting .......................................... 03-25
Armrest Electronic Control Module (ECM) Shuttle Shifting ................................................ 03-26
for Transmission System ................................... 03-37 Filler Cap ............................................................ 03-44
Final Drive - Assemble
Assembly Procedure ..................................... 03-245
B Final Drive - Disassemble
Disassembly Procedure ................................ 03-239
Breather (Common Sump) ................................. 03-44 Final Drive - Install ............................................ 03-250
Final Drive - Remove ........................................ 03-228
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CAN Data Link ........................................ 03-13, 03-99
Charge Pressure Relief Valve ............................ 03-19 General Information
Power Take-Off (PTO) System ......................... 03-2
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Common Sump ....................................... 03-16, 03-42

Breather .......................................................... 03-44 Transmission System ........................................ 03-2
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Filler Cap ........................................................ 03-44 General Testing and Adjusting Information ...... 03-303
Hydraulic Oil Drain Plug .................................. 03-45
Sight Gauge .................................................... 03-45
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Control Settings for Transmission System ......... 03-34 H

Desired Engine Speed .................................... 03-34
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Desired Ground Speed ................................... 03-34 Hydraulic Oil Cooler ................................ 03-22, 03-62
Downshift Setting ............................................ 03-34 Hydraulic Oil Cooler - Test ............................... 03-326
Upshift Setting ................................................ 03-34 Pressure Test of Hydraulic Oil Cooler ........... 03-326
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Hydraulic Oil Drain Plug ..................................... 03-45

Hydraulic Oil Filter ................................................ 03-3
D Bypass Valve .................................................. 03-48
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Hydraulic Oil Filter (Transmission) ..................... 03-18

Data Link for Transmission System ................... 03-39 Hydraulic Pump Drive - Install
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Differential Housing - Assemble Installation Procedure ................................... 03-132

Assembly Procedure ..................................... 03-299 Hydraulic Pump Drive - Remove
Differential Housing - Disassemble Removal Procedure ...................................... 03-125
Disassembly Procedure ................................ 03-298 Hydraulic Pump Drive Assembly ...................... 03-130
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Differential Housing - Install Hydraulic Pump Drive Disassembly ................. 03-127

Installation Procedure ................................... 03-300 Hydraulic System for Power Take-Off (PTO) ..... 03-97
Differential Housing - Remove Hydraulic System Schematic
Removal Procedure ...................................... 03-296 (Power Take-Off) .............................................. 03-116
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Disassembly and Assembly ............................. 03-123 Hydraulic System Schematic (Transmission) ..... 03-64
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Electrical Control System Inching Pedal

for Power Take-Off (PTO) .................................. 03-96 Position Sensor ............................................... 03-32
Electrical Schematic Input Components of Transmission System
for Power Take-Off System .............................. 03-106 Sensors
Electrical Schematic for Transmission System .. 03-40 Position Sensor (Inching Pedal) ............... 03-32
Electronic Control Modules Position Sensor (Shift Lever) .................... 03-31
for Transmission System ................................... 03-35 Speed Sensor (Transmission Input) ......... 03-33
Elevated Oil Reservoir (EOR) .............................. 03-3 Speed Sensor (Transmission Output) ...... 03-33
Engine Frame and Powertrain - Connect Temperature Sensor (Hydraulic Oil) ......... 03-34
Connection Procedure .................................. 03-140 Speed Sensor (Transmission Output) ............. 03-33
Engine Frame and Powertrain - Separate Switch (Upshift) ............................................... 03-28
Separation Procedure ................................... 03-135 Switches
Switch (One-Touch) .................................. 03-30
79033095 C Rev. 03-329

Index
Switch (Upshift) ........................................ 03-28 No Signal Current ........................................... 03-54
Temperature Sensor (Hydraulic Oil) ............... 03-34 Oil Flow in a De-energized Valve .................... 03-55
Oil Flow in a Valve with less than
Maximum Signal Current ............................. 03-57
L Oil Flow in a Valve with
Maximum Programmed Current Signal ....... 03-59
Location of Electronic Components Valve Operation .............................................. 03-53
for Power Take-Off System ................................ 03-98 Valve Ports ...................................................... 03-53
Location of Electronic Components Modulating Valves (Transmission) ............ 03-3, 03-19
for Transmission System ..................................... 03-9
Machine ECM ................................................. 03-14
Modulating Valves (Transmission Clutch) ...... 03-15 O
Position Sensor (Inching Pedal) ..................... 03-11
Position Sensors (Shift Lever) .......................... 03-9 Oil Sampling Valve ............................................. 03-48
Pressure Sensor (Charge) .............................. 03-13 One-Touch Switch .............................................. 03-30
Speed Sensor (Transmission Input) ............... 03-12 Output Components of Transmission System .... 03-38
Speed Sensor (Transmission Output) ............ 03-12 Modulating Valves (Transmission clutch) ........ 03-38
Switch (Downshift) .......................................... 03-10 Solenoid Valves (Creeper Gear) ..................... 03-39
Switch (Inching Pedal) .................................... 03-11
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Switch (One Touch) ........................................ 03-10

Switch (One-Touch) ............................. 03-11, 03-27 P
Switch (Upshift) ............................................... 03-10
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Temperature Sensor (Hydraulic Oil) ............... 03-12 Park Brake Cable Adjustment Procedure ......... 03-227
Location of Hydraulic Components Parking Brake - Assemble
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for Power Take-Off System .............................. 03-101 Assembly Procedure ..................................... 03-223
Location of Hydraulic Components Parking Brake - Disassemble
for Transmission System Disassembly Procedure ................................ 03-218
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Common Sump ............................................... 03-16 Planetary Clutch Pack ........................................ 03-74

Hydraulic Oil Cooler ........................................ 03-22 Position Sensor (Inching Pedal) .............. 03-11, 03-32
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Hydraulic Oil Filter (Transmission) .................. 03-18 Position Sensor (Shift Lever) .............................. 03-31
Modulating Valves (Transmission) .................. 03-19 Power Management
Relief Valve (Charge Pressure) ...................... 03-19 Constant Engine Speed .................................. 03-26
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Relief Valve (Transmission Lube) ................... 03-19 Power Management Switch ..................... 03-11, 03-30
Suction Screens .............................................. 03-17 Power Take-Off - Remove
Tandem Charge Pump ................................... 03-18 Removal Procedure ...................................... 03-189
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Transmission Clutches ................................... 03-20 Power Take-Off (PTO) Assembly ..................... 03-200
Lube Pressure Relief Valve ............................... 03-19 Power Take-Off (PTO) Clutch Pressure
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- Test and Adjust .............................................. 03-323

Power Take-Off (PTO) Disassembly ................ 03-191
M Power Take-Off (PTO) Installation ................... 03-207
Power Take-Off (PTO) Removal ...................... 03-189
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Machine ECM .................................................. 03-100 Power Take-Off (PTO) System .......................... 03-93
Machine Electronic Control Module (ECM) General Information .......................................... 03-2
for Transmission System ................................... 03-35 Modulating Valve .......................................... 03-100
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Modulating Valve (Power Take-Off) .... 03-100, 03-107 PTO clutch .................................................... 03-105
Less Than Maximum Signal Current ............ 03-112 Power Take-Off Clutch ..................................... 03-105
Maximum Programmed Signal Current ........ 03-114 Pressure Sensor (Charge) ................................. 03-34
No Signal Current ......................................... 03-110 PTO Switch ........................................................ 03-98
Oil Flow in a Valve with less than
Maximum Signal Current ........................... 03-113
Oil Flow in a Valve with R
Maximum Programmed Current Signal ..... 03-115
Oil Flow with No Signal Current .................... 03-111 Relief Valve (Charge Pressure) ..... 03-3, 03-19, 03-60
Schematic ..................................................... 03-108 Valve Operation .............................................. 03-61
Valve Operation ............................................ 03-110 Relief Valve (Charge Pressure)
Valve Ports ................................................... 03-109 - Remove and Install ........................................ 03-124
Modulating Valve (Power Take-Off) Installation Procedure ................................... 03-124
- Remove and Install ........................................ 03-188 Removal Procedure ...................................... 03-124
Installation Procedure ................................... 03-188 Relief Valve (Charge) - Test and Adjust ........... 03-307
Removal Procedure ...................................... 03-188 Adjust Pressure Setting of Relief Valve
Modulating Valve (Transmission) ....................... 03-51 (Charge Pressure) ..................................... 03-309
Less Than Maximum Signal Current .............. 03-56 Pressure Test for Relief Valve
Maximum Programmed Signal Current .......... 03-58 (Charge Pressure) ..................................... 03-307
03-330 79033095 C Rev.

Index
Relief Valve (Transmission Lube) ...................... 03-19 Intermediate Shaft Assembly ........................ 03-177
Relief Valve (Transmission Lubrication) Output Shaft Assembly ................................. 03-174
- Remove and Install ........................................ 03-123 Reverse Shaft Assembly ............................... 03-179
Installation Procedure ................................... 03-123 Transmission Assembly ................................ 03-180
Removal Procedure ...................................... 03-123 Transmission - Disassemble
Disassembly Procedure ................................ 03-147
Input Shaft Disassembly ............................... 03-164
S Intermediate Shaft Disassembly ................... 03-158
Output Shaft Disassembly ............................ 03-161
Scavenge Pump ................................................... 03-3 Reverse Shaft Disassembly .......................... 03-155
Suction Screen ............................................... 03-17 Transmission - Install
Sensors Installation Procedure ................................... 03-185
Temperature Sensor (Hydraulic Oil) ............... 03-34 Transmission - Remove
Transmission Input Speed .............................. 03-33 Removal Procedure ...................................... 03-145
Transmission Output Speed ........................... 03-33 Transmission Clutch Calibration ....................... 03-312
Service Brake - Install Accessing Calibrations
Installation Procedure ................................... 03-213 for Transmission Solenoid Valves ............. 03-312
Service Brake - Remove Transmission Clutch Pressure - Test ............... 03-315
Removal Procedure ...................................... 03-209 Clutch Pressure Test .................................... 03-315
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Service Brake Cable Adjustment ..................... 03-217 Pressure Test for Lubrication Oil .................. 03-320
Shift Lever Position Switch ................................ 03-31 Transmission Clutches ............................ 03-20, 03-66
Sight Gauge ....................................................... 03-45 Regular Clutch Pack ....................................... 03-72
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Steering Differential - Assemble Transmission Power Flow .................................. 03-78

Assembly Procedure ..................................... 03-278 Transmission System
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Steering Differential - Disassemble Clutches .......................................................... 03-66

Disassembly Procedure ................................ 03-263 ECM ................................................................ 03-35
Steering Differential - Install Electrical Control System .................................. 03-6
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Installation Procedure ................................... 03-292 Elevated Oil Reservoir (EOR) ........................... 03-3
Steering Differential - Remove General Information .......................................... 03-2
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Removal Procedure ...................................... 03-258 Hydraulic Oil Filter ............................................. 03-3

Suction Screen Hydraulic Schematic ....................................... 03-64
Scavenge Pump .................................. 03-17, 03-44 Hydraulic System .............................................. 03-8
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Tandem Charge Pump ........................ 03-17, 03-43 Introduction ....................................................... 03-3

Switch (Downshift) ............................................. 03-28 Location of Electronic Components .................. 03-9
Switch (Inching Pedal) ............................ 03-11, 03-29 Modulating Valves ........................................... 03-51
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Switch (One Touch) ........................................... 03-99 Modulating Valves (Transmission) .................... 03-3
Switch (One-Touch) ........................................... 03-27 Planetary Clutch Pack ..................................... 03-74
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Switch (Power Management) ............................. 03-29 Power Flow ..................................................... 03-78

Systems Operation Relief Valve (Charge Pressure) ........................ 03-3
Power Take-Off (PTO) System ......................... 03-2 Scavenge Pump ................................................ 03-3
Transmission System ....................................... 03-2 Tandem Charge Pump ...................................... 03-3
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Tandem Charge Pump ................... 03-3, 03-18, 03-49 Virtual Terminal ..................................... 03-14, 03-100
Oil Flow ........................................................... 03-49 Visual Inspection .............................................. 03-306
Suction Screen ............................................... 03-17
Test Ports
Hydraulic Oil Cooler ........................................ 03-24
Lube Pressure (Transmission) ........................ 03-23
Modulating Valves (Transmission) .................. 03-23
Relief Valve (Charge Pressure) ...................... 03-23
Testing and Adjusting Information
Determine Probable Causes ......................... 03-305
Reduce List of Probable Causes .................. 03-305
Test System .................................................. 03-305
Troubleshooting Procedure .......................... 03-305
Understand Symptom ................................... 03-305
Verify Symptom ............................................ 03-305
Transmission - Assemble
Assembly Procedure ..................................... 03-168
Input Shaft Assembly .................................... 03-172
79033095 C Rev. 03-331

Index
NOTES
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03-332 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
04 - Frame
Contents
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UNDERCARRIAGE SYSTEM OPERATION

Introduction [Undercarriage (Mobil-Trac) System] ......................................................................................... 04-1
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Undercarriage (Mobil-Trac) System Components ......................................................................................... 04-2

Mobil-trac System Track .......................................................................................................................... 04-2
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Drive Wheel ............................................................................................................................................. 04-2

Front Idler ................................................................................................................................................ 04-3
Midwheel ................................................................................................................................................. 04-3
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Tension Cylinder ..................................................................................................................................... 04-4

Choosing Correct Belt ............................................................................................................................. 04-6
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General Ag Belts ................................................................................................................................... 04-10

Extreme Application Belts ..................................................................................................................... 04-10
Special Application Belts ....................................................................................................................... 04-10
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Average Ground Pressure for Mobil-trac System Belts ......................................................................... 04-11

Front Idlers, Drive Wheels, and Midwheels ........................................................................................... 04-12
Undercarriage (Mobil-Trac) Gauge Spacing ................................................................................................ 04-13
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Procedure to Change Gauge Spacing for Mobil-trac System ............................................................... 04-13

Moving Undercarriage ........................................................................................................................... 04-18
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Measuring for Desired Gauge Change .................................................................................................. 04-19

Installing Collets and Restraint Clamps After a Gauge Change ............................................................ 04-23
(Mobil-Trac) Belt System ............................................................................................................................. 04-24
Basic Rules for Maximizing Track Life .................................................................................................. 04-24
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Rubber Track Terminology .................................................................................................................... 04-25

Part and Serial Number Location (Track) .............................................................................................. 04-26
Wheel Part/Date Code Location ............................................................................................................ 04-26
Treadbar Wear Measurement ............................................................................................................... 04-27
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Treadbar Wear Patterns and Characteristics ........................................................................................ 04-28

Guide Lugs ............................................................................................................................................ 04-30
Carcass Typical Wear Patterns and Characteristics ............................................................................. 04-31
Drivewheels and Idlers .......................................................................................................................... 04-32
Midrollers Typical Wear Patterns and Characteristics ........................................................................... 04-33
Undercarriage (Mobil-Trac) Track Tension/Detension ................................................................................. 04-34
Detensioning Drive Tracks .................................................................................................................... 04-34
Tensioning Track ................................................................................................................................... 04-36
Releasing Pressure Between Nipple and Filler Valve ........................................................................... 04-41
FRAME DISASSEMBLY AND ASSEMBLY

Undercarriage Drive Track (Mobil-Trac) ...................................................................................................... 04-43
Track Removal ...................................................................................................................................... 04-43
Inspection .............................................................................................................................................. 04-46
Drive Track Installation .......................................................................................................................... 04-48
Undercarriage Pressure Sensor .................................................................................................................. 04-50
Pressure Sensor Removal .................................................................................................................... 04-50
Pressure Sensor Installation ................................................................................................................. 04-52
Undercarriage Tensioner Rupture Disc ....................................................................................................... 04-54
79033095 C Rev. 04-i

Contents
Rupture Disc Removal .......................................................................................................................... 04-54
Rupture Disc Installation ....................................................................................................................... 04-56
Undercarriage Tensioner ............................................................................................................................. 04-58
Tensioner Removal ............................................................................................................................... 04-58
Tensioner Disassembly ......................................................................................................................... 04-60
Accumulator Removal ........................................................................................................................... 04-62
Accumulator Installation ........................................................................................................................ 04-63
Tensioner Assembly .............................................................................................................................. 04-64
Tensioner Installation ............................................................................................................................ 04-66
Undercarriage Idler Hub .............................................................................................................................. 04-68
Idler Hub Removal ................................................................................................................................. 04-68
Idler Hub Installation .............................................................................................................................. 04-69
Undercarriage Swing Link and Lever ........................................................................................................... 04-70
Swing Link and Lever Removal ............................................................................................................. 04-70
Swing Link and Lever Disassembly ....................................................................................................... 04-72
Swing Link and Lever Assembly ........................................................................................................... 04-74
Swing Link and Lever Installation .......................................................................................................... 04-76
Installing Duo-Cone Seals ........................................................................................................................... 04-79
Assembly and Installation of Conventional Duo-Cone Seals ................................................................ 04-79
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Required Tools ...................................................................................................................................... 04-79

Correct Assembly of Conventional Duo-Cone Seal .............................................................................. 04-79
Assembly and Installation Procedure .................................................................................................... 04-80
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Acceptable Lubricants for Assembly ..................................................................................................... 04-84

Result of Incorrect Assembly ................................................................................................................. 04-85
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Undercarriage Midwheel Assembly ............................................................................................................. 04-86

Midwheel Assembly Removal ............................................................................................................... 04-86
Midwheel Disassembly .......................................................................................................................... 04-87
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Midwheel Assembly ............................................................................................................................... 04-90

Midwheel Assembly Installation ............................................................................................................ 04-92
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Undercarriage Reaction Arm ....................................................................................................................... 04-93

Disassembly .......................................................................................................................................... 04-93
Assembly ............................................................................................................................................... 04-96
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Maintenance ........................................................................................................................................ 04-100

Undercarriage Assembly ........................................................................................................................... 04-101
Undercarriage Removal ...................................................................................................................... 04-101
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Undercarriage Installation ................................................................................................................... 04-104

Roller Frame Restraint Group .................................................................................................................... 04-106
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Roller Frame Restraint Group Removal .............................................................................................. 04-106

Roller Frame Restraint Group Installation ........................................................................................... 04-108
Drawbar (Wide Swing) ............................................................................................................................... 04-110
Drawbar (Wide Swing) Removal ......................................................................................................... 04-110
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Drawbar (Wide Swing) Installation ...................................................................................................... 04-113

Powered Drawbar (Hydraulic Controlled) .................................................................................................. 04-117
Powered Drawbar (Hydraulic Controlled) Removal ............................................................................. 04-117
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Powered Drawbar (Hydraulic Controlled) Installation .......................................................................... 04-124

Drawbar (3-pt Hitch) .................................................................................................................................. 04-131
Drawbar (3-PT Hitch) Removal ........................................................................................................... 04-131
Drawbar (3-PT Hitch) Installation ........................................................................................................ 04-133
Special Application Hitch ........................................................................................................................... 04-134
Special Application Hitch Removal ...................................................................................................... 04-134
Special Application Hitch Installation ................................................................................................... 04-137
Step (Upper) .............................................................................................................................................. 04-140
Step (Upper) Removal ......................................................................................................................... 04-140
Step (Upper) Installation ...................................................................................................................... 04-140
Fuel Tank ................................................................................................................................................... 04-141
Fuel Tank Removal ............................................................................................................................. 04-141
Fuel Tank Installation .......................................................................................................................... 04-148
Auxiliary Fuel Tank .................................................................................................................................... 04-155
Auxiliary Fuel Tank Removal ............................................................................................................... 04-155
Auxiliary Fuel Tank Installation ............................................................................................................ 04-157

Belt Alignment (Mobil-Trac) ....................................................................................................................... 04-159
04-ii 79033095 C Rev.

Contents
Introduction .......................................................................................................................................... 04-159
Checking Belt Alignment ..................................................................................................................... 04-159
Adjusting Belt Alignment ..................................................................................................................... 04-160
Further Alignment Steps - I ................................................................................................................. 04-162
Further Alignment Steps - II ................................................................................................................ 04-163
Checking Oil Levels ................................................................................................................................... 04-164
Idlers and Midwheels without Sight Gauge ......................................................................................... 04-164
Idlers Wheels with Sight Gauge .......................................................................................................... 04-164
Midwheels with Sight Gauge ............................................................................................................... 04-165
Drive Wheels ....................................................................................................................................... 04-166
FRAME SPECIFICATIONS
Undercarriage ............................................................................................................................................ 04-167
Front Idler ............................................................................................................................................ 04-167
Procedure for Installation of Lever ...................................................................................................... 04-168
Idler Specifications .............................................................................................................................. 04-169
Midwheel ............................................................................................................................................. 04-170
Procedure for Setting Bearings for Midwheel ...................................................................................... 04-172
Midwheel Specifications ...................................................................................................................... 04-173
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Torque Procedure for Drive Wheel Collet Bolts .................................................................................. 04-174

Drive Wheel Specifications .................................................................................................................. 04-175
Belt Tensioner ............................................................................................................................................ 04-176
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Accumulator (Belt Tension) ................................................................................................................. 04-176

Tensioner Pressure Sensor ................................................................................................................. 04-177
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Disc Relief Valve ................................................................................................................................. 04-178

Fuel Tank ................................................................................................................................................... 04-179
Main Tank ............................................................................................................................................ 04-179
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Auxiliary Tank ...................................................................................................................................... 04-180

Drawbar (Standard) ................................................................................................................................... 04-181
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INDEX ........................................................................................................................................................... 04-183

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79033095 C Rev. 04-iii

Contents
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04-iv 79033095 C Rev.

Undercarriage System Operation
UNDERCARRIAGE SYSTEM OPERATION
INTRODUCTION [UNDERCARRIAGE
(MOBIL-TRAC) SYSTEM]
FIG. 1: MT800 series agricultural machines use
patented Mobil-trac system with latest technology in order
to provide following characteristics:
• Speed
• Mobility
• Versatility
• Traction
• Flotation
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• A smooth ride in field

• Low compaction g00891795
Undercarriage system uses six axles on MT800 to FIG. 1

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significantly lower load on each axle. Result of lower load

on each axle is lower compaction. Undercarriage system
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relies upon high tension in order to create friction between

driver and track. High friction is used to propel machine.
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1. Mobil-trac System Track

2. Drive Wheel
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3. Midwheel
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4. Front Idlers
Mobil-trac system is also designed to vary gauge spacing
without detensioning track. Machine operation and
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performance is affected to a large degree by following

items:
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• Selection of Tracks
• Front Idlers, Drive Wheels, and Midwheels
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• Training Techniques
NOTE: Refer to Undercarriage (Mobil-trac) Gauge
Spacing in this section.
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79033095 C Rev. 04-1

UNDERCARRIAGE (MOBIL-TRAC)
SYSTEM COMPONENTS
Mobil-trac System Track

FIG. 2: A Mobil-trac system belt is located on each side
of machine.
Mobil-trac system belt is used to provide following
functions:
• Provide high tractive efficiency for less slip.
• Low ground pressure in order to provide less
compaction.
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g00892198
FIG. 2
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Drive Wheel
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FIG. 3: A drive wheel is located on each side toward rear

of machine.
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Drive wheel has following functions:

• Power from final drive flows through drive wheel.
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Friction between drive wheel and belt causes belt to

turn.
• A 51.0 mm (2.0 in) rubber coating is used in order to
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improve suspension and ride.

• Chevron pattern that is molded into drive wheel helps
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removal of debris.
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g00841126
FIG. 3
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04-2 79033095 C Rev.

Front Idler
FIG. 4: A front idler is located on each side toward front
of machine.
Front idler has following functions:
• Guide belt back to drive wheel.
• Tensioning or detensioning point for belt.
• Allow counterweights to be attached to machine.
• A 51.0 mm (2.0 in) rubber coating is used to improve
suspension and ride.
g00892204
FIG. 4
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Midwheel
FIG. 5: Midwheels are located between drive wheel and
front idler of machine.
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Midwheels have following functions:

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• Provide additional support for weight of machine.

• Act as additional axles to provide a more comfortable
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ride.
• A 51.0 mm (2.0 in) rubber coating is used to improve
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suspension and ride.

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g00841116
FIG. 5
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79033095 C Rev. 04-3

Tension Cylinder
FIG. 6: Tension cylinder (1) is located on each side of
machine. Tension cylinder is located above midwheels
between front idler and drive wheel.
Tension cylinder performs following functions:
• Belt tensioner provides a constant belt tension for
each belt.
• Tension cylinder will extend or tension cylinder will
compress in order to absorb shocks.
g00891795
FIG. 6
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P031105002
FIG. 7
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FIG. 7: Tensioner cylinder (1) for undercarriage on

Mobil-trac system is used in order to provide tension for
belts. A tensioner cylinder is on each undercarriage.
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Each tensioner cylinder has a dry nitrogen charged

accumulator (2). Accumulator (2) will allow tensioner
cylinder to move back and forth in order to maintain belt
tension.
Dry nitrogen in accumulator has following benefits:
• Dry nitrogen keeps moisture out of one side of
cylinder.
• Dry nitrogen reduces corrosion in one side of
cylinder.
Residual oil in cylinder will provide following features:
• Opposite side of cylinder is kept relatively free of
corrosion.
• Residual oil lubricates seals.
Tensioner cylinder has a coating of nickel and a coating of
chrome for added durability.
04-4 79033095 C Rev.

Belt tensioner for undercarriage is fully charged at 20100
kPa (2900 psi).
NOTE: MT800 belt tensioner for undercarriage will
provide 222.4 kN (50000 lb) of force. Nominal
belt tension will be 111.2 kN (25000 lb).
Use following procedure if system pressure is lower than
16890 to 17580 kPa (2450 to 2550 psi). Also, use
following procedure if system pressure is higher than
21029 to 21719 kPa (3050 to 3150 psi):
NOTE: Refer to Undercarriage (Mobil-trac) Belt
Tension/Detension in this section for correct
procedure for recharging hydraulic tension
cylinder.
NOTE: Hydraulic oil pressure in hydraulic tension
cylinder for Mobil-trac System will fluctuate with
temperature. Machines that are being used in
extreme cold weather conditions may require
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hydraulic tension cylinder to be recharged. This

would need to be done to avoid warnings of low
belt tension. If hydraulic tension cylinder is
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recharged, hydraulic oil pressure should be

reduced when machine returns to normal
in
ambient conditions. Standard charge pressure

for hydraulic tension cylinder is 19,995 kPa
(2,900 psi). Charge pressure will typically drop to
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18,615 kPa (2,700 psi) after charging hydraulic

tension cylinder.
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An electrical warning system will warn operator if belt

tension drops below a preset value.
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FIG. 8: A guard protects tension cylinder and

accumulator. Purge screw (1) for tension cylinder must be
removed to remove guard.
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P031105001
FIG. 8
79033095 C Rev. 04-5

Choosing Correct Belt
FIG. 9: Machines can be configured with one of several
different belts (1). Matching correct belt to application
improves machine's performance.
Flotation is best with wide belts. Penetration (traction) of
tread bars is better on narrow belts.
NOTE: Even with narrow belts, contact area of a
mobil-trac system machine is greater than
contact area of a comparable wheel type
machine.
Balance between slippage and flotation must be
considered when you equip a machine with wide belts.
Following four types of belts are available for machine:
• General Ag belts 1
P031105003
• Extreme Application belts
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FIG. 9
• Special Application belts
Following differences are between different types of belts:
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• Number of tread bars

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• Height of tread bar

• Top width of tread bar
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• Length of guide blocks

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• Protection of Belt
Height of tread bar has increased from previous designs
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on General Ag belt and Extreme Application belt.

Additional height increases life of belt. Center-to-center
distance between tread bars has decreased. Belt has
more tread bars per foot.
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Tips of tread bars are wider on Extreme Application belt.

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Angle of relief is steeper. Extreme Application belt may

not expel sticky mud as well as General Ag belt.
Length of guide blocks on Extreme Application belt was
on
increased for sidehill applications. Guide blocks have

more contact length. This will reduce untracking and
increase performance of belt for sidehill applications.
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04-6 79033095 C Rev.

Type and Weight Available Sizes Tread Bars Guide Blocks

Quantity Height Width
General Ag Belt 699 mm (27.5 inch) 100 68.5 mm (2.7 inch) 41 mm (1.6 inch) 522
Chevron1
General Ag Belt 762 mm (30 inch) 100 68.5 mm (2.7 inch) 41 mm (1.6 inch) 522
Chevron3
General Ag Belt 914 mm (36 inch) 100 68.5 mm (2.7 inch) 41 mm (1.6 inch) 522
Chevron4
Extreme 457 mm (18 inch) 100 75 mm (3 inch) 64 mm (2.5 inch) 525
Application6 Chevron1
Extreme 699 mm (27.5 inch) 100 75 mm (3 inch) 64 mm (2.5 inch) 525
Fo

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Special Application7 762 mm (30 inch) 100 64 mm (2.5 inch) 64 mm (2.5 inch) 525
Chevron3
in
Special Application7 914 mm (36 inch) 100 64 mm (2.5 inch) 64 mm (2.5 inch) 525
Chevron4
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NOTE: 1These belts require a gauge of at least 2286 mm

(90 inch).
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2
Length of guide block is 115 mm (4.5 inch).
3
These belts require a gauge of at least 2349.5
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mm (92.5 inch).
4
These belts require a gauge of at least 2502 mm
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(98.5 inch).
5
Length of guide block is 315 mm (5.3 inch).
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6
These belts have protection of Belt, wider tread
bar tips, and angle of relief is steeper.
7
These belts have extra layers of rubber on
on
inside surface of belt for added protection. Tread

bars are shorter, otherwise this belt is very similar
to Extreme Application Belt.
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79033095 C Rev. 04-7

Belt Type Belt Row Tread Self- Ride Draw Loose Rock Exten Level Resist- Groun
Width Spac Bar Clean on bar Soil y Soil -sive of ance d
mm / -ing Pene- -ing the Load Con- Con- Road Soil to Pene-
inch tratio Roa dition ditio ing Distur Untrac tration
n d n -banc k-ing
e
General 406/16 +++ +++ +++ + + ++ + + + ++ +
Ag Belt
457/18 +++ +++ +++ + + ++ + + + ++ +
508/20 +++ +++ +++ + + +++ + ++ + ++ +
635/25 ++ +++ +++ + + +++ + ++ + ++ +
699/27. ++ +++ +++ + + +++ + ++ + ++ +
5
762/30 + +++ +++ + + +++ + ++ + ++ +
914/36 + +++ +++ + + +++ + ++ + ++ +
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Extreme 356/14 +++ +++ ++ +++ ++ ++ +++ ++ ++ +++ ++

Application
Belt 406/16 +++ +++ ++ +++ ++ ++ +++ ++ ++ +++ ++
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457/18 +++ +++ ++ +++ +++ ++ +++ ++ ++ +++ ++

in
508/20 +++ +++ ++ +++ +++ +++ +++ ++ ++ +++ ++

635/25 ++ ++ ++ +++ +++ +++ +++ +++ ++ +++ ++
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699/27. ++ + ++ +++ +++ +++ +++ +++ ++ +++ ++

5
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762/30 + + ++ +++ +++ +++ +++ +++ ++ +++ ++

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914/36 + + ++ +++ +++ +++ +++ +++ ++ +++ ++

Low Profile 406/16 +++ + + ++ +++ ++ ++ ++ +++ ++ +++
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457/18 +++ + + ++ +++ ++ ++ ++ +++ ++ +++

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635/25 ++ + + ++ +++ ++ ++ +++ +++ ++ +++

Special 762/30 + + ++ +++ +++ +++ +++ +++ ++ +++ ++
Application
914/36 + + ++ +++ +++ +++ +++ +++ ++ +++ ++
on
Extreme Ag 635/25 ++ +++ +++ ++ ++ +++ ++ + + +++ +

Belt
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04-8 79033095 C Rev.

Following factors should be considered when choosing Loose Soil Conditions - Wider belts are better in loose
proper belt for customer. Local experience is main factor soil conditions than narrow belts. General Ag belts and
in determining correct type of belt for application. extreme application belts are better than low profile belts
in loose soil conditions.
Row Spacing - Use of machine in row crop applications
will dictate width of belt. Treadbars on extreme application Rocky Soil Conditions - Extreme application belts and
belts are closer to edge of belt. A narrower belt might be special application belts are preferred belt for rocky soil
necessary in order to prevent crop damage. conditions. Extreme application belts and special
application belts have additional protection on inside layer
Treadbar Penetration - General Ag belt will penetrate
of belt.
better than other belt types. A narrow belt will penetrate
better than a wide belt. Tip pressure is higher on a narrow Extensive Roading - Roading directly affects life of belt.
belt. Extreme application belts will have a longer belt life. Wider
belts wear better than narrow belts when roading
Cleaning - General Ag belt will clean better in sticky soil extensively.
conditions than other belt types. General Ag belt has
more space between treadbars. Relief angle on treadbars Level of Soil Disturbance - Low profile belts will disturb
is shallower. soil the least. Wider belts are better than narrow belts.
Ride on Road - Belts with additional rubber on road will Resistance to Untracking - Extreme application belts
improve ride on road. Suspension on machine will reduce and special application belts will provide greatest
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importance of this factor. Low Profile Belts will have worst resistance to untracking. Extreme application belts have
ride quality. Ride quality may decrease as treadbars wear. longer guide blocks.
Drawbar Load - Wider belts are better when machine Ground Penetration - Extreme application belts and low
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has a large drawbar or three-point hitch load. profile belts will provide better traction in solid soils. Wider
in
rolling stock will also improve penetration on treadbars.

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79033095 C Rev. 04-9

General Ag Belts Special Application Belts
General Ag belts are preferred belts for most agricultural Tips of tread bars are wider on Special Application belt
applications. See Table 01 for characteristics of General than General Ag belt. Angle of relief is steeper.
Ag Belts.
Special Application belt may not expel sticky mud as well
as General Ag belt.
Extreme Application Belts
Length of guide blocks on Special Application belt was
Tips of tread bars are wider on Extreme Application belt. increased for high side load applications same as
Angle of relief is steeper. Extreme Application belt. Guide blocks have more contact
Extreme Application belt may not expel sticky mud as well length. This will reduce untracking and increase
as General Ag belt. performance of belt for high side load applications.
Length of guide blocks on Extreme application belt was Special Application tread bars are shorter than General
increased for sidehill applications. Guide blocks have Ag or Extreme Application belts. This feature allows
more contact length. This will reduce untracking and machine to slip out easier, which helps to protect belt and
increase performance of belt for sidehill applications. powertrain.
Extreme application belts are designed for high drawbar Special Application belts are designed for extremely
abrasive and rocky conditions.
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loads and extremely abrasive conditions.

Extreme application belts have additional protection on Special application belts have additional protection on
inside diameter of belt. This feature protects belt from soil inside diameter of belt. More layers of rubber on inside
surface, than on Extreme Application belt, helps to protect
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that is rocky and soil that is abrasive.

main cables from rock damage. This feature provides
Extreme application belts are used for applications that additional protection of belt from soil that is rocky, than
in
involve a substantial amount of work on inclines and on Extreme Application belt.

downward slopes. Working on inclines can apply more
Special Application belts are used for applications that
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load on uphill side of guide block. As a result, some

applications on side slopes can cause guide blocks to involve a substantial amount of work on inclines, on
wear faster than tread bars. downward slopes, and in rocky conditions. Working on
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inclines can apply more load on uphill side of guide block.

In some cases, wear of guide block will determine life of As a result, some applications on side slopes can cause
belt. For these applications, extreme application belts guide blocks to wear faster than tread bars.
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have longer guide blocks.

In some cases, wear of guide block will determine life of
Longer guide blocks give lower individual loading to each belt. For these applications, Special Application belts
guide block when machine is running on slopes. have longer guide blocks.
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See Tables 01 for characteristics of extreme application Longer guide blocks give lower individual loading to each
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belts. guide block when machine is running on slopes or when

belt sees high side loads.
See Table 01 for characteristics of Special Application
on
belts.
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04-10 79033095 C Rev.

Average Ground Pressure for Mobil-trac
System Belts
FIG. 10: Reducing ground pressure is important in
prevention of ground compaction. Wider belts provide
better flotation. Penetration (traction) of treadbars is better
on narrow belts.
Balance between treadbar penetration and flotation must
be considered when you choose type of belt for machine.
NOTE: Even with narrow belts, contact area of belts is
greater than contact area of tires that are on a
comparable wheel type machine.
The table provides average ground pressures for MT800
Mobil-trac System belts.
P031105004
FIG. 10
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Average Ground Pressure

Type of Belt 17236 kg 22680 kg
(38,000lb)1 (50,000 lb)2
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457mm (18 inch) 61.6 kPa (8.9 psi) 81.3 kPa (11.8 psi)3
in
699mm (27.5 inch) 40.3 kPa (5.9 psi) 53 kPa (7.7 psi)
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762mm (30 inch) 37 kPa (5.4 psi) 49 kPa (7.1 psi)

914mm (36 inch) 30.8 kPa (4.5 psi) 41 kPa (5.9 psi)
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NOTE: 1This is approximate machine shipping weight for

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all of models.
2
This is maximum GVW.
3
Limit roading speed to 24 kph (15 mph) when
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ballasted weight of machine exceeds 20,411 kg

(45,000 lb) with this belt configuration.
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79033095 C Rev. 04-11

Front Idlers, Drive Wheels, and Midwheels
FIG. 11: Three widths of components are available.
• Front Idlers
• Midwheels
• Drive Wheels
Components are available in following three widths:
• Narrow
• Medium
• Wide
This enables width of components to be matched to belt
g00841126
width. Correct combination maximizes traction while
minimizing compaction. FIG. 11
Matching components provides following benefits:
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• Increased belt life

• Increased flotation
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• Reduced compaction
in
• Reduced component wear

The table indicates available combinations for belts and
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wheel components for MT800.

NOTE: Maximum gross vehicle weight (GVW) of
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machine is determined by width of components

in Mobil-trac system.
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Refer to Operation and Maintenance Manual, Ballasting

for Tractive Performance, for more information about
maximum GVW.
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Width of 457 mm 699 mm 762 mm 914 mm

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the Belt (18 inch) (27.5 inch) (30 inch) (36 inch)
Idler
Medium Required Compatible Compatible Compatible
on
Wide Non- Recommended Recommended Recommended

Compatible
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Midwheel
Compatible
Driver
Compatible
04-12 79033095 C Rev.

UNDERCARRIAGE (MOBIL-TRAC) GAUGE
SPACING
Procedure to Change Gauge Spacing for

Mobil-trac System
The table shows required tools to change gauge spacing
for Mobil-trac System.
Required Tools
Part Number Description Quantity
203-9712 Axle Gauge 1
Change Tool Group
207-1601 Rubber Lubricant 1
203-5584(1) Bracket 1
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IU-7498(2) Support Stand Assembly 4
1. This part number includes two brackets.

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2. This part number includes one stand.

in
Tools for following procedure are provided with

203-9712 Axle Gauge Change Tool Group:
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FIG. 12: Following tools, provided with 203-9712 Axle

Gauge Change Tool Group, are shown for use on
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Hardbar to change gauge:

1. Bracket
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2. Threaded rod
3. 8 mm (0.32 inch) bolt and washer
2
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4. M12 x 1.75 x 35 mm bolt and washer

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1
3
4
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00658357
FIG. 12
FIG. 13: Following tools, provided with 203-9712 Axle
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Gauge Change Tool Group, are shown for use on Rear

Axle to change gauge:
5. Bracket 6
6. Threaded rod
00658438
FIG. 13
79033095 C Rev. 04-13

FIG. 14: Make sure that you thoroughly clean hardbar
(1) and rear axle (2) before you start following procedure.
2
ch-0012
FIG. 14
FIG. 15: Loosen two bolts (1) on both sides of
undercarriage. Loosen bolts so that there is
approximately 12.7 mm (0.50 in) space between cap (2)
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and undercarriage. 1
NOTE: This Step must be done while machine is still on
ground.
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NOTE: If MT800 undercarriage system is equipped with

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Rollerframe Restraint Group, refer to

Disassembly and Assembly, Rollerframe
Restraint Group, Removal, in this section.
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IMPORTANT: Do not use a petroleum based lubricant. 2

This type of lubricant may cause a deterioration
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00658409
of rubber based bearing material that is on
bearing cap and undercarriage. FIG. 15
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FIG. 16: Apply 207-1601 Rubber Lubricant (1) to

hardbar with a nozzle or a squirt bottle. Make sure that
you apply lubricant on bearing surfaces on both sides of
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undercarriage. This will help make moving undercarriage 3

much easier. If necessary, use a pry bar (2) in order to lift
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cap (3).
1
This will allow lubricant to flow underneath bearing
surface.
on
2
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N120705003
FIG. 16
04-14 79033095 C Rev.

FIG. 17: Install 203-5584 brackets (1) on front of
machine.
Raise front of machine by using an appropriate lifting
device. Place lifting device under cast boss on front
1
housing.
NOTE: Make sure that belt is off of ground by at least 50
mm (2 in).
Support front of machine with 1U-7498 support stands
(2). 2
00868537
FIG. 17
FIG. 18: Raise rear of machine off of ground by using an
appropriate lifting device. Support machine with 1U-7498
support stands (1). Rear support stands should be placed
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under plate (2) that is part of wide swinging drawbar or

flanges that are located on final drive housings.
NOTE: Make sure that machine is off of ground by at 2
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least 50 mm (2 in).
1
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N120705004
FIG. 18
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FIG. 19: Remove bolts and washers (1) that are on

hardbar.
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N120705005
FIG. 19
FIG. 20: Install bracket (1) on hardbar. Use two bolts and
washers (2) that were originally on hardbar.
1
N120705006
FIG. 20
79033095 C Rev. 04-15

FIG. 21: Install threaded rod (1) on cap (2) by using bolt
(3). Make sure that one washer (4) is located on each side 2 3
of bracket (5). 5
N121005001
FIG. 21
FIG. 22: Install pin (1) into bracket (2).
1
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2
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N121005002
FIG. 22
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FIG. 23: Remove all of bolts and washers from collets

except for bolts (1). Bolts (1) are located on joint between
two collets. 3
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Back out bolts (1) by 19.0 mm (0.75 in).

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These bolts will hold collets if there is any sudden

movement. 2 2
NOTE: You may need to back out bolts (6) more than
on
19.0 mm (0.75 in) to allow undercarriage to freely

move on axle. Make sure that enough thread
remains in driver in order to safely hold collets.
1
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Temporarily hold adjustment bracket onto end of axle.

This will indicate available positions for pusher bolts (2) N121105001
and threaded rod. Do not remove plate (3) on end of axle. FIG. 23
Plate will secure drive wheel if there is any sudden
movement.
Install pusher bolts (2) in available positions indicated in
previous step.
NOTE: Pusher bolts (2) are bolts that were removed
previously from collets.
Alternate turning bolts (2) clockwise so that collet slowly
retracts from drive wheel.
NOTE: If necessary, additional pusher bolts may be
needed.
04-16 79033095 C Rev.

FIG. 24: Remove plate (1) by removing M12 x 35 mm
bolts and washers (2).
1
2
00814682a
FIG. 24
FIG. 25: Temporarily hold adjusting bracket onto end of
axle. This will identify hole for installing threaded rod.
Install threaded rod (1) and tighten jam nut (2). 1 2
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N121105002
FIG. 25
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FIG. 26: Use M12 x 35 mm bolts and washers in order to

install bracket (1). Make sure that one washer (2) is
located on each side of bracket (1).
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00658438
FIG. 26
FIG. 27: Install pin (1).
1
N121105003
FIG. 27
79033095 C Rev. 04-17

Moving Undercarriage
FIGS. 28–29: Turn adjustment nut (1) to move
undercarriage on rear axle.
1
Turn adjustment nut (2) in order to move undercarriage on
hardbar.
NOTE: Make sure that you adjust both sets of tooling
evenly so that undercarriage does not bind on
hardbar or rear axle.
For information about measuring for a gauge change, see
Measuring for Desired Gauge Change, Dimensions for
Gauge in this section.
00658438
FIG. 28
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2 00658485
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FIG. 29
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04-18 79033095 C Rev.

Measuring for Desired Gauge Change
FIGS. 30–31: Measure distance (1) from end of hardbar
to cap. Measure distance (2) from end of rear axle to 1
collet.
NOTE: Measure to face on MT800 collet.
See illustrations and tables that are in Dimensions for
Gauge sections. These sections will provide complete
details for measuring hardbar and rear axle.
P043005001
FIG. 30
2
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P043005002
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FIG. 31
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79033095 C Rev. 04-19

Dimensions for MT800 Gauge
Fo
AA
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EF
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N121105009
FIG. 32
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FIG. 32: Locations for Measuring Gauge:

(AA) Surface of collet
(EF) Machined surface on cap
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04-20 79033095 C Rev.

MT800 Gauge
Dimensions
Gauge Dimension for Hardbar (1) Dimension for Rear Axle (2)
2286 mm 481.1 to 484.1 mm 481.1 to 484.1 mm
(90 inch) (18.94 to 19.06 in) (18.94 to 19.06 in)
2336.8 mm 455.7 to 458.7 mm 455.7 to 458.7 mm
(92 inch) (17.94 to 18.06 in) (17.94 to 18.06 in)
2387.6 mm 430.3 to 433.3 mm 430.3 to 433.3 mm
(94 inch) (16.94 to 17.06 in) (16.94 to 17.06 in)
2438.4 mm 404.9 to 407.9 mm 404.9 to 407.9 mm
(96 inch) (15.94 to 16.06 in) (15.94 to 16.06 in)
2489.2 mm 379.5 to 382.5 mm 379.5 to 382.5 mm
(98 inch) (14.94 to 15.06 in) (14.94 to 15.06 in)
Fo
2540.0 mm 354.1 to 357.1 mm 354.1 to 357.1 mm

(100 inch) (13.94 to 14.06 in) (13.94 to 14.06 in)
2590.8 mm 328.7 to 331.7 mm 328.7 to 331.7 mm
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(102 inch) (12.94 to 13.06 in) (12.94 to 13.06 in)

2641.6 mm 303.3 to 306.3 mm 303.3 to 306.3 mm
in
(104 inch) (11.94 to 12.06 in) (11.94 to 12.06 in)

2692.4 mm 277.9 to 280.9 mm 277.9 to 280.9 mm
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(106 inch) (10.94 to 11.06 in) (10.94 to 11.06 in)

2743.2 mm 252.5 to 255.5 mm 252.5 to 255.5 mm
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(108 inch) (9.94 to 10.06 in) (9.94 to 10.06 in)

2794.0 mm 227.1 to 230.1 mm 227.1 to 230.1 mm
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(110 inch) (8.94 to 9.06 in) (8.94 to 9.06 in)

2844.8 mm 201.7 to 204.7 mm 201.7 to 204.7 mm
(112 inch) (7.94 to 8.06 in) (7.94 to 8.06 in)
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2895.6 mm 176.3 to 179.3 mm 176.3 to 179.3 mm

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(114 inch) (6.94 to 7.06 in) (6.94 to 7.06 in)

2946.4 mm 150.9 to 153.9 mm 150.9 to 153.9 mm
(116 inch) (5.94 to 6.06 in) (5.94 to 6.06 in)
on
2997.2 mm 125.5 to 128.5 mm 125.5 to 128.5 mm

(118 inch) (4.94 to 5.06 in) (4.94 to 5.06 in)
3048.0 mm 100.1 to 103.1 mm 100.1 to 103.1 mm
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(120 inch) (3.94 to 4.06 in) (3.94 to 4.06 in)

3098.8 mm 74.7 to 77.7 mm 74.7 to 77.7 mm
(122 inch) (2.94 to 3.06 in) (2.94 to 3.06 in)
3149.6 mm 49.3 to 52.3 mm 49.3 to 52.3 mm
(124 inch) (1.94 to 2.06 in) (1.94 to 2.06 in)
3200.4 mm 23.9 to 26.9 mm 23.9 to 26.9 mm
(126 inch) (0.94 to 1.06 in) (0.94 to 1.06 in)
3251.2 mm -1.5 to 1.5 mm -1.5 to 1.5 mm
(128 inch) (-0.06 to 0.06 in) (-0.06 to 0.06 in)
1. See callout (AD) in illustration that follows.

2. See callout (AB) in illustration that follows.
79033095 C Rev. 04-21

FIG. 33: Callouts in view of hardbar for gauge dimension
are:
(AD) Dimension for gauge
(EF) Machined surface AD
EG
(EG) Plate
(EH) Hardbar
Measure distance (AD) from machined surface (EF) to
outside of plate (EG). EF
See table for dimension (AD) for hardbar. This table
provides correct dimension (AD) for each of different EH
gauge widths. Q020205001
FIG. 33
FIG. 34: Callouts in view of face of collet are:
(AA) Surface of collet
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(AB) Dimension for gauge

(AC) Axle AB
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Measure distance (AB) from surface of collet (AA) to edge

of axle (AC). AA
in
See table for dimension (AB) for axle. This table provides
correct dimension (AB) for each different gauge width.
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AC
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Q020205003
FIG. 34
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04-22 79033095 C Rev.

Installing Collets and Restraint Clamps
After a Gauge Change
FIG. 35: After you obtain desired machine gauge
dimension, use following procedure in order to prepare
machine for use: 1
NOTE: Leave tooling for gauge change in place until
hardware for collets and hardbar can be
tightened. This will hold undercarriage in desired
position.
Tighten bolts (1) securely before removing tooling.
Tighten two bolts (1) on both sides of undercarriage to a
torque of 700 to 900 Nm (515 to 665 lbf ft).
NOTE: If MT800 undercarriage system is equipped with
Rollerframe Restraint Group, refer to
N121005002
Disassembly and Assembly, Rollerframe
Restraint Group, Install, in this section. FIG. 35
Fo
FIG. 36: Remove pusher bolts and replace all of bolts

and washers in original locations. 4
12 10
NOTE: Coat threads of collet bolts with anti-seize prior to
r
installation. 8
Do not use any type of lubricant when installing
in
6
collets. mating tapered surfaces of collets and
outer hub must be installed dry. Failure to install
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properly may decrease life of drive wheel support

bearing.
1 2
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Tighten bolts and washers securely before removing

tooling.
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IMPORTANT: Failure to follow next steps may allow bolts

to become loose. 5 7
Figure shows sequence for tightening bolts and washers
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on collets. Tighten bolts on collets to 530 Nm (391 lbf ft).

11
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Use a crisscross pattern as you perform torque 9

sequence. Begin torque sequence with bolt (1). Perform 3
N121305001
this sequence a total of three times.
FIG. 36
IMPORTANT: If surface (A) and (B) are mismatched in
on
excess of 0.8 mm (0.31 in) remove collets and

repeat tightening procedure.
Perform a fourth tightening sequence at 460 Nm (339 lbf
ly
ft). If bolt number 12 rotates when 460 Nm (339 lbf ft) is

applied, perform a fifth pass at 460 Nm (339 lbf ft).
FIG. 37: Lower machine to ground by using appropriate
lifting devices or jacks.
P031105004
FIG. 37
79033095 C Rev. 04-23

(MOBIL-TRAC) BELT SYSTEM 2. Maintain Track Alignment
It is very important to periodically check alignment on
Basic Rules for Maximizing Track Life your tracked machine. Alignment can and will change due
to wear in the track components throughout the life of the
Basic rules in maximizing track life are: machine, not only during the break-in period. Poor
• Follow the correct break-in procedures alignment, if left uncorrected, will cause heating and
premature wear, and the eventual destruction of one side
• Maintain the proper track alignment of the guide lug, as well as reducing the life of the mating
• Know ways to maximize the tread bar life midrollers.
• Use the correct operational techniques The primary way to check alignment is to check the
temperature of the guide lugs during field operation or
1. New Track Break-in observe if scuffing is occurring. If there is a significant
Tracks (specifically the guide lugs) will benefit greatly from difference in the temperatures between opposite sides of
the correct break-in procedures. The correct break-in can the guide lug, then the track may be out of alignment. A
help reduce the initial amount of guide lug and midroller second way to check alignment is to drive without any
wear. During the break-in period, the track components steering input on a flat surface for at least 3 complete
under go a polishing-in process. New rubber surfaces track revolutions, then coast to a stop without braking.
Observe if there is clearance with the midrollers on both
Fo
benefit from contact with the dry soil in order to facilitate

smooth break-in and minimize guide lug scuffing. Tracks sides of the guide lugs. The amount of clearance should
should be operated in dry soil as soon as possible. A be roughly the same. If one side has no clearance, then
significant amount of operation, especially roading, before the track is likely out of alignment.
r
introduction into the soil should be avoided. Refer to Testing and Adjustment Section, Belt Alignment
(Mobil-trac), in this section for specific ways to correct the
in
Rule #1 - You must always break-in a new set of

tracks, if possible, in dry and dusty conditions. alignment.
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Rule #2 - Always avoid extended roading at high Rule #3 - Track alignment is the owner's
speeds with a new set of tracks during the break-in responsibility to periodically check and maintain
period, or guide lug and wheel edge damage could properly. Always check alignment whenever tracks
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result. are installed, whenever new undercarriage

components are installed, or if tread gauge width is
changed.
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04-24 79033095 C Rev.

Rubber Track Terminology
FIG. 38: Tracks are constructed using a combination of
natural and synthetic rubber in combination with steel 5
6
reinforcing plies and a continuous wound main cable.
Main cable gives track tension strength, while at the same
time maintaining lateral flexibility. Bias and reinforcement 2
plies protect main cable, provide good internal track
alignment, and further increase lateral stiffness to better
distribute loads across track width.
4
Tread bars are molded into specific shapes, with each
shape giving a distinct performance advantage in specific
applications. 1
3
To discuss belts, wear characteristics, and belt issues
better, certain terms must be defined as they are 00300858
frequently referenced throughout document. Illustration FIG. 38

shows some of basic terminology used when referring to
track construction:
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1. Main Cable
2. Guide Lug
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3. Outside Diameter (OD) Bias Plies (for cable

protection and alignment)
in
4. Tread bar
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5. Inside Diameter (ID) Track Surface

6. Inside Diameter (ID) Bias Ply (for cable protection)
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79033095 C Rev. 04-25

Part and Serial Number Location (Track)
FIG. 39: Track part numbers as well as serial numbers
are both located on side or edge strip of track.
• Part Number - 1R1325
• Date Code - MMYYYY
• Serial Number - 0000
CPB-0370-011
FIG. 39
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Wheel Part/Date Code Location

FIG. 40: Midrollers are not serialized, but do include date
codes that are used for manufacturing traceability. Date
r
codes are found on edge of wheel rubber. Additional date

codes can found on steel and may also help on
in
traceability, if rubber date code is not visible.

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CPB-0370-004
FIG. 40
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04-26 79033095 C Rev.

Treadbar Wear Measurement
FIGS. 41–42: Position a straight edge as shown below,
approximately 1/3 of way in from track edge. Use a caliper
or a ruler to measure down to carcass surface in order to
obtain treadbar height in 4 locations. (A, B, C, D).
NOTE: Make sure to measure on a flat surface of track
(not on a curved section that is wrapped around
C
a wheel). D
NOTE: A belt is considered 100% worn when only B
12.7mm (0.5 in) tread bar height is left. At this
time, belt should be replaced. A
N122005001
FIG. 41
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CPB-0370-003
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FIG. 42
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79033095 C Rev. 04-27

Treadbar Wear Patterns and
Characteristics
FIG. 43: Treadbar wear is a result of two different wear
mechanisms:
1. Abrasive action during transfer of power to ground.
2. Scrubbing action as treadbar leaves and enters
ground contact, or when turning on hard surfaces.
Rate of treadbar wear is heavily influenced by following
factors:
• Total machine weight
• Machine balance
• Average drawbar load and vertical weight
• Soil conditions
Fo
• Amount of road travel

• Amount of turning (contour fields, short fields, etc.)
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CPB-0370-005
FIG. 43
in
FIG. 44: Trailing Edge Wear: Treadbars will normally

wear more on trailing edge (as viewed from top of track).
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Primary tillage applications at high drawbar loads, and

machines with high hitch vertical loads, will generally
rn
cause this pattern. This type of wear pattern is driven by

scrubbing action as tread comes off of ground at
drivewheel while under load.
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Improperly balanced or tail heavy machines will exhibit

higher amounts of trailing edge wear. By properly
balancing machine while under operation, and by
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reducing load on back of machine, trailing edge wear may

be minimized.
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CPB-0370-006
FIG. 44
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FIG. 45: Roading Wear: Roading of machine has a

large influence on treadbar wear rates. Roading can wear
treadbars up to 15 times faster than field operation. It is
important to minimize amount of high-speed roading
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whenever possible. If large roading distances need to be

covered, extended track life can be obtained by
transporting rather than roading machine. If roading is A
done, lowering maximum travel speed can reduce wear.
Graphic shows how wear life (A) decreases as amount of
roading (B) increases.
B N122005002
FIG. 45
04-28 79033095 C Rev.

FIGS. 46–47: Treadbars will also wear at different rates
across width of track. General appearance of uneven
wear can vary, depending on track width.
On narrower tracks (1) (14 to 18 inches), outer parts of
treadbar will wear much faster than center. On wider track 1
widths (2) (20 to 36 inches) wear will occur in center of
treadbar. This is because area with highest wear will
usually be under wheel path. In addition, it is normal for
inside row of treadbars closest to machine to wear slightly
faster than outside row, due to higher loading conditions.
Greater wear is also seen on side of machine used most
frequently to turn. In conditions where turning occurs
frequently in only one direction, swapping tracks from side
N122005003
to side periodically will better even out wear between
sides. FIG. 46
In both trailing edge and roading wear, wear is influenced
by track width and by weight and load concentration of
wheels. Operation with wider midrollers and in softer soils
Fo
where load is better distributed, will tend to minimize this

effect.
2
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N122005004
FIG. 47
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79033095 C Rev. 04-29

Guide Lugs
FIGS. 48–49: Typical guide wear patterns are revealed
usually only after an initial break-in period. Break-in of
replacement track on an in-service machine will usually
take much less time, due to presence of already broken-in
wheels. See section on Track Break-in for more
information.
Ideal operating condition for guide lug break-in is dry and
dusty soils. Dust acts as a dry lubricant to assist in
polishing and break-in phase, and helps minimize early
hour break-in scuffing and chunking.
If damage is seen on both sides of guide lug, it is likely
due to break-in. If damage is seen only on one side of
guide lug, it is more likely due to misalignment. CPB-0370-014
After initial break-in period, guide lug appearance will FIG. 48

stabilize and most additional wear will generally occur on
Fo
leading edge. If guide lugs continue to chunk and scuff,

one of following conditions may exist:
• Track may be misaligned (due to adjustment or due to
r
mechanical problems)
• Track operation on steep side slopes
in
• Track operation in abrasive or sharp soil conditions

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Source of track misalignment can either be due to

improper alignment adjustment, improper gauge width
adjustment (or gauge width movement has occurred),
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mechanical track system damage, or uneven wear in CPB-0370-013

undercarriage components.
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FIG. 49
IMPORTANT: It is important to identify cause of
misalignment before guide lug wear progresses
too far.
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Operation on steep side slopes will increase guide lug

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side loading and wear. Correct alignment is critical for

operation in these conditions. In addition, operation on
side slopes with narrow track is not recommended (18
inch gauge with MT800). When using tracks on side
on
slopes, alternate track operation on downhill side of

machine to help even out guide lug wear. If machine must
always be operated with same side downhill, consider
periodically moving tracks to opposite sides of machine.
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04-30 79033095 C Rev.

Carcass Typical Wear Patterns and
Characteristics
FIGS. 50–51: Photos show carcass wear patterns and
characteristics from smooth soils.
CPB-0370-018
FIG. 50
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CPB-0370-016
FIG. 51
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79033095 C Rev. 04-31

FIGS. 52–53: Photos show carcass wear patterns and
characteristics from abrasive soils.
Carcass wear can vary greatly depending on environment
and application. As track accumulates hours of operation,
it will show many surface blemishes on outside and inside
carcass surfaces, including; cuts, scrapes, scratches,
nicks, surface cracks, slits, etc.
Carcass will deform to allow most debris to pass by
without damage. In cases where sharp objects are
contacted, then varied degrees of minor carcass damage
can result, and is considered normal.
CPB-0370-017
FIG. 52
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CPB-0370-015
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FIG. 53
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Drivewheels and Idlers

Drivewheels and idlers are not usual wear items, and are
intended to last life of machine in most applications. Any
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sort of wear should be viewed with concern, and

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troubleshooting should be done immediately to find

source of problem.
Traction of a friction drive system relies on sharpness of
edges of drivewheel rubber to wipe mud and moisture out
on
of ID of track. Anytime edge is damaged, or rounded,

effectiveness of wheel at grabbing track ID (inside track
traction) is diminished.
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04-32 79033095 C Rev.

Midrollers Typical Wear Patterns and
Characteristics
FIGS. 54–55: Midwheels are intended for trouble free
operation in typical agricultural applications, in which
speed, weight, and roading are not excessive.
Factors influencing midroller life are:
• Total unit load
• Extent of abrasive conditions causing physical
damage
• Peak temperatures seen during operation and
roading
NOTE: Operation in non-agricultural applications
increases total load and also exposes midrollers CPB-0370-020
to more abrasive conditions and debris not
normally seen in Ag applications. Customers FIG. 54
Fo
should be aware that overall life may be reduced

in these conditions.
During service, midrollers initially see rubber worn from
r
edges. Typical wear patterns are numerous small nicks

and chunks, some small sections with rubber loss, and a
in
slight amount of rubber separation at edges.

Midroller Replacement Criteria: Operate midrollers
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until such time that one or more of following conditions

occur:
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• 1/3 of midroller rubber width from either side is lost

• Any area where midroller rubber loss extends across
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CPB-0370-019
entire roller width
FIG. 55
• Midroller no longer turns freely
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• Midroller face begins to build-up with dirt due to lack

of rubber thickness
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IMPORTANT: Replace midrollers in sets if significant

wear is seen on opposite side. Do not pair a worn
midroller on same axle as a new midroller, or
else new midroller will end up taking majority of
on
overall axle loading.

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79033095 C Rev. 04-33

UNDERCARRIAGE (MOBIL-TRAC) TRACK
TENSION/DETENSION
Detensioning Drive Tracks

FIG. 56: Connect one end of 1U-9058 track tensioning
hose group to quick coupler (1). Quick coupler is on lower
left-hand side of hydraulic valve bank.
m
WARNING: High Pressure Tensioner
Cylinder. Do not remove any parts from
undercarriage until all pressure has been
relieved to avoid possible personal injury. 1
Relieve pressure via track tension hose
group as described in this procedure or by
opening bleed valve one turn maximum and
discharge oil through bleed hose.
T011005001
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FIG. 56
FIG. 57: Tighten all hand valves (1) on track tensioning

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hose group (2).

2
Remove cap from nipple on track tensioner. Connect
in
hose coupler to nipple.

NOTE: If you cannot connect charging hose to nipple,
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there may be a buildup of hydraulic pressure

between filler valve and nipple. To release
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pressure, refer to Release Pressure Between

Nipple and Filler Valve section.
1
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00815735a
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FIG. 57
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FIG. 58: Start engine. Run engine at low idle. Place

implement control lever (1) in float position.
1
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S113005001
FIG. 58
04-34 79033095 C Rev.

FIG. 59: Open all hand valves (1) on track tensioning
hose group (2).
2
00815735a
FIG. 59
FIG. 60: Slowly open filler valve (1) a maximum of one
turn to release pressure from track tensioner into
implement hydraulic system.
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NOTE: Guard removed for clarity.

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1
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S110205003
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FIG. 60
FIG. 61: After pressure from track tensioner is fully
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released and tensioner (1) stops moving, it may be

necessary to pull front idler rearward to fully retract track
tensioner.
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00758196
FIG. 61
FIG. 62: Close filler valve (1), stop engine, and remove
track tensioning hose group.
Repeat procedure for opposite side.
S110205003
FIG. 62
79033095 C Rev. 04-35

Tensioning Track
m
WARNING: High Pressure Cylinder. Do not
remove any parts unless all hydraulic
pressure has been relieved to avoid
possible personal injury. Refer to
Detensioning Track section for more
information.
NOTE: This procedure includes provision to bleed air

from tensioner cylinder and also to verify
accumulator nitrogen pressure.
FIG. 63: Verify that filler valve (1) and bleeder valve (2)
are closed on tensioner cylinder.
NOTE: Guard removed for clarity. 2
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1
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S110205004
FIG. 63
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FIG. 64: Connect one end of 1U-9058 track tensioning

hose group to quick coupler (1). Quick coupler is on lower
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left-hand side of hydraulic valve bank.

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T011005001
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FIG. 64
FIG. 65: Tighten all hand valves (1) on track tensioning
hose group (2).
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Remove cap from nipple on track tensioner. Connect 2

hose coupler to nipple.
NOTE: If you cannot connect charging hose to nipple,
there may be a buildup of hydraulic pressure
between filler valve and nipple. To release
pressure, refer to Release Pressure Between
Nipple and Filler Valve section. 1
00815735a
FIG. 65
04-36 79033095 C Rev.

FIG. 66: Open bleeder valve (1) by 1/4 turn to 1/2 turn.
Direct oil drain hose (2) into a suitable container. If
necessary, add more hose to oil drain hose.
P031005001
FIG. 66
FIG. 67: Start engine. Run engine at low idle. Hold
implement control lever (1) in EXTEND position.
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S113005001
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FIG. 67
FIG. 68: Open all hand valves (1) on track tensioning
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hose group.
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00815735a
FIG. 68
FIG. 69: Slowly open filler valve (1) by 1/2 turn to 1 turn.
NOTE: This allows track tensioner to fill. Also, this purges 1
air from oil drain hose.
When no large bubbles remain in drain stream, tighten
bleeder valve (2) to 21 to 35 Nm (16 to 26 lbf ft).
Continue charging system a minimum of 20 seconds after
bleeder valve has been tightened. While maintaining 2
19995 ± 345 kPa (2900 ± 50 psi) inlet pressure, tighten
needle valve on charging hose.
P031005001
FIG. 69
79033095 C Rev. 04-37

FIG. 70: Place implement control lever (1) in FLOAT
position.
S113005001
FIG. 70
FIG. 71: Open hand valve (1) on track tensioning hose
group by a small amount to relieve hydraulic pressure
from track tensioner.
Fo
Watch pressure gauge closely. Observe when a sudden

decrease in hydraulic pressure occurs. Last pressure
value that was observed before sudden decrease
indicates nitrogen pressure in accumulator. Nominal 1
r
nitrogen pressure is 15168 ± 1034 kPa (2200 ± 150 psi)

at 20 degrees C (68 degrees F).
in
NOTE: Refer to Nitrogen Pressure Correction for

Ambient Temperature Table for more information.
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00815735b
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FIG. 71
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04-38 79033095 C Rev.

Low nitrogen pressure may indicate that the accumulator
is faulty. If necessary, repair or replace accumulator
before preceding.
IMPORTANT: A rupture disc is used as a pressure
release on track tensioner. In event of tensioner
overpressure, this disc will vent oil and relieve all
track tension. If oil is released, inspect
accumulator and check for gas leakage. Replace
any accumulator that will not maintain nitrogen
pressure.
Nitrogen Pressure Correction for Ambient
Temperature
Due to the variability of accumulator nitrogen pressure
with changes in temperature, multiply the specified
pressure for the accumulator by the appropriate value in
the following table.
Fo
Nitrogen Pressure Correction for Ambient Temperature Table

Ambient 4C 10 C 16 C 21 C 27 C 32 C 38 F 43 C
Temperature (40 F) (50 F) (60 F) (70 F) (80 F) (90 F) (100 F) (110 F)
r
Correction 0.95 0.97 0.98 1.00 1.02 1.04 1.06 1.08

in
Factor
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Example:
If specified nitrogen pressure for accumulator is 15168
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kPa (2200 psi) and ambient air temperature is 32 C (90

F), corrected pressure would be 15168 kPa (2200 psi) x
1.04 = 15775 kPa (2288 psi). Since the stated tolerance is
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1034 kPa (150 psi), the measured pressure should be

between 16809 kPa (2438 psi) and 14741 kPa (2138
psi)15775 ± 1034 kPa (2288 ± 150 psi).
u
NOTE: Nitrogen temperature may be different than

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indoor ambient temperature if tensioner

assembly has been stored outdoors just prior to
performing tensioning procedure. In this case, an
infrared thermometer may be used to estimate
nitrogen temperature by measuring surface
on
temperature of accumulator. If accumulator

surface temperature cannot be accurately
measured, or if the outdoor ambient temperature
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was below 4 C (40 F), allow tensioning system to

warm indoors for a minimum of 2 hours prior to
measuring nitrogen pressure.
79033095 C Rev. 04-39

FIG. 72: Running engine at low idle, set implement
circuit number 1 for continuous operation and activate
circuit to extend.
Slowly open hand valve (1) on track tensioning hose
group and allow system to charge for a minimum of two
minutes.
NOTE: Track may appear to be tensioned almost 1
immediately after you begin to charge track
tensioner. However, a minimum of two minutes is
required to ensure correct oil charge for track
tensioner.
While maintaining 19995 ± 345 kPa (2900 ± 50 psi) inlet 00815735b
pressure, close hand valve (1) on track tensioning hose
group to isolate pressure gauge and track tensioner. FIG. 72
Place implement control lever in float.
NOTE: If 19,650 to 20,340 kPa (2,850 to 2,950 psi)
Fo
cannot be achieved during charging procedure,

relief pressure of implement hydraulic system
may be low. For further information, refer to
adjusting Implement Hydraulic Pressure section.
r
FIG. 73: Tighten filler valve (1) to 21 to 35 Nm (16 to 26

in
lbf ft).
Open hand valve on track tensioning hose group to
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relieve pressure in hose. Disconnect charging hose and

stop engine.
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NOTE: This process should charge track tensioner to a

pressure of at least 19,650 to 20,340 kPa (2,850
to 2,950 psi). Pressure of track tensioner will 1
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decrease by approximately 1380 kPa (200 psi)

after machine operation. Pressure decreases
because of extension of track tensioner after
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track seats into components of undercarriage. S110205003

This is normal. You do not need to recharge track
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FIG. 73
tensioner.
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04-40 79033095 C Rev.

Releasing Pressure Between Nipple and
Filler Valve
FIG. 74: Verify that filler valve (1) is tightened to 21 to 35
Nm (16 to 26 lbf ft).
Loosen the nipple (2) a maximum of one turn. It is normal 3
for a few drops of oil to leak around the threads. Retighten
nipple after oil no longer leaks from threads. 2
NOTE: If a significant amount of oil leaks/sprays from
nipple, immediately tighten nipple.
This indicates that the filler valve may not be
sealing correctly and the tensioner system can 1
only be safely discharged through the use of the
bleed valve (3).
S113005003
FIG. 74
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79033095 C Rev. 04-41

NOTES
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04-42 79033095 C Rev.

Frame Disassembly and Assembly
FRAME DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE DRIVE TRACK

(MOBIL-TRAC)
Track Removal
m
WARNING: Personal injury or death can
result from servicing drive track. Machine
must be on a hard, level surface before
drive track is removed or personal injury or
death could occur.
FIG. 75: Before you remove track, clean undercarriage

so that undercarriage is free of excess mud and free of
debris.
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P030611002
FIG. 75
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FIG. 76: Park machine on a hard, level surface. There

should be an adequate work area around machine. Place
transmission control lever (1) in Park position.
1
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P012405001
FIG. 76
FIG. 77: Install 203-5584 bracket (1) on front of
machine.
Raise front of machine by using an appropriate lifting
device. Place lifting device under cast boss on front 1
housing.
NOTE: Make sure that track is off of ground by at least
203 mm (8 in).
Support front of machine with 1U-7498 support stands 2
(2).
00868537
FIG. 77
79033095 C Rev. 04-43

FIG. 78: Raise rear of machine off of ground by using an
appropriate lifting device. Support machine with 1U-7498
support stands (1). Rear support stands should be placed
under plate (2) that is part of wide swinging drawbar or
flanges that are located on final drive housings.
NOTE: Make sure that machine is off of ground by at 2
least 203 mm (8 in).
00868552
FIG. 78
FIG. 79: Detension Track.
NOTE: Refer to Detensioning Track section for more
Fo
information. 1
Remove a mounting bolt from idler or idler
counterweights. Attach link bracket (1).
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NOTE: Removing track does not require removal of idler

counterweights or idler.
in
2
Use a come-along (2) to completely retract tensioner.
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NOTE: Tensioner must be completely retracted. If track

tensioner has not been retracted completely,
track removal and installation will be difficult.
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00758196
FIG. 79
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FIG. 80: Attach tooling 1U-9055 Front Idler Lifter (1) to

an appropriate lifting device. Secure tooling to outside
drive wheel (2). Remove mounting bolts securing outside 2
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drive wheel. Remove outside drive wheel from

undercarriage.
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00758208
FIG. 80
04-44 79033095 C Rev.

FIGS. 81–82: Use a hoist or a lift truck in order to support
track.
IMPORTANT: Use special care when you use a prybar to
lift guide blocks out of front idler. Make sure that
you do not damage track with prybar.
Pull track off of inside drive wheel. Move track forward and
slide track outward from underneath midwheels. Lift guide
blocks out of front idler.
00819175
FIG. 81
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00819176
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FIG. 82
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79033095 C Rev. 04-45

Inspection
FIG. 83: General Ag track is composed of several layers
of cable. Cables are similar to cables in automotive tires.
Most important set of cables is located about 8 mm (0.3
in) beneath inside surface of track. These cables are
called 0 degree cables (1). 0 degree cables carry the load
from track tension.
Refer to Undercarriage (Mobil-trac) System, (Mobil-trac)
Track System, in this section for more information on
terminology, wear measurement, wear
patterns/characteristics, maximizing track life, and part
and serial number location.
1
Other sets of cables are located between 0 degree cables 2
and outside surface of track. These cables are called 00300858
breaker cables (2). Breaker cables lie at various angles in FIG. 83

order to provide lateral support. Also, breaker cables
protect 0 degree cables.
Fo
When any of cables are exposed to moisture by cuts or

gouges in rubber, cables can rust.
r
Any damaged 0 degree cables that protrude above

surface of track should be repaired. Repair cables by
in
clipping or grinding cable. Clip or grind cable so that cable

is below surface of track. This will prevent additional
damage.
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04-46 79033095 C Rev.

FIG. 84: Cuts, gouges, and minor wear on guide blocks
(1) will not cause operational problems.
A general Ag track that is missing more than one-third of
2 3
total guide blocks should be repaired. A general Ag track
that is missing more than three consecutive guide blocks
may come off machine. This could damage other
components on undercarriage.
1
An extreme application track that is missing two or more
consecutive guide blocks should be replaced. An extreme
application track that is missing more than one-fourth of
total guide blocks should be repaired. 4
Portions of treadbar (2) that separate from track will not
5
P031205001
significantly reduce traction.
FIG. 84
Replace a track when height of treadbar is less than 13
mm (0.5 in) and when track slippage routinely exceeds 10
percent.
Fo
Pieces of rubber may separate from following

components on undercarriage:
• Idlers (3)
r
• Midwheels (4)
in
• Drive Wheels (5)

Rubber may come off components because of rocks and
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debris that enter undercarriage. Replace any idler or any

midwheel that has 50 percent of rubber missing.
rn
If there is missing rubber on drive wheel that is due to

damage, replace drive wheel when there is slippage
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between track and drive wheel.

NOTE: Inspect bottom inside of track for any
accumulation of oil. An accumulation of oil on
u
inside of track would indicate possibility of

leaking idler (3), midwheels (4), or drive wheel
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(5).
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79033095 C Rev. 04-47

Drive Track Installation
FIGS. 85–86: To install track, use a suitable lifting device
or a lift truck to lift track onto front idler (1).
NOTE: Make sure that guide blocks engage groove in
idler.
Slide bottom of track under midwheels (2). Slide track until
guide blocks (3) are centered between midwheels. 3
2
00819175
FIG. 85
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00819176
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FIG. 86
FIG. 87: Install track over inside drive wheel.
u
Attach tooling 1U-9055 Front Idler Lifter (1) to an

appropriate lifting device. Secure tooling to outside drive 2 1
se
wheel (2).
Install outside drive wheel. Tighten bolts to a torque of
800 to 1000 Nm (590 to 738 lbf ft).
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NOTE: You may use guide bolts in order to help install

driver.
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00758208
FIG. 87
04-48 79033095 C Rev.

FIG. 88: Remove come-along (1) that was used to
retract tensioner.
Install idler or idler counterweight bolt removed earlier. 1
Tighten bolt to a torque of 800 to 1000 Nm (590 to 738 lbf
ft).
Tension Track.
NOTE: Refer to Tensioning Track section for more
information.
00758196
FIG. 88
FIG. 89: Raise front of machine by using an appropriate
lifting device. Place lifting device under cast boss on front
housing.
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1
Remove 1U-7498 support stands (2) from under front of
machine and remove lifting device.
r
Remove 203-5584 brackets (1) from front of machine. 2

in
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00868537
FIG. 89
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FIG. 90: Raise rear of machine by using an appropriate

lifting device. Remove 1U-7498 support stands (1) from
under rear (2) of machine and remove lifting device.
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P020105001
FIG. 90
79033095 C Rev. 04-49

UNDERCARRIAGE PRESSURE SENSOR
Pressure Sensor Removal

FIG. 91: Detension track.
information.
00815735b
Fo
FIG. 91
FIG. 92: Loosen and remove bolt (1), washer (2) and
bushing (3) that secures pin (4).
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2
in
4
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1
3
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P080405001
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FIG. 92
FIG. 93: Remove pin (1).
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Raise tensioner assembly several inches and block

tensioner to gain access to pressure sensor.
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P080405002
FIG. 93
04-50 79033095 C Rev.

FIG. 94: Disconnect electrical harness (1) from pressure
sensor.
1
P080405003
FIG. 94
FIG. 95: Remove pressure sensor (1).
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P080405004
FIG. 95
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79033095 C Rev. 04-51

Pressure Sensor Installation
FIG. 96: Install pressure sensor (1) to tee (2).
2 1
P080405004
FIG. 96
FIG. 97: Connect electrical harness (1) to pressure
Fo
sensor.
r in
te
rn
1
P080405003
al
FIG. 97
FIG. 98: Unblock tensioner and install pin (1).
u se
on
1
ly
P080405002
FIG. 98
04-52 79033095 C Rev.

FIG. 99: Install bushing (1), washer (2) and bolt (3) to
secure pin (4). Tighten bolt to 200 to 280 Nm (148 to 207
lbf ft).
2
4
3
1
P080405001
FIG. 99
FIG. 100: Tension track.
Fo
information.
r in
te
rn
00815735b
FIG. 100
al
u se
on
ly
79033095 C Rev. 04-53

UNDERCARRIAGE TENSIONER RUPTURE
DISC
Rupture Disc Removal

FIG. 101: Detension track.
information.
Fo
00815735b
FIG. 101
FIG. 102: Loosen and remove bolt (1), washer (2) and
r
bushing (3) that secures pin (4).

in
2
4
te
rn
1
al
3
u
P080405001
FIG. 102
se

Raise tensioner assembly several inches and block
tensioner to gain access to rupture disc.
on
ly
P080405002
FIG. 103
04-54 79033095 C Rev.

FIG. 104: Loosen and remove rupture disc (1) and
O-ring (2).
1
2
P080405005
FIG. 104
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 04-55

Rupture Disc Installation
FIG. 105: Install rupture disc (1) and O-ring (2). Tighten
rupture disc to 30 to 33 Nm (22 to 24 lbf ft).
1
2
P080405005
FIG. 105
FIG. 106: Unblock tensioner and install pin (1).
Fo
r in
te
1
rn
P080405002
al
FIG. 106
FIG. 107: Install bushing (1), washer (2) and bolt (3) to
u
secure pin (4). Tighten bolt to 200 to 280 Nm (148 to 207

lbf ft).
se
2
4
on
3
ly
1
P080405001
FIG. 107
04-56 79033095 C Rev.

FIG. 108: Tension track.
information.
00815735b
FIG. 108
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 04-57

UNDERCARRIAGE TENSIONER
Tensioner Removal
FIG. 109: Detension track and remove front idler.
information.
00815735b
Fo
FIG. 109
FIG. 110: Disconnect harness assembly (1).
r in
1
te
rn
al
u
se
P012905001
FIG. 110
on
FIG. 111: Remove cover (1) from track tensioner.

ly
P012905003
FIG. 111
04-58 79033095 C Rev.

FIG. 112: Attach a suitable hoist and a suitable sling in
order to remove pin (1).
P012905004
FIG. 112
1 2
Remove track tension cylinder (2).
Fo
r in
te
rn
P012905004
FIG. 113
al
u se
on
ly
79033095 C Rev. 04-59

Tensioner Disassembly
Required Tools
Tool Part Number Part Description Quantity
A 1P-0510 Driver Gp 1
FIG. 114: Remove bolts (1).

Remove guide (2) and rod assembly (3).
2
1
Fo
P012905005
r
FIG. 114
in
FIG. 115: Remove seal (1), bolt (2), and spacer (2).
2 3
te
rn
1
al
u se
P013005001
FIG. 115
on
FIG. 116: Remove guide (1) from rod assembly (2).

1
ly
P013005002
FIG. 116
04-60 79033095 C Rev.

FIG. 117: Remove wear rings (1), seals (2), and snap
ring (3).
1 2
P013005003
FIG. 117
FIG. 118: Remove seals (1).
Use Tooling (A) in order to remove bearing (2).
Fo
2
r in
1
te
rn
P013005004
FIG. 118
al
u se
on
ly
79033095 C Rev. 04-61

Accumulator Removal
FIG. 119: Remove tensioner from machine.
NOTE: Refer to Tensioner Removal section for more
information.
R120805001
FIG. 119
FIG. 120: Remove clamp (1) by loosening and removing
Fo
nuts and bolts (2) on both side of accumulator.

1
r in
te
2
rn
R120805002
al
FIG. 120
FIG. 121: Remove accumulator (1) with O-ring (2) from
u
tensioner. 2
se
on
ly
1
R120805003
FIG. 121
04-62 79033095 C Rev.

Accumulator Installation
FIG. 122: Install accumulator (1) with O-ring (2) to
tensioner. 2
1
R120805003
FIG. 122
FIG. 123: Install clamp (1) with bolt and washer (2).
Fo
Secure with lock nut.

Repeat procedure for opposite side of accumulator. 1
r in
te
2
rn
R120805002
al
FIG. 123
FIG. 124: Install tensioner to machine.
u
NOTE: Refer to Tensioner Installation section for more

se
information.
on
ly
R120805001
FIG. 124
79033095 C Rev. 04-63

Tensioner Assembly
Required Tools
A 1P-0510 Driver Gp 1
FIG. 125: Use Tooling (A) in order to install bearing (2).

Install seals (1).
1
Fo
P013005004
r
FIG. 125
in
FIG. 126: Install wear rings (1), seals (2), and snap ring
(3).
te
rn
1 2
al
3
u se
P013005003
FIG. 126
on
FIG. 127: Install guide (1) on rod assembly (2).

1
ly
P013005002
FIG. 127
04-64 79033095 C Rev.

FIG. 128: Install spacer (3), bolt (2), and seal (1).
2 3
P013005001
FIG. 128
FIG. 129: Install rod assembly (3) and guide (2).
Install bolts (1).
2
Fo
NOTE: After cylinder is assembled, fill cylinder with

approximately 4 L (1 gal) of hydraulic oil.
r
3
in
1
te
rn
P012905005
FIG. 129
al
u
se
on
ly
79033095 C Rev. 04-65

Tensioner Installation
FIG. 130: Attach a suitable hoist and a suitable sling in
order to install track tension cylinder (2). 1 2
Install pin (1).
P012905004
FIG. 130
Fo
1
r in
te
rn
P012905004
al
FIG. 131
FIG. 132: Install cover (1) on track tensioner.
u
1
se
on
ly
P012905003
FIG. 132
04-66 79033095 C Rev.

FIG. 133: Connect harness assembly (1).
Fo
P012905001
FIG. 133
FIG. 134: Install front idler and tension track.
r
NOTE: Refer to Undercarriage (Mobil-Trac) Track

in
Tension section for more information.

te
rn
al
u
00815735b
FIG. 134
se
on
ly
79033095 C Rev. 04-67

UNDERCARRIAGE IDLER HUB
Idler Hub Removal

FIG. 135: Remove Track.
NOTE: Refer to Undercarriage Drive Track (Mobil-trac),
Removal section for more information.
IMPORTANT: Cleanliness is an important factor. Before
Remove bolts and remove idler wheel.
IMPORTANT: When removing cover, oil will come out of
cavity, use a suitable container to capture all of
oil.
P030611002
Fo
FIG. 135
FIG. 136: Remove bolts (1) and cover (2).
r
Remove bolts (3), plate (4), and bearing (5) from hub (6).
6
in
te
5
rn
3 4
2
al
u se
1
P013005005
FIG. 136
on
FIG. 137: Remove bearing cup (6) from hub (1).

Remove seal (2) and seal (3). Remove bearing cone (4) 2
ly
and bearing cup (5).

1 4 3
5
P013005006
FIG. 137
04-68 79033095 C Rev.

Idler Hub Installation
Required Tools
A 1U-8698 Duo-Cone Seal Installer As 1
FIG. 138: Lower temperature of bearing cups. Install

bearing cup (1) and bearing cup (2) in hub (6).
4
assembly, all parts should be thoroughly cleaned 6 3 5
2
Lint may be deposited on parts that may cause
later trouble. Inspect all parts. If any parts are 1
replacement.
Fo
Install bearing cone (3). Use Tooling (A) to install seal (4)
and seal (5).
P013005006
r
NOTE: Refer to Installing Duo-Cone Seals section for

more information. FIG. 138
in
FIG. 139: Install bearing (2), plate (3), and bolts (4) in
hub (1).
te
Install cover (5) and bolts (6). Tighten bolts in a crisscross

pattern.
1
rn
Fill hub with 0.379 L (0.4005 qt) of SAE 50 Synthetic oil.

al
4 3
u
5
se
on
6
P013005005
ly
FIG. 139
FIG. 140: Install idler wheel and install bolts.
Tighten front idler bolts to 800 to 1000 Nm (590 to 738 lbf
ft).
Install Track.
Install section for more information.
P030611002
FIG. 140
79033095 C Rev. 04-69

UNDERCARRIAGE SWING LINK AND
LEVER
Swing Link and Lever Removal
Required Tools
A 1U-7505 Hydraulic Jack 1

IMPORTANT: Cleanliness is an important factor. Before
Fo

Remove bolts and remove idler wheels.
r
NOTE: Idler weights will need to be removed prior to

removing idler.
in
P030611002
te
FIG. 141
FIG. 142: Remove idler hubs
rn
NOTE: Refer to Undercarriage (Mobil-trac) Idler Hub,

Removal, in this section.
al
u se
on
ly
00881348a
FIG. 142
04-70 79033095 C Rev.

FIG. 143: Remove pin (1) in order to remove rod
assembly (2). 2
1
Use pin (1), a suitable strap, and a suitable hoist in order
to support swing link.
Remove bolts (3) and washers. 3
Remove bolt (4), washer, and spacer. 4
Remove lock plate (5).
Remove bolt (6).
NOTE: Repeat steps on opposite side.
6
Fo
P013005007
FIG. 143
FIG. 144: Remove bolts (1) and washers.
r
Remove cap (2).

in
te
rn
al
u se
1 2
P013005007
FIG. 144
on
FIG. 145: Place swing link (1) and lever (2) on Tooling
(A).
1
ly
Remove swing link (1) and lever (2).
2
P013005008
FIG. 145
79033095 C Rev. 04-71

Swing Link and Lever Disassembly
FIG. 146: Place swing link (1) and lever (2) on wood
blocks, as shown.
1
P013005009
FIG. 146
FIG. 147: Remove seal (2), thrust ring (3), and bearing
Fo
(4). 1
Lever (1) can be turned in order to repeat step on 2
opposite side.
r
3
in
te
4
rn
P013105001
al
FIG. 147
u
Remove nuts (2) and washers. 1

se
Remove U-bolts (3).

on
ly
2
P013105002
FIG. 148
04-72 79033095 C Rev.

FIG. 149: Remove swing link (1) from lever (2).
1
2
P013105003
FIG. 149
FIG. 150: If necessary, remove pin (1) from lever (2) with
a standard press. 2
Fo
1
r in
te
rn
P013105004
FIG. 150
al
u se
on
ly
79033095 C Rev. 04-73

Swing Link and Lever Assembly
FIG. 151: If pin (1) was removed from lever (2), use a
standard press to install pin. 2
1
P013105004
FIG. 151
FIG. 152: Install lever (1) onto swing link (2).
Fo
2
1
r in
te
rn
P013105003
al
FIG. 152
FIG. 153: Install U-bolts (1).
u
Install nuts (2) and washers. 3

se
Install bolts (3) and washers.

on
ly
2
P013105002
FIG. 153
04-74 79033095 C Rev.

FIG. 154: Install bearing (1), thrust ring (2), and seal (3)
onto lever (4). 4
Lever can be turned to repeat step on opposite side. 3
P013105001
FIG. 154
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 04-75

Swing Link and Lever Installation
Required Tools
FIG. 155: Place lever (1) and swing link (2) on Tooling
(A). Position lever and swing link under frame.
2
Install lever and swing link on frame.
A
Fo
r in
1
te
P013005008
FIG. 155
rn
al
u se
on
ly
04-76 79033095 C Rev.

FIGS. 156–157: Install cap (8).
Install bolts (7) and washers, do not tighten at this time.
Install bolt (6).
NOTE: Track alignment will be necessary.
Install lock plate (5).
Install bolt (4), washer, and spacer.
Tighten bolts (7) and (3) to 400 to 520 Nm (295 to 385 lbf
ft).
Repeat steps on opposite side.
Remove pin (1) in order to remove strap that supports
swing link.
7 8
Install rod assembly (2).
Fo
P013005007
Install pin (1).
FIG. 156
NOTE: Cap (8) that holds swing link arm to front portion
of MTS frame could be misaligned by amount of 2
r
tolerance in bolt holes. If this cap is misaligned, 1

misalignment causes idler to tilt to one side or
in
other and results in track not aligning properly.

A second dowel pin will be added to front cap in 3
te
future to aid in alignment process. 4

rn
al
u
5
se
6
P013005007
on
FIG. 157
ly
79033095 C Rev. 04-77

FIG. 158: Install idler hubs
NOTE: Refer to Undercarriage (Mobil-trac) Idler Hub,
Install idler wheels and bolts.
Fo
00881348a
FIG. 158
FIG. 159: Install idler weights (1) if required.
r
Install Track.
in
NOTE: Refer to Undercarriage Drive Track (Mobil-trac), 1

Install, in this section.
te
rn
al
u
P030611002
FIG. 159
se
on
ly
04-78 79033095 C Rev.

INSTALLING DUO-CONE SEALS
Assembly and Installation of Conventional

Duo-Cone Seals
This instruction provides procedure for assembling and
installing conventional Duo-Cone Seals.
When Duo-Cone Seals are installed and assembled, you
must use correct procedures. Duo-Cone Seal may fail
from one or more mistakes that are made during
assembly or during installation of seal components.
Refer to Special Instruction, SEHS8484, Tool and
Specification Chart for Conventional Duo-Cone Seals.
Required Tools
Use tools in the table in order to correctly measure
Fo
spacing of Duo-Cone Seals after seals are installed.
Required Tools
r
Item Quantity Part Number Description

in
10 1 6V-3075 Dial Indicator

11 1 6V-6167 Contact Point
te
12 1 3P-1565 Collet Assembly

rn
13 1 165-8958 Dial Indicator Base

al
Correct Assembly of Conventional

Duo-Cone Seal
FIG. 160: Callouts shown in figure are:
u
1 2
(1) Seal ring 5
se
(2) Rubber toric ring 3

(3) Housing retaining lip
on
(4) Housing ramp

(5) Seal ring housing
(6) Seal ring face 6 4
ly
7
(7) Seal ring ramp 9
(8) Seal ring retaining lip
(9) Installation tool
8
P013105005
FIG. 160
79033095 C Rev. 04-79

Assembly and Installation Procedure
m
WARNING: Avoid prolonged skin contact
with isopropyl alcohol. Avoid breathing
vapors in enclosed areas without adequate
ventilation and do not smoke.
FIG. 161: Remove any film, dust or other foreign matter

from following components: 2
5
NOTE: Seal rings have very sharp edges. Protective
gloves should be worn in order to prevent injury. 3
• Rubber toric ring (2)
• Housing ramp (4)
• Seal ring ramp (7)
• Housing retaining lip (3)
4
7
• Seal ring retaining lip (8)
Fo
• Seal ring housing (5)

Use isopropyl alcohol or other approved cleaning agents.
r
Use a clean lint free cloth for wiping. All components

should be completely dry before proceeding.
in
8
Isopropyl alcohol is flammable. Do not use near open
00446486a
flame, welding operations, or around heated surfaces
te
exceeding 482 degrees C (900 degrees F). FIG. 161

NOTE: Never permit oil to contact rubber toric ring (2),
rn
housing ramp (4) or seal ring ramp (7) before

both seal rings are assembled in final position.
al
FIGS. 162–163: Put rubber toric ring (2) on seal ring (1).
Make sure that rubber toric ring is positioned at bottom of
seal ring ramp (7). Rubber toric ring must rest against 1
u
retaining lip (8). Rubber toric ring must be straight in seal

ring. Rubber toric ring must not be twisted.
se
NOTE: Be careful when you are working on rubber toric

ring. Nicks, cuts or scratches may cause leaks.
on
2
ly
P013105006
FIG. 162
2
8 P013105007
FIG. 163
04-80 79033095 C Rev.

FIG. 164: Use towels or a mat (A) that is made of foam
to aid with installing toric ring (2). 9
Install rubber toric ring (2) on seal ring (1) with installation 1
tool (9). Lightly dampen lower half of rubber toric ring (2)
with an appropriate lubricant.
Refer to Acceptable Lubricants for Assembly in this
section for additional information.
A
2
Use following techniques in order to dampen rubber toric
ring:
• Wipe seal with a lint free cloth.
• Place towels or a mat that is made of foam at bottom P013105008
of a container. Soak towels or mat with lubricant. Dip
rubber toric seal in container. FIG. 164
NOTE: Periodically inspect installation tool for damage. If

necessary, replace installation tool.
Fo
FIG. 165: Make sure that lower half of rubber toric ring
(2) is still wet. Use installation tool (9) in order to position
seal ring (1) and rubber toric ring (2) squarely against seal
r
ring housing (5). Make sure that you use sudden pressure
and even pressure when you press a toric ring that has a
in
small diameter. Press rubber toric ring (2) under housing

retaining lip (3) that is part of seal ring housing (5). Use 9 1 2
following steps in order to install a rubber toric ring that
te
has a large diameter:

• Push rubber toric ring over seal ring retaining lip on
rn
one side.
• Tap installation tool with a rubber mallet on opposite
5
al
side of rubber toric ring. Tap installation tool until 3

rubber toric ring is past seal ring retaining lip of
housing.
u se
P013105009
FIG. 165
FIG. 166: Callouts shown in figure are:
on
10
• Assembled height (B)
B B
• Dial indicator (10) 13 12
ly
• Contact point (11)

• Collet assembly (12)
• Dial indicator base (plastic) (13)
Check assembled height (B) at four locations that are 90
degrees from each other. Use a calibrated 6V-3075 Dial
Indicator and related tools in table in order to measure 11
assembled height. Difference in height must not exceed
P013105010
1.0 mm (.04 in). Refer to illustration.
FIG. 166
79033095 C Rev. 04-81

FIG. 167: Do not adjust seal ring (1) by pushing on seal
ring or by pulling on seal ring. Use installation tool (9) in
order to push down on seal (2). 9
1
P013105011
FIG. 167
FIGS. 168–169: Examples of incorrect assembly.
Rubber toric ring (2) may twist during installation if seal is
not completely wet or if there are burrs or fins on housing
Fo
retaining lip (3) that is part of seal ring housing (5). 1

Misalignments, twists and bulges of rubber toric ring will 3 2
5
cause Duo-Cone Seal failures. If correct installation is not
r
obvious, remove toric ring from housing and repeat

installation procedure.
in
te
rn
P013105012
FIG. 168
al
u se
on
ly
00446494
FIG. 169
04-82 79033095 C Rev.

FIG. 170: Wipe seal ring face (6) that is part of seal ring
(1) by using a lint free cloth. No particles of any kind are 6 1 2
permissible on sealing surfaces. A small piece of paper
from a paper towel can force apart seal ring face, which
will cause a leak.
5
Fo
P020105003
FIG. 170
FIG. 171: Apply a thin film of clean oil on entire seal ring
r
face of one or both seals. Use a lint free cloth or brush in

order to distribute oil evenly. Be careful not to get any oil
in
on rubber toric rings. Lubricate seal faces by using same

oil that was used during assembly. Dye may have been
te
used in oil that was used during assembly. Use same kind
of oil without dye in order to lubricate seal faces.
rn
al
u
00534623
FIG. 171
se
FIG. 172: Make sure that both seal ring housings (5) are
in correct alignment and that seal ring housings are
concentric. Move parts slowly and move parts carefully
on
toward each other.

NOTE: Do not force seal ring and seal ring housing
together in a sudden manner. Seal component
ly
could be scratched or seal component could be

broken if components are slammed together.
Tighten bolts after components are in correct position.
5
P020105004
FIG. 172
79033095 C Rev. 04-83

Acceptable Lubricants for Assembly
Following liquids are acceptable lubricants for assembly:
NOTE: Do not use any liquid that leaves an oil film. Do
not use any liquid that does not evaporate
quickly. All of guidelines for safety and all of
guidelines for disposal must be followed when
you use a flammable liquid.
• Quaker Solvo Clean 68-0
• Houghto-Grind 60 CT
• Isopropyl alcohol
m
WARNING: Avoid prolonged skin contact
with isopropyl alcohol. Avoid breathing
vapors in enclosed areas without adequate
ventilation and do not smoke.
Fo
Isopropyl alcohol is flammable. Do not use near open

flame, welding operations, or around heated surfaces
exceeding 482 degrees C (900 degrees F).
r
Some seal kits come with silicone toric rings. Silicone toric
rings can be chilled for easier installation. This will allow
in
toric ring to contract for easier installation.

Seals should be placed in a freezer for 5 minutes.
te
Temperature in freezer should be between -40 degrees C

(-40 degrees F) to -18 degrees C (0 degrees F). Chilling
should be done prior to installation. Contraction will be
rn
sufficient to allow installation. Seals should be allowed to

warm to room temperature prior to further assembly.
al
u se
on
ly
04-84 79033095 C Rev.

Result of Incorrect Assembly
FIG. 173: Slipping of rubber toric ring (2) on housing
ramp or on seal ring ramp may result in uneven pressure 2
on seal face. Uneven pressure on seal face causes
galling, scoring, and leakage.
If rubber toric ring slips at one location but not all the way
around seal ring, toric ring will twist.
Twisted toric ring could be cocked. Seals that are cocked
will cause uneven pressure on seal face. Seals that are
cocked may also cause possible galling, scoring, and
leakage.
Twisted toric ring could oscillate when ring is rotated.
Seals that oscillate may allow dirt into seal joint. This is P020105005
caused by pumping action that is created by toric ring that
is oscillating. FIG. 173
FIG. 174: Illustration shows a toric ring that is assembled
Fo
incorrectly. Upper housing is stationary. Lower housing is

rotating.
r in
te
rn
00446499a
al
FIG. 174
FIG. 175: Illustration shows same seal after lower
u
housing has rotated 180 degrees. In this position, there

will be high pressure at point (B) and at point (X). These
se
points of high pressure may result in galling of toric rings.

There will be low pressure at point (A) and at point (Y) that
will result in possible leakage. A B
on
Y X
ly
00446500
FIG. 175
79033095 C Rev. 04-85

UNDERCARRIAGE MIDWHEEL
ASSEMBLY
Midwheel Assembly Removal
Required Tools
Item Quantity Part Number Description

Removal, in this section.
Fo

r in
P030611002
te
FIG. 176
rn
Remove roller assemblies (2).

al
1
u se
on
ly
P020105006
FIG. 177
04-86 79033095 C Rev.

FIG. 178: Install Tooling (A) under midwheel assembly
(3). 4
3
Remove nuts (4) and washers.
Remove U-bolt (5).
Lower midwheel assembly (3) to ground.
NOTE: If necessary, remove pin assembly.
A
Fo
P020105007
FIG. 178
r
Midwheel Disassembly
in
FIG. 179: It is not necessary to remove track or

midwheel assembly in order to perform following
procedure. It will be necessary to detension track.
te
NOTE: Refer to Undercarriage (Mobil-Trac) Track

Tension/Detension, Detension Track section for
rn
more information.
1
al
u se
2
on
P020105006
FIG. 179
ly
79033095 C Rev. 04-87

Required Tools
A 4C-9439 Spanner Wrench As 1

maintenance, testing, adjusting and repair of
product. Be prepared to collect fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
FIG. 180: Place midwheel assembly (1) on wood blocks,
as shown. 3
2
Remove bolts (2) and washers.
Fo
Remove cover (3). 1

Remove gasket (4).
r in
te
4
rn
P020105008
FIG. 180
al
FIG. 181: Bend lock washer (1). Use Tooling (A) (not
shown) in order to remove bearing nut (2).
Remove washer (3) and roller bearing (4).
u
1
se
on
3 4
ly
2 P020105009
FIG. 181
FIG. 182: Remove hub (1) and bearing cone (2).
Remove duo-cone seal (3) from hub (1).
4
3
Remove duo-cone seal (4) from retainer (5). 1 2
P020105010
FIG. 182
04-88 79033095 C Rev.

FIG. 183: Remove bearing cups (1) and (2) from hub (3).
NOTE: Repeat this procedure for midwheels that are 1
being serviced.
3
P020105011
FIG. 183
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 04-89

Midwheel Assembly
Required Tools
A 173-6703 Duo-Cone Seal Installer As 1
B 4C-9439 Spanner Wrench As 1
FIG. 184: Lower temperature of bearing cups (1) and

(2). 2
Install bearing cups and into hub (3).
3
1
Fo
r
P020105011
in
FIG. 184
te
FIG. 185: Place midwheel assembly on wood blocks, as

shown. 1
Install duo-cone seal (1) into retainer (2). 3
rn
4 5
Use Tooling (A) (not shown) in order to install duo-cone
seal into retainer and duo-cone seal (3) into hub (4). Refer
al
to Installing Duo-Cone Seals in this section.

Install bearing cone (5) and hub.
u se
P020105010
on
FIG. 185
ly
04-90 79033095 C Rev.

FIG. 186: Install roller bearing (1) and lock washer (2)
and lock washer (3).
Use Tooling (B) (not shown) in order to install nut (4).
NOTE: Make sure bearing is loose and slides easily on 3
axle, and locknut rotates freely on axle threads.
Tighten nut to 27 to 41 Nm (20 to 30 lbf ft). Rotate hub at
least three revolutions. Again, tighten nut to a torque of 27
to 41 Nm (20 to 30 lbf ft).
If any locknut slot and lock washer tang are aligned, bend
the aligned tang into engagement with the slot to lock in 1
place. If none of the tangs and slots are aligned, tighten 2
4
locknut until the most nearly aligned tang and slot line up. P020105009
Bend the aligned tang into engagement with the slot to FIG. 186
lock in place.
NOTE: If necessary, repeat step.
Fo
FIG. 187: Install gasket with bead surface toward hub.

Install cover (3). 2 1
Install bolts (2) and washers on midwheel assembly (3).
r
Fill hub with approximately 0.002 L (0.0021 qt) of SAE 50 3

in
Synthetic oil.
te
rn
al
P020105008
FIG. 187
u se
on
ly
79033095 C Rev. 04-91

Midwheel Assembly Installation
Required Tools
FIG. 188: Install Tooling (A) under midwheel assembly

(1). 3
1
NOTE: If pin assembly was removed, install pin
assembly in center of midwheel assembly.
Raise midwheel assembly (1) up to frame.
Orientation mark (symbol X) of pin assembly to be X
positioned from bottom -10 to 10 degrees.
Install U-bolt (2).
Fo
Install nuts (3) and washers.

Tighten nuts to 460 Nm (339 lbf ft)
r
Remove Tooling (A) from midwheel assembly.

2
in
A
te
P020105007
FIG. 188
rn
FIG. 189: Install roller assembly (1).

al

Install Track.
u

2
se
Tighten bolts (1) to 230 to 310 Nm (169 to 229 lbf ft).

on
ly
P020105006
FIG. 189
04-92 79033095 C Rev.

UNDERCARRIAGE REACTION ARM
Disassembly
FIG. 190: Remove the undercarriage (1) from machine.
NOTE: Refer to Undercarriage Assembly, Removal
suitable containers before opening any 1
containing fluids.
Remove the track from the undercarriage and both drive
P111012005
wheels from the rear hub.
FIG. 190
Fo
FIG. 191: Use a suitable lifting device to support the

reaction arm assembly (1). 2
Loosen and remove five bolts with washers (2) that
r
secures the reaction arm assembly (1). Remove the

in
reaction arm assembly.

te
1
rn
al
T020705008
FIG. 191
FIG. 192: Drain oil from drive wheel support that is being
u
disassembled.
1
se
Locate magnetic plug (1) on inboard hub at twelve o-clock

position.
Clean area around plug. Remove plug and clean any
accumulated metal particles from plug magnet.
on
ly
T020705010
FIG. 192
FIG. 193: Clean area around outboard plugs (1) and (2).
Remove both plugs and allow oil to drain into an approved
container. Clean any accumulated metal particles from 1
magnetic plug.
Dispose of all fluids according to local regulations and
mandates.
After oil has finished draining, reinstall plugs to help
prevent contamination.
2
T020705011
FIG. 193
79033095 C Rev. 04-93

FIG. 194: Install tooling and suitable lifting device to
inner hub (1). 2
NOTE: Weight of inner hub is approximately 32 kg (70
lb).
NOTE: Place a suitable container under hub in order to
1
catch oil that may spill when hub is removed.
Remove bolts with washers (2) from the inner hub (1).
Install three M24 bolts into the outer threaded holes and
tighten progressively to force the hub off. Remove the
inner hub.
NOTE: The reaction arm assembly can be removed from U031205001
frame and bolted to an engine stand for ease of FIG. 194
service. The reaction arm assembly can then be
rotated from vertical to side to side.
FIG. 195: Remove duo-cone seal (1) from inner hub (2).
NOTE: Duo-cone seals must be kept in matched sets if
Fo
they are to be reused. 1

r in
2
te
rn
T011605006
FIG. 195
al
FIG. 196: Remove key (1) from slot (2) in bearing and
outer hub.
u
2
se
1
on
ly
U031205002
FIG. 196
FIG. 197: Install tooling and suitable lifting device to
support casting (1). Lift support casting assembly off of
outer hub (2).
Remove wave spring (3).
1
2
T013005003
FIG. 197
04-94 79033095 C Rev.

FIG. 198: Remove bearing (1) from outer hub (2).
Remove key (3).
1
2
3
T013005005
FIG. 198
FIG. 199: Remove Duo-Cone seal (1) from outer hub
(2).
1
Fo
they are to be reused.

2
r in
te
T013005006
FIG. 199
rn
FIG. 200: Remove duo-cone seals (1) from both sides of

drive wheel support.
al

they are to be reused.
u se
1
on
1
T011605009
FIG. 200
ly
FIG. 201: Remove retaining ring (1).

Remove housing assembly (2) from drive wheel support 1
(3) using a suitable press.
3
2
T013005007
FIG. 201
79033095 C Rev. 04-95

Assembly
FIG. 202: Press housing assembly (1) into drive wheel
support (2) until seated firmly against shoulder in support.
1
T013005008
FIG. 202
FIG. 203: Install retaining ring (1) to retain housing in
support (2).
Fo
1
r
2
in
te
rn
T013005009
FIG. 203
al
FIG. 204: Use tooling to install Duo-Cone seals into both

sides of drive wheel support.
u
more information.
se
NOTE: Duo-cone seals must be kept in matched sets.

on
ly
T013005010
FIG. 204
FIG. 205: Install dowels (1) in outer hub (2).
1
U031205003
FIG. 205
04-96 79033095 C Rev.

FIG. 206: Install Duo-Cone seal (1) to outer hub (2).
more information. 1
NOTE: Duo-cone seals must be kept in matched sets. 2
U031205004
FIG. 206
FIG. 207: Install key (1) to outer hub (2). Align slot in
bearing (3) to key and install bearing.
Lightly coat bearing with a film of SAE 50 Synthetic oil. 3
Fo
2
r
1
in
te
U031205005
FIG. 207
rn
FIG. 208: Install wave spring (1) to outer hub (2).

al
1
u se
2
on
T013005014
FIG. 208
ly
FIG. 209: Carefully lower support casting assembly (1)

onto outer hub (2). Prop casting assembly as needed to
ensure that top surface of casting is parallel to top surface
of hub.
T013005015
FIG. 209
79033095 C Rev. 04-97

FIG. 210: Lightly coat inner bearing (1) with a film of
SAE 50 Synthetic oil. Align slot on bearing with slot on 1
outer hub (2).
T013005016
FIG. 210
FIG. 211: Install key (1).
NOTE: Do not tap key to be flush with bearing however it
is acceptable if the key drops flush with the
Fo
bearing under its own weight.

1
r in
te
T013005017
FIG. 211
rn
FIG. 212: Install Duo-Cone seal (1) to inner hub (2).

al

more information. 1
NOTE: Duo-cone seals must be kept in matched sets.
u
Apply a 4 mm (0.157 in) continuous bead of anaerobic

2
se
sealant at the corner of the inside diameter of the inner

hub.
on
T013005019
FIG. 212
ly
FIG. 213: Install inner hub (1) with bolts and washers (2).
Progressively tighten bolts in an alternating pattern until 2
hub surfaces come into contact.
1
T013005018
FIG. 213
04-98 79033095 C Rev.

FIG. 214: Remove both oil fill plugs (1). Add 1.4 L (47.4
oz) of AGCO Synthetic Transmission Fluid SAE 50 oil or
equivalent.
Reinstall plugs in outer hubs. 1
1
U031205006
FIG. 214
FIG. 215: Install drive wheel support (1) with five bolts
with washers (2). Tighten bolts to 900 Nm (664 lbf ft). 2
Fo
r in
1
te
T020705008
FIG. 215
rn
FIG. 216: Install undercarriage and track.

NOTE: Refer to Undercarriage Assembly, Install section
al

Make sure to follow the correct Collet Tightening
u
procedure. Failure to do so could result in the

loosening of the collet bolts and machine
se
damage could result.

on
P111012005
FIG. 216
ly
79033095 C Rev. 04-99

Maintenance
Oil Level Check
NOTE: Inspect oil level frequently if machine is operated
in extremely wet or muddy conditions. Change oil
every 500 hours under these conditions.
FIG. 217: With machine on hard, level surface, drive
forward or rearward slightly to locate magnetic plug (1)
between nine o’clock and ten o’clock or between two
o’clock and three o’clock position. Place chocks at front
and rear of tracks.
1
NOTE: Magnetic plug is identified by a 4.76 mm (3/16 in)
hex socket inset, whereas the non-magnetic plug
has a 5.56 mm (7/32 in) hex socket inset.
Clean area around magnetic plug then remove plug.
Maintain oil level to bottom of threaded hole. Remove any
Fo
accumulated metal particles from magnetic plug. If

needed, add AGCO Synthetic Transmission Fluid SAE 50 T011005004
oil or equivalent. Reinstall plug and tighten. FIG. 217
r
Oil Change
in

forward or rearward slightly to locate magnetic plug (1) on
inboard hub at twelve o-clock position. Place chocks at 1
te
front and rear of tracks.

rn

al
u
T011105002
se
FIG. 218
on

magnetic plug.
After oil has finished draining, install one plug in lower
ly
threaded hole.
Remove wheel chocks and drive machine rearward
slightly until open threaded hole is between two o’clock
and three o’clock position. Replace chocks at front and
rear of tracks. 2
Add AGCO Synthetic Transmission Fluid SAE 50 oil or
T011105001
equivalent to upper threaded hole in outer hub until oil
level reaches bottom of threaded hole. Reinstall plugs in FIG. 219
both inner and outer hubs.
04-100 79033095 C Rev.

UNDERCARRIAGE ASSEMBLY
Undercarriage Removal
Required Tools
A 140-7741 Strap 1
140-7742 Sleeve 1
B 1U-7498 Support Stand As 1
1U-7501 Extension Tube (1) 1
Fo
r in
te
rn
al
u se
on
00891349
FIG. 220
ly
FIG. 220: If installed, remove undercarriage weight

package.
NOTE: Refer to Undercarriage Weights Removal section
79033095 C Rev. 04-101

NOTE: You do not need to remove belt to remove
undercarriage from machine.
P030611002
FIG. 221
FIG. 222: Adjust gauge to maximum width.
NOTE: Refer to Undercarriage (Mobil-trac) System,
Fo
Undercarriage (Mobil-trac) Gauge Spacing

section for correct adjustment.
r in
te
rn
00658438
FIG. 222
al
FIG. 223: Remove bolt (1) and washer.

Slide guard in order to disconnect harness assembly (2).
u
1 2
se
on
ly
P020105017
FIG. 223
04-102 79033095 C Rev.

FIG. 224: Install Tooling (A) through rear hole of frame
assembly (3), as shown.
Install Tooling (B) in order to support machine. A
Raise frame assembly and pull frame assembly away
from machine.
B
Fo
00905457a
FIG. 224
r in
te
rn
al
u se
on
ly
79033095 C Rev. 04-103

Undercarriage Installation
Required Tools
A 140-7741 Strap 1
140-7742 Sleeve 1
B 1U-7498 Support Stand As 1
1U-7501 Extension Tube (1) 1
FIG. 225: Install Tooling (B) in order to support machine.

Install Tooling (A) through rear hole of frame assembly
(3), as shown. A
Raise frame assembly and push frame assembly onto
Fo
machine.
r
3
in
te
rn
B
al
00905457a
FIG. 225
u
FIG. 226: Connect harness assembly (1). Slide guard

into original position.
se
Install bolt (2) and washer.

2 1
on
ly
P020105017
FIG. 226
04-104 79033095 C Rev.

FIG. 227: Adjust gauge to desired width.
NOTE: Refer to Undercarriage (Mobil-trac) System,
Undercarriage (Mobil-trac) Gauge Spacing,
section for correct adjustment.
00658438
FIG. 227
FIG. 228: Install belt if belt was removed.
NOTE: Refer to Undercarriage Drive Belt (Mobil-trac),
Fo

r in
te
rn
P030611002
FIG. 228
al
FIG. 229: If equipped, install undercarriage weight

package.
NOTE: Refer to Undercarriage Weights Installation
u

se
on
ly
00891349
FIG. 229
79033095 C Rev. 04-105

ROLLER FRAME RESTRAINT GROUP
Roller Frame Restraint Group Removal

FIG. 230: Clean oil, dirt, and crop material from area on
machine where work is to be done. 1
Remove bolt (1) with washer securing locking bracket (2)
to top of inner restraint clamp on hardbar. Repeat
procedure to remove locking bracket from outer clamp.
NOTE: If machine was ordered as a special application
machine from factory, it will have lock brackets on
it. If it is an agricultural machine being converted 2
to a special applications machine it will need lock
brackets installed.
L209002
Fo
FIG. 230
FIG. 231: Remove locking brackets (1) from top of inner
top restraint clamp (2) and outer top clamp.
r in
te
1
rn
2
al
L209002
u
FIG. 231
FIG. 232: Remove two bolts (1) with washers through
se
top restraint clamp (2) into bottom restraint clamp (3).
1
on
ly
3
2
L208007
FIG. 232
04-106 79033095 C Rev.

FIG. 233: Remove bottom restraint clamp (1) with wear
pad (2). Remove plastic wear pad from bottom restraint
clamp.
L209004
FIG. 233
FIG. 234: Remove top restraint clamp (1) with wear pad
(2) located towards existing hardbar clamp located inside
front axle of machine. 1
Fo
r in
2
te
rn
L208008
FIG. 234
al
FIG. 235: Remove plastic wear pad (1) from top restraint
clamp (2).
2
u
Repeat procedure for opposite side of front axle of

machine.
se
1
on
ly
L208007
FIG. 235
79033095 C Rev. 04-107

Roller Frame Restraint Group Installation
FIG. 236: Clean oil, dirt, and crop material from area on
machine where work is to be done.
Fasten plastic wear pad (1) to top restraint clamp (2). 2
L208007
FIG. 236
FIG. 237: Position top restraint clamp (1) with wear pad
Fo
(2) towards existing hardbar clamp located inside front 3

axle of machine. Place restraint clamp tight against
existing hardbar clamp (3) as shown in figure.
1
r in
te
2
rn
L208008
al
FIG. 237
FIG. 238: Position bottom restraint clamp (1) with wear
u
pad (2) towards existing hardbar clamp.

se
1
on
2
ly
L209004
FIG. 238
04-108 79033095 C Rev.

FIG. 239: Insert bolt (1) through top restraint clamp (2).
Screw bolt into bottom restraint clamp (3). Install washers
on bolt prior to installing bolt. Tighten bolts to 800 Nm
(590 lbf ft) dry torque.
1
L208007
FIG. 239
FIG. 240: Place locking bracket (1) on top of top restraint
clamp (2). Place locking bracket over two bolts on top
restraint clamp. Place other lock bracket over outer
Fo
hardbar clamp.
NOTE: If lock will not fit over bolt heads, flip bracket end
for end. If bracket will still not fit, advance torque
r
on one bolt to next location.

in
NOTE: If machine was ordered as a special application

machine from factory, it will have lock brackets on 1
it. If it is an agricultural machine being converted
te
to a special applications machine it will need lock 2

brackets installed.
rn
L209002
FIG. 240
al
FIG. 241: Secure locking bracket (1) to top of clamp with

bolt (2). Install washer on bolt prior to installing bolt.
Tighten bolt to 31 Nm (23 lbf ft) dry torque.
u
Repeat procedure for opposite side of front axle of

se
machine.
2
1
on
ly
L209002
FIG. 241
79033095 C Rev. 04-109

DRAWBAR (WIDE SWING)
Drawbar (Wide Swing) Removal
Required Tools
A Lifting Sling 1
B Retaining Ring Pliers 1
FIG. 242: Remove brackets (1) with pins from each side
of drawbar.
Fo
1
r in
te
rn
N121012003
al
FIG. 242
FIG. 243: Remove eight bolts (1). Remove top bumpers
u
(2) and bottom bumpers (3) from each side of drawbar.

Remove spacer (4).
se
5
Remove cover (5).
1
on
ly
3
4
N121112001
FIG. 243
04-110 79033095 C Rev.

FIG. 244: Remove bolts (1) with washers (2). Remove
plate (3) and drawbar pin (4).
1
Fo
N121112002
FIG. 244
FIG. 245: Attach Tooling (A) to drawbar (1). Slide
r
drawbar out of bracket assembly (2). Drawbar weighs

in
te
rn
A
al
u se
2
1
on
N121112003
FIG. 245
ly
79033095 C Rev. 04-111

FIGS. 246–247: Remove wear plate (1).
Use Tooling (B) in order to remove retaining rings (2) from 7
pins (3).
Support bracket assembly (4). Slide pins with washers (5)
out of frame. Remove rollers (6) with spacers (7) and (8).
Use a hammer and a punch in order to remove bearings
(9) from rollers. 4
1 8
6
5 2
3
Fo
N121112004
FIG. 246
r
6
in
te
rn
9
al
N121112005
FIG. 247
u
FIG. 248: Install Tooling (A) and a suitable lifting device.

se
Remove bolts (1) with washers. Remove support

assembly (2).
on
2
A
ly
1
N121112006
FIG. 248
04-112 79033095 C Rev.

Drawbar (Wide Swing) Installation
Required Tools
A Lifting Sling 1
B Driver Group 1
C Retaining Ring Pliers 1

Fo
replacement.
FIG. 249: Install Tooling (A) and a suitable lifting device.
Install support assembly (1). Install bolts (2) with washers.
r in
1
te
A
rn
al
u se
2
N121112006
FIG. 249
on
ly
79033095 C Rev. 04-113

FIGS. 250–251: Use Tooling (B) in order to install
bearings (1) in rollers (2). 4
Support bracket assembly (3). Install rollers with spacers
(4) and (5). Install pins (6) with washers (7) in frame.
Use Tooling (C) in order to install retaining rings (8) on
pins.
Install wear plate (9). 3
9 5
2
7 8
6
Fo
N121112004
FIG. 250
r
2
in
te
rn
1
al
N121112005
FIG. 251
u
FIG. 252: Attach Tooling (A) to drawbar (1). Slide

se
drawbar in bracket assembly (2). Remove Tooling (A).

Drawbar weighs approximately 68 kg (150 lb).
on
ly
2
1
N121112003
FIG. 252
04-114 79033095 C Rev.

FIG. 253: Install drawbar pin (1) and plate (2). Install
bolts (3) with washers (4).
3
Fo
N121112002
FIG. 253
FIG. 254: Install cover (1).
r
Install spacer (2). Install top bumpers (3) and bottom

in
bumpers (4) on each side of drawbar. Install eight bolts 1

(5).
5
te
rn
al
3
u se
4
2
on
N121112001
FIG. 254
ly
79033095 C Rev. 04-115

FIG. 255: Install brackets (1) with pins on each side of
drawbar.
Fo 1
N121012003
FIG. 255
r in
te
rn
al
u se
on
ly
04-116 79033095 C Rev.

POWERED DRAWBAR (HYDRAULIC
CONTROLLED)
Powered Drawbar (Hydraulic Controlled)

Removal
Required Tools
A Lifting Sling 1
FIG. 256: Begin by moving to rear of machine and

remove drawbar (1).
1
Fo
r in
te
P051605001
rn
FIG. 256
FIG. 257: Disconnect cylinders (1) from drawbar.
al
Loosen and remove retaining bolts with washers (2) from

underneath machine.
1
u se
on
2
ly
P051605002
FIG. 257
FIG. 258: Remove cylinder pins (1) from top of bracket
(2).
1
P051605004
FIG. 258
79033095 C Rev. 04-117

that secure bracket to drawbar.
P051605005
FIG. 259
FIG. 260: Remove pins (1).
Fo
r in
1
te
rn
P051905001
FIG. 260
al
FIG. 261: Loosen and remove two bolts with washers (1)
that secure drawbar pin retainer (2).
u
2
se
on
ly
1
P051905002
FIG. 261
FIG. 262: Remove two drawbar pin retainers (1).
P051905003
FIG. 262
04-118 79033095 C Rev.

FIG. 263: Remove drawbar pin (1).
1
P051905004
FIG. 263
FIG. 264: Using an appropriate lifting device remove
drawbar (1). Weight of drawbar is approximately 68 kg
(150 lb).
Fo
1
r in
te
rn
P051905005
FIG. 264
al
FIG. 265: Remove pins (1) and remove brackets (2).

1
u se
on
2
2
ly
P051905006
FIG. 265
and bumper (2). Repeat this procedure for opposite side.
1
2
P051905007
FIG. 266
79033095 C Rev. 04-119

FIG. 267: Loosen and remove two bolts with washers
(1), bumper (2) and spacer (3). Repeat this procedure for
opposite side. 3
2
P051905008
FIG. 267
FIG. 268: Remove cover (1).
Fo
1
r in
te
rn
P051905009
FIG. 268
al
u se
on
ly
04-120 79033095 C Rev.

FIGS. 269–270: Disassemble roller bracket.
Remove wear plate (1). 6
Use Tooling (B) in order to remove retaining rings (2) from
pins (3).
Support bracket assembly (4). Slide pins (3) with washers
(4) out of frame. Remove rollers (5) with spacers (6) and
(7). 4
Use a hammer and a punch in order to remove bearings 1
(8) from rollers. 7
5
4 2
3
Fo
N121112004
FIG. 269
r
5
in
te
rn
8
al
N121112005
FIG. 270
u
FIG. 271: Remove support assembly.

se
Install Tooling (A) and a suitable lifting device. Remove

bolts (1) with washers. Remove support assembly (2).
on
2
A
ly
1
N121112006
FIG. 271
79033095 C Rev. 04-121

FIG. 272: Loosen and remove five bolts with washers (1)
that secure cylinder guard (2). Remove cylinder guard.
1 2
P052105001
FIG. 272
and two nuts with washers (2). Remove guard (3). 3
Fo
1
r in
te
2
rn
P052105002
FIG. 273
al
FIG. 274: Remove U-bolt (1) and remove hydraulic lines

from cylinder. 1
u
2
se
on
ly
P052105003
FIG. 274
FIG. 275: Loosen and remove bolt with washer (1) that
secures loop clip (2). Loosen and remove nut with washer
(3) and remove bolt (4). Remove clamp (5). 4
5
2
1
P052105005
FIG. 275
04-122 79033095 C Rev.

FIG. 276: Disconnect hydraulic line (1) from rod end of
cylinder. Disconnect hydraulic line (2) from base end of
cylinder.
P052105006
FIG. 276
FIG. 277: Remove retaining clip (1).
Fo
r in
1
te
rn
P052105004
FIG. 277
al
FIG. 278: Remove cylinder pin (1) and remove cylinder

(2).
u
Remove cylinder for opposite side.

se
2
on
1
ly
P052105007
FIG. 278
79033095 C Rev. 04-123

Powered Drawbar (Hydraulic
Controlled) Installation
Required Tools
A Lifting Sling 1
B Driver Group 1
C Retaining Ring Pliers 1

Fo

replacement.
FIG. 279: Move hydraulic cylinder (1) for drawbar into
r
position onto machine. Install cylinder with pin (2).

in
te
rn
1
al
2
u
P052105007
FIG. 279
se
FIG. 280: Install retaining clip (1) on both ends of pin.

on
ly
P052105004
FIG. 280
04-124 79033095 C Rev.

FIG. 281: Install hydraulic line (1) to rod end of cylinder.
Install hydraulic line (2) to base end of cylinder.
P052105006
FIG. 281
FIG. 282: Secure hydraulic line (1) for rod end of cylinder
with loop clip (2). Secure loop clip with bolt and washer
(3).
Fo
5
Install clamp (4) to cylinder. Attach loop clip that secures
hydraulic line for base end of cylinder to clamp. Fasten
clamp with bolt (5) and secure with nut and washer (6).
6
r
1
in
4
2
te
3
rn
P052105005
FIG. 282
al
FIG. 283: Install U-bolt (1) to cylinder (2).

1
u
2
se
on
ly
P052105003
FIG. 283
FIG. 284: Move guard (1) into position on cylinder. Route
U-bolt through mounting holes on guard. Secure guard 1
two nuts with washers (2). Mount front of guard with two
bolts with washers (3).
Repeat this procedure for opposite side cylinder. 3
2
P052105002
FIG. 284
79033095 C Rev. 04-125

FIG. 285: Install guard (1) to front of drawbar cylinders.
Secure guard with five bolts with washers (2).
2 1
P052105001
FIG. 285
FIG. 286: Install support assembly.
Install Tooling (A) and move into position using a suitable
Fo
lifting device. Install support assembly (1) using bolts with

washers (2).
1
r
A
in
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rn
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2
u
N121112006
FIG. 286
se
on
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04-126 79033095 C Rev.

FIGS. 287–288: Assemble roller bracket.
Use Tooling (B) in order to install bearings (1) in rollers
(2). 2
Support bracket assembly (3). Install rollers (2) with
spacers (4) and (5). Install pins (6) with washers (7) in
frame.
Use Tooling (C) in order to install retaining rings (8) on
pins (6).
Install wear plate (9). 1
N121112005
FIG. 287
4
Fo
3
r
9
in
5
2
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7 8
rn
6
al
N121112004
FIG. 288
u
FIG. 289: Install cover (1).

se
1
on
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P051905009
FIG. 289
79033095 C Rev. 04-127

FIG. 290: Install bumper (1) with spacer (2) to bottom of
roller bracket (3) with bolts and washers (4). 3
2
4
1
P051905008
FIG. 290
FIG. 291: Install bumper (1) to top of roller bracket (2)
with bolts and washers (3).
2
Fo
Install bumpers to other side of roller bracket.

r in
3
te
1
rn
P051905007
FIG. 291
al
FIG. 292: Install brackets (1) to both sides of roller

bracket and secure with pins (2) and lock in place. 2
u se
on
1
1
ly
P051905006
FIG. 292
FIG. 293: Using an appropriate lifting device move
drawbar (1) into position. Weight of drawbar is
P051905005
FIG. 293
04-128 79033095 C Rev.

FIG. 294: Install drawbar pin (1).
1
P051905004
FIG. 294
FIG. 295: Install two drawbar pin retainers (1) to drawbar
pin.
Fo
r in
1
te
rn
P051905003
FIG. 295
al
FIG. 296: Secure drawbar retainer (1) with bolts and

washers (2).
u
1
se
on
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2
P051905002
FIG. 296
FIG. 297: Install brackets (1) to drawbar with two pins
(2).
P051905001
FIG. 297
79033095 C Rev. 04-129

FIG. 298: Secure pins from top using bolts with washers
(1).
P051605005
FIG. 298
FIG. 299: Align cylinders to bracket on drawbar. Mount
cylinders with pins (1).
1
Fo
r in
te
rn
P051605004
FIG. 299
al
FIG. 300: Secure cylinder pins with bolts and washers

(1).
u se
on
1
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P051605002
FIG. 300
04-130 79033095 C Rev.

DRAWBAR (3-PT HITCH)
Drawbar (3-PT Hitch) Removal
Required Tools
A Support Stand Assembly 2
1
Fo
r
N121112007
in
FIG. 301
FIG. 302: Install Tooling (A). Remove bolts (1), washers
te
(2), pin (3), and a spacer.

rn
al
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3
on
2
1 A
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N121112008
FIG. 302
79033095 C Rev. 04-131

FIG. 303: Attach a suitable lifting device to drawbar (1).
Remove drawbar.
1
Fo
N121112009
FIG. 303
r in
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rn
al
u se
on
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04-132 79033095 C Rev.

Drawbar (3-PT Hitch) Installation
Install drawbar.
Fo
1
N121112009
FIG. 304
r
FIG. 305: Install pin (1), washers (2), bolts (3), and a
in
spacer. Remove Tooling (A).

te
rn
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u
1
se
2
on
3 A
N121112008
FIG. 305
ly
N121112007
FIG. 306
79033095 C Rev. 04-133

SPECIAL APPLICATION HITCH
Special Application Hitch Removal
m
CAUTION: Make sure engine has been shut
down and key removed from ignition.
Disconnect battery by turning off battery
disconnect switch.
FIG. 307: Special application hitch (1) is located at rear

of machine.
Fo
1
r
P080505002
FIG. 307
in
FIG. 308: Begin by removing electrical connector

te
bracket (1). Loosen and remove bolts with washers (2)

that secure bracket. Remove bracket and move out of
way. 1
rn
al
u
2
se
P080505003
FIG. 308
on
FIG. 309: Remove implement valve bank (1) from hitch.

NOTE: Refer to Hydraulic Division Implement Valve 1
ly
P080605001
FIG. 309
04-134 79033095 C Rev.

FIG. 310: Use a suitable lifting device to support special
application hitch.
NOTE: Approximate weight of special application hitch is
139 kg (307 lb).
Loosen and remove ten bolts with washers (1). Carefully
1
remove hitch (2).
P080605002
FIG. 310
FIG. 311: Remove belly guard (1) if machine is equipped
with belly guard option.
Fo
NOTE: Refer to Accessory Division Belly Guard

1
r in
te
rn
P080605004
FIG. 311
al
FIG. 312: Loosen and remove two bolts with washers

(1). Remove drawbar pin retainer (2) and remove drawbar
pin (3).
u
3
se
2
on
1
ly
P080605005
FIG. 312
79033095 C Rev. 04-135

FIG. 313: Remove two washers (1).
P080605006
FIG. 313
FIG. 314: Loosen and remove eight bolts with washers
(1) that mount drawbar pivot support (2). Remove
drawbar pivot support.
2
Fo
r
1
in
te
rn
P080605007
FIG. 314
al
u se
on
ly
04-136 79033095 C Rev.

Special Application Hitch Installation
m
CAUTION: Make sure engine has been shut
down and key removed from ignition.
Disconnect battery by turning off battery
disconnect switch.
FIG. 315: Clean mounting surface (1) of all debris.
1
Fo
P080605008
FIG. 315
r
FIG. 316: Install drawbar pivot support (1) to machine

in
with eight bolts with washers (2).

1
te
rn
2
al
u
P080605007
se
FIG. 316
FIG. 317: Install two washers (1).
on
1
ly
P080605006
FIG. 317
79033095 C Rev. 04-137

FIG. 318: Install drawbar pin (1) and drawbar pin retainer
(2). Secure pin with two bolts with washers (3). Tighten
bolts to 45 to 65 Nm (33 to 48 lbf ft).
P080605005
FIG. 318
FIG. 319: Install belly guard (1) to machine if equipped
with belly guard option.
Fo
NOTE: Refer to Accessory Division Belly Guard

1
r in
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rn
P080605004
FIG. 319
al
FIG. 320: Use a suitable lifting device to move special

application hitch into position.
NOTE: Approximate weight of special application hitch is
u
139 kg (307 lb).

se
Install hitch with ten bolts with washers (1). Tighten bolts
1
to 800 to 1000 Nm (590 to 738 lbf ft).
on
2
ly
P080605002
FIG. 320
FIG. 321: Install implement valve bank (1) to hitch.
NOTE: Refer to Hydraulic Division Implement Valve 1
P080605001
FIG. 321
04-138 79033095 C Rev.

FIG. 322: Install electrical connector bracket (1) to hitch
with two bolts with washers (2). Tighten bolts to 48 to 72
Nm (35 to 53 lbf ft).
1
2
P080505003
FIG. 322
Fo
r in
te
rn
al
u se
on
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79033095 C Rev. 04-139

STEP (UPPER)
Step (Upper) Removal

FIG. 323: Attach a suitable lifting sling to step (1).
Remove bolts (2) and remove step (1).
2
Fo
r
N121112010
in
FIG. 323
te
Step (Upper) Installation

FIG. 324: Attach a suitable lifting sling to step (1).
rn
Position step (1) and install bolts (2).

al
1
u
2
se
on
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N121112010
FIG. 324
04-140 79033095 C Rev.

FUEL TANK
Fuel Tank Removal

containing fluids.
and mandates.
Drain fuel from tank.
NOTE: Refer to Operation and Maintenance Manual
Fuel Tank Water and Sediment - Drain.
FIG. 325: Remove bolts (1). Remove fender (2).
Fo
1
r
2
in
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rn
al
u
1
se
N121912004
FIG. 325
on
ly
N121912005
FIG. 326
79033095 C Rev. 04-141

FIG. 327: Remove bolts (1). Disconnect harness
assemblies (2).
1
Fo 2
N121912006
FIG. 327
r in
te
rn
al
1
u se
on
N121912007
FIG. 328
ly
04-142 79033095 C Rev.

1
Fo
N121912008
FIG. 329
FIG. 330: Remove cover (1) and remove bolts (2).
r in
te
1
2
rn
al
u
N121912009
se
FIG. 330
FIG. 331: Remove bolts (1) and bolts (2). Remove
fender (3). 3
on
ly
N122012001
FIG. 331
79033095 C Rev. 04-143

FIG. 332: Remove bolts (1). Remove clamps (2) and
disconnect wire assembly (3).
2
Fo
N122012002
FIG. 332
FIG. 333: Disconnect hose assembly (1). Remove
r
clamps (2). Remove bolts (3). Disconnect hose assembly

(4).
in
Repeat the steps for other side of machine. 1

te
NOTE: Following steps are for left-hand fuel tank.

rn
3
al
4
2
u se
on
N122012003
FIG. 333
FIG. 334: Remove bolts (1) and nuts. Remove bolts (2)
ly
and nuts.
1
2
N122012004
FIG. 334
04-144 79033095 C Rev.

FIG. 335: Attach a suitable strap around left-hand fuel
tank (1). Remove bolts (2) and bolts (3). Remove fuel
tank. Weight of fuel tank is approximately 193 kg (425 lb). 1
NOTE: Following steps are for right-hand fuel tank.
2
3
Fo
N122012005
FIG. 335
r in
2
te
rn
1
al
N122012006
u
FIG. 336
se
FIG. 337: Disconnect hose assembly (1) and hose

assembly (2).
on
ly
2
N122012007
FIG. 337
79033095 C Rev. 04-145

1
Fo
N122012008
FIG. 338
r
Disconnect tube assembly (3).

in
1
2
te
1
rn
al
u
3
se
on
N122012009
FIG. 339
ly
04-146 79033095 C Rev.

FIG. 340: Attach a lifting strap around right-hand fuel
tank (1).
Fo
N122012010
FIG. 340
FIG. 341: Remove bolts (1) and remove fuel tank.
r
Weight of fuel tank is approximately 170 kg (375 lb).

in
te
rn
al
1
u se
on
N122012011
FIG. 341
ly
79033095 C Rev. 04-147

Fuel Tank Installation
Following steps are for installation of right-hand fuel tank.
FIG. 342: Attach a lifting strap around right-hand fuel
tank (1).
1
Fo
r
N122012010
FIG. 342
in
FIG. 343: Install fuel tank and install bolts (1). Weight of
fuel tank is approximately 170 kg (375 lb).
te
rn
al
u
1
se
on
N122012011
ly
FIG. 343
04-148 79033095 C Rev.

FIG. 344: Connect tube assembly (1). Install plate (2)
and install bolts (3).
3
2
3
1
Fo
N122012009
FIG. 344
r in
te
rn
al
1
u se
on
N122012008
FIG. 345
FIG. 346: Connect hose assembly (1) and hose
ly
assembly (2).
2
N122012007
FIG. 346
79033095 C Rev. 04-149

FIG. 347: Install plate (1) and install bolts (2).
N122012006
FIG. 347
FIG. 348: Following steps are for installation of left-hand
fuel tank.
Attach a suitable strap around left-hand fuel tank (1). 1
Fo
Install fuel tank. Install bolts (2) and bolts (3). Weight of
fuel tank is approximately 193 kg (425 lb).
r in
2
te
3
rn
al
N122012005
u
FIG. 348
se
FIG. 349: Install bolts (1) and nuts. Install bolts (2) and
nuts.
1
on
ly
2
N122012004
FIG. 349
04-150 79033095 C Rev.

FIG. 350: Connect hose assembly (1). Install clamps (2).
Install bolts (3). Connect hose assembly (4).
3
4
2
Fo
N122012003
FIG. 350
FIG. 351: Install bolts (1). Connect wire assembly (2)
r
and install clamps (3).

in
te
1
rn
2
al
u se
3
on
N122012002
FIG. 351
ly
79033095 C Rev. 04-151

FIG. 352: Install fender (1). Install bolts (2) and bolts (3).
1
3
Fo
N122012001
FIG. 352
FIG. 353: Install cover (1) and install bolts (2).
r in
te
1
2
rn
al
u
N121912009
se
FIG. 353
FIG. 354: Install bolts (1).
on
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N121912008
FIG. 354
04-152 79033095 C Rev.

FIG. 355: Install bolts (1).
1
Fo
N121912007
FIG. 355
FIG. 356: Connect harness assemblies (1). Install bolts
r
(2).
in
te
2
rn
1
al
u se
on
N121912006
FIG. 356
ly
79033095 C Rev. 04-153

Fo 1
N121912005
FIG. 357
FIG. 358: Install fender (1). Install bolts (2).
r
Repeat steps for other side of machine. 2

in
Fill fuel tanks.

NOTE: Refer to Operation and Maintenance Manual
te
Fuel System - Fill. 1

rn
al
u
se
2
N121912004
on
FIG. 358
ly
04-154 79033095 C Rev.

AUXILIARY FUEL TANK
Auxiliary Fuel Tank Removal
Required Tools
A Hydraulic Jack 1

containing fluids.
Fo
and mandates.
Remove guards on right-hand side of machine. Refer to
Guards Removal section for more information.
r
FIGS. 359–360: Close valves (1) and valve (2) on fuel

in
lines.
te
rn
1
al
u se
N121912001
FIG. 359
on
2
ly
N121912002
FIG. 360
79033095 C Rev. 04-155

FIG. 361: Drain fuel from hose assemblies in a suitable
container for disposal or storage. Disconnect hose
assembly (1) from auxiliary fuel tank (2). Disconnect tube 1
assembly (3) from auxiliary fuel tank. Position Tooling (A) 2
under auxiliary fuel tank.
Remove bolts (4). Remove auxiliary fuel tank. 3
4
4
Fo
N121912003
FIG. 361
r in
te
rn
al
u se
on
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04-156 79033095 C Rev.

Auxiliary Fuel Tank Installation
FIG. 362: Position Tooling (A) under auxiliary fuel tank
(1). Install auxiliary fuel tank. Connect tube assembly (2)
to auxiliary fuel tank. Connect hose assembly (3) to 3
auxiliary fuel tank. 1
Install bolts (4).
4 2
4
Fo
N121912003
FIG. 362
r
FIGS. 363–364: Open valves (1) and valve (2) on fuel

in
lines.
Install guards on right-hand side of machine.
te
NOTE: Refer to Guards Installation section for more

information.
rn
1
al
u se
N121912001
FIG. 363
on
2
ly
N121912002
FIG. 364
79033095 C Rev. 04-157

NOTES
Fo
r in
te
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on
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04-158 79033095 C Rev.

BELT ALIGNMENT (MOBIL-TRAC)
Introduction
Test is used to check alignment of belt. If belt is not
aligned, there will be excessive wear and heating of guide
blocks. This can significantly reduce life of belts.
Belt alignment between guide blocks and undercarriage
components is adjustable.
Perform Check Belt Alignment procedure in all of following
situations:
• After replacing any component of undercarriage,
check belt alignment.
Fo
• When guide blocks become hot during use, check

belt alignment.
• When guide blocks show noticeable wear, check belt
r
alignment.
in
Checking Belt Alignment

te
1. Drive machine on a smooth, level surface for a

distance of 61 to 91 m (200 to 300 ft). Drive machine
at a speed less than 8 km/h (5 mph).
rn
2. Allow machine to coast to a stop. Do not turn steering

wheel.
al
3. Put transmission control lever in Park position and

stop engine.
u
4. Put chocks at front of belts and put chocks at rear of

belts.
se
FIG. 365: A drawing of measuring clearance between

inside edges of front midwheel and side of guide block is
shown.
1
on
5. Measure clearance between inside edges of front

midwheel (1) and side of guide block (2). If distances
(3) on each side of guide block (2) are within 2.0 mm
ly
(.08 in), belts are aligned correctly. If belts are not 3 3

aligned correctly, adjust belt alignment. 2
Refer to Adjusting Belt Alignment in this section.
P021405008
FIG. 365
79033095 C Rev. 04-159

Adjusting Belt Alignment
Introduction
FIG. 366: A drawing of right-hand side of undercarriage
(A) is shown.
By adjusting bolt (1) and corresponding bolt on opposite
side of lever (2), you can adjust alignment of guide blocks
to midwheels.
Dimension (B) and corresponding dimension on other
side of lever will determine alignment of guide blocks to
midwheels.
When dimension (B) is smaller, guide blocks will track A
closer to outside midwheels. When dimension (B) is
larger, guide blocks will track closer to inside midwheels.
Fo
1
r
2
in
te
A B
rn
P021405009
FIG. 366
al
u se
on
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04-160 79033095 C Rev.

Procedure to Adjust Belt Alignment
Use following steps to cause guide blocks to ride
closer to outside midwheels:
NOTE: Do not turn adjusting bolts by more than 1/4 turn.
1. Move machine to a smooth horizontal location. Move
away from working machines and personnel. Lower
implements and lower three-point hitch to ground.
2. Move transmission control lever to Park position.
3. Turn off engine.
FIG. 367: Photo of right-hand side of undercarriage.
2
4. Remove bolt (1).
3
5. Remove lock plate (2).
6. Remove corresponding small bolt and lock plate on
opposite side of frame.
Fo
7. Loosen corresponding large bolt on other side of

frame by 1/4 turn. (Turn bolt counterclockwise.) 1
r
8. Tighten bolt (3) to 200 Nm (150 lbf ft).

9. Install lock plate and bolt.
in
10. Install corresponding lock plate and small bolt on P021405010

other side of frame.
te
FIG. 367
Use following steps to cause guide blocks to
ride closer to inside midwheels:
rn
NOTE: Do not turn adjusting bolts by more than 1/4 turn.

al
11. Remove lock plate (2) and bolt (1).

12. Loosen bolt (3) by 1/4 turn. (Turn bolt
counterclockwise.)
u
13. Remove corresponding small bolt and lock plate from

se
other side of frame.

14. Tighten corresponding bolt on other side of frame to a
torque of 200 Nm (150 lbf ft).
on
15. Install lock plate and small bolt on other side of frame.
16. Install lock plate (2) and bolt (1).
ly
17. Check belt alignment again.

Refer to Checking Belt Alignment in this section.
18. Repeat Step 4 through Step 16 until belt alignment is
correct.
79033095 C Rev. 04-161

Further Alignment Steps - I
If alignment procedures do not produce acceptable
results, further adjustment is necessary.
1. Confirm that hardbar and axle measurement are
correct. If hardbar clamp or axle collet has slipped,
reset to correct measurement and torque retaining
bolts.
2. Inspect idlers, drivers, midrollers, and belts for
damage or excessive wear.
3. If swing link adjustment lever does not appear to get
full travel, try following:
a. Be sure there is not dirt or debris buildup around
adjustment lever to limit travel. Clean as required.
b. Roll machine forward a short distance to allow
idler to seat. Adjust idler lever again as far as
Fo
possible or until desired position is achieved with

hand tools.
c. Adjust idler lever with idler lifted off of ground so
r
machine weight is not on idler and lever screw

will turn easier.
in
d. Use an impact wrench to move lever through full

travel.
te
IMPORTANT: Use caution, do not damage threads.

rn
If swing link is at maximum adjustment,

movement of undercarriage may be necessary to
align belts. This requires adjusting hardbar only.
al
4. Adjust undercarriage frame alignment.

a. If guide blocks are rubbing inside midwheels and
u
swing links are adjusted all way inside, move

undercarriage out 10 mm (0.39 in) on hardbar.
se
b. If guide blocks are rubbing outside midwheels

and swing links are adjusted all way out, move
undercarriage in 10 mm (0.39 in) on hardbar.
on
c. Follow steps in Checking Alignment in this

section.
d. If belts are still not properly aligned, an additional
ly
10 mm (0.39 in) of adjustment on hardbar can be

made.
NOTE: An alternate method to step 4d is to adjust
undercarriage of opposite side. This will have
same affect as additional 10 mm (0.39 in) of
adjustment.
IMPORTANT: Do not exceed 20 mm (0.78 in) difference
from hardbar to axle measurements on each
undercarriage.
04-162 79033095 C Rev.

Further Alignment Steps - II
In some cases it has been found that completing both of
belt alignment procedures may not be enough to properly
align belts. Cap that holds swing link arm to front portion
of MTS frame could be misaligned by amount of tolerance
in bolt holes. If this cap is misaligned, this causes idler to
tilt to one side or other and results in belt not aligning
properly.
Processes are in place in production to ensure proper
alignment of idler when MTS undercarriages are built.
Also, a second dowel pin will be added to front of cap to
aid in alignment process.
If belt cannot be properly aligned using procedures listed
in Adjusting Belt Alignment section and if MTS has to be
moved more than 10 mm (0.3875 in) according to Further
Alignment Steps - I section, then use following procedure
to properly align belts.
Fo
FIG. 368: Graphic of Swing Arm Cap

Remove track belt on undercarriage to make adjustments
2
r
to cap (1). Follow instructions found in Disassembly and

Assembly, Undercarriage Drive Belt (Mobil-Trac), to
in
remove track belt.

3
Loosen four bolts (2) securing cap (1) to frame (3). (Two
te
on top and two on bottom)

Turn cap in direction away from side of belt that has been
rn
rubbing hard. If right-hand side of belt has been rubbing

hard, turn cap to left as far as it will go and then torque 1
bolts. If left-hand side of belt has been rubbing hard, turn
al
MT0810
cap to right as far as it will go and then torque bolts.
Typically, bolts will not allow cap to turn too far and make FIG. 368
belt out of alignment on other side.
u
After adjusting idler, properly torque four cap retaining

se
bolts (2) to 400 to 520 Nm (295 to 385 lbf ft).

Install track belt. Follow instructions found in Disassembly
and Assembly, Undercarriage Drive Belt (Mobil-Trac), to
install track belt.
on
Align belts following instructions in Adjusting Belt

Alignment section.
ly
If belts still cannot be properly aligned, contact Product

Reliability Group.
79033095 C Rev. 04-163

CHECKING OIL LEVELS
Idlers and Midwheels without Sight Gauge

FIG. 369: Park machine on a hard, level surface. Place
chocks at front of belts and at rear of belts.
Clean area around filler plug (1). Then, remove plug.
Maintain oil level to bottom of threads of hole for filler plug.
If oil level is low, add oil. See Specifications section for 1
quantity and oil specifications. 1
Install filler plug.
NOTE: Make sure that you do not spill oil on belts.
Belt slippage could increase if oil is on belts.
NOTE: Inspect oil level frequently if machine is operated K921061
in extremely wet conditions or extremely muddy FIG. 369
conditions and annually prior to beginning of
Fo
season.
Idlers Wheels with Sight Gauge

r
Oil Level Check

in

te

Park machine on hard, level surface. Place chocks at front
rn
and rear of tracks.

FIG. 370: Clean sight glass (1) with a soft, damp cloth.
al
Oil level should be maintained between lower 1/3 and

upper 1/3 of sight glass. If needed, add AGCO Synthetic
Transmission Fluid SAE 50 oil or equivalent through
2
u
fill/drain plug (2).

1
se
NOTE: When adding oil make sure fill plug is located

above sight glass.
on
T011005003
ly
FIG. 370
Oil Change
forward or rearward slightly to locate fill/drain plug (1) at
the six o’clock position. Place chocks at front and rear of
tracks.
1
Clean area around fill/drain plug. Remove plug and allow 2
oil to drain into an approved container. Reinstall plug.
Remove wheel chocks and drive machine forward or
rearward slightly until threaded hole is approximately at
twelve o’clock position. Replace chocks at front and rear
of tracks. Add AGCO Synthetic Transmission Fluid SAE
50 oil or equivalent until oil level reaches mid point on
sight glass (2). Reinstall plug. T011005003
FIG. 371
04-164 79033095 C Rev.

Midwheels with Sight Gauge
Oil Level Check
Park machine on hard, level surface. Place chocks at front
and rear of tracks.
FIG. 372: Clean sight glass (1) with a soft, damp cloth.
Oil level should be maintained between lower 1/3 and
upper 1/3 of sight glass. If needed, add AGCO Synthetic
Transmission Fluid SAE 50 oil or equivalent through
fill/drain plug (2). 2
NOTE: When adding oil make sure fill plug is located
1
above sight glass.
Fo
r
T011005002
FIG. 372
in
Oil Change
te

forward or rearward slightly to locate fill/drain plug (1) at
rn
the six o’clock position. Place chocks at front and rear of

tracks.
al
Clean area around fill/drain plug. Remove plug and allow 1

oil to drain into an approved container. Reinstall plug. 2
Remove wheel chocks and drive machine forward or
u
rearward slightly until threaded hole is approximately at

twelve o’clock position. Replace chocks at front and rear
se
of tracks. Add AGCO Synthetic Transmission Fluid SAE

50 oil or equivalent until oil level reaches mid point on
sight glass (2). Reinstall plug. T011005002
FIG. 373
on
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79033095 C Rev. 04-165

Drive Wheels
Oil Level Check
forward or rearward slightly to locate magnetic plug (1)
between nine o’clock and ten o’clock or between two
o’clock and three o’clock position. Place chocks at front
and rear of tracks.
1
NOTE: Magnetic plug is identified by a 4.76 mm (3/16 in)
hex socket inset, whereas the non-magnetic plug
has a 5.56 mm (7/32 in) hex socket inset.
Clean area around magnetic plug then remove plug.
Maintain oil level to bottom of threaded hole. Remove any
Fo
accumulated metal particles from magnetic plug. If

needed, add AGCO Synthetic Transmission Fluid SAE 50 T011005004
oil or equivalent. Reinstall plug and tighten. FIG. 374
r
Oil Change
in

forward or rearward slightly to locate magnetic plug (1) on
inboard hub at twelve o-clock position. Place chocks at 1
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front and rear of tracks.

rn

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T011105002
se
FIG. 375
on

magnetic plug.
After oil has finished draining, install one plug in lower
ly
threaded hole.
Remove wheel chocks and drive machine rearward
slightly until open threaded hole is between two o’clock
and three o’clock position. Replace chocks at front and
rear of tracks. 2
Add AGCO Synthetic Transmission Fluid SAE 50 oil or
T011105001
equivalent to upper threaded hole in outer hub until oil
level reaches bottom of threaded hole. Reinstall plugs in FIG. 376
both inner and outer hubs.
04-166 79033095 C Rev.

Frame Specifications
FRAME SPECIFICATIONS
UNDERCARRIAGE
Front Idler
1 2
3
4 5
Fo
6
r
6
in
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P021405011
g00836829
FIG. 377
u se
FIG. 377: Illustration of front idler hub with swing arm

and lever is shown.
1. Install plate with stamped markings toward outside of
idler.
on
2. Torque for twelve M24X3 bolts - 800 to 1000 Nm (590

to 738 lbf ft).
ly
3. Rubber toric seals and all surfaces that contact seals

must be clean and dry before assembly. Prior to
assembly, apply a thin film of oil to contacting
surfaces of metal seal rings. Seal rings must be
assembled square with bore and toric ring. Bulging or
twisting of seal ring should not occur. Refer to
Disassembly and Assembly, Installation of
Conventional Duo-Cone Seals, in this section.
4. Install gasket so that raised bead contacts hub.
5. When assembly is complete, fill each hub to plug
level with SAE 50 Synthetic oil.
Oil volume when oil has reached plug level:
• MT800-0.5 L (0.53 qt)
6. Torque for two M24X3 bolts - 200 Nm (148 lbf ft).
79033095 C Rev. 04-167

Procedure for Installation of Lever
6
7 10
8
9
6
A
9
Fo
8
7
r
11
in
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P021405012
FIG. 378
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FIG. 378: Illustration of lever for adjusting front idler is

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shown.
1. Install bearing (7) into bore of frame. Bearing should
be recessed by 0.5 to 1.5 mm (0.02 to 0.06 in).
u
2. Install bearing (7) into bore of cap.

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3. Apply a thin oil film in diameter of counterbore of

frame. Also, apply a thin oil film in diameter of
counterbore of cap.
on
4. Install seal (9) into counterbores. Sharp edge of seal

should extend out of counterbores. Rings of seal
assembly must be fully assembled. There should be
ly
no oil between rings of seal assembly. Seal assembly

must contact bottom of counterbore.
5. Install thrust ring (8) into cap and onto top side of
lever.
6. Install lever (10) into frame.
7. Install cap (11) onto roller frame.
04-168 79033095 C Rev.

Idler Specifications
Fo
P052305002
FIG. 379
r in
FIG. 379: Idler Wheel

Specifications:
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Make:................................................................................................................................................................Camoplast
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Type:.............................................................................................................................................................Rubber/Steel
Diameter: .............................................................................................................................................. 950 mm (37.4 in)
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Bolt Circle Diameter:........................................................................................................................... 335 mm (13.19 in)

Bolt Size ............................................................................................................................... M24 (0.94 in) 12 per Wheel
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79033095 C Rev. 04-169

Midwheel
3
3
8
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7 4
in
1 5 6
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2 P021505001
FIG. 380
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FIG. 380: Illustration of midwheel assembly with an

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exploded view of midwheel is shown.

1. When assembly is complete, fill each hub to plug
level with SAE 50 Synthetic oil:
u
• MT 800-0.225 L (0.24 qt)

se
NOTE: To ensure that surfaces that are being sealed are

free of oil, grease, and fuel, wipe surfaces with a
rag that has been soaked in isopropyl alcohol.
on
2. Install gasket so that raised bead contacts hub.

3. Rubber toric seals and all surfaces that contact seals
must be clean and dry before assembly. Prior to
ly
assembly, apply a thin film of oil to contacting

surfaces of metal seal rings. Seal rings must be
assembled square with bore and toric ring. Bulging or
twisting of seal ring should not occur. Refer to
Disassembly and Assembly, Installation of
Conventional Duo-Cone Seals, in this section.
4. Torque for thirty-two M16 X 2 bolts - 230 to 310 Nm
(169 to 229 lbf ft).
04-170 79033095 C Rev.

FIG. 381: Alignment mark (X) for midwheel pivot pin
assembly: -10 to 10 degrees.
P021505002
FIG. 381
FIG. 382: Dimension (A) for both sides of pin assembly -
49.5 to 51.5 mm (1.961 to 2.039 in).
A
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P021505003
FIG. 382
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79033095 C Rev. 04-171

Procedure for Setting Bearings for
Midwheel
3
3
Fo
8
r in
7 4
1
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5 6
2 P021505001
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FIG. 383
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FIG. 383: Illustration of midwheel assembly with an

exploded view of midwheel is shown.
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1. Bearing cone (7) must slide easily on axle. Nut (5)

must rotate freely on threads that are located on axle.
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2. Tighten nut (5) to a torque of 27 to 41 Nm (20 to 30 lbf

ft).
3. Rotate hub (8) for three revolutions.
on
4. Tighten nut (5) to a torque of 27 to 41 Nm (20 to 30 lbf

ft).
ly
5. Repeat step 3 and step 4.

6. Bend lock tang (6) into slot in locknut (5).
NOTE: When lock tang (6) and nut (5) are not properly
aligned, tighten nut (5) until nearest slot aligns
with lock tang (6).
04-172 79033095 C Rev.

Midwheel Specifications
Fo
P052305003
FIG. 384
r in
FIG. 384: Midwheels

Specifications:
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Make:................................................................................................................................................................Camoplast
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Optional:...................................................................................................................................... Polyurethane/Steel
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Diameter: ........................................................................................................................................... 355.6 mm (14.0 in)

Bolt Circle Diameter:............................................................................................................................. 170 mm (6.69 in)
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Bolt Size ..................................................................................................................................M16 (0.63 in) 8 per Wheel

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79033095 C Rev. 04-173

Torque Procedure for Drive Wheel Collet
Bolts
4
12 10
8 6
A
1 2
5 7
Fo
9 11
3
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N050105001
FIG. 385
in
FIG. 385: Tighten bolts in sequence shown in illustration.

te
Tighten bolts on collets to 530 Nm (391 lbf ft). Use a

crisscross pattern as you perform torque sequence.
rn
Begin torque sequence with bolt (1). Perform this

sequence a total of three times.
IMPORTANT: If surface (A) and (B) are mismatched in
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excess of 0.8 mm (0.31 in) remove collets and

repeat tightening procedure.
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Perform a fourth tightening sequence at 460 Nm (339 lbf

ft). If bolt number 12 rotates when 460 Nm (339 lbf ft) is
se
applied, perform a fifth pass at 460 Nm (339 lbf ft).

IMPORTANT: Over tightening bolts may decrease life of
Reaction Arm Bearings. Follow Torque
Procedure to ensure that proper torque is
on
achieved.
IMPORTANT: Coat threads of collet bolts with anti-seize
lubricant prior to installation.
ly
Do not use any type of lubricant when installing

collets. Mating tapered surfaces of collets and
outer hub must be installed dry. Failure to install
properly may decrease life of drive wheel support
bearing.
04-174 79033095 C Rev.

Drive Wheel Specifications
Fo
P052305004
FIG. 386
r in
FIG. 386: Drive Wheel

Specifications:
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Make:................................................................................................................................................................Camoplast
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Diameter: .......................................................................................................................................... 1550 mm (61.02 in)
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Bolt Circle Diameter:.................................................................................................... 400 mm (15.75 in) 18 per Wheel

Bolt Size ............................................................................................................................... M24 (0.94 in) 18 per Wheel
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79033095 C Rev. 04-175

BELT TENSIONER
FIG. 387: Callouts for illustration of right-hand and
left-hand belt tensioner groups are shown.
1. Adapter
2. Pressure Sensor
3. Accumulator
Use machine hydraulics in order to fill tensioner, using
adapter (1), with TO-2 10W30 oil: 3
• MT800- approximately 5L (5.3 qt)
Specifications for Part No. 194-6726 Pressure Sensor (2)
are:
Installation torque - 8 to 12 Nm (5.9 to 8.9 lbf ft)
Maximum operating pressure - 34501 kPa (5004 psi) 1
Fo
NOTE: Readings for tensioner pressure on an ET may

not correlate directly with reading for hard gauge 2
pressure. This is due to tolerance in pressure
sensor and gauge.
r in
P021505005
FIG. 387
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Accumulator (Belt Tension)

rn
FIG. 388: Specifications for Accumulator (3), shown in

illustration are:
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MT800 accumulator, Part No. 189-3166, 3

specifications:
• Pre-charge pressure - 15158 kPa (2199 psi)
u
• Service pressure -27560 kPa (4000 psi)

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• Minimum burst pressure - 137800 kPa (20000 psi)

• Gas volume - 10000 mL (610 in3)
• Maximum working temperature - 130 degrees C (266
on
degrees F)
P021505006
• Minimum working temperature - -35 degrees C (-31
degrees F) FIG. 388
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04-176 79033095 C Rev.

Tensioner Pressure Sensor
Fo
P080605009
FIG. 389
r in
FIG. 389: Tensioner Pressure Sensor

Input:
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Supply Voltage (Polarity Protected): ...............................................................................................................8 TO 30 V

rn
Supply Current Consumption:................................................................................................................................4.5mA

Nominal Pressure: ............................................................................................................................... 400bar (5800 psi)
al
Overload Pressure:......................................................................................................................... 1200 bar (17400 psi)

Burst Pressure: ............................................................................................................................... 4000 bar (58000 psi)
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Output:
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Nom. Output Signal (Short Circuit Protected): ..................................................................................................1 TO 5 V

Accuracy: ................................................................................................................................................ +-0.5% FS/ 10K
Thermal Zero Point Shift:....................................................................................................................>+-0.15% FS/ 10K
on
Thermal Span Shift:............................................................................................................................>+-0.15% FS/ 10K

Response Time (Liquids) (10-90%): ......................................................................................................................... 1ms
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Durability,................................................................................................................P=10-90% FS: >10 x 10^6 CYCLES

Output Impedance:......................................................................................................................................... =<90 OHM
Load (Connected To 0 V): ................................................................................................................... RL>=10000 OHM
Environmental:
Temperature Range:....................................................................................................... -40 TO +125 C (-40 TO 257 F)
Vibration Stability: .................................................................................................. 20g, 10-2000 Hz PER EN60068-2-6
Shock Resistance:.................................................................................................................. 100g PER EN60068-2-27
Enclosure: .................................................................................................................................................................IP 67
EMC - Emission:................................................................................................................................................EN55022
EMC - Immunity:.................... RF FIELD 100 V/m, 26 Mhz - 1 Ghz PER EN61000-6-2, EN61000-4-6, EN61000-4-3
79033095 C Rev. 04-177

Disc Relief Valve
Fo
P080705001
FIG. 390
r in
FIG. 390: Disc Relief Valve

Specifications:
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Rupture Disc Material:...............................................................................................................Nickel or Stainless Steel

rn
Valve Body Material:................................................................................................................................................ Brass

Burst Pressure: .............................................................................................................................. 44800 kPa (6498 psi)
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04-178 79033095 C Rev.

FUEL TANK
Main Tank
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P052205001
FIG. 391
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FIG. 391: Standard fuel tank on 800 series machine is

mounted on both sides of cab. Tank has a capacity of
u
1080 L (280 gal).

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79033095 C Rev. 04-179

Auxiliary Tank
Fo
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P052205002
FIG. 392
rn
FIG. 392: Auxiliary fuel tank is optional on 800 series

al
machine. Auxiliary fuel tank is located toward front of

machine in between frame rails. Tank has a capacity of 95
L (25 gal).
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on
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04-180 79033095 C Rev.

DRAWBAR (STANDARD)
Fo
P052305001
r
FIG. 393
in
FIG. 393: Drawbar

Specifications:
te
Type:......................................................................................................................................Wide Swinging with Rollers

rn
Type:................................................................................................................................................... ASAE S482 Cat IV

Pin Diameter: ................................................................................................................................ 50.8 mm (2.00 in)
al
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79033095 C Rev. 04-181

NOTES
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use
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04-182 79033095 C Rev.

Index
INDEX
A I
Acceptable Lubricants Idler Hub Installation ........................................... 04-69

for Duo-Cone Assembly ..................................... 04-84 Idler Hub Removal .............................................. 04-68
Accumulator (Belt Tension) .............................. 04-176 Idler Specifications ........................................... 04-169
Accumulator Installation ..................................... 04-63 Idlers and Midwheels without Sight Gauge ...... 04-164
Accumulator Removal ........................................ 04-62 Idlers Wheels with Sight Gauge ....................... 04-164
Assembly and Installation Inspection ........................................................... 04-46
of Conventional Duo-Cone Seals ....................... 04-79 Installing Duo-Cone Seals .................................. 04-79
Auxiliary Fuel Tank .......................................... 04-155 Required Tools ................................................ 04-79
Auxiliary Fuel Tank Installation ........................ 04-157
Auxiliary Fuel Tank Removal ........................... 04-155
Auxiliary Tank .................................................. 04-180 L
Lever Installation Procedure ............................. 04-168

Fo
Belt Alignment (Mobil-Trac) ............................. 04-159 M

r
Adjusting Belt Alignment ............................... 04-160

Checking the Belt Alignment ......................... 04-159 Main Tank ......................................................... 04-179
in
Further Alignment Steps - I ........................... 04-162 Midwheel .......................................................... 04-170

Further Alignment Steps - II .......................... 04-163 Midwheel Assembly ............................................ 04-90
Belt Tensioner .................................................. 04-176 Midwheel Assembly Installation ......................... 04-92
te
Midwheel Assembly Removal ............................ 04-86

Midwheel Bearing Setting Procedure ............... 04-172
rn
C Midwheel Disassembly ....................................... 04-87

Midwheel Specifications ................................... 04-173
Checking Oil Levels ......................................... 04-164 Midwheels with Sight Gauge ............................ 04-165
al
Drive Wheels ................................................ 04-166

Correct Assembly
of Conventional Duo-Cone Seal ........................ 04-79 O
u
Oil Change ............................ 04-164, 04-165, 04-166

se
D Oil Level Check ..................... 04-164, 04-165, 04-166
Disc Relief Valve .............................................. 04-178

Drawbar (3-pt Hitch) ......................................... 04-131 P
on
Drawbar (3-PT Hitch) Installation ..................... 04-133

Drawbar (3-PT Hitch) Removal ........................ 04-131 Powered Drawbar (Hydraulic Controlled) ......... 04-117
Drawbar (Standard) ......................................... 04-181 Powered Drawbar (Hydraulic Controlled)
Drawbar (Wide Swing) ..................................... 04-110 Installation ........................................................ 04-124
ly
Drawbar (Wide Swing) Installation ................... 04-113 Powered Drawbar (Hydraulic Controlled)
Drawbar (Wide Swing) Removal ...................... 04-110 Removal ........................................................... 04-117
Drive Track Installation ...................................... 04-48 Pressure Sensor Installation .............................. 04-52
Drive Wheel Specifications .............................. 04-175 Pressure Sensor Removal ................................. 04-50
Drive Wheel-Collet Bolt Torque Procedure ...... 04-174
Duo-Cone Seals Assembly
and Installation Procedure ................................. 04-80 R
Reaction Arm Assembly ..................................... 04-96

F Reaction Arm Disassembly ................................ 04-93
Releasing the Pressure Between the Nipple
Frame Disassembly and Assembly .................... 04-43 and the Filler Valve ............................................. 04-41
Front Idler ......................................................... 04-167 Result of Incorrect Assembly Duo-Cone Seals .. 04-85
Fuel Tank ............................................ 04-141, 04-179 Roller Frame Restraint Group .......................... 04-106
Fuel Tank Installation ....................................... 04-148 Roller Frame Restraint Group Installation ........ 04-108
Fuel Tank Removal .......................................... 04-141 Roller Frame Restraint Group Removal ........... 04-106
Rupture Disc Installation .................................... 04-56
Rupture Disc Removal ....................................... 04-54
79033095 C Rev. 04-183

Index
S
Special Application Hitch ................................. 04-134

Special Application Hitch Installation ............... 04-137
Special Application Hitch Removal .................. 04-134
Step (Upper) .................................................... 04-140
Step (Upper) Installation .................................. 04-140
Step (Upper) Removal ..................................... 04-140
Swing Link and Lever ......................................... 04-70
Swing Link and Lever Assembly ........................ 04-74
Swing Link and Lever Disassembly ................... 04-72
Swing Link and Lever Installation ...................... 04-76
Swing Link and Lever Removal ......................... 04-70
Tensioner Assembly .......................................... 04-64

Tensioner Disassembly ...................................... 04-60
Fo
Tensioner Installation ......................................... 04-66

Tensioner Pressure Sensor ............................. 04-177
Tensioner Removal ............................................ 04-58
r
Track Removal ................................................... 04-43

in
U
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Undercarriage .................................................... 04-167

Undercarriage Assembly .................................. 04-101
rn
Undercarriage Assembly Installation ............... 04-104

Undercarriage Assembly Removal .................. 04-101
Undercarriage Drive Track (Mobil-Trac) ............. 04-43
al
Undercarriage Idler Hub ..................................... 04-68

Undercarriage Midwheel Assembly ................... 04-86
Undercarriage Pressure Sensor ........................ 04-50
u
Undercarriage Reaction Arm ............................. 04-93

Undercarriage Tensioner ................................... 04-58
se
Undercarriage Tensioner Rupture Disc ............. 04-54

on
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04-184 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
05 - Steering and Brake System

Contents
Fo
STEERING AND BRAKE SYSTEM OPERATION

Introduction .................................................................................................................................................... 05-1
r
Steering System ...................................................................................................................................... 05-1

Service Brakes ........................................................................................................................................ 05-1
in
Hydraulic Trailer Brakes (Optional) ......................................................................................................... 05-1

Air Trailer Brakes (Optional) .................................................................................................................... 05-2
Parking Brakes ........................................................................................................................................ 05-2
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Steering System ............................................................................................................................................ 05-3

Steering System Theory of Operation ..................................................................................................... 05-3
rn
Steering Hydraulic System ...................................................................................................................... 05-4

Steering Electrical System ...................................................................................................................... 05-5
Primary Steering Hydraulic System ......................................................................................................... 05-6
al
Location of Electronic Components for Steering System ........................................................................ 05-7

Location of Hydraulic Components for Steering System ....................................................................... 05-11
Steering System Input Components ...................................................................................................... 05-17
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Electronic Control Module for Steering System ..................................................................................... 05-19

Steering System Output Components ................................................................................................... 05-20
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Data Link for Steering System ............................................................................................................... 05-21

Common Sump (Steering) ..................................................................................................................... 05-22
Hydraulic Oil Filter (Steering and Parking Brake) .................................................................................. 05-27
Tandem Charge Pump (Steering) ......................................................................................................... 05-30
on
Steering Pump ....................................................................................................................................... 05-30

Steering Motor ....................................................................................................................................... 05-44
Hydraulic System Schematic (Steering) ................................................................................................ 05-48
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Differential Steering Mechanical Components ...................................................................................... 05-49

Differential Steering System .................................................................................................................. 05-51
Final Drive ............................................................................................................................................. 05-63
Brake System .............................................................................................................................................. 05-67
Introduction (Service Brake System) ..................................................................................................... 05-67
Service Brake System ........................................................................................................................... 05-68
Service Brake Components ................................................................................................................... 05-70
Priority Valve (Priority and Accumulator Charge Valve) ........................................................................ 05-72
Service Brake Control Valve ................................................................................................................. 05-74
Service Brakes ...................................................................................................................................... 05-76
Hydraulic Schematic for Service Brakes ............................................................................................... 05-79
Hydraulic Trailer Brake Valve System (Optional) ........................................................................................ 05-80
Introduction ............................................................................................................................................ 05-80
Hydraulic Trailer Brake System ............................................................................................................. 05-81
Hydraulic Trailer Brake Components .................................................................................................... 05-82
Air Trailer Brake System (CE Only) ............................................................................................................. 05-87
Introduction ............................................................................................................................................ 05-87
Air Trailer Brake System ....................................................................................................................... 05-87
Air Trailer Brake Components ............................................................................................................... 05-87
79033095 C Rev. 05-i

Contents
Parking Brake System ................................................................................................................................. 05-91
Introduction (Parking Brake System) ..................................................................................................... 05-91
Parking Brake System ........................................................................................................................... 05-92
Parking Brake System Electrical Components ...................................................................................... 05-94
Parking Brake System Hydraulic Components ..................................................................................... 05-96
Input Components of Parking Brake System ........................................................................................ 05-98
Parking Brake System ECMs ................................................................................................................ 05-99
Output Components of Parking Brake System .................................................................................... 05-101
Data Link for Parking Brake System ................................................................................................... 05-102
Parking Brake Control Valve ............................................................................................................... 05-103
Towing a Machine That has a Dead Engine ....................................................................................... 05-108
Parking Brake ...................................................................................................................................... 05-109
Hydraulic System Schematic (Parking Brake) ..................................................................................... 05-111
STEERING AND BRAKE SYSTEM DISASSEMBLY AND ASSEMBLY

Scavenge (Gear) Pump ............................................................................................................................. 05-113
Scavenge Pump Removal ................................................................................................................... 05-113
Scavenge Pump Installation ................................................................................................................ 05-114
Steering Pump ........................................................................................................................................... 05-115
Fo
Steering Pump Removal ..................................................................................................................... 05-115

Steering Pump Disassembly ............................................................................................................... 05-117
Steering Pump Assembly .................................................................................................................... 05-128
r
Steering Pump Installation .................................................................................................................. 05-141

Steering Motor ........................................................................................................................................... 05-142
in
Steering Motor Removal ...................................................................................................................... 05-142

Steering Motor Disassembly ............................................................................................................... 05-144
Steering Motor Assembly .................................................................................................................... 05-151
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Steering Motor Installation ................................................................................................................... 05-162

Secondary Steering Valve Actuator (CE Only) .......................................................................................... 05-163
rn
Secondary Steering Valve Actuator Removal ..................................................................................... 05-163

Secondary Steering Valve Actuator Installation .................................................................................. 05-164
Solenoid Valve - Secondary Steering (CE only) ........................................................................................ 05-165
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Solenoid Valve - Secondary Steering Removal .................................................................................. 05-165

Solenoid Valve - Secondary Steering Installation ............................................................................... 05-167
Brake Valve Assembly ............................................................................................................................... 05-169
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Brake Valve Assembly Removal ......................................................................................................... 05-169

Brake Valve Assembly Installation ...................................................................................................... 05-171
se
Brake Accumulator .................................................................................................................................... 05-172

Brake Accumulator Removal ............................................................................................................... 05-172
Brake Accumulator Installation ............................................................................................................ 05-173
Secondary Brake Valve (CE Only) ............................................................................................................ 05-174
on
Secondary Brake Valve Removal ........................................................................................................ 05-174

Secondary Brake Valve Installation ..................................................................................................... 05-175
Air Trailer Brake Valve ............................................................................................................................... 05-176
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Air Trailer Brake Valve Removal ......................................................................................................... 05-176

Air Trailer Brake Valve Installation ...................................................................................................... 05-178
Hydraulic Trailer Brake Valve (Optional) ................................................................................................... 05-179
Hydraulic Trailer Brake Removal ......................................................................................................... 05-179
Hydraulic Trailer Brake Installation ...................................................................................................... 05-183
STEERING AND BRAKE TESTING AND ADJUSTING

Machine Preparation ........................................................................................................................... 05-187
Testing and Adjusting Procedure ........................................................................................................ 05-187
Test Equipment ................................................................................................................................... 05-187
Warming the Hydraulic Oil ................................................................................................................... 05-188
Know the Machine ............................................................................................................................... 05-189
Understand the Symptoms .................................................................................................................. 05-189
Verify the Symptom ............................................................................................................................. 05-189
Determine the Probable Causes ......................................................................................................... 05-189
Reduce the List of Probable Causes ................................................................................................... 05-189
Test the System .................................................................................................................................. 05-189
05-ii 79033095 C Rev.

Contents
Visual Inspection ................................................................................................................................. 05-189
Steering System Testing and Adjusting ..................................................................................................... 05-190
Relief Valve (Charge) - Test and Adjust .............................................................................................. 05-190
Steering Pump High Pressure Cutoff Pressure Test ........................................................................... 05-194
High Pressure Relief Valve - Test and Adjust ..................................................................................... 05-201
Steering Drift ....................................................................................................................................... 05-207
Steering Wheel Calibration .................................................................................................................. 05-208
Steering Servo Valve Calibration ........................................................................................................ 05-209
Steering Pump Neutral - Test and Adjust ............................................................................................ 05-210
Steering Motor Case Drain Pressure Test .......................................................................................... 05-222
Service Brake System Testing and Adjusting ............................................................................................ 05-227
Service Brakes - Adjust and Purge ..................................................................................................... 05-227
Trailer Brakes (Air) - Purge ................................................................................................................. 05-231
Trailer Brakes (Hydraulic) - Purge ....................................................................................................... 05-232
Service Brake System Accumulator .................................................................................................... 05-233
Service Brake System Pressure - Test ............................................................................................... 05-240
INDEX ........................................................................................................................................................... 05-243

Fo
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79033095 C Rev. 05-iii

Contents
NOTES
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05-iv 79033095 C Rev.

Steering and Brake System Operation
STEERING AND BRAKE SYSTEM OPERATION
INTRODUCTION
FIG. 1: This module discusses the features and
operation of steering system and brake system. In
addition, major electrical components and hydraulic
components are discussed.
Steering System
Steering system will provide a method that is efficient and
reliable to steer the machine. Machine turns when one
track increases speed and other track decreases speed.
Steering differential changes power distribution to
mobil-trac system. Power is distributed differently than a
conventional steering system. P111012005
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FIG. 1
Service Brakes
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All machines are equipped with a hydraulic brake control

system which uses pressurized oil from implement
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hydraulic system to engage service brakes. Hydraulic oil

from implement pump will charge an accumulator.
Pressurized oil from accumulator is modulated to service
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brakes by service brake control valve.

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Hydraulic Trailer Brakes (Optional)

All machines can be equipped with an optional Hydraulic
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Trailer Brake system that uses pressurized oil from

implement hydraulic system to engage trailer brakes.
When service brake pedal is depressed service brake
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valve will send a signal to trailer brake valve. Trailer brake

valve will send pressurized oil from implement hydraulic
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pump to engage trailer brakes.

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79033095 C Rev. 05-1

Air Trailer Brakes (Optional)
All machines can be equipped with an optional Air Trailer
Brake system. An air compressor generates compressed
air for air brake system. An air dryer is used to remove
moisture from compressed air stored in an air tank. An
actuator valve will receive a hydraulic signal from parking
brake control valve when parking brake is released.
Actuator arm will retract to move lever on trailer control
valve to control pressure in dual lines of trailer brakes and
to send air to trailer control valve for single brake line.
When pressure at brake pedal is increased, flow to air
brakes is increased for advanced retardation of trailer.
Parking Brakes
All machines are equipped with a hydraulic parking brake
on input shaft to steering differential. Parking brake is
spring applied and hydraulically released. Parking brake
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valve controls oil flow to parking brake. Parking brake

valve uses pressurized oil from charge pump.
Parking brake is actuated with transmission control lever.
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Engage parking brake after stopping machine.

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Previous models used a separate hand lever to engage

parking brake. Parking brake was engaged manually.
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05-2 79033095 C Rev.

STEERING SYSTEM
Steering System Theory of Operation

Machines are equipped with a hydraulic system that Hydraulic Oil Filter
provides steering output to steering differential.
Hydraulic oil filter protects steering system from
Steering system on machine is similar to steering system damaging contamination. Hydraulic filter has a 7.5 micron
on a wheeled machine. When machine is traveling rating.
forward and steering wheel is turned to right, machine will
travel to right. Steering Pump
When machine is traveling in reverse and steering wheel Steering pump is an axial piston pump with following
is turned to right, machine will travel to right. characteristics:
Steering system has following main components: • Variable displacement
• Steering Wheel Position Sensors • Bidirectional flow
• Tandem Charge Pump Steering pump produces output only when machine must
be steered. During straight travel, pump destrokes and
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• Hydraulic Filter
pump output is zero. This will prevent machine from
• Steering Pump turning until input is received from steering wheel.
• Steering Motor Steering pump has a maximum displacement of 125
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cm3/rev (7.6 in3/rev) and maximum flow rate of 353

• Steering Differential liters/min (93.3 gal/min).
in
• Secondary Steering Valve (CE Only)

Steering Motor
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• Steering Motor Bypass Valve (CE Only)

Steering motor is a fixed displacement bent axis motor
• Secondary Steering Actuators (CE Only) with following characteristics:
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Steering Wheel Position Sensors • Bidirectional

Three sensors determine position of steering wheel. • Bent axis
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Steering wheel can turn 172 degrees in either direction. • Fixed displacement
Steering wheel will automatically return to center position
with springs. Hydraulic steering motor has a displacement of 107
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cm3/rev (6.53 in3/rev).

Tandem Charge Pump
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Direction of turn depends on direction of rotation of

Charge pump consists of two fixed displacement gear steering motor. Speed of rotation determines amount of
pumps in same housing. Large section of tandem charge speed differential between belts.
pump provides oil for steering and transmission systems.
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Small section of tandem charge pump provides oil for Steering Differential
implement and brake systems.
Steering differential is located in differential case. Steering
Large section has a displacement of 57 cm3/rev (3.5 differential controls distribution of power between two
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in3/rev) and maximum flow of 153 liters/min (40.4 belts of mobil-trac system.
gal/min). Small section has a displacement of 37cm3/rev
(2.25 in3/rev) and maximum flow of 100 liters/min (26.4
gal/min). Tandem charge pump as a whole is capable of
producing maximum flow of 253 liters/min (66.8 gal/min).
79033095 C Rev. 05-3

Steering Hydraulic System
10
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8 9
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14 15 16 17
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P010412001
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FIG. 2
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FIG. 2: Hydraulic block diagram for steering system with (15) Charge pressure
electrical components.
(16) Sump
(1) Steering differential
on
(17) Activated components

(2) Steering speed sensors
(3) Steering position sensors
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(4) VT display
(5) Machine ECM
(6) Steering motor
(7) Steering pump
(8) Steering solenoids
(9) Steering solenoids
(10) Relief valve
(11) Hydraulic Oil filter
(12) Tandem charge pump
(13) Common sump
(14) System pressure
05-4 79033095 C Rev.

Steering Electrical System
5
8
2
9
14
15
17
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P081812001
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FIG. 3
FIG. 3: Electrical block diagram for steering system Machine ECM controls steering system for machine.
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consists of following components: Machine ECM collects data from inputs of steering
system. Machine ECM also collects data from other
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(2) Speed sensor (steering) systems to determine desired turning radius. Machine
(3) Position sensor (steering) ECM will actuate solenoid valves for right-hand steer or
left-hand steer to turn machine.
(4) VT display
on
Left-hand steering solenoid valve (8) and right-hand

(5) Machine ECM steering solenoid valve (9) receive proportional signals
(8) Left-hand steering solenoid from machine ECM. Solenoid valves control hydraulic
flow of oil to steering motor.
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(9) Right-hand steering solenoid

CAN data link is a communication bus used to
(14) Filter bypass switch (steering/transmission) communicate with following components:
(15) CAN data link • Engine ECM
(17) Optional ECM's and service connector • Machine ECM
(18) Dash panel cluster • Armrest ECM
Steering position sensors (3) send proportional signals to • Display module for VT
machine ECM (5). Signals tell machine ECM position of
steering wheel. Machine ECM will actuate solenoid • Electronic Technician (ET)
valves for left-hand steer (8) or right-hand steer (9) • Other optional electronic control modules
proportional to position of steering wheel.
Steering speed sensor (2) sends two proportional signals
to machine ECM (5). Sensor tells machine ECM speed of
steering motor. Speed sensor tells machine ECM
direction of rotation of steering motor.
79033095 C Rev. 05-5

Primary Steering Hydraulic System
8 10
11
1
7
12
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13
19
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14 15 16 17 18
P010412003
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FIG. 4
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FIG. 4: Block diagram for steering hydraulic system: Hydraulic oil filter (11) filters oil from larger section of
tandem charge pump. Filtered hydraulic oil is routed to
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(1) Differential steering unit

relief valve (10) (charge pressure) and to steering pump
(6) Steering motor (7). Relief valve (charge pressure) controls oil pressure
supplied by tandem charge pump. Excess flow is routed
(7) Steering pump to hydraulic oil cooler.
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(8) To Oil Cooler Steering pump contains a solenoid control valve that
(10) Relief valve (charge pressure) receives signals from ECM. This solenoid control valve
directs oil that controls direction and angle of swashplate.
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(11) Hydraulic oil filter Swashplate controls output of steering pump.

(12) Tandem charge pump Oil flow from steering pump flows to steering motor (6).
(13) Common sump Steering motor converts oil flow into an input for
differential steering unit (1). Oil flow returns to steering
(14) System pressure pump in a closed loop system.
(15) Charge pressure Rotation of steering motor will turn input gear for
(16) Sump differential steering unit. This causes machine to turn.
Direction of rotation of steering motor will determine
(17) 1st pressure reduction direction of turn for machine. Speed of rotation of steering
motor will determine speed of turn for machine.
(18) Cooling oil
Oil can return to common sump by following paths:
(19) Suction screen
• Steering pump case drain
Oil from common sump (13) is drawn through suction
screen (19) by tandem charge pump (12). • Steering motor case drain
Larger section of tandem charge pump provides a
hydraulic oil flow used by steering system.
05-6 79033095 C Rev.

Steering System
Electronic system for steering system consists of following
components:
• Position sensor (steering wheel)
• Speed sensor (steering motor)
• Filter bypass switch (steering)
• CAN data link
• Machine electronic control module (ECM)
• Armrest electronic control module (ECM)
• Solenoid valve (left steer)
• Solenoid valve (right steer)
• Secondary Steering Valve (CE Only)
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Position Sensor (Steering Wheel)

FIG. 5: Position sensor (1) for steering system is located
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on shaft for steering wheel. Sensor is located beneath

dash panel cluster.
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There are three sensors. Sensors are mounted and 1

serviced as one unit. Sensors signal machine ECM of
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position of steering wheel.

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N110805015
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FIG. 5
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Speed Sensor (Steering Motor)

FIG. 6: Steering motor is located on top side of
differential housing. Speed sensor (1) is located on back
on
side of steering motor.

1
Speed sensor signals ECM of speed that steering motor
is rotating. Speed sensor also signals ECM of direction
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that steering motor is rotating.
P081812002
FIG. 6
79033095 C Rev. 05-7

Filter Bypass Switch (Steering/Transmission)
FIG. 7: Filter bypass switch (1) for steering/transmission
is located on left-hand side of machine in front of rear
axle. Bypass switch is mounted on filter base. Bypass
switch (1) for steering/transmission and bypass switch (2) 1 2
for implement are mounted next to each other. Filter
bypass switch for steering/transmission is outer switch (1)
in tandem arrangement of two filters and two switches.
Switch signals ECM that filter is restricted. A warning will
be displayed on VT display, an indicator light will
illuminate, and fault code will be set and an audible alarm
will sound.
Refer to Testing and Adjusting, Input Components for P010412005
Steering System, for more information. FIG. 7
CAN Data Link

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FIG. 8: There are three CAN Busses in machine.

Connectors to these busses are:
(1) Powertrain Bus
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(2) Auxiliary Bus

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(3) ISO Bus

1
CAN data link is located in wire harness. Connectors for
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CAN data link is located in cab wall on right-hand side of

seat. 2 3
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CAN data link is used to communicate with following

components: P091812009
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• Armrest ECM FIG. 8

• Machine ECM
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• Display Module for VT

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• Other electronic components
Machine ECM
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FIG. 9: Machine ECM (1) is located on left-hand side of

machine beneath floorplate of cab in front of instructional
seat.
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Machine ECM controls following components:

• Hydraulic control valves 1
• Transmission
• Steering
• Parking brake
• PTO
N110905003
FIG. 9
05-8 79033095 C Rev.

Armrest ECM
FIG. 10: Armrest electronic control module (ECM) (1) is
located in console beneath armrest.
Following components are inputs to armrest ECM:
• Position sensors (hydraulic control lever)
• Button (one-touch)
1
• Switch (roading lockout)
Armrest ECM communicates with machine ECM to
control amount of oil flow that is sent to implement.
CAN data link is used to communicate between other
electronic control modules and components. P100812005
FIG. 10
Solenoid Valve (Left Steer)

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FIG. 11: Solenoid valve (1) for left-hand steer is located

on left-hand side of transmission case on steering pump.
Solenoid valve controls swashplate for steering pump.
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NOTE: Solenoid for left-hand steer is activated during 1

left-hand forward turns and right-hand reverse
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turns.
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P081912013
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FIG. 11
Solenoid Valve (Right Steer)

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FIG. 12: Solenoid valve (1) for right-hand steer is located

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on left-hand side of transmission case on steering pump.

Solenoid valve controls swashplate for steering pump.
NOTE: Solenoid for right-hand steer is activated during
on
right-hand forward turns and left-hand reverse

turns.
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P081912013
FIG. 12
79033095 C Rev. 05-9

Secondary Steering Solenoid Valve (CE Only)
FIG. 13: Secondary steering solenoid valve (1) is located
under right-hand front corner of cab and mounted to cab
pedestal.
P010412007
FIG. 13
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05-10 79033095 C Rev.

Steering System
Common Sump
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N102912004
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FIG. 14
FIG. 14: Common sump (1) supplies oil to all of hydraulic

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systems on machine.
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Common sump is located in lower portions of following

cases:
• Transmission
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• Final drive
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79033095 C Rev. 05-11

FIG. 15: Suction screen (1) for tandem charge pump is
located behind hydraulic oil filters. Suction screen will filter
particles larger than 200 microns. Suction screen filters all
differential sump oil before oil is routed to inlet of tandem
charge pump.
1
P010412008
FIG. 15

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FIG. 16: Suction screen (1) for scavenge pump is

located on left-hand side of machine behind steering
pump. Suction screen will filter particles larger than 540
microns. Suction screen filters all transmission sump oil
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before oil is routed to inlet of scavenge pump. 1

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P010412009
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FIG. 16
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05-12 79033095 C Rev.

Tandem Charge Pump
FIG. 17: Tandem charge pump (1) is located on
left-hand side of machine in front of left-hand final drive.
Tandem charge pump is a two-section gear pump.
Tandem Charge Pump Large Section
Large section of tandem charge pump supplies oil to
• Steering hydraulic system
• PTO hydraulic system 1
• Parking brake hydraulic system P081812003
• Secondary Steering System (CE Only) FIG. 17
Tandem Charge Pump Small Section

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Small section of tandem charge pump supplies oil to

• Service brake hydraulic system
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• Implement hydraulic system

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• Three-point hitch hydraulic system (If equipped)

• Steerable three-point hitch hydraulic system
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• Hydraulic power beyond (If equipped)

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• Steering Differential lubrication

• Elevated oil reservoir
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79033095 C Rev. 05-13

Hydraulic Oil Filter (Transmission and Steering)
FIG. 18: Hydraulic oil filter (1) for steering hydraulic
system is located on left-hand side of machine in front of
left-hand final drive. Hydraulic oil filter for steering and
transmission hydraulic system is outboard filter.
Hydraulic filter will filter particles larger than 7.5 microns.
Hydraulic oil filter will filter all charge oil before oil is routed
to transmission and steering hydraulic systems.
1
P081812004
FIG. 18

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FIG. 19: Hydraulic oil cooler (1) is located directly behind

air-to-air aftercooler (removed for clarity) on right-hand
side of cooling package. Cooler is a dual core cooler.
Transmission and steering hydraulic oil core (2) is located
1
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on left-hand side of cooler. Implement and differential

hydraulic oil core (3) is located on right-hand side of
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2
cooler.
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P010712001
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FIG. 19
Steering Pump
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FIG. 20: Steering pump (1) is located on lower left-hand

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side of transmission. Steering pump is a axial piston

pump.
Steering pump will respond to signals from machine
ECM. Pump will provide required flow needed to actuate
on
hydraulic steering motor.

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P081912013
FIG. 20
05-14 79033095 C Rev.

Steering Motor
FIG. 21: Steering motor (1) is mounted to rear differential
case above of left-hand final drive. Steering motor is a
fixed displacement bent axis motor that is bidirectional.
Steering motor provides input for steering differential. 1
Steering differential will subtract rotation from one belt
and add rotation to opposite belt. This steers the machine.
P081812005
FIG. 21
Secondary Steering Actuator (CE Only)

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FIG. 22: Secondary Steering Actuator (1) is located on

end of steering shaft. Secondary steering actuator is
mounted to underside of cab at front center of cab.
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Secondary steering actuator provides oil to right-hand

service brake to turn machine to right and supplies oil to
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left-hand service brake to turn machine to left. This only

occurs if machine is operating in secondary steering
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mode. Machine is only operating in secondary steering

mode if primary steering is not functioning properly.
Typically secondary steering actuator is not sending oil to
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service brakes. When machine is operating in secondary

steering mode, machine's capabilities and function are
limited.
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P011812003
FIG. 22
79033095 C Rev. 05-15

Secondary Steering Solenoid Valve (CE Only)
FIG. 23: Secondary steering valve (1) is located under
right-hand front corner of cab. Secondary steering valve is
mounted on left-hand front cab pedestal.
Secondary steering valve engages and disengages
secondary steering motor. Solenoid valve will be engaged
in primary steering mode and disengaged in secondary
steering mode. Valve directs oil provided by secondary
steering actuator to its respective service brake to turn
machine when in secondary steering mode. This valve
also provides charge oil to steering motor bypass valve.
1
P011812004
FIG. 23
Steering Motor Bypass Valve (CE Only)

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FIG. 24: Steering motor bypass valve (1) is located on

steering motor on head of motor.
Steering motor bypass valve allows steering motor to turn
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freely when in secondary steering mode. Steering motor

bypass valve is normally closed. When secondary
in
steering mode is engaged, charge oil from secondary

steering valve will open bypass valve allowing steering
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motor to turn freely.
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P081912014
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FIG. 24
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05-16 79033095 C Rev.

Steering System Input Components
Position Sensor (Steering Wheel)
FIG. 25: Position sensor for steering signals machine
ECM that operator wants to turn machine to right or to left.
Position sensor sends three proportional signals to ECM.
Signals are pulse width modulated signals (PWM) that
are generated at a frequency of 500 Hz. Signals are
received on connector J1 on pins 2, 14, and 24 of
machine ECM.
When steering wheel is in center position ECM sees a
duty cycle of 46.5% to 53.5%. When steering wheel is
rotated from center position, duty cycle will vary from 50%
to 10% and from 50% to 90%.
ECM receives proportional signals and ECM will send a g00786426
proportional signal to corresponding solenoid valve to turn
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machine. FIG. 25
ECM monitors position sensors for abnormal frequencies
or abnormal pulse width signals. If a fault occurs on one
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signal, a diagnostic code will be set and machine will

continue to operate. A warning will be displayed. If a fault
in
occurs on more than one signal, a diagnostic code will be

set and machine will automatically be placed in neutral
gear. Parking brake will automatically be applied when
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machine comes to a stop.

NOTE: CE Only: If one position sensor has an abnormal
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frequency or abnormal pulse width signal,

machine will automatically go into secondary
steering. Machine operation is limited in
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secondary steering mode.

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79033095 C Rev. 05-17

Speed Sensor (Steering Motor)
FIG. 26: Speed sensor for steering motor signals
machine ECM of speed that steering motor is rotating.
Speed sensor for steering motor also signals machine
ECM of direction that steering motor is rotating.
Speed sensor sends two proportional signals to ECM.
Signals are frequency modulated signals and are directly
proportional to RPM of steering motor. Sensor can
produce a frequency from 1 Hz to 3500 Hz. Signals are
received on connector J1 on pins 15 and 25 of machine
ECM.
ECM monitors speed sensor for abnormal frequencies or
abnormal pulse width signals. If a fault occurs, a
diagnostic code will be set and a warning will be displayed g00786427
on VT. Steering system will then operate in an open loop FIG. 26
mode.
NOTE: CE Only: If ECM monitors a fault on steering
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motor speed sensor, machine will go into

secondary steering mode. Machine operation is
limited in secondary steering mode.
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Filter Bypass Switch (Steering)

in
FIG. 27: Filter bypass switch for steering signals

machine ECM that filter is restricted.
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Switch is a pressure switch and has one set of normally

closed contacts.
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Switch activates when pressure exceeds 248 to 304 kPa

(36 to 44 psi) and switch will open. When pressure drops
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below 179 kPa (26 psi), machine ECM will receive a

signal on connector J1 on pin 55.
A warning will be displayed on virtual terminal (VT), a
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warning light will illuminate on display, a fault code will be

logged and an audible alarm will sound.
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g00786428
FIG. 27
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05-18 79033095 C Rev.

Electronic Control Module for Steering
System
Machine ECM
FIG. 28: Machine electronic control module (ECM)
controls various systems for machine. For steering
system, machine ECM controls steering solenoid valves.
Inputs to machine ECM for steering system:
• Position sensor (steering wheel) (signal 1)
• Speed sensor (steering motor) (signal 1)
2
• Speed sensor (steering motor) (signal 2) 1
P011812006
• Filter bypass switch (steering)
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FIG. 28
Outputs from machine ECM for steering system:
• Solenoid valve (right steer)
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• Solenoid valve (left steer)

in

electronic control modules.
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J1 Connector J2 Connector
Pin Description Pin Description
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2 STR WHL POS SNSR #3 1 +12V BATTERY

4 ROCKSHAFT POSITION SNSR 2 GND
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6 J1939 DATA LINK 12 PROP RTN 17-20 (J2-25, 40, 41)

7 CAT DATA LINK - 18 PROP RTN (J2-3, 16, 24)
8 CAT DATA LINK + 22 GND
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9 SWG/DIGITAL SNSR RETURN 23 + 12V BATTERY

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10 5V SNSR SUPPLY 24 REAR HITCH LOWER SOL

11 8V SNSR SUPPLY 25 REAR HITCH RAISE SOL
12 SW/SNSR RETURN 36 ON/OFF RTN 1-4 (J2-44, 45, 55, 68)
13 10V SNSR SUPPLY 38 BRAKE CHARGE FILTER BYPASS SW
on
14 STR WHL POS SNSR #2 46 GND

15 STEER MTR SPD SNSR #1 47 + 12V BATTERY
18 J1939 DATA LINK + 52 PROP RTN 1-4 (J2-4, 58, 61, 64, 65)
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20 SERV BRAKE ACCUM PRESS SW (NO) 55 SECONDARY STEER SOL

22 PARK BRAKE LIMIT/PRESSURE SW 64 LEFT STEER SOL
24 STR WHL POS SNSR #1 65 RIGHT STEER SOL
25 STEER MTR SPD SNSR #1
27 STEERABLE HITCH POSITION SNSR
36 HITCH FENDER SW COMMON
37 HITCH FENDER SW LOWER
38 HITCH FENDER SW RAISE
45 HYD OIL LEVEL SW
51 CHARGE PRESS SNSR
55 IMP/STEER CHARGE FLTR BYPASS SW
NOTE: J1 and J2 are 70 pin connectors. Contacts not

listed are not used or may be used in other
systems.
79033095 C Rev. 05-19

Steering System Output Components
Solenoid Valve (Steering)
FIG. 29: Machine ECM controls solenoid valves for
steering system.
Solenoid valves are proportional valves. ECM sends a
proportional current to valves to steer machine.
Valves control swashplate of steering pump. Swashplate
controls amount of hydraulic oil sent to steering motor.
Swashplate also controls direction of flow of hydraulic oil
to steering motor.
ECM monitors solenoid valves for fault detection. If a fault
is detected, ECM will display a warning and a diagnostic
code will be logged in memory. ECM will automatically
place transmission in neutral gear. If fault was a short to a g00786653
positive battery terminal, parking brake will automatically
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be initiated and engine will be shut down. Fault will need FIG. 29
to be cleared before machine can be operated.
NOTE: CE Only: If ECM detects a fault in thsteering
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solenoids, machine will go into secondary

steering mode. In secondary steering mode,
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machine operation is limited.

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05-20 79033095 C Rev.

Data Link for Steering System
6
8
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5
9
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3 2 1
10
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P111112001
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FIG. 30
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FIG. 30: Block Diagram of Connections of Data Links. CAN data link is a communication bus used to
communicate with following components:
(1) Auxiliary CAN bus data link
• Engine ECM
on
(2) ISO CAN bus data link

• Machine ECM
(3) Powertrain CAN bus data link
• Armrest ECM
(4) Armrest ECM
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• Display module for VT

(5) Machine ECM
• Other optional electronic control modules
(7) VT Display (Virtual Terminal)
(8) Steering Wheel Position Sensor
(9) Steering Motor Speed Sensor
(10) Steering Solenoids (Right and Left)
79033095 C Rev. 05-21

Common Sump (Steering)
Common Sump
2
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P011812008
FIG. 31
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FIG. 31: Common Sump (1) and Elevated Oil Reservoir

(2).
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Common sump has a refill capacity of 246 liters (65 gal)

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and consists of following housings:

• Transmission case
• Differential case
on
• Final drive cases

Common sump is shared by following systems:
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• Brake hydraulic system
05-22 79033095 C Rev.

5 6 7
3
9
10
12
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11
P011812007
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FIG. 32
in
FIG. 32: Hydraulic schematic of common sump.

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Hydraulic schematic consists of following components:

(3) Suction Screen (scavenge pump)
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(4) Scavenge Pump

(5) Filler cap
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(8) Suction Screen (tandem charge pump)

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(9) Ecology Drain

(10) Common Sump
on
(11) Left-hand Final Drive

(12) Right-hand Final Drive
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79033095 C Rev. 05-23

FIGS. 33–34: Two magnets are located in bottom of
common sump to attract any metallic contaminants. One
magnet (1) is located in differential case. One magnet (2)
is located in transmission case.
1
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P011812009
FIG. 33
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g00871749
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FIG. 34
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05-24 79033095 C Rev.

FIG. 35: Suction screen (1) for common sump is located
directly behind hydraulic pump for implements.
Suction screen filters all differential sump oil before oil is 1
routed to inlet side of tandem charge pump. Suction
screen will filter particles larger than 200 microns.
Refer to Testing and Adjusting, Tandem Charge Pump, for
more information about charge oil circuits.
P010412008
FIG. 35

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FIG. 36: Suction screen (1) for scavenge pump is

located on left-hand side of machine. Suction screen is
under steering pump. Suction screen filters all 1
transmission sump oil before oil is routed to inlet side of
r
scavenge pump. Suction screen will filter particles larger

than 540 microns.
in
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P010412009
al
FIG. 36
Breather (Common Sump)

u
FIG. 37: Breather (1) is located on left-hand side of

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machine in front of cab. This breather serves as a

breather for common sump. Breather will filter particles
larger than 7 micron.
1
on
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P081812007
FIG. 37
79033095 C Rev. 05-25

Filler Cap
FIG. 38: Filler cap (1) is located at rear of machine to
left-hand of implement valve stack.
Filler cap allows hydraulic oil to be added to common
sump.
P081812008
FIG. 38
Sight Gauge
Fo
FIG. 39: Sight gauge (1) is located at rear of machine by

PTO if equipped.
Oil level in common sump may be visually inspected by
r
using sight gauge.

in
Refer to Operation and Maintenance Manual, Hydraulic

System Oil Level - Check, for procedure used for
checking hydraulic oil level. 1
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P081812009
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FIG. 39
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05-26 79033095 C Rev.

Hydraulic Oil Filter (Steering and Parking
Brake)
Location of Hydraulic Oil Filter
FIG. 40: Hydraulic oil filter (1) is used to filter steering
and transmission oil.
Filter is located on left-hand side of machine in front of
left-hand final drive. Hydraulic oil filter is a 7.5-micron filter.
P081812004
Fo
FIG. 40
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79033095 C Rev. 05-27

Oil Flow
1
10
SS
DIFF
SOS
SOS
6 4
2 b a
5
MB Fe Fa(G) PS T2 T1 R
7 B
8 3
Fo
MA S MH X2 X1
r
9
P111112002
in
FIG. 41
FIG. 41: Hydraulic Schematic for Oil Filter.
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(2) Common Sump
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(4) Bypass Valve
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(5) Oil Sampling valve

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(6) Scavenge Pump

(7) Final Drive Housings
(8) Steering Pump
on
(9) Suction Screen

(10) To Park Brake and Transmission Systems
ly
Large section of tandem charge pump draws hydraulic oil

from common sump through suction screen. Oil flows to
hydraulic oil filter.
Filtered oil then flows to following systems:
• Steering Hydraulic System
• Parking Brake Hydraulic System
• Transmission Hydraulic System
If bypass valve is closed, hydraulic oil will flow through
See Bypass Valve for information about hydraulic oil flow
when bypass valve is open.
05-28 79033095 C Rev.

Bypass Circuit
FIG. 42: Filter head of hydraulic oil filter (steering) (1)
contains bypass valve (2) and bypass switch (3).
Bypass Valve
2
IMPORTANT: Do not operate machine when hydraulic oil
filter is in bypass mode. Operating machine in
bypass mode may cause damage to internal
components of machine.
3
Bypass valve will open when a 495 kPa (72 psi) pressure
differential is felt between inlet and outlet pressure. This
will allow unfiltered oil to bypass filter and flow directly to 1
implement circuit. P081812010
Following items will typically cause an oil filter to be FIG. 42

bypassed:
• Cold oil
Fo
• Excessive contamination in the oil
Bypass Switch
r
Bypass switch notifies operator whenever filter is close to

in
plugging.
Bypass switch is a normally closed 12 volt switch.
te
Bypass switch will open when a 248 to 304 kPa (36 to 44

psi) pressure differential is felt between inlet and outlet
rn
pressure.
Bypass switch will signal machine ECM. Event will be
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shown on Virtual Terminal (VT), warning light on dash will

be illuminated, fault code will be logged and an audible
alarm will sound. Warning level for event is a Level
2-Special.
u
Refer to Operation and Maintenance Manual, VT Event

se
Screen, for more information about warning levels.
Oil Sampling Valve

on
FIG. 43: Oil-sampling valve (6) is located at rear of

machine to right-hand of hydraulic oil filler cap.
Use oil-sampling valve to obtain a sample of hydraulic oil
ly
for analysis.
System Oil Sample - Obtain, for additional information
about sampling valve.
P081812008
FIG. 43
79033095 C Rev. 05-29

Tandem Charge Pump (Steering)
left-hand side of machine in front of left-hand final drive.
Tandem charge pump is a two-section gear pump. Large
section of tandem charge pump supplies oil for steering
hydraulic system. 1
Refer to Systems Operation, Tandem Charge Pump, for
more information.
P081812003
FIG. 44
Steering Pump
Fo
General Description
FIG. 45: Machines is equipped with a differential
r
steering system.
in
Steering pump (1) is located on left-hand side of machine

on lower portion of transmission. 1
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Steering pump has following characteristics:

• Electro-hydraulic control
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• Variable displacement
• Overcenter swashplate movement
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• Axial piston pump

P081812004
• Control for a closed loop system
FIG. 45
u
• Clockwise rotation (driven end)

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• Bidirectional flow
Charge pressure oil from tandem charge pump provides
oil used by steering pump. Pressure of charge oil is
on
regulated by relief valve (charge pressure) at 2065 to

2135 kPa (300 to 310 psi). Charge pressure oil lubricates
internal pump components and splines of steering pump.
Charge pressure oil will make up for normal, internal loss
ly
of oil.
Steering pump uses charge pressure oil in following
circuits:
• High pressure oil
• Low pressure oil
• Control oil
• Make up oil
• Case drain oil
05-30 79033095 C Rev.

Steering Pump Components
2 9
8
3
4
10
5 6 7 11
Fo
12
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13 14 15
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P011812014
FIG. 46
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FIG. 46: Cross sectional drawing of steering pump The oil is supplied to the steering pump from two sources:
al
showing hydraulic oil flow for a right-hand turn.

• Return oil from the steering motor
The drawing consists of the following components:
• Charge pressure oil from the tandem charge pump
u
(2) Swashplate Actuator (make up oil)

(3) Swashplate
When there is a swashplate angle, high-pressure oil is
se
(4) Output Shaft

pushed ahead of the pistons (5) and the high-pressure oil
(5) Piston
goes through the outlet passage of the port plate (7). The
(6) Spring
spring (6) is compressed between the barrel assembly (8)
(7) Port Plate
and the output shaft (4). This creates a seal between the
on
(8) Barrel Assembly

barrel assembly (8) and the port plate (7). The
(9) Crossover Relief Valve
low-pressure oil is sealed from the high-pressure oil. The
seal is between the spherical faces of the port plate (7)
(11) Electro Servo Valve
ly
and the barrel assembly (8). This is a metal seal that has
(12) Pressure Override Valve
an oil film.
(13) System Pressure
(14) Charge Pressure The oil leaves the pump through port-A or port-B for the
(15) Sump steering closed loop. The high-pressure oil flows from the
The electric servo valve (11) receives signals from the pump to the drive motor. The oil returns to the pump as
machine ECM to control the position of the swashplate low-pressure oil through the steering closed loop.
actuator (2). The position of the swashplate actuator will
determine the angle of the swashplate. The nine pistons
(5) are in the barrel assembly (8). The output shaft (4) and
the barrel assembly (8) will rotate when the engine is
running. When the barrel assembly (8) rotates, each
piston (5) follows the angle of the swashplate (3). As the
pistons (5) follow the swashplate angle the pistons move
in and out of the cylinders of the barrel assembly. The
reciprocating pistons create oil flow in the steering closed
loop.
79033095 C Rev. 05-31

FIG. 47: Swashplate (Center Position): The swashplate
can angle to either side. The swashplate (3) will A
determine the direction of the oil flow. When the
swashplate turns in the direction of the swashplate angle
(A), the oil will flow to the port-A. When the swashplate 3
turns in the direction of the swashplate angle (B), the oil
will flow to the port-B.
The bidirectional oil flow allows the steering pump to
provide two directions of the oil flow in the steering closed
loop. The direction of the oil flow will determine the
direction of the turn.
The amount of swashplate angle will determine the length
of the stroke of the pistons (5). At the neutral position, the
stroke of the piston and the delivery of the oil is zero. The
maximum stroke is caused by an inclination of the 5
swashplate at 15 degrees on either side.
If the swashplate angle is at zero, the pistons do not move B
Fo
in and out of the barrel. There is no oil flow to the steering P011812015
motor and the machine will not turn. FIG. 47
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05-32 79033095 C Rev.

NOTES
Fo
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79033095 C Rev. 05-33

Electric Servo Valve
14 16
2
15
17 18
13
19
Fo
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20
in
21
22
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24
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23
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25 26
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N111205002
FIG. 48
on
FIG. 48: The callouts for the cross sectional drawing of (21) Lever
the electric servo valve are:
(22) Spool
(2) Swashplate Actuator
(23) Solenoid
ly
(13) Feedback Lever

(24) Cavity
(14) Cavity
(15) Push Pin
(26) Sump
(16) Solenoid
This section will describe the operation of the following
(17) Eccentric Null Pin components:
(18) Lever • Mechanism that strokes the pump
(19) Pin • Steering pump controls
(20) Feedback Spring • Feedback lever
05-34 79033095 C Rev.

The current is applied to the solenoid (16). The push pin
(15) on the solenoid (16) will actuate movement in the
spool (22).
The spool (22) will engage the lever (21). The lever (21)
will move off the pin (19) for the feedback lever. The
feedback lever will not move when the force in the
feedback spring (20) is equal to the force from the
electrical current in the solenoid (16).
The spool (22) allows the charge pressure oil to flow to
the cavity (14). The charge pressure oil will move the
swashplate actuator (2). The movement of the
swashplate actuator (2) will cause the steering pump to
stroke. The cavity (24) is drained to the sump.
When the swashplate actuator (2) moves, the feedback
lever (13) is moved. The feedback lever (13) will pivot
around the eccentric null pin (17). The pivoting informs
the controls of the location of the steering pump
Fo
displacement. The pin (19) for the feedback lever will

push the lever (18).
The lever (18) tries to raise the spring force. The
r
command has not changed in the solenoid. to keep

equilibrium, the spool (22) will shift. The spool (22) will
in
move against the push pin (15).

The system now balances the forces. The metered
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charge pressure oil is allowed to move in and out of the

cavity (14). The metered charge pressure oil is used to
rn
maintain the desired stroke as the system pressure

changes.
The two springs are used to center the actuator (2).
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The feedback lever (13) is connected to the following

components:
u
• Spool (22) for the electric servo valve

se
• Swashplate actuator (2)

• Eccentric null pin (17)
The feedback lever (13) maintains the pump flow for any
on
given signal from the machine ECM that is supplied to the

solenoids.
The feedback lever is part of the electric servo valve, but
ly
the feedback lever provides feedback from the

components that are listed above. As the swashplate
actuator (2) shifts and as the spool (22) shifts, the
eccentric null pin (17) will pivot either the lever (18) or the
lever (21). This movement will extend the feedback spring
(20). The feedback spring applies a small amount of
resistance to the movement of the spool (22). The
resistance that is supplied by the feedback spring (20) will
prevent the spool from drifting.
79033095 C Rev. 05-35

Swashplate Actuator
15
2
Fo 25
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26
24
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28
27
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29 30
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N111205002
FIG. 49
on
FIG. 49: The callouts for the cross sectional drawing of The swashplate actuator (2) is used to control the
the swashplate actuator are: swashplate angle. See the illustration to view the
connection of the swashplate actuator to the swashplate.
ly
The pressure of the control oil that is supplied to the

(15) Cavity swashplate actuator is a result of the amount of force that
(24) Cavity is required to move the swashplate actuator (2) in the
desired direction. The maximum control oil pressure that
(25) Centering Spring can be applied to the swashplate actuator is equal to the
(26) Centering Spring charge pressure oil. The centering springs (25) and (26)
are used to maintain a neutral position when the machine
(27) Nut ECM is not sending a turning signal.
(28) Bolt The bolt (28) and nut (27) are used to adjust the center
(29) Charge Pressure position of the swashplate actuator.
(30) Sump
05-36 79033095 C Rev.

Steering Pump Stall
11
13
9
2 14
15
Fo
r
12
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10
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16 17 18 19 20
P012112003
FIG. 50
u se
FIG. 50: The callouts for the hydraulic block diagram for The pressure override valve (12) will direct the control oil
a stall of the steering pump are: for the swashplate actuator (2) to the common sump. The
swashplate actuator will be moved toward the NEUTRAL
(2) Swashplate Actuator position by the centering springs. The swashplate angle
on
(10) Crossover Relief Valve will be decreased to reduce the pump output. The output
of the pump will maintain the pressure setting of the
(11) Electric Servo Valve pressure override valve.
ly
(12) Pressure Override Valve The pressure override valve will continue to relieve the
(13) Feedback Lever control oil until one of the following changes:
(14) To Filter • The signal for the machine ECM is reduced.
(15) Tandem Charge Pump • The external load for the steering system is reduced.
(18) Sump
(19) 1st Pressure Reduction
(20) Activated Components
If the operator stalls the steering system, the electric
servo valve (11) will react to the signal from the machine
ECM that is being sent. Also, the electric servo valve will
maintain a maximum shifted position.
79033095 C Rev. 05-37

Pressure Override Valve
39 29
38
36 37
Fo
r
30
in
33 32 31
35 34
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40 41 42 43
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P011812016
FIG. 51
al
FIG. 51: The callouts for the cross sectional drawing of The pressure override valve limits the output pressure of
the pressure override valve are: the steering pump by relieving the control oil pressure of
u
the steering pump. The steering pump will destroke and

(29) Port-A
the amount of the oil flow will be reduced.
se
(30) Shuttle Valve

The pressure override valve will relieve the control oil until
(31) Chamber the output pressure of the steering pump is in equilibrium
with the setting of the pressure override valve.
(32) Piston
on
The pressure override valve has four passages:

(33) Valve
(29) Port-A
(34) Spring
ly
(38) Port-B
(35) Nut
(37) Control Oil
(36) Screw
(39) Case Drain
(37) Control Oil
The pressure override valve should be adjusted to open
(38) Port-B when the high-pressure oil reaches the maximum system
(39) Case Drain pressure. The maximum system pressure is the charge
pressure plus 417 bar (6048 psi).
The shuttle valve (30) will close either port-A or port-B
(41) Charge Pressure depending on the direction of the oil flow. This will prevent
(42) Sump the passage that contains the high-pressure oil from
flowing to the passage that contains the low-pressure oil.
05-38 79033095 C Rev.

The high-pressure oil enters the pressure override valve
through the passage for the port-A (29) or through the
passage for the port-B (38). The passage is determined
by the pump port that contains the high-pressure oil. The
shuttle valve (30) is moved to the left if the high-pressure
oil is in the pilot line for the port-A. The shuttle valve (30) is
moved to the right if the high-pressure is in the pilot line
for the port-B. The oil is sent to the chamber (31).
When the system pressure exceeds the pressure
override valve setting, the pressure in the chamber (31)
moves the piston (32) and the valve (33) to the left against
the spring (34). The valve (33) opens and the valve allows
the control oil to flow to the case drain. The centering
springs for the swashplate actuator will then be able to
reduce the angle of the swashplate. This will reduce the
output of the pump.
The pressure override valve will modulate the oil flow to
prevent the control oil pressure from being totally relieved.
Fo
The control pressure is necessary to satisfy the signal

from the machine ECM.
The pressure setting of the pressure override valve can
r
be adjusted. The adjustment is made with the nut (35)

and the adjusting screw (36). The adjusting screw (36) is
in
used to adjust the tension on the spring (34).

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When the pressure override valve opens, the control oil

that is applied to the swashplate actuator is allowed to
flow into the steering pump case. As the control oil is
rn
drained, the centering spring will move the swashplate

actuator to decrease the output of the steering pump.
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The oil in the steering pump case is drained to the

common sump. The valve will close if the oil pressure in
the steering pump case is too high.
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79033095 C Rev. 05-39

Crossover Relief Valves
41 40
42
43
44
39 29
Fo
45 46 47 48
r
P011812017
in
FIG. 52
te
FIG. 52: Cross sectional drawing of crossover relief When oil pressure in cavity for spring (40) becomes
valves showing hydraulic oil flow for a right-hand turn. greater than force of spring (43), pilot valve (42) will open.
rn
Oil in chamber of spring (40) will flow around pilot valve

Callouts for cross sectional drawing of crossover relief (42) to drain.
valves are:
al
When oil pressure in chamber of spring (40) drops, only

(29) Port-A force of spring (40) is acting against valve (41). Force on
(39) Port-B opposite side of valve (41) is larger than force of spring
(40) Spring
u
(40). Therefore, valve will open. Oil from pump port can
(41) Valve now go into chamber (44).
se
(42) Pilot Valve

(43) Spring Crossover relief valve should be adjusted to open at 467
(44) Makeup Oil Chamber bar (6773 psi) above charge pressure.
Crossover relief valve also acts as a makeup valve for
on

closed loop circuit. If oil pressure in one of ports for pump
(47) Sump
is below pressure of charge oil, makeup oil will open valve
(41). This will allow makeup oil to flow into pump port
Crossover relief valves are designed to relieve
ly
below pressure of charge oil. When pressure in pump

high-pressure spikes from output ports of steering pump.
port reaches pressure of charge oil, force of spring (40)
Valves are not capable of handling large flows. Valves
closes valve (41).
also contain makeup valves. When low-pressure port of
steering pump needs oil, makeup valve will open and When engine is started, charge pressure oil will be
makeup valve will allow charge oil to satisfy need. supplied for following components of steering pump:
Crossover relief valves are also called high-pressure relief
valves. • Electric servo valve
There is a crossover relief valve for following ports: • Crossover relief valves
(29) Port-A • Pressure override valve

(39) Port-B Crossover relief valve for each port will remain open until
Oil from pump ports will enter through passages for each both sides of closed loop system fill with charge oil.
port. Oil flows into chamber of spring (40). Valve (41) is
held closed by spring (40) and pressure of oil in spring
cavity. Pressure of oil acts against pilot valve (42). Force
of spring (43) keeps pilot valve (42) closed until oil from
pump port reaches relief pressure.
05-40 79033095 C Rev.

Straight Travel
11
13
9
2
14
15
Fo
r
12
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10
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16 17 18
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P012112001
FIG. 53
u se
FIG. 53: Callouts for hydraulic block diagram for straight

travel are:
on

(11) Electric Servo Valve
ly
(12) Pressure Override Valve

(13) Feedback Lever
(14) To Filter
(17) Sump
There is no signal from machine ECM during straight
travel. Centering springs center spool for electric servo
valve (11) in neutral position. Springs for swashplate
actuator (2) maintain a neutral swashplate position.
Steering pump will not produce any flow.
79033095 C Rev. 05-41

Turn
11
13
9
2
14
15
Fo
r
12
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10
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16 17 18 19 20
P012112002
FIG. 54
u se
FIG. 54: Callouts for hydraulic block diagram for a turn When operator turns steering wheel, a signal for a turn is
are: sent by machine ECM. Solenoid that is energized will shift
spool in electric servo valve (11). Spool will direct charge
oil to swashplate actuator (2) and charge pressure oil will
on
(10) Crossover Relief Valve move swashplate actuator. Swashplate will upstroke
pump. Pump will create oil flow in closed loop system and
(11) Electric Servo Valve steering motor will turn machine.
ly
(12) Pressure Override Valve Spool in electric servo valve (11) and swashplate actuator
(13) Feedback Lever (2) react with feedback lever (13) to maintain pump flow
for any given signal from machine ECM supplied to
(14) To Filter solenoids.
(15) Tandem Charge Pump Refer to Feedback Lever section for more information.
(16) System Pressure Steering pump will continue output until signal from
(17) Charge Pressure machine ECM is changed.
(18) Sump
05-42 79033095 C Rev.

Test Ports
FIG. 55: Test ports are used to evaluate oil pressures for
following circuits:
(Mh) Pump output X2
(X2) Control oil for port-A X1
Mh
(X1) Control oil for port-B
Fo
P012112004
FIG. 55
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79033095 C Rev. 05-43

Steering Motor
Location of Steering Motor
FIG. 56: Steering motor (1) is located in a horizontal
position on top of differential case. Differential case is
located between two final drive cases.
1
Steering motor for machine is a 107 cm3 (6.53 in3)
steering motor.
Direction of steering motor's rotation determines direction
of turn of machine. Rate of rotation determines speed
difference between belts.
P081812005
FIG. 56
Fo
Operation of Steering Motor

FIG. 57: Steering motor is bidirectional fixed
r
displacement piston motor. Steering motor is operated by 1

high pressure oil from steering pump. A change in
in
direction of oil flow through steering motor does not

change output torque from shaft of steering motor. 3
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Callouts for illustration:

(1) Top of Motor
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2
(2) Port-A
(3) Port-B
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Oil from steering pump flows through port-A (2) or port-B P081812011
(3) into inlet slot on head of motor. Then oil flows into inlet
FIG. 57
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slot in port plate.

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05-44 79033095 C Rev.

10
6
5
7
8
9
Fo
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11 12 13
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P012112007
FIG. 58
u
FIG. 58: Following items make up rotating group of Oil flow through steering motor can be in either direction.
steering motor making a right-hand turn: A change to direction of oil flow changes direction of
se
rotating components.
(5) Output shaft
(5) Output shaft
(6) Case Drain Port
(7) Piston
on
(7) Piston
(8) Barrel
(8) Barrel
(9) Retaining port plate
(9) Retaining port plate
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Rotating group turns linear motion of hydraulic oil into

(10) Speed Sensor Location
rotary motion. Rotary motion will turn output shaft
(11) System Pressure clockwise or counterclockwise.
(12) Sump Control plate and flushing valve receive hydraulic oil from
steering pump through port-A or port-B. Port-A and
(13) Activated Components port-B are located in head of steering motor.
NOTE: Speed sensor in location (10) will measure output
shaft speed.
79033095 C Rev. 05-45

Flushing Valve
10
2 3
11 12 13 14
Fo
P012112008
FIG. 59
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FIG. 59: Callouts for flushing valve with flow for a

in
right-hand turn are:

(2) Port-A
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(3) Port-B
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(10) Shuttle valve

(11) System pressure
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(12) Charge pressure

(13) Sump
u
(14) Activated components

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Flushing valve provides lubrication and cooling to internal

components of steering motor. Also, flushing valve
removes hot oil from high pressure circuits of steering
system.
on
Flushing valve will drain approximately 4 liters/min (1.06

gal/min) from low pressure side of closed loop circuit.
ly
Shuttle valve (10) is shifted by high pressure side of

closed loop circuit. Shuttle valve opens a path which
allows oil on low pressure side to flow through an orifice
and across relief valve. Pressure drop across orifice limits
amount of oil drained.
When drain oil leaves steering motor, oil is routed to
differential steering unit for lubrication.
05-46 79033095 C Rev.

air-to-air after cooler. Air-to-air after cooler is removed in
this figure for clarity.
1
Hydraulic oil cooler provides cooling for all hydraulic
systems using oil from common sump.
Hydraulic oil cooler is split into two different sections.
Each section of tandem charge pump sends hydraulic oil
through a dedicated section of oil cooler.
P010712001
FIG. 60
Fo
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79033095 C Rev. 05-47

Hydraulic System Schematic (Steering)
11 1
12 10
SS
DIFF
SOS
SOS
6 4
2 b a
5
7 B
8 3
Fo
MA S MH X2 X1
r
9
in
P111112002
FIG. 61
te
FIG. 61: Hydraulic Schematic (Steering) Large section of tandem charge pump draws hydraulic oil
from common sump through suction screen. Oil flows to
rn

Filtered oil flows to following systems:
(2) Common Sump
• Steering Hydraulic System
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• Parking Brake Hydraulic System
(4) Bypass Valve
• Transmission Hydraulic System
u
(5) Oil Sampling valve

If bypass valve is closed, hydraulic oil will flow through
se
(6) Scavenge Pump hydraulic oil filter.

(7) Final Drive Housings Oil flows to steering pump, parking brake system or
transmission.
(8) Steering Pump
on
Steering pump sends oil flow to steering motor. Oil in

(9) Suction Screen steering system is closed loop except case drain leakage.
(10) To Park Brake and Transmission Systems
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(11) Steering Motor

(12) Steering Pump Case Drain
05-48 79033095 C Rev.

Differential Steering Mechanical
Components
Steering Wheel
FIG. 62: Steering pump output is controlled by direction
and amount of steering wheel (1) rotation. Signal
pressure increases as steering wheel is turned. This
causes turning radius of machine to decrease.
P081812012
Fo
FIG. 62
Final Drive
r
FIG. 63: Final drive (1) is attached to rear of machine. A

final drive unit is located on each side of case for
in
differential steering.
Final drive is used to transmit power to drive wheels. 1
te
rn
al
u se
on
P012212001
FIG. 63
ly
79033095 C Rev. 05-49

Differential Steering Unit
6
5
2 8
4
7 9
3
1
Fo
17 10
11
r
13
16
12
in
15 14
te
P012112012
FIG. 64
rn
FIG. 64: Differential steering unit is located in case for Differential steering unit will receive rotation input from
al
differential steering behind transmission. steering motor. Direction of rotation from steering motor
determines direction of turn of machine. Rate of rotation
Callouts for differential steering unit illustration are:
determines speed difference between belts.
u
(1) Right Outer Axle Shaft

(2) Carrier
se
(3) Planetary Gears (Steering)

(4) Sun Gear
on
(5) Planetary Gears (Drive)

(6) Transmission Pinion
ly
(7) Center Axle Shaft

(8) Planetary Gear Set
(9) Carrier
(10) Left Outer Axle Shaft
(11) Sun Gear
(12) Ring Gear
(13) Bevel Gear
(14) Ring Gear
(15) Carrier
(16) Sun Gear
(17) Ring Gear
05-50 79033095 C Rev.

Differential Steering System
Differential Steering System Lubrication
1 7
2
Fo
3
6
r in
4
te
5
9 8
rn
P012212002
FIG. 65
al
FIG. 65: Following components are shown in hydraulic

schematic for lubrication of differential steering system
u
illustration:
se
(1) Differential lube (right axle)

(2) Differential lube (left axle)
(3) Bearing lube
on
(4) Lube oil for bevel gear

(5) Check valve (elevated oil reservoir)
ly
(6) Elevated oil reservoir

(7) Drain valve (elevated oil reservoir)
(8) Filter Oil from Lube Pump and Implement Return
(9) To Implement Pump
Differential steering system is lubricated by oil from
elevated oil reservoir (EOR).
79033095 C Rev. 05-51

FIG. 66: Following components are shown in illustration
of hydraulic schematic for return oil from scavenge pump: 1
(1) Scavenge Pump
(2) Left-hand Final Drive
(3) Right-hand Final Drive
Both final drives are lubricated by scavenge pump (1).
Hydraulic oil pumped by scavenge pump is returned to
common sump through both final drives. There is a fitting
3
on top of each final drive case. Hydraulic oil flows from top
of case through components of final drive. Consequently,
hydraulic oil flows to common sump.
At rated engine speed, scavenge pump delivers
approximately 76 liters/min (20 gal/min) of oil to each final
drive. Oil also provides cooling to service brakes.
2
Fo
P012212003
FIG. 66
r in
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al
u se
on
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05-52 79033095 C Rev.

Differential Steering System Components
11 12
13
14
9
10 15
16
8 17
Fo
18
r
19
in
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20
rn
21
25 24
al
22
23
u
26 27 28 29
se
P012212004
FIG. 67
on
FIG. 67: Steering differential contains three sets of (15) Ring gear
planetary gears and one pinion and bevel gear set. First (16) Planetary gears (drive)
ly
set of planetary gears is planetary gears for steering. (17) Carrier

Second set of planetary gears is planetary gears for drive. (18) Bevel gear shaft
Third set of planetary gears is used to equalize power of (19) Bevel gear
steering differential. (20) Center axle shaft
(21) Planetary gears (drive)
Following components make up differential steering (22) Sun gear
system: (23) Left outer axle shaft
(8) Transmission pinion (24) Carrier
(9) Ring gear (25) Ring gear
(10) Sun gear (26) Input components
(11) Right outer axle shaft (27) Planetary components
(12) Sun gear (28) Output components
(13) Planetary gears (steering) (29) Steering components
(14) Carrier
79033095 C Rev. 05-53

Differential Steering Unit
8
16
14 21
10
20 24
13
11
Fo
9 23
22
r
19
12
18 15 25
in
17
te
P012112012
FIG. 68
rn
FIG. 68: Power flows through differential steering system (22) Sun Gear
al
in following three ways:

• Transmission power flow
(24) Carrier
u
• Steering power flow

(25) Ring Gear
• A combination of transmission power flow and
se
steering power flow

Callouts for differential steering unit illustration are:
on
(9) Ring Gear

(10) Sun Gear
ly

(12) Sun Gear
(14) Carrier
(15) Ring Gear
(17) Carrier
(18) Bevel Gear Shaft
(19) Bevel Gear
05-54 79033095 C Rev.

NOTES
Fo
r in
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u se
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79033095 C Rev. 05-55

Transmission Power Flow
11 14
10 15
31
16
17
8
18
19
Fo
20
r in
21
30
te
25 24
22
rn
23
al
26 27 28 29
P012212005
FIG. 69
u se
8
16
on
14 21
10
20 24
ly
11
22 23
19
18 15 25
17
P012112012
FIG. 70
05-56 79033095 C Rev.

FIGS. 69–70: Two figures illustrate transmission power This input is converted to a lower speed and a higher
flow with no steering input and machine is either in torque by following components:
forward or reverse.
Callouts for transmission power flow and differential unit
(24) Carrier
for transmission power flow figures are:
(25) Ring gear
Next, output is sent through carrier (24) to left-hand outer
(10) Sun Gear
axle shaft (23).
Both outer axle shafts have same power. Also, both outer
(14) Carrier axle shafts have same rotational direction. Therefore,
machine moves straight in forward or rearward direction.
(15) Ring Gear
(17) Carrier
(18) Bevel Gear Shaft
Fo
(19) Bevel Gear

r
(22) Sun Gear

in

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(24) Carrier
(25) Ring Gear
rn
(26) Input Components

(27) Planetary Components
al
(28) Output Components

(29) Steering Components
u
(30) Left Side

se
(31) Right Side

Power from transmission flows through transmission
pinion (8) to bevel gear (19).
on
Bevel gear (19) sends power through bevel gear shaft

(18) to carrier (14). Power from carrier (14) flows in two
directions.
ly
Half of power is sent through planetary gears (16) to ring

gear (15). This power is at a lower speed and a higher
torque. Ring gear (15) sends power through carrier (17) to
right-hand outer axle shaft (11).
Other half of power at a higher speed and a lower torque
is sent through planetary gears (16) to sun gear (10). Sun
gear (10) sends power through center axle (20) to sun
gear (22).
Input from sun gear (22) is a higher speed and a lower
torque.
79033095 C Rev. 05-57

Counter-Rotation
11 13
10 15
31
17
Fo
r
20
in
21
te
30
24
rn
22
23
al
26 27 28 29
u
P012212006
FIG. 71
se
21
on
10
20 24
13
ly
11
23
22
15 25
17
P012112012
FIG. 72
05-58 79033095 C Rev.

FIGS. 71–72: Two figures illustrate steering power flow. This input from sun gear (22) is converted by following
Transmission is in neutral. components to a lower speed and a higher torque:
Callouts for transmission power flow and differential unit (21) Planetary gears (drive)
for transmission power flow figures are:
(24) Carrier
(10) Sun Gear
(25) Ring gear
Output is sent through carrier (24) to left-hand outer axle
(13) Planetary Gears (Steering) shaft (23).
(15) Ring Gear Both outer axle shafts have same power. However,
direction of shaft rotation is opposite. Therefore, machine
(17) Carrier counter-rotates.
(22) Sun Gear
Fo
(24) Carrier
(25) Ring Gear
r

in

te

(30) Left Side
rn
(31) Right Side

Following components are held stationary:
al
• Transmission input pinion

• Bevel gear
u
• Planet gears for the drive function.

se
When transmission is in NEUTRAL position and parking

brake is engaged, power input from steering motor flows
through ring gear (15).
on
Power input from ring gear (15) divides in two directions.

Half of power is sent through planetary gears (steering)
(13) to carrier (17). This power is at a lower speed and a
ly
higher torque. Power from carrier (17) flows to right-hand

outer axle shaft (11).
Other half of power at a higher speed and a lower torque
is sent through planetary gears (steering) (13) to sun gear
(10) that rotates in opposite direction.
Sun gear (10) sends power through center axle shaft (20)
to sun gear (22).
Input from sun gear (22) is a higher speed and a lower
torque.
79033095 C Rev. 05-59

Turning with Steering and Transmission Input
11 12
13
9 10
15
31
16
8
17
Fo
r
20
in
21
te
30
25 24
rn
22
23
al
26 27 28 29
u
P012212007
FIG. 73
se
16 8 21
on
10
20 24
13
ly
11
9 23
12 22
15 25
17
P012112012
FIG. 74
05-60 79033095 C Rev.

FIGS. 73–74: Two figures illustrate steering and
transmission power flow with transmission in forward or
reverse and while steering machine.
Callouts for transmission power flow and differential unit
for transmission power flow while turning with steering
and transmission input are:
(9) Ring Gear
(10) Sun Gear
(12) Sun Gear
(15) Ring Gear
Fo
(17) Carrier
r

in
(22) Sun Gear

te
(24) Carrier
rn
(25) Ring Gear

al

u

se
(30) Left Side

(31) Right Side
Transmission power flow is independent of input from
on
steering motor. When power from both steering motor

and transmission are applied to differential steer unit,
power input from transmission flows through system as if
transmission is working individually.
ly
Power from steering motor is still divided. Half of power

goes in one direction and other half of power goes in
opposite direction.
Amount of power to one outer axle shaft is greater. This
causes speed of that shaft to increase while speed of
other outer axle shaft decreases.
Rotational direction and amount of power to axle shafts
are controlled by transmission. Steering motor controls
difference in speed between axle shafts and direction of
turn.
Steering direction is determined by rotational direction of
steering motor and by rotational direction of ring gear (9).
See Table 3 for more information.
79033095 C Rev. 05-61

TABLE 3
Input Components Forward Left Turn Reverse Left Turn Forward Right Turn Reverse Right Turn
Rotation of steering Counterclockwise Clockwise Clockwise Counterclockwise
motor and ring gear
(9)
Rotation of Counterclockwise Clockwise Counterclockwise Clockwise
transmission pinion
Rotation of steering Counterclockwise Counterclockwise Clockwise Clockwise
wheel
NOTE: Rotation of steering motor and transmission

pinion viewed from drive end.
When machine makes a left-hand turn, rotation of ring
Fo
gear and transmission pinion is same direction.

Power to ring gear flows to planetary gears (drive).
Planetary gears (drive) send power through sun gear to
r
center axle shaft.

in
Also, power from sun gear is added to center axle shaft.

Combined power through center axle shaft flows to sun
te
gear.
Input from sun gear is a higher speed and a lower torque.
rn
This input from sun gear is converted by following

components to a lower speed and a higher torque:
al

(24) Carrier
u
(25) Ring gear

se
Output is sent through carrier to left-hand outer axle shaft.

Result of lower speed and higher torque causes rotational
speed of axle shaft to increase. This causes speed of
on
opposite axle shaft to decrease an equal amount.

Speed of center axle shaft increases when power to sun
gear adds to power at sun gear.
ly
Increase in power causes speed of sun gears to increase.

When speed of sun gear increases, planetary gears
(drive) also increase in speed. Carrier maintains a
constant speed. Speed of ring gear decreases as a result
of increase in speed of sun gears and increase in speed
of planet gears.
Reduction in speed of ring gear causes a reduction in
speed of carrier. Speed of right-hand outer axle shaft
decreases. This speed difference between outer axle
shafts permits machine to turn to left. Increase in speed to
left-hand outer axle shaft will always be equal to decrease
in speed to right-hand outer axle shaft.
When machine turns to right, rotation of ring gear is
opposite transmission pinion. Power to ring gear flows
through planetary gears (steering).
Power from planetary gears (steering) flows to carrier.
Also, power from ring gear is added to carrier.
05-62 79033095 C Rev.

Combined power flows will increase speed of following
components:
(9) Ring gear
(17) Carrier
(11) Right outer axle shaft
When speed of ring gear increases, speed of sun gear
decreases.
A decrease in speed of sun gear causes following
components to decrease in speed:
(20) Center axle shaft
(22) Sun gear
(24) Carrier
(23) Left outer axle shaft
Fo
Speed of right-hand outer axle shaft increases. Speed of

left-hand outer axle shaft decreases. This speed
difference between outer axle shafts permits machine to
turn to right.
r
Final Drive
in
Final Drive Location

te
FIG. 75: Final drive (1) is attached to case for differential

steering. A final drive unit is located on each side of case
rn
for differential steering. 1

al
u se
P012212008
on
FIG. 75
ly
79033095 C Rev. 05-63

Final Drive Function
4
Fo
5
P012212009
FIG. 76
r in
FIG. 76: Cross-sectional View of Final Drive: Final drive

is used to transmit power from differential steering unit to
te
drive wheels.
Callouts for illustration:
rn
(2) Sun Gear

(3) Carrier
al
(4) Planetary Gears

(5) Tapered Roller Bearings
u
(6) Axle Shaft

se
Power is sent from differential steering unit through sun

gear (2). Sun gear is lubricated by oil from elevated oil
reservoir (EOR). Sun gear is connected to planetary
gears (4). Reduction at planetary gears is 6.2 to 1.
on
Planetary gears send power through carrier (3).

Carrier sends power through axle shaft (6). Axle shaft is
supported by two tapered roller bearings (5). Axle shaft
ly
will use power to turn drive wheels. Drive wheels then turn
belts on mobil-trac system.
05-64 79033095 C Rev.

FIG. 77: Schematic of Return Hydraulic Oil from
Scavenge Pump. 7
(7) Scavenge pump
(8) Left final drive
(9) Right final drive
Both final drives are lubricated by scavenge pump (7) and
oil from elevated oil reservoir. Hydraulic oil pumped by
scavenge pump is returned to common sump through
9
both final drives. There is a fitting on top of each final drive
case. Hydraulic oil flows from top of case through
components of final drive. Consequently, hydraulic oil
flows to common sump.
approximately 76 liters/min (20 gal/min) of oil to each final
drive. Oil also provides cooling to service brakes.
8
Fo
P012212003
FIG. 77
r in
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u se
on
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79033095 C Rev. 05-65

NOTES
Fo
r in
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05-66 79033095 C Rev.

BRAKE SYSTEM
Introduction (Service Brake System)

FIG. 78: Machine is equipped with a hydraulic brake
control system. This system uses pressurized oil from
implement hydraulic system to engage service brakes.
Implement pump charges an accumulator. Pressurized oil
from accumulator is modulated to service brakes by brake
control valve.
Pressure stored in brake accumulator will permit full
braking power even when implement hydraulic system is
not in operation. A fully charged brake accumulator will
provide four to six full applications of service brakes
before accumulator will need to be recharged.
P111012005
FIG. 78
Fo
r in
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u se
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79033095 C Rev. 05-67

Service Brake System
3
5
1
4
2
7
Fo
8
9
r in
10 11 12 13
te
15 16 17 14
P012212010
rn
FIG. 79
al
FIG. 79: Drawing of Hydraulic Block Diagram for Service Hydraulic oil from hydraulic oil tank flows to implement
Brake System. Service brake hydraulic system uses hydraulic pump. Flow from implement hydraulic pump
hydraulic force from implement hydraulic system to apply flows to priority and accumulator valve (6).
service brakes.
u
Upon start-up, priority and accumulator charge valve (6)

Callouts for hydraulic block diagram: directs oil into service brake accumulator (3). When
se
service brake accumulator (3) is fully charged, priority and

(1) Service Brakes
accumulator charge valve (6) allows full hydraulic flow to
(2) Service Brake Valve be available for implement control valves (4) and three
point hitch valves (if equipped).
on
(3) Service Brake Accumulator

Load sense circuit from priority and accumulator charge
(4) Implement Control Valves valve (6) is used to provide a signal back to implement
(5) Elevated Oil Reservoir pump for recharging of service brake accumulator (3).
ly
(6) Priority and Accumulator Charge Valve When operator depresses service brake pedal, service
brake valve (2) allows oil from service brake accumulator
(7) Parking Brake Valve (3) to flow to service brakes (1).
(8) Parking Brake
(9) Common Sump
(12) Sump
(13) Accumulator Pressure
(16) Load Sense
(17) 2nd Pressure Reduction
05-68 79033095 C Rev.

Pressure stored in service brake accumulator permits full
braking power even when implement hydraulic system is
not in operation. A fully charged service brake
accumulator will provide four to six full brake applications
before service brake accumulator requires recharging.
NOTE: Engine must be running to recharge service
brake accumulator. When engine is not running,
about four to six brake applications can be
expected prior to completely emptying service
brake accumulator.
NOTE: During startup (engine cranking), a load sense
signal from brake system is temporarily disabled.
This allows better starting performance of
machine during cold weather. Once machine is
started, load sense will function normally and
charge service brake accumulator.
NOTE: CE Only: Service brake operation works same if
Fo
machine is in secondary steering mode or if

machine is in primary steering mode. Difference
is that when in secondary steering mode, service
brakes are separated and in primary steering
r
mode, service brakes are connected together. In

either operation, service brake pressure will be
in
equal on both of service brakes unless machine

is in secondary steering mode and turning.
te
While service brake accumulator is being recharged,

hydraulic flow and hydraulic pressure may be partially
rn
reduced for a very short time to following valves:

• Hydraulic control valve bank
al
• Three-point hitch valve (If equipped)

• Steerable hitch valve (If equipped)
u
• Hydraulic trailer brake valve (If equipped)

se
This reduction in flow should not noticeably affect

operation of hydraulic devices attached to these valves.
When operator releases service brake pedal, brake valve
releases hydraulic oil pressure. Hydraulic oil is returned to
on
common sump.
ly
79033095 C Rev. 05-69

Service Brake Components
Priority and Accumulator Charge Valve
FIG. 80: Priority and accumulator charge valve (1) is
located at rear of machine below cover for air conditioner.
After engine start-up, priority and accumulator charge
valve directs hydraulic oil into accumulator to recharge 1
accumulator, as required. Charge spool for accumulator is
part of priority and accumulator charge valve.
P081912001
FIG. 80
Fo
Service Brake Accumulator

FIG. 81: Service brake accumulator (1) is located in front
r
of transmission below cab.

Pressure stored in accumulator will permit full braking
in
power even when implement hydraulic system is not in

operation. A fully charged accumulator will provide four to
te
six full applications of service brakes before accumulator

will need to be recharged.
rn
NOTE: Engine must be running to recharge service

brake accumulator. When engine is not running,
more than four to six brake applications can be
al
expected prior to completely emptying service 1

brake accumulator. P081912002
Accumulator will be recharged 10 seconds from engine FIG. 81

u
start-up. Cut-in pressure for accumulator is 122 to 132 bar

se
(1755 to 1905 psi). Accumulator will recharge to cut out

pressure of 169 to 177 bar (2450 to 2550 psi) in five
seconds.
on
ly
05-70 79033095 C Rev.

Service Brake Valve
FIG. 82: Service brake valve (1) is in front of
transmission below cab.
1
P081912002
FIG. 82
FIG. 83: When service brake pedal (1) is depressed,
service brake valve allows hydraulic oil to flow from
Fo
service brake accumulator to service brakes.

r
1
in
te
rn
P081912003
al
FIG. 83
Service Brakes
u
FIG. 84: Service brakes (1) are located in differential

se
case.
Machine uses oil cooled multi-disc brakes. One multiple
disc brake is located on each side of machine. Service
brake pedal actuates both brakes. Service brakes are
on
lubricated by hydraulic oil in differential case.

Refer to Powertrain/Disassembly and Assembly, for
service brake replacement.
ly
1
P012312001
FIG. 84
79033095 C Rev. 05-71

Priority Valve (Priority and Accumulator
Charge Valve)
FIG. 85: Priority and accumulator charge valve (1) for
machine is located in intermediate valve stack at rear of
machine below cover for air conditioner.
Priority and accumulator charge valve will send hydraulic
oil to service brake accumulator. Priority and accumulator
valve will allow hydraulic oil to flow to following valves:
1
• Hydraulic trailer brake valve (If equipped) P081912004
Hydraulic oil flow from priority valve charges service brake FIG. 85
accumulator when hydraulic pressure in service brake
Fo
accumulator falls below a preset level.

Priority and accumulator charge valve will recharge
accumulator before full hydraulic flow is sent to valves.
r
When service brake accumulator is being recharged,

hydraulic oil flow and pressure will be slightly reduced to
in
valves for a short time.

This reduction in pressure and flow should not noticeably
te
affect operation of components connected to these

valves.
rn
Priority and accumulator charge valve will direct hydraulic

oil flow to service brake accumulator. Hydraulic oil flow
al
from priority and accumulator charge valve is used to

charge service brake accumulator when hydraulic
pressure in service brake accumulator falls below a preset
level.
u
Load sense circuit will send a signal from priority and

se
accumulator charge valve to upstroke implement

hydraulic pump. Hydraulic oil will flow to recharge service
brake accumulator.
on
If pressure at implement pump is not high enough to

charge service brake accumulator, check valve will unseat
increasing signal pressure in load sense circuit to
implement pump. This will upstroke implement hydraulic
ly
pump to required level to charge service brake

accumulator.
05-72 79033095 C Rev.

Implement hydraulic pump will provide required hydraulic
oil flow to meet demand for all following valve groups:
• Service brake valve
When service brake accumulator has reached preset
level, priority spool will shift to direct full flow to valves.
These valves will continue to receive full flow from
implement hydraulic pump until service brake
accumulator drops below preset limit.
When service brake accumulator drops below preset
level, accumulator spool will shift to direct oil flow to
Fo
service brake accumulator. As a result, other valve groups

will experience a slight drop in hydraulic flow to charge
service brake accumulator.
NOTE: If for some unforeseen problem, implement pump
r
flow is restricted, priority will be given to service

in
brake system and other systems may not receive

any flow.
te
rn
al
u se
on
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79033095 C Rev. 05-73

Service Brake Control Valve
FIG. 86: Service brake valve (1) is located in front of
transmission on right-hand side of machine. Service
brake valve uses oil in service brake accumulator to
operate service brakes. Linkage from brake pedal is
connected to service brake valve. As operator depresses
brake pedal, service brake valve distributes appropriate
amount of oil to activate service brakes.
Priority and accumulator charge valve is supplied with
hydraulic oil by implement hydraulic pump and directs
hydraulic oil to all of following valves:
• Service brake valve 1
P081912002
FIG. 86
Fo

FIG. 87: Illustration of service brake valve (1) shows
location of following ports: 4
r
2
(2) Port to tank
in
(3) Port to service brakes

te
(4) Port from service brake accumulator

rn
3 1
al
P081912005
FIG. 87
u se
on
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05-74 79033095 C Rev.

6 8 12
5 10 9
15
7
Fo
11 14 13
r
16 17 18 19
in
P012312005
te
FIG. 88
rn
FIG. 88: Cross-Sectional View of Service Brake Valve: Pressure is held in brake system until brake pedal is
depressed further or brake pedal is released. If operator
(5) Linkage reduces brake pressure, oil flows from service brake (14)
al
(6) Spring to tank port until pressure regulating spring balances the
(7) Piston hydraulic reaction against seat (8). Flow to tank port
(8) Seat stops, and new brake line pressure is maintained.
u
(9) Ball Valve

(10) Passage Amount of effort applied to service brake pedal is directly
se
(11) To Tank proportional to brake line pressure. This relationship

(12) Seat provides feel when applying brakes on machine.
(13) From Accumulator
Accumulator is Charged and Brakes are Released:
(14) To Service Brakes
When brakes are released and accumulator is fully
on
(15) Brake Pedal

charged, chamber behind seat (8) will drain to tank port.
(17) 1st Pressure Reduction When operator releases service brake pedal, linkage (5)
(18) Sump will release pressure on pressure regulating spring.
ly
(19) Activated Components Pressure regulating spring will allow ball valve against
Application of the Service Brakes: When operator seat. Hydraulic oil from service brakes will flow to tank
depresses service brake pedal, linkage (5) will push on port to common sump.
pressure regulating spring (6). Pressure regulating spring
pushes piston (7). Piston pushes seat (8) against ball When accumulator is fully charged, priority and
valve (9). This action closes off passage (10) from tank accumulator charge valve will send all pump flow to
port (11). implement control valves.
At same time, ball valve is unseated from seat (12).

Hydraulic oil from accumulator will flow past ball valve and
to service brakes (14).
As pressure to brakes increases, pressure pushes on
seat. Seat then moves against force of pressure
regulating spring until hydraulic oil flow from accumulator
stops.
79033095 C Rev. 05-75

Service Brakes
Location of Service Brakes
FIG. 89: Service brakes (1) are located in case for
steering differential. There is a service brake assembly on
each side of case for steering differential.
Service brake assemblies are oil cooled multi-disc brakes.
Service brakes are lubricated with oil from steering
differential.
Service brakes consist of following components:
• Two friction discs
• Actuator piston
• End plate
• Separator plate
Fo
1
r
P012312001
in
FIG. 89
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05-76 79033095 C Rev.

Service Brake Operation
2 3
6 5
Fo
4
r in
7 8 9
te
P012312006
FIG. 90
rn
FIG. 90: Callouts for Cross-Sectional View of Service Engagement of Service Brakes: Actuator piston (3) of
al
Brake: service brakes receives oil from service brake valve, after
service brake pedal has been depressed. Actuator piston
(2) Friction Discs will press against one of friction discs (2). Friction disc will
u
(3) Actuator Piston press against separator plate (6). Separator plate will
move against second friction disc. Second friction disc will
(4) Planetary Carrier Assembly
se
press against end plate (5). Friction discs of each brake

(5) End Plate assembly are splined to planetary carrier assembly (4).
(6) Separator Plate Service brake assembly for right-hand side of machine is
splined to planetary carrier assembly used for steering
on
(7) Planetary Components control. Service brake assembly for left-hand side of
(8) Output Components machine is splined to planetary carrier assembly for
equalizing power.
ly
(9) Moving Components

Compression of friction discs that are splined to planetary
carrier assemblies will slow machine.
Disengagement of Service Brakes: When service
brake pedal is released, service brake valve will release
pressure on actuator piston (3). Actuator piston will
retract. Friction discs will retract from separator plate and
from end plate.
NOTE: Only actuator piston is spring retracted.
79033095 C Rev. 05-77

Cooling Service Brakes
FIG. 91: Hydraulic Schematic for Scavenge Pump:
(7) Scavenge Pump 7
(8) Left-hand Final Drive and Service Brake
(9) Right-hand Final Drive and Service Brake
Both service brakes are cooled by hydraulic oil from
scavenge pump and lube oil from EOR. Hydraulic oil
pumped by scavenge pump is returned to common sump
through both final drives. There is a fitting on top of each
9
final drive case. Hydraulic oil flows from top of case
through components of final drive and service brakes.
This hydraulic oil cools service brakes. Hydraulic oil flows
to common sump.
approximately 76 liters/min (20 gpm) of oil to each final
Fo
drive. This oil cools each service brake.

8
P012212003
FIG. 91
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on
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05-78 79033095 C Rev.

Hydraulic Schematic for Service Brakes
DIFF
14
11
10
Fo
SOS
SOS
13
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9
in
12
DIFF
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X
XMSN
Y
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5 6
2
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15 16 8
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S L1
17
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7 18
4 3
P111112003
on
FIG. 92
ly
FIG. 92: Hydraulic Schematic for Service Brakes: (12) Service Brake Valve
(1) Steering Filter (13) Service Brake Accumulator
(2) Filler Cap (14) Elevated Oil Reservoir
(3) Suction Screen (Tandem Charge Pump) (15) Left-Hand Service Brake (Final Drive)
(4) Ecology Drain (16) Right-Hand Service Brake (Final Drive)
(5) Breather (Common Sump) (17) To Park Brake Valve
(6) Tandem Charge pump (18) To Implement Valve Bank
(7) Implement Hydraulic Pump
(8) Hydraulic Trailer Brake Valve
(9) Priority Valve
(10) Steerable Hitch Valve
(11) Intermediate Valve Stack Top Plate
79033095 C Rev. 05-79

HYDRAULIC TRAILER BRAKE VALVE
SYSTEM (OPTIONAL)
Introduction
FIG. 93: Machine can be equipped with a hydraulic
trailer brake.
Hydraulic trailer brake valve (1) is located at bottom of
intermediate valve stack.
P081912006
Fo
FIG. 93
FIG. 94: Connector (1) for hydraulic trailer brake is
located at rear of machine next to electrical connector for
r
trailer.
in
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1
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P081912007
FIG. 94
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on
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05-80 79033095 C Rev.

Hydraulic Trailer Brake System
3
5
1
4
2
19
6
18
7
Fo
8
9
r in
10 11 12 13
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15 16 17 14
P111212001
rn
FIG. 95
al
FIG. 95: Block drawing of hydraulic trailer brake system. Trailer brake valve will direct pressurized hydraulic oil to
implement valve stack and to connector for trailer brake.
(1) Service Brakes
Hydraulic oil from implement hydraulic pump will travel
u
(2) Service Brake Valve

through priority valve. Pressurized hydraulic oil will travel
(3) Service Brake Accumulator to trailer brake valve.
se
(4) Implement Control Valves When service brake pedal is depressed, service brake
(5) Elevated Oil Reservoir valve will direct hydraulic pressure to connector for trailer
on
(6) Priority and Accumulator Charge Valve brake.

(7) Parking Brake Valve Pressure from trailer brake valve to connector for trailer
brake valve will rise with an increased pressure signal to
ly
(8) Parking Brake trailer brake valve from service brake valve. Amount of
(9) Common Sump effort applied to service brake pedal is directly
proportional to pressure at connector for hydraulic trailer
(10) System Pressure brake.
(11) Charge Pressure When pedal is released, pressure in trailer brake will be
(12) Sump released to differential.

(16) Load Sense
(18) Trailer Brake Valve
(19) Trailer Brake Coupler
79033095 C Rev. 05-81

Hydraulic Trailer Brake Components
Priority and Accumulator Charge Valve
FIG. 96: Priority and accumulator charge valve (1) is
located at rear of machine below cover for air conditioner.
Priority and accumulator charge valve is positioned just
above hydraulic trailer brake valve (2) (if equipped) at 1
bottom of intermediate valve stack.
After engine start-up, priority and accumulator charge
valve will send pressurized hydraulic oil from implement
hydraulic pump to service brake accumulator. Priority and
accumulator charge valve will allow hydraulic oil to flow to
following valves: 2
P081912006
FIG. 96
Fo
Hydraulic Trailer Brake Valve

r
FIG. 97: Hydraulic trailer brake valve (1) is located at

in
bottom of intermediate valve stack.

When service brake pedal is depressed, service brake
te

valve will send pressurized oil to hydraulic trailer brake
coupler to engage trailer brakes.
rn
Hydraulic oil from implement hydraulic pump will travel

through priority valve. Pressurized hydraulic oil will travel
al
to trailer brake valve. 1

u

P081912006
valve will direct hydraulic pressure to connector for trailer
se
brake. FIG. 97
Pressure from trailer brake valve to connector for trailer
brake valve will rise with an increased pressure signal to
trailer brake valve from service brake valve. Amount of
on
effort applied to service brake pedal is directly

proportional to pressure at connector for hydraulic trailer
brake.
ly
Pressure reading at connector for trailer brake will be

higher than 105 bar (1450 psi) with 4135 kPa (600 psi).
Pressure at connector for hydraulic trailer brake should
not exceed 150 bar (2175 psi).
05-82 79033095 C Rev.

1
Fo
2
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3
4
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Q012912004
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FIG. 98
FIG. 98: Hydraulic Trailer Brake Valve Exploded View

on
Main Components:
(1) Valve Body
(2) Priority Spool
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(3) Brake Cartridge

(4) Sequence Valve
(5) Brake Signal Input Bleed
79033095 C Rev. 05-83

2
7
3
A 4
6
Fo
B 8
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9
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C
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D
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Q013012001
se
FIG. 99
FIG. 99: Hydraulic Trailer Brake Valve Cut Away - Pump pressure is blocked from trailer brake work port
Neutral Position when brake signal is absent and brake valve is in neutral.
on
(1) Pump Pressure

(2) Return Pressure
ly
(3) Brake Pilot Oil

(4) Load Sense
(5) Trailer Brake Supply
(6) Trailer Brake Work Port
(7) Priority Spool
(8) Brake Cartridge
(9) High Pressure Relief Valve
(A) Load Sense Port
(B) Brake Signal Input Port
(C) Tank Port
(D) Trailer Brake Work Port
05-84 79033095 C Rev.

2
7
3
A 4
6
Fo
B 8
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9
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C
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D
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Q013012002
se
FIG. 100
FIG. 100: Hydraulic Trailer Brake Valve Cut Away - When brake pedal is depressed, signal pressure is sent
Activated Position to brake signal input port and brake cartridge is shifted to
on
right. This allows pump pressure to exit valve at work port.

(1) Pump Pressure
If pressure exceeds 135 bar (1958 psi), pressure relief
(2) Return Pressure
valve opens and pressure is sent to tank port.
ly
(3) Brake Pilot Oil

(4) Load Sense
(5) Trailer Brake Supply
(6) Trailer Brake Work Port
(7) Priority Spool
(8) Brake Cartridge
(9) High Pressure Relief Valve
(A) Load Sense Port
(B) Brake Signal Input Port
(C) Tank Port
(D) Trailer Brake Work Port
79033095 C Rev. 05-85

Implement Pump
FIG. 101: All machines are equipped with a hydraulic
brake control system, which uses pressurized oil from
implement hydraulic system to engage service brake. 1
Hydraulic oil from implement pump (1) will charge
accumulator. Pressurized oil from accumulator is
modulated to service brake by service brake control valve.
Implement pump is located on left-hand side of machine
in front of final drive.
P081812003
FIG. 101
Service Brake Valve

Fo
FIG. 102: Service brake valve (1) is in front of

transmission below cab.
r
valve allows hydraulic oil to flow from service brake

accumulator to service brakes.
in
All machines can be equipped with an optional Hydraulic

Trailer Brake system that uses pressurized oil from
te
implement hydraulic system to engage trailer brakes.

rn

valve will send pressurized oil from implement hydraulic 1
pump to engage trailer brakes. P081912002
al
FIG. 102
Hydraulic Trailer Brake Coupler

u
FIG. 103: Coupler (1) for hydraulic trailer brake is located

se
at rear of machine next to electrical connector for trailer.

on
1
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P081912007
FIG. 103
05-86 79033095 C Rev.

AIR TRAILER BRAKE SYSTEM (CE ONLY)
Introduction
Machine can be equipped with an air brake system for
trailers.
Air Trailer Brake System

Air brake system contains following major components:
• Air Compressor
• Air Brake Reservoir and Air Dryer
• Actuator Control Valve
• Control Valve Assembly for the Air Brakes
Air Trailer Brake Components

Fo
Air Compressor
FIG. 104: Air compressor (1) is located on left-hand side
r
of engine.
Compressor generates compressed air for air brake 1
in
system. Compressor uses a single piston and is a

gear-driven unit connected to front of engine. External
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lubrication is not necessary. Compressor is connected to

engine lubrication system.
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P011512001
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FIG. 104
on
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79033095 C Rev. 05-87

Air Tank and Air Dryer
2
Fo
3
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P012312011
FIG. 105
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FIG. 105: Air tank and air dryer

u
(1) Main Air Tank

se
(2) Regeneration Air Tank

(3) Air Dryer
Air tank (1) stores compressed air. Air tank must be
on
drained at fifty hour intervals. Air tank is equipped with a

drain valve located at bottom of air tank.
Regeneration air tank (2) stores air for regenerating
ly
desiccant cartridge in air dryer.

Dryer (3) removes moisture from compressed air. Dryer
has a replaceable filter.
Refer to Operations and Maintenance Manual,
Maintenance Interval Schedule, for more information.
05-88 79033095 C Rev.

Actuator Valve and Trailer Control Valve (Dual
Brake Line)
FIG. 106: Actuator valve (1) and trailer control valve (2)
are located on left-hand side of machine.
Actuator valve will receive a hydraulic signal from parking
brake control valve when parking brake is released.
Actuator arm will retract to move lever on trailer control
valve. When lever is retracted compressed air is now able
to travel to brake control valve for single brake line. 1
Trailer control valve controls pressure in dual lines of
trailer brakes. When pressure at brake pedal is increased,
flow to air brakes is increased for advanced retardation of
trailer. 2
P111212002
FIG. 106
Trailer Control Valve (Single Brake Line)

Fo
FIG. 107: Trailer control valve (1) controls system for

single brake line. Trailer control valve for single brake line
works with trailer control valve for dual brake line.
r
Single brake line maintains air pressure on trailer brake.

in
Trailer brake is held in released position. When service

brake pedal is depressed trailer control valve vents air
te
pressure to atmosphere. Reduction in air pressure will

allow spring force in trailer brake to overcome air 1
pressure. Reduction in pressure is required for slowing of
rn
trailer.
al
P081912008
FIG. 107
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on
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79033095 C Rev. 05-89

Air Couplings for the Trailer Brakes
FIG. 108: Black coupling is used for single line brake
system and connects machine with trailer. Black coupling
is equipped with an internal valve. and connects the
machine with the trailer. Valve is normally closed. Valve
opens when hose for trailer is connected.
g00573510
FIG. 108
FIG. 109: Red coupling is use for dual line brake system.
Fo
Red coupling is equipped with an internal valve and

connects supply line between machine and trailer. Valve
is normally closed. Valve opens when hose for trailer is
connected.
r in
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g00573525
al
FIG. 109
FIG. 110: Yellow coupling is used for dual line brake
u
system. Yellow coupling is equipped with an internal valve

and connects line for control between machine and trailer.
se
Valve is normally closed. Valve opens when hose for

trailer is connected.
on
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g00573525
FIG. 110
05-90 79033095 C Rev.

PARKING BRAKE SYSTEM
Introduction (Parking Brake System)

FIG. 111: Parking brake on machine is spring applied
and hydraulically released. An electro-hydraulic valve
controls parking brake.
Parking brake (1) has six friction discs splined to input
pinion for transmission. Electronic controls prevent
steering differential from turning while parking brake is
engaged.
Fo
1
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P012312014
in
FIG. 111
FIG. 112: Parking brake valve (1) is equipped with an
te
override mode for tow position. Override mode for tow

position allows operator to release parking brake under
rn
dead engine conditions using service brake system.

al
1
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P081912009
FIG. 112
on
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79033095 C Rev. 05-91

Parking Brake System
Parking Brake System Electrical Components
1 3
2
8
Fo
4
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5
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7
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6 6
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P111212003
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FIG. 113
FIG. 113: Electrical Block Diagram for Parking Brake A signal is sent to armrest ECM when parking brake
on
System switch is activated. Machine ECM actuates parking brake

by controlling solenoid valves for parking brake.
Electronic system for parking brake consists of following
components: IMPORTANT: Machine should come to a complete stop
prior to engaging park brake. Premature park
ly
(1) Dash panel cluster brake wear and/or eventual park brake failure will
(2) VT display occur if continual park brake engagement with
machine still moving occurs.
(3) Machine ECM
NOTE: If machine ECM senses a diagnostic problem,
(4) Parking brake switch machine ECM may automatically energize
(5) Armrest ECM parking brake after machine has come to a
complete stop to prevent injury.
(6) Solenoid valve (parking brake)(No.1) and (No. 2)
(7) Auxiliary CAN data link
(8) Powertrain CAN data link
When shift lever for transmission control is in PARK
position, parking brake switch will be activated.
05-92 79033095 C Rev.

Parking Brake System Hydraulic Components
3
5
1
4
2
18
6
7
Fo
8
9
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10 11 12 13
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15 16 17 14
P012212010
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FIG. 114
FIG. 114: Block Diagram for Hydraulic Oil Flow for (16) Load Sense
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Parking Brake System

Block diagram for parking brake consists of following
u
components:
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(1) Service Brakes

Parking brake control valve (7) provides electrical control
(2) Service Brake Valve
of spring applied, hydraulic released parking brake.
Parking brake control valve receives hydraulic oil from
on
(4) Implement Control Valves large section of tandem charge pump (18). Parking brake
control valve sends hydraulic oil to parking brake to
(5) Elevated Oil Reservoir
release parking brake. Parking brake control valve also
ly
(6) Priority and Accumulator sends hydraulic oil from parking brake to sump to engage
parking brake.
(7) Parking Brake Control Valve
Parking brake control valve sends hydraulic oil to lubricate
(8) Parking Brake parking brake.
(9) Common Sump Parking brake control valve is also used to correctly direct
(10) System Pressure oil during dead engine conditions. Hydraulic pressure
from service brake accumulator disengages spring
(11) Charge Pressure applied parking brake. To disengage parking brake,
(12) Sump hydraulic pressure is needed. Parking brake must be
disengaged to tow machine.
79033095 C Rev. 05-93

Parking Brake System Electrical
Components
Electronic system for parking brake consists of following
components:
• Switch (parking brake)
• CAN data link
• Machine ECM
• Armrest ECM
• Solenoid valves (parking brake)
Switch (Parking Brake)

FIG. 115: Parking brake switch is located on base of
transmission control lever (1).
Switch signals machine ECM that operator wants to
Fo
engage parking brake.

r
1
in
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P081912011
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FIG. 115
CAN Data Link

al

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(1) Powertrain Bus

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(2) Auxiliary Bus

(3) ISO Bus
1
on
CAN data link are located in cab wall on right-hand side of

seat. 2 3
ly

• Machine ECM
05-94 79033095 C Rev.

Machine ECM
FIG. 117: Machine ECM (1) is located in floor of cab.
Machine ECM communicates with armrest ECM, dash
cluster and VT through powertrain CAN BUS network.
P101312002
FIG. 117
Armrest ECM
Fo
FIG. 118: Armrest ECM is located in console below

armrest. Switches and levers located in console
communicate directly to armrest ECM. Armrest ECM then
communicates to machine ECM, dash cluster, and VT
r
using powertrain CAN BUS network.

in
1
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P100812005
al
FIG. 118
Solenoid Valves (Parking Brake)

u
FIG. 119: Solenoid valves (1) for parking brake are

se
located on left-hand side of machine in front of left-hand

final drive. Solenoid valves for parking brake are behind
oil filters.
Solenoid valves control flow of hydraulic oil to parking
on
brake clutch. 1
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P081912009
FIG. 119
79033095 C Rev. 05-95

Parking Brake System Hydraulic
Components
Parking Brake Valve
FIG. 120: Parking brake valve (1) is located behind
hydraulic oil filters in front of left-hand final drive.
Parking brake control valve provides electrical control of
spring applied, hydraulic released parking brake.
Parking brake control valve is also used to correctly direct
oil during dead engine conditions. Hydraulic pressure 1
from accumulator for service brakes is used to disengage
spring applied parking brake. To disengage parking brake,
hydraulic pressure is needed. Depress knob to release
parking brakes. Parking brake must be disengaged to tow
machine. Knob will return to normal position when engine
is turned on and charge pressure is built. P081912009
Fo
FIG. 120
Secondary Brake Valve (CE Only)

r
FIG. 121: Parking brake valve (1) is located above

pumps in front of left-hand final drive.
in
Secondary brake valve is used to slow machine if primary 1

service brakes are inoperable. Secondary brake valve
te
releases oil from parking brake to sump to engage

parking brake.
rn
NOTE: Secondary brake system is only designed for one

application. If secondary brake system is used,
parking brake should be inspected for premature
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wear or failure.
P081912012
u
FIG. 121
se
Secondary Brake Lever (CE Only)

FIG. 122: Parking brake lever (1) is located on left-hand
side of operator seat.
on
Secondary brake lever is connected to secondary brake

valve with a cable. Secondary brake lever engages and
disengages secondary brake. 1
ly
Control lever does not lock in any position. When lever is

released, lever will return to original position and
secondary brake control will be released.
P012312019
FIG. 122
05-96 79033095 C Rev.

Parking Brake
FIG. 123: Parking brake (1) is attached to front of
differential case. Remove differential case from
transmission case to have access to parking brake.
IMPORTANT: Do not engage parking brake while
machine is moving unless primary service brake
fails. Use of parking brake as a service brake in
regular operation will cause severe damage to
brake system.
Use parking brake to hold machine stationary. Always
engage parking brake and stop engine before leaving
machine.
1
Fo
P012312014
FIG. 123
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79033095 C Rev. 05-97

Input Components of Parking Brake
System
Switch (Parking Brake)
FIG. 124: Parking brake switch for Parking Brake
System signals armrest ECM that operator wants to
Switch is a two-position microswitch. Switch has a set of
normally open contacts and a set of normally closed
contacts.
When switch is actuated, a signal is received by pin 17 of
armrest ECM.
If input signals from switch are incorrect, a diagnostic
code will be set. After machine comes to a stop, parking
brake will be engaged until fault is cleared.
Fo
g00787066
FIG. 124
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05-98 79033095 C Rev.

Parking Brake System ECMs
Machine ECM
FIG. 125: Machine ECM (1) is located in floor of cab.
Machine ECM communicates with armrest ECM, dash
cluster and VT through powertrain CAN BUS network.
Following table shows pins for J1 and J2 connectors of
machine ECM. 1
NOTE: Pins not on table are either not used or not used
in this system.
P101312002
FIG. 125
Fo
r

in

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on

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45 HYD OIL LEVEL SW
79033095 C Rev. 05-99

Armrest ECM
FIG. 126: Armrest ECM is located in console below
communicate directly to armrest ECM. Armrest ECM
using powertrain CAN BUS network.
Following table shows pins for connectors of armrest
ECM. 1
in this system.
Pin Description
P100812005
1 POWER -
2 POWER +12V FIG. 126
3 ISO & SERVICE CAN +
4 ISO & SERVICE CAN -
Fo
8 SENSOR +3.33V
10 SENSOR +1.66V
11 MACHINE CAN +
r
12 MACHINE CAN -
14 ONE TOUCH SWITCH
in
21 ROADING LOCKOUT SWITCH

23 AUTO GUIDE SWITCH
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31 HITCH SWITCH - RAISE

32 HITCH SWITCH - LOWER
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33 HITCH DEPTH LEVER POSITION

34 IMPLEMENT #1 LEVER POSITION
al

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50 ROCKER SWITCH BACKLIGHTING
on
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05-100 79033095 C Rev.

Output Components of Parking Brake
System
Solenoids
FIG. 127: Machine ECM controls solenoid valves (1) and
(2) for parking brake.
Solenoid valves are an on/off valve. ECM sends a signal 1
to valves to actuate parking brake.
2
Solenoid valves control flow of hydraulic oil to parking
brake clutch. See table below for responses of solenoids
in relation to parking brake.
Solenoid Solenoid Parking Brake Status

(No. 1) (No. 2)
P012412001
OFF OFF HOLD
Fo
FIG. 127
OFF ON ENGAGEMENT
ON OFF RELEASE
r
ON ON ENGAGEMENT
in

is detected, ECM will log diagnostic code in memory.
te
ECM will engage parking brake after machine has come

to a stop. If fault was a short to ground on solenoid valve,
rn
parking brake can not be released.

Knob is pressed in for manual release. Knob will return to
original position when engine is started and charge
al
pressure is built.
u se
on
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79033095 C Rev. 05-101

Data Link for Parking Brake System
5
Fo
8
3 2 1
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9
4
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P111212004
FIG. 128
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FIG. 128: Block Diagram of Connections of Data Links.

al
(1) Auxiliary CAN bus data link

(2) ISO CAN bus data link
u
(3) Powertrain CAN bus data link

se
(4) Armrest ECM

(5) Machine ECM
on

(8) Park Brake Solenoids
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(9) Park Brake Switch
05-102 79033095 C Rev.

Parking Brake Control Valve
Parking Brake Control Valve Location
FIG. 129: Parking brake control valve (1) is located on
left-hand side of machine in front of final drive.
Parking brake control valve provides electrical control of
spring applied, hydraulic released parking brake.
Parking brake control valve is also used to correctly direct
oil at dead engine conditions. Hydraulic pressure from
1
accumulator for service brakes disengages spring applied
parking brake. To disengage parking brake, hydraulic
pressure is needed. Parking brake must be disengaged to
tow machine.
Knob is pressed in for manual release. Knob will return to
P081912009
original position when engine is started and charge
pressure is built. FIG. 129
Fo
Parking Brake Control Valve Modes

Parking brake control valve can operate in three different
r
modes:
• On
in
• Off
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• Tow
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on
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79033095 C Rev. 05-103

Parking Brake - On Position (Park Brake Engaged)
4 6
3
2 7
Fo
r
8
in
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10 9
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11 12 13 14 15
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P012412003
FIG. 130
u se
FIG. 130: Hydraulic Oil Flow in On Position. (Park Brake (14) Trapped Oil
Engaged).
Following components are in hydraulic block diagram for
When parking brake control valve is in On position, spool
on
Parking Brake:
(8) is in a de-energized state. Charge circuit oil will flow
(2) Knob through spool and charge circuit oil will lubricate parking
brake.
(3) Spool
ly
Spool (9) is in a energized state. Hydraulic oil from

(4) Check Valve parking brake piston (5) will flow through spool and
(5) Parking Brake Piston hydraulic oil will flow to tank. Parking brake is applied
through normal methods.
(6) Check Valve
(7) From Charge Circuit
(8) Spool
(9) Spool
(10) From Service Brakes
(13) Sump
05-104 79033095 C Rev.

Parking Brake - Off Position (Park Brake Released)
4 6
3
2 7
Fo
8
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10 9
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11 12 13 14 15
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P012412004
FIG. 131
u se
FIG. 131: Hydraulic Oil Flow in Off Position. (Park Brake (14) Trapped Oil
Released).
When parking brake control valve is in Off position, spool
on
Parking Brake:
(8) is in an energized state. Charge circuit oil will flow
(2) Knob through spool and charge circuit oil will unseat check
valve(6). Hydraulic oil will flow to parking brake piston (5).
(3) Spool
ly
Spool (9) is in a de-energized state. Spool will block

(4) Check Valve hydraulic oil from flowing to tank. Parking brake is
(5) Parking Brake Piston released through normal methods.
(6) Check Valve
(7) From Charge Circuit
(8) Spool
(9) Spool
(13) Sump
79033095 C Rev. 05-105

Parking Brake - Tow Position (Park Brake
Released)
4 6
3
2
Fo
7
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8
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10 9
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11 12 13 14 15
P012412005
u
FIG. 132
se
FIG. 132: Hydraulic Oil Flow in Tow Position. (Park (14) Trapped Oil
Brake Released).
on

Parking Brake: Tow position is used to create a passage. Passage is
used to move oil from accumulator for service brake to
(2) Knob parking brake.
ly
(3) Spool Refer to Operation and Maintenance Manual, Towing

Information, for more information on towing machine.
(4) Check Valve
Spool (8) and spool (9) are de-energized. Pull knob (2) in
(5) Parking Brake Piston outward direction. Rotate knob to Detent position.
(6) Check Valve Hydraulic oil from service brake valve will flow through
(7) From Charge Circuit spool (3) and hydraulic oil will unseat check valve (4).
Operator will need to depress service brake pedal to get
(8) Spool oil to flow through spool (3). Hydraulic oil will enter parking
(9) Spool brake piston (5) and hydraulic oil will disengage parking
brake.
NOTE: Parking brake can be applied from cab after a
(11) System Pressure dead engine failure.
(13) Sump
05-106 79033095 C Rev.

Parking Brake Manual Control Handle
FIG. 133: Manual control handle (1) for parking brake is
located between driver's seat and instructional seat. This
manual control handle can also be used to engage
parking brake. Manual control handle is independent of
any electronic control system.
Manual control handle for parking brake may be used in 1
following conditions:
• Fault on parking brake solenoid. (This would be
indicated on virtual terminal (VT).)
• No electrical power. (Key is turned to Start or
Accessory position and nothing happens.)
P111212005
• Machine has failed in a gear or neutral. FIG. 133
• Tow override function is being used.
To manually engage parking brake, pull up on handle and
Fo
hold handle for approximately 5 seconds. Operator will

need to use approximately 133 N (30 lb) of force to
r in
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79033095 C Rev. 05-107

Towing a Machine That has a Dead Engine
If machine has a dead engine perform the following
procedure before attempting to tow machine.
NOTE: The following procedure will enable machine to
perform five brake applications.
Charged Accumulator Units

FIG. 134: Parking brake valve is located behind
implement and hydraulic filters on left side of machine.
Push up on control lever (1).
Press service brake pedal and hold service brake pedal
for five seconds to release parking brake.
Follow basic towing procedures for a stuck machine.
When towing is completed control lever (1) will return to 1
its original position when engine is started and charge
Fo
pressure is built.
If machine has electrical power, turn ignition key on, and P012412006
place transmission control in park position.
r
FIG. 134
If machine does not have electrical power, pull manual
in
lever to engage parking brake.

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Discharged Accumulator
FIG. 135: If accumulator for parking brake has
rn
discharged, use a hand hydraulic pump with a pressure

gauge and a quick disconnect.
Connect quick disconnect to pressure tap (2) located on
al
tube to accumulator. Pressurize park brake to at least

2240 kPa (325 psi) and maintain while towing machine.
2
u
Secure hand hydraulic pump to machine. Follow basic

towing procedures for a stuck machine.
se
When towing of machine has been completed, release

pressure on park brake by turning key on to accessory
position. If there is no electrical power, pull manual lever
T022212004
left of seat.
on
FIG. 135
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05-108 79033095 C Rev.

Parking Brake
Parking Brake Location
4 3
Fo
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6
7
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5
2
on
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1804376
FIG. 136
FIG. 136: Parking brake is attached to front of differential Parking brake consists of following components:
case. Parking brake is splined to input pinion (3) of
(1) Actuator piston
transmission.
(2) Lubrication line
Parking brake is a multiple disc brake. Parking brake is
lubricated with oil from transmission charge oil at (3) Input pinion
lubrication line (2). Spring tension is used to apply parking
brake. Hydraulic pressure is required to release parking (4) Friction discs
brake. (5) Separator plates
(6) Springs
(7) End Plate
79033095 C Rev. 05-109

Parking Brake Disengagement
To disengage parking brake, electro-hydraulic parking
brake valve directs oil to actuator piston (1). Actuator
piston will compress springs (6). When springs are
compressed, tension on friction discs (4) and separator
plates (5) is released.
Parking brake can be disengaged and engaged after a
dead engine failure or an electrical failure.
Refer to Operation and Maintenance Manual, Towing
Machine, for information about disengaging parking brake
on a stalled machine.
Parking Brake Engagement

To engage parking brake, machine should come to a
complete stop.
IMPORTANT: Do not engage parking brake while
Fo
machine is moving unless service brakes fail.

Use of parking brake as a service brake in
regular operation will cause severe damage to
parking brake.
r
Move transmission control lever to PARK position. Parking

in
brake valve will reduce hydraulic pressure on piston.

Springs in parking brake will expand against separator
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plates and friction discs. Friction discs will effectively hold

input pinion from rotating.
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05-110 79033095 C Rev.

Hydraulic System Schematic (Parking
Brake)
DIFF
14
11
10
Fo
SOS
SOS
13
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12 9
in
DIFF
X
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XMSN
Y
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5 6
2 B
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15 16 8
S L1
17
u se
7 18
4 3
P111112003
on
FIG. 137
FIG. 137: Following components are shown in Hydraulic (12) Service Brake Valve
ly
Schematic for Service and Parking Brakes:

(1) Steering Filter
(14) Elevated Oil Reservoir
(2) Filler Cap
(15) Left Service Brake (Final Drive)
(3) Suction Screen (Tandem Charge Pump)
(16) Right Service Brake (Final Drive)
(4) Ecology Drain
(17) To Park Brake Valve
(5) Breather (Common Sump)
(18) To Implement Valve Bank
(6) Tandem Charge pump
(7) Implement Hydraulic Pump
(8) Hydraulic Trailer Brake Valve
(9) Priority Valve
(10) Steerable Hitch Valve
(11) Intermediate Valve Stack Top Plate
79033095 C Rev. 05-111

NOTES
Fo
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05-112 79033095 C Rev.

Steering and Brake System Disassembly and Assembly
STEERING AND BRAKE SYSTEM DISASSEMBLY AND
ASSEMBLY
SCAVENGE (GEAR) PUMP

FIG. 138: Scavenge (gear) pump (1) is mounted to front
of steering (piston) pump (2) and is located on left-hand
side of transmission. 1 2
Scavenge Pump Removal
m
hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in
hydraulic system after engine has been
stopped. Serious injury can be caused if
Fo
this pressure is not released before any

service is done on hydraulic system. P081812004
FIG. 138
Make sure all work tools have been lowered
r
to ground, and oil is cool before removing

any components or lines. Remove oil filler
in
cap only when engine is stopped, and filler

cap is cool enough to touch with bare hand.
te

rn

al

u

se

should be thoroughly cleaned. This helps prevent
dirt from entering internal mechanism.
NOTE: Put identification marks on all lines, on all hoses,
on
on all wires, and on all tubes for installation

purposes. Plug all lines, hoses, and tubes. This
helps prevent fluid loss and keeps contaminants
ly

FIG. 139: Remove guards (1).
Drain hydraulic system into a suitable container for
storage or disposal.
1
P082012003
FIG. 139
79033095 C Rev. 05-113

FIG. 140: Disconnect pressure line (1) from B-port of
pump.
Disconnect supply line (2) from S-port of pump. 1
2
P082012004
FIG. 140
FIG. 141: Remove two bolts (1) holding gear pump to
steering pump.
Fo
r in
1
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P082012005
FIG. 141
rn
Scavenge Pump Installation

al
FIG. 142: Mount gear pump to steering pump with two

bolts (1).
u

se

on

replacement.
1
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P082012005
FIG. 142
FIG. 143: Connect pressure line (1) from B-port of
pump.
Connect supply line (2) from S-port of pump. 1
Fill hydraulic system with approved oil and check system
for leaks.
Attach side guards.
2
P082012004
FIG. 143
05-114 79033095 C Rev.

STEERING PUMP
FIG. 144: Steering (piston) pump (1) is located on
left-hand side of transmission. Scavenge (gear) pump (2)
is mounted to front of steering pump. 2 1
Steering Pump Removal
m
FIG. 144
Fo


r

in

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rn

al
should be thoroughly cleaned. This will help dirt

from entering internal mechanism.
u
NOTE: Put identification marks on all lines, hoses, wires,

and tubes for installation purposes. Plug all lines,
se
hoses, and tubes. This helps prevent fluid loss

and keeps contaminants from entering system.
Remove Scavenge Pump. Refer to Scavenge Pump
Removal section.
on

ly
FIG. 145: Disconnect pressure hoses (1) from steering

pump.
Disconnect wire harness (2) from steering pump.
1
P082012006
FIG. 145
79033095 C Rev. 05-115

FIG. 146: Disconnect filter line (1) from T2-port of
steering pump.
1
P082012007
FIG. 146
FIG. 147: Disconnect filter line (1) from T1-port of
steering pump.
Fo
r in
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1
P082012008
FIG. 147
rn
FIG. 148: Support steering pump (1) and remove four

bolts (2) holding steering pump to pump drive (3).
al
Slide pump straight out to disengage pump from drive and

remove pump. 3
u
1
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2
on
P082012009
FIG. 148
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05-116 79033095 C Rev.

Steering Pump Disassembly
Required Tools
A Pliers 1
C Spring Compressor 1
D Slide Hammer Puller Gp 1
Remove steering pump. Refer to Steering Pump Removal

section.
m
Fo

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service is done on hydraulic system.

in
Make sure all attachments have been

lowered, oil is cool before removing any
components or lines. Remove oil filler cap
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only when engine is stopped, and filler cap

is cool enough to touch with bare hand.
rn

al

u

se
and mandates.
should be thoroughly cleaned. This will help
on

FIG. 149: Remove bolts (2) and (3) from servo valve (1).
1 2
ly
Remove servo valve (1) from housing (4).
N111612003
FIG. 149
79033095 C Rev. 05-117

FIG. 150: Remove bolts (5) from flange (6).
Remove flange (6) from housing (4).
4
5 6
Fo
N111612004
FIG. 150
FIG. 151: Remove bolts (8) from head (7).
r
Remove head (7) from housing (4). 4

in
Remove coupler (9).

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7
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8
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9
u
se
on
N111612005
FIG. 151
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05-118 79033095 C Rev.

FIG. 152: Remove O-ring seal (10) from head (7).
NOTE: Mark proper orientation of port plate (11) for
installation purposes.
Remove port plate from head (7).
m
parts and/or covers under spring pressure.
Spring force will be released when covers
are removed. 7
Be prepared to hold spring loaded covers
as bolts are loosened.
10
11
Fo
N111612006
FIG. 152
r
FIGS. 153–154: Remove O-ring seal (12) from head (7).

Remove relief valve (13) from head (7). Remove O-ring
7
in
12 13
seal (14) from relief valve (13). 14
13
te
Remove test port (15) from head (7). Remove O-ring seal
(16) from test port (15). 20 22
rn
Remove compensator valve (22) from head (7).

Remove retainer (18) and (20) from compensator valve
(22). Remove spring (19) from compensator valve (22). 14
al
Remove control piston (17) from head (7).

Remove O-ring seal (21) from compensator valve (22).
u
17
15 18 21
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16 19 N111612007
FIG. 153
19
on
17 18 21
20 22
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N111612008
FIG. 154
79033095 C Rev. 05-119

FIG. 155: Remove rotating assembly (23) from housing
(4). 4
23
Fo
N111612009
FIG. 155
FIG. 156: Remove pistons (24) from retainer plate (25).
r
NOTE: Mark location of pistons (24) for assembly

in
purposes. 24
25
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N111612010
FIG. 156
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05-120 79033095 C Rev.

FIG. 157: Remove ball joint (26) from barrel assembly
(27).
26
27
Fo
N111912001
FIG. 157
FIG. 158: Remove spring assembly (28) and shim (29)
r
from barrel assembly (27).

in
28
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29 27
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N111912002
FIG. 158
FIG. 159: Use Tooling (B) to remove retaining ring (30)
ly
from barrel assembly (27).

B
m
parts and/or covers under spring pressure. 27
are removed.
as the bolts are loosened.
30
N111912003
FIG. 159
79033095 C Rev. 05-121

FIG. 160: Remove washers (31) and spring (32) from
barrel assembly (27).
m
are removed.
27 31 32 31
N111912004
FIG. 160
FIG. 161: Remove retaining ring (33) from housing (4).
4
Fo
r in
33
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N111912005
rn
FIG. 161
FIG. 162: Remove seal (34) from housing (4).
al
NOTE: Use Tooling (D) for removal of seal (34).

u se
on
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4
34
N111912006
FIG. 162
05-122 79033095 C Rev.

FIG. 163: Remove retaining ring (35) from housing (4).
Remove shaft assembly (36) and O-ring seal (37) from
housing (4).
4 37
35 36
Fo
N111912007
FIG. 163
FIG. 164: Remove swashplate assembly (38).
r in
38
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N111912008
u
FIG. 164
se
FIG. 165: Remove slide (39), two rods (40), and two
bearings (41).
40
39
on
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41
N111912009
FIG. 165
79033095 C Rev. 05-123

FIG. 166: Remove two bearings (42).
42
Fo
N111912010
FIG. 166
FIG. 167: Remove plug assembly (44) and joint pin (43).
r
Repeat Step for the opposite side.

in
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44
rn
43
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N111912011
u
FIG. 167
se
FIG. 168: Remove four bolts (45) and servo valve (46).
on
45
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46
N111912012
FIG. 168
05-124 79033095 C Rev.

FIG. 169: Use Tooling (A) and a suitable press to
remove retaining ring (47).
A
m
are removed.
47
N111912013
FIG. 169
FIG. 170: Use Tooling (C) and a suitable press to

remove ring assembly (48).
Fo
48
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N111912014
rn
FIG. 170
FIG. 171: Remove spring retainer (49). Remove springs
al
(50), (51), and (52). Remove spring retainer (53).

50 51 52 53
49
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N111912015
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FIG. 171
FIG. 172: Remove nut (54) and cover (55).
NOTE: Measure nut (54) for installation.
55
54
N111912016
FIG. 172
79033095 C Rev. 05-125

FIG. 173: Remove O-ring seal (56) from cover (55).
55
56
N111912017
FIG. 173
FIG. 174: Use Tooling (A) and a suitable press to
remove retaining ring (57).
A 57
Fo
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N111912018
FIG. 174
rn
FIG. 175: Remove O-ring seal (58) and ring assembly

(59). Remove spring retainer (60). Remove springs (61),
al
(62), and (64). Remove spring retainer (63) and rod (65). 61 65
60
u
64
se
59 63
62
on
58
N111912019
FIG. 175
ly
FIG. 176: Remove four bolts (66) and cover (67).
66
67
N111912020
FIG. 176
05-126 79033095 C Rev.

FIG. 177: Remove O-ring seal (68) from cover (67).
67
68
N112012001
FIG. 177
FIG. 178: Remove guide ring (69) and ring (70).
70
69
Fo
r in
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N112012002
FIG. 178
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79033095 C Rev. 05-127

Steering Pump Assembly
Required Tools
Tools Part Description Qty
A Pliers 1
C Spring Compressor 1
D Shrink Tubing 1
E Alignment Plug 1
F Test Ring 1
G Measuring Bell 1
H Measuring Hub 1
Fo
I Driver Gp 1

r

in

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replacement.
rn
FIG. 179: Install ring (70) and guide ring (69).

al
70
69
u se
on
N112012002
FIG. 179
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FIG. 180: Install O-ring seal (68) to cover (67).
67
68
N112012001
FIG. 180
05-128 79033095 C Rev.

FIG. 181: Install cover (67) and four bolts (66).
66
67
N111912020
FIG. 181
FIG. 182: Install spring retainer (63) and rod (65). Install
springs (61), (62), and (64). Install spring retainer (60).
Install O-ring seal (58) and ring assembly (59). 61 65
m
Fo
WARNING: Improper assembly of parts

that are spring loaded can cause bodily
60
injury.
64
r
To prevent possible injury, follow the 59 63

established assembly procedure and wear
in
protective equipment. 62
58
te
N111912019
FIG. 182
rn
FIG. 183: Use Tooling (A) and a suitable press to install

al
retaining ring (57).

A 57
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on
N111912018
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FIG. 183
FIG. 184: Install O-ring seal (56) to cover (55).
55
56
N111912017
FIG. 184
79033095 C Rev. 05-129

FIG. 185: Install cover (55) and nut (54).
55
54
N111912016
FIG. 185
FIG. 186: Install spring retainer (53). Install springs (50),
(51), and (52). Install spring retainer (49).
m
WARNING: Improper assembly of parts 50 51 52 53
Fo
that are spring loaded can cause bodily 49

injury.
To prevent possible injury, follow the
r

protective equipment.
in
te
N111912015
FIG. 186
rn
FIG. 187: Use Tooling (C) and a suitable press to Install

al
ring assembly (48).
C
u
48
se
on
N111912014
ly
FIG. 187
FIG. 188: Use Tooling (A) and a suitable press to install
A
m
are removed.
47
N111912013
FIG. 188
05-130 79033095 C Rev.

FIG. 189: Install servo valve (46) and four bolts (45).
45
46
N111912012
FIG. 189
FIG. 190: Install two bearings (42).
Fo
42
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N111912010
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FIG. 190
se
FIG. 191: Install two bearings (41), two rods (40), and
slide (39).
40
39
on
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41
N111912009
FIG. 191
79033095 C Rev. 05-131

FIG. 192: Install swashplate assembly (38).
38
N111912008
FIG. 192
FIG. 193: Install joint pin (43) and plug assembly (44).
Repeat Step for the opposite side.
Fo
44
r
43
in
te
N111912011
FIG. 193
rn
FIG. 194: Install Tooling (D) over shaft assembly (36) to

protect the shaft during installation. Install shaft assembly
al
(36) and O-ring seal (37) to housing (4). Remove Tooling

(D) after installation.
Install retaining ring (35) to housing (4).
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on
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4 37
35 36
N111912007
FIG. 194
05-132 79033095 C Rev.

FIG. 195: Use Tooling (I) to install seal (34) to housing
(4).
4
34
N111912006
FIG. 195
Fo
FIG. 196: Install retaining ring (33) to housing (4).
4
r in
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33
rn
N111912005
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FIG. 196
FIG. 197: Install washer (31), spring (32) and washer
(31) in barrel assembly (27).
u
30
m
WARNING: Improper assembly of parts 31
se

injury.
To prevent possible injury, follow the 27
on
Install retaining ring (30). 32

ly
Use the following steps to determine the correct shim

N112012003
thickness on the rotating group.
FIG. 197
FIG. 198: Determining shim thickness.
a. Place port plate (11) onto a surface plate. The flat
side of the port plate should rest on the surface plate. 11
N112012004
FIG. 198
79033095 C Rev. 05-133

FIG. 199: Installing tooling.
b. Place Tooling (E) on the inside diameter of port plate E
(11). The chamfered side faces upward. 11
N112012005
FIG. 199
FIG. 200: Installing barrel assembly.
c. Install barrel assembly (27) onto Tooling (E) and port
plate (11).
Fo
r
11
27
in
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N112012006
FIG. 200
rn

al
d. Install Tooling (F) on top of the barrel assembly (27),

as shown. F 27
u se
on
N112012007
FIG. 201
ly
FIG. 202: Installing ball joint.

e. Make sure that all the springs and shims have been
removed from ball joint (26). Install the ball joint over
Tooling (F). 26 27
N112012008
FIG. 202
05-134 79033095 C Rev.

FIG. 203: Installing retainer plate.
f. Install retainer plate (25) onto ball joint (26). 26
25
N112012009
FIG. 203
FIGS. 204–205: Tooling assembly.
g. Bolt Tooling (G) and Tooling (H) together. Place
Tooling (G) and (H) on top of the retainer plate (25),
H
Fo
as shown.
G
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N112012010
FIG. 204
rn
H
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G 25
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on
N112012011
FIG. 205
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FIG. 206: Measuring tool.

h. Use a Vernier scale or a similar tool to measure the
dimension in Step i below.
g00875881
FIG. 206
79033095 C Rev. 05-135

FIG. 207: Measurement.
i. Measure distance from top of surface plate to top of
Tooling (G). Record dimension as Dimension (X).
Measure distance from top of Tooling (G) to top of
retainer plate (25). Record dimension as Dimension
(W).
CALCULATION
Subtract Dimension (W) from Dimension (X) to obtain
Dimension (Y).
Dimension (Y) is the Lift-Off Height. g00586062
FIG. 207
NOTE: Correct Lift-Off height is 131.0+0.0−0.2 mm
(5.1575+0.0−0.0079 in) for standard machines.
Call this height Dimension (Z).
Fo
CALCULATION
Subtract Dimension (Y) from Dimension (Z) to obtain
thickness of shim (66). This will provide the correct
r
Lift Off Height.

in
FIG. 208: Installing shims.

te
Install shim (29). Refer to previous steps for correct size.

Install springs (28) into barrel assembly (27) in correct 28
sequence.
rn
29 27
al
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on
N111912002
ly
FIG. 208
05-136 79033095 C Rev.

FIG. 209: Install ball joint (26) on the shim and barrel
assembly (27).
26
27
Fo
N111912001
FIG. 209
FIG. 210: Install pistons (24) and retainer plate (25).
r in
24
25
te
rn
al
u se
on
N111612010
FIG. 210
FIG. 211: Preparing for installing rotating assembly.
ly
Wrap a piece of nylon string around pistons, as shown.
g00875902
FIG. 211
79033095 C Rev. 05-137

FIG. 212: Lower rotating assembly (23) into the pump.
Use the nylon string to hold the assembly together during
installation. Remove the nylon string. 23
N112012012
FIG. 212
FIGS. 213–214: Installing valves in head.
7
m
13
14
Fo
injury. 13
To prevent possible injury, follow the 20 22
r
in
Install O-ring seal (21) to compensator valve (22). 14

Install piston (17) to head (7).
te
Install retainer (18) to compensator valve (22). Install

spring (19) to compensator valve (22). Install retainer (20) 17
rn
to compensator valve (22). 15 18 21

16 19 N111612007
Install compensator valve (22) to head (7).
al
FIG. 213
Install O-ring seal (16) to test port (15). Install test port
(15) to head (7). 19
17 18 21
u
Install O-ring seal (14) to relief valve (13). Install relief 20

valve (13) to head (7). 22
se
Install O-ring seal (12) to head (7).

on
ly
N111612008
FIG. 214
05-138 79033095 C Rev.

FIG. 215: Install port plate (11) to head (7).
Install O-ring seal (9) to head (7).
10
11
Fo
N111612006
FIG. 215
FIG. 216: Install coupler (9).
r
Install head (7) to housing (4). 4

in
Install bolts (8) to head (7).

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7
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8
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9
u se
on
N111612005
FIG. 216
ly
79033095 C Rev. 05-139

FIG. 217: Install flange (6) to housing (4).
Install bolts (5) to flange (6).
4
5 6
Fo
N111612004
FIG. 217
FIG. 218: Install servo valve (1) to housing (4).
r
Install bolts (2) and (3) to servo valve (1). 1 2

in
End By:
te
a. Install steering pumps. Refer to Disassembly and

Assembly Steering Pump - Install.
3
rn
al
use
4
on
N111612003
FIG. 218
ly
05-140 79033095 C Rev.

Steering Pump Installation
FIG. 219: Support steering pump (1) with an appropriate
lifting device and mount steering pump to pump drive (2)
with four bolts (3).
Slide pump straight into pump drive to engage drives. 2
NOTE: Cleanliness is an important factor. Before 1
in cleaning fluid. Allow the parts to air dry. Wiping 3
replacement. P082012009
FIG. 219
FIG. 220: Connect filter line (1) to T1-port of steering
pump.
Fo
r in
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1
rn
P082012008
FIG. 220
al
FIG. 221: Connect filter line (1) to T2-port of steering

pump.
1
u se
on
ly
P082012007
FIG. 221
FIG. 222: Connect pressure hoses (1) to steering pump.
Connect wire harness (2) to steering pump.
Fill steering pump with clean hydraulic oil.
Fill hydraulic system with approved oil. Refer to Operation 1
and Maintenance Manual Hydraulic System Oil - Change
for the correct procedure.
Install Scavenge Pump. Refer to Scavenge Pump
Installation section for more information. 2
P082012006
FIG. 222
79033095 C Rev. 05-141

STEERING MOTOR
FIG. 223: Steering motor (1) is located on top of
transmission below intermediate valve stack.
Steering Motor Removal
m
hydraulic oil pressure and hot oil. 1
P082012010
FIG. 223
Fo

r

in

te

rn

al

u
and on all tubes for installation purposes. Plug all

lines, hoses, and tubes. This helps to prevent
se
fluid loss and this helps to keep contaminants

FIG. 224: Drain any hydraulic oil into a suitable container
for storage or disposal.
on
Remove side guard and disconnect hydraulic hoses (1) to

A- and B-ports.
ly
P082012011
FIG. 224
05-142 79033095 C Rev.

FIG. 225: Disconnect hydraulic line (1).
P082012013
FIG. 225
FIG. 226: Disconnect hydraulic hose (1) to steering
motor.
Disconnect wiring harness from steering speed sensor
Fo
(2).
1
2
r in
te
P082012012
FIG. 226
rn
FIG. 227: Remove four bolts (1) holding steering motor

to transmission and remove steering motor.
al
u
1
se
on
P082012014
FIG. 227
ly
79033095 C Rev. 05-143

Steering Motor Disassembly
Required Tools
A Retaining Ring Pliers 1
B Bolt 1
C Crossblock 1
D Retaining Ring Pliers 1
E Bearing Puller Gp 1
F Shrink Tubing 1
Start By:
a. Remove steering motor. Refer to Disassembly and
Fo
Assembly Steering Motor - Remove.

r

in

te

and mandates.
rn

al

FIG. 228: Removing head.
u
1. Mark head and housing for proper alignment during

reassembly. Remove bolts (2) from housing (1).
se
Remove head (3).

2. Remove speed sensor.
on
ly
2 3
1
N112112003
FIG. 228
05-144 79033095 C Rev.

FIG. 229: Removing flushing valve plate.
3. Remove O-ring seal (4). Mark position of flushing
valve plate (5) for installation purposes. Remove
flushing valve plate. 4
N112112004
FIG. 229
FIG. 230: Removing washer.
4. Remove washer (6).
Fo
6
r in
te
N112112005
FIG. 230
rn
FIG. 231: Removing pin.

al
5. Use suitable Tooling to remove pin (7).

7
u se
on
N112112006
FIG. 231
ly
FIG. 232: Removing spring.

6. Remove spring (8). 8
N112112007
FIG. 232
79033095 C Rev. 05-145

FIG. 233: Removing spring holder.
7. Use a pair of needle nose pliers to remove spring
holder (9).
8. Repeat Step 4 through Step 6 on the other side.
N112112008
FIG. 233
FIG. 234: Removing center pin.
9. Use suitable Tooling to remove center pin (10).
Fo
10
r in
te
N112112009
FIG. 234
rn

al
10. Install Tooling (B).

u
B
se
on
N112112010
FIG. 235
ly
FIG. 236: Removing retaining ring.

11. Use Tooling (A) to remove retaining ring (11).
11
N112112011
FIG. 236
05-146 79033095 C Rev.

FIG. 237: Removing cover.
12. Remove cover (12). 12
N112112012
FIG. 237
FIG. 238: Removing shaft seal.
13. Remove shaft seal (13).
Fo
r
13
in
te
N112112013
FIG. 238
rn
FIG. 239: Removing O-ring.

al
14. Remove O-ring seal (14).

u
14
se
on
N112112014
FIG. 239
ly
FIG. 240: Removing shims.

15. Remove shims (15).
15
N112112015
FIG. 240
79033095 C Rev. 05-147

16. Install Tooling (C). Install Tooling (F).
N112112016
FIG. 241
FIG. 242: Removing rotating group.
17. Remove rotating group from housing (1). 1
Fo
r in
te
N112112017
FIG. 242
rn
FIG. 243: Removing barrel.

al
18. Remove Tooling (B). Remove barrel (16).
B
u se
on
16
N112112018
FIG. 243
ly
FIG. 244: Removing spring and shim.

19. Remove spring (17) and shim (18) from barrel (16). 16
17 18
N112612001
FIG. 244
05-148 79033095 C Rev.

FIG. 245: Removing screws.
20. Remove screws (19) from retainer plate (20).
19
20
N112612002
FIG. 245
FIG. 246: Removing pistons.
21. Remove pistons (21) from retainer plate (20). 20
Fo
r in
21
te
N112612003
FIG. 246
rn
FIG. 247: Remove piston rings.

al
22. Break out piston rings (22). 22

21
u
se
on
N112612004
FIG. 247
ly
FIG. 248: Removing shim and center pin.

23. Remove shim (23) and center pin (24).
23
24
N112612005
FIG. 248
79033095 C Rev. 05-149

FIG. 249: Remove retaining ring.
24. Use Tooling (D) to remove retaining ring (25).
25
N112612006
FIG. 249
FIG. 250: Removing bearings.
25. Use Tooling (E) to remove bearing (26) and bearing 26
(27) from shaft (28).
28
Fo
27
r
E
in
te
N112612007
FIG. 250
rn
al
u se
on
ly
05-150 79033095 C Rev.

Steering Motor Assembly
Required Tools
A Retaining Ring Pliers 1
B Bolt 1
C Crossblock 1
D Retaining Ring Pliers 1
E Measuring Tool 1
F Driver Group 1
G Shrink Tubing 1
NOTE: Install all components in original locations.

Fo
NOTE: Internal components of piston pump are

machined to fine tolerances. Be sure to protect
surfaces of these components during
r
maintenance procedure.
in
NOTE: Replace all O-ring seals and gaskets. Apply a

light film of 10W oil to all components before
assembly.
te

rn

al

trouble later. Inspect all parts. If any parts are
replacement. All disassembly and all assembly
u
procedures must be performed on a clean work

se
surface and in a clean hydraulic area. Keep

cleaned parts covered and protected at all times.
FIG. 251: Use a suitable press to install bearing (26) and
bearing (27) on shaft (28).
on
26
ly
27
28
N112612008
FIG. 251
79033095 C Rev. 05-151

FIG. 252: Use Tooling (D) to install retaining ring (25).
Following steps are necessary to select thickness of shim
(17). Thickness of shim determines lift off limitation at
various displacement angles.
25
N112612006
FIG. 252
FIG. 253: Install shim (23) and center pin (24).
Fo
23
r in
24
te
N112612005
FIG. 253
rn
FIG. 254: Install new piston rings (22). Heat piston rings
to 80 degrees C (176 degrees F). Lower temperature of
al
piston.
22
NOTE: Piston rings are marked. Marking must be visible 21
from piston end.
u se
on
N112612004
FIG. 254
ly
FIG. 255: Install pistons (21) into retainer plate (20).
20
21
N112612003
FIG. 255
05-152 79033095 C Rev.

FIG. 256: Install screws (19) to secure retainer plate
(20). Tighten to a torque of 14 to 17 Nm (10 to 12.5 lbf ft).
19
20
N112612002
FIG. 256
FIG. 257: Install spring (17) into barrel (16).
17
Fo
16
r in
te
N112612009
FIG. 257
rn
FIG. 258: Install barrel (16). Install Tooling (B) to secure

barrel.
al
B
u se
on
16
N112112018
FIG. 258
ly
FIG. 259: Install rotating group into housing (1).

NOTE: Raise temperature of housing (1) to 80 degrees 1
C (176 degrees F). Lower temperature of rotating
group.
N112112017
FIG. 259
79033095 C Rev. 05-153

FIG. 260: Remove Tooling (B).
N112612010
FIG. 260
FIG. 261: Install shims (15).
Fo
15
r in
te
N112112015
FIG. 261
rn
FIG. 262: Install O-ring seal (14).

al
u
14
se
on
N112112014
FIG. 262
ly
FIG. 263: Use Tooling (F) and a soft hammer to install

seal (13).
13
N112612011
FIG. 263
05-154 79033095 C Rev.

FIG. 264: Install cover (12) and retaining ring (11).
NOTE: Pull rotating group outward until end stop is
reached.
11
12
N112112011
FIG. 264
FIG. 265: Install center pin (10).
Fo
10
r in
te
N112112009
FIG. 265
rn
FIG. 266: Use a pair of needle nose pliers to install

spring holder (9).
al
u
se
9
on
N112112008
FIG. 266
ly
FIG. 267: Install spring (8).
m
injury.
To prevent possible injury, follow the
N112112007
FIG. 267
79033095 C Rev. 05-155

FIG. 268: Use suitable Tooling to install pin (7).
Repeat previous steps on other side.
7
N112112006
FIG. 268
FIG. 269: Install washer (6).
Fo
6
r in
te
N112112005
FIG. 269
rn
FIG. 270: Install flushing valve plate (5) in position that

was previously marked for reassembly. 5
al
u se
on
N112612012
FIG. 270
ly
FIG. 271: Measuring shim thickness.

Install Tooling (F). With a depth micrometer, measure
depth to control plate. Take this measurement in more
than one location. Tighten bolt on Tooling (E). E
This will push control plate and cylinder downward.
Continue downward until resistance is met. Do not use
force. Again measure depth to control plate.
Difference between two measurements is correct
thickness of shim (18).
Remove Tooling (F).
N112612013
FIG. 271
05-156 79033095 C Rev.

FIG. 272: Remove flushing valve plate (5).
5
N112612012
FIG. 272
Fo
B
r in
te
N112612010
FIG. 273
rn
FIG. 274: Use Tooling (A) to remove retaining ring (11).

al
11
u se
on
N112112011
FIG. 274
ly
FIG. 275: Remove cover (12).
12
N112112012
FIG. 275
79033095 C Rev. 05-157

FIG. 276: Remove O-ring seal (14).
14
N112112014
FIG. 276
FIG. 277: Remove shims (15).
Fo
15
r in
te
N112112015
FIG. 277
rn
FIG. 278: Install Tooling (C) to remove rotating group.

al
C
u se
on
N112112016
FIG. 278
ly
FIG. 279: Remove rotating group from housing.
N112112017
FIG. 279
05-158 79033095 C Rev.

FIG. 280: Remove Tooling (B) and barrel (16).
16
N112112018
FIG. 280
FIG. 281: Remove spring (17) from barrel (16).
17
Fo
16
r in
te
N112612009
FIG. 281
rn
FIG. 282: Install spring (17) and shim (18) that was
determined in previous step in barrel (16). 16
al
17 18
u
se
on
N112612001
FIG. 282
ly
FIG. 283: Install Tooling (B) to secure barrel (16).
16
N112112018
FIG. 283
79033095 C Rev. 05-159

FIG. 284: Install rotating group into housing (1).
NOTE: Raise temperature of housing (1) to 80 degrees 1
C (176 degrees F). Lower temperature of rotating
group.
N112112017
FIG. 284
Fo
B
r in
16
te
N112112018
FIG. 285
rn
FIG. 286: Install shims (15).

al
Remove Tooling (G) from shaft (28).
15
u se
on
N112112015
FIG. 286
ly
FIG. 287: Install O-ring seal (14).
14
N112112014
FIG. 287
05-160 79033095 C Rev.

FIG. 288: Install cover (12). Use Tooling (A) to install
NOTE: Pull rotating group outward until end stop is
reached. 11
N112112011
FIG. 288
FIG. 289: Install O-ring seal (4). Install flushing valve
plate (5) in position previously marked for reassembly.
Fo
4
r
5
in
te
N112112004
FIG. 289
rn
FIG. 290: Install head (3). Install bolts (2). Turn shaft and
tighten bolts at same time. Tighten bolts (2) to 48 Nm (35
al
lbf ft).
Install speed sensor.
u
End By: Install steering motor. Refer to Disassembly and

Assembly Steering Motor - Install.
se
on
ly
2 3
1
N112112003
FIG. 290
79033095 C Rev. 05-161

Steering Motor Installation
FIG. 291: Mount steering motor with new O-ring to
transmission with four bolts (1).
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts. 1
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.
P082012014
FIG. 291
FIG. 292: Connect hydraulic hose (1) to steering motor.
Fo
Connect wiring harness to steering speed sensor (2).

r
1
2
in
te
rn
P082012012
FIG. 292
al
FIG. 293: Connect hydraulic line (1).

u
1
se
on
ly
P082012013
FIG. 293
FIG. 294: Connect hydraulic hoses (1) to A- and B-ports.
Install side guards.
Fill steering motor with clean hydraulic oil.
Fill hydraulic system with approved oil. Refer to Operation
and Maintenance Manual Hydraulic System Oil - Change 1
for correct procedure.
P082012011
FIG. 294
05-162 79033095 C Rev.

SECONDARY STEERING VALVE
ACTUATOR (CE ONLY)
FIG. 295: Secondary steering valve actuator (1) is
mounted to bottom of cab.
NOTE: Cab wall is transparent for clarity.
Secondary Steering Valve Actuator 1

Removal
m
stopped. Serious injury can be caused if P082112001
this pressure is not released before any FIG. 295
service is done hydraulic system.
Fo
Make sure all implements have been

lowered to ground, and oil is cool before
removing any components or lines.
r
Remove oil filler cap only when engine is

stopped, and the filler cap is cool enough to
in
touch with bare hand.

te

rn

al

u

se

NOTE: Put identification marks on all hoses for
installation purposes. Plug all the hoses. This
on
helps to prevent fluid loss and keep contaminants

FIG. 296: Disconnect inlet hose (1) and common sump
ly
hose (2).
Disconnect brake hoses (3) from actuator. 3
P082112002
FIG. 296
79033095 C Rev. 05-163

FIG. 297: Remove three bolts (1) holding steering
actuator (2) and gasket (3) to cab. 3
P082112003
FIG. 297
Secondary Steering Valve Actuator

Installation
Fo
FIG. 298: Mount steering actuator (1) and gasket (2) to

cab with three bolts (3). 2
r
assembly, all parts should be thoroughly cleaned 1

in

te

replacement. 3
rn
NOTE: Cab wall is transparent for clarity.

P082112003
al
FIG. 298
FIG. 299: Connect inlet hose (1) and common sump
hose (2).
u
Connect brake hoses (3) from actuator. 3

se
1
on
2
ly
P082112002
FIG. 299
05-164 79033095 C Rev.

SOLENOID VALVE - SECONDARY
STEERING (CE ONLY)
FIG. 300: Solenoid valve (1) for secondary steering is
located on right-hand side of machine beneath front
corner of cab.
Solenoid Valve - Secondary Steering 1

Removal
m
P082112004
service is done on hydraulic system. FIG. 300
Fo

r
stopped, and filler cap is cool enough to

in

te

rn

containing fluids.
al

u

se

and keep contaminants from entering system.
on
FIG. 301: Coil (1) can be removed from solenoid valve

without removing valve assembly from machine by 2
ly
disconnecting electrical connector (2) from basic coil

assembly and removing nut (3) from solenoid valve 1
sleeve. Slide basic coil assembly from valve sleeve.
P082112004
FIG. 301
79033095 C Rev. 05-165

FIG. 302: Disconnect electrical connector (1) from
solenoid (2). 3
Disconnect hydraulic line (3) from fitting in G2-port. 1
2
P082112005
FIG. 302
FIG. 303: Disconnect hose (1) from port-4 of solenoid
valve.
3
Disconnect hose (2) from fitting in port-1.
Fo
Disconnect hose (3) from fitting in port-2.

2
r in
te
1
P082112006
FIG. 303
rn
FIG. 304: Disconnect hose (1) from fitting in port-3.

al
Disconnect hose (2) from fitting in POUT-port. 2

u
se
1
on
P082112007
FIG. 304
ly
FIG. 305: Disconnect hydraulic hose (1) from fitting in

T-port.
Remove two bolts (2) holding valve and mounting bracket
to chassis.
2
1
P082112008
FIG. 305
05-166 79033095 C Rev.

Solenoid Valve - Secondary Steering
Installation
replacement.
FIG. 306: Mount valve and mounting bracket to chassis
with two bolts (1).
Connect hydraulic hose (2) from fitting in T-port.
1
Fo
r
2
in
P082112008
FIG. 306
te
FIG. 307: Connect hose (1) to fitting in port-3.

Connect hose (2) to fitting in POUT-port. 2
rn
al
u
1
se
P082112007
FIG. 307
on
FIG. 308: Connect hose (1) to port-4 of solenoid valve.

Connect hose (2) to fitting in port-1. 3
ly
Connect hose (3) to fitting in port-2.
1
P082112006
FIG. 308
79033095 C Rev. 05-167

FIG. 309: Connect wiring harness to connector (1) on
solenoid (2). 3
Connect hydraulic line (3) to fitting in G2-port. 1
2
P082112005
FIG. 309
FIG. 310: If removed, slide basic coil assembly (1) onto
valve sleeve. Install nut (2) onto solenoid valve sleeve to 3
retain basic coil assembly. Tighten nut to 7 Nm (5 lbf ft).
1
Fo
Connect electrical connector (3) to basic coil assembly.

r
2
in
te
P082112004
FIG. 310
rn
al
u se
on
ly
05-168 79033095 C Rev.

BRAKE VALVE ASSEMBLY
FIG. 311: Brake valve (1) is mounted to a bracket
attached to transmission below drive shaft.
Brake Valve Assembly Removal
m
hydraulic system after the engine has been
1
P082112009
FIG. 311
Fo


r

in

te

containing fluids.
rn

al

u

se

FIG. 312: Remove clip-pin (1) holding rod end to shaft
(2).
2
on
1
ly
P082112010
FIG. 312
79033095 C Rev. 05-169

FIG. 313: Disconnect hoses (1) from Tee-fitting in P-port.
Disconnect hoses (2) from Tee-fitting in A-port.
2
P082112011
FIG. 313
FIG. 314: Disconnect hydraulic line (1) from T-port.
1
Fo
r in
te
P082112012
FIG. 314
rn
FIG. 315: Remove two bolts (1) holding brake valve

assembly to bracket.
al
u se
on
1
P082112013
FIG. 315
ly
05-170 79033095 C Rev.

Brake Valve Assembly Installation
FIG. 316: Mount brake valve assembly to bracket with
two bolts (1).
replacement.
1
P082112013
FIG. 316
FIG. 317: Connect hydraulic line (1) to T-port.
Fo
1
r in
te
rn
P082112012
FIG. 317
al
FIG. 318: Connect hoses (1) to Tee-fitting in P-port.

Connect hoses (2) to Tee-fitting in A-port.
2
u se
on
1
ly
P082112011
FIG. 318
FIG. 319: Install clip-pin (1) holding rod end to shaft (2).
P082112010
FIG. 319
79033095 C Rev. 05-171

BRAKE ACCUMULATOR
FIG. 320: Brake accumulator (1) is mounted to a cross
member below drive shaft.
1
Brake Accumulator Removal
m
P082112014
Make sure all of the implements have been
FIG. 320
Fo


r

in

te

rn

al

u

se

Release pressure in brake accumulator by depressing
brake pedal 30 times with engine off to discharge
on
accumulator.
FIG. 321: Disconnect sensor (1).
ly
Disconnect hydraulic hose (2) from Tee-fitting.

Loosen bolts (3) and remove accumulator. 3
2
P082112015
FIG. 321
05-172 79033095 C Rev.

Brake Accumulator Installation
replacement.
FIG. 322: Install accumulator into clamp and tighten bolt
(2).
Connect hydraulic hose (2) from Tee-fitting. 1
Connect sensor (3).
2
Charge brake accumulator.
3
Fo
r
P082112015
in
FIG. 322
te
rn
al
u se
on
ly
79033095 C Rev. 05-173

SECONDARY BRAKE VALVE (CE ONLY)
FIG. 323: Secondary brake valve (1) is mounted on
left-hand side of chassis above pumps.
Secondary Brake Valve Removal
m
stopped. Serious injury can be caused if 1
pressure is not released before any service
is done on hydraulic system.
P082112018
Make sure all implements have been FIG. 323
Fo


r

in

te

rn

al

u

se
hoses, and tubes. This helps to prevent fluid low

and this helps to keep contaminants from
FIG. 324: Disconnect hydraulic hose (1) to fitting in
on
T-port. 2
Disconnect hydraulic line (2) to Tee-fitting in B-port.
ly
P082112018
FIG. 324
05-174 79033095 C Rev.

FIG. 325: Remove cotter pin from clevis pin (1).
Remove two bolts (2) holding valve to bracket and remove
valve. 2
1
P082112019
FIG. 325
Secondary Brake Valve Installation

Fo

r

in
replacement.
FIG. 326: Mount valve to bracket with two bolts (1).
te
Install clevis pin (2) into valve rod end and secure with
cotter pin. 1
rn
al
u se
2
P082112019
FIG. 326
on
FIG. 327: Connect hydraulic hose (1) to fitting in T-port.

2
Connect hydraulic line (2) to Tee-fitting in B-port.
ly
P082112018
FIG. 327
79033095 C Rev. 05-175

AIR TRAILER BRAKE VALVE
FIG. 328: Air trailer brake valve (1) is mounted on
left-hand side of chassis above pumps.
Air Trailer Brake Valve Removal
m
hydraulic oil pressure and hot oil. 1
P082112016
FIG. 328
removing components or lines. Remove oil
filler cap only when engine is stopped, and
Fo
filler cap is cool enough to touch with bare

hand.

r

in

te

rn

al

u

se

FIG. 329: Disconnect air lines (1) from port-1 and port-2
of air valve.
on
Disconnect hydraulic hose (2) from port-41.

ly
2
P082112017
FIG. 329
05-176 79033095 C Rev.

FIG. 330: Disconnect hydraulic line (1) from valve
actuator (2).
2
Remove clevis pin (3) holding actuator arm to valve.
3
P082112020
FIG. 330
FIG. 331: Remove four bolts (1) holding valve assembly
bracket to chassis.
Fo
r
1
in
te
P082112021
FIG. 331
rn
al
u se
on
ly
79033095 C Rev. 05-177

Air Trailer Brake Valve Installation
replacement.
FIG. 332: Mount valve assembly bracket to chassis with
four bolts (1).
Fo
1
r
P082112021
in
FIG. 332
FIG. 333: Connect hydraulic line (1) to valve actuator (2).
te
Install clevis pin (3) connecting actuator arm to valve. 2

rn
1
al
u
3
se
P082112020
FIG. 333
FIG. 334: Connect air lines (1) to port-1 and port-2 of air
on
valve.
Connect hydraulic hose (2) to port-41.
ly
2
P082112017
FIG. 334
05-178 79033095 C Rev.

HYDRAULIC TRAILER BRAKE VALVE
(OPTIONAL)
FIG. 335: Hydraulic trailer brake valve is mounted on
bottom of intermediate valve stack (1).
Hydraulic Trailer Brake Removal 1
m
this pressure is not released before service
is done on hydraulic system.
P082212001
FIG. 335
removing components or lines. Remove oil
Fo
filler cap only when engine is stopped, and

filler cap is cool enough to touch with bare
hand.
r

in

te

rn

al

u

se

hoses, and tubes. This helps to prevent fluid loss
on
FIG. 336: Disconnect drain hoses (1) to stack.

Disconnect wiring harness (2) from solenoids.
ly
P082212002
FIG. 336
79033095 C Rev. 05-179

FIG. 337: Disconnect hydraulic hoses (1) to steerable
hitch valve, if equipped.
P082212003
FIG. 337
FIG. 338: Disconnect hydraulic line (1) from supply port
of priority valve.
Disconnect hydraulic hose (2) from rear remote supply
2
Fo
port of priority valve.

1
r in
te
P082212004
FIG. 338
rn
FIG. 339: Disconnect hydraulic hose (1) from load sense

port.
al
1
u se
on
P082212005
FIG. 339
ly
FIG. 340: Disconnect hydraulic line (1) from return port.

1
P082212006
FIG. 340
05-180 79033095 C Rev.

FIG. 341: Disconnect hydraulic hose (1) from Tee-fitting
in brake charge port.
1
Disconnect hydraulic line (2) from brake signal port.
Disconnect hydraulic line (3) from tank port.
2
P082212007
FIG. 341
FIG. 342: Disconnect hydraulic hose (1) from brake
supply port.
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1
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P082212008
FIG. 342
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FIG. 343: Remove bolt (1) holding clamp to valve stack

mount.
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P082212009
FIG. 343
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FIG. 344: Support intermediate valve stack with an

appropriate lifting device and remove two bolts (1) holding
bracket (2).
Remove bolt (3) holding valve stack bracket to 2 3
transmission and remove valve stack. 1
P082212010
FIG. 344
79033095 C Rev. 05-181

FIG. 345: Remove three bolts (1) holding mounting plate
(2) to bottom of valve stack.
2
1
P082212011
FIG. 345
FIG. 346: Remove four nuts holding stack together and
remove top section (1), steerable hitch valve (2), priority
valve (3) and trailer brake valve (4) from studs.
1 2
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3
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4
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P082212012
FIG. 346
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05-182 79033095 C Rev.

Hydraulic Trailer Brake Installation
replacement.
FIG. 347: Install trailer brake valve (1), priority valve (2),
steerable hitch valve (3) and top section (4) onto studs
and secure with four nuts.
4 3
2
Fo
1
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P082212012
in
FIG. 347
FIG. 348: Attach mounting plate (1) to bottom of valve
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stack with three bolts (2).

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1
1
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P082212011
FIG. 348
FIG. 349: Support intermediate valve stack with an
on
appropriate lifting device and bolt valve stack bracket to

transmission with bolt (1) and spacer.
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Secure bracket (2) and valve stack mount with two bolts 2 1
(3). 3
FIG. 349
79033095 C Rev. 05-183

FIG. 350: Secure clamp to valve stack mount with bolt
(1).
P082212009
FIG. 350
FIG. 351: Connect hydraulic hose (1) to brake supply
port.
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1
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P082212008
FIG. 351
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FIG. 352: Connect hydraulic hose (1) to Tee-fitting in

brake charge port.
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1
Connect hydraulic line (2) to brake signal port.
Connect hydraulic line (3) to tank port.
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2
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3
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P082212007
FIG. 352
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FIG. 353: Connect hydraulic line (1) to return port.

1
P082212006
FIG. 353
05-184 79033095 C Rev.

FIG. 354: Connect hydraulic hose (1) to load sense port.
P082212005
FIG. 354
FIG. 355: Connect hydraulic line (1) to supply port of
priority valve.
Connect hydraulic hose (2) to rear remote supply port of
2
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priority valve.
1
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P082212004
FIG. 355
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FIG. 356: Connect hydraulic hoses (1) to steerable hitch

valve, if equipped.
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P082212003
FIG. 356
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FIG. 357: Connect drain hoses (1) to stack.

Connect wiring harness (2) to solenoids.
Fill hydraulic system with approved oil. 1
P082212002
FIG. 357
79033095 C Rev. 05-185

NOTES
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05-186 79033095 C Rev.

Steering and Brake Testing and Adjusting
STEERING AND BRAKE TESTING AND ADJUSTING

INFORMATION
Machine Preparation
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machine.

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2. Lower all implements and three-point hitch to ground.

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position.
in
(140 degrees F), if necessary. See Warming the

Hydraulic Oil for procedure.
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rn

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Testing and Adjusting Procedure

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When defining a problem in any hydraulic system,

following procedure should be followed:
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Inspection. If visual inspection is completed and problem
is not identified, perform mechanical system tests. If
on
mechanical system tests are completed and problem is

not identified, perform electrical system tests.
Since more than one cause may exist for a problem,
ly
troubleshooting section may suggest specific inspections

identify most probable cause.
Test Equipment
• Digital Pressure Indicator
79033095 C Rev. 05-187

FIGS. 358–359: If necessary, install hose assembly into
(+) quick coupler and (-) quick coupler of any hydraulic
control valve. Place hydraulic control lever in Extend
Detent position. Adjust needle valve accordingly to heat
hydraulic oil. 1
NOTE: During a diagnosis in any of hydraulic systems,
temperature must be a minimum of 60 degrees C
2
(140 degrees F). Temperature of hydraulic oil can
be viewed on Summary screen of Virtual
Terminal (VT). Q121612001
FIG. 358
Refer to Virtual Terminal (VT) Division, for more
information.
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Troubleshooting Procedure
Use following six steps to begin troubleshooting machine:
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• Know the machine.

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• Understand the symptom.

• Verify the symptom.
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• Determine the probable causes.

• Reduce the list of probable causes.
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g00807309
• Test the system.

FIG. 359
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Use the previous steps to troubleshoot this machine.

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on
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05-188 79033095 C Rev.

Know the Machine Visual Inspection
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Understand operation of machine. Know if symptom is WARNING: Do not check for leaks with
characteristic of normal operation or if symptom is an your hands. Pin hole (very small) leaks can
indication of component failure. result in a high velocity oil stream that will
be invisible close to the hose. This oil can
Read system operation information to understand
systems of machine. Operator must understand Use cardboard or paper to locate pin hole
interaction of systems on machine. leaks.
m
Understand the Symptoms WARNING: Sudden movement of machine
Question operator about problem. or release of oil under pressure can cause
• Ask about performance of machine prior to symptom. machine.
• Determine time of first occurrence of symptoms. To prevent possible injury, perform
Fo
symptom. Determine order of occurrences. Use following procedure to perform a visual inspection.
• Ask operator about steps that have been taken to 1. Move machine to a smooth horizontal location.
troubleshoot machine.
r

3. Make sure transmission control lever is in PARK
in
• Ask about preventive maintenance of machine. Many position.

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Inspect machine. Look for problems. Notice any unusual (140 degrees F).
odors in the air. Listen for unusual noises.
Refer to Testing and Adjusting, General Testing and
rn
Adjusting Information, for more information about

Verify the Symptom warming hydraulic oil.
Operate machine. When possible, repeat conditions that
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5. Move all hydraulic control levers through FLOAT

caused symptom. Check gauges inside cab. Notice any position to relieve hydraulic pressure.
unusual odors in air. Listen for unusual noises.
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Determine the Probable Causes 7. Remove appropriate guards.

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Once information is gathered, create a list of probable Refer to Operations and Maintenance Manual
causes. Determine subsystem that is cause of symptom. Guards - Remove and Install, for more information.
Use list of probable causes in Troubleshooting, Electrical
and Hydraulic Systems, as a guide. 8. Perform following visual inspections.
on
9. Measure oil level.

Reduce the List of Probable Causes
10. Check for air in sump oil. Check immediately after
stopping machine. Check sight gauge at rear of
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List probable causes. Identify probable causes that are

easy to verify. When possible, eliminate probable causes machine next to PTO shaft. Check for air bubbles in
that are easy to check. sight gauge.
11. Remove filter elements. Check for particles removed
Test the System from oil by filter element. Use a magnet to separate
Use operational tests to verify cause of symptom. Once metallic particles from nonmetallic particles. Bronze
cause has been identified, repair suspect component. colored particles indicate clutch failure. Brass
Then, test system again. particles or shiny steel particles indicate pump failure.
Rubber particles indicate seal failure or hose failure.
12. Inspect all oil lines and connections for damage or
leaks.
13. Inspect control linkages for broken or damaged
components.
79033095 C Rev. 05-189

STEERING SYSTEM TESTING AND
ADJUSTING
Relief Valve (Charge) - Test and Adjust

Relief Valve (Charge Pressure) Pressure Test
The following test procedure will verify whether the oil
pressure controlled by relief valve (charge pressure) is
within specified limit. Relief valve limits maximum charge
pressure in hydraulic system.
Undercarriage has been removed for photographic
Required Tools
Fo

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FIG. 360: Table below provides a list of required tools if a

dataview tool group (1) is used to perform following test
in
procedure. A dataview tool group is not shown in following

test procedure.
1
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Dataview Tool Group

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Description Quantity
DataView Tool Gp 1
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Pressure Sensor 1
0 to 6895 kPa (0 to 1000 psi)
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g00787927
FIG. 360
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FIG. 361: Use tools in table below to complete following

test procedure. A1
A2
on

Tool Item Description Quantity A4
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A1 Fitting (Test) 1
A A2 Pressure Gauge 1
A3 Hose Assembly 1 A3
A4
A4 Coupler 1
P012512001
FIG. 361
05-190 79033095 C Rev.

Test Procedure
FIG. 362: Pressure gauge with a hose and coupling are
attached to charge pressure test port of steering pump.
1
m
machine.
IMPORTANT: Care must be taken to ensure that fluids A

are contained during performance of inspection, P012512002
maintenance, testing, adjusting, and repair of FIG. 362
Fo

A pressure gauge is used in following test procedure:
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in

position.
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3. Warm oil to minimum temperature of 55 to 75

degrees C (131 to 167 degrees F).
rn
Refer to Warming the Oil section in General Testing

and Adjusting Information, for more information about
warming hydraulic oil.
al

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Refer to Operation and Maintenance Manual Guards
- Remove and Install.
on
7. Connect tooling (A) to test port (1).

8. Start engine. Run engine at rated speed.
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9. Make sure temperature of hydraulic oil is at least 60

degrees C (140 degrees F) and record pressure
setting of relief valve (charge pressure). Pressure
setting should be 2065 to 2135 kPa (300 to 310 psi).
10. If pressure setting is not within specified limit refer to
Relief Valve (Charge Pressure) Pressure Adjust.
79033095 C Rev. 05-191

Relief Valve (Charge Pressure) Pressure Adjust
Following adjustment procedure will verify whether oil
pressure controlled by relief valve (charge pressure) is
within specified limit. Relief valve limits maximum charge
pressure in hydraulic system.
Required Tools
FIG. 363: Table below provides a list of required tools if
dataview tool group (1) is used to perform following
adjustment procedure.
Dataview Tool Group 1

Fo
DataView Tool Gp 1
r
Pressure Sensor 1
0 to 6895 kPa (0 to 1000 psi)
in
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g00787927
FIG. 363
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test procedure. A1
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A2
A4
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Tool Item Description Quantity

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A1 Fitting (Test) 1
A4
on
A4 Coupler 1
P012512001
FIG. 364
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05-192 79033095 C Rev.

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machine.

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FIGS. 365–366–367: Pressure gauge is used in following

test procedure:
1
r

in
position.
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warming hydraulic oil. A
P012512002
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position to relieve hydraulic pressure. FIG. 365

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6. Remove appropriate guards. 3 2

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Refer to the Operation and Maintenance Manual

Guards - Remove and Install.
7. Install tooling (A) to the test port (1).
on
8. Remove two bolts (2) from cap (3).

9. Remove cap (3).
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10. Start engine. Run engine at rated speed.

P012812001
11. Turn adjusting screw (4) to adjust pressure setting.
Turn adjusting screw clockwise to increase pressure FIG. 366
or counterclockwise to decrease pressure setting.
12. Adjust pressure setting until pressure on tooling (A)
measures 2065 to 2135 kPa (300 to 310 psi).
13. After obtaining correct pressure setting, remove
tooling (A) from test port (1).
14. Install cap (3) by using two bolts (2).
15. Stop engine. 4
P012812002
FIG. 367
79033095 C Rev. 05-193

Steering Pump High Pressure Cutoff
Pressure Test
High Pressure Cutoff Test
Test is performed on machine to check maximum normal
operating pressure for steering system.
Undercarriage for left-hand side has been removed for
photographic purposes.
procedure. 1
Fo
Required Tools (Dataview Tool Group)

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in
DataView Tool Gp 1
Pressure Sensor 1
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0 to 517 bar (0 to 7500 psi)

Pressure Sensor 1
rn
g00787042
0 to 6900 kPa (0 to 1000 psi)
FIG. 368
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pressure gauges will be used to perform following test A1 A3 B1
procedure.
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B2 B3
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A A1 Pressure Gauge 0 to 4,000 1 B4
on
kPa (0 to 580 psi)

A2 Fitting (Test) 1
A4
A3 Coupler 2
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P012812011
A4 Hose Assembly 1
FIG. 369
B B1 Pressure Gauge 0 to 4,000 1
kPa (0 to 580 psi)
B2 Fitting (Test) 1
B3 Coupler 2
B4 Hose Assembly 1
05-194 79033095 C Rev.

m
WARNING: Sudden movement of the
machine or release of oil under pressure
can cause serious injury to persons on or
near the machine.
To prevent possible injury, perform the
adjusting the hydraulic system.

Fo

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in
position.
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Guards - Remove and Install, for more information.
FIG. 370: Port (Mh) location.
on
8. Install tooling (A) to port (Mh) at location (1).

9. Route tooling (A) into cab of machine.
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Mh
T071612001
FIG. 370
79033095 C Rev. 05-195

FIG. 371: Photo of connecting tooling (B) to port (2).
10. Connect tooling (B) to test port (2). 2 B
11. Route tooling (B) into cab of machine.
12. Start engine. Run engine at high idle (2200 rpm).
NOTE: Do not engage pump more than 15 seconds at a
time to prevent overheating.
13. Fully activate service brakes and hold service brakes
in activated position.
14. With engine speed at high idle (2200 rpm) slowly
move steering wheel to Maximum Steer Right P012912002
position. Maximum position puts steering system in a FIG. 371

Steer Stall Condition.
NOTE: Machine must not move. If machine moves,
check brake system.
Fo
a. Record pressure reading from port (Mh) at

location (1) and test port (2).
b. Pressure at port (Mh) should be 454.5 to 465.5
r
bar (6590 to 6750 psi).

c. Pressure at test port (2) should read 2065 to
in
2135 kPa (300 to 310 psi).

15. Add pressure from test port (2) to pressure from port
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(Mh).
16. Repeat Step 14 through Step 15 for Maximum Steer
rn
Left position.
17. If combined pressure for Maximum Steer Left or
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Maximum Steer Right is higher than 475.1 to 486.9

bar (6890 to 7060 psi), lower cutoff pressure.
If combined pressure for Maximum Steer Left or
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Maximum Steer Right is lower than 475.1 to 486.9

se
bar (6890 to 7060 psi), check following possible

causes:
a. Pump cutoff controls are adjusted incorrectly or
failed.
on
b. Motor flushing valve is stuck or malfunctioning.

c. Motor has failed or motor is leaking.
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d. Steering charge pressure is low.

e. Pump has failed or pump is leaking.
f. Crossover relief/makeup valves are set too low or
valves are malfunctioning.
05-196 79033095 C Rev.

Steering Pump High Pressure Cutoff Adjustment
m
result from sudden machine movement.
Sudden movement of machine can cause
injury to persons on or near machine.
To prevent injury or death, make sure that
area around machine is clear of personnel
and obstructions before operating
machine.
NOTE: If machine is on ground, machine could spot turn

during this procedure. Following procedure
should be performed while machine is lifted off
ground.
Refer to Operation and Maintenance Manual,
Undercarriage (Mobil-trac) Gauge Spacing, for correct
procedure for supporting machine off ground.
Fo
Adjustment is performed on pressure override valve to

check maximum normal operating pressure for steering
system.
r
Undercarriage has been removed from left-hand side for

in
Required Tools
te

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procedure. 1
al

u
DataView Tool Gp 1
se
Pressure Sensor 1
0 to 517 bar (0 to 7500 psi)
Pressure Sensor 1 g00787042
on
0 to 6900 kPa (0 to 1000 psi)

FIG. 372

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pressure gauges will be used to perform following test A1 A3 B1

procedure.
B2 B3
A A1 Pressure Gauge 0 to 600 1 B4
bar (0 to 8700 psi)
A2 Fitting (Test) 1
A3 Coupler 2 A4
A4 Hose Assembly 1 P012812011
B B1 Pressure Gauge 0 to 4000 1 FIG. 373

kPa (0 to 580 psi)
B2 Fitting (Test) 1
B3 Coupler 2
B4 Hose Assembly 1
79033095 C Rev. 05-197

m
machine.

Fo
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2 1
3
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4
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5 6 7 8 9
P012912003
FIG. 374
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FIG. 374: Components of High Pressure Cutoff

Adjustment in Steering Pump Port Plate (Front View).
(1) Port-A
(2) Port-B
(3) Locknut
(4) Adjustment Screw
(5) System Pressure
(6) Charge Pressure
(7) Sump
05-198 79033095 C Rev.

FIG. 375: Connect tooling (A) to port (Mh) location.
Mh
T071612001
FIG. 375
FIG. 376: Photo of connecting tooling (B) to port (2).
2 B
Fo
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P012912002
FIG. 376
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79033095 C Rev. 05-199

Use two people to perform following adjustment 14. Fully activate service brakes and hold service brakes
procedure: in activated position.
1. Move machine to a smooth horizontal location. 15. Loosen locknut (3).
2. Lower all implements and three-point hitch to ground. 16. Turn adjustment screw (4) counterclockwise until
adjusting screw is stopped.
position. 17. Turn steering wheel in direction to be adjusted.
4. Warm oil to minimum temperature of 55 to 75 18. Turn adjusting screw (4) clockwise until port (Mh) at
degrees C (131 to 167 degrees F). location (1) is 454.5 to 465.5 bar (6590 to 6590 psi).
Refer to Warming the Oil section in General Testing NOTE: One turn of adjustment screw (4) will change
and Adjusting Information, for more information about pressure 83 bar (1200 psi).
19. Add pressure from test port (2) to pressure at port
5. Move all hydraulic control levers through FLOAT (Mh).
20. If total is 475.1 to 486.9 bar (6890 to 7060 psi), cutoff
6. Stop engine and remove key. pressure is correct.
Fo
7. Put machine on jack stands. 21. Tighten locknut (3).

Undercarriage (Mobil-trac) Gauge Spacing, for
r
correct procedure for supporting machine off ground.

in

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9. Install tooling (A) to port (Mh) at location (1).

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11. Connect tooling (B) to test port (2).
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12. Route tooling (B) into cab of machine.

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NOTE: Do not engage pump more than 15 seconds at a

time to prevent overheating.
se
on
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05-200 79033095 C Rev.

High Pressure Relief Valve - Test and
Adjust
High Pressure Relief Valve Test
Test is used to check high pressure relief valve (crossover
relief valve). High pressure relief valves are designed to
relieve high pressure spikes from output ports of steering
pump.
Required Tools
Fo
procedure. Dataview tool group is not shown in following

procedure. 1
r
Dataview Tool Group

in
DataView Tool Gp 1
te
Pressure Sensor 1
0 to 517 bar (0 to 7500 psi)
rn
g00787042
FIG. 377
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pressure gauges will be used to perform following test
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procedure. A1
B2
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B1
on
A A1 Pressure Gauge 0 to 600 1

bar (0 to 8700 psi)
A2 Fitting (Test) 1
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B B1 Couplers 2 P012812003
B2 Hose Assembly 1 FIG. 378
79033095 C Rev. 05-201

Testing Procedure
m
machine.

Fo
FIG. 379: Following components are shown in end view

of steering pump: 2
• Pressure Override Valve (1)
r
• Crossover Relief Valves (2)

in

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position.
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position to relieve hydraulic pressure. 1

P012812004
5. Stop engine and remove key. FIG. 379

6. Remove the appropriate guards.
on
Refer to the Operations and Maintenance Manual,

ly
7. Verify and record charge pressure of system for

reference.
Refer to Testing and Adjusting, Relief Valve (Charge)
- Test and Adjust, for more information.
8. Adjust pressure override valve (1) clockwise to stop.
Count number of rotations.
High pressure override valve is now out of
adjustment. Pump will not destroke to limit pressure.
9. Attach tooling (A) to tooling (B).
10. Attach Tooling to port (Mh).
11. Route Tooling into cab of machine.
12. Start engine and run engine at low idle.
in activated position.
05-202 79033095 C Rev.

14. With engine speed at low idle, rotate steering wheel
to Maximum Steer Right position.
NOTE: Do not engage pump for more than 15 seconds
at a time to prevent overheating.
15. Record pressure reading from port (Mh). Pressure
reading from port (Mh) should be charge pressure
plus 509 bar (7382 psi).
16. With engine speed at low idle, rotate steering wheel
to Maximum Steer Left position.
17. Record pressure reading from port (Mh). Pressure
reading from port (Mh) should be charge pressure
plus 509 bar (7382 psi).
Reference: If pressure needs to be adjusted refer to
High Pressure Relief Valve Adjust.
18. If pressure is correct, return pressure override valve
Fo
to original position or use Steering Pump High

Pressure Cutoff Pressure Test to correctly set
pressure for pressure override valve.
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79033095 C Rev. 05-203

High Pressure Relief Valve Adjust
m
machine.
NOTE: If machine is on ground, machine could spot turn

during this procedure. Following procedure
should be performed while machine is lifted off
ground.
Refer to Operation and Maintenance Manual
Undercarriage (Mobil-trac) Gauge Spacing for correct
Fo
Use following procedure to adjust pressure for relief valve.

Required Tools
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Hydraulic adjustment procedures may be performed

in
using either one of following test equipment:

te

rn

adjustment procedure. 1
al
Dataview Tool Group

u
DataView Tool Gp 1
se
Pressure Sensor 1
0 to 517 bar (0 to 7500 psi)
on
g00787042
FIG. 380
ly

procedure. A1
B2
B1
0 to 600 bar (0 to 8700 psi)
A2 Fitting (Test) 1
P012812003
B B1 Couplers 2
FIG. 381
B2 Hose Assembly 1
05-204 79033095 C Rev.

m
machine.

Fo
NOTE: Following procedure requires two people.

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79033095 C Rev. 05-205

3 3
4 8
5 7
6
Fo
9 10 11 12
P012812005
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FIG. 382
in
FIG. 382: Following components are shown in cross 7. Put machine on jack stands.
sectional view of high pressure relief valves of steering
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pump:
(3) Adjustment Screw correct procedure for supporting the machine off
rn
(4) Makeup Oil ground.

(5) Passage B
(6) Port B
al
(7) Port A Refer to Operations and Maintenance Manual,

(8) Passage A Guards - Remove and Instal, for more information.
(9) System Pressure
u
(10) Charge Pressure 9. Attach tooling (A) to tooling (B).

(11) Sump 10. Attach Tooling to port (Mh).
se

Pressure gauges are used in following adjustment NOTE: Person doing adjustment needs to view tooling.
procedure. 11. Start engine and run engine at low idle.
on
1. Move machine to a smooth horizontal location. 12. Fully activate service brakes and hold service brakes
2. Lower all implements and three-point hitch to ground. in activated position.
3. Make sure transmission control lever is in PARK 13. Rotate steering wheel in direction that requires
ly
position. adjustment.
4. Warm oil to minimum temperature of 55 to 75 NOTE: Do not engage pump for more than 15 seconds
degrees C (131 to 167 degrees F). at a time to prevent overheating.
Refer to Warming the Oil section in General Testing 14. Turn adjustment screw (3) clockwise until pressure is
and Adjusting Information, for more information about charge pressure plus 509 bar (7382 psi).
warming hydraulic oil. One turn of adjustment screw (3) is equal to 152 bar
5. Move all hydraulic control levers through FLOAT (2200 psi).
position to relieve hydraulic pressure. 15. Adjust cutoff pressure for steering pump.
6. Stop engine and remove key. Refer to Testing and Adjusting, Steering Pump High
Pressure Cutoff Pressure Test, for more information.
05-206 79033095 C Rev.

Steering Drift
Test is used to check steering system. Test will show if
steering system needs to be physically adjusted or pump
deadband for steering system requires adjustment.
FIG. 383: Course to be driven to test for steering drift is
shown in illustration. Use following procedure. C
1. Verify that tracks are properly aligned.
Undercarriage (Mobil-trac) Belt Alignment -
Check/Adjust.
2. Check track for uneven wear. If one track is worn
excessively and other track is not worn, machine will
drift. G
NOTE: Driving tests should be performed on a solid level
surface. Operator should not turn steering wheel H
Fo
at any time.
3. Drive machine for a distance of 6.1 m (20 ft) to 9.1 m
(30 ft) (E). B
r
4. Attach a plumb bob to drawbar. Mark location of

D
plumb bob on ground (A).
in
5. Drive machine for a distance of 30.5 m (100 ft) (F).

te
Mark location of plumb bob on ground. Mark will be

position (B).
rn
6. Drive machine for a distance of 30.5 m (100 ft) (G).

Mark location of plumb bob on ground. Mark will be
position (C).
F
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7. Stretch a line between points (A) and (C). Measure

distance (D) from line to center mark (B).
u
8. Calculate drift by multiplying dimension (D) by four.

Maximum allowable drift (H) is 1.2 m (4 ft) over a
se
distance of 61 m (200 ft).

9. Repeat driving test in opposite direction using same
course. A
on
10. Average calculated drift from two driving tests.

E
If dimension is greater than 1.2 m (4 ft) steering system
may be out of adjustment. See Systems g00495792
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Operation/Testing and Adjusting, Steering Pump

FIG. 383
Upstroke/Deadband Test.
79033095 C Rev. 05-207

Steering Wheel Calibration
Accessing Calibrations For The Steering Wheel
Calibration is required when one of following conditions
occur:
• Component has been replaced.
• ECM has been replaced.
Electronic Technician service tool (ET) is used to access
calibration procedures. A message on ET screen will give
instructions that guide user through calibration procedure.
Refer to Manual provided with ET for more information.
Fo
Modules (ECM) is shown.

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list electronic control modules that are on machine.

in

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g00803086
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FIG. 384
FIG. 385: Typical ET Screen of a Calibration Menu is
shown.
u

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Another drop-down menu will appear. Menu will list

each available calibration.
5. Select Steering Wheel Sensor Calibration.
on
6. Select OK after reading WARNING carefully.

7. Select Begin.
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8. Follow all instructions on ET screen to complete

calibration procedures.
g00803143
NOTE: Calibration will require certain conditions to be set
prior to start of calibration. For example, set shift FIG. 385
lever to Park. User must ensure that all setup for
conditions of calibration are satisfied.
05-208 79033095 C Rev.

Steering Servo Valve Calibration
Accessing Calibrations For The Steering Servo
Valve
occur:
• Adjustments to steering system
Virtual Terminal (VT) is not shown in following calibration
procedure. Electronic Technician service tool (ET) is used
to access calibration procedures. A message on ET
calibration procedure. Refer to Manual provided with ET
Fo
Modules (ECM) is shown.
r
in

list electronic control modules on the machine.
te

rn

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g00803086
u
FIG. 386
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FIG. 387: Typical ET Screen of a Calibration Menu is

shown.
on
Another drop-down menu will appear. Menu will list

each available calibration.
5. Select Arm Steering System/Solenoid Calibration.
ly

7. Select Begin.
8. Follow all instructions on ET to complete calibration
procedures.
g00803143
prior to start of calibration. For example, set shift FIG. 387
lever to PARK. User must ensure that all the
setup for the conditions of calibration are
satisfied.
79033095 C Rev. 05-209

Steering Pump Neutral - Test and Adjust
Testing the Electro-servo Valve
There are two factors that affect pump null position:
• Steering servo valve.
• Mechanical centering of pump swashplate
(mechanical upstroke adjustment).
These two factors affect deadband and centering around
neutral position.
Pump deadband is total variation of these factors. When
pump is commanded to stroke, pressure will rise until
tolerance of two factors is taken up in one direction or
other direction.
Total deadband is not adjustable, but band can be
adjusted to a neutral position.
Fo
This test should be performed to determine whether

steering servo valve needs adjustment. Also, this test
should be performed to determine whether mechanical
r
centering needs adjustment.

Perform this test if one of following conditions
in
exist:
te
• Steering pump upstrokes while transmission control

lever is in Park position.
rn
• Transmission control lever is in Park position. Belts

turn while machine is in a raised position.
If following conditions occur, an electrical problem
al
exists in steering system:

• Steering pump only upstrokes when transmission
u
control lever is in Neutral position.

• Belts only turn while machine is in a raised position.
se
Transmission control lever is in Neutral position.

If necessary, calibrate steering wheel first.
Refer to Testing and Adjusting, Steering Wheel -
on
Calibrate, for more information.

Undercarriage for left-hand side has been removed for
ly
Required Tools
05-210 79033095 C Rev.

procedure. Dataview tool group is not shown in following
procedure. 1
Dataview Tool Group

DataView Tool Gp (Accessories are 1
included)
Pressure Sensor 2
0 to 6900 kPa (0 to 1000 psi) g00787042
Nipple Assembly 2 FIG. 388
FIG. 389: The table below provides a list of required

tools if pressure gauges will be used to perform following A1
Fo
test procedure. A2
A4
r

in

A A1 Fitting (Test) 2
te
A2 Pressure Gauge 0 to 4,000 2 A3

kPa (0 to 580 psi) A4
rn
P012512001
A3 Hose Assembly 2
FIG. 389
A4 Couplers 4
al
B Nipple Assembly 2
u se
on
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79033095 C Rev. 05-211

Testing Procedures
m
machine.

Fo
Pressure gauges are used for following test procedure.

r

in
position.
te

rn

al

u

se

FIG. 390: Photo using required tooling (B) for pressure
on
gauges at ports (X1) and (X2).

8. Install tooling (B) in ports (X1) and (X2).
ly

B
11. Record pressure differential.
12. Pressure difference between port (X1) and port (X2)
should not exceed 414 kPa (60 psi).
Proceed to Adjustment of Servo Valve for Steering,
if pressure difference between port (X1) and (X2) is T071612001
above 414 kPa (60 psi) and following conditions FIG. 390
exist:
• Tracks are moving when transmission control lever is
in Neutral position.
in Park position.
05-212 79033095 C Rev.

Proceed to Mechanical Upstroke Adjustment, if
pressure difference between port (X1) and (X2) is
less than 414 kPa (60 psi) and following conditions
exist:
in Neutral position.
in Park position.
FIG. 391: Photo of installing required tooling for pressure
gauge to port (Mh).
13. Connect tooling (A) to port (Mh) at test port (1).
Mh
m
WARNING: To avoid personal injury due to
unexpected machine movement, make sure
Fo
area is free of personnel before starting

engine or operating machine.
With engine running and transmission in
r
T071612001
Neutral position, this machine spot turns
when steering wheel is turned. FIG. 391
in
Be prepared to apply service brakes to

counteract any unexpected machine
te
movement that might occur when engine

starts.
rn
16. Make sure transmission control lever is in Neutral

position.
al

in activated position for approximately 7 seconds.
Turn steering wheel to right or left for approximately 7
u
seconds. Permit steering wheel to return to center

se
position.
NOTE: Do not hold machine in a steer stall condition for
more than 15 seconds at a time.
NOTE: Make sure that steering wheel has returned to
on
center position before checking pressure on

Tooling (A).
ly
18. Tooling (A) will show charge pressure if neutral

position of steering pump is correct.
19. If pressure is greater than charge pressure, neutral
position may need to be adjusted. Servo valve may
need to be adjusted or neutral position of steering
pump may need to be adjusted.
Perform Adjustment of Servo Valve for Steering first.
Then perform Mechanical Upstroke Adjustment.
Make sure to disconnect solenoids before performing
mechanical test.
79033095 C Rev. 05-213

Adjustment of Servo Valve for Steering
If transmission control lever is in Park position and pump
upstrokes, perform this adjustment.
Pump deadband is pressure that is necessary to
counteract control springs. This is also pressure
necessary to begin to upstroke pump. Pressure can be
higher in one direction or in other direction by use of
neutral adjusting screw.
Calibrate solenoids after performing following adjustment
procedure.
Refer to Testing and Adjusting, Calibrating Steering
Solenoids, for more information.
m
Fo

Sudden movement of the machine can
cause injury to persons on or near
r
machine.
in
the area around machine is clear of

personnel and obstructions before
te
operating machine.
IMPORTANT: If machine is on ground, machine could

rn
spot turn during this procedure. Following

procedure should be performed while machine is
lifted off ground.
al

u

se

on
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05-214 79033095 C Rev.

Required Tools
using either one of the following tools:
Dataview Tool Group

DataView Tool Gp (Accessories included) 1
Pressure Sensor 2
0 to 517 bar (0 to 7500 psi)
Fo
Nipple Assembly 2
g00787042
FIG. 392
r in

pressure gauges will be used to perform following A1
adjustment procedure. A2
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rn

al
u

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A4 Couplers 4 FIG. 393

B Nipple Assembly 2
on
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79033095 C Rev. 05-215

m
machine.

Fo

r
position.
in

te

rn

al

7. Put machine on jack stands.
u

se

correct procedure for supporting the machine off
ground.
on

ly
FIG. 394: Photo shown using required tooling for

pressure gauges at ports (X) and (X2).
9. Install tooling (B) in ports (X1) and (X2).
B
T071612001
FIG. 394
05-216 79033095 C Rev.

FIG. 395: Neutral adjustment screw (3) is an eccentric
adjuster. One-fourth revolution of screw is maximum
adjustment. A small amount of movement of screw (3)
makes a large pressure difference.
12. Adjust screw (3) to balance pressure between port
(X1) and port (X2). Pressure difference between port
3
(X1) and port (X2) should not exceed 414 kPa (60
psi).
13. Calibrate solenoids.
Refer to Testing and Adjusting, Steering Servo Valve -
Calibrate, for more information.
If machine is still drifting or if machine is turning in place,
adjust mechanical deadband.
Refer to Testing and Adjusting, Steering Pump
Fo
P012812009
FIG. 395
r in
te
rn
al
u se
on
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79033095 C Rev. 05-217

Mechanical Upstroke Adjustment
NOTE: Following adjustment is usually performed as a
bench test after rebuilding steering pump.
Perform following procedures before performing
mechanical upstroke adjustment:
• Refer to Systems Operation/Testing and Adjusting,
Steering Servo Valve - Calibrate.
• See Adjustment of Servo Valve.
NOTE: Perform this procedure on machine only if
adjustment screw has become loose. Following
procedure is normally a bench test procedure.
m
Fo

r
machine.
in
IMPORTANT: If machine is on ground, machine could

spot turn during this procedure. Following
te
procedure should be performed while machine is

lifted off ground.
rn

al
Raise machine off ground to perform adjustment

procedure. Move undercarriage to widest gauge
position.
u
If machine cannot be raised, remove steering

se
pump. Perform adjustment procedure on a

hydraulic test bench.
Pump deadband is pressure necessary to counteract
on
control springs. This is also pressure necessary to begin

to upstroke pump. Pressure can be bias in one direction
or in other direction by use of neutral adjusting screw.
ly

05-218 79033095 C Rev.

Required Tools
using either one of following tools:
Dataview Tool Group

DataView Tool Gp (Accessories are 1
included)
Pressure Sensor 2
Fo
0 to 517 bar (0 to 7500 psi)

Nipple Assembly 2 g00787042
FIG. 396
r in

pressure gauges will be used to perform following A1
adjustment procedure. A2
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rn

al
u

se
A4 Couplers 4 FIG. 397

B Nipple Assembly 2
on
C C1 Pressure Gauge 0 to 4,000 1

kPa (0 to 580 psi)
C2 Fitting (Test) 1
ly
C3 Hose Assembly 1
C4 Couplers 1
79033095 C Rev. 05-219

m
machine.

Fo

r
position.
in

te

rn

al

7. Put machine on jack stands.
u

se

correct procedure for supporting machine off ground.
on

9. Disconnect steering solenoids.
ly
FIG. 398: Port (Mh) location.

10. Connect tooling (C) to port (Mh) at test port (1).
11. Route tooling (C) into cab of machine.
Mh
T071612001
FIG. 398
05-220 79033095 C Rev.

FIGS. 399–400: Components shown in illustrations are
neutral adjusting screw (1) and locknut (2) on steering 1
pump.
13. To adjust neutral position of pump control, loosen
locknut (2). Use a hex wrench to turn neutral
adjustment screw (1).
14. Rotate neutral adjustment screw (1) until tooling (C) is
reading 6895 kPa (1000 psi).
NOTE: Damage to tooling may occur if a steer stall
condition occurs. Use caution to prevent a steer
stall condition.
15. Mark location.
P012812009
16. Rotate neutral adjustment screw (1) in opposite
direction until tooling (C) reads 6895 kPa (1000 psi). FIG. 399
17. Mark location.
1
Fo
18. Rotate neutral adjustment screw (1) to a point

between two marks.
19. Tighten locking nut (2) on neutral adjustment screw
r
(1).
in
20. Check neutral position of steering pump to be sure

that gauge is not reading a pressure.
te
21. Tighten locknut (2). Remove tooling (C).

22. Calibrate steering solenoids. 2
rn
P012812010
Refer to Testing and Adjusting, Steering Servo Valve -
Calibrate, for more information. FIG. 400
al
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on
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79033095 C Rev. 05-221

Steering Motor Case Drain Pressure Test
Case Drain Pressure Test
This test is performed on machine to check pressure in
steering motor case.
procedure.
1
Fo
DataView Tool Gp 1
r
Pressure Sensor 1
in
Fitting 1
g00787042
Swivel Elbow 1
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FIG. 401
Face Seal Nut 1
Nut 1
rn
Reducer 1
al
O-Ring Seal used with 6V-8939 O-ring 1

reducer
O-Ring Reducer 1
u
O-Ring Seal used with 6V-8942 O-ring 1

se
reducer
Face Seal Plug 1
O-Ring Seal used with 6V-9510 face seal 1
on
plug
ly
05-222 79033095 C Rev.

FIGS. 402–403: Table 26 provides a list of required tools
if pressure gauges will be used to perform following test A4
procedure. A1

A2
kPa (0 to 36 psi)
A3
A2 Coupler 2 A2
A4 Fitting 1 FIG. 402

B B1 Fitting 1 B7 B3
B2 B1 B4
B2 Swivel Elbow 1
B3 Face Seal Nut 1
Fo
B4 Nut 1
B5 Reducer (This reducer is not 1
shown in Illustration)
r
B6 O-ring Seal used with 1

in
6V-8939 reducer
C
B7 O-Ring Reducer 1
te
P012912004
B8 O-Ring Seal used with 1
6V-8942 O-ring reducer FIG. 403
rn
C C1 Face Seal Plug 1

C2 O-Ring Seal used with 1
al
6V-9510 face seal plug

u se
on
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79033095 C Rev. 05-223

Test Procedure
m
machine.

Fo
A Pressure gauge is used for following test procedure.

r

in
position.
te

rn

al

u

se

FIG. 404: Steering motor (2) is located next to
on
intermediate valve stake (3). 3 1

8. Remove hose (1) from steering motor (2).
2
ly
9. Attach tooling (C) to existing hose (1).

10. Attach tooling (B) to steering motor (2).
13. Record reading on pressure gauge.
14. Put transmission in Neutral and apply service brakes. P011812005
Turn steering wheel in either direction.
FIG. 404
NOTE: Do not put steering system in a stall condition for
15. Record reading on pressure gauge.
16. Second pressure reading should not increase by
more than 415 kPa (60 psi). If pressure increase is
more than 415 kPa (60 psi), flow from steering motor
case drain should be checked.
05-224 79033095 C Rev.

Steering Motor Case Drain Flow Test
Flow of steering motor case drain is measured to
determine if steering motor is leaking hydraulic oil.
FIGS. 405–406: Table below provides a list of required
tools used to perform following test procedure. A4
A1
A2
kPa (0 to 36 psi)
A2 Coupler 2 A3
A4 Fitting 1 P012512001
B B1 Fitting 1 FIG. 405

Fo
B2 Swivel Elbow 1 B7 B3 B4
B2 B1
B3 Face Seal Nut 1
r
B4 Nut 1
in
B5 Reducer (This reducer is not 1

shown in Illustration)
B6 O-ring Seal used with 1
te
6V-8939 reducer
B7 O-Ring Reducer 1 C
rn
B8 O-Ring Seal used with 1

P012912004
6V-8942 O-ring reducer
al
FIG. 406
C C1 Face Seal Plug 1
C2 O-Ring Seal used with 1
6V-9510 face seal plug
u se
Test Procedure
m
on
machine.
ly

Case drain flow is checked by removing tooling (A2) from
tooling (A). Tooling (A) is positioned so that oil will flow into
a suitable container to measure volume.
position.
79033095 C Rev. 05-225

Refer to Warming Oil section in General Testing and
FIG. 407: Steering motor (2) is located next to
intermediate valve stake (3). 3 1
8. Remove existing hose (1) from steering motor (2).
2
Fo
9. Install tooling (C) to existing hose (1).

10. Attach tooling (B) to steering motor (2).
r
12. Remove tooling (A2) from tooling (A).

in
13. Place tooling (A) in a appropriate container.

te
P011812005
15. Put transmission in Neutral and apply service brakes. FIG. 407
Turn steering wheel in either direction.
rn
NOTE: Do not put steering system in a stall condition for

al
16. Maintain position of steering wheel for 10 seconds.

Note oil volume. Increase in oil volume should be less
u
than 17 liters/min (4.50 gal/min) or flow rate should be

more than 5 liters/min (1.3 gal/min).
se
17. If increase in oil volume is greater than 0.33 liter (0.35

qt) or flow rate is less than 5 liters/min (1.3 gal/min),
steering motor should be checked for leakage.
on
ly
05-226 79033095 C Rev.

SERVICE BRAKE SYSTEM TESTING AND
ADJUSTING
Service Brakes - Adjust and Purge

Brake Cable Adjustment Procedure
Perform following procedure if brake pedal has too much
play before resistance is felt. To get better performance
from service brake system, pedal should have between 0
and 12.7 mm (1/2 in) of travel before firm resistance is felt.
1 5
Fo
4
r
6
in
7
8
te
10
rn
al
9
u se
d-9518
FIG. 408
on
FIG. 408: Components are shown in bottom view of

service brake valve and brake cable installation:
1. Cable Conduit End Fitting
ly
2. Forward Nut
3. Aft Nut
4. Cable End Fitting
5. Jam Nut
6. Cable Yoke
7. Lever Arm
8. Stem Yoke
9. Stem Jam Nut
10. Input Stem
NOTE: Direction arrow points to front of machine
79033095 C Rev. 05-227

Perform following procedure to adjust pedal travel before
resistance is felt:
1. Loosen forward nut (2) on cable conduit end fitting
(1).
2. Unthread aft nut (3) to within a 6.0 mm (1/4 in) of
cable conduit end fitting (conduit end fitting is not
threaded on last 6.0 mm (1/4 in)).
3. Pull forward on cable assembly to create force on
brake valve through lever arm (7) and input stem (10).
While in this position, thread aft nut (3) forward to
within 3.0 mm (1/8 in) of bracket face.
4. Thread forward nut (2) up to forward face of bracket
and tighten the nut to 34 Nm (25 lbf ft). This will take
slack out of cable.
5. Check pedal in cab for free play. Adjust cable more if
necessary.
Fo
6. Start machine and check service brake pressure. Be

sure that when releasing service brake pedal
pressure in brake system returns to approximately 0
r
kPa (0 psi).
in
If there is not enough adjustment available with conduit

end nuts to create a firm pedal, further adjustment can be
made in linkage. Cable yoke (6) may be threaded on to
te
cable end fitting (4) further as long as cable yoke is not

causing interference with cable end fitting and lever arm
rn
(7). Stem yoke (8) may also be adjusted by unthreading

stem yoke out to be even with end of input stem (10).
al
u se
on
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05-228 79033095 C Rev.

Purge the Service Brakes 7. Place tow override valve in detent position.
Procedure is used to purge air from hydraulic lines to Refer to Operation and Maintenance Manual for
allow service brakes to apply desired braking action. additional information about tow override valve.
Two 1.07 m (3.5 ft) pieces of transparent hose will be 8. Start engine. Transmission control lever should be in
needed to perform this procedure. Hose should have an Park position.
inside diameter of 76.2 mm (3/8 in).
9. Depress service brake pedal for 20 seconds. Low
IMPORTANT: Purge air from braking system whenever brake accumulator warning will appear. Release
maintenance is performed that requires opening service brake pedal and wait 10 seconds to allow
system to atmosphere. Air in braking system will accumulator to recharge.
not allow brakes to release properly and may
10. Repeat Step 9 once.
cause damage to braking system.
11. Stop engine and return tow override valve to original
position.
maintenance, testing, adjusting, and repair of NOTE: Must return tow override valve to normal
machine. Be prepared to collect fluid with operating position. If you leave tow override
suitable containers before opening any valve in detent position, service brake
compartment or disassembling any component accumulator will continue to drain when machine
Fo
containing fluids. Dispose of all fluids according is in park and service brakes are depressed. As
to local regulations and mandates. a result, service brakes may not work properly.
r
12. Perform purging procedure for hydraulic trailer brakes

or air brakes (If equipped). Shut engine off.
in

position.
te

rn

al

u

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on
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79033095 C Rev. 05-229

FIG. 409: Photo of clear plastic tubes connected to
purging screws (1) and (2).
13. Connect a clear plastic tube to purging screws (1) 2
and (2). Place discharge of tubes into a container of 1
clean oil. Discharge of tubes should be located below
oil level.
14. Start engine and allow accumulator to reach full
charge. Accumulator pressure should be within
working limits throughout purging procedure.
15. Open purging screws (1) and (2).
16. Press brake pedal to achieve enough flow to force air
g00869114
from system.
17. (CE Only) When clear oil starts to flow out of tubes, FIG. 409
slowly turn steering wheel to left-hand and hold for
ten seconds. Next, slowly turn steering wheel to
right-hand and hold for ten seconds. Make sure brake
Fo
pedal is depressed while performing this procedure.

18. (CE Only) Repeat Step 17 two times.
r
19. Release brake pedal for a period of 30 seconds after

clear oil flows out tubes.
in
20. Apply brake pedal again until clear oil flows from
tubes.
te
21. Close purging screws (1) and (2).

22. Shut off engine.
rn
23. Check service brake system for leaks.

al
u se
on
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05-230 79033095 C Rev.

Trailer Brakes (Air) - Purge
Procedure is used to purge air from hydraulic signal line to
trailer control valve (air). This will allow air trailer brake to
apply desired braking action.
One 1.07 m (3.5 ft) piece of transparent hose will be
required to perform this procedure. Hose should have an
position.
(68 degrees F).
5. Stop engine.
Fo
NOTE: Step 6 through Step 8 may be skipped if steps

were already performed in Service Brakes -
Purge procedure.
r
6. Place machine in tow override mode.

in
7. Start machine. Transmission control lever should be

in Park position. Depress service brake pedal for 20
seconds. Low brake accumulator warning will appear.
te
Release service brake pedal and wait 10 seconds to

allow accumulator to recharge.
rn

9. Stop machine and return tow override valve to
al
original position.
NOTE: Must return tow override valve to normal
operating position. If leaving tow override valve in
u
detent position, service brake accumulator will

continue to drain when machine is in park and
se
service brakes are depressed. As a result,

service brakes may not work properly.
FIG. 410: Trailer control valve (1) is located at rear of
on
machine under cover behind air conditioning cover.

10. Connect a clear plastic tube to purging screw (2).
Place discharge of tube into a container of clean oil.
ly
Discharge of tube should be located below oil level. 1

11. Open purging screw (2).
12. Start machine and press brake pedal to force air form
system. 2
13. Close purging screw (2) when clear oil is flowing from
tube.
P012312012
14. Position transmission control lever in Park position.
Turn off engine. FIG. 410
79033095 C Rev. 05-231

Trailer Brakes (Hydraulic) - Purge
Procedure is used to purge air from hydraulic lines to
allow hydraulic trailer brake to apply desired braking
action.
One 1.07 m (3.5 ft) piece of transparent hose will be
required to perform this procedure. Hose should have an
position.
(68 degrees F).
5. Stop engine.
Fo
NOTE: Step 6 through Step 8 may be skipped if steps

were already performed in the Service Brakes -
Purge procedure.
r
6. Place machine in tow override mode.

in
7. Start machine. Transmission control lever should be

in Park position. Depress service brake pedal for 20
seconds. Low brake accumulator warning will appear.
te
Release service brake pedal and wait 10 seconds to

allow accumulator to recharge.
rn

9. Stop machine and return tow override valve to
al
original position.
NOTE: Must return tow override valve to normal
operating position. If leaving tow override valve in
u
detent position, service brake accumulator will

continue to drain when machine is in park and
se
service brakes are depressed. As a result,

service brakes may not work properly.
FIG. 411: Hydraulic trailer brake valve (3) is located on
on
left-hand rockshaft support.

10. Connect a clear plastic tube to purging screw (1) or 1
(2). Place discharge of tube into a container of clean
ly
oil. Discharge of tube should be located below oil

level.
11. Open purging screw (1).
12. Press brake pedal to force air from system. 2
13. Close purging screw (1) when clear oil is flowing from
3
tube.
P013012001
14. Position transmission control lever in Park position.
Turn off engine. FIG. 411
05-232 79033095 C Rev.

Service Brake System Accumulator
Accumulator Nitrogen Charge Test
Test indicates pressure of nitrogen gas in accumulator.
Pressure of nitrogen gas in accumulator is variable with
ambient temperature. Accumulator is used to deliver
pressurized oil for brakes even when engine is not
running.
FIG. 412: Table below provides a list of required tools
used to perform following test procedure. A1 A2 A9
Required Tools (Pressure Gauges)
A6
Nitrogen Charging Group 1 A4 A5
A1 Fitting 1 A3
Fo
A2 Disc Coupling Assembly 1

A8
A3 Hose Assembly 1
r
A4 Coupling 1 A7
A
in
A5 Fitting 2
A10
A6 Needle Valve 1
te
A11
A7 Pressure Gauge 1 P013012002
rn
A8 Regulator 1 FIG. 412

A9 Nitrogen Charging Chuck 1
al

A11 Hose Assembly 1
u se
B Laser Infrared Thermometer 1

Gp
NOTE: Items (A1) through item (A11) are part of Nitrogen

on
Charging Group. These items are pre

assembled.
ly
79033095 C Rev. 05-233

Test Procedure
Pressure of nitrogen gas is variable with ambient
temperature. Use tooling (B) to check ambient
temperature. Accumulator must be at same temperature
as surrounding air. Use table below as a reference for
ambient temperature and nitrogen pressure.
Charging Pressure and Temperature Relationship for a 72 bar (1050 psi) Accumulator
Temperature Pressure
-7 degrees C (20 degrees F) 6581 kPa (955 psi)
4 degrees C (40 degrees F) 6856 kPa (994 psi)
10 degrees C (50 degrees F) 70 bar (1014 psi)
Fo

r

in

te

rn
NOTE: Pressure may vary by 70 kPa (10 psi) plus or

minus.
al

u
position.
se

on
5. Push brake pedal 30 times to discharge accumulator.

To be sure pressure of nitrogen charge is correct, all
hydraulic oil must be removed from accumulator.
ly
NOTE: When checking charge of an accumulator, be

sure that you remove all oil from oil end of
accumulator. This can be done by charging
accumulator and applying brakes repeatedly.
Accumulator is discharged when application of
service brakes does not decrease pressure of
nitrogen.
05-234 79033095 C Rev.

FIG. 413: Photo of service brake system accumulator.
6. Remove cap (1).
1
P013012003
FIG. 413
FIG. 414: Service brake system accumulator is located
in front of transmission below cab.
A6 A10
7. Attach chuck (A10) to nitrogen charging valve (2).
Fo
8. Be sure valve (A6) is completely closed. Rotate

handle on valve (A10) counterclockwise until valve is
completely open.
r
9. Use pressure gauge (A7) to check amount of 2

A7
in
nitrogen charge in accumulator.

10. Use tooling (B) to check temperature of accumulator.
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Use table below to determine nitrogen pressure in

accumulator. P013012004
FIG. 414
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11. If pressure is too high, slowly open valve (A6) to lower

pressure.
12. If pressure is too low, charge accumulator.
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Reference: See Charging Procedure for Accumulator.

13. Rotate handle on valve (A10) clockwise until valve is
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completely closed. Disconnect coupling assembly

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(A4).
14. Slowly open valve (A6) to release pressure in line
(A11).
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15. Remove test equipment.

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79033095 C Rev. 05-235

Accumulator Charging Procedure
Following procedure is used to charge accumulator for
service brake system.
FIG. 415: Table below provides a list of required tools
used to perform following test procedure. A1 A2 A9
A6
Nitrogen Charging Group 1 A4 A5
A1 Fitting 1 A3
A2 Disc Coupling Assembly 1
A8
A3 Hose Assembly 1
A4 Coupling 1 A7
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A
A5 Fitting 2
A10
A6 Needle Valve 1
A11
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A7 Pressure Gauge 1 P013012002

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A8 Regulator 1 FIG. 415

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A11 Hose Assembly 1

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B Laser Infrared Thermometer 1

Gp
NOTE: Items (A1) through item (A11) are part of Nitrogen

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Charging Group. These items are pre

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assembled.
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05-236 79033095 C Rev.

temperature. Use Tooling (B) to check ambient
as surrounding air. Use table below as a reference for
Charging Pressure and Temperature Relationship for a 72 bar (1050 psi) Accumulator
4 degrees C (40 degrees F) 6856 kPa (994 psi)
Fo

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NOTE: Pressure may vary by 70 kPa (10 psi) plus or

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minus.
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position.
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5. Push on brake pedal 30 times to discharge
accumulator. To ensure pressure of nitrogen charge
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is correct, all hydraulic oil must be removed from

accumulator.
NOTE: When charging an accumulator, be sure that you
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remove all oil from oil end of accumulator. This

can be done by charging accumulator and
applying brakes repeatedly. Accumulator is
discharged when application of service brakes
does not decrease pressure of nitrogen.
79033095 C Rev. 05-237

6. Assemble tooling (A).
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WARNING: Dry nitrogen is only gas
approved for use in accumulators. Charging
of oxygen gas in an accumulator will cause
an explosion. An explosion can be
eliminated by using nitrogen gas cylinders
with standard CGA (Compressed Gas
Association, Inc.) No. 580 connectors.
When nitrogen gas is ordered, make sure to
order the cylinders with CGA No. 580
connectors.
Do not rely on color codes or other
methods of identification to tell the
difference between nitrogen and oxygen
cylinders. In any application, never use an
adapter to connect your nitrogen charging
group to a valve outlet used on both
nitrogen, oxygen, or other gas cylinders. BE
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SURE YOU USE DRY NITROGEN (99.8%

purity).
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7. Connect chuck (A9) to a dry nitrogen cylinder.

8. Close valve (A6) and open valve on nitrogen cylinder.
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9. Turn adjustment screw on regulator assembly (A8).

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Stop turning adjustment screw when pressure on

gauge of regulator assembly (A8) is equal to pressure
needed to correctly charge accumulator.
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NOTE: Use table above as a reference for correct

charging pressure.
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FIG. 416: Photo of service brake system accumulator.

10. Remove cap (1).
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P013012003
FIG. 416
05-238 79033095 C Rev.

FIG. 417: Service brake system accumulator is located
in front of transmission below cab.
A6 A10
Rotate valve handle (A10) counterclockwise until
valve is completely open.
12. Open valve (A6) to charge accumulator.
13. Nitrogen pressure must equalize. When pressure 2
readings are stable, record pressure readings from A7
gauge. If pressure on gauge (A7) is equal to pressure
on gauge (A8), then accumulator is correctly
charged.
P013012004
14. If there is a decrease in pressure on gauge (A7), FIG. 417
open valve (A6) and allow more nitrogen to enter
accumulator.
NOTE: Perform Step 13 through Step 14 as many times
as necessary. When valve (A7) is closed reading
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on gauge (A7) should match reading on table

above.
15. Turn off valve (A6).
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16. Turn off valve on nitrogen cylinder.

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17. Turn valve handle (12) on chuck (13)

counterclockwise until valve handle (12) stops.
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18. Turn adjustment screw (10) to relieve pressure in line

(4). Open valve (7) to relieve pressure in line (14).
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19. Remove tooling (A).

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79033095 C Rev. 05-239

Service Brake System Pressure - Test
Following test procedure will check pressure of oil
delivered to service brakes.
procedure. A dataview tool group is not shown in following
test procedure. 1

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DataView Tool Gp 1
Pressure Sensor 1
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0 to 6895 kPa (0 to 1000 psi)

g00787042
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FIG. 418
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test procedure. A1
A2
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A4
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A1 Fitting (Test) 1
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A3
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A4 Coupler 2 P012512001
FIG. 419
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05-240 79033095 C Rev.

Test Procedure
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machine.

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position.
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(140 degrees F).

Refer to Testing and Adjusting, General Testing and
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Adjusting Information, for information on warming oil.

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FIG. 420: The test port (1) is by the service brake valve.
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7. Connect tooling (A) to test port (1).

8. Start engine. Run engine at high idle.
on
60 degrees C (140 degrees F). Record pressure of

hydraulic oil being delivered to service brake.
Pressure of oil being delivered to service brake
should be 4481 to 5171 kPa (650 to 750 psi).
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10. Remove tooling (A) from test port.

11. Stop engine. 1
P013012005
FIG. 420
79033095 C Rev. 05-241

NOTES
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05-242 79033095 C Rev.

Index
INDEX
A Differential Steering System ............................... 05-51

Differential Steering System Components ......... 05-53
Accessing Calibrations Differential Steering System Lubrication ............ 05-51
For The Steering Servo Valve .................... 05-209 Differential Steering Unit ......................... 05-50, 05-54
Accessing Calibrations Discharged Accumulator .................................. 05-108
For The Steering Wheel ............................. 05-208 Disengagement of the Service Brakes ............... 05-77
Accumulator Charging Procedure .................... 05-236
Accumulator Nitrogen Charge Test .................. 05-233
Actuator Valve and E
Trailer Control Valve (Dual Brake Line) ....... 05-89
Adjustment of the Electric Servo Valve ........................................... 05-34
Servo Valve for the Steering ...................... 05-214 Electronic Components for Steering System ........ 05-7
Air Compressor .................................................. 05-87 Electronic Control Module for Steering System .. 05-19
Air Couplings for the Trailer Brakes ................... 05-90 Engagement of the Service Brakes .................... 05-77
Air Tank and Air Dryer ....................................... 05-88
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Air Trailer Brake Components ............................ 05-87

Air Trailer Brake System .................................... 05-87 F
Air Trailer Brake System (CE Only) ................... 05-87
Filler Cap ............................................................ 05-26
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Air Trailer Brake Valve ..................................... 05-176

Air Trailer Brake Valve Installation ................... 05-178 Filter Bypass Switch (Steering) .......................... 05-18
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Air Trailer Brake Valve Removal ...................... 05-176 Filter Bypass Switch (Steering/Transmission) ...... 05-8
Air Trailer Brakes (Optional) ................................ 05-2 Final Drive ............................................... 05-49, 05-63
Application of the Service Brakes ...................... 05-75 Final Drive Function ........................................... 05-64
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Armrest ECM ............................... 05-9, 05-95, 05-100 Final Drive Location ............................................ 05-63
Flushing Valve .................................................... 05-46
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Brake Accumulator ........................................... 05-172

Brake Accumulator Installation ........................ 05-173 General Testing and Adjusting Information ...... 05-187
Brake Accumulator Removal ........................... 05-172
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Brake Cable Adjustment Procedure ................. 05-227

Brake System ..................................................... 05-67 H
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Brake Valve Assembly ..................................... 05-169

Brake Valve Assembly Installation ................... 05-171 High Pressure Cutoff Test ................................ 05-194
Brake Valve Assembly Removal ...................... 05-169 High Pressure Relief Valve - Test and Adjust .. 05-201
Breather (Common Sump) ................................. 05-25 High Pressure Relief Valve Adjust ................... 05-204
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Bypass Circuit .................................................... 05-29 High Pressure Relief Valve Test ...................... 05-201
Bypass Switch .................................................... 05-29 Hydraulic Components for Steering System ...... 05-11
Bypass Valve ..................................................... 05-29 Hydraulic Oil Cooler ................................ 05-14, 05-47
Hydraulic Oil Filter ................................................ 05-3
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Hydraulic Oil
C Filter (Steering and Parking Brake) .............. 05-27
Hydraulic Oil
CAN Data Link .......................................... 05-8, 05-94 Filter (Transmission and Steering) ............... 05-14
Case Drain Pressure Test ................................ 05-222 Hydraulic Schematic for Service Brakes ............ 05-79
Charged Accumulator Units ............................. 05-108 Hydraulic System
Common Sump ....................................... 05-11, 05-22 Schematic (Parking Brake) ......................... 05-111
Common Sump (Steering) ................................. 05-22 Hydraulic System
Cooling Service Brakes ...................................... 05-78 Schematic (Steering) .................................... 05-48
Counter-Rotation ................................................ 05-58 Hydraulic Trailer Brake Components ................. 05-82
Crossover Relief Valves ..................................... 05-40 Hydraulic Trailer Brake Coupler ......................... 05-86
Hydraulic Trailer Brake Installation ................... 05-183
Hydraulic Trailer Brake Removal ...................... 05-179
D Hydraulic Trailer Brake System .......................... 05-81
Hydraulic Trailer Brake Valve ............................. 05-82
Data Link for Parking Brake System ................ 05-102 Hydraulic Trailer Brake Valve (Optional) .......... 05-179
Data Link for Steering System ........................... 05-21 Hydraulic Trailer Brake Valve System ................ 05-80
Determine the Probable Causes ...................... 05-189 Hydraulic Trailer Brakes (Optional) ...................... 05-1
Differential Steering Mechanical Components ... 05-49
79033095 C Rev. 05-243

Index
I Priority and Accumulator Charge Valve .. 05-70, 05-82
Priority Valve
Implement Pump ................................................ 05-86 (Priority and Accumulator Charge Valve) ..... 05-72
Input Components of Parking Brake System ..... 05-98 Purge the Service Brakes ................................. 05-229
Introduction (Parking Brake System) ................. 05-91
R
K
Reduce the List of Probable Causes ................ 05-189
Know the Machine ........................................... 05-189 Relief Valve
(Charge Pressure) Pressure Adjust ........... 05-192
Relief Valve
L (Charge Pressure) Pressure Test .............. 05-190
Relief Valve (Charge) - Test and Adjust ........... 05-190
Location of Hydraulic Oil Filter ........................... 05-27
Location of Service Brakes ................................ 05-76
Location of Steering Motor ................................. 05-44 S
Scavenge (Gear) Pump .................................... 05-113

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M Scavenge Pump Installation ............................. 05-114

Scavenge Pump Removal ................................ 05-113
Machine ECM ................................ 05-8, 05-95, 05-99 Secondary Brake Lever (CE Only) ..................... 05-96
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Machine ECM for the Steering System .............. 05-19 Secondary Brake Valve (CE Only) ........ 05-96, 05-174
Machine Preparation ........................................ 05-187 Secondary Brake Valve Installation .................. 05-175
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Mechanical Upstroke Adjustment .................... 05-218 Secondary Brake Valve Removal ..................... 05-174
Modes of the Parking Brake Control Valve ...... 05-103 Secondary Steering Actuator (CE Only) ............. 05-15
Secondary Steering
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Solenoid Valve (CE Only) .................. 05-10, 05-16

O Secondary Steering
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Valve Actuator (CE Only) ........................... 05-163

Oil Flow .............................................................. 05-28 Secondary Steering
Oil Sampling Valve ............................................. 05-29 Valve Actuator Installation .......................... 05-164
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Operation of Steering Motor ............................... 05-44 Secondary Steering

Output Components Valve Actuator Removal ............................. 05-163
of Parking Brake System ........................... 05-101 Service Brake Accumulator ................................ 05-70
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Service Brake Components ................................ 05-70

Service Brake Control Valve .............................. 05-74
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P Service Brake Operation .................................... 05-77

Service Brake System ............................. 05-67, 05-68
Parking Brake ....................................... 05-97, 05-109 Service Brake System Accumulator ................. 05-233
Parking Brake - Service Brake System Pressure - Test ............ 05-240
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Off Position (Park Brake Released) ........... 05-105 Service Brake

Parking Brake - System Testing and Adjusting .................... 05-227
On Position (Park Brake Engaged) ............ 05-104 Service Brake Valve ................................ 05-71, 05-86
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Parking Brake - Service Brakes .............................. 05-1, 05-71, 05-76

Tow Position (Park Brake Released) ......... 05-106 Service Brakes - Adjust and Purge .................. 05-227
Parking Brake Control Valve ............................ 05-103 Sight Gauge ....................................................... 05-26
Parking Brake Control Valve Location ............. 05-103 Solenoid Valve -
Parking Brake Disengagement ........................ 05-110 Secondary Steering (CE only) .................... 05-165
Parking Brake Engagement ............................. 05-110 Solenoid Valve -
Parking Brake Location .................................... 05-109 Secondary Steering Installation .................. 05-167
Parking Brake Manual Control Handle ............. 05-107 Solenoid Valve -
Parking Brake System ............................ 05-91, 05-92 Secondary Steering Removal ..................... 05-165
Parking Brake System ECMs ............................. 05-99 Solenoid Valve (Left Steer) .................................. 05-9
Parking Brake Solenoid Valve (Right Steer) ................................ 05-9
System Electrical Components ......... 05-92, 05-94 Solenoid Valve (Steering) ................................... 05-20
Parking Brake Solenoid Valves (Parking Brake) ........................ 05-95
System Hydraulic Components ......... 05-93, 05-96 Solenoids .......................................................... 05-101
Parking Brake Valve .......................................... 05-96 Speed Sensor (Steering Motor) .......................... 05-18
Parking Brakes ..................................................... 05-2 Steering and Brake System Operation ................. 05-1
Position Sensor (Steering Wheel) ...................... 05-17 Steering and Brake Testing and Adjusting ....... 05-187
Pressure Override Valve .................................... 05-38 Steering Differential .............................................. 05-3
Primary Steering Hydraulic System ..................... 05-6 Steering Drift .................................................... 05-207
05-244 79033095 C Rev.

Index
Steering Electrical System ................................... 05-5 U
Steering Hydraulic System ................................... 05-4
Steering Motor ................. 05-3, 05-15, 05-44, 05-142 Understand the Symptoms ............................... 05-189
Steering Motor Assembly ................................. 05-151
Steering Motor Bypass Valve (CE Only) ............ 05-16
Steering Motor Case Drain Pressure Test ....... 05-222 V
Steering Motor Disassembly ............................ 05-144
Steering Motor Installation ............................... 05-162 Verify the Symptom .......................................... 05-189
Steering Motor Removal .................................. 05-142 Visual Inspection .............................................. 05-189
Steering Motor Speed Sensor .............................. 05-7
Steering Pump ................. 05-3, 05-14, 05-30, 05-115
Steering Pump Assembly ................................. 05-128 W
Steering Pump Components .............................. 05-31
Steering Pump Disassembly ............................ 05-117 Warming the Hydraulic Oil ................................ 05-188
Steering Pump
High Pressure Cutoff Adjustment ............... 05-197
Steering Pump
High Pressure Cutoff Pressure Test .......... 05-194
Steering Pump Installation ............................... 05-141
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Steering Pump Neutral - Test and Adjust ........ 05-210

Steering Pump Removal .................................. 05-115
Steering Pump Stall ........................................... 05-37
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Steering Servo Valve Calibration ..................... 05-209

Steering System .......................................... 05-1, 05-3
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Steering System Input Components .................. 05-17

Steering System Output Components ............... 05-20
Steering System Testing and Adjusting ........... 05-190
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Steering System Theory of Operation .................. 05-3

Steering Wheel .................................................. 05-49
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Steering Wheel Calibration .............................. 05-208

Steering Wheel Position Sensor .......................... 05-7
Steering Wheel Position Sensors ........................ 05-3
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Straight Travel .................................................... 05-41

Suction Screen (Scavenge Pump) .......... 05-12, 05-25
Suction Screen
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(Tandem Charge Pump) ................... 05-12, 05-25

Swashplate Actuator .......................................... 05-36
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Switch (Parking Brake) ........................... 05-94, 05-98
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Tandem Charge Pump .............................. 05-3, 05-13

Tandem Charge Pump (Steering) ...................... 05-30
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Tandem Charge Pump Large Section ............... 05-13

Tandem Charge Pump Small Section ................ 05-13
Test Equipment ................................................ 05-187
Test Ports ........................................................... 05-43
Test the System ............................................... 05-189
Testing and Adjusting Procedure ..................... 05-187
Testing the Electro-servo Valve ....................... 05-210
Testing the Flow of
the Steering Motor Case Drain .................. 05-225
Towing a Machine That has a Dead Engine .... 05-108
Trailer Brakes (Air) - Purge .............................. 05-231
Trailer Brakes (Hydraulic) - Purge .................... 05-232
Trailer Control Valve (Single Brake Line) ........... 05-89
Transmission Power Flow .................................. 05-56
Troubleshooting Procedure .............................. 05-188
Turn .................................................................... 05-42
Turning with Steering and Transmission Input ... 05-60
79033095 C Rev. 05-245

Index
NOTES
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05-246 79033095 C Rev.

Contents
Challenger ®
Rubber Tracked Tractor
SERVICE MANUAL
79033095 C Rev.
06 - Implement Hydraulic and Three-Point Hitch

Systems
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Contents
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IMPLEMENT AND THREE-POINT HITCH SYSTEMS OPERATION

General Information ....................................................................................................................................... 06-1
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Introduction .............................................................................................................................................. 06-1

Implement Hydraulic System ................................................................................................................... 06-1
Three-Point Hitch .................................................................................................................................... 06-2
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Implement Hydraulic System ......................................................................................................................... 06-3

Introduction (Implement System) ............................................................................................................ 06-3
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Implement System ................................................................................................................................... 06-5

Implement System Electronic Component Locations ............................................................................ 06-10
Implement System Hydraulic Component Locations ............................................................................. 06-14
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Features of Implement System ............................................................................................................. 06-22

Implement System Input Components .................................................................................................. 06-25
Implement System Control Settings ...................................................................................................... 06-27
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Electronic Control Modules for Implement System ............................................................................... 06-28

Output Components of Implement System ........................................................................................... 06-31
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Data Link for Implement System ........................................................................................................... 06-32

Common Sump (Implement) ................................................................................................................. 06-33
Hydraulic Oil Filter (Implement) ............................................................................................................. 06-40
Tandem Charge Pump .......................................................................................................................... 06-42
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Hydraulic Pump (Implement) ................................................................................................................. 06-44

Intermediate Valve Stack ...................................................................................................................... 06-58
Priority Valve ......................................................................................................................................... 06-59
Hydraulic Control Valves ....................................................................................................................... 06-62
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Solenoid Valve (Service Brake) ............................................................................................................. 06-67

Hydraulic Power Beyond (If Equipped) ................................................................................................. 06-67
Hydraulic Motor Case Drain (If Equipped) ............................................................................................. 06-68
Three-Point Hitch System ............................................................................................................................ 06-71
Introduction (Three-Point Hitch System) ............................................................................................... 06-71
Three-Point Hitch System ..................................................................................................................... 06-72
Hitch Assembly ...................................................................................................................................... 06-78
Three-Point Hitch Electronic Component Locations .............................................................................. 06-80
Three-Point Hitch Hydraulic Component Locations .............................................................................. 06-85
Three-Point Hitch System Features ...................................................................................................... 06-88
Three-Point Hitch Input Components .................................................................................................... 06-93
Three-Point Hitch Control Settings ........................................................................................................ 06-96
Electronic Control Modules for Three-Point Hitch System .................................................................... 06-97
Three-Point Hitch Output Components ................................................................................................. 06-98
Data Link for Three-Point Hitch System ................................................................................................ 06-99
Three-Point Hitch Control Valve .......................................................................................................... 06-100
Accumulator (Three Point-Hitch) ......................................................................................................... 06-105
Control Valve (Steerable Three-Point Hitch) ....................................................................................... 06-105
79033095 C Rev. 06-i

Contents
Hydraulic Schematics ................................................................................................................................ 06-112
HYDRAULIC AND THREE-POINT HITCH DISASSEMBLY AND ASSEMBLY

Tandem Charge Pump .............................................................................................................................. 06-125
Tandem Charge Pump Removal ......................................................................................................... 06-125
Tandem Charge Pump Installation ...................................................................................................... 06-127
Implement (Piston) Pump .......................................................................................................................... 06-128
Implement Pump Removal .................................................................................................................. 06-128
Implement Pump Installation ............................................................................................................... 06-130
Scavenge (Gear) Pump ............................................................................................................................. 06-131
Scavenge Pump Removal ................................................................................................................... 06-131
Scavenge Pump Installation ................................................................................................................ 06-132
Steering (Piston) Pump .............................................................................................................................. 06-133
Steering Pump Removal ..................................................................................................................... 06-133
Steering Pump Installation .................................................................................................................. 06-135
Hydraulic Filter ........................................................................................................................................... 06-137
Hydraulic Filter Removal ..................................................................................................................... 06-137
Hydraulic Filter Installation .................................................................................................................. 06-140
Control Valve (Implement) ......................................................................................................................... 06-142
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Control Valve (Implement) - Drawbar Configuration ........................................................................... 06-143

Control Valve (Implement) - Three-Point Hitch Configuration ............................................................. 06-163
Control Valve Module Installation, Repair, Replacement and Calibration ........................................... 06-170
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Control Valve (Three-Point Hitch) .............................................................................................................. 06-172

Control Valve (Three-Point Hitch) Disassembly .................................................................................. 06-172
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Control Valve (Three-Point Hitch) Assembly ....................................................................................... 06-173

Intermediate Valve Stack ........................................................................................................................... 06-174
Intermediate Valve Stack Removal ..................................................................................................... 06-174
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Intermediate Valve Stack Disassembly ............................................................................................... 06-177

Intermediate Valve Stack Assembly .................................................................................................... 06-178
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Intermediate Valve Stack Installation .................................................................................................. 06-179

Relief Valve ................................................................................................................................................ 06-181
Relief Valve Removal .......................................................................................................................... 06-181
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Relief Valve Installation ....................................................................................................................... 06-182

Oil Cooler Bypass Valve ............................................................................................................................ 06-183
Oil Cooler Bypass Valve Removal ...................................................................................................... 06-183
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Oil Cooler Bypass Valve Installation ................................................................................................... 06-183

Three-Point Hitch ....................................................................................................................................... 06-184
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Three-Point Hitch Removal ................................................................................................................. 06-184

Three-Point Hitch Installation .............................................................................................................. 06-189
Rockshaft ................................................................................................................................................... 06-194
Rockshaft Removal ............................................................................................................................. 06-194
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Rockshaft Installation .......................................................................................................................... 06-196

Accumulator (Three-Point Hitch) ............................................................................................................... 06-199
Accumulator (Three-Point Hitch) Removal .......................................................................................... 06-199
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Accumulator (Three-Point Hitch) Installation ....................................................................................... 06-200

Three-Point Hitch Cylinder ......................................................................................................................... 06-201
Three-Point Hitch Cylinder Removal ................................................................................................... 06-201
Three-Point Hitch Cylinder Installation ................................................................................................ 06-203
Steering Cylinder (Three-Point Hitch) ........................................................................................................ 06-205
Steering Cylinder (Three-Point Hitch) Removal .................................................................................. 06-205
Steering Cylinder (Three-Point Hitch) Installation ............................................................................... 06-207
HYDRAULIC AND THREE-POINT SYSTEM TESTING AND ADJUSTING

Machine Preparation ........................................................................................................................... 06-209
Testing Procedure ............................................................................................................................... 06-209
Test Equipment ................................................................................................................................... 06-210
Warming the Hydraulic Oil ................................................................................................................... 06-210
Visual Inspection ........................................................................................................................................ 06-212
Control Valve Test Port Location ............................................................................................................... 06-213
Drawbar Configuration ........................................................................................................................ 06-213
Three-Point Hitch Configuration .......................................................................................................... 06-213
06-ii 79033095 C Rev.

Contents
Elevated Oil Reservoir (EOR) Test ............................................................................................................ 06-214
Introduction .......................................................................................................................................... 06-214
Required Tools .................................................................................................................................... 06-214
EOR Test Procedure ........................................................................................................................... 06-215
Hydraulic Pump Pressure Tests ................................................................................................................ 06-216
Low Pressure Standby Test ................................................................................................................ 06-216
Margin Pressure Test .......................................................................................................................... 06-218
High Pressure Stall Test ...................................................................................................................... 06-222
High Pressure Cutoff Test ................................................................................................................... 06-227
Implement Valve Pilot Pressure Test ......................................................................................................... 06-231
Introduction .......................................................................................................................................... 06-231
Required Tools .................................................................................................................................... 06-231
Implement Valve Pilot Pressure Test Procedure ................................................................................. 06-232
Implement Hydraulic Operational Checks ................................................................................................. 06-233
Resequencing and Calibration of Valve Sections ...................................................................................... 06-234
Configuration and Resequencing ........................................................................................................ 06-238
Valve Section Calibration .................................................................................................................... 06-244
Flashing Software ................................................................................................................................ 06-247
Resequencing and Calibration Process Completion ........................................................................... 06-250
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Hydraulic Oil Cooler Tests ......................................................................................................................... 06-251

Hydraulic Oil Cooler Pressure Test ..................................................................................................... 06-251
Oil Cooler Bypass Valve Pressure Test .............................................................................................. 06-253
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Three-Point Hitch Operational Checks ...................................................................................................... 06-255

Three-Point Hitch Cylinder Drift ........................................................................................................... 06-256
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Three-Point Hitch Control Valve Solenoid - Calibrate ................................................................................ 06-256

Introduction .......................................................................................................................................... 06-256
Required Tools .................................................................................................................................... 06-256
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Calibration Procedure .......................................................................................................................... 06-257

Three-Point Hitch Sensors-Calibrate ......................................................................................................... 06-261
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Required Tools .................................................................................................................................... 06-261

Calibration Procedure .......................................................................................................................... 06-261
Three-Point Hitch (Steerable) Sensors - Calibrate .................................................................................... 06-264
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Accumulator (Three-Point Hitch) - Test and Charge ................................................................................. 06-265

Accumulator Nitrogen Charge Test ..................................................................................................... 06-265
Accumulator Charging Procedure ....................................................................................................... 06-267
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INDEX ........................................................................................................................................................... 06-271

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79033095 C Rev. 06-iii

Contents
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06-iv 79033095 C Rev.

Implement and Three-Point Hitch Systems Operation
IMPLEMENT AND THREE-POINT HITCH SYSTEMS
OPERATION
GENERAL INFORMATION
Introduction
FIG. 1: This module discusses features and operation of
the implement hydraulic system and three-point hitch
system. In addition, major electrical components and
hydraulic components are discussed. The following
machines are covered in this module:
• MT835C
• MT845C
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• MT855C
• MT865C
• MT875C
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P111012005
FIG. 1
Implement Hydraulic System
in
FIG. 2: Implement hydraulic system provides a metered

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flow of pressurized oil. Quick couplers distribute

pressurized oil to implements. Pressurized oil is used to
operate implements.
rn
Implement hydraulic system has following

features:
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• Closed center
• Load sensing
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• Pressure and flow compensating

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• User-Selectable priority on Circuits 1 and 2 P081812003
When flow demand of implements exceeds output of FIG. 2

hydraulic pump (1), system will reduce flow to each active
on
circuit to attempt to maintain flow to prioritized circuit.

Flow from each circuit will be reduced by same
percentage of flow commanded.
ly
Implement hydraulic system is controlled with electronics.

Virtual Terminal (VT) allows operator to precisely control
flow rate and detent time for each individual hydraulic
control valve.
Additionally, flow priority can be selected for circuits 1 and
2, forcing flow demands for these circuits to be satisfied
before sending any remaining flow capacity to other
circuits.
Machines utilize a new elevated oil reservoir in addition to
common sump. Elevated oil reservoir ensures that
hydraulic pump for implement hydraulic system has a
steady supply of oil regardless of pump demand or slope
of machine.
A load sensing relief valve is used to limit maximum
system pressure. Compensator valve serves as a backup
to load sensing relief valve for limiting maximum system
pressure.
79033095 C Rev. 06-1

Three-Point Hitch
FIG. 3: Steerable three-point hitch is used to mount
implements to machine.
Three-point hitch utilizes an electro-hydraulic system to
operate linkage. Standard three-point hitch is equipped
with a quick hitch. Lift capacity of three-point hitch is 8845
kg (19500 lb).
Draft control operates in response to engine speed.
The system for slip control allows three-point hitch to raise
in response to slippage between ground and Mobil-trac
system belts.
Steering function of three-point hitch provides assistance
to machine's differential steering system while a mounted
implement is working in ground.
Hydraulic cylinders attached to draft arms provide
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steering.
Virtual Terminal (VT) allows operator to precisely control P091112008
various functions of three-point hitch.
FIG. 3
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06-2 79033095 C Rev.

IMPLEMENT HYDRAULIC SYSTEM
Introduction (Implement System)

FIG. 4: Machine is equipped with a hydraulic system that
provides necessary power to operate attached
implements. Implement hydraulic system is similar to
previous models.
Implement hydraulic system has following main
components:
• Common sump and elevated oil reservoir (EOR)
• Hydraulic filter
• Hydraulic pump
• Hydraulic control valves P091112009
• Electronic controls FIG. 4

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Common Sump
FIG. 5: Common sump (1) provides system oil for
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implement hydraulic system and all remaining hydraulic

systems on machine. Elevated Oil Reservoir (EOR) (2)
in
provides clean oil to satisfy instantaneous demands of 2

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1
P011812008
FIG. 5
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Implement Hydraulic Filter

FIG. 6: Hydraulic filter (1) protects implement hydraulic
system from damaging contamination. Hydraulic filter will
filter particles in charge oil and return oil that are larger
on
than 7.5 microns.

1
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P081812004
FIG. 6
79033095 C Rev. 06-3

Implement Hydraulic Pump
FIG. 7: Implement hydraulic pump (1) is capable of
producing a maximum flow of 223 liters/min (59 gal/min).
An optional 165 liters/min (43.5 gal/min) implement
hydraulic pump is also available. Implement hydraulic
pump is a variable displacement axial piston pump with
load sensing and pressure compensation.
Pump output only takes place when an implement
demands flow. When demand is low, pump destrokes and
pump output is reduced. This conserves power that can
be used on other systems.
1
P081812003
FIG. 7
Hydraulic Control Valves

Fo
FIG. 8: Machine is equipped with at least four hydraulic

control valves (1). Hydraulic control valves are
electronically controlled. Machine may be equipped with a
maximum of six hydraulic control valves.
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Each hydraulic control valve has capability of delivering

in
3.8 to 113.6 liters/min (1 to 30 gal/min).

Optional high flow valves are available for special
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application machines. Each high flow valve will have

capability of delivering 3.8 to 155 liters/min (1.0 to 55 1
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gal/min).
P091112010
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FIG. 8
Electronic Controls (Hydraulic Levers)

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FIG. 9: Hydraulic control valves are controlled by inputs

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from hydraulic levers (1) located in console.

1
on
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P081912011
FIG. 9
06-4 79033095 C Rev.

Implement System
1 7 8
2 5
3
9 10
6
4
15 16
12
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14
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11
13
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17 18 19
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P110712002
FIG. 10
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FIG. 10: Electrical and hydraulic components of Operator can initiate a hydraulic function by using
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implement system. one of following controls:

(1) Implement Filter Bypass Switch (1) Hydraulic control levers 5-6
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(2) Hydraulic Control Levers 1-6 (2) Hydraulic control levers 1-6
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(3) Roading Lockout Switch (3) Roading lockout switch

(4) One-Touch Button (4) One-touch switch
(6) Armrest ECM Controls will send a signal to armrest ECM (6). ECM
on
processes signal before sending signal to appropriate

(5) Machine ECM
solenoid (8) on hydraulic control valve bank (9).
(7) Virtual Terminal (VT)
Signal that is sent to solenoid on hydraulic control valve
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(8) Solenoids can be altered by Virtual Terminal (VT) (7).

(9) Hydraulic Control Valves Selected hydraulic control valve will send oil to implement
(10). Increased demand for oil will cause hydraulic pump
(10) Implement (11) to upstroke.
(11) Hydraulic Pump Hydraulic pump is supplied with oil from elevated oil
(12) EOR reservoir (EOR) (12). Tandem charge pump (13) draws oil
from common sump (14). Oil passes through hydraulic
(13) Charge Pump filter (15) before being routed toEOR.
(14) Common Sump Oil from hydraulic pump passes through intermediate
(15) Filter valve bank (16) before being routed to hydraulic control
valve bank.
(16) Intermediate Valve Stack
(17) Sump
(19) First Pressure Reduction
79033095 C Rev. 06-5

Implement Electronic Control System
6
5
7
8
3
2
1
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4
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10
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11
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P110512009
FIG. 11
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FIG. 11: Electrical block diagram for the implement

system
(1) Hydraulic Control Levers 1 - 6
on
(2) Armrest ECM

(3) Switch (Roading Lockout)
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(4) One-Touch Button

(5) Machine (ECM)
(6) Implement Filter Bypass Switch
(8) Dash panel cluster
(9) Powertrain CAN BUS
(10) Auxiliary CAN BUS
(11) Hydraulic Control Solenoids 1 - 6 (valves)
Hydraulic control valves (No. 1 through No. 4) are
standard equipment, while hydraulic control valves (No. 5
and No. 6) are optional.
06-6 79033095 C Rev.

CAN BUS is a communication bus that is used to
• Engine ECM
• Machine ECM
• Armrest ECM
Hydraulic control lever sends a pulse width modulated
signal (PWM) to armrest ECM. ECM verifies signal is
operating within a range. If signal is out-of-range, a fault
code will be set. ECM processes signal and ECM sends a
signal to hydraulic control solenoid that is proportionate to
input signal. ECM also monitors circuit for solenoid
valves. If a malfunction in circuit is detected, a fault code
Fo
will be set. Hydraulic control solenoid will open hydraulic

valve to allow oil flow to implement.
Signal sent to hydraulic control solenoid can be altered by
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roading lockout switch or by VT.

in
When roading lockout switch is enabled, ECM will place

hydraulic control solenoids in hold mode. If a hydraulic
control is in float mode, ECM will continue float mode. If a
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hydraulic control is operating detent mode, ECM will finish

detent mode. Hydraulic control will then be placed in hold
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mode.
Roading lockout switch will also disable decelerator pedal
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and auto guidance.

VT display can be used to set amount of maximum flow.
Maximum flow rate can be set from 0% to 100% on each
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hydraulic control. ECM will reduce signal to solenoid by

percent of maximum flow rate and by position of hydraulic
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control lever. Solenoid will open hydraulic valve to obtain

desired flow rate in accordance with signal from ECM.
on
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79033095 C Rev. 06-7

Implement Hydraulic System
26
24 12
27
25
16 15
23 13
30
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28
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29 11
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9 14
22
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31 32 33
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34 35 36
P013112003
FIG. 12
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FIG. 12: Implement hydraulic system block diagram. (28) Load Sense Signal
Implement hydraulic system consists of following (29) Implement valve reference signal
components:
(30) Hydraulic Oil Cooler
on
(9) Hydraulic Control Valve Bank

(11) Hydraulic Pump
(32) Sump
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(12) Elevated Oil Reservoir (EOR)

(14) Common Sump
(35) Load Sense
(15) Hydraulic Filter
(36) Reduced Pilot Oil Pressure
(16) Intermediate Valve Bank
Oil from common sump (14) is drawn through suction
(22) Suction Screen screen (22) by tandem charge pump (13). Oil passes
through hydraulic oil cooler (30) before being routed to
(23) Hydraulic Power Beyond
hydraulic filter (15). Filtered oil is routed to EOR (12).
(24) Differential Lube
When implement hydraulic pump (11) demands oil, oil
(25) Check Valve from EOR and oil from tandem charge pump combine to
feed implement hydraulic pump.
(26) Case Drain Return Port
(27) Case Drain Filter
06-8 79033095 C Rev.

Oil from hydraulic pump is routed to inlet manifold of Precompensated Pressure
intermediate valve bank (16). Priority valve and
Hydraulic control valve bank on machine utilizes parallel
accumulator charging valve located in inlet manifold will
logic. Parallel logic system operates in one of two modes.
allow oil flow not needed for service brakes to be routed to
Oil flow demand from attached implement determines
hydraulic control valve bank (9). Next, operator selects
mode of operation for parallel logic system.
hydraulic control valve that will send oil to implement.
Also, oil may bypass hydraulic control valve bank and flow Additionally, flow priority can be selected for circuits 1 and
directly to implement through hydraulic power beyond 2, forcing flow demands for these circuits to be satisfied
connections (23). before sending any remaining flow capacity to other
circuits.
Return oil from implement flows through appropriate
hydraulic control valve before being routed through
Condition One
hydraulic filter (15). If hydraulic pump demands oil, filtered
return oil is routed back to hydraulic pump. If there is no Flow demanded by hydraulic control valve bank is
demand, return oil is routed to EOR (12). Once EOR is less than maximum output of pump.
full, oil is routed to differential steer lubrication system
(24). Any remaining oil not used by EOR or used for In this condition, all hydraulic control valves have an equal
lubrication returns to common sump (14) through check opportunity to obtain oil flow. Demands of hydraulic
valve (25). control valve bank are satisfied. This is known as parallel
logic.
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Case drain oil from a hydraulic motor on an implement is

routed through case drain return port (26) (if equipped). Condition Two
Case drain oil is also used in differential steer lubrication
Flow demanded by hydraulic control valve bank is
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system (24) before returning to common sump (14). Case

drain return port is equipped with a filter (27). more than maximum output of pump.
in
Load sensing signal (28) and implement valve reference If pump output is exceeded in parallel logic hydraulic
signal (29) are routed from hydraulic control valve bank to system, circuits with lowest pressure are satisfied first.
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hydraulic pump to influence pump output. Load sensing Circuits with highest pressure are satisfied last.
signal is routed through load sensing relief valve located
in hydraulic control valve bank. This relief valve limits Example
rn
pressure of load sensing signal to 181 to 185 bar (2625 to No. 1 hydraulic control valve demands 114 liters/min (30
2685 psi). Hydraulic pump has a margin pressure of 1900 gal/min) at 13790 kPa (2000 psi). No. 2 hydraulic control
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to 2100 kPa (275 to 305 psi). Combination of load valve demands 95 liters/min (25 gal/min) at 6900 kPa
sensing signal and margin pressure is system pressure. (1000 psi). Available pump output is 167 liters/min (44
Maximum system pressure is limited to 200 to 206 bar gal/min).
(2900 to 2988 psi).
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In this example, oil demand is 38 liters/min (10 gal/min)

Implement valve reference signal provides a true greater than available pump output. Pump output is
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representation of supply pressure as oil enters hydraulic exceeded.

control valve bank.
In this parallel logic hydraulic system, circuits with the
lowest pressure are satisfied first, so No. 2 hydraulic
on
control valve will have its demand met fully. No. 1

hydraulic control valve demands will not be fully met since
circuits with highest pressure are satisfied last.
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79033095 C Rev. 06-9

Implement System Electronic Component
Locations
Electronic system for implement consists of
• Levers (hydraulic control) (No. 1 through No. 6)
• Switch (implement filter bypass)
• CAN data link
• VT Display (Virtual Terminal)
• Solenoid valves (hydraulic control) (No. 1 through No.
Fo
6)
Levers (Hydraulic Control)

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FIG. 13: Hydraulic control levers (1 through 6) are

located on VT in front of handrest.
in
Hydraulic control levers signal armrest ECM that operator

wants to activate hydraulic control valve for implements
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(No. 1 through No. 6). 6

5
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3 4
1 2
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P012405001
FIG. 13
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Switch (Roading Lockout)

FIG. 14: Switch (1) is located on VT behind handrest.
on
Switch signals ECM that operator wants to disable

following functions:
• Hydraulic control valves
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• Deceleration pedal
• Auto guidance
1
P020112001
FIG. 14
06-10 79033095 C Rev.

Button (One-Touch)
FIG. 15: One-touch button (1) is located on transmission
control lever.
Button signals ECM that operator wants to perform
multiple operations with a single command.
1
P020112002
FIG. 15
Switch (Implement Filter Bypass)

Fo
FIG. 16: Implement filter bypass switch (1) is located on

left-hand side of machine in front of rear axle. Bypass
switch is mounted on filter base. Bypass switch for
implement filter is mounted next to bypass switch for
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steering filter. Bypass switch for implement filter is inner

switch in tandem arrangement of two switches and two
in
filters.
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Switch signals ECM that implement filter is restricted. A

warning will be displayed on Virtual Terminal (VT), an 1
audible alarm will sound and a warning light will illuminate
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on dash.
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P010412005
FIG. 16
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CAN Data Link

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(1) Powertrain Bus
on
(2) Auxiliary Bus

(3) ISO Bus
1
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CAN data link is located in cab wall on right-hand side of

seat. 2 3

• Machine ECM
79033095 C Rev. 06-11

Machine ECM
FIG. 18: Machine ECM (1) is located on left-hand side of
machine beneath floorplate of cab in front of trainer seat.
Machine ECM controls following components:
• Transmission 1
• Steering
• Parking brake
• PTO
N110905003
FIG. 18
Armrest ECM
Fo

located in console, beneath armrest.
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in

1
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control amount of oil flow that is sent to implement.

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electronic control modules and components. P100812005
FIG. 19
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06-12 79033095 C Rev.

Virtual Terminal (VT) Display
FIG. 20: VT display (1) is located on VT in front of
VT display allows operator to adjust following
functions for implement system: 1
• Flow rate
• Detent time
Refer to Operation and Maintenance Manual, VT
Hydraulic Control Valve Screen, for a detailed description
of VT screens associated with implement hydraulic
system.
P012205003
FIG. 20
Hydraulic Control Valve Solenoid Valves

Fo
FIG. 21: Hydraulic control valves (1) are located on rear

of machine. Solenoid valves (2) are located on right-hand
side of hydraulic control valves.
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2
Hydraulic control valves control flow of hydraulic oil to
in
components on implement. Two solenoids are supplied

for each hydraulic control valve: Proportional and On/Off
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(Extend Only).
1
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P091112012
FIG. 21
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79033095 C Rev. 06-13

Implement System Hydraulic Component
Locations
Common Sump
FIG. 22: Common sump (1) provides system oil for
implement hydraulic system and all remaining hydraulic
systems on machine. Elevated oil reservoir (EOR) (2)
provides clean oil to satisfy instantaneous demands of 2
1
P011812008
Fo
FIG. 22
Elevated Oil Reservoir

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FIG. 23: Elevated oil reservoir (1) is located in upper

front portion of differential housing. Elevated oil reservoir
in
is a source of filtered oil for hydraulic pump for implement

hydraulic system. 1
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P020112005
FIG. 23
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Suction Screen
FIG. 24: Tandem charge pump suction screen (1) for
common sump is located directly in front of left-hand final
drive.
Suction screen will filter particles that are larger than 200 1
microns. Suction screen filters all sump oil before oil is
routed to inlet of tandem charge pump.
P010412008
FIG. 24
06-14 79033095 C Rev.

Solenoid Valve (Service Brake)
FIG. 25: Solenoid valve (1) is located in priority valve on
top of differential housing.
Solenoid valve prevents accumulator for service brakes
from being charged during engine start-up. This keeps
hydraulic pump for implement hydraulic system at low 1
pressure standby during engine start-up.
P100112001
FIG. 25
Hydraulic Oil Filter (Implement)

Fo
FIG. 26: Hydraulic filter (1) for implement hydraulic

final drive. Hydraulic filter for implement hydraulic system
is inboard filter.
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1
Hydraulic filter will filter all charge oil and return oil before
in
oil is routed to inlet of hydraulic pump for implement

hydraulic system. Hydraulic filter will filter particles larger
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than 7.5 microns.

rn
P081812004
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FIG. 26
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79033095 C Rev. 06-15

Tandem Charge Pump
left-hand side of machine and behind hydraulic pump for
Charge pump is a two-section gear pump.
Large Section
Large section of tandem charge pump supplies oil
to following hydraulic systems:
• Steering hydraulic system 1
P081812003
FIG. 27
• Parking brake system
Small Section
Fo
Small section of tandem charge pump supplies oil

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• Three-point hitch hydraulic system (If equipped)
in
• Steerable three-point hitch hydraulic system (If

equipped)
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• Hydraulic trailer brake system (If equipped)

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06-16 79033095 C Rev.

Hydraulic Pump (Implement)
FIG. 28: Implement hydraulic pump (1) is located on
left-hand side of machine in front of final drive.
Implement hydraulic pump is an axial piston pump. Pump
is capable of delivering 165 liters/min (43.5 gal/min). An
optional 223 liters/min (59 gal/min) hydraulic pump is also
available. Hydraulic pump delivers a maximum output
pressure of 200 to 206 bar (2900 to 2988 psi).
Hydraulic pump supplies oil to following
components:
1
• Three-point hitch control valve (If equipped) P081812003
• Steerable three-point hitch control valve (If equipped) FIG. 28

Fo

• Hydraulic trailer brake system (If equipped)
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Compensator Valve
FIG. 29: Compensator valve (1) is bolted to top of
in
hydraulic pump.
Compensator regulates pump output flow in
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response to following signals:

• Load sensing signal
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• Implement valve reference signal 1

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Compensator valve also serves as a backup for limiting

maximum system pressure.
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P020112007
FIG. 29
on
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79033095 C Rev. 06-17

Intermediate Valve Stack
FIG. 30: Intermediate valve stack (1) is located on top of
differential housing. Intermediate valve stack may be
equipped with a total of three valves.
1
Intermediate valve stack provides hydraulic oil flow to
three-point hitch and to hydraulic control valves once
demands of service brakes are satisfied.
Following valves are located in intermediate valve
stack:
• Hydraulic trailer brake valve
• Priority valve and accumulator charging valve
P100112001
• Three-point hitch control valve
FIG. 30
• Steerable three-point hitch control valve

Fo
FIG. 31: Hydraulic control valve bank (1) is located at

rear of machine. Machine may be equipped with a total of
six hydraulic control valves.
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Hydraulic control valves control delivery and return of

in
hydraulic oil flow to implements attached to machine. 1

Each hydraulic control valve has following
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positions:
• Hold
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• Extend
• Extend Detent
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P100112002
• Retract FIG. 31
• Retract Detent
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• Float
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Load Sense Relief Valve

FIG. 32: Load sensing relief valve (1) is located on end
cover of hydraulic control valve bank.
on
Load sensing relief valve is used for governing system

pressure. Relief valve is set at 181 to 185 bar (2625 to
2685 psi). Relief valve is adjustable.
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P100112003
FIG. 32
06-18 79033095 C Rev.

Hydraulic Power Beyond (If Equipped)
FIG. 33: Hydraulic power beyond (if equipped) is located
at rear of machine on top of hydraulic control valve bank.
NOTE: CE machines use a different style of coupler.
3
Hydraulic power beyond allows oil flow from hydraulic
pump to bypass hydraulic control valve bank.
Hydraulic power beyond is equipped with following
couplers:
(1) Pressure 2
(2) Return
1
(3) Load sensing P100112004
FIG. 33
Hydraulic Motor Case Drain (If Equipped)
FIG. 34: Port: Case drain return port (1) (if equipped) is
Fo
located at rear of machine. If machine is equipped with a

three-point hitch, case drain return port will be located on
rear right-hand side of machine. If machine is equipped 2
with a wide swing drawbar, case drain return port will be
r
located at rear center of machine.

in
Case drain port serves as a low pressure return for case

drain oil from hydraulic components mounted on
implements. Flow capacity for case drain return port is 5.7
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liters/min (1.5 gal/min).

Filter: Case drain circuit is equipped with a case drain
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filter (2). Return oil is filtered before oil enters lube circuit.
Filter will filter particles larger than 25 microns.
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1
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P100112005
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FIG. 34
on
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79033095 C Rev. 06-19

air-to-air after cooler (transparent in figure for clarity).
Hydraulic oil cooler provides cooling for all hydraulic 1
systems that use oil from common sump.
P100112006
FIG. 35
Oil Cooler Bypass Valve

Fo
FIG. 36: Oil cooler bypass valve (1) is located in filter

housing for hydraulic filter (implement).
1
If oil pressure in hydraulic oil cooler becomes excessive,
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oil cooler bypass valve will divert oil around hydraulic oil
cooler.
in
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P100112007
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FIG. 36
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on
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06-20 79033095 C Rev.

Test Ports
FIG. 37: Following test ports are located on end cover of
hydraulic control valve bank:
(1) Pilot Supply Pressure
3
(2) Pump Supply Pressure
(3) Return Pressure 1
2
Test port (1) will measure pressure of pilot supply. Test
port (2) will measure actual pump output being delivered
to manifold of hydraulic control valve bank. Test port (3)
will measure pressure in return oil circuit.
P100112008
FIG. 37
FIG. 38: Load sense test port (1) is located on bottom of
implement hydraulic valve stack.
Fo
1
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P110712003
FIG. 38
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FIG. 39: Test port (4) is located near hydraulic pump for
implement hydraulic system. Test port (4) will measure
pressure of oil in elevated oil reservoir.
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P100112009
FIG. 39
FIG. 40: Test ports (5) are located on implement filter
housing. Test ports (5) will measure pressure differential
across hydraulic oil cooler.
P100112010
FIG. 40
79033095 C Rev. 06-21

Features of Implement System
Hydraulic Control Lever Operation
FIG. 41: Hydraulic control levers have following
positions: 4 1 2
(1) Hold
5
(2) Extend 6 3
(3) Extend Detent
(4) Retract
(5) Retract Detent
(6) Float
Hold (1) — Hold position is used to hydraulically lock P110512011
implement circuit when not using implement circuit. FIG. 41
IMPORTANT: Do not hold an implement control lever in
Fo
extend or retract position for an extended period

of time after a remote cylinder has reached end
of travel. This places excess stress on hydraulic
r
components and may lead to component failure.

in
Extend (2) — Pull back hydraulic control lever from Hold

position to Extend position to extend a hydraulic cylinder.
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Extend Detent (3) — Pull back hydraulic control lever

from Hold position and through Extend position until a
higher point of resistance is felt. Continue to pull lever
rn
through this point of resistance. This will begin cycle for

detent. Release lever. Lever will return to Hold position.
However, hydraulic control valve will continue to operate in
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detent function until cycle is complete. Move hydraulic

control lever out of Hold position to deactivate cycle of
detent function.
u
IMPORTANT: Do not hold an implement control lever in

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extend or retract position for an extended period

of time after a remote cylinder has reached end
of its travel. This places excess stress on
hydraulic components and may lead to
on
component failure.
Retract (4) — Push hydraulic control lever from Hold
position to Retract position to retract a hydraulic cylinder.
ly
Retract Detent (5) — Push hydraulic control lever from

Hold position and through Retract position until first point
of higher resistance is felt. Continue to push lever through
first point of resistance. This will begin cycle for detent.
Release lever. Lever will return to Hold position. However,
implement control valve will continue to operate in detent
function until cycle is complete. Move hydraulic control
lever out of Hold position to deactivate cycle of detent
function.
Float (6) — Move hydraulic control lever all way forward
to place hydraulic control valve in Float position. When
hydraulic control lever is in Float position, hydraulic
cylinder extends or hydraulic cylinder retracts to follow
ground contour. Hydraulic control lever will not
automatically return to Hold position. Use Float position to
retract a single-acting cylinder. Also, use Float position as
Off position for hydraulic motors.
06-22 79033095 C Rev.

Roading Lockout Switch
FIG. 42: Lockout switch has following positions:
(1) Lock position 1
(2) Unlock position 2
Roading lockout switch should be used whenever
machine is operated on road.
Switch signals armrest ECM that operator wants to
disable following features:
• Decelerator pedal
P093012011
• Auto guidance
FIG. 42
• Steerable hitch
When switch is placed in LOCK position, ECM will place
Fo
all implement functions in hold mode unless one of

following functions are being performed:
Float - When switch is placed in LOCK position and a
r
hydraulic lever is positioned in float mode, ECM will

remain in float mode. When hydraulic lever is moved out
in
of float mode, ECM will place implement function in hold

mode.
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Detent - When switch is placed in LOCK position and a

hydraulic lever is performing detent mode, ECM will
remain in detent mode. When hydraulic lever is moved out
rn
of hold position or when time has elapsed in detent mode,

ECM will then place implement function in hold mode.
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on
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79033095 C Rev. 06-23

One-Touch
FIG. 43: One-touch button (1) is located on shift handle.
One-touch feature will allow multiple operations to be
performed with a single command.
One-touch feature has two modes of operation:
• Shift mode 1
• One-touch mode
Shift Mode
Shift mode is only active if NO one touch actions are
programmed. Shift mode allows transmission to P031911001
automatically shift a programmed number of gears.
FIG. 43
Shift mode will be disabled when one-touch mode is
active. To activate shift mode after using one-touch,
one-touch needs to be cleared.
Fo
Refer to Operation and Maintenance Manual, One Touch

Recording, for procedure that is used for clearing
one-touch sequence.
r
One-Touch Mode
in
One-touch mode will record a sequence of operations for

end of row (raise sequence) or beginning of row (work
te
sequence).
Recorded sequence of operations can then be performed
rn
by depressing one-touch button (raise sequence or work

sequence).
al
Following functions can be recorded and

performed in one-touch mode:
• Transmission (upshift)
u
• Transmission (downshift)
se
• Engine speed (RPM) (Increased or Decreased)

• Three-point hitch (raise)
on
• Three-point hitch (lower)

• Hydraulic control (extend detent)
• Hydraulic control (retract detent)
ly
• Hydraulic control (float)

• Power take-off (on/off control)
• Area accumulation in the performance monitor (on/off
control)
NOTE: Power management mode is automatically
disengaged when one-touch is active.
06-24 79033095 C Rev.

Implement System Input Components
FIG. 44: Roading lock out switch (1) is located in console
in front of armrest. Switch signals armrest ECM that
operator wants to disable following functions: 1
• Hydraulic Control Valves
• Decelerator Pedal
• Auto Guidance
• Hitch
• Steerable Hitch
P093012011
Switch is a two-position rocker switch. Switch has a set of
normally open contacts and a set of normally closed FIG. 44
contacts. When switch is in unlock position, terminals 2
and 1 are closed. A +3.33V battery signal is received by
Fo
pin 21 of armrest ECM.

When switch is in lock position, terminals 2 and 4 are
closed. A +1.66V battery signal is received by pin 21 of
r
armrest ECM.
in
ECM recognizes change in voltage and reacts

appropriately.
te
If input signals from switch are incorrect, ECM will disable

this feature. A diagnostic code will also be set by ECM.
rn
One-Touch Button
FIG. 45: One-touch button (1) signals armrest ECM that
al
operator wants to perform multiple operations with a

single command.
u
Button is normally closed between pin 10 and pin 12

which sends a +3.33V signal to pin 14 of armrest ECM.
se
When button is depressed, pin 10 and pin 11 are closed 1

which sends a +1.66V signal to pin 14 of armrest ECM.
If input signals from button are incorrect, ECM will disable
one-touch feature. A diagnostic code will be set by ECM.
on
P031911001
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FIG. 45
Implement Filter Bypass Switch

FIG. 46: Implement filter bypass switch signals ECM that
implement filter is restricted. A warning will be displayed
on VT display, a diagnostic code will be logged, a warning 1
light will be lit and an audible alarm will sound.
Switch is a pressure switch. Switch has one set of
normally closed contacts. When switch is in normal state,
machine ECM will receive a signal on connector J1 on pin
55. When switch is activated, signal will open.
(1) Pin 1
2
(2) Pin 2 P051912001
FIG. 46
79033095 C Rev. 06-25

Hydraulic Lever Position Sensor
FIG. 47: Hydraulic Lever Position Sensor:
(1) Ground - Brown
(2) +12V Power - White 1
(3) U Signal - Green
Hydraulic control levers signal armrest ECM that operator
wants to activate one of hydraulic control valves for 2
implements (No. 1 through No. 6).
Hydraulic control lever sends a proportional signal to 3
ECM. Signal is pulse width modulated signal (PWM)
generated at a constant frequency of 500 Hz. Signal will P110612001
vary duty cycle according to position.
FIG. 47
When hydraulic control lever is in neutral position a duty
cycle of 50% ±3% is seen by ECM. When hydraulic
control lever is moved from neutral position, duty cycle will
Fo
vary from 50% to 10% and from 50% to 90%.

Following list indicates pins of ECM which receives signal
for hydraulic lever (No. 1 through No. 6).
r
Hydraulic lever (No. 1) - Signal is received on pin 34 of

in
armrest ECM.
te
armrest ECM.
rn
armrest ECM.
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armrest ECM
armrest ECM.
u

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armrest ECM.
ECM receives proportional signals and ECM will send a
proportional signal to corresponding hydraulic control
valve.
on
ECM monitors hydraulic control levers for abnormal

frequencies or abnormal pulse width signals. A diagnostic
code will be set and hydraulic control lever will not
ly
function.
06-26 79033095 C Rev.

Implement System Control Settings
Implement system controls hydraulic control valves (No. 1
through No. 6). Hydraulic control valves (No. 1 through
No. 4) are standard equipment. Hydraulic control valves
(No. 5 and No. 6) are optional equipment.
Hydraulic control valves (No. 5 and No. 6) will need to be
setup, if equipped. VT will display status of valves as
Installed or Not Installed.
Hydraulic control valves (No. 1 through No. 6) have
following control settings that can be changed within VT
display:
• Detent time
• Flow rate
Control Valve Operation, for more information.
Fo
Adjusting Detent Time

Each hydraulic control valve has an adjustable Detent
r
Time. This allows operator to control length of time for

hydraulic oil flow applied to an implement. Operator uses
in
VT screens to enter desired Detent Time. Same Detent

Time is used for RETRACT DETENT and EXTEND
DETENT. Detent Time can be adjusted from 0 to 20
te
seconds in one-second increments. Also, when Detent

Time is continuous, a (C) will be displayed on screen.
rn
Detent Time will become effective once operator enters

desired Detent Time. Detent Time is saved between
engine start-ups.
al
Adjusting Flow Rate

Each implement control valve has an adjustable hydraulic
u
flow rate. This allows operator to control rate of hydraulic

se
oil flow that is applied to an implement. Operator uses VT

screens to enter desired Flow Rate. Flow rate can be
adjusted from 0% to 100% in 0.2% increments. Flow Rate
will become effective once operator enters desired Flow
on
Rate. Flow rate is saved between engine start-ups.

Following table compares Flow Rate percentage to
approximate pump output.
ly
Flow Rate Approximate Flow (liters/min (gal/min))

0% 3.8 liters/min (1 gal/min)
50% 82.5 liters/min (21.8 gal/min)
100% 117 liters/min (31 gal/min)
NOTE: 117 liters/min (31 gal/min) is maximum flow from

an individual hydraulic control valve.
Flow Rate for an individual hydraulic control valve can be
adjusted in range of 3.8 liters/min (1 gal/min) to 117
liters/min (31 gal/min).
79033095 C Rev. 06-27

Electronic Control Modules for Implement
System
Implement system uses two electronic control modules
(ECM) to control various functions.
Following electronic control modules are used in
implement system:
• Machine ECM
• Armrest ECM
Machine ECM
FIG. 48: Machine ECM controls various systems for
machine and has two connectors: J1 and J2
Following components are inputs to machine ECM for
implement system:
Fo
• Implement Filter Bypass Switch

• Armrest ECM
• VT Display J1
r
Following components are outputs from machine ECM for

J2
in
implement system:
• Solenoid Valves
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g00585949
• Load Sense Blocking Valve
FIG. 48
• Dash Cluster
rn
• VT Display
al

electronic control modules and diagnostic tools.
Refer to table 1 for contact description for J1 and J2
u
connectors of machine ECM.

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on
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06-28 79033095 C Rev.

Fo

r

in

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45 HYD OIL LEVEL SW

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NOTE: J1 and J2 are 70 pin connectors. Contacts that

are not listed are not used or may be used in
u
other systems.
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79033095 C Rev. 06-29

Armrest ECM
FIG. 49: Armrest ECM (1) is located in console below
communicate directly to armrest ECM. Armrest ECM
using CAN BUS network.
1
• Roading Lockout Switch
• One-Touch Button
• VT Display P100812005
• Dash Cluster FIG. 49

Following components are outputs from armrest ECM:
• Machine ECM
Fo
• VT Display
• Dash Cluster
r
Following table shows pins for J1 and J2 connectors of

machine ECM.
in
in this system.
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Pin Description
rn
1 POWER -
2 POWER +12V
al
3 ISO & SERVICE CAN +

4 ISO & SERVICE CAN -
8 SENSOR +3.33V
u
10 SENSOR +1.66V
se
11 MACHINE CAN +
12 MACHINE CAN -
14 ONE TOUCH SWITCH
21 ROADING LOCKOUT SWITCH
on
23 AUTO GUIDE SWITCH

31 HITCH SWITCH - RAISE
32 HITCH SWITCH - LOWER
ly
33 HITCH DEPTH LEVER POSITION

50 ROCKER SWITCH BACKLIGHTING
06-30 79033095 C Rev.

Output Components of Implement System
Armrest ECM activates solenoid valves for hydraulic
control valves. Solenoid valves (No. 5 through No. 6) are
optional equipment.
For each hydraulic control, there are two solenoid valves
(on/off and proportional). Valves receive a proportional
current from ECM. Maximum amount of current can be
set through VT display by changing Flow Rate parameter.
is detected, ECM will log diagnostic code in memory and
ECM will shut off power to valve.
On/Off Solenoid Valve

FIG. 50: Hydraulic control valve on/off solenoid valve (1)
(extend only).
On/off solenoid valves control whether hydraulic oil flow is
Fo
sent to an implement.
r
1
in
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P051912002
rn
FIG. 50
Proportional Solenoid Valve

al
FIG. 51: Hydraulic control valve proportional solenoid

valve (1).
u
Proportional valves control amount of hydraulic oil that is 1

sent to an implement.
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P051912002
FIG. 51
Load Sense Blocking Valve

FIG. 52: Load sense blocking valve (1) is located in
intermediate valve bank.
Solenoid valve prevents steer/priority valve from being
active during engine start-up. This keeps hydraulic pump
for implement hydraulic system at low pressure standby
during engine start-up.
1
P110712004
FIG. 52
79033095 C Rev. 06-31

Data Link for Implement System
1
5 6
4 8
7
9 10
Fo
3
r in
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11
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P110612003
FIG. 53
FIG. 53: Block diagram of connections of data links CAN data link is a communication bus that is used
al
to communicate with following components:

(1) ISO BUS
• Engine ECM
(2) Powertrain BUS
u
• Machine ECM
(3) Auxiliary BUS
se
• Armrest ECM
(4) Machine ECM
• Display module for the VT
(5) Engine ECM
on

(8) Auto Guide
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(9) Lighting ECM (three ECMs)

(10) Steerable Hitch Solenoid Controller
(11) Implement Control Valve Solenoid Controllers (four
standard - six optional)
06-32 79033095 C Rev.

Common Sump (Implement)
Common Sump
FIG. 54: Transmission and rear end house two oil
reservoirs:
(1) Elevated oil reservoir (EOR)
(2) Common sump 1
Common sump consists of following housings:
• Transmission housing
• Differential housing
• Final drive housing
2
NOTE: Transmission housing is separate from P011812008
differential housing and final drive housing but
share oil. FIG. 54
Fo
Common sump is shared by following systems:

r

in

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Common sump has a refill capacity of 246 liters (65 gal).
rn
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79033095 C Rev. 06-33

FIGS. 55–56: Two magnets are located in bottom of
common sump to attract any metallic contaminants. One
magnet (1) is located in differential housing. One magnet
(2) is located in transmission housing.
1
Fo
g00870424
FIG. 55
r in
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2
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P100112011
FIG. 56
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on
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06-34 79033095 C Rev.

4 6
3 8
Fo
2
9
r
P100112012
FIG. 57
in
FIG. 57: Hydraulic schematic of common sump.

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(2) Common sump

rn

(4) Scavenge pump
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(5) Filler cap

u
(7) Tandem charge pump

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(9) Ecology drain
on
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79033095 C Rev. 06-35

FIG. 58: Tandem charge pump will draw oil from
common sump through suction screen (1) whenever
engine is running. Suction screen is rated at 200 microns. 1
Oil is drawn from outside of suction screen to inside
before going to inlet of tandem charge pump.
A 20.7 kPa (3 psi) bypass valve (2) is located at end of
suction screen. If oil is cold during initial start-up,
unfiltered oil is allowed to bypass suction screen.
Main suction port is located on centerline of differential 2
housing. This ensures a positive flow of oil to tandem
charge pump during slope operation.
g00890980
FIG. 58

Fo
FIG. 59: Scavenge pump will draw oil from common

sump (transmission housing) through suction screen (1)
whenever engine is running. Suction screen is rated at 1
r
540 microns.
in

approximately 76 liters/min (20 gal/min) of oil to final
te
drives. Oil provides cooling to service brakes.

rn
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g00890976
FIG. 59
u
Breather
se
FIG. 60: Breather (1) is located near left-hand rear

corner of engine. Breather serves as a breather for
common sump. Breather will filter particles larger than 7 1
on
micron.
ly
P100112013
FIG. 60
06-36 79033095 C Rev.

Filler Cap
FIG. 61: Filler cap (1) is located at rear of machine to
left-hand of implement valve stack. Filler cap allows
hydraulic oil to be added to common sump.
P100112014
FIG. 61
Sight Gauge
Fo
FIG. 62: Oil level in common sump may be visually

inspected by using sight gauge (1). Sight gauge is located
at rear of machine near PTO.
r
NOTE: If operating machine on a steep slope, hydraulic

oil level must be maintained at FULL mark.
in
Refer to Operation and Maintenance Manual, Hydraulic 1

System Oil Level - Check, for procedure used for
te
checking hydraulic oil level.

rn
P100112015
al
FIG. 62
Oil Drain Plug

u
FIG. 63: Hydraulic oil is drained from common sump by

se
removing drain plug (1). Drain plug is located in bottom of

rear transmission housing. Common sump may also be
equipped with an ecology drain.
on
System Oil - Change, for more information about 1

changing hydraulic oil.
ly
P100112016
FIG. 63
79033095 C Rev. 06-37

Elevated Oil Reservoir (EOR)
FIG. 64: Elevated oil reservoir (EOR) (1) holds
approximately 45.4 liters (12 gal) of oil.
EOR (1) is located in upper front portion of differential 1
housing.
P100112017
FIG. 64
FIG. 65: Schematic of elevated oil reservoir.
(1) Line from Oil Cooler 5
Fo

r
(4) Power Beyond Drain

in
(5) Differential Lube Circuit

4
(6) Bearing Lube 6
te
(7) Bevel Gear

3
rn
Oil from small section of tandem charge pump is routed

through oil cooler to hydraulic filter. 7
2
al
1
u
P100112018
se
FIG. 65
FIG. 66: Inlet passage (1) and outlet passage (2) from
EOR are shown. 1
on
Filtered oil enters inlet passage on outside of differential

housing. Inlet passage fills EOR. EOR supplies filtered oil
through outlet passage to inlet of hydraulic pump for 2
ly
g00894104
FIG. 66
06-38 79033095 C Rev.

Check Valve (Elevated Oil Reservoir)
FIG. 67: Check valve (1) maintains following items:
• Oil level in EOR
• Lube pressure for differential steer lubrication system 2
If EOR is full, oil overflow will drain to common sump
through line check valve, and lube line (2). Oil overflow 1
from EOR lubricates bevel gear and pinion before falling
into common sump.
Also, check valve has capability of dumping large
amounts of return oil. Check valve opens at 45 to 65 kPa
(6.5 to 9.5 psi).
Test port can be used to check opening pressure of check g00894106
valve.
FIG. 67
Fo
r in
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79033095 C Rev. 06-39

Hydraulic Oil Filter (Implement)
Hydraulic Oil Filter Location
FIG. 68: Implement hydraulic filter (1) is located on
left-hand side of machine in front of final drive. Filter for
implement hydraulic system is inboard of filter for 2
transmission and steering hydraulic systems.
1
Hydraulic filter is a 7.5 micron filter.
Filter receives oil from small section of tandem charge
pump (2).
P100112007
FIG. 68
Fo
Oil Flow
FIG. 69: Schematic of hydraulic filter (implement).
3
r
(1) Line from Charge Pump, Oil Cooler, and Valve Bank
in
(2) Hydraulic Filter (Implement)

(3) Line to EOR, Test Port, and Implement Pump
4
te
(4) Bypass Valve 2

Charge oil from small section of tandem charge pump is
rn
routed to oil cooler and then to hydraulic filter. Return oil

from hydraulic control valve bank is routed to hydraulic
1
al
filter. Once combination of charge oil and return oil is

filtered by hydraulic filter, supply oil is routed to following P100112019
places:
FIG. 69
u
• Elevated Oil Reservoir

se
• Inlet of the Hydraulic Pump

on
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06-40 79033095 C Rev.

Implement Filter Bypass Circuit
FIG. 70: Hydraulic filter base contains bypass valve (1)
and bypass switch (2).
Implement Filter Bypass Valve 1

Bypass valve will open when a 496 kPa (72 psi) pressure
differential is felt between inlet pressure and outlet
pressure. This will allow unfiltered oil to bypass filter and
flow directly to implement circuit.
2
Following items will typically cause an oil filter to
be bypassed:
• Cold oil
• Excessive contamination in oil
• Full sediment capacity
Fo
Implement Filter Bypass Switch

Bypass switch notifies operator whenever filter is close to P100112020
plugging.
FIG. 70
r
Bypass switch is a normally closed 12 volt switch.

in
Bypass switch will open when a 248 to 304 kPa (36 to 44

psi) pressure differential is felt between inlet pressure and
outlet pressure.
te
Bypass switch will signal machine ECM. Event will be

shown on Virtual Terminal (VT). Warning level for event is
rn
a Level 2-Special.
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on
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79033095 C Rev. 06-41

Tandem Charge Pump
left-hand side of machine behind implement hydraulic
pump for implement hydraulic system. Tandem charge 1
pump is a two-section gear pump.
Charge pump is driven by drive shaft splined to
implement pump.
Oil from common sump enters charge pump through inlet.
Inlet feeds oil to both sections of tandem gear pump.
P100112007
FIG. 71
Large Section
Fo
FIG. 72: Large section (1) of tandem charge pump is

located near driven end of pump. Oil from common sump
enters charge pump through inlet. 1
r
Large section of tandem charge pump supplies oil

in

te

rn
• Parking brake system

P092912005
al
FIG. 72
Small Section
u
FIG. 73: Small section (1) of tandem charge pump.

se
Small section of tandem charge pump is located at

opposite end of drive shaft (2). 1
Small section of tandem charge pump supplies oil 2
on

• Elevated oil reservoir
ly

• Three-point hitch hydraulic system (if equipped)
• Steerable three-point hitch hydraulic system (if
equipped) P092912005
• Hydraulic power beyond (if equipped) FIG. 73
• Differential steer lubrication (if equipped)

• Hydraulic Trailer brake system (CE machines only)
06-42 79033095 C Rev.

NOTES
Fo
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79033095 C Rev. 06-43

2
12 13 3
18
15
1
4
Fo
r
14
in
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17 19
5
rn
16
al
P010305002
u
FIG. 74
se
FIG. 74: Implement hydraulic pump (12) is mounted to (14) Drive shaft
rear of pump drive. Pump drive is located on left-hand
side of machine. (15) Pump inlet
on
(16) Pump outlet

Callouts for illustration of implement Hydraulic pump are:
(1) Load sensing signal (17) Bias spring
ly
(2) Pressure and flow compensator valve (18) Swashplate

(19) Actuator piston
(3) Margin spring
(4) Flow compensator spool (A) Sump
(5) Implement valve reference signal

(12) Hydraulic pump
(13) Cylinder barrel assembly
06-44 79033095 C Rev.

Hydraulic pump has following characteristics:
• variable displacement
• load sensing
• compensation for pressure
• compensation for flow
This piston type pump has variable flow and pressure.
Flow and pressure are dependent on system demands
that are sensed by pressure and flow compensator valve
(2).
Hydraulic pump has the following components:
Cylinder barrel assembly (13) — Cylinder barrel
contains nine pistons. Cylinder barrel assembly rotates
whenever engine is running. Pistons move oil into and out
of barrel.
Fo
Drive shaft (14) — Rotation of pump is counterclockwise

when pump is viewed from drive end. Cylinder barrel
assembly is splined to drive shaft.
r
Bias spring (17) — If there is no pressure behind

actuator piston, bias spring will hold swashplate at
in
maximum angle.
Swashplate (18) — Displacement of pump is controlled
te
by angle of swashplate. Angle of swashplate causes

pistons to move in and out of rotating barrel.
rn
Actuator piston (19) — When oil pressure increases

behind actuator piston, piston will overcome force of bias
spring causing angle of swashplate to be reduced.
al
Pressure and flow compensator valve (2) —

Pressure and flow compensator valve controls delivery of
oil and return of oil to actuator piston.
u
When engine is Off, pressure and flow compensator valve

se
does not receive a load sensing signal (1) or Implement

valve reference signal (5). Margin spring (3) pushes flow
compensator spool (4) completely to right. Any pressure
behind actuator piston (19) is vented to case drain across
on
flow compensator spool.

When there is no pressure behind actuator piston, bias
spring (17) is able to hold swashplate (18) at maximum
ly
angle.
When engine is started, drive shaft (14) starts to rotate.
Oil flows into piston bore from pump inlet (15). Oil is
forced out of pump outlet (16) and into system as cylinder
barrel assembly (13) rotates.
79033095 C Rev. 06-45

Compensator Valve
4 2
3
20 5
Fo
r
6 7
in
8 9
10
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A
11
rn
P010305003
al
FIG. 75
FIG. 75: Callouts for illustration of compensator valve Compensator valve (2) is bolted to top of hydraulic pump.
u
are: Compensator valve compensates for pressure variations

se
and flow variations in implement hydraulic system. Flow

(1) Load sensing signal
compensator spool (4) regulates pump output flow in
(2) Pressure and flow compensator valve response to following signals:
(3) Margin spring • Load sensing signal (1)
on
(4) Flow compensator spool • Implement valve reference signal (5)

(5) Implement valve reference signal Load sensing signal (1) is received through pump signal
ly
control network.
(6) Cutoff spring
(7) Pressure compensator spool
(8) Case drain passage
(9) Orifice
(10) Pump output pressure
(11) Signal passage to actuator piston
(20) Margin pressure adjusting screw
(A) Sump
06-46 79033095 C Rev.

FIG. 76: Implement valve reference signal (1) originates
from bottom of hydraulic control valve bank. This signal
accounts for any line loss between hydraulic pump and
inlet manifold for hydraulic control valve bank. Therefore, 1
Implement valve reference signal represents true pump
output pressure delivered to hydraulic control valve bank.
This lowers flow variance.
Flow supplied by hydraulic pump is amount that is
required to keep supply pressure 1900 to 2100 kPa (275
to 305 psi) above pressure of load sensing signal.
Difference between pressure of Implement valve
reference signal and pressure of load sensing signal is
P092912006
called margin pressure. Flow compensator spool controls
margin pressure. FIG. 76
Margin pressure is equal to spring force value of margin
spring.
Margin pressure is adjusted by turning adjustment screw
Fo
on flow compensator spool.

Pressure compensator spool limits maximum system
pressure to 225 to 235 bar (3265 to 3405 psi).
r
NOTE: Flow compensator spool limits system pressure

to 200 to 206 bar (2900 to 2988 psi). If load
in
sensing relief valve is not adjusted correctly,

pressure compensator spool serves as a
te
backup.
Pressure and flow compensator valve has an orifice in
rn
signal passage to actuator piston. Orifice is used to

regulate response rate of actuator piston by creating a
consistent leak path.
al
NOTE: Orifice must be installed with slot for screwdriver

parallel to spool bores.
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on
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79033095 C Rev. 06-47

Low Pressure Standby
2
18
12 3
1
Fo
4
r in
17
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19
16 5
rn
A B C D
al
E
u
P010305004
se
FIG. 77
FIG. 77: Callouts for illustration of implement hydraulic (D) Pump input
pump are:
on
(E) Implement valve reference signal

(F) Load sensing signal
(2) Pressure and flow compensator valve
When hydraulic pump (12) produces flow, system
ly
(3) Margin spring pressure begins to increase because oil flow from pump
outlet (16) is blocked at closed center implement control
(4) Flow compensator spool
valves.
Implement valve reference signal (5) is felt at bottom end
(12) Hydraulic pump of flow compensator spool. Flow compensator spool
moves upward against margin spring (3). This permits
(16) Pump outlet system oil to flow to actuator piston (19).
(17) Bias spring When pressure on actuator piston (19) increases, force of
(18) Swashplate bias spring (17) is overcome and swashplate (18) is
moved to a slight angle.
(A) Sump
(B) Pump output
(C) Reduced pump output
06-48 79033095 C Rev.

Hydraulic pump (12) produces enough flow to
compensate for normal system leakage when swashplate
(18) is at a slight angle. Also, hydraulic pump has
sufficient pressure to provide instantaneous response
when an implement is activated.
If there is no flow demand from an implement hydraulic
circuit, no load sensing signal (1) is generated.
Pressure at pump outlet (16) must only overcome force of
margin spring (3). Pressure at pump outlet is called low
pressure standby. Low pressure standby is approximately
2415 kPa (350 psi).
Low pressure standby is higher than margin pressure.
This is due to a higher back pressure created by oil
blocked at closed center valves when valves are in hold
position.
When hydraulic pump is at low pressure standby,
Implement valve reference signall (5) pushes flow
Fo
compensator spool (4) to top. This further compresses

margin spring. An increased amount of supply oil from
pump outlet will flow to actuator piston (19) slightly
r
destroking the hydraulic pump.

NOTE: Amount of system leakage and adjustments to
in
flow compensator spool can cause margin

pressure to equal low pressure standby. Margin
te
pressure can never be higher than low pressure

standby.
rn
Low pressure standby is not adjustable. Low pressure

standby can vary from one machine to another machine.
Also, low pressure standby can vary in same hydraulic
al
pump as system leakage increases.

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on
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79033095 C Rev. 06-49

Upstroke
2
3
18
12
1
4
Fo
r in
17
19 5
te
16
A B D E
rn
F
al
P010405001
u
FIG. 78
se
FIG. 78: Callouts for illustration of implement hydraulic (D) Pump input
pump are:
on
(F) Load sensing signal

When an implement hydraulic circuit requires flow,
(3) Margin spring pressure from pump outlet (16) is reduced. Reduced
ly
pump output pressure causes force of spring (3) and load

sensing signal (1) to be greater than Implement valve
(5) Implement valve reference signall reference signal (5). This force is on top end of flow
compensator spool (4). Force is greater than pump
(12) Hydraulic pump supply pressure and Implement valve reference signal at
(16) Pump outlet bottom end of spool.
(17) Bias spring Spool moves to bottom which blocks flow of oil to actuator
piston (19). Oil in chamber for actuator piston is vented to
(18) Swashplate case drain across flow compensator spool (4). This allows
(19) Actuator piston bias spring (17) to move swashplate (18) to a greater
angle.
(A) Sump
Pump now produces more flow. This condition is known
(B) Pump output as upstroking.
06-50 79033095 C Rev.

Following conditions can result in upstroking
pump:
• If implement hydraulic circuit is initially activated from
low pressure standby, load sensing signal increases
pump output flow. This increased pump output flow is
routed to position of a main control spool of a
hydraulic control valve that demands oil.
• If a main control spool in a hydraulic control valve is in
a given position, pump will slightly upstroke to
compensate for system leakage.
• Hydraulic pump will upstroke when demand
increases from changing position of main control
spool in a hydraulic control valve.
• If another implement hydraulic circuit is engaged,
there is a need for increased pump flow.
• If demand on implement hydraulic system remains
Fo
constant or demand increases, hydraulic pump will

upstroke when engine speed decreases.
• If accumulator for service brakes needs charging,
r
there is a need for increased pump flow.

NOTE: Load sensing signal pressure does not need to
in
increase to upstroke hydraulic pump.

te
For example, if one implement hydraulic circuit is

activated at an operating pressure of 138 bar (2000 psi),
system pressure is 158 bar (2290 psi). Pressure of 158
rn
bar (2290 psi) is a combination of margin pressure and

pressure of signal oil.
al
If another implement hydraulic circuit is activated at an

initial operating pressure of 6900 kPa (1000 psi),
maximum pressure of load sensing signal will still be 138
u
bar (2000 psi). Supply oil will decrease momentarily to

provide more flow that is now needed at additional circuit.
se
Pressure of load sensing signal and margin spring is now

higher than Implement valve reference signal at bottom
end of spool. Flow compensator spool is pushed to
bottom. This allows oil behind actuator piston to be vented
on
to case drain. Angle of swashplate now increases and

hydraulic pump provides more flow.
ly
79033095 C Rev. 06-51

Constant Flow
2
18 3
12
1
4
Fo
r in
17
19 5
te
16
A B C
rn
D E F
al
P010405002
FIG. 79
u se
FIG. 79: Callouts for illustration of implement hydraulic (F) Load sense signal
pump are:
When a constant flow of oil is demanded by an implement
(1) Load sensing signal hydraulic circuit, supply oil pressure from pump outlet (16)
on
will increase at flow compensator spool (4).

Following pressures will react on top end of flow
(3) Margin spring
compensator spool:
ly

• Margin spring (3)
• Load sensing signal (1)
(12) Hydraulic pump
Following pressure will react on bottom end of flow
(16) Pump outlet compensator spool:
(17) Bias spring • Implement valve reference signal (5)
(18) Swashplate Once pressures become equal on each end of spool, flow
compensator spool will meter oil to actuator piston (19)
(19) Actuator piston and system will stabilize.
(A) Sump Swashplate (18) is held at a relative constant angle to
(B) Pump output maintain required flow.
(D) Pump input
06-52 79033095 C Rev.

Destroke
2
18 3
12
1
4
Fo
r in
17
19 5
te
16
A B C
rn
D E F
al
P010405003
FIG. 80
u
FIG. 80: Callouts for illustration of implement hydraulic When less flow is required, hydraulic pump (12)
se
pump are: destrokes. Hydraulic pump destrokes when pressure of

Implement valve reference signal (5) becomes greater
than pressure of load sensing signal (1) and margin
(2) Pressure and flow compensator valve spring (3).
on
(3) Margin spring Flow compensator spool (4) moves to top which allows
more oil flow to actuator piston (19). Pressure on actuator
(4) Flow compensator spool piston is now increased.
ly
(5) Implement valve reference signal Increased pressure overcomes force of bias spring (17)
(12) Hydraulic pump which moves swashplate (18) to a reduced angle. When
pressure of Implement valve reference signal matches
(16) Pump outlet combined pressure of load sensing signal and margin
(17) Bias spring spring, flow compensator spool returns to a metering
position. Hydraulic pump will return to constant flow.
(18) Swashplate
(A) Sump
(B) Pump output
(D) Pump input
(F) Load sense signal
79033095 C Rev. 06-53

Following conditions result in destroking hydraulic
pump:
• When a main control spool for a hydraulic control
valve is moved to hold position.
• If main control spool for a hydraulic control valve is
moved to a position that requires less flow.
• If multiple hydraulic control valves are being used,
hydraulic pump will destroke when there is a
reduction in demand from any one of hydraulic
control valves.
• If there is a slight reduction in highest operating
pressure, or a reduction in built-in system leakage.
• If engine speed increases.
• When accumulator for service brakes finishes
charging.
Fo
When hydraulic pump destrokes, supply oil pressure from

pump outlet decreases on bottom side of flow
compensator spool.
r
Force on top of flow compensator spool is sum of

following pressures:
in
• Margin spring
te

Following force reacts on bottom of flow
rn
compensator spool:
• Implement valve reference signal
al
Once forces become equal on each end of spool, flow

compensator spool will meter oil to actuator piston and
system will stabilize.
u
NOTE: Load sensing signal pressure does not need to

se
decrease to destroke hydraulic pump.

For example, if two implement hydraulic circuits are
activated at operating pressures of 138 bar (2000 psi) and
69 bar (1000 psi), system pressure is 158 bar (2290 psi).
on
If implement hydraulic circuit which is activated at 69 bar

(1000 psi) is returned to hold position, maximum pressure
of load sensing signal will still be 138 bar (2000 psi).
ly
However, pressure of Implement valve reference signal is

momentarily increased due to reduced oil flow required in
implement hydraulic circuits.
Implement valve reference signal moves flow
compensator spool to top which allows more oil flow
behind actuator piston. Angle of swashplate now
decreases and hydraulic pump provides less flow.
06-54 79033095 C Rev.

High Pressure Stall
12 7
Fo 1
16 5
in
te
A B C
rn
D E F
P010405004
FIG. 81
al
FIG. 81: Callouts for illustration of implement hydraulic Margin pressure of 1900 to 2100 kPa (275 to 305 psi)
u
pump are: above load sensing signal is still maintained while

hydraulic pump is at high pressure stall.
se

(2) Pressure and flow compensator valve If hydraulic pump is at high pressure stall, maximum
(3) Margin spring system pressure will be 200 to 206 bar (2900 to 2988
(7) Pressure compensator spool psi).
on

If load sensing relief valve is not adjusted correctly,
(12) Hydraulic pump
pressure compensator spool serves as a backup to
(16) Pump outlet
protect hydraulic system.
(A) Sump
ly
(B) Pump output Hydraulic pump is now at minimum flow and supply oil at
(C) Reduced pump output pump outlet is at maximum pressure. These conditions
(D) Pump input are maintained for a single implement in a stall condition.
(E) Implement valve reference signal During these conditions, the need for a main system relief
(F) Load sense signal valve in implement hydraulic system is eliminated.
If multiple implement hydraulic circuits are activated,
If hydraulic pump (12) is at high pressure stall or hydraulic pump still produces flow while one circuit is at
maximum system pressure, pressure of load sensing high pressure stall. This flow meets needs of other circuits
signal (1) and margin spring (3) is equal to pressure of operating at a lower work port pressure. Hydraulic pump
Implement valve reference signal (5). could be producing maximum flow while pressure of
supply oil from pump outlet is at maximum.
Load sensing relief valve (21) limits maximum system
pressure at any pump displacement. Load sensing relief
valve is set at 181 to 185 bar (2625 to 2685 psi).
79033095 C Rev. 06-55

1
5
7
Fo
r in
21
te
12 P010405005
FIG. 82
rn
al
u se
21
on
P092912007
ly
FIG. 83
FIGS. 82–83: Callouts for Three-Point Hitch Control Valve
and pump compensator valve are:
(7) Pressure compensator spool
(12) Hydraulic pump
(21) Load sensing relief valve
Load sensing relief valve (21) is located on left-hand side
of inlet manifold for hydraulic control valves. This valve
protects implement hydraulic system by limiting maximum
system pressure.
06-56 79033095 C Rev.

High Pressure Cutoff
6
18 3
12 7
1
4
Fo
17
r
19 16 5
in
te
A B C
rn
D E F P010405006
FIG. 84
al
FIG. 84: Callous for illustration of implement hydraulic Combined pressure of load sensing signal (1) and margin
u
pump are: spring (3) forces flow compensator spool to bottom. This
combined pressure must be at least 225 to 235 bar (3265
se
(1) Load sensing signal to 3405 psi). When flow compensator spool moves to
(3) Margin spring bottom, a passage will normally be opened. This allows
(4) Flow compensator spool oil that is holding actuator piston (19) to be vented to case
(5) Implement valve reference signal drain. This will cause implement hydraulic pump to
on
(6) Cutoff spring upstroke until system pressure is 212 bar (3075 psi).
(12) Hydraulic pump
(16) Pump outlet Implement valve reference signal (5) is also greater than
(17) Bias spring 212 bar (3075 psi).
ly
(18) Swashplate
If pressure of supply oil from pump outlet (16) is greater
than 212 bar (3075 psi), supply oil pushes compensator
(A) Sump
spool toward top against cutoff spring.
(B) Pump output
(C) Reduced pump output Movement of pressure compensator spool blocks oil from
(D) Pump input actuator piston from flowing to case drain. This allows
(E) Implement valve reference signal supply oil to flow to actuator piston.
(F) Load sense signal
Pressure compensator spool (7) is in parallel with flow Increase in pressure on actuator piston overcomes force
compensator spool (4). Pressure compensator spool of bias spring (17). Swashplate (18) moves and hydraulic
serves as a backup for protecting hydraulic system if load pump destrokes.
sensing relief valve is not adjusted correctly and limits
maximum system pressure at any pump displacement.
Pressure compensator spool is forced to bottom during
normal operation by cutoff spring (6). Cutoff spring has a
spring force value of 225 to 235 bar (3265 to 3405 psi).
79033095 C Rev. 06-57

Intermediate Valve Stack
FIG. 85: Intermediate valve stack is located on top of
differential housing. Intermediate valve stack may be
equipped with a total of three valves.
(1) Steerable Three-Point Hitch Control Valve (If
equipped)
(2) Priority Valve
2 1
(3) Hydraulic Trailer Brake Valve (If equipped)
Intermediate valve stack provides hydraulic oil flow to
three-point hitch and hydraulic control valves once
demands of service brakes are satisfied.
3
Hydraulic trailer brake valve is not included in
precompensated pressure. This valve receives oil flow
priority after service brakes.
P100212001
Three-point control valve acts in parallel with remaining
Fo
FIG. 85
valves in hydraulic control valve stack (implement).
Steerable three-point hitch control valve is included in
precompensated pressure. When operation of multiple
r
hydraulic control valve results in a flow demand that

exceeds output of hydraulic pump, oil flow to steerable
in
three-point hitch control valve is proportionally reduced.

te
Priority valve is located on bottom of intermediate valve

stack when not equipped with a trailer brake valve. Priority
valve gives oil flow priority to service brakes.
rn
In addition, this valve charges accumulator for service

brakes. If machine is not equipped with a three-point hitch
al
or trailer brakes, this will be only valve located in

intermediate valve stack.
All of supply oil from hydraulic pump (implement) is routed
u
to intermediate valve stack. Oil flow that is not needed by

service brakes or hydraulic trailer brakes (if equipped) is
se
routed to hydraulic control valve bank.

Pressure oil is sent to accumulator for service brakes.
Then a load sensing signal from accumulator charging
on
valve is sent to hydraulic pump (implement).

Internal oil leakage is routed to common sump. If machine
is equipped with a three-point hitch, return oil from
ly
steerable three-point hitch control valve is also routed to

sump.
06-58 79033095 C Rev.

Priority Valve
FIG. 86: Priority valve (1) is located in intermediate valve
stack above final drive. There may be a steerable hitch
valve (2) and/or a hydraulic trailer brake valve (3) in
intermediate valve stack with priority valve depending on
options of machine. 2
This valve directs oil flow to braking system as a priority
over implement hydraulic system.
1
3
P092612006
FIG. 86
FIG. 87: Priority Valve Exploded View
Fo
Main Components:
(1) Valve Body
(2) Load Sense Blocking Valve
r
3
(3) Load Sense Blocking Solenoid 2
4
in
(4) Priority Valve

(5) Brake Charge Valve
te
1
rn
al
u se
on
5
Q012912001
FIG. 87
ly
79033095 C Rev. 06-59

1 7
2 B A
3
C
4
6
Fo
8
r
D
in
te
9
rn
al
E
u
Q012912002
FIG. 88
se
FIG. 88: Priority Valve Cut Away - Flow to Implement When no charge pressure is present at brake charge port
Valve Stack brake charge valve is shifted to left by spring.
on
(1) Pump Pressure Pump pressure slides priority valve to left, compressing
(2) Return Pressure spring and allowing pump pressure to flow to rear remote
(3) Control Pressure supply port.
ly
(4) Restricted Flow

(5) Load Sense
(6) Trapped Oil
(7) Load Sense Solenoid
(8) Priority Valve
(A) Pump Supply Port
(B) Rear Remote Supply Port
(C) Load Sense Port
(D) Brake Charge Port
(E) Return Port
06-60 79033095 C Rev.

1 7
2 B A
3
C
4
6
Fo
8
r
D
in
te
9
rn
al
E
u
Q012912003
FIG. 89
se
FIG. 89: Priority Valve Cut Away - Flow to Brake Charge When brake system requests pressure, brake charge
Circuit valve is shifted to right and hydraulic pressure is sent from
on
pump through priority valve and out brake charge port.

(1) Pump Pressure
(2) Return Pressure As brake system request is diminished, priority valve
(3) Control Pressure shifts to allow more pump hydraulic flow to go to
ly
(4) Restricted Flow implement system.

(5) Load Sense
(6) Trapped Oil
(7) Load Sense Solenoid
(8) Priority Valve
(A) Pump Supply Port
(B) Rear Remote Supply Port
(C) Load Sense Port
(D) Brake Charge Port
(E) Return Port
79033095 C Rev. 06-61

FIG. 90: Hydraulic control valve stack (1) is located at
rear of machine. Machine may be equipped with a total of
six hydraulic control valves.
P100212002
FIG. 90
FIG. 91: Oil ports for delivery and return of oil to valve
bank are shown.
Fo
2
(1) Supply oil from priority valve
(2) Implement valve reference signal routed back to
r
hydraulic pump
(3) Return oil back to hydraulic filter
in
(4) Load sensing signal back to hydraulic pump

te
(5) Load sensing signal back to priority valve 3

Hydraulic control valves control delivery and return of
rn
hydraulic oil flow to implements attached to machine.

Each hydraulic control valve has following 1
al
positions:
• HOLD
u
• EXTEND 5 4 P100212003
• RETRACT
se
FIG. 91
• FLOAT
on
ly
06-62 79033095 C Rev.

Hold Valve Function
1 2
B A
3 4
5 6
7 8
10
Fo
9
r
13
in
te
12
rn
al
u
11
se
Q012112003
FIG. 92
on
FIG. 92: Cut away of valve in Hold position - trapped When valve is in Hold position, both solenoids (9 and 10)
pressure. are off. Main spool valve (11) is centered. Poppet valves
(12) are seated and pressure in ports is trapped and not
(1) Pilot Sump Pressure allowed to return to tank.
ly
(2) Compensated Pressure

(3) Pilot Pressure
(4) Pump Pressure
(5) Work Port Pressure
(6) Coupler Sump Pressure
(7) Return Pressure
(8) Dirty Oil Coupler Drain
(9) On/Off Solenoid
(10) Proportional Solenoid
(11) Main Spool Valve
(12) Poppet Valve
(13) Compensator Valve
(A) A-port
(B) B-port
79033095 C Rev. 06-63

Extend Valve Function
1 2
B A
3 4
5 6
7 8
10
Fo
9
r
13 14
in
12
te
rn
al
11
u se
Q012112002
FIG. 93
on
FIG. 93: Cut away of valve in Extend position - A-port When operator signals valve to extend, a pulse width
pressure. modulation (PWM) signal is sent to proportional solenoid
(10) and pressure is applied to left-hand end of main
(1) Pilot Sump Pressure spool valve (11). Spool valve slides to right-hand end of
ly
(2) Control Pressure bore. Proportional solenoid pin rides up ramp and gives
(3) Pilot Pressure feedback as to position of spool valve.
(4) Pump Pressure
(5) Workport Pressure Pump Pressure (4) is allowed into right-hand passage.
(6) Coupler Sump Pressure Pump pressure lifts release valve (14) off of seat and
(7) Return Pressure pressure is sent to coupler in A-port.
(8) Dirty Oil Coupler Drain
Pilot pressure (3) forces left-hand poppet valve (12) to
(9) On/Off Solenoid
press release valve pin off of seat and allow release valve
to open. This allows return pressure (7) passage back to
tank.
(12) Poppet Valve
(14) Release Valve
(A) A-port
(B) B-port
06-64 79033095 C Rev.

Retract Valve Function
1 2
B A
3 4
5 6
7 8
10
Fo
14
9
14
r
13
in
12
te
rn
al
11
u se
Q012112001
FIG. 94
on
FIG. 94: Cut away of valve in Retract position - B-port When operator signals valve to retract, a pulse width
pressure. modulation (PWM) signal is sent to proportional solenoid
(10) and pressure is applied to right-hand end of main
(1) Pilot Sump Pressure spool valve (11) ramp. On/Off solenoid is activated and oil
ly
(2) Compensated Pressure trapped in left-hand end of main spool is released to allow
(3) Pilot Pressure spool to slide. Spool valve slides to left-hand end of bore.
(4) Pump Pressure Proportional solenoid pin rides up ramp and gives
(5) Workport Pressure feedback as to position of spool valve.
(6) Coupler Sump Pressure
(7) Return Pressure Pump Pressure (4) is allowed into left-hand passage.
(8) Dirty Oil Coupler Drain Pump pressure lifts release valve (14) off of seat and
(9) On/Off Solenoid pressure is sent to coupler in B-port.
Pilot pressure (3) forces right-hand poppet valve (12) to
press release valve pin off of seat and allow release valve
(12) Poppet Valve
to open. This allows return pressure (7) passage back to
tank.
(14) Release Valve
(A) A-port
(B) B-port
79033095 C Rev. 06-65

Float Valve Function
1 2
B A
3 4
5 6
9
Fo
8
r
12
in
11
te
rn
al
u
10
se
Q012112004
FIG. 95
on
FIG. 95: Cut away of valve in Float position. When operator signals valve to go to float, a pulse width
modulation (PWM) signal is sent to proportional solenoid
(1) Pilot Sump Pressure (10) to open fully and pressure is applied to right-hand
(2) Compensated Pressure end of main spool valve (11) ramp. On/Off solenoid is
ly
(3) Pilot Pressure activated and oil trapped in left-hand end of main spool is
(4) Pump Pressure released to allow spool to slide. Spool valve slides
(5) Return Pressure completely to left-hand end of bore. Proportional solenoid
(6) Coupler Sump Pressure pin rides up ramp and gives feedback as to position of
(7) Dirty Oil Coupler Drain spool valve.
(8) On/Off Solenoid
(9) Proportional Solenoid Pump Pressure (4) is blocked. Pilot pressure (3) forces
(10) Main Spool Valve both poppet valves (12) to press release valve pins off of
(11) Poppet Valve seats and allow release valves to open. This allows return
(12) Compensator Valve pressure (7) passage back to tank.
(A) A-port
(B) B-port
06-66 79033095 C Rev.

Solenoid Valve (Service Brake)
FIG. 96: Solenoid valve (1) is located in priority valve in
intermediate valve stack above final drive.
When solenoid valve is energized, load sensing signal
from accumulator to hydraulic pump is blocked.
This valve prevents hydraulic pump for implement
hydraulic system from upstroking to charge accumulator
for service brakes. Blockage of load sensing signal only
occurs during engine start-up. This prevents excessive
parasitic loads on starter while cranking engine.
1
P090912007
FIG. 96
Hydraulic Power Beyond (If Equipped)

Fo
FIG. 97: Callouts for hydraulic power beyond (if

equipped) are:
3
(1) Pressure
r
(2) Return
in
(3) Load sensing signal 1

te
Ports for hydraulic power beyond are located at rear of

machine in hydraulic control valve bank. 2
rn
Hydraulic power beyond allows hydraulic pump flow to

bypass hydraulic control valve bank. Implements that are
attached to hydraulic power beyond will receive desired oil
al
P100212004
flow before implements that are attached to hydraulic
control valve bank. FIG. 97
Hydraulic power beyond acts in parallel with hydraulic

u
control valve bank.

se
Therefore, hydraulic power beyond is not included in

pressure compensated system.
Hydraulic power beyond will provide a continuous flow of
on
oil whenever engine is running. Typically, implements that

are equipped with a dedicated control valve are attached
to hydraulic power beyond.
ly
Hydraulic power beyond is equipped with following

couplers:
• Pressure
• Return
• Load sensing
Couplers are available in following sizes:
• 12.7 mm (1/2 in) for less than 60 liters/min (16
gal/min) of continuous flow
• 19.05 mm (3/4 in) for more than 60 liters/min (16
gal/min) of continuous flow
A 12.7 mm (1/2 in) return coupler or a 19.05 mm (3/4 in)
return coupler is also available for use as a low pressure
return.
79033095 C Rev. 06-67

Hydraulic Motor Case Drain (If Equipped)
FIG. 98: Case drain return port (1) (if equipped) is
located at rear of machine. If machine is equipped with a
three-point hitch, case drain return port will be located on
rear right-hand side of machine. If machine is equipped
with a wide swing drawbar, case drain return port will be 1
located at rear center of machine.
Case drain port serves as a return for case drain oil from
hydraulic components mounted on implements.
Case drain return port is designed for following
types of oil:
• Low pressure oil
P100212004
• Low volume of oil FIG. 98
Flow capacity for case drain return port is 5.7 liters/min
(1.5 gal/min).
Fo
Case drain oil enters machine through the port. Oil will
pass through case drain filter before being routed to
differential steer lubrication system.
r
Overflow from elevated oil reservoir combines with

case drain oil to lubricate following items:
in
• Right axle
te
• Left axle
• Bearing
rn
• Bevel gear
FIG. 99: Case drain circuit is equipped with a case drain
al
filter (1). Filter will filter particles larger than 25 microns.
1
u se
on
P100212005
ly
FIG. 99
06-68 79033095 C Rev.

FIG. 100: Hydraulic oil cooler (1) is located directly
behind air-to-air after cooler (transparent in figure for
clarity). 1
Cooler provides cooling for all hydraulic systems that use
oil from common sump.
Cooler is split into two different sections. Each section of
tandem charge pump sends hydraulic oil through a
dedicated section of cooler.
Oil cooler keeps hydraulic oil at correct operating
temperature.
Hydraulic oil from small section of tandem charge pump P100112006
passes through oil cooler before being routed to oil filter. FIG. 100
If pressure differential between inlet and outlet of
hydraulic oil cooler exceeds 345 kPa (50 psi), oil cooler
Fo
bypass valve will divert oil around hydraulic oil cooler.

Following conditions could cause oil cooler bypass
valve to divert oil around hydraulic oil cooler:
r
• Cold hydraulic oil

in
• Restriction in a hydraulic oil line

• Restriction in hydraulic oil cooler
te
FIG. 101: Oil cooler bypass valve (1) is located in filter

housing for hydraulic filter (implement).
1
rn
al
u se
P100112007
on
FIG. 101
ly
79033095 C Rev. 06-69

NOTES
Fo
r in
te
rn
al
u se
on
ly
06-70 79033095 C Rev.

THREE-POINT HITCH SYSTEM
Introduction (Three-Point Hitch System)

FIG. 102: Machine is equipped with a three-point hitch
with steering capabilities.
Three-point hitch steering provides assistance to
machine's differential steering system while an implement
is working in ground.
Three-point hitch is controlled by Virtual Terminal (VT).
VT allows operator to change following parameters:
• Raise Limit
• Raise Rate
• Lower Rate
• Slip Sensitivity
Fo
• Draft Sensitivity
VT allows steerable three-point hitch to be
operated in following two Steer Modes:
r
• Manual P091112008
in
FIG. 102
• Float
te
Three-point hitch is designed to optimize design of

track-type machine. Three-point hitch provides optimum
balance that provides excellent performance in field and
rn
on road.
Quick hitch is designed specifically for loads of a
al
track-type machine. Quick hitch can be quickly and easily

converted from Category III to Category IVN. This allows
a wide variety of implements to be attached to machine.
u se
on
ly
79033095 C Rev. 06-71

Three-Point Hitch System
Following diagram shows electrical components and
hydraulic components of three-point hitch.
10 17
2
19
1 9
5
3 7
4 6
18
Fo
16 8
13
r in
15
te
11
14 12
rn
P110612005
FIG. 103
al
FIG. 103: Following components are shown in (15) Common sump

thillustration:
u
(16) Filter
(1) Raise/work switch
se
(17) Position sensor (steer)

(2) Raise/lower switch (left and right-hand fender)
(18) Hitch Control Valve (Steer)
(3) Three-Point hitch control lever
(19) Three-point hitch steer cylinders
on
(4) One-touch button

Operator can operate vertical functions of
(5) Machine ECM three-point hitch by using one of following
controls:
(6) Armrest ECM
ly
• Raise/work switch (1)

(7) Solenoids
• Raise/lower switch (fender mount) (2)
(8) Hitch Control Valve (Height)
• Three-point hitch control lever (3)
(9) Position sensor (lift)
• One-touch button (4)
(10) Virtual Terminal
(11) Three-point hitch lift cylinders
(12) Hydraulic pump
(13) Elevated oil reservoir (EOR)
(14) Charge pump
06-72 79033095 C Rev.

Controls will send a signal to either armrest ECM or
machine ECM. ECM processes signal before sending
signal to appropriate solenoid on three-point hitch control
valve.
Height position sensor will tell machine ECM actual
position of hitch. ECM will raise or lower hitch until
position of hitch matches position of three-point hitch
control lever.
Operator can use Virtual Terminal (VT) Display to adjust
Raise Rate and Lower Rate for three-point hitch by
adjusting strength of signal sent to solenoids on
three-point hitch control valve.
Three-point hitch control valve will send oil to three-point
hitch lift cylinders. Increased demand for oil will cause
hydraulic pump to upstroke.
Hydraulic pump is supplied with oil from elevated oil
reservoir (EOR). Tandem charge pump draws oil from
Fo
common sump. Oil passes through hydraulic filter before

being routed to elevated oil reservoir.
Operator can select following modes of operation
r
for steerable three-point hitch:

in
Lateral operation of steerable three-point hitch is

controlled by Virtual Terminal (VT).
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• Float feature
• Manual Feature
rn
Height position sensor and steer position sensor provide

feedback to machine ECM. Height position sensor tells
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ECM vertical position of hitch. Steer position sensor tells

ECM lateral position of hitch. ECM processes signal
before sending signal to appropriate solenoid on
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steerable three-point hitch control valve.

se
Steerable three-point hitch control valve will send oil to

steering cylinders. Increased demand for oil will cause
hydraulic pump to upstroke.
Hydraulic pump is supplied with oil from elevated oil
on
reservoir (EOR). Tandem charge pump draws oil from

common sump. Oil passes through hydraulic filter before
being routed to elevated oil reservoir.
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79033095 C Rev. 06-73

Three-Point Hitch Electronic Control System
11
1
15 12
16
6
8
14 7
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13 5
2
17
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4
3
in
10
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9
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R021512001
FIG. 104
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FIG. 104: Electronic system for hitch consists of Machine ECM controls right-hand steer solenoid valve (4)
following components: and left-hand steer solenoid valve (5) for three-point hitch.
(1) Machine electronic control module (ECM) Machine ECM receives information from position sensor
on
(2) Solenoid valve (hitch raising) (6) to sense lateral location of hitch and hitch lift position
(3) Solenoid valve (hitch lowering) sensor (7) to sense hitch height. ECM will also gather
(4) Solenoid valve (right steer) information over powertrain CAN BUS (8) from armrest
(5) Solenoid valve (left steer) ECM (17).
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(6) Position sensor (steerable hitch)

Signal sent to hitch solenoids can be altered by
(7) Position sensor (hitch lift)
following features:
(8) Powertrain CAN BUS
(9) Position sensor (hitch lever) • Hitch lever (9)
(10) Switch (raise/work)
(11) Switch (raise/lower) (left fender) • Switch (raise/work) (10)
(12) Switch (raise/lower) (right fender) • Switch (raise/lower) (11 and 12)
(13) Button (one-touch)
(14) Switch (roading lockout) • Switch (one-touch) (13)
(15) VT display • Switch (roading lockout) (14)
(16) Dash panel cluster
(17) Armrest electronic control module (ECM) • Draft control
• Slip control
Machine ECM (1) controls raise solenoid (2) and lower • External forces
solenoid (3) for three-point hitch.
06-74 79033095 C Rev.

Hitch lever sends a proportional signal to armrest ECM. Following list contains features used in steerable
Armrest ECM sends signal to machine ECM which three-point hitch system.
compares signal of hitch lever to signal of hitch height
• Float Feature
position sensor. Machine ECM will send a signal to raise
or lower solenoids to raise or lower hitch until position of • Manual Feature
hitch is equal to position of hitch lever. Machine ECM will
maintain correct height by varying current to solenoids to Float feature is used to aid in steering of machine or aid in
compensate for external forces on hitch. hooking up to an implement. Three-point hitch will freely
move laterally depending on external forces applied to
Raise/work switch is used to operate hitch. Raise/work three-point hitch.
switch sends signals to armrest ECM. Armrest ECM will
send signal to machine ECM to raise hitch to position Manual feature is used to hold steering of three-point
defined within VT display or ECM will lower hitch to hitch in a selected position. By using VT display, operator
position set by hitch lever. can move three-point hitch laterally or operator can hold
three-point hitch laterally in a selected position.
Raise/lower fender switches are used to aid in attachment
of implement. Raise/lower switches send signals to Refer to Operation and Maintenance Manual, VT
machine ECM. ECM will slowly raise or lower hitch. Three-Point Hitch (Steerable) Screen, for more details.
User can set following parameters through VT

Fo
display:
• Raise Limit
• Raise Rate
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• Lower Rate
in
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Refer to Operation and Maintenance Manual, Three-Point
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Hitch, for more details.

CAN BUS is a communication bus that is used to
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• Engine ECM
• Armrest ECM
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• Display module for the VT

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• Electronic Diagnostic Tool (EDT)

on
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79033095 C Rev. 06-75

Three-Point Hitch Hydraulic System
11
7 6
10
5
3
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13 12 1
8
in
2
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A B C D E
P100612002
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FIG. 105
FIG. 105: Following components are shown in (E) Steering Pressure Lines
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illustration:
Oil from common sump is drawn through suction screen
se
(1) Common Sump by tandem charge pump. Hydraulic filter filters oil from
small section of tandem charge pump. Filtered oil is
(2) Suction Screen
routed to EOR.
on
(4) Hydraulic Filter

(5) Check Valve
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(7) Differential Lube
(8) Hydraulic Pump
(9) Three-Point Hitch Lift Control Valve
(10) Steerable Three-Point Hitch Control Valve
(11) Steering Cylinders
(12) Accumulator
(13) Three-Point Hitch Lift Cylinders
(A) System Pressure
(B) Charge Pressure
(C) Load Sense Signal
(D) Return
06-76 79033095 C Rev.

Three-Point Hitch Vertical Functions
When three-point hitch is commanded to raise, oil from
EOR and oil from tandem charge pump combine to feed
hydraulic pump.
Oil from hydraulic pump is routed to intermediate valve
stack. Oil for three-point hitch lift cylinders is routed
through priority valve then to three-point hitch control
valve in implement control valve stack. Oil from
three-point hitch control valve is directed to three-point
hitch lift cylinders.
When three-point hitch is lowered, return oil from
three-point hitch lift cylinders flows through three-point
hitch control valve and is routed through hydraulic oil filter
then to EOR. Once EOR is full, oil is routed to differential
steer lubrication system. Any remaining oil not used by
EOR or used for lubrication returns to common sump
through check valve.
Fo
Load sensing signal is routed from priority valve in

intermediate valve stack to implement control valve stack
to hydraulic pump to influence pump output. Combination
r
of load sensing signal and margin pressure is system

pressure. Maximum system pressure is limited to 20000
in
to 20600 kPa (2900 to 2988 psi).

Accumulator is used to dampen any shock loads that
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occur while roading a heavy implement.

Three-Point Hitch Steering
rn
When three-point hitch steering is activated, oil from EOR

and oil from tandem charge pump combine to feed
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hydraulic pump.
Oil from hydraulic pump is routed to intermediate valve
stack. Oil from steerable three-point hitch control valve is
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directed to steering cylinders.

se
Steerable three-point hitch is controlled by Virtual

Terminal (VT).
VT allows steerable three-point hitch to be
operated in following modes:
on
• Manual
• Float
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Steering cylinders are double acting cylinders. Return oil

from steering cylinders flows through steerable
three-point hitch control valve before being routed to
EOR.
79033095 C Rev. 06-77

Hitch Assembly
Three-point hitch will accept implements
conforming to following standards:
• Category lll
• Category lVN
• Category lV
Several adjustments can be made to three-point hitch
linkage to accommodate operational requirements of
different implements.
Refer to Operation and Maintenance Manual, Implement
Leveling, for more information about adjusting three-point
hitch linkage.
Three-Point Hitch Components

FIG. 106: Following items are major components of
Fo
three-point hitch:
(1) Lift links 3
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(2) Top link

6
in
(3) Lift arms 1

(4) Draft arms
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(5) Quick Hitch 2

(6) Rockshaft
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5
Lift Links
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Lift links are used for vertical leveling of implement. Lift

links are positioned between lift arms and draft arms.
4
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Top Link
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Top link adjusts fore/aft pitch of implement relative to P091112008

machine. Also, top link provides upper single point of
attachment to implement or quick hitch. FIG. 106
Top link is positioned between rear case of machine and

on
quick hitch. If machine is not equipped with a quick hitch,

top link may be attached directly to implement.
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Lift Arms
Three-point hitch lift cylinders attach to bottom of lift arms.
Lift arms are raised by three-point hitch lift cylinders.
Rockshaft
Lift arms are splined to rockshaft. This ensures that both
lift arms will travel at same speed.
Lift Cylinders
Three-point hitch lift cylinders are responsible for lifting
entire three-point hitch linkage.
Steering Cylinders
Steering cylinders are responsible for lateral movement of
entire three-point hitch linkage.
06-78 79033095 C Rev.

Draft Arms
Draft arms provide two lower points of attachment to
implement or quick hitch. Draft arms allow draft load from
implement to be transferred to machine.
Quick Hitch
Standard quick hitch provides a fast, easy method for
attaching and for removing three-point hitch implements.
Quick hitch is set at factory for category III implements.
Quick hitch can be set to accept category IVN. A quick
hitch is available for category IV implements.
Refer to Operation and Maintenance Manual, Quick
Hitch, for more information about converting quick hitch.
Fo
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79033095 C Rev. 06-79

Three-Point Hitch Electronic Component
Locations
Electronic system for hitch consists of following
components:
• Position sensor (hitch lever)
• Position sensor (hitch lift)
• Position sensor (three-point hitch steering)
• Solenoid valves (hitch)
• Solenoid valves (three-point hitch steering)
• Switch (raise/work)
• Switch (raise/lower)
Fo

• Virtual Terminal Display (VT)
r
• CAN Data Link

in
Position Sensor (Hitch Lever)

te
FIG. 107: Hitch lever (1) is located on operator console

on right-hand side of handrest. Position sensor is located
at base of hitch lever.
rn
Hitch lever signals Armrest ECM that operator wants to 1

place three-point hitch at a specific height.
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P100712001
FIG. 107
on
Position Sensor (Hitch Lift)

FIG. 108: Position sensor (1) is located on right-hand
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rear end of machine. Position sensor is mounted near top

of three-point hitch directly in front of lift cylinder. Position
sensor is located beneath base plate of lever that
measures vertical movement.
Sensor signals machine ECM of height of three-point
hitch. 1
P100712002
FIG. 108
06-80 79033095 C Rev.

Position Sensor (Hitch Steering)
FIG. 109: Position sensor (1) for hitch steering is located
on rear of machine on front side of three-point hitch's
frame. Position sensor is physically located beneath a
protective cover.
Sensor signals machine ECM of lateral position of
three-point hitch. 1
NOTE: Cover is removed for clarity.
P100712003
FIG. 109
Switch (Raise/Work)
Fo
FIG. 110: Raise/work switch (1) is located on console in

front of transmission control lever.
Raise/work switch is used to raise and lower three-point
r
hitch by sending a signal to armrest ECM.

1
Depressing Raise position of switch will raise three-point
in
hitch to a height defined within VT display. Depressing

Work position of switch will lower three-point hitch to
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position set by hitch lever.

rn
P100712004
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FIG. 110
Switch (Raise/Lower) (Fender)

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FIG. 111: There are two raise/lower switches. One

raise/lower switch (1) is located on left-hand fender at rear
se
of machine. Second raise/lower switch (2) is located on

right-hand fender at rear of machine. 1 2
Raise/lower switch signals machine ECM that operator
on
wants to slowly raise or slowly lower three-point hitch.

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P100712005
FIG. 111
79033095 C Rev. 06-81

Button (One-Touch)
FIG. 112: One-touch button (1) is located on
transmission control lever.
Button signals armrest ECM that operator wants to
1
P020112002
FIG. 112
CAN Data Link

Fo

(1) Powertrain Bus
r
(2) Auxiliary Bus

in
(3) ISO Bus

1
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CAN data link are located in cab wall on right-hand side of

seat. 2 3
rn

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• Machine ECM
u

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Machine ECM
on
FIG. 114: Machine ECM (1) is located on left-hand side

of machine beneath floorplate of cab.
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Machine ECM controls operation of three-point hitch.

1
P100712006
FIG. 114
06-82 79033095 C Rev.

Armrest ECM
located in console, beneath armrest.
• Position sensors (hitch depth lever)
1
control amount of oil flow sent to hitch.
P100812005
CAN data link is used to communicate between other FIG. 115
electronic control modules and components.
Virtual Terminal (VT) Display

Fo
FIG. 116: VT display (1) is located on console in front of

hydraulic control levers. 1
VT allows operator to adjust following functions for
r
hitch system:
in
• Speed (raising)
• Speed (lowering)
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• Height (maximum)
• Draft control
rn
• Slip control
P031911004
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Refer to Operation and Maintenance Manual, VT FIG. 116

Hydraulic Control Valve Screen, for a detailed description
of VT screens associated with three-point hitch system.
u
Solenoid Valves (Hitch Lift)

se
FIG. 117: Hitch control valve is located on rear of

machine on top of three-point hitch. Hitch solenoids (1)
are two solenoids on front of hitch control valve.
on
Solenoid valves control flow of hydraulic oil to three-point

hitch to control vertical movement of hitch. Valves control
1
speed and position of hitch.
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P100712007
FIG. 117
79033095 C Rev. 06-83

Solenoid Valves (Hitch Steering)
FIG. 118: Hitch control valve is located on rear of
machine on top of transmission in intermediate valve
stack. Two solenoids (1) for hitch steering are on
right-hand side of hitch control valve.
Solenoid valves control hydraulic flow to cylinders that 1
steer three-point hitch. Valves control lateral position of
three-point hitch.
P082012002
FIG. 118
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06-84 79033095 C Rev.

Three-Point Hitch Hydraulic Component
Locations
FIG. 119: Hydraulic pump (1) is located on left-hand side
of machine in front of final drive. Hydraulic pump is an
axial piston pump.
Pump is capable of delivering 165 liters/min (43.5
gal/min). An optional 223 liters/min (59 gal/min) is also
available. Hydraulic pump delivers a maximum output
pressure of 20 000 to 20 600 kPa (2900 to 2988 psi).
Hydraulic pump supplies oil to following
components:
• Intermediate valve stack
1
• Hydraulic control valves P081812003
Fo
• Three-point hitch control valve FIG. 119
• Steerable three-point hitch control valve

r
• Hydraulic power beyond

in
Compensator Valve
FIG. 120: Compensator valve (1) is bolted to top of
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hydraulic pump.
Compensator regulates pump output flow in
1
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response to following signals:

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• Implement valve reference signal

Compensator valve also serves as a backup for limiting
maximum system pressure.
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P081812003
FIG. 120
on
Hydraulic Filter (Implement)

FIG. 121: Hydraulic filter (1) for implement hydraulic
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final drive. Filter is located inboard of filter for transmission

and steering hydraulic systems. This filter also filters oil
delivered to three-point hitch control valve.
Hydraulic filter will filter particles that are larger than 7.5
microns. Hydraulic filter filters all charge oil and return oil 1
before oil is routed to EOR and then to inlet of hydraulic
pump for implement hydraulic system.
P091012008
FIG. 121
79033095 C Rev. 06-85

Three-Point Hitch Control Valve
FIG. 122: Three-point hitch control valve (1) is located at
rear of machine in implement hydraulic control valve
bank. Three-point hitch control valve is second valve from 1
left-hand side.
Three-point hitch control valve controls delivery and
return of hydraulic oil to three-point hitch lift cylinders.
P070709004
FIG. 122
Steerable Three-Point Hitch Control Valve

Fo
FIG. 123: Steerable three-point hitch control valve (1) is

located at rear of machine in intermediate valve stack.
Steerable three-point hitch control valve is located at top
of intermediate valve stack.
r
Steerable three-point hitch control valve controls delivery 1

in
and return of hydraulic oil to steering cylinders.

te
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P082012002
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FIG. 123
Steering Cylinders
u
FIG. 124: Steering cylinders (1) are mounted between a

se
flange on differential case and draft arms.

Cylinders provide assistance to machine's differential
steering system while an implement is working in ground.
1
on
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P100712008
FIG. 124
06-86 79033095 C Rev.

Three-Point Hitch Lift Cylinders
FIG. 125: Rod end of three-point hitch lift cylinders (1) is
attached to lift arms. Piston end of cylinders is attached to
three-point hitch frame. Three-point hitch lift cylinders are
used to raise three-point hitch linkage.
Lift capacity of three-point hitch lift cylinders is 8845 kg
(19 500 lb) measured at 610 mm (24 in) behind attaching
points.
1
Fo
P091112008
FIG. 125
r
Accumulator (Three-Point Hitch)

in
FIG. 126: Accumulator (1) for hydraulic system of

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three-point hitch is located in front of hydraulic control

valve bank.
rn
Accumulator dampens shock loads in hydraulic system

that often occur when roading heavy implements.
1
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P092412003
FIG. 126
on
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79033095 C Rev. 06-87

Three-Point Hitch System Features
Following list contains special features that are
used in three-point hitch system:
• Switch (raise/lower) (fender)
• Draft control
• Slip control
• Float feature
• Manual feature
Fo

FIG. 127: Hitch lever (1) is used to set working depth of
three-point hitch. Pushing hitch lever toward forward
r
position signals Armrest ECM to lower hitch to a height

proportional to position of hitch lever.
1
in
Pulling hitch lever toward rearward position signals

armrest ECM to raise hitch to a height that is defined
te
within VT display.
ECM receives proportional signal from hitch lever. ECM
rn
will send a proportional signal to corresponding hydraulic

control valves of three-point hitch to maintain correct
height.
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P100712001
FIG. 127
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on
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06-88 79033095 C Rev.

Switch (Raise/Work)
FIG. 128: Raise/work switch signals armrest ECM that
operator wants to vertically move hitch. Switch is primary 1
control for three-point hitch.
(1) Work (lower) position
(2) Raise position 2
RAISE position of raise/work switch is used to raise hitch
to Raise Limit. Raise Limit is defined by user within VT.
WORK position of raise/work switch is used to lower hitch
to position set by hitch lever.
NOTE: If hitch is raising as a result of raise/work switch P093012009
and movement of hitch needs to be stopped,
FIG. 128
depress WORK position of raise/work switch.
Hitch will immediately stop and remain in current
position. If hitch is lowering as a result of
raise/work switch and movement of hitch needs
Fo
to be stopped, depress RAISE position of

raise/work switch. Hitch will immediately stop and
remain in current position.
r
When raise/work switch is held in WORK position, hitch

in
will lower past position set by hitch lever. When switch is

released, hitch will raise back to position set by hitch lever.
te
One-touch feature can be used to record raise/work

switch for playback at a later time.
rn
If ECM detects a failed component in three-point hitch

system, switch will be inactive. Raise/work switch will
operate in a closed loop circuit.
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FIG. 129: Raise/lower switch signals machine ECM that
u
operator wants to slowly raise or slowly lower to hitch. 1

se
Raise/lower switch is used to aid in attaching of

implement.
(1) Raise position 2
on
(2) Lower position

Switch operates hitch in an open loop circuit. Position of
hitch lever is ignored when raise/lower switch is used to
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lower hitch. Raise Limit height that is defined within VT

display is ignored when raise/lower switch is used to raise
hitch.
P093012010
ECM allows three-point hitch to move in both directions FIG. 129
until cylinder stops are reached.
79033095 C Rev. 06-89

FIG. 130: Roading lockout switch should be used
whenever machine is operated on road.
1
(1) Lock position
(2) Unlock position
Switch signals armrest ECM that operator wants to 2
disable following features:
• Auto guidance
P093012011
• Hitch FIG. 130
• Steerable hitch
When switch is placed in LOCK position, ECM will prevent
Fo
any hitch movement.

NOTE: When lockout switch is depressed and hitch is in
motion, hitch will continue to move until
r
destination is reached.
in
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06-90 79033095 C Rev.

One-Touch Button
FIG. 131: One-touch (1) feature signals armrest ECM
that multiple operations are to be performed with a single
command.
One-touch feature has two modes of operation:
• Shift mode
• One-touch mode
Refer to Operation and Maintenance Manual, VT One
Touch Screen, for more details.
Shift Mode 1
Shift mode allows transmission to automatically shift a P012405001
programmed number of gears.
FIG. 131
Shift mode will be disabled when one-touch mode is
active.
Fo
One-Touch Mode
One-touch mode will record a sequence of operations for
r
end of row (raise sequence) or beginning of row (work

sequence).
in
Recorded sequence of operations can then be performed

by depressing one-touch button (raise sequence or work
te
sequence).
Following functions can be recorded and
rn
performed in one-touch mode:

• Transmission (upshift)
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• Transmission (downshift)
• Engine speed (RPM)
u
• Three-point hitch (raise)

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• Three-point hitch (lower)

• Hydraulic control (extend detent)
• Hydraulic control (retract detent)
on
• Hydraulic control (float)

• Power take-off (on/off control)
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• Area accumulation in performance monitor (on/off

control)
NOTE: Power management mode is automatically
disengaged when one-touch is active.
79033095 C Rev. 06-91

Draft Control Float
Draft control is a feature used to automatically adjust Float feature is used to aid in steering of machine or to aid
height of hitch for field conditions. in hooking up to an implement. Float feature is set within
VT display.
Draft control monitors RPM of engine. If engine RPM falls
below a minimum engine RPM, ECM will raise hitch to In float mode, three-point hitch will freely move laterally
regain engine RPM. depending on external forces applied to hitch.
Parameter for Draft Sensitivity can be set through VT Following conditions must be met for float feature
display. to be active.
Refer to Operation and Maintenance Manual, Three-Point • Float mode is selected within VT display.
Hitch.
• Power take-off is disengaged.
Following conditions must be met for draft control
• Vertical hitch position is captured to lever position.
to operate:
• Raise/lower switch (fender) is in the neutral position.
• Three-point hitch is captured.
A damping of three-point hitch can be set by changing
• Calibration mode is not selected.
parameter for Steer Damping within VT display. Damping
Fo
• Desired engine speed is greater than 1400 rpm. will restrict oil flow to steering cylinders of three-point
hitch. Damping can be set from free floating to a locked
• Setting for Draft Sensitivity is greater than zero. position. A 100% damping will lock hitch. A 0% damping
• Power Management is operating on Manual setting. will allow free floating.
r
• Machine is traveling in a forward gear. Refer to Operation and Maintenance Manual, Three-Point
in
Hitch Screen, for more information.

• Inching pedal is not depressed.
Manual
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Slip Control
Manual feature is used to hold steering of three-point
Slip control is a feature used to automatically adjust hitch in a selected position. Manual feature is set within
rn
height of hitch for changing field conditions. VT display.

Slip control monitors amount of slip of machine. If slip of In manual mode, operator can move three-point hitch
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machine becomes too great, ECM will raise hitch to laterally or operator can hold three-point hitch laterally in a
reduce amount of slip. selected position.
Parameter for Slip Sensitivity can be set through VT Following conditions must be met for manual
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display. feature to be active.

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Refer to Operation and Maintenance Manual, Three-Point • Manual mode is selected within VT display.
Hitch.
• Power take-off is disengaged.
Following conditions must be met for Slip control
to operate: • Raise/lower switch (fender) is in neutral position.
on
• Setting for Slip Sensitivity is greater than zero. • Vertical hitch position is captured to lever position.
• Three-point hitch is captured. • Steerable hitch position is captured.
ly
• Ground speed is greater than 4.8 km/h (3 mph). Operator can position three-point hitch by changing
parameter for Steer Offset within VT. Three-point hitch
• Inching pedal is not depressed. can be moved from full left-hand position to full right-hand
• Ground speed sensor is used for true ground speed. position.
Following methods can be used to capture
steerable hitch:
• Manually adjust Steer Offset to current hitch position.
• Raise hitch and lower the hitch.
Refer to Operation and Maintenance Manual, Three-Point
Hitch Screen, for more information.
06-92 79033095 C Rev.

Three-Point Hitch Input Components
Switch (Raise/Work)
FIG. 132: Raise/work switch signals armrest ECM that
operator wants to vertically move three-point hitch.
Switch is a three-position rocker switch. Middle position is
neutral position. RAISE position and WORK position are
momentary positions.
When switch is in neutral position, terminals 2 and 4 and
terminals 7 and 5 are closed. An equal voltage signal is
placed on pin 31 and pin 32 of armrest ECM.
Pressing switch in RAISE position closes terminals 2 and
4 and terminals 7 and 8 of switch. A 1.67V signal is
placed on pin 32 and 3.33V signal on pin 31 of armrest
P100812003
ECM. Difference in voltage tells ECM to raise hitch.
FIG. 132
Pressing switch in WORK position closes terminals 2 and
Fo
1 and terminals 7 and 5 of switch. A 3.33V signal is

placed on pin 32 and 1.67V signal on pin 31 of armrest
ECM. Difference in voltage tells ECM to lower hitch.
r
If incorrect input signals are seen by ECM, ECM will

produce a diagnostic code and switch will be disabled.
in

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FIG. 133: Raise/lower switch signals machine ECM that

operator wants to slowly raise or lower three-point hitch.
rn
Switch is a three-position rocker switch. Middle position is

neutral position. RAISE position and LOWER position are
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momentary positions.
When switch is in neutral position, contacts 2 and 3 are
closed. A grounded signal is placed on pin 39 of machine
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ECM for left-hand fender switch and pin 36 for right-hand

fender switch.
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Pressing switch in RAISE position closes terminals 2 and

1 of switch. A grounded signal is placed on pin 38 of
P100812002
machine ECM.
FIG. 133
on
Pressing switch in LOWER position closes terminals 2

and 4 of switch. A grounded signal is placed on pin 37 of
machine ECM.
ly
If incorrect input signals are seen by ECM, ECM will

produce a diagnostic code and switch will be disabled.
79033095 C Rev. 06-93

Switch (Roading Lockout)
FIG. 134: Roading lockout switch signals armrest ECM
that operator wants to disable following functions:
• Auto guidance
• Hitch
• Steerable hitch
Switch is a two-position rocker switch. Switch has a set of
normally open contacts and a set of normally closed
contacts. P100812001
When switch is in UNLOCK position, terminals 2 and 1 FIG. 134

are closed. A 3.33V signal is received by pin 21 of armrest
ECM.
Fo
When switch is in LOCK position, terminals 2 and 4 are

closed. A 1.67V signal is received by pin 21 of armrest
ECM.
r
If input signals from switch are incorrect, ECM will disable

this feature. A diagnostic code will also be set by ECM.
in
Button (One-Touch)
te
FIG. 135: One-touch button (1) signals armrest ECM

that operator wants to perform multiple operations with a
rn
single command.
al
u se
1
P012405001
on
FIG. 135
ly
06-94 79033095 C Rev.

FIG. 136: Hitch lever signals armrest ECM that operator
wants three-point hitch at a specific height.
hitch lever is a position sensor. Hitch lever sends a
proportional signal to ECM. Signal is a pulse width
modulated signal (PWM) generated at a frequency of 500
Hz. Signal produces a duty cycle between 10% and 90%.
PWM signal is seen by armrest ECM on pin 33.
Position sensor may need to be calibrated.
ECM monitors hitch lever for abnormal frequencies or
abnormal pulse width signals. A diagnostic code will be
set and hitch lever and raise/work switch will be disabled.
g00764812
Position Sensor (Hitch Lift) FIG. 136

FIG. 137: Position sensor signals machine ECM of
Fo
vertical position of three-point hitch.

Position sensor sends a proportional signal to ECM.
Signal is a pulse width modulated signal (PWM)
r
generated at a frequency of 500 Hz. Signal produces a

duty cycle between 10% and 90%.
in
PWM signal is seen by machine ECM on connector J1 on

pin 4.
te
ECM monitors position sensor for abnormal frequencies

or abnormal pulse width signals. A diagnostic code will be
rn
set and hitch lever and raise/work switch will be disabled.

g00334076
Position sensor may need to be calibrated.
al
FIG. 137
u se
on
ly
79033095 C Rev. 06-95

Three-Point Hitch Control Settings
VT allows operator to change several parameters that
affect operation of three-point hitch.
m
WARNING: Movement of hitch linkage and
implements can cause personal injury.
Before operating three-point hitch, ensure
no person or object is in area of implement
or hitch.
VT allows operator to change following

parameters:
• Raise Limit
• Raise Rate
• Lower Rate
Fo
• Manual
r
• Float
in
Manual feature and float feature are used for steering of

hitch.
te
VT is used to change modes of operation. See Operation

and Maintenance Manual, Virtual Terminal (VT), for more
information.
rn
al
u se
on
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06-96 79033095 C Rev.

Electronic Control Modules for Three-Point
Hitch System
FIGS. 138–139: Three-point hitch uses two electronic
control modules (ECM) connected to CAN BUS network 1
to control solenoids for three-point hitch:
• Armrest ECM (1)
• Machine ECM (2)
P100712009
• One-Touch button FIG. 138
Following components are inputs to machine ECM:
Fo
• Switch (raise/lower) (fender)

2
• Position sensor (hitch lift)
r
• Position sensor (hitch steering)

Following components are outputs from machine
in
ECM:
te
• Solenoid valve (raising)

• Solenoid valve (lowering)
rn
• Solenoid valve (left-hand steer) P100712010
• Solenoid valve (right-hand steer) FIG. 139

al
Machine ECM uses these inputs and inputs from other

systems to control raise, lower, left-hand steer and
right-hand steer hydraulic solenoid valves. Inputs from
u
other systems are retrieved from CAN BUS Link.

se
CAN BUS link is a serial communication bus that is

used to communicate with following components:
• Armrest ECM
on
• Machine ECM
ly
• Dash cluster
79033095 C Rev. 06-97

Three-Point Hitch Output Components
Solenoid Valves (Hitch Lift)
FIG. 140: Machine ECM activates solenoid valves for
hitch.
• Solenoid valve (hitch raise)
• Solenoid valve (hitch lower)
There are two solenoid valves for hitch. Raise solenoid
controls raising of three-point hitch. Lower solenoid
controls lowering of three-point hitch.
Also, there are two solenoid valves for steerable hitch.
Left-hand solenoid steers three-point hitch to left.
Right-hand solenoid steers three-point hitch to right.
Solenoid valves are proportional valves. Valves control g00775956
amount of hydraulic oil sent to hitch and steerable hitch.
Fo
Valves receive a proportional current from ECM. FIG. 140

Maximum velocity can be set through VT display by
adjusting Raise Rate and Lower Rate.
r

in
ECM will shut off power to valves.
Solenoid Valves (Steerable Hitch)

te
FIG. 141: Machine ECM activates solenoid valves for

steerable hitch.
rn
• Solenoid valve (left-hand steer)

al
• Solenoid valve (right-hand steer)

There are two solenoid valves for steerable hitch.
Left-hand steer solenoid and right-hand steer solenoid.
u
Solenoid valves are proportional valves and control

se
amount of hydraulic oil sent to hitch steer cylinders.

Valves receive a proportional current from ECM.
on
g00775956
ECM will shut off power to valves.
FIG. 141
ly
06-98 79033095 C Rev.

Data Link for Three-Point Hitch System
1
5 6
4 8
7
9 10
Fo
3
r in
12
te
11
rn
P110612007
al
FIG. 142
FIG. 142: Block diagram of connections of data links CAN data link is a communication bus that is used
to communicate with following components:
(1) ISO BUS
u
• Engine ECM
(2) Powertrain BUS
se
• Machine ECM
(3) Auxiliary BUS
• Armrest ECM
(4) Machine ECM
(5) Engine ECM
on

ly
(8) Auto Guide

(9) Lighting ECM (three ECMs)
(10) Steerable Hitch Solenoid Controller
(11) Implement Control Valve Solenoid Controllers (four
standard - six optional)
(12) Three-Point Hitch Control Valve Solenoid Controller
79033095 C Rev. 06-99

Three-Point Hitch Control Valve
FIG. 143: Three-point hitch control valve (1) is located at
rear of machine in implement hydraulic control valve
bank. Three-point hitch control valve is second valve from 1
base.
Three-point hitch control valve controls delivery and
return of hydraulic oil to three-point hitch lift cylinders.
Three-point hitch control valve has following
positions:
• HOLD
• RAISE
P070709004
• LOWER
FIG. 143
Three-point hitch control valve is not included in pressure
compensated system. When operation of multiple
hydraulic control valves results in a flow demand that
Fo
exceeds output of hydraulic pump, oil flow to three-point

hitch control valve is not proportionally reduced.
Three-point hitch control valve acts in parallel with
r
remaining valves in hydraulic control valve bank.

Compensator spool located in main spool has a lower
in
margin pressure setting than remainder of valves in

hydraulic control valve bank. This allows three-point hitch
te
control valve to receive hydraulic flow first.

FIG. 144: Hitch control valve exploded view. Main
rn
components:
5
(1) Valve Body
al
4 6
(2) Main Spool
(3) Solenoid A
u
(4) Solenoid B 7
3
se
(5) Poppet Valve

(6) Compensator
(7) Hitch Relief Valve
on
ly
2
1
Q012712003
FIG. 144
06-100 79033095 C Rev.

Hitch Control Valve in Hold Position
1 2
3 4
5 6 7
A B
8
9
11
Fo
r
12
in
te
rn
al
10
u se
Q012612002
FIG. 145
on
FIG. 145: Cut away view of Hitch Control Valve in Hold When hitch valve is in neutral position, both solenoids are
Position off, main spool is centered and pump pressure is blocked.
(1) Pressure No hydraulic flow is sent to hitch lift cylinders and return
ly
(2) Return path is blocked.

(3) Sump
(4) Pilot
(5) Pump Pressure
(8) Solenoid A
(9) Solenoid B
(11) Poppet Valve
(12) Release Valve
(A) Work Port
(B) Return Port
79033095 C Rev. 06-101

Hitch Control Valve Lower Position
1 2
3 4
7
5 6
13 14 A B
8
9 11
Fo
12
r in
te
rn
al
10
u se
Q012712001
FIG. 146
on
FIG. 146: Cut away view of Hitch Control Valve in Lower When hitch valve is in lower position, solenoid B (9) is
Position switched on allowing control pressure to shift main spool
(10) to right. With spool shifted to right, pilot pressure
(1) Pressure moves release valve (12) to press poppet valve (11) off of
ly
(2) Return seat to allow pressure in work port (A) to be released to

(3) Sump return port and flow to tank.
(4) Pilot
(5) Pump Pressure
(8) Solenoid A
(9) Solenoid B
(11) Poppet Valve
(12) Release Valve
(13) Control Pressure
(14) Load Sense Pressure
(A) Work Port
(B) Return Port
06-102 79033095 C Rev.

Hitch Control Valve Raise Position
1 2
3 4
7
5 6
13 14 A B
8
9 11
Fo
r
12
in
te
rn
al
10
u se
Q012712002
FIG. 147
on
FIG. 147: Cut away view of Hitch Control Valve in Raise When hitch valve is in raise position, solenoid A (8) is
Position switched on allowing control pressure to shift main spool
(10) to left. With spool shifted to left, pump pressure
(1) Pressure presses poppet valve (11) off of seat to allow hydraulic
ly
(2) Return flow in work port (A). Hitch return oil is allowed to flow to
(3) Sump tank.
(4) Pilot
(5) Pump Pressure
(8) Solenoid A
(9) Solenoid B
(11) Poppet Valve
(12) Release Valve
(14) Load Sense Pressure
(A) Work Port
(B) Return Port
79033095 C Rev. 06-103

Manual Lowering
FIG. 148: If engine becomes inoperable, relief valve (1)
can be used to manually lower three-point hitch.
Following procedure will manually actuate relief valve.
This allows oil in three-point hitch lift cylinders to return to
common sump. 1
Three-point hitch may be lowered by using
following procedure:
1. Use an allen wrench to remove protective cap that
covers relief valve.
m
implements can cause personal injury. P100812004
Before operating three-point hitch, ensure FIG. 148
or hitch.
Fo
2. Insert appropriate allen wrench into end of relief

valve.
3. Turn allen wrench in clockwise direction in small
r
increments until hitch begins to lower. Be careful not

to lower hitch too fast.
in
4. Once three-point hitch is lowered, return relief to

original setting by turning allen wrench in
te
counterclockwise direction.
5. Replace protective cover.
rn
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on
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06-104 79033095 C Rev.

Accumulator (Three Point-Hitch)
FIG. 149: Accumulator (1) for hydraulic system of
three-point hitch is located in front of hydraulic control
valve bank.
Accumulator dampens shock loads in hydraulic system
that often occur when roading a heavy implement.
Accumulator allows cylinders to retract slightly to dampen 1
shock loads. Shock loads that cannot be damped by
accumulator will cause relief valve to open.
Accumulator and relief valve provide protection to
following items:
• Three-point hitch hydraulic system P092412003
FIG. 149
• Three-point hitch components
• Differential housing
Fo
Control Valve (Steerable Three-Point Hitch)

FIG. 150: Steerable three-point hitch control valve (1) is
r
located at rear of machine in intermediate valve bank.

Steerable three-point hitch control valve is located at top
in
of intermediate valve bank.

Steerable three-point hitch control valve controls delivery 1
te
and return of hydraulic oil to steering cylinders.

Steerable three-point hitch control valve has
rn
following positions:
• Hold
al
• Left Steer
P082012002
• Right Steer
FIG. 150
u
• Float
se
Steerable three-point hitch control valve is included in

Pressure compensated system. When operation of
multiple hydraulic control valves results in a flow demand
that exceeds output of hydraulic pump, oil flow to
on
steerable three-point hitch control valve is proportionally

reduced.
ly
79033095 C Rev. 06-105

FIG. 151: Steerable Hitch Valve Exploded View.
Main components:
6 7
5
(1) Valve Body 6
(2) Main Spool
(3) Proportional Solenoid 4
(4) On/Off Solenoid
3
(5) Valve Controller
8
(6) Relief Valve
(7) Coupler Block 9
(8) Poppet Valve
(9) Compensator 2
Fo
Q012712004
r
FIG. 151
in
te
rn
al
u
se
on
ly
06-106 79033095 C Rev.

Steerable Hitch Control Valve Hold Position
1 2 3 4
9 5 6 7 8
16
B A
10
Fo
11 13
15
r in
14
te
rn
al
12
u se
Q012812001
FIG. 152
on
FIG. 152: Steerable Hitch Control Valve Hold Position When valve is in Hold position, both solenoids are off and
cut away view main spool is centered. Poppet valves are seated and
work port pressure is held steady.
(1) Work Port Pressure
ly
(2) Return Pressure

(3) Pilot Pressure
(4) Sump
(5) Pump Pressure
(7) Cross Relief Passage
(11) On/Off Solenoid
(12) Main Spool
(13) Compensator
(14) Release Valve
(15) Poppet Valve
(16) Relief Valve
(A) Work Port A
(B) Work Port B
79033095 C Rev. 06-107

Steerable Hitch Control Valve Right-Steer Position
1 2 3 4
9 5 6 7 8
16
B A
10
Fo
11 13 15
r in
14
te
rn
al
12
u se
Q012812002
FIG. 153
on
FIG. 153: Steerable Hitch Control Valve Right-Steer When valve is in Right-Steer position, On/Off solenoid is
Position cut away view on and proportional solenoid is proportionally on.
(1) Work Port Pressure Control pressure is allowed to right end of main spool and
ly
(2) Return Pressure spool is shifted to left. Right release valve receives pilot
(3) Pilot Pressure pressure and unseats poppet valve allowing return
(4) Sump pressure to flow to tank.
(5) Pump Pressure
Pump pressure pushes left-hand poppet valve off of seat
and increases work port pressure. Hydraulic flow is sent
to steering cylinder and hitch is turned.
(9) Valve Controller If there is a shock to three-point hitch steering system,
(10) Proportional Solenoid relief valve will open and allow excess pressure to dump
(11) On/Off Solenoid into opposite work port which is opened to tank.
(12) Main Spool
(13) Compensator
(14) Release Valve
(15) Poppet Valve
(16) Relief Valve
(A) Work Port A
(B) Work Port B
06-108 79033095 C Rev.

Steerable Hitch Control Valve Left-Steer Position
1 2 3 4
9 5 6 7 8
16
B A
10
Fo
11 13 15
r in
14
te
rn
al
12
u se
Q012812003
FIG. 154
on
FIG. 154: Steerable Hitch Control Valve Left-Steer When valve is in left-hand steer position, On/Off solenoid
Position cut away view is off and proportional solenoid is proportionally on.
(1) Work Port Pressure Control pressure is allowed to left-hand end of main spool
ly
(2) Return Pressure and spool is shifted to right. Left-hand release valve
(3) Pilot Pressure receives pilot pressure and unseats left-hand poppet
(4) Sump valve allowing return pressure to flow to tank.
(5) Pump Pressure
Pump pressure pushes right-hand poppet valve off of
seat and increases work port pressure. Hydraulic flow is
sent to steering cylinder and hitch is turned.
(9) Valve Controller If there is a shock to three-point hitch steering system,
(10) Proportional Solenoid relief valve will open and allow excess pressure to dump
(11) On/Off Solenoid into opposite work port which is opened to tank.
(12) Main Spool
(13) Compensator
(14) Release Valve
(15) Poppet Valve
(16) Relief Valve
(A) Work Port A
(B) Work Port B
79033095 C Rev. 06-109

Steerable Hitch Control Valve Float Position
1 2 3 4
9 5 6 7 8
16
B A
10
Fo
11 13 15
r in
14
te
rn
al
12
u se
Q012812004
FIG. 155
on
FIG. 155: Steerable Hitch Control Valve Float Position When valve is in Float position, On/Off solenoid is on and
cut away view proportional solenoid is fully on.
(1) Work Port Pressure Control pressure is allowed to right end of main spool and
ly
(2) Return Pressure spool is shifted to left. Both release valves receive pilot
(3) Pilot Pressure pressure and unseat poppet valves allowing pressure to
(4) Sump flow to tank. Hitch steer cylinders are free to move.
(5) Pump Pressure
(11) On/Off Solenoid
(12) Main Spool
(13) Compensator
(14) Release Valve
(15) Poppet Valve
(16) Relief Valve
(A) Work Port A
(B) Work Port B
06-110 79033095 C Rev.

NOTES
Fo
r in
te
rn
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on
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79033095 C Rev. 06-111

HYDRAULIC SCHEMATICS
Item Description Application

VALVE GP-4, -5, -6 W/ DRAWBAR
1 VALVE GP-IMPL 4, HITCH; IMPL 5, HITCH W/ HITCH
VALVE GP-4 HF; -6 HF OPTIONAL W/ SPL APP
2 COUPLER GP-IMPL 4, HITCH; IMPL 5, HITCH INCLUDED W/ HITCH
3 PUMP-HYD PISTON, 63CC STANDARD
PUMP-HYD PISTON, 85CC OPTIONAL
4 PUMP-HYD PISTON, 125CC
5 MOTOR GP-PISTON, 107CC STANDARD
6 PUMP GP-GEAR, (MT800)
7 PUMP GP-GEAR
VALVE GP-1 (PRI) STANDARD
8 VALVE GP-2 (PRI, HTB) INCLUDED W/ HTB
VALVE GP-2 (PRI, SH) INCLUDED W/ HITCH
VALVE GP-3 (PRI, SH, HTB) INCLUDED W/ HITCH AND HTB
Fo
9 FILTER GP-OIL
10 CORE AS-OIL COOLER (TWO SECTION)
11 FILTER GP-HYD
r
12 VALVE GP-MDL-C (NINE VALVES)

13 VALVE GP-RELIEF
in
14 VALVE-RELIEF 520 kPa (75.4 psi)

te
16 VALVE AS-BRAKE
17 ACCUMULATOR AS
rn
18 VALVE AS-PARK BRAKE

19 VALVE AS-CHECK
20 ACCUMULATOR AS INCLUDED W/ HITCH
al
21 CYLINDER GP-LIFT INCLUDED W/ HITCH

22 CYLINDER GP-STEER (THREE-POINT HITCH) INCLUDED W/ HITCH
23 CYLINDER GP-STEER (DRAWBAR) OPTIONAL W/ DRWBR
u
24 COUPLER GP-PWR BYND OPTIONAL

se
25 CASE DRAIN AR OPTIONAL

26 COUPLER-QK CONNECT OPTIONAL W/ HTB
27 SCREEN
28 CAP-BREATHER
on
29 BREATHER-0.75NPT, 2 MICRON
30 SCREEN
31 VALVE GP-DRAIN, ECOLOGY OPTIONAL
ly
32 TO IMPLEMENT VALVE CONFIGURATIONS

33 DIFFERENTIAL LUBE
34 ELEVATED OIL RESERVOIR
35 PINION BEARING LUBE
36 BEVEL GEAR LUBE
37 TRANSMISSION
38 TRANSMISSION CASE
39 DIFFERENTIAL CASE
40 PTO
P SYSTEM PRESSURE
R RETURN OIL FLOW
Metric English Metric English

260 bar 3771 psi 12 bar 174 psi
30 bar 435 psi 182.5 bar 2647 psi
4.96 bar 72 psi 2.76 bar 40 psi
3.45 bar 50 psi
06-112 79033095 C Rev.

Fo
r in
te
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on
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Foldout Graphics
FIG. 156
FIG. 156: Replace this page with 11 x 17 Foldout Copy.
79033095 C Rev. 06-113

NOTES
Fo
r in
te
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al
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on
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06-114 79033095 C Rev.

R P PS
32
30 BAR
1 3.5 bar
0.8 mm (0.031 in)
EXT
23
RET
Fo
r
EXT
in
RET
te
rn
al
EXT
u
RET
se
on
EXT
ly
RET
24
LS
R
P
183
Bar
LS
P111012002
FIG. 157
FIG. 157: Implement Valve Configurations with Drawbar

Only
79033095 C Rev. 06-115


P SYSTEM PRESSURE
R RETURN OIL FLOW
LS LOAD SENSE
EXT EXTEND PORT
RET RETRACT PORT
Fo
Metric English
3.5 bar 51 psi
30 bar 435 psi
r
0.8 mm 0.031 in
220 bar 3191 psi
in
183 bar 2654 psi

te
rn
al
u se
on
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06-116 79033095 C Rev.

R P PS
1 Sump Check
3.5 bar
PILOT PRESSURE
30 BAR
32
COUPLER SUMP
PILOT SUMP
RETURN
POWER BEYOND LS BLEED
0.8 mm
EXT
RET
2
Fo
EXT
r
RET
in
te
EXT
rn
RET
al
u
EXT
se
RET
24
on
20
LS
ly
R
P
HITCH
RAISE 220 BAR RELIEF
(MANUAL LOWER)
HITCH
RETURN
21
183
Bar
LS
P111012003
FIG. 158
FIG. 158: Implement Valve Configurations with

Three-Point Hitch
79033095 C Rev. 06-117


3 PUMP-HYD PISTON, 63CC STANDARD
PUMP-HYD PISTON, 85CC OPTIONAL
4 PUMP-HYD PISTON, 125CC
5 MOTOR GP-PISTON, 107CC
6 PUMP GP-GEAR, (MT800)
7 PUMP GP-GEAR
VALVE GP-1 (PRI) STANDARD
8 VALVE GP-2 (PRI, HTB) INCLUDED W/ HTB
VALVE GP-2 (PRI, SH) INCLUDED W/ HITCH
VALVE GP-3 (PRI, SH, HTB) INCLUDED W/ HITCH AND HTB
9 FILTER GP-OIL
10 CORE AS-OIL COOLER (TWO SECTION)
Fo
11 FILTER GP-HYD
12 VALVE GP-MDL-C (NINE VALVES)
13 VALVE GP-RELIEF
r

in
16 VALVE AS-BRAKE
17 ACCUMULATOR AS
te
18 VALVE AS-PARK BRAKE

19 VALVE AS-CHECK
rn

22 CYLINDER GP-STEER (THREE-POINT HITCH) INCLUDED W/ HITCH
al

25 CASE DRAIN AR OPTIONAL
u
26 COUPLER-QK CONNECT OPTIONAL W/ HTB

se
27 SCREEN
28 CAP-BREATHER
29 BREATHER-0.75NPT, 2 MICRON
30 SCREEN
on
31 VALVE GP-DRAIN, ECOLOGY OPTIONAL

33 DIFFERENTIAL LUBE
ly
34 ELEVATED OIL RESERVOIR

35 PINION BEARING LUBE
36 BEVEL GEAR LUBE
37 TRANSMISSION
38 TRANSMISSION CASE
39 DIFFERENTIAL CASE
40 PTO
41 VALVE AS-SECONDARY BRAKE
42 VALVE GP-SECONDARY STEERING
43 CONTROL GP-SECONDARY STEERING
P SYSTEM PRESSURE
R RETURN OIL FLOW
Metric English Metric English Metric English Metric English

260 bar 3771 psi 12 bar 174 psi 4.96 bar 72 psi 2.76 bar 40 psi
30 bar 435 psi 182.5 bar 2647 psi 3.45 bar 50 psi
06-118 79033095 C Rev.

Fo
r in
te
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al
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on
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Foldout Graphics
FIG. 159
FIG. 159: Replace this page with 11 x 17 Foldout Copy.
79033095 C Rev. 06-119

NOTES
Fo
r in
te
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al
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on
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06-120 79033095 C Rev.

32
R P PS
1 3.5 bar
30 bar
0.8 mm
EXT
23
RET
Fo
r
EXT
in
RET
te
rn
al
EXT
RET
u se
on
EXT
RET
ly
24 44
LS
R
P
183 bar
LS
Q010812004
FIG. 160
FIG. 160: Implement Valve Configurations with Drawbar

Only (CE Only)
79033095 C Rev. 06-121


32 TO IMPLEMENT VALVE CONNECTIONS
44 COLLECTION BOTTLE
P SYSTEM PRESSURE
R RETURN OIL FLOW
LS LOAD SENSE
EXT EXTEND PORT
RET RETRACT PORT
Fo
Metric English
3.5 bar 51 psi
r
30 bar 435 psi

0.8 mm 0.031 in
in
220 bar 3191 psi

183 bar 2654 psi
te
rn
al
u se
on
ly
06-122 79033095 C Rev.

R P PS
3.5 bar
32
30 bar
1
0.8 mm
EXT
RET
2
Fo
EXT
r
RET
in
te
EXT
rn
RET
al
u
EXT
se
RET
24
on
44
20
LS
ly
R
P
220 bar
21 183 bar
LS
Q010812005
FIG. 161
FIG. 161: Implement Valve Configurations with

Three-Point Hitch (CE Only)
79033095 C Rev. 06-123

EXT
RET
1
Fo
r in
te
P102912003
FIG. 162
rn
FIG. 162: Implement Hydraulic Control Valve (1)

al
Schematic
u se
1
2
LS
R
on
220 BAR
ly
183
Bar
LS
P111012004
FIG. 163
FIG. 163: Three-Point Hitch Control Valve (1) Schematic

with Lift Cylinders (2) and Accumulator (3)
06-124 79033095 C Rev.

Hydraulic and Three-Point Hitch Disassembly and Assembly
HYDRAULIC AND THREE-POINT HITCH DISASSEMBLY
AND ASSEMBLY
TANDEM CHARGE PUMP

FIG. 164: Tandem charge pump (1) is mounted to back
of implement variable piston pump (2). Piston pump is
mounted to pump drive.
Tandem Charge Pump Removal
m
Fo
this pressure is not released before any 2

FIG. 164
r

in

te

rn

al

u

se

on

ly

1
P082012003
FIG. 165
79033095 C Rev. 06-125

FIG. 166: Drain hydraulic oil into a suitable container for
Disconnect filter hydraulic lines (1) from pump.
1
P090212001
FIG. 166
FIG. 167: Loosen hose clamp (1) and remove suction
hose (2) from pump inlet.
Fo
r in
1
te
2
P090212002
FIG. 167
rn
FIG. 168: Remove two bolts (1) holding tandem charge

pump (2) to variable pump and remove tandem charge
al
pump.
u se
2
1
on
P090212003
FIG. 168
ly
06-126 79033095 C Rev.

Tandem Charge Pump Installation
replacement.
FIG. 169: Mount tandem charge pump (1) to variable
pump with two bolts (2). Ensure drive splines are properly
engaged before tightening bolts to 100 Nm (74 lbf ft).
1
Fo
2
r
P090212003
FIG. 169
in
FIG. 170: Attach suction hose (1) to pump inlet and

te
secure with hose clamp (2).

rn
al
u
2
se
1
P090212002
FIG. 170
FIG. 171: Connect filter hydraulic lines (1) to pump.
on
Fill tandem charge pump with an approved clean

hydraulic oil.
ly
1
P090212001
FIG. 171
79033095 C Rev. 06-127

IMPLEMENT (PISTON) PUMP
FIG. 172: Implement variable piston pump (1) is
mounted to pump drive and tandem charge pump (2) is
mounted to back of piston pump.
Implement Pump Removal
m
this pressure is not released before any 1
FIG. 172
Fo


r

in

te

rn

al

u

se

from entering the system.
on

1
ly
Remove tandem charge pump. Refer to Tandem Charge

Pump Removal section for more information.
P082012003
FIG. 173
06-128 79033095 C Rev.

FIG. 174: Disconnect pump reference hose (1).
Disconnect load sense hose (2).
Disconnect pump output hose (3).
1
2 3
P091012001
FIG. 174
FIG. 175: Remove three bolts (1) holding supply hose to
pump inlet.
Fo
r in
1
te
P091012002
FIG. 175
rn
FIG. 176: Remove four bolts (1) holding piston pump to

pump drive. Slide pump straight out to disengage pump
al
splines and remove pump.

u se
on
1
P091012003
FIG. 176
ly
79033095 C Rev. 06-129

Implement Pump Installation
replacement.
FIG. 177: Slide pump straight into pump drive to engage
pump splines. Secure piston pump to pump drive with
four bolts (1).
Fo
1
r
P091012003
in
FIG. 177
FIG. 178: Connect supply hose to pump inlet with three
te
bolts (1).
rn
al
u
1
se
P091012002
FIG. 178
FIG. 179: Connect pump reference hose (1).
on
Connect load sense hose (2).

Connect pump output hose (3).
ly
2 3
P091012001
FIG. 179
06-130 79033095 C Rev.

SCAVENGE (GEAR) PUMP
FIG. 180: Scavenge (gear) pump (1) is mounted to front
of steering (piston) pump (2) and is located on left-hand
side of transmission. 1 2
Scavenge Pump Removal
m
FIG. 180
Fo


r

in

te

rn

al

u

se

helps to prevent fluid loss and this helps to keep
on

1
ly
P082012003
FIG. 181
79033095 C Rev. 06-131

FIG. 182: Disconnect pressure line (1) from B-port of
pump.
Disconnect supply line (2) from S-port of pump. 1
2
P082012004
FIG. 182
FIG. 183: Remove two bolts (1) holding gear pump to
steering pump.
Fo
r in
1
te
P082012005
FIG. 183
rn
Scavenge Pump Installation

al
FIG. 184: Mount gear pump to steering pump with two

bolts (1).
u

se

on

replacement.
1
ly
P082012005
FIG. 184
FIG. 185: Connect pressure line (1) from B-port of
pump.
Connect supply line (2) from S-port of pump. 1
for leaks.
Attach side guards.
2
P082012004
FIG. 185
06-132 79033095 C Rev.

STEERING (PISTON) PUMP
FIG. 186: Steering (piston) pump (1) is mounted to
pump drive on left-hand side of transmission. Scavenge
(gear) pump (2) is mounted to front of steering pump. 2 1
Steering Pump Removal
m
FIG. 186
Fo


r

in

te

rn

al

u

se

on

1
ly
Remove scavenge pump. Refer to Scavenge (Gear)

Pump Removal section for more information.
P082012003
FIG. 187
79033095 C Rev. 06-133

FIG. 188: Disconnect wiring harness from solenoid
connector (1).
Remove eight bolts holding hydraulic hoses (2) from A-
and B-ports.
2
P091012004
FIG. 188
FIG. 189: Disconnect hydraulic line (1) from T2-port.
1
Fo
r in
te
P091012005
FIG. 189
rn
FIG. 190: Disconnect hydraulic hose (1) from Fa-port.

al
u se
on
1
P091012006
FIG. 190
ly
FIG. 191: Support pump with an appropriate lifting

device and remove four bolts (1) holding pump to pump
drive.
Slide pump straight out to disengage splines and remove
1
pump.
P091012007
FIG. 191
06-134 79033095 C Rev.

Steering Pump Installation
replacement.
FIG. 192: Support pump with an appropriate lifting
device and slide pump straight into pump drive to engage
splines.
Secure pump to pump drive with four bolts (1).
1
Fo
r
P091012007
in
FIG. 192
FIG. 193: Connect hydraulic hose (1) to Fa-port.
te
rn
al
u se
1
P091012006
FIG. 193
FIG. 194: Connect hydraulic line (1) to T2-port.
on
1
ly
P091012005
FIG. 194
79033095 C Rev. 06-135

FIG. 195: Connect wiring harness to solenoid connector
(1).
Secure hydraulic hoses (2) to A- and B-ports with eight
bolts.
2
Install scavenge pump. Refer to Scavenge (Gear) Pump
for leaks.
P091012004
FIG. 195
FIG. 196: Install guards (1).
Fo
1
r in
te
P082012003
FIG. 196
rn
al
u se
on
ly
06-136 79033095 C Rev.

HYDRAULIC FILTER
FIG. 197: Hydraulic filter (1) is located behind guards on
left-hand side of machine and in front of drive axle.
Hydraulic Filter Removal
m
1
P091012008
FIG. 197
Fo

r

in

te

rn

al

u

se

on
1
ly
P082012003
FIG. 198
79033095 C Rev. 06-137

1
3
2
P091112001
FIG. 199
Disconnect hydraulic hose (2) from T1-port. 3
4
Fo

1
r
2
in
te
P091112002
FIG. 200
rn

al

Disconnect hydraulic hose (3) from C2-port. 3
4
u

se
1
on
P091112003
FIG. 201
ly
FIG. 202: Disconnect wiring harness (1) from pressure

sensors (2).
1
2
P091112004
FIG. 202
06-138 79033095 C Rev.

FIG. 203: Disconnect vent hose (1).
P091112005
FIG. 203
FIG. 204: Remove three bolts (1) holding side guard (2)
to filter mount.
Fo
r in
2
1
te
P091112006
FIG. 204
rn
FIG. 205: Remove four bolts (1) holding filter assembly

to mounting bracket (2).
al
u
1 2
se
on
P091112007
FIG. 205
ly
79033095 C Rev. 06-139

Hydraulic Filter Installation
replacement.
FIG. 206: Attach filter assembly to mounting bracket (1)
with four bolts (2).
2 1
Fo
r
P091112007
in
FIG. 206
FIG. 207: Attach side guard (1) to filter mount with three
te
bolts (2).
rn
al
2
u
1
se
P091112006
FIG. 207
FIG. 208: Connect vent hose (1).
on
ly
P091112005
FIG. 208
06-140 79033095 C Rev.

FIG. 209: Connect wiring harness (1) to pressure
sensors (2).
1
2
P091112004
FIG. 209
Fo
4 3
r
2
in
1
te
P091112003
FIG. 210
rn

al
Connect hydraulic hose (2) to T1-port. 3

4
u

1
se
2
on
P091112002
FIG. 211
ly

Install side guards. 1
3
2
P091112001
FIG. 212
79033095 C Rev. 06-141

CONTROL VALVE (IMPLEMENT)
FIG. 214: Implement control valves are mounted two
different ways depending on drawbar (1) and three-point 1
hitch (2) configuration.
Three-point hitch configurations have valve bank (3)
located above remote couplers (4).
P090312001
FIG. 213
2
Fo
3
r in
4
te
P090312002
rn
FIG. 214
al
u se
on
ly
06-142 79033095 C Rev.

Control Valve (Implement) - Drawbar
Configuration
Control Valve (Implement) Removal
m
Make sure all of attachments have been
Fo

r

in

te

thdisassembly procedure, exterior of component
rn

al

u

se
FIG. 215: Disconnect wiring harness (1) from control

valve solenoids.
on
ly
P090312003
FIG. 215
79033095 C Rev. 06-143

FIG. 216: Disconnect steerable hitch hoses (1).
1
P090312004
FIG. 216
FIG. 217: Loosen hose clamps and remove drain hoses
(1).
Fo
r
1
in
te
P090312005
FIG. 217
rn
FIG. 218: Disconnect steerable hitch hoses (1).

al
u se
on
1
P090312006
FIG. 218
ly

Disconnect return hose (2) and supply hose (3).
1
2 3
P090312007
FIG. 219
06-144 79033095 C Rev.

FIG. 220: Attach a suitable lifting device and remove
three bolts (1) holding control valve bank (2) to mount (3)
and remove valve bank.
1
P090312009
FIG. 220
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 06-145

Control Valve Bank (Implement) Disassembly
beginning disassembly procedure, exterior of
FIG. 221: Remove four nuts (1) holding top cap section
from studs.
1
Fo
r
P052212001
in
FIG. 221
te
FIG. 222: Remove top cap section (1).
1
rn
al
u se
P052212002
FIG. 222
on
FIG. 223: Remove individual control valve sections (1).

Standard machines come equipped with four sections. 1
Five and six section valve banks are optional.
ly
NOTE: Be sure not to lose dime valves (2) located in top

of each valve.
P052212003
FIG. 223
06-146 79033095 C Rev.

FIG. 224: Remove hitch control valve (1) from power
beyond base (2).
Remove studs from power beyond base. 1
P052212004
FIG. 224
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 06-147

Control Valve (Implement) Disassembly
15
16
6
5
24
Fo
19
r
22 8
in
25
10
23
te
rn
14
13
al
21
1
u
17
se
3 18
11
20
2
on
4
1
ly
9
Q011312001
FIG. 225
FIG. 225: Control Valve Exploded View
06-148 79033095 C Rev.

Callout Description Callout Description

1 Valve Control Kit 14 Direct Solenoid Kit
2 Plug Kit 15 Dust Cover Kit
3 Poppet Valve 16 Dust Cover Seal Kit
4 Coupler Interface Seal Kit 17 Valve Seal Kit
5 Coupler Kit 18 Handle Seal Kit
6 Coupler Seal Kit 19 Relief Valve Seal Kit
7 Relief Valve Kit 20 Compensator Spool Kit
8 Handle Kit 21 Sleeve Kit
9 Seal Plate Kit 22 Coupler Block, 1/2, Top/Mid Kit
10 Husco LSVC Elec Group 23 Bolt - M6x1THDx20
Fo
11 Clamp Kit 24 Bolt - M6x1THDx85

12 Comp Spring, STD Kit 25 Plug Assembly - 1/2-20 HX Socket
r
13 Proportional Solenoid Kit

in

te

rn

al

FIG. 226: Remove six screws (1) holding port doors (2)
u
and faceplate (3) onto coupler section (4).

4
se
1
on
ly
3
2
P052212005
FIG. 226
FIG. 227: Remove faceplate (1) to gain access to
couplers (2).
P052212006
FIG. 227
79033095 C Rev. 06-149

FIG. 228: Remove gasket (1) with faceplate (2).
P052212007
FIG. 228
FIG. 229: Remove snap ring (1).
Fo
r in
1
te
P052212008
FIG. 229
rn
FIG. 230: Press down on lever (1) to eject couplers (2).

al
2
u se
on
1
P052212009
FIG. 230
ly
FIG. 231: Remove couplers (1).

NOTE: Be prepared to catch and contain fluids in an
approved container.
P052212010
FIG. 231
06-150 79033095 C Rev.

FIG. 232: Remove snap ring (1) holding lever (2).
P052212011
FIG. 232
FIG. 233: Remove lever (1).
NOTE: Be prepared to catch and contain fluids in an
approved container. 1
Fo
r in
te
P052212012
FIG. 233
rn
FIG. 234: Valve (1) is located in rear of coupler section.

al
u
1
se
on
P052212013
FIG. 234
ly
FIG. 235: Remove valve (1) with hex wrench.

NOTE: Coupler section will be free from valve once both
valves have been unscrewed.
1
P052212014
FIG. 235
79033095 C Rev. 06-151

FIG. 236: Poppet springs (1) may fall out when coupler
section is separated from valve section.
P052212015
FIG. 236
FIG. 237: Remove controller (1) from directional
solenoid (2) and proportional solenoid (3).
1
Fo
3
2
r in
te
Q011312002
FIG. 237
rn
FIG. 238: Remove screws (1) holding clamp (2).

al
Lift solenoids out of control valve.
2
u se
1
on
Q011312002
FIG. 238
ly
FIG. 239: Remove poppet valve assemblies (1).

Remove sleeves (2). 3
Remove plug (3) and compensator assembly (4). 4
Remove O-ring (5). 2
1
Q011312003
FIG. 239
06-152 79033095 C Rev.

FIG. 240: Remove plug (1) and main spool valve (2).
NOTE: Spool may have to be pushed out from other side
of valve.
1
2
Q011412001
FIG. 240
FIG. 241: Remove two screws (1) holding cover plate (2)
and gasket.
Gently press valve spool out of valve by carefully inserting
Fo
a non-marring tool into hole (3) below cover plate. 1

r
2
in
3
te
Q011412001
FIG. 241
rn
FIG. 242: Replace all O-rings and ensure dime valves

are in good condition.
al
u se
on
ly
Q011412002
FIG. 242
79033095 C Rev. 06-153

Control Valve (Implement) Assembly
beginning assembly procedure, exterior of
assembly procedures on a clean work surface.
Keep components covered and protected at all
times.
FIG. 243: Replace all O-rings and ensure dime valves
are in good condition.
Fo
r in
te
rn
Q011412002
FIG. 243
al
FIG. 244: Secure cover plate (1) and new gasket with
two screws (2). Tighten screws to 8.5 to 10.5 Nm (6.3 to
u
7.7 lbf ft).

2
se
on
1
ly
Q011412001
FIG. 244
FIG. 245: Install main spool valve (1) and plug (2).
NOTE: Slot (3) in spool should face toward solenoids. 3
Tighten plug to 89.4 to 111.2 Nm (66 to 82 lbf ft).
2
1
Q011412001
FIG. 245
06-154 79033095 C Rev.

FIG. 246: Install poppet valve assemblies (1).
Install sleeves (2). 4
Install compensator assembly (3) and plug (4). 3
Tighten plug to 89 to 111 Nm (66 to 82 lbf ft). 2
Install O-ring (5). 1
Q011312003
FIG. 246
FIG. 247: Insert directional solenoid (1) and proportional
solenoid (2) into appropriate control valve ports and
secure with clamp (3) and screws (4).
1 2
Fo
Tighten screws to 8.1 to 10.9 Nm (6 to 8 lbf ft).

NOTE: Position solenoids so that connectors are 3
orientated as in figure. Solenoid connectors will
r
need to align with controller connectors.

4
in
te
Q011312002
FIG. 247
rn
FIG. 248: Install controller (1) onto directional solenoid

(2) and proportional solenoid (3).
al
1
u
3
2
se
on
Q011312002
FIG. 248
ly
FIG. 249: Place poppet springs (1) into correct position.
P052212015
FIG. 249
79033095 C Rev. 06-155

FIG. 250: Place coupler section to valve section and
install valve (1) with hex wrench.
NOTE: Coupler section will be attached to valve section
once valves have been installed.
Tighten valves to 73 to 89 Nm (54 to 66 lbf ft).
1
P052212014
FIG. 250
FIG. 251: Install and tighten bolts (1) to 8.5 to 10.5 Nm
(6.3 to 7.7 lbf ft).
Install and tighten plug (2) to 4.5 to 5.5 Nm (3.3 to 4.1 lbf
Fo
ft).
1
r
2
in
1
te
rn
al
Q011412003
u
FIG. 251
se
FIG. 252: Install lever (1).
1
on
ly
P052212012
FIG. 252
06-156 79033095 C Rev.

FIG. 253: Install snap ring (1) to secure lever (2).
P052212011
FIG. 253
FIG. 254: Press down on lever and install couplers (1)
and seals.
Fo
1
r in
te
P052212010
FIG. 254
rn
FIG. 255: Press couplers (1) into coupler section and

raise levers (2) to hold couplers.
al
1
use
on
2
P052212009
FIG. 255
ly
FIG. 256: Install snap ring (1).
P052212008
FIG. 256
79033095 C Rev. 06-157

FIG. 257: Install faceplate (1) with gasket (2).
P052212007
FIG. 257
FIG. 258: Place faceplate (1) over cover couplers (2).
Fo
1
r in
2
te
P052212006
FIG. 258
rn
FIG. 259: Secure port doors (1) and faceplate (2) onto
coupler section (3) with six screws (4). Tighten screws to
al
4.5 to 5.5 Nm (3.3 to 4.1 lbf ft). 3

4
u se
2
on
1
P052212005
FIG. 259
ly
06-158 79033095 C Rev.

Control Valve Bank (Implement) Assembly
NOTE: Check all O-ring seals for wear or damage. If
necessary, replace O-ring seals.
NOTE: Cartridges, solenoids, spools and valves are not
serviceable. Cartridges, solenoids and valves
may be replaced. Replace entire hydraulic valve
if spools are worn or damaged.
FIG. 260: Install studs into power beyond base (1).
Install hitch control valve (2) onto studs in power beyond
base. 2
Fo
r
1
in
P052212004
te
FIG. 260
FIG. 261: Install individual control valve sections (1) onto
rn
studs. Ensure all O-rings are in position.

1
Standard machines come equipped with four sections.
al
Five and six section valve banks are optional.

u se
on
P052212003
FIG. 261
FIG. 262: Install top cap section (1).
ly
P052212002
FIG. 262
79033095 C Rev. 06-159

FIG. 263: Secure top cap section onto studs with four
nuts (1). Tighten to 50 Nm (37 lbf ft).
P052212001
FIG. 263
Fo
r in
te
rn
al
u se
on
ly
06-160 79033095 C Rev.

Control Valve (Implement) Installation
necessary, replace O-ring seals.
FIG. 264: Attach a suitable lifting device and attach
control valve bank (1) to mount (2) with three bolts (3).
2
Fo
3
P090312009
r
FIG. 264
in

Connect return hose (2) and supply hose (3).
te
1
rn
al
2 3
u
P090312007
se
FIG. 265
FIG. 266: Connect steerable hitch hoses (1).
on
ly
1
P090312006
FIG. 266
79033095 C Rev. 06-161

FIG. 267: Attach drain hoses (1) and tighten hose
clamps.
P090312005
FIG. 267
FIG. 268: Connect steerable hitch hoses (1).
Fo
r in
te
1
P090312004
FIG. 268
rn
FIG. 269: Connect wiring harness (1) to control valve

solenoids.
al
u se
1
on
P090312003
FIG. 269
ly
06-162 79033095 C Rev.

Control Valve (Implement) - Three-Point
Hitch Configuration
Control Valve Section (Implement) Removal
m
Make sure all of attachments have been
Fo

r

in

te

rn

al

u

se
FIG. 270: Disconnect wiring harness from control valve

solenoids (1).
on
ly
P090412001
FIG. 270
79033095 C Rev. 06-163

(1).
1 P090412002
FIG. 271
1
Fo
r in
te
P090412003
FIG. 272
rn
FIG. 273: Disconnect load sense hose (1).

al
Disconnect Tee-fitting (2) with hose to variable piston

pump.
1
u
2
se
on
P090412004
FIG. 273
ly
FIG. 274: Disconnect return hose (1).

Disconnect three-point hitch return-port line (2).
Disconnect hydraulic lines (3) from work port-A.
2
1
3
P090412005
FIG. 274
06-164 79033095 C Rev.

FIG. 275: Disconnect supply hose (1).
Disconnect three-point hitch work-port line (2).
Disconnect hydraulic lines (3) from work port-B.
2
1 3
P090412006
FIG. 275
FIG. 276: Attach a suitable lifting device and remove five
bolts (1) holding control valve bank section (2) to mounts
and remove valve bank section. 2
Fo
r in
1 1
te
P090412007
FIG. 276
rn
al
u se
on
ly
79033095 C Rev. 06-165

Remote Coupler Removal
m
Make sure all attachments have been

Fo

r

in

te

rn

al

FIG. 277: Disconnect hydraulic lines (1) to work port-A
u
and lines (2) to work port-B.

se
1 2
on
ly
P090412008
FIG. 277
FIG. 278: Attach a suitable lifting device and remove four
bolts (1) holding coupler section (2) to mounts and
remove coupler section.
2
P090412009
FIG. 278
06-166 79033095 C Rev.

Remote Coupler Installation
assembly procedure, exterior of component
FIG. 279: Attach a suitable lifting device and install
coupler section (1) to mounts with four bolts (2).
1
P090412009
Fo
FIG. 279
FIG. 280: Connect hydraulic lines (1) to work port-A and
lines (2) to work port-B.
r
1 2
in
te
rn
P090412008
al
FIG. 280
u se
on
ly
79033095 C Rev. 06-167

Control Valve Section (Implement) Installation
FIG. 281: Attach a suitable lifting device and mount
control valve bank section (1) to mounts with five bolts (2).
1
2 2
Fo
P090412007
FIG. 281
FIG. 282: Connect supply hose (1).
r
Connect three-point hitch work-port line (2).

in
Connect hydraulic lines (3) to fittings in work port-B.
2
te
1 3
rn
al
P090412006
FIG. 282
u
FIG. 283: Connect return hose (1).

se
Connect three-point hitch return-port line (2).

Connect hydraulic lines (3) to fittings in work port-A.
2
on
1
3
ly
P090412005
FIG. 283
06-168 79033095 C Rev.

FIG. 284: Connect load sense hose (1).
Connect Tee-fitting (2) with hose from variable piston
pump.
1
2
P090412004
FIG. 284
1
Fo
r in
te
P090412003
FIG. 285
rn
FIG. 286: Install drain hoses (1) and tighten hose

clamps.
al
u se
on
1
P090412002
FIG. 286
ly
FIG. 287: Connect wiring harness to control valve

solenoids (1).
P090412001
FIG. 287
79033095 C Rev. 06-169

Control Valve Module Installation, Repair,
Replacement and Calibration
Diagnosing and Repairing Damaged Modules
FIG. 288: Hydraulic control valve module (1).
Valve modules can be swapped amongst valves for
testing. Valve modules can not be permanently swapped
between valves due to valve specific calibration values.
Example: Implement valve switch number 3 will always
control the module that came off of implement valve
number 3, regardless of where module has been moved
to. Number 3 switch and number 3 module are connected 1
to each other.
Calibration values are stored in each module mounted on
each valve. Each module is calibrated at valve factory to
work with solenoids and valve that module is attached to.
Fo
P021212001
FIG. 288
FIG. 289: Calibration is then programmed into that
r
specific module. Valve factory keeps a record of each

valve stack assembled and an identification decal (1) is 1
in
placed on each valve stack.

When a new module is installed on an existing valve and
te
original calibration values are installed in new module,

valve should perform normally.
rn
If a hydraulic valve module is damaged, an attempt

should be made to retrieve calibration values from old
valve if possible using an Electronic Diagnostic Tool
al
(EDT). This code can be used to reprogram new

replacement module for that specific valve assembly.
u
If it is not possible to retrieve calibration values from old

module, use identification decal on top of valve stack to
se
Q020212001
retrieve calibration codes for all valves on stack from
manufacturer’s data base. FIG. 289
on
ly
06-170 79033095 C Rev.

Adding New Valve Sections
If additional valves are being installed on a machine, Flow Priority Functions
modules on new valves will already have calibration
Flow priority selection: any implement valve can be
codes loaded in modules.
selected through the VT to receive priority flow. Only one
Keep all valve components as clean as possible during valve should be selected as a priority function during
installation on valves and use new O-ring kits for any operation.
section that has been separated. One new O-ring kit is
Flow testing an implement pump: it is possible to select
sent with each new valve. O-ring kits will include two load
several implement valves as priority function. This is
sense valves that go between valve sections (dime
available so technicians can test maximum flow output
valves). Cleanliness must be stressed during
from the implement pump. Select valves one and three as
disassembly and assembly of valve sections.
priority and allow flow through these two valves to achieve
Switches in cab are exclusive to their location and simply maximum flow.
need to be installed. After all hardware is installed on
NOTE: One valve alone cannot handle maximum pump
machine, use EDT to reconfigure machine for new
output.
number of valves to be used.
After machine reconfiguration, only one valve section
should be added at a time.
Fo
Example: If a four section valve stack is being updated to

a six section stack (adding two sections). Only connect
number five valve module to CAN bus until number five
r
module has been identified by armrest control unit. After

in
number five implement valve is identified, hook number

six implement valve module to CAN bus at module. Next
configure number six implement valve to number six
te
implement valve switch and save settings.

rn
Recalibrating Implement Valve Module

If an implement valve module or solenoids have been
replaced and original values cannot be retrieved or a
al
calibration drift is suspected, there are options avaiable.

Option 1: Using load sense values: technicians can
u
adjust calibration values with an EDT and monitoring load

sense pressure. Monitor load sense pressure to find initial
se
flow starting values. Then enter a predetermined 99%

flow value to set top end.
Option 2: Using a flow meter: this method is more
accurate and needed to provide accuracy needed when
on
using laser leveling systems. Technicians can adjust

calibration values with an EDT and flow meter. Use flow
meter values to find initial flow values [0 to 0.05 liters/min
ly
(0 to 0.013 gal/min)]. Then select values that will result in

a 99% flow value [140 liters/min (37 gal/min)] from a valve
assembly to set maximum flow desired.
79033095 C Rev. 06-171

CONTROL VALVE (THREE-POINT HITCH)
FIG. 290: Three-point hitch control valve (1) is located
near base of implement control valve bank.
Control Valve (Three-Point Hitch)

Disassembly 1
disassembly procedures on a clean work P090912001
surface. Keep components covered and FIG. 290
Remove implement control valve. Refer to Control Valve
Fo
(Implement) - Three-Point Hitch Configuration - Control

Valve Section Removal section for more information.
FIG. 291: Remove four nuts (1) holding control valve
r
bank section together.

in
1
te
rn
al
P090912002
FIG. 291
u
FIG. 292: Remove top section (1), control valve sections

se
(2) and three-point hitch valve (3) from studs in bottom 4 2 1

section (4).
NOTE: Standard machines are equipped with four
on
sections. Optional machines may have five

sections in three-point hitch configurations and
five or six sections in drawbar configurations.
ly
3
P090912003
FIG. 292
06-172 79033095 C Rev.

Control Valve (Three-Point Hitch)
Assembly
necessary, replace the O-ring seals.
FIG. 293: Install four studs for appropriate valve bank
configuration into holes (1) in power beyond section.
NOTE: Standard machines are equipped with four
sections. Optional machines may have five
sections in three-point hitch configurations and 1
five or six sections in drawbar configurations.
Fo
r
P090912004
FIG. 293
in
FIG. 294: Install three-point hitch valve section (1),

te
control valve sections (2) and top section (3) onto studs in 4 2 3
bottom section (4).
rn
al
u
1
se
P090912003
FIG. 294
FIG. 295: Secure control valve bank sections together
on
with four nuts (1). Tighten to 50 Nm (37 lbf ft).

ly
P090912002
FIG. 295
79033095 C Rev. 06-173

INTERMEDIATE VALVE STACK
FIG. 296: Intermediate valve stack (1) is located above
final drive and behind cab.
Intermediate Valve Stack Removal

1
m
pressure is not released before service is
done on hydraulic system.
P090912005
FIG. 296
Fo

r

in

te

rn

al

u

se

(1).
on
Disconnect wiring harness (2) from steerable hitch, if 1

equipped, and priority valve.
ly
P090912006
FIG. 297
06-174 79033095 C Rev.

FIG. 298: Disconnect hydraulic hoses (1) to steerable
hitch valve.
P090912007
FIG. 298
FIG. 299: Disconnect hydraulic line (1) to pump supply
port of priority valve.
1 2
Disconnect hydraulic hose (2) to rear remote supply port
Fo
of priority valve.
r in
te
P090912008
FIG. 299
rn
FIG. 300: Disconnect hydraulic hose (1) to rear stack

load sense port.
al
1
u se
on
P090912009
FIG. 300
ly
FIG. 301: Disconnect hydraulic hose (1) from Tee-fitting

in brake charge port. 1
Disconnect hydraulic hose (2) from brake supply port.
2
P090912010
FIG. 301
79033095 C Rev. 06-175

FIG. 302: Disconnect hydraulic line (1) from return port.
Disconnect hydraulic line (2) from tank port. 1
Disconnect hydraulic line (3) from brake signal input port.
3 2
P090912011
FIG. 302
FIG. 303: Remove two bolts (1) holding bracket and
hose clamp to mounting plate.
Attach a suitable lifting device to intermediate valve stack
Fo
and remove two bolts (2) holding stack to chassis.

2
Remove valve stack.
r in
1
te
P090912012
FIG. 303
rn
al
u se
on
ly
06-176 79033095 C Rev.

Intermediate Valve Stack Disassembly
FIG. 304: Remove three bolts (1) holding mounting
bracket (2) and hydraulic trailer brake control valve (3), if
equipped, to priority valve.
1 3
2
Fo
P090912013
FIG. 304
FIG. 305: Remove four nuts (1) holding valve stack
r
together.
in
1
te
rn
al
P090912014
u
FIG. 305
se
FIG. 306: Remove top section (1) and steerable hitch

control valve (2), if equipped, from studs in priority valve
(3). 1
on
2
ly
P090912015
FIG. 306
79033095 C Rev. 06-177

Intermediate Valve Stack Assembly
FIG. 307: Install four studs for appropriate valve bank
configuration into holes (1) in priority valve.
Install steerable hitch control valve (2), if equipped, and
3
top section (3), onto studs in priority valve.
2
1
Fo
P090912015
FIG. 307
FIG. 308: Secure valve stack together with four nuts (1).
r

in
1
te
rn
al
P090912014
u
FIG. 308
se
FIG. 309: Attach hydraulic trailer brake control valve (1),

if equipped, and mounting bracket (2) to priority valve with
three bolts (3).
on
3 1
ly
2
P090912013
FIG. 309
06-178 79033095 C Rev.

Intermediate Valve Stack Installation
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.
FIG. 310: Attach a suitable lifting device to intermediate
valve stack and secure stack to chassis with two bolts (1).
Attach bracket and hose clamp to mounting plate with two
bolts (2).
1
Fo
2
r
P090912012
in
FIG. 310
FIG. 311: Connect hydraulic line (1) to return port.
te
Connect hydraulic line (2) to tank port. 1

Connect hydraulic line (3) to brake signal input port.
rn
al
u se
3 2
P090912011
FIG. 311
FIG. 312: Connect hydraulic hose (1) to Tee-fitting in
on
brake charge port. 1

Connect hydraulic hose (2) to brake supply port.
ly
2
P090912010
FIG. 312
79033095 C Rev. 06-179

FIG. 313: Connect hydraulic hose (1) to rear stack load
sense port.
P090912009
FIG. 313
FIG. 314: Connect hydraulic line (1) to pump supply port
of priority valve.
1 2
Connect hydraulic hose (2) to rear remote supply port of
Fo
priority valve.
r in
te
P090912008
FIG. 314
rn
FIG. 315: Connect hydraulic hoses (1) to steerable hitch

valve.
al
1
u se
on
P090912007
FIG. 315
ly
FIG. 316: Install drain hoses (1) and tighten hose

clamps.
Connect wiring harness (2) to steerable hitch, if equipped, 1
and priority valve.
P090912006
FIG. 316
06-180 79033095 C Rev.

RELIEF VALVE
FIG. 317: Relief valve is located on left-hand side of
powertrain above solenoids.
Relief Valve Removal 1
m
P091512001
FIG. 317
Fo
cap is cool enough to touch with your bare

hand.

r

in

te

rn

al

u

se

FIG. 318: Remove six bolts (1) holding relief valve (2) to
on
powertrain.
ly
1
P091512002
FIG. 318
79033095 C Rev. 06-181

Relief Valve Installation
replacement.
FIG. 319: Attach relief valve (1) to powertrain with six
bolts (2).
1
Fo
2
r
P091512002
in
FIG. 319
te
rn
al
u se
on
ly
06-182 79033095 C Rev.

OIL COOLER BYPASS VALVE
FIG. 320: Oil cooler bypass valve (1) is located on
left-hand side of powertrain above solenoids and under
relief valve.
1
Oil Cooler Bypass Valve Removal
Remove relief valve (charge pressure). Refer to Relief
Valve Removal section for more information.
P091512003
FIG. 320
FIG. 321: Remove snap ring (1) and remove oil cooler
bypass valve (2).
Fo
2
1
r in
te
rn
P091512004
FIG. 321
al
Oil Cooler Bypass Valve Installation

u

se

on
replacement.
FIG. 322: Install oil cooler bypass valve (1) and install
snap ring (2).
ly
Install relief valve (charge pressure). Refer to Relief Valve

2
P091512004
FIG. 322
79033095 C Rev. 06-183

THREE-POINT HITCH
Three-Point Hitch Removal
Required Tools
A Support Stand Assembly 2
B Lever Puller Hoist 1
m
implements can cause personal injury.
Before operating three-point hitch, ensure
or hitch.

Fo

r

in

te
NOTE: Put identification marks on all hose assemblies

and on all tube assemblies for installation
purposes. Plug all hose assemblies and all tube
rn
assemblies. Cap all fittings. This helps to prevent

fluid loss, and this helps to keep contaminants
al

FIG. 323: Remove control valve bank (1) and remote
coupler sections (2). Refer to Control Valve (Implement) -
u
Three-Point Hitch Configuration Removal.

1
se
Relieve hydraulic system pressure in three-point hitch.

on
2
ly
P090312002
FIG. 323
FIG. 324: Remove all cable straps. Remove harness
assembly (1).
1
P090512001
FIG. 324
06-184 79033095 C Rev.

FIG. 325: Support quick hitch on a suitable block. Attach
a suitable lifting strap to top link (1).
Remove pin assembly (2). Position top link (3) out of the 1
way.
2
P090512002
FIG. 325
FIG. 326: Attach a suitable lifting device to quick hitch
(1). Remove pin assemblies (2) and remove quick hitch.
Fo
1
r in
2
te
P090512003
FIG. 326
rn
FIG. 327: Attach a suitable lifting device to top link

assembly (1). Top link weighs approximately 23 kg (50 lb).
al
Remove retaining ring and pin (2).

u
1
se
2
on
P090512004
FIG. 327
ly
FIG. 328: Remove two bolts (1) holding bracket (2) to

three-point hitch and move assembly out of the way.
2
P090512005
FIG. 328
79033095 C Rev. 06-185

FIG. 329: Remove snap rings and pins (1) holding
steerable hitch cylinders (2) to three-point hitch assembly
(3). 1
3
2
P090512006
FIG. 329
Fo
r
1
in
te
P090512007
FIG. 330
rn
FIG. 331: Install Tooling (A). Remove bolts (1), washers

(2), and pin (3). Pin also secures bottom of three-point
al
hitch.
u se
on
3
ly
2
A
1
g00903292
FIG. 331
06-186 79033095 C Rev.

Remove drawbar.
1
Fo
g00903294
FIG. 332
FIG. 333: Remove bolt (1) holding position sensor rod
r
(2) to bracket (3).

in
te
rn
2
3
al
1
P090512008
u
FIG. 333
se
FIG. 334: Disconnect hydraulic line (1) from Tee-fitting.

on
1
ly
P090512010
FIG. 334
79033095 C Rev. 06-187

FIG. 335: Attach a suitable lifting device to rockshaft (1).
Attach a suitable lifting strap to center of three-point hitch
(2). Attach Tooling (B) to strap around center of 1
three-point hitch.
B
Fo
r in
g00903311
te
FIG. 335
FIG. 336: Remove bolts (1) and remove pin (2). Remove
rn
three-point hitch.
al
1
u se
2
on
P090512009
FIG. 336
ly
06-188 79033095 C Rev.

Three-Point Hitch Installation
Required Tools
A Support Stand As 2
B Lever Puller Hoist 1
FIG. 337: Attach a suitable lifting device to rockshaft (1).

Attach a suitable lifting strap to the center of three-point
hitch (2). Attach Tooling (B) to strap around center of 1
three-point hitch.
Fo
2
r in
B
te
rn
al
u
g00903311
se
FIG. 337
FIG. 338: Install three-point hitch. Lower temperature of
pin (1) to -55 to -45 degrees C (-67 to -49 degrees F).
Lubricate pin.
on
Install pin and install bolts (2). Tighten bolts to 200 to 280
Nm (147 to 207 lbf ft). Measure gap between differential
case and pin. Remove bolts.
ly
2
Install minimum shim thickness minus 0.25 mm (0.0098
in). Install bolts and tighten to a torque of 200 to 280 Nm
(147 to 207 lbf ft).
Inspect the lip seals on both sides. 1
P090512009
FIG. 338
79033095 C Rev. 06-189

FIG. 339: Connect hydraulic line (1) to Tee-fitting.
P090512010
FIG. 339
FIG. 340: Attach position sensor rod (1) to bracket (2)
with bolt (3).
Fo
r
1
in
2
3
te
P090512008
FIG. 340
rn

Install drawbar.
al
u se
on
ly
1
g00903294
FIG. 341
06-190 79033095 C Rev.

FIG. 342: Install pin (1), bolts (2), and washers (3). Pin
also secures bottom of three-point hitch.
2
Fo
g00903292
FIG. 342
r in
te
rn
1
al
P090512007
u
FIG. 343
se
FIG. 344: Secure steerable hitch cylinders (1) to

three-point hitch assembly (2) with pins (3). 4
Secure pins with snap rings (4). 3
on
2
ly
1
P090512006
FIG. 344
79033095 C Rev. 06-191

FIG. 345: Mount bracket (1) to three-point hitch with two
bolts (2).
1
P090512005
FIG. 345
FIG. 346: Attach a suitable lifting device to top link
assembly (1). Top link weighs approximately 23 kg (50 lb).
Secure link assembly with pins (2) and snap rings.
Fo
2 1
r in
te
P090512004
FIG. 346
rn
FIG. 347: Attach a suitable lifting device to quick hitch

(1). Secure quick hitch with pin assemblies (2).
al
1
u se
on
2
P090512003
FIG. 347
ly
FIG. 348: Support quick hitch on a suitable block.

Position top link (1) to quick hitch and secure with pin
assembly (2).
1
P090512002
FIG. 348
06-192 79033095 C Rev.

FIG. 349: Route harness assembly (1) along three-point
hitch and secure with cable straps.
1
P090512001
FIG. 349
FIG. 350: Install control valve bank (1) and remote
coupler sections (2). Refer to Control Valve (Implement) -
Three-Point Hitch Configuration Installation.
1
Fo
Test hydraulic system for leaks using a piece of

cardboard.
m
WARNING: Never use your hand to test for
r
hydraulic leaks. Hydraulic pressure can

penetrate skin and cause severe injury.
in
2
Fill hydraulic system with an approved oil. Refer to
appropriate Operation and Maintenance Manual for
te
correct procedure. P090312002
FIG. 350
rn
al
u se
on
ly
79033095 C Rev. 06-193

ROCKSHAFT
Rockshaft Removal
FIG. 351: Remove snap rings and pins (1) holding
steerable hitch cylinders (2) to three-point hitch assembly
(3). Position cylinders out of way. 1
3
2
P090512006
FIG. 351
Fo
FIG. 352: Remove bolt (1) holding position sensor rod

(2) to bracket (3).
r in
te
2
3
rn
1
al
P090512008
FIG. 352
FIG. 353: Remove left fender (1). Refer to Fender
u
Removal section in Appearance Division for more

information. 1
se
Rotate three-point assembly to right until frame contacts

fuel tank support.
on
ly
P090812001
FIG. 353
FIG. 354: Remove bolt (1), washer, and spacer. Remove
pin (2). Position upper link (3) out of the way. Repeat this
step for other link. 1
P090812002
FIG. 354
06-194 79033095 C Rev.

FIG. 355: Remove bolt (1) holding height sensor control
arm (2) to lift arm (3).
1
2
P090812004
FIG. 355
FIG. 356: Attach a suitable lifting sling to lift arms (1).
Remove bolts (2), washer, and spacer. Remove pin (3).
Position hitch cylinder (4) out of the way. Repeat this step
for other hitch cylinder. 2
Fo
1
r in
3 4
te
P090812003
FIG. 356
rn
FIG. 357: Attach a suitable lifting device to lift arm (1).

Remove retaining ring (2). Slide lift arm off of rockshaft. 2
al
Repeat process for other lift arm. 1

u se
on
P090812005
FIG. 357
ly
FIG. 358: Remove thrust washers (1). Slide rockshaft (2)

out of housing. Attach a suitable lifting sling to rockshaft.
Remove rockshaft. 1
P090812006
FIG. 358
79033095 C Rev. 06-195

FIG. 359: Use Tooling (A) to remove lip seals (1) and
bearing (2). 1
Repeat process for other bushing.
2
P090812007
FIG. 359
Rockshaft Installation
FIG. 360: Use Tooling (A) to install lip seals (1) and
bearing (2). 1
Fo
Repeat process for other bushing.

r in
te
2
rn
P090812007
FIG. 360
al
FIG. 361: Attach a suitable lifting sling to rockshaft (1).

Install rockshaft. Install thrust washers (2).
2
u se
on
1
ly
P090812006
FIG. 361
Slide lift arm onto rockshaft. Install retaining ring (2). 2
Repeat process for other lift arm. 1
P090812005
FIG. 362
06-196 79033095 C Rev.

FIG. 363: Attach a suitable lifting sling to lift arms (1).
Position hitch cylinder (2) into lift arm. Secure cylinder
with pin (3). Secure pin with bolt (4), washer, and spacer.
4
Repeat this step for the other hitch cylinder.
1
3 2
P090812003
FIG. 363
FIG. 364: Attach height sensor control arm (1) to lift arm
(2) with bolt (3).
3
Fo
1
r
2
in
te
P090812004
FIG. 364
rn
FIG. 365: Install upper link (1) into lift arm and secure
with pin (2). Secure pin with bolt (3), washer, and spacer.
al
3
Repeat this step for other link.
2
u se
1
on
P090812002
FIG. 365
ly
FIG. 366: Rotate frame assembly to original location.

Attach steerable hitch cylinders (1) to three-point hitch
assembly (2) and secure with snap rings and pins (3). 3
2
1
P090512006
FIG. 366
79033095 C Rev. 06-197

FIG. 367: Attach position sensor rod (1) to bracket (2)
with bolt (3).
1
2
3
P090512008
FIG. 367
FIG. 368: Install left-hand fender (1). Refer to Fender
Installation section in Appearance Division for more
information. 1
Fo
r in
te
P090812001
FIG. 368
rn
al
u se
on
ly
06-198 79033095 C Rev.

ACCUMULATOR (THREE-POINT
HITCH)
Accumulator (Three-Point Hitch) Removal
m
Fo

r

in

te

rn

al
Release pressure in hitch accumulator.

FIG. 369: Disconnect hydraulic hose (1).
u se
on
1
ly
P090812009
FIG. 369
FIG. 370: Disconnect hydraulic line (1). Disconnect
fitting (2) from chassis. 1 2
Remove bolt (3) and remove hitch accumulator (4).
P090812008
FIG. 370
79033095 C Rev. 06-199

Accumulator (Three-Point Hitch)
Installation
replacement.
FIG. 371: Mount hitch accumulator (1) to chassis with
bolt (2). 4 3
Attach fitting (3) to chassis. Connect hydraulic line (4).
1
Fo
2
r in
P090812008
FIG. 371
te
FIG. 372: Connect hydraulic hose (1).

rn

correct procedure.
al
1
u se
P090812009
FIG. 372
on
ly
06-200 79033095 C Rev.

THREE-POINT HITCH CYLINDER
Three-Point Hitch Cylinder Removal
m

Fo

r

in

te

rn

al

u

se
FIG. 373: Remove bolt (1), washer, and spacer. Remove

pin (2). Position upper link (3) out of the way.
1
Repeat step for other link.
on
2
ly
P090812002
FIG. 373
79033095 C Rev. 06-201

FIG. 374: Remove bolt (1) holding height sensor control
arm (2) to lift arm (3).
1
2
P090812004
FIG. 374
FIGS. 375–376: Attach a suitable lifting device to lift arm
(1). 2
Remove bolt (2), washer, and spacer. Remove pin (3).
Fo
Remove lift arm from rod end of hitch cylinder. 3

Disconnect hose assemblies (4). Repeat this step for
other side of lift arm (4). Position lift arms against step (5).
r
1
in
te
rn
4
al
P090812010
u
FIG. 375
se
5
on
ly
P090812011
FIG. 376
06-202 79033095 C Rev.

FIG. 377: Attach a suitable lifting device to hitch cylinder
(1). Remove bolt (2), washer, and spacer. Remove pin (3).
Remove hitch cylinder.
2
3
Fo
N120612015
FIG. 377
r
Three-Point Hitch Cylinder Installation

in

te

rn

replacement.
al
FIG. 378: Attach a suitable lifting device to hitch cylinder

(1). Install hitch cylinder. Install pin (2). Install bolt (3),
washer, and spacer.
u se
on
ly
3
2
N120612015
FIG. 378
79033095 C Rev. 06-203

Connect hose assemblies (2). 4
Install lift arm on rod end of hitch cylinder. Install pin (3).
Install bolt (4), washer, and spacer.
3
Repeat step for other side of lift arm.
2
Fo
P090812010
FIG. 379
FIG. 380: Attach height sensor control arm (1) to lift arm
r
(2) with bolt (3).

3
in
1
te
rn
2
al
P090812004
u
FIG. 380
se
FIG. 381: Position upper link (1) to original location.

Install pin (2). Install bolt (3), washer, and spacer.
3
Repeat step for other link.
on

appropriate Operation and Maintenance Manual for 2
correct procedure.
ly
P090812002
FIG. 381
06-204 79033095 C Rev.

STEERING CYLINDER (THREE-POINT
HITCH)
Steering Cylinder (Three-Point Hitch)

Removal
m
Fo

r

in

te

rn

al

NOTE: Put identification marks on all hoses for
u
installation purposes. Plug all tubes to prevent

fluid loss and keep contaminants from entering
se
system.
NOTE: Use manual locks to lock hitch from pivoting.
FIG. 382: Remove six bolts (1) holding plate (2) to
on
chassis.
ly
1
P090812012
FIG. 382
79033095 C Rev. 06-205

FIG. 383: Disconnect hose assemblies from base end
(1) of steering cylinders.
Disconnect hose assemblies from rod end (2) of steering
cylinders.
1
2
P090812013
FIG. 383
FIG. 384: Support steering cylinder (1) with an
appropriate lifting device. Remove retaining rings (2) from
top of pins (3). Remove pins and remove steering
cylinders. Weight of steering cylinder is approximately 43
Fo
kg (95 lb). 3
r in
2 1
te
P090812014
FIG. 384
rn
al
u se
on
ly
06-206 79033095 C Rev.

Steering Cylinder (Three-Point Hitch)
Installation
replacement.
FIG. 385: Support steering cylinder (1) with an
appropriate lifting device. Weight of steering cylinder is
Install steering cylinders and secure with pins (2). Secure
pins with retaining rings (3).
2
Fo
r
3 1
in
P090812014
FIG. 385
te
FIG. 386: Connect hose assemblies from base end (1)

of steering cylinders.
rn
Connect hose assemblies from rod end (2) of steering

cylinders.
al
u
1
se
2
P090812013
FIG. 386
on
FIG. 387: Attach plate (2) to chassis with six bolts (1).
ly

correct procedure.
1
P090812012
FIG. 387
79033095 C Rev. 06-207

NOTES
Fo
r in
te
rn
al
u se
on
ly
06-208 79033095 C Rev.

Hydraulic and Three-Point System Testing and Adjusting
HYDRAULIC AND THREE-POINT SYSTEM TESTING AND
ADJUSTING

INFORMATION
Machine Preparation
m
machine.
Fo
(1) Move machine to smooth horizontal location.

(2) Lower all implements and three-point hitch to
r
ground.
in
(3) Make sure transmission control lever is in PARK

position.
te
(4) Warm oil to minimum temperature of 55 to 75

degrees C (131 to 167 degrees F). Refer to Warming the
Hydraulic Oil for procedure.
rn
(5) Move all hydraulic control levers through FLOAT

al
(6) Stop engine and remove key.

(7) Remove appropriate guards.
u
Testing Procedure
se
When defining a problem in any hydraulic system,

following procedure should be followed:
Perform visual checks in Visual Inspection section. If
on
visual inspection is completed and problem is not

identified, perform mechanical system tests. If mechanical
system tests are completed and problem is not identified,
ly
perform electrical system tests.

Electronics Division. Electrical troubleshooting section
lists probable causes of a known problem.
electrical troubleshooting section may suggest specific
inspections or instrument tests. These inspections and
tests will help identify most probable cause.
79033095 C Rev. 06-209

Test Equipment

FIG. 388: Install hose assembly (1) into quick coupler of
any hydraulic control valve. Place hydraulic control lever in
EXTEND DETENT position. Adjust valve (2) accordingly
to heat hydraulic oil.
NOTE: During diagnosis in any hydraulic system,
temperature must be minimum of 55 to 75
Fo
degrees C (131 to 167 degrees F). Temperature

2
of hydraulic oil can be viewed on Virtual Terminal
(VT).
r
Q121612001
Troubleshooting Procedure FIG. 388

in
Use following six steps to begin troubleshooting

machine:
te
• Know the machine.

rn
• Understand the symptom.

• Verify the symptom.
al
• Determine the probable causes.

• Reduce the list of probable causes.
u
• Test the system.

se
Know the Machine

Understand operation of machine. Know if symptom is
characteristic of normal operation or an indication of
on
component failure.
Read systems operation information to understand
systems of machine. You must understand interaction of
ly
systems on machine.
06-210 79033095 C Rev.

Understand the Symptom
Question operator about problem.
• Ask about performance of machine prior to symptom.
• Determine time of first occurrence of symptoms.
symptom. Determine order of occurrences.
• Ask operator about steps taken to troubleshoot
machine.
• Ask about preventive maintenance of machine. Many
Inspect machine. Look for problems. Notice any unusual
odors. Listen for unusual noises.
Fo
Verify the Symptom

Operate machine. When possible, repeat conditions that
r
caused symptom. Check gauges inside cab. Notice any

unusual odors. Listen for unusual noises.
in
Determine the Probable Causes

te
Once information is gathered create a list of probable

causes. Determine subsystem that is cause of symptom.
rn
Reduce the List of Probable Causes

al
List probable causes in order of probability. Identify

probable causes that are easy to verify. When possible,
eliminate probable causes that are easy to check.
u
Test the System

se
Use operational tests to verify cause of symptom. Once

cause has been identified, repair suspect component.
Then, test system again.
on
ly
79033095 C Rev. 06-211

VISUAL INSPECTION
m
WARNING: Do not check for leaks with
your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will
be invisible close to hose. This oil can
Use cardboard or paper to locate pin hole
leaks.
m
machine.
To prevent possible injury, perform procedure that follows

before testing and adjusting hydraulic system.
Use following procedure to perform a visual
Fo
inspection:
(1) Move machine to smooth horizontal location.
(2) Lower all implements and three-point hitch to
r
ground.
in
(3) Make sure transmission control lever is in PARK

position.
te
(4) Warm oil to minimum temperature of 55 to 75

degrees C (131 to 167 degrees F) if necessary.
rn
(5) Move all hydraulic control levers through FLOAT

al
(6) Stop engine and remove key.

(7) Remove appropriate guards.
u
Perform following visual inspections:

(1) Measure oil level.
se
(2) Check for air in oil in sump. Check immediately after

stopping machine. Check sight gauge at rear of machine
next to PTO shaft. Check for air bubbles in sight gauge.
on
(3) Remove filter elements. Check for particles that are

removed from oil by filter element. Use a magnet to
separate metallic particles from nonmetallic particles.
ly
Bronze colored particles give an indication of a clutch

failure. Brass particles or shiny steel particles give an
indication of a pump failure. Rubber particles give an
indication of a seal or hose failure.
(4) Inspect all oil lines and connections for damage or
leaks.
(5) Inspect control linkages for broken or damaged
components.
06-212 79033095 C Rev.

CONTROL VALVE TEST PORT LOCATION
Drawbar Configuration
FIG. 389: System Pressure (P), Pilot Supply Pressure
(PS) and Return Pressure (R) Test Ports
R
PS
R012712001
FIG. 389
Fo
FIG. 390: Load Sense Test Port (LS)

r
LS
in
te
rn
R012712002
FIG. 390
al
Three-Point Hitch Configuration

u
FIG. 391: Load Sense Test Port (LS)

se
LS
on
ly
R012612001
FIG. 391
FIG. 392: System Pressure (P), Pilot Supply Pressure
(PS) and Return Pressure (R) Test Ports
R
P
PS
R012612002
FIG. 392
79033095 C Rev. 06-213

ELEVATED OIL RESERVOIR (EOR) TEST
Introduction
Test indicates if check valve for elevated oil reservoir is
functioning correctly. Once EOR is full, check valve should
open at 55 kPa (8 psi).
Required Tools
FIG. 393: Hydraulic test procedures may be performed
• DataView
1
Table below provides list of required tools if Data View (1)
will be used to perform following test procedure.
Fo
Required Tools (DataView)

r
DataView Tool Gp 1
g00787042
in
Pressure Sensor 1
FIG. 393
0 to 690 kPa (0 to 100 psi)
te
FIG. 394: Table below provides list of required tools if

rn
procedure. A2
A1
al

u
A1 Coupler 2
se
A Hose As 1
A2 Pressure Gauge 1
0 to 400 kPa (0 to 58 psi) Q122112001
on
Fitting 1 FIG. 394

ly
06-214 79033095 C Rev.

EOR Test Procedure
procedure.
m
machine.
1. Move machine to smooth horizontal location.

Fo

r
position.
in

te

rn

al

FIG. 395: Photo showing quick disconnect (1).
u
7. Connect Tooling (A) to quick disconnect (1).

Tooling (A2) will read pressure in elevated oil
se
reservoir. 1
NOTE: If guard beneath pump is not removed, attach
Tooling (B) to quick disconnect (1). Connect
on
Tooling (A) to Tooling (B).

9. Make sure all hydraulic control levers are in HOLD
ly
position.
R010612001
10. Tooling (A) should read approximately 45 to 65 kPa
FIG. 395
(6.5 to 9.5 psi) once EOR is full.
79033095 C Rev. 06-215

HYDRAULIC PUMP PRESSURE TESTS
Low Pressure Standby Test

Introduction
Pump output pressure that is needed to compensate for
any system leakage is referred to as low pressure
standby. Also, this pressure provides hydraulic pump with
an instantaneous response when an implement is
activated. Perform test with all implement valve controls in
BLOCK and engine speed set to 990 to 1010 rpm. No
hydraulic control valves are activated while pump is at low
pressure standby. Low pressure standby is approximately
2415 kPa (350 psi).
Required tools
Fo

• DataView
1
r

Table below provides list of required tools if DataView (1)
in

te

rn
DataView Tool Gp 1
g00787042
al
Pressure Sensor 1
0 to 6895 kPa (0 to 1000 psi) FIG. 396
u

se
procedure.
A1
on

A1 Pressure Gauge 1 A2
ly
0 to 4000 kPa (0 to 580 psi)

A
A2 Coupler 1
Q122112002
FIG. 397
06-216 79033095 C Rev.

Low Pressure Standby Test Procedure
m
machine.
Fo

r

in
position.
te

rn

al

u
FIG. 398: Tooling installed on quick disconnect of

se
hydraulic control valve bank.

7. Connect tooling (A) to quick disconnect (1). Tooling
will read low pressure standby of implement hydraulic
on
system. A
IMPORTANT: Do not move any hydraulic control levers.
Leave hydraulic control levers in HOLD position
or damage may occur to pressure gauges.
ly

1
position. Q122212001
10. Tooling should read approximately 2415 kPa (350 FIG. 398
psi).
NOTE: Low pressure standby is higher than margin
pressure due to higher back pressure created by
oil blocked at closed center valves when valves
are in HOLD position. See Margin Pressure Test
for more information about margin pressure.
Low pressure standby is not adjustable. Low pressure
standby can vary from one machine to another machine.
Also, low pressure standby can vary in same hydraulic
pump as system leakage increases.
79033095 C Rev. 06-217

Margin Pressure Test
Introduction
Test indicates difference between pump output pressure
and pressure of load sensing signal. Difference in
pressure is called margin pressure. Margin pressure is
2000 to 2200 kPa (290 to 319 psi) and is adjusted with
flow compensator spool on implement pump.
Set engine speed to 1490 to 1510 rpm. Set valve section
3 to EXTEND with 50% flow command in Virtual Terminal
(VT) and connect a loop line with an adjustable relief
valve to section 3. Set implement valve supply pressure to
9350 to 11350 kPa (1355 to 1645 psi) by adjusting
hydraulic test stand relief valve.
Required Tools
Fo

• DataView
1
r

Table below provides list of required tools if Data View (1)
in

te

rn
DataView Tool Gp 1
Pressure Sensor 2 g00787042
al
0 to 51710 kPa (0 to 7500 psi)

FIG. 399
FIGS. 400–401: Table below provides list of required

u
tools if pressure gauges will be used to perform following

se
test procedure.
A1
A3
on

A1 Pressure Gauge 0 to 2 A2
24800 kPa (0 to 3600 psi)
ly
A
A2 Coupler 2
Q122112002
B1 Coupler Hose 2
FIG. 400
B B2 Valve 1
B1
B2
Q121612001
FIG. 401
06-218 79033095 C Rev.

Margin Pressure Test Procedure
m
machine.
Fo

r

in
position.
te

rn

al
5. Move hydraulic control levers through FLOAT position

to relieve hydraulic pressure.
u

se

7. Connect tooling (A) to quick disconnect (1). Tooling
(A) will read system pressure of implement hydraulic
on
system. A
ly
1
Q122212001
FIG. 402
79033095 C Rev. 06-219

FIG. 403: LS quick disconnect (1) on hydraulic control
valve bank.
8. Connect tooling (A) to quick disconnect (1). Tooling 1
(A) will read load sense pressure of implement
hydraulic system.
9. Start engine. Run engine at 1490 to 1510 rpm.
10. Connect a loop line with an adjustable relief valve to
section 3. Set valve section 3 to EXTEND with 50%
flow command in Virtual Terminal (VT).
11. Set implement valve supply pressure to 9350 to
11350 kPa (1355 to 1645 psi) by adjusting valve. R011212004
12. Tooling (A) in load sense pressure port should read FIG. 403
approximately 2000 to 2200 kPa (289 to 320 psi) less
than supply pressure by adjusting flow compensator
spool.
Fo
Refer to Adjusting the Flow Compensator Spool for

more information.
13. If adjustment is made, repeat Steps 9 through Step
r
14 to verify adjustment.
in
te
rn
al
u se
on
ly
06-220 79033095 C Rev.

Adjusting the Flow Compensator Spool
Margin pressure test indicates if flow compensator spool
must be adjusted. Adjustments to flow compensator spool
can be made on machine.
Flow Compensator Spool Adjustment Procedure

FIG. 404: Flow compensator spool (1) is located on
compensator valve.
m
Fo

machine.
r

in

adjusting hydraulic system. 1
te

R010612002
rn
FIG. 404
position.
al

u

se
FIG. 405: Flow compensator (4) with adjusting screw (3)

and locknut (2). 2
6. Loosen locking nut.
on
7. Rotate adjustment screw to adjust flow compensator

spool. 3
Rotate adjustment screw clockwise to increase
ly
margin pressure.
Rotate adjustment screw counterclockwise to
decrease margin pressure.
8. Tighten locking nut. 4
g00787448
9. Perform margin pressure test again to verify
adjustment. FIG. 405
79033095 C Rev. 06-221

High Pressure Stall Test
Introduction
Test indicates if load sensing relief valve is set correctly.
Load sensing relief valve limits system pressure to 19700
to 20300 kPa (2856 to 2944 psi).
Hydraulic pump has margin pressure of 2100 kPa (305
psi). Combination of load sensing signal and margin
pressure is system pressure. If hydraulic pump is at high
pressure stall, maximum system pressure should be
19700 to 20300 (2856 to 2944 psi).
Required Tools
• DataView 1
Fo

Table below provides list of required tools if DataView (1)
r in

te
DataView Tool Gp 1
g00787042
rn
Pressure Sensor 1
FIG. 406
0 to 51710 kPa (0 to 7500 psi)
al

procedure.
u
D1
se

D2
on
D1 Pressure Gauge 0 to 1
24800 kPa (0 to 3600 psi)
D
D2 Coupler 1
ly
Q122112002
FIG. 407
06-222 79033095 C Rev.

High Pressure Stall Test Procedure
m
machine.
Fo

r

in
position.
te
degrees C (131 to 167 degrees F). Refer to Warming

the Oil section in General Testing and Adjusting
rn
Information, for more information about warming

hydraulic oil.
al

u

se

7. Connect Tooling (D) to quick disconnect (1).
Tooling (D) will implement system pressure.
D
on
8. Disconnect hydraulic implement lines from one

hydraulic control valve.
ly
10. Locate hydraulic control lever for hydraulic control

valve that was selected in Step 8. Move hydraulic 1
control lever to EXTEND position and hold in
EXTEND position. Q122212001
11. Tooling (D) should read 19700 to 20300 kPa (2857 FIG. 408
to 2944 psi). This is high pressure stall.
12. If high pressure stall reading is not correct, verify
margin pressure is 2000 to 2200 kPa (290 to 319 psi).
See Margin Pressure Test for procedure for checking
margin pressure.
If margin pressure is correct, adjust load sensing
relief valve. Refer to Adjusting the Load Sensing
Relief Valve for procedure.
13. If adjustment is made, repeat Steps 9 through 12 until
pressure gauge reads 19700 to 20300 kPa (2857 to
2944 psi).
79033095 C Rev. 06-223

Adjusting the Load Sensing Relief Valve
If load sensing relief valve does not limit maximum system
pressure to 19700 to 20300 kPa (2857 to 2944 psi), this
adjustment procedure will provide necessary steps to
adjust load sensing relief valve.
Required Tools
• DataView
DataView (1) will be used to perform following test
procedure.
1
Fo
DataView Tool Gp 1
r
Pressure Sensor 1
0 to 51710 kPa (0 to 7500 psi)
in
Table below provides list of required tools if pressure

te
g00787042
gauges will be used to perform following test procedure.
FIG. 409
rn

al
A1 Pressure Gauge 1
A 0 to 24800 kPa (0 to 3600 psi)
u
A2 Coupler 1
se
on
ly
06-224 79033095 C Rev.

Load Sensing Relief Valve Adjustment Procedure
m
machine.
Fo

r

in
position.
te

rn

al

u

se

7. Connect Tooling (A) to quick disconnect (1).
Tooling (A) will read system pressure of implement
on
hydraulic system. A
8. Disconnect hydraulic implement lines from one of
hydraulic control valves.
ly

10. Locate hydraulic control lever for hydraulic control 1
valve that was selected in Step 8. Move hydraulic
control lever to EXTEND position. Hold hydraulic Q122212001
control lever in EXTEND position or place lever in FIG. 410
EXTEND DETENT position.
79033095 C Rev. 06-225

FIG. 411: Location of load sensing relief valve (2), with
locknut and adjusting screw.
11. Tooling (A) should read 19700 to 20300 kPa (2857
to 2944 psi). If Tooling (A) does not read 19700 to 2
20300 kPa (2857 to 2944 psi), load sensing relief
valve (2) will need to be adjusted.
Loosen locknut and turn adjusting screw clockwise to
increase system pressure.
Turn adjusting screw counterclockwise to decrease
system pressure.
Release hydraulic control lever once Tooling (A) R010412001
reads 19700 to 20300 kPa (2857 to 2944 psi). FIG. 411
12. Tighten locknut.
13. Move hydraulic control lever to EXTEND position to
verify maximum system pressure. Tooling (A)
Fo
should read 19700 to 20300 kPa (2857 to 2944 psi).

If maximum system pressure is not correct, repeat Steps
10 through 13 until Tooling (A) reads 19700 to 20300
r
kPa (2857 to 2944 psi).

in
te
rn
al
u se
on
ly
06-226 79033095 C Rev.

High Pressure Cutoff Test
Introduction
Test indicates if cutoff spring and pressure compensator
spool are functioning correctly. Pressure compensator
spool serves as a backup for protecting implement
hydraulic system if load sensing relief valve is not
adjusted correctly. Pressure compensator spool will limit
maximum system pressure to 22500 to 23500 kPa (3265
to 3405 psi).
Required Tools
• DataView
Fo

procedure.
r
1
in
te
DataView Tool Gp 1
Pressure Sensor 1
rn
0 to 51710 kPa (0 to 7500 psi)

al
g00787042
FIG. 412
u

se

procedure.
E1
on

E2
ly
E1 Pressure Gauge 0 to 1
40000 kPa (0 to 5800 psi)
E
E2 Coupler 1
Q122112002
FIG. 413
79033095 C Rev. 06-227

High Pressure Cutoff Test Procedure
m
machine.
Fo

r

in
position.
te

rn

al

u

se

7. Connect Tooling (E) to quick disconnect (1).
Tooling (E) will read system pressure of implement
on
hydraulic system. E
8. Disconnect hydraulic implement lines from one of
ly

10. Locate hydraulic control lever for hydraulic control 1
valve that was selected in Step 8. Move hydraulic
control lever to EXTEND position. Hold hydraulic Q122212001
control lever in EXTEND position or place lever in FIG. 414
EXTEND DETENT position.
06-228 79033095 C Rev.

FIG. 415: Location of load sensing relief valve (1) on
hydraulic control valve shown.
11. Tooling (E) should read 19700 to 20300 kPa (2856
to 2944 psi). 1
Turn load sensing relief valve (1) clockwise until valve
bottoms out.
Tooling (E) should read 22500 to 23500 kPa (3265
to 3405 psi). This is cutoff pressure.
Release hydraulic control lever.
12. If high pressure cutoff is not 22500 to 23500 kPa R010412001
(3265 to 3405 psi), pressure compensator spool will
need to be adjusted. FIG. 415
Refer to Adjusting the Pressure Compensator Spool

Valve section for procedure.
13. When high pressure cutoff is adjusted correctly at
Fo
22500 to 23500 kPa (3265 to 3405 psi), load sensing

relief valve will need to be readjusted to 19700 to
20300 kPa (2856 to 2944 psi).
r
Refer to Adjusting the Load Sense Relief Valve

section for procedure.
in
14. Return load sensing relief valve in counterclockwise

direction (see High Pressure Stall Test).
te
rn
al
u se
on
ly
79033095 C Rev. 06-229

Adjusting the Pressure Compensator Spool (High
Pressure Cutoff)
Introduction
High pressure cutoff test indicates if pressure
compensator spool must be adjusted. Adjustments to
pressure compensator spool can be made on machine.
FIG. 416: Pressure compensator spool (1) is located on
Fo
compensator valve.
m
r

machine.
in

te
adjusting hydraulic system. 1

rn

R010612002
FIG. 416
al

position.
u

se

FIG. 417: Pressure compensator adjusting screw (1)
and locknut (2) is shown.
on
6. Loosen locking nut.

7. Rotate adjustment screw to adjust pressure 2
compensator spool.
ly
a. Rotate adjustment screw clockwise to increase 1

high pressure stall.
b. Rotate adjustment screw counter-clockwise to
decrease high pressure stall.
8. Tighten locking nut.
9. Perform high pressure cutoff test again to verify g00787516
adjustment. FIG. 417
06-230 79033095 C Rev.

IMPLEMENT VALVE PILOT PRESSURE
TEST
Introduction
Implement valve functionality is controlled through use of
pilot pressure. Pilot pressure is controlled through use of
pressure reducing valve. Valve setting is 2700 to 3300
kPa (391 to 479 psi).
When pump is operating at Low Pressure Standby, pump
output pressure is lower than valve setting so pilot
pressure will be approximately same as Low Pressure
Standby.
When pump is operating at any pressure above pressure
reducing valve setting, pilot pressure will be limited to
2700 to 3300 kPa (391 to 479 psi).
Fo
Required Tools
r
• DataView
in

te

procedure.
rn
1
al
DataView Tool Gp 1
u
Pressure Sensor 1
0 to 6894 kPa (0 to 1000 psi)
se
g00787042
on
FIG. 418

ly
procedure.
E1

E1 Pressure Gauge 1 E2
E 0 to 6894 kPa (0 to 1000 psi)
E2 Coupler 1 Q122112002
FIG. 419
79033095 C Rev. 06-231

Implement Valve Pilot Pressure Test
Procedure
m
machine.
Fo


r

in

position.
te

rn

al

u

se

7. Connect Tooling (E) to quick disconnect (1).
on
Tooling (E) will read pilot supply pressure of

8. Disconnect hydraulic implement lines from one of E
ly

10. Locate hydraulic control lever for hydraulic control
valve selected in Step 8. Move hydraulic control lever
to EXTEND position. Hold hydraulic control lever in
1 R012012001
EXTEND position. FIG. 420
11. Tooling (E) should read 2700 to 3300 kPa (391 to
479 psi). Pilot pressure setting is not adjustable.
06-232 79033095 C Rev.

IMPLEMENT HYDRAULIC OPERATIONAL
CHECKS
m
machine.

Fo

Operational checks can be used to find a leak in
implement hydraulic system. Checks can also be used to
r
detect faulty hydraulic control valve or faulty hydraulic

pump.
in
Warm oil to minimum temperature of 55 to 75 degrees C

(131 to 167 degrees F).
te
Refer to Warming the Oil section in General Testing and

rn

Extend and retract implement cylinders several times.
al
1. Watch implement cylinders as cylinder rods move.

Movement of cylinder rods should be smooth and
regular.
u
2. Listen for noise from pump.

se
3. Allow implement cylinders to travel full stroke in each

direction.
4. Place each hydraulic control valve in HOLD position
on
while implement is off ground. Watch for excessive

cylinder rod drift.
Drift of implement cylinders can be caused by
ly
following conditions:
• Leakage of oil past piston seals
• Too much clearance between main spool and valve
body
79033095 C Rev. 06-233

RESEQUENCING AND CALIBRATION OF
VALVE SECTIONS
FIG. 421: Locate access panel (1) inside cab directly to
right of operator’s seat.
P050614001
FIG. 421
Fo
FIG. 422: Remove panel by turning thumb screws (1).

r in
te
1
rn
al
P050614005
FIG. 422
u
FIG. 423: Using a laptop computer with the AGCO

se
Electronic Diagnostic Tool software installed, connect

CAN 2 X 4 adaptor cable from channels 1/2 to middle 1
diagnostic connector (1).
IMPORTANT: Setting the sequence and calibration of
on
additional valve sections will be the same for all

machine models.
EDT will ask what model machine to be worked
ly
with.
It is required to enter the number of any
additional valve sections being added.
Additional valve sections need to be electrically Q012614004
connected, resequenced and calibrated one at a
time. FIG. 423
06-234 79033095 C Rev.

1
1
Q020414010 Q020414011
FIG. 424
Fo
FIG. 424: Connect harness to any additional valve

section (1).
IMPORTANT: Machine harness will now be connected to
r
valve sections one through five.

in
te
rn
al
1
u se
on
ly
Q012714001
FIG. 425
FIG. 425: Open EDT. Select Challenger (1).
79033095 C Rev. 06-235

Fo 1
Q012714002
FIG. 426
in
FIG. 426: Select vehicle.

te
(Select specific machine model.)

rn
In this case MT700C is selected (1).

al
u se
on
ly
Q012714003
FIG. 427
FIG. 427: Make sure connection (1) in cab is secure.

Should be “Cab Diagnostic Connector” (1 of 2) in access
panel to lower right of operator seat.
06-236 79033095 C Rev.

1
Fo
2
r in
Q012714004
FIG. 428
te
FIG. 428: Network scan pictured.

rn
Shown are auxiliary valves (1) found in network.

Indicators (2) will be green if valve is connected and
communicating.
al
u se
on
ly
79033095 C Rev. 06-237

Configuration and Resequencing
3
Fo
r in
Q012714005
te
FIG. 429
rn
FIG. 429: Press wrench icon (1). After selecting vehicle

configuration (2) press start (3).
al
u se
on
ly
Q012714006
FIG. 430
FIG. 430: Wait a few seconds for EDT to retrieve

configuration. Screen should appear as above.
06-238 79033095 C Rev.

1 3
2
Fo
1
r in
Q012714007
FIG. 431
te
FIG. 431: Use blue arrows (1) to scroll up or down until

you find and highlight auxiliary valves (2).
rn
To change number of valves press edit (3).

al
u se
on
1
ly
Q012714008
FIG. 432
FIG. 432: Highlight number of valves (1).
79033095 C Rev. 06-239

1
Fo
r
Q012714009
in
FIG. 433
te
FIG. 433: Press O.K.(1) after selecting number of valves.

rn
al
u se
on
ly
2
1
Q012714010
FIG. 434
FIG. 434: See current configuration (1) is four valves and

new configuration (2) is five valves.
06-240 79033095 C Rev.

1
Fo
r
Q012714011
in
FIG. 435
te
FIG. 435: Press icon with green check mark (1) to

change configuration. Both current and new configuration
rn
now show five valves.

al
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on
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Q012714012
FIG. 436
FIG. 436: After changing valve numbers, close screen

by pressing close button (1).
79033095 C Rev. 06-241

1
Fo
r in
Q020314001
FIG. 437
te
FIG. 437: Press “change valve I.D.” (1).

rn
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u se
2
on
1 3
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Q020314003
FIG. 438
FIG. 438: Highlight line fifteen (1) and key new value (2).
In this case it is number five.
When finished press OK (3).
06-242 79033095 C Rev.

1
Fo
r
Q012714024
in
FIG. 439
te
FIG. 439: After editing the values, press “Save Values”

(1).
rn
Calibrate new valve section per precedure below and

repeat procedure for additional valve section, if equipped.
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on
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79033095 C Rev. 06-243

Valve Section Calibration
2
Fo
r in
Q012714013
te
FIG. 440
rn
FIG. 440: Calibrate valves by pressing calibration icon

(1) and then start (2).
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on
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Q012714014
FIG. 441
FIG. 441: To see calibration values, press “read values”

button (1).
06-244 79033095 C Rev.

1
Fo
r
Q012714015
in
FIG. 442
te
FIG. 442: Wait until EDT loads values (1) to table.

rn
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u se
on
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Q020414006
FIG. 443
FIG. 443: Word “complete” (1) displayed when all values

have been loaded.
79033095 C Rev. 06-245

Fo
1 2
r
3
Q012714024
in
FIG. 444
te
FIG. 444: Edit values (1) as needed. Save values (2)

rn
and press “Exit” (3) to exit.

Contact AGCO Technical Services and Support for
correct calibration values for new valves or if calibration
al
values are lost.

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on
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06-246 79033095 C Rev.

Flashing Software
1
Fo
r in
Q012714026
te
FIG. 445
rn
FIG. 445: Press icon (1) as shown to flash software.

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on
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Q012714027
FIG. 446
FIG. 446: Press start (1) to begin.

Can flash whole group of valves or each one individually.
79033095 C Rev. 06-247

B 1
Fo
r in
Q012714028
FIG. 447
te
FIG. 447: Flash in progress (1).

rn
Green circle if flash is successful (A).

Red circle (B) if flash fails.
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Q012714029
FIG. 448
FIG. 448: When flashing is complete, press “close” (1) to

exit.
06-248 79033095 C Rev.

1
Fo
r
Q012714030
in
FIG. 449
te
FIG. 449: On network scan screen, can see the auxiliary

valve hardware version and software version (1) by
rn
selecting valve to check.

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79033095 C Rev. 06-249

Resequencing and Calibration Process
Completion
FIG. 450: When valve sections have been successfully
sequenced and calibrated, close Electronic Diagnostic
Tool and power off laptop. 1
Can now disconnect adaptor cable from diagnostic
connector (1) in electrical panel.
Q012614004
FIG. 450
Fo
FIG. 451: Replace access panel (1) inside cab directly to

right of operator’s seat.
r in
1
te
rn
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P050614001
FIG. 451
u
FIG. 452: Secure panel by turning thumb screws (1).

se
on
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P050614005
FIG. 452
06-250 79033095 C Rev.

HYDRAULIC OIL COOLER TESTS
Hydraulic Oil Cooler Pressure Test

Test indicates pressure differential between inlet and
outlet of hydraulic oil cooler.
Required Tools
• DataView
Data View (1) will be used to perform following test
procedure.
1
Fo

r
DataView Tool Gp 1
in
Pressure Sensor 2
0 to 690 kPa (0 to 100 psi)
te
g00787042
rn
FIG. 453

al

procedure. A2
A1
u

se

Coupler 4
on
A1 Hose As 2
A Pressure Gauge 2 Q122112001
0 to 1000 kPa (0 to 145 psi)
ly
A2 FIG. 454
Fitting 2
79033095 C Rev. 06-251

Hydraulic Oil Cooler Pressure Test Procedure
procedure.
m
machine.
Fo

r

in

position.
te
4. Warm oil to minimum temperature of 60 Degrees C

(140 Degrees F).
rn
NOTE: The temperature of the hydraulic oil must be

at least 60 Degrees C (140 Degrees F) to ensure
accuracy of this test.
al

u

se

on
FIG. 455: Cooler line quick disconnects (1) and (2).

7. Connect Tooling (A) to quick disconnect pressure 2
taps. Tooling (A) will read inlet and outlet pressure of
ly
hydraulic oil cooler.

position.
10. Difference between gauges should be approximately 1
310 to 380 kPa (45 to 55 psi). If pressure differential
of 310 to 380 kPa (45 to 55 psi) is not obtained,
perform pressure test for bypass valve. R010612003
FIG. 455
Refer to Bypass Valve Pressure Test for procedure for
testing bypass valve.
06-252 79033095 C Rev.

Oil Cooler Bypass Valve Pressure Test
Introduction
Test indicates if bypass valve for hydraulic oil cooler is
operating correctly.
Required Tools
• DataView
Data View (1) will be used to perform following test
procedure.
1
Fo

DataView Tool Gp 1
r
Pressure Sensor 2
in
0 to 690 kPa (0 to 100 psi)

te
g00787042
FIG. 456
rn

al

procedure. A2
A1
u

se

A1 Coupler 4
Hose As 2
on
A Pressure Gauge 2
0 to 1000 kPa (0 to 145 psi) Q122112001
A2
ly
Fitting 2 FIG. 457

B - Fitting Cap Plugs 2
79033095 C Rev. 06-253

Bypass Valve Pressure Test Procedure
procedure.
m
machine.
Fo

r

in

position.
te

rn

FIG. 458: Oil cooler hoses (1) connected to filter
al
manifold.
6. Disconnect cooler hoses from filter manifold. Use
Tooling (B) to cap hoses and manifold.
u
m
WARNING: Hot oil and components can 1
se
cause personal injury.

Do not allow hot oil or components to
contact skin.
on
R010612004
ly
FIG. 458
FIG. 459: Cooler line quick disconnects (1) and (2).

7. Connect Tooling (A) to quick disconnect. Tooling 2
(A) will verify if bypass valve for hydraulic oil cooler is
position.
10. Difference between gauges should read 1
approximately 310 to 380 kPa (45 to 55 psi).
R010612003
FIG. 459
06-254 79033095 C Rev.

THREE-POINT HITCH OPERATIONAL
CHECKS
m
machine.

Fo

Operational checks can be used to find a leak in
three-point hitch hydraulic system. Checks can also be
r
used to detect a faulty three-point hitch control valve or a

faulty hydraulic pump.
in
Warm hydraulic oil to minimum temperature of 55 to 75

te
Refer to Warming the Oil section in General Testing and

rn

Extend and retract three-point hitch lift cylinders several
al
times.
1. Watch lift cylinders as cylinders move. Movement of
cylinders should be smooth and regular.
u
2. Listen for noise from pump.

se
3. A low pressure setting of relief valve for three-point

hitch can cause hitch to lower during roading. A high
pressure setting of relief valve can cause a reduction
on
in life of components of hydraulic system.

4. Place three-point hitch control valve in HOLD position
while mounted implement is off ground. Watch for
ly
excessive cylinder rod drift.

Drift in three-point hitch lift cylinders can be
caused by following conditions:
• Leakage of oil past piston seals
• Too much clearance between main spool and valve
body
79033095 C Rev. 06-255

Three-Point Hitch Cylinder Drift
Use following procedure to check three-point hitch
cylinder drift.
1. Load three-point hitch with 2270 kg (5000 lb).
2. Fully raise three-point hitch.
3. Table shows acceptable drift for three-point hitch.
Three-Point Hitch Cylinder Drift

Temperature Drift in 5 Minutes
49 degrees C (120 degrees F) 0 to 4 mm (0 to 0.16 inch)
THREE-POINT HITCH CONTROL VALVE

SOLENOID - CALIBRATE
Fo
Introduction
r
occur:
in

te
• Normal wear on component

rn
Required Tools
al
Caterpillar Electronic Technician service tool (ET) is used

u

se
on
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06-256 79033095 C Rev.

Fo
r in
te
rn
g00803086
al
FIG. 460
FIG. 460: ET screen of available electronic control

u
modules (ECM) is shown.

se
NOTE: Once communication has been established, ET
will list electronic control modules on machine.
on
2. Choose menu item Hitch Control.

ly
79033095 C Rev. 06-257

Fo
r in
te
rn
g00803194
FIG. 461
al
FIG. 461: ET screen of calibration menu for ECM is

shown.
u

NOTE: Another drop-down menu will appear. Menu will
se
list each available calibration.

5. Select Rear Hitch Solenoid Calibrations.
on
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06-258 79033095 C Rev.

Fo
r in
te
g00803202
rn
FIG. 462
al
FIG. 462: ET screen of warning label for calibration of

hitch solenoids is shown.
u

se
on
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79033095 C Rev. 06-259

Fo
r in
te
g00803203
rn
FIG. 463
al
FIG. 463: ET screen of calibration for hitch valves is

shown.
u
7. Select Rear Hitch Raise/Lower Solenoid Calibration.

se
8. Select Begin.
procedures.
on
prior to start of calibration. For example, set shift

lever to PARK. User must ensure that all setup
for conditions of calibration are satisfied.
ly
06-260 79033095 C Rev.

THREE-POINT HITCH
SENSORS-CALIBRATE
occur:
Required Tools
Caterpillar Electronic Technician service tool (ET) is used
Fo
r in
te
rn
al
u se
on
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g00803086
FIG. 464
FIG. 464: ET screen of available electronic control

modules (ECM) is shown.
NOTE: Once communication has been established, ET
will list electronic control modules on machine.
2. Choose menu item Hitch Control.
79033095 C Rev. 06-261

Fo
r in
te
rn
g00803194
FIG. 465
al
FIG. 465: ET screen of calibration menu for ECM is

shown.
u

NOTE: Another drop-down menu will appear. Menu will
se
list each available calibration.

5. Select Rear Hitch Height Sensor Calibration or select
Rear Hitch Control Lever Sensor Calibration.
on
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06-262 79033095 C Rev.

Fo
r in
te
g00803421
rn
FIG. 466
al
FIG. 466: ET screen of warning label for calibration of

three-point hitch sensors
u

se

procedures.
prior to start of calibration. For example, set shift
on
lever to PARK. User must ensure that all setup

for conditions of calibration are satisfied.
ly
79033095 C Rev. 06-263

THREE-POINT HITCH (STEERABLE)
SENSORS - CALIBRATE
VT display is used to access calibration procedure for
position sensor for steerable three-point hitch. Calibration
procedure is located in Three-Point Hitch Steering
screens.
occur:
• Linkage for three-point hitch was adjusted.
Refer to Operation and Maintenance Manual, VT
Fo
Three-Point Hitch (Steerable) Screen, for calibration

procedure for sensors.
r in
te
rn
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06-264 79033095 C Rev.

ACCUMULATOR (THREE-POINT HITCH) -
TEST AND CHARGE
Accumulator Nitrogen Charge Test

Introduction
Test indicates pressure of nitrogen gas in accumulator for
three-point hitch. Pressure of nitrogen gas in accumulator
is variable with ambient temperature. Accumulator is used
to dampen pressure spikes that occur in three-point hitch
hydraulic system. Pressure spikes are often encountered
while machine is roading with heavy three-point hitch
mounted implement.
Required Tools
FIG. 467: Table below provides list of required tools for
testing and charging accumulator for three-point hitch. A3
Fo
A5
A2
r
_ _ Nitrogen Charging 1
in
Group
A7
A1 Hose Assembly 1
te
A2 Fitting 2 A4
A3 Coupling 2
rn
A5 Regulator 1
al
A6 Chuck 1 A10 A3
A A7 Hose Assembly 1
A8 Pipe Tee 1
u
A9 Fitting 1 A1
A8
se
A10 Needle Valve 1

A11 Coupling 1 A11 A9 R011112001
B - Laser Infrared 1 FIG. 467

Thermometer Group
on
NOTE: Item (A1) through item (A11) are part of Nitrogen

Charging Group. These items are preassembled.
ly
Accumulator Charge Test Procedure

as surrounding air. Use following table as reference for
79033095 C Rev. 06-265

Charging pressure and temperature relationship for a 16600 kPa (2407 psi) accumulator
-7 Degrees C (20 Degrees F) 6581 kPa (955 psi)
4 Degrees C (40 Degrees F) 6856 kPa (994 psi)
NOTE: The pressure may vary by 70 kPa (10 psi).

Fo

r
position.
in

te

FIG. 468: Photo of cap (1) on accumulator. Accumulator
rn
is located below implement valve stack.

5. Remove cap.
al
6. Connect nitrogen charging chuck (A6) to

accumulator.
7. Ensure valve on chuck (A6) is completely closed.
u
Attach chuck (A6) to nitrogen charging valve (13).

se
8. Ensure valve (A10) is completely closed. Rotate

handle on chuck (A6) counterclockwise until valve is
completely open. 1
R011112002
on
9. Use pressure gauge (A4) to check amount of

FIG. 468
nitrogen charge in accumulator.
10. Use Tooling (B) to check temperature of
ly
accumulator. Use table to determine nitrogen

pressure in accumulator.
11. If pressure is too high, slowly open valve (A10) until
desired pressure is reached.
12. If pressure is too low, Charge accumulator.
Refer to Charging Procedure for the Accumulator.
13. Rotate handle on chuck (A6) clockwise until valve is
completely closed. Disconnect coupling assembly
(A11).
14. Slowly open valve (A10) to release pressure in line
(A7).
15. Remove test equipment.
16. Install cap.
06-266 79033095 C Rev.

Accumulator Charging Procedure
Introduction
Following procedure is used to charge accumulator for
three-point hitch hydraulic system.
Required Tools
FIG. 469: Table below provides list of required tools for
testing and charging accumulator for three-point hitch. A3 A5
A2
_ _ Nitrogen Charging 1
Group
A7
A1 Hose Assembly 1
A2 Fitting 2 A4
Fo
A3 Coupling 2
A5 Regulator 1
r
A6 Chuck 1 A10 A3
in
A A7 Hose Assembly 1
A8 Pipe Tee 1
te
A9 Fitting 1 A1
A10 Needle Valve 1 A8
rn
A11 Coupling 1 A11 A9 R011112001
B - Laser Infrared 1 FIG. 469

al
Thermometer Group
NOTE: Item (A1) through item (A11) are part of Nitrogen

Charging Group. These items are preassembled.
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on
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79033095 C Rev. 06-267

Charge Procedure
as surrounding air. Use table below to determine correct
amount of nitrogen pressure to use.
Charging pressure and temperature relationship for a 16,600 kPa (2407 psi) accumulator
Fo

r

in
NOTE: Pressure may vary by 70 kPa (10 psi).

te

rn
position.
al

u
FIG. 470: Photo of cap (1) on accumulator. Accumulator

is located below implement valve stack.
se
5. Remove cap.
NOTE: Make sure that valve (A10) is completely closed.
m
on
WARNING: Dry nitrogen is only gas

approved for use in accumulators. Charging
of oxygen gas in an accumulator will cause
an explosion. An explosion can be
ly
eliminated by using nitrogen gas cylinders

with standard CGA (Compressed Gas 1
Association, Inc.) No. 580 connectors.
R011112002
When nitrogen gas is ordered, make sure to
order the cylinders with CGA No. 580 FIG. 470
connectors.
Do not rely on color codes or other
methods of identification to tell difference
between nitrogen and oxygen cylinders. In
any application, never use an adapter to
connect your nitrogen charging group to a
valve outlet used on both nitrogen, oxygen,
or other gas cylinders. BE SURE YOU USE
DRY NITROGEN (99.8% purity).
6. Connect fitting on regulator assembly (A5) to dry

nitrogen cylinder.
06-268 79033095 C Rev.

7. Ensure valve (A10) is completely closed before
opening valve on nitrogen cylinder.
8. Turn adjustment screw on regulator assembly (A5).
Stop turning adjustment screw when pressure on
gauge of regulator assembly (A5) is equal to pressure
needed to correctly charge accumulator.
NOTE: Use table as a reference for correct charging
pressure.
Rotate valve handle on chuck (A6) counterclockwise
until valve is completely open.
10. Slowly open valve (A10) to charge accumulator.
11. Nitrogen pressure must equalize. When pressure
readings are stable, record pressure readings from
gauge. If pressure on gauge (A4) is equal to pressure
on gauge (A5), then accumulator is correctly
Fo
charged.
12. If there is decrease in pressure on gauge (A4), open
valve (A10) and allow more nitrogen to enter
r
accumulator.
NOTE: Perform Step 11 through Step 12 as many times
in
as necessary. When valve (A10) is closed,

reading on gauge (A4) should match reading in
te
table.
13. Close valve on chuck (A6).
rn
14. Close valve on nitrogen cylinder.

al
15. Turn adjustment screw on regulator (A5) to relieve

pressure in line (A1). Open valve (A10) to relieve
pressure in line (A7).
u
16. Remove Tooling (A).

se
17. Install cap.

on
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79033095 C Rev. 06-269

NOTES
Fo
r in
te
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06-270 79033095 C Rev.

Index
INDEX
A D
Accumulator (Three-Point Hitch) ....................... 06-87, Data Link for Implement System ........................ 06-32
..............................................................06-105, 06-199 Data Link for Three-Point Hitch System ............. 06-99
Accumulator (Three-Point Hitch) Destroke ............................................................. 06-53
- Test and Charge ...................................... 06-265 Determine the Probable Causes ...................... 06-211
Accumulator (Three-Point Hitch) Installation .... 06-200 Draft Arms .......................................................... 06-79
Accumulator (Three-Point Hitch) Removal ....... 06-199 Draft Control ....................................................... 06-92
Accumulator Charge Test Procedure ............... 06-265 Drawbar Configuration ..................................... 06-213
Accumulator Charging Procedure .................... 06-267
Accumulator Nitrogen Charge Test .................. 06-265
Adjusting Detent Time ........................................ 06-27 E
Adjusting Flow Rate ........................................... 06-27
Adjusting the Flow Compensator Spool ........... 06-221 Electronic Control Modules
Adjusting the Load Sensing Relief Valve ......... 06-224 for Implement System .................................. 06-28
Fo
Adjusting the Pressure Compensator Spool .... 06-230 Electronic Control Modules
Armrest ECM ............................... 06-12, 06-30, 06-83 for Three-Point Hitch System ....................... 06-97
Electronic Controls (Hydraulic Levers) ................. 06-4
Elevated Oil Reservoir ............................. 06-14, 06-38
r
B Elevated Oil Reservoir (EOR) Test .................. 06-214

in
EOR Test Procedure ........................................ 06-215

Breather ............................................................. 06-36 Extend Valve Function ....................................... 06-64
Button (One-Touch) ..................... 06-11, 06-82, 06-94
te
Bypass Valve Pressure Test ............................ 06-253

Bypass Valve Pressure Test Procedure .......... 06-254 F
rn
Features of Implement System .......................... 06-22

C Filler Cap ............................................................ 06-37
al
Flashing Software ............................................. 06-247

Calibration Procedure ......................... 06-257, 06-261 Float ................................................................... 06-92
CAN Data Link ........................................ 06-11, 06-82 Float Valve Function ........................................... 06-66
u
Check Valve (Elevated Oil Reservoir) ................ 06-39 Flow Compensator

Common Sump .............................. 06-3, 06-14, 06-33 Spool Adjustment Procedure ...................... 06-221
se
Compensator Valve ..................... 06-17, 06-46, 06-85

Configuration and Resequencing ..................... 06-238
Constant Flow .................................................... 06-52 G
Control Valve (Implement) ............................... 06-142
on
Control Valve (Implement) General Information .............................................. 06-1

- Drawbar Configuration ............................. 06-143 General Testing and Adjusting Information ...... 06-209
Control Valve (Implement)
- Three-Point Hitch Configuration .............. 06-163
ly
Control Valve (Implement) Assembly ............... 06-154 H

Control Valve (Implement) Disassembly .......... 06-148
Control Valve (Implement) Installation ............. 06-161 High Pressure Cutoff .......................................... 06-57
Control Valve (Implement) Removal ................ 06-143 High Pressure Cutoff Test ................................ 06-227
Control Valve (Steerable Three-Point Hitch) .... 06-105 High Pressure Cutoff Test Procedure .............. 06-228
Control Valve (Three-Point Hitch) .................... 06-172 High Pressure Stall ............................................. 06-55
Control Valve High Pressure Stall Test ................................... 06-222
(Three-Point Hitch) Assembly .................... 06-173 High Pressure Stall Test Procedure ................. 06-223
Control Valve Hitch Assembly ................................................... 06-78
(Three-Point Hitch) Disassembly ............... 06-172 Hitch Control Valve in Hold Position ................. 06-101
Control Valve Bank (Implement) Assembly ...... 06-159 Hitch Control Valve Lower Position .................. 06-102
Control Valve Bank Hitch Control Valve Raise Position ................... 06-103
(Implement) Disassembly .......................... 06-146 Hold Valve Function ........................................... 06-63
Control Valve Section Hydraulic and Three-Point
(Implement) Installation .............................. 06-168 System Testing and Adjusting .................... 06-209
Control Valve Section Hydraulic Control Lever Operation ..................... 06-22
(Implement) Removal ................................. 06-163 Hydraulic Control Valve Solenoid Valves ........... 06-13
Control Valve Test Port Location ..................... 06-213 Hydraulic Control Valves ............... 06-4, 06-18, 06-62
Hydraulic Filter ................................................. 06-137
79033095 C Rev. 06-271

Index
Hydraulic Filter (Implement) ............................... 06-85 Lift Links ............................................................. 06-78
Hydraulic Filter Installation ............................... 06-140 Load Independent Flow Division (LIFD) ............... 06-9
Hydraulic Filter Removal .................................. 06-137 Load Sense Blocking Valve ................................ 06-31
Hydraulic Lever Position Sensor ........................ 06-26 Load Sense Relief Valve .................................... 06-18
Hydraulic Motor Load Sensing
Case Drain (If Equipped) .................. 06-19, 06-68 Relief Valve Adjustment Procedure ............ 06-225
Hydraulic Oil Cooler ................................ 06-20, 06-69 Low Pressure Standby ....................................... 06-48
Hydraulic Oil Cooler Pressure Test .................. 06-251 Low Pressure Standby Test ............................. 06-216
Hydraulic Oil Cooler Low Pressure Standby Test Procedure ............ 06-217
Pressure Test Procedure ........................... 06-252
Hydraulic Oil Cooler Tests ............................... 06-251
Hydraulic Oil Filter (Implement) ............... 06-15, 06-40 M
Hydraulic Oil Filter Location ............................... 06-40
Hydraulic Power Machine ECM .............................. 06-12, 06-28, 06-82
Beyond (If Equipped) ........................ 06-19, 06-67 Machine Preparation ........................................ 06-209
Hydraulic Pump (Implement) ....... 06-17, 06-44, 06-85 Manual ................................................................ 06-92
Hydraulic Pump Pressure Tests ...................... 06-216 Manual Lowering .............................................. 06-104
Hydraulic Schematics ...................................... 06-112 Margin Pressure Test ....................................... 06-218
Margin Pressure Test Procedure ..................... 06-219
Fo
I
O
r
Implement (Piston) Pump ................................ 06-128

Implement Electronic Control System .................. 06-6 Oil Cooler Bypass Valve ........................ 06-20, 06-183
in
Implement Filter Bypass Circuit ......................... 06-41 Oil Cooler Bypass Valve Installation ................ 06-183
Implement Filter Bypass Switch .............. 06-25, 06-41 Oil Cooler Bypass Valve Removal ................... 06-183
Implement Filter Bypass Valve .......................... 06-41 Oil Drain Plug ..................................................... 06-37
te
Implement Hydraulic Filter ................................... 06-3 Oil Flow .............................................................. 06-40

Implement Hydraulic Operational Checks ........ 06-233 On/Off Solenoid Valve ........................................ 06-31
rn
Implement Hydraulic Pump .................................. 06-4 One-Touch ......................................................... 06-24

Implement Hydraulic System ............. 06-1, 06-3, 06-8 One-Touch Button ................................... 06-25, 06-91
Implement Pump Installation ............................ 06-130 One-Touch Mode .................................... 06-24, 06-91
al
Implement Pump Removal ............................... 06-128 Output Components of Implement System ........ 06-31
Implement System ............................................... 06-5
Implement System Control Settings ................... 06-27
u
Implement System P
Electronic Component Locations ................. 06-10
se
Implement System Position Sensor (Hitch Lever) ...... 06-80, 06-88, 06-95
Hydraulic Component Locations .................. 06-14 Position Sensor (Hitch Lift) ...................... 06-80, 06-95
Implement System Input Components ............... 06-25 Position Sensor (Hitch Steering) ........................ 06-81
Implement Valve Pilot Pressure Test ............... 06-231 Priority Valve ...................................................... 06-59
on
Implement Valve Proportional Solenoid Valve ............................... 06-31

Pilot Pressure Test Procedure ................... 06-232
Intermediate Valve Stack ........... 06-18, 06-58, 06-174
ly
Intermediate Valve Stack Assembly ................ 06-178 Q

Intermediate Valve Stack Disassembly ............ 06-177
Intermediate Valve Stack Installation ............... 06-179 Quick Hitch ......................................................... 06-79
Intermediate Valve Stack Removal .................. 06-174
Introduction (Implement System) ......................... 06-3
Introduction (Three-Point Hitch System) ............ 06-71 R
Reduce the List of Probable Causes ................ 06-211

K Relief Valve ...................................................... 06-181
Relief Valve Installation .................................... 06-182
Know the Machine ........................................... 06-210 Relief Valve Removal ....................................... 06-181
Remote Coupler Installation ............................. 06-167
Remote Coupler Removal ................................ 06-166
L Resequencing and
Calibration of Valve Sections ..................... 06-234
Large Section ..................................................... 06-42 Resequencing and
Levers (Hydraulic Control) ................................. 06-10 Calibration Process Completion ................. 06-250
Lift Arms ............................................................. 06-78 Retract Valve Function ....................................... 06-65
Lift Cylinders ...................................................... 06-78 Roading Lockout Switch .............. 06-23, 06-25, 06-90
06-272 79033095 C Rev.

Index
Rockshaft .............................................. 06-78, 06-194 Three-Point Hitch Cylinder Drift ........................ 06-256
Rockshaft Installation ....................................... 06-196 Three-Point Hitch Cylinder Installation ............. 06-203
Rockshaft Removal .......................................... 06-194 Three-Point Hitch Cylinder Removal ................ 06-201
Three-Point Hitch
Electronic Component Locations .................. 06-80
S Three-Point Hitch Electronic Control System ..... 06-74
Three-Point Hitch
Scavenge (Gear) Pump ................................... 06-131 Hydraulic Component Locations .................. 06-85
Scavenge Pump Installation ............................ 06-132 Three-Point Hitch Hydraulic System .................. 06-76
Scavenge Pump Removal ............................... 06-131 Three-Point Hitch Input Components ................. 06-93
Shift Mode ............................................... 06-24, 06-91 Three-Point Hitch Installation ........................... 06-189
Sight Gauge ....................................................... 06-37 Three-Point Hitch Lift Cylinders .......................... 06-87
Slip Control ........................................................ 06-92 Three-Point Hitch Operational Checks ............. 06-255
Small Section ..................................................... 06-42 Three-Point Hitch Output Components .............. 06-98
Solenoid Valve (Service Brake) .............. 06-15, 06-67 Three-Point Hitch Removal .............................. 06-184
Solenoid Valves (Hitch Lift) ..................... 06-83, 06-98 Three-Point Hitch Sensors-Calibrate ................ 06-261
Solenoid Valves (Hitch Steering) ............ 06-84, 06-98 Three-Point Hitch System ....................... 06-71, 06-72
Steerable Hitch Three-Point Hitch System Features ................... 06-88
Control Valve Float Position ....................... 06-110 Top Link .............................................................. 06-78
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Steerable Hitch Troubleshooting Procedure .............................. 06-210

Control Valve Hold Position ....................... 06-107
Steerable Hitch
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Control Valve Left-Steer Position ............... 06-109 U

Steerable Hitch
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Control Valve Right-Steer Position ............ 06-108 Understand the Symptom ................................. 06-211
Steerable Three-Point Hitch Control Valve ........ 06-86 Upstroke ............................................................. 06-50
Steering (Piston) Pump .................................... 06-133
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Steering Cylinder (Three-Point Hitch) .............. 06-205

Steering Cylinder V
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(Three-Point Hitch) Installation .................. 06-207

Steering Cylinder Valve Section Calibration ................................. 06-244
(Three-Point Hitch) Removal ..................... 06-205 Verify the Symptom .......................................... 06-211
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Steering Cylinders (Three-Point Hitch) ... 06-78, 06-86 Virtual Terminal (VT) Display .................. 06-13, 06-83
Steering Pump Installation ............................... 06-135 Visual Inspection .............................................. 06-212
Steering Pump Removal .................................. 06-133
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Suction Screen (Scavenge Pump) ..................... 06-36

Suction Screen W
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(Tandem Charge Pump) ................... 06-14, 06-36

Switch (Implement Filter Bypass) ...................... 06-11 Warming the Hydraulic Oil ................................ 06-210
Switch (Raise/Lower) (Fender) .... 06-81, 06-89, 06-93
Switch (Raise/Work) .................... 06-81, 06-89, 06-93
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Switch (Roading Lockout) ....................... 06-10, 06-94

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Tandem Charge Pump ............... 06-16, 06-42, 06-125

Tandem Charge Pump Installation .................. 06-127
Tandem Charge Pump Removal ..................... 06-125
Test Equipment ................................................ 06-210
Test Ports ........................................................... 06-21
Test the System ............................................... 06-211
Testing Procedure ............................................ 06-209
Three-Point Hitch .................................... 06-2, 06-184
Three-Point Hitch
(Steerable) Sensors - Calibrate ................. 06-264
Three-Point Hitch Components .......................... 06-78
Three-Point Hitch Configuration ....................... 06-213
Three-Point Hitch Control Settings .................... 06-96
Three-Point Hitch Control Valve ........... 06-86, 06-100
Three-Point Hitch
Control Valve Solenoid - Calibrate ............. 06-256
Three-Point Hitch Cylinder ............................... 06-201
79033095 C Rev. 06-273

Index
NOTES
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06-274 79033095 C Rev.

Schematics
Hydraulic
33
C5 C1
25
13
10
C6 C2
14
DIFF
C7 C3
34
15
35
DIFF
C8 C4
DIFF
Fo
DIFF
3.5 bar
30 BAR
36 8
C9
40
ri
0.8 mm (0.031 in)
12
nt
235 Bar
(3408 psi)
er
235 Bar
(3408 psi)
37 22
na
11
4.96 bar
R 2.76 bar 4.96 bar
2.76 bar
lu
SOS
SOS
17
3.45 bar
9 10 16
se
P
19
18
on
SS
DIFF
3 1 6
DIFF
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XMSN
Y
2
28 7
SV2
SV1
29 a
3
b
38 39 7 5 8 4
B B
DIFF
S L1 26
A
MA S MH X2 X1
6 32
30 4
31 27 P111012001
FIG. 156
Implement and Three-Point Hitch Systems Hydraulic Schematic
06–113

P SYSTEM PRESSURE
R RETURN OIL FLOW
LS LOAD SENSE
EXT EXTEND PORT
RET RETRACT PORT
Fo
Metric English
ri
3.5 bar 51 psi
30 bar 435 psi
nt
0.8 mm 0.031 in
220 bar 3191 psi
er
183 bar 2654 psi
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on
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06–114
Schematics
Hydraulic
33
C5 C1
13
25
13 DIFF
10
C6 C2
14 14 DIFF
R
15 DIFF
C7 C3
34
15
P
35
DIFF
C8 C4
DIFF
Fo
DIFF
3.5 bar
30 bar
36 8
C9
40
ri
0.8 mm
12
nt
235 bar
EXT
37
er
RET
235 bar
11 22
na
42 2.76 bar 4.96 bar 4.96 bar
2.76 bar
lu
43 XMSN
5 SOS
SOS
17
3.45 bar
9 41
se
10 16
L R
19
18
on
DIFF
SS
R L
DIFF
XMSN
DIFF
X 3 1 6
ly
XMSN
28 7 2
29 b a
3 SV2
SV1
38 39 MB Fe Fa(G) PS T2 T1 R
B B
7 5 8 4
DIFF
A
S L1 26
MA S MH X2 X1
6 32
30 4
31 Q010812003
FIG. 159
Implement and Three-Point Hitch Systems Hydraulic Schematic, CE only
06–119

32 TO IMPLEMENT VALVE CONNECTIONS
44 COLLECTION BOTTLE
P SYSTEM PRESSURE
R RETURN OIL FLOW
LS LOAD SENSE
EXT EXTEND PORT
Fo
RET RETRACT PORT
ri
Metric English
3.5 bar 51 psi
nt
30 bar 435 psi
0.8 mm 0.031 in
er
220 bar 3191 psi
183 bar 2654 psi
na
lu
se
on
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06–120
Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
07 - Electrical Schematics
Contents
Fo
ELECTRICAL SCHEMATICS
Chassis Electrical Schematics ....................................................................................................................... 07-1
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Cab Electrical Schematics ............................................................................................................................. 07-3

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79033095 C Rev. 07-i

Contents
NOTES
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07-ii 79033095 C Rev.

Electrical Schematics
ELECTRICAL SCHEMATICS
CHASSIS ELECTRICAL SCHEMATICS
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FIG. 1
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FIG. 1: MT 800 C Chassis Schematic

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79033095 C Rev. 07-1

NOTES
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07-2 79033095 C Rev.

CAB ELECTRICAL SCHEMATICS - SN:
EFF...CXX1001
RF-C24
CM-C23
PORCH_LAMP_B 658-RF35 BR-18 603-RF37 PK-18 1 BK-18 LH_BEACON
1 WF-C1
206-RF29 BK-18 SUBWOOFER_PREAMP 171-CM211 RD-18 1 BATTERY 206-RF8 BK-18 2 BK-18 603-RK1 PK-18
1
CM-C41 200-CM167 BK-18 2 BATTERY NEG DASH_CLUSTER 200-RK2 BK-18
CM-C33 POWER_MANAGE_SW
RF-C15 C560-WF4 OR-18 A3 L + IN AR-C2 680-CM203 YL-18 3 J1939 HI RF-C16
W-C3 116-CM297 RD-18 1 COMPRESSOR PWR C561-WF3 YL-18 A4 R + IN 681-CM202 GN-18 4 J1939 LO
ENGINE_AB_SW
RR_LH_TURN_LAMP BK-18 605-RF1 YL-18 C560-CM244 OR-18 B + RR_LH_SPEAKER 116-CM66 RD-12 116-CM296 RD-18 2 COMPRESSOR PWR SEAT GROUP - STANDARD 200-WF2 BK-18 A9 GND AR-C8 391-AR48 WH-20 1 mom 605-RF36 YL-18 A BK-18 FR_LH_TURN_LAMP
BK-18 206-RF2 BK-18 4 504-W6 YL-18 C566-CM247 PK-18 A -
CM-S17
116-CM296 RD-18 200-CM154 BK-18 3 COMPRESSOR GND 123-WF1 RD-18 A12 BAT 391-AR96 WH-20 206-RF34 BK-18 G BK-18 BEACON JUMPER
TO REAR WIPER 1 503-W5 BR-18 2
116-CM297 RD-18 200-CM301 BK-18 4 COMPRESSOR GND C566-WF5 PK-18 B3 L - IN 391-AR90 WH-20 1 mom U721-AR62 PK-20 2
RF-C14
1
MOTOR 2 200-W1 BK-16 116-CM299 RD-16 G985-CM267 PU-18 5 OPS SWITCH SEAT GROUP - DELUXE C567-WF6 PU-18 B4 R - IN 391-AR99 WH-20 393-AR16 WH-20 3 PWR MANAGE SWITCH ROADING_LIGHT_SW
6 119-W9 PK-16 J766-CM277 PU-18 6 OPS SWITCH A2 NC F764-AR98 GN-20 2 393-AR100 WH-20 4 mom
LIGHT_SW MT900 ONLY
LH_LEFT_FLOOD_LAMP 1 608-RF26 PK-18 3 503-W5 BR-18 504-W6 YL-18 200-CM154 BK-18 116-CM299 RD-16 7 HEATER PWR A10 NC 393-AR40 WH-20 3 5 mom POSITION FUNCTION TERM CONNECTED 658-RF33 BR-18 PORCH_LAMP_A
W-S3 1
2 206-RF30 BK-18 5 504-W7 YL-18 200-CM298 BK-16 200-CM298 BK-16 8 HEATER GND A523-WF7 PU-18 B5 GAIN #2 393-AR92 WH-20 4 mom 393-AR119 WH-20 6 206-RF71 BK-18
1 2
TOP BEGIN OF ROW 2&4, 7&8 OFF 1
200-W3 BK-16 206-CM205 BK-18 200-CM301 BK-18 9 NC A11 NC 5 mom U722-AR24 GY-20 7
RF-C13 W-S1 1 WF-C4 MIDDLE OFF 2&4, 5&7 2 BACKLT PWR
200-W2 BK-16 616-CM241 RD-18 G985-CM267 PU-18 10 NC EXT_GAIN_CONTROL_KNOB B1 NC 393-AR123 WH-20 6 391-AR96 WH-20 8 mom
W-C2
1 2
3 BOTTOM END OF ROW 1&2, 5&7 1
L 200-W1 BK-16 615-CM237 RD-18 J766-CM277 PU-18 11 NC B2 NC F763-AR95 WH-20 7 391-AR46 WH-20 200-HW1 BK-16
LH_CTR_FLOOD_ATCH
2 POTENTIOMETER 1 1
1 609-RF7 YL-18 GND
119-W11 PK-16 W-S2
12 NC A1 NC 391-AR99 WH-20 8 mom 220-AR115 BK-20 9
3 ROADING
2 206-RF31 BK-18 H MOTOR GN-16 4 527-W13 GN-18 119-W10 PK-16 1 2
A524-WF8 BR-18 B6 GAIN #1 391-AR37 WH-20 220-AR15 BK-20
4
1 119-W9 PK-16 A5 NC 220-AR17 BK-20 9 1333-AR53 PK-20 10
LOW BEAM
RF-C12 T° BK-16 2 200-W3 BK-16 CM-C7 A6 NC 220-AR59 BK-20 1333-AR52 PK-20 11
GY-16 6 119-W11 PK-16 CM-C55 WF-C3 SUBWOOFER_SPKR WF-C2 A7 NC 1333-AR42 PK-20 10 12 CM-C26 5
P B+ HI BEAM L
LH_RIGHT_FLOOD_ATCH 1 667-RF55 OR-16 BR-16 3 526-W12 YL-18 508-CM232 PU-18 B + FR_LH_SPEAKER A8 NC 1333-AR91 PK-20 11 1333-AR18 PK-20
- GND
2 206-RF19 BK-16 OR-16 5 509-CM233 WH-18 A 123-CM363 RD-18 1 123-WF1 RD-18 A E541-WF9 BU-18 B10 L - OUT 12 141-CM230 RD-18 1 H MOTOR GN-16 501-WJ4 GN-16
RAISE_WORK_SW
200-CM364 BK-18 2 200-WF2 BK-18 B E540-WF10 PK-18 B9 L + OUT 1333-AR25 PK-20 AR-C3 650-CM53 OR-18 2
RF-C11 SIDE_WIPER_MOTOR 504-W8 YL-18 C561-CM365 YL-18 3 C561-WF3 YL-18 C E543-WF11 WH-18 B12 R - OUT 3 T° RF-C4
L W-C1 HI BEAM PASS
BK-16 200-WJ2 BK-16
200-W4 BK-16 W-C4 C560-CM366 OR-18 4 C560-WF4 OR-18 D E542-WF12 OR-18 B11 R + OUT AR-C22 AUTOGUIDE_SW 391-AR46 WH-20 1 634-CM54 WH-18 4
mom P
GY-16 118-WJ6 RD-16
GND B+
H MOTOR GN-16 4 504-RF64 YL-18 400877X1 C566-CM367 PK-18 5 C566-WF5 PK-18 E B7 NC 391-AR103 WH-20 610-CM67 OR-18 5
6 LH TURN
BR-16 500-WJ1 BR-16 4 501-RF51 GN-18
5 2 540-CM58 WH-18
1 4 504-W7 YL-18 C567-CM368 PU-18 6 C567-WF6 PU-18 F B8 NC 393-AR123 WH-20 1 J780-AR27 BU-20 2 6
7 INPUT
OR-16 502-WJ5 RD-16 1
REAR_WIPER_MOTOR T° 2 200-RF61 BK-18 1 119-W14 PK-16
4 1
393-AR101 WH-20 393-AR119 WH-20 3 7
BK-16
3 8 RH TURN FR_WIPER_MOTOR 2 200-RF52 BK-18
GY-16 6 119-RF65 RD-14 TO REAR WIPER 2 200-W2 BK-16 526-W12 YL-18 SIDE_WIPER_RL AR-C15 THROTTLE_LEVER_POS_SNSR U749-AR35 PU-20 2 393-AR139 WH-20 4 mom RAISE-WORK SWITCH 539-CM62 BU-18 8 6 118-RF149 RD-14
P B+
BR-16 3 503-RF62 BR-18 HARNESS 6 119-W10 PK-16 400292X1 4285721M91 3 5 mom 320-CM162 OR-18 9 TO HORN SWITCH
500-WJ3 BR-16 3 500-RF75 BR-18
5 505-RF120 BU-18 3 503-W5 BR-18 527-W13 GN-18 G512-AR152 BU-18 220-AR8 BK-20 1 GROUND 391-AR37 WH-20 4 6 POSITION FUNCTION TERM CONNECTED 123-CM109 RD-18 10 WR-C1 WR-C2
OR-16 mom 5 502-RF5 RD-18
5 G511-AR151 GN-18 153-AR6 RD-20 2 +12V 391-AR124 WH-20 5 R905-AR26 PK-20 7 200-CM112 BK-18 11 CH1365298 400571X1
RF-C2 TOP WORK 2&4, 7&8
G510-AR150 WH-18 C912-AR60 GN-20 3 SIGNAL 6 391-AR103 WH-20 8 mom E539-CM163 BU-18 12 A 123-WR1 WH-18 A PWR
MIDDLE NEUTRAL 2&4, 5&7 REMOTE STEER SW
153-AR4 RD-20 7 1333-AR76 PK-20-CAVS B 200-WR2 BK-18 B
OUTSIDE_AIR_TEMP BOTTOM RAISE 1&2, 5&7
BK-18 1 C551-RF50 GN-18 SIDE WIPER ATTACHMENT AR-S5
153-AR45 RD-20 220-AR59 BK-20 8 220-AR115 BK-20 9 C 650-WR3 OR-18 C
BK-18 2 C581-RF48 PU-18 153-AR22 RD-20 1 2
153-AR6 RD-20 220-AR7 BK-20 9 1333-AR18 PK-20 D E539-WR4 BU-18 D ASWC
T°
BLOWER 3 579-BR-12 1 153-AR36 RD-18 153-AR38 RD-20 AR-C19 1333-AR25 PK-20 10 153-AR45 RD-20 1333-AR51 PK-20 10
GND 1 200-BK-12 2 MOTOR 1333-AR50 PK-20 11 220-AR49 BK-20 11
1 +B
CM-C24
POWER 2 111-YL-12 220-AR15 BK-20 153-AR38 RD-20 1 +12VDC 12 220-AR77 BK-20-CAVS 12
ARM_REST_ECU
105-CM38 RD-18 4 220-AR63 BK-20 2 GROUND 680-AR153 YL-20 1333-AR76 PK-20-CAVS 147-CM207 RD-18 A +BATT
111-CM180 RD-14 A592-CM293 BU-16 BLOWER MOTOR AR-C24 N913-AR83 YL-20 3 SHIFT LVR POS 681-AR155 GN-20 J766-CM210 PU-18 B GROUND INCHING_PEDAL_POS_SNSR
CM-S11 B CM-C27 CREEPER 9 WASH
111-CM206 RD-14 A592-CM291 BU-16 1 2
DELUXE_HVAC_PANEL CLUTCH RELAY NEG 5 E554-PK-18 168-2313 220-AR49 BK-20 4 CM-C40 F843-CM32 YL-18 C SIG
85 86 220-AR8 BK-20
111-CM213 RD-10 A592-CM191 BU-16 1478G-AR75 WH-18 1478L-AR72 WH-18 3 INT
200-CM223 BK-12 PWR 111-CM206 RD-14 1 105-CM38 RD-18 CM-C21 POWER - 1 220-AR39 BK-20 220-AR39 BK-20
AR-S3
220-AR17 BK-20 AR-C16 1478L-AR72 WH-18 1478R-AR73 WH-18 FUTURE AUDIO EXPANSION 119-CM92 RD-16 1
A 30 87
CLUTCH RL 1 2
200-CM224 BK-16 A593-CM294 OR-16 CM-S18

BACKLIGHTING 614-CM221 PU-18 2 306-CM304 GN-16 111-YL-10 POWER +12V 2 153-AR22 RD-20 220-AR114 BK-18 220-AR63 BK-20 1478R-AR73 WH-18 1478G-AR75 WH-18 2
206-CM222 BK-18 A593-CM290 OR-16 1 2
GND 206-CM222 BK-18 3 308-CM40 YL-18 A BK-18 POWERTRAIN CAN + 3 680-AR154 YL-20 220-AR21 BK-20 1 393-AR101 WH-20 1671-AR47 RD-18 3
306-CM304 GN-16 A593-CM192 OR-16 SERIAL LINK POS 818-CM219 BR-18 4 649-CM1 PK-18 B BK-18 POWERTRAIN CAN - 4 681-AR156 GN-20 220-AR77 BK-20-CAVS F783-AR2 GN-20 2 UPSHIFT COMMON 393-AR108 WH-20 4
R NC
SERIAL LINK NEG 819-CM220 GY-18 MODE DOOR GND 39 A593-OR-18 A593-OR-18 105-CM130 RD-18 C BK-18 OPEN (D/A IN) 5 391-AR84 WH-20 3 UPSHIFT NO L914-AR125 BU-20 F711-AR64 YL-18 VT 501-CM281 GN-18 5 2 +BATT
J764-CM208 BR-18 INCHING_PEDAL_SW
1 1
308-CM40 YL-18 A594-CM195 WH-16 CM-S34
NC 519-PK-16 AUX CAN + 6 K900-AR127 YL-18 391-AR48 WH-20 393-AR134 WH-20 4 UPSHIFT NC F712-AR66 GN-18 502-CM282 RD-18 6 6 HIGH
NO 1
513-CM214 OR-14 OFF 7 K990-AR128 GN-18 5 LOW
A594-CM217 WH-16 1 2
KEY_START_SW PRESS SW SIG 9 513-OR-18 513-OR-14 DOOR_SW AUX CAN - 5 391-AR124 WH-20 G510-AR150 WH-18 7
519-CM227 PK-14 ACC C 8
A594-CM226 WH-16 200-BK-12 SENSOR +3.33V 393-AR19 WH-20 F781-AR3 BR-20 6 DOWNSHIFT COMMON 391-AR102 WH-20 G511-AR151 GN-18 VIDEO-SIGNAL 8 F769-CM29 BU-18
589-CM215 GN-16 A595-CM194 GN-16 STD_HVAC_PANEL CM-C16 ON PRESS SW RTN 3 589-GN-14 589-GN-14 OPEN (SENSOR GND) 9 391-AR90 WH-20 391-AR132 WH-20 7 DOWNSHIFT NO G512-AR152 BU-18 CAR-GROUND 506-CM146 PU-18 9 E974-CM30 GN-18
ST S
614-CM221 PU-18 111-CM180 RD-14 SOLAR SNSR RTN 34 U729-YL-18 U729-YL-18 SENSOR +1.66V 10 391-AR65 WH-20 AR-S9
391-AR74 WH-20 393-AR135 WH-20 8 DOWNSHIFT NC CAMERA SUPPLY 500-CM280 BR-18 10 10 PARK
A596-CM193 YL-16 CM-S33

PWR 1 111-CM180 RD-14 111-CM206 RD-14 SOLAR SNSR 15 U730-PK-18 U730-PK-18 ISO CAN + 11 F711-AR41 YL-18 391-AR65 WH-20 1 2
391-AR84 WH-20 9 220-AR7 BK-20 CAMERA GROUND 11 WHEN SWITCH IS ADDED TO TRACTOR, SWITCH ACTUATES
A592-CM191 BU-16 A596-CM216 YL-16 BLOWER LOW 2 A592-CM291 BU-16 200-CM224 BK-16 MODE DOOR FDBK 29 A595-GN-18 A595-GN-18 115-CM72 RD-18 ISO CAN - 12 F712-AR43 GN-18 391-AR140 WH-18 391-AR132 WH-20 F907-AR23 GN-20 10 ONE TOUCH COMMON 220-AR44 BK-20 VIDEO-GROUND 12 TO NO POSITION
1 2
1 IMPL_LEVER_POS_1_SNSR
A592-CM291 BU-16 A596-CM225 YL-16 BLOWER PURGE 3 A596-CM216 YL-16 206-CM222 BK-18 SERIAL POS 17 818-BR-18 818-BR-18 PWR OUTLET OPEN (D/A IN) 13 391-AR133 WH-20 391-AR74 WH-20 11 ONE TOUCH NO 1333-AR50 PK-20 AR-C4 FRONT_WIPER_SW
A593-CM192 OR-16 A604-CM75 OR-18 BLOWER MED 4 A593-CM290 OR-16 614-CM221 PU-18 SERIAL NEG 18 819-GY-18 819-GY-18 200-CM295 BK-18 ONE TOUCH SWITCH 14 F907-AR23 GN-20 393-AR136 WH-20 12 ONE TOUCH NC 1333-AR122 PK-20 AR-C14
1
A593-CM290 OR-16 E974-CM30 GN-18 BLOWER HI 5 A594-CM217 WH-16 MODE DOOR NEG 23 A596-YL-18 A596-YL-18 UPSHIFT SWITCH 15 F783-AR2 GN-20 393-AR16 WH-20 220-AR12 BK-20 1 BK-18 GROUND A592-CM293 BU-16
A594-CM217 WH-16 F769-CM29 BU-18 GND 6 200-CM224 BK-16 A592-CM291 BU-16 MODE DOOR POS 13 A594-WH-18 A594-WH-18 DOWNSHIFT SWITCH 16 F781-AR3 BR-20 393-AR40 WH-20 AR-C13 153-AR10 RD-20 2 RD-18 +12V 153-AR45 RD-20 1 BATTERY A593-CM294 OR-16
A594-CM226 WH-16 F843-CM32 YL-18 AC SWITCH 7 521-CM218 YL-16 A593-CM290 OR-16 OUTSIDE AIR 8 C551-GN-18 C551-GN-18 PARK BRAKE SWITCH 17 F780-AR61 PK-20 AR-S10
393-AR134 WH-20 U706-AR13 BR-20 3 YL-18 SIGNAL 1671-AR47 RD-18 2 KEY SWITCH INPUT A594-CM195 WH-16
A595-CM194 GN-16 G845-CM111 PU-18 NC 8 A594-CM217 WH-16 OUTSIDE AIR RTN 38 C581-PU-18 C581-PU-18 FNR POSITION 18 N913-AR83 YL-20 393-AR19 WH-20 2
393-AR135 WH-20 F780-AR61 PK-20 A PARK BRAKE COMMON AR-C12 220-AR49 BK-20 3 BATTERY GND A595-CM194 GN-16
159-CM57 RD-18
1
A596-CM216 YL-16 H750-CM21 BR-18 A596-CM216 YL-16 THROTTLE LEVER POSITION 19 C912-AR60 GN-20 393-AR141 WH-18 393-AR136 WH-20 393-AR137 WH-20 B PARK BRAKE NO 4 CHASSIS GROUND A596-CM193 YL-16
A596-CM225 YL-16 H751-CM22 OR-18 THERMOSTAT RTN 36 566-YL-18 OPERATOR PRESENT SW - ON 20 G985-AR105 PU-18 393-AR137 WH-20 391-AR133 WH-20 C PARK BRAKE NC 391-AR20 WH-20 1 AR-C5 IMPL_LEVER_POS_2_SNSR 5 LEFT AUDIO SIGNAL A604-CM75 OR-18 200-CM98 BK-18
C551-CM64 GN-18 H752-CM25 YL-18 CM-C28 521-CM218 YL-16 ROADING LOCK SWITCH 21 E916-AR55 BR-20 391-AR85 WH-20 6 RIGHT AUDIO SIGNAL E974-CM30 GN-18 G845-CM111 PU-18
C581-CM286 PU-18 THERMOSTAT 818-CM219 BR-18 RTN AIR RTN 32 C582-PU-18 CREEPER/DIFF LOCK SWITCH 22 L914-AR125 BU-20 K911-AR31 GN-20 2 220-AR14 BK-20 1 BK-18 GROUND 7 AUDIO GROUND F769-CM29 BU-18
J766-CM277 PU-18 CM-S25
J764-CM41 BR-18 111-YL-10 1 111-CM213 RD-10 819-CM220 GY-18 AUTO GUIDE SWITCH 23 U749-AR35 PU-20 680-AR67 YL-18 680-AR153 YL-20 SHIFT_HANDLE 393-AR94 WH-20 3 153-AR11 RD-20 2 RD-18 +12V F711-AR64 YL-18 8 CAN DATA LINK 1 + F843-CM32 YL-18
1 2
J764-CM19 BR-18 T°
521-YL-16 2 521-CM218 YL-16 OUTLET AIR RTN 37 C580-YL-18 PWR MANAGEMENT SW - MAX 24 U722-AR24 GY-20 680-AR154 YL-20 220-AR15 BK-20 508325D1 393-AR88 WH-20 U707-AR97 GN-20 3 YL-18 SIGNAL F712-AR66 GN-18 9 CAN DATA LINK 1 - G845-CM111 PU-18 CM-C25
U729-CM189 YL-18 J764-CM208 BR-18 A592-BU-14 3 A592-CM191 BU-16 PWR MANAGEMENT SW - CRUISE 25 U721-AR62 PK-20 220-AR17 BK-20 4 680-AR153 YL-20 10 CAN DATA LINK 2 + H750-CM21 BR-18
U730-CM190 PK-18 J766-CM24 PU-18 A593-OR-16 4 A593-CM192 OR-16 521-CM218 YL-16 OUTLET AIR INPUT 27 C579-YL-18 OUTLET TEMP ENGINE SPEED SWITCH A 26 F763-AR95 WH-20 681-AR68 GN-18 681-AR155 GN-20 391-AR48 WH-20 393-AR108 WH-20 681-AR155 GN-20 11 CAN DATA LINK 2 - R800-CM2 OR-18 1 SNSR 1 PWR
CM-S22
501697D1 27 IMPL_LEVER_POS_3_SNSR
1 2
J766-CM210 PU-18 BLOWER 519-PK-16 5 589-CM215 GN-16 818-CM219 BR-18 T°
ENGINE SPEED SWITCH B F764-AR98 GN-20 681-AR156 GN-20 391-AR90 WH-20 K910-AR29 BU-20 5 AR-C6 12 USB - +5V SUPPLY H751-CM22 OR-18 J764-CM19 BR-18 2 SNSR 1 GND
J766-CM184 PU-18 RESISTOR PTO SWITCH - ENGAGE 28
589-GN-16 6 519-CM227 PK-14 819-CM220 GY-18 K910-AR29 BU-20 889-AR30 GY-20 393-AR16 WH-20 391-AR85 WH-20 6 13 USB - GROUND H752-CM25 YL-18 H750-CM21 BR-18 3 SNSR 1 OUT
J766-CM277 PU-18 MOTOR 200-BK-12 7 200-CM223 BK-12 PTO SWITCH - DISENGAGE 29 K911-AR31 GN-20 958-AR117 YL-18 393-AR40 WH-20 391-AR102 WH-20 7 220-AR104 BK-20 1 BK-18 GROUND 14 USB - DATA - J764-CM19 BR-18 R800-CM70 OR-18 4 SNSR 2 PWR
- + 589-GN-16 8 513-CM214 OR-14 111-CM213 RD-10 RETURN AIR INPUT 22 C554-PK-18 RTN AIR TEMP OPEN (D OUT) 30 1333-AR53 PK-20 8 153-AR86 RD-20 2 RD-18 +12V 15 USB - DATA + J764-CM208 BR-18 R799-CM20 BR-18 5 SNSR 2 GND STEERING_SNSR_BOX
9 U729-CM189 YL-18 200-CM223 BK-12 501697D1 HITCH SWITCH - RAISE 31 J780-AR27 BU-20 1333-AR42 PK-20 1333-AR42 PK-20 9 U708-AR107 BU-20 3 YL-18 SIGNAL G510-AR150 WH-18 16 RS232 RxD J766-CM24 PU-18 H751-CM22 OR-18 6 SNSR 2 OUT
BLOWER_MOTOR T°
R799-CM20 BR-18 10 U730-CM190 PK-18 513-CM214 OR-14 115-CM136 RD-18 AUX_PWR HITCH SWITCH - LOWER 32 R905-AR26 PK-20 1333-AR53 PK-20 E916-AR55 BR-20 10 G511-AR151 GN-18 17 RS232 TxD J766-CM210 PU-18 7 NC
1
CM-C18 11 A595-CM194 GN-16 519-CM227 PK-14 200-CM137 BK-18 HITCH DEPTH LEVER POSITION 33 889-AR30 GY-20 F763-AR95 WH-20 11 G512-AR152 BU-18 18 RS232 GND R799-CM20 BR-18 8 NC
1 IMPL_LEVER_POS_4_SNSR
CM-S5
R800-CM36 OR-18 12 818-CM219 BR-18 THERMOSTAT IN 26 C509-WH-18 THERMOSTAT PROBE IMPLEMENT #1 LEVER POSITION 34 U706-AR13 BR-20 1478G-AR75 WH-18 F764-AR98 GN-20 12 AR-C11 1687-AR79 WH-20-CAVS 19 DIGITAL INPUT - TECU R800-CM2 OR-18 9 NC
1 159-CM132 RD-18 1 2
R800-CM2 OR-18 13 819-CM220 GY-18 589-CM215 GN-16 T°
133-9014 IMPLEMENT #2 LEVER POSITION 35 U707-AR97 GN-20 1478L-AR72 WH-18 K910-AR29 BU-20 20 ANALOG INPUT - TECU R800-CM70 OR-18 H752-CM25 YL-18 10 SNSR 3 OUT
2 157-CM71 RD-14 R800-CM70 OR-18 A596-YL-16 14 A596-CM225 YL-16 A592-CM191 BU-16 IMPLEMENT #3 LEVER POSITION 36 U708-AR107 BU-20 1478R-AR73 WH-18 K911-AR31 GN-20 220-AR33 BK-20 1 BK-18 GROUND 1688-AR78 WH-20-CAVS 21 ANALOG INPUT - NAVIGATOR U727-CM23 WH-18 J766-CM24 PU-18 11 SNSR 3 GND
3 175-CM61 RD-14 U727-CM23 WH-18 A594-WH-16 15 A594-CM226 WH-16 A593-CM192 OR-16 A592-BU-18 IMPLEMENT #4 LEVER POSITION 37 U711-AR69 YL-20 1671-AR47 RD-18 L914-AR125 BU-20 AR-C10 153-AR89 RD-20 2 RD-18 +12V 1686-AR82 WH-20-CAVS 22 DIGITAL INPUT 1 - NAVIGATOR U729-CM189 YL-18 U727-CM23 WH-18 12 SNSR 3 PWR
4 308-CM39 YL-18 U729-CM189 YL-18 C568-WH-12 16 C551-CM64 GN-18 A594-CM226 WH-16 IMPLEMENT #5 LEVER POSITION 38 U712-AR70 PK-20 C912-AR60 GN-20 U749-AR35 PU-20 U711-AR69 YL-20 3 YL-18 SIGNAL 1685-AR81 WH-20-CAVS 23 DIGITAL INPUT 2 - NAVIGATOR U730-CM190 PK-18
5 322-CM116 GY-18 U730-CM190 PK-18 17 C581-CM286 PU-18 A595-CM194 GN-16 +5 VDC 24 A592-BU-18 (2) +5 VDC IMPLEMENT #6 LEVER POSITION 39 U719-AR71 OR-20 E916-AR55 BR-20 393-AR94 WH-20 1 1684-AR80 WH-20-CAVS 24 DIGITAL INPUT 3 - NAVIGATOR
6 108-CM37 RD-18 PURGE_RL 18 A596-CM225 YL-16 WATER VLV GND 35 A528-YL-18 (3) WATER VALVE GND ISO 11783 ECU_PWR RELAY 40 958-AR117 YL-18 F763-AR95 WH-20 220-AR15 BK-20 393-AR16 WH-20 25 DIGITAL OUTPUT 1 - TECU CM-C3
7 C974-CM161 PU-18 C551-CM64 GN-18 WATER VLV POS 31 A530-OR-18 (4) WATER VALVE POS OPEN (D/A IN) 41 391-AR48 WH-20 E916-AR55 BR-20 2 AR-C20 IMPL_LEVER_POS_5_SNSR 26 DIGITAL OUTPUT 2 - TECU 130-CM99 RD-18
8 506-CM146 PU-18 105-CM38 RD-18 C581-CM286 PU-18 WATER VLV NEG 21 A529-WH-18 (6) WATER VALVE NEG OPEN (D/A IN) 42 F764-AR98 GN-20 393-AR16 WH-20 3 147-CM207 RD-18 U729-CM189 YL-18 1 SOLAR_SENSOR
9 507-CM147 WH-18 108-CM37 RD-18 STD_(CONDITIONER_GP) U729-CM189 YL-18 WATER VLV FDBK 25 A526-PK-18 OPEN (D/A IN) 43 F780-AR61 PK-20 1333-AR53 PK-20 391-AR20 WH-20 4 220-AR113 BK-20 1 BK-18 GROUND U730-CM190 PK-18 2
10 519-CM227 PK-14 111-CM180 RD-14 U730-CM190 PK-18 (1) WATER VALVE FDBK OPEN (D/A IN) 44 F781-AR3 BR-20 J780-AR27 BU-20 391-AR48 WH-20 5 153-AR5 RD-20 2 RD-18 +12V 159-CM57 RD-18
45 NAVIGATOR CM-C5
11 513-CM214 OR-14 111-CM206 RD-14 HVAC_DELUXE WATER VALVE OPEN (D/A IN) F783-AR2 GN-20 R905-AR26 PK-20 6 U712-AR70 PK-20 3 YL-18 SIGNAL AR-C9 200-CM98 BK-18
12 589-CM215 GN-16 111-CM213 RD-10 B POST 156-5863 OPEN (D/A/F IN) 46 F907-AR23 GN-20 U721-AR62 PK-20 7
13 1465-CM373 RD-18 128-CM51 RD-14 DELUXE HVAC BOX OPEN (D/A/F IN) 47 G985-AR105 PU-18 U722-AR24 GY-20 8 1333-AR76 PK-20-CAVS 1 +12V BACKLIGHT A594-CM195 WH-16 1 MOTOR +
14 1461L-CM327 OR-18 130-CM386 RD-18 OPEN (D/A/F IN) 48 220-AR44 BK-20 9 AR-C21 IMPL_LEVER_POS_6_SNSR 220-AR77 BK-20-CAVS 2 GROUND A596-CM193 YL-16 2 MOTOR -
15 1461R-CM328 OR-18 147-CM165 RD-18 OPEN (D/A/F IN) 49 J780-AR27 BU-20 153-AR5 RD-20 220-AR15 BK-20 10 1688-AR78 WH-20-CAVS 3 U signal A592-CM293 BU-16 3 + 5V
16 1462L-CM329 OR-18 150-CM209 RD-14 ROCKER SWITCH BACKLIGHTING 50 1333-AR42 PK-20 K900-AR127 YL-18 153-AR9 RD-20 11 220-AR109 BK-20 1 BK-18 GROUND 1687-AR79 WH-20-CAVS 4 +U ref A595-CM194 GN-16 4 MODE DOOR
17 1462R-CM330 OR-18 150-CM271 RD-14 AR-S1
153-AR10 RD-20 1333-AR122 PK-20 12 153-AR93 RD-20 2 RD-18 +12V 1684-AR80 WH-20-CAVS 5 SELECT A593-CM294 OR-16 5 RTN
18 1469-CM331 GY-18 152-CM308 RD-14 105-CM130 RD-18 K910-AR29 BU-20 153-AR4 RD-20 1 2
153-AR11 RD-20 1333-AR53 PK-20 U719-AR71 OR-20 3 YL-18 SIGNAL 1685-AR81 WH-20-CAVS 6 ESC 6
19 A604-CM75 OR-18 152-CM358 RD-14 649-CM1 PK-18 CM-C19 AR-C1 K911-AR31 GN-20 153-AR86 RD-20 1686-AR82 WH-20-CAVS 7 OK
MODE_DOOR_ACTUATOR
20 998-CM55 BR-18 157-CM71 RD-14 G985-CM267 PU-18 153-AR36 RD-18 K990-AR128 GN-18 153-AR89 RD-20
21 892-CM128 BR-18 159-CM132 RD-18 153-CM49 RD-18 1 153-AR36 RD-18 220-AR114 BK-18 153-AR93 RD-20
HITCH_DEPTH_POS_SNSR
22 893-CM33 GN-18 175-CM61 RD-14 J766-CM277 PU-18 220-CM4 BK-18 2 220-AR114 BK-18 391-AR140 WH-18 L914-AR125 BU-20 AR-C18
23 179-CM63 RD-14 125-CM129 QUAD_CABLE 958-CM35 YL-18 3 958-AR117 YL-18 393-AR141 WH-18 N913-AR83 YL-20 153-AR45 RD-20
24 G845-CM111 PU-18 322-CM116 GY-18 F711-CM76 QUAD_CABLE 4 680-AR67 YL-18 R905-AR26 PK-20 220-AR49 BK-20 220-AR106 BK-20 1 GROUND BRAKE_LAMP_SW BRAKE LAMP SW
25 330-CM306 YL-18 F712-CM81 QUAD_CABLE G985-CM267 PU-18 5 G985-AR105 PU-18 681-AR68 GN-18 U706-AR13 BR-20 153-AR9 RD-20 2 +12V
26 K972-CM240 BR-16 513-CM214 OR-14 6 391-AR140 WH-18 958-AR117 YL-18 U707-AR97 GN-20 220-AR33 BK-20 889-AR30 GY-20 3 SIGNAL SWITCH TERMINALS
27 680-CM90 YL-18 N981-CM34 QUAD_CABLE 7 393-AR141 WH-18 U708-AR107 BU-20 220-AR12 BK-20 POSITION CONNECTED
NC
28 681-CM84 GN-18 519-CM227 PK-14 125-CM44 QUAD_CABLE 1671-CM106 RD-18 8 1671-AR47 RD-18 1478G-AR75 WH-18 U711-AR69 YL-20 220-AR14 BK-20 130-CM99 RD-18
AR-S2 1 1
29 F711-CM60 QUAD_CABLE 9 1478L-AR72 WH-18 U712-AR70 PK-20 220-AR21 BK-20 1 2
220-AR104 BK-20 NO BRAKE OFF C & NO
30 R799-CM20 BR-18 589-CM215 GN-16 F712-CM68 QUAD_CABLE K900-CM262 YL-18 10 K900-AR127 YL-18 1478R-AR73 WH-18 U719-AR71 OR-20 220-AR106 BK-20
31 J766-CM184 PU-18 N981-CM45 QUAD_CABLE K990-CM168 GN-18 11 K990-AR128 GN-18 1671-AR47 RD-18 U721-AR62 PK-20 220-AR109 BK-20 BRAKE ON C & NC
32 U727-CM23 WH-18 622-CM360 PU-14 12 G510-AR150 WH-18 U722-AR24 GY-20 220-AR113 BK-20 141-CM230 RD-18 A604-CM75 OR-18
33 R800-CM36 OR-18 624-CM359 YL-18 13 G511-AR151 GN-18 G510-AR150 WH-18 U749-AR35 PU-20 119-CM92 RD-16
34 998-CM55 BR-18 14 G512-AR152 BU-18 G511-AR151 GN-18 AR-S4
220-AR77 BK-20-CAVS 109-CM374 RD-14 123-CM109 RD-18
35 J764-CM41 BR-18 A334-CM396 BU-16 123-CM363 RD-18 15 G512-AR152 BU-18 CBL-AR1_125-AR129 QUAD-RD 1 2
CBL-AR2_125-AR1 QUAD-RD 680-AR153 YL-20 141-CM230 RD-18
36 147-CM165 RD-18 A572-CM59 PK-14 200-CM364 BK-18 680-CM93 YL-18 16 680-AR67 YL-18 G985-AR105 PU-18 AR-S6
681-AR155 GN-20 200-CM7 BK-10 104-CM355 RD-14 171-CM211 RD-18
37 128-CM51 RD-14 A772-CM394 GN-18 681-CM86 GN-18 17 681-AR68 GN-18 K900-AR127 YL-18 CBL-AR1_N981-AR130 QUAD-BK 1 2
CBL-AR2_N981-AR56 QUAD-BK 889-AR30 GY-20 200-CM112 BK-18
38 306-CM303 GN-18 A958-CM392 WH-18 1478L-CM352 WH-18 18 1478L-AR72 WH-18 K990-AR128 GN-18 AR-S7
1478G-AR75 WH-18 200-CM52 BK-10 106-CM356 RD-10 200-CM167 BK-18 FUSE/RELAY_BLOCK_1
39 179-CM63 RD-14 C888-CM391 YL-18 1478G-CM354 WH-18 1478R-CM353 WH-18 19 1478R-AR73 WH-18 CBL-AR1_F711-AR116 QUAD-YL 1 2
CBL-AR2_F711-AR32 QUAD-YL 1478L-AR72 WH-18
B1 D1
40 330-CM306 YL-18 C974-CM161 PU-18 1478L-CM352 WH-18 1478G-CM354 WH-18 20 1478G-AR75 WH-18 CBL-AR1_125-AR129 QUAD-RD F711-AR41 YL-18 AR-S8
1478R-AR73 WH-18 200-CM80 BK-10 117-CM108 RD-10 320-CM162 OR-18
41 K952-CM56 BR-18 K952-CM56 BR-18 21 CBL-AR1_F711-AR116 QUAD-YL CBL-AR1_F712-AR112 QUAD-GN CBL-AR2_F712-AR34 QUAD-GN 1671-AR47 RD-18 500-CM280 BR-18
30
86
1 2
42 A572-CM59 PK-14 K972-CM240 BR-16 1478R-CM353 WH-18 125-CM129 QUAD_CABLE 22 CBL-AR1_125-AR129 QUAD-RD CBL-AR1_F712-AR112 QUAD-GN F712-AR43 GN-18 F711-AR64 YL-18 200-CM98 BK-18 120-CM110 RD-14 501-CM281 GN-18
43 E974-CM30 GN-18 C560-CM366 OR-18 N981-CM34 QUAD_CABLE 23 CBL-AR1_N981-AR130 QUAD-BK CBL-AR1_N981-AR130 QUAD-BK CBL-AR3_125-AR57 QUAD-RD AR-S11
F712-AR66 GN-18 502-CM282 RD-18 SPARE RELAY
44 F769-CM29 BU-18 C561-CM365 YL-18 F711-CM76 QUAD_CABLE 24 CBL-AR1_F711-AR116 QUAD-YL CBL-AR3_125-AR57 QUAD-RD 1 2
CBL-AR2_125-AR1 QUAD-RD G510-AR150 WH-18 206-CM12 BK-18 121-CM265 RD-18 506-CM146 PU-18
45 F843-CM32 YL-18 C566-CM367 PK-18 F712-CM81 QUAD_CABLE 25 CBL-AR1_F712-AR112 QUAD-GN CBL-AR3_F711-AR111 QUAD-YL CBL-AR3_N981-AR58 QUAD-BK G511-AR151 GN-18 539-CM62 BU-18
87A
85
87
AR-S12
46 H750-CM21 BR-18 C567-CM368 PU-18 26 CBL-AR3_F712-AR110 QUAD-GN 1 2
CBL-AR2_N981-AR56 QUAD-BK G512-AR152 BU-18 206-CM158 BK-18 171-CM211 RD-18 540-CM58 WH-18 B2 C2 D2
47 H751-CM22 OR-18 200-CM223 BK-12 27 CBL-AR3_N981-AR58 QUAD-BK CBL-AR3_F711-AR111 QUAD-YL AR-S13
U706-AR13 BR-20 610-CM67 OR-18
48 H752-CM25 YL-18 200-CM224 BK-16 125-CM44 QUAD_CABLE 28 CBL-AR3_125-AR57 QUAD-RD 1 2
CBL-AR2_F711-AR32 QUAD-YL U707-AR97 GN-20 A572-CM59 PK-14 180-CM310 RD-14 634-CM54 WH-18
49 A334-CM396 BU-16 206-CM222 BK-18 N981-CM45 QUAD_CABLE 29 CBL-AR3_N981-AR58 QUAD-BK CBL-AR3_F712-AR110 QUAD-GN AR-S14
F711-AR64 YL-18 U708-AR107 BU-20 650-CM53 OR-18
50 150-CM209 RD-14 200-CM137 BK-18 F711-CM60 QUAD_CABLE 30 CBL-AR3_F711-AR111 QUAD-YL 1 2
CBL-AR2_F712-AR34 QUAD-GN U711-AR69 YL-20 C974-CM161 PU-18 181-CM311 RD-14 680-CM203 YL-18
Fo
51 150-CM271 RD-14 306-CM303 GN-18 200-CM154 BK-18 F712-CM68 QUAD_CABLE 31 CBL-AR3_F712-AR110 QUAD-GN F712-AR66 GN-18 U712-AR70 PK-20 681-CM202 GN-18
B3 D3
52 152-CM308 RD-14 306-CM304 GN-16 200-CM295 BK-18 U719-AR71 OR-20 130-CM99 RD-18 206-CM389 BK-18 182-CM312 RD-14 E539-CM163 BU-18
53 152-CM358 RD-14 ARMREST 147-CM207 RD-18
30
86
CM-S48
54 1 2
200-CM298 BK-16 C888-CM391 YL-18 183-CM313 RD-14 104-CM355 RD-14
55 125-CM44 QUAD_CABLE 306-CM361 GN-18 200-CM301 BK-18 159-CM57 RD-18 105-CM17 RD-18 SPARE RELAY
56 N981-CM45 QUAD_CABLE 220-CM4 BK-18 200-CM98 BK-18 998-CM55 BR-18 184-CM314 RD-14 106-CM356 RD-10
57 308-CM39 YL-18 TR-C2 110-CM350 RD-18
87A
85
87
58 308-CM40 YL-18 105-CM130 RD-18 CM-C10 172-CM27 RD-14 185-CM315 RD-14 121-CM265 RD-18 B4 C4 D4
59 624-CM359 YL-18 506-CM146 PU-18 105-CM130 RD-18 649-CM1 PK-18 115-CM72 RD-18 J-C1 1 TR-C1 206-CM12 BK-18 150-CM300 RD-12
400711X1
60 622-CM360 PU-14 507-CM147 WH-18 J766-CM277 PU-18 115-CM136 RD-18 2 172-TR6 RD-14 152-CM307 RD-12
61 614-CM221 PU-18 200-CM127 BK-16 125-CM129 QUAD_CABLE 116-CM66 RD-12 1 3 614-TR1 PU-18 1 614-CM65 PU-18 614-CM65 PU-18 186-CM316 RD-14 153-CM49 RD-18
62 C888-CM391 YL-18 680-CM90 YL-18 F711-CM76 QUAD_CABLE 153-CM49 RD-18 2 4 A572-TR5 PK-14 206-TR2 BK-18 2 206-CM12 BK-18 A572-CM59 PK-14 187-CM317 RD-14
63 A772-CM394 GN-18 681-CM84 GN-18 200-CM223 BK-12 F712-CM81 QUAD_CABLE 172-J1 RD-14 3 5 A572-TR5 PK-14 3 A572-CM59 PK-14 171-CM211 RD-18
A958-CM392 WH-18 B5 D5
64 892-CM128 BR-18 200-CM224 BK-16 N981-CM34 QUAD_CABLE 680-CM93 YL-18 172-J1 RD-14 4 6 172-TR6 RD-14 4 172-CM27 RD-14 320-CM162 OR-18 180-CM310 RD-14
65 893-CM33 GN-18 206-CM148 BK-18 681-CM86 GN-18 7 184-CM314 RD-14
30
86
66 130-CM386 RD-18 1461L-CM327 OR-18 125-CM44 QUAD_CABLE 958-CM35 YL-18 8 539-CM62 BU-18 185-CM315 RD-14 FUSE_BLOCK_1
67 1461R-CM328 OR-18 206-CM222 BK-18 F711-CM60 QUAD_CABLE 1671-CM106 RD-18 9 206-TR2 BK-18 206-CM103 BK-18 SPARE RELAY A1
68 1462L-CM329 OR-18 F712-CM68 QUAD_CABLE K900-CM262 YL-18 10 614-TR1 PU-18 540-CM58 WH-18 515-CM26 OR-18 C01 A01 15A
69 F711-CM60 QUAD_CABLE 1462R-CM330 OR-18 306-CM361 GN-18 N981-CM45 QUAD_CABLE K990-CM168 GN-18 11 131-CM8 RD-18 FUSE
87A
10A 15A
85
87
70 F712-CM68 QUAD_CABLE 1465-CM373 RD-18 TRAILER SW JUMPER 12 610-CM67 OR-18 FUSE FUSE B6 C6 D6 A2
1469-CM331 GY-18 308-CM39 YL-18 130-CM387 RD-18 104-CM355 RD-14 C02 A02 15A
C551-CM64 GN-18 308-CM40 YL-18 200-CM124 BK-14 TRAILER SWITCHES 634-CM54 WH-18 106-CM356 RD-10 10A 15A FUSE
C581-CM286 PU-18 506-CM146 PU-18 200-CM127 BK-16 C421-CM388 PU-18 109-CM374 RD-14 FUSE FUSE A3
507-CM147 WH-18 200-CM223 BK-12 650-CM53 OR-18 117-CM108 RD-10 C03 A03 K952-CM393 BR-18 10A
614-CM221 PU-18 200-CM224 BK-16 CM-S51

120-CM110 RD-14 130-CM384 RD-16 15A 15A A772-CM394 GN-18 FUSE
680-CM90 YL-18 B7 D7
J766-CM277 PU-18 206-CM125 BK-14 105-CM38 RD-18 1 2
105-CM17 RD-18 126-CM47 RD-14 FUSE FUSE A4
125-CM44 QUAD_CABLE 105-CM130 RD-18 105-CM197 RD-18 126-CM48 RD-14 10A
30
86
C04 A04
F711-CM60 QUAD_CABLE 681-CM84 GN-18 206-CM126 BK-14 206-CM389 BK-18 108-CM37 RD-18 CM-S36
130-CM385 RD-18 181-CM311 RD-14 30A 20A 157-CM71 RD-14 FUSE
F712-CM68 QUAD_CABLE 892-CM128 BR-18 206-CM148 BK-18 614-CM390 PU-18 108-CM174 RD-18 108-CM239 RD-18 200-CM6 BK-18 FUSE FUSE ITALIAN TRAILER A5
N981-CM45 QUAD_CABLE 893-CM33 GN-18 206-CM222 BK-18 TERM_STRIP_CP 200-CP24 BK-10 TERM_STRIP 108-CM337 RD-18
1 2
200-CM14 BK-18 BRAKES RELAY

C05 A05 20A
150-CM300 RD-12
1461L-CM327 OR-18 206-CM362 BK-14 200-CM7 BK-10 CIGAR_LIGHTER C888-CM391 YL-18 110-CM350 RD-18 200-CM375 BK-18 183-CM313 RD-14 135-CM143 RD-18
87A
30A 10A
85
87
112-RF121 RD-18 1461R-CM328 OR-18 220-CM175 BK-18 200-CM80 BK-10 200-CM6 BK-18 199-CP2 RD-14 614-CP15 PU-18 MATING CONNECTOR 199-UP2 RD-14 HOUSING 131-CM8 RD-18 111-CM180 RD-14 206-CM102 BK-18 FUSE FUSE B8 C8 D8 A6
RF-S17 1 1 1 1 CM-S32
112-RF122 RD-18 112-RF102 RD-18 1462L-CM329 OR-18 200-CM7 BK-10 198-CP6 RD-14 206-CP20 BK-18 CM-C15 198-UP6 RD-14 111-CM206 RD-14 111-CM113 RD-10 306-CM361 GN-18 C06 A06 A958-CM392 WH-18 152-CM307 RD-12
1 2
1 1 1 1 2
20A
r
112-RF123 RD-18 1462R-CM330 OR-18 200-CM52 BK-10 200-CM14 BK-18 169-CP11 RD-14 169-CP7 RD-14 169-UP11 RD-14 200-CM50 BK-18 115-CM72 RD-18 111-CM213 RD-10 320-CM162 OR-18 186-CM316 RD-14 30A 30A 190-CM9 RD-14 C421-CM388 PU-18
1 1 CM-S71
118-RF149 RD-14 118-RF53 RD-14 1465-CM373 RD-18 200-CM223 BK-12 200-CM52 BK-10 169-CP9 RD-14 169-UP9 RD-14 115-CM136 RD-18 115-CM72 RD-18 115-CM256 RD-18 322-CM116 GY-18 FUSE FUSE 130-CM385 RD-18 A7
1 1 1 CM-C14
1 2
118-RF137 RD-18 1469-CM331 GY-18 200-CM80 BK-10 116-CM66 RD-12 115-CM136 RD-18 330-CM306 YL-18 C07 A07 200-CM375 BK-18 10A 121-CM265 RD-18
C551-CM64 GN-18 CM-S27
200-CM124 BK-14 200-CM98 BK-18 169-CP9 RD-14 CP-S1
153-CM49 RD-18 516-CM31 OR-18 187-CM317 RD-14 30A 30A 191-CM11 RD-14 109-CM374 RD-14 FUSE
B9 D9
119-RF65 RD-14 C581-CM286 PU-18 105-CM130 RD-18 200-CM171 BK-12 1 2
200-CM127 BK-16 200-CM159 BK-16 169-CP11 RD-14 1 2 RADAR 1 998-CM55 BR-18 680-CM93 YL-18 116-CM66 RD-12 FUSE FUSE A8
200-RF111 BK-18 118-CM145 RD-14 200-CM137 BK-18 200-CP13 BK-10 169-CP8 RD-14 200-UP12 BK-10 CONVENIENCE 2 C974-CM161 PU-18 681-CM86 GN-18 118-CM145 RD-14 622-CM360 PU-14 10A 105-CM17 RD-18
30
86
1 1 C08 A08
RF-S1
200-RF112 BK-18 190-CM9 RD-14 200-CM167 BK-18 169-CP12 RD-14 CONNECTOR 3 143-CM10 RD-18 119-CM118 RD-14 624-CM359 YL-18 182-CM312 RD-14 30A 30A 192-CM15 RD-14 FUSE
200-RF52 BK-18 1 2
200-RF12 BK-14 J766-CM277 PU-18 191-CM11 RD-14 CM-S28
200-CM295 BK-18 200-CM196 BK-18 4 958-CM35 YL-18 119-CM92 RD-16 958-CM309 YL-18 FUSE FUSE TRAILER WORK A9
200-RF61 BK-18 125-CM44 QUAD_CABLE 192-CM15 RD-14 200-CM173 BK-12 200-CM154 BK-18 200-CM375 BK-18 198-CP6 RD-14 198-UP6 RD-14 1671-CM106 RD-18 123-CM109 RD-18 958-CM383 YL-18 C09 A09 LIGHTS RELAY 15A 104-CM355 RD-14
1 1 2
220-RF99 BK-18 220-RF138 BK-18 F711-CM60 QUAD_CABLE 193-CM16 RD-14 200-CM298 BK-16 206-CM12 BK-18 K900-CM262 YL-18 123-CM140 RD-16 109-CM374 RD-14 193-CM16 RD-14 FUSE
87A
15A 30A
85
87
RF-S18
220-RF100 BK-18 1 2
220-RF97 BK-18 F712-CM68 QUAD_CABLE 306-CM361 GN-18 200-CM301 BK-18 206-CM102 BK-18 169-CP8 RD-14 199-CP2 RD-14 169-UP8 RD-14 199-UP2 RD-14 K990-CM168 GN-18 A334-CM396 BU-16 FUSE FUSE B10 C10 D10 A10
N981-CM45 QUAD_CABLE 206-CM103 BK-18 126-CM47 RD-14 A772-CM394 GN-18 C10 A10 30A 106-CM356 RD-10
1 CM-S4
206-RF2 BK-18 308-CM3 YL-18 CM-S14 CM-S26
206-CM158 BK-18 199-CP2 RD-14 199-UP2 RD-14 157-CM71 RD-14 1 2
126-CM46 RD-14 A958-CM392 WH-18 10A 30A 160-CM302 RD-10 624-CM359 YL-18 FUSE
206-RF29 BK-18 RF-S4
308-CM39 YL-18 1 2
200-CM172 BK-12 1 2
200-CM159 BK-16 206-CM389 BK-18 105-CM38 RD-18 126-CM48 RD-14 C421-CM388 PU-18 FUSE FUSE 622-CM360 PU-14
206-RF30 BK-18 1 2
206-RF32 BK-14 RF-C3 CM-C30 308-CM40 YL-18 200-CM224 BK-16 108-CM37 RD-18 128-CM51 RD-14 K952-CM393 BR-18
206-RF31 BK-18 CAB STUD 200-CM124 BK-14 614-UP15 PU-18 614-CM157 PU-18 111-CM180 RD-14 K952-CM395 BR-18 KEY SWITCHED BATTERY POS BATTERY POS
POWER PORT 1
206-RF19 BK-16 112-RF102 RD-18 1 112-CM347 RD-18 500-CM280 BR-18 200-CM196 BK-18 200-CM127 BK-16 206-CP20 BK-18 1 160-CP21 RD-16 206-UP20 BK-18 206-UP20 BK-18 206-CM158 BK-18 111-CM206 RD-14 130-CM386 RD-18 K972-CM240 BR-16 CBL-LL1 RD-4 CBL-LL1 RD-4
1 1 1 1
206-RF27 BK-18 220-RF97 BK-18 2 220-CM175 BK-18 501-CM281 GN-18 200-CM6 BK-18 200-CM223 BK-12 206-CP19 BK-18 2 200-CP22 BK-16 206-UP19 BK-18 169-UP7 RD-14 169-CM13 RD-14 111-CM213 RD-10 130-CM99 RD-18 130-CM384 RD-16 107-CM105 RD-10
in
CM-S16
206-RF8 BK-18 352-RF63 BU-18 3 352-CM186 BU-18 502-CM282 RD-18 200-CM42 BK-16 200-CM14 BK-18 200-CM224 BK-16 614-CP15 PU-18 614-UP15 PU-18 128-CM51 RD-14 130-CM387 RD-18 130-CM385 RD-18
1 1 2
206-RF34 BK-18 RF-S7

353-RF72 GN-18 4 353-CM187 GN-18 506-CM146 PU-18 200-CM98 BK-18 206-CM125 BK-14 614-CP18 PU-18 614-UP18 PU-18 130-CM386 RD-18 115-CM256 RD-18 FUSE/RELAY_BLOCK_2
206-RF46 BK-18 1 2
206-RF43 BK-14 308-RF59 YL-18 5 308-CM3 YL-18 515-CM26 OR-18 200-CM167 BK-18 169-UP8 RD-14 UP-S1
147-CM165 RD-18 131-CM8 RD-18 116-CM66 RD-12 330-CM306 YL-18
206-RF71 BK-18 500-RF75 BR-18 6 500-CM280 BR-18 516-CM31 OR-18 200-CM375 BK-18 206-CM126 BK-14 169-UP9 RD-14 1 2
150-CM209 RD-14 135-CM143 RD-18 123-CM140 RD-16 306-CM361 GN-18
501-RF51 GN-18 501-CM281 GN-18 126-CM46 B1 D1
206-RF45 BK-18 7 614-CM107 PU-18 206-CM148 BK-18 200-CP10 BK-10 CP-S5
169-UP11 RD-14 150-CM271 RD-14 157-CM71 RD-14 RD-14
206-RF56 BK-18 502-RF5 RD-18 8 502-CM282 RD-18 614-CM221 PU-18 220-CM4 BK-18 206-CM222 BK-18 200-CP24 BK-10 169-UP22 RD-14 CM-C13 152-CM308 RD-14 157-CM71 RD-14
30
86
1 2 CM-S70
503-RF62 BR-18 9 503-CM284 BR-18 680-CM90 YL-18 220-CM175 BK-18 206-CM362 BK-14 147-CM165 RD-18 147-CM250 RD-16 135-CM143 RD-18
1 1 2
206-RF15 BK-18 504-RF64 YL-18 10 504-CM199 YL-18 680-CM91 YL-18 206-CM102 BK-18 220-CM175 BK-18 POWER PORT 1 158-CM142 RD-10 152-CM358 RD-14 147-CM207 RD-18 CM-S72
141-CM230 RD-18 NEUTRAL RELAY
206-RF40 BK-18 RF-S6
206-RF24 BK-14 505-RF120 BU-18 11 505-CM231 BU-18 680-CM94 YL-18 206-CM389 BK-18 169-CP12 RD-14 169-UP22 RD-14 2 160-CM28 RD-10 159-CM132 RD-18 150-CM271 RD-14 1 2
150-CM300 RD-12 158-CM179 RD-10
206-RF41 BK-18 206-RF69 BK-14 515-RF70 OR-18 12 515-CM26 OR-18 681-CM83 GN-18 206-CM12 BK-18 158-CP3 RD-10 3 200-CM52 BK-10 175-CM61 RD-14 150-CM209 RD-14 160-CM302 RD-10
87A
85
87
1 2 CM-S24 CP-S3 CM-S73
206-RF42 BK-18 516-RF16 OR-18 13 516-CM31 OR-18 681-CM84 GN-18 206-CM252 BK-16 206-CM103 BK-18 198-CP6 RD-14 158-CP1 RD-10 198-UP6 RD-14 179-CM63 RD-14 152-CM358 RD-14 152-CM307 RD-12 B2 C2 D2
1 2 1 2 1 2
CM-C11
206-RF60 BK-18 614-RF44 PU-18 14 614-CM107 PU-18 681-CM87 GN-18 206-CM158 BK-18 200-CM137 BK-18 158-CP4 RD-10 158-UP3 RD-10 UP-S3
322-CM116 GY-18 152-CM308 RD-14 169-CM13 RD-14 K952-CM395 BR-18
632-RF49 RD-18 15 632-CM287 RD-18 892-CM128 BR-18 206-CM148 BK-18 200-CM154 BK-18 158-UP4 RD-10 1 2
330-CM306 YL-18 175-CM61 RD-14 A334-CM396 BU-16
308-RF59 YL-18 638-RF57 PK-18 16 638-CM285 PK-18 893-CM33 GN-18 206-CM222 BK-18 200-CM295 BK-18 158-UP1 RD-10 622-CM360 PU-14 153-CM49 RD-18 179-CM63 RD-14 117-CM108 RD-10 1 K972-CM240 BR-16
647-RF28 OR-18 17 647-CM288 OR-18 G500-CM339 WH-18 160-CP16 RD-10 CP-S2
160-UP17 RD-10 UP-S2
624-CM359 YL-18 CM-S38
190-CM9 RD-14 183-CM313 RD-14 2 FUSE_BLOCK_2 126-CM48 RD-14
500-RF75 BR-18 648-RF21 PK-18 18 648-CM289 PK-18 G501-CM340 GN-18 CM-S31
206-CM125 BK-14 200-CM298 BK-16 206-CP19 BK-18 160-CP17 RD-10 1 2
206-UP19 BK-18 160-UP21 RD-10 1 2
998-CM55 BR-18 158-CM142 RD-10 1 2
158-CM179 RD-10 191-CM11 RD-14 120-CM114 RD-14 3 126-CM47 RD-14
501-RF51 GN-18 649-RF54 PK-18 649-CM1 PK-18 205-CM117 BK-14 B3 D3
19 G502-CM341 BK-18 206-CM229 BK-10 206-CM126 BK-14 200-CM301 BK-18 614-CP18 PU-18 614-UP18 PU-18 A334-CM396 BU-16 158-CM155 RD-10 192-CM15 RD-14 4 C01 A01
1 1 2
TO CONN M-C1
X1
502-RF5 RD-18 658-RF76 BR-18 20 658-CM242 BR-18 206-CM362 BK-14 220-CM4 BK-18 A572-CM59 PK-14 193-CM16 RD-14 184-CM314 RD-14 5 128-CM51 RD-14 20A 15A 123-CM140 RD-16
30
86
400 T2
807
503-RF62 BR-18 680-RF81 YL-18 21 680-CM94 YL-18 CP-C1 UP-C1 CM-C58 A772-CM394 GN-18 159-CM57 RD-18
CM-S7
159-CM5 RD-18 1671-CM106 RD-18 180-CM310 RD-14 6 LOC A-5(SH1) FUSE FUSE
NN-
RD-4
1 2
504-RF64 YL-18 681-RF82 GN-18 22 681-CM87 GN-18 K900-CM376 YL-18 CBL-NN1 BK-0 A958-CM392 WH-18 159-CM132 RD-18 181-CM311 RD-14 7 (CHASSIS) C02 A02 HORN RELAY
CM-S41 CM-S57
505-RF120 BU-18 680-RF83 YL-18 23 680-CM91 YL-18 K900-CM246 YL-18 160-CP5 RD-10 1 MATING 160-UP5 RD-10 1 1 160-CM100 RD-10 C888-CM391 YL-18 160-CM28 RD-10 160-CM302 RD-10 182-CM312 RD-14 8 147-CM250 RD-16 10A 20A 116-CM66 RD-12
1 2
1 1 2
681-RF84 GN-18 24 681-CM83 GN-18 K900-CM255 YL-18 CAB/CHASSIS 158-CP1 RD-10 2 CONNECTOR 158-UP1 RD-10 2 2 158-CM155 RD-10 C974-CM161 PU-18 160-CM100 RD-10 185-CM315 RD-14 9 FUSE FUSE
87A
te
85
87
RF-S10
UP-C6
CBL-HH1
603-RF37 PK-18 1 2
603-RF39 PK-18 118-RF53 RD-14 25 118-CM145 RD-14 PASSTHROUGH 200-CP24 BK-10 3 200-UP23 BK-10 3 3 200-CM7 BK-10 K952-CM56 BR-18 186-CM316 RD-14 10 C03 A03 B4 C4 D4
119-RF65 RD-14 603-RF38 PK-18 119-RF65 RD-14 26 119-CM104 RD-14 524652D1 POWER PORT 82 158-CP3 RD-10 4 200-UP10 BK-10 4 4 200-CM80 BK-10 K972-CM240 BR-16 169-CM13 RD-14 108-CM239 RD-18 187-CM317 RD-14 11 172-CM27 RD-14 15A 15A 169-CM13 RD-14 320-CM162 OR-18
RF-S3 1
200-RF61 BK-18 605-RF1 YL-18 605-RF9 YL-18 190-RF17 RD-14 27 190-CM9 RD-14 K990-CM377 GN-18 15 160-CP17 RD-10 POWER PORT 1 158-UP3 RD-10 172-CM27 RD-14 109-CM374 RD-14 539-CM62 BU-18 12 FUSE FUSE 322-CM116 GY-18
1 2 CM-S42 1
206-RF2 BK-18 191-RF18 RD-14 28 191-CM11 RD-14 K990-CM156 GN-18 31 200-CP14 BK-10 200-CP23 BK-10 2 160-UP17 RD-10 131-CM8 RD-18 175-CM61 RD-14 111-CM113 RD-10 540-CM58 WH-18 13 C04 A04
1 2
1 CP-S4
206-RF19 BK-16 605-RF36 YL-18 RF-S9
192-RF68 RD-14 29 192-CM15 RD-14 K990-CM166 GN-18 GROUND STUDS 200-CP13 BK-10 1 2
3 200-UP14 BK-10 UP-S4
158-CM142 RD-10 179-CM63 RD-14 118-CM145 RD-14 610-CM67 OR-18 14 30A 30A 158-CM179 RD-10 200-CM14 BK-18
206-RF29 BK-18 606-RF47 GY-18 2
606-RF10 GY-18 193-RF67 RD-14 30 193-CM16 RD-14 200-CP14 BK-10 200-UP14 BK-10 1 2
158-CM155 RD-10 190-CM9 RD-14 119-CM118 RD-14 634-CM54 WH-18 15 FUSE FUSE 106-CM356 RD-10
UP-C5
1
206-RF30 BK-18 606-RF13 GY-18 200-RF12 BK-14 B5 D5

31 200-CM124 BK-14 125-CM18 QUAD_CABLE 200-UP12 BK-10 160-CM28 RD-10 191-CM11 RD-14 128-CM51 RD-14 650-CM53 OR-18 16 C05 A05
206-RF31 BK-18 607-RF14 PK-18 206-RF24 BK-14 32 206-CM362 BK-14 F711-CM73 QUAD_CABLE 160-CM100 RD-10 192-CM15 RD-14 130-CM384 RD-16 K900-CM152 YL-18 17 159-CM5 RD-18 10A 10A 1671-CM106 RD-18
30
86
503-RF62 BR-18 608-RF26 PK-18 206-RF32 BK-14 33 206-CM125 BK-14 F712-CM77 QUAD_CABLE POWER PORT 82 158-CP4 RD-10 POWER PORT 1 158-UP4 RD-10 169-CM13 RD-14 193-CM16 RD-14 131-CM8 RD-18 K990-CM169 GN-18 18 FUSE FUSE
1
504-RF64 YL-18 609-RF7 YL-18 206-RF43 BK-14 34 206-CM126 BK-14 N981-CM69 QUAD_CABLE 15 160-CP16 RD-10 2 160-UP21 RD-10 200-CM6 BK-18 C06 A06 ISO PWR RELAY A1
1
505-RF120 BU-18 612-RF11 WH-18 615-RF74 RD-16 35 615-CM251 RD-16 31 200-CP10 BK-10 3 200-UP23 BK-10 200-CM7 BK-10 200-CM14 BK-18 147-CM250 RD-16 108-CM239 RD-18 10A 15A 179-CM63 RD-14 15A
1
605-RF1 YL-18 613-RF20 RD-18 616-RF73 RD-16 36 616-CM283 RD-16 EAME USER PWR HARNESS REAR CONSOLE 200-CM50 BK-18 159-CM5 RD-18 CM-C53 FUSE FUSE FUSE
87A
85
87
RF-S5 CM-S23
608-RF26 PK-18 630-RF3 PU-18 1 2
630-RF6 PU-18 1461L-RF115 OR-18 37 1461L-CM322 OR-18 200-CM52 BK-10 200-CM50 BK-18 1 2
200-CM112 BK-18 172-CM27 RD-14 C07 A07 B6 C6 D6 A2
609-RF7 YL-18 630-RF66 PU-18 1461R-RF116 OR-18 38 1461R-CM323 OR-18 200-CM80 BK-10 200-CM159 BK-16 181-CM311 RD-14 121-CM265 RD-18 A 119-CM118 RD-14 10A 15A 175-CM61 RD-14 958-CM309 YL-18 15A
658-RF35 BR-18 658-RF33 BR-18 RF-S2

1462L-RF113 OR-18 39 1462L-CM324 OR-18 206-CM158 BK-18 200-CM167 BK-18 182-CM312 RD-14 120-CM269 RD-18 B FUSE FUSE 117-CM108 RD-10 FUSE
667-RF55 OR-16 658-RF35 BR-18 1 2
658-RF76 BR-18 1462R-RF114 OR-18 40 1462R-CM325 OR-18 C551-CM64 GN-18 614-CM157 PU-18 200-CM196 BK-18 183-CM313 RD-14 205-CM345 BK-18 C C08 A08 A3
C551-RF50 GN-18 658-RF58 BR-18 1465-RF118 RD-18 41 1465-CM338 RD-18 108-CM174 RD-18 998-CM55 BR-18 200-CM375 BK-18 186-CM316 RD-14 118-CM145 RD-14 15A 15A 126-CM46 RD-14 200-CM6 BK-18 10A
CM-C49 AUX RADIO
C581-RF48 PU-18 667-RF55 OR-16 1469-RF110 GY-18 42 1469-CM326 GY-18 C581-CM286 PU-18 108-CM337 RD-18 CM-C51 C974-CM161 PU-18 206-CM102 BK-18 187-CM317 RD-14 FUSE FUSE 104-CM355 RD-14 FUSE
RF-S12 COMMUNICATION B7 D7
680-RF91 YL-18 1 2
680-RF83 YL-18 C551-RF50 GN-18 43 C551-CM64 GN-18 110-CM350 RD-18 206-CM103 BK-18 C09 A09 A4
C581-RF48 PU-18 44 C581-CM286 PU-18 108-CM174 RD-18 112-CM347 RD-18 123-CM181 RD-18 135-CM183 RD-18 A BATTERY 1 200-CM6 BK-18 306-CM361 GN-18 20A 10A 115-CM256 RD-18 10A
30
86
206-RF8 BK-18 680-RF133 YL-18 680-RF81 YL-18 G500-RF103 WH-18 45 G500-CM339 WH-18 108-CM337 RD-18 135-CM183 RD-18 123-CM181 RD-18 B SW POWER 200-CM7 BK-10 322-CM116 GY-18 F712-CM77 QUAD_CABLE FUSE FUSE FUSE
206-RF34 BK-18 RF-S13
680-RF131 YL-18 G501-RF104 GN-18 46 G501-CM340 GN-18 C551-CM64 GN-18 110-CM350 RD-18 119-CM92 RD-16 CM-S21
200-CM200 BK-18 200-CM200 BK-18 C GROUND 2 108-CM174 RD-18 200-CM14 BK-18 330-CM306 YL-18 N981-CM69 QUAD_CABLE C10 A10 ISO ECU RELAY A5
206-RF71 BK-18 681-RF92 GN-18 1 2
681-RF84 GN-18 G502-RF105 BK-18 47 G502-CM341 BK-18 119-CM92 RD-16 119-CM104 RD-14 1 2
119-CM170 RD-16 206-CM212 BK-18 3 200-CM52 BK-10 500-CM280 BR-18 105-CM197 RD-18 F711-CM73 QUAD_CABLE 10A 10A 141-CM230 RD-18 10A 110-CM350 RD-18
rn
135-RF134 RD-18 48 135-CM61 RD-18 C581-CM286 PU-18 119-CM118 RD-14 119-CM118 RD-14 119-CM176 RD-16 206-CM235 BK-18 4 1465-CM338 RD-18 200-CM80 BK-10 501-CM281 GN-18 117-CM108 RD-10 125-CM18 QUAD_CABLE FUSE FUSE FUSE
87A
85
87
603-RF37 PK-18 681-RF134 GN-18 681-RF82 GN-18 49 123-CM109 RD-18 352-CM186 BU-18 CM-C43 5 1465-CM373 RD-18 200-CM98 BK-18 502-CM282 RD-18 B8 C8 D8 A6
605-RF36 YL-18 681-RF132 GN-18 50 123-CM140 RD-16 123-CM109 RD-18 123-CM177 RD-18 353-CM187 GN-18 6 506-CM146 PU-18 120-CM110 RD-14 KEY SWITCHED KEY SWITCHED 958-CM383 YL-18 10A 153-CM49 RD-18
CM-S29 CM-S1 1
658-RF33 BR-18 C551-RF50 GN-18 K900-RF4 YL-18 51 K900-CM376 YL-18 135-CM143 RD-18 123-CM140 RD-16 123-CM178 RD-18 614-CM234 PU-18 353-CM382 GN-18 1 7 200-CM159 BK-16 515-CM26 OR-18 120-CM79 RD-18 CM-C29 CM-C31 120-CM110 RD-14 FUSE
1 2 1 2
1
C581-RF48 PU-18 K990-RF22 GN-18 52 K990-CM377 GN-18 135-CM61 RD-18 123-CM363 RD-18 123-CM181 RD-18 647-CM288 OR-18 2 8 200-CM167 BK-18 516-CM31 OR-18 120-CM114 RD-14 CBL-PP1 RD-2 A7
125-RF79 QUAD_CABLE 53 125-CM18 QUAD_CABLE 112-CM347 RD-18 614-CM234 PU-18 614-CM270 PU-18 3 9 206-CM343 BK-18 200-CM196 BK-18 614-CM65 PU-18 120-CM269 RD-18 125-CM319 QUAD_CABLE 1 206-CM102 BK-18 10A 171-CM211 RD-18
LICENSE_PLATE_LAMP_A RF-C19 CM-S30
125-RF142 QUAD_CABLE N981-RF80 QUAD_CABLE 54 N981-CM69 QUAD_CABLE 119-CM104 RD-14 614-CM351 PU-18 135-CM143 RD-18 1 2
135-CM183 RD-18 615-CM236 RD-16 352-CM379 BU-18 4 10 614-CM344 PU-18 200-CM375 BK-18 614-CM107 PU-18 CM-S45
120-CM115 RD-18 F711-CM134 QUAD_CABLE 2 CBL-HH1 RD-4 107-CM105 RD-10 FUSE
125-RF85 QUAD_CABLE 125-RF142 QUAD_CABLE 125-CM129 QUAD_CABLE 200-CM127 BK-16 206-CM12 BK-18 B9 D9
55 135-CM61 RD-18 135-CM185 RD-18 616-CM238 RD-16 353-CM382 GN-18 5 11 614-CM221 PU-18 1 2
N981-CM318 QUAD_CABLE 3 A8
1 630-RF3 PU-18 N981-RF143 QUAD_CABLE 56 N981-CM34 QUAD_CABLE 206-CM148 BK-18 E539-CM163 BU-18 632-CM287 RD-18 353-CM381 GN-18 6 12 206-CM102 BK-18 614-CM234 PU-18 121-CM265 RD-18 F712-CM135 QUAD_CABLE 4 20A 185-CM315 RD-14
30
86
2 206-RF27 BK-18 N981-RF143 QUAD_CABLE F711-RF87 QUAD_CABLE 57 F711-CM73 QUAD_CABLE 352-CM186 BU-18 200-CM198 BK-18 638-CM285 PK-18 648-CM289 PK-18 7 206-CM103 BK-18 614-CM351 PU-18 180-CM310 RD-14 FUSE
N981-RF86 QUAD_CABLE F712-RF88 QUAD_CABLE 58 F712-CM77 QUAD_CABLE 353-CM187 GN-18 200-CM127 BK-16 CM-S37
200-CM200 BK-18 647-CM288 OR-18 352-CM379 BU-18 206-CM158 BK-18 614-CM157 PU-18 181-CM311 RD-14 111-CM113 RD-10 ECU RELAY A9
F711-RF144 QUAD_CABLE 59 F711-CM76 QUAD_CABLE 503-CM284 BR-18 123-CM363 RD-18 200-CM364 BK-18 200-CM201 BK-18 648-CM289 PK-18 352-CM378 BU-18 8 206-CM389 BK-18 614-CM390 PU-18 182-CM312 RD-14 165-CM397 RD-10 20A 184-CM314 RD-14
LICENSE_PLATE_LAMP_B RF-C18
1 2
F711-RF144 QUAD_CABLE F712-RF148 QUAD_CABLE 60 F712-CM81 QUAD_CABLE 504-CM199 YL-18 200-CM364 BK-18 200-CM346 BK-18 658-CM242 BR-18 206-CM235 BK-18 622-CM360 PU-14 183-CM313 RD-14 FUSE
87A
CM-C9 ISO_CAN_TBC
85
87
F711-RF146 YL-18 505-CM231 BU-18 1478G-CM354 WH-18 206-CM259 BK-18 9 105-CM130 RD-18 624-CM359 YL-18 184-CM314 RD-14 B10 C10 D10 A10
1 630-RF66 PU-18 F711-RF89 QUAD_CABLE 507-CM147 WH-18 1478L-CM352 WH-18 206-CM148 BK-18 CM-S39
614-CM270 PU-18 10 118-CM145 RD-14 185-CM315 RD-14 516-CM31 OR-18 20A 180-CM310 RD-14
2 206-RF56 BK-18 200-RF111 BK-18 615-CM251 RD-16 206-CM204 BK-18 1 2
206-CM212 BK-18 RADIO_ANTENNA 614-CM258 PU-18 11 190-CM9 RD-14 CM-S6
680-CM95 YL-18 186-CM316 RD-14 A FUSE
F712-RF148 QUAD_CABLE 200-RF112 BK-18 616-CM283 RD-16 1478R-CM353 WH-18 206-CM205 BK-18 12 191-CM11 RD-14 680-CM96 YL-18 187-CM317 RD-14 125-CM131 QUAD_CABLE B 113-CM357 RD-10
RH_LEFT_FLOOD_ATCH 1 2
F712-RF147 GN-18 1461L-RF115 OR-18 C560-CM366 OR-18 206-CM235 BK-18 110-CM350 RD-18 192-CM15 RD-14 680-CM138 YL-18 200-CM196 BK-18 C
RF-C9 F712-RF90 QUAD_CABLE 1461R-RF116 OR-18 632-CM287 RD-18 C561-CM365 YL-18 CM-C1 ANTENNA 193-CM16 RD-14 680-CM275 YL-18
CM-S40
N981-CM133 QUAD_CABLE D
1 2
1
RF-S14
1462L-RF113 OR-18 638-CM285 PK-18 C566-CM367 PK-18 352-CM186 BU-18 112-CM347 RD-18 306-CM361 GN-18 680-CM119 YL-18 205-CM117 BK-14 F711-CM139 QUAD_CABLE E 113-CM357 RD-10
1 613-RF20 RD-18 1 2
125-RF85 QUAD_CABLE 1462R-RF114 OR-18 658-CM242 BR-18 C567-CM368 PU-18 353-CM187 GN-18 1 1 - CAN - HIGH 500-CM280 BR-18 CM-S59 CM-S3
205-CM82 BK-18 F712-CM153 QUAD_CABLE F
2 206-RF42 BK-18 RF-S15
125-RF79 QUAD_CABLE 647-CM288 OR-18 503-CM284 BR-18 2 2 - CAN - LOW 501-CM281 GN-18 680-CM94 YL-18 1 2
680-CM257 YL-18 1 2
205-CM101 BK-18
RD-2
1 2
N981-RF86 QUAD_CABLE RF-S22
648-CM289 PK-18 504-CM199 YL-18 3 3 - PARK LIGHTS 502-CM282 RD-18 680-CM93 YL-18 CM-S2
205-CM345 BK-18
RH_CTR_FLOOD_ATCH N981-RF80 QUAD_CABLE 2
1465-RF118 RD-18 1461L-CM322 OR-18 206-CM205 BK-18 505-CM231 BU-18 123-CM177 RD-18 4 4 - IGNITION 353-CM381 GN-18 206-CM343 BK-18 506-CM146 PU-18 680-CM91 YL-18 2
680-CM85 YL-18
RF-C8 RF-S19 1 1
F711-RF93 YL-18 F711-RF89 QUAD_CABLE 1465-RF119 RD-18 1461L-CM327 OR-18 508-CM232 PU-18 507-CM147 WH-18 5 5 - PWR ANTENNA 353-CM97 GN-18 206-CM235 BK-18 515-CM26 OR-18 680-CM90 YL-18 539-CM62 BU-18
1 2 CM-S50 MPR_RELAY CM-C52
F711-RF87 QUAD_CABLE 1465-RF117 RD-18 1461R-CM323 OR-18 509-CM233 WH-18 508-CM232 PU-18 123-CM178 RD-18 - DIM 632-CM287 RD-18 614-CM344 PU-18 516-CM31 OR-18 540-CM58 WH-18
al
CBL-MM3
6 6
RF-S20 1 2
CM-C20 PTRAIN_J1939_RESISTOR_1 515120D1 400484X1
1 612-RF11 WH-18 F712-RF94 GN-18 1 2
F712-RF90 QUAD_CABLE 1461R-CM328 OR-18 615-CM237 RD-18 509-CM233 WH-18 135-CM185 RD-18 7 7 - BATTERY 614-CM270 PU-18 614-CM107 PU-18 CM-S10
680-CM203 YL-18 610-CM67 OR-18
2 206-RF40 BK-18 F712-RF88 QUAD_CABLE 1469-RF110 GY-18 1462L-CM324 OR-18 614-CM234 PU-18 200-CM201 BK-18 8 8 - POWER GND 352-CM378 BU-18 614-CM221 PU-18 681-CM88 GN-18 634-CM54 WH-18 BK-16 206-CM103 BK-18
520 -T2
1 2
198
198
520 T2
G500-RF103 WH-18 1469-RF108 GY-18 1462L-CM329 OR-18 616-CM241 RD-18 614-CM351 PU-18 614-CM270 PU-18 C561-CM370 YL-18 9 9 - SPKR RR + 352-CM188 BU-18 680-CM90 YL-18 681-CM89 GN-18 650-CM53 OR-18 680-CM95 YL-18 A BK-16 515-CM26 OR-18
MM
PP-
RF-S21
RR_RIGHT_FLOOD_LAMP G501-RF104 GN-18 1 2
1469-RF109 GY-18 1462R-CM325 OR-18 C560-CM244 OR-18 C567-CM372 PU-18 10 10 - SPKR RR - 680-CM91 YL-18 681-CM144 GN-18 680-CM95 YL-18 681-CM89 GN-18 B
RF-C10 G502-RF105 BK-18 1469-RF106 GY-18 1462R-CM330 OR-18 C566-CM247 PK-18 511-CM249 BR-18 11 11 - SPKR RF + 681-CM276 GN-18
CM-S43
681-CM120 GN-18 680-CM96 YL-18 C CBL-PP1 RD-2 CBL-MM2 RD-2
CM-S56 1 2
1 1
190-RF17 RD-14 1469-RF107 GY-18 1465-CM338 RD-18 615-CM237 RD-18 1 2
615-CM236 RD-16 512-CM253 GN-18 12 12 - SPKR RF - 680-CM94 YL-18 CM-S60
680-CM119 YL-18
1 607-RF14 PK-18 191-RF18 RD-14 1465-CM373 RD-18 135-CM61 RD-18 615-CM251 RD-16 508-CM232 PU-18 13 13 - SPKR LF + 681-CM83 GN-18 681-CM87 GN-18 681-CM164 GN-18 680-CM257 YL-18 2
1 2
CM-C4 AUX_VALVE_J1939_RESISTOR_1 1
206-RF41 BK-18 192-RF68 RD-14 190-RF17 RD-14 1469-CM326 GY-18 112-CM347 RD-18 509-CM233 WH-18 14 - SPKR LF - 206-CM259 BK-18 681-CM84 GN-18 681-CM86 GN-18 681-CM88 GN-18 CBL-MM1 RD-0 CBL-MM2 RD-2
3
2 14
CM-S58 CM-S54 1
193-RF67 RD-14 191-RF18 RD-14 1469-CM331 GY-18 119-CM104 RD-14 616-CM241 RD-18 1 2
616-CM238 RD-16 C560-CM369 OR-18 15 15 - SPKR LR + 206-CM264 BK-18 681-CM87 GN-18 681-CM83 GN-18 1 2
681-CM122 GN-18 681-CM89 GN-18 CAB/CHASSIS
352-RF63 BU-18 192-RF68 RD-14 200-CM127 BK-16 616-CM283 RD-16 C566-CM371 PK-18 16 16 - SPKR LR - 614-CM258 PU-18 892-CM128 BR-18 CM-S55
681-CM120 GN-18 K900-CM243 YL-18 A PASSTHROUGH
353-RF72 GN-18 193-RF67 RD-14 614-CM260 PU-18 893-CM33 GN-18 681-CM84 GN-18 681-CM202 GN-18 681-CM164 GN-18 K990-CM261 GN-18 B
RF-C25 HTD_MIRRORS_LH_(MT900) ROOF_CONTROLER 1 2
PORCH_LAMP_C 658-RF58 BR-18 515-RF70 OR-18 206-RF69 BK-14 206-CM148 BK-18 632-CM287 RD-18 CM-C2 1 17 - POWER GROUND G500-CM339 WH-18 892-CM128 BR-18 C
1
1
206-RF60 BK-18 516-RF16 OR-18 RF-C17 352-CM186 BU-18 638-CM285 PK-18 2 18 - AMP SENSE 614-CM228 PU-18 G501-CM340 GN-18 892-CM128 BR-18 893-CM33 GN-18 POWER DISTRIBUTION BLOCKS
353-RF72 GN-18 1469-RF107 GY-18 1 VERT RET GRAY (A KEY) 353-CM187 GN-18 647-CM288 OR-18 3 19 - RSA ENABLE G502-CM341 BK-18 893-CM33 GN-18
614-RF44 PU-18 353-RF124 GN-18 1461L-RF115 OR-18 2 VERTICAL 609-RF7 YL-18 1 LH CTR FLOOD ROOF RR 503-CM284 BR-18 648-CM289 PK-18 4 20 - CELL_TEL_MUTE K900-CM246 YL-18 958-CM309 YL-18 G500-CM339 WH-18 CM-C44
RR_RH_TURN_LAMP 1462L-RF113 OR-18 3
CM-S52
RF-C7 615-RF74 RD-16 353-RF125 GN-18 HORIZONTAL 613-RF20 RD-18 2 RH LT FLOOD ROOF RR 504-CM199 YL-18 658-CM242 BR-18 E539-CM163 BU-18 5 21 - STEER WHEEL K900-CM255 YL-18 958-CM35 YL-18 1 2
958-CM383 YL-18 G501-CM340 GN-18
616-RF73 RD-16 200-RF111 BK-18 4 HEAT GND 667-RF55 OR-16 3 LH RT FLOOD ROOF RR 505-CM231 BU-18 6 22 - RR SEAT AUDIO K990-CM156 GN-18 G502-CM341 BK-18 G501-CM340 GN-18 A GUIDANCE RS232
CM-S35
BK-18 A 606-RF13 GY-18 632-RF49 RD-18 352-RF63 BU-18 1465-RF117 RD-18 5 HEAT BAT 603-RF39 PK-18 4 BEACONS 507-CM147 WH-18 1461L-CM327 OR-18 1 2
1461L-CM332 OR-18 K990-CM166 GN-18 1671-CM106 RD-18 G500-CM339 WH-18 B CONNECTOR
BK-18 G 206-RF15 BK-18 638-RF57 PK-18 352-RF126 BU-18 1469-RF106 GY-18 6 HORIZ RET 630-RF6 PU-18 5 LISCENSE A/B 615-CM251 RD-16 1461L-CM322 OR-18 1478L-CM352 WH-18 7 23 - LEFT AUX IN 125-CM18 QUAD_CABLE A334-CM396 BU-16 G502-CM341 BK-18 C
647-RF28 OR-18 352-RF127 BU-18 608-RF26 PK-18 6 LH LT FLOOD ROOF RR 616-CM283 RD-16 CM-S53
9 24 - AUX SHIELD GND 658-CM242 BR-18 F711-CM73 QUAD_CABLE A958-CM392 WH-18 CM-S13
K900-CM255 YL-18
648-RF21 PK-18 308-RF59 YL-18 RF-C26 HTD_MIRRORS_RH_(MT900) 607-RF14 PK-18 7 RH RT REAR FLOOD RR 632-CM287 RD-18 1461R-CM328 OR-18 1 2
1461R-CM333 OR-18 1478G-CM354 WH-18 8 25 - AUX COMMON 615-CM236 RD-16 F712-CM77 QUAD_CABLE A772-CM394 GN-18 2
K900-CM182 YL-18
CM-C32
1
649-RF54 PK-18 515-RF70 OR-18 190-RF17 RD-14 8 BATT+ (CKT3) 638-CM285 PK-18 1461R-CM323 OR-18 CM-S65
1478R-CM353 WH-18 10 26 - RIGHT AUX IN 616-CM238 RD-16 N981-CM69 QUAD_CABLE C421-CM388 PU-18 K900-CM243 YL-18
1461L-RF115 OR-18 516-RF16 OR-18 191-RF18 RD-14 9 BATT+ (CKT4) 647-CM288 OR-18 1462L-CM329 OR-18 1462L-CM334 OR-18 12 27 - AUX ON/OFF E539-CM163 BU-18
112-AJ1 RD-18 603-RF39 PK-18 1469-RF109 GY-18 1 VERT RET
K900-RF4 YL-18 CAN HI 648-CM289 PK-18
1 2
112-RF123 RD-18 1461R-RF116 OR-18 10 1462L-CM324 OR-18 11 28 - POWER GROUND 108-CM174 RD-18 G500-CM339 WH-18 205-CM82 BK-18 A AGCO EDT SERVICE CONNECTOR
112-AJ2 RD-18 1461R-RF116 OR-18 2 VERTICAL
K990-RF22 GN-18 CAN LO 658-CM242 BR-18
112-RF121 RD-18 1462L-RF113 OR-18 605-RF9 YL-18 11 108-CM337 RD-18 G501-CM340 GN-18 K900-CM152 YL-18 120-CM79 RD-18 B
1462R-RF114 OR-18 3 HORIZONTAL CM-S66 CM-C45 CM-S9
F712-AJ3 GN-18 F712-RF94 GN-18 1462R-RF114 OR-18 606-RF10 GY-18 612-RF11 WH-18 12 RH CTR FLOOD ROOF RR 1461L-CM322 OR-18 1462R-CM330 OR-18 1462R-CM335 OR-18 MIRROR_SW 110-CM350 RD-18 G502-CM341 BK-18 K900-CM246 YL-18 680-CM96 YL-18 C A = ECU GROUND
200-RF112 BK-18 4 HEAT GND
1 2
CM-C50 1 2
F711-AJ4 YL-18 F711-RF93 YL-18 1465-RF118 RD-18 607-RF14 PK-18 1461L-CM327 OR-18 1462R-CM325 OR-18 119-CM92 RD-16 K900-CM246 YL-18 K900-CM262 YL-18 681-CM88 GN-18 D B = ECU POWER
681-RF92 GN-18 1469-RF110 GY-18 1465-RF119 RD-18 5 HEAT BAT C = POWERTRAIN BUS - CAN HI
608-RF26 PK-18 RF-C6 1461R-CM323 OR-18 206-CM264 BK-18 119-CM118 RD-14 K900-CM255 YL-18 E
680-RF91 YL-18 609-RF7 YL-18 1469-RF108 GY-18 6 HORIZ RET
GREEN (C KEY) D = POWERTRAIN BUS - CAN LO
1461R-CM328 OR-18 1465-CM338 RD-18 108-CM174 RD-18 206-CM274 BK-18 PWR 1 108-CM337 RD-18 K900-CM262 YL-18 F
PARTIAL FLOOD H = LIGHT/AUX BUS - CAN HI
u
G502-AJ7 BK-18 G502-RF105 BK-18 612-RF11 WH-18 647-RF28 OR-18 1 1462L-CM324 OR-18 1465-CM373 RD-18 108-CM337 RD-18 614-CM228 PU-18 2 123-CM109 RD-18 CM-S8
K990-CM156 GN-18 G
220-AJ8 BK-18 220-RF99 BK-18 613-RF20 RD-18 648-RF21 PK-18 2 FULL FLOOD 1462L-CM329 OR-18 110-CM350 RD-18 614-CM266 PU-18 RH HORIZ MIRROR 3 1462R-CM335 OR-18 123-CM140 RD-16 K952-CM56 BR-18 1 2
K990-CM261 GN-18 K900-CM182 YL-18 H J = LIGHT/AUX BUS - CAN LO
CM-S67
220-AJ9 BK-18 220-RF100 BK-18 614-RF44 PU-18 632-RF49 RD-18 3 HAZARD 1462R-CM325 OR-18 1469-CM331 GY-18 1 2
1469-CM336 GY-18 112-CM347 RD-18 LH HORIZ MIRROR 4 1462L-CM334 OR-18 135-CM143 RD-18 K990-CM263 GN-18 K990-CM263 GN-18 J
112-AJ10 RD-18 112-RF122 RD-18 190-RF17 RD-14 615-RF74 RD-16 4 INPUT ANALOG 3 1462R-CM330 OR-18 1469-CM326 GY-18 119-CM170 RD-16 CM-C2 CM-C45 GND 5 200-CM346 BK-18 614-CM234 PU-18 K952-CM393 BR-18
G500-AJ11 WH-18 G500-RF103 WH-18 191-RF18 RD-14 616-RF73 RD-16 649-RF54 PK-18 5 DOOR PIN 1465-CM373 RD-18 119-CM176 RD-16 LH/RH MIRROR MTR RTN 6 1469-CM336 GY-18 614-CM351 PU-18 K952-CM395 BR-18
G501-AJ12 GN-18 G501-RF104 GN-18 192-RF68 RD-14 630-RF6 PU-18 638-RF57 PK-18 6 BEACON 1465-CM338 RD-18 1478L-CM352 WH-18 200-CM198 BK-18 LH VERT MIRROR 7 1461L-CM332 OR-18 K990-CM169 GN-18 CM-C22
CM-S20
193-RF67 RD-14 632-RF49 RD-18 308-RF59 YL-18 7 KEY SW IGN 1469-CM326 GY-18 1478G-CM354 WH-18 200-CM346 BK-18 RH VERT MIRROR 8 1461R-CM333 OR-18 E539-CM163 BU-18 K972-CM240 BR-16 K990-CM166 GN-18 1 2
352-RF63 BU-18 638-RF57 PK-18 8 KEY SW START 1469-CM331 GY-18 1478R-CM353 WH-18 206-CM235 BK-18 1 4 1 4 CM-C37 K990-CM156 GN-18 K990-CM168 GN-18 205-CM101 BK-18 A ISO SERVICE CONNECTOR
NOT
353-RF72 GN-18 647-RF28 OR-18 9 KEY SW ACC CM-S15
503-CM284 BR-18 3 6 3 6 USED K990-CM166 GN-18 120-CM115 RD-18 B
515-RF70 OR-18 648-RF21 PK-18 10 ADDRESS 0 C560-CM244 OR-18 1 2
C560-CM369 OR-18 504-CM199 YL-18 353-CM97 GN-18 1 K990-CM168 GN-18 125-CM18 QUAD_CABLE 680-CM119 YL-18 C A = ECU GROUND
516-RF16 OR-18 649-RF54 PK-18 352-RF126 BU-18 11 ADDRESS 1 C560-CM366 OR-18 505-CM231 BU-18 2 5 2 5 353-CM187 GN-18 125-CM18 QUAD_CABLE N981-CM69 QUAD_CABLE 681-CM120 GN-18 D B = ECU POWER
667-RF55 OR-16 353-RF125 GN-18 12 ADDRESS 2 507-CM147 WH-18 9 11 13 15 638-CM285 PK-18 2 F711-CM73 QUAD_CABLE F711-CM73 QUAD_CABLE E C = POWERTRAIN BUS - CAN HI
CM-S47
614-RF44 PU-18 K900-RF4 YL-18 C561-CM245 YL-18 C561-CM370 YL-18 3 F712-CM77 QUAD_CABLE F712-CM77 QUAD_CABLE F D = POWERTRAIN BUS - CAN LO
CM-C42
1 2 10 12 14 16 CM-C1 WIPER_SW_REAR H = ISO BUS - CAN HI
615-RF74 RD-16 K990-RF22 GN-18 RF-C1 C561-CM365 YL-18 614-CM270 PU-18 352-CM188 BU-18 4 N981-CM69 QUAD_CABLE G 118-RF149 RD-14
112-AJ1 RD-18 616-RF73 RD-16 BLACK (B KEY) 400452X1 1 3 5 7 352-CM186 BU-18 5 CM-C35 F711-CM141 YL-18 H J = ISO BUS - CAN LO 200-RF52 BK-18
CM-S68
112-AJ2 RD-18 632-RF49 RD-18 220-RF138 BK-18 615-RF74 RD-16 1 PORCH LAMPS(SHORT) + B C561-CM245 YL-18 C566-CM247 PK-18 C566-CM371 PK-18 1461L-CM332 OR-18 2 4 6 8 6 CM-C6 F712-CM74 GN-18 J
2
se
F712-AJ3 GN-18 638-RF57 PK-18 118-RF137 RD-18 616-RF73 RD-16 2 PORCH LAMPS(LONG) - A C567-CM248 PU-18 C566-CM367 PK-18 1461R-CM333 OR-18 7 BAT RD-14 1 119-CM170 RD-16 500-RF75 BR-18
220-RF138 BK-18 RADIO CONNECTOR CM-C12
F711-AJ4 YL-18 647-RF28 OR-18 135-RF134 RD-18 118-RF137 RD-18 614-RF44 PU-18 3 BACKLIGHT CAB CM-S69
1462L-CM334 OR-18 206-CM274 BK-18 8 BAT RD-18 2 119-CM176 RD-16 511-CM249 BR-18 B + 501-RF51 GN-18
118-RF149 RD-14 648-RF21 PK-18 680-RF131 YL-18 680-RF131 YL-18 605-RF9 YL-18 4 LH TURN RR_RH_SPEAKER C567-CM248 PU-18 1 2
C567-CM372 PU-18 1462R-CM335 OR-18 206-CM212 BK-18 9 GND BK-18 3 200-CM198 BK-18 512-CM253 GN-18 A - 502-RF5 RD-18
200-RF52 BK-18 649-RF54 PK-18 681-RF132 GN-18 681-RF132 GN-18 606-RF10 GY-18 5 RH TURN C567-CM368 PU-18 1465-CM338 RD-18 614-CM266 PU-18 10 HIGH SPD WH-14 4 505-CM231 BU-18 105-CM197 RD-18 A CAT ET SERVICE CONNECTOR
CM-S61 RF-C23
G502-AJ7 BK-18 206-RF45 BK-18 1461L-RF115 OR-18 F711-RF146 YL-18 516-RF16 OR-18 6 ECU RELAY 1465-CM373 RD-18 614-CM234 PU-18 11 LOW SPD YL-14 5 504-CM199 YL-18 FR_RH_SPEAKER 125-CM319 QUAD_CABLE 2
125-CM131 QUAD_CABLE 200-CM196 BK-18 B
CM-C34
1
220-AJ8 BK-18 206-RF46 BK-18 1461R-RF116 OR-18 F712-RF147 GN-18 515-RF70 OR-18 7 MAIN POWR RELAY E539-CM163 BU-18 1469-CM336 GY-18 12 PARK BU-14 6 503-CM284 BR-18 C A = BATTERY POWER
220-AJ9 BK-18 1462L-RF113 OR-18 353-RF124 GN-18 8 +3.3 VDC 400460X1 WASHER BR-18 7 507-CM147 WH-18 N981-CM318 QUAD_CABLE
CM-S62
N981-CM133 QUAD_CABLE 893-CM33 GN-18 D B = BATTERY GROUND 603-RF38 PK-18 1 BK-18 RH_BEACON
1 2
112-AJ10 RD-18 500-RF75 BR-18 1462R-RF114 OR-18 352-RF127 BU-18 9 +1.6 VDC RD 1 614-CM351 PU-18 511-CM249 BR-18 8 892-CM128 BR-18 E D = CAT DATALINK POS 206-RF45 BK-18 2 BK-18
CM-S63
G500-AJ11 WH-18 501-RF51 GN-18 1465-RF118 RD-18 F711-RF146 YL-18 206-RF69 BK-14 10 GROUND BK 2 206-CM204 BK-18 512-CM253 GN-18 F711-CM134 QUAD_CABLE 1 2
F711-CM139 QUAD_CABLE 681-CM164 GN-18 F E = CAT DATALINK NEG
G501-AJ12 GN-18 502-RF5 RD-18 1469-RF110 GY-18 F712-RF147 GN-18 192-RF68 RD-14 11 BATT+(CKT1) F711-CM141 YL-18 680-CM257 YL-18 G F = POWERTRAIN BUS - CAN LO RF-C5
CM-S64
603-RF38 PK-18 193-RF67 RD-14 12 BATT+(CKT2) COURTESY_LAMP RADIO BEZEL RADIO BEZEL F712-CM135 QUAD_CABLE 1 2
F712-CM153 QUAD_CABLE H G = POWERTRAIN BUS - CAN HI
606-RF47 GY-18 135-RF134 RD-18 F712-CM74 GN-18 J 606-RF47 GY-18 A BK-18 FR_RH_TURN_LAMP
206-RF46 BK-18 G BK-18
FIG. 2
on
FIG. 2: MT 800 C Cab Schematic

ly
79033095 C Rev. 07-3

NOTES
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07-4 79033095 C Rev.

CAB ELECTRICAL SCHEMATICS SN:
EFF...DXX1001
Fo
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FIG. 3
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FIG. 3: MT 800 C Cab Schematic

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79033095 C Rev. 07-5

NOTES
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07-6 79033095 C Rev.

Index
INDEX
Cab Electrical Schematics .......................... 07-3, 07-5

Chassis Electrical Schematics ............................. 07-1
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79033095 C Rev. 07-7

Index
NOTES
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07-8 79033095 C Rev.

Contents
Challenger ®
Rubber Tracked Tractor
SERVICE MANUAL
79033095 C Rev.
08 - Air System
Contents
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AIR SYSTEM OPERATION

Theory of Operation ....................................................................................................................................... 08-1
r
Air System Components ................................................................................................................................ 08-1

Air System Component Function ................................................................................................................... 08-3
in
Air Compressor ....................................................................................................................................... 08-3

Air Dryer .................................................................................................................................................. 08-4
Regeneration Tank .................................................................................................................................. 08-4
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Main Tank ................................................................................................................................................ 08-5

Air Pressure Sensor ................................................................................................................................ 08-6
rn
Coupler .................................................................................................................................................... 08-6
AIR SYSTEM DISASSEMBLY AND ASSEMBLY

al
Air Compressor .............................................................................................................................................. 08-7

Air Compressor Removal ........................................................................................................................ 08-7
Air Compressor Installation ..................................................................................................................... 08-9
u
Air Dryer ....................................................................................................................................................... 08-12

Air Dryer Removal ................................................................................................................................. 08-12
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Air Dryer Installation .............................................................................................................................. 08-14

Main Air Tank ............................................................................................................................................... 08-15
Main Air Tank Removal ......................................................................................................................... 08-15
Main Air Tank Installation ...................................................................................................................... 08-17
on
Regeneration Tank ...................................................................................................................................... 08-19

Regeneration Tank Removal ................................................................................................................. 08-19
Regeneration Tank Installation .............................................................................................................. 08-21
Coupler ........................................................................................................................................................ 08-22
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Coupler Removal ................................................................................................................................... 08-22

Coupler Installation ................................................................................................................................ 08-24
AIR SYSTEM COMPONENT SPECIFICATIONS

Main Air Tank ............................................................................................................................................... 08-25
Regeneration Tank ...................................................................................................................................... 08-26
Air Compressor ............................................................................................................................................ 08-27
Air Dryer ....................................................................................................................................................... 08-28
INDEX ............................................................................................................................................................. 08-29
79033095 C Rev. 08-i

Contents
NOTES
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08-ii 79033095 C Rev.

Air System Operation
AIR SYSTEM OPERATION
THEORY OF OPERATION
The air system on this machine is optional. Air
compressor is mounted directly to left-hand side of
engine. Compressor is water cooled and oil lubricated. Air
is drawn into top of compressor and pushed or expelled
out rear.
Air flows to air dryer mounted to right-hand frame rail. Air
dryer is connected to main air tank and regeneration tank.
Air coupler is connected to end of main air tank and is
mounted to front of right-hand frame rail for air tools.
Conformité Européenne or European Certified (CE)
machines also use compressed air to operate trailer
brake option.
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AIR SYSTEM COMPONENTS

r in
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1
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3
5
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6
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2
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4
P080412009
FIG. 1
FIG. 1: Air system component layout.

(1) Air Compressor
(2) Air Dryer
(3) Regeneration Tank
(4) Main Tank
(5) Coupler
(6) Air Pressure Sensor
79033095 C Rev. 08-1

FIG. 2: Air compressor hose connections.
(1) Air Inlet 1
(2) Coolant Inlet
(3) Coolant Outlet
2 3
(4) Air Outlet
(5) Oil Line
4
Fo
5
P080412010
FIG. 2
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3
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2 6
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1 4
5
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P011412004
FIG. 3
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FIG. 3: Air component schematic.

Air system components:
• Air Compressor (1)
• Air Dryer (2)
• Regeneration Tank (3)
• Main Tank (4)
• Air Coupler (5)
• Pressure Sensor (6)
08-2 79033095 C Rev.

AIR SYSTEM COMPONENT FUNCTION
Air Compressor
FIG. 4: A 444.6 L/min (15.7 ft3/min) air compressor (1) is
mounted to left-hand side of engine and produces 8.3 bar
(120 psi) at 1800 RPM. Compressor is gear driven.
P080412011
FIG. 4
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FIG. 5: An oil line (1) is connected from bottom of

compressor housing to engine block.
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P080412012
FIG. 5
FIG. 6: A coolant line (1) is plumbed from engine into
u
front of compressor head and another coolant line (2) is 2

plumbed from rear of compressor head back to engine.
se
3
Air is drawn into compressor through a large air line (3)
into top of compressor. Compressed air is pushed
through an air line (4) at rear of compressor head and
diverted to air dryer.
on
1
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4
P080412013
FIG. 6
79033095 C Rev. 08-3

Air Dryer
FIG. 7: Air dryer (1) is mounted to right-hand frame rail
with three bolts (2). 1
NOTE: Right-hand side frame rail has been made
transparent in this figure for clarity. 2
P080412014
FIG. 7
FIG. 8: Three air lines are connected to air dryer. Line (1)
from air compressor is connected to left-hand port. Line
(2) to regeneration tank is connected to middle port. Line
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(3) to main tank is connected to right-hand port.

3
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1
2
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P080112007
FIG. 8
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Regeneration Tank
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FIG. 9: Regeneration tank (1) is mounted to inside of

right-hand frame rail with two bolts (2).
NOTE: Right-hand side frame rail has been made 1
u
2
transparent in this figure for clarity.
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on
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P080412015
FIG. 9
FIG. 10: Regeneration tank (1) is connected to middle
port (2) of air dryer. Regeneration tank provides an air
supply to regenerate the desiccant in air dryer.
1
2 P080412018
FIG. 10
08-4 79033095 C Rev.

Main Tank
FIG. 11: Main tank (1) is mounted to inside of right-hand
frame rail with four bolts (2).
NOTE: Right-hand side frame rail has been made
transparent in this figure for clarity.
1
2
P080412016
FIG. 11
FIG. 12: An air line goes from right-hand port (1) of air
dryer to right-hand end of main tank (2).
Fo
2
An air line (3) from left-hand end of main tank is routed to
a coupler at left-hand front corner of machine.
There is a drain valve (4) in bottom of main tank. 1
r in
te
3 4
rn
P080412017
FIG. 12
al
FIG. 13: A pressure sensor (1) is fitted into a port on

right-hand end of main tank. Maximum pressure for
pressure sensor is 1135 kPa (165 psi).
u
Sensor sends a signal to machine ECM.

se
1
on
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P080412019
FIG. 13
79033095 C Rev. 08-5

Air Pressure Sensor
FIG. 14: Air pressure sensor (1) is fitted into a port on
right-hand end of main tank and sensor sends a signal to
machine ECM when activated. Maximum pressure for
sensor is 1135 kPa (165 psi).
P080412019
FIG. 14
Coupler
Fo
FIG. 15: An air coupler (1) is mounted to frame at

right-hand front corner of machine. This coupler provides
a connection for use of air tools for servicing machine.
r
1
in
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rn
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P080412005
FIG. 15
u se
on
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08-6 79033095 C Rev.

Air System Disassembly and Assembly
AIR SYSTEM DISASSEMBLY AND ASSEMBLY
AIR COMPRESSOR
Air Compressor Removal
m
maintenance on engine, allow engine and
components to cool.

Fo

r

in

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rn

al

u

se

on
Park machine on a hard level surface. Move gear shift

lever to neutral and engage parking brake. Turn off engine
and remove key.
ly
FIG. 16: Air compressor (1) is located on left side of

engine.
P073112001
FIG. 16
79033095 C Rev. 08-7

FIG. 17: Disconnect water coolant line (1).
Disconnect air outlet line (2).
m
WARNING: Allow engine coolant to cool
before opening coolant system. Hot coolant 1
can cause severe burns.
2
m
WARNING: Release air pressure from
system. Pressurized air can cause personal
injury.
P073112002
FIG. 17
FIG. 18: Disconnect air inlet line (1).

Disconnect water coolant line (2). 1
Fo
2
r in
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P073112003
rn
FIG. 18
FIG. 19: Disconnect oil line (1).
al
u
1
se
on
P073112004
ly
FIG. 19
FIG. 20: Support air compressor with an appropriate
lifting device and remove lower mounting bolt (1).
Remove three bolts (2) holding air compressor to engine.
Slide compressor straight back to disengage splines.
2
P080112001
FIG. 20
08-8 79033095 C Rev.

Air Compressor Installation
beginning assembly procedure, all components
Precision components can be damaged by
contaminants or by dirt. Perform assembly
procedures on a clean work surface. Keep
components covered and protected at all times.
Fo
FIG. 21: Install straight adapter (1) into air inlet port.
Install 90-degree adapter (2) into water port.
r
1
2
in
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rn
P080112005
al
FIG. 21
FIG. 22: Install straight adapter fitting (1) into water port.
u
Install straight adapter fitting (2) into air discharge port.

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1
on
2
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P080112003
FIG. 22
FIG. 23: Install straight adapter fitting (1) into oil port.
P080112004
FIG. 23
79033095 C Rev. 08-9

FIG. 24: Attach mount (1) to rear of air compressor with
two bolts (2).
P080112002
FIG. 24
FIG. 25: Support air compressor with an appropriate
lifting device and slide compressor, with new gasket,
straight forward to engage splines.
Fo
Secure compressor to engine with three bolts (1).

Secure rear mount to engine with lower mounting bolt (2). 1
r
2
in
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P080112001
FIG. 25
rn
FIG. 26: Connect oil line (1).

al
1
u se
on
P073112004
FIG. 26
ly
FIG. 27: Connect air inlet line (1).

Connect water coolant line (2). 1
P073112003
FIG. 27
08-10 79033095 C Rev.

FIG. 28: Connect water coolant line (1).
Connect air outlet line (2).
1
2
P073112002
FIG. 28
Fo
r in
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rn
al
u se
on
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79033095 C Rev. 08-11

AIR DRYER
FIG. 29: Air dryer (1) is located on inside of right-hand
frame rail.
Air Dryer Removal
m
components to cool.
NOTE: Put identification marks on all hoses, on all hose 1

assemblies for installation purposes. Any engine P080112006
ports and coolant ports should be plugged or FIG. 29
Fo

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in

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rn

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se

on
and remove key.

FIG. 30: Remove bolts holding belly guards (1) to
chassis, if equipped.
ly
Remove four bolts (2) holding fan blast guard (3) to

chassis and remove fan blast guard.
2
3
1
P040212001
FIG. 30
08-12 79033095 C Rev.

FIG. 31: Release air pressure from air system by
opening air drain valve (1) in bottom of main air tank.
m
injury.
1
P080112011
FIG. 31
FIG. 32: Disconnect air line (1) to main air tank.

Disconnect air line (2) to regeneration tank.
Fo
r
2
in
1
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P080112007
rn
FIG. 32
FIG. 33: Disconnect input line (1) from air compressor.
al
u se
1
on
P080112008
ly
FIG. 33
FIG. 34: Remove three bolts (1) holding air dryer to
frame rail.
NOTE: Right-hand frame rail has been made
semi-transparent for clarity.
P080112009
FIG. 34
79033095 C Rev. 08-13

Air Dryer Installation
FIG. 35: Install 90-degree fitting (1) into inlet port.
Install straight adapter fitting (2) into regeneration port.
Install straight adapter fitting (3) into main tank port.
beginning assembly procedure, all components 1 3
components covered and protected at all times. 2 P080112010
FIG. 35
FIG. 36: Mount air dryer to frame rail with three bolts (1).
Fo
NOTE: Right-hand frame rail has been made

semi-transparent for clarity.
r in
1
te
rn
P080112009
FIG. 36
al
FIG. 37: Connect input line (1) from air compressor.

u se
1
on
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P080112008
FIG. 37
FIG. 38: Connect air line (1) from main air tank.
Connect air line (2) from regeneration tank.
Start engine. Allow pressure to build, turn off engine and
test for leaks.
Install belly guards and fan blast guard.
1
P080112007
FIG. 38
08-14 79033095 C Rev.

MAIN AIR TANK
FIG. 39: Main air tank (1) is located on inside of
right-hand frame rail.
Main Air Tank Removal

ports and coolant ports should be plugged or 1
to prevent fluid loss, and helps keep P080112006
FIG. 39
Fo

r

in

te

and remove key.
rn

al

2
3
u se
on
1
P040212001
FIG. 40
ly

m
injury.
1
P080112011
FIG. 41
79033095 C Rev. 08-15

FIG. 42: Disconnect air line (1) for air coupler.
P080112012
FIG. 42
FIG. 43: Disconnect air line (1) from air dryer.
Disconnect electrical wire (2) to pressure sensor.
Fo
2
r
1
in
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P080112013
FIG. 43
rn
FIG. 44: Remove four bolts (1) holding main air tank to
chassis.
al
u se
on
1
P080112014
FIG. 44
ly
08-16 79033095 C Rev.

Main Air Tank Installation
FIG. 45: Install Tee-fitting (1) into air tank port.
Fo
1
r
P080112017
in
FIG. 45
FIG. 46: Install straight adapter fitting (1) into air tank
te
port.
Install 90-degree fitting (2) into adapter.
rn
Install pressure sensor (3) into 90-degree fitting.

3
al
u
1
se
2
P080112016
FIG. 46
FIG. 47: Install air tank into mounting straps (1).
on
ly
P080112015
FIG. 47
79033095 C Rev. 08-17

FIG. 48: Mount main air tank to chassis with four bolts
(1).
1
P080112014
FIG. 48
FIG. 49: Connect air line (1) from air dryer.
Connect electrical wire (2) to pressure sensor.
Fo
2
r
1
in
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P080112013
FIG. 49
rn
FIG. 50: Connect air line (1) for air coupler.

al

test for leaks.
u
1
se
on
P080112012
FIG. 50
ly
FIG. 51: Mount fan blast guard (1) to chassis with four
bolts (2).
Mount belly guards (3) to chassis, if equipped.
2
1
3
P040212001
FIG. 51
08-18 79033095 C Rev.

REGENERATION TANK
FIG. 52: Regeneration tank (1) is located on inside of
right-hand frame rail.
Regeneration Tank Removal 1

FIG. 52
Fo

r

in

te

and remove key.
rn

al

2
3
u se
on
1
P040212001
FIG. 53
ly

m
injury.
1
P080112011
FIG. 54
79033095 C Rev. 08-19

FIG. 55: Disconnect air line (1) from air dryer.
P080412001
FIG. 55
FIG. 56: Support regeneration tank with an appropriate
lifting device and remove two bolts (1) holding
regeneration tank to chassis.
1
Fo
r in
te
P080412002
FIG. 56
rn
al
u se
on
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08-20 79033095 C Rev.

Regeneration Tank Installation
FIG. 57: Install 90-degree fitting (1) into side port.
1
P080412004
FIG. 57
FIG. 58: Install three plugs (1) into end and bottom ports.
Fo
r in
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1
rn
P080412003
FIG. 58
al
FIG. 59: Support regeneration tank with an appropriate

lifting device and mount regeneration tank to chassis with
two bolts (1).
u
1
se
on
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P080412002
FIG. 59
FIG. 60: Connect air line (1) from air dryer to 90-degree
fitting.
1
test for leaks.
P080412001
FIG. 60
79033095 C Rev. 08-21

bolts (2).
2
1
3
P040212001
FIG. 61
COUPLER
FIG. 62: Air coupler (1) is mounted on right-hand frame
Fo
rail.
Coupler Removal
r

in

te

any other connections are removed. This helps 1
rn

FIG. 62
al

u

se

on

and remove key.
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2
3
1
P040212001
FIG. 63
08-22 79033095 C Rev.

m
injury.
1
P080112011
FIG. 64
FIG. 65: Disconnect air line (1) from air tank.

Fo
r in
1
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P080412006
rn
FIG. 65
FIG. 66: Remove nut (1) holding coupler to mounting
al
bracket.
u se
1
on
P080412007
ly
FIG. 66
FIG. 67: Remove coupler (1) from 45-degree fitting (2).
1
2
P080412008
FIG. 67
79033095 C Rev. 08-23

Coupler Installation
FIG. 68: Install coupler (1) onto 45-degree fitting (2).
beginning assembly procedure, all components 1
should be thoroughly cleaned. This will help to 2
P080412008
FIG. 68
FIG. 69: Mount coupler to mounting bracket with nut (1).
Fo
r in
1
te
rn
P080412007
FIG. 69
al
FIG. 70: Connect air line (1) from air tank.

test for leaks.
u se
on
1
ly
P080412006
FIG. 70
bolts (2).
2
1
3
P040212001
FIG. 71
08-24 79033095 C Rev.

Air System Component Specifications
AIR SYSTEM COMPONENT SPECIFICATIONS
MAIN AIR TANK
2
Fo
r in
1
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P073012002
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FIG. 72
FIG. 72: Main Air Tank
u
General
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Ports (four) ...................................................................................................................................................M22 x 1.5-12

Capacity ................................................................................................................................................. 20 liters (5.3 gal)
Drain Valve (1)
on
Maximum Working Pressure............................................................................................................. 2200 kPa (319 psi)

Temperature Range....................................................................................-40 to 80 degrees C (-40 to 176 degrees F)
ly
Pressure Sensor (2)

Input Voltage .......................................................................................................................................................8 to 30 V
Output Voltage ......................................................................................................................................................1 to 5 V
Nominal Pressure .............................................................................................................................. 1000 kPa (145 psi)
Overload Pressure............................................................................................................................. 3000 kPa (435 psi)
Temperature Range..................................................................................-40 to 125 degrees C (-40 to 257 degrees F)
79033095 C Rev. 08-25

REGENERATION TANK
Fo
r in
P073012001
FIG. 73
te
FIG. 73: Regeneration Tank

General
rn
Ports (four) ........................................................................................................................................................ M22 x 1.5

Capacity ................................................................................................................................................... 5 liters (1.3 gal)
al
Temperature Range..................................................................................-50 to 100 degrees C (-58 to 212 degrees F)

Maximum Working Pressure............................................................................................................. 1896 kPa (275 psi)
u se
on
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08-26 79033095 C Rev.

AIR COMPRESSOR
1
Fo
r in
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P082612001
FIG. 74
rn
FIG. 74: Air Compressor

General
al
Swept Air Displacement at 1250 rpm ............................................................................... 444.6 liters/min (15.7 ft3/min)
Maximum Power Required Loaded at 1800 rpm.................................................................................... 3.4 kW (4.6 hp)
u
Maximum Power Required Unloaded at 1800 rpm ................................................................................ 1.1 kW (1.5 hp)
se
Pressure Relief Valve (1)................................................................................................................... 1724 kPa (250 psi)

Ports
Air Inlet .......................................................................................................................... No. 14 port (1-3/16-12-2B THD)
on
Air Discharge ......................................................................................................................No. 10 port (7/8-14-2B THD)

Water Ports ...........................................................................................................................No. 8 port (3/4-16-2B THD)
ly
Oil Inlet ................................................................................................................................No. 4 port (7/16-20-2B THD)

Governor Port ..................................................................................................................................... 1/8-27 NPTF THD
79033095 C Rev. 08-27

AIR DRYER
2
Fo
r
3 5
4
in
P073012004
FIG. 75
te
FIG. 75: Air Dryer

General
rn
Unloader Valve Setting .........................................................................................................................800 kPa (116 psi)

Temperature Range....................................................................................-40 to 65 degrees C (-40 to 149 degrees F)
al
Safety Valve Setting........................................................................................................................... 1400 kPa (203 psi)

Desiccant Cartridge (1) ........................................................................................................................................Spin-on
u
Ports
se
Compressor ......................................................................................................................................(2) - M22 x 1.5 THD

Regeneration Tank............................................................................................................................(3) - M12 x 1.5 THD
Exhaust .........................................................................................................................................................................(4)
on
Main Tank..........................................................................................................................................(5) - M22 x 1.5 THD

ly
08-28 79033095 C Rev.

Index
INDEX
Air Component Schematic ................................... 08-2

Air Compressor ...................... 08-1, 08-3, 08-7, 08-27
Air Compressor Installation .................................. 08-9
Air Compressor Removal ..................................... 08-7
Air Dryer ............................... 08-1, 08-4, 08-12, 08-28
Air Dryer Installation ........................................... 08-14
Air Dryer Removal .............................................. 08-12
Air Pressure Sensor .................................... 08-1, 08-6
Air System Component Function ......................... 08-3
Air System Component Specifications ............... 08-25
Air System Components ...................................... 08-1
Air System Disassembly and Assembly ............... 08-7
Air System Operation ........................................... 08-1
Fo
C
r
Coupler ............................................ 08-1, 08-6, 08-22

in
Coupler Installation ............................................ 08-24

Coupler Removal ............................................... 08-22
te
D
rn
Desiccant ............................................................. 08-4

al
M
u
Main Air Tank ....................... 08-1, 08-5, 08-15, 08-25

Main Air Tank Installation ................................... 08-17
se
Main Air Tank Removal ...................................... 08-15
R
on
Regeneration Tank .............. 08-1, 08-4, 08-19, 08-26

Regeneration Tank Installation .......................... 08-21
Regeneration Tank Removal ............................. 08-19
ly
79033095 C Rev. 08-29

Index
NOTES
Fo
r
in
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use
on
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08-30 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
09 - Virtual Terminal
Contents
Fo
SYSTEMS OPERATION
Introduction .................................................................................................................................................... 09-1
r
Virtual Terminal .............................................................................................................................................. 09-1

Screen Layout ................................................................................................................................................ 09-2
in
Engine Screen ......................................................................................................................................... 09-3

Transmission Screen ............................................................................................................................... 09-3
Hydraulic Screen ..................................................................................................................................... 09-4
te
Measures - INST Screen ......................................................................................................................... 09-6

Measures - Field Screen ......................................................................................................................... 09-6
rn
Power Management Screen .................................................................................................................... 09-7

One Touch Screen .................................................................................................................................. 09-8
Tractor Settings Screen ........................................................................................................................... 09-9
al
Diagnostic Trouble Code (DTC) Screen ................................................................................................ 09-10

Hitch Screen .......................................................................................................................................... 09-11
Auto-Guide Screen ...................................................................................................................................... 09-12
u
Steering Calibration ..................................................................................................................................... 09-13

Slip Calibration ............................................................................................................................................. 09-15
se
Ground Speed Radar ................................................................................................................................... 09-17

Radar Unit ............................................................................................................................................. 09-17
Radar Connector ................................................................................................................................... 09-17
Radar Calibration .................................................................................................................................. 09-18
on
Radar Specifications ............................................................................................................................. 09-20
VIRTUAL TERMINAL DISASSEMBLY AND ASSEMBLY

ly
Machine Electronic Control Module (ECM) Removal and Installation ......................................................... 09-21
Machine ECM Removal ......................................................................................................................... 09-21
Machine ECM Installation ...................................................................................................................... 09-22
Lighting Electronic Control Module (ECM) Removal and Installation .......................................................... 09-24
Lighting ECM (Located in Floor) ............................................................................................................ 09-24
Lighting ECM (Located in Roof) ............................................................................................................ 09-27
Armrest Electronic Control Module (ECM) Removal and Installation .......................................................... 09-29
Armrest ECM Removal .......................................................................................................................... 09-29
Armrest ECM Installation ....................................................................................................................... 09-30
Ground Speed Sensor Removal and Installation ......................................................................................... 09-32
Ground Speed Sensor Removal ........................................................................................................... 09-32
Ground Speed Sensor Installation ........................................................................................................ 09-32
INDEX ............................................................................................................................................................. 09-33
79033095 C Rev. 09-i

Contents
NOTES
Fo
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use
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09-ii 79033095 C Rev.

Systems Operation
SYSTEMS OPERATION
INTRODUCTION
FIG. 1: The monitoring system for machine is the Virtual
Terminal (1). Virtual terminal is used to control machine’s
systems and displays information from other electronic
control modules on machine.
m
WARNING: If virtual terminal is not 1
functioning, do not operate machine.
Personal injury or death can result from a
warning event not indicated by an alarm or
display.
Fo
P111203001
FIG. 1
r
VIRTUAL TERMINAL
in
FIG. 2: Virtual terminal displays machine information on

console. Button (1) and dial (2) help navigate selected 1 2
te
screens. Home button (3) returns user to main menu.

Selection button (4) allows movement between active
sets. Escape button (5) returns user to previous screen.
rn
The following information is provided by virtual terminal:

operating parameters, diagnostics, service intervals,
al
warning event and operation modes. 4

Instantaneous and lifetime total information regarding 5
machine condition and performance are constantly 3
u
compiled. Adjustment of settings to match application are

se
also available.
P111203001
Use virtual terminal to adjust:
FIG. 2
on
• Three-point hitch steering

• PTO
ly
• Hydraulic control valve

• Auto-Guide navigation
Virtual terminal displays information at front of right-side
console. Location provides maximum view to operator
while maintaining maximum view of ground.
Operator is able to adjust many settings to match
machine to desired application.
79033095 C Rev. 09-1

Systems Operation
Operator provides input by using:
• Button
• Control dial
If a warning event occurs, a detailed message appears on
virtual terminal. Indicator on dash lights and an alarm
alerts operator to check event.
When engine key start switch is turned on, virtual terminal
automatically checks operation of:
• Sensors
• Electronic control modules
• Monitor
SCREEN LAYOUT
FIG. 3: Virtual terminal viewing screens
Fo
2 3
4
Main Menu Viewing Icons
r
1 Engine Screen
1
in
2 Transmission Screen
3 Hydraulic Valve(s) Screen
te
4 Fuel Field Screen 5 6 7

8
rn
5 Average Fuel Field Screen

9 10
6 Power Management Screen P103002001
al
7 One Touch Headland Screen

FIG. 3
8 Settings Screen
u
9 Diagnostic Trouble Codes

se
10 Hitch Screen
on
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09-2 79033095 C Rev.

Systems Operation
Engine Screen
FIG. 4: From main menu, select a specific viewing
screen by scrolling forward or back using control dial on
side of terminal. To select highlighted icon (1), push
center of control dial.
P103002001
FIG. 4
FIG. 5: After selecting Engine icon from main menu,
Fo
current information for machine is displayed.

r
1 Engine Percentage Load 1 4

in
2 Intake Manifold Temperature

3 Engine Oil Pressure
te
4 Battery Voltage 3 6 5
rn
5 Intake Manifold Pressure 2

6 Coolant Temperature P100711051
al
Transmission Screen FIG. 5
FIG. 6: Transmission Viewing Screen (1)

u
From main menu, select a specific viewing screen by

se
scrolling forward or back using control dial on side of

terminal. To select highlighted icon, push center of control
dial.
1
on
ly
P103002001
FIG. 6
79033095 C Rev. 09-3

Systems Operation
FIG. 7: After selecting Transmission icon from main
menu, current information will be displayed for machine.
1 Current Gear 1
2 Machine Speed
4
2 6
3 PTO Speed 5
4 Selected Gear 3
5 Transmission Oil Temperature
To move to next screen, push button on terminal by

P100711052
transmission icon (6).
FIG. 7
FIG. 8: To change each item selection (1), use control
dial on side of terminal and scroll to highlight selected box
and press center of control dial. Use control dial to scroll
Fo
up or down to select information then press center of

control dial.
r
1
in
te
rn
P100711021
FIG. 8
al
Hydraulic Screen
u

se

on
1
ly
P103002001
FIG. 9
09-4 79033095 C Rev.

Systems Operation
FIG. 10: Hydraulic Viewing Screen
After selecting Hydraulic icon from main menu, current
information is displayed for machine.
1 Current Gear
1 5
2 Set Speed A Switch
7
3 PTO
2
4 Constant Ground Speed 3 6
5 Machine Speed
6 Set Speed B Switch
4 P100711028
FIG. 10
To select next screen, push button on terminal by
hydraulic icon (7).
FIG. 11: To change each item selection, use control dial
Fo
on side of terminal and scroll to highlight selected box and

press center of control dial. Use control dial to scroll up or 2
down to select information, then press center of control 4
r
dial.
in
1 Hydraulic Valve Number 3

1
2 Detent Time
te
3 Maximum Retract Position

5
rn
4 Maximum Extend Position

P100711029
al
Next screen can be seen by pressing a hydraulic valve

selection button (5) to view information for hydraulic valve. FIG. 11
Press center of control dial to select.
u
FIG. 12: To change each item selection (1), use control

dial on side of terminal and scroll to highlight selected box
se
and press center of control dial. Use control dial to scroll

up or down to select information then press center of
control dial.
2
on
1
2 Retract Port 3
ly
3 Extend Port 4
4 Detent Time
5
5 Priority P100711030
FIG. 12
79033095 C Rev. 09-5

Systems Operation
Measures - INST Screen
screen by scrolling forward or backward using control dial
on side of terminal. To select highlighted icon (1), push
1
P103002001
FIG. 13
FIG. 14: Measures - INST Viewing Screen
Fo
After select Measures - INST icon from main menu,

current information is displayed for machine.
1 4
r
2 5
in
1 INST Engine Percentage Load

2 INST Area Rate
3 6
te
3 INST Fuel per Area

rn
4 INST Fuel Economy

5 INST Fuel Rate P100711032
al
6 INST Power Specific Fuel Economy FIG. 14
Measures - Field Screen

u

se

on
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P103002001
FIG. 15
09-6 79033095 C Rev.

Systems Operation
FIG. 16: After selecting Measures Field icon from main
menu, current information is displayed for machine.
1 Distance 4
2 Area
1 2
3 Engine Percentage Load 5
4 Field Time 3 6
5 Area Rate 7
6 Power Specific Fuel Economy
P100711034
To select next screen, push button on terminal by

Measures Fuel icon (7). FIG. 16
FIG. 17: Measure - Fuel Viewing Screen

Fo
1 Fuel Pressure 1 4
2 Load Rate 5
r
2
3 Power Specific Fuel Economy
in
4 Fuel Temperature 3 6
te
5 Fuel Rate
6 Fuel per Acre
rn
P100711035
FIG. 17
al
Power Management Screen

u

se

on
1
ly
P103002001
FIG. 18
79033095 C Rev. 09-7

Systems Operation
FIG. 19: Power Management Viewing Screen
After selecting Power Management Icon from main menu,
1 3
1 Switch Status - Engine A
2 4
2 Constant Ground Speed
3 Switch Status - Engine B
4 Decelerator Set Speed
P100711038
FIG. 19
FIG. 20: To change item selection (1), use control dial on

side of terminal and scroll to highlight selected box and
Fo
press center of control dial. Use control dial to scroll up or

down to select information, then press center of control
dial. 1
r in
te
rn
P100711040
FIG. 20
al
One Touch Screen

u

se

on
1
ly
P103002001
FIG. 21
09-8 79033095 C Rev.

Systems Operation
FIG. 22: One Touch Viewing Screen
P100711036
FIG. 22
Tractor Settings Screen

Fo

r in
1
te
rn
P103002001
al
FIG. 23
FIG. 24: Tractor Settings Viewing Screen
u
After selecting Tractor Settings icon from main menu,

se

3
1 Daytime Backlighting
1
4
on
2 Lighten Shutdown Timer 2

3 Night Time Backlighting 5
ly
4 Implement Width
5 Engine Idle Shutdown Timer
P100711007
FIG. 24
79033095 C Rev. 09-9

Systems Operation
FIG. 25: Tractor Settings Viewing Screen
To change item selections (1), use control dial on side of
terminal and scroll to highlight selected box and press
center of control dial. Use control dial to scroll up or down
to select information then press center of control dial.
P100711009
FIG. 25
Diagnostic Trouble Code (DTC) Screen

Fo
FIG. 26: DTC Stored or Active Viewing Screen (1)

From main menu, select a specific viewing screen by
scrolling forward or back using control dial on side of
r
terminal. To select highlighted icon (1), push center of

control dial.
in
1
te
rn
P103002001
al
FIG. 26
FIG. 27: After selecting DTC Stored or Active Viewing
u
Settings icon from main menu, machine’s current

se
information is displayed.
Continue to next screen (1) by pressing button adjacent to
icon and pressing center of control dial.
1
on
ly
P102311002
FIG. 27
09-10 79033095 C Rev.

Systems Operation
FIG. 28: Information for DTC - Active Viewing Settings
Screen is displayed.
P102311001
FIG. 28
Hitch Screen
Fo

r in
1
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rn
P103002001
al
FIG. 29
FIG. 30: Hitch Viewing Screen
u
After selecting Hitch icon from main menu, current

se
machine information is displayed. 1

4
1 Raise Hitch Rate
on
2 Captive Hitch Position

5 7
2
3 Lower Hitch Rate
ly
4 Slip Sensitivity 3
6
5 Draft Control
P100711022
6 Steer Position
FIG. 30
Continue to next screen (7) by pressing button on terminal
by icon and pressing center of control dial.
79033095 C Rev. 09-11

Systems Operation
FIG. 31: To change item selections, scroll to highlight
box (1) and press center of control dial. Push button on
terminal next to steer position icon to select next screen
(2).
1 2
P100711023
FIG. 31
FIG. 32: To change item selections (1), use control dial
on side of terminal and scroll to highlight selected box and
press center of control dial. Use control panel to scroll up
Fo
or down to select information, the press center of control

dial.
1
r in
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rn
P100711049
FIG. 32
al
AUTO-GUIDE SCREEN
u
FIG. 33: Auto-Guide Viewing Screen

se
To select a specific viewing screen (1), scroll forward or

back using control dial on side of terminal. To select 1
highlighted icon, push center of control dial.
on
ly
P101411010
FIG. 33
09-12 79033095 C Rev.

Systems Operation
STEERING CALIBRATION
FIG. 34: Use scroll wheel (1) to highlight machine icon
(2). Press center button on wheel to select. 2 1
Q030406001
FIG. 34
FIG. 35: Press hard key (1) to select configuration menu.
1
Fo
r in
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rn
Q030406002
FIG. 35
al
FIG. 36: Press hard key (1) to select calibration menu.

1
u se
on
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Q030406003
FIG. 36
FIG. 37: Use scroll wheel to highlight steering calibration
start button (1). Press center of wheel to select.
Q030406004
FIG. 37
79033095 C Rev. 09-13

Systems Operation
FIG. 38: Automatic Steering Calibration is Armed.
R010611004
FIG. 38
FIG. 39: Calibration will complete when the following
conditions have been met:
- Engine speed is above 1950 RPM
Fo
- Ground speed is above 16 km/hr (10 mph)

- Hydraulic transmission oil temperature is above 40 C
(104 F)
r
- Steering wheel is centered

in
te
R010611006
FIG. 39
rn
FIG. 40: Engine Speed (1), Ground Speed (2), Hydraulic

Oil Temperature (3).
al
u
1
2 3
se
on
R010611005
FIG. 40
ly
09-14 79033095 C Rev.

Systems Operation
SLIP CALIBRATION
Q030406001
FIG. 41
1
Fo
r in
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Q030406002
FIG. 42
al

1
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on
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Q030406003
FIG. 43
FIG. 44: Use scroll wheel to highlight slip calibration start
button (1). Press center of wheel to select.
Q030406004
FIG. 44
79033095 C Rev. 09-15

Systems Operation
FIG. 45: Slip Calibration Setup
- During calibration ensure that there is no slipping of 1
MTS belt.
2
- Set machine speed to a forward speed of 8 kph (5 mph).
- Press hard key next to check mark icon (1) to accept
setting and begin calibration.
- Drive machine at a constant ground speed for 4
seconds.
- If calibration needs to be aborted press hard key next to
X (2). R010611001
FIG. 45
FIG. 46: Slip Calibration in Progress.
When calibration has been started, following message 1
“Slip calibration in progress” appears on screen. After a 4
Fo
second pass, press hard key next to check mark (1).

r in
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R010611002
FIG. 46
rn
FIG. 47: Slip Calibration Successful.

al
When slip calibration has been completed following

message “Slip calibration successful” appears on screen.
u se
on
R010611003
FIG. 47
ly
09-16 79033095 C Rev.

Systems Operation
GROUND SPEED RADAR
Radar Unit
FIG. 48: Machine may be equipped with an optional
radar (1).
m
WARNING: Do not look directly into face of
the ground speed sensor while in
operation. Eye injury may occur from low
intensity microwave signal emitted.
P112006013
FIG. 48
Fo
Radar Connector
FIG. 49: Some implement electronic controls use signal
r
from radar. Implements requiring signal can use four-pin

connector (1).
in
m
WARNING: Improper wiring may damage
controller or other components in electrical
te
systems. See dealer for more information

and wiring pin-out.
rn
1
al
u
K908179
FIG. 49
se
FIG. 50: Connector is located beneath cover (1) behind

operator seat. This connection functions only if a radar
unit is installed.
on
1
ly
P100911002
FIG. 50
79033095 C Rev. 09-17

Systems Operation
Radar Calibration
Use an accurate measuring device, mark off a distance of
122 m (400 ft). This is the distance you will need to travel
to correctly calibrate the radar.
Q030406001
Fo
FIG. 51
1
r in
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rn
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Q030406002
FIG. 52
u

1
se
on
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Q030406003
FIG. 53
09-18 79033095 C Rev.

Systems Operation
FIG. 54: Use scroll wheel to highlight radar calibration
start button (1). Press center of wheel to select.
Q030406004
FIG. 54
FIG. 55: Once distance is marked and machine is at
start point, Press OK hard key (1) to start calibration.
Fo
1
r in
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Q030406005
FIG. 55
rn
FIG. 56: Follow on screen commands during calibration

process. At end point press OK hard key (1).
al
1
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Q030406006
FIG. 56
ly
FIG. 57: Machine radar is now calibrated.
Q030406007
FIG. 57
79033095 C Rev. 09-19

Systems Operation
Radar Specifications
Fo
r in
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R020805001
al
FIG. 58
FIG. 58: Ground Speed Sensor

u
Specifications:
se
Microwave Frequency:...........................................................................24.125 GHz with a range of 24.05 to 24.2 GHz

Scaling Factor: ..............................................................................................................................................58.9 Hz/mph
on
Wiring Table
PIN FUNCTION
ly
1 Signal
2 Ground
3 Battery (12V)
4 PRGM (Radar Present)
09-20 79033095 C Rev.

Virtual Terminal Disassembly and Assembly
VIRTUAL TERMINAL DISASSEMBLY AND ASSEMBLY
MACHINE ELECTRONIC CONTROL

MODULE (ECM) REMOVAL AND
INSTALLATION
Machine ECM Removal

FIG. 59: Turn off battery disconnect switch (1).
1
Fo
r
Q020512002
in
FIG. 59
FIG. 60: Remove floor mat (1).
te
1
rn
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u se
Q020412001
FIG. 60
on
FIG. 61: Remove bolts and floorplate (1).

1
ly
Q020412003
FIG. 61
79033095 C Rev. 09-21

FIG. 62: Disconnect harness assemblies (1). Remove
bolts (2) and machine ECM (3).
3 2
P111303003
FIG. 62
Machine ECM Installation

Fo
FIG. 63: Install machine ECM (1) and secure with four
bolts (2). Connect harness assemblies (3).
3
r in
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1 2
rn
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P111303003
FIG. 63
FIG. 64: Secure floorplate (1) with six screws.
u
1
se
on
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Q020412003
FIG. 64
09-22 79033095 C Rev.

FIG. 65: Install floor mat (1).
Q020412001
FIG. 65
FIG. 66: Turn on battery disconnect switch (1).
1
Fo
r in
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Q020512002
FIG. 66
rn
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on
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79033095 C Rev. 09-23

LIGHTING ELECTRONIC CONTROL
INSTALLATION
Lighting ECM (Located in Floor)

Lighting ECM Removal
1
Fo
Q020512002
r
FIG. 67
in
FIG. 68: Remove floor mat (1).

te
1
rn
al
u
Q020412001
se
FIG. 68
FIG. 69: Remove bolts and floorplate (1).
on
1
ly
Q020412004
FIG. 69
09-24 79033095 C Rev.

FIG. 70: Disconnect harness assemblies (1).
Q020412005
FIG. 70
FIG. 71: Remove bolts (1) holding lighting ECMs (2) and
remove ECMs.
2
Fo
1
r in
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Q020412006
FIG. 71
rn
Lighting ECM Installation

al
FIG. 72: Secure lighting ECMs (1) with bolts (2).
1
u se
2
on
ly
Q020412006
FIG. 72
FIG. 73: Connect harness assemblies (1).
Q020412005
FIG. 73
79033095 C Rev. 09-25

FIG. 74: Install floorplate (1) and secure with six bolts.
Q020412004
FIG. 74
FIG. 75: Install floor mat (1).
1
Fo
r in
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Q020412001
FIG. 75
rn

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1
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on
Q020512002
FIG. 76
ly
09-26 79033095 C Rev.

Lighting ECM (Located in Roof)
Lighting ECM Removal
Q020512002
FIG. 77
Fo
FIG. 78: Remove bolts (1) holding roof to cab and lift roof
up to allow access to lighting ECM.
1
r in
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rn
Q020412010
al
FIG. 78
FIG. 79: Disconnect harness (1) from ECM (2).
u
Remove four screws (3) holding lighting ECM to cab and 2

remove ECM.
se
3
1
on
ly
Q020412011
FIG. 79
79033095 C Rev. 09-27

Lighting ECM Installation
FIG. 80: Mount lighting ECM (1) to cab with four screws
(2). 1
Connect harness (3) to ECM.
2
3
Q020412011
FIG. 80
FIG. 81: Mount roof to cab and secure with bolts (1).
Fo
1
r in
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rn
Q020412010
FIG. 81
al
1
u se
on
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Q020512002
FIG. 82
09-28 79033095 C Rev.

ARMREST ELECTRONIC CONTROL
INSTALLATION
Armrest ECM Removal

1
Fo
Q020512002
FIG. 83
FIG. 84: Disconnect harness (1).
r
Support console and remove four bolts (2) holding

in
console to support.
2
te
1
rn
al
Q020412007
u
FIG. 84
se
FIG. 85: Remove five screws (1) holding lower console

panel to console and remove lower portion.
on
ly
1
Q020412008
FIG. 85
79033095 C Rev. 09-29

FIG. 86: Disconnect harness (1) from armrest ECM (2).
Remove two screws (3) holding ECM to bracket and
remove ECM. 2
Q020412009
FIG. 86
Armrest ECM Installation

FIG. 87: Mount armrest ECM (1) to bracket and with two
Fo
screws (2).
Connect harness (3) to armrest ECM. 1
r in
2
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3
rn
Q020412009
FIG. 87
al
FIG. 88: Attach lower console panel to console with five

screws (1).
u se
on
1
ly
Q020412008
FIG. 88
09-30 79033095 C Rev.

FIG. 89: Mount console to support with four bolts (1).
Connect harness (2).
1
Q020412007
FIG. 89
1
Fo
r in
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Q020512002
FIG. 90
rn
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79033095 C Rev. 09-31

GROUND SPEED SENSOR REMOVAL AND
INSTALLATION
Ground Speed Sensor Removal

FIG. 91: Remove bolts (3) from bracket (4).
Disconnect wiring harness (1) from back of radar sensor
(2).
Remove radar sensor (2) and bracket (4) from frame rails.
3 1
2
4
Fo
P111303001
FIG. 91
r
Ground Speed Sensor Installation

in
FIG. 92: Place radar sensor (2) and bracket (4) in frame
rails. 3
te
Connect wiring harness (1) to back of radar sensor (2).

1
Install four bolts (3).
rn
4
2
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P111303001
FIG. 92
on
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09-32 79033095 C Rev.

Index
INDEX
A G
Area ..................................................................... 09-7 Ground Speed Radar ......................................... 09-17

Area Rate ............................................................. 09-7 Ground Speed Sensor Installation ..................... 09-32
Armrest ECM Installation ................................... 09-30 Ground Speed Sensor Removal ........................ 09-32
Armrest ECM Removal ...................................... 09-29 Ground Speed Sensor
Armrest Electronic Control Module (ECM) Removal and Installation ............................. 09-32
Removal and Installation .............................. 09-29
Auto-Guide Navigation ......................................... 09-1
Auto-Guide Screen ............................................ 09-12 H
Average Fuel Field Screen .................................. 09-2
Hitch Screen .............................................. 09-2, 09-11
Hydraulic Control Valve ........................................ 09-1
B Hydraulic Screen .................................................. 09-4
Hydraulic Valve Number ....................................... 09-5
Fo
Battery Voltage .................................................... 09-3 Hydraulic Valve(s) Screen .................................... 09-2
I
r
C
in
Captive Hitch Position ........................................ 09-11 Implement Width .................................................. 09-9

Constant Ground Speed ............................. 09-5, 09-8 INST Area Rate .................................................... 09-6
Control Dial .......................................................... 09-2 INST Engine Percentage Load ............................. 09-6
te
Coolant Temperature ........................................... 09-3 INST Fuel Economy ............................................. 09-6

Current Gear ............................................... 09-4, 09-5 INST Fuel per Area .............................................. 09-6
rn
INST Fuel Rate ..................................................... 09-6

INST Power Specific Fuel Economy .................... 09-6
D Intake Manifold Pressure ...................................... 09-3
al
Intake Manifold Temperature ............................... 09-3

Daytime Backlighting ........................................... 09-9
Decelerator Set Speed ......................................... 09-8
u
Detent Time ......................................................... 09-5 L

Diagnostic Trouble Code (DTC) Screen ............ 09-10
se
Diagnostic Trouble Codes .................................... 09-2 Lighten Shutdown Timer ...................................... 09-9
Distance ............................................................... 09-7 Lighting ECM (Located in Floor) ......................... 09-24
Draft Control ....................................................... 09-11 Lighting ECM (Located in Roof) ......................... 09-27
Lighting ECM Installation ......................... 09-25, 09-28
on
Lighting ECM Removal ............................ 09-24, 09-27

E Lighting Electronic Control Module (ECM)
Removal and Installation ............................. 09-24
Electronic Control Modules .................................. 09-2 Load Rate ............................................................. 09-7
ly
Engine Idle Shutdown Timer ................................ 09-9 Lower Hitch Rate ................................................ 09-11
Engine Oil Pressure ............................................. 09-3
Engine Percentage Load ............................ 09-3, 09-7
Engine Screen ............................................ 09-2, 09-3 M
Extend Port .......................................................... 09-5
Machine ECM Installation ................................... 09-22
Machine ECM Removal ...................................... 09-21
F Machine Electronic Control Module (ECM)
Removal and Installation ............................. 09-21
Field Time ............................................................ 09-7 Machine Speed ........................................... 09-4, 09-5
Fuel Field Screen ................................................. 09-2 Maximum Extend Position .................................... 09-5
Fuel per Acre ....................................................... 09-7 Maximum Retract Position ................................... 09-5
Fuel Pressure ....................................................... 09-7 Measures - Field Screen ...................................... 09-6
Fuel Rate ............................................................. 09-7 Measures - INST Screen ...................................... 09-6
Fuel Temperature ................................................ 09-7
Night Time Backlighting ........................................ 09-9
79033095 C Rev. 09-33

Index
O
One Touch Headland Screen .............................. 09-2

One Touch Screen ............................................... 09-8
Power Management Screen ....................... 09-2, 09-7

Power Specific Fuel Economy ............................. 09-7
Priority .................................................................. 09-5
PTO ............................................................. 09-1, 09-5
PTO Speed .......................................................... 09-4
Radar Calibration ............................................... 09-18

Radar Connector ................................................ 09-17
Fo
Radar Specifications .......................................... 09-20

Radar Unit .......................................................... 09-17
Raise Hitch Rate ................................................ 09-11
r
Retract Port .......................................................... 09-5

in
S
te
Selected Gear ...................................................... 09-4

Sensors ................................................................ 09-2
rn
Set Speed A Switch ............................................. 09-5

Set Speed B Switch ............................................. 09-5
Settings Screen .................................................... 09-2
al
Slip Calibration ................................................... 09-15

Slip Sensitivity .................................................... 09-11
Steer Position ..................................................... 09-11
u
Steering Calibration ........................................... 09-13

Switch Status - Engine A ..................................... 09-8
se
Switch Status - Engine B ..................................... 09-8
T
on
Three-Point Hitch ................................................. 09-1

Three-Point Hitch Steering ................................... 09-1
ly
Tractor Settings Screen ....................................... 09-9

Transmission Oil Temperature ............................. 09-4
Transmission Screen .................................. 09-2, 09-3
Virtual Terminal .................................................... 09-1
09-34 79033095 C Rev.

Contents
Challenger ®
MT835C /MT845C / MT855C / MT865C / MT875C
SERVICE MANUAL
79033095 C Rev.
10 - Cab
Contents
Fo
CAB...........................................................................................................................................................................
Cab ................................................................................................................................................................ 10-1
r
Introduction .............................................................................................................................................. 10-1

Cab Removal and Installation ........................................................................................................................ 10-2
in
Cab Removal ........................................................................................................................................... 10-2

Cab Installation ........................................................................................................................................ 10-9
Cab Filtration ............................................................................................................................................... 10-15
te
General Information ............................................................................................................................... 10-15

Primary Fresh Air Filter ......................................................................................................................... 10-15
rn
Recirculation Filter ................................................................................................................................. 10-17

Operator Seat .............................................................................................................................................. 10-20
Standard Seat ....................................................................................................................................... 10-20
al
Deluxe Seat ........................................................................................................................................... 10-22

Separating Seat into Three Components .............................................................................................. 10-25
Disassembly of Seat Suspension .......................................................................................................... 10-25
u
Inspection of Seat Suspension .............................................................................................................. 10-27

Assembly of Seat Suspension ............................................................................................................... 10-28
se
Disassembly of Seat Adjustment Rails/Lateral Isolator ......................................................................... 10-29

Inspection of Seat Adjustment Rails/Lateral Isolator Components ....................................................... 10-29
Reassembly of Seat Adjustment Rails/Lateral Isolator ......................................................................... 10-29
Disassembly of Seat Back and Bottom Cushion ................................................................................... 10-29
on
Inspection of Seat Back and Bottom Cushion Components .................................................................. 10-30

Reassembly of Seat Back and Bottom Cushion .................................................................................... 10-30
Reassembly of Three Seat Components .............................................................................................. 10-30
ly
Installation ............................................................................................................................................. 10-31

Deluxe Seat ................................................................................................................................................. 10-32
Deluxe Adjustments .............................................................................................................................. 10-32
Floor Mat ...................................................................................................................................................... 10-33
Removal ................................................................................................................................................ 10-33
Inspection .............................................................................................................................................. 10-33
Installation ............................................................................................................................................. 10-34
Bottom Panel(s) ........................................................................................................................................... 10-35
Removal ................................................................................................................................................ 10-35
Inspection .............................................................................................................................................. 10-35
Installation ............................................................................................................................................. 10-35
Seat Belts and Instructor’s Seat .................................................................................................................. 10-36
Steering Pedestal ........................................................................................................................................ 10-37
Removal ................................................................................................................................................ 10-37
Installation ............................................................................................................................................. 10-40
Rear View Mirror .......................................................................................................................................... 10-42
Removal ................................................................................................................................................ 10-42
Inspection .............................................................................................................................................. 10-42
Installation ............................................................................................................................................. 10-42
79033095 C Rev. 10-i

Contents
Internal Trim/Shields .................................................................................................................................... 10-43
Removal and Installation of Cab Rear Shield ........................................................................................ 10-43
Removal and Installation of Fuse Panel Cowling .................................................................................. 10-43
Removal and Installation of Right Hand Rear Cab Post Cowling .......................................................... 10-43
Removal and Installation of Left Hand Rear Cab Post Cowling ............................................................ 10-44
Operator Console - Remove ........................................................................................................................ 10-45
Removal Procedure ............................................................................................................................... 10-45
Operator Console - Disassemble ................................................................................................................. 10-46
Disassembly Procedure ........................................................................................................................ 10-46
Operator Console - Assemble ..................................................................................................................... 10-49
Assembly Procedure ............................................................................................................................. 10-49
Operator Console - Install ............................................................................................................................ 10-51
Installation Procedure ............................................................................................................................ 10-51
Door ............................................................................................................................................................. 10-52
Removal ................................................................................................................................................ 10-52
Installation ............................................................................................................................................. 10-52
Door Handle ................................................................................................................................................. 10-54
Removal ................................................................................................................................................ 10-54
Installation ............................................................................................................................................. 10-55
Fo
INDEX ............................................................................................................................................................. 10-57

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10-ii 79033095 C Rev.

Cab
CAB
CAB
Introduction
FIG. 1: Cab has a Roll Over Protection Structure
(ROPS).
m
CAUTION: Roll Over Protection Structure
(ROPS) is manufactured to meet strict
safety standards. No attempt should be
made to alter ROPS in any manner (i.e.
welding, drilling, etc.)
If ROPS is damaged, changing its integral
structure, replace as a complete unit. Never
attempt to repair a damaged ROPS.
Fo
Cab has been designed for operator safety, comfort and

convenience. P090803001
r
Cab is control center of machine. Operator can easily FIG. 1

monitor and adjust machine functions using conveniently
in
located controls.
te
rn
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79033095 C Rev. 10-1

Cab
CAB REMOVAL AND INSTALLATION
Cab Removal
NOTE: Put identification marks on all hoses, hose
assemblies, wires and tube assemblies for
installation purposes. Plug all hose and tube
assemblies to help prevent fluid loss and
IMPORTANT: Ensure fluids are contained during
inspection, maintenance, testing, adjusting and
repair of machine. Be prepared to collect fluid
with suitable containers before opening any
containing fluids.
and mandates.
m
Fo

components to cool.
r
m
in

te

prevent injury.
rn

al
gauges indicate system is empty of

refrigerant.
u
removed. Slowly loosen fitting. If system is

still under pressure, release it slowly in a
se
well-ventilated area.
on

ly

may be present.
to properly remove refrigerant from air
conditioning system.
10-2 79033095 C Rev.

Cab
equipment can service air conditioning system.
IMPORTANT: Whenever air conditioning system is
opened, replace air conditioning accumulator.
IMPORTANT: Park machine on a hard, level surface.
1
Fo
P082103001
FIG. 2
r
Rotate and remove key to disconnect battery (1).

in
1
te
rn
al
P082103001
u
FIG. 3
se
FIG. 4: Disconnect window washer hoses (1) from pump

(2).
Remove P-clip (3) and cable straps (4). Fasten washer
on
hoses (1) out of the way.
4
ly
2 1
3
P091503001
FIG. 4
79033095 C Rev. 10-3

Cab
FIG. 5: Remove bolts (1) and plate (2) located at bottom
of machine behind front axle (3).
2 1
P102303001
FIG. 5
FIG. 6: Service brake control (1) is on right side, behind
front axle.
Fo
r in
te
1
rn
P102303002
FIG. 6
al
FIG. 7: Remove P-clip (1).

u se
1
on
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P102303003
FIG. 7
FIG. 8: Rotate spring retainer pin (1) and remove spring
retainer pin (1) from yoke (2).
Loosen nuts (3) and remove service brake cable.
3
P102303004
FIG. 8
10-4 79033095 C Rev.

Cab
FIG. 9: Remove park brake cable.
Park brake cable (1) is located on inside of left front frame,
behind hydraulic tank connected to park brake valve (2).
Disconnect park brake cable (1) and remove from bracket 1
(3) and fasten out of the way. 3
P093003001
FIG. 9
FIG. 10: Remove heater core hoses (2) located on right
rear side of cab. Loosen hose clamps (1) and remove
heater core hoses (2). Plug ends of hose to prevent fluid
Fo
from escaping and dirt entering system.

1
r in
2
te
rn
P093003002
FIG. 10
al
FIG. 11: Remove air conditioning lines

u

se
air conditioning lines (1).

on
1
ly
P093003003
FIG. 11
FIG. 12: Remove floormat (1).
P093003004
FIG. 12
79033095 C Rev. 10-5

Cab
FIG. 13: Remove floor sound insulation (1).
P093003005
FIG. 13
FIG. 14: Remove bolts (1) and access panels (2).
2
Fo
r
1
in
1
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2
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P093003006
FIG. 14
al
FIG. 15: Remove wire harness (1) power cable (2) and
fasten away from cab.
u
1
2
se
on
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P093003007
FIG. 15
FIG. 16: Remove wire harness (1) and fasten away from
cab.
1
P093003008
FIG. 16
10-6 79033095 C Rev.

Cab
FIG. 17: Install approved lifting device into lifting holes
91) on top of cab. Weight of cab is approximately 907 kg
(2000 lb).
1
1 1
1
P093003009
FIG. 17
FIG. 18: Remove rear cab mounting bolts (1).
Fo
r in
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1
rn
P093003010
FIG. 18
al
FIG. 19: Remove left front cab mounting bolt (1).

u se
on
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1
P093003011
FIG. 19
FIG. 20: Remove right front cab mounting bolt (1).
P093003012
FIG. 20
79033095 C Rev. 10-7

Cab
FIG. 21: Remove cab (1) with approved lifting device.
Weight of cab is approximately 907 kg (2000 lb).
P093003009
FIG. 21
Fo
r in
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u se
on
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10-8 79033095 C Rev.

Cab
Cab Installation
FIG. 22: Install cab mounting hardware. Ensure
mounting surface is clean and free of rust. Install four sets
of mounting pads (1).
P093003013
FIG. 22
FIG. 23: Install approved lifting device and install cab (2).
Fo
Weight of cab is approximately 907 kg (2000 lb).

r in
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2
rn
P093003014
al
FIG. 23
FIG. 24: Install hardware at four mounting locations.
u
Install mounting pads (1), sleeve (2), washer (3), washer

(4) and bolt (5).
se
1
2
3
on
4
ly
5
N041106004
FIG. 24
FIG. 25: Install right rear cab mounting hardware (1).
1
N041006001
FIG. 25
79033095 C Rev. 10-9

Cab
FIG. 26: Install left rear cab mounting hardware (1).
N041006002
FIG. 26
FIG. 27: Install left front cab mounting hardware (1).
Fo
1
r in
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P093003015
rn
FIG. 27
FIG. 28: Install right front cab mounting hardware (1).
al

u se
1
on
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P093003016
FIG. 28
FIG. 29: Install wire harness (1).
1
1
N033106010
FIG. 29
10-10 79033095 C Rev.

Cab
FIG. 30: Install wire harness (1), power cable (3) and
P-clip (2).
3 2
1
N033106009
FIG. 30
FIG. 31: Install access panels (2) and bolts (1).
Fo
2
r
1 1
in
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2
P093003006
rn
FIG. 31
FIG. 32: Install floor sound insulation (1).
al
u se
1
on
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P093003005
FIG. 32
FIG. 33: Install floormat (1).
P093003004
FIG. 33
79033095 C Rev. 10-11

Cab
FIG. 34: Install four hoses (1) on steering orbital (2).
Tighten to 40 Nm (29 lbf ft). 3
Install P-clips (3) onto power cable (4). Tighten bolts to 12 4
Nm (106 lbf in).
1
1
3 2
N041106001
FIG. 34
FIG. 35: Install air conditioning lines
Fo

and charge air conditioning system.
r
1
in
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N033106004
FIG. 35
rn
FIG. 36: Install air conditioning lines (2) with cable ties
(1) on bracket (3).
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1
1
1
u se
3
2
on
N033106005
FIG. 36
ly
FIG. 37: Install heater core hoses (2) tighten hose

clamps (1). Tighten hose clamps to 7.5 Nm (66 lbf in). 1
N033106001
FIG. 37
10-12 79033095 C Rev.

Cab
FIG. 38: Fasten heater core hoses (2) with cable ties (1)
on bracket (3). 1 3
1
N033106003
FIG. 38
FIG. 39: Install spring retainer pin (1) through yoke (2)
and lever (5). Rotate spring retainer pin (1) to lock into 5 2
place. Install service brake cable (4) and tighten nuts (3).
Fo
1
4
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3
in
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N041406002
FIG. 39
rn
FIG. 40: Install bolt, washers, nut and P-clip (1).

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u
1
se
on
N041406004
FIG. 40
ly
FIG. 41: Install belly pan (2) bolts and washers (1).
Weight of belly pan is approximately 17 kg (38 lb).
1 1
2 1
1
N041406003
FIG. 41
79033095 C Rev. 10-13

Cab
FIG. 42: Install on bracket (3) connect park brake cable
(1) on park brake valve (2).
3 1
N032906003
FIG. 42
FIG. 43: Install hose (1), P-clip (3) and cable straps (4).
Connect window washer hoses (1) to pumps (2).
2
Fo
3 4
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N031906005
FIG. 43
rn
FIG. 44: Insert key (1) rotate to connect battery at

battery disconnect switch.
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1
on
P082103001
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FIG. 44
10-14 79033095 C Rev.

Cab
CAB FILTRATION
General Information
m
CAUTION: Chemical residue may be
present in dirt on filter elements. Wear
protective gear while servicing filter
elements.
Cab is pressurized. Primary and recirculation filters purify

cab’s internal air.
NOTE: Key must be in OFF position before servicing cab
filters.
Primary Fresh Air Filter

FIG. 45: Primary fresh air filter (1) is located in roof
overhang on door side of cab.
Fo
Filter removes dust particles drawn into air system and is

partially cleaned each time cab door is closed, when back
pressure flushes primary air filter. Before removing filter,
r
close all windows and door. Back pressure from cab helps
dislodge loose dirt on underside of filter.
in
1
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rn
P102703001
FIG. 45
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Removal
FIG. 46: Loosen thumb screw (1) on left side of panel.
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on
1
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P102703002
FIG. 46
79033095 C Rev. 10-15

Cab
FIG. 47: Lower panel (3) to remove primary air filter (4).
3
N050103010
FIG. 47
Filter Maintenance
Inspect filter every 250 hours of operation. Replace cab
Fo
filters every 1500 hours or once a year, whichever comes

first.
IMPORTANT: Periodic sweeping and/or vacuuming of
r
cab interior is recommended. Headliners and

cowlings should be wiped clean or vacuumed
in
periodically. The machine’s exterior should be

washed to reduce potential contact with
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hazardous material. Disposal of wash water,

cloths and vacuumed material should be handled
according to published regulations and pesticide
rn
label instructions.
IMPORTANT: Become familiar with Chemical Safety
al
prior to machine operation.
Cleaning
u
To rid filter of dust, hold filter and tap on flat surface with
se
dirty side down.

NOTE: Tapping too hard can cause damage.
Compressed air can also be used, blow air through
on
element in direction opposite of normal airflow.

IMPORTANT: Keep nozzle a minimum of 25.4 mm (1 in.)
from surface. Excessive air pressure causes
ly
damage.
m
WARNING: To avoid personal injury, always
wear eye and face protection when using
pressurized air.
10-16 79033095 C Rev.

Cab
Installation
FIG. 48: Slide new primary air filter (1) into place.
IMPORTANT: Ensure airflow arrows on filter are pointing
up for proper operation.
Lift panel (2) into place and tighten thumb screw to
replace.
NOTE: Seals must come in contact with surface to 1
eliminate air bypass.
2
N050103010
FIG. 48
Recirculation Filter
Fo
Recirculation filter purifies air for HVAC pressurization fan

and draws air from inside cab. Premature pressurization
r
and fan motor failure occurs if filter is not in place.

Recirculation filter is only filter for pressurization fan.
in
m
WARNING: Charcoal filter is used to lower
levels of contamination in cab during
te
spraying operations. It does not replace or

eliminate need for personal protective
devices. Follow all recommendations of
rn
chemical manufacturer regarding personal

protection, handling and disposal of
al
chemicals.
NOTE: Optional charcoal filters are available from local

dealer.
u
NOTE: Any chemical contaminants allowed into cab

se
while door is open are not filtered.

Filter life is affected by environmental conditions and
should be replaced when odor, taste or other symptom of
on
contamination is detected.
m
WARNING: Inadequate sealing may cause
filter malfunction. Personal injury could
ly
result. Isoamyl acetate, which has a

banana-like odor, may be used to check
seal. Periodically inspect door gasket for
damage.
IMPORTANT: Once filter is removed from its protective

packaging, immediate installation must follow.
Exposure to environment reduces validity of filter.
NOTE: Store replacement filters in original packaging in
a clean dry area away from exposure to any
chemicals. If stored in cab, floor areas should be
kept clean of any foreign material.
NOTE: The vapor absorption (carbon) section of these
filters cannot be cleaned. Replace filter if odor,
taste or other indication of contamination is
detected.
79033095 C Rev. 10-17

Cab
Removal
FIG. 49: Loosen thumb screw (1) to remove filter cover
(2).
P102703003
FIG. 49
FIG. 50: Remove filter element (1) positioned behind
Fo
filter cover.
r
1
in
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P102703004
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FIG. 50
Filter Maintenance
u
Inspect filter every 250 hours of operation. Replace cab

se
filters every 1500 hours or once a year, whichever comes

first.
IMPORTANT: Periodic sweeping and/or vacuuming of
cab interior is recommended. Headliners and
on
cowlings should be wiped clean or vacuumed

periodically. Machine’s exterior should be
washed to reduce potential contact with
ly
hazardous material. Disposal of wash water,

cloths and vacuumed material should be handled
according to published regulations and pesticide
label instructions.
IMPORTANT: Become familiar with chemical safety
before operating machine.
10-18 79033095 C Rev.

Cab
Installation
FIG. 51: Position filter element (1) into place. Ensure air
flow arrows are pointing back to ensure proper operation.
P102703004
FIG. 51
FIG. 52: Tighten thumb screw (1) so cover (2) is securely
Fo
positioned over filter.

2
r
1
in
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P102703003
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FIG. 52
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on
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79033095 C Rev. 10-19

Cab
OPERATOR SEAT
Standard Seat
Standard Seat Adjustments
FIG. 53: Lumbar Support Adjustment (1) - turn knob
clockwise to increase or counterclockwise to decrease
support.
1
Fo
P102703005
FIG. 53
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FIG. 54: Additional Adjustments

in
To adjust armrest height (1) rotate knurled wheel on

armrest to desired angle.
2
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To adjust height (2) press and hold top of switch to raise

seat, release switch at desired height. Press and hold
bottom of switch to lower seat, release switch at desired
rn
height. 8 7 1
Lift seat backrest angle adjustment (3) to tilt backrest to
al
desired position. Release control to lock backrest in 5

position. 4
3
Pull fore/aft seat movement isolator (4) to activate fore/aft 6
u
P102703006
seat movement isolator. Push down handle while moving
se
seat in fore/aft directions. Handle drops in place. Seat is FIG. 54

now in fixed position. Seat can be held in one of two
positions. Seat may be held in a stationary position. Seat
also isolates 51 mm (2.2 in) in fore/aft position.
on
Pull up on lateral adjustment (5) to allow movement of

seat from side to side. Push down handle to isolate seat in
a fixed position.
ly
Dampening adjustment changes stiffness of ride. Lift

dampening adjustment (6) up to decrease or push
forward to increase amount of stiffness.
Pull up on fore/aft adjustment (7) to slide seat forward or
backward, release to lock seat in place.
Swivel lever (8) allows seat to swivel. Seat locks in two
positions left of center. Seat swivels a total of 10 degrees
to the left.
Seat locks in one of five positions to right of center in five
degree increments. Seat swivels a total of 25 degrees to
right.
Seat is also allowed to swivel without locking in any
position.
Lift handle partially upward, swivel seat to desired
position, push handle (8) down to lock in position.
Lift handle (8) fully upward to allow seat to swivel freely.
10-20 79033095 C Rev.

Cab
Seat Removal
m
CAUTION: Turn off engine and remove key
from ignition.
FIG. 55: Remove two bolts (1) holding shift console to

right side of seat. Lower shift console to floor.
P102703007
Fo
FIG. 55
FIG. 56: Loosen and remove two bolts (1) on right side
of base plate.
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1
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P102703008
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FIG. 56
se
FIG. 57: Loosen and remove two bolts (1) on left side of
base plate.
on
1
ly
P102703009
FIG. 57
79033095 C Rev. 10-21

Cab
FIG. 58: Using backrest recline adjustment lever (1) fold
back of seat forward.
m
CAUTION: Seat is extremely heavy.
Lift seat assembly and remove from cab. Cushions,

1
suspension and base plate are removed as a unit.
P102703010
FIG. 58
Disassembly
Seat is made up of three components:
Fo
Seat back and cushion

Seat adjustment rails (includes lateral isolator assembly)
r
Seat suspension
in
Disassembly, inspection and reassembly of complete seat

consists of first disassembling seat into three
te
components, then inspecting and reassembling each.

Three components will then be reassembled to each
other.
rn
Deluxe Seat
al
Deluxe Seat Adjustments

FIG. 59: Lumbar Support Adjustment (1) - Turn knob
u

support. 1
se
Seat Backrest Angle Adjustment (2) - Lift control to tilt

backrest to desired position. Release control (2) to lock
backrest in position.
on
2
ly
P102703011
FIG. 59
10-22 79033095 C Rev.

Cab
To adjust height press and hold top of switch (1) to raise 1
or bottom of switch (1) to lower seat, release switch at
desired height.
Press top of heated seat and backrest button (2) to turn 5 2
6 3 4
on or bottom to turn off heated seat and backrest.
To adjust armrest height rotate knurled wheel (3) on
armrest to desired angle.
Press top of dampening adjustment button (4) for a softer 7
or bottom of button for a firmer ride. 8
Swivel lever (5) allows seat to swivel. Seat locks in two P102703012
to the left. FIG. 60
Pull up on fore/aft adjustment (6) to slide seat forward or
Fo
backward, release to lock seat in place.

Dampening adjustment changes stiffness of ride. Lift
dampening adjustment up to decrease or push forward to
r
increase amount of stiffness.

in
Pull up on lateral adjustment (7) to allow movement of

seat from side to side. Push down handle to isolate seat in
a fixed position.
te
Seat is also allowed to swivel without locking in any

position.
rn
Pull fore/aft seat movement isolator (8) to activate fore/aft

seat movement isolator. Push down handle while moving
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seat in fore/aft directions. Handle drops in place. Seat is

now in fixed position. Seat can be held in one of two
positions. Seat may be held in a stationary position. Seat
u
also isolates 51 mm (2.2 in) in fore/aft position.

se

right.
on
Seat Removal
m
CAUTION: Turn off engine and remove key
from ignition.
ly
FIG. 61: Remove two bolts (1) holding shift console to

right side of seat. Lower shift console to floor.
1
P102703008
FIG. 61
79033095 C Rev. 10-23

Cab
FIG. 62: Loosen and remove two bolts (1) on right side
of base plate.
1
P102803011
FIG. 62
FIG. 63: Loosen and remove two bolts (1) on left side of
base plate.
Fo
1
r in
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P102703009
FIG. 63
al
FIG. 64: Using backrest recline adjustment lever (1) fold

back of seat forward.
m
u
CAUTION: Seat is extremely heavy.

se
1
Lift seat assembly and remove from cab. Cushions,
suspension and base plate are removed as a unit.
on
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P102703013
FIG. 64
Disassembly
Seat is made up of three components:
Seat back and cushion
Seat adjustment rails (includes lateral isolator assembly)
Seat suspension
Disassembly, inspection and reassembly of complete seat
consists of first disassembling seat into three
components, then inspecting and reassembling each.
Three components are then reassembled to each other.
10-24 79033095 C Rev.

Cab
Separating Seat into Three Components
FIG. 65: Remove bottom seat cushion (2) from seat (1)
by lifting from base.
P102703014
FIG. 65
FIG. 66: Loosen and remove four allen screws (1)
Fo
holding “L” brackets. Seat back remain connected to

suspension by wire harness and will be disconnected
later.
r
Slide seat assembly forward.

1 1
in
Remove three small plastic nuts (1) on rear of seat

retaining suspension bellows (2) in place on suspension
frame. Pull bellows up to expose seat wire harness
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connector.
rn
N051103005
FIG. 66
al
FIG. 67: Cut small plastic tie strap holding seat harness
in place and unplug seat compressor connector from
u
main harness. Cut second plastic tie retaining harness to

upper portion of suspension and remove seat cushion 1
se
and back from seat suspension.

Remove four nuts and bolts from seat adjustment rails.
Lift adjustment rails and lateral isolator from seat
on
suspension. 2
ly
P102803010
FIG. 67
Disassembly of Seat Suspension
m
CAUTION: All air must be released from air
bag before work begins on suspension.
Serious injury can result if air pressure is
not released.
Carefully pull bellows over small plastic retaining clips at

top and bottom of suspension.
NOTE: Be careful not to tear holes in rubber bellows.
79033095 C Rev. 10-25

Cab
Remove bolts from suspension frame.
NOTE: It is not necessary to remove clips from
suspension unless damaged and replacement is
required.
Place a wooden block approximately 165 mm (6-1/2
inches) long at rear of seat between upper and lower
suspension plates to support suspension while air bag is
removed.
FIG. 68: Remove compressor supply tube (1) from fitting
at top of air bag.
1
Fo
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N051103007
FIG. 68
in
FIG. 69: Remove bolt from top of air bag retaining plate
(1). Fitting can stay in place on air bag.
te
rn
1
al
u se
N051103008
FIG. 69
FIG. 70: Flip suspension over, leaving wood block in
on
place and remove phillips head screw (1) from bottom of

air bag and suspension lower plate. 1
Air bag is now free from suspension and can be removed
ly
through front of suspension.
P102703015
FIG. 70
10-26 79033095 C Rev.

Cab
FIG. 71: Remove nut (1) from long retaining pin (2)
spanning rear of lower suspension plate.
Separate scissors suspension linkage from lower
suspension plate by twisting to left or right enough to
allow one front bottom rollers to come out from under 1
bottom plate guide track. Lift scissors suspension from 2
bottom plate.
N051103010
FIG. 71
FIG. 72: Cut two plastic tie straps retaining compressor
wire harness to scissors suspension. Remove two small
screws (1) holding compressor in place and remove
compressor from suspension.
Fo
1
r in
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N051103011
FIG. 72
rn
FIG. 73: Remove C-clip (1) from rod end of dampening

shock absorber. Remove nylon roller off base end of
al
shock absorber pivot and slide shock absorber off

suspension. Remove nylon bearings from shock absorber
pivots. White bearing is on rod end and black bearing on
u
base end. 1
se
Remove two nuts holding base end, bracket end or

fore/aft isolator shock absorber to top plate.
Remove two screws holding fore/aft isolator lock lever to
top plate.
on
Flip suspension so top plate is down. Remove scissors N051503001

suspension from top plate by disengaging front rollers
from guide track. Roll rear rollers from guide track and lift FIG. 73
ly
scissors from top plate.

Remove fore/aft isolator shock absorber, fore/aft isolation
locking handle and remaining bushings and rollers from
scissors suspension by sliding off respective pivot points.
Inspection of Seat Suspension

Check rubber bumpers on top plate for wear, do not
remove unless significant wear is apparent. Bumpers can
be taken off top plate by removing center screw.
Use an ohm meter to check release solenoid coil for an
open circuit and total coil resistance.
79033095 C Rev. 10-27

Cab
Place ohm meter leads across two white wires in Inspect dampening shock absorber for wear or damage. If
compressor harness. Meter should show continuity with a adjustment knob requires replacement, drive roll pin out
total resistance reading of approximately 31 ohms. If an of knob and replace.
open circuit or a circuit with high resistance is found,
Inspect all bushings and rollers on suspension and
entire compressor must be replaced as solenoid coil is
replace any worn or damaged.
not sold separately from compressor.
Inspect scissors assembly for cracked welds or broken
To remove and inspect release solenoid valve, unscrew
components. Replace if necessary.
small nut and lift solenoid coil off valve stem.
Unscrew release valve from compressor body. Assembly of Seat Suspension
Release valve can be disassembled and cleaned by Place a small amount of grease on OD and IO of tube
unscrewing stem from valve body. Valve consists of bushings. Install two bushings into bottom rear tube of
O-ring, seat, spring, solenoid stem and valve body. Clean scissors suspension.
any contamination from valve. Make sure holes in valve
body are clear of debris. If valve is found to be faulty, Place a small amount of grease on pivots for dampening
replace complete compressor. shock absorber. Install nylon bearings on dampening
shock absorber pivots. White bearing is on rod end and
Reassemble release valve and screw into compressor black is on base end. Slide dampening shock absorber on
body. Use pipe thread sealant on valve threads. Outlet
Fo
scissors suspension pivots and retain rod end on pivot

hold of valve can point in any direction when tightened with spring nut.
into body.
Lubricate ID of black rollers. Install rollers on front pivots
Reassemble solenoid coil to release valve using
r
of scissors suspension.
hardware removed.
Place a small amount of grease on guide tracks of lower
in
NOTE: There is a stepped washer and rubber seal under plate. Install scissors suspension into lower plate of seat
solenoid. Step of washer fits into solenoid body. by twisting scissors suspension right or left and sliding
te
Use an ohm meter to check compressor motor for an scissors into plate rails.
open circuit and total coil resistance. Place ohm meter Line up holes in lower plate with tube at rear of scissors
rn
leads across orange and black wires in compressor suspension. Install long pivot pin into rear tube of
harness. Meter should show continuity with a total suspension, install nut on pin and tighten securely.
resistance reading of approximately 0.05 ohms. If an
al
open circuit or a circuit with high resistance is found, NOTE: Bolt has a locating point to keep it from turning
entire compressor must be replaced as motor is not sold during assembly. Line up raised point with notch
separately from compressor. in lower plate.
u
Check small fiber filter on top of compressor for Place a small amount of grease on OD and ID of bearing
contamination and clean as necessary. To clean filter for fore/aft isolate locking handle assembly. Slide bearing
se
remove small retainer. end of handle onto rear left pivot of scissors suspension.
Check air bag supply tube and make sure ferrules and Lubricate ID and OD of spacer and bearing for fore/aft
tubing are not damaged, replace if necessary. Connect air isolator shock absorber with grease. Install spacer over
on
bag to supply tube. Activate compressor motor by bearing for shock absorber. Install bearing and spacer on
applying 12 volts to orange wire in compressor harness right rear pivot of scissors suspension. Install base end of
connector. Attach black wire to ground. Compressor shock absorber onto bearing. Make sure bracket for rod
activates and inflates air bag. Place bag in a container of end of shock absorber is facing up.
ly
water and check for air leaks. Lubricate ID and OD of rollers for upper pivots of scissors
m
CAUTION: Do not overinflate air bag using suspension with grease. Install rollers on upper pivots of
compressor. Inflate only enough to check scissors suspension. Install a wood block between front
for leaks. bars of scissors suspension to hold it up during assembly.
Install compressor assembly on scissors suspension by
Check fore/aft isolator locking handle for broken springs attaching plastic mount to mounting tab using two small
or damaged parts. Handle is available only as a complete screws. Compressor sits on top of tab and bolts come into
assembly and must be replaced if damage is found to any plastic mount from bottom. Route compressor wire
components. harness under air bag upper mounting plate. Use two
Remove nut from rod end of fore/aft isolator. Remove plastic tie straps to hold compressor harness to
washers, rubber bushings and bracket. Inspect all suspension.
components for wear and replace as necessary. Insert air bag into place in suspension. Install top air bag
Reassemble washers, bushings and brackets to rod end mounting bolt. Attach supply tube to top fitting on air bag.
of shock absorber and tighten nut securely. Make sure supply tube fittings at compressor and air bag
NOTE: “L” portion of bracket contains two square holes are tight.
and faces away from shock absorber body. Flip assembly over so bottom plate is facing up. Install air
bag bottom mounting screw into bottom of air bag.
10-28 79033095 C Rev.

Cab
Flip assembly back over so four rollers are facing up. Inspect fore/aft adjustment lever and rails for wear.
Lubricate guide tracks of upper plate with grease. Install Locking pawl must not be worn so as not to engage rail
plate on scissors assembly. Ensure four top rollers enter bolts securely. Replace rails or lever if necessary.
guide tracts properly.
NOTE: Rails are sold as a complete assembly only. No
Install two screws holding fore/aft isolator locking lever to individual rail components are sold separately.
top plate.
Install two nuts holding base end, bracket end, of fore/aft Reassembly of Seat Adjustment
isolator shock absorber to top plate. Rails/Lateral Isolator
Remove wood block from suspension and allow it to Reinstall adjustment rails on lever by lining up notch on
collapse on air bag. handle and sliding rail onto handle.
Reinstall bellows around suspension by hooking it to NOTE: Fore/aft adjustment lever has an offset to right
small retaining clips. Leave three small nuts off rear of hand side of seat when rails are properly
bellows for access to wiring harness during reassembly of installed. Rails are under handle when
three seat components. assembled correctly.
Reinstall fore/aft slide rail and handle assembly on lateral
Disassembly of Seat Adjustment isolator using four mounting bolts and spacers.
Fo
Rails/Lateral Isolator
Reassemble pivot handle to top pivot plate using bolt and
Remove four bolts attaching pivoting seat base to seat nut. Make sure plastic washer is in proper position
adjustment rails/lateral isolator portion of seat. between handle and plate. Install pivot handle spring in
r
position on top plate and cotter pin.

Remove four shoulder bolts retaining top plate of pivoting
in
seat base to bottom plate. Separate halves of pivot base. Reassemble top and bottom pivoting base plates by
installing top plate on nylon ring and pivot balls. Lay top
Remove spring from swivel lever lock rod on top pivot nylon wear plate over top plate and install four shoulder
te
base plate. Remove pivot handle bolt and remove handle

bolts.
from top plate.
NOTE: Apply a small amount of grease on nylon wear
rn
Move inner portion of fore/aft slide rails out of way by plates and adjoining surfaces of top and bottom
lifting on adjustment handle and sliding assembly,
plates to lubricate pivot assembly.
exposing four bolts, front and rear of rails, attaching slide
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rails to lateral isolate. Remove four bolts and spacers Tighten four shoulder bolts and nuts enough to take any
attaching slide rail assembly to lateral isolator. side to side wobble out of top and bottom plates.
To remove rail from adjustment handle, twist rail so IMPORTANT: Do not over tighten nuts to bind up pivoting
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locating notch on slide rail lines up with raised locator on portion of assembly. Do not leave nuts loose to
cause plates to have excessive wobble.
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adjustment lever rod. Remove rail from handle. Repeat for

rail on other side of lever.
Reinstall pivot base on seat adjusting rails/lateral isolator
assembly using four attaching bolts.
Inspection of Seat Adjustment
on
Rails/Lateral Isolator Components Disassembly of Seat Back and Bottom

On bottom half of pivoting seat base, inspect nylon wear Cushion
surfaces and steel balls that base pivots on. Replace if
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worn or damaged. Remove seat wire harness from seat back cushion by
unsnapping wire ties at rear of seat.
Inspect seat swivel lever and components on top half of
Remove two screws retaining seat switch in right hand
pivoting seat base. Replace any worn components.
armrest.
Check swivel lever locking rod mounted in top half of pivot
base. Rod should not be worn or bound in stanchion Pull switch out of armrest far enough to expose seat
switch harness connector. Disconnect harness and
brackets. Be sure cotter pin is in good condition.
remove switch from seat.
Inspect lateral isolator assembly for worn or damaged
parts. lateral isolator is available as a complete assembly Unlock small wire tie retaining wire harness in right hand
armrest and pull harness from seat.
only and does not have individually serviceable parts. If
worn or damaged parts are found, replace entire lateral Lift up small access cover from right hand side of seat to
isolator assembly. expose bolt attaching male half of seat belt to seat
bottom. Remove bolt from seat. It is not necessary to hold
NOTE: Disassembly of lateral isolator is not necessary
as it is serviced as a complete assembly only. weld nut on inside of seat with a wrench.
Loosen allen head bolt attaching right hand armrest to
pivot shaft. Slide armrest off shaft.
79033095 C Rev. 10-29

Cab
Remove three bolts attaching left armrest to seat bottom. Reassembly of Seat Back and Bottom
Remove armrest from seat bottom. Bolts have weld nuts Cushion
on inside of seat that do not need to be held with a
wrench. Install right hand side seat pivot into seat bottom joint.
There are two small spacers for two bolts attaching left Line up left hand seat back bracket with seat bottom
hand armrest to seat bottom. Remove these spacers bracket and install two mounting bolts, washers and nuts
from seat bottom. and tighten securely.
Remove bolt attaching female portion of seat belt to left Ensure seat back cover material is in position around left
hand armrest. hand bracket. Install plastic seat back cover into place
Remove three plastic retainers holding bottom left hand and press three plastic retainers into seat back.
side of plastic seat back in place. Reinstall female portion of seat belt to left hand arm rest
using single retaining bolt and nut. Tighten bolt to 41 Nm
Remove three plastic retainers holding bottom left hand
side of plastic seat back in place. Retainers can be (30 ft-lb).
removed by prying up on seat back with a flat putty knife. Install two spacers into side of seat bottom left hand
corner.
Pull seat back over material away from attaching bracket
to expose two mounting bolts on bracket. Remove two Attach left hand armrest to seat bottom using three
Fo
bolts from bracket. Bolts have a flat washer and nut on capscrews (washer under bottom bolt). Tighten
inside of frame. capscrews to 27 Nm (20 lbf ft).
NOTE: It may be necessary to cut some small retaining Install male portion of seat belt on seat bottom using bolt
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rings attaching fabric cover of seat to frame. and washer. Tighten bolt to 41 Nm (30 lbf ft). Snap plastic
These rings are used during manufacturing and cover over top of bolt.
in
do not require replacement during reassembly.

Slide right hand armrest to seat back pivot. Tighten allen
On right hand side of seat back, pull foam and seat cover head screw to retain armrest on pivot.
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material away from right hand seat back pivot. Lift seat
back from seat bottom and separate seat components. Route wire harness into right hand armrest and connect
seat switch to harness.
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Inspection of Seat Back and Bottom Install plastic tie strap to retain harness to right hand
Cushion Components armrest.
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Inspect seat belt male and female halves for wear or Install two screws retaining switch in right hand armrest.
damage. Make sure belt meet and latch properly. Reinstall plastic tie straps on harness on rear of seat
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Check belt webbing for damage or wear and replace if back.

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necessary.
Reassembly of Three Seat Components
Test seat switch using an ohm meter on individual pins in
wire harness connector. The following wires should have Place adjustment rails/lateral isolator on seat scissors
continuity between them based on switch position. suspension.
on
Install four nuts and capscrews attaching seat adjustment

Switch Position Wires with Continuity rails/lateral isolator to top plate of scissors suspension.
Tighten capscrews to 27 Nm (20 lbf ft).
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Off None
Install seat switch on adjustment rails/lateral isolator using
Raise Black - Yellow two nuts.
Lower Gray - Yellow Place seat back and bottom cushion on adjustment
rails/lateral isolator and install four capscrews and tighten
Inspect seat wire harness for damaged pin connectors or securely.
wiring. Replace as necessary. Use an ohm meter to
check harness continuity using diagram shown. Route seat wire harness down to back of scissors
suspension. Place suspension bellows and plug into
Check seat back and bottom cushion for wear or damage. compressor wire harness. Install a plastic tie strap around
Replace components as necessary. harness to hold in place on scissors suspension.
Inspect armrests for wear or damage to outer covering. Pull bellows into position around back of suspension.
Ensure height adjustments function properly. Replace Install three plastic nuts on plastic retainers at
components as necessary. suspension.
NOTE: Height adjustment controls are not sold
separately from armrests. Complete armrest
must be replaced if height adjustment is found to
be faulty.
10-30 79033095 C Rev.

Cab
Installation
Using an appropriate lifting device, raise seat up into cab
and position on mounting plate.
m
CAUTION: Seat is extremely heavy, use an
appropriate lifting device.
Reconnect seat wiring harness at rear of seat.

Install four bolts and nuts securing seat to mounting plate
and tighten bolts to 54 Nm (40 lbf ft).
Fo
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79033095 C Rev. 10-31

Cab
DELUXE SEAT
Deluxe Adjustments
FIG. 74: Lumbar Support Adjustment (1) - Turn knob
support.
1
P102703016
Fo
FIG. 74
9
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To adjust Armrest Height Adjustment (1) rotate knurled

wheel on armrest to attain desired angle.
2
in
To adjust Height Adjustment (2) press and hold top of

switch to raise seat. Release switch at desired height.
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Press and hold bottom of switch to lower seat. Release

switch at desired height.
7
8 1
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Lift Seat Backrest Angle Adjustment (3) to tilt backrest to

desired position. Release control to lock backrest in 5
position. 6 3
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Pull Fore/Aft Seat Movement Isolator (4) to activate 4

fore/aft seat movement isolator. Push down handle while P102703017
moving seat in fore/aft directions. Handle drops in place.

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FIG. 75
Seat is now in fixed position. Seat can be held in one of
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two positions. Seat may be held in a stationary position or

can isolate 51 mm (2.2 in.) in fore/aft position.
Pull up on Lateral Adjustment (5) to allow movement of
seat from side to side. Push down on handle to isolate
on
seat in a fixed position.

Dampening Adjustment changes stiffness of ride. Lift
dampening adjustment (6) up to decrease or forward to
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increase amount of stiffness.

Pull up on Fore/Aft Adjustment (7) to slide seat forward or
backward. Release handle to lock seat in place.
Swivel lever (8) allows seat to swivel. Seat locks in two
to the left.
right. Seat is also allowed to swivel without locking in any
position.
Lift handle partially up, swivel seat to desired position,
push down handle (8) to lock seat in position.
Heated Seat and Backrest switch (9) activates heated
seat and backrest. Push upper portion of switch to turn on
or lower portion to turn off.
10-32 79033095 C Rev.

Cab
FLOOR MAT
Removal
Park machine on a level surface, set park brake.
FIG. 76: Carefully remove floormat (1).
1
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P093003004
FIG. 76
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FIG. 77: Carefully remove floor sound insulation (1).

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P093003005
FIG. 77
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Inspection
Mat is made of dense molded rubber providing a wear
on
surface for cab floor and acts as an acoustic buffer to

reduce cab noise.
Mat can be washed with a mild detergent and water.
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NOTE: Do not use petroleum-based solvent as it

deteriorates rubber.
Inspect mat for damage and replace as necessary.
79033095 C Rev. 10-33

Cab
Installation
FIG. 78: Lift sound barrier (1) into cab. For best results,
start with right front corner of mat and position in place.
Work mat into position around entire base of steering
pedestal.
1
P093003005
FIG. 78
FIG. 79: Lift floor mat (1) into cab in same manner as
Fo
sound barrier.
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1
P093003004
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FIG. 79
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10-34 79033095 C Rev.

Cab
BOTTOM PANEL(S)
Removal
Park machine on a level surface and set park brake.
Remove floor mat.
Remove sound barrier.
FIG. 80: There are 6 bolts (1) securing left and right and
9 bolts securing center floor panel to bottom of cab.
Remove necessary panels from cab.
NOTE: Floor panels are heavy, use an appropriate lifting
device to remove from cab.
Inspection
Check foam insulation strips on perimeter of cab bottom
Fo
for damage. Replace if necessary.

1
Check condition of speed nuts (attached to cab floor)
retaining panel screws. Replace as necessary.
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N033106008
FIG. 80
in
Installation
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Using an appropriate lifting device, place floor panel(s)

into cab and position over speed nuts in cab floor.
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NOTE: Floor panels are heavy, use an appropriate lifting

device to install in cab.
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FIG. 81: Use anti-seize lubricant on capscrews (1) used

to retain floor panel. Tighten capscrews securely.
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Reinstall cab sound barrier.

Reinstall seat into cab.
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CAUTION: Seat is heavy, use an
appropriate lifting device to install in cab.
on
1
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N033106008
FIG. 81
79033095 C Rev. 10-35

Cab
SEAT BELTS AND INSTRUCTOR’S SEAT
FIG. 82: Seat belts are equipped with an automatic
retractor lock, activated if belt is pulled or jerked.
Fasten seat belt catch (1) into buckle (2). Place belt low
across lap of operator.
1
Seat belts should be worn at all times during machine
operation. 3
1
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WARNING: When using retractable seat 2
belts, do not use seat belt extensions or
personal injury or death can result.
Retractor system may or may not lock up
depending on size of operator and length of
extension. If retractor does not lock up, seat 2
P102703018
belt will not retain operator.
FIG. 82
Instructor’s seat (3) is provided for training and technician
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diagnostic purposes only.
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WARNING: Instructor’s seat is provided
only for training operators or diagnosing
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machine problems. Keep all riders off

machine and equipment.
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10-36 79033095 C Rev.

Cab
STEERING PEDESTAL
Removal
Park machine on a level surface and set park brake.
Remove seat from cab.
Disconnect battery cables from batteries.
Remove temperature sender from engine block by
unscrewing it from adapter on side of engine. A small
amount of engine coolant will be lost during sending unit
removal. Plug adapter in engine block.
Cut all plastic tie straps retaining sending unit capillary
tube to engine components. Carefully pull capillary tube
toward cab and allow it to lay under cab floor.
NOTE: Temperature sender location on engine block
varies based on engine model.
Fo
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CAUTION: Engine coolant must be at
ambient temperature before temperature
sending unit is removed from side of
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engine. Heated engine coolant can cause

severe injury if it contacts skin.
in
FIG. 83: Remove right and left hand cowlings from sides
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of steering pedestal by removing four bolts (1) at base of

each cowling.
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NOTE: Floor mat must be peeled back to access bolts. 2

Remove two screws (2) securing steering shaft cowling to
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steering pedestal. Remove cowling from pedestal.
1
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P102803009
FIG. 83
on
FIG. 84: Turn two screws (1), retaining instrument panel

in dash, a 1/4 turn.
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Pull instrument panel forward enough to access wire

harness. 1
NOTE: Instrument panel pulls out from pedestal
approximately 152mm (6 in).
N041303002
FIG. 84
79033095 C Rev. 10-37

Cab
FIG. 85: Unplug electrical connectors (1) attached to
rear of instrument panel.
Lower (white) connectors push into socket on rear of
panel and center (blue) connectors have a locking clamp
molded into them. Squeeze clamp to release connector
from rear of instrument panel.
1
N041303003
FIG. 85
FIG. 86: Remove oil supply capillary tube (1) from rear of
oil pressure gauge. Cap line and gauge port.
Fo
Cut plastic strap on left hand side of steering pedestal

bracket retaining wire harness and temperature sending 1
unit capillary tube in place.
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Carefully pull capillary tube and sending unit up and out of

grommet on left hand side of steering pedestal floor pan.
in
NOTE: Do not bend, kink or damage coolant

temperature sender capillary tube.
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Unplug wire harness connectors for ignition switch,

acknowledge/reset switch, digit select switch, rotary light
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switch, windshield wiper/washer switches. N041303004
FIG. 86
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FIG. 87: Remove screws (1) holding dash panel to

steering pedestal and remove panel.
NOTE: Viewed from windshield side of pedestal.
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Remove cold start ether button from steering

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column by prying it out of steering column

cowling.
Unplug two wires from switch and pull them from
steering column. 1
on
Locate wire harness connector for multi-function

switch and unplug it from main cab harness.
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N041303005
FIG. 87
FIG. 88: Remove four allen head bolts (1) retaining
steering column to dash pedestal.
There may be shim washers under two top allen head
bolts to space steering column away from dash cowling.
Lift steering column from cab. Steering shaft pulls out of
rubber boot in cab floor.
Steering shaft is splined to steering coupler under cab.
Shaft will pull free of coupler when lifted up.
1
N041303006
FIG. 88
10-38 79033095 C Rev.

Cab
FIG. 89: Loosen and remove nuts (1) holding brake
pedal switch to steering pedestal. Remove switch from
mounting bracket.
NOTE: Do not unplug wires from brake pedal switch.
Switch has very delicate connectors that will
loosen and be damaged if wires are removed
and installed repeatedly.
Unplug connector for front windshield wiper motor.
1
Remove capscrews and nuts for three P clips retaining
main cab wire harness to steering pedestal frame. Cut
any remaining plastic tie straps retaining harness in place.
Pull main wire harness to right and lay on right hand side P102803008
cab console. FIG. 89

Loosen two large nuts holding clutch cable in position on
cable bracket.
Fo
Unscrew shoulder bolt from clutch pedal. Shoulder bolt

passes through isolated clutch cable end.
NOTE: Thread locking compound is used on shoulder
bolt threads. A small amount of heat may be
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required to loosen bolt threads.

in
Loosen jam nut under isolated cable end. Unscrew

isolated cable end from clutch cable.
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NOTE: Thread locking compound is used on isolator

threads. A small amount of heat may be required
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to loosen isolator from cable threads.

Remove large nut and washer from top of bracket and
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slide it over cable end.

IMPORTANT: Count and record exact number of turns
isolated cable end is installed on clutch cable.
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This will assist in reassembly procedure.

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Pull cable downward out of mounting bracket.

Remove grommet and spacer from clutch cable bracket.
Remove snap ring retaining clutch pedal onto steering
on
pedestal pivot and pull pedal from pedestal.

NOTE: Machines equipped with a Powershift
transmission have a return spring installed on
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clutch pedal. Slide clutch pedal to left and allow it

to pivot upward to relieve spring tension, then
remove clutch pedal.
Remove cotter pin and clevis pin from brake rod top
clevis. Move brake rod away from pedal.
Remove outer snap ring from brake pedal pivot shaft.
Push down on brake pedal and slide to right enough so
pedal clears rubber stamp.
Allow pedal to pivot upward to relax spring tension and
unhook spring from steering pedestal. Remove pedal
from pivot shaft.
79033095 C Rev. 10-39

Cab
FIG. 90: Steering pedestal frame is held to cab frame
with bolts (1) coming through floor.
Access to four bolts is from under cab. Remove
capscrews from under cab floor.
On left hand side of pedestal floor plate, push grommets
holding clutch cable and engine oil pressure capillary tube
down through cab floor.
There is no need to remove cable and tube from
grommets, push grommet down from pedestal to free
cable and tube.
On right hand side of pedestal floor plate, pull rubber boot 1
for brake linkage upward and slide it up brake rod. P102803007
Tilt top of pedestal toward center of cab to expose bottom FIG. 90

clevis on brake rod.
Remove cotter and clevis pin and lift brake rod from
Fo
pedestal.
Lift steering pedestal from cab.
Installation
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Push clutch cable and engine oil pressure capillary tube

in
down into floor opening below cab floor.

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Lift steering pedestal into position.

Tilt pedestal toward center of cab and install brake rod
rn
and boot into right hand side of pedestal base.

Attach brake rod lower clevis onto lower brake linkage by
installing clevis and cotter pin.
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Position splined steering coupler stub shaft (attached to

steering valve) into steering column boot at base of
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pedestal so it sticks up into cab.

Place pedestal into position on cab floor and install four
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mounting bolts from under cab. Tighten bolts to 65 Nm

(40 lbf ft).
Ensure brake pedal rubber boot is installed into right hand
on
side of base of steering pedestal.

Push clutch cable and engine oil pressure capillary tube
up into holes in left hand side of pedestal base. Clutch
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cable is installed into smaller inside hole.

Be sure inside snap ring is in position on brake pivot shaft.
Install cable and tube grommets into place in pedestal
base.
Install brake pedal return spring onto pedal and pedestal
bracket. Bottom of spring hooks through hole in bracket
and into notch from inside out.
Pull pedal toward right side of cab and slide it onto brake
pedal pivot. Install snap ring on end of pivot shaft.
NOTE: It is easiest to install brake pedal spring onto
pedal and pedestal before placing pedal on pivot
shaft.
Install brake rod top clevis, clevis and cotter pin on brake
pedal.
10-40 79033095 C Rev.

Cab
Install clutch pedal on pivot shaft and retain in place with a Make sure rubber boot for steering shaft is in place at
snap ring. Pull pedal toward left side of cab and slide it on base of steering pedestal.
clutch pedal pivot. Install snap ring on end of pivot shaft.
There is a plastic bushing that fits into top of rubber boot
There is a return spring on the clutch pedal. Hook spring to provide a bearing surface for steering shaft. Position it
onto pedal and pedestal bracket. Bottom of spring hooks properly.
through hole in bracket and into notch from inside out.
Connect multi-function switch wire harness connector.
NOTE: It is easiest to install clutch pedal spring onto
Reattach two wires to cold start ether button. Press button
pedal and pedestal before placing pedal on pivot
back into position on steering column.
shaft.
Install steering column cowling onto pedestal and attach
Install grommet and spacer into mounting bracket.
with mounting screws.
Grommet and spacer are a tight fit into one another and
Reinstall dash cowling onto steering pedestal with four
into bracket. Use liquid soap to aid in assembly, do not
attaching screws.
use oil as it will deteriorate rubber.
Reconnect wire harness plugs to ignition switch,
Thread clutch cable through spacer and grommet. Place
acknowledge/reset switch, digit select switch, rotary light
large washer and nut onto cable and tighten against
switch, windshield wiper switches and windshield washer
grommet and bracket.
Fo
switch.
A large washer and nut is positioned on top and bottom of
Place instrument panel into position on dash cowling.
bracket and threaded portion of clutch cable will be
roughly centered when large nuts are tightened. Route engine coolant temperature gauge capillary tube
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down through engine oil pressure capillary tube grommet

Clean any old thread locking compound from cable end
and reconnect it into sensing port on engine block.
in
and isolate. Install jam nut on cable and place a small

amount of thread locker on threaded end of cable. Use pipe thread sealant on threads of sending unit when
installing it on engine.
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Install cable isolator end on cable same amount of turns

as recorded in step #17 of removal. Tighten jam nut NOTE: Replace any lost engine coolant during removal
against isolator end. of sending unit.
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IMPORTANT: Isolator end should be threaded on cable Install engine oil pressure capillary tube onto gauge port
at least 15 complete turns to get a minimum at rear of instrument cluster.
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thread engagement on cable.

Reconnect four plug-in connectors to instrument panel.
Check threads in clutch pedal and threads on shoulder Make sure connectors are firmly pushed into instrument
bolt. Make sure no old thread locking compound remains. cluster.
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Install shoulder bolt through isolator end and into clutch

Reinstall instrument cluster into dash panel and secure
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pedal. Use thread locking compound on bolt threads.

Tighten securely. with two screws by turning 1/4 turn.
Route cab main wire harness along front right corner of Install a plastic tie strap around cab wire harness, oil
cab and up to steering pedestal. Install wire harness into pressure capillary tube, multi-function switch harness and
on
three P clips and attach clips to pedestal using hardware engine temperature capillary tube. Secure all harnesses
removed. Install any plastic ties cut during removal to hold and tubes to left hand leg of pedestal bracket.
harness in place. Check all wire harness routings in pedestal, be sure no
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Reconnect front windshield wiper motor harness wires are pinched or routed in such a way as to cause
connector into motor. damage during operation.
Reinstall brake pedal switch onto its mounting bracket Reinstall left and right steering pedestal side cowling
using two mounting nuts. Make sure it is adjusted so pieces and attach with mounting screws and single bolt at
plunger of switch is pushed inward (closed) when brake the base of cowling.
pedal is all the way up (against rubber stop). Install seat into cab as detailed in this section.
Lift steering column into place on steering pedestal Reconnect battery cables to the batteries
bracket.
Check function of all electrical switches located on
Ensure splined tube end of steering column mates with steering pedestal.
splined shaft of steering coupler in center of rubber boot.
Check adjustment of clutch cable.
Install four allen head screws and nuts that retain steering
column to steering pedestal.
NOTE: Reinstall any shim washers under two top allen
head bolts taken out during steering column
removal. These washers space steering column
away from dash cowling.
79033095 C Rev. 10-41

Cab
REAR VIEW MIRROR
Removal
FIG. 91: Remove 2 bolts (1) securing mirror to cab frame
and remove mirror from machine.
Inspection
Inspect mirror and bracket for damage. Replace if 1
necessary.
NOTE: Mirror has convex lens (wide view), causes
objects to appear farther away than actual.
P102703020
Fo
FIG. 91
Installation
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FIG. 92: Secure mirror to cab frame using large

mounting screws (1). Tighten screws securely.
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P102703020
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FIG. 92
on
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10-42 79033095 C Rev.

Cab
INTERNAL TRIM/SHIELDS
Removal and Installation of Cab Rear

Shield
FIG. 93: Loosen two latches (1) attaching rear cab shield
to cab frame and lift shield from cab.
Fuse panel wire harnesses can be accessed with cab
rear shield removed.
Reinstall cab rear shield by placing it in position on weld
studs and reinstalling two latches (1).
1
Fo
p102703021
FIG. 93
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Removal and Installation of Fuse Panel

Cowling
in
FIG. 94: Remove two screws (1) retaining cowling to cab

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rear shelf. There are three additional flow controls in right

rear corner of cab. Tilt cowling and pull from around flow
control bracket and control knobs.
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To reinstall, place cowling into position. A velcro strip on

left edge holds it in place. Install two screws holding
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cowling in place.
1
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N043003001
FIG. 94
on
Removal and Installation of Right Hand

Rear Cab Post Cowling
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Disconnect batteries. If machine is equipped with an

optional TMC (Tractor Management Center) remove
cowling screws.
FIG. 95: Remove cowling capscrews (1) and pull cowling
from cab post. If equipped with a TMC, remove TMC
module mounting bracket from cab post.
P102703022
FIG. 95
79033095 C Rev. 10-43

Cab
FIG. 96: Remove fuse panel cover (1) from fuse panel.
In right hand corner of fuse panel, loosen three screws for
auxiliary three pin connector harness. Pull harness from
under fuse panel cowling. Three pin auxiliary connector
socket is fastened to cowling with two rivets. It will be
necessary to drill out rivets to remove socket and harness
from cowling.
Route three pin auxiliary connector harness under fuse
panel cowling and reattach it to fuse panel. Wires are 1
attached to panel as follows:
Front screw (toward engine) Black-AP2 n051503003
Center screw White-AP3 FIG. 96

Rear screw Red-AP1
NOTE: Machine may have been manufactured with
three wires located differently then described
(white/rear, black/middle, red/front). By installing
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them as described, pins in connector socket will

match most accessories requiring a power
source from machine.
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Install cowling into place on right rear cab post. Install

in
three cowling capscrews.

If machine is equipped with a TMC, be sure TMC module
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mounting bracket is in place under bottom two screws.

Reinstall TMC (if equipped) cowling into place with
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screws.
Reconnect batteries.
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Removal and Installation of Left Hand Rear

Cab Post Cowling
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Disconnect batteries
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FIG. 97: Remove three capscrews holding cowling (1) in

place on left hand rear cab post.
Position cowling in place on cab door post and install
on
three mounting bolts.

If a new cowling piece has been installed, replace safety
decal installed on cowling.
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Reconnect batteries.
P102703023
FIG. 97
10-44 79033095 C Rev.

Cab
OPERATOR CONSOLE - REMOVE
Removal Procedure
FIG. 98: Console Removal
Disconnect harness assembly. Support operator console
(1) and remove two handles (2). 1
2
P102703008
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FIG. 98
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79033095 C Rev. 10-45

Cab
OPERATOR CONSOLE - DISASSEMBLE
Disassembly Procedure
Remove operator console.
FIG. 99: Remove bolts (1), bolts (2) and bolt (3). Loosen
bolt (4) and clamp holding harness assembly.
1
2
3
4
Fo
P111303015
FIG. 99
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FIG. 100: Removing implement controls.

1 2
Remove bolts (1), bolt (2), bolt (5) and bolt (3) from plate
in
(4). Remove implement control (6) and handle (7).

7
Repeat step for remaining implement controls.
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3
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g00868076
FIG. 100
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10-46 79033095 C Rev.

Cab
FIG. 101: Removing throttle control.
Remove screws (1), washers (2), washers (3) and throttle
control (4) from operator console.
2
3
1
Fo
g00869262
FIG. 101
FIG. 102: Disassembly of gear shift.
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Remove screws (1). Remove screw (2) and washer (3). 1 1

4
in
9
Separate handle assembly (4) from handle assembly (5).
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Remove up shift switch (6). Remove down shift switch (7). 2

Remove auto shift switch (8).
6
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Remove spring (9) and spring (10) from trigger (11).

3 7
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5
11
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g00877517
FIG. 102
79033095 C Rev. 10-47

Cab
FIG. 103: Removing transmission control.
Remove screw (1) and washer (2) from transmission 1
3
control (3). Remove transmission control (3) and cable 2
assembly (4).
Remove operator console.
4
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g00877512
FIG. 103
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10-48 79033095 C Rev.

Cab
OPERATOR CONSOLE - ASSEMBLE
Assembly Procedure
FIG. 104: Installing transmission control.
Install transmission control (1) and cable assembly (2).
Install screw (3) and washer (4) in transmission control
1
(1). 4
3
2
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FIG. 104
FIG. 105: Assembling gear shift.
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1
NOTE: Assemble shift handle. The wires from up shift 4
switch, down shift switch and auto shift switch 9
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should not contact trigger.

2
Install spring (9) and spring (10) in trigger (11).
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6
Install up shift switch (6). Install down shift switch (7).
Install auto shift switch (8). 3
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Connect handle assembly (4) and handle assembly (5). 11

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Install screws (1). Install screw (2) and washer (3).

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g00877517
FIG. 105
79033095 C Rev. 10-49

Cab
FIG. 106: Installing throttle control.
Install throttle control (1), screws (2), washers (3) and
washers (4) in operator console.
1
2
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g00869262
FIG. 106
FIG. 107: Assembling implement controls.
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Install implement control (1) and handle (2) in plate (3).

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Install bolts (4). 1

4
Repeat for remaining implement controls.
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Installing operator console. 2

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g00868076
FIG. 107
FIG. 108: Install bolts (1), (2) and (3).
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Tighten bolt (4) and clamp holding harness assembly.

1
P111303015
FIG. 108
10-50 79033095 C Rev.

Cab
OPERATOR CONSOLE - INSTALL
FIG. 109: Installing the console (2).
Use two people to install operator console. Position
console in place and tighten handles (1). 2
P102703008
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FIG. 109
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79033095 C Rev. 10-51

Cab
DOOR
Removal
FIG. 110: Open cab door(1).
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WARNING: Door is heavy. Removal of door
requires at least two service personnel.
1
P102803006
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FIG. 110
FIG. 111: Remove pin (1) from top and bottom hinges.
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Remove door.
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P102803005
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FIG. 111
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Installation
Lift door into position, lining up hinges.
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WARNING: Door is heavy. Removal of door

requires at least two service personnel.
Insert pins into hinges.

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Setting Door Striker Location

FIG. 112: Striker (1) is located midway between top and
bottom on front door frame.
Loosen door striker.
Close door until seal just touches door frame.
1
IMPORTANT: Do not compress seal.
Center striker vertically in latch.
Move striker horizontally until it just contacts latch.
Mark location on frame.
Open door and shift striker outboard horizontally 4 mm
(0.16 in). P102803004
Tighten striker in this location. FIG. 112
10-52 79033095 C Rev.

Cab
Verify Cab Pressurization
Verify cab pressurization reaches a minimum of 6.6 mm
(.26 in) of water with HVAC ventilation/pressurizer system
on minimum blower speed.
NOTE: A manometer is required to measure
pressurization. It’s maximum error shall not
exceed ± 10%.
Test Conditions
The pressurizer system shall be completely powered by
standard equipment on machine, with engine operating at
rated speed. All machine accessories pertinent to
operation of enclosure, enclosure components, air filters
and blowers shall be standard production parts or
equivalent, adjusted within manufacturer's specification
limits. Clean air filters are recommended since amount of
dirt in filter may affect pressurization.
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NOTE: Only one occupant may be inside cab during test.
Test Procedure
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Cab must be equipped with all applicable equipment.

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Pressurized system shall be operated using minimum

outside air, with minimum blower speed setting.
Pressurization system shall be in operation for a minimum
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of fifteen minutes prior to obtaining results. To obtain

uniform results, neither cooling not heating system shall
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be in operation during pressurization system tests.

Record operator enclosure pressurization.
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79033095 C Rev. 10-53

Cab
DOOR HANDLE
Removal
FIG. 113: Loosen and remove two screws (1) to remove
cowling from cab side of door handle.
P102803001
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FIG. 113
FIG. 114: Loosen and remove two screws (1) from
inside of door.
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P102803002
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FIG. 114
FIG. 115: Loosen and remove bolt (1) to release door
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bar.
Remove handle mechanism. 1
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P102803003
FIG. 115
10-54 79033095 C Rev.

Cab
Installation
FIG. 116: Install bolt (1) to attach door bar.
P102803003
FIG. 116
FIG. 117: Install two screws (1) to reinstall door handle.
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P102803002
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FIG. 117
FIG. 118: Install two screws (1) to reinstall cowling.
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1
P102803001
FIG. 118
79033095 C Rev. 10-55

Cab
NOTES
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10-56 79033095 C Rev.

Index
INDEX
A R
Air Filters Rear View Mirror ................................................ 10-42

Cab ................................................................. 10-15 Recirculation Filter .............................................. 10-17
Assembly of Seat Suspension ........................... 10-28 Roll Over Protection Structure .............................. 10-1
B S
Battery disconnect switch .................................... 10-3 Seat Belts ........................................................... 10-36

Bottom Panel ..................................................... 10-35 Seat Removal ..................................................... 10-21
Seat Suspension Components ........................... 10-27
Separating Seat into Three Components ........... 10-25
C Setting Door Striker Location ............................. 10-52
Standard Seat .................................................... 10-20
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Cab Air Filter ...................................................... 10-15 Standard Seat Adjustments ................................ 10-20
Cab Filtration ...................................................... 10-15 Steering Pedestal ............................................... 10-37
Cab Installation .................................................... 10-9
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Cab Removal ....................................................... 10-2

Cab Removal and Installation .............................. 10-2 V
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Verify Cab Pressurization ................................... 10-53

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Deluxe Seat Adjustments ................................... 10-22

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Disassembly of Seat Suspension ...................... 10-25

Door ................................................................... 10-52
Door Handle ....................................................... 10-54
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Filter Maintenance ............................................. 10-16

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Floor Mat ............................................................ 10-33

Fuse Panel Cowling ........................................... 10-43
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Instructor’s Seat ................................................. 10-36

Internal Trim/Shields .......................................... 10-43
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Lumbar Support Adjustment .............................. 10-20
Operator Console - Assemble ............................ 10-49

Assembly Procedure ....................................... 10-49
Operator Console - Disassemble ....................... 10-46
Disassembly Procedure .................................. 10-46
Operator Console - Install .................................. 10-51
Installation Procedure ..................................... 10-51
Operator Console - Remove .............................. 10-45
Removal Procedure ........................................ 10-45
79033095 C Rev. 10-57

Index
NOTES
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10-58 79033095 C Rev.

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Challenger ®
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SERVICE MANUAL
79033095 C Rev.
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Volume 2
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NOTE TO THE RECIPIENT - This packet is one component of two or more components required to
comprise a complete publication. The following items, shipped under separate part number, are
used with this publication:
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• Volume 2: Divisions 11-14 printed packet

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Printed in U.S.A.
March, 2013
Printing Batch Number

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Challenger ®
SERVICE MANUAL
79033095 C Rev.
Volume 2
CONTENTS
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Volume 1
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INTRODUCTION................................................................................................................................................................. 01
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ENGINE ............................................................................................................................................................................... 02
POWERTRAIN .................................................................................................................................................................... 03
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FRAME ................................................................................................................................................................................ 04
STEERING AND BRAKE SYSTEM .................................................................................................................................. 05
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IMPLEMENT HYDRAULIC AND THREE-POINT HITCH SYSTEMS.............................................................................. 06

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ELECTRICAL SCHEMATICS ............................................................................................................................................ 07

AIR SYSTEM....................................................................................................................................................................... 08
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VIRTUAL TERMINAL ......................................................................................................................................................... 09

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CAB ..................................................................................................................................................................................... 10
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Volume 2
HEATING VENTILATION AND AIR CONDITIONING............................................................................................11

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BALLASTING .........................................................................................................................................................12
APPEARANCE GROUP.........................................................................................................................................13
ELECTRONICS ......................................................................................................................................................14

Printed in U.S.A.
March, 2013
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Contents
Challenger ®
MT835C /MT845C / MT855C / MT865C / MT875C
SERVICE MANUAL
79033095 C Rev.
11 - Heating Ventilation and Air Conditioning

Contents
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General Information ....................................................................................................................................... 11-1

System Operation .................................................................................................................................... 11-1
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Theory of Operation ................................................................................................................................ 11-2

Basics of Refrigeration ............................................................................................................................ 11-2
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Heating Ventilation and Air Conditioning System .......................................................................................... 11-4

Components ............................................................................................................................................ 11-4
Manual and Electronic Heating, Ventilation and Air Conditioning Controls ............................................. 11-4
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Cab Pressurization .................................................................................................................................. 11-4

Removal of Moisture from Cab Airflow .................................................................................................... 11-4
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Cab Airflow Circulation ............................................................................................................................ 11-4

Cab Airflow Heating ................................................................................................................................. 11-4
Cab Airflow Cooling ................................................................................................................................. 11-5
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Control Panel ................................................................................................................................................. 11-6

Automatic Temperature Control (ATC) - If Equipped .............................................................................. 11-6
ATC Features .......................................................................................................................................... 11-6
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Automatic Temperature Controls ............................................................................................................ 11-6

Maximum Cooling or Heating .................................................................................................................. 11-8
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Manual Temperature Control System (If Equipped) ................................................................................ 11-8

Control Module ............................................................................................................................................ 11-10
Module Input/Output Signals ................................................................................................................. 11-10
Initialization (Start-Up) ........................................................................................................................... 11-10
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Compressor/Clutch ................................................................................................................................ 11-11

Air Conditioning System .............................................................................................................................. 11-12
System Schematic ................................................................................................................................. 11-12
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Refrigerant Compressor ........................................................................................................................ 11-13

Refrigerant Condenser .......................................................................................................................... 11-13
Orifice Tube ........................................................................................................................................... 11-14
Evaporator Coil ...................................................................................................................................... 11-14
Refrigerant Pressure Switches .............................................................................................................. 11-16
Sunlight Sensor ..................................................................................................................................... 11-16
Temperature Sensors ............................................................................................................................ 11-17
Refrigerant Compressor .............................................................................................................................. 11-18
Sensors For Refrigerant System ........................................................................................................... 11-18
Compressor Clutch ................................................................................................................................ 11-18
Suction (Suction Side) ........................................................................................................................... 11-19
Pumping ................................................................................................................................................ 11-19
Compression (Discharge Side) ............................................................................................................. 11-19
Compressor Operation .......................................................................................................................... 11-19
Refrigerant Relief Valve ............................................................................................................................... 11-20
Refrigerant Condenser ................................................................................................................................ 11-21
Sensor (Temperature) ................................................................................................................................. 11-22
Cab Temperature .................................................................................................................................. 11-22
Ambient Temperature ............................................................................................................................ 11-22
79033095 C Rev. 11-i

Contents
Ventilation Duct Temperature ................................................................................................................ 11-22
Evaporator Coil Probe ........................................................................................................................... 11-22
Evaporator Coil ............................................................................................................................................ 11-23
Electrical Schematic .................................................................................................................................... 11-24
Standard Box ......................................................................................................................................... 11-24
Deluxe Box ............................................................................................................................................ 11-25
Control Panel ........................................................................................................................................ 11-27
Refrigerant Accumulator .............................................................................................................................. 11-29
Heater System Overview ............................................................................................................................. 11-30
Actuator Motor (Water Valve) ...................................................................................................................... 11-32
Schematic for Testing the Water Valve ................................................................................................. 11-32
AirFlow ......................................................................................................................................................... 11-33
Airflow Components .............................................................................................................................. 11-33
Blower Fan ............................................................................................................................................ 11-33
Airflow Intake ......................................................................................................................................... 11-34
Fresh Air ................................................................................................................................................ 11-34
Recirculation .......................................................................................................................................... 11-34
Head, Foot and Defrost ......................................................................................................................... 11-35
Motor (Air Conditioning Blower) ................................................................................................................... 11-35
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Automatic Temperature Control (Fan) ................................................................................................... 11-35

Manual Fan Control ............................................................................................................................... 11-36
Speed Control .............................................................................................................................................. 11-37
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Automatic Fan Speed Control ............................................................................................................... 11-37

Manual Mode Fan Speed Control ......................................................................................................... 11-37
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Sunlight Sensor ..................................................................................................................................... 11-37

Actuator Motor (Damper Assembly) ............................................................................................................ 11-38
Lubricants .................................................................................................................................................... 11-39
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Compressors ......................................................................................................................................... 11-39

Clutch .................................................................................................................................................... 11-39
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Condensers ........................................................................................................................................... 11-39

Receiver-Drier ....................................................................................................................................... 11-40
Air Conditioner Blower/Fan and Motor Assembly .................................................................................. 11-40
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Air Conditioner System Ducts ............................................................................................................... 11-40

Receiver/Drier ....................................................................................................................................... 11-41
Expansion Valve .................................................................................................................................... 11-42
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Temperature Sensors ............................................................................................................................ 11-43

Heater System Operation ...................................................................................................................... 11-43
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Heater Components and Controls ......................................................................................................... 11-43

Service Tools ............................................................................................................................................... 11-46
Safety and Safety Tools ........................................................................................................................ 11-46
Air Conditioning System Service Tools ................................................................................................. 11-46
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Inspection & Maintenance-without gauges ............................................................................................ 11-49

Performance Inspection - Engine Running ............................................................................................ 11-50
Heater System Inspection ..................................................................................................................... 11-51
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Troubleshooting and Service Procedures .................................................................................................... 11-53

Manifold Gauge Set Installation ............................................................................................................ 11-53
Troubleshooting by Manifold Gauge Set Readings ............................................................................... 11-55
Review of Frequent Problem Areas ...................................................................................................... 11-62
Refrigerants ................................................................................................................................................. 11-65
Description and Properties of Refrigerants ........................................................................................... 11-65
Changes in Service Procedures ............................................................................................................ 11-65
Recovering and Recycling Refrigerant .................................................................................................. 11-66
Evacuating and Charging Air Conditioning System ............................................................................... 11-70
Component Repair or Replacement ............................................................................................................ 11-72
Hoses and Fittings ................................................................................................................................. 11-72
Lines ...................................................................................................................................................... 11-72
Expansion Valves .................................................................................................................................. 11-72
Expansion Tubes ................................................................................................................................... 11-72
Receiver-Drier and Accumulator ........................................................................................................... 11-72
Compressor and Clutch ......................................................................................................................... 11-72
Servicing Compressor ........................................................................................................................... 11-72
Heating, Ventilation and Air Conditioning Control System Variations - Troubleshooting ...................... 11-73
Binary and Trinary Switch - Troubleshooting Air Conditioning .............................................................. 11-73
11-ii 79033095 C Rev.

Contents
Refrigerant ............................................................................................................................................. 11-74
Troubleshooting preparation ........................................................................................................................ 11-77
General Troubleshooting ............................................................................................................................. 11-77
Visual Inspection .......................................................................................................................................... 11-78
Troubleshooting Faults With Service Codes (Active) .................................................................................. 11-78
Service Codes ....................................................................................................................................... 11-78
Entering Active Troubleshooting ........................................................................................................... 11-79
Troubleshooting Using Active Diagnostics ............................................................................................ 11-79
Checking Temperature Sensors ............................................................................................................ 11-79
Checking Compressor Clutch ................................................................................................................ 11-80
Checking Refrigerant Pressure Switches .............................................................................................. 11-80
Checking Sunlight Sensor ..................................................................................................................... 11-80
Checking Actuator for Water Valve ....................................................................................................... 11-81
Checking Blower Fan ............................................................................................................................ 11-81
Checking Mode Door Actuator .............................................................................................................. 11-81
Leak Checking ............................................................................................................................................. 11-82
Visual Inspection ................................................................................................................................... 11-82
Soap Bubble Detection .......................................................................................................................... 11-82
Shop Type Electronic Detectors ............................................................................................................ 11-82
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Leak Detection Dyes ............................................................................................................................. 11-82

Oil Level Measurement (in vehicle) ............................................................................................................. 11-82
Shaft Turning Smoothness Inspection .................................................................................................. 11-82
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Clutch Inspection ................................................................................................................................... 11-83

Unusual Noise not due to Compressor ................................................................................................. 11-83
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Unusual Noises Due to Compressor ..................................................................................................... 11-83

Valve Plate Test .................................................................................................................................... 11-83
General Service Information .................................................................................................................. 11-83
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Compressor Repaired Internally and Reinstalled in System ................................................................. 11-84

Compressor Replaced by a New Compressor of Same Type ............................................................... 11-84
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Oil Charge Determination for Long Hose Applications .......................................................................... 11-84

Troubleshooting A/C Control ....................................................................................................................... 11-86
Problem List .......................................................................................................................................... 11-86
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Refrigerant Recovery ................................................................................................................................... 11-88

Manifold Gauge Set (Refrigerant) - Install ................................................................................................... 11-89
Refrigerant System - Evacuate .................................................................................................................... 11-90
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Refrigerant System - Flush .......................................................................................................................... 11-92

Refrigerant Leakage Test ............................................................................................................................ 11-93
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Dye ........................................................................................................................................................ 11-93

Leak Detector ........................................................................................................................................ 11-93
Refrigerant Compressor Oil Check .............................................................................................................. 11-94
Complete Check of Compressor Oil ...................................................................................................... 11-94
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Refrigerant System - Charge ....................................................................................................................... 11-95

Relationship of Temperature and Pressure (R-134a Refrigerant) ......................................................... 11-95
Procedure for Labeling .......................................................................................................................... 11-97
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Charging System ................................................................................................................................... 11-97

Complete Charge of System from a Refrigerant Tank with a Scale ............................................................ 11-99
Adding Additional Refrigerant to a System With Low Charge ................................................................... 11-100
Manifold Gauge Set (Refrigerant) - Remove ............................................................................................. 11-101
Sunlight Sensor - Test ............................................................................................................................... 11-101
Control Panel-Test ..................................................................................................................................... 11-103
Tests for Standard Control Panel ........................................................................................................ 11-103
Test for Automatic Control Panel ........................................................................................................ 11-103
Refrigerant Compressor ............................................................................................................................ 11-105
Compressor ......................................................................................................................................... 11-105
Clutch .................................................................................................................................................. 11-106
Relief Valve ......................................................................................................................................... 11-106
Belt ..................................................................................................................................................... 11-106
System Capacities for Refrigerant ............................................................................................................. 11-107
INDEX ........................................................................................................................................................... 11-109
79033095 C Rev. 11-iii

Contents
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11-iv 79033095 C Rev.

Systems Operating
SYSTEMS OPERATING
GENERAL INFORMATION
Features and operation of the heating, ventilation and air
conditioning system along with components are found in
this section.
System Operation
FIG. 1: The air conditioning cycle is divided into high and
low pressures sides. 1 2
Item Description
3
4 12 11
5
1 Low side (low pressure)
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2 High side (high pressure)

6 10
3 Expansion valve
4 Low pressure liquid 9
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5 Heat moves from inside air to refrigerant 8
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6 Evaporator M112903002-1
FIG. 1
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7 Low pressure vapor

8 Compressor
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9 High pressure vapor

10 Condenser
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11 Heat moves from refrigerant to outside air

12 High pressure liquid
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High pressure side refers to the side of the system where

high pressure and high temperature exist. The high
pressure side is from outlet side of compressor, through
condenser and to thermal expansion valve (TXV) or fixed
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orifice tube (FOT).

Expansion valve or fixed orifice tube is the dividing point
between high and low pressure sides. Low pressure side
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is the term used for the portion of the air conditioning

system in which low pressure and low temperature exist.
From expansion valve or orifice tube, through evaporator,
to inlet side of compressor, refrigerant is in a low pressure
state.
Refrigerant in the air conditioning cycle is divided into
either a gas or liquid state.
Refrigerant changes state in both condenser and
evaporator. Refrigerant enter condenser as a vapor.
Vapor cools in condenser and changes into a liquid.
Refrigerant remains a liquid through orifice tube or
expansion valve and into evaporator. Liquid refrigerant
absorbs heat in evaporator and boils into a vapor.
Refrigerant remains a vapor through compressor and
back to condenser.
79033095 C Rev. 11-1

Systems Operating
Compressor moves refrigerant through system.
Refrigerant is compressed into a high pressure gas.
Refrigerant is compressed into a high pressure gas and
heated above ambient air temperature. Compressor
moves hot high pressure gas into condenser where
refrigerant cools. Refrigerant condenses into a liquid as
refrigerant cools. As refrigerant condenses into a liquid
heat is released to condenser and air flowing through
condenser.
Liquid refrigerant flows from condenser to expansion
valve or orifice tube. Orifice tube and expansion valve
both have a small opening through which refrigerant must
pass. A small opening reduces pressure or refrigerant
entering evaporator.
Refrigerant flows from orifice tube or expansion valve into
evaporator as a low pressure liquid. The reduced
pressure permits refrigerant to boil into a vapor. As
refrigerant boils, refrigerant absorbs heat. heat is
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transferred from air passing over evaporator surfaces to

colder refrigerant. Refrigerant leaving evaporator is
completely vaporized.
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Refrigerant changes to a gas and carries heat out of cab

and back to compressor. Air passing over evaporator
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surfaces is cooled by releasing heat to refrigerant. Each

time cab air is circulated across evaporator fins, air gets
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cooler. Refrigerant is drawn back into compressor as a

low pressure gas and cycle is repeated.
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When the capillary tube senses the air has cooled to

temperature selected by operator, capillary tube signals
thermostat switch to disengage compressor clutch.
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Refrigerant stops circulating through system. When

temperature rises, switch activates clutch and cycle
begins again.
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Theory of Operation
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The compressor is the heart of the air conditioning

system. Compressor has a suction and discharge (low
and high) side. On high side of compressor, marked “dis”
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on compressor head, refrigerant is discharged from

compressor. In condenser, during sub-cooling process,
refrigerant leaves condenser, enters receiver-drier where
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desiccant inside drier filters liquid refrigerant. Liquid

refrigerant leaves drier and moves onto TXV, which
meters or controls amount of refrigerant flowing into
evaporator. As liquid refrigerant is pulled through
evaporator it changes state in superheat process from a
liquid mist to a low temperature, low pressure gas.
Refrigerant is now fully on suction and low side of air
conditioning system, it is then pulled into compressor as a
low temperature, low pressure gas, since liquid refrigerant
cannot be compressed. At this point, process begins
again.
Basics of Refrigeration
Air conditioning is based on the process of heat transfer.
When a warmer object is placed next to a colder object,
the warmer object loses heat and becomes cooler and
the colder object absorbs heat and becomes warmer. An
air conditioning system receives heat from cab and
releases to outside air.
11-2 79033095 C Rev.

Systems Operating
Intensity of heat is measured with a thermometer in
degrees Celsius or Fahrenheit. Quantity of heat is
measured in calories or British Thermal Units (BTUs).
BTU is amount of heat needed to raise one pound of
water one degree Fahrenheit. A calorie is similar to a BTU
except measured in metric units.
When enough BTUs are added to or subtracted from a
liquid, liquid turns into a vapor or a solid, called “change of
state.”
For example, a pound of water at 100 degrees C (212
degrees F) must have 970 BTUs added to change water
to a vapor at the same temperature. As a substance
changes state, large amounts of heat are absorbed or
released without changing temperatures.
Liquids absorb the greatest amount of heat when boiled.
Therefore, boiling point of a liquid refrigerant needs to be
lower than temperature of area to be cooled. Refrigerant
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R134a is used in most air conditioning systems due to a

very low boiling point -30 degrees C (-22 degrees F).
As R134a boils, heat from cab is absorbed until cab is
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cooled, this is the basis of an air conditioning system.

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79033095 C Rev. 11-3

Systems Operating
HEATING VENTILATION AND AIR
CONDITIONING SYSTEM
FIG. 2: Location of heating, ventilation and air
Heating, ventilation and air conditioning system is used to
provide a comfortable cab for operator. Heating,
ventilation and air conditioning (1) is located at rear of
cab. 1
Components
Heating, ventilation and air conditioning system provides
manual or electronic controls, cab pressurization, removal
of moisture from cab airflow, airflow circulation, heating
and cooling.
P111303004
Manual and Electronic Heating, Ventilation FIG. 2

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and Air Conditioning Controls

Machines are equipped with a manual control for
standard configuration. Optional deluxe cab has an
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electronic control.
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Electronic control uses a control module to provide:

Automatic temperature control
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Automatic fan control

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LED display
On-board diagnostics
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Start-up memory
Solar-powered load sensor
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Outside temperature display

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Cab Pressurization
Heating, ventilation and air conditioning system is used to
provide positive cab air pressure to prevent unfiltered air
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from entering cab.
Removal of Moisture from Cab Airflow

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Heating, ventilation and air conditioning system uses air

conditioning system to condense moisture in air.
Temperature of air is changed by heating system, if
necessary. Condensed moisture is collected as a liquid
and allowed to drain.
Cab Airflow Circulation

Airflow is essential for heating, ventilation and air
conditioning system to work properly. Operator controls
direction and amount of airflow.
Cab Airflow Heating

Heating, ventilation and air conditioning system circulates
air passed heater core to heat air. Engine coolant is
circulated through core, located in Heating, ventilation
and air conditioning unit.
11-4 79033095 C Rev.

Systems Operating
Cab Airflow Cooling
Heating, ventilation and air conditioning system circulates
air passed evaporator core to cool airflow. Evaporator is
cooled by refrigerant circulated in air conditioning system.
Evaporator core is located in Heating, ventilation and air
conditioning unit.
Air conditioning system is a closed loop circuit using
pressure changes of refrigerant to cool cab.
Machine is equipped with an orifice tube system.
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79033095 C Rev. 11-5

Systems Operating
CONTROL PANEL
Machine is equipped with either an automatic
temperature control (ATC) which is optional or the
standard manual temperature control.
Automatic Temperature Control (ATC) - If

Equipped
ATC allows operator to have control of cab temperature
and/or continuously variable blower fan speed by using
control module. Operator controls temperature from 16-32
degrees C (60 - 90 degrees F).
ATC Features
ATC provides:
Automatic temperature control
Fo
Automatic blower fan control

Manual control of blower fan speed
r
Three-position airflow control

Custom push button and/or rotary control panel
in
Four-digit lighted LED

te
Display in degrees Fahrenheit or Celsius

On-board diagnostics with displayed error codes
rn
Memory used to resume last setting at start-up

ATC increases airflow during heavy sunlight
al
Display of outside air temperature

u
Component Protection
Control module for ATC provides:
se
Evaporator freeze protection

High/Low Pressure Switch
on
Low Pressure Switch (Limiting Cycle)
Automatic Temperature Controls

ly
FIG. 3: Automatic Control Panel

Control panel is located on right rear cab post and has the
following controls and display:
Rotary switch (1) for mode of airflow
Up/down level switches (3) for temperature 6 2
Fan speed rotary control (4) 1
3
Outside temperature button (6)
Lighted LED (2) 4 5
Tractor ignition (5)
P091103001
Mode Control Rotary Switch
FIG. 3
Mode control rotary switch (1)
Switch controls discharge mode of airflow.
11-6 79033095 C Rev.

Systems Operating
Heater/air conditioner is turned on when mode switch is
turned clockwise from OFF (labeled 0) to:
HEAD_FOOT
HEAD-FOOT-DEFROST
DEFROST
NOTE: Mode switch only controls airflow to front vents.

Fo
Air continues to circulate through rear and side

vents. Operator controls airflow by opening and
closing vents.
r
LED display is lit when Mode Control Rotary Switch is

turned on. Current temperature setpoint is displayed. In
in
DEFROST mode, air conditioner and heater are enabled.

Air conditioner removes moisture while heater warms cab
te
air, quickly removing humidity.
Up/Down Level Switches for Temperature

rn
Press temperature up button to increase or

al
down button to decrease temperature

setpoint. Holding temperature up or down
buttons causes temperature setpoint to
continuously increase or decrease. Once
u
desired temperature setpoint is achieved,

se
system holds temperature by controlling

compressor clutch, water valve and blower
fan speed.
Fan Speed Rotary Control

on
Fan operates whenever engine start switch

and Mode Control Rotary Switch are ON.
ly
When in AUTO, system is in automatic

temperature control mode, including
automatic control of blower fan speed. When
rotary switch is turned clockwise from AUTO,
operator can control fan speed manually. Fan
provides cab pressurization to minimize dust.
When possible, operate tractor with windows
closed to keep cab pressurized.
Outside Temperature Button
Press outside temperature button to display

outside temperature. LED displays
temperature while button is held and for five
seconds after release.
79033095 C Rev. 11-7

Systems Operating
LED Display
LED is 7.62 mm (0.3 inch) and displays four characters.
Units of Temperature
Displayed on LED in Fahrenheit or Celsius.
To change display, simultaneously press outside
temperature button and one button used to change
temperature.
Maximum Cooling or Heating

Automatic Temperature Control System (If
Equipped)
For maximum air conditioning output:
Set temperature setpoint to 16 degrees C (61degrees F).
Fo
Turn blower fan switch to maximum.

NOTE: AUTO allows control module to control operation
of air conditioning, do not use AUTO.
r
Follow steps below for maximum heater output:

in
Set temperature setpoint to 32 degrees C (90 degrees F),

Turn blower fan switch to maximum.
te
NOTE: AUTO allows control module to control operation

of air conditioning, do not use AUTO.
rn
Manual Temperature Control System (If

al
Equipped)
Manual heating, ventilation and air conditioning controls
are standard equipment.
u
FIG. 4: Manual Temperature Controls allow operator to

se
control:
Air conditioning switch (1)
Fan speed switch (2) 1
on
Temperature control (3)
Manual Controls 2
ly
3
Air Conditioning Switch
Press switch to turn air conditioning on, press

again to turn off.
P091103002
Operate air conditioning and heating
simultaneously to defrost windshield. Air FIG. 4
conditioner removes moisture while heater
warms cab air.
Temperature Control
Temperature control knob adjusts blend of

heated and cooled air. Turn knob clockwise
for warmer or counter clockwise for cooler air.
11-8 79033095 C Rev.

Systems Operating
Fan Speed Switch
Four fan speeds are available. Turn switch

counter clockwise to select low or clockwise
to select HIGH or PURGE.
Fan operates whenever engine start switch is
ON. Fan provides cab pressurization to
minimize dust. When possible, operate unit
with windows closed to keep cab
pressurized. Fan will not operate when fan
speed switch is off.
Fo
r in
te
rn
al
u se
on
ly
79033095 C Rev. 11-9

Systems Operating
CONTROL MODULE
FIG. 5: Main control module (1) is located in heating,
ventilation and air conditioning unit, mounted under
blower fan assembly. Control module is for automatic
controlled system, available on optional deluxe cab.
1
N041803001
FIG. 5
Fo
Module Input/Output Signals

Main control module (1) processes output signals from
control panel controlling following components:
r
Air conditioning compressor clutch

in
Blower motor speed

Water valve actuator
te
Defrost damper actuator

rn
When in AUTO, control panel monitors signals for:

Cab temperature
al
Outside (ambient) temperature

Evaporator
u
Direct Sunlight
se
Position of actuator for water valve

Position of damper actuator for defrost
Pressure sensors for refrigerant
on
Relay for compressor clutch
Initialization (Start-Up)
ly
Operation mode is first determined when control module

receives power. If system is in OFF mode, controller
sends code for OFF mode to control panel. If control
module is in ON mode, controller determines mode of
operation. Operation mode is directly related to sensor
inputs.
Operator enters a temperature setpoint on control panel.
Control module uses information retrieved from sensors
to control water valve and/or refrigerant compressor.
When signal is received from control panel, control
module responds according to command entered. AUTO
mode controls temperature in cab. This depends on
proper function of control module and proper function of
components module controls.
11-10 79033095 C Rev.

Systems Operating
In automatic fan mode, fan is in low speed until
initialization of water valve or refrigerant compressor
occurs. After sensor readings stabilize, fan speed
changes to speed of control point determined by control
module. In manual mode, fan speed will be low speed
until water valve initializes. Fan speed changes to achieve
operator’s desired setpoint retrieved by control module.
Compressor/Clutch
Clutch can be active in any mode except OFF.
Compressor clutch is activated to maintain temperature
setpoint. In defrost mode, clutch is forced to operate to
remove moisture from cab airflow.
System operates in manual mode when an error is
detected in cab temperature sensor. System operates
with a setpoint corresponding to the following setpoints:
16 degrees C (60 degrees F) - full air conditioning
Fo
24 degrees C (75 degrees F) - neutral (no cooling or

heating)
r
32 degrees C (90 degrees F) - full heat

Setpoint settings between those above generate a
in
proportional amount of cooling or heating.

In any mode, the following sensors can disable activation
te
of the clutch:
Evaporator temperature sensor
rn
Low pressure switch

al
High pressure switch

Trip points of temperature sensor are determined by
control module allowing system to maintain cab
u
temperature. Trip points for evaporator temperature

sensor increase as less cooling is required. Trip points
se
increase to maintain a stable temperature at setpoint.

The following trip points for evaporator temperature
sensor control compressor clutch in full air conditioning or
on
defrost:
Turn off compressor clutch at 1 degree C (31 degrees F)
Turn on compressor clutch at 3 degrees C (37 degrees F)
ly
If either low or high pressure switch transitions to an open

circuit, clutch is deactivated until switches close.
NOTE: Compressor clutch must be on for more than one
second and off for more than eleven seconds to
prevent a rapid cycle, shortening compressor
clutch life.
79033095 C Rev. 11-11

Systems Operating
AIR CONDITIONING SYSTEM
System Schematic
Schematic Diagram of Refrigerant and Coolant
Lines (Air Conditioning System with Orifice Tube)
1 8
9 2
Fo
4 7
3
r in
te
rn
5
6
al
u
N020803003
se
FIG. 6
FIG. 6: General Diagram

on
Condenser Coil (1)

Compressor (2)
ly
Orifice Tube (3)

Condenser Fan (4)
Evaporator Coil (5)
Accumulator (6)
Low Pressure Switch (7)
High Pressure Switch (8)
In-line Filter (9)
11-12 79033095 C Rev.

Systems Operating
Refrigerant Compressor
FIG. 7: Refrigerant Compressor (1) is belt driven and is
located on engine’s left front. Magnetic clutch (2) engages
compressor.
Compressor separates low and high pressure sides of
system and is basically a pump which has two functions: 2 1
It raises refrigerant temperature and pressure by
compression.
It functions as a pump to circulate required volume of
refrigerant and refrigerant oil around system.
P091103003
FIG. 7
Fo
Refrigerant Condenser
FIG. 8: Refrigerant Condenser (1) is located in front of
radiator. The condenser is combined with fuel cooler and
r
consists of a number of turns of continuous coil mounted

in a series of thin cooling fins. These coils provide
in
maximum heat transfer in a contained amount of space.

Refrigerant gas leaves compressor and moves through a
te
high pressure hose to condenser. Inside condenser gas

“changes state” and becomes a liquid. It is still hot and 1
rn
under pressure. Heat energy was involved in “change of

state,” but temperature did not change. The same kind of
action happens inside air conditioning system. Refrigerant
al
gas gives up a lot of heat energy to outside air as it

“changes state” in condenser. Air moving through
P111303005
condenser absorbs heat from refrigerant. The amount of
u
airflow through condenser is the major factor in how well FIG. 8

the condenser functions.
se
Condenser receives hot, high-pressure refrigerant vapor

from compressor. Hot vapor passes through condenser
coils. Outside air is pulled through condenser by engine
fan. Heat moves from hot refrigerant vapor into cooler
on
outside air flowing across condenser coils and fins.

When refrigerant vapor reaches pressure and
temperature induces a change of state, a large quantity of
ly
heat is transferred to outside air and refrigerant changes

to a high-pressure cool liquid and moves on to
receiver/drier.
79033095 C Rev. 11-13

Systems Operating
Orifice Tube
FIG. 9: Orifice Tube (1) is located in supply line for
evaporator coil. Orifice tube is used to meter refrigerant
flow in air conditioning system.
P091103005
FIG. 9
Fo
Evaporator Coil
FIG. 10: Evaporator coil (2) is located in heating,
ventilation and air conditioning unit. The evaporator coil is
r
located directly behind heater coil (1). Expansion valve or

other type of metering device bleeds high pressure
in
refrigerant into evaporator coil, where pressure is low.

Refrigerant expands rapidly in this low pressure 1
2
te
environment. When it expands it “changes state”. The

sudden drop in pressure brings refrigerant temperature
down quickly inside evaporator coil (2). Refrigerant is
rn
sprayed into evaporator by high side pressure when

expansion valve opens. Refrigerant absorbs heat from air
when blower forces air through fins. When thermostat
al
probe senses upper limit of thermostat heat setting, a

circuit closes. Compressor clutch engages and P091103006
compressor operates and moves more refrigerant to high
FIG. 10
u
side of system.
se
Evaporator core is incorporated with evaporator core as a

single unit.
NOTE: Moisture in air (humidity) condenses on fins of
evaporator as water droplets which drain out of
on
evaporator through a drain hose. This action

dehumidifies air in cab as part of system
operation and contributes to operator comfort.
ly
Cab air forced across evaporator coil gives up heat

energy to cold refrigerant inside coil. Cooled air circulates
in cab for occupant comfort. Refrigerant continues to
expand and absorb heat energy in evaporator coil.
Refrigerant changes from liquid to gas before it leaves
evaporator on the way back to compressor. Refrigerant
gas moves to compressor through a low pressure
(suction) hose. When compressor is operating, it sucks
refrigerant gas back inside, compressing and raising its
temperature and pressure.
11-14 79033095 C Rev.

Systems Operating
Some of air conditioning system operation is controlled by
operator and some is automatic. Operator can turn
system on and off, regulate air velocity with blower control
and in some designs adjust thermostat control. System
and component operating range settings automatically
cycle clutch on and off. Operation of expansion valve or
other refrigerant metering device at inlet to evaporator is
automatic.
m
WARNING: When an air conditioning
system is operating, high pressure side
components, fittings and high pressure
lines or hoses can be hot enough to burn
skin if touched. This includes compressor,
clutch, hoses, condenser, receiver-drier and
any control devices or metal tubing. Low
pressure side will be cool to the touch. In
operation the air conditioning system is
under load and high side pressures
Fo
normally range between 150 to 250 pounds

per square inch for R-12 and high for some
other refrigerants.
r
Evaporator core consists of numerous copper tubes

mounted on a series of thin aluminum cooling fins. Some
in
of these copper tubes are devoted to heater and carry

coolant from engine. Remainder of these tubes are
te
devoted to evaporator and carry air conditioning

refrigerant.
rn
Evaporator is designed to transfer heat from outside air to

cold atomized liquid refrigerant as it movers through
copper tubing. Cold atomized refrigerant inside tubing
al
cools fins of evaporator. As the warmer outside air passes

through the fins and is cooled, moisture from air
condenses on fins. Water droplets from fins drain into a
u
drip tray and then out the air box through drain tubes at
either end of drip tray.
se
To ensure moisture flows freely from drip tray, a drain

hose is located along each of the rear corners of cab.
Dust and other airborne particles may also be trapped in
on
condensed moisture droplets. In this way, air conditioning

system dehumidifies, filters and cools cab air.
NOTE: It is very important to keep outside and
ly
recirculation air filters clean and properly

installed. Otherwise, evaporator will become
clogged with dust and debris which will
dramatically reduce system performance.
Just as evaporator transfers heat from air to liquid
refrigerant, heater core transfers heat from liquid engine
coolant to air going into cab.
Engine coolant is pumped by engine water pump through
heater hose to heater core. As coolant passes through
copper tubing, heat is transferred from coolant to air.
Coolant then returns to engine through heater return
hose.
79033095 C Rev. 11-15

Systems Operating
By using air conditioning evaporator core and heater core
simultaneously, operator modulates temperature of air
entering cab.
m
WARNING: When an air conditioning
system is operating, high pressure side
components, fittings and high pressure
lines or hoses can be hot enough to burn
skin if touched. This includes compressor,
clutch, hoses, condenser, receiver-drier and
any control device or metal tubing. The
lower pressure side will be cool to the
touch. In operation, air conditioning system
is under load and high side pressures
normally range between 150 and 250
pounds per square inch for R-12 and higher
for some other refrigerants.
Refrigerant Pressure Switches

Fo
FIG. 11: Low Pressure Switch (1) is located on input line

of accumulator.
r in
1
te
rn
al
P091103007
FIG. 11
u
Sunlight Sensor
se
FIG. 12: Sunlight Sensor is used for automatic

temperature control system. Deluxe cab is equipped with
this option. Sunlight sensor (1) is located in front of
on
console.
Sunlight sensor is used to detect presence of sunlight
through cab window. When sunlight is detected, control
ly
module increases fan speed to provide operator with

increased airflow, compensating for heat of sunlight.
1
See Systems Operation/Testing and Adjusting Speed
Control for additional information.
P091003017
FIG. 12
11-16 79033095 C Rev.

Systems Operating
Temperature Sensors
FIG. 13: Right Side View of Cab
Heating, ventilation and air conditioning unit (1)
Outside (Ambient) Air Temperature Sensor (2)
Sunlight Sensor (3) 2 3
P091003016
FIG. 13
FIG. 14: Cab Air Temperature Sensor (1)
Fo
1
r in
te
rn
P091003015
al
FIG. 14
FIG. 15: Ventilation Duct Temperature Sensor (1)
u
Evaporator Coil Temperature Sensor (2)

se
2
on
ly
1
P091003014
FIG. 15
79033095 C Rev. 11-17

Systems Operating
REFRIGERANT COMPRESSOR
FIG. 16: Refrigerant Compressor Components
Magnetic Clutch and Pulley Assembly (1)
Compressor (2)
Arc Compressor (3) 2
Refrigerant compressor causes flow of refrigerant in air
3
Compressor provides suction, pumping and compression 1
in refrigerant circuit. As compressor increases pressure of
refrigerant, a relative increase in refrigerant temperature
takes place.
Sensors For Refrigerant System P091003013
FIG. 16
Two sensors monitor refrigerant pressure:
Fo
Pressure sensor for side of high pressure

Pressure sensor for side of low pressure
Pressure sensor on side of high pressure ensures
r
pressure does not go too high or too low. If either

condition occurs, compressor shuts off to protect system.
in
Pressure sensor on side of low pressure ensures

pressure does not go too low. If this occurs, compressor
te
shuts off to protect system.

rn
Compressor Clutch
Clutch Operation
al
FIG. 17: Compressor Clutch Components

Magnetic Clutch and Pulley Assembly (1)
u
1
Drive Plate (2) 5
se
2
Bearing (3)
Shaft (4)
on
Coil Assembly (5)

Compressor is driven clockwise by engine. A belt
connects engine to clutch and pulley assembly. Pulley
ly
assembly is located on clutch. Drive plate is fastened to

shaft of compressor. Clutch and pulley assembly turns on
bearing and are not connected to shaft. Electric current
from thermostat controls a magnetic field in coil assembly.
Magnetic field pulls drive plate against clutch and pulley
assembly turning shaft operating compressor. When
current to coil assembly is stopped, magnetic field is
removed. This allows drive plate to move away from
clutch and pulley assembly, turning freely on bearing.
Sequence of connecting and disconnecting pulley to
compressor shaft is called compressor cycling and is
controlled by thermostat. Thermostat is used to monitor
3
4
temperature of evaporator coil.
N020803009
FIG. 17
11-18 79033095 C Rev.

Systems Operating
Suction (Suction Side)
Suction lowers refrigerant pressure in evaporator.
Metered restriction, which is provided by orifice tube,
allows high pressure liquid to be reduced to a low
pressure liquid, helping with evaporation of refrigerant,
leading to continuous cooling.
Pumping
Pumping circulates refrigerant in air conditioning system,
leading to continuous cooling.
Compression (Discharge Side)

When pressure increases, temperature of saturation
increases. Compressor changes refrigerant from a low to
high pressure vapor. Change must occur for latent heat of
condensation to be given up when refrigerant is sent
Fo
through condenser.
Compressor Operation
r
FIG. 18: Compressor Operation

1 2 1 2
in
Intake Valve (1)

Exhaust Valve (2)
te
Intake Valve (3) 4

4
Exhaust Valve (4) 3
rn
Intake Stroke (5)

3
al
Compression Stroke (6)

Compressor uses reed valves to control entrance and exit
of refrigerant gas.
5 6
u
As piston moves down in bore, reed valve opens on N020803010

se
suction side and reed valve closes on discharge side. Low FIG. 18
pressure refrigerant gas has weight, due to a heat transfer
characteristic and is drawn from evaporator into
compressor. As piston moves up in bore, compressor
on
pressurizes gas. This increases intensity of heat.

Since temperature is a measurement of heat intensity,
temperature of gas increases. Gas is high pressure and
ly
temperature. Gas closes reed valve on suction side and

gas opens reed valve on discharge side. Gas is forced
through a hose to condenser.
Pressure increase is accomplished by adding a restriction
in high pressure side of system. Restriction is caused by
an orifice tube.
79033095 C Rev. 11-19

Systems Operating
REFRIGERANT RELIEF VALVE
FIG. 19: Relief Valve
Body (1)
1
5
Packing (2)
Valve (3)
Spring (4)
Relief Valve (5)
Relief valve is located on compressor at high pressure
outlet. Valve protects system by discharging refrigerant
into atmosphere when high pressure reaches a preset 2 3 4
amount to prevent catastrophic failure. N050803004
FIG. 19
Fo
r in
te
rn
al
u se
on
ly
11-20 79033095 C Rev.

Systems Operating
REFRIGERANT CONDENSER
FIG. 20: Condenser Operation
Condenser (1) 2
1
Refrigerant from compressor (2)
Refrigerant to orifice tube (3)
Condenser fan (4)
3
Condenser (1) is located behind front cooler package.
Refrigerant enters condenser from compressor. 4
Condenser uses forced air to cool high pressure and
temperature refrigerant vapor. Condenser also uses
forced air to condense high pressure and temperature
refrigerant vapor. N020803012
FIG. 20
FIG. 21: Large volumes of forced air must be moved
Fo
through condenser coils (1) by fan. Air is cooler than

refrigerant gas inside condenser. Heat flows from hot
refrigerant gas to cooler air.
r
Heat is transferred from refrigerant to outside air in

condenser. This transfer occurs in the opposite direction
in
as transfer occurring in evaporator coil. Fins are provided

on outside surface of condenser for efficient heat transfer.
te
If refrigerant is not cooled enough, air inside cab at

evaporator coil will not be cooled sufficiently. To prevent
this situation, good ventilation must be provided,
rn
increasing efficiency. From condenser, refrigerant flows to 1

orifice tube.
P111303005
al
When refrigerant leaves compressor, refrigerant is a FIG. 21

vapor. High pressure and temperature refrigerant leaves
compressor. Increase in refrigerant pressure causes an
u
increase in temperature of refrigerant. Refrigerant vapor

leaves compressor and enters condenser.
se
Refrigerant must be converted to a high pressure and

temperature liquid. Refrigerant must be converted to a
liquid to increase air conditioning system efficiency.
on
Condenser converts refrigerant vapor into a high pressure

and temperature liquid.
When refrigerant vapor leaves compressor it enters
ly
condenser. Condenser is in a location exposed to outside

air. To convert refrigerant into a liquid, refrigerant must
lose heat. Refrigerant must reach temperature of
saturation, then vapor becomes liquid. Temperature of
saturation of refrigerant depends on pressure of
refrigerant.
79033095 C Rev. 11-21

Systems Operating
SENSOR (TEMPERATURE)
3 1 4
1
Fo
N020803004
FIG. 22
r
FIG. 22: Right Side of Cab

in
Temperature sensors are used for automatic temperature

control system. Deluxe cab is equipped with this option.
te
Automatic temperature control system uses:

Cab airflow temperature
rn
Outside (ambient) temperature

Ventilation duct temperature
al
Evaporator core probe

u
Cab Temperature
se
Temperature of airflow inside cab is measured by

temperature sensor (3) located in heating, ventilation and
air conditioning unit (2). Cab airflow is drawn through
recirculation filter and passed sensor.
on
Ambient Temperature
Ambient air temperature (outside) is measured by sensor
ly
(1) located near drive motor for rear window wiper. Sensor
monitors outside temperature.
Ventilation Duct Temperature

Ventilation duct temperature is measured by sensor (4) in
blower fan housing. Sensor monitors temperature of
cooled or heated air.
Evaporator Coil Probe

Probe is inserted into evaporator coil to measure
temperature. Probe limits control signal of clutch for
refrigerant compressor. Control signal for clutch is
interrupted when evaporator coil temperature is below 0
degrees C (32 degrees F), preventing freeze up of
evaporator coil. Moisture in airflow condenses and
freezes below 0 degrees C (32 degrees F). Frozen
moisture inhibits airflow through evaporator coil.
11-22 79033095 C Rev.

Systems Operating
EVAPORATOR COIL
FIG. 23: Evaporator (1) is located in heating, ventilation
and air conditioning unit in front of heater coil.
Purpose of evaporator is to transfer heat in operator's
compartment to refrigerant.
P091003011
FIG. 23
FIG. 24: Evaporator Operation
Fo
In an orifice tube system, evaporator receives liquid

refrigerant from orifice tube. Liquid refrigerant received by 2
evaporator has low pressure and temperature. Since
r
pressure of liquid refrigerant is low, temperature of 1

saturation of refrigerant is low. At temperature of
in
saturation, refrigerant changes from a liquid to a vapor.

3
Refrigerant from Orifice Tube (1)
te
Evaporator (2)
rn
Refrigerant to Compressor (3) 4

Blower Fan (4) N020803014
al
Blower fan exposes evaporator coil to air inside cab. Heat FIG. 24
from air inside cab is absorbed by evaporator. Evaporator
transfers heat to refrigerant. When heat is absorbed by
u
refrigerant, refrigerant temperature reaches temperature

of saturation. Refrigerant changes from a liquid to vapor.
se
(amount of heat required to reach temperature of

saturation is called latent heat of vaporization.) Vaporized
refrigerant leaves evaporator. Vaporized refrigerant
carries away cab heat. Vaporized refrigerant returns to
on
compressor when refrigerant leaves evaporator. Process

is repeated continuously.
Evaporator coil temperature is monitored by a
ly
temperature sensor inserted into evaporator coil.
79033095 C Rev. 11-23

Systems Operating
ELECTRICAL SCHEMATIC
Standard Box
1 6
7
4
8
9 10
Fo
11
12
r
2
in
te
13
rn
3
al
u
N020803005
se
FIG. 25
FIG. 25: Standard Heating, Ventilation and Air

on
Conditioning Box
Item Description Item Description

ly
1 Blower motor 9 Thermostat

2 High Speed Relay 10 Thermostat Out
3 Purge Speed Relay 11 Ground
4 Blower Resistor 12 High Speed
5 Battery Power 13 Purge Speed
6 Low Speed
7 Medium Speed
8 Thermostat In
11-24 79033095 C Rev.

Systems Operating
Deluxe Box
39
40
Fo
r in
te
rn
al
u se
41
on
42
ly
43
44
45
46
47
48
50
49
N020803006
FIG. 26
79033095 C Rev. 11-25

Systems Operating
FIG. 26: Deluxe Heating, Ventilation and Air
Conditioning Box
Item Description Item Description

3 Blower 46 Water Valve Negative
1 Ground 47 Water Valve Positive
2 Power 48 Water Valve Feedback
5 Clutch Relay Negative 49 Heating, Ventilation and Air Conditioning Control Module
39 Mode Door Ground 50 Water Valve
9 Pressure Switch Signal
3 Pressure Switch Return
34 Solar Sensor Return
15 Solar Sensor
Fo
29 Mode Door Feedback

17 Serial Positive
r
18 Serial Negative
in
23 Mode Door Negative

te
13 Mode Door Positive

8 Outside Air
rn
38 Outside Air Return

36 Thermostat Return
al
32 Return Air Return

37 Outlet Air Return
u
27 Outlet Air Input

se
22 Return Air Input

26 Thermostat In
on
24 +5VDC
35 Water Valve Ground
ly
31 Water Valve Positive

21 Water Valve Negative
25 Water Valve Feedback
39 Blower Motor
40 Clutch Relay
41 Outlet Temperature
42 Return Air Temperature
43 Thermostat Probe
44 +5 VDC
45 Water Valve Ground
11-26 79033095 C Rev.

Systems Operating
Control Panel
1
2 3
5
6
7
Fo
10 8
9
r in
11
12
te
13 16
rn
14
15 20 21
al
22
u
17
18
se
23
24
19
on
25 26
ly
27
28
29
31
32 30 N021203002
FIG. 27
FIG. 27: Heating, Ventilation and Air Conditioning

Control Panel
79033095 C Rev. 11-27

Systems Operating
Item Description
1 USB
2 Air conditioning Fuse
3 Accessory Power
4 Air conditioning Relay
5 to machine ground
6 Solar Sensor (deluxe only)
7 Air Conditioning Clutch Solenoid
8 Arc Suppressor
9 Air Conditioning High Pressure Switch
10 Air Conditioning Low Pressure Switch
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11 +5 VDC Relay
12 Ground
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13 Motor Negative
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14 Motor Positive
15 Mode Door Feedback
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16 Mode Door Actuator

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17 to backlight circuit
18 to ground
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19 Deluxe heating, ventilation and air conditioning panel

20 Power
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21 Lights
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22 Ground
23 Serial Link Positive
24 Serial Link Negative
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25 Purge
26 High
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27 Medium
28 Low
29 Air Conditioning Push Button Switch
30 Blower Switch
31 to ground
32 Standard heating, ventilation and air conditioning panel
11-28 79033095 C Rev.

Systems Operating
REFRIGERANT ACCUMULATOR
FIG. 28: Refrigerant Flow Through Air Conditioning
System and Accumulator Components
Compressor (1)
Condenser Coil (2) 2
Orifice Tube (3)
Evaporator Coil (4)
Accumulator (5)
Accumulator Inlet (6) 1
Desiccant (7)
Liquid Refrigerant (8)
Oil Drain Hole (9)
3
5
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Accumulator Outlet (10)

High pressure/temperature air conditioning refrigerant as
vapor (A)
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High pressure/temperature air conditioning refrigerant as

liquid (B)
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6
Low pressure/temperature air conditioning refrigerant as
liquid (C)
4
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Low pressure/temperature air conditioning refrigerant as

vapor (D)
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N020803016
FIG. 28
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Accumulator is located at outlet of evaporator coil.

Accumulator separates remaining liquid refrigerant from
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refrigerant vapor passing through evaporator coil.

Accumulator retains liquid refrigerant separated. 6 5
Accumulator releases vapor to compressor.
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Oil drain hole is located in bottom of accumulator. Oil

drain hole drains separated refrigerant oil and some liquid
refrigerant back to compressor.
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Flow of refrigerant out of accumulator to compressor is

mostly vapor. Vapor contains a small amount of liquid 7
refrigerant coming from oil drain hole.
Desiccant is a moisture collection agent located in base of 9
accumulator. Accumulator must be replaced when
desiccant is saturated with moisture. 8
Accumulator should be replaced:
10
• If system is opened
N020803017
• Annually
FIG. 29
79033095 C Rev. 11-29

Systems Operating
HEATER SYSTEM OVERVIEW
Heater and air conditioner system both have the same
basic function of moving heat. They take advantage of
nature’s laws where heat energy always moves from a
warmer to a cooler area. In a heater system there is no
“change of state” involved in system operation. System is
sealed and operates under pressure, but pressure is low
when compared to an air conditioner.
A heater system uses engine coolant to carry excess heat
energy to cab air. Water pump forces hot coolant through
a hose from engine block and heater core. Coolant is
returned to engine cooling system either at suction side of
water pump or radiator.
A control cable, attached to a water valve between water
pump and heater inlet is used to control flow of coolant to
heater. Heater fan or blower forces cab air through heater
core where heat energy moves from engine coolant to air
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in cab.
FIG. 30: Heater Core (1) is located in heating, ventilation
and air conditioning unit.
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Airflow is forced passed heater core to gain heat from

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engine coolant circulated through heater core. Airflow is

created by blower fan in heating, ventilation and air
conditioning unit.
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Heater core is constructed of copper and aluminum as

these metals are excellent conductors of heat. Heater
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core and water valve are connected with a heater hose.

These connections are critical and should be checked
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periodically for leaks. 1

Heater cores are like small radiators. Fin and tube P091003010
construction is designed to route coolant flow for best
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passable heat energy transfer from coolant to cab air. FIG. 30

hoses to engine are connected to core with clamps. Core
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outlet may be larger or same size as inlet.

FIG. 31: Water Valve (1) with Cable Connection for
Standard Cab.
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P091003009
FIG. 31
11-30 79033095 C Rev.

Systems Operating
FIG. 32: Water Valve with Actuator Motor for Deluxe Cab
Actuator motor (1) (water valve) is located on right rear of
heating, ventilation and air conditioning unit.
Water valve controls amount of water flowing into heater
core. Foreign matter on outside surface of heater core
can cause a poor exchange of heat. Heating system
loses capability to heat when heater core gets dirty.
Outside surface of heater core should be cleaned when
system is checked.
Sixteen position valve actuator controls position of water
valve. Position of water valve is dependent on amount of
heat required. Position of water valve changes as 1
P091003008
selected temperature changes. A potentiometer detects
position of water valve and sends information back to FIG. 32
control module.
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79033095 C Rev. 11-31

Systems Operating
ACTUATOR MOTOR (WATER VALVE)
FIG. 33: Actuator Motor Components
1
Water Control Valve (2)
4
Coolant Supply Line (3)
Coolant Return Line (4)
2 3 P091003007
FIG. 33
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Schematic for Testing the Water Valve

FIG. 34: Water Valve Schematic
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(A) Inside Actuator

(B) 6-Pin Actuator
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N020803023
FIG. 34
11-32 79033095 C Rev.

Systems Operating
AIRFLOW
Airflow Components
8 2
3
1
1
4
5
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6
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N020803024
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FIG. 35
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FIG. 35: Airflow Components

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Air Filter (Fresh Air) (2)

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Air Filter (Recirculation) (3)

Damper Control (Deluxe Cab) (4)
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Recirculated Air Inlet (5)

Fresh Air Inlet (6)
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Blower Fan (7)

Sealing Area (8)
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Blower Fan
FIG. 36: Internal components with rear cover removed
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Blower (5) is located in heating, ventilation and air

conditioning unit.
Blower can produce a maximum airflow of 400 cfm (11.3 3
cubic meters/minute), producing surround flow delivery of 4 5
air. Air is directed through vents positioned in high and low
positions. 6
Blower has the following openings:
Inlet for fresh and recirculated air (4).
Outlet for vents on left side of cab (1). 1 2
Outlet for vents on front console (3). P091003006
Outlet for vents on right side of cab (6). FIG. 36
Motor (2) drives blower.
79033095 C Rev. 11-33

Systems Operating
Airflow Intake
Heating, ventilation and air conditioning unit draws air
from fresh air inlet and heating, ventilation and air
conditioning unit recirculates air in cab.
Heating, ventilation and air conditioning unit is
designed to draw 20% fresh air from outside and
80% air from inside of cab and is not adjustable.
Fresh Air
FIG. 37: Fresh airflow
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P091003005
FIG. 37
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FIG. 38: Fresh air filter

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Fresh air is drawn through cab filter (1) located above cab
door. Filter collects dust particles from air. Air travels down 1
rear cab supports to heating, ventilation and air
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conditioning unit.
Maintenance of air filter (cab)
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If necessary, filter should be cleaned or replaced. Ensure

seal on filter still seals to ensure dust is not drawn into
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system.
N050103008
Recirculation
on
FIG. 38
FIG. 39: Recirculated air intake
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P091003004
FIG. 39
11-34 79033095 C Rev.

Systems Operating
FIG. 40: Recirculated air filter
Recirculated air is drawn through cab recirculation filter
located behind operator's seat. Recirculation filter (1)
collects dust particles from air. 1
Heating, ventilation and air conditioning unit is directly
behind filter.
Filter should be cleaned, inspected or replaced when
necessary.
N050103012
FIG. 40
Head, Foot and Defrost

FIG. 41: Airflow to vents
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Vents on front console direct cab airflow toward operator's

top, sides and feet.
Rear posts for ROPS are incorporated with air ducting.
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Operator has ability to control vents in all cabs. However,

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deluxe cab uses a motorized damper to control airflow for

front console.
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Damper is automatically controlled by control module. If

tractor is not equipped with deluxe cab, operator must
adjust vents for desired direction of flow.
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P091103008
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FIG. 41
MOTOR (AIR CONDITIONING BLOWER)

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FIG. 42: Blower components

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Fan (1) is located in heating, ventilation and air

conditioning unit and is used to circulate air for heating,
ventilation and air conditioning system. Motor (2) drives 1
on
fan.
Motor rotation is clockwise.
2
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Automatic Temperature Control (Fan)

Auto Mode
Fan speed is determined by system and is based on N050803008
difference between setpoint and actual temperature in
FIG. 42
cab. A larger difference in temperature results in a faster
fan speed.
Heating or cooling occurs if temperature in cab is too hot
or too cold. Fan speed is held to a minimum. This
condition occurs when cab is heating or cooling quickly
and temperature overshoots setpoint temperature.
79033095 C Rev. 11-35

Systems Operating
In automatic mode, fan speed is limited by temperature of
outlet duct. If temperature of duct is less than 22 degrees
C (72 degrees F), fan speed is limited to low speed. Fan
speed gradually increases as temperature of duct
increases. This continues until temperature of duct
reaches 35 degrees C (95 degrees F). Limit is disabled if
a duct temperature sensor error occurs. In automatic
mode, all changes in fan speed are done gradually.
Manual Mode
Fan speed directly corresponds to position of fan speed
control. Control is a potentiometer allowing infinite
adjustment. Initial fan speed on start-up gradually
increases to desired fan speed. As more light is detected
on solar sensor, fan speed increases in proportion to
amount of light detected. Any changes in fan speed due
to solar load is gradual. Solar load sensor will only be able
to change fan speed by about 33 percent of total range. If
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fan speed is set on low, effect of full solar loading will not
be able to force fan to high speed.
Manual Fan Control

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Manual fan speed switch provides operator with five

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speed selections, including off. Fan speed is independent.

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11-36 79033095 C Rev.

Systems Operating
SPEED CONTROL
Automatic Fan Speed Control

Speed controller consists of control panel and main
control module. Fan speed rotary control must be
positioned to AUTO to allow automatic control of fan.
Speed controller for fan regulates amount of voltage
supplied to blower motor. Controller operates in a linear
mode on ground side of blower motor.
Fan speed controller also provides thermal protection in
the event of a short circuit. This protection is also provided
for a stalled motor or any other condition causing
excessive heat sink temperature. Limit of output current is
proportional to sensed output voltage causing current to
feedback in event of a stalled motor or a short circuit to
Vbatt. Output faults cause temperature in heat sink to
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rise. Insufficient airflow also causes temperature in heat

sink to rise. Thermal protection is a two-stage process.
When heat sink temperature is greater than
approximately 70 degrees C (158 degrees F), thermal
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protection causes output to attempt maximum output

voltage. If temperature in heat sink continues to rise
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above approximately 105 degrees C (221 degrees F),

output turns off. Output turns on when heat sink
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temperature lowers to approximately 70 degrees C (158

degrees F).
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Manual Mode Fan Speed Control

Fan speed directly corresponds to fan speed control
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position. In automatic or manual mode, initial fan speed

on start-up gradually increases to desired speed.
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Sunlight Sensor
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FIG. 43: Sunlight sensor

(1) Sunlight sensor
(2) Console
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Sunlight sensor affects automatic and manual fan speeds.

As more sunlight is detected, fan speed increases. Any
changes in fan speed are gradual. Controller changes 2
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speed by 33% of complete speed range.

1
P091103009
FIG. 43
79033095 C Rev. 11-37

Systems Operating
ACTUATOR MOTOR (DAMPER
ASSEMBLY)
FIG. 44: Actuator motor schematic
Actuator motor (1)
Inside actuator (2) 1
2-Pin connector (3)
Actuator motor is used in one position on heating,
ventilation and air conditioning system to control a 2
damper for airflow to front window defrost.
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N020803033
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FIG. 44
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11-38 79033095 C Rev.

Systems Operating
LUBRICANTS IMPORTANT: Heavy duty vehicles are subject to severe
extended use and much more vibration and road
Lubricants, like other system components, are developed shock than passenger cars. For this reason,
for use with specific refrigerants. Mineral oil works very secure compressor mounting, accurate pulley
well with R-12 but becomes chemically unstable with alignment and proper belt tension are very
R-134a. important. The compressor mounting bracket is
adjustable to allow for proper belt tension.
Polyalkylene glycols, called PAGs, are being considered
by many for use with R-134a. In addition, a family of Pulley alignment and belt tension are critical for efficient
ester- based lubricants are being given serious compressor operation and good belt life. To tension V-belt
consideration. properly, compressor or it’s mounting bracket must be
adjustable and securely bolted in position when attached
Lubricants are in system to protect compressor from wear
to engine.
and failure. With R-134a compressor manufacturer
specifies lubrication best suited to its product. On new
R-134a systems labeling should identify the type and Clutch
amount of lubricant. Clutch is driven by engine through a V-belt running in a
All PAG-based lubricants are not necessarily the same. grooved clutch pulley. Clutch pulley rides on ball bearings
Different compressor manufacturers use different and can turn without driving compressor shaft. Heavy
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additives. Unlike mineral oil lubrication for R-12, you may duty clutches have double row ball bearings. An
need to keep several different lubricants on hand for use electromagnetic coil is mounted inside pulley housing and
with R-134a. bolted to compressor body. Clutch drive plate is bolted to
compressor shaft. There is a small amount of clearance
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In retrofit systems, use lubricant recommended by between plate, pulley and oil.
compressor manufacturer.
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When air conditioning system thermostat control in

Lubricants coming out of an air conditioning system evaporator calls for cooling, current flows through coil
should never be reused. Contaminants and moisture are inside pulley. This sets up a magnetic field between drive
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probably contained in such material. plate and pulley. Magnetic field locks pulley to drive plate,
causing pulley to turn compressor shaft. When clutch is
Compressors
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not engaged, pulley spins free without turning

compressor.
When compressor is engaged and driven by engine
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through clutch pulley, compressor functions as a pump to Electrical connection to clutch coil is made through lead
move refrigerant and refrigeration oil around air and ground wire.
conditioning system. Compressor pistons move back and
forth within their cylinders as compressor shaft revolves. Condensers
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A special lubricating oil is used for each air conditioning

Condensers transfer heat energy to outside air.
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compressor. This oil, called refrigeration oil, is formulated

to be moisture-free and compatible with refrigerant used. Refrigerant flows through condenser tubing from top to
It circulates throughout air conditioning system. bottom. Fittings are located for convenience of assembly.
Lubrication used with R-12 is not compatible with R-134a. As hot refrigerant gas from compressor moves through
condenser tubing, it gives up heat energy to outside air
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We generally refer to an air conditioning system as having stream. Refrigerant gas becomes cooler and at the right
a suction or low (pressure) side and a discharge or high temperature and pressure will “change state” in
(pressure) side. The two sides of system are divided at condenser and become a liquid. This change usually
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compressor and at expansion valve (refrigerant metering takes place in the bottom third of condenser.
device) coated at inlet to evaporator.
Condenser function requires movement of a large
Compressor pulls refrigerant gas from evaporator, amount of air between condenser fins. Air passing
through low pressure suction hose, inlet service valve and through fins absorb BTUs of heat energy from hot, high
one-way reed valves and into compressor. During pressure refrigerant gas inside condenser. Engine
compression strokes, refrigerant gas is forced out of radiator or auxiliary fans must work properly and the
compressor through more one way reed valves, an outlet condenser fins must be kept clear of debris or
service valve and a high pressure discharge hose to obstructions for efficient condenser function.
condenser. Pressure from compressor action moves
refrigerating through condenser, receiver-drier and NOTE: When refrigerant gas gives up heat to outside air
connecting hoses to expansion valve. and becomes a liquid inside condenser - it is still
hot.
Power to the compressor is delivered through the clutch
pulley. Pulley is driven by a V-belt connected to another Most condensers are mounted in front of radiator and
pulley powered by engine. attached to radiator supports for hood assembly. This
location is the least costly for several reasons: engine
cooling fan eliminates the need for a separate condenser
motor/fan assembly; refrigerant hose to and from
condenser can be shorter and condenser is better
protected from the weather.
79033095 C Rev. 11-39

Systems Operating
Receiver-Drier
Receiver-driver functions as a drier, refrigerant filter and
temporary storage tank for refrigerant moving through air
conditioning system. When refrigerant leaves condenser
as a liquid, it flows to receiver-drier. Refrigerant enters top
and flows through a desiccant material and filter before it
moves on through a pickup tube near tank bottom. The
most common desiccant is a molecular sieve. This is a
porous material, usually in the form of 1/8 inch balls,
attracting and holding moisture.
NOTE: Moisture (water) or particles can cause system
malfunctions and corrosion. They can block
natural flow of refrigerant at expansion valve.
Moisture can change state there and form ice. It
may also mix with other elements inside system
(refrigerant and oil) to form acid.
Some refrigerant leaving condenser is part liquid and part
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vapor. When this happens, receiver-drier acts as a

separator. Liquid refrigerant settles to bottom of tank
where pickup tube inlet is located. Receiver-driers vary in
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size and shape and many have a sight glass to aid in

system diagnosis and charging. A sight glass may include
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a moisture indicator to alert if system is contaminated with

moisture. There are high capacity units, variations in
mounting location, fitting types and number and position
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of filter elements for receiver-driers.

Sandwiched between the two metal baffles are a screen,
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two fiberglass filter pads and at least ten cubic inches of

desiccant. In this design, desiccant is squeezed between
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two filter pads. This helps prevent movement of molecular

sieve material as refrigerant flows through. As a result,
there is less chance of desiccant breakdown and loss
material reaching and blocking expansion valve.
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Air conditioning system design may include single or

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multi-function pressure switches, a pressure relief valve or

fuse plug. These are usually mounted on or connected to
receiver-drier.
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Air Conditioner Blower/Fan and Motor

Assembly
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In heating, ventilation and air conditioning systems a

blower assembly is positioned to move air through
evaporator coil and heater core. For efficient air
movement, air must be confined within a housing.
Fans are used to move air through fins of condenser.
Air Conditioner System Ducts

System ducts control airflow direction. Air conditioning
system ducts.
11-40 79033095 C Rev.

Systems Operating
Receiver/Drier
FIG. 45: Liquid refrigerant continues to move inside
system, out of condenser through a tube or hose to
receiver-drier. Receiver-drier (1) serves as a small
storage tank and filter for refrigerant. It is also a good
location to mount pressure switches and often contains a
sight glass (small window) used to view activity inside
system. Receiver-drier (1), also separates gas (bubbles) 1
from liquid with a pick-up tube.
Receiver/drier (1) is attached to condenser mounting
frame on rear of condenser. It is a storage tank which
receives high pressure, cool liquid refrigerant from
condenser through an inlet line and delivers refrigerant
through an outlet line to thermostatic expansion valve.
P111303006
Receiver/drier (1) stores liquid refrigerant to be sure a FIG. 45
steady flow to thermostatic expansion valve is maintained
under widely different operating conditions.
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Receiver/drier consists of several components:

Drier section contains a desiccant to absorb any moisture
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within system and a filter prevents entry of foreign

particles.
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A high-pressure relief valve, mounted on outside of

receiver/drier, provides protection for system in case of
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extremely high pressure spikes.
Receiver/Drier Sight Glass

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A sight glass is located on top of receiver/drier. Sight

glass normally shows a solid column of refrigerant. Sight
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glass is used to observe condition of refrigerant as

follows:
Clouded - Desiccant is escaping from receiver/drier and is
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circulating through system. Receiver/drier must be

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replaced and system purged (refrigerant replaced).

NOTE: At high ambient temperature above 38 degrees C
(100 degrees F), a cloudy sight glass does not
indicate abnormal operation.
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Oil Streaks, Foam or Bubbles - Insufficient refrigerant in

system. Occasionally bubbles during initial operation is
normal.
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Clear - A correct charge, an overcharge, or a complete

lack of refrigerant. An overcharge is indicated when test
gauge readings are above normal.
NOTE: Any moisture in air conditioning system is
extremely harmful. Moisture not absorbed by
receiver/drier will circulate with refrigerant and
droplets may collect and freeze in the
thermostatic expansion valve orifice. This action
blocks refrigerant flow and stops cooling action.
Moisture reacts with refrigerant R134a to form a
corrosive hydrochloric acid.
79033095 C Rev. 11-41

Systems Operating
Desiccant can only absorb a limited amount of moisture Block or H-type expansion valve gets its name from
before reaching saturation point and ability to retain cross-sectional view of valve.
moisture is dependent upon temperature. As temperature
There are two refrigerant passages which form legs of
increases, ability to absorb decreases. This explains why
“H”. One passage is in high-pressure refrigerant line from
an air conditioning system may operate satisfactorily
receiver/drier to evaporator inlet. Other passage is
when outside temperatures are low but stop cooling when
low-pressure refrigerant line from evaporator to
ambient temperatures increase and saturated desiccant
compressor.
releases moisture into system.
Expansion valve contains a “thinking” or master segment
Expansion Valve which is coupled to slave segment actually accomplishing
desired action. Master segment is on evaporator outlet
When refrigerant moves from receiver-drier, it travels line, where pressure and temperature are monitored.
through another high pressure hose to a metering device Slave, or actual control valve, is located on evaporator
at inlet of evaporator coil. Metering device can be an inlet line.
expansion valve, an expansion tube or a combination
(multiple function) valve. Between compressor and this During manufacture of expansion valve, refrigerant is
point inside system, pressure is high and can range from permanently sealed in a chamber, above diaphragm. A
150 to 250 pounds per square inch. Expansion valve metal pin acts as an internal temperature sensing probe
(TXV) is closely connected to evaporator. A diaphragm and conducts evaporator outlet heat to sealed refrigerant
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opens valve by exerting pressure on spring. Pressure above diaphragm. Evaporator outlet pressure acts on
comes from gas inside diaphragm housing on top of valve underside of diaphragm. Diaphragm movement is
and in sealed sensing bulb. Sensing tube is located in transmitted to ball and spring valve via pushrod.
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outlet of evaporator. Gas in valve diaphragm housing and Liquid refrigerant flow is controlled by opposite forces of
sensing tube expands when it gets warmer and forces pushrod forcing ball off its seat and valve spring exerting
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expansion valve open at metering orifice. pressure on ball to keep it on its seat.
Expansion valve is located in cab air box. It is connected During air conditioning “off” condition, pressure on bottom
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to inlet and outlet lines leading into evaporator and of expansion valve diaphragm rises above pressure on
performs the following functions: When refrigerant moves top of diaphragm, allowing valve spring to close valve.
from receiver-drier, it travels through another high
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pressure hose to a metering device at inlet of evaporator When air conditioning system is activated, expansion
coil. Metering device can be an expansion valve, an valve meters refrigerant flow to evaporator by sensing
expansion tube or a combination (multiple function) valve. system pressure and temperature in outlet line of
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Between compressor and this point inside system, evaporator core.

pressure is high and can range from 150 to 250 pounds A pressure decrease or temperature increase in
per square inch. Expansion valve (TXV) is closely
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evaporator outlet line causes diaphragm to move

connected to evaporator. A diaphragm opens valve by downward. Pushrod moves downward and forces ball off
exerting pressure of spring. Pressure comes from gas
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its seat allowing refrigerant to flow into evaporator.

inside diaphragm housing on top of valve and in sealed
sensing bulb. Sensing tube is located in outlet of A pressure increase or temperature decrease in
evaporator and picks up heat from warm refrigerant evaporator outlet line causes diaphragm and pushrod to
leaving evaporator. Gas in valve diaphragm housing and move upward. Spring forces ball onto its seat in orifice
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sensing tube expands when it gets warmer and forces closing off refrigerant into evaporator.
expansion valve open at metering orifice.
• Metering action - a metered orifice changes liquid
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refrigerant from a high to a low pressure.

• Modulating action - a thermostatically controlled valve
within expansion valve body controls volume of liquid
refrigerant passing through orifice and ensures
refrigerant is fully vaporized within evaporator. Liquid
refrigerant can damage compressor.
• Controlling action - valve responds to changes in
cooling requirements. When heat load on system
increases, valve opens to increase refrigerant flow
and, when less cooling is required (or increased
compressor volume due to increased engine speed),
valve closes and decreases refrigerant flow.
Operation
All needed temperature and pressure sensing functions
are consolidated into this basic unit and no external tubes
are required for these purposes.
11-42 79033095 C Rev.

Systems Operating
Temperature Sensors
Temperature sensors are used for automatic temperature
control system. Deluxe cab is equipped with this option
and uses the following temperature sensors:
• Temperature of cab airflow
• Outside (ambient temperature)
• Ventilation duct temperature
• Evaporator core probe
Heater System Operation

Heater and air conditioner systems both have same basic
function of moving heat, taking advantage of nature’s laws
where heat energy always moves from a warmer to a
cooler area. In a heater system there is no “change of
state” involved in system operation. System is sealed and
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operates under pressure, but pressure is low when

compared to an air conditioner.
A heater system uses engine coolant to carry excess heat
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energy to cab air. Heart of system is water pump. Water

pump forces hot coolant through a hose from engine
in
block and through heater core. Coolant is returned to

engine cooling system either at suction side of water
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pump or to radiator.
A control cable, attached to a water valve between water
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pump and heater inlet, is used to control flow of coolant to

heater. Heater fan or blower forces cab air through heater
core where heat energy moves from engine coolant to air
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in cab.
Heater Components and Controls

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Engine Coolant or Anti-freeze

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Ethylene glycol-type coolant (anti-freeze) is mixed with

water and used in most vehicle cooling systems today.
Additives in coolant formula lubricate water pump, reduce
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chance of rust or corrosion, and prevent foaming.

Although it is often called permanent anti-freeze, additives
break down in time and loose their protective qualities.
For this reason, coolant should be changed at regular
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intervals. Five main reasons to use coolant in engine are:

1. It has a much lower freezing point than water.
2. It has a higher boiling point than water.
3. It is inexpensive.
4. It prevents corrosion for a reasonable period of time.
5. It absorbs and gives off heat energy effectively under
a great range of operating conditions.
79033095 C Rev. 11-43

Systems Operating
Mixing 60% ethylene glycol with 40% water protects
cooling system from freezing to -65 degrees C (-85
degrees F). Adding more anti-freeze does not prevent
freeze up at lower temperatures, cut it does raise boiling
point of solution.
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WARNING: Use care in handling
anti-freeze. It is a petroleum based liquid
that can irritate skin and eyes. Sweet taste
is appealing to animals and can be deadly if
consumed. Check for local regulations on
disposal and recycling.
Cooling System Thermostat and Radiator Pressure

Cap
These two cooling system control devices affect heater
system operation, including coolant temperature,
circulation, boiling point and coolant overflow and
recovery system.
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1. Thermostat - controls direction of coolant flow from

water pump, through engine and radiator. As engine
warms up thermostat opens, allowing coolant to flow
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to radiator. Coolant gives up excess engine heat to

outside air as it moves through radiator. If engine is
in
cold, thermostat stays hot and coolant by-passes

radiator and circulates in engine, as well as heater
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core.
2. Radiator - radiator cap seals cooling system at inlet
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on top of radiator. Caps are pressure rated to match

cooling system design. Each pound of pressure on
cooling system raises boiling point of coolant -16
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degrees C (3 degrees F), so pressure cap extends

cooling system operating range above normal boiling
point. Coolant can flow through heater core
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regardless of thermostat position.

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Altitude lowers boiling point of coolant by -16 degrees C

(2 degrees F) for every 1000 foot increase of elevation
above sea level. Pressure cap tends to compensate for a
lower boiling point at higher altitude. When high system
on
pressure forces radiator cap to open, coolant escapes to

coolant reservoir. A low pressure or slight vacuum inside
system sucks coolant back to radiator from reservoir.
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Water Pump
Modern water pumps have a centrifugal design. Vanes or
impellers in pump circulate coolant.
Heater Components and Controls

Basic heater system components discussed:
1. Heater core
2. Heater system ducts
3. Blower or fan and motor assembly
4. Hoses and fittings
5. Controls
11-44 79033095 C Rev.

Systems Operating
Heater Core
Most heater cores are of tube and fin construction, with
inlet and outlet on one end of core. Hoses connect core to
engine and are held securely by hose clamps. In heater
core heat energy moves from hot engine coolant to air in
cab.
Heater System Ducts

Ducts direct and control air as it circulates through
heating system. Heater core housing is usually part of
duct system as is blower or fan assembly. Air outlet duct
openings are usually located close to floor. Outlets are
positioned to direct warm air to feet and body of
occupants.
All heater/defroster systems pick up some outside air and
mix it with cab air. They often have doors inside duct
system to regulate, mix or restrict airflow as part of heater
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components. Arrows indicate airflow pattern through duct

system. This view of a typical heater system does not
include heater hoses, clamps, a water valve or controls.
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Blower or Fan and Motor Assembly

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Air movement in a heater system depends on blower or

fan. Operator selects motor speed to control amount of air
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circulated through system. Motors have one to four

speeds, depending on heater design. Both single and
double entry blower wheels are used.
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Hoses and Fittings

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Heater hoses are usually 5/8”, but may be 3/4” or 1” sizes.

Heater inlet hose may be smaller or same size as heater
outlet hose. Hoses are usually held in place by clamps.
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Some water valves shunt excess flow or pressure back to

coolant return hose, assuring full flow of coolant and
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relieving pressure on valve.
Controls
Controls allow operator to turn heater on and off and
on
regulate direction and quantity of warm airflow. When

system is turned on, water valve opens to allow hot
engine coolant to flow through heater core. Blower motor
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circulates cab air through heater core to warm air. Water

valves may be cable or air operated.
In a typical heater system, other controls encountered,
position doors inside ducts to direct airflow. Defroster
control is main one found in basic heater systems. This is
usually a cable controlled door diverting warm air to
windshield or floor.
In heating, ventilation and air conditioning systems the
number of doors in system and their function vary
depending on system design. Doors operate electrically,
manually or automatically, by cable, vacuum, compressed
air or by some combination of these controls. In certain
heating, ventilation and air conditioning systems, defrost
mode activates air conditioning system. Air conditioner
dries heated air flowing to clear windshield.
79033095 C Rev. 11-45

Systems Operating
SERVICE TOOLS Air Conditioning System Service Tools
The basic air conditioner and heater service tools include Basic air conditioning tools include:
some special tools and test equipment as well as normal
1. Recovery/recycling station
tool chest items. In this section is described and
explained basic tools, test and other equipment, and 2. Refrigerant dispensing valves and containers
safety.
3. Manifold gauge set
Safety and Safety Tools 4. System service valves
Safety is important to all individuals in the work 5. Vacuum pumps
environment. Air conditioner and heater systems are as 6. Leak detectors
safe or safer to work on as other vehicle systems, but a
little different. 7. Flushing kit
While servicing heating, ventilation and air conditioning 8. Heater system service tools
systems there is exposure to high pressures,
9. Other equipment
temperatures and several chemical hazards. Moving belts
and pulleys are normal shop hazards.
Recovery/Recycling Station
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In addition to exercising caution in work, always wear

Recovery/recycling station performs two closed loop
safety goggles or a face shield when using refrigerant or
processes. Station removes refrigerant from air
Halide leak detector, adjusting service valves or manifold
conditioning system in recovery mode. Refrigerant is
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gauge set connectors. Safety goggles or a transparent

contained in an external cylinder for storing, recycling,
face shield are practical safety items. One or the other is
reclaiming or transporting. Typically, refrigerant is not
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absolutely required.
reusable until it is recycled. Contaminants in refrigerant
Refrigerant inside a container and in parts of air are reduced in recycle mode. Contaminants could include
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conditioning system is a liquid under pressure. When moisture, acidity and particulate matter.
refrigerant escapes or is released to the air, its
NOTE: Separate stations are required for R-12 and
temperature drops instantly. If it spills on skin or in eyes,
R-134a.
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flood area with cool water and seek medical attention

immediately.
Refrigerant Dispensing Valves and Containers
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Compressor creates pressure when it runs. If pressure

Bulk containers should always be used with a scale or
get too high, the weakest point may separate or blow out.
charging station capable of measuring refrigerant put into
A system restriction, too much refrigerant, or improper
system.
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charging procedures are all potentially dangerous.
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WARNING: All containers with refrigerant
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Someone else may have serviced the system before and

are under pressure (to contain refrigerant).
put too much refrigerant in air conditioner. The only way to
Any heat increases pressure. Containers
know how much refrigerant is in system is to take it all out.
are not designed to withstand excessive
Evacuate system and charge it with a weighed amount of
heat even when empty and should never be
refrigerant, based on manufacturer specs. If too much
on
exposed to high heat or flame because they

refrigerant is in system for proper cooling and more is
can explode.
added, a component may rupture and serious injury may
follow.
There are several other tools that could be used when
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R-12 refrigerant becomes a poisonous gas when it burns. charging an air conditioning system with refrigerant.
Do not smoke around refrigerant. These are a charging meter (refrigerant scale) or a
charging station.
Do not grab hold of a clutching fan to stop it when it is
disengaged but turning at low RPM. The fan can seriously Manifold Gauge Set
injure hands.
Manifold gauge set is a tool used for internal system
Be sure work area has plenty of ventilation and no gas or diagnosis and service. A typical manifold has two screw
other fumes are present. Do not use a Halide leak type hand valves to control access to system, two gauges
detector or refrigerant without adequate ventilation. Do and three hoses. Gauges are used to read system
not run vehicle engine during a performance inspection or pressure or vacuum. Manifold and hoses are for access
when charging system without adequate ventilation. to inside of an air conditioner, to remove air and moisture
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CAUTION: Fire or explosion hazards exist and to put in or remove refrigerant from system. Shutoff
under certain conditions with R-134a. A valves are required within 12 inches of hose ends to
combustible mixture can form when air minimize refrigerant loss.
pressures are above atmospheric pressure
and a mixture of air and R-134a exist. For
this reason do not pressure test air
conditioning systems with compressed air.
11-46 79033095 C Rev.

Systems Operating
Manifold gauge sets are color coded. An R-12 gauge set System Service Valves - 134a only
normally has a blue low side hose, a red high side hose
New and unique service hose fittings have been specified
and a yellow or white utility (center) hose. An R-134a
for R-134a systems. The purpose is to avoid cross-mixing
gauge set will have a blue hose with a black stripe for low
of refrigerants and lubricants with R-12 based systems.
side, a red hose with a black stripe for high side and a
Service port on system are quick disconnect with no
yellow hose with a black stripe for utility (center) hose.
external threads. Low side fitting has a small diameter
Different style end fittings are used on R-12 and R-134a than high-side attachment.
hose sets. R-12 hose sets use a 1/4 female refrigeration
flare (FFL) on all hose ends. A shutoff valve is required on Vacuum Pumps
all three hoses with 12 inches of end connected to air
Air and moisture inside an air conditioner contaminate
conditioning system or service equipment. R-134a hose
system. The combination of refrigerant and refrigerant oil
sets use a 1/2 ACME female nut on gauge end. Special
form acid and sludge. Moisture inside a system can
quick disconnect couplings are normally combined with a
freeze at expansion valve orifice, blocking flow of
shutoff valve on high and low side hoses. Free end of
refrigerant temporarily. The result is erratic system
utility hose contains a 1/2 ACME female nut and a shutoff
function. A vacuum pump is used to remove air and
device within 12 inches of hose end.
moisture from inside of hoses and components of air
These special hoses and fittings are designed to minimize conditioner, but special care must be taken to keep
refrigerant loss and to preclude putting the wrong components clean and moisture free.
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refrigerant in a system.
When vacuum pump is hooked up to system through
Two hoses (left and right) connect to low and high sides of manifold gauge set (service valves are open), pump
system, usually at compressor on R-12 systems. Center sucks air out. Result is a negative pressure or vacuum.
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(utility) hose is used to remove refrigerant from system, Air is removed in just a few minutes. However, humidity in
evacuate air and moisture, or add refrigerant. Gauges are air may condense inside system so moisture must be
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calibrated for either high or low pressure and vacuum. removed. Moisture vaporizes in a vacuum when a
The term compound gauge set is often used because low sufficient vacuum level is reached. Vacuum level is
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pressure gauge responds to pressure and vacuum. measured in inches of mercury. Vacuum pump must
Separate gauge sets are required for R-12 and R-134a. operate long enough to cause any condensed moisture
inside to vaporize so pump can suck it out of system.
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IMPORTANT: Many gauges have dials with metric and

US scales to measure pressure. The more In heavy duty applications it is most difficult to remove
expensive manifold gauge sets have liquid filled moisture as hoses have more bends and connections
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gauges and additional valves and fittings where moisture can hide. For this reason, vacuum pump
incorporated in manifold. All gauges are capacity and length of pumping time are important. A
breakable and should be handled with a higher pump capacity and longer pumping time ensure all
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reasonable amount of care. moisture is out of system. There are two types of vacuum
pumps, rotary vane and piston type, which require an
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High pressure gauge registers system pressure from 0 -

electrical source for power. Rotary vane pumps are
3447 kPa (0 to 500 psi). Low pressure gauge registers thought by many to be superior because they are
pressure from 0 to 140 kPa (0 to 1034 psi) clockwise and powerful and quiet.
vacuum from 0 - 762 (0 to 30 in Hg) counter clockwise.
on
There are a few important rules and procedures that must Leak Detectors
be followed concerning gauge set hookup. Both rules and
Halide Leak Detector (R-12)
procedures are for safety and to protect air conditioning
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system. Basic rules are covered briefly here. Gauge set There are two types of leak detectors in use. Least
hookup should not be done until after performing a expensive is called a Halide leak detector.
complete visual and performance inspection of all air
conditioning system components. Inspect engine, cooling A Halide propane torch leak detector can be used to find
system and other engine drive devices. Engine cooling system leaks as low as five ounces per year. It includes a
propane tank and torch assembly. Torch assembly
system problems can cause false gauge readings and
incorrect air conditioning system diagnosis. Worn drive includes a control valve and tube, pickup hose, orifice at
belts or hoses are dangerous to work around. top of tube and copper reactor plate. A chimney
surrounds the orifice and copper plate and has a window
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WARNING: Never attempt to hook up cut out. Chimney shields propane gas flame. Flame color
manifold gauge set with engine running. is analyzed through window.
Never connect gauge set until ensuring
hand valves on manifold are closed. Never
connect gauges to air conditioning system
until a visual and performance inspection
are complete.
79033095 C Rev. 11-47

Systems Operating
In use, ignite propane and adjust flame to heat up reactor A thermostat tester has a built in thermometer and a
plate. Burning propane gas sucks air up pickup tube heating element. Put water and thermostat in tester, turn
(oxygen in air also burns with propane). To detect leaks, on heating element and observe thermostat to see if it
move pickup tube slowly about air conditioning system. functions. Thermostat should begin to open at from -13 to
Take care to move tube below potential leak points -16 degrees C (3 to 9 degrees F) below it’s rated
because R-12 present is drawn up tube and burned. temperature and should be fully open at rated
When R-12 is present in flame, copper reacts with it and temperature.
flame changes color.
Other Equipment
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WARNING: An open flame in shop is
dangerous. Halide leak detector should be Pulley alignment bar and belt tension gauge may already
used with care. Be sure there is adequate be a part of normal tool chest items. They are good tools
ventilation to carry away fumes from torch. to have for other service work. In air conditioning systems,
Remember refrigerant changes to a belt alignment and tension are important for efficient
poisonous gas when burned. compressor clutch operation and belt and clutch bearing
service life.
Electronic Leak Detector
A fin comb is used to clean bugs and debris from
Electronic leak detectors are safer than Halide system condenser and evaporator fins and straighten if bent.
and about ten times more sensitive. Some designs can These combs are made of molded plastic with a series of
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detect an R-12 or R-134a leak as low as one half ounce grooves to correspond with condenser and evaporator fin
per year. There are two types of electronic detectors, spacing.
positive ion and negative corona. These technical terms,
Dial-type or digital thermometer is used to measure
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positive ion and negative corona, are used in describing

temperature at evaporator fins or air coming out of ducts.
the electronic elements and their function in these
in
detectors. Negative corona type detector has a longer A variety of compressor service tool kits are available.
service life and require less power. These contain special tools need for clutch removal,
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compressor tear down, service and repair. To check

Electronic detectors have a probe moved around air
compressor oil level, make own oil dipstick or purchase
conditioning system. Where refrigerant is present, a
one for each type of compressor.
change in current flow inside probe is sensed by an
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electrical circuit. This activates a buzzer which signals Compressor oil injectors are available connected to
user of a refrigerant leak. manifold gauge set or charging station to dispense
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refrigeration oil.
Flushing Kit
It’s a good idea to have a torque wrench, a vacuum tester,
A flushing kit is used to remove contaminants from air a Schrader valve core remove/installer and any other
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conditioning system hoses, evaporator and condenser. special system tests needed if servicing specific systems.
Any other components should be bench checked or
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replaced as flushing is either not effective or will cause Earlier mentioned, refrigerant scales or charging meters
damage. Flushing these components is recommended and charging stations. They are all designed to provide an
when replacing compressor or finding contamination in accurate measure of refrigerant used when charging air
other system components (receiver-drier, expansion conditioning system. More elaborate charging stations
on
valve or at connection). Flushing must be done with a combine refrigerant supply, manifold, gauges, a heated
“closed-loop: flushing kit using Recovery/Recycle station. charging cylinder, hoses and vacuum pump on an easily
moved cart or stand. Some even have refrigeration oil
dispensing and leak detection capability built in. The more
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Heater System Service Tools

expensive units have electronic controls.
In addition to normal tool box items, several test devices
are required for effective cooling system service. These Charging Stations, Basic Description of Use
are a pressure tester, hydrometer and thermostat tester.
Pressure tester is a simple hand pump with a pressure 1. After repairing air conditioning system use station to
gauge, hose and adapters. Adapters are used to connect evacuate air and moisture. Station adds
tester to radiator filler neck or to pressure cap. Use pump recovered/recycled refrigerant to air conditioning
to apply pressure to cooling system or cap. Check for system. A metering device is used in conjunction with
system leaks or for cap function. this station to monitor amount of refrigerant added.
A special cooling system hydrometer is used to draw 2. This all purpose recovery/recycling/recharging station
coolant from radiator into a clear tube containing a float. provides all necessary service features in one
Float has a scale read and related to a scale on package. Station recycles refrigerant during
hydrometer. Hydrometer scale corresponds to a evacuation cycle. A microprocessor control allows
temperature level at which coolant freezes. automatic recovery shutoff, programmable
evacuation and charging cycles.
11-48 79033095 C Rev.

Systems Operating
Other electronic devices worth consideration are an IMPORTANT: Even when operator alerts as to what is
electronic digital thermometer or electronic sight glass. wrong heating, ventilation and air conditioning
The advantage of electronic thermometer is reading system, perform a visual inspection. Always
speed (it will give a reading in a few seconds or less), make a visual inspection before connecting up
accuracy and temperature range, all in one unit. manifold gauge set. Never add refrigerant to a
system until a complete visual and performance
NOTE: Separate charging stations are required for R-12 inspection is complete.
and R-134a.
Electronic sight glass is an ultrasonic device with two Inspect Parts
sensors. Sensors are clamped to a metallic tube (not a Look at system for what might come loose, leak, wear out
hose) carrying refrigerant inside system and connected to or become dirty and not function the way it should.
an electronic signaling device. Type of refrigerant
metering device used in system and where electronic • Condenser - Is it free of leaves, bugs, bird feathers or
sight glass is clamped affect how tester signals system mud? Condenser must be relatively clean to work
charge condition. well as a heat exchanger. Condenser fin comb, air
hose and nozzle, or soap and water may be used.
Inspection & Maintenance-without gauges Where possible, check condenser mounting bolts or
screws and tighten if necessary.
There are three main reasons for regular inspection and
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maintenance procedures: Condenser failure often results from loose hoses.

Hose movement causes fatigue failure of condenser
1. Save money in the long run by reducing down time tubing adjacent to fittings. Make sure hoses are
and often prevent more costly repairs. securely clamped.
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2. Help insure driver comfort and safety. While inspecting condenser check receiver-drier sight
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3. They add to store of knowledge about systems and glass and connections. Look to see if sight glass has
maintain level of efficiency. a moisture indicator showing moisture in system.
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NOTE: Following inspection procedure should take • Components Under Hood

about 15 to 20 minutes, longer if corrective steps, Look at compressor mounting bracket, compressor
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part replacement or adding refrigerant is clutch assembly, drive belt and pulley alignment.
necessary. Mounting bracket, compressor, clutch and drive
pulley should be fastened securely and a clutch
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Visual Inspection-System Off groove (there may be two grooves) should be in line
Observations and corrective measures taken may be with drive pulley. Tighten all bolts during inspection.
different depending on circumstances. The following
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• Drive Belt
inspection procedures are explained in more detail below:
Drive belt should be tight and in good condition. Use
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1. Observe system a belt tension gauge to check tension (120 pounds

2. Inspect Parts maximum). With experience, feel belt tension by
twisting. Try feeling belt tension after using gauge,
3. Check Hoses and Fittings when tension is correct. Replace belts if frayed or
on
worn.
4. Check for Refrigerant Leaks
If clutch pulley/belt alignment is obviously off, loosen
Use following procedure as a general rule in performing a
compressor or mounting bracket, or both - and use
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visual inspection with air conditioning system off:

alignment bar to line up clutch pulley with drive pulley.
Tighten compressor mounting bolts first, then bolts
Observe System
holding bracket. Mounting bracket should have slots
First inspection step is answer the following questions, if or other means of adjustment to allow adjustment to
possible: tension of drive belt. When using a pry bar to apply
tension, do not pry against compressor. Pry against
• Has heating, ventilation and air conditioning system mounting bracket.
been in use recently?
• Did operator explain or describe any problems with Check Hoses and Fittings
system? Check all hoses and fittings. Look for places where hoses
• Did someone else recently work on system? flex when cab is tilted. Any place hoses or fittings are
fastened, clamped, connected, bent or secured are
potential wear points. This applies to places where hoses
are not clamped or supported but should be (often near
condenser). All of these spots are potential leak or
damage points. Tighten, refasten, add or replace as
indicated by inspection.
79033095 C Rev. 11-49

Systems Operating
Check for Refrigerant Leaks 2. Turn air conditioning system on - Powers thermostat
and clutch. If it does not come on, use air
System refrigerant leaks can be anywhere but there are conditioning mode switch to check leads to switch. A
obvious places. Look for signs of refrigerant oil forced out “click” should be heard from thermostat and clutch
with refrigerant leakage. One location leaks frequently drive plate will “snap” against clutch pulley.
occur is compressor shaft seal. Shaft and seal are hidden Thermostat cycling can not be checked on and off
behind clutch assembly, but centrifugal force will throw oil until performance inspection is complete.
off shaft and against engine, bracket or whatever is close.
Check these points when examining compressor clutch 3. Check fuses - If there is a failure and are sure all
and mounting bracket. A solution of soap and water connections are clean and tight, check fuses - in cab
applied around potential leak points works well for and in line.
detecting leaks. A leak in evaporator may be indicated if
4. Check clutch engagement - Get out and look at
while feeling around condensate drain hole, oil is present.
clutch since sight and sound of clutch engaging may
NOTE: Inexpensive dry nitrogen gas can be added to not be present. If engaged, drive plate will be against
system instead of R-12 if system pressures are pulley and not slightly spaced from it. If not sure
low. Dispense gas at no more than 200-250 psi clutch is engaged, look for lead wire connector near
as this is sufficient pressure to cause or indicate clutch. Break and close connection. Clutch
a leak point in air conditioning system. disengages and engages again.
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NOTE: A leaking heater core could also result in coolant 5. Test blower speed operation - Some systems have a
at condensate drain. common switch turning on air conditioner and
powering blower motor. Test blower speed operation
Feel for oil at bottom of all connections if system is not too by adjusting this or separate blower control switch.
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hot. Of course, a few minutes with an electronic leak Feeling airflow from ducts or note blower sound
detector is the best way to check for leaks. Pressure is (speed) changes.
in
different in a system at rest, will equalize from 60 to 95

psi, depending on outside air temperature. This means
Performance Inspection - Engine Running
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there is more pressure in low side of system at rest than

during normal system operation. Just the opposite is true The purpose of visual and electrical inspection is to detect
of high side; at rest, high side pressure is lower Use obvious problems and assure air conditioning system
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detector to check for leaks in high side when air function for an accurate performance inspection.
conditioner is operating, if a leak is suspected and it can Misleading information could be obtained if performance
not be found with system at rest.
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inspection is performed first. Problem areas discovered

during performance inspection can give false clues or
Electrical System Inspection symptoms and result in repair errors and come backs.
The following performance inspection procedures are
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Two stages of an electrical inspection are explained in

more detail below: explained in more detail below:
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1. Inspect electrical connectors 1. Inspect system component cycling and cab

temperature levels
2. Check electrical current flow and device functions
2. Check clutch cycling under load
Use following procedures to perform an electrical system
on
inspection: 3. Check sight glass

Performance inspection does not cover pressure and
Inspect Electrical Connections temperature sensitive safety devices (cutout switches, fan
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First, while making visual inspection under hood (cab) control, Trinary etc.). Testing these devices requires use
take a moment and check all electrical connections of manifold gauge set for observation of internal system
visually and by feel. Look for any corrosion on leads or pressures during tests.
connectors and clean them. Make sure all leads and Use the following procedures as a general rule in a
wires are properly supported and securely connected. performance inspection:
Check Electrical Current Flow and Device Inspect System Component Cycling and Cab
Functions
Temperature Levels
Perform following steps to check current flow and
electrical device functions:
1. Turn ignition on - Check current flow, ignition must be
on.
11-50 79033095 C Rev.

Systems Operating
A. Turn on engine and air conditioner - Inspect for system
component cycling and cab temperature levels. Sight Glass Conditions
NOTE: System performance testing will be much faster if Sight Glass Condition
all doors and windows in cab are closed. Cab air
must cool down to thermostat control setting Clear System OK
levels before system components will cycle on Overcharge
and off, indicating correct function. This is called
‘stabilizing system’ and takes about five minutes No refrigerant
of operation. In very hot weather system may not
Foam, Bubbles or Low on refrigerant
cycle. Mist
B. Check thermometer readings - In cab, use
May be air in system
thermometer to measure air temperature at vents. When
evaporator is easy to reach with a thermometer probe A few intermittent bubbles
without removing some of dash or duct work, use probe during clutch cycling is OK
to measure evaporator temperature. When air
conditioning unit is on and working correctly, observe Streaked May be low on refrigerant
thermometer dial needle move down to about 0 degrees May be oil streaks as oil
C (32 degrees F), then rise -12 to -14 degrees C (6 to 10
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circulates
degrees F) and move back down again. Movement up
and down indicates cycling clutch and thermostat, or Clouded Desiccant breakdown
orifice tube and accumulator pressure switch (to clutch)
Contaminated system
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are functioning correctly. In systems with a non-cycling

clutch, movement indicates correct function of refrigerant
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metering device. Heater System Inspection

Needle movement is called “temperature swing.” When A heater system inspection is really a combination engine
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thermostat setting can be adjusted, range of swing should cooling system and heater inspection. All heater/cooling
change. For example, from full cooling (cold) to moderate system rubber parts deteriorate due to air (ozone), heat,
(between cold and warm), swing may change from 0 to 3 coolant and oils. Replace at regular intervals to prevent
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degrees to 0 to 6 degrees C (32 to 38 degrees to 32 to 42 breakdown on road. Metal parts and gaskets are subject
degrees F). to malfunction or breakdown due to fatigue and corrosion.
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These readings at vents will be higher and temperature Coolant has a limited life and should be replaced
swing slower and not as obvious. Also blower speed regularly. If dirty, cooling system should be drained and
causes temperature levels to read higher (high air speed) flushed or back flushed (using special equipment) before
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or lower (low air speed) at the same thermostat setting. refilling with clean water and anti-freeze. Coolant must be
When measuring air temperature, an electronic hot when using hydrometer to check protection
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thermometer/pyrometer is a great tool, allowing easy (freeze-up) level. The following inspection procedures are
measurement of cab air temperature at several locations. explained in more detail below:
Check Clutch Cycling Under Load 1. Check heater control valve function
on
The following operating inspections, visual and by feel, 2. Inspect other functions
are done outside cab while waiting for system to stabilize.
Check Heater Control Valve Function
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A. Lift hood - With hood up (or cab tilted) observe clutch

cycling under load. Many air conditioner/heater systems depend on heater
control valve for temperature control and positive closure.
B. Touch suction and discharge lines - Soon after system Check heater control valve function as follows:
start up, safely feel suction and discharge lines and note
change in temperature. Discharge line will get hot (after Cool engine - start with cool engine, set temperature to
awhile if may be too hot to touch) and suction line will get cold with fan off. As engine warms up, feel heater return
cooler. hose. If hose feels warm or hot, heater control valve is
leaking internally. This type of leak can seriously reduce
Check Sight Glass air conditioning performance.
Sight glass is the only point inside air conditioner visible Warm up engine - let engine warm up to normal operating
during operation. Check sight glass through window on temperature and set both fan and temperature on high.
top of receiver-drier (or separate in-line sight glass). If Feel both heater supply and return hoses. If there is a
system is functioning properly and cooling cab noticeable difference in temperature, it indicates a low
adequately, sight glass should be clear (nothing will be flow of coolant through heater core (at partially closed or
seen in it). If it is not clear when system is first turned on, blocked heater control valve). This could result in poor
wait a few minutes for system to stabilize, then look again. heating performance during cold weather conditions.
79033095 C Rev. 11-51

Systems Operating
Inspect Other Functions
There are some things that can’t be seen or felt when
inspecting thermostat, heater core, radiator pressure cap,
electrical switch and control valve functions. Some of
these can be checked with pressure and thermostat
testers. A hand pump pressure tester can also be used to
check for coolant leaks. This is done by using pump to
raise pressure inside system above normal operating
pressure to force small suspected leaks to show up.
Heater/cooling electrical and valve component inspection
is the same as air conditioner inspection. Controls are
operated for functionality to maintain or vary cab
temperature and airflow.
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11-52 79033095 C Rev.

Systems Operating
TROUBLESHOOTING AND SERVICE
PROCEDURES
Manifold Gauge Set Installation
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CAUTION: Never hook up gauge set when
engine and air conditioner are running. Be
sure all valves on manifold are closed all
the way (clockwise). Check hose
connections on manifold for tightness.
Locate low and high side system service fittings and

remove their protective caps. Position or hang manifold
gauge set in a convenient location.
Manifold gauge set is a necessary tool in troubleshooting
air conditioning system problems. The following steps are
performed during and after installing manifold gauge set.
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1. Purging air from gauge set hoses

2. Adding refrigerant to system
3. Stabilizing air conditioning system
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Purging Air from Gauge Set Hoses

Environmental regulations require all service hoses have
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a shutoff valve within 12 inches of service end. These

valves are required to ensure only a minimal amount of
refrigerant is lost to atmosphere. R-12 gauge set hoses
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have a valve near end of all three hoses. R-134a gauge

sets have a combination quick disconnect and shutoff
valve on high and low sides. Utility (center) hose also
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requires a valve.
NOTE: Manifold gauges read system pressure when
hand valves are closed if hose end valves and
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stem type service valves (if included) are open.

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Adding Refrigerant to System

Once gauges are connected, some refrigerant may need
to added to the air conditioning system before doing an
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effective performance inspection. However, if leaks are

obvious, repair prior to adding refrigerant.
FIG. 46: Initial purging is best accomplished when
ly
connected to recovery or recycle equipment.

NOTE: Loss of some refrigerant is not unusual over an
extended period of time. Adding refrigerant is a
typical procedure when air conditioning system is
maintained on a regular basis.
When adding refrigerant to system, connect center hose
from manifold gauge set to refrigerant dispensing valve on
container.
Before adding refrigerant to system study sight glass
while engine is running and air conditioner is on. Even if a
leak is found during system inspection and is corrected, N032803002
there is no way to know how much refrigerant has leaked.
FIG. 46
Check gauges for unusually high or low readings, or a
lack of pressure. Following procedure and using
knowledge and experience, decide if it is safe and makes
sense to add refrigerant.
79033095 C Rev. 11-53

Systems Operating
Now refrigerant can be added to system. For safety and
to prevent system damage, use following procedure.
1. Turn engine on and set idle at 1200 to 1500 RPM and
turn air conditioner on.
m
CAUTION: Do not open high pressure hand
valve on manifold gauge set. Compressor
could pump refrigerant into container and
cause it to burst. Be sure to keep refrigerant
container upright to prevent liquid
refrigerant from entering compressor.
2. Open refrigerant dispensing valve on container and

low pressure hand valve on manifold. This allows
refrigerant to enter system as a gas on low pressure
or suction side of compressor. Compressor pulls
refrigerant into system.
3. Add refrigerant until gauges read in normal range and
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sight glass appears clear. Sight glass may not be

clear for a moment just before or after clutch cycles
on and off but should generally be clear. Gauge
readings fluctuate as compressor cycles on and off.
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NOTE: Pressures within air conditioning system vary

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with ambient temperature. A normal pressure

range is defined as follows:
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Low side - 15-30 PSIG

High side - 150-280 PSIG
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If R-134a is used in place of R-12, high side

readings will be about 20 psi higher. For this
reason many OEMs are recommending an
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increase in condenser capacity when retrofitting

to new refrigerant, R-134a.
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CAUTION: If gauges show any abnormally

high or low pressures as refrigerant is
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added, stop and investigate probable

cause. Never add more than one pound of
refrigerant. If system is low enough on
refrigerant to require more than that
on
amount, stop and check again for leaks.

Recover all refrigerant, repair, evacuate and
recharge. Dry nitrogen gas can be added to
air conditioning system instead of R-12 if
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pressures are below normal and a leak is

suspected. Nitrogen gas is sold in cylinders
under high pressure, 1800 to 2000 psi. Be
sure cylinder has a pressure regulating
valve to control pressure when dispensing
nitrogen gas. Dispose gas at no more than
200-250 psi, as this is sufficient pressure to
cause or indicate a leak point.
4. When the gauges show normal, close the hand valve

on the manifold, the hose end shutoff valve, and the
valve on the refrigerant container. You can now
proceed with the performance inspection.
11-54 79033095 C Rev.

Systems Operating
Stabilizing Air Conditioning System
For reliable gauge readings as an aid in troubleshooting,
the air conditioning system must be stabilized.
m
CAUTION: Be sure tools and equipment
are clear of all moving parts of engine and
air conditioner.
Start engine and set to a fast idle of 1200 to 1500 rpm.

Turn on air conditioner. After a quick in-cab performance
test of control function, blower speeds and airflow, set air
conditioning system controls to maximum cooling and
blower speed on high. All windows must be closed. If cab
temperature is hot (unit has been sitting in sun with
windows closed), open windows for a minute or to let hot
air out. Run engine and air conditioner about five minutes
for system to stabilize. In hot humid weather or where air
conditioning condenser can’t receive adequate airflow
from engine fan a floor fan may be required to force
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sufficient airflow through condenser fins. This helps to

stabilize system by simulating ram airflow found under
normal operating conditions.
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When a vehicle has a tilt cab or hood and condenser is

part of grill, use floor fan to get air to the condenser. Tilt
in
cab or hood back to normal position, carefully routing

manifold gauge set and hoses away from moving parts.
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Then place gauges so system pressure can be read.
Troubleshooting by Manifold Gauge Set

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Readings
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The series of figures that follow show gauges with typical

readings indicating air conditioning system problems.
Each figure is followed by troubleshooting tips, probable
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causes for gauge readings shown and appropriate

service and repair procedures.
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Low Refrigerant Charge in System

FIG. 47: Low charge
on
Tip Bubbles in sight glass. Air from

vents in cab is only slightly cool
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Cause Insufficient refrigerant (charge) in

system.
Repair Check for leaks with leak
Procedure detector. If a leak is found at a
connection, tighten and add
refrigerant as necessary. If a
component or line is leaking
(defective), recover all refrigerant
from system. Replace defective N032803001
part and check compressor oil
level and replace missing oil. FIG. 47
Evacuate and recharge with
refrigerant, then check air
conditioning operation and
performance.
79033095 C Rev. 11-55

Systems Operating
Air and/or Moisture in the System
FIG. 48: Air/moisture
Tip The sight glass may be clear or

show some bubbles. The air from
vents in the cab is only slightly
cool. In a cycling clutch type
system with a thermostatic
switch, the switch may not cycle
the clutch on and off, so the low
pressure gauge will not fluctuate.
Cause Air and/or moisture in the
system.
Repair Test for leaks, especially around n032803005
Procedure the compressor shaft seal area.
When the leak is found, recover FIG. 48
refrigerant from the system and
repair the leak. Replace the
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receiver-drier or accumulator
because the desiccant may be
saturated with moisture (there is
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no way to tell). Check the

compressor and replace any
refrigeration oil lost due to
in
leakage. Evacuate the recharge

the system with refrigerant, then
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check air conditioning operation

and performance.
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Excessive Air and/or Moisture in System

FIG. 49: Excessive air/moisture
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Tip There may be occasional

bubbles in sight glass. Air from
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vents in cab is only slightly cool.

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Cause System contains excessive air

and/or moisture.
Repair Test for leaks, recover refrigerant
Procedure from system, replace
on
receiver-drier or accumulator.
Desiccant is saturated with
moisture. Check and replace any
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compressor oil lost due to N032803006

leakage. Evacuate and recharge
system, then check air FIG. 49
performance.
11-56 79033095 C Rev.

Systems Operating
Expansion Valve (TXV) Stuck Closed or Plugged
FIG. 50: Expansion valve
Tip Air from vents in cab is only

slightly cool. Expansion valve
body is frosted or sweating.
Cause Expansion valve malfunction
could mean valve is stuck in
closed position, filter screen is
clogged, moisture in system has
frozen at expansion valve orifice,
or sensing bulb is not operating.
In vehicles where TXV and
sensing bulb are accessible,
perform following test.
N032803007
Test 1. Warm diaphragm and valve FIG. 50

body in hand or carefully with a
heat gun. Activate system and
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watch to see if low pressure

gauge rises.
2. Next, carefully spray a little
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nitrogen or any substance below

32 degrees F, on capillary coil
in
(bulb) or valve diaphragm. Low

side gauge needle should drop
and read at a lower (suction)
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pressure. This indicates valve

was part way open and that
action closed it. Repeat test, but
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first warm valve diaphragm or

capillary with hand. If low side
gauge drops again, valve is not
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stuck.
3. Clean surfaces of evaporator
outlet and capillary coil or bulb.
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Make sure coil or bulb is securely

clamped to evaporator outlet
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tube and insulation is in place.

Next proceed with recovering
refrigerant from system.
on
Repair Inspect expansion valve screen

Procedure (except block type valves). To do
this, recover all refrigerant from
system. Disconnect inlet hose
ly
fitting from expansion valve.

Remove, clean and replace
screen, then reconnect hose.
Any signs of contamination will
require flushing system. Next,
replace receiver-drier. Evacuate
and recharge system with
refrigerant and check air
performance.
NOTE: If expansion valve tests did not cause low

pressure gauge needle to rise and drop and if
other procedures described did not correct
problem, expansion valve is defective. Recover
all refrigerant from system again and replace
expansion valve and receiver-drier. Evacuate
and recharge system with refrigerant, then check
air conditioning operation and performance.
79033095 C Rev. 11-57

Systems Operating
Expansion Valve (TXV) Stuck Open
FIG. 51: Stuck open
Tip Air from vents in cab is warm or

only slightly cool.
Cause Expansion valve is stuck open
and/or capillary tube (bulb) is not
making proper contact with
evaporator outlet tube. Liquid
refrigerant may be flooding
evaporator making it impossible
for refrigerant to vaporize and
absorb heat normally. In vehicles
where TXV and sensing bulb are
accessible, check capillary tube N032803008
for proper mounting and contact FIG. 51
with evaporator outlet tube. Then
perform following test. If TXV is
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not accessible, proceed to Repair

Procedure.
Test 1. Operate air conditioning
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system on it’s coldest setting for

a few minutes. Carefully spray a
little nitrogen or other cold
in
substance, on capillary tube coil

(bulb) or valve head.
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2. Low pressure (suction) side

gauge needle should drop on
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gauge. This indicates valve has

closed and is not stuck open.
Repeat test, but first warm valve
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diaphragm with hand.

3. If low side gauge shows a drop
again, valve is not stuck. Clean
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surfaces of evaporator outlet and

capillary coil or bulb. Make sure
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coil or bulb is securely fastened

to evaporator outlet and covered
with insulation material. Operate
system and check performance.
on
Repair If test did not result in proper

Procedure operation of expansion valve,
valve is defective and must be
ly
replaced. Recover all refrigerant

from system and replace
expansion valve and
receiver-drier. Evacuate and
recharge system with refrigerant,
then check air conditioning
operation and performance.
11-58 79033095 C Rev.

Systems Operating
System High Pressure Side Restriction
FIG. 52: High side restriction
Tip Air from vents in cab is only

slightly cool. Look for sweat or
frost on high side hoses and
tubing, and frost appearing right
after point of restriction. Hose or
line may be cool to touch near
restriction.
Cause There could be a kink in a line or
other restriction in high side of
system.
Repair After defective component N032803009
Procedure containing restriction is located,
recover all refrigerant. Replace FIG. 52
defective component and
receiver-drier. Evacuate and
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recharge system with refrigerant,

then check air conditioning
operation and performance.
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79033095 C Rev. 11-59

Systems Operating
Compressor Malfunction
FIG. 53: Malfunction
Tip Compressor may be noisy during

operation.
Cause Defective reed valves or other
compressor components. If
compressor is not noisy, there
may be a worn or loose
compressor clutch drive belt.
Repair If a belt is worn or loose, replace
Procedure or tighten it and recheck system
performance and gauge
readings. To inspect and service N032803010
compressor, isolate (front seat
the stem type compressor FIG. 53
service valves) and recover
refrigerant, or fully recover R-12
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from systems containing

Schrader valves. Remove
compressor cylinder head and
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check appearance of reed valve

plate assembly. If defective,
replace valve plate and install
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with new gaskets, or replace

compressor assembly.
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If particles of desiccant are found

in compressor, remove and
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replace compressor and

receiver-drier. Before doing so,
back flush other system
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components (except expansion

valve) using a flushing kit. If there
are stem type valves and
compressor is isolated,
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remaining system must be

purged of refrigerant before
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disconnecting and flushing

system components. After
flushing, reassemble
components. Always check oil
on
level in compressor, even if

installing a new or rebuilt unit.
Tighten all connections and
evacuate system. Recharge air
ly
conditioner with refrigerant and

check system operation and
performance.
NOTE: Rotary compressors have a limited oil reservoir.

Extra oil must be added for all truck installations.
11-60 79033095 C Rev.

Systems Operating
Condenser Malfunction or System Overcharge
FIG. 54: Malfunction or overcharge
Tip Air from vents in cab may be

warm. In R-12 systems there can
be bubbles in sight glass. High
pressure hoses and lines will be
very hot. Don’t forget to check
engine cooling system
components - fan and drive belt,
fan clutch operation and radiator
shutter.
Cause Condenser is not functioning
correctly or there may be an
overcharge of refrigerant inside N032803011
system. Another possibility is FIG. 54
lack of (ram) airflow through
condenser fins during testing.
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Engine cooling system

component malfunction can
cause high pressure by blocking
airflow (radiator shutter) or not
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providing airflow (fan clutch) in

sufficient quantity.
in
Repair Inspect condenser for dirt, bugs

Procedure or other debris and clean if
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necessary. Be sure condenser is

securely mounted and there is
adequate clearance (about 1-1/2
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inches) between it and radiator.

Check radiator pressure cap and
cooling system, including fan, fan
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clutch, drive belts and radiator

shutter assembly. Replace any
defective parts and recheck air
conditioning system operation,
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gauge readings and

performance.
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If problem continues, system

may be over-charged (have too
much refrigerant inside). Recover
on
system slowly until low and high

pressure gauges read below
normal and bubbles appear in
sight glass. Add refrigerant until
ly
pressures are normal and

bubbles disappear. Add another
quarter to half pound of
refrigerant and recheck air
conditioning system operation,
gauge readings and
performance.
If high gauge readings do not
change, recover all refrigerant
and flush or replace condenser.
Also replace receiver-drier or
accumulator then connect
components and evacuate
system. Recharge air conditioner
with refrigerant and check
system operation and
performance.
79033095 C Rev. 11-61

Systems Operating
Thermostatic Switch Malfunction
FIG. 55: Switch malfunction
Tip Low side gauge needle may

fluctuate in a very narrow range
compared to a normal range.
Compressor clutch may be
cycling on and off more
frequently than it should.
Low side gauge needle may
fluctuate in an above normal
range as clutch cycles. This may
be an indication thermostat is set
too high (factory setting may
have been adjusted). A new N032803012
thermostat may have been FIG. 55
installed incorrectly (capillary
tube not inserted between
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evaporator fins in proper

position).
Cause Thermostatic switch is not
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functioning properly or at all.

Repair Replace thermostatic switch.
in
Procedure When removing old thermostat,

replace it with one of same type.
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(Operate in a factory preset

temperature range.) Take care in
removing and handling
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thermostat and then capillary

tube attached to it. Don’t kink or
break tube.
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Position new thermostat capillary

tube at or close to same location
and seating depth between
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evaporator coil fins as old one.

Connect electrical leads.
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Review of Frequent Problem Areas

In heating, ventilation and air conditioning systems a
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limited number of things can go wrong. Moving parts of

compressor, clutch and expansion valve or refrigerant
metering device can malfunction or break down from
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metal fatigue, contamination, abnormal pressure or lack

of lubrication. Electrical connections may erode, become
disconnected or break. Fuses blow from shorts or
overload. Belts slip or break.
Vibration from engine or road surface can work bolts and
air or vacuum lines loose, or rub and break or wear parts
out. Motors may burn out. Inside of system can become
contaminated from moisture, air or desiccant material
breakdown. Refrigerant may leak out of system quickly or
very slowly. Moisture in system can combine with
refrigerant to form acid and attack (corrode) metal parts
from inside. Moisture and refrigeration oil can combine to
form sludge blocking refrigerant flow.
The following problems are discussed in more detail in
this section
1. Belts and compressor clutch
2. Condenser
11-62 79033095 C Rev.

Systems Operating
3. Refrigerant lines, hoses and fittings
4. Refrigerant metering valves
5. Other problems
Belts and Compressor Clutch

The most frequent repairs are replacing belts and
servicing or replacing compressor or clutch. Heavy duty
vehicle operation puts a lot of stress on these parts. There
are several main reasons.
There is often continuous operation for long periods of
time. There may be frequent sudden RPM variations
when shifting gears up or down. For this reason air
conditioning clutches used in heavy duty systems usually
have double row ball bearings. Vibration and road shock
contribute to loose or broken mounting brackets, electrical
connections and fittings. Belts, bearings and compressor
reed valves wear out.
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System leaks, high operating pressures, malfunctioning

engine cooling system components all cause compressor
problems and failures. When refrigerant and refrigeration
r
oil leaks out of a system or there is contamination

in
blocking oil flow, compressor will be starved for oil and

seize.
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Condenser
Condensers get dirty and dirt reduces heat movement by
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insulting condenser. Fittings come loose or break from

stress if condenser or connecting hoses are not secured
properly to keep effects of vibration at a minimum.
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Heat transfer efficiency and pressure in condenser are

affected by amount of outside air flowing through
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condenser fins. A lack of airflow can mean refrigerant

doesn’t give up enough heat energy to outside air (it
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doesn’t change state). Refrigerant arrives at evaporator

as a gas and can’t pick up any heat energy from cab air.
In cab, air from vents is only slightly cool or warm.
One possible cause of condenser malfunction could be
on
engine cooling system. This is why fan clutches and

radiator shutters are often controlled or overridden by air
conditioning switch function.
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Refrigerant Line, Hoses and Fittings

Problems with these parts may be caused by normal
deterioration, vibration damage, lack of maintenance or
human error (improper installation or replacement). All
rubber parts are attacked by ozone (oxygen) in air.
Rubber parts break down slowly and become more
vulnerable to effects of vibration with time.
Heavy duty vehicle vibration causes stress on all lines,
fittings and connections. Regular maintenance includes
checking and tightening any suspect line, or hose
retainers, or grommet position where grommet is
protecting a line or hose from abrasion. Any insulating
material wrapped around hoses must be in place and
securely fastened.
79033095 C Rev. 11-63

Systems Operating
Refrigerant Metering Valves
When considering valve problems there are obvious
differences in valve construction and what can go wrong.
If a valve is clogged with sludge or other obstruction,
result is a valve problem but cause is contamination in
system. Valves get stuck open or closed, although most
often closed when gas charge is lost from diaphragm
housing in a traditional TXV. Capillary tube can vibrate
loose from evaporator outlet tube. Capillary can break
and small quantities of temperature sensitive gas can
escape. Diagnosis of a valve as defective calls for
replacement.
Other Problems - Leaks, Moisture and Adding

Refrigerant - Before any refrigerant was put inside air
conditioning system, a vacuum pump was used to
evacuate any air and moisture. Vacuum is really a force
pulling against all hoses, fittings and components from
Fo
inside. When system is charged with refrigerant, pressure

goes from minus (a vacuum) to plus pressure inside
hoses and all components. Refrigerant and refrigeration
r
oil are trying to escape from system at all times.

Technicians frequently add refrigerant to a system,
in
replacing refrigerant seepage through system

connections or fittings. If system has been maintained
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regularly (every three to six months), adding a small

amount of refrigerant may result in normal system
function. Best procedure is to check all connections and
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look for, find and repair any leaks before adding

refrigerant.
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When leak detector indicates presence of a leak, There is

no way to know how long system has been leaking.
Finding one leak doesn’t mean there are not others.
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Without experience, it will be hard to guess how much

refrigerant may have leaked.
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Find the leak. Recover all refrigerant and repair system.

Moisture absorbing capacity of any desiccant material is
limited and cannot be measured. For that reason, replace
on
receiver-drier or accumulator. Evacuate system for an

hour and recharge with refrigerant.
When a compressor shaft seal has leaked oil and
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refrigerant charge is a little low, shaft seal may have

leaked because air conditioner was not used. Seal can
get a little out of round from weight of crankshaft and leak
above shaft. Running compressor may cause seal to
swell and close up leak. Shaft rotation causes force
around seal and puts life back into it. To prevent this from
happening, manufacturer’s recommend regular air
conditioning system operation a minimum of every couple
of weeks even in cold weather.
Compressor can cause a vacuum inside system if a
restriction exists. Moisture and air can be sucked in under
some conditions, pulling these contaminants in through a
small space where refrigerant and refrigerant oil has
leaked out.
11-64 79033095 C Rev.

Systems Operating
REFRIGERANTS
Description and Properties of Refrigerants

Refrigerants are contained in closed system of an air
conditioner and circulate under pressure, moving heat
energy from cab to outside air. Different refrigerant
requires different operating pressures, causing refrigerant
to undergo a “change of state”.
Changes in Service Procedures

Since 1992, the EPA has required that any refrigerant
removed from an air conditioning system be recovered
and recycled before reuse. Unlike purging which releases
ozone depleting refrigerant into atmosphere, recovery
process allows use of the same refrigerant over and over.
A major difference between purge and recovery/recycle
Fo
procedures is refrigerant is contained in an externally

sealed container when undergoing recovery/recycle
procedures to ensure environmentally safe processing.
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Following steps are required to reuse a refrigerant in an

in
Prepare station for recovery process

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Recover refrigerant from air conditioning system

Recycle recovered refrigerant
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Perform maintenance or repair system

Flush air conditioning system when necessary
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Evacuate air conditioning system

Charge air conditioning system with recycled refrigerant
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Recycling refrigerant involves the following processes:

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• Recovery - recovering a refrigerant when removed

from an air conditioning system (to repair or replace a
component) and then store, transport, recycle or
reclaim it. This is a closed loop process. Recovered
on
refrigerant may vary in quality.

• Recycle - recycling a refrigerant when removing
contaminants such as moisture, acidity and
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particulate matter. Many refrigerants are reusable at

this stage.
• Reclaim - reclaiming a refrigerant when sending it to
an outside facility which can restore it to a new
product specification. This reprocessing usually
includes both a chemical analysis and distillation of
recycled refrigerant.
Recharging an air conditioning system requires:
• Flush - flushing certain air conditioning system
components and hoses to remove contaminants.
Flushing prepares air conditioning system for new
refrigerant.
• Evacuate - evacuating air conditioning system to
remove moisture and air.
• Charge - charging air conditioning system by adding
new refrigerant to system.
79033095 C Rev. 11-65

Systems Operating
Recovering and Recycling Refrigerant
Recovery/Recycle Station
When troubleshooting indicates a component in a closed
air conditioning system be replaced or removed for
service, refrigerant must be removed from system. A
handy, dual purpose station performs both recovery and
recycle procedures, allowing to follow new guidelines for
handling used refrigerant. Recovered refrigerant can then
be recycled to reduce contaminants and reused.
Equipment is also available to just remove or extract
refrigerant. Extraction equipment does not clean
refrigerant. It is used to recover refrigerant from an air
conditioning system prior to servicing.
To accomplish this, recovery/recycle station separates oil
from refrigerant and filters refrigerant multiple times to
reduce moisture, acidity and particulate matter found in a
Fo
used refrigerant.
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CAUTION: Mixing refrigerant types
damages equipment. Dedicate one
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recovery/recycle station to each type of

refrigerant processing to avoid equipment
in
damage.
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Recycle equipment must meet certain standards as

published by Society of Automotive Engineers and carry a
UL approved label. Basic principles of operation remain
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the same for all machines, even if details of operation

differ somewhat.
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A full system recovery is not necessary when servicing or

replacing a compressor with stem type service valves.
These valves may be front seated to isolate remainder of
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air conditioning system from compressor. Refrigerant

stays in system and only refrigerant in compressor is
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recovered, recycled and replaced.

NOTE: Keep collection cylinder in an upright position for
duration of recovery/recycle cycle to ensure no
liquid is drawn back into system.
on
Draining Oil from Previous Recovery Cycle

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In preparation for recovery:

Place power switch and controller on recovery unit in OFF
position.
Plug in recovery station to correct power source.
Drain recovered oil through valve marked OIL DRAIN on
front of machine.
Place controller knob in ON position. Low pressure gauge
will show a rise.
Immediately switch to OFF position and allow pressure to
stabilize. If pressure does not rise to between 5 psig and
10 psig, switch controller ON and OFF again.
When pressure reaches 5 to 10 psig, open OIL DRAIN
valve, collect oil in an appropriate container and dispose
of container as indicated by local, state or Federal
Regulation. Oil is not reusable due to contaminants
absorbed during its previous use.
11-66 79033095 C Rev.

Systems Operating
Performing Recovery Cycle
Follow steps to recover:
Ensure equipment is designated for refrigerant being
recovered.
Record sight glass oil level. Having drained it, should be
zero.
Check cylinder refrigerant level before beginning recovery
to ensure adequate capacity.
Confirm all shut-off valves are closed before connecting
Attach appropriate hoses to system being recovered.
Start recovery process by operating equipment according
to manufacturer’s instructions.
Continue extraction until a vacuum exists in air
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If an abnormal amount of time elapses after system
reaches 0 psig and does not drop steadily into vacuum
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range, close manifold valves and check system pressure.

If it rises to 0 psig and stops, there is a major leak.
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Check system pressure after recovery equipment stops.

After five minutes, system pressure should not rise above
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“0” gauge pressure. If pressure continues to rise, restart

and begin recovery sequence again. This cycle should
continue until system is void of refrigerant.
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Check sight glass oil level to determine amount of oil to be

replaced.
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Mark cylinder with a RECOVERED (red) magnetic label

to reduce the chance of charging a system with
contaminated refrigerant. Keep a record of amount of
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refrigerant recovered.
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WARNING: Check sight glass oil level to
determine amount lost during recovery.
Add this amount of oil back into system.
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Performing Recycling Procedure

Recovered refrigerant contained in cylinder must undergo
recycle procedure before it can be reused. Recycle or
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clean mode is a continuous loop design and cleans

refrigerant rapidly. Follow equipment manufacturer’s
instruction for this procedure.
Purging Non-Condensable Gases (Air)

During purging and refrigerant recovery, air can be
trapped in refrigerant container. Air must not be put into
air conditioning system. Result is higher operating
pressures and possible system damage.
A simple check can be performed as follows:
Store recovered refrigerant at constant temperatures
above 18.7 degrees C (65 degrees F). Container should
include a pressure gauge reading to 1 psi increments.
Container should not be in direct sunlight or near a heat
source.
Use calibrated thermometer to establish temperature
within 4 inches of container.
79033095 C Rev. 11-67

Systems Operating
Compare pressures for like temperatures. Note separate
charts for R-12 and R134a. If container pressure is equal
to or less than pressure shown in table, excess air is not
present.
If container pressure is greater than shown in table,
connect container to recovery or recycle equipment with
pressure gauge in place.
Bleed a small amount of vapor from container until
pressure is below that shown on table, then close valve.
Tank temperature may change during bleed off process.
Mild shaking assists in temperature stabilizing, but it is a
good idea to let it sit for several hours before rechecking
pressure against table.
If pressure remains above that shown on table, excess air
or another contaminant (i.e., another refrigerant) is still
present. Material must be recycled or reclaimed.
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If pressure is equal or below that shown on table identify

cylinder as “recycled”.
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11-68 79033095 C Rev.

Systems Operating
R-12 Allowable Container Pressure

Degrees F Psig Degrees F Psig Degrees F Psig Degrees F Psig Degrees F Psig
65 74 75 87 85 102 95 118 105 136
66 75 76 88 86 103 96 120 106 138
67 76 77 90 87 105 97 122 107 140
68 78 78 92 88 107 98 124 108 142
69 79 79 94 89 108 99 125 109 144
70 80 80 96 90 110 100 127 110 146
71 82 81 98 91 111 101 129 111 148
72 83 82 99 92 113 102 130 112 150
73 84 83 100 93 115 103 132 113 152
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74 86 84 101 94 116 104 134 114 154

Degrees C kPa Degrees C kPa Degrees C kPa Degrees C kPa Degrees C kPa
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18.3 510 23.9 600 29.4 703 35.0 814 406.6 938
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18.9 517 24.4 607 30.0 710 35.6 827 411.1 952
19.4 524 25.0 620 30.6 724 36.1 841 41.7 965
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20.0 638 25.6 634 31.1 738 36.7 855 42.2 979
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20.6 545 26.1 648 31.7 745 37.2 862 42.8 993
21.1 552 26.7 662 32.2 758 37.8 876 43.3 1007
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21.7 565 27.2 676 32.8 765 38.3 889 43.9 1020
22.2 572 27.8 683 33.3 779 38.9 896 44.4 1034
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22.8 579 28.3 690 33.9 793 39.4 910 45.0 1048
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23.3 593 28.9 696 34.4 800 40.0 924 45.6 1062
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79033095 C Rev. 11-69

Systems Operating
R-134a Allowable Container Pressure

Degrees F Psig Degrees F Psig Degrees F Psig Degrees F Psig Degrees F Psig
65 69 76 85 87 103 98 125 109 149
66 70 77 86 88 105 99 127 110 151
67 71 78 88 89 107 100 129 111 153
68 73 79 90 90 109 101 131 112 156
69 74 80 91 91 111 102 133 113 158
70 76 81 93 92 113 103 135 114 160
71 77 82 95 93 115 104 137 115 163
72 79 83 96 94 117 105 139 116 165
73 80 84 98 95 118 106 142 117 168
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118 171
74 82 85 100 96 120 107 144 119 173
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75 83 86 102 97 122 108 146 120 176

in
Degrees C kPa Degrees C kPa Degrees C kPa Degrees C kPa Degrees C kPa
18 476 25 593 32 752 39 917 46 1124
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19 483 26 621 33 765 40 945 47 1158

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20 503 27 642 34 793 41 979 48 1179

21 524 28 655 35 814 42 1007 49 1214
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22 545 29 676 36 841 43 1027

23 552 30 703 37 876 44 1055
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24 572 31 724 38 889 45 1089

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Flushing Air Conditioning System Evacuating and Charging Air Conditioning

Flushing has long been recommended as a means of System
removing contaminants or other debris from certain
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system components. Normal flushing materials, such as Evacuate system once air conditioner components are
repaired or replacement parts are secured and air
R-11, are now prohibited.
conditioning system is reassembled. Evacuation removes
Using compressed air is not a good method of flushing. air and moisture from system. air conditioning system is
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Air should never be used in an R-134a system. ready for charging process, which adds new refrigerant to
system.
The primary use of a flushing kit is to remove
contaminants from air conditioning system hoses, Evacuating System
evaporator and condenser. Any other component of an air
conditioning system should be bench checked or Evacuate system once air conditioner components are
replaced, since flushing may be ineffective or may repaired or replacements parts are secured and air
damage a component. Flushing is usually performed after conditioning system is reassembled. Evacuation removes
recovery process. It is recommended before replacing air and moisture from system. air conditioning system is
compressor or when contamination is found in other ready for charging process, which adds new refrigerant to
components (receiver-drier, expansion valve or system.
connections). Some recover/recycle machines have
optional “flush kits”. The only proper way to flush system Follow this procedure:
components is to use refrigerant in a closed-loop system. 1. Tighten all connections and attach a vacuum pump to
center hose of gauge set.
2. Start vacuum pump and open both hand valves on
manifold all the way. Run pump for five minutes, then
close hand valves and shut pump off.
11-70 79033095 C Rev.

Systems Operating
3. Check gauge readings for five minutes. If gauge 5. Check sight glass when nearing the point when
needles move up, system is not sealed and there is a specified amount of refrigerant has been added.
leak. Air and moisture are being sucked into system Keep adding refrigerant until sight glass clears or
by vacuum. specified refrigerant charge has been added. Use an
oil injector to replace oil drained from system.
4. Tighten any loose connections. Restart pump and Remember, a large leak may have resulted in nearly
open hand valves on gauges again. Repeat vacuum all lubricant being lost.
test.
6. Close valve on refrigerant container. Close hand
5. Run vacuum pump for at least an hour to remove valve on gauge set and check gauge readings.
moisture from system. Gauges should read in normal range.
Moisture must turn to gas before pump can pull it out. 7. Turn engine and air conditioning system off. Check
Moisture takes time to boil away, so that it can be drawn for leaks. If system checks out, back seat service
out of system. valves. Remove manifold gauge set hose fittings from
Vacuum pump can draw most of the air out pretty quickly. compressor.
But a deep vacuum requires more time; the deeper the
vacuum the longer it takes to get there. To ensure the Charging System with Liquid Refrigerant
least possible amount of air and moisture in system, buy This process is used as a time-saver, but requires much
a good quality vacuum pump, care for it and use it for at
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more care to avoid compressor damage.

least an hour.
1. Check amount of refrigerant recovered, and add
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WARNING: Lubricants removed during approximately two thirds of that amount, and no more
recovery process must be replaced with
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than recommended by manufacturer (in pounds and

new lubricants. ounces).
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Charging Air Conditioning System 2. Connect center service hose from gauge set to
refrigerant container dispensing valve.
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When adding a full charge of refrigerant, put it in as a gas

or as a liquid. Adding refrigerant as a liquid is faster but 3. Add refrigerant liquid through compressor discharge
can damage compressor if done incorrectly. The service valve (high side of system). If an accumulator
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procedure used, and where refrigerant is added in system is used, add liquid refrigerant (and gas during final
make a difference. When using refrigerant as a liquid, charging) via a Schrader valve.
never add more than two thirds of system requirements
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4. Open refrigerant dispensing valves and hand valves

as a liquid. Finish charging system using gas. Always
on hose and gauge set. Liquid refrigerant flows into
keep refrigerant containers in an upright position so no
system.
liquid is drawn into system.
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5. When two thirds of recorded, actual recovered

Charging Refrigerant Gas (on Low Side) amount of refrigerant has been added, shut off
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refrigerant supply. If adding liquid refrigerant at

Perform this procedure to charge with refrigerant gas:
compressor high side service fitting, there may be
1. Use a charging meter or station to select exact liquid in compressor. Attach a wrench to nut holding
amount of refrigerant required. Never add more than clutch to compressor shaft. Turn compressor shaft a
on
the amount of refrigerant recommended by few times in direction of normal rotation to clear any
manufacturer (in pounds and ounces). To measure, liquid from compressor.
use a container and scale, or charging station.
6. Finish charging system with refrigerant gas by
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2. Connect center service hose from gauge set to starting engine and air conditioning system.
refrigerant container dispensing valve. Purge hose of
any air using refrigerant gas pressure from container.
3. Run engine at 1200 to 1500 RPM, with air
conditioning unit on maximum cool.
4. Open dispensing valve, then low side hand valve on
manifold.
NOTE: If there are no manufacturer’s charging
specifications, watch sight glass first for bubbles,
then clearing.
79033095 C Rev. 11-71

Systems Operating
COMPONENT REPAIR OR REPLACEMENT Expansion Valves
The following service and repair procedures are not any When removing expansion valve from system, remove
different than typical vehicle service work. However, air insulation, clean area and disconnect line from
conditioning system parts are made of soft metals receiver-drier. Detach capillary (bulb) and external
(copper, aluminum, brass, etc.). equalizer tube, if present from mounting locations.
Remove expansion valve from evaporator inlet.
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CAUTION: All service procedures Expansion valve service is limited to cleaning or replacing
described are only performed after air filter screen. If this is not the problem, replace valve. If
conditioning system refrigerant has been there is any debris in a block-type valve, replace it. Secure
recovered. Never use regular shop oil or capillary and equalizer, if used, and replace any insulating
joint compound to lubricate or seal any air material.
conditioning connections.
NOTE: To help prevent air, moisture or debris from

Expansion Tubes
entering an open system, cap or plug open lines, A clogged or defective expansion tube must be replaced.
fittings or components as soon as disconnected. There are special tools available to remove and replace
Keep all connections (also caps or plugs) clean tubes at their location. If there is not one available, use a
so no debris can accidentally get inside system. pair of needle-nose pliers. Put a little refrigerant oil in
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As a general rule in air conditioning service, replace any evaporator inlet to lubricate expansion tube for easier
gaskets and O-rings with new ones. Use fresh removal. Discard old tube. Lubricate new tube and O-ring
refrigeration oil to lubricate connections, gaskets and and insert until it seats against dimples in evaporator inlet.
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O-rings. The following parts are discussed further in this

section: Receiver-Drier and Accumulator
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Hoses and Fittings Receiver-drier and accumulator can not be serviced or

repaired, replace whenever air conditioning system is
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opened for service. If receiver-drier or accumulator has a

Expansion Valves pressure switch to control clutch, it should be removed
and installed on new unit.
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Expansion Tubes
Receiver-Drier and Accumulator Compressor and Clutch
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Compressor and Clutch Problems with clutch assembly can be due to low voltage,
electrical failure in coil, lead wire or a bad pulley bearing.
Hoses and Fittings First, verify electrical power is reaching clutch. Lead wire
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and bearing can be replaced and clutch assembly

Use the same type and size of hose during replacement. reinstalled. If coil fails, it must be replaced. If clutch shows
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When hoses or fittings are shielded or clamped to prevent obvious signs of excessive heat, replace complete
vibration damage, be sure these are in position or assembly. Compressor can fail due to shaft seal leaks,
secured. On R-134a systems make sure replacement defective valve plates, bad bearings or problems
hose has been designed for this refrigerant. associated with high pressure, heat or lack of lubrication.
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Machine crimped fittings are preferred over those fittings

which use hose clamps. Properly crimped ferrules make Servicing Compressor
stronger connections than hose clamps and are
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Air conditioning systems and compressors depends on

recommended by manufacturers of refrigerant hose.
refrigeration oil for lubrication and safe operation.
Steel fittings are preferred over aluminum in heavy duty
Whenever an air conditioning system is opened for
applications. Use reusable fittings on the nylon-lined hose
service, check compressor oil level and add clean
brands.
refrigeration oil as required by manufacturer specs. This is
especially important with a rotary compressor that has no
Lines oil sump.
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Always use two wrenches when disconnecting or WARNING: Different lubricants are used in
connecting air conditioning fittings attached to metal lines. R-12 and R-134a systems. Do not mix.
Copper and aluminum tubing can kink or break easily.
Tube O-ring type fittings require only 18 foot pounds of Compressor Repair
torque for correct sealing. When there are grommets or
clamps used to prevent line vibration, be sure these are in Compressor service and repair is usually more costly
place and secured. than replacement with a new or rebuilt compressor. There
is limited compressor and clutch service and repair
coverage because each compressor make (and model)
requires special tools and procedures for complete repair
capability. Compressor manufacturers publish service
manuals for their products.
11-72 79033095 C Rev.

Systems Operating
Heating, Ventilation and Air Conditioning b. Clutch should engage. Operate air conditioning
Control System Variations - system for five minutes at maximum cooling.
Disconnect jumper wire and reconnect switch leads.
Troubleshooting If clutch will not engage, and pressure is over 50
Troubleshooting for components is discussed below: PSIG, replace switch.
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Binary and trinary switches CAUTION: Do not operate air conditioning
system with incorrect refrigerant charge or
Air operated controls compressor damage may occur.
CTC system
Compressor cycles, but air conditioning system does
not cool
Binary and Trinary Switch -
Troubleshooting Air Conditioning All electrical components in clutch circuit appear to
be functioning properly.
High/low pressure function of binary and trinary switches
Power to trinary is good and compressor still runs
acts as a circuit breaker for air conditioning system.
continuously.
Switch interrupts current flow to clutch when there is
abnormal pressure in system. A combination of High side cutout switch may not be functioning, one
components or wiring problems could cause system to of the problems described below are causing
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malfunction. In many cases, problems associated with abnormal pressures.

these switches are the result of a malfunction elsewhere
in system. 1. Check high side pressure. If it approaches 300
PSIG, a serious problem is indicated.
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NOTE: Terminal numbers are molded into top of trinary

switch. Terminals 1 and 2 control compressor a. Air conditioning system may be overcharged.
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clutch and are identical to two terminals on b. There may not be enough airflow through
binary switch. condenser or it may be blocked by debris.
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Air Conditioning Compressor Clutch Circuit c. Condenser may be too small for operating
conditions.
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In normal operation, binary and trinary terminals 1 and 2

should form a closed circuit. They supply power to clutch d. There may be a restriction inside system (bent
if air conditioning system is properly charged with or kinked lines or hoses, sludge or moisture in
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refrigerant and outside air temperature is above 40 system, etc.)

degrees C (4 degrees F). e. Thermostat may not be functioning.
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Air Conditioning Clutch Does Not Engage Fan clutch or shutter cycles too often or stays on
1. With system on, check power at trinary switch with too long.
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voltmeter or trouble light: 1. Connect gauge set to air conditioning

a. Terminal 1 or 2 should have power. system:
b. If no power, there is a problem with air conditioning a. Watch high pressure side increase until
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unit or wiring. range pressure is reached.
2. Both terminals have power: b. If fan engages or shutter opens at proper

pressure, trinary is good.
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a. Problem is either clutch or wiring from switch to

clutch. c. Problem is condenser - check for debris or
lack of airflow through condenser fins.
3. Power to and from binary or trinary check are good: Condenser may be too small for conditions.
a. Use manifold gauge set to check out system 2. Fan or shutter cycles at less than 180 PSIG
pressures. (Outside temperature must be above 4 or remains on below 150 PSIG:
degrees C (40 degrees F).
a. Trinary is functioning below it’s proper
b. If system pressure is below 40 PSIG, check for operating range and must be replaced.
refrigerant leaks. If good, add refrigerant to obtain
correct pressure.
4. Air conditioning system pressure and power supply to
switch check are good:
a. Connect a temporary jumper wire between
terminals 1 and 2.
79033095 C Rev. 11-73

Systems Operating
Fan clutch will not activate
1. Check power supply to terminals 3 and 4
with voltmeter or trouble light. System
pressure must be above 230 PSIG (restrict
airflow through condenser if necessary to
achieve this pressure). Check opposite
terminals for switch function. If switch does
not close and activate fan clutch, replace
trinary.
NOTE: Some air-clutching engine-fan systems use
normally closed trinary switches. When operating
pressure is reached, fan circuit opens and fan
turns on.
2. Faulty solenoid (air-clutching fans) or wiring.
If trinary switch functions in above test, check
wiring to solenoid valve, fan or relay, and
determine if valve or relay is functioning
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properly.
Refrigerant
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Refrigerants used in air conditioning systems are

commonly referred to as R-12 or R-134a. They have no
in
color, have only a slight odor, non-toxic, non-corrosive and

non-flammable chemicals in form of liquefied gas.
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Because boiling point of a refrigerant is far below -18

degrees C (0 degrees F), it is sold in sealed metal
containers so it won’t evaporate.
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WARNING: Although refrigerants are safe
to use, they can be dangerous if common
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sense is not used. air conditioning systems

operate under pressure. Containers of
refrigerants are also under pressure. At 25
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degrees C (77 degrees F) outside

temperature, pressure inside refrigerant
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container is 551.6 kPa (80 psi). When

released into air, a refrigerant boils away
and becomes a gas and its temperature
drops instantly. Breathing refrigerant gas
on
can result in respiratory problems,

especially for people with cardiovascular
disease.
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Refrigerants have ability to absorb and move a lot of heat

energy from inside cab to outside. Refrigerant in system is
controlled to change state at just the right temperature
and pressure. Vehicle operating conditions such as
engine RPM and air temperature influence actual air
conditioning system operating temperature and pressure.
These factors, along with relative humidity, influence
operator comfort, how efficiently system moves heat
energy from the cab to outside air.
When a refrigerant changes from a high pressure liquid to
a low pressure gas in evaporator, refrigerant is much
cooler than air in cab. Nature’s law takes effect and heat
energy in cab air moves into refrigerant in evaporator coil.
Refrigerant gets warmer and cab air colder.
11-74 79033095 C Rev.

Systems Operating
When refrigerant enters condenser, from compressor, as
a high temperature high pressure gas, it is much hotter
than outside air. Again, nature’s law takes effect and heat
energy in refrigerant moves into air as air passes through
condenser fins.
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WARNING: As controlled by federal law
and in agreement with other countries,
production of R-12 is being phased out. Air
conditioner systems with R-134a are
appearing in many vehicles. These two
refrigerants must not be mixed. This means
different equipment must be used when
handling each refrigerant.
Society of Automotive Engineers (SAE) has
created certain standards or recommended
practices for handling refrigerants. For
example, different service fittings are
specified for R-12 and R-134a.
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Combining R-12 and R-134a can result in

poor cooling performance, higher operating
pressures and inadequate lubricant
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circulation.
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79033095 C Rev. 11-75

Systems Operating
NOTES
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11-76 79033095 C Rev.

TROUBLESHOOTING PREPARATION Do not smoke when recovering or recycling refrigerant.
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WARNING: Contact with refrigerant can Do not smoke when charging system.
result in personal injury. Do not smoke when performing leak test on system.
System is under pressure at all times, even Do not smoke when flushing system.
if engine is not running. Heat should never
be applied to a charged system. Do not leave refrigerant drums exposed to direct sunlight.
Keep face and hands away as contact with Do not carry refrigerant drums in cab.
refrigerant can cause frostbite. Dispose of any open, but unused poly-alkaline glycol
Protective goggles must be worn when (PAG) oil. Moisture contaminates unused oil and air
refrigerant lines are opened, even if gauges conditioning system.
indicate system is empty of refrigerant.
Always use caution when a fitting is GENERAL TROUBLESHOOTING
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removed. Slowly loosen fitting. If system is

Low refrigerant charge causes a loss of cooling ability and
still under pressure, evacuate system and
lubrication in compressor resulting in compressor
recovering refrigerant before removing
resulting in compressor failure.
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fitting.
Refrigerant overcharge causes a loss of cooling ability.
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Severe damage to compressor results when an

overcharged system contains excess liquid refrigerant. An
Inhaling air conditioner refrigerant gas overcharged system fails twice as fast as an
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through a lit cigarette or other smoking undercharged system.

Too much oil in system contributes to a low refrigerant
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charge.
gas can cause bodily harm or death.
A small amount of moisture penetrates hoses used in
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R134a systems. Change accumulator, desiccant and filter
annually. Moisture causes sludge and moisture plugging
may be present.
systems and formation of ice at orifice tube assembly.
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Before any checks of air conditioning and

Gauge readings for an undercharged R134a system may
heating system are made, move machine to
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appear as symptoms of overcharge under certain

a level surface and lower all implements to
conditions, occurring when ambient temperature is above
ground. Ensure transmission is in neutral
32 degrees C (90 degrees F) or in high humidity. Incorrect
or park and parking brake is engaged. Keep
gauge readings lead to a loss of cooling ability and
all personnel away from machine or where
on
compressor failure.
visible.
Refrigerant removed from a system cannot be weighed
Make a visual inspection of complete air conditioning and accurately. A 20-30 percent error can occur as a result of
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heating system. recovery device inaccuracies.

Perform charging and leak testing in a well-ventilated Check scale for accuracy after every 30 days or uses.
area.
If system pressure rises above 0 kPa (0 psi) within 5
Avoid contact with refrigerant to prevent frostbite. minutes of recovery, system must be recovered again
until pressure does not increase. Recovering system
Always wear goggles when working on or testing any part
again empties accumulator of refrigerant.
of air conditioning system.
Presence of frost on accumulator is a normal condition.
Place a clean cloth over any open valve or connection.
Thickness of frost depends on ambient temperature and
Never weld or solder charged components. humidity.
Never steam clean charged components.
79033095 C Rev. 11-77

Perform regular maintenance on refrigerant service units TROUBLESHOOTING FAULTS WITH
and change oil in vacuum pumps.
SERVICE CODES (ACTIVE)
Secure lines and wires to prevent damage.
Machine must be equipped with deluxe cab to display
Formation of black sludge deposits in system are caused active information and error codes. Standard cab does
by presence of moisture in R134a systems and by mixing not have this ability.
charges of R134a and R12.
Active diagnostics displays information on control panel
Presence of white foam during recovery is normal, and assists in servicing HVAC unit.
caused by mixing oil and refrigerant.
R134a system charges must be within 0.03 kg (1 oz) to Service Codes
0.06 kg (2 oz) of specified charge for machine.
A loss of cooling ability or failure of compressor may be ERROR CODE PROBLEM
caused by one or more of the following conditions.
E0 No faults detected
• Low charge
E1 Cab sensor shorted
• Overcharge
E2 Cab sensor disconnected
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• Too much oil

E3 Evaporator probe shorted
• Dirty or plugged filter
E4 Evaporator probe disconnected
• Dirty or plugged condenser
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E5 Outlet duct sensor shorted

• Dirty or plugged evaporator
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E6 Outlet duct sensor disconnected

• Dirty or plugged orifice tube
E7 Ambient sensor shorted
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VISUAL INSPECTION E8 Ambient sensor disconnected

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Before a performance check of air conditioning system E9 Water valve shorted

check:
E10 Water valve disconnected
Condenser and evaporator for dirt, insects, plastic bags,
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etc. obstructing airflow. E13 Water valve failed, stuck or

unresponsive*
Clean fresh and recirculation air filters.
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E14 Mode door stuck, actuator

For a loose belt on compressor. disconnected, failed or
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unresponsive*
Evaporator drain tube for obstruction.
Start machine and set air conditioner on HIGH. Feel E17 ECU module underpowered, failed,
or disconnected - serial
accumulator with hand. In a properly charged system,
communication wires disconnected
on
entire accumulator will be cool or cold to touch. or damaged.
* Cycle ignition power to clear error.

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11-78 79033095 C Rev.

Entering Active Troubleshooting Checking Temperature Sensors
Turn control panel on. Procedure to verify temperature sensor readings for
following sensors:
Press outside temperature button three times quickly to
view stored error codes. CAB - Cab air temperature
Press and hold outside temperature button for five DUCT - Duct air temperature
seconds to view active diagnostics.
EVAP - Evaporator core temperature
LED shows CAB and display updated information.
Current temperature measured by cab temperature SUN - Sunlight sensor
sensor is displayed. DOOR - Mode Door Actuator Feedback Position
NOTE: Display continuously updates information. 1. Measure temperature near sensor being checked.
Press outside temperature button to scroll through 2. Enter active troubleshooting.
available information.
3. CAB is first code displayed. Continue until verified
Following diagnostics can be displayed: sensor is displayed. Displayed temperature should be
near thermometer reading.
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Definition of DISPLAY 4. If temperatures are not similar verify:

Display Definition • Thermometer accuracy.
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CAB Cab Airflow Temperature • Temperature sensor wiring connections in cab.

DUCT Duct Air Temperature • Check displayed temperature for other modes to
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verify control module is not faulty.

EVAP Evaporator Core Temperature
• If all temperature sensors display 54 degrees C
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A-C Compressor Clutch (On/Off) 65 degrees F), replace control module for
HEAT Water Valve Position (0-100% open) HVAC unit.
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• Check power to control module.

PRES Pressure Cut Out Switch (On/Off)*
• Check serial communications between control
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SUN Sunlight Value (0-100)** panel and control module for damage.
FAN Blower Fan Duty Cycle (0-100)*** • Check for poor wire connections.
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DOOR Mode Door Actuator Feedback Position 5. Probable Solutions

(0-100% of travel)
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• Repair faulty wire connections.

* Off position is caused by exceeding pressure limit
7 psi. • Replace temperature sensor and verify proper
operation.
** 100 is maximum value
on
• Replace control module and verify proper

*** 100 is maximum speed operation.
Control panel can be operated in all functions while

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displaying active diagnostics. Operator is able to change

set point temperature, vent mode and blower fan speed.
To return system to normal operation, turn unit off and on
again.
Troubleshooting Using Active Diagnostics

Several systems can be checked with active diagnostics.
79033095 C Rev. 11-79

Checking Compressor Clutch Checking Refrigerant Pressure Switches
NOTE: Perform test in air temperature greater than 21 Use procedure to verify operation of refrigerant pressure
degrees C (70 degrees F) as clutch may not switches:
engage below that temperature. Warm outside
air with heat source, if necessary. NOTE: Perform test in air temperatures greater than 21
degrees C (70 degrees F), as clutch may not
1. Turn rotary switch to DEFROST. engage below that temperature. Warm outside
air with heat source, if necessary.
2. Enter active troubleshooting.
1. Turn rotary switch to Head-Foot position.
3. CAB is displayed first. Continue until A-C for
compressor clutch is displayed. 2. Set temperature control to maximum heat.
4. Compressor clutch should be engaged in defrost 3. Enter active troubleshooting.
mode and LED should display ON, indicating
4. LED displays CAB. Continue until display displays
compressor clutch is on.
PRES for refrigerant pressure switches.
NOTE: Perform test in air temperatures greater than 21
degrees C (70 degrees F) as clutch may not 5. LED displays ON, indicating sufficient, but not
excessive pressure in system.
engage below that temperature. Warm outside
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air with heat source, if necessary. 6. If LED displays OFF, verify air conditioning system
5. If LED displays OFF, verify: has proper charge of refrigerant.
7. If refrigerant charge is correct, verify:
• Outside temperature is at least 21 degrees C (70
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degrees F). • High and low pressure switches for damage.

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• Verify refrigerant charge in air conditioning • Wire connections.

system.
• Wire harness for damage or poor terminal
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• Verify connections to refrigerant pressure connections.

switches.
8. If items in step 6 are operational, replace pressure
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• Verify all wire connections. switches and check for normal information.
6. If no other problems can be found and display shows 9. System does not operate normally. Replace control
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OFF, replace control module. module and check for normal operation.
7. If LED displays ON but clutch does not engage,
verify: Checking Sunlight Sensor
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• Check voltage being supplied to compressor Use procedure to verify operation of sunlight sensor:
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clutch. 1. Turn blower speed control to AUTO.

• Verify wire connection at compressor clutch. 2. Adjust set point temperature to equal cab
• Verify wire connection at relay in HVAC unit. temperature.
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8. If LED displays ON and compressor clutch is not 3. Enter active troubleshooting.

receiving 12 volts, replace control module. 4. LED displays CAB, continue until SUN for sunlight
sensor is displayed.
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9. Replace compressor clutch if proper voltage is being

supplied but it does not engage. 5. Cover sunlight sensor.
6. Display should read a number below 10. Display
could be as low as 0 and blower fan speed should be
low.
11-80 79033095 C Rev.

7. Uncover sensor. Position machine to allow sunlight to Checking Blower Fan
hit sensor. Value displayed should increase.
Use following procedure to verify operation of blower fan:
NOTE: Use a bright light to simulate sunlight if sunlight is
not available. NOTE: Typically, problems with blower fan are obvious.
However, a check of output control of control
8. After 15 seconds of light exposure, speed of blower module to blower motor may be necessary.
fan should increase automatically.
1. Enter active troubleshooting.
NOTE: Verify by setting active troubleshooting to view
FAN output. 2. CAB is first code displayed, continue until FAN is
displayed and check signal being sent to fan from
9. Cover sensor again, blower fan speed should control module.
decrease automatically.
3. Display shows pulse width modulation sent to blower
NOTE: Verify by setting active troubleshooting to FAN. motor. Value ranges from 27-100. Vary blower fan
10. If sensor continues displaying zero during direct speed and verify pulse width modulation changes.
sunlight: NOTE: In AUTO, fan speed may not reach lowest
• Check wire connections. possible speed due to control module logic.
4. If speed does not change, replace control panel.
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• Check for wire harness damage.

11. Replace sunlight sensor and verify normal operation. Checking Mode Door Actuator
12. If problem continues, replace control module.
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Verify operation of mode door actuator:

Checking Actuator for Water Valve 1. Enter active troubleshooting.
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Use following procedure to verify water valve actuator: 2. CAB is first code displayed, continue until DOOR is
displayed and check signal being sent to actuator
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1. Verify engine coolant system is full of coolant. from control module.

2. Turn rotary switch to Head-Foot position. 3. Display shows current position of actuator, ranging
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3. Enter active troubleshooting. from 0-100.

NOTE: Value will not normally reach 0 or 100 due to door
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4. CAB is first code displayed. Continue until HEAT is

displayed. stops preventing extreme movements of
actuator.
5. Engine coolant must be near operating temperature.
4. Turn rotary switch to change position of actuator and
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6. Set temperature control to maximum heat, display verify displayed value changes.
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should increase to 100. Heated air should be felt at

vents when display shows a high number. 5. If displayed value does not change, inspect wire
connections and damage to wiring harness.
7. Set temperature control to maximum cooling, display
should decrease to 0. Heated air should diminish and 6. Replace actuator and check for normal operation.
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air should cool. 7. If problem continues, replace control panel and check
8. If displayed number does not change in steps 6 and 7 for normal operation.
or does not reach 0 or 100, check: 8. If problem continues, replace control module and
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• Wire connections for water valve actuator and check for normal operation.
wire harness for damage
9. Replace water valve and check for normal operation.
NOTE: Flush coolant system if a significant amount of
debris is found. Determine and correct source of
debris.
10. If problem continues, replace control module.
79033095 C Rev. 11-81

LEAK CHECKING OIL LEVEL MEASUREMENT (IN VEHICLE)
Oil level in compressor should be checked when a system
Visual Inspection component has been replaced, when an oil leak is
Although oil seepage does not necessarily indicate suspected or when it is specified as a diagnostic
leakage of refrigerant, it should be considered a sign a procedure.
leak may exist. Look for: 1. Run compressor for 10 minutes with engine at idle.
• Oil seepage in shaft seal area (between clutch and 2. Recover all refrigerant from system, slowly so as not
compressor) - repairable. to lose any oil.
• Pinching or extrusion of front housing O-ring - 3. Determine mounting angle of compressor from
non-repairable. horizontal (i.e., oil plug or adapter on top).
• Oil around cylinder head (gasket, service valves, 4. Remove oil filler plug. Using a socket wrench on
fittings) - repairable. armature retaining nut, turn shaft clockwise.
• Oil around oil plug - repairable. 5. Insert oil dipstick up to stop with angle pointing in
• Stripped threads - nonrepairable. correct direction.
6. Remove dipstick and count number of notches
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• Oil around crack in compressor body -

non-repairable. covered by oil.
7. Add or subtract oil to meet specifications shown in
Soap Bubble Detection table.
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Any leak showing up as bubbles on compressor requires 8. Reinstall oil plug. Seat and O-ring must be clean and
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repair. not damaged. Torque to 15-20 Nm (11-15 lbf ft)

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Shop Type Electronic Detectors Mounting Angle Acceptable Oil Level in

(Degrees) Increments
• Ensure detector being used is sensitive to R134a
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refrigerant. Many leak detectors intended for R-12 SD5H14 SD7H15

cannot detect R134a leaks.
0 3-5 5-7
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• Use leak detector in accordance with manufacturer’s

instructions. 10 4-6 6-8
• Leak rate at any portion of compressor should not 20 5-7 7-9
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exceed 1.0 oz/year. Make sure a suspected leak is an

actual flow of refrigerant, not a small pocket of 30 6-8 8-10
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refrigerant trapped in a recess. Cleaning suspect 40 7-9 9-11

area with soap and water (never a solvent) or blowing
off area with compressed air can help confirm a 50 8-10 10-12
suspected leak.
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60 8-10 11-13
• Leak check procedures should be in accordance with
SAE J1628. 90 8-10 16-18
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Leak Detection Dyes Shaft Turning Smoothness Inspection

Use of leak detection dyes is not recommended as their 1. If on machine, remove refrigerant from air
chemical compositions are proprietary and the effects on conditioning system and disconnect hoses.
oil and elastomers are unknown. 2. If on bench, uncap fittings.
3. Using a socket wrench on armature retaining nut,
turn shaft clockwise only.
4. If sever rough spots or catches are felt while turning
shaft, compressor has been damaged internally and
must be replaced.
11-82 79033095 C Rev.

Clutch Inspection Unusual Noises Due to Compressor
1. Measure voltage at clutch. Low voltage at clutch may 1. Suction pressure less than 5 psi can cause unusual
be due to poor ground or power connection or noise. Charge refrigerant to proper amount and test
problems with vehicle electrical system. Check for by applying heat to evaporator to increase suction
tight fit of field coil retaining snap ring. pressure.
2. Measure current draw when clutch is engaged. 2. Clutch bearing
Normal current should be 3.6-4.2A at 12 VDC.
3. Oil level
• Overcurrent - Short circuit within field coil or in
4. Valve noise
compressor clutch.
• No current - Open circuit. Valve Plate Test
• If a short or open is found in field coil, it must be 1. Suction or discharge valve breakage causes a
replaced. clacking found at idle.
3. Air Gap 2. If head gasket failure occurs, discharge pressure will
• Clutch air gap should be 0.4-.08 mm be low and suction pressure will be high at idle.
(0.016-0.031 in). Measure with a feeler gauge.
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3. Valve and gasket condition can be checked as

• Adjust follows:
4. Suspected Clutch Rotor Bearing Noise • Connect gauge set to suction and discharge
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service valves
• Remove drive belt.
• Run compressor for 5 minutes at idle and stop
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• With clutch disengaged, rotate pulley by hand. If

excessive roughness or wobble is found, replace • Observe time for discharge pressure and suction
pressure to equalize. If less than 2 minutes, in a
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clutch rotor assembly.

TVX system, a valve or gasket may be damaged.
Unusual Noise not due to Compressor CCOT systems will equalize more quickly.
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Unusual noises may be caused by components other General Service Information

than compressor.
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A new receiver-drier or accumulator-drier needs to be

1. Compressor Mounting - Check for: installed if a compressor is replaced or an internal repair
• Loose belt - see belt tension specifications. is made.
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• Broken bracket or compressor mounting ear. 1. Keep dirt and foreign material from getting on or into
compressor or system. The area around hose fittings
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Replace broken component.

should be carefully cleaned with a non-petroleum
• Missing, broken or loose mounting bolts. based solvent before connections are broken. All
Replace, reinstall or tighten. parts to be reused or installed should be cleaned with
a non-petroleum based solvent and blown dry with
on
• Flush fit of compressor to bracket and vehicle

clean compressed air or lint-free cloths.
engine. Replace any part not properly fitted.
2. Trouble-free installation and operation of compressor
• Loose or wobbling crankshaft pulley. Check for
require:
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damage to pulley, incorrect center bolt torque or

center bolt bottoming. Repair to vehicle • Correct pulley alignment
manufacturer’s specifications.
• Correct fit of compressor mounting surfaces to
• Bad idler pulley bearing. Replace if necessary. bracket and correct fit of bracket to engine.
Clearance between compressor and bracket
2. Other Engine components - Check for noise in:
should not exceed 0.2mm (.008 in) per ear for
• Alternator bearing ear-mount compressors or 0.4 mm (0.016 in)
total for two ears.
• Air pump (if present)
• Correct torque of all mounting bolts and nuts
• Water pump bearing
• Correct drive belt tension
• Valves
• Timing belt or chain
• Power steering pump (if present)
• Loose engine mount bolts
79033095 C Rev. 11-83

3. Never operate compressor at high speed or for a Compressor Replaced by a New
prolonged time without a sufficient refrigerant charge Compressor of Same Type
in system. Probable results are overheating, internal
damage and seizure. 1. Drain oil from old compressor; measure and record
4. If an internal repair is performed on a R134a amount.
compressor, evacuate AC system for at least 45 2. Drain oil from new compressor
minutes before recharging to remove moisture which
may have been absorbed by PAG oil in compressor. 3. Add new oil of correct type to new compressor. Use
same quantity as was removed from old compressor.
5. Parts which require lubrication before assembly, such
as O-rings, should be lubricated with clean refrigerant 4. Reinstall oil plug. Seal and O-ring must be clean and
oil. not damaged. Torque to 15 to 20 Nm (11 to 15 lbf ft).
5. It is recommended oil quantity be confirmed after
Compressor Repaired Internally and installation of new compressor.
Reinstalled in System
Oil Charge Determination for Long Hose
1. Before any internal repair is done, drain oil from
compressor.
Applications
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• Remove oil plug and drain as much oil as TXV Systems, less than 56 oz Refrigerant Charge
possible into a suitable container.
1. Desired oil charge for systems with unusually long
• Remove caps (if present) from suction and hoses, such as trucks, tractors can be determined
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discharge ports based on total refrigerant charge when less than

1600 g (56 oz) refrigerant is used.
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• Drain oil from suction and discharge ports into a

suitable container while turning shaft clockwise 2. Calculate desired oil charge as below:
only with a socket wrench on armature retaining
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nut. 3. For a new compressor to be used in this type of

system, subtract standard oil charge from desired
2. Measure and record amount of oil drained from total oil charge to determine how much oil should be
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compressor. added.
3. Inspect oil for signs of contamination such as 4. Remove oil filter plug and charge compressor with
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discoloration of foreign material. amount of additional oil. Use only new oil of correct
type.
4. Perform repair to compressor.
5. Reinstall oil plug. Seat and O-ring must be clean and
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5. Add same amount of new oil to compressor as was

not damaged. Torque to 15 to 25 Nm (11 to 18 lbf ft).
measured earlier. Be sure to use correct oil for
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compressor.
TXV Systems, more than 56 oz. Refrigerant
6. Reinstall oil plug. Seal and o-ring must be clean and
no damaged. Torque to 15 to 20 Nm (11 to 15 lbf ft). For systems with more than 1600 g (56 oz) refrigerant,
testing is required to determine oil charge.
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Be careful not to cross thread oil plug.

7. Confirm oil quantity after reinstallation or compressor. 1. Charge system with refrigerant.
2. Set up machine as follows:
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• Doors open
• Maximum blower speed
• Ambient temperature of at least 24 degrees C
(75 degrees F).
11-84 79033095 C Rev.

3. Run compressor at a speed listed in table below for
10-15 minutes.
4. While maintaining engine speed, turn off AC system
and immediately turn off engine.
5. Recover refrigerant from system.
6. Remove compressor from vehicle.
7. Remove oil plug and drain as much oil as possible
into a suitable container.
8. Drain oil from suction and discharge ports into a
suitable container while turning shaft clockwise only
with a socket wrench on armature retaining nut.
9. Measure and record volume of oil drained from
compressor.
10. Approximately 15 cc (0.5 fl oz) remains in
compressor as a film coating internal surfaces. Add
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15 cc (0.5 fl oz) to recorded volume of oil. This is

calculated amount of oil in compressor.
11. The amount of oil in compressor after running for
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10-15 minutes should be as per table below, if proper

amount of oil was in system. Determine from table
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what correct amount of oil should be for particular

speed.
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Comp. RPM Coil in compressor

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cc fl oz
1,000 100 3.4
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2,000 75 2.5
3,000 50 1.7
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4,000 40 1.3
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5,000 35 1.2
Vehicle doors open
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Maximum blower speed

Ambient temperature at least l75 degrees F
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79033095 C Rev. 11-85

TROUBLESHOOTING A/C CONTROL No Cooling
1. Turn down heat with control button.
Problem List
2. Turn mode switch to enable defrost mode.
• No display
3. Voltage is present at refrigerant compressor clutch.
• No blower fan
4. Verify circuit breakers and/or fuses are intact.
• No heat
5. Correct voltage is present at relay for clutch on wire
• No cooling harness.
• System is putting out hot air when cooling is needed. 6. Verify system is fully charged with refrigerant.
• No HVAC system function 7. Verify heater valve is closed
• No fan or erratic fan Probable Solution
• Electric actuator for airflow is not moving or working 1. Inspect relay for clutch. If necessary, replace relay.
properly.
2. Replace heater valve.
No Display
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System is putting out cool air when heat is needed

1. Turn control panel on with mode switch.
1. Cab airflow temperature sensor is connected
2. Check LED for light. correctly.
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3. Verify control panel is connected properly. 2. Verify water valve is working properly.
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4. Check connection of wire harness to machine.

Probable Solutions
5. Verify control panel is receiving 12 volts.
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1. Replace temperature sensor for cab airflow.

6. Verify control panel is properly grounded.
2. Replace control module.
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Probable Solution
System is putting out hot air when cooling is
1. Replace control panel. needed.
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No Blower Fan 1. Verify cab airflow temperature sensor is connected

correctly.
1. Turn blower fan to high.
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2. Verify water valve is working properly. Ensure water

2. Ensure blower fan is connected properly. valve is not stuck open.
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3. Verify circuit breakers and fuses are intact. 3. Verify compressor clutch is working properly.
4. Verify HVAC unit is receiving 12 volts
Probable Solution
on
5. Verify blower motor has 12 volts.

1. Replace temperature sensor for cab airflow.
6. Verify blower motor is properly grounded.
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Probable solution
No Fan or Erratic Fan
1. Replace fuse or circuit breaker.
1. Set rotary control for blower fan to maximum speed.
2. Replace blower motor.
2. Ensure blower fan is connected properly.
3. Replace electronic control module.
3. Verify circuit breakers or fuses are intact.
No Heat 4. Verify HVAC unit is receiving 12 volts.
1. Turn up heat with control button. 5. Verify blower motor is receiving 12 volts when rotary
2. Verify warm coolant is flowing to heater core. control is at maximum speed.
3. Verify water valve is working correctly. Probable Solutions

4. Inspect water valve for jammed components. 1. Replace blower motor.
Probable Solution 2. Replace control module.
1. Replace water valve. Nothing Works

• Fan
11-86 79033095 C Rev.

• Compressor clutch
• Water control valve
1. Check for error code 17.
2. Verify control module is receiving 12 volts.
NOTE: Use a voltmeter to check voltage. This can be
verified by disconnecting and reconnecting DT
connector (four pin) on control module. A faint
click can be heard in module indicating electrical
power is energizing an internal relay.
3. Verify serial communication ports are not damaged.
4. Verify control panel is connected properly.
5. Verify wire harness is connected to machine properly.
6. Verify pin 17 and 18 are connected securely into DT
connector (40 pin) on control module. Pins must
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make good contact.
Probable Solution
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Electric Actuator for Mode of Airflow is not Moving

or Working Properly
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1. Verify control module is receiving electrical power.

2. Verify no error codes.
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3. Verify component for electric actuator is not jammed.

4. Inspect wire harness and connections.
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Probable Solutions
1. Replace electric actuator for mode of airflow.
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on
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79033095 C Rev. 11-87

REFRIGERANT RECOVERY
2
1
7
5
4
14
8
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6
9
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3
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15 10
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17
11
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13
12
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18 16
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N021303044
FIG. 56
on
FIG. 56: Refrigerant Recovery Tools (14) Blue Hose (Liquid)

(1) Low Pressure Valve (15) Red Hose (Vapor)
(2) High Pressure Valve (16) Refrigerant Pump
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(3) Yellow Charging Hose (17) Filter Dryer

(4) Blue Low Pressure Hose (18) Scale for Measuring Refrigerant
(5) Red High Pressure Hose (A) Low Pressure Side (Suction)
(6) Manifold Gauge Set (B) High Pressure Side (Discharge)
(7) Control Panel (C) Refrigerant Compressor
(8) Inlet on Recovery Station IMPORTANT: Effective July 1, 1992 regulations prohibit
venting of any refrigerant into atmosphere. Use
(9) Accumulator / Oil Separator
proper procedure and equipment to reclaim.
(10) Drain Valve
If service work is required on air conditioning system,
(11) Pressure Valve on Accumulator refrigerant must be reclaimed before removing or
installing components.
(12) Compressor
(13) Refrigerant Tank
11-88 79033095 C Rev.

1. Use refrigerant identifier to detect refrigerants not MANIFOLD GAUGE SET (REFRIGERANT) -
R134a. Refrigerant identifier prevents refrigerants
from contaminating recovery and charging tools and
INSTALL
detect a percentage of air in system. 1. Use a refrigerant identifier to verify air conditioning
2. Close valves by turning clockwise. Install manifold system contains R134a refrigerant.
gauge set. 2. Connect manifold gauge set to service ports near
NOTE: Do not operate engine. refrigerant compressor. Service ports for charging
are located on refrigerant lines. Connect low pressure
3. Attach yellow charging hose of manifold gauge set to hose to service port on suction side of compressor.
recovery station inlet. Connect high pressure hose to service port on
4. Slowly open valves releasing air from yellow charging discharge side of compressor. Ensure valved
hose with valves on refrigerant tank open. One valve couplings are turned counterclockwise for installation.
is for vapor, the other liquid. Turn valved couplings clockwise to open valves.
5. Plug recovery station into an electrical outlet and turn 3. Turn pressure valves clockwise and ensure both
switch ON. pressure valves on manifold gauge set are closed.
6. Press compressor start. Compressor starts and 4. Place a clean rag over loosened charging hose fitting
at manifold gauge set to prevent spray of compressor
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amber ‘compressor on’ light lights. Compressor

automatically shuts off when recovery of refrigerant is oil. Open low pressure valve on gauge set about 1/2
complete. turn. Keep valve open for 2 to 3 seconds to flush air
from low pressure hose. Close low pressure valve on
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7. Drain refrigerant oil from accumulator. Open gauge set. Repeat this process for high pressure
accumulator pressurizing valve long enough so some valve. Tighten charging hose fitting at manifold gauge
in
discharge from compressor flows back to set.

accumulator. Slowly open oil drain valve and drain oil
into measuring cup. Do not allow a complete loss of NOTE: Use refrigerant identifier to prevent non-134A
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pressure in accumulator/oil separator. When oil stops refrigerant from contaminating recovery and
draining, close oil drain valve. charging tools.
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8. If 15 CC (0.9 cubic inches) of compressor oil was lost

during recovery process, new oil must be added.
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79033095 C Rev. 11-89

REFRIGERANT SYSTEM - EVACUATE
Refrigerant must be recovered if replacement or repair of
a component is necessary. If system has lost charge after
a long period of time, refrigerant in system must be
recovered. Perform evacuating procedure to clear system
of all air and moisture. A complete charge must never be
given to a system without first performing evacuating
procedure. Review the following information before
evacuating system.
If system has been left open for more than 1/2 hour,
system has been exposed to air or moisture and a new
receiver-dryer, in-line dryer or desiccant accumulator
must be installed. Moisture combines with metals in
refrigerant system to produce highly corrosive
by-products, oxides, iron hydroxide and aluminum
hydroxide. Moisture can freeze expansion valve and
orifice tube. If there is water in system it must be removed
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by pumping system with a vacuum pump and boiling

water. Refer to Table below.
Evacuation process time increases when air conditioning
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system has:
• Been rebuilt.
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• Been flushed.
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• Has new components.

• Has been retrofitted.
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Boiling Point of Water Under Vacuum

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Work Area Temp Vacuum Needed to Boil

(degrees) Water
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38 degrees C (100
degrees) 95 kPa (28 inch Hg)
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32 degrees C (90 97 kPa (29 inch Hg)

degreesF)
27 degrees C
98 kPa (29 inch Hg)
on
(81degrees F)
21 degrees C (70
99 kPa (29 inch Hg)
degrees F)
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NOTE: After completing leak test, system must be

evacuated for a minimum of 30 minutes. To
correctly evacuate system, vacuum gauge must
be less than three inches away from system port.
If gauge is more than three inches away, pull
vacuum and allow system to equalize for ten
minutes to ensure an accurate gauge reading.
IMPORTANT: All refrigerant must be recovered before
evacuating procedure is started. Never discharge
refrigerant through vacuum pump and never into
atmosphere. Always use refrigerant identifier tool
to prevent system contamination.
11-90 79033095 C Rev.

1 2
3
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7
6
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8
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4 5
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9 10
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N021303045
FIG. 57
on
FIG. 57: Refrigerant System Evacuation Components

Lower Pressure Valve (1)
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High Pressure Valve (2)

Charging Hose (3)
Compressor Block Fitting (Discharge) (4)
Compressor Block Fitting (Suction) (5)
Service Valve (Discharge) (6)
Service Valve (Suction) (7)
Venter Exhaust Valve (8)
Line from Condenser (9)
Line from Evaporator (10)
79033095 C Rev. 11-91

1. After refrigerant is recovered from system, close low REFRIGERANT SYSTEM - FLUSH
and high pressure valves. Disconnect charging hose
of manifold gauge set from refrigerant service unit. IMPORTANT: Do not use solvents, compressed air, etc.
to clean any system components.
2. Check oil level in vacuum pump and add oil if
needed. Change oil if contamination is indicated. Flush system if a component failure causes metal
particles or other foreign material to be circulated through
3. Connect electrical plug from vacuum pump to an system.
approved electrical outlet.
Debris in system can cause a compressor to fail
4. Connect charging hose to inlet fitting on vacuum repeatedly. Use following procedure to flush system.
pump.
1. Determine type of refrigerant in system.
5. Turning counterclockwise, completely open low and
high pressure valves on manifold gauge set. NOTE: Use a refrigerant identifier to prevent refrigerant
not 134a from contaminating tools.
6. Turn power switch on to start pump motor.
2. Remove compressor.
7. Turn counterclockwise to open vented exhaust valve.
3. Remove in-line dryer and accumulator.
NOTE: Vented exhaust valve must be closed until
vacuum pump has started. 4. Flush remainder of system. Use an Air Conditioning
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Flushing Unit and flushing solution.

8. Operate vacuum pump until low pressure gauge
indicates a pressure between 95 kPa (28 inch hg) 5. Blow out system with dry shop air for 5 to 10 minutes.
and 98 kPa (29 inch hg). Once value is reached,
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6. Replace any failed component.

close vented exhaust valve. Operate vacuum pump
for at least 90 minutes after vented exhaust valve is 7. Install new in-line dryer and accumulator.
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closed. Use a 113 L/min (4 cfm) pump. Make

allowances for pumps smaller than 113 L/min (4 cfm) 8. Install new compressor.
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cfm. NOTE: New compressor comes with correct amount of

refrigerant oil.
NOTE: 95 kPa (28 inch hg) to 98 kPa (29 inch hg) is
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required specification at sea level. For every 305 9. Evacuate system.

m (1000 Ft) above sea level, decrease required
specification by 3 kPa (1 inch hg). Less vacuum 10. Charge system.
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is required at high elevations.

9. System may have a leak if specific vacuum cannot be
reached. Repair all leaks and repeat first step of
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evacuating procedure.
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NOTE: Evacuating procedure removes air and moisture

from system. Do not use vacuum pump primarily
to indicate a system leak.
on
10. Close valve completely after 95 kPa (28 inch hg) to

98 kPa (29 inch hg) vacuum has been reached and
held for an additional 90 minutes. Turn power switch
on vacuum pump OFF. Maximum amount of vacuum
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loss in five minutes must not exceed 7 kPa (2 inch

hg). Excessive vacuum loss is an indication of a
possible system leak. Repair all leaks and repeat first
step of evacuating procedure.
11. System is ready for a complete charge if vacuum loss
does not exceed 7 kPa (2 inch hg) in five minutes.
11-92 79033095 C Rev.

REFRIGERANT LEAKAGE TEST Leak Detector
Refrigerant leak detectors are designed to detect leaks as
Dye small as 12.0 mL (.40 Fl oz) per year of refrigerant in
Dye is used to identify points of leakage. system. Perform following to determine if a leak is
present.
Finding and repairing refrigerant leaks is important as air
conditioner is a closed circuit system. System must contain at least 0.4 kg (.88 lb) of refrigerant.
Install manifold gauge set to determine if pressure exists
System must contain at least 0.4 kg (.88 lb) of refrigerant. in system. A leak test can be performed if system
Install manifold gauge set to determine if pressure exists. indicates pressure.
A leak test can be performed if system indicates
pressure. NOTE: For best results, place sensor tip below possible
leaks as refrigerant vapor is heavier than air.
NOTE: Refrigerant vapor is heavier than air. For best
results, place black light directly below possible NOTE: Leaks in high pressure side of system are easily
leaks. found if air conditioner is operated for a few
minutes. Leak test must be performed
NOTE: Leaks in high pressure side of system are easily immediately after unit is turned OFF. Leak test for
found if air conditioner is operated for 5 to 10 high pressure side is performed before
minutes. Leak test must be performed
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pressures in system equalize. Leaks in low

immediately after unit is turned OFF. Leak test for pressure side of system are easily found if air
high pressure side is performed before conditioner has been turned OFF for several
pressures in system equalize. Leaks in low minutes. Leak test for low pressure side is
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pressure side of system are easily found if air performed after pressures in system equalize.
conditioner has been OFF for 5 to 10 minutes.
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Leak test for low pressure side is performed after 1. Move sensor tip along possible leak points at a rate of
system pressures equalize. one inch per second.
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1. Move black light along possible leak points. When a 2. If leak is caused by a loose fitting or connection,
leak is present, black light illuminates dye in recovery of refrigerant from system may not be
necessary. Tighten loose connection and perform
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refrigerant.
performance check procedure. If necessary, add
NOTE: Leaks indicated by dye should always be refrigerant to air conditioning system.
confirmed with an electronic leak detector.
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2. If a leak is found in air conditioning system, use a

refrigerant leak detector to confirm leak detected by
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black light.
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79033095 C Rev. 11-93

REFRIGERANT COMPRESSOR OIL
CHECK
A special refrigerant oil is used in air conditioning system.
Oil mixes completely with refrigerant so all components
receive lubrication. A check of refrigerant oil in
compressor give an indication of amount of oil in system.
NOTE: If there is evidence of a major oil loss, check
compressor oil.
The following may cause oil loss:
• Broken refrigerant hose
• Hose fitting (leaks)
• Badly leaking compressor seal
• Component damage
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Complete Check of Compressor Oil

When replacement of a component is necessary, follow
procedures below to determine amount of refrigerant oil
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(lost oil) needed in compressor.

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FIG. 58: Compressor Components

2
Pulley (1)
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Hose (Low Pressure) (2)

Hose (High Pressure) (3)
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Electrical Harness (4) 1 3

4
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Service Valve (Low Pressure) (5)

Service Valve (High Pressure) (6) 5
7
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Plug (Oil Change) (7) 6

8
Belt (Engine Driven Component) (8) N021303046
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FIG. 58
1. Operate engine at 1000 rpm. Set temperature on
maximum cooling and move fan speed switch to
HIGH. System stabilizes in a minimum of 10 minutes.
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2. Stop engine. Remove refrigerant charge from

system. Install a plug in all open lines.
3. Remove compressor from machine. Place protective
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caps on all fittings and hoses.
11-94 79033095 C Rev.

4. Place compressor in a horizontal position so oil plug
is facing downward and remove oil plug. Drain oil into
a clean container. Rock compressor back and forth to
remove all oil and rotate shaft to drain remaining oil in
sump. Inspect oil for contaminants, metal chips,
rubber particles or any other foreign material.
Dispose of oil in a suitable container. Use following as
a guide for adding oil to compressor.
• If amount of oil drained from compressor is 177
mL (6 fl oz) to 237 mL (8 fl oz), put same amount
of new refrigerant oil in. Never add more than 237
mL (8 fl oz) of oil.
• If amount of oil drained from compressor is less
than 177 mL (6 fl oz), add 177 mL (6 fl oz) to 237
mL (8 fl oz) of new refrigerant oil.
If too much oil has been added to system and a total
of more than 325 mL (11 fl oz) is in system, cooling
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capacity of system is reduced. If too little oil has been

added to system, compressor may fail due to a lack of
lubrication.
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If failure of a component causes particles of metal or

other foreign material to be present in system, it is
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necessary to flush system.

• Add oil to compressor through oil plug or inject oil
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through ports for charging. Compressor must be

positioned so refrigerant oil does not flow out
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service valves. Do not rest compressor on shaft.

Turn compressor shaft by hand when filling
compressor. Oil slowly flows into compressor.
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Only use refrigerant oil approved and

recommended.
• Add oil to any component being installed.
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• Inject oil into system through ports for low

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pressure charging.
5. After correct amount of refrigerant oil has been added
to system, install compressor and drive belt.
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REFRIGERANT SYSTEM - CHARGE

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Relationship of Temperature and Pressure

(R-134a Refrigerant)
Use table to determine pressure and contamination level
of a container. Table can be used for a non-operating air
conditioning system. System must be stabilized to
ambient temperature by not operating for 10 to 12 hours
while stored out of direct sunlight.
If pressure measured at any specific temperature does
not match pressure given in chart, the following may exist:
• Contaminants in system
• Incorrect refrigerant
79033095 C Rev. 11-95

Relationship Between Temperature and Pressure Relationship Between Temperature and Pressure
(R-134a Refrigerant) (R-134a Refrigerant)
Temp degrees C Pressure Temp degrees C Pressure

(degrees F) kPa (psi) (degrees F) kPa (psi)
18 C (0.0 F) 44 kPa (6.4 psi) 6 C (43.0 F) 261 kPa (37.9 psi)
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6 C (22.0 F)
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137 kPa (19.8 psi) 13 C (55.0 F) 352 kPa (51.0 psi)

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0 C (32.0 F) 191 kPa (27.7 psi) 18 C (65.0 F) 440 kPa (63.8 psi)
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2 C (35.0 F) 209 kPa (30.3 psi) 20 C (68.0F) 469 kPa (68.0 psi)
24 C (76.0 F) 551 kPa (79.9 psi)
25 C (77.0 F) 562 kPa (81.5 psi)
11-96 79033095 C Rev.

Relationship Between Temperature and Pressure Relationship Between Temperature and Pressure
(R-134a Refrigerant) (R-134a Refrigerant)
Temp degrees C Pressure Temp degrees C Pressure

(degrees F) kPa (psi) (degrees F) kPa (psi)
28 C (83.0 F) 630 kPa (91.4 psi) 48 C (118.0F) 1138 kPa (165.1 psi)
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38 C (100.0F) 852 kPa (123.5 psi)

Procedure for Labeling
38 C (101.0 F) 866 kPa (125.6 psi)
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Use cable strap to label air conditioning system indicating

39 C (102.0 F) 881 kPa (127.8 psi) system charge.
39 C (103.0 F) 896 kPa (129.9 psi)
Charging System
40 C (104.0 F) 911 kPa (132.1 psi)
NOTE: An accurate refrigerant charge can only be
41 C (105.0 F) 926 kPa (134.3 psi) determined by weight or temperature of
41 C (106.0 F) 941 kPa (136.5 psi) evaporator core. Pressures can not be used to
determine if air conditioning system is correctly
42 C (107.0 F) 956 kPa (138.7 psi) charged. Do not add or remove part of
refrigerant.
42 C (108.0 F) 972 kPa (141.0 psi)
NOTE: Never charge liquid or gas through discharge
43 C (109.0 F) 988 kPa (143.3 psi) (high) side of system when engine is in
43 C (110.0 F) 1004 kPa (145.6 psi) operation.
44 C (111.0 F) 1020 kPa (147.9 psi)

44 C (112.0 F) 1036 kPa (150.3 psi)
79033095 C Rev. 11-97

IMPORTANT: In expansion valve system, using poly
alkaline glycol (PAG), sight glass is not a reliable
way to determine system charge.
NOTE: For expansion valve systems containing PAG oil,
sight glass can not be used to charge system. To
achieve a full system charge, refrigerant must be
recovered from system and must be evacuated.
After system has been recovered and system
has been evacuated, charge system with correct
amount of refrigerant. This is the only
recommended procedure.
NOTE: If engine is running, charge system with
refrigerant gas through low pressure side. Never
charge liquid refrigerant through suction (low
pressure) side of air conditioning system. If
engine is not running, charge with liquid or gas
through high pressure side.
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NOTE: Check the following before charging system:

1. Condenser and evaporator
• Inspect condenser and evaporator for foreign
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material inhibiting airflow, dirt, insects, plastic

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bags, etc.
• Check both fan motors are running when working
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with roof or remote mounted condensers and

check for restrictions. A clean condenser leads to
extended compressor life.
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2. Check for a loose belt on compressor.

3. Clean fresh and recirculation air filters.
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4. Check moisture indicator on either receiver-dryer or

in-line dryer, replace if moisture indicator is pink or
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white. System is normal if moisture indicator is blue.

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5. Check condensation tube on evaporator to ensure

tube is not plugged and valve is properly in place.
NOTE: A new receiver-dryer requires 2-3 hours of
operation before an accurate reading for
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moisture can be attained.

NOTE: Preferred method for charging air conditioning
system is:
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• Recover refrigerant.
• Evacuate system.
• Charge system with correct amount of refrigerant
measured by weight.
NOTE: System needs to be charged with correct amount
of refrigerant after system has been recovered
and evacuated. Measure refrigerant by weight.
11-98 79033095 C Rev.

COMPLETE CHARGE OF SYSTEM FROM
A REFRIGERANT TANK WITH A SCALE
Use of a refrigerant tank and scale is necessary to charge
system. Use following procedure to charge system.
NOTE: When charging system with a liquid, ensure
engine is not running.
1 2
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10
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N021303047
FIG. 59
FIG. 59: Charging System Components (8) Service Valve (Suction)

(1) Low Pressure Valve (9) Refrigerant Tank
(2) High Pressure Valve (10) Valve on Top of Refrigerant Tank
(3) Charging Hose (11) Scale
(4) Low Pressure Hose (E) Vapor
(5) High Pressure Hose (F) Liquid
(6) Manifold Gauge Set
(7) Service Valve (Discharge)
79033095 C Rev. 11-99

1. Find refrigerant capacity for system to be charged. 5. Start engine and operate at 1000 rpm.
2. Install high and low pressure and purge hoses. 6. Move temperature control knob to MAXIMUM cool
and fan switch to HIGH.
3. Hand tighten charging hose from manifold gauge set
directly to refrigerant tank valve. Open valve on top of NOTE: Recovering refrigerant and evacuating system is
refrigerant tank, allowing flow of refrigerant through preferred method for charging air conditioning
charging hose to manifold gauge set. system. After system has been recovered and
evacuated, charge system with correct amount
4. Loosen hose at manifold gauge set for two to three of refrigerant, measured by weight.
seconds, tighten connection to purge air from line.
7. Open low pressure valve on manifold gauge set to
5. Place refrigerant tank on scale so valve is at bottom release refrigerant into low pressure hose. Low
and check weight of tank. pressure hose connects to suction service valve on
NOTE: A heater blanket may be required when charging compressor. Note reading on pressure gauge.
an air conditioning system with a partially full Gauge reading should not exceed normal operating
refrigerant tank. ranges during procedure. Slowly add refrigerant until
accumulator is cool. Temperature of vents inside cab
6. Open high pressure valve on manifold gauge set should decrease during procedure.
allowing liquid refrigerant to charge system through
8. After accumulator becomes cool, add 0.34 kg (0.750
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high pressure side of compressor.

lb) of refrigerant to system for reserve, measured by
7. Check weight of refrigerant tank often. Weight weight.
decreases as refrigerant leaves tank and enters
9. To prevent additional flow of refrigerant into
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system. When required amount of refrigerant (system

capacity) has entered system, close valve and high compressor, close low pressure valve. Allow system
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pressure valve. Closing valves stops flow of to stabilize for five minutes. Inlet and outlet on
refrigerant. For example, 1.8 kg (4 lb) of refrigerant accumulator should be cool.
has entered a system with 1.8 kg (4 lb) capacity.
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NOTE: If low pressure valve is opened completely, low

8. To ensure correct system operation, disconnect pressure gauge reading appears excessively
charging hose and conduct a performance check. high until system becomes fully charged.
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10. Gauge reading for low pressure valve should be

ADDING ADDITIONAL REFRIGERANT TO within normal range after system is charged. Gauge
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A SYSTEM WITH LOW CHARGE reading for high pressure valve should be within
normal range after charging. If gauge readings are
IMPORTANT: Failure to properly follow procedure may within normal range, proceed. If gauge readings are
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cause compressor failure. The following not within normal range, skip next step.
procedure is not preferred method for charging 11. If pressure on suction side or discharge pressure
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an air conditioning system. Preferred method is become too high, system is overcharged. Close valve
measuring refrigerant by weight. on refrigerant tank completely to stop flow of
NOTE: Procedure is applicable only if inlet air refrigerant to charging hose. Turn off engine, recover
temperature at condenser is between 21 charge, evacuate system and recharge system to
on
degrees C (70.0 degrees F) and 32 degrees C correct charge.

(90.0 degrees F). Procedure may be repeated a 12. Move air conditioning controls to OFF and stop
second time to achieve proper charge with this engine.
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method.
13. Remove manifold gauge set.
IMPORTANT: If system has no refrigerant, evacuate
system before charging and measure refrigerant
by weight.
1. Connect manifold gauge set to discharge and service
ports on compressor.
2. Ensure low and high pressure valves are closed on
manifold gauge set.
3. Turn valve on tank counterclockwise to release
refrigerant to charging hose.
NOTE: Ensure cylinder of refrigerant is upright allowing
refrigerant to enter as a gas.
4. Loosen hose connection on charging hose at
manifold gauge set for two to three seconds, tighten
connection allowing air to be released from charging
hose.
11-100 79033095 C Rev.

MANIFOLD GAUGE SET (REFRIGERANT) -
REMOVE
Remove charging hoses properly. A low system charge
results from incorrectly removing charging hoses. To
ensure accuracy of refrigerant charge, refrigerant should
be removed from charging hoses. Follow steps below to
remove refrigerant from charging hoses:
1. Allow compressor to continue operation. Close valve
on high pressure side. Valve is located near charging
ports on compressor. Disconnect high pressure hose
from air conditioning system.
2. Open high and low pressure valves at gauge set.
Refrigerant in hoses is removed by compressor
through low pressure hose.
3. Close valve on low pressure side. Valve is located
near charging ports on compressor. Disconnect low
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pressure hose from air conditioning system. System

is now charged.
NOTE: After manifold gauge set is removed, it is
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necessary to cap charging valves.

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SUNLIGHT SENSOR - TEST

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FIG. 60: Blower Control Knob

1. Position speed control for blower (1) to AUTO.
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2. Adjust temperature setting for cab to approximate

temperature.
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N021303048
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FIG. 60
FIG. 61: Outside Temperature Button
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3. Enter advanced diagnostic mode by pressing outside

temperature button (1) three times quickly, then hold 1
for 5 seconds. Text CAB is displayed.
4. Press button for outside temperature repeatedly to
scroll through to SUN position.
N021303049
FIG. 61
79033095 C Rev. 11-101

FIG. 62: Top of Steering Console
5. Cover solar load sensor (1) located on top of steering
console (2). Display should be less than 10.
6. Uncover sensor and position machine so sensor is in
2
direct sunlight. Displayed value automatically
increases. 1
NOTE: If there is not enough sunlight or if test is being
conducted indoors, use a flashlight. Hold
flashlight close to sensor, after 15 seconds of
bright light exposure, blower fan should increase
automatically. Covering sensor again should
cause fan speed to decrease. Verify by setting
N021303050
display to view FAN output. If sensor continues to
read zero even in sunlight, check connections of FIG. 62
sensor and wire harness. If necessary, replace
solar sensor. If solar load sensor is not faulty and
no other problems can be found, replace ECM.
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11-102 79033095 C Rev.

CONTROL PANEL-TEST Push Button for Temperature
Machine can be equipped with one of two cabs. Standard 1. Set temperature to highest setting 32 degrees C (90
cab uses a manual control and deluxe use an automatic degrees F).
system to control HVAC. Use appropriate test for unit 2. Set control for blower fan to AUTO.
being serviced.
Test Result
Tests for Standard Control Panel
1. Blower fan speed changes to full speed.
Air Conditioning Switch 2. Heating system turns on.
1. With machine running, turn speed selector for blower a. Actuator for water valve opens water valve.
fan to high.
b. Temperature of supply line at heater core
2. Turn on air conditioner. increases as engine temperature increases.
Test Result Push Button for Temperature

1. Refrigerant compressor engages. 1. Set temperature to lowest setting 15.5 degrees C (60
degrees F).
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a. Supply line temperature at evaporator coil

decreases. 2. Set blower control fan to AUTO.
Temperature Control Test Result

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1. Turn temperature control clockwise for warm air. 1. Speed of blower fan changes to full speed.
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2. Air conditioning system turns on.

Test Result
a. Refrigerant compressor clutch engages.
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1. Water valve should be fully open.

a. Temperature of supply line at heater core should b. Supply line at evaporator coil temperature
decreases.
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increase with engine temperature.
Speed Control for Blower Fan Push Button for Temperature

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1. Set temperature to equal temperature of cab.

1. Turn ignition switch on.
2. Change speed control for blower fan to all positions. 2. Set control for blower fan to AUTO.
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Test Result
Test Result
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1. Blower fan should change speed to reflect change in 1. Speed of blower fan changes to low speed.
control position. 2. Air conditioning turns on.
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Test for Automatic Control Panel Control for Mode of Airflow

1. Change control for mode of airflow.
LED Display Test
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1. Turn system off. Test Result

2. Turn ignition on. 1. Airflow from vents changes to match control.
Test Result Control for Mode of Airflow (Defrost)

1. LED briefly flashes 8888. 1. Change control for mode of airflow to defrost.
Speed Control for Blower Fan Test Result

1. Turn HVAC system on. 1. Refrigerant clutch compressor engages.
2. Direct airflow to vents for defrost.
Test Result
1. LED displays last set point selected.
2. Blower fan circulates air. Temperature selected
determines speed of blower. Speed of blower fan
increases relative to difference in temperature.
79033095 C Rev. 11-103

NOTES
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11-104 79033095 C Rev.

SPECIFICATIONS
REFRIGERANT COMPRESSOR
Compressor
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P082703004
FIG. 63:
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FIG. 63:
Torque for oil plug (1)......................................................................................................... 8 to 12 Nm (71 to 107 lbf in)
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NOTE: Oil plug is pressurized

Type of compressor .................................................................................................... Sanden International A9XS-6000
Type of 4C-2959 Air Conditioner Lubricant............................................................................................................... PAG
Oil capacity of compressor................................................................................................................. 300 mL (10 fl oz)
Type of refrigerant............................................................................................................................................. HFC134a
Type of compression........................................................................................................................... 7 swing cylinders
Capacity of cylinders...................................................................................................... 154.9 cc/rev (9.45 cu inch/rev)
Power consumption ...................................................................................................................................................34W
Rotation.............................................................................................................................................................Clockwise
Recommended RPM for compressor .........................................................................................................2300 to 2700
Maximum allowable continuous RPM...................................................................................................................... 4000
11-105
Clutch
Rotation.............................................................................................................................................................Clockwise
Voltage of magnetic clutch................................................................................................................................... 12 VDC
Relief Valve
Final installation torque (2) ............................................................................................ 18 to 32 Nm (158 to 282 lbf in)
Opening pressure of relief valve (3) ................................................................................................. 4137 kPa (600 psi)
Belt
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P082703005
FIG. 64:
FIG. 64: Belt Routing
Belt (1)........................................................................................................................................................................ PV8
Belt Tightener spring force at 38.4 degrees (2) ................................................... 15.7 to 24.3 Nm (11.8 to 18.2 lbf ft)
11-106
SYSTEM CAPACITIES FOR REFRIGERANT
m
WARNING: Personal injury can result from contact with refrigerant.
This system is under pressure at all times, even if engine is not running. Heat should never be
applied to a charged system.
Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.
Protective goggles must always be worn when refrigerant lines are opened, even if gauges indicate
system is void of refrigerant.
Always use caution when a fitting is removed. Slowly loosen fitting. If system is still under pressure,
evacuate system recovering refrigerant before removing fitting.
Personal injury or death can result from inhaling refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.
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Before any checks of air conditioning and heating system are made, move machine to a smooth
horizontal surface. Lower all implements to ground. Make sure transmission is in neutral or park
and parking brake is engaged. Keep all other personnel away from machine or where they can be
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seen.
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Model Product Amount of

Identification Charge
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Number
MT735 AKN1-Up 2.1 kg (4.65 lb)
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MT745 ALA1-Up 2.1 kg (4.65 lb)

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MT755 ALM1-Up 2.1 kg (4.65 lb)

MT765 AMS1-Up 2.1 kg (4.65 lb)
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MT835 BAM1-Up 2.3 kg (5 lb)

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MT845 BBP1-Up 2.3 kg (5 lb)

MT855 BCC1-Up 2.3 kg (5 lb)
MT865 BDS1-Up 2.3 kg (5 lb)
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11-107
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11-108
Index
INDEX
A E
Actuator Motor (Damper Assembly) ................... 11-38 Electrical Schematic for the Heating and
Actuator Motor (Water Valve) ............................ 11-32 Air Conditioning System ................................ 11-24
Adding Refrigerant to System ............................ 11-53 Engine Coolant or Anti-freeze ............................ 11-43
Air and/or Moisture in the System ...................... 11-56 Evacuating and Charging AC System ................ 11-70
Air Conditioner Blower/Fan and Evacuating System ............................................. 11-70
Motor Assembly ............................................ 11-40 Evaporator Coil ........................................ 11-14, 11-23
Air Conditioner System Ducts ............................ 11-40 Evaporator Coil Probe ........................................ 11-22
Air Conditioning and Heating Excessive Air and/or Moisture in System ........... 11-56
System Schematic ........................................ 11-12 Expansion Valve ................................................. 11-42
Air Conditioning Process ...................................... 11-2 Expansion Valve (TXV) Stuck Closed or
Air Flow .............................................................. 11-33 Plugged ......................................................... 11-57
Airflow Intake ..................................................... 11-34 Expansion Valve (TXV) Stuck Open .................. 11-58
Ambient Temperature ........................................ 11-22
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ATC Features ....................................................... 11-6

Automatic Fan Speed Control ............................ 11-37 F
Automatic Temperature Control ........................... 11-6
Flushing AC System ........................................... 11-70
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Flushing Kit ......................................................... 11-48

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Blower Fan ......................................................... 11-33 G

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Blower or Fan and Motor Assembly ................... 11-45

General Information .............................................. 11-1
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General Troubleshooting Information ................. 11-77

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Cab Airflow Circulation ......................................... 11-4 H

Cab Airflow Cooling ............................................. 11-5
Cab Airflow Heating ............................................. 11-4 Head, Foot and Defrost ...................................... 11-35
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Cab Pressurization ............................................... 11-4 Heater Components and Controls ...................... 11-44
Charging AC System ......................................... 11-71 Heater Core ........................................................ 11-45
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Charging Refrigerant Gas (on Low Side) ........... 11-71 Heater Core (Cab) .............................................. 11-30
Charging System with Liquid Refrigerant ........... 11-71 Heater System Ducts ......................................... 11-45
Clutch ................................................................. 11-39 Heater System Inspection .................................. 11-51
Clutch Operation ................................................ 11-18 Heater System Operation ................................... 11-43
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Component Protection ......................................... 11-6

Component Repair or Replacement .................. 11-72
Components ......................................................... 11-4 I
Compression (Discharge Side) .......................... 11-19
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Compressor Clutch ............................................ 11-18 Initialization (Start-Up) ........................................ 11-10

Compressor Malfunction .................................... 11-60
Compressor Operation ....................................... 11-19
Compressor Repair ............................................ 11-72 L
Compressor/Clutch ............................................ 11-11
Compressors ...................................................... 11-39 Leak Detectors ................................................... 11-47
Condenser Malfunction or LED Display .......................................................... 11-8
System Overcharge ...................................... 11-61 Low Refrigerant Charge in System .................... 11-55
Control Module ................................................... 11-10 Lubricants ........................................................... 11-39
Control Panel ....................................................... 11-6
Control Panel - Test ......................................... 11-103
Cooling System Thermostat and M
Radiator Pressure Cap ................................. 11-44
Machine Preparation for Troubleshooting .......... 11-77
Manifold Gauge Set ............................................ 11-46
D Manifold Gauge Set (Refrigerant) - Install .......... 11-89
Manifold Gauge Set Installation ......................... 11-53
Description and Properties of Refrigerants ........ 11-65 Manual and Electronic HVAC Controls ................ 11-4
Manual Fan Control ............................................ 11-36
79033095 C Rev. 11-109

Index
Manual Mode Fan Speed Control ...................... 11-37 T
Manual Temperature Control System .................. 11-8
Maximum Cooling or Heating ............................... 11-8 Temperature Sensors .............................. 11-17, 11-43
Mode Control Rotary Switch ................................ 11-6 Theory of operation .............................................. 11-2
Module Input/Output Signals .............................. 11-10 Thermostatic Switch Malfunction ........................ 11-62
Motor (Air Conditioning Blower) ......................... 11-35 Troubleshooting Air Conditioner Control ............ 11-86
Troubleshooting and Service Procedures .......... 11-53
Troubleshooting by Manifold Gauge
O Set Readings ................................................. 11-55
Troubleshooting Faults With
Orifice Tube ....................................................... 11-14 Service Codes (Active) .................................. 11-78
Checking the Actuator for the Water Valve ..... 11-81
Checking the Blower Fan ................................ 11-81
P Checking the Compressor Clutch ................... 11-80
Checking the Mode Door Actuator .................. 11-81
Performing Recycling Procedure ....................... 11-67 Checking the Refrigerant
Pumping ............................................................. 11-19 Pressure Switches ..................................... 11-80
Purging Non-Condensable Gases (Air) ............. 11-67 Checking the Sunlight Sensor ......................... 11-80
Checking the Temperature Sensors ............... 11-79
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Entering Active Troubleshooting ..................... 11-79

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Receiver/Drier Sight Glass ................................. 11-41 U

Receiver-Drier .................................................... 11-40
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Recirculation ...................................................... 11-34 Units of Temperature ............................................ 11-8

Recovering and Recycling Refrigerant .............. 11-66
Recovery/Recycle Station .................................. 11-66
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Recovery/Recycling Station ............................... 11-46 V

Refrigerant ......................................................... 11-74
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Refrigerant Accumulator ......................... 11-29, 11-41 Vacuum Pumps .................................................. 11-47

Refrigerant Compressor .......................... 11-13, 11-18 Ventilation Duct Temperature ............................. 11-22
Refrigerant Compressor Oil - Check .................. 11-94
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Refrigerant Condenser ............................ 11-13, 11-21

Refrigerant Dispensing Valves and W
Containers ..................................................... 11-46
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Refrigerant Leakage - Test ................................ 11-93 Water Pump ....................................................... 11-44

Refrigerant Pressure Switches .......................... 11-16
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Refrigerant Recovery ......................................... 11-88

Refrigerant Relief Valve ..................................... 11-20
Refrigerant System - Charge ............................. 11-95
Refrigerant System - Evacuate .......................... 11-90
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Refrigerant System - Flush ................................ 11-92

Refrigerants ....................................................... 11-65
Removal of Moisture from Cab Airflow ................. 11-4
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Safety and Safety Tools ..................................... 11-46

Schematic for Testing the Water Valve .............. 11-32
Sensor (Temperature) ........................................ 11-22
Sensors For Refrigerant System ........................ 11-18
Service Tools ..................................................... 11-46
Speed Control .................................................... 11-37
Stabilizing AC System ........................................ 11-55
Suction (Suction Side) ....................................... 11-19
Sunlight Sensor ....................................... 11-16, 11-37
Sunlight Sensor - Test ..................................... 11-101
System High Pressure Side Restriction ............. 11-59
11-110 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
12 - Ballasting
Contents
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WEIGHT REMOVAL AND INSTALLATION

Front Weights ................................................................................................................................................ 12-1
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Removal .................................................................................................................................................. 12-1

Installation ............................................................................................................................................... 12-8
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Idler Weights ................................................................................................................................................ 12-15

Removal ................................................................................................................................................ 12-15
Installation ............................................................................................................................................. 12-16
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Undercarriage Weights ................................................................................................................................ 12-18

Removal ................................................................................................................................................ 12-18
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Installation ............................................................................................................................................. 12-19
BALLAST SPECIFICATIONS
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Weights ........................................................................................................................................................ 12-21

Adding Weights ..................................................................................................................................... 12-23
Maximum Machine Weight .................................................................................................................... 12-24
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Ballasting for Towed Scrapers .............................................................................................................. 12-25

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INDEX ............................................................................................................................................................. 12-27

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79033095 C Rev. 12-i

Contents
NOTES
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12-ii 79033095 C Rev.

Weight Removal and Installation
WEIGHT REMOVAL AND INSTALLATION
FRONT WEIGHTS
The procedure for removing and installing front weights is
same throughout 700, 800 and 900 series machine.
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WARNING: Front weights are extremely
heavy and require proper handling
equipment to remove. Failure to use proper
procedures and equipment may result in
personal injury or death due to crushing.
Removal
20 Front Weight Option
FIG. 1: If 20 front weight option is being removed, there
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will be two bolts (1) that secure weight plates together

using two plates (2). 2
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N050705002
FIG. 1
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secure front weights.

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1
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P072905003
FIG. 2
79033095 C Rev. 12-1

FIG. 3: Use a suitable lifting device and slide each
weight (1) off mounting bracket (2) and remove. Remove
weights until plate (3) has been reached. Seven weights
will have to be removed.
NOTE: The weight of each plate is approximately 46 kg
(102 lb). 2
The weights must now be removed from opposite side.
3
1
P072905004
FIG. 3
secure weights (2).
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P072905005
FIG. 4
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weight (1) off mounting bracket (2) and remove. Remove
weights until plate (3) has been reached. Seven weights
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will have to be removed. 1

Remove plate (3).
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P072905006
FIG. 5
FIG. 6: Remove three weights (1) on left-hand side of
flagpin (2).
P072905007
FIG. 6
12-2 79033095 C Rev.

FIG. 7: Remove plate (1) and three weights (2) from
right-hand side of flagpin. 2
1
P072905008
FIG. 7
FIG. 8: Remove bolt with washer (1) that secures
flagpin.
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N041812016
FIG. 8
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FIG. 9: Remove flagpin (1).

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N041812017
FIG. 9
FIG. 10: Use a suitable lifting device to support mounting
bracket (1).
1
NOTE: The weight of mounting bracket is approximately
499 kg (1099 lb).
Loosen and remove twelve bolts with washers (2) that
secure mounting bracket (1) to machine. Remove
mounting bracket.
P072905009
FIG. 10
79033095 C Rev. 12-3

FIG. 11: If 32 front weight option is being removed, there
will be six bolts (1) that secure weight plates together 2 1
using three plates (2). 1
N050705001
FIG. 11
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that secure front weights.
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P072905012
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FIG. 12
weight (1) off mounting bracket (2) and remove.
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(102 lb).
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P072905013
FIG. 13
12-4 79033095 C Rev.

FIG. 14: Remove all weights until plate (1) is reached. At
this point you must move to opposite side to continue 1
removing weights.
P072905014
FIG. 14
that secure weights (2).
1
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P072905015
FIG. 15
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FIG. 16: Use a suitable lifting device slide each weight

(1) off mounting bracket (2) and remove.
Remove all weights until next set of retaining bolts (3) are 1
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reached.
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3 2
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P072905016
FIG. 16
that secure weights (2).
1
2
P072905017
FIG. 17
79033095 C Rev. 12-5

FIG. 18: Continue removing weights (1) until plate (2)
that secured retaining bolts is reached. Remove plate.
1
P072905018
FIG. 18
FIG. 19: Continue removing weights (1) until flagpin (2)
is reached. At this point weights will have to be removed
from opposite side.
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P072905019
FIG. 19
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FIG. 20: Remove weights (1) until plate (2) that holds
retaining bolts is reached. Remove plate.
2
At this point remaining weights can be removed.
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P072905020
FIG. 20
FIG. 21: Remove bolt with washer (1) that secures
flagpin.
N041812016
FIG. 21
12-6 79033095 C Rev.

FIG. 22: Remove flagpin (1).
N041812017
FIG. 22
FIG. 23: Use a suitable lifting device to support mounting
bracket (1).
1
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499 kg (1099 lb).
Loosen and remove twelve bolts with washers (2) that
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secure mounting bracket to machine. Remove mounting

bracket.
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P072905009
FIG. 23
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79033095 C Rev. 12-7

Installation
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WARNING: Front weights are extremely

FIG. 24: Using a suitable lifting device move mounting
bracket (1) into position on machine.
1
499 kg (1099 lb).
Install mounting bracket with twelve bolts with washers
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P072905009
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FIG. 24
FIG. 25: Install flagpin (1).
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N041812017
FIG. 25
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FIG. 26: Secure flagpin (1) with bolt and washer (2).
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N041812016
FIG. 26
12-8 79033095 C Rev.

FIG. 27: Use a suitable lifting device to install front
weights. 1
Install each weight individually to end of mounting bracket
and slide inward.
(102 lb).
Install three weights (1) to right-hand side of flagpin (2).
P072905010
FIG. 27
FIG. 28: Install three weights (1) to left-hand side of
flagpin. Install plate (2) for retaining bolts.
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P072905011
FIG. 28
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FIG. 29: Install additional weights (1) to left-hand side of

flagpin. Seven weights will have to be installed on each
side with 20 weight option.
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P072905006
FIG. 29
FIG. 30: Install plate (1) to three weights (2) that were
previously installed to right-hand side of flagpin.
Install additional weights (3) to right-hand side of flagpin. 1
Seven weights will have to be installed on each side with
20 weight option. 3
2
P072905004
FIG. 30
79033095 C Rev. 12-9

FIG. 31: Secure weights (1) with a bolt and washer (2).
The bolt with be routed through weights and two plates.
1 2
P072905005
FIG. 31
FIG. 32: Secure weights (1) with bolt and washer (2).
The bolt with be routed through weights and two plates.
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P072905003
FIG. 32
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FIG. 33: The graphic shows cutaway view of twenty front

weights installed. Two bolts (1) and two plates (2) are
used to secure weights. 1 2
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N050705002
FIG. 33
12-10 79033095 C Rev.

FIG. 34: Using a suitable lifting device move mounting
bracket (1) into position on machine.
1
499 kg (1099 lb).
Install mounting bracket with twelve bolts with washers
P072905009
FIG. 34
FIG. 35: Install flagpin (1) to mounting bracket (2).
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N041812017
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FIG. 35
FIG. 36: Secure flagpin (1) with bolt and washer (2).
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N041812016
FIG. 36
79033095 C Rev. 12-11

FIG. 37: Use a suitable lifting device to install front
weights. 1
Install each weight individually to end of mounting bracket
and slide inward.
(102 lb).
Install three weights (1) to right-hand side of flagpin (2).
2
P072905010
FIG. 37
FIG. 38: Install plate (1) to right-hand side of weights (2)
that were previously installed. 2
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P073005001
FIG. 38
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FIG. 39: Install an additional three weights (1) and plate

(2) to right-hand side of flagpin. 1
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P073005002
FIG. 39
FIG. 40: Install three weights (1) to left-hand side of
flagpin. Install plate (2) for retaining bolts.
2
1
P073005003
FIG. 40
12-12 79033095 C Rev.

FIG. 41: Install four additional weights (1) to left-hand
side of flagpin. Secure weights with two bolts with 2
washers (2). The bolts will be routed through weights and
three plates. Tighten bolts to 240 Nm (177 lbf ft).
1
P072905017
FIG. 41
FIG. 42: Install an additional nine weights (1) to left-hand
side of flagpin.
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P072905016
FIG. 42
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FIG. 43: Secure weights (1) with two bolts with washers
(2). The bolts with be routed through weights and one 2
plate. Tighten bolts to 240 Nm (177 lbf ft).
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P072905015
FIG. 43
FIG. 44: Install an additional ten weights (1) to right-hand
side of flagpin.
1
P072905013
FIG. 44
79033095 C Rev. 12-13

FIG. 45: Secure weights (1) with two bolts with washers
(2). The bolts with be routed through weights and two
plates. Tighten bolts to 240 Nm (177 lbf ft).
2
P072905012
FIG. 45
FIG. 46: The graphic shows cutaway view of thirty-two
front weights installed. Six bolts (1) and three plates (2) 2
are used to secure weights. 1 1
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N050705001
FIG. 46
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12-14 79033095 C Rev.

IDLER WEIGHTS
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WARNING: Idler weights are extremely
Removal
The procedure for removing idler weights will be same for
all idler weights.
FIG. 47: Remove six bolts with washers (1) at three
locations that secure each auxiliary idler weights. Remove
auxiliary idler weight (2).
NOTE: The weight of auxiliary idler weight is
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P073005004
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FIG. 47
FIG. 48: Remove six bolts with washers (1) at three
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locations that secure next auxiliary idler weight. Remove

auxiliary idler weight (2).
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Continue procedure until all auxiliary idler weights are 2

removed.
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P073005005
FIG. 48
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FIG. 49: Removal of base idler weight

Loosen and remove six bolts with washers (1) that secure
base idler weight (2) to idler. Remove base idler weight. 2
Repeat procedure for any other idler weights that are
needed to be removed.
NOTE: The weight of base idler weight is approximately
57 kg (125 lb).
1
P073005006
FIG. 49
79033095 C Rev. 12-15

Installation
FIG. 50: Partial sets of idler weights may be installed.
NOTE: 36 idler weights are not compatible with 2286 mm
(90 in) gauge setting. The inner weights will
interfere will interfere with frame of machine
before gauge setting is reached.
However, the difference in number of weights between
inside front idler and outside front idler can only be one
weight.
KA15341
FIG. 50
FIG. 51: The illustration shows examples of the
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acceptable combinations of idler weights. (Other

combinations are possible.) 2 1 1 2 1 1
2
(1) Base idler weight
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(2) Auxiliary idler weight

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00490409
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FIG. 51
FIG. 52: The illustration shows examples of
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unacceptable combinations of idler weights. (Other

combinations are possible.) 1 2
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2 1 1
(1) Base idler weight
(2) Auxiliary idler weight
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00490412
FIG. 52
12-16 79033095 C Rev.

FIG. 53: Remove six bolts (1) from front idlers.
Clean all mating surfaces. 1 1
1
1 K921063
FIG. 53
FIG. 54: Use six bolts with washers (1) to install base
idler weight (2). Tighten bolts to 800 to 1000 Nm (595 to
744 lbf ft). The auxiliary idler weights will then be installed
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2
to base idler weight.
NOTE: The weight of base idler weight is approximately
57 kg (125 lb).
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P073005006
FIG. 54
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FIG. 55: Align handles (1) of auxiliary idler weight (2).

This will achieve correct orientation for clearance holes.
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Install auxiliary idler weight in recesses around outer edge

of base idler weight. Use six bolts with washers (3) to
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secure auxiliary idler weight. 2

If necessary, install additional auxiliary idler weights. Align
on
clearance holes with threaded holes. 3

NOTE: Proper orientation of idler weights is only 1
important when you install auxiliary idler weight
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onto base idler weight. P073005007
Repeat procedure on other idlers that additional weight is FIG. 55

needed.
NOTE: The weight of auxiliary idler weight is
79033095 C Rev. 12-17

UNDERCARRIAGE WEIGHTS
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WARNING: Undercarriage weights are
extremely heavy and require proper
handling equipment to remove. Failure to
use proper procedures and equipment may
result in personal injury or death due to
crushing.
Removal
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00891349
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FIG. 56
FIG. 56: Remove nuts (1) and washers (2) from ends of
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threaded rods.
Remove threaded rods (3) from counterweights and
retaining nuts (4).
Remove weights individually from bracket (5). Capture
retaining nuts as center weights are removed.
Remove bolts (6) and washers (7) to remove bracket (8)
from undercarriage.
NOTE: The weight of undercarriage weights are
12-18 79033095 C Rev.

Installation
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5 10
00891349
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FIG. 57
FIG. 57: Use M24 x 3.0 bolts (1) and washers (2) to
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attach bracket (3) to undercarriage. Tighten bolts to 800

Nm (590 lbf ft).
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If removed, attach three bolts (4), washers (5), and

spacers (6) to center of bracket (3) providing fore and aft
location of weights.
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Install weights individually onto bracket and make sure

retainer nuts (7) are installed as shown.
Install threaded rods (8) through counterweights and
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retaining nuts.
Install washers (9) and tighten nuts (10) to 270 Nm (199
lbf ft) to secure counterweights.
NOTE: The weight of undercarriage weights are
79033095 C Rev. 12-19

NOTES
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12-20 79033095 C Rev.

Ballast Specifications
BALLAST SPECIFICATIONS
WEIGHTS
Weights are added to machine for the following two
reasons:
• Drawbar pull of machine
• Balance of machine
FIG. 58: Three types of weights are available for 800
series machines.
Front Weights (1) - Front weights are available. The
front weights require a mounting bracket. 1
The mounting bracket weighs 499 kg (1099 lb). The front
weights are segmented. This permits installation and
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removal by hand. Each weight weighs 46 kg (102 lb).

Idler Weights (2) - Idler weights are available. Idler
weights can be installed on inside and outside of front
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idlers. A maximum of 18 idler weights can be installed on

each side. The idler weights are segmented. This permits
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installation and removal by hand. Each weight weighs 57

kg (125 lb). 2 3
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Undercarriage Weights (3) - Undercarriage weights P022105006

can be installed on inside and outside of each
FIG. 58
undercarriage. A maximum of 32 undercarriage weights
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can be installed on each undercarriage. The weights are

segmented. This allows removal and installation by hand.
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Each weight weighs 34 kg (75 lb).

The package of 32 front weights is roughly equivalent to
3400 kg (7496 lb) of idler weights. The relation between
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idler weights and front weights is around 1 to 0.66. The

front weight that is 46 kg (102 lb) is equivalent to 75 kg
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(165 lb) of idler weight.

Front weights are recommended instead of idler weights
when machine is equipped with a mounted implement.
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Front weights are more efficient for balancing machine.

You can install front weights more quickly than idler
weights.
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However, idler weights are recommended when machine

is equipped with a drawbar or trailed implement. Idler
weights are most efficient form of ballast for machine. The
weight is directly on undercarriage for increased pulling
and steering performance. The installation of idler weights
requires more time than installation of front weights.
Undercarriage weights are primarily intended for use as
ballast.
The specific groups of weight in Table are recommended.
Some groups that are listed are not available from factory.
Weights can usually be installed in any number until
maximum ballasted weight is reached.
Do not use undercarriage weights in scraper applications.
79033095 C Rev. 12-21

Front Weights
Individual
Group Total Weight
Weight
Mounting Bracket for 499 kg (1099 lb)
the Front Weights
14 Front Weights 1143 kg (2520 lb)(1) 46 kg (102 lb)
(1)(2)
20 Front Weights 1419 kg (3128 lb) 46 kg (102 lb)
26 Front Weights 1695 kg (3737 lb)(1) 46 kg (102 lb)
(1)(2)
32 Front Weights 1971 kg (4345 lb) 46 kg (102 lb)
(1)The total weight includes mounting bracket
(2)Available from factory
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Idler Weights
Group Total Weight Individual

Weight
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4 Idler Weights 227 kg (500 lb) 57 kg (125 lb)

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(1)
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28 Idler Weights 1588 kg (3500 lb)(1) 57 kg (125 lb)

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36 Idler Weights 2041 kg (4500 lb)(2) 57 kg (125 lb)

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(1)Available from the factory

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Under Carriage Weights
Group Total Weight Individual

Weight
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Mounting bracket for 136 kg (300 lb) each

-
undercarriage weights
32 Undercarriage 1361 kg (3000 lb)(1)(2) 34 kg (75 lb)
Weights
64 Undercarriage 2722 kg (6000 lb)(1)(2) 34 kg (75 lb)
Weights
(1)The total weight includes mounting bracket
(2)Available from factory
12-22 79033095 C Rev.

Adding Weights
Use following procedure to choose proper ballast
arrangement for machine.
1. Determine usage of machine.
2. Weigh machine to determine what total weight is.
3. Observe machine while machine is operating under
load. Check amount of slippage. See Measuring and
Reducing MTS slippage for more information.
4. Determine recommended level of ballast that is
needed and install accordingly.
5. Observe balance of machine.
6. Observe stability of machine. The machine should be
stable while Steering, braking, and roading.
7. If machine is not properly ballasted, adjust position of
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weights. Repeat Steps 5 and 6 until machine is

operating within recommendations.
Additional Suggestions
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If recommendations do not produce an even distribution

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of weight, use following suggestions:

Shift weight to front of machine - If you are using a
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heavy three-point hitch mounted implement that weighs

more than 4086 kg (9008 lb) exchange idler weight for
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front weight. This will help to balance machine. If you are

pulling a trailed implement, exchange front weight for idler
weights.
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Readjust implement gauge wheels or install

implement gauge wheels - When implement is in
ground, machine should not support weight of implement.
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Lower gauge wheels to keep implement at desired depth

while three-point hitch control lever is all the way forward.
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If implement is not equipped with gauge wheels, install

gauge wheels.
Remove quick hitch from three-point hitch - When
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you remove quick hitch from three-point hitch, you move

implement 89 mm (3.5 in) closer to machine. This equals
addition of approximately 227 kg (500 lb) of front weight.
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Increase sensitivity of draft control - The draft control

raises implement when draft load is too high. Therefore,
load on machine is more stable.
79033095 C Rev. 12-23

Maximum Machine Weight
IMPORTANT: If total machine weight exceeds 22679 kg Maximum Ballasted Weight - The maximum
(50000 lb), sustained operation at full power recommended ballasted weight is 22679 kg (50000 lb). A
drawbar loads at ground speeds below 6.4 km/h machine can be operated at this weight in all gears at full
(4.0 mph) will reduce power train life. If it is power.
necessary to operate at full load below 6.4 km/h
However, additional ballast up to 2722 kg (6000 lb) can be
(4.0 mph) for extended periods of time, machine
used in cases of wet or slippery ground conditions such
weight should be limited to 22679 kg (50000 lb)
that total ballasted weight does not exceed 25401 kg
maximum.
(56000 lb). If excessive slippage is noted at ground
IMPORTANT: For satisfactory power train life, maximum speeds below 6.4 km/h (4.0 mph) with machine operating
recommended continuous operating weight weight above 22679 kg (50000 lb), reduce load.
should not exceed 22679 kg (50000 lb). This
The maximum ballasted weight of machine is weight of
weight must include any added ballast, additional
machine and any attachments that are permanently
weight due to optional belts, weight of empty
fastened. Three point hitch mounted attachments or
chemical tanks and brackets, and added weight
tongue weight from pulled implements is not included in
of other items secured to machine.
ballasted weight calculation.
However, additional ballast can be used, up to a
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maximum ballasted weight of 25401 kg (56000 The following items are typical examples of permanent
lb) in cases of wet or slippery ground conditions. attachments:
If excessive slippage is noted at ground speeds • Ballast (front weights and idler weights)
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below 6.4 km/h (4.0 mph) with machine • Amount of fuel in tank
operating weight above 22679 kg (50000 lb),
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reduce load. • Chemical tanks and brackets

Machines can be operated at maximum laden • Mounting brackets and hardware for aftermarket
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weight not to exceed 27215 kg (60000 lb). The equipment

maximum laden weight should include the
additional weight from liquid chemicals, fertilizer, • Bulldozer blade
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and weight of three point hitch mounted • Three-point hitches

implements.
• Mobil-trac System belts
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IMPORTANT: If machine is equipped with medium

midwheels, reduce speed to a maximum of 24 NOTE: This machine is not authorized for commercial
km/h (15 mph) when roading if machine weighs towed scraper applications unless it is equipped
with special application option. If machine is
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more than 20411 kg (45000 lb) as undercarriage

component life can be reduced under rough used for a light-duty agricultural scraper
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roading conditions. application, maximum allowable ballast is 22679

kg (50000 lb) because of weight transfer from
tongue on scraper.
Maximum Vehicle Weight
Maximum Laden Weight - The maximum laden weight
on
Midwheels Maximum Maximum of machine is weight of machine plus any items that are
Ballasted Laden Weight considered to be easily detached from machine.
Weight
The following items are typical examples of items that are
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Midwheels 25,401 kg 27,215 kg easily detached:

(56,000 lb) (60,000 lb)
• Chemicals that are consumed from chemical tanks
• Implements that are mounted to three-point hitch
12-24 79033095 C Rev.

Ballasting for Towed Scrapers
Proper ballasting is necessary for optimum performance
and ride quality. It is recommended to ballast machine
with approximately 65 percent of machine weight on front
axle when towing scraper pans.
While scraper is loading, observe profile of machine.
Correct amount of counterweight will keep full print of
track (belt) on ground ensuring maximum amount of
horsepower is transferred to drawbar. Proper balance will
transfer weight from rear of machine forward and whole
undercarriage will carry weight of machine and scraper
evenly. If improper balance causes excessive loading on
rear of machine, life of drive wheels and axles may be
reduced.
FIG. 59: Start with a full set of front weights (1) and
observe how machine rides on ground while scraper is
loading. If necessary, add idler weights (2) until proper
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balance is achieved.
IMPORTANT: Maximum operating weight should not
exceed 24,041 kg (53,000 lb). This weight
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includes any added ballast, additional weight due 1

to optional belts, and weight of any additional
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attached equipment. Do not use undercarriage

weights in scraper applications.
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ch-0004
FIG. 59
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79033095 C Rev. 12-25

NOTES
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12-26 79033095 C Rev.

Index
INDEX
Numerics
20 Front Weights Installation ............................... 12-8

20 Front Weights Removal .................................. 12-1
32 Front Weights Installation ............................. 12-11
32 Front Weights Removal .................................. 12-4
Adding Weights .................................................. 12-23
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Ballasting for Towed Scrapers ........................... 12-25

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F
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Front Weights ............................................ 12-1, 12-21

Front Weights Installation .................................... 12-8
Front Weights Removal ....................................... 12-1
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Idler Weights ........................................... 12-15, 12-21

al
Idler Weights Installation .................................... 12-16

Idler Weights Removal ....................................... 12-15
u
U
se
Undercarriage Weights ........................... 12-18, 12-21

Undercarriage Weights Installation .................... 12-19
Undercarriage Weights Removal ....................... 12-18
on
W
ly
Weights .............................................................. 12-21
79033095 C Rev. 12-27

Index
NOTES
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r
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use
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12-28 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
13 - Appearance Group
Contents
Fo
APPEARANCE GROUP DISASSEMBLY AND ASSEMBLY

Hood .............................................................................................................................................................. 13-1
r
Hood Removal ......................................................................................................................................... 13-1

Hood Installation ...................................................................................................................................... 13-3
in
Standard Step Group ..................................................................................................................................... 13-4

Standard Step Removal .......................................................................................................................... 13-4
Standard Step Group Disassembly ......................................................................................................... 13-5
te
Standard Step Group Assembly .............................................................................................................. 13-6

Standard Step Installation ....................................................................................................................... 13-8
rn
Pivoting Step Group (Optional) ...................................................................................................................... 13-9

Pivoting Step Removal ............................................................................................................................ 13-9
Pivoting Step Group Disassembly ......................................................................................................... 13-11
al
Pivoting Step Group Assembly .............................................................................................................. 13-14

Pivoting Step Installation ....................................................................................................................... 13-17
Extremity Arms ............................................................................................................................................ 13-18
u
Extremity Arm Removal ......................................................................................................................... 13-18

Extremity Arm Disassembly .................................................................................................................. 13-19
se
Extremity Arm Assembly ....................................................................................................................... 13-19

Extremity Arm Installation ...................................................................................................................... 13-20
Mirrors .......................................................................................................................................................... 13-21
Mirror Removal ...................................................................................................................................... 13-21
on
Mirror Installation ................................................................................................................................... 13-23

Fenders ........................................................................................................................................................ 13-26
Fender Removal .................................................................................................................................... 13-26
Fender Installation ................................................................................................................................. 13-29
ly
Hand Rails ................................................................................................................................................... 13-32

Hand Rail Removal ............................................................................................................................... 13-32
Hand Rail Installation ............................................................................................................................ 13-32
Head Lights .................................................................................................................................................. 13-33
Head Light Removal .............................................................................................................................. 13-33
Head Light Disassembly ........................................................................................................................ 13-35
Head Light Assembly ............................................................................................................................ 13-36
Head Light Installation ........................................................................................................................... 13-37
INDEX ............................................................................................................................................................. 13-39
79033095 C Rev. 13-i

Contents
NOTES
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13-ii 79033095 C Rev.

Appearance Group Disassembly and Assembly
APPEARANCE GROUP DISASSEMBLY AND ASSEMBLY
HOOD
FIG. 1: Hood (1) protects engine and keeps debris from
cooling group. Front work lights are mounted in hood.
P082912006
Fo
FIG. 1
Hood Removal
r
FIG. 2: Unlatch hood fasteners (1).

in
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rn
1
al
u
P082912007
FIG. 2
se
FIG. 3: Open hood.

on
ly
P082912008
FIG. 3
79033095 C Rev. 13-1

FIG. 4: Unplug wiring harness connector (1).
NOTE: Hood side panel is removed for clarity.
P082912009
FIG. 4
FIG. 5: Support hood with an appropriate lifting device.
Disconnect gas cylinders (1) from support at lower
mounting point (2).
Fo

1
r
2
in
te
P082912010
FIG. 5
rn
FIG. 6: Open access door (1).

al
1
u se
on
P082912011
FIG. 6
ly
FIG. 7: Remove hinge bolts (1) and remove hood.
P082912011
FIG. 7
13-2 79033095 C Rev.

Hood Installation
FIG. 8: Mount hood to chassis with four hinge bolts (1).
P082912011
FIG. 8
FIG. 9: Support hood with an appropriate lifting device.
Connect gas cylinders (1) to support at lower mounting
Fo
point (2).
1
r in
2
te
rn
P082912010
FIG. 9
al
FIG. 10: Plug in wiring harness connector (1).

u se
1
on
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P082912009
FIG. 10
FIG. 11: Close hood and latch hood fasteners (1).
P082912007
FIG. 11
79033095 C Rev. 13-3

STANDARD STEP GROUP
FIG. 12: Step group (1) is mounted on left-hand side of
machine and gives operator safe access to cab. There
are two step group options:
• Standard
• Pivoting 1
P082612002
FIG. 12
Standard Step Removal

Fo
FIG. 13: Remove eight bolts (1) holding outboard hand

rail (2) to step assembly.
r in
te
2
rn
1
al
P082712001
FIG. 13
FIG. 14: Support platform with an appropriate lifting
u
device and remove four bolts (1) holding platform to

chassis.
se
on
1
ly
P082712002
FIG. 14
FIG. 15: Support step assembly with an appropriate
lifting device and remove three bolts (1) holding front
mounting tube to chassis.
Remove four bolts (2) holding rear support tube to chassis 2
and remove step assembly.
1
P082712003
FIG. 15
13-4 79033095 C Rev.

Standard Step Group Disassembly
FIG. 16: Remove eight bolts (1) holding inboard hand rail
(2) to step assembly, if equipped.
P082712004
FIG. 16
FIG. 17: Loosen bolts (1) securing step assembly (2) to
support tubes (3).
Fo
Slide support tubes out of step assembly.

r
2
1
in
te
3
rn
P082712005
FIG. 17
al
FIG. 18: Remove two hinge bolts (1) and remove

storage compartment lid (2).
2
m
WARNING: Hinge bolts contain hinge 1
u
springs. Be careful when removing hinge

bolts. Springs under pressure can cause
se
personal injury.
on
ly
P072212013
FIG. 18
FIG. 19: Remove cotter pin (1) in prop rod (2) and
remove prop rod.
2
Remove plugs (3) in any unused threaded holes in step
assembly.
3
1
P072212014
FIG. 19
79033095 C Rev. 13-5

FIG. 20: Remove two screws (1) holding lid latch (2) to
step assembly.
2
Repeat procedure for latch on other side.
1
P072212015
FIG. 20
Standard Step Group Assembly

FIG. 21: Attach lid latch (1) to step assembly with two
Fo
screws (2).
1
r in
te
2
rn
P072212015
FIG. 21
al
FIG. 22: Install prop rod (1) into hole and secure with
cotter pin (2).
1
u
Install plugs (3) into any unused threaded holes in step

assembly.
se
on
3
2
ly
P072212014
FIG. 22
FIG. 23: Install storage compartment lid (1) to step
assembly and secure with two hinge bolts (2).
1
m
personal injury.
P072212013
FIG. 23
13-6 79033095 C Rev.

FIG. 24: Slide support tubes (1) into step assembly.
Tighten bolts (2) securing step assembly (3) to support
tubes to 50 to 70 Nm (37 to 52).
3
2
1
P082712005
FIG. 24
FIG. 25: Mount inboard hand rail (1) to step assembly
with eight bolts (2), if equipped.
Fo
1
r in
2
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P082712004
FIG. 25
rn
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u se
on
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79033095 C Rev. 13-7

Standard Step Installation
lifting device and attach front mounting tube to chassis
with three bolts (1).
Attach rear support tube to chassis with four bolts (2). 2
1
P082712003
FIG. 26
device and attach platform to chassis with four bolts (1).
Fo
r in
1
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P082712002
rn
FIG. 27
FIG. 28: Mount outboard hand rail (1) to step assembly
al
with eight bolts (2).

u se
1
on
2
P082712001
ly
FIG. 28
13-8 79033095 C Rev.

PIVOTING STEP GROUP (OPTIONAL)
FIG. 29: Pivoting step group is optional and mounted on
left-hand side of machine. Pivoting step is used to give
operator safe access to cab.
Lower portion (1) of step pivots upward to give extra
ground clearance.
P082712006
FIG. 29
Pivoting Step Removal

Fo
FIG. 30: Remove eight bolts (1) holding outboard hand

rail (2) to step assembly.
r in
2
te
1
rn
al
P082712007
FIG. 30
u
device and remove four bolts (1) holding platform to

se
chassis.
on
ly
1
P082712008
FIG. 31
79033095 C Rev. 13-9

FIG. 32: Disconnect wire harness (1) from pivot motor
(2).
2
P082712009
FIG. 32
lifting device and remove three bolts (1) holding front
mounting tube to chassis.
Fo
Remove four bolts (2) holding rear support tube to chassis

and remove step assembly.
r
2
1
in
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P082712010
FIG. 33
rn
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u se
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13-10 79033095 C Rev.

Pivoting Step Group Disassembly
FIG. 34: Remove eight bolts (1) holding inboard hand rail
(2) to step assembly and remove, if equipped.
P082712011
FIG. 34
FIG. 35: Remove pin (1) holding upper pivot bracket (2)
to step mount (3). 2
Fo
r in
1
te
3
rn
P072312003
FIG. 35
al
FIG. 36: Remove two bolts (1) holding lower pivot

cylinder bracket (2) to step assembly.
u se
2
on
1
ly
P072312004
FIG. 36
FIG. 37: Remove pin (1) holding cylinder (2) to upper
pivot cylinder bracket (3).
Remove bolt (4) holding cylinder to lower pivot cylinder
bracket (5).
4
3
1
2
5
P072312010
FIG. 37
79033095 C Rev. 13-11

FIG. 38: Remove two bolts (1) holding bracket (2) to step
assembly.
2
1
P072312005
FIG. 38
FIG. 39: Loosen bolts (1) securing step assembly (2) to
support tubes (3).
Slide support tubes out of step assembly.
Fo
2
r
1
in
te
3
P082712012
FIG. 39
rn
FIG. 40: Remove two hinge bolts (1) and remove

storage compartment lid (2).
2
al
m
u
personal injury.
se
on
P072212013
FIG. 40
ly
FIG. 41: Remove cotter pin (1) in prop rod (2) and
remove prop rod.
2
Remove plugs (3) in any unused threaded holes in step
assembly.
3
1
P072212014
FIG. 41
13-12 79033095 C Rev.

FIG. 42: Remove two screws (1) holding lid latch (2) to
step assembly.
2
1
P072212015
FIG. 42
FIG. 43: Remove two bolts (1) holding guard plate (2) to
step assembly.
Fo
r
1
in
2
te
P072312007
FIG. 43
rn
FIG. 44: Remove hex head bolts (1) holding lower step
assembly hinge (2) to upper step assembly.
al
u
2 1
se
on
P072312008
FIG. 44
ly
FIG. 45: Remove two bolts (1) holding hinge plate (2) to
step assembly.
2 1
Repeat procedure for other side of step assembly.
P072312009
FIG. 45
79033095 C Rev. 13-13

Pivoting Step Group Assembly
FIG. 46: Mount hinge plate (1) and rubber seal (2) to
step assembly with two bolts (3). 2
1 3
P072312009
FIG. 46
FIG. 47: Attach lower step assembly hinge (1) to upper
step assembly with hex head bolt (2).
Fo
r
1 2
in
te
rn
P072312008
FIG. 47
al
FIG. 48: Attach guard plate (1) to step assembly with two
bolts (2).
u se
2
on
1
ly
P072312007
FIG. 48
FIG. 49: Attach lid latch (1) to step assembly with two
screws (2).
1
2
P072212015
FIG. 49
13-14 79033095 C Rev.

FIG. 50: Install prop rod (1) into hole and secure with
cotter pin (2).
1
Install plugs (3) into any unused threaded holes in step
assembly.
3
2
P072212014
FIG. 50
FIG. 51: Install storage compartment lid (1) to step
assembly and secure with two hinge bolts (2).
1
m
Fo

personal injury.
r in
te
P072212013
FIG. 51
rn
FIG. 52: Slide support tubes (1) into step assembly.

al
Tighten bolts (2) securing step assembly (3) to support

tubes to 50 to 70 Nm (37 to 52).
u se
3
2
on
1
P082712012
FIG. 52
ly
FIG. 53: Attach bracket (1) to step assembly with two

bolts (2).
1
2
P072312005
FIG. 53
79033095 C Rev. 13-15

FIG. 54: Insert pin (1) securing cylinder (2) to upper pivot
cylinder bracket (3).
Secure cylinder to lower pivot cylinder bracket (4) with bolt
(5).
5
3
1
2
4
P072312010
FIG. 54
FIG. 55: Attach lower pivot cylinder bracket (1) to step
assembly with two bolts (2).
Fo
r
1
in
te
2
P072312004
FIG. 55
rn
FIG. 56: Insert pin (1) securing upper pivot bracket (2) to
step mount (3).
al
2
u se
1
on
3
P072312003
FIG. 56
ly
FIG. 57: Mount inboard hand rail (1) to step assembly

with eight bolts (2), if equipped.
P082712011
FIG. 57
13-16 79033095 C Rev.

Pivoting Step Installation
lifting device and attach front mounting tube to chassis
with three bolts (1).
Attach rear support tube to chassis with four bolts (2).
2
1
P082712010
FIG. 58
FIG. 59: Connect wire harness (1) to pivot motor (2).
Fo
2
r in
1
te
rn
P082712009
FIG. 59
al

device and attach platform to chassis with four bolts (1).
u se
on
1
ly
P082712008
FIG. 60
FIG. 61: Mount outboard hand rail (1) to step assembly
with eight bolts (2).
P082712007
FIG. 61
79033095 C Rev. 13-17

EXTREMITY ARMS
FIG. 62: Extremity arms (1) are mounted to bottoms of
platforms and provide adjustable supports for amber
flashing lights.
P082712013
FIG. 62
Extremity Arm Removal

Fo
FIG. 63: Disconnect wiring harness (1) from amber

flashing light (2). Remove wiring harness from extremity
arm. 2
r in
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rn
1
al
P082712014
FIG. 63
FIG. 64: Support extremity arm (1) and remove two
u
screws (2) holding arm to platform.

se
Repeat procedure on other side of machine.

on
1
ly
2
P082712015
FIG. 64
13-18 79033095 C Rev.

Extremity Arm Disassembly
FIG. 65: Remove two bolts (1) holding reflector (2) to
extremity arm.
P082712016
FIG. 65
FIG. 66: Remove two nuts (1) holding amber flashing
light (2) to extremity arm (3).
Fo
2
r in
3
te
1
rn
P082712017
FIG. 66
al
Extremity Arm Assembly

FIG. 67: Mount amber flashing light (1) to extremity arm
u
(2) with two nuts (3).

1
se
on
2
ly
3
P082712017
FIG. 67
FIG. 68: Attach reflector (1) to extremity arm with two
bolts (2).
P082712016
FIG. 68
79033095 C Rev. 13-19

Extremity Arm Installation
FIG. 69: Support extremity arm (1) and secure arm to
platform with two screws (2).
2
P082712015
FIG. 69
FIG. 70: Route wiring harness through extremity arm.
Connect wiring harness (1) to amber flashing light (2).
Fo
2
Repeat procedure on other side of machine.
r in
te
1
rn
P082712014
FIG. 70
al
u se
on
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13-20 79033095 C Rev.

MIRRORS
FIG. 71: Mirrors (1) are mounted on sides of fender
platform or cab.
1
P082712018
FIG. 71
Mirror Removal
Fo
Left-Hand Mirror Removal

FIG. 72: Disconnect wiring harness (1) from work light
r
(2).
in
2
te
rn
1
al
P082812001
FIG. 72
u
FIG. 73: Remove nut (1) holding work light (2) to support
se
and remove work light.
2
on
ly
1
P082812008
FIG. 73
FIG. 74: Disconnect wiring harness (1) from mirror
controls.
P082812002
FIG. 74
79033095 C Rev. 13-21

FIG. 75: Loosen eight bolts (1) holding clamps on mirror
support tubes (2).
Slide mirror support tubes out of clamps and remove
mirror support.
2
P082812003
FIG. 75
Right-Hand Mirror Removal

FIG. 76: Disconnect wiring harness (1) from work light
(2).
Fo
2
r in
1
te
rn
P082812004
FIG. 76
al
FIG. 77: Remove nut (1) holding work light (2) to support
and remove light.
u
1
se
2
on
P082812005
ly
FIG. 77
FIG. 78: Disconnect wiring harness (1) from mirror
controls.
P082812006
FIG. 78
13-22 79033095 C Rev.

FIG. 79: Loosen eight bolts (1) holding clamps on mirror
support tubes (2).
Slide mirror support tubes out of clamps and remove
mirror support.
P082812007
FIG. 79
Mirror Installation
Left-Hand Mirror Installation
Fo
FIG. 80: Slide mirror support tubes (1) into clamps and
install mirror support.
r
Tighten eight bolts (2) holding clamps on mirror support

tubes.
in
1
te
2
rn
P082812003
al
FIG. 80
FIG. 81: Connect wiring harness (1) to mirror controls.
u se
on
1
ly
P082812002
FIG. 81
FIG. 82: Attach work light (1) to support with nut (2).
2
P082812008
FIG. 82
79033095 C Rev. 13-23

FIG. 83: Connect wiring harness (1) to work light (2).
1
P082812001
FIG. 83
Right-Hand Mirror Installation

FIG. 84: Slide mirror support tubes (1) into clamps and
install mirror support.
Fo
Tighten eight bolts (2) holding clamps on mirror support

tubes.
r
1
in
2
te
rn
P082812007
FIG. 84
al
FIG. 85: Connect wiring harness (1) to mirror controls.

u se
1
on
P082812006
ly
FIG. 85
FIG. 86: Attach work light (1) to support with nut (2).
2
1
P082812005
FIG. 86
13-24 79033095 C Rev.

FIG. 87: Connect wiring harness (1) to work light (2).
P082812004
FIG. 87
Fo
r in
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u se
on
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79033095 C Rev. 13-25

FENDERS
FIG. 88: Fenders (1) are located above drive belts and
keep material, thrown from tracks, from flying up into air.
Fenders also offer a place for tail lights (2) to be mounted
and three-point hitch switches (3) to be placed, if
equipped.
1 2
3
P082812019
FIG. 88
Fender Removal
Fo
FIG. 89: Remove two nuts (1) and four bolts (2) holding
fender guard (3) to fender.
2
r in
te
rn
1 3
al
P082812009
FIG. 89
FIG. 90: Disconnect wiring harness (1) to switch, if
u
equipped.
se
on
1
ly
P082812010
FIG. 90
FIG. 91: Remove two nuts (1) holding guard (2) to
fender.
1 2
P082812011
FIG. 91
13-26 79033095 C Rev.

FIG. 92: Support fender and remove two bolts (1)
holding fender to chassis.
P082812012
FIG. 92
FIG. 93: Remove two bolts (1) holding fender to chassis.
Fo
r in
1
te
P082812013
FIG. 93
rn
FIG. 94: Remove extremity arm (1).

al
Refer to Extremity Arm Removal section for more

information.
u se
on
1
P082812014
FIG. 94
ly
FIG. 95: Remove bolt (1) holding step to chassis.
P082812018
FIG. 95
79033095 C Rev. 13-27

FIG. 96: Remove three bolts (1) holding tail light
assembly to fender.
1
P082812015
FIG. 96
FIG. 97: Disconnect wiring (1) from tail light assembly
and remove tail light assembly.
Fo
1
r in
te
P082812016
FIG. 97
rn
FIG. 98: Remove four bolts (1) holding fender to chassis

and remove fender (2).
al
Repeat procedure for other fender.
2
u se
on
1
P082812017
FIG. 98
ly
13-28 79033095 C Rev.

Fender Installation
FIG. 99: Mount fender (1) to chassis with four bolts (2).
Tighten bolts to 15 to 21 Nm (11 to 15 lbf ft).
2
P082812017
FIG. 99
FIG. 100: Route wiring (1) for tail lights through fender
and connect wiring to tail light assembly.
Fo
r
1
in
te
rn
P082812016
FIG. 100
al
FIG. 101: Secure tail light assembly to fender with three

bolts (1).
1
u se
on
ly
P082812015
FIG. 101
FIG. 102: Attach step to chassis with bolt (1).
P082812018
FIG. 102
79033095 C Rev. 13-29

FIG. 103: Install extremity arm (1).
Refer to Extremity Arm Installation section for more
information.
1
P082812014
FIG. 103
FIG. 104: Attach fender to chassis with two bolts (1).
Fo
r in
1
te
P082812013
FIG. 104
rn
FIG. 105: Attach fender to chassis with two bolts (1).

al
u
1
se
on
P082812012
FIG. 105
ly
FIG. 106: Attach guard (1) to fender with two nuts (2).
2 1
P082812011
FIG. 106
13-30 79033095 C Rev.

FIG. 107: Connect wiring harness (1) to three-point hitch
switch, if equipped.
P082812010
FIG. 107
FIG. 108: Attach fender guard (1) to fender with two nuts
(2) and four bolts (3).
3
Fo
r in
2 1
te
P082812009
FIG. 108
rn
al
u se
on
ly
79033095 C Rev. 13-31

HAND RAILS
FIG. 109: Hand rails are mounted to sides of step
groups. Outboard hand rail (1) is standard. An inboard
hand rail (2) is optional. Both hand rails are removed and 2
installed same way.
P082812020
FIG. 109
Hand Rail Removal

Fo
FIG. 110: Support hand rail and remove four bolts (1) at
both top and bottom mounting points and remove hand
rail.
r
Repeat procedure for inboard hand rail, if equipped.

in
te
1
rn
al
P072912002
FIG. 110
Hand Rail Installation

u se
FIG. 111: Insert rubber mounting bushing (1) into holes

in hand rail mounting plate (2). Place washer plate (3) on 1 3
both sides of rubber bushing. 4 5
Attach hand rail to step group with four washers (4) and 3
on
bolts (5) at both top and bottom mounting points. Tighten

bolts to 55 Nm (41 lbf ft).
Repeat procedure for inboard hand rail, if equipped.
ly
P072912003
FIG. 111
13-32 79033095 C Rev.

HEAD LIGHTS
FIG. 112: There are three different head light groups:
• Standard Lights
• Deluxe Lights
• HID Lights
All three groups have the same general removal and
installation. HID light group has ballasts that other groups
do not have.
P082812021
FIG. 112
Head Light Removal

Fo
FIG. 113: Open or remove hood.

Refer to Hood Removal section for more information.
r in
te
rn
al
P082812022
FIG. 113
FIG. 114: Disconnect wiring harness (1) from head lights
u
(2).
se
1
2
on
ly
P082912001
FIG. 114
FIG. 115: In HID equipped machines, disconnect wiring
to ballasts (1) as well as wiring to HID lights (2).
P020705007
FIG. 115
79033095 C Rev. 13-33

FIG. 116: In HID equipped machines, remove ballasts
(1) from cross rail (2). 1
P020605004
FIG. 116
FIG. 117: Remove four bolts (1) holding braces (2) to
hood.
Fo
2
r
1
in
te
rn
P082912002
FIG. 117
al
FIG. 118: Remove four bolts (1) holding light assembly

to hood and remove assembly.
u se
1
on
ly
P082912003
FIG. 118
13-34 79033095 C Rev.

Head Light Disassembly
FIG. 119: Remove four screws (1) holding hood emblem
(2) to head light assembly. 2
P082912004
FIG. 119
FIG. 120: Remove four screws (1) holding light bracket
(2) and panels (3) to head light assembly. 3
Fo
2
r in
te
1
rn
P082912005
FIG. 120
al
FIG. 121: Remove three screws (1) holding head lights

(2) into fixture (3). 1 2
u se
on
3
ly
P072912007
FIG. 121
FIG. 122: Turn light bulb (1) until free and pull out to
replace bulb.
1
P072912008
FIG. 122
79033095 C Rev. 13-35

Head Light Assembly
FIG. 123: Insert light bulb (1) and turn until seated to
replace bulb.
1
P072912008
FIG. 123
FIG. 124: Mount head lights (1) into fixture (2) with three
screws (3). 3 1
Fo
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te
2
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P072912007
FIG. 124
al
FIG. 125: Attach light bracket (1) and panels (2) to head
light assembly with four screws (3). 2
u
1
se
on
3
ly
P082912005
FIG. 125
FIG. 126: Attach hood emblem (1) to head light
assembly with four screws (2). 1
P082912004
FIG. 126
13-36 79033095 C Rev.

Head Light Installation
FIG. 127: Mount light assembly to hood with four bolts
(1).
P082912003
FIG. 127
FIG. 128: Install braces (1) to hood with four bolts (2).
Fo
1
r
2
in
te
rn
P082912002
al
FIG. 128
FIG. 129: In HID equipped machines, mount one ballast
(1) on each side of cross rail (2). Mount ballasts together 1
u
and to cross rail using two brackets (3) and six bolts with
washers and nuts (4). Tighten bolts to 2.25 Nm (2 lbf ft). 2
se
4
on
3
ly
P020605004
FIG. 129
FIG. 130: In HID equipped machines, connect wiring to
ballasts (1) as well as wiring to HID lights (2).
P020705007
FIG. 130
79033095 C Rev. 13-37

FIG. 131: Connect wiring harness (1) to head lights (2).
1
2
P082912001
FIG. 131
Fo
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al
u se
on
ly
13-38 79033095 C Rev.

Index
INDEX
D Pivoting Step Installation .................................... 13-17

Pivoting Step Removal ......................................... 13-9
Deluxe Lights ..................................................... 13-33
R
E
Right-Hand Mirror Installation ............................. 13-24
Extremity Arm Assembly .................................... 13-19 Right-Hand Mirror Removal ................................ 13-22
Extremity Arm Disassembly ............................... 13-19
Extremity Arm Installation .................................. 13-20
Extremity Arm Removal ..................................... 13-18 S
Extremity Arms ................................................... 13-18
Standard Lights .................................................. 13-33
Standard Step Group ........................................... 13-4
F Standard Step Group Assembly ........................... 13-6
Fo
Standard Step Group Disassembly ...................... 13-5

Fender Installation ............................................. 13-29 Standard Step Installation .................................... 13-8
Fender Removal ................................................ 13-26 Standard Step Removal ....................................... 13-4
r
Fenders .............................................................. 13-26

in
H
te
Hand Rail Installation ......................................... 13-32

Hand Rail Removal ............................................ 13-32
rn
Hand Rails ......................................................... 13-32

Head Light Assembly ......................................... 13-36
Head Light Disassembly .................................... 13-35
al
Head Light Installation ....................................... 13-37

Head Light Removal .......................................... 13-33
Head Lights ........................................................ 13-33
u
HID Lights .......................................................... 13-33

Hood .................................................................... 13-1
se
Hood Installation .................................................. 13-3

Hood Removal ..................................................... 13-1
on
Inboard Hand Rail (Optional) ............................. 13-32

ly
Left-Hand Mirror Installation ............................... 13-23

Left-Hand Mirror Removal .................................. 13-21
Mirror Installation ............................................... 13-23

Mirror Removal .................................................. 13-21
Mirrors ................................................................ 13-21
Pivoting Step Group (Optional) ............................ 13-9

Pivoting Step Group Assembly .......................... 13-14
Pivoting Step Group Disassembly ..................... 13-11
79033095 C Rev. 13-39

Index
NOTES
Fo
r
in
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use
on
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13-40 79033095 C Rev.

Contents
Challenger ®
SERVICE MANUAL
79033095 C Rev.
14 - Electronics
Introduction .................................................................................................................................................... 14-1

Fo
General Information ................................................................................................................................. 14-1

Service Tools ........................................................................................................................................... 14-3
Connector Locations ............................................................................................................................... 14-5
r
Dash Panel Cluster ................................................................................................................................. 14-6

Machine Preparation for Troubleshooting ............................................................................................... 14-9
in
Symptom Procedures .................................................................................................................................. 14-11

Transmission ......................................................................................................................................... 14-11
te
Power Take-Off ..................................................................................................................................... 14-16

Steering System .................................................................................................................................... 14-18
Brake System ........................................................................................................................................ 14-23
rn
Implement System ................................................................................................................................. 14-27

Three-Point Hitch System ..................................................................................................................... 14-41
Diagnostic System Procedures .................................................................................................................... 14-44
al
Electrical Connectors - Inspect .............................................................................................................. 14-44

Charging System ................................................................................................................................... 14-52
Starting System ..................................................................................................................................... 14-60
u
Pulse Width Modulated Sensor ............................................................................................................. 14-61

Sensor Signal Voltage ........................................................................................................................... 14-63
se
Sensor Dynamic Operation ................................................................................................................... 14-65

Switch Circuits ....................................................................................................................................... 14-67
Diagnostic Code List .................................................................................................................................... 14-69
Diagnostic Codes for SA 00 .................................................................................................................. 14-69
on
Diagnostic Operation ................................................................................................................................... 14-84

Troubleshooting Procedures ................................................................................................................. 14-84
Failure Mode Identifier (FMI) ................................................................................................................. 14-85
ly
Detailed FMI Explanation ...................................................................................................................... 14-86

Using Virtual Terminal Display ..................................................................................................................... 14-89
Warning Levels ...................................................................................................................................... 14-89
Using Electronic Technician (ET) To Determine Diagnostic Codes ............................................................ 14-90
Accessing Diagnostic Codes ................................................................................................................. 14-90
Electrical Connector - Inspect ...................................................................................................................... 14-91
Wiring Harness Open Circuit Test ............................................................................................................... 14-97
Wiring Harness Short Circuit Test ............................................................................................................... 14-97
Electronic Control Module (ECM) - Flash Program ..................................................................................... 14-97
Electronic Control Module (ECM) - Replace ................................................................................................ 14-98
Connector Contact Description .................................................................................................................... 14-98
Machine ECM ........................................................................................................................................ 14-98
Implement ECM ................................................................................................................................... 14-100
Hitch ECM ........................................................................................................................................... 14-101
MIDS ECM .......................................................................................................................................... 14-101
Display Module (Dash) ........................................................................................................................ 14-102
Keypad Module ................................................................................................................................... 14-102
Translator ECM ................................................................................................................................... 14-102
Parameters ................................................................................................................................................ 14-103
79033095 C Rev. 14-i

Contents
Glossary of Electrical Terms ...................................................................................................................... 14-115
Electrical Schematics ................................................................................................................................. 14-115
Implement System Electrical Schematic ............................................................................................. 14-116
Three-Point Hitch System Schematic .................................................................................................. 14-120
Transmission System Schematic ........................................................................................................ 14-124
Power Take-Off System Schematic .................................................................................................... 14-126
Steering System Schematic ................................................................................................................ 14-128
Brake System Schematic .................................................................................................................... 14-130
Arm Rest Controls And Switches ........................................................................................................ 14-132
SA 00 - SPN 91 - FMI 08 ........................................................................................................................... 14-135
SA 00 - SPN 91 - FMI 13 ........................................................................................................................... 14-138
SA 00 - SPN 94 - FMI 03 ........................................................................................................................... 14-140
SA 00 - SPN 94 - FMI 04 ........................................................................................................................... 14-143
SA 00 - SPN 94 - FMI 15 ........................................................................................................................... 14-145
SA 00 - SPN 94 - FMI 17 ........................................................................................................................... 14-148
SA 00 - SPN 100 - FMI 01 ......................................................................................................................... 14-150
SA 00 - SPN 100 - FMI 03 ......................................................................................................................... 14-152
SA 00 - SPN 100 - FMI 04 ......................................................................................................................... 14-155
SA 00 - SPN 100 - FMI 10 ......................................................................................................................... 14-157
Fo
SA 00 - SPN 100 - FMI 17 ......................................................................................................................... 14-159

SA 00 - SPN 100 - FMI 18 ......................................................................................................................... 14-161
SA 00 - SPN 102 - FMI 03 ......................................................................................................................... 14-163
r
SA 00 - SPN 102 - FMI 04 ......................................................................................................................... 14-166

SA 00 - SPN 102 - FMI 10 ......................................................................................................................... 14-168
in
SA 00 - SPN 105 - FMI 00 ......................................................................................................................... 14-170

SA 00 - SPN 105 - FMI 03 ......................................................................................................................... 14-172
SA 00 - SPN 105 - FMI 04 ......................................................................................................................... 14-174
te
SA 00 - SPN 105 - FMI 15 ......................................................................................................................... 14-176

SA 00 - SPN 105 - FMI 16 ......................................................................................................................... 14-178
rn
SA 00 - SPN 108 - FMI 03 ......................................................................................................................... 14-180

SA 00 - SPN 108 - FMI 04 ......................................................................................................................... 14-183
SA 00 - SPN 110 - FMI 00 ......................................................................................................................... 14-185
al
SA 00 - SPN 110 - FMI 03 ......................................................................................................................... 14-187

SA 00 - SPN 110 - FMI 04 ......................................................................................................................... 14-189
SA 00 - SPN 110 - FMI 15 ......................................................................................................................... 14-191
u
SA 00 - SPN 110 - FMI 16 ......................................................................................................................... 14-194

SA 00 - SPN 168 - FMI 00 ......................................................................................................................... 14-196
se
SA 00 - SPN 168 - FMI 01 ......................................................................................................................... 14-198

SA 00 - SPN 168 - FMI 02 ......................................................................................................................... 14-200
SA 00 - SPN 174 - FMI 00 ......................................................................................................................... 14-202
SA 00 - SPN 174 - FMI 03 ......................................................................................................................... 14-204
on
SA 00 - SPN 174 - FMI 04 ......................................................................................................................... 14-206

SA 00 - SPN 174 - FMI 15 ......................................................................................................................... 14-208
SA 00 - SPN 174 - FMI 16 ......................................................................................................................... 14-210
ly
SA 00 - SPN 190 - FMI 00 ......................................................................................................................... 14-212

SA 00 - SPN 190 - FMI 08 ......................................................................................................................... 14-214
SA 00 - SPN 190 - FMI 15 ......................................................................................................................... 14-216
SA 00 - SPN 620 - FMI 03 ......................................................................................................................... 14-218
SA 00 - SPN 620 - FMI 04 ......................................................................................................................... 14-220
SA 00 - SPN 626 - FMI 05 ......................................................................................................................... 14-222
SA 00 - SPN 626 - FMI 06 ......................................................................................................................... 14-224
SA 00 - SPN 630 - FMI 02 ......................................................................................................................... 14-226
SA 00 - SPN 631 - FMI 02 ......................................................................................................................... 14-227
SA 00 - SPN 637 - FMI 13 ......................................................................................................................... 14-228
SA 00 - SPN 639 - FMI 09 ......................................................................................................................... 14-230
SA 00 - SPN 651 - FMI 05 ......................................................................................................................... 14-233
SA 00 - SPN 651 - FMI 06 ......................................................................................................................... 14-235
SA 00 - SPN 652 - FMI 05 ......................................................................................................................... 14-237
SA 00 - SPN 652 - FMI 06 ......................................................................................................................... 14-239
SA 00 - SPN 653 - FMI 05 ......................................................................................................................... 14-241
SA 00 - SPN 653 - FMI 06 ......................................................................................................................... 14-243
SA 00 - SPN 654 - FMI 05 ......................................................................................................................... 14-245
SA 00 - SPN 654 - FMI 06 ......................................................................................................................... 14-247
14-ii 79033095 C Rev.

Contents
SA 00 - SPN 655 - FMI 05 ......................................................................................................................... 14-249
SA 00 - SPN 655 - FMI 06 ......................................................................................................................... 14-251
SA 00 - SPN 656 - FMI 05 ......................................................................................................................... 14-253
SA 00 - SPN 656 - FMI 06 ......................................................................................................................... 14-255
SA 03 - SPN 678 - FMI 03 ......................................................................................................................... 14-257
SA 03 - SPN 678 - FMI 04 ......................................................................................................................... 14-259
SA 00 - SPN 723 - FMI 08 ......................................................................................................................... 14-261
SA 00 - SPN 729 - FMI 05 ......................................................................................................................... 14-263
SA 00 - SPN 729 - FMI 06 ......................................................................................................................... 14-265
SA 00 - SPN1072 - FMI 05 ........................................................................................................................ 14-267
SA 00 - SPN 1072 - FMI 06 ....................................................................................................................... 14-270
SA 00 - SPN 1073 - FMI 05 ....................................................................................................................... 14-273
SA 00 - SPN 1073 - FMI 06 ....................................................................................................................... 14-276
SA 00 - SPN 1079 - FMI 03 ....................................................................................................................... 14-279
SA 00 - SPN 1079 - FMI 04 ....................................................................................................................... 14-281
SA 03 - SPN 96 - FMI 03 ........................................................................................................................... 14-283
SA 03 - SPN 96 - FMI 04 ........................................................................................................................... 14-285
SA 03 - SPN 117 - FMI 01 ......................................................................................................................... 14-287
SA 03 - SPN 127 - FMI 01 ......................................................................................................................... 14-289
Fo
SA 03 - SPN 161 - FMI 02 ......................................................................................................................... 14-291

SA 03 - SPN 168 - FMI 01 ......................................................................................................................... 14-293
SA 03 - SPN 177 - FMI 00 ......................................................................................................................... 14-295
r
SA 03 - SPN 177 - FMI 03 ......................................................................................................................... 14-296

SA 03 - SPN 177 - FMI 04 ......................................................................................................................... 14-298
in
SA 03 - SPN 177 - FMI 14 ......................................................................................................................... 14-300

SA 03 - SPN 191 - FMI 00 ......................................................................................................................... 14-302
SA 03 - SPN 191 - FMI 12 ......................................................................................................................... 14-304
te
SA 03 - SPN 473 - FMI 03 ......................................................................................................................... 14-307

SA 03 - SPN 473 - FMI 04 ......................................................................................................................... 14-310
rn
SA 03 - SPN 564 - FMI 03 ......................................................................................................................... 14-312

SA 03 - SPN 564 - FMI 05 ......................................................................................................................... 14-314
SA 03 - SPN 564 - FMI 06 ......................................................................................................................... 14-316
al
SA 03 - SPN 590 - FMI 09 ......................................................................................................................... 14-318

SA 03 - SPN 590 - FMI 12 ......................................................................................................................... 14-321
SA 03 - SPN 2000 - FMI 02 ....................................................................................................................... 14-324
u
SA 03 - SPN 598 - FMI 02 ......................................................................................................................... 14-325

SA 03 - SPN 598 - FMI 07 ......................................................................................................................... 14-330
se
SA 03 - SPN 598 - FMI 14 ......................................................................................................................... 14-333

SA 03 - SPN 617 - FMI 03 ......................................................................................................................... 14-336
SA 03 - SPN 617 - FMI 05 ......................................................................................................................... 14-338
SA 03 - SPN 617 - FMI 06 ......................................................................................................................... 14-340
on
SA 03 - SPN 618 - FMI 03 ......................................................................................................................... 14-342

SA 03 - SPN 618 - FMI 05 ......................................................................................................................... 14-344
SA 03 - SPN 618 - FMI 06 ......................................................................................................................... 14-346
ly
SA 03 - SPN 625 - FMI 02 ......................................................................................................................... 14-348

SA 03 - SPN 625 - FMI 09 ......................................................................................................................... 14-350
SA 03 - SPN 625 - FMI 12 ......................................................................................................................... 14-353
SA 03 - SPN 639 - FMI 09 ......................................................................................................................... 14-356
SA 03 - SPN 2005 - FMI 02 ....................................................................................................................... 14-360
SA 03 - SPN 677 - FMI 03 ......................................................................................................................... 14-364
SA 03 - SPN 677 - FMI 05 ......................................................................................................................... 14-366
SA 03 - SPN 677 - FMI 06 ......................................................................................................................... 14-368
SA 03 - SPN 678 - FMI 03 ......................................................................................................................... 14-370
SA 03 - SPN 678 - FMI 04 ......................................................................................................................... 14-372
SA 03 - SPN 684 - FMI 00 ......................................................................................................................... 14-374
SA 03 - SPN 684 - FMI 01 ......................................................................................................................... 14-376
SA 03 - SPN 684 - FMI 08 ......................................................................................................................... 14-378
SA 03 - SPN 734 - FMI 03 ......................................................................................................................... 14-381
SA 03 - SPN 734 - FMI 05 ......................................................................................................................... 14-383
SA 03 - SPN 734 - FMI 06 ......................................................................................................................... 14-385
SA 03 - SPN 735 - FMI 03 ......................................................................................................................... 14-387
SA 03 - SPN 735 - FMI 05 ......................................................................................................................... 14-389
SA 03 - SPN 735 - FMI 06 ......................................................................................................................... 14-391
79033095 C Rev. 14-iii

Contents
SA 03 - SPN 736 - FMI 03 ......................................................................................................................... 14-393
SA 03 - SPN 736 - FMI 05 ......................................................................................................................... 14-395
SA 03 - SPN 736 - FMI 06 ......................................................................................................................... 14-397
SA 03 - SPN 737 - FMI 03 ......................................................................................................................... 14-399
SA 03 - SPN 737 - FMI 05 ......................................................................................................................... 14-401
SA 03 - SPN 737 - FMI 06 ......................................................................................................................... 14-403
SA 03 - SPN 738 - FMI 03 ......................................................................................................................... 14-405
SA 03 - SPN 738 - FMI 05 ......................................................................................................................... 14-407
SA 03 - SPN 738 - FMI 06 ......................................................................................................................... 14-409
SA 03 - SPN 739 - FMI 03 ......................................................................................................................... 14-411
SA 03 - SPN 739 - FMI 05 ......................................................................................................................... 14-413
SA 03 - SPN 739 - FMI 06 ......................................................................................................................... 14-415
SA 03 - SPN 961 - FMI 14 ......................................................................................................................... 14-417
SA 03 - SPN 1638 - FMI 00 ....................................................................................................................... 14-418
SA 03 - SPN 1638 - FMI 03 ....................................................................................................................... 14-420
SA 03 - SPN 1638 - FMI 04 ....................................................................................................................... 14-422
SA 03 - SPN 1713 - FMI 14 ....................................................................................................................... 14-424
SA 03 - SPN 1713 - FMI 31 ....................................................................................................................... 14-427
SA 03 - SPN 1873 - FMI 00 ....................................................................................................................... 14-430
Fo
SA 03 - SPN 1873 - FMI 01 ....................................................................................................................... 14-433

SA 03 - SPN 1873 - FMI 08 ....................................................................................................................... 14-435
SA 03 - SPN 1873 - FMI 12 ....................................................................................................................... 14-438
r
SA 03 - SPN 1873 - FMI 13 ....................................................................................................................... 14-441

SA 03 - SPN 1883 - FMI 13 ....................................................................................................................... 14-443
in
SA 03 - SPN 2602 - FMI 14 ....................................................................................................................... 14-445

SA 03 - SPN 2613 - FMI 01 ....................................................................................................................... 14-447
SA 03 - SPN 2613 - FMI 18 ....................................................................................................................... 14-449
te
SA 03 - SPN 2833 - FMI 14 ....................................................................................................................... 14-451

SA 03 - SPN 2833 - FMI 31 ....................................................................................................................... 14-454
rn
SA 03 - SPN 2858 - FMI 02 ....................................................................................................................... 14-457

SA 03 - SPN 2905 - FMI 03 ....................................................................................................................... 14-460
SA 03 - SPN 2905 - FMI 05 ....................................................................................................................... 14-462
al
SA 03 - SPN 2905 - FMI 06 ....................................................................................................................... 14-464

SA 03 - SPN 2906 - FMI 03 ....................................................................................................................... 14-466
SA 03 - SPN 2906 - FMI 05 ....................................................................................................................... 14-468
u
SA 03 - SPN 2906 - FMI 06 ....................................................................................................................... 14-470

SA 03 - SPN 2910 - FMI 03 ....................................................................................................................... 14-472
se
SA 03 - SPN 2910 - FMI 05 ....................................................................................................................... 14-474

SA 03 - SPN 2910 - FMI 06 ....................................................................................................................... 14-476
SA 03 - SPN 2924 - FMI 14 ....................................................................................................................... 14-478
SA 03 - SPN 3359 - FMI 14 ....................................................................................................................... 14-481
on
SA 03 - SPN 126 - FMI 31 ......................................................................................................................... 14-484

SA 03 - SPN 3454 - FMI 02 ....................................................................................................................... 14-487
SA 03 - SPN 3509 - FMI 03 ....................................................................................................................... 14-492
ly
SA 03 - SPN 3509 - FMI 04 ....................................................................................................................... 14-494

SA 03 - SPN 3513 - FMI 03 ....................................................................................................................... 14-496
SA 03 - SPN 3513 - FMI 04 ....................................................................................................................... 14-498
SA 03 - SPN 3825 - FMI 12 ....................................................................................................................... 14-500
SA 03 - SPN 4056 - FMI 03 ....................................................................................................................... 14-503
SA 03 - SPN 4056 - FMI 05 ....................................................................................................................... 14-505
SA 03 - SPN 4056 - FMI 06 ....................................................................................................................... 14-507
SA 03 - SPN 520192 - FMI 14 ................................................................................................................... 14-509
SA 03 - SPN 520256 - FMI 14 ................................................................................................................... 14-512
SA 03 - SPN 520257 - FMI 14 ................................................................................................................... 14-515
SA 03 - SPN 520258 - FMI 14 ................................................................................................................... 14-518
SA 03 - SPN 520259 - FMI 14 ................................................................................................................... 14-521
SA 03 - SPN 520386 - FMI 03 ................................................................................................................... 14-524
SA 03 - SPN 520386 - FMI 05 ................................................................................................................... 14-526
SA 03 - SPN 520386 - FMI 06 ................................................................................................................... 14-529
SA 03 - SPN 520386 - FMI 12 ................................................................................................................... 14-532
SA 03 - SPN 520386 - FMI 13 ................................................................................................................... 14-534
SA 03 - SPN 520387 - FMI 03 ................................................................................................................... 14-537
SA 03 - SPN 520387 - FMI 05 ................................................................................................................... 14-539
14-iv 79033095 C Rev.

Contents
SA 03 - SPN 520387 - FMI 06 ................................................................................................................... 14-542
SA 03 - SPN 520387 - FMI 12 ................................................................................................................... 14-545
SA 03 - SPN 520387 - FMI 13 ................................................................................................................... 14-547
SA 03 - SPN 520581 - FMI 31 ................................................................................................................... 14-550
SA 03 - SPN 520674 - FMI 02 ................................................................................................................... 14-553
SA 03 - SPN 520706 - FMI 07 ................................................................................................................... 14-556
SA 03 - SPN 520726 - FMI 03 ................................................................................................................... 14-559
SA 03 - SPN 520726 - FMI 05 ................................................................................................................... 14-561
SA 03 - SPN 520726 - FMI 06 ................................................................................................................... 14-563
SA 03 - SPN 520726 - FMI 13 ................................................................................................................... 14-565
SA 03 - SPN 520727 - FMI 03 ................................................................................................................... 14-567
SA 03 - SPN 520727 - FMI 05 ................................................................................................................... 14-569
SA 03 - SPN 520727 - FMI 06 ................................................................................................................... 14-571
SA 03 - SPN 520727 - FMI 13 ................................................................................................................... 14-573
SA 03 - SPN 520967 - FMI 02 ................................................................................................................... 14-575
SA 03 - SPN 2003 - FMI 02 ....................................................................................................................... 14-578
SA 03 - SPN 520967 - FMI 09 ................................................................................................................... 14-581
SA 03 - SPN 521004 - FMI 31 ................................................................................................................... 14-586
SA 03 - SPN 521409 - FMI 03 ................................................................................................................... 14-588
Fo
SA 03 - SPN 521409 - FMI 05 ................................................................................................................... 14-590

SA 03 - SPN 521409 - FMI 06 ................................................................................................................... 14-592
SA 03 - SPN 521469 - FMI 00 ................................................................................................................... 14-594
r
SA 03 - SPN 521469 - FMI 01 ................................................................................................................... 14-596

SA 03 - SPN 521469 - FMI 02 ................................................................................................................... 14-599
in
SA 03 - SPN 521469 - FMI 08 ................................................................................................................... 14-602

SA 03 - SPN 521470 - FMI 00 ................................................................................................................... 14-605
SA 03 - SPN 521470 - FMI 01 ................................................................................................................... 14-607
te
SA 03 - SPN 521470 - FMI 02 ................................................................................................................... 14-610

SA 03 - SPN 521470 - FMI 08 ................................................................................................................... 14-613
rn
SA 03 - SPN 521471 - FMI 00 ................................................................................................................... 14-616

SA 03 - SPN 521471 - FMI 01 ................................................................................................................... 14-620
SA 03 - SPN 521471 - FMI 08 ................................................................................................................... 14-624
al
SA 03 - SPN 521471 - FMI 12 ................................................................................................................... 14-627

SA 03 - SPN 521471 - FMI 13 ................................................................................................................... 14-630
SA 03 - SPN 521472 - FMI 00 ................................................................................................................... 14-632
u
SA 03 - SPN 521472 - FMI 01 ................................................................................................................... 14-636

SA 03 - SPN 521472 - FMI 08 ................................................................................................................... 14-640
se
SA 03 - SPN 521472 - FMI 12 ................................................................................................................... 14-643

SA 03 - SPN 521472 - FMI 13 ................................................................................................................... 14-646
SA 03 - SPN 521473 - FMI 00 ................................................................................................................... 14-648
SA 03 - SPN 521473 - FMI 01 ................................................................................................................... 14-652
on
SA 03 - SPN 521473 - FMI 02 ................................................................................................................... 14-656

SA 03 - SPN 521473 - FMI 08 ................................................................................................................... 14-659
SA 03 - SPN 521473 - FMI 12 ................................................................................................................... 14-662
ly
SA 03 - SPN 521473 - FMI 13 ................................................................................................................... 14-665

SA 03 - SPN 521475 - FMI 02 ................................................................................................................... 14-667
SA 03 - SPN 521476 - FMI 00 ................................................................................................................... 14-671
SA 03 - SPN 521476 - FMI 01 ................................................................................................................... 14-673
SA 03 - SPN 521476 - FMI 08 ................................................................................................................... 14-675
SA 03 - SPN 521476 - FMI 13 ................................................................................................................... 14-678
SA 03 - SPN 521760 - FMI 03 ................................................................................................................... 14-680
SA 03 - SPN 521760 - FMI 05 ................................................................................................................... 14-682
SA 03 - SPN 521760 - FMI 06 ................................................................................................................... 14-685
SA 05 - SPN 69 - FMI 02 ........................................................................................................................... 14-689
SA 05 - SPN 69 - FMI 03 ........................................................................................................................... 14-692
SA 05 - SPN 69 - FMI 04 ........................................................................................................................... 14-695
SA 05 - SPN 69 - FMI 05 ........................................................................................................................... 14-697
SA 05 - SPN 91 - FMI 08 ........................................................................................................................... 14-699
SA 05 - SPN 91 - FMI 13 ........................................................................................................................... 14-702
SA 05 - SPN 601 - FMI 02 ......................................................................................................................... 14-704
SA 05 - SPN 601 - FMI 03 ......................................................................................................................... 14-707
SA 05 - SPN 601 - FMI 04 ......................................................................................................................... 14-710
SA 05 - SPN 601 - FMI 05 ......................................................................................................................... 14-712
79033095 C Rev. 14-v

Contents
SA 05 - SPN 639 - FMI 19 ......................................................................................................................... 14-714
SA 05 - SPN 2034 - FMI 02 ....................................................................................................................... 14-718
SA 05 - SPN 2038 - FMI 02 ....................................................................................................................... 14-722
SA 05 - SPN 2240 - FMI 02 ....................................................................................................................... 14-726
SA 05 - SPN 689 - FMI 02 ......................................................................................................................... 14-730
SA 05 - SPN 689 - FMI 03 ......................................................................................................................... 14-733
SA 05 - SPN 689 - FMI 04 ......................................................................................................................... 14-736
SA 05 - SPN 689 - FMI 05 ......................................................................................................................... 14-738
SA 05 - SPN 898 - FMI 00 ......................................................................................................................... 14-740
SA 05 - SPN 898 - FMI 01 ......................................................................................................................... 14-743
SA 05 - SPN 1231 - FMI 19 ....................................................................................................................... 14-745
SA 05 - SPN 1235 - FMI 19 ....................................................................................................................... 14-749
SA 05 - SPN 1504 - FMI 31 ....................................................................................................................... 14-753
SA 05 - SPN 1787 - FMI 03 ....................................................................................................................... 14-755
SA 05 - SPN 1787 - FMI 04 ....................................................................................................................... 14-758
SA 05 - SPN 1787 - FMI 05 ....................................................................................................................... 14-760
SA 05 - SPN 1875 - FMI 00 ....................................................................................................................... 14-762
SA 05 - SPN 1875 - FMI 01 ....................................................................................................................... 14-765
SA 05 - SPN 1875 - FMI 03 ....................................................................................................................... 14-768
Fo
SA 05 - SPN 1875 - FMI 04 ....................................................................................................................... 14-771

SA 05 - SPN 1894 - FMI 02 ....................................................................................................................... 14-773
SA 05 - SPN 1894 - FMI 03 ....................................................................................................................... 14-777
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SA 05 - SPN 1894 - FMI 04 ....................................................................................................................... 14-780

SA 05 - SPN 1894 - FMI 05 ....................................................................................................................... 14-782
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SA 05 - SPN 1919 - FMI 00 ....................................................................................................................... 14-785

SA 05 - SPN 1919 - FMI 01 ....................................................................................................................... 14-788
SA 05 - SPN 1919 - FMI 03 ....................................................................................................................... 14-791
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SA 05 - SPN 1919 - FMI 04 ....................................................................................................................... 14-794

SA 05 - SPN 1931 - FMI 00 ....................................................................................................................... 14-796
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SA 05 - SPN 1931 - FMI 01 ....................................................................................................................... 14-799

SA 05 - SPN 1931 - FMI 03 ....................................................................................................................... 14-802
SA 05 - SPN 1931 - FMI 04 ....................................................................................................................... 14-805
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SA 05 - SPN 1943 - FMI 00 ....................................................................................................................... 14-807

SA 05 - SPN 1943 - FMI 01 ....................................................................................................................... 14-810
SA 05 - SPN 1943 - FMI 03 ....................................................................................................................... 14-812
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SA 05 - SPN 1943 - FMI 04 ....................................................................................................................... 14-815

SA 05 - SPN 1955 - FMI 00 ....................................................................................................................... 14-817
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SA 05 - SPN 1955 - FMI 01 ....................................................................................................................... 14-820

SA 05 - SPN 1955 - FMI 03 ....................................................................................................................... 14-822
SA 05 - SPN 1955 - FMI 04 ....................................................................................................................... 14-825
SA 05 - SPN 1967 - FMI 00 ....................................................................................................................... 14-827
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SA 05 - SPN 1967 - FMI 01 ....................................................................................................................... 14-830

SA 05 - SPN 1967 - FMI 03 ....................................................................................................................... 14-832
SA 05 - SPN 1967 - FMI 04 ....................................................................................................................... 14-835
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SA 05 - SPN 1979 - FMI 00 ....................................................................................................................... 14-837

SA 05 - SPN 1979 - FMI 01 ....................................................................................................................... 14-840
SA 05 - SPN 1979 - FMI 03 ....................................................................................................................... 14-842
SA 05 - SPN 1979 - FMI 04 ....................................................................................................................... 14-845
SA 05 - SPN 2825 - FMI 00 ....................................................................................................................... 14-847
SA 05 - SPN 2825 - FMI 01 ....................................................................................................................... 14-849
SA 05 - SPN 2832 - FMI 31 ....................................................................................................................... 14-851
SA 05 - SPN 2858 - FMI 02 ....................................................................................................................... 14-853
SA 05 - SPN 2000 - FMI 02 ....................................................................................................................... 14-856
SA 05 - SPN 2970 - FMI 02 ....................................................................................................................... 14-857
SA 05 - SPN 2970 - FMI 03 ....................................................................................................................... 14-859
SA 05 - SPN 2970 - FMI 04 ....................................................................................................................... 14-861
SA 05 - SPN 2970 - FMI 05 ....................................................................................................................... 14-863
SA 05 - SPN 2971 - FMI 03 ....................................................................................................................... 14-865
SA 05 - SPN 2971 - FMI 04 ....................................................................................................................... 14-867
SA 05 - SPN 2971 - FMI 05 ....................................................................................................................... 14-869
SA 05 - SPN 3507 - FMI 06 ....................................................................................................................... 14-871
SA 05 - SPN 3510 - FMI 03 ....................................................................................................................... 14-873
SA 05 - SPN 3510 - FMI 04 ....................................................................................................................... 14-878
14-vi 79033095 C Rev.

Contents
SA 05 - SPN 3511 - FMI 03 ....................................................................................................................... 14-882
SA 05 - SPN 3511 - FMI 04 ....................................................................................................................... 14-887
SA 05 - SPN 3646 - FMI 02 ....................................................................................................................... 14-891
SA 05 - SPN 3646 - FMI 03 ....................................................................................................................... 14-894
SA 05 - SPN 3646 - FMI 04 ....................................................................................................................... 14-897
SA 05 - SPN 3646 - FMI 05 ....................................................................................................................... 14-900
SA 05 - SPN 3652 - FMI 02 ....................................................................................................................... 14-903
SA 05 - SPN 3652 - FMI 03 ....................................................................................................................... 14-906
SA 05 - SPN 3652 - FMI 04 ....................................................................................................................... 14-909
SA 05 - SPN 3652 - FMI 05 ....................................................................................................................... 14-912
SA 05 - SPN 3653 - FMI 02 ....................................................................................................................... 14-915
SA 05 - SPN 3653 - FMI 03 ....................................................................................................................... 14-918
SA 05 - SPN 3653 - FMI 04 ....................................................................................................................... 14-921
SA 05 - SPN 3653 - FMI 05 ....................................................................................................................... 14-923
SA 05 - SPN 520193 - FMI 02 ................................................................................................................... 14-926
SA 05 - SPN 520193 - FMI 03 ................................................................................................................... 14-929
SA 05 - SPN 520193 - FMI 04 ................................................................................................................... 14-932
SA 05 - SPN 520193 - FMI 05 ................................................................................................................... 14-935
SA 05 - SPN 520194 - FMI 02 ................................................................................................................... 14-938
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SA 05 - SPN 5243 - FMI 02 ....................................................................................................................... 14-941

SA 05 - SPN 520194 - FMI 03 ................................................................................................................... 14-944
SA 05 - SPN 5243 - FMI 03 ....................................................................................................................... 14-949
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SA 05 - SPN 520194 - FMI 04 ................................................................................................................... 14-952

SA 05 - SPN 5243 - FMI 04 ....................................................................................................................... 14-956
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SA 05 - SPN 520194 - FMI 05 ................................................................................................................... 14-959

SA 05 - SPN 5243 - FMI 05 ....................................................................................................................... 14-964
SA 05 - SPN 520196 - FMI 31 ................................................................................................................... 14-967
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SA 05 - SPN 520197 - FMI 02 ................................................................................................................... 14-968

SA 05 - SPN 520197 - FMI 03 ................................................................................................................... 14-970
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SA 05 - SPN 520197 - FMI 04 ................................................................................................................... 14-973

SA 05 - SPN 520197 - FMI 05 ................................................................................................................... 14-975
SA 05 - SPN 521474 - FMI 02 ................................................................................................................... 14-978
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SA 05 - SPN 521474 - FMI 03 ................................................................................................................... 14-981

SA 05 - SPN 521474 - FMI 04 ................................................................................................................... 14-984
SA 05 - SPN 521474 - FMI 05 ................................................................................................................... 14-987
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SA 05 - SPN 521893 - FMI 03 ................................................................................................................... 14-990

SA 05 - SPN 521893 - FMI 04 ................................................................................................................... 14-993
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SA 05 - SPN 521893 - FMI 05 ................................................................................................................... 14-996

SA 05 - SPN 521894 - FMI 03 ................................................................................................................... 14-999
SA 05 - SPN 521894 - FMI 04 ................................................................................................................. 14-1002
SA 05 - SPN 521894 - FMI 05 ................................................................................................................. 14-1004
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SA 55 - SPN 002055 - FMI 02 ................................................................................................................. 14-1011

................................................................................................................................................................. 14-1015
SA 161 - SPN 158 - FMI 00 ..................................................................................................................... 14-1016
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SA 161 - SPN 158 - FMI 18 ..................................................................................................................... 14-1019

SA 161 - SPN 628 - FMI 12 ..................................................................................................................... 14-1022
SA 161 - SPN 639 - FMI 19 ..................................................................................................................... 14-1023
SA 161 - SPN 701 - FMI 05 ..................................................................................................................... 14-1026
SA 161 - SPN 701 - FMI 06 ..................................................................................................................... 14-1029
SA 161 - SPN 702 - FMI 05 ..................................................................................................................... 14-1032
SA 161 - SPN 702 - FMI 06 ..................................................................................................................... 14-1035
................................................................................................................................................................. 14-1039
SA 162 - SPN 158 - FMI 00 ..................................................................................................................... 14-1040
SA 162 - SPN 158 - FMI 18 ..................................................................................................................... 14-1043
SA 162 - SPN 628 - FMI 12 ..................................................................................................................... 14-1046
SA 162 - SPN 639 - FMI 19 ..................................................................................................................... 14-1047
SA 162 - SPN 701 - FMI 05 ..................................................................................................................... 14-1048
SA 162 - SPN 701 - FMI 06 ..................................................................................................................... 14-1051
SA 162 - SPN 702 - FMI 05 ..................................................................................................................... 14-1054
SA 162 - SPN 702 - FMI 06 ..................................................................................................................... 14-1057
................................................................................................................................................................. 14-1061
SA 163 - SPN 158 - FMI 00 ..................................................................................................................... 14-1062
SA 163 - SPN 158 - FMI 18 ..................................................................................................................... 14-1065
79033095 C Rev. 14-vii

Contents
SA 163 - SPN 628 - FMI 12 ..................................................................................................................... 14-1068
SA 163 - SPN 639 - FMI 19 ..................................................................................................................... 14-1069
SA 163 - SPN 701 - FMI 05 ..................................................................................................................... 14-1072
SA 163 - SPN 701 - FMI 06 ..................................................................................................................... 14-1075
SA 163 - SPN 702 - FMI 05 ..................................................................................................................... 14-1078
SA 163 - SPN 702 - FMI 06 ..................................................................................................................... 14-1081
................................................................................................................................................................. 14-1085
SA 164 - SPN 158 - FMI 00 ..................................................................................................................... 14-1086
SA 164 - SPN 158 - FMI 18 ..................................................................................................................... 14-1089
SA 164 - SPN 628 - FMI 12 ..................................................................................................................... 14-1092
SA 164 - SPN 639 - FMI 19 ..................................................................................................................... 14-1093
SA 164 - SPN 701 - FMI 05 ..................................................................................................................... 14-1096
SA 164 - SPN 701 - FMI 06 ..................................................................................................................... 14-1099
SA 164 - SPN 702 - FMI 05 ..................................................................................................................... 14-1102
SA 164 - SPN 702 - FMI 06 ..................................................................................................................... 14-1105
................................................................................................................................................................. 14-1111
SA 165 - SPN 158 - FMI 00 ..................................................................................................................... 14-1112
SA 165 - SPN 158 - FMI 18 ..................................................................................................................... 14-1115
SA 165 - SPN 628 - FMI 12 ..................................................................................................................... 14-1118
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SA 165 - SPN 639 - FMI 19 ..................................................................................................................... 14-1119

SA 165 - SPN 701 - FMI 05 ..................................................................................................................... 14-1122
SA 165 - SPN 701 - FMI 06 ..................................................................................................................... 14-1125
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SA 165 - SPN 702 - FMI 05 ..................................................................................................................... 14-1128

SA 165 - SPN 702 - FMI 06 ..................................................................................................................... 14-1131
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................................................................................................................................................................. 14-1137
SA 166 - SPN 158 - FMI 00 ..................................................................................................................... 14-1138
SA 166 - SPN 158 - FMI 18 ..................................................................................................................... 14-1141
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SA 166 - SPN 628 - FMI 12 ..................................................................................................................... 14-1144

SA 166 - SPN 639 - FMI 19 ..................................................................................................................... 14-1145
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SA 166 - SPN 701 - FMI 05 ..................................................................................................................... 14-1148

SA 166 - SPN 701 - FMI 06 ..................................................................................................................... 14-1151
SA 166 - SPN 702 - FMI 05 ..................................................................................................................... 14-1154
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SA 166 - SPN 702 - FMI 06 ..................................................................................................................... 14-1157

................................................................................................................................................................. 14-1163
SA 170 - SPN 158 - FMI 00 ..................................................................................................................... 14-1164
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SA 170 - SPN 158 - FMI 18 ..................................................................................................................... 14-1166

SA 170 - SPN 628 - FMI 12 ..................................................................................................................... 14-1168
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SA 170 - SPN 639 - FMI 19 ..................................................................................................................... 14-1169

SA 170 - SPN 701 - FMI 05 ..................................................................................................................... 14-1172
SA 170 - SPN 701 - FMI 06 ..................................................................................................................... 14-1174
SA 170 - SPN 702 - FMI 05 ..................................................................................................................... 14-1176
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SA 170 - SPN 702 - FMI 06 ..................................................................................................................... 14-1178

................................................................................................................................................................. 14-1183
SA 175 SPN 639 - FMI 19 ....................................................................................................................... 14-1183
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SA 208 - SPN 2208 - FMI 02 ................................................................................................................... 14-1185

SA 208 - SPN 2354 - FMI 05 ................................................................................................................... 14-1187
SA 208 - SPN 2354 - FMI 06 ................................................................................................................... 14-1190
SA 208 - SPN 2368 - FMI 05 ................................................................................................................... 14-1193
SA 208 - SPN 2368 - FMI 06 ................................................................................................................... 14-1195
SA 208 - SPN 2370 - FMI 05 ................................................................................................................... 14-1197
SA 208 - SPN 2370 - FMI 06 ................................................................................................................... 14-1199
SA 208 - SPN 2653 - FMI 05 ................................................................................................................... 14-1201
SA 208 - SPN 2653 - FMI 06 ................................................................................................................... 14-1203
SA 208 - SPN 2655 - FMI 05 ................................................................................................................... 14-1205
SA 208 - SPN 2655 - FMI 06 ................................................................................................................... 14-1207
SA 208 - SPN 4011 - FMI 05 ................................................................................................................... 14-1209
SA 208 - SPN 4011 - FMI 06 ................................................................................................................... 14-1211
SA 209 - SPN 882 - FMI 05 ..................................................................................................................... 14-1213
SA 209 - SPN 882 - FMI 06 ..................................................................................................................... 14-1215
SA 209 - SPN 2209 - FMI 02 ................................................................................................................... 14-1217
SA 209 - SPN 2362 - FMI 05 ................................................................................................................... 14-1220
SA 209 - SPN 2362 - FMI 06 ................................................................................................................... 14-1223
SA 209 - SPN 2368 - FMI 05 ................................................................................................................... 14-1226
14-viii 79033095 C Rev.

Contents
SA 209 - SPN 2368 - FMI 06 ................................................................................................................... 14-1228
SA 209 - SPN 2370 - FMI 05 ................................................................................................................... 14-1230
SA 209 - SPN 2370 - FMI 06 ................................................................................................................... 14-1232
SA 209 - SPN 2386 - FMI 05 ................................................................................................................... 14-1234
SA 209 - SPN 2386 - FMI 06 ................................................................................................................... 14-1236
SA 209 - SPN 2873 - FMI 02 ................................................................................................................... 14-1238
SA 209 - SPN 2875 - FMI 02 ................................................................................................................... 14-1241
SA 209 - SPN 3507 - FMI 06 ................................................................................................................... 14-1243
SA 209 - SPN 3508 - FMI 05 ................................................................................................................... 14-1245
SA 209 - SPN 3508 - FMI 06 ................................................................................................................... 14-1247
SA 209 - SPN 3976 - FMI 06 ................................................................................................................... 14-1249
SA 210 - SPN 46 - FMI 00 ....................................................................................................................... 14-1251
SA 210 - SPN 46 - FMI 01 ....................................................................................................................... 14-1253
SA 210 - SPN 46 - FMI 03 ....................................................................................................................... 14-1255
SA 210 - SPN 46 - FMI 04 ....................................................................................................................... 14-1257
SA 210 - SPN 1083 - FMI 00 ................................................................................................................... 14-1259
SA 210 - SPN 1083 - FMI 01 ................................................................................................................... 14-1261
SA 210 - SPN 1083 - FMI 03 ................................................................................................................... 14-1263
SA 210 - SPN 1083 - FMI 04 ................................................................................................................... 14-1265
Fo
SA 210 - SPN 1084 - FMI 00 ................................................................................................................... 14-1267

SA 210 - SPN 1084 - FMI 01 ................................................................................................................... 14-1269
SA 210 - SPN 1084 - FMI 03 ................................................................................................................... 14-1271
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SA 210 - SPN 1084 - FMI 04 ................................................................................................................... 14-1273

SA 210 - SPN 2210 - FMI 02 ................................................................................................................... 14-1275
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SA 210 - SPN 2360 - FMI 05 ................................................................................................................... 14-1277

SA 210 - SPN 2360 - FMI 06 ................................................................................................................... 14-1279
SA 210 - SPN 2368 - FMI 05 ................................................................................................................... 14-1282
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SA 210 - SPN 2368 - FMI 06 ................................................................................................................... 14-1285

SA 210 - SPN 2370 - FMI 05 ................................................................................................................... 14-1288
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SA 210 - SPN 2370 - FMI 06 ................................................................................................................... 14-1291

SA 210 - SPN 2376 - FMI 05 ................................................................................................................... 14-1294
SA 210 - SPN 2376 - FMI 06 ................................................................................................................... 14-1296
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SA 210 - SPN 2392 - FMI 05 ................................................................................................................... 14-1298

SA 210 - SPN 2392 - FMI 06 ................................................................................................................... 14-1300
SA 210 - SPN 2404 - FMI 05 ................................................................................................................... 14-1302
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SA 210 - SPN 2404 - FMI 06 ................................................................................................................... 14-1305

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INDEX ......................................................................................................................................................... 14-1309

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79033095 C Rev. 14-ix

Contents
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use
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14-x 79033095 C Rev.

Troubleshooting
TROUBLESHOOTING
INTRODUCTION
General Information
5 6 7 8
3
4
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10 12 13
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11
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2
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Q102612006
FIG. 1
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FIG. 1: Block Diagram Of Electronic Control Modules

(ECM)
(1) CAN 1 Powertrain
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(2) CAN 2 Auxiliary

(3) CAN 3 ISO
(4) Armrest ECM
(5) Dash Panel
(6) Engine ECM
(7) Machine ECM
(8) Virtual Terminal Display
(9) Hydraulic Control Valves
(10) Lighting ECM
(11) Lighting ECM
(12) Lighting ECM
(13) Hitch Valve
79033095 C Rev. 14-1

Troubleshooting
Troubleshooting electronic control modules of machine Repairs are considered complete when system event is
requires additional information from machine Service no longer present and parameter appears to read
Manual, Electrical System Schematic and Operation and condition of machine correctly.
Maintenance Manual.
NOTE: If an event is displayed for a switch and switch is
Refer to Electrical System Schematic in manual for being replaced, use Electrical System Schematic
complete representation of machine being diagnosed. as a troubleshooting aid. Check components that
are listed here: wire harness, switch, and ECM.
When troubleshooting procedure instructs service
personnel to repair harness, always use Electrical Quick Reference
System Schematic in manual to trace circuits. Perform
continuity checks at connectors to locate harness failures. • See Troubleshooting, Diagnostic Codes Procedures,
At component connectors, always check ground circuit. section for failures that have diagnostics
Power circuits of control require less than 2 ohms of (TX/SPN/FMI).
resistance between ground contacts of connector and
• See Troubleshooting, Switch Circuits, section for
frame ground. Signal circuits (sensors, switches,
failures in operation of alert indicators.
solenoids etc.) require less than 5 ohms of resistance for
normal operation. Resistance greater than 5 ohms can
cause incorrect diagnosing of problems.
Fo
Repairs of machine harness should be performed with

wire of same gauge. All joints should be soldered. All
joints should be taped tightly. Use vinyl tape or shrink
sleeving for all repairs to harness. Repairs to data link
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circuit in harness must maintain same twist ratio in wiring

that was provided in original harness. Two wires of CAT
in
data link must maintain a twist rate of 2 ±1 turns per inch.

Twisting is VERY IMPORTANT! Twisting will minimize
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electrical interference to other circuits caused by data link.

Interference to data link from other circuits will also be
minimized.
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During troubleshooting, inspect all component and

harness connections before any component is replaced.
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Electrical problems can be caused if harness connections

are not clean and tight. Electrical problem can be
permanent or electrical problem can be intermittent.
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Make sure that connections are tight before other tests

are made.
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Failure of an electrical component can cause failure of

one or more related components. Always attempt to find
cause of electrical system failure and then correct cause
on
of electrical system failure before replacing a component.

Some machine functions that use solenoid valves require
a suppressor diode across valve coil. If suppressor diode
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is faulty, electronic noise generated by solenoids turning

on and off can cause erratic operation of display
components. If erratic operation of display components
appears to be associated with an activity such as blade
operation, check appropriate suppressor diode for proper
operation.
Data events and maintenance events are defined by
machine's configuration software. Diagnostic functions for
a given event are also defined in configuration software.
Electronic control module may wait up to 30 seconds
before displaying a system event on Virtual Terminal (VT).
During troubleshooting, allow an adequate amount of
time for ECM to report that a new condition exists. For
example, when unplugging a sensor from machine
harness, ECM may wait up to 30 seconds before
reporting condition. Likewise, when condition is corrected,
several minutes may be required before event ceases to
be reported.
14-2 79033095 C Rev.

Troubleshooting
Service Tools
Following service tools should be used to aid in
troubleshooting electrical system.
Service Tools
Part Number Part
CAT Electronic Technician
237-5130 Digital Multimeter
257-9140
8T-3224 Needle Tip Group
7X-1710 Multimeter Probe Group
8T-8726 Adapter Cable Assembly
6V-3000 Connector Repair Kit (Sure Seal)
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175-3700 Connector Repair Kit (Deutsch DT)

4C-3406 Connector Repair Kit (Deutsch)
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4C-8195 Control Service Tool (Switch Box)

in
FIG. 2: Connections for Caterpillar Electronic Technician

(ET) 1
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Components that are needed to use CAT Electronic

Technician to determine diagnostic codes are listed:
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3 4
(1) A personal computer with an installed current 2
version of Caterpillar Electronic Technician software.
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(2) 139-4166 Datalink Cable

(3) 7X-1425 Cable and 4C-6805 Adapter
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(4) Special Publication JEBD3003, Special Publication

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JERD2124, Special Publication JERD2129; Caterpillar 5

Electronic Technician software. P050908001
(5) 171-4400 Communication Adapter Tool with Special FIG. 2

Publication, NEXG4323, Communications Adapter
on
Software.
FIG. 3: Connections for Communication Adapter II and
Caterpillar Electronic Technician (ET).
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Components that are needed to use Communication 1 2

Adapter II and CAT Electronic Technician to determine
diagnostic codes are listed:
(1) Cable
(2) 171-4400 Communication Adapter II
(3) Service diagnostic cable
4
(4) Current version of Caterpillar Electronic Technician
software and a personal computer
3
Reference: See Special Publication, NEHS0758, P050908002
Communications Adapter II User's Manual Contains FIG. 3

Software.
NOTE: Caterpillar Electronic Technician (ET) is a
software program that can be used on a personal
computer.
79033095 C Rev. 14-3

Troubleshooting
To use Electronic Technician (ET), order following
materials: Special Publication, JERD2124, ET Single Use
Program License, Special Publication, JEHP1026,
Information and Requirements Sheet, 7X-1425 Data Link
Cable and Data Subscription and Special Publication,
JERD2142, Data Subscription. Special Publication,
JEHP1026, Information and Requirements Sheet lists
required hardware and features of ET.
Caterpillar Electronic Technician (ET) is not required to
determine diagnostic codes and ET is not required to
clear diagnostic codes. However, process of determining
diagnostic codes is easier and faster by using ET. ET can
also display information on history of a diagnostic code
and parameter status of diagnostic codes. These features
allow ET to be a useful tool for troubleshooting.
Electronic Technician (ET) is used to communicate to
ECM (electronic control module) over data link by
connecting to machine diagnostic connector. For more
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information and locations of connectors, see

Troubleshooting, Electrical Components and Connector
Locations, and Electrical System Schematic in your
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machine's Service Manual.

For instructions on servicing Sure Seal connectors, see
in
Special Instruction, SMHS7531. For instructions on

servicing Deutsch DT connectors, see Special Instruction,
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SEHS9615.
Use digital multimeter for making continuity checks or for
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measuring voltage. For instructions about use of

237-5130 digital multimeter, see Special Instruction,
SEHS7734.
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7X-1710 multimeter probe measures voltage at

connectors without disconnecting connectors. Probe
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cable are pushed into back of connector along wire.

8T-8726 Adapter Cable has a 3-pin breakout. Adapter
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cable is used for measurements in sensor circuits.

NOTE: Except for harness tests, using continuity testers
such as 8T-0500 Continuity Tester or voltage
on
testers such as 5P-7277 Voltage Tester is not

recommended for today’s Caterpillar electrical
circuits.
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14-4 79033095 C Rev.

Troubleshooting
Connector Locations
Service Tool Connector
FIG. 4: Service tool connector is located on fuse panel
plate. Connector is facing toward the operator’s seat.
1
Service tool connector is used to communicate with
2
(1) Guidance RS232
(2) ET - Electronic Service Connector 3
(3) EDT - Electronic Diagnostic Service Connector
4
(4) ISO Service Connector
P090808005
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FIG. 4
Machine ECM
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Machine ECM is located beneath floor plate on left side of

cab in front of trainer seat.
in
Virtual Terminal Display

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FIG. 5: Display (1) is located at the front of the armrest

on the right side of the operators seat. 1
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P121802003
FIG. 5
79033095 C Rev. 14-5

Troubleshooting
Dash Panel Cluster
Status Indicators
2 1
5 4 3
6 7 8
13 15
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16 11 12
9 10
14
17
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P110611001
in
FIG. 6
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FIG. 6: Dash panel cluster (10) No.1 Trailer Turn Signals - Green indicator
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illuminates when first trailer signal is active.

(1) NEUTRAL Status - Green indicator illuminates
when the transmission is in NEUTRAL. (11) No.2 Trailer Turn Signals - Green indicator
illuminates when second trailer signal is active.
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(2) Not used.

(12) Right Turn Signal - Flashes unison with right turn
(3) PTO Status - Green indicator illuminates when PTO
signal. Indicator color is green.
is engaged.
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(13) High Beam Headlamp - Blue indicator illuminates

(4) Auto Power Management - Green indicator when high beam lights are activated.
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illuminates when auto power management function is

active (14) Current Gear Display - Indicates current gear being
used by transmission. When in Park or Neutral, P or N is
(5) Automatic Steering - Indicator illuminates white displayed, respectively.
when automatic steering is ready, but not active. Indicator
on
color is green when automatic steering is active. (15) Selected Gear Display - Indicates gear selected by
operator. When in Park or Neutral, P or N is displayed,
(6) Differential lock - Amber indicator illuminates when respectively.
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differential lock is engaged.

(16) Machine Speed Display - Indicates machine speed
(7) Not used. in KPH or MPH units.
(8) Roadway travel mode - Red indicator illuminates (17) Engine Hour Display - Indicates total accumulated
when roading lockout switch is activated.
engine hours.
(9) Left Turn Signal - Flashes in unison with left turn
signal. Indicator color is green.
14-6 79033095 C Rev.

Troubleshooting
Warning Indicators
3 4
5 6 7
10
1 2 8 9
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P110611001
FIG. 7
in
FIG. 7: Dash panel cluster (6) Powertrain Oil Temperature - Red indicator
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illuminates when powertrain oil temperature is above

(1) Hydraulic Oil Filter - Amber indicator illuminates normal operating range. If powertrain overheating is
when hydraulic oil filter is blocked or partially blocked.
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indicated, stop the machine as soon as practical and

Replace filter as soon as practical to minimize risk of investigate the cause.
hydraulic system damage.
(7) Hydraulic Oil Temperature - Red indicator
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(2) Powertrain Oil Filter - Amber indicator illuminates illuminates when hydraulic system oil temperature is
when powertrain oil filter is blocked or partially blocked. above normal operating range. If hydraulic system
Replace filter as soon as practical to minimize risk of overheating is indicated, stop the machine as soon as
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powertrain system damage. practical and investigate the cause.

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(3) Engine Oil Pressure - Red indicator illuminates (8) Not used.
when engine oil pressure fall below operating range. If low
engine oil pressure is indicated, stop engine as soon as (9) Hydraulic Oil Level - Red indicator illuminates when
practical to minimize the chance of engine damage from hydraulic system oil level is below safe operating range. If
lack of lubrication. this indicator is illuminated, stop the machine as soon as
on
practical and check hydraulic oil level.

(4) Air System Pressure - Red indicator illuminates
when pressure in air system (optional equipment) falls (10) Not used.
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below normal operating range.

(5) Engine Coolant Temperature - Red indicator
illuminates when engine coolant temperature is above
normal operating range. If engine overheating is
indicated, stop engine as soon as practical and
investigate the cause.
79033095 C Rev. 14-7

Troubleshooting
Gauges
1 2 3 4
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P110611001
FIG. 8
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FIG. 8: Dash panel indicator lights illuminates for:

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(1) Engine Coolant Temperature - Bar graph indicates

engine coolant temperature. This display will flash if
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gauge indicates operation in the upper red region

adjacent to bar graph. If engine overheating is indicated,
stop engine as soon as practical and investigate the
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cause.
(2) Engine Oil Pressure - Bar graph indicates engine oil
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pressure. This display will flash if gauge indicates

operation in the lower red region adjacent to bar graph. If
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low engine oil pressure is indicated, stop engine as soon

as practical to minimize the chance of engine damage
from lack of lubrication.
(3) Battery Voltage - Bar graph indicates battery voltage
on
level. This display will flash if gauge indicates operation in

either the upper or lower red regions adjacent to bar
graph. If system voltage is indicated above or below
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normal operating range, stop machine in a safe place and

investigate cause.
(4) Fuel Gauge - Bar graph indicates machine fuel
level. This display will flash if gauge indicates operation
in the lower red region adjacent to bar graph.
14-8 79033095 C Rev.

Troubleshooting
Machine Preparation for Troubleshooting
Preparation of Machine
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machine.

hitch to ground.
3. Make sure that transmission control lever is in PARK
position.
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4. Warm oil to a minimum temperature of 60⋅C (140⋅F),

if necessary. See Warming Hydraulic Oil for
procedure that warms hydraulic oil.
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5. Move all of hydraulic control levers through FLOAT

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Reference: Refer to Operations and Maintenance
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Manual, Guards - Remove and Install, for more

information.
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Procedure
When you are defining a problem in any of hydraulic
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systems, following procedure should be followed:

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Inspection. If you complete visual inspection and problem

is not identified, perform mechanical system tests. If you
complete mechanical system tests and problem is not
identified, perform electrical system tests.
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Troubleshooting Manual, Electrical and Hydraulic
Systems. Troubleshooting manual lists probable causes
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of a known problem.
troubleshooting section may suggest specific inspections
identify most probable cause.
Test Equipment
79033095 C Rev. 14-9

Troubleshooting
Warming Hydraulic Oil
FIGS. 9–10: If necessary, install FT2220 Hose Assembly
into (+) quick coupler and (-) quick coupler of any
hydraulic control valve. Place hydraulic control lever in
EXTEND DETENT position. Adjust needle valve
accordingly to heat hydraulic oil.
NOTE: Make sure that you set Detent Time on Virtual
Terminal (VT) to be continuous.
Reference: Refer to Operation and Maintenance
Manual, Hydraulic Control Valve Operation, for more
information.
NOTE: During a diagnosis in any of hydraulic systems,
remember that correct oil flow and pressure are g00833470
necessary for correct operation. Oil pressure is FIG. 9
temperature must be a minimum of 60 ⋅C (140
⋅F). Temperature of hydraulic oil can be viewed
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on Information screen of Virtual Terminal (VT).

Reference: See Systems Operation/Testing and
Adjusting, Virtual Terminal (VT), for more information.
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g00807309
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FIG. 10
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14-10 79033095 C Rev.

Troubleshooting
SYMPTOM PROCEDURES
Transmission
FIG. 11: Modulating Valves (Transmission Control
Valves) MT700C A
Each transmission control valve has a designated letter,
B
C
as shown. Letters have been cast into transmission
housing. D
E
Each transmission control valve controls an individual F
clutch. Each letter is assigned to a corresponding G
transmission control valve.
H
These letters are used in following table to show clutches J
that are engaged for each gear.
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Also, no more than one clutch is ever engaged on a shaft. P090308001
FIG. 11
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FIG. 12: Modulating Valves (Transmission Control

Valves) MT800C A
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B
C
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D
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E
F
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G
H
J
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P090308004
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FIG. 12
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79033095 C Rev. 14-11

Troubleshooting
Engine RPM at 2100
Reverse Input Intermediate Output Machine
Gear
Shaft Shaft Shaft Shaft Speed
Fourth gear (reverse) A - - J 14.19 km/h (8.82 mph)
Third gear (reverse) A - - H 5.84 km/h (3.63 mph)
Second gear (reverse) A - - B 5.18 km/h (3.22 mph)
First gear (reverse) A - - G 2.14 km/h (1.33 mph)
Neutral - - - J -
First gear - C - G 2.67 km/h (1.66 mph)
Second gear - D - G 3.40 km/h (2.11 mph)
Third gear - - E G 4.28 km/h (2.66 mph)
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Fourth gear - - F G 5.44 km/h (3.38 mph)

Fifth gear - C - B 6.49 km/h (4.03 mph)
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Sixth gear - C H 7.31 km/h (4.54 mph)

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Seventh gear - D - B 8.24 km/h (5.12 mph)

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Eighth gear - D - H 9.27 km/h (5.76 mph)

Ninth gear - - E B 10.43 km/h (6.48 mph)
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Tenth gear - - E H 11.73 km/h (7.29 mph)

Eleventh gear - - F B 13.23 km/h (8.22 mph)
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Twelfth gear - - F H 14.90 km/h (9.26 mph)

Thirteenth gear - C - J 17.73 km/h (11.02 mph)
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Fourteenth gear - D - J 22.53 km/h (14 mph)

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Fifteenth gear - - E J 28.52 km/h (17.72 mph)

Sixteenth gear - - F J 36.21 km/h (22.50 mph)
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Problem List
Following problems are covered in story:
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• Machine Does Not Move in Any Gear

• Transmission Does Not Shift Into All of Gears
• A Warning Event for Replacing Hydraulic Oil Filters is
Displayed on Virtual Terminal (VT)
• Transmission Shifts Too Hard
• A Warning Event for Low Hydraulic Oil Pressure is
Displayed on Virtual Terminal (VT)
• A Warning Event for Elevated Hydraulic Oil
Temperature is Displayed on Virtual Terminal (VT)
• Transmission Locks Into One Gear
• Transmission Slips
• Inching Control Does Not Work Properly
14-12 79033095 C Rev.

Troubleshooting
Machine Does Not Move in Any Gear 6. Repair any failed components or replace any failed
components that are found during pressure tests.
1. Check Virtual Terminal (VT) for any diagnostic code
displayed. 7. If a specific gear is missing, identify clutches that are
used for that gear. See above table.
Reference: See appropriate stories in
Troubleshooting book that relate to diagnostic codes. 8. Look for a gear that uses similar clutches.
Repair any suspect components, as required.
9. Use a known working transmission control valve to
2. Check common sump for correct type of oil and replace suspect transmission control valve. For
check common sump for correct quantity of oil. example, if fourth gear (reverse) is working then you
can use either transmission control valve (A) or (J) as
Reference: Refer to Operation and Maintenance a working transmission control valve. This will isolate
Manual, Hydraulic System Oil Level - Check, for faulty solenoid valve. Replace any faulty solenoid
additional information. valves that are found during test.
3. Perform calibration procedure for transmission
clutches. A Warning Event for Replacing Hydraulic Oil Filters
is Displayed on Virtual Terminal (VT)
Reference: Refer to Systems Operation/Testing and
Adjusting, Transmission Clutch Calibration, for 1. Replace hydraulic oil filters.
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additional information. Reference: Refer to Operation and Maintenance

4. Repair any problems that are found in calibration Manual, Hydraulic System Oil Filters - Replace, for
procedure. additional information.
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NOTE: Operate machine. If transmission does not 2. Check Virtual Terminal (VT) for any diagnostic code
function properly, continue with next step. displayed.
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5. Perform pressure tests for transmission. Reference: See appropriate stories in

Troubleshooting book that relate to diagnostic codes.
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Reference: Refer to Systems Operation/Testing and Repair any suspect components, as required.
Adjusting for additional information.
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6. Repair any failed components that are found while Transmission Shifts Too Hard.
you perform pressure tests. 1. Check Virtual Terminal (VT) for any diagnostic code
displayed.
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Transmission Does Not Shift Into All of Gears

1. Check Virtual Terminal (VT) for any diagnostic code Troubleshooting book that relate to diagnostic codes.
displayed.
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2. Check reservoir for correct type of oil and check

Troubleshooting book that relate to diagnostic codes. reservoir for correct quantity of oil.
2. Check reservoir for correct type of oil and check Manual, Hydraulic System Oil Level - Check, for
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reservoir for correct quantity of oil. additional information.

Reference: Refer to Operation and Maintenance 3. Perform calibration procedure for transmission
Manual, Hydraulic System Oil Level - Check, for clutches.
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additional information.
3. Perform calibration procedure for transmission Adjusting, Transmission Clutch Calibration, for
clutches. additional information.
Reference: Refer to Systems Operation/Testing and 4. Repair any problems that are found in calibration
Adjusting, Transmission Clutch Calibration, for procedure.
NOTE: Operate machine. If transmission does not
4. Repair any failed components or replace any failed function properly, continue with next step.
components that are found during calibration
procedure. 5. Perform pressure tests for transmission.
NOTE: Operate machine. If transmission does not Reference: Refer to Systems Operation and Testing
function properly, continue with next step. and Adjusting for additional information.
5. Perform pressure tests for transmission. 6. Repair any failed components or replace any failed
components that are found during pressure tests.
Reference: Refer to Systems Operation and Testing
and Adjusting for additional information. 7. If a specific gear is missing, identify clutches that are
used for that gear. See above table.
8. Look for a gear that uses similar clutches.
79033095 C Rev. 14-13

Troubleshooting
9. Use a known working transmission control valve to b. Check fan drive belt. Speed of fan may be
replace suspect transmission control valve. For reduced if fan drive belt is loose or if fan drive belt
example, if fourth gear (reverse) is working then you is damaged. If fan drive belt is damaged, replace
can use either transmission control valve (A) or (J) as belt.
a working transmission control valve. This will isolate
Reference: Refer to Operation and
faulty solenoid valve. Replace any faulty solenoid
Maintenance Manual for additional information.
valves that are found during test.
5. There appears to be air in hydraulic oil.
A Warning Event for Low Hydraulic Oil Pressure is
Displayed on Virtual Terminal (VT) a. Find location of entry of air into system.
1. Check Virtual Terminal (VT) for any diagnostic code b. As required, repair components or replace
displayed. components.
Reference: See appropriate stories in 6. If there is air in hydraulic oil, there may be a problem
Troubleshooting book that relate to diagnostic codes. with implement hydraulic system.
Repair any suspect components, as required. Reference: See Troubleshooting, Implement
NOTE: Operate machine. If a warning event for low System, for necessary information.
hydraulic oil pressure is still on, continue with
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next step. Transmission Locks Into One Gear
2. Check reservoir for correct type of oil and check 1. Check Virtual Terminal (VT) for any diagnostic code
reservoir for correct quantity of oil. displayed.
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Reference: refer to Operation and Maintenance Reference: See appropriate stories in

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Manual, Hydraulic System Oil Level - Check, for

additional information. Repair any suspect components, as required.
2. Find gear locked. Find clutches that are used to
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3. Perform pressure tests for transmission.

engage gear locked. See above table.
3. Perform pressure tests for transmission.
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Adjusting for additional information.

A Warning Event for Elevated Hydraulic Oil Adjusting for additional information.
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Temperature is Displayed on Virtual Terminal (VT)

1. Check Virtual Terminal (VT) for any diagnostic code Transmission Slips
displayed. 1. Check Virtual Terminal (VT) for any diagnostic code
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Reference: See appropriate stories in displayed.

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Troubleshooting book that relate to diagnostic codes. Reference: See appropriate stories in
Repair any suspect components, as required. Troubleshooting book that relate to diagnostic codes.
2. Check reservoir for correct type of oil and check Repair any suspect components, as required.
reservoir for correct quantity of oil.
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Reference: Refer to Operation and Maintenance reservoir for correct quantity of oil.
Manual, Hydraulic System Oil Level - Check, for Reference: Refer to Operation and Maintenance
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additional information. Manual, Hydraulic System Oil Level - Check, for

3. Check hydraulic oil cooler. additional information.
a. Check cooler for dirt or foreign material. Clean 3. Perform calibration procedure for transmission
cooler, if necessary. clutches.
Reference: Refer to Operation and Reference: Refer to Systems Operation/Testing and

Maintenance Manual, Cooling Cores - Clean, for Adjusting, Transmission Clutch Calibration, for
additional information. additional information.
b. Check cooler for damage. As required, repair 4. Repair any problems that are found in calibration
components or replace components. procedure.
c. Check cooler lines for damage. As required, 5. Perform pressure tests for transmission.
repair components or replace components. Reference: Refer to Systems Operation/Testing and
4. Air flow across cooler is low. Adjusting for additional information.
a. Check fan for damage. If fan is damaged, replace 6. Repair any problems that are found during pressure
fan. tests.
14-14 79033095 C Rev.

Troubleshooting
7. If pressure is correct, clutches may be worn. As
required, repair components or replace components.
Inching Control Does Not Work Properly

displayed.
2. Perform calibration procedure for inching pedal.
Adjusting, Transmission Clutch Calibration, for
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79033095 C Rev. 14-15

Troubleshooting
Power Take-Off
Power Take-Off will not Engage
displayed.
3. Perform pressure test for power take-off.
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and Adjusting, Power Take-Off (PTO) Clutch

Pressure - Test and Adjust, for additional information.
4. Power take-off valve has failed. Replace power
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take-off valve with a new valve.

NOTE: Operate machine. If power take-off does not
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function properly, continue with next step.

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5. Seals in clutch pack for power take-off are leaking.

Replace seals for clutch pack.
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Power Take-Off will not Disengage

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displayed.
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3. Perform pressure test for power take-off.
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and Adjusting, Power Take-Off (PTO) Clutch
Pressure - Test and Adjust, for additional information.
4. Power take-off valve may have failed. Replace power
take-off valve with a new valve.
NOTE: Operate machine. If power take-off does not
function properly, continue with next step.
14-16 79033095 C Rev.

Troubleshooting
FIGS. 13–14: Piston (1) and Spring (2).
5. If brake is not working properly, power take-off may
free wheel. Piston (1) may be stuck. Repair piston or 1
replace piston.
6. Springs (2) for power take-off may have failed.
Replace spring for power take-off.
7. Friction material may have failed.
2
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P051208001
FIG. 13
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1
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2
P051208002
FIG. 14
79033095 C Rev. 14-17

Troubleshooting
Steering System 5. Check hydraulic oil level in common sump. Level may
be too low.
Troubleshooting for Steering Hydraulic System a. Check hydraulic oil level in common sump to
Problem List determine if there is enough oil in hydraulic tank.
• Temperature of hydraulic oil in common sump is high. Reference: Refer to Operation and
Maintenance Manual, Hydraulic System Oil Level
• There is a large amount of air in oil. - Check.
• Charge oil pressure for steering hydraulic system is b. Check for oil aeration by taking an oil sample. If
not correct. aeration is found, see There is a large amount of
• Steering pump oil pressure is not correct. air in oil.
• Machine turns slowly in both directions. 6. Outside air temperature may be too hot.
• Machine turns slowly in one direction. a. Change operating techniques to reduce load on
system.
• Machine turns in opposite direction of steering wheel
in forward and/or reverse.
• Turns of machine are jerky or turns are unstable.
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• Machine turns correctly during roading, but machine

turns slowly in one direction when machine is loaded.
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• Engine lugs more than normal when you steer

machine.
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• Engine speed surges when you steer machine.

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• Machine drifts in one direction in first gear when

engine is at low idle.
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• Steering wheel rotation is excessive before turn

begins.
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Probable Causes
Temperature of hydraulic oil in common sump is
high.
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1. Check actual temperature of oil.

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a. Insert a thermometer into oil filler tube.

b. If temperature is below 107 ⋅C (224 ⋅F), there is
an electrical problem with temperature sensing
on
system.
Reference: Refer to Troubleshooting TX 03 -
SPN 1638.
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2. Check oil coolers. Oil cooler is divided into two

sections.
a. Make sure that oil coolers are not packed with
debris.
3. Determine if either one of oil cooler bypass valves are
stuck open.
a. Determine cause. If necessary, repair oil cooler
bypass valve.
4. Check techniques of operator. Load on system may
be too high.
NOTE: Make sure that engine is running at high idle.
This will ensure that oil cooler is working at full
capacity.
a. Change operating techniques to reduce load on
system.
14-18 79033095 C Rev.

Troubleshooting
FIG. 15: Flow compensator spool and orifice.
7. Verify that pump proceeds to low pressure standby
1
when implements and hitch are not being operated.
a. Perform low pressure standby test.
Reference: Refer to Systems Operation/Testing
and Adjusting, Hydraulic Pump Discharge
Pressure -Tests.
b. If pump does not proceed to low pressure
standby, make sure that flow compensator spool
(1) moves freely inside compensator valve. Also,
make sure that orifice (2) is free of debris. 2
P051208003
c. If necessary, repair failure.
FIG. 15
8. Make sure that correct viscosity of oil is in system.
Manual.
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9. Verify that load sensing relief valve opens at correct

oil pressure.
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a. Perform high pressure stall test for hydraulic

pump.
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Pressure -Tests.
10. Check hydraulic pump (implement) for wear.
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a. Perform pump efficiency check.

11. Make sure that pressure override relief valve is
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adjusted correctly.
• Test high pressure cutoff of steering pump.
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and Adjusting, Steering Pump High Pressure
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Cutoff Pressure Test.

12. Make sure that charge relief valve is adjusted
correctly.
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a. Perform pressure test for charge oil of steering

system.
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and Adjusting Relief Valve (Charge) - Test and

Adjust.
13. Check for a restriction in an oil passage.
• Determine cause. If necessary, repair machine.
14. Check steering pump for excessive wear.
15. There may be a problem with transmission hydraulic
system.
Reference: See Troubleshooting, Transmission, for
more information.
79033095 C Rev. 14-19

Troubleshooting
There is a large amount of air in oil. Reference: Refer to Systems Operation/Testing
1. Check hydraulic oil level in common sump.
a. Check hydraulic oil level to determine if there is 2. Make sure that pilot oil pressure from electric servo
enough oil in common sump. valve is correct.
a. Test pilot oil pressure from electric servo valve.
Maintenance Manual, Hydraulic System Oil Level
- Check. Reference: Refer to Systems Operation/Testing
and Adjusting, Steering Servo Valve - Test and
2. Check for a leak in oil line between common sump
Adjust.
and pump.
3. Make sure that electric servo valve is operating
a. Repair leak, if necessary. correctly.
3. Check for leakage around seals in hydraulic
a. Check upstroke of steering pump.
cylinders.
a. If necessary, repair seals. and Adjusting, Steering Pump
Charge oil pressure for steering hydraulic system Upstroke/Deadband Test.
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is not correct. 4. Make sure that charge pump is operating correctly.

1. Check hydraulic oil level in common sump. a. Check charge oil pressure.
a. Check hydraulic oil level to determine if there is
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enough oil in common sump. and Adjusting, Relief Valve (Charge) - Test and
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Reference: Refer to Operation and Adjust.

Maintenance Manual Hydraulic System Oil Level
b. If charge oil pressure is not correct, see charge
- Check.
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oil pressure for steering hydraulic system is not

2. Make sure that correct viscosity of oil is in system. correct.
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Reference: Refer to Operation and Maintenance 5. Check for excessive leakage in modulating valves
Manual, Lubricant Viscosities. (transmission) and modulating valve (PTO). Also,
check for excessive leakage in seals for transmission
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3. Charge relief valve is not adjusted correctly. shafts.

a. Perform pressure test for charge oil of steering 6. Check steering pump for excessive wear.
system and transmission system.
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and Adjusting, Relief Valve (Charge) - Test and Machine turns slowly in both directions.
Adjust. 1. Check for proper voltage to solenoids on electric
4. High pressure cutoff of pressure override relief valve servo valve.
is not adjusted.
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a. Use Electronic Technician to view percent of

a. Test high pressure cutoff of steering system. voltage being supplied to solenoids.
Reference: Refer to Systems Operation/Testing 2. Check for leaks in circuit between steering pump and
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and Adjusting, Steering Pump High Pressure steering motor.

Cutoff Pressure Test. a. Repair any leaks, if necessary.
5. Check charge pump for excessive wear.
a. Perform pump efficiency test. adjusted correctly.
6. Check flushing valve for steering motor. a. Test high pressure cutoff of steering pump.
Reference: Refer to Systems Operation/Testing and Reference: Refer to Systems Operation/Testing
Adjusting, Steering Motor Case Drain Pressure Test. and Adjusting, Steering Pump High Pressure
7. Check flushing orifice for steering pump.
b. If steering pump oil pressure is not correct, see
Steering pump oil pressure is not correct. steering pump oil pressure is not correct.
adjusted correctly.
a. Test high pressure cutoff of steering pump.
14-20 79033095 C Rev.

Troubleshooting
4. Check steering motor for excessive wear. a. Test high pressure cutoff of steering pump.
a. Test case drain pressure of steering motor. Reference: Refer to Systems Operation/Testing
Reference: Refer to Systems Operation/Testing Cutoff Pressure Test.
and Adjusting, Steering Motor Case Drain
Pressure Test. 3. Make sure that electric servo valve operates correctly.
b. Check flushing valve for steering motor. Reference: Refer to Systems Operation/Testing and
Adjusting, Steering Servo Valve - Test and Adjust.
Machine turns slowly in one direction.
4. Check for debris in oil.
1. Check for proper voltage to solenoids on electric
servo valve. a. If there is debris in oil, find cause of debris.
a. Use Electronic Technician to view voltage Machine turns correctly during roading, but
supplied to solenoids. machine turns slowly in one direction when
machine is loaded.
2. Check for leaks in circuit between steering pump and
steering motor. 1. Make sure that pressure override relief valve is
adjusted correctly.
a. Repair any leaks, if necessary.
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3. Make sure that pilot oil pressure from electric servo
valve is correct. Reference: Refer to Systems Operation/Testing
a. Test pilot oil pressure from electric servo valve.
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Reference: Refer to Systems Operation/Testing 2. Check tension of belts.
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and Adjusting, Steering Servo Valve - Test and

Adjust. Reference: Refer to Operation and Maintenance
Manual Undercarriage (Mobil-trac) Belt
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4. Make sure that electric servo valve is operating Tension/Detention.

correctly.
Engine lugs more than normal when you steer
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a. Check upstroke of steering pump.

machine.
Reference: Refer to Systems Operation/Testing 1. Make sure that pressure override relief valve is
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and Adjusting, Steering Pump adjusted correctly.

5. Check tension of belts.
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Reference: Refer to Operation and Maintenance and Adjusting, Steering Pump High Pressure
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Manual, Undercarriage (Mobil-trac) Belt

Tension/Detention.
2. Make sure that crossover relief valves are adjusted
correctly.
adjusted correctly.
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and Adjusting, High Pressure Relief Valve -Test
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and Adjusting, Steering Pump High Pressure and Adjust.

Machine turns in opposite direction of steering
be too high.
wheel in forward and/or reverse.
a. Change operating techniques to reduce load on
1. Make sure that wiring to solenoid valves on electric system.
servo valve is correct.
Engine speed surges when you steer machine.
Reference: Refer to Electrical Schematic for more
information. 1. Make sure that pressure override relief valve is
adjusted correctly.
Turns of machine are jerky or turns are unstable.
1. Check for a large amount of air in oil.
a. Take a sample of oil from sump. and Adjusting, Steering Pump High Pressure
b. If there is a large amount of air in oil, see There is Cutoff Pressure Test.
a large amount of air in oil.
2. Make sure that crossover relief valves are adjusted
2. Make sure that pressure override relief valve is correctly.
adjusted correctly.
79033095 C Rev. 14-21

Troubleshooting
and Adjusting, High Pressure Relief Valve -Test
and Adjust.
3. Make sure that pilot oil pressure from port (X1) and
port (X2) on electric servo valve is correct.
Adjusting, Steering Servo Valve -Test and Adjust.
Machine drifts in one direction in first gear when
engine is at low idle.
1. Check tension of belts.
Manual, Undercarriage (Mobil-trac) Belt
Tension/Detention.
2. Check deadband of steering system.
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Adjusting, Steering Pump Upstroke/Deadband Test.
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3. Make sure that steering pump is nullified.

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Adjusting, Steering Pump Upstroke/Deadband Test.

Steering wheel rotation is excessive before turn
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begins.
1. Check steering pump oil pressure.
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b. If steering pump oil pressure is not correct, see

steering pump oil pressure is not correct.
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2. Make sure that electric servo valve is operating

correctly.
a. Check operation of electric servo valve.
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3. Check steering motor for excessive wear.

a. Test case drain pressure for steering motor.
and Adjusting, Steering Motor Case Drain
Pressure Test.
14-22 79033095 C Rev.

Troubleshooting
Brake System Service brakes do not release.
1. Check service brake pedal linkage for proper
Troubleshooting for Brake System adjustment.
Problem List Reference: Refer to Specifications, Service Brakes,
• When brakes are applied, brakes react slowly. for more information.
• Service brakes do not release. 2. Check operation of brake valve.
• Braking is insufficient. a. Inspect ball valve within brake valve.
• Brakes will not release completely. b. Inspect pistons within brake valve for binding.
• Service brakes do not operate. c. Inspect drain passage for a restriction.
• Application of service brake is not smooth. d. Replace brake valve.
• Accumulator charging cycle repeats frequently when 3. Check brakes for damage.
brakes are not being used. a. Inspect brakes and repair brakes, as required.
• Accumulator starts to charge, but accumulator does Braking is insufficient.
not reach high limit.
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1. Check hydraulic oil level in common sump. Level may

• Accumulator charges frequently while brakes are be too low. Check for oil aeration. If necessary, purge
being held. brake lines of air.
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• Accumulator charging time is too long. Reference: Refer to Operation and Maintenance
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• Accumulator fails to start charging.

proper procedure for checking hydraulic oil level.
• Charging valve cycles very rapidly.
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Probable Causes Adjusting, Service Brakes - Purge, for more

When brakes are applied, brakes react slowly. information.
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1. Check hydraulic oil level in common sump. Level may 2. Check hydraulic lines and fittings for leaks.
be too low. Check for oil aeration. If necessary, purge a. Inspect components and repair components, as
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brake lines of air. required.

Reference: Refer to Operation and Maintenance 3. Check service brake pedal linkage for proper
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adjustment.
Reference: Refer to Specifications, Service Brakes,
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Reference: Refer to Systems Operation/Testing and for more information.

Adjusting, Service Brakes - Purge, for more
information. 4. Check brake line for dents which may restrict oil flow.
a. Replace any damaged brake lines.
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2. Check hydraulic lines and fittings for any leaks.

a. Repair hydraulic lines, if necessary. 5. Check dry nitrogen charge in accumulator.
3. Check brake lines for dents. A restriction may cause Reference: Refer to Systems Operation/Testing and
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a decrease in oil flow. Adjusting, Service Brake System Accumulator, for

more information.
a. Replace damaged brake line, if necessary.
a. If necessary, replace accumulator for service
4. Check dry nitrogen charge in accumulator. brake system.
Reference: Refer to Systems Operation/Testing and 6. Check operation of brake valve.
Adjusting, Service Brake System Accumulator, for
more information. a. Cap line from brake valve. Actuate brakes. If
pressure builds up in line capped, problem is in
a. If necessary, replace accumulator for service brakes or in parking brake valve.
brake system.
b. Inspect brake valve for a broken pressure
5. Check service brake pedal linkage for proper regulating spring.
adjustment.
c. Inspect brake valve for a cut boot which allows
Reference: Refer to Specifications, Service Brakes, dirt to accumulate under piston flange.
d. Replace brake valve.
6. Check brakes for damage.
7. Check operation of parking brake valve.
a. Inspect brakes and repair brakes, as required.
79033095 C Rev. 14-23

Troubleshooting
a. Replace tow override portion of parking brake c. Inspect brake valve for a broken pressure
valve. regulating spring.
b. Replace parking brake valve. d. Inspect brake valve for a cut boot which allows
dirt to accumulate under piston flange.
e. Replace brake valve.
b. Inspect brake pads and repair brake pads, as
required. a. Replace tow override portion of parking brake
valve.
Brakes will not release completely.
b. Replace parking brake valve.
adjustment. 8. Check brakes for damage.
Reference: Refer to Specifications, Service Brakes, a. Inspect brakes and repair brakes, as required.
Application of service brake is not smooth.
2. Check drain passage to brake valve for excessive
back pressure.
adjustment.
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a. Inspect drain passage for a restriction. Remove

Reference: Refer to Specifications, Service Brakes,
restriction.
3. Check operation of brake valve.
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2. Install a pressure gauge at brakes.

a. Inspect brake valve for stuck pistons. Repair
a. Check for fluctuations in pressure as brakes are
in
brake valve, as required.

applied.
b. Replace brake valve.
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a. Inspect brake valve for excessive shims in brake
a. Inspect brakes and repair brakes, as required. valve. Repair brake valve, as required.
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Service brakes do not operate. b. Replace brake valve.

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1. Check hydraulic oil level in common sump. Level may 4. Check brakes for damage.
be too low. Check for oil aeration.
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Accumulator charging cycle repeats frequently

when brakes are not being used.
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1. Check accumulator lines and accumulator fittings for

2. Make sure that knob for tow override is not pulled out.
leaks.
a. If necessary, repair lines and fittings for
adjustment.
on
accumulator or replace lines and fittings for

Reference: Refer to Specifications, Service Brakes, accumulator.
2. Check dry nitrogen charge in accumulator.
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4. Check for a broken brake line or a damaged brake

line.
a. Replace any broken brake lines or damaged more information.
brake lines.
a. If necessary, replace accumulator.
5. Check for adequate pressure from hydraulic pump for
3. Check line to accumulator for a restriction.
a. Replace line.
Adjusting, Hydraulic Pump Discharge Pressure - 4. Check operation of brake valve.
Test, for more information about checking pressures
for hydraulic pump. a. Inspect brake valve for leaking seals, a leaking
poppet, or a leaking pilot valve ball.
b. Make sure that ball valve is seating.
a. Cap line from brake valve. Actuate brakes. If
pressure builds up in line capped, problem is in c. Replace brake valve.
brakes. Accumulator starts to charge, but accumulator
b. Inspect brake valve for stuck pistons. Repair does not reach high limit.
brake valve, as required.
14-24 79033095 C Rev.

Troubleshooting
1. Check hydraulic oil level in common sump. Level may 1. Check hydraulic oil level in common sump. Level may
be too low. Check for oil aeration. be too low. Check for oil aeration.
Reference: Refer to Operation and Maintenance Reference: Refer to Operation and Maintenance
Manual, Hydraulic System Oil Level - Check, for Manual, Hydraulic System Oil Level - Check, for
proper procedure for checking hydraulic oil level. proper procedure for checking hydraulic oil level.
2. Check for adequate pressure from hydraulic pump for 2. Check for adequate pressure from hydraulic pump for
implement hydraulic system. implement hydraulic system.
Reference: Refer to Systems Operation/Testing and Reference: Refer to Systems Operation/Testing and
Adjusting, Hydraulic Pump Discharge Pressure - Adjusting, Hydraulic Pump Discharge Pressure -
Test, for more information about checking pressures Test, for more information about checking pressures
for hydraulic pump. for hydraulic pump.
3. Check operation of brake valve. 3. Check operation of brake valve.
a. Inspect pilot valve body for damaged O-rings. a. Inspect brake valve for a charging valve spring
broken or damaged.
b. Inspect charging valve spool for damaged
O-rings. b. Check for dirt in filter and charging orifice of
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brake valve.
c. Replace brake valve.
c. Check poppet for being stuck or partially closed.
Accumulator charges frequently while brakes are
being held. d. Replace brake valve.
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1. Check brake line and fittings for leaks. 4. Check operation of brake priority valve.
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a. Repair components, as required. a. Check for a sticky valve spool or a sticky check
valve.
2. Check setting of tow override portion of parking brake
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valve. b. Replace brake priority valve.

Reference: Refer to Systems Operation/Testing and Accumulator fails to start charging.
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Adjusting, Parking Brake Control Valve, for more

1. Check hydraulic oil level in common sump. Level may
information.
be too low. Check for oil aeration.
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Reference: Refer to Systems Operation/Testing and Manual, Hydraulic System Oil Level - Check, for
Adjusting, Service Brake System Accumulator, for proper procedure for checking hydraulic oil level.
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more information.
2. Check for adequate pressure from hydraulic pump for
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a. If necessary, replace accumulator. implement hydraulic system.

4. Check operation of brake valve. Reference: Refer to Systems Operation/Testing and
Adjusting, Hydraulic Pump Discharge Pressure -
a. Cap line from brake valve. Actuate brakes. If
on
Test, for more information about checking pressures

pressure builds up in line capped, problem is in for hydraulic pump.
brakes.
b. Inspect brake valve for stuck pistons. Repair
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brake valve, as required. a. Inspect brake valve for a broken pilot valve
spring.
c. Inspect brake valve for a broken pressure
regulating spring. b. Inspect brake valve for a broken charging valve
spring.
d. Inspect brake valve for a cut boot which allows
dirt to accumulate under piston flange. c. Inspect brake valve for a damaged O-ring on
charge spool.
e. Replace brake valve.
d. Inspect brake valve for a stuck charge spool.
e. Check for dirt in filter or for dirt in charging orifice
a. Replace tow override portion of parking brake
of brake valve.
valve.
f. Replace brake valve.
b. Replace parking brake valve.
4. Check operation of brake priority valve.
a. Check for a sticky valve spool or for a sticky
a. Inspect brakes and repair brakes, as required. check valve.
Accumulator charging time is too long. b. Replace brake priority valve.
79033095 C Rev. 14-25

Troubleshooting
Charging valve cycles very rapidly.
1. Check setting of tow override portion of parking brake
valve.
Adjusting, Parking Brake Control Valve, for more
information.
more information.
a. If necessary, replace accumulator.
a. Inspect brake valve for a worn pilot valve.
b. Replace brake valve.
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14-26 79033095 C Rev.

Troubleshooting
Implement System Change operating techniques to reduce load on
system.
Troubleshooting for Implement Hydraulic System 5. Make sure that hydraulic hose connections for
Problem List implement are correct.
• Temperature of hydraulic oil in common sump is too 6. Check hydraulic oil level in common sump. Level may
high. be too low.
• Pump makes unusual noises. a. Check hydraulic oil level in common sump to
determine if there is enough oil in hydraulic tank.
• There is a large amount of air in oil.
• Pump pressure is too low. Maintenance Manual, Hydraulic System Oil Level
• Pump pressure is too high. - Check.
• There is a pause before pressure is achieved in all b. Check for oil aeration by taking an oil sample. If
circuits. aeration is found, see There is a large amount of
air in oil.
• Signal pressure is not zero when all of valves are in
HOLD position. 7. Outside air temperature may be too hot.
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• Any implement moves when control lever is in HOLD a. Change operating techniques to reduce load on
position. system.
• Implement falls slightly when implement is moving

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from a partially raised position to a fully raised

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position.
• Cycle times are too slow for all implements.
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• Cycle time is too slow for an implement.

• Cycle time is too fast for an implement.
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• Implement control valve does not return to HOLD

position when hydraulic cylinders reach end of stroke.
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Probable Causes
Temperature of hydraulic oil in common sump is
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too high.
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1. Check actual temperature of oil.

a. Insert a thermometer into oil filler tube.
b. If temperature is below 107 ⋅C (224 ⋅F), there is
on
an electrical problem with temperature sensing

system.
Reference: Refer to Troubleshooting, TX 03 -
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SPN 1638.
2. Check oil coolers. Oil cooler is divided into two
sections.
a. Make sure that oil coolers are not packed with
debris.
3. Determine if either one of oil cooler bypass valves are
stuck open.
a. Determine cause. If necessary, repair oil cooler
bypass valve.
be too high.
NOTE: Make sure that engine is running at high idle.
This will ensure that oil cooler is working at full
capacity.
79033095 C Rev. 14-27

Troubleshooting
FIG. 16: Flow compensator spool and orifice.
8. Verify that pump proceeds to low pressure standby
1
when implements and hitch are not being operated.
a. Perform low pressure standby test.
Pressure -Tests.
b. If pump does not proceed to low pressure
standby, make sure that flow compensator spool
(1) moves freely inside compensator valve. Also,
make sure that orifice (2) is free of debris. 2
P051208003
c. If necessary, repair failure.
FIG. 16
FIG. 17: MT700C Load Sensing Test Port
9. Verify that pressure in load sensing circuit is 0 kPa (0
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psi). Check pressure at test port (1).

a. If pressure in load sensing circuit is not 0 kPa (0
psi), brake valve or brake accumulator may be
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commanding hydraulic pump to upstroke.

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P090308002
FIG. 17
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FIG. 18: MT800C Load Sensing Test Port (1)

10. Make sure load sensing drain valve (1) is not
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plugged.
a. If necessary, repair failure.
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P090808007
FIG. 18
FIG. 19: MT700C Load Sensing Drain Valve
11. Make sure that load sensing drain valve (1) is not
plugged.
1
P090308003
FIG. 19
14-28 79033095 C Rev.

Troubleshooting
FIG. 20: MT800C Load Sensing Drain Valve (1).
P090808006
FIG. 20

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Manual, Lubricant Viscosities.
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oil pressure.
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pump.
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Pressure -Tests.
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a. Perform Pump Efficiency Check.
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adjusted correctly.
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16. Make sure that charge relief valve is adjusted
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correctly.
a. Perform pressure test for charge oil of steering
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system and transmission system.

and Adjusting, Relief Valve (Charge) - Test and
Adjust.
17. Check for a restriction in an oil passage.
a. Determine cause. If necessary, repair machine.
18. Check steering pump for excessive wear.
19. There may be a problem with transmission hydraulic
system. See Troubleshooting Transmission, for more
information.
20. Make sure that check valve for elevated oil reservoir
is functioning correctly.
Adjusting, Elevated Oil reservoir - Test.
79033095 C Rev. 14-29

Troubleshooting
Implement pump makes unusual noises.
Refer to Operation and Maintenance Manual
Lubricant Viscosities.
2. Determine if hitch relief valve opens at low oil
pressure.
a. Make sure that hitch relief valve is backed out all
way.
3. Check for a loose connection of oil line on inlet side of
pump. Check for aeration of oil.
a. Tighten connection, if necessary.
5. Make sure that plastic plug in pump case drain port
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has been removed.

6. Verify that elevated oil reservoir has sufficient
pressure under various operating conditions.
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Adjusting, Elevated Oil Reservoir - Test.
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a. If elevated oil reservoir does not have pressure,

check valve may be stuck in open position.
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b. If necessary, replace check valve.

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7. Make sure that service brakes are operating correctly.

There is a large amount of air in oil.
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1. Check for a leak in oil line between common sump

and pump.
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a. Repair leak, if necessary.

2. Check for leakage around seals in hydraulic
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cylinders.
a. If necessary, repair seals.
System pressure is too low.
on

oil pressure.
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pump.
Pressure - Test.
2. Determine if flow compensator spool is adjusted
correctly.
a. Perform Margin Pressure Test on hydraulic
pump.
Pressure - Test.
3. Make sure that pressure compensator spool is
adjusted correctly.
a. Perform High Pressure Stall Test on hydraulic
pump.
14-30 79033095 C Rev.

Troubleshooting
Pressure - Test.
4. Inspect load sensing signal circuit for leaks.
a. If necessary, repair any leaks.
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79033095 C Rev. 14-31

Troubleshooting
FIG. 21: Flow spool spring.
5. Inspect flow spool spring (1) and verify that spring is 1
not broken.
6. Check for pump wear.
• Perform Pump Efficiency Check.
7. Ensure that swash plate is not blocked and ensure
that actuator spring is not broken.
• Repair pump, if necessary.
8. Make sure that priority spool in intermediate valve
bank is not stuck.
P051208003
Pump pressure is too high.
FIG. 21
1. Determine if flow compensator spool in compensator
valve is adjusted correctly.
a. Perform Margin Pressure Test.
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Pressure - Test.
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oil pressure.
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pump.
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Pressure - Test.
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adjusted correctly.
a. Perform High Pressure Stall Test on implement
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pump.
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Pressure - Test.
4. Make sure that load sensing lines are not blocked.
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FIG. 22: Flow compensator spool.

5. Make sure that flow compensator spool (1) moves
1
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freely.
a. Repair compensator valve, if necessary.
6. Make sure that orifice (2) is free of debris.
7. Make sure that pump is destroking. Ensure that
swash plate is not blocked and ensure that actuator
piston is not stuck.
a. Repair pump, if necessary.
2
P051208003
FIG. 22
14-32 79033095 C Rev.

Troubleshooting
There is a pause before pressure is achieved in all
circuits.
1. There may be air in load sensing signal circuit.
a. Purge air from hydraulic system by cycling
system several times.
2. Make sure that flow compensator spool in
compensator valve is adjusted correctly.
Pressure - Test.
plugged.
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P090308003
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FIG. 23
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P090808006
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FIG. 24

oil pressure.
pump.
Pressure - Test.
5. Replace load sensing drain valve.
6. Check for a sticking priority spool in intermediate
valve bank.
79033095 C Rev. 14-33

Troubleshooting
FIG. 25: Flow compensator spool.
7. Make sure that flow compensator spool (1) moves
1
freely.
a. Repair compensator valve, if necessary.
8. Make sure that orifice (2) is free of debris.
2
P051208003
FIG. 25
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14-34 79033095 C Rev.

Troubleshooting
Signal pressure is not zero when all of valves are in
HOLD position.
1. Make sure that all controls are in HOLD position.
Manual, Hydraulic Control Valve Operation.
2. Make sure load sensing drain valve is not plugged.
1
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P090308003
FIG. 26
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P090308006
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FIG. 27
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plugged.
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4. Make sure that accumulator charging valve for

service brakes is functioning correctly.
Adjusting, Service Brake System - Test.
5. Make sure that load sensing signal circuit is
connected to sump.
a. Verify that all of lines are connected properly.
6. Make sure that three-point hitch is calibrated.
Adjusting for calibration procedures for three-point
hitch.
7. Check pressure in work port. If there is pressure,
solenoid valve is not fully closing.
a. Check current to solenoid.
79033095 C Rev. 14-35

Troubleshooting
b. Repair solenoid or replace solenoid.
Any implement moves when control lever is in

HOLD position.
1. Make sure that none of hydraulic control levers are in
a DETENT position.
2. Check for a leak in a connection between hydraulic
control valve and cylinders.
a. Repair connection, if necessary.
3. Check hydraulic control valve and check valves for
excessive wear.
a. Repair valve, if necessary.
4. Check piston seal in hydraulic cylinder for excessive
wear.
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a. Repair piston seal, if necessary.

5. Check work port pressure. If there is pressure,
solenoid valve may be sticking.
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a. If necessary, repair solenoid or replace solenoid

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valve.
6. Check electrical current to solenoid valves.
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Implement falls slightly when implement is moving

from a partially raised position to a fully raised
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position.
1. There may be air in load sensing signal circuit.
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a. Purge air from implement hydraulic system by

cycling system several times.
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Pressure - Test.
3. Make sure that solenoid valves are calibrated
correctly.
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FIG. 28: Flow spool spring.

4. Inspect flow spool spring (1) and verify that spring is 1
not broken.
oil pressure.
pump.
Pressure -Tests.
P051208003
FIG. 28
14-36 79033095 C Rev.

Troubleshooting
FIG. 29: Spring (1) for flow compensator spool and
Spring (2) for pressure compensator spool. 1
a. Perform High Pressure Stall Test.
Pressure - Test.
b. Replace spring (2) if pressure compensator
spool cannot be adjusted correctly.
2
7. Make sure that signal passages in main stem of P051208003
control valve are not blocked.
FIG. 29
a. Repair control valve, if necessary.
8. Check control valve for foreign material.
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a. Clean control valve, if necessary.

9. Check load sensing lines for blockage.
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79033095 C Rev. 14-37

Troubleshooting
Cycle times are too slow for all implements.
1. Make sure that Flow Rates for hydraulic control
valves are adjusted correctly.
information about adjusting flow rates.
2. Check current applied to solenoid valve.
3. Make sure that solenoid valve is functioning correctly.
a. If necessary, repair solenoid or replace solenoid
valve.
4. Make sure that flow compensator spool is adjusted
correctly.
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Pressure -Test.
b. Repair system, if necessary.
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5. Make sure that load sensing relief valve is adjusted

correctly.
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a. Perform High Pressure Stall Test.

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Pressure - Test.
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6. Check for blockage in load sensing signal circuit.

Check for leakage in circuit.
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a. Repair circuit, if necessary.

7. Make sure that pump fully strokes. Ensure that
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actuator piston moves freely and ensure that swash

plate is not blocked.
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14-38 79033095 C Rev.

Troubleshooting
plugged.
1
P090308003
FIG. 30
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P090308006
FIG. 31
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9. Check for proper operation of service brakes.

10. Check for a sticking spool in intermediate valve bank.
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Cycle time is too slow for an implement.

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1. Make sure that Flow Rate for hydraulic control valve

is adjusted correctly.
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information about adjusting Flow Rates.
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a. Check current applied to solenoid.
b. If necessary, repair solenoid or replace solenoid
valve.
4. Make sure that signal flowing to compensator valve is
not blocked.
Pressure - Test.
b. If necessary, adjust flow compensator spool to
set correct margin pressure. If correct margin
pressure cannot be achieved, there may be
blockage in load sensing signal circuit.
79033095 C Rev. 14-39

Troubleshooting
and Adjusting, Compensator Valve - Adjust.
c. Repair circuit, if necessary.
5. Check for leakage around piston seals of hydraulic
cylinders.
a. Repair piston seals, if necessary.
6. Check for a broken spring in hydraulic control valve.
a. Replace spring, if necessary.
7. Make sure that pump fully strokes. Ensure that
actuator piston moves freely and ensure that swash
plate is not blocked.
Cycle time is too fast for an implement.
1. Make sure that Flow Rate for hydraulic control valve
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is adjusted correctly.
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information about adjusting flow rates.

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a. Check current applied to solenoid.

b. If necessary, repair solenoid or replace solenoid
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valve.
Hydraulic control valve does not return to HOLD
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position when hydraulic cylinders reach end of

stroke.
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1. Make sure that Detent Time for valve is not set for
continuous operation.
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information about Detent Times.
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14-40 79033095 C Rev.

Troubleshooting
Three-Point Hitch System
Troubleshooting for Three-Point Hitch Hydraulic
System
Problem List
• Hitch relief valve is too noisy.
• Hitch drifts too much or implement drifts too much.
• Hitch moves slowly or hitch does not move.
• Hitch moves when control lever has not been moved.
• Hitch moves too fast.
Probable Causes
Hitch relief valve is too noisy.
FIG. 32: Manual lowering valve (1).
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1. Make sure that manual lowering valve (1) is backed

out all way.
2. Verify that hitch relief valve is adjusted correctly.
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a. If necessary, replace hitch relief valve.

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Reference: Refer to Systems Operation/Testing 1
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Pressure - Tests. P090308003
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b. Repair compensator valve, if necessary. FIG. 32

oil pressure.
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pump.
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Pressure -Tests.
5. Make sure that springs in hitch relief valve have not
failed.
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a. Replace springs, if necessary.

6. Make sure that three point hitch is not overloaded.
79033095 C Rev. 14-41

Troubleshooting
Hitch drifts too much or implement drifts too much. 2. Check for a leak in connection between hitch valve
and hydraulic cylinders.
1. Check current applied to solenoids.
a. Repair leak, if necessary.
2. Check for leakage around piston seals in hydraulic
cylinders. 3. Check piston seals in hydraulic cylinders for
excessive wear.
3. Check setting of hitch relief valve.
4. Check solenoid valve for excessive wear.
a. Adjust relief valve, if necessary.
a. Repair solenoid valve, if necessary.
4. Make sure that spool in control valve is centered
correctly. 5. Check spool in hitch valve for excessive wear.
a. Inspect control valve for a broken spring. a. Repair spool, if necessary.
b. Make sure that control spool moves freely. 6. Check for foreign material in solenoid valve. Check
for foreign material in hitch valve.
c. Repair control valve, if necessary.
a. Repair valves, if necessary.
5. Check for excessive wear on control spools and
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check valves of three-point hitch control valve. 7. Check hitch relief valve for excessive wear.
a. Replace any worn components, if necessary. a. If necessary, replace hitch relief valve.
6. Make sure that solenoids for three-point hitch control 8. Inspect check valve and orifice.
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valve are calibrated correctly.

a. If necessary, repair check valve or replace check
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Hitch moves slowly or hitch does not move. valve.

1. Check for a fault code on display of Virtual Terminal. Hitch moves too fast.
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a. If there is a fault code, refer to Troubleshooting 1. Check electrical components of hitch control system
manual for more information. for correct adjustment and operation.
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2. Verify that there is enough weight on hitch. Reference: Refer to Systems Operation/Testing and
Adjusting Implement and Three-Point Hitch, manual
a. Add weight to hitch to increase rate of lowering.
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3. Determine if problem is electrical or hydraulic.
a. Actuate hitch. Use a compass to determine if
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solenoids are magnetized.

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b. If solenoids are not magnetized during operation,

there is an electrical problem.
Reference: Refer to Troubleshooting manual for
more information.
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c. If solenoids are magnetized, proceed to next

step.
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4. Make sure that implement hydraulic system is

a. If necessary, perform High Pressure Stall Test.
Pressure - Test.
5. Verify that hitch relief valve is adjusted correctly.
a. If necessary, replace hitch relief valve.
Hitch moves when control lever has not been
moved.
1. Check for a fault code on display for Virtual Terminal
(VT).
a. If there is a fault code, refer to Troubleshooting
manual.
14-42 79033095 C Rev.

Troubleshooting
FIG. 33: Hitch Relief Valve (1).
• To lower hitch, loosen set nut and use allen wrench to
back out plug to release pressure and lower hitch.
P090308007
FIG. 33
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79033095 C Rev. 14-43

Troubleshooting
DIAGNOSTIC SYSTEM PROCEDURES
Electrical Connectors - Inspect

Use procedure under following situation:
Use following steps to help determine if connector is
cause of problem. If a problem is found in electrical
connector, repair connector and verify that problem has
been corrected.
Following background information is related to
procedure:
Many of operational procedures and diagnostic code
procedures in troubleshooting guide will instruct you to
check a specific electrical connector. Engines use a
variety of Deutsch and AMP connectors.
Intermittent electrical problems are often caused by poor
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connections. Always check for an active diagnostic code

before breaking any connections. Also, always check for
an active diagnostic code after connector is reconnected
to verify that problem disappears.
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Simply disconnecting connectors and then reconnecting

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connectors can temporarily solve a problem at times. If

occurs, likely causes are loose terminals, bent terminals,
improperly crimped terminals, corrosion, or harness
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routing improper.
Original source of problem must then be identified to
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ensure that problem does not reoccur.

Follow procedure to thoroughly inspect connectors to
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determine if connectors are cause of problem.

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14-44 79033095 C Rev.

Troubleshooting
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g00693506
FIG. 34
FIG. 34: ECM connectors (AMP)
79033095 C Rev. 14-45

Troubleshooting
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FIG. 35
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FIG. 35: Connector receptacles (Deutsch) and

connector plugs (Deutsch).
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(1) Wedge (receptacle)

(2) Wedge (plug)
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(3) Terminal pin

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(4) Stamped and formed socket terminal

(5) Machined socket terminal
(6) Sealing plug
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14-46 79033095 C Rev.

Troubleshooting
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FIG. 36
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FIG. 36: Routing of Harness and insertion of plug. 2. CHECK ALLEN HEAD SCREW ON ECM
CONNECTOR.
(1) Correctly routed harness
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a. Be sure that connector bolt is properly tightened.

(2) Correctly inserted plug Be careful not to overtighten bolt and break bolt.
(3) Incorrectly routed harness b. Do not exceed 6.0 Nm (55 lbf in) of torque on
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(4) Incorrectly inserted plug connector bolt of ECM when 70-pin connector is
being installed on ECM.
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1. CHECK LOCKING OF DT CONNECTOR

(DEUTSCH) AND CHECK LOCK RING OF HD Expected Result:
STYLE CONNECTOR (DEUTSCH).
ECM connector is secure and connector bolt of ECM
is properly torqued.
on
a. Be sure that connector is properly locked. Also

be sure that two halves of connector can not be Results:
pulled apart.
• YES — ECM connector is secure and connector
ly
b. Verify that latch tab of connector is properly bolt of ECM is properly torqued.
latched. Also verify that latch tab of connector
returns to Fully Latched position. Proceed to step 3.
Expected Result: • Not YES — ECM connector is not secure and
connector bolt of ECM is not properly torqued.
Connector will securely lock. Connector and locking
mechanism is without cracks or breaks. Repair: Secure ECM connector. Be sure that
connector bolt is properly torqued.
Results:
Proceed to step 3.
• YES — Connector locks securely.
3. PERFORM A PULL TEST ON EACH WIRE
Proceed to step 2.
TERMINAL CONNECTION.
• Not YES — Connector does not lock securely. a. Each terminal and each connector should
Repair: Repair connector or replace connector, withstand 45 N (10 lbf) of pull. Each wire should
as required. remain in connector body. This test checks
whether wire was properly crimped in terminal
Proceed to step 2. and whether terminal was properly inserted into
connector.
79033095 C Rev. 14-47

Troubleshooting
b. DT connectors use an orange wedge to lock • Not YES — Problem is with harnesses and
terminals in place. connectors.
c. Check to be sure that orange wedge is not Repair: Repair harness and/or connectors or
missing and that orange wedge is installed replace harness and/or connectors that are
properly on DT connectors. causing problem.
NOTE: Terminals should ALWAYS be crimped onto Proceed to step 5.
wires by using a crimp tool. Do not solder
5. CHECK WIRES FOR NICKS IN INSULATION OR
terminals. Use 1U-5804 Crimp Tool.
ABRASION.
.
a. Carefully inspect each wire for signs of abrasion,
Expected Result:
nicks, or cuts.
Each terminal and each connector withstands 45 N
Following areas are locations that should be
(10 lbf) of pull. Each wire remains in connector body.
checked:
Results:
• Exposed insulation
• YES — Each terminal and each connector
• Points of rubbing wire against engine
withstands 45 N (10 lbf) of pull. Each wire
Fo
remains in connector body. • Points of rubbing wire against a sharp point

Proceed to step 4. b. Check all of hold down clamps for harness to
verify that harness is properly clamped. Also
• Not YES — Each terminal and each connector
r
check all of hold down clamps for harness to

does not withstand 45 N (10 lbf) of pull.
verify that harness is not compressed by clamp.
in
Repair: Repair wiring or replace connector or Pull back harness sleeves to check for a flattened
terminal. portion of wire. Flattened portion of wire is
caused by clamp that holds harness.
te
Proceed to step 4.
Expected Result:
4. MONITOR ELECTRONIC SERVICE TOOL WHILE
rn
WIRING AND CONNECTORS ARE BEING Wires are free of abrasion, nicks, or cuts and harness
PULLED. is properly clamped.
al
a. If there is an active diagnostic code that pertains Results:

to circuit, perform following test:
• YES — Wires are free of abrasion, nicks, or cuts
Monitor Active Diagnostic Code screen of and harness is properly clamped.
u
electronic service tool while all harnesses and

Proceed to step 6.
connectors that connect to component with
se
active diagnostic code are pulled. If harness is • Not YES — Wires are not free of abrasion, nicks,
being pulled and active diagnostic code or cuts and harness is properly clamped.
disappears there is a problem in wiring or
connector. Repair: Repair wires or replace wires, as
on
required.
b. If there are no active diagnostic codes that
pertain to circuit, perform following test: Proceed to step 6.
ly
Monitor Status Screen of electronic service tool

for component while harnesses are being pulled.
If harness is being pulled and reading changes
erratically, there is a problem in wiring or
connector.
Expected Result:
Problem appears to be external to harnesses and
connectors. Pulling on harness and connectors has
no effect on component status of active diagnostic
code or engine performance.
Results:
• YES — Problem appears to be external to
harnesses and connectors. Pulling on harness
and connectors has no effect on component
status of active diagnostic code or engine
performance.
Proceed to step 5.
14-48 79033095 C Rev.

Troubleshooting
Fo
g00705443_1
FIG. 37
r
FIG. 37: Connector seals (1). Moisture can also travel from one connector
through inside of a wire to ECM Connector. If
in
6. CHECK CONNECTORS FOR MOISTURE OR moisture is found in ECM connector, thoroughly

CORROSION. check all connectors and wires on harness that
te
a. Be sure that connector seals and white sealing connect to ECM. ECM is not source of moisture.
plugs are in place. If any of seals or plugs are Do not replace an ECM if moisture is found in
missing, replace seal or plug. If necessary, either ECM connector.
rn
replace connector. NOTE: If corrosion is evident on pins, sockets or

b. Check all of wiring harnesses to verify that connector, use only denatured alcohol to remove
al
harness does not make a sharp bend out of a corrosion. Use a cotton swab or a soft brush to
connector. This will deform connector seal and remove corrosion. Do not use any cleaners that
will create a path for entrance of moisture. contain 1,1,1 trichloro-ethylene because 1,1,1
trichloro-ethylene may damage connector.
u
Thoroughly inspect ECM connectors J1/P1 and

J2/P2 for evidence of moisture entry. Expected Result:
se
NOTE: It is normal to see some minor seal abrasion on All of connectors should be completely coupled and
ECM connector seals. Minor seal abrasion will all of seals should be completely inserted. Harness
not allow entry of moisture. and wiring should be free of corrosion, abrasion or
on
pinch points.
c. If moisture or corrosion is evident in connector,
source of moisture entry must be found and Results:
source of moisture entry must be repaired. If • YES — All of connectors should be completely
ly
source of moisture entry is not repaired, problem coupled and all of seals should be completely
will reoccur. Simply drying connector will not fix inserted. Harness and wiring should be free of
problem. Likely paths for entrance of moisture corrosion, abrasion or pinch points.
are illustrated in following list:
Proceed to step 7.
• Missing seals
• Not YES — All of connectors are not coupled
• Improperly installed seals and all of seals are not completely inserted.
• Nicks in exposed insulation Harness and wiring is not free of corrosion,
abrasion or pinch points.
• Improperly mated connectors
Repair: Repair connectors or wiring and/or
replace connectors or wiring. Ensure that all of
seals are properly in place and ensure that
connectors are completely coupled.
79033095 C Rev. 14-49

Troubleshooting
Verify that repair eliminates problem by running
engine for several minutes and by checking
again for moisture. If moisture reappears,
moisture is wicking into connector. Even if
moisture entry path is repaired, it may be
necessary to replace wires that have moisture.
These wires may have moisture trapped inside
insulation. Verify that repair eliminates problem.
Proceed to step 7.
7. INSPECT CONNECTOR TERMINALS.
a. Verify that terminals are not damaged. Verify that
terminals are properly aligned in connector and
verify that terminals are properly located in
connector.
Expected Result:
Terminals are properly aligned and terminals appear
Fo
undamaged.
Results:
r
• YES — Terminals are properly aligned and

terminals appear undamaged.
in
Proceed to step 8.
• Not YES — Terminals are not properly aligned or
te
terminals appear damaged.

Repair: Repair terminals and wiring and/or
rn
replace terminals and wiring.

Proceed to step 8.
al
u se
on
ly
14-50 79033095 C Rev.

Troubleshooting
Fo
g00640220_1
FIG. 38
r
FIG. 38: Pin retention of connector.

in
(1) Contact of pin

(2) Contact of socket
te
8. CHECK INDIVIDUAL PIN RETENTION INTO

SOCKET.
rn
NOTE: This is especially important for intermittent

problems.
al
a. Use a new pin. Insert pin into each socket one at

a time to check for a good grip on pin by socket.
u
b. Use a new socket. Insert socket over each pin

one at a time to check for a good grip on pin by
se
socket. Pins are located on mating side of

connector.
c. Contact terminal should stay connected when
on
connector is held in position shown in Fig. 38.

Contact terminal is pin or socket.
Expected Result:
ly
Pins and sockets appear to be OK.

Results:
• YES — Pins and sockets appear to be OK.
STOP.
• Not YES — Pins and sockets are not OK.
Repair: Replace terminal.
STOP.
79033095 C Rev. 14-51

Troubleshooting
Charging System Specifications For Alternators
Specifications For Alternators Peak Minimum

Current Peak
Peak Minimum Rating Current
Current Peak (Amperes) (Amperes)
Rating Current
(Amperes) (Amperes) 6T-1395, 7T-2095, 33 30
OR-3653
12 Volt Alternators
6N-9294, OR-5217, 35 32
8C-5535 32 28 OR-3482
7N-4784, OR-5201 40 36 5N-5692, OR-2698 45 41
6T-1396, 7T-2096, 51 46 5S-9088, 100-5047, 50 45
8C-5908, OR-3654 112-5041, 3E-7578,
OR-5206, OR-3667,
9W-2648, 9W-2949, 55 49 OR-3668
8T-9700, 105-2811*
109-2362, 9W-3043, 55 50
34-3268, 68-4139,
Fo
112-8032, OR-36522
7T-2876, 100-8223,
144-9954 4N-3986, OR-5203 60 54
OR-4327 1 3E-77721
r
105-2812 1 OR-94371
in
OR-9273 1 105-31321
3E-7295† 155-7434, 132-21563, 70 63
te
107-79773, OR-82793
7G-7889 60 54
169-4319, 167-7812 75 67.5
rn
8C-5510‡, OR-5200 61 55
107-7976, 114-2401, 75 68
8N-2268 75 68
OR-8997, 3E-7577,
al
3E-7892, OR-3616 85 77 OR-3615
149-2064 90 81 165-5140 100 90

u
105-28131 9X-7803, OR-3749 100 90

se
OR-92741 Noncurrent 12 Volt Alternators

105-28141 6T-1193 18 16
OR-4328 **
7N-6118, 6N-5460, 40 36
on
OR-94104 4N-4540
9X-03412 6T-1195 42 38
ly
8C-6163, OR-1699, 105 95 7X-1340 45 41

107-2519
9G-6079, 6T-1194 63 57
167-7816 110 99
Noncurrent 24 Volt Alternators
9X-6796, 9X-9096, 115 104
121-4134, 121-4136, 9G-6081, 6T-1196 40 36
OR-3527
* An Ignition Terminal IG is used. System voltage must be supplied
3E-8827, 121-4135, 130 117 to terminal to turn on alternator. Some of these alternators use IG
117-13793 terminal as a sense terminal.
† A Diode trio D+ is used. Alternator requires an external excitation.
152-8746 135 122 ‡ An Ignition Terminal I is used. Alternator can be externally excited
through terminal.
125-9597, OR-8332 145 131 **A Regulator Terminal REG is used. Alternator requires an
external excitation.
24 Volt Alternators
2P-1204, 3Y-8200 19 17
2Y-8310 21 19
14-52 79033095 C Rev.

Troubleshooting
Often when problems with charging system are being 3. CONTINUE TO CHECK RESISTANCE IN
investigated, alternator is not problem. If a low battery EXCITATION CIRCUIT.
condition is present test batteries first. See Special
NOTE: This step is only for alternators with external
Instruction, SEHS7633, Battery Test Procedure for more
excitation when terminal for excitation is labelled:
information. If engine cranks slowly, then test starting
IG.
system. See Service Magazine, SEPD0020, Testing
Starter On Engine for more information. If a warning a. Turn key start switch to ON position.
indicator for charging system is ON, see Service
Magazine, SEBD1751, Difference Between Alternator b. Verify voltage at excitation terminal. Connect red
Indicator In Electronic Monitoring System (EMS) And Low lead from a multimeter to excitation terminal.
Voltage Indicator In Operating Monitoring System (OMS). Connect black test lead to a ground source
(alternator case ground).
NOTE: Severely discharged batteries can cause low
system voltage. This can occur even while NOTE: For G3B, K3A, and L3A alternators, Insert a
engine is running above idle, and alternator is 7X-1710 Multimeter Probe Group into rear of
working properly. Proper low engine idle is also middle wire in connector. See figure below. Insert
important. probes spoon lead between seal and wire that
surrounds wire and outer shell of connector. Do
1. DETERMINE METHOD OF EXCITATION FOR not insert probe between wire insulation and
ALTERNATOR. black seal. This terminal IG is terminal for
Fo
excitation.
a. Check rear of your alternator to determine
method of excitation. See above table to verify c. Read voltage shown on multimeter.
proper alternator excitation.
r
Expected Result:
in
Test method 1. These alternators have a I, REG, or

D+ terminal. Test method 2. These alternators are
te
self-excited. Test method 3. These alternators have a

IG terminal.
rn
Results:
• Method 1 — Alternator has a I, REG, or D+
al
terminal. Proceed to step 2.

• Method 2 — Alternator is self-excited. Proceed to
step 4.
u
• Method 3 — Alternator has an IG terminal.

se
Proceed to step 3.
2. CHECK RESISTANCE IN EXCITATION CIRCUIT.
a. Turn key start switch to ON position.
on
b. Verify voltage at excitation terminal. Connect red

lead from a multimeter to excitation terminal.
Connect black lead to a ground source
ly
(alternator case ground).

c. Read voltage shown on multimeter.
Expected Result:
Voltage reads at least 0.2 volts.
Results:
• YES — Voltage reads 0.2 volts or more.
Excitation circuit is correct. Proceed to step 4.
• NO — Voltage is less than 0.2 volts. There is a
problem in wiring harness to alternator or there is
a poor electrical connection. Correct problem
and operate generator set. Watch for a
recurrence of problem.
STOP.
79033095 C Rev. 14-53

Troubleshooting
FIG. 39: Technique used to puncture wire for
alternator is shown.
Expected Result:
Voltage measurement is within 0.5 volts of battery
voltage.
Results:
• YES — Voltage reads battery voltage. Excitation
circuit is correct. Proceed to step 4
• NO — Voltage measured is within 0.5 volt of
battery voltage. There is a problem in wiring
harness to alternator or there is a poor electrical
connection. Correct problem and operate
generator set. Watch for a recurrence of problem.
STOP.
4. CHECK SYSTEM VOLTAGE.
Fo
a. Before you start generator set, connect a g00496660

voltmeter between B+ terminal and case of FIG. 39
alternator. Turn OFF all electrical loads.
r
b. Turn key to ON position but do not start engine.

in
Read voltage on voltmeter. Make a note of

voltage that was measured.
te
Expected Result:
This voltage should be approximately system voltage.
rn
Results:
• YES — Voltage is approximately system voltage.
al
Proceed to step 5.
• NO —Voltage is less than system voltage.
u
Proceed to step 7.
se
5. CHECK OPERATION OF ALTERNATOR.

a. Voltmeter remains connected between B+
terminal and case of alternator.
on
b. Start generator set. Set throttle to at least 75

percent. Read voltage on voltmeter. Make a note
of voltage that was measured.
ly
Expected Result:
Voltage measurement is greater than voltage that
was recorded in previous test step, Check System
Voltage.
Results:
• VOLTAGE HIGHER — Voltage measurement is
greater than voltage that was observed in
previous test step, Check System Voltage.
Voltage is also less than maximum voltage listed
in specifications for alternator. Alternator is
partially charging battery.Proceed to step 6.
14-54 79033095 C Rev.

Troubleshooting
• VOLTAGE TOO HIGH — Voltage measurement Expected Result:
is greater than voltage that was observed in
Drive system of alternator is functioning correctly. No
previous test step, Check System Voltage.
corrections to drive system were necessary.
Voltage is also greater than maximum voltage
listed in specifications for alternator. Alternator is Results:
over charging.Proceed to step 19.
• YES — Drive system of alternator is functioning
• VOLTAGE LOWER — Voltage is not higher than correctly. No corrections were necessary.
voltage that was observed in previous test
step.Proceed to step 7. Proceed tostep 8.
6. TEST ALTERNATOR OUTPUT. • NO — Drive system of alternator was not

functioning correctly. Corrections were
NOTE: For proper output current, refer to above table. necessary.
a. Be sure that batteries are NOT fully charged. Repair: Be sure that problems have been
corrected. Exit procedure and retest alternator
NOTE: A fully charged battery may have open circuit
charging system.
voltage above 12.5 volts on 12 volt systems. 24
volt systems may be as high as 25 volts. STOP.
Fo
b. If batteries are fully charged, then crank engine 8. TEST CHARGING CIRCUIT.
for 30 seconds. This action reduces battery
voltage. Operate lights for 10 minutes while a. Verify that nut on B+ alternator terminal is tight.
engine is off as an alternative. Also, verify that wire has a good connection to B+
r
terminal.
c. Connect 9U-5795 Current Probe or 8T-0900
b. Start engine and set throttle to at least 75
in
Ammeter to a DMM (digital multimeter).

Multimeter must have a peak hold feature. Clamp percent. Turn ON all electrical accessories for
probe around alternator output wire B+. Before remainder of test step. Allow engine to run for at
te
you clamp probe around wire, be sure that probe least 3 minutes before continuing.
is zeroed. c. Measure voltage between B+ alternator terminal
rn
d. Set digital multimeter to peak hold or max mode and alternator case ground. Make a note of
on mV scale. measured voltage. Perform next measurement
immediately.
al
e. Turn on all electrical accessories: lights, air

conditioning, and radio. d. Measure voltage across battery. Put red lead on
battery positive terminal, and put black lead on
f. Start generator set, and immediately set throttle battery negative terminal. Make a note of voltage
u
to at least 75%. Peak current will appear on that was measured.

se
voltmeter in peak hold or max mode.

Expected Result:
Expected Result:
Voltage at battery should be less than voltage at
Current reading should be at least 90% of specified alternator. Difference in voltages should not be more
on
peak output. than 1 volt on 12 volt systems. Difference should not

be more than 2 volts on 24 volt systems.
Results:
Results:
• YES — Current is at least 90% of specified peak
ly
output. • YES — Voltage at battery is less than voltage at

alternator. Also, difference in voltages is less than
Proceed to step 13.
1 volt for 12 volt systems and difference is less
• NO — Current is less than 90% of specified peak than 2 volts for 24 volt systems. Wiring related to
output. alternator is correct
Proceed to step 7. Repair: There is an internal problem with
alternator. Repair alternator or replace alternator.
7. CHECK DRIVE SYSTEM OF ALTERNATOR.
STOP.
a. Check condition of alternator drive belt. Clean
pulley and replace drive belt if drive belt is oily. • NO — Voltage at battery is less than voltage at
Dry drive belt if belt is wet. Replace drive belt, if alternator. However, difference in voltages is
belt is worn. greater than 1 volt for 12 volt systems and
difference is greater than 2 volts for 24 volt
b. Check tension of alternator drive belt. Adjust systems.
drive belt to correct tension.
Proceed to step 9.
c. Check nut on alternator pulley. Tighten nut if nut
is loose. 9. TEST POSITIVE SIDE OF CHARGING CIRCUIT.
79033095 C Rev. 14-55

Troubleshooting
a. Measure voltage between frame ground and B+ a. Start engine and set throttle to at least 75%.
alternator terminal. Make a note of voltage that
b. Connect a voltmeter between B+ terminal and
was measured. Perform next measurement
alternator case ground.
immediately.
c. Disconnect wire from R terminal. Select YES if R
b. Measure voltage between frame ground and +
terminal is not used on generator set.
battery post. Make a note of voltage that was
measured. Expected Result:
Expected Result: Voltage does not change.
Voltage difference does not exceed 1 volt on 24 volt Results:
systems or 0.5 volts on 12 volt systems.
• YES — Voltage does not change.
Results:
Proceed to step 12.
• YES — Voltage difference does not exceed
tolerance. Positive circuit is good. • NO — Voltage rises and alternator begins
charging.
Proceed to step 10.
Repair: Wire to R terminal is shorted. Repair
• NO — Voltage difference exceeds tolerance. wiring or replace wiring. Exit procedure and
Fo
retest alternator charging system.

Repair: There is high resistance in positive side
of charging circuit caused by one of following STOP.
conditions:
r
12. RESTORE RESIDUAL MAGNETISM OF ROTOR.

• An electrical connection has loosened.
a. Connect one end of a jumper wire to B+ terminal
in
• An electrical connection has corroded. of alternator.

• Main relay has failed. NOTE: Use terminal D+ on following alternators: K1, N1,
te
and N3.
• A circuit breaker has failed.
b. Connect other end of jumper wire to R terminal of
rn
Repair problem or replace any component that

alternator for two seconds.
has failed. Exit procedure and retest alternator
charging system. Expected Result:
al
STOP. Voltage output rises on B+ terminal. Residual

magnetism of rotor has been restored.
10. TEST NEGATIVE SIDE OF CHARGING CIRCUIT.
u
Results:
a. Check voltage between negative battery post
se
and alternator case ground. • YES — Voltage output rises. Residual

magnetism of rotor has been restored. Alternator
Expected Result:
is now charging.
Voltage does not exceed 1 volt on 24 volt systems or
Repair: Exit procedure and retest alternator
on
0.5 volts on 12 volt systems.

charging system.
Results:
STOP.
• YES — Voltage difference does not exceed
ly
• NO — Voltage output does not rise.

tolerance. Negative circuit is good.
Repair: There is an internal problem with
Proceed to step 11.
• NO — Voltage difference exceeds tolerance.
STOP.
Repair: There is high resistance in negative side
13. TEST FOR UNDESIRABLE CURRENT FLOW IN
of charging circuit caused by one of following
ALTERNATOR CHARGING SYSTEM.
conditions:
a. Turn off all of accessories. Turn key switch to
OFF position.
• Alternator ground has loosened.
b. Clamp a 9U-5795 Current Probe or 8T-0900
• Engine ground has opened. Ammeter around main ground cable. Clamp tool
with positive side away from battery. Reset probe
Repair problem or replace any component that (zero) before you clamp probe around wire. Read
has failed. Exit procedure and retest alternator current on meter. Make a note of current that was
charging system.
measured.
STOP. Expected Result:
11. TEST CIRCUIT OF R TERMINAL.
14-56 79033095 C Rev.

Troubleshooting
Current is below 2 amperes. YES selection is b. Connect an ammeter between disconnected
dependent on presence of a main disconnect switch battery ground cable and one of negative battery
on generator set being tested. terminals. Connect red positive lead of ammeter
to cable. Negative lead should be connected to
Results: battery terminal. If a multimeter is being utilized
• YES- WITH DISCONNECT SWITCH — Current for test, use 10 ampere connections to avoid
is below 2 amperes.For generator sets with a damage.
main disconnect switch, proceed to step 14. NOTE: Standard acceptable current draw is 50
• YES - WITHOUT DISCONNECT SWITCH — milliamperes. A current draw above 50
Current is below 2 amperes.For generator sets milliamperes usually indicates a problem.
without a main disconnect switch, proceed to Contact a dealer for more information.
step 15. Expected Result:
• NO — Current is above 2 amperes. There is a Current is below.050 amperes (50 milliamperes).
current draw in system.Proceed to step 16.
Results:
14. MEASURE CURRENT OF SYSTEM BY USING
MAIN DISCONNECT SWITCH. • YES — Current is below 0.050 amperes.
Charging system is currently good. Problem is a
Fo
a. Turn disconnect switch to ON position. possible intermittent current draw in system.

b. Connect an ammeter across disconnect switch Batteries may have failed. Check that NO
terminals. Connect red lead to terminal on frame accessories were ON during test.
r
side. Connect black lead to terminal on battery STOP.

side. If a multimeter is being utilized for test, use
in
10A connections to avoid damage. • NO — Current is above 0.050 amperes. There is

excessive current flow in system.
c. Turn disconnect switch to OFF position and read
te
current. Make a note of measured current. Proceed to step 16.

NOTE: Standard acceptable current draw is 50 16. TEST CURRENT OF ALTERNATOR OUTPUT
rn
milliamperes. A current draw above 50 BELOW 2 AMPERES.

milliamperes usually indicates a problem.
a. Turn key switch to OFF position.
Contact a dealer for more information.
al
b. Connect 9U-5795 Current Probe or 8T-0900

Expected Result:
Ammeter to a DMM (digital multimeter). Clamp
Current is below 0.050 amperes (50 milliamperes). probe around B+ wire of alternator. Before you
u
clamp probe around wire, ensure that probe is

Results: zeroed.
se
• YES — Current is below 0.050 amperes. c. Read current on meter. Make a note of current
Charging system is functioning properly Failure is that was measured.
possibly an intermittent draw in system. Batteries
may have failed. Ensure that NO accessories Expected Result:
on
were ON during test. Exit procedure and retest

Current is under 2 amperes.
alternator charging system.
Results:
STOP.
ly
• YES — Current is under 2 amperes.

• NO — Current is above 0.050 amperes. There is
a draw in system. Proceed to step 17.
Proceed to step 16. • NO — Current is over 2 amperes.
15. MEASURE CURRENT OF SYSTEM BY Repair: There is an internal problem with
REMOVING NEGATIVE BATTERY CABLE. alternator. Repair alternator or replace alternator.
a. Disconnect ground cable from negative battery STOP.
post. There may be more than one battery
connected to ground. Disconnect all of batteries 17. TEST OUTPUT CURRENT OF ALTERNATOR
that are connected to ground. Do not disconnect BELOW 0.015 AMPERES.
cables that are between batteries that are a. Disconnect wire from B+ terminal of alternator.
connected in series. Set multimeter on 10 amp scale. Connect red
lead of multimeter to wire that was disconnected.
Connect black lead of multimeter to B+ terminal
of alternator. Make a note of current that was
measured.
Expected Result:
79033095 C Rev. 14-57

Troubleshooting
Current is less than 0.015 amperes. Repair: Exit procedure and retest alternator
charging system.
Results:
STOP.
• YES — Current is under 0.015 amperes.
Alternator is operating correctly. There may be a 19. TEST FOR AN OVERCHARGING CONDITION
current draw on generator set. FROM ALTERNATOR.
Proceed to step 18. a. Verify that nut on B+ alternator terminal is tight.
Also, verify that wire has a good connection to B+
• NO — Current is over 0.015 amperes. terminal.
Repair: There is an internal problem with b. Start engine and set throttle to at least 75
alternator. Repair alternator or replace alternator. percent. Turn ON all electrical accessories for
STOP. remainder of test step. Allow engine to run for at
least 3 minutes before continuing.
18. IDENTIFY SOURCE OF EXCESSIVE CURRENT
DRAW. c. Measure voltage between B+ terminal of
alternator and case of alternator. Make a note of
a. Make sure that every electrical component is voltage that was measured. Perform next
turned OFF. Make sure that key switch is turned measurement immediately.
Fo
OFF. Make sure that dome lights are OFF.

d. Measure voltage across battery. Put red lead on
b. Clamp a 9U-5795 Current Probe or 8T-0900 positive terminal of battery, and put black lead on
Ammeter around main ground cable. Clamp tool negative terminal of battery. Make a note of
r
with positive side away from battery. Reset probe voltage that was measured.
(zero) before clamping probe around wire. Use
in
current probe if draw is above approximately 2 Expected Result:

amperes. Use Ammeter if draw is below Voltage at battery should be less than voltage at
approximately 2 amperes.
te
alternator. On systems that are 12 volt, difference in

c. Remove fuses or open circuit breakers one at a voltages should not be more than 1 volt. On systems
time. Check current after each fuse has been that are 24 volt, difference should not be more than 2
rn
removed or each circuit breaker has been volts.

opened. After observing current, reinstall fuse or Results:
al
close circuit breaker. Start with main circuits first,

and proceed to smaller circuits. • YES — Voltage at battery is less than voltage at
alternator. Also, difference in voltages is less than
d. Check if any components on circuit are ON. 1 volt for 12 volt systems and difference is less
u
e. If everything is OFF, then disconnect electrical than 2 volts for 24 volt systems. Wiring related to
se
components on circuit one at a time. Monitor alternator is correct

current after each component is disconnected. Repair: There is an internal problem with
f. All of components in circuit should be alternator. Repair alternator or replace alternator.
disconnected. If problem still exists, then check
on
STOP.
wiring in circuit. There may be circuit leakage
through corrosion or circuit leakage through a • NO — Voltage at battery is less than voltage at
short. alternator. However, difference in voltages is
ly
greater than 1 volt for 12 volt systems and

NOTE: Standard acceptable current draw is 50 difference is greater than 2 volts for 24 volt
milliamperes. A current draw above 50 systems.
milliamperes usually indicates a problem.
Contact a dealer for more information. Proceed to step 20.
Expected Result: 20. TEST POSITIVE SIDE OF CHARGING CIRCUIT.
Source of excessive current draw was determined. a. Measure voltage between frame of generator set
and B+ terminal of alternator. Make a note of
Results: voltage that was measured. Perform next
• YES — Source of excessive current draw was measurement immediately.
determined. b. Measure voltage between frame of generator set
Repair: Repair problem or replace any and positive terminal of battery. Make a note of
component that has failed. Exit procedure and voltage that was measured.
retest alternator charging system. Expected Result:
STOP. Voltage difference does not exceed 1 volt on 24 volt
• NO — Source of excessive current draw was not systems or 0.5 volts on 12 volt systems.
determined. Results:
14-58 79033095 C Rev.

Troubleshooting
• VOLTAGE YES - ALT. WITHOUT IG/S TERM. —
Voltage difference does not exceed tolerance.
Positive circuit is good.
Repair: There is an internal problem with
STOP.
• VOLTAGE EXCESSIVE - ALL ALT. — Voltage
difference exceeds tolerance.
Repair: There is high resistance in positive side
of charging circuit caused by one of following
conditions:
• An electrical connection has corroded.
• Main relay has failed.
Fo
• A circuit breaker has failed.

Correct problem. Exit procedure and retest
alternator charging system.
r
STOP.
in
• VOLTAGE YES - ALT. WITH IG/S TERM. —

Voltage difference does not exceed tolerance.
Positive circuit is good.
te
Proceed to step 21.

rn
21. TEST FOR OVERCHARGING

a. Start engine and set throttle to at least 75
al
percent.
b. Measure voltage between sense terminal S
and/or IG terminal to case of alternator.
u
Expected Result:
se
Voltage at S terminal and/or IG terminal is above

specification.
Results:
on
• YES — Measured voltage exceeds specification.

There is an internal malfunction in alternator. See
appropriate service manual for alternator to test
ly
internal components and connections.

STOP.
• NO — Measured voltage is below measurement
that was taken in initial test. Sense circuit in
generator set has high resistance. Correct
problem. Exit procedure and retest alternator
charging system.
STOP.
79033095 C Rev. 14-59

Troubleshooting
Starting System • YES — +battery voltage is present. Key start
switch or machine harness (wire (307-OR)) has
ECM activates neutral start relay when conditions that are failed. Check key start switch and machine
listed below have been met: harness.
• Key start switch is in START position. Repair: If necessary, replace key start switch
• Seat switch is in CLOSED position. and/or machine harness.
• Shift lever is in NEUTRAL position. STOP.
ECM detects a failure in circuit for start relay and electrical • NO — +battery voltage is NOT present. Harness
system. If SPN 0444 or SPN 0168 are present diagnostic circuit operates correctly. It is unlikely that ECM is
code must be corrected before performing following faulty. Perform these Steps again.
procedure, Check key start switch. See Testing and Repair: If cause is not found, replace ECM. See
Adjusting, Troubleshooting Diagnostic Codes. Testing and Adjusting, Electronic Control Module
1. CHECK KEY START SWITCH IN START POSITION. (ECM) - Replace.
a. Make sure that SPN 0444 and SPN 0168 are not STOP.
present. If diagnostic codes exist, correct failure
before proceeding.
Fo
b. Disconnect ECM from machine harness.

c. Turn disconnect switch to ON position (if
r
equipped).
in
d. Turn and hold key start switch in START position.

e. At machine harness connector for ECM,
te
measure voltage between contact J2-39 (wire

(306-GN)) and contact J2-2 (ground).
rn
Expected Result:
+battery voltage should be present.
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Results:
• YES — +battery voltage is present.
u
Proceed to step 2.
se
• NO — +battery voltage is NOT present. Key start

switch or machine harness (wire (306-GN)) has
failed. Check key start switch and machine
harness.
on
Repair: If necessary, replace key start switch

and/or machine harness.
STOP.
ly
2. CHECK KEY START SWITCH IN OFF POSITION.

a. ECM remains disconnected from machine
harness.
b. Turn key start switch to OFF position.
c. At machine harness connector for ECM,
measure voltage between contact J2-39 (wire
(306-GN)) and contact J2-2 (ground).
Expected Result:
+battery voltage should be present.
Results:
14-60 79033095 C Rev.

Troubleshooting
Pulse Width Modulated Sensor
FIG. 40: Schematic symbol for a typical pulse width
modulated sensor (PWM)
NOTE: In addition to these tests, diagnostics screens of
Virtual Terminal are helpful for troubleshooting
sensors.
When you are testing a sensor, it is necessary to identify
connector contacts and harness wires. Electrical System
Schematic shows connector contact numbers and
corresponding wire numbers. See Electrical System
Schematic in Service Manual for machine.
On all machines, wire numbers and connector contacts
are identified by these general rules: g00315944
• +V wire numbers are from 100 to 199. +V contact FIG. 40

corresponds to wire number.
Fo
• Ground wire number is between 200 and 299.

Ground contact corresponds to wire number.
• Wire number for signal circuits is from 400 to 499.
r
Signal contact corresponds to wire number.

For an example, see above figure:
in
• +V wire is wire number 113.

te
• +V contact is contact A.
• Ground wire is wire number 201.
rn
• Ground contact is contact B.

• Signal wire is wire number 443.
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• Signal contact is contact C.

u
Tools Needed
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257-9140 Multimeter 1
7X-1710 Multimeter Probe Group 1
1. TROUBLESHOOT SENSORS.
on
Troubleshoot sensor circuits in following order.

a. Perform Diagnostic Function, Sensor Signal
ly
Voltage procedure. This procedure checks

sensor voltages at sensor while circuits remain
connected. DISCONNECT NOTHING.
Troubleshoot as is before disconnecting any
circuits. Disconnecting circuits first may alter a
poor connection. Proving original cause of a
problem may be difficult or impossible.
Expected Result:
Diagnostic Function, Sensor Signal Voltage
procedure has determined cause of problem.
Results:
• YES — This test step has determined cause of
problem.
STOP.
79033095 C Rev. 14-61

Troubleshooting
• NO — This test step has NOT determined cause
of problem.
Proceed to step 2.
2. TROUBLESHOOT SENSORS
a. Perform Diagnostic Function, Sensor Dynamic
Operation procedure. This is an additional test.
This will test sensor during actual operating
conditions.
Expected Result:
Diagnostic Function, Sensor Dynamic Operation,
procedure has determined cause of problem.
Results:
• YES — This test step has determined cause of
problem.
Fo
STOP.
• NO — This test step has NOT determined cause
of problem.
r
Repair: If sensor and harness are correct, it is

likely that main display module has failed.
in
Replace main display module. See Testing and

Adjusting, Module - Replace.
te
STOP.
rn
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on
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14-62 79033095 C Rev.

Troubleshooting
Sensor Signal Voltage Sensor Voltage Specifications
NOTE: Electronic control module is connected. Sensor Voltage Test
Sensor Voltage Specifications 3E-5370 Temperature Sensor Group And 131-0784

Temperature Sensor
Sensor Voltage Test
Temperature Signal Voltage* Duty Cycle
100-3055 Temperature Sensor And 131-0427
Temperature Sensor −40 to 20°C (−40 0.8 to 1.5 VDC 4 to 11%
to −4°F)
Temperature Signal Voltage* Duty Cycle
−20 to 0°C (−4 to 1.5 to 2.5 VDC 11 to 22%
−20 to 0°C (−4 to 1.1 to 1.4 VDC 11 to 15% 32°F)
32°F)
0 to 20°C (32 to 2.5 to 3.7 VDC 22 to 34%
0 to 20°C (32 to 1.4 to 2.0 VDC 15 to 23% 68°F)
68°F)
20 to 40°C (68 to 3.7 to 4.8 VDC 34 to 46%
20 to 40°C (68 to 2.0 to 3.1 VDC 23 to 37% 104°F)
104°F)
40 to 60°C (104 to 4.8 to 6.0 VDC 46 to 59%
Fo
40 to 60°C (104 3.1 to 4.5 VDC 37 to 55% 140°F)

to 140°F)
60 to 80°C (140 to 6.0 to 7.2 VDC 59 to 71%
60 to 80°C (140 4.5 to 5.7 VDC 55 to 71% 176°F)
r
to 176°F)
80 to 100°C (176 7.2 to 8.1 VDC 71 to 81%
in
80 to 100°C (176 5.7 to 6.6 VDC 71 to 82% to 212°F)

to 212°F)
100 to 120°C (212 8.1 to 8.8 VDC 81 to 87%
te
100 to 120°C 6.6 to 7.2 VDC 82 to 89% to 248°F)

(212 to 248°F)
120 to 140°C (248 8.8 to 9.2 VDC 87 to 92%
rn
120 to 140°C 7.2 to 7.4 VDC 89 to 93% to 275°F)

(248 to 275°F)
* Voltages that are listed in table are guidelines for troubleshooting.
al
* Voltages that are listed in table are guidelines for troubleshooting. Values should not be considered to be exact. Tolerance for these
Values should not be considered to be exact. Tolerance for these measurements is ±10 percent. Proper operation of sensor is more
measurements is ±10 percent. Proper operation of sensor is more important. Output voltage of sensor should change smoothly
important. Output voltage of sensor should change smoothly when temperature changes.
u
when temperature changes.

Locate suspect sensor. Identify sensor wires and
se
connector contacts. See Diagnostic Function, Pulse

Width Modulated (PWM) Sensor - Test. DO NOT
DISCONNECT ANY HARNESS CONNECTORS AT
THIS TIME. Turn key start switch to ON position. DO NOT
on
START ENGINE.
1. CHECK SENSOR POWER.
ly
a. Identify supply circuit and ground circuit at

connector of sensor.
b. Insert 7X-1710 Cable Probes into back of
connector of sensor. Place leads of probe along
side of wires of supply circuit and wires of ground
circuit.
c. Measure system voltage.
79033095 C Rev. 14-63

Troubleshooting
Expected Result: Repair: Repair machine harness or replace
machine harness. Repeat test step to verify that
Voltage measured is between 7.5 and 8.5 VDC. problem has been corrected. If problem has not
Results: been corrected replace main display module.
See Testing and Adjusting, Module - Replace.
• YES — Voltage is between 7.5 and 8.5 VDC.
System voltage is present. STOP.
Proceed to step 2. 3. CHECK SIGNAL CIRCUIT FOR MACHINE
HARNESS.
• NO — Voltage is not between 7.5 and 8.5 VDC.
There is an open circuit. Trace supply circuit and a. At machine harness connector for main display
ground circuit in machine harness. module, identify signal and ground circuits.
Repair: Repair machine harness or replace NOTE: DO NOT DISCONNECT HARNESS
machine harness. CONNECTOR.
STOP. b. Push 7X-1710 Cable Probes in back of machine
harness connector along side of signal and
2. CHECK SIGNAL VOLTAGE. ground circuit wires.
a. At sensor connector, identify signal and ground
Fo
c. Measure signal voltage.

circuits.
d. Compare measurement with voltage that was
b. Push 7X-1710 Cable Probes in back of sensor measured in previous test, Check signal voltage.
connector along side of signal and ground circuit
r
wires. Expected Result:

in
c. Measure signal voltage and record signal Main display module is receiving a valid signal
voltage. voltage of 1.0 to 7.0 VDC.
te
NOTE: If a precise signal voltage is necessary, use Results:

specifications that are listed in provided tables. • YES — Main display module is receiving a valid
rn
Expected Result: signal voltage. If problem has been corrected exit

procedure. No further testing is required. If
Measured signal voltage is approximately between problem still persists, further testing is required.
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1.0 and 7.0 VDC. Signal voltage is between 1.0 and

9.0 VDC with 3E-5370 Temperature Sensor Group. Proceed to test step 4.
Results: • NO — Voltage is different from voltage that was
u
measured in previous test. Machine harness has

• FROM 1.0 TO 7.0 (9.0) VDC — Voltage is an open in signal or ground circuits.
se
between 1.0 and 7.0 VDC (9.0 VDC for 3E-5370

Temperature Sensor Groups). Signal voltage at Repair: Repair machine harness or replace
sensor is correct. machine harness.
Repair: Harness and main display module are STOP.
on
working properly. Voltage measured is correct. 4. CHECK SENSOR DYNAMIC OPERATION

Sensor has failed. Replace sensor.
Perform following diagnostic procedure: Sensor
Proceed to step 3.
ly
Dynamic Operation.
• GREATER THAN 7.0 (9.0) — Voltage is NOT Results:
between 1.0 and 7.0 VDC. (Voltage is
approximately 9.0 VDC for 3E-5370 Temperature • YES — STOP.
Sensor Groups.) Signal voltage is not correct.
• REPAIRED, YES — STOP.
Signal circuit of machine harness is shorted to
+battery circuit.
Repair: Repair machine harness or replace
machine harness. Repeat test step to verify that
problem has been corrected. If problem has not
been corrected replace main display module.
See Testing and Adjusting, Module - Replace.
STOP.
• LESS THAN 1.0 VDC — Voltage is less than 1.0
VDC. Signal voltage is not correct. Signal circuit
of machine harness is shorted to ground.
14-64 79033095 C Rev.

Troubleshooting
Sensor Dynamic Operation Sensor Voltage Specifications *
NOTE: Electronic control module is connected. Sensor Dynamic Test
Sensor Voltage Specifications * 3E-5370 Temperature Sensor Group And 131-0784

Temperature Sensor
Sensor Dynamic Test
Temperature Signal Voltage† Duty Cycle
100-3055 Temperature Sensor And 131-0427
Temperature Sensor −40 to 20°C (−40 0.8 to 1.5 VDC 4 to 11%
to −4°F)
Temperature Signal Voltage† Duty Cycle
−20 to 0°C (−4 to 1.5 to 2.5 VDC 11 to 22%
−40 to 20°C (−40 1.0 to 1.1 VDC 10 to 11% 32°F)
to −4°F)
0 to 20°C (32 to 2.5 to 3.7 VDC 22 to 34%
−20 to 0°C (−4 to 1.1 to 1.4 VDC 11 to 15% 68°F)
32°F)
20 to 40°C (68 to 3.7 to 4.8 VDC 34 to 46%
0 to 20°C (32 to 1.4 to 2.0 VDC 15 to 23% 104°F)
68°F)
40 to 60°C (104 to 4.8 to 6.0 VDC 46 to 59%
Fo
20 to 40°C (68 to 2.0 to 3.1 VDC 23 to 37% 140°F)

104°F)
60 to 80°C (140 to 6.0 to 7.2 VDC 59 to 71%
40 to 60°C (104 to 3.1 to 4.5 VDC 37 to 55% 176°F)
r
140°F)
80 to 100°C (176 7.2 to 8.1 VDC 71 to 81%
in
60 to 80°C (140 to 4.5 to 5.7 VDC 55 to 71% to 212°F)

176°F)
100 to 120°C (212 8.1 to 8.8 VDC 81 to 87%
te
80 to 100°C (176 5.7 to 6.6 VDC 71 to 82% to 248°F)

to 212°F)
120 to 140°C (248 8.8 to 9.2 VDC 87 to 92%
rn
100 to 120°C (212 6.6 to 7.2 VDC 82 to 89% to 275°F)

to 248°F)
* If you desire, use these specifications with following procedure.
al
120 to 140°C (248 7.2 to 7.4 VDC 89 to 93% † Voltages that are listed in table are guidelines for troubleshooting.
to 275°F) Values should not be considered to be exact. Tolerance for these
measurements is ±10 percent. Proper operation of sensor is more
* If you desire, use these specifications with following procedure. important. Output voltage of sensor should change smoothly
u
† Voltages that are listed in table are guidelines for troubleshooting. when temperature changes.
Values should not be considered to be exact. Tolerance for these
se
measurements is ±10 percent. Proper operation of sensor is more

To use following procedure, it is necessary to know
important. Output voltage of sensor should change smoothly
when temperature changes.
connector contact of main display module and contact
that corresponds to service code. See Electrical System
Schematic in Service Manual for machine to determine
on
proper connector contact of main display module. Use

7X-1710 Cable Probe on connector contact of sensor
signal wire on main display module.
ly
NOTE: Sensors are provided power from main display

module. Therefore, main display module must be
connected for sensors to function.
Two items are checked in test:
• A sensor signal is present at main display module.
• For an increase and/or a decrease in system being
monitored, signal voltage will increase and/or signal
voltage will decrease.
1. CHECK INITIAL SIGNAL VOLTAGE.
a. Engine coolant and temperature sensors should
be below operating temperature.
b. Ensure that engine coolant and temperature
sensors are below normal. Ensure that key
switch is OFF and that sensor is connected to
machine harness.
79033095 C Rev. 14-65

Troubleshooting
c. Turn key switch to ON position. DO NOT START • NO — Voltage does not increase during test
ENGINE. procedure. Probable cause is a failed sensor.
d. At machine harness connector for main display Repair: Sensor has failed. Replace sensor.
module, measure voltage and record voltage
STOP.
(VDC) between signal contact and frame ground.
For correct operation, approximate voltage is
between 1.0 and 7.0 VDC. Approximate voltage
is between 1.0 and 9.0 VDC for 3E-5370
131-0784 Temperature Sensor Groups.
NOTE: When precise specifications for signal voltage
are necessary, use specifications that are listed
in provided tables.
Expected Result:
Voltage measured is within specifications.
Results:
Fo
• YES — Approximate voltage is between 1.0 and

7.0 VDC. Approximate voltage is between 1.0
and 9.0 VDC for 3E-5370 / 131-0784
Temperature Sensor Groups. Signal voltage to
r
main display module is correct.

in
Proceed to step 2.
• NO — Approximate voltage is not between 1.0
te
and 7.0 VDC. Approximate voltage is not

between 1.0 and 9.0 VDC for 3E-5370 /
131-0784 Temperature Sensor Groups. Signal
rn
voltage to main display module is not correct.

Probable cause is a failed sensor.
al
Repair: Sensor has failed. Replace sensor.

STOP.
u
2. CHECK SIGNAL VOLTAGE WITH NEW

CONDITIONS.
se
a. Increase temperature, pressure or fuel level of

system being tested. Following procedures are
examples: Run engine to increase temperature
on
of engine coolant. Operate implement controls to

increase temperature of hydraulic oil. Add fuel to
fuel tank to increase level of fuel.
ly
b. At machine harness connector for main display

module, measure voltage (VDC) between signal
contact and frame ground.
c. Voltage (VDC) is greater than voltage that was
recorded in previous test, Check initial signal
voltage. Voltage increases smoothly.
NOTE: Difference in voltage seen between test and
previous test is dependent on amount of change
that was introduced in system.
Expected Result:
Voltage increases during test procedure.
Results:
• YES — Voltage increase during test procedure
and sensor operates smoothly. Sensor has not
failed.
STOP.
14-66 79033095 C Rev.

Troubleshooting
Switch Circuits 3. CHECK SIGNAL CIRCUIT OF HARNESS.
When a filter has been replaced and bypass switch a. Turn key start switch and disconnect switch to
continues to indicate that a problem exists, further OFF position.
troubleshooting is necessary to isolate fault. Refer to b. Use Electrical System Schematic to trace signal
Systems Operations section of applicable Service Manual wire from switch back to ECM.
for additional information on individual switches.
c. Determine signal contact (connector contact) of
Possible causes of these failures are listed below: machine harness at ECM.
• Signal circuit in machine harness is open. d. Disconnect machine harness connectors J1 and
• Switch has failed. J2 from ECM.
• ECM has failed. e. At machine harness connector for ECM,

measure resistance between signal contact and
1. CHECK FOR AN OPEN IN HARNESS contact 2 of switch.
a. Locate switch that corresponds to data event Expected Result:
displayed on message center. (If necessary, use
Electrical System Schematic to assist in locating Resistance is less than 5 ohms.
switch.)
Fo
Results:
b. Disconnect signal wire from switch. • YES — Resistance is less than 5 ohms. Signal
c. Place a jumper wire from signal wire to ground circuit of harness is correct.
r
wire. Proceed to step 4.

in
Expected Result: • NO — Resistance is greater than 5 ohms.

Data event is no longer active on message center. Repair: Signal circuit of harness is not correct.
te
Results: Repair machine harness or replace machine

harness.
• YES — Data event is no longer active on
rn
message center. STOP.
Repair: Switch has failed. Check or replace 4. CHECK GROUND CIRCUIT OF HARNESS.
al
switch. a. Key start switch and disconnect switch remain in

STOP. OFF position.
u
• NO — Data event remains on message center. b. Machine harness connectors J1 and J2 remain
Machine harness is open or ECM has failed. disconnected.
se
Proceed to step 2. c. Use Electrical System Schematic to trace ground

for switch.
2. CHECK VOLTAGE OF ECM.
d. At switch, measure resistance between ground
on
a. Remove jumper that was used in previous test wire and frame ground.
step.
Expected Result:
b. Signal wire remains disconnected.
Resistance is less than 5 ohms.
ly
c. Measure pull-up voltage from signal wire to

ground wire with a digital multimeter. Results:
Expected Result: • YES — Resistance is less than 5 ohms.
Voltage is 8 ± 0.5 volts. Repair: Machine harness is not cause of failure.

ECM has failed. It is unlikely that ECM has failed.
Results: Exit procedure and perform procedure again. If
• YES — Voltage is 8 ± 0.5 volts. fault is not found, replace ECM. See Testing and
Adjusting, Electronic Control Module (ECM) -
Repair: Voltage is correct. ECM has failed. It is Replace.
unlikely that ECM has failed. Exit procedure and
perform procedure again. If fault is not found, STOP.
replace ECM. See Testing and Adjusting, • NO — Resistance is greater than 5 ohms.
Electronic Control Module (ECM) - Replace.
Repair: Machine harness has failed. Repair
STOP. machine harness or replace machine harness.
• NO — Voltage is not 8 ± 0.5 volts. STOP.
Proceed to step 3.
79033095 C Rev. 14-67

Troubleshooting
NOTES
Fo
r in
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14-68 79033095 C Rev.

Diagnostic Code Procedures
DIAGNOSTIC CODE PROCEDURES
DIAGNOSTIC CODE LIST Engine ECM (SA 00) (Engine)

Diagnostic Codes for SA 00 (SPN)
Failure Mode Identifier (FMI)
Engine ECM (SA 00) (Engine)
For troubleshooting procedures, see procedure
(SPN) with same diagnostic code.
Failure Mode Identifier (FMI) SPN Component
For troubleshooting procedures, see procedure /
with same diagnostic code. FMI
SPN Component 16 Above Normal Operating Range - Moderately

/ Severe
FMI 0108 Barometric Pressure
Fo
0091 Decelerator Pedal Position 03 Shorted to High Source

08 Abnormal Sensor Frequency 04 Shorted to Ground
r
13 Out of Calibration 0110 Engine Coolant Temperature

0094 Engine Fuel Delivery Pressure
in
00 Above Normal Operational Range - Most

03 Shorted to High Source Severe
te
04 Shorted to Ground 03 Shorted to High Source
15 Above Normal Operating Range - Least 04 Shorted to Ground

rn
Severe 15 Above Normal Operating Range - Least

17 Below Normal Operating Range - Least Severe
al
Severe 16 Above Normal Operating Range - Moderately

0100 Engine Oil Pressure Severe
u
01 Below Normal Operational Range - Most 0168 Battery Potential

Severe 00 Above Normal Operational Range - Most
se
04 Shorted to Ground 01 Below Normal Operational Range - Most

Severe
on
10 Abnormal Rate of Change

02 Erratic, Intermittent, or Incorrect
17 Below Normal Operating Range - Least
Severe 0174 Engine Fuel Temperature
ly
18 Below Normal Operating Range - Moderately 00 Above Normal Operational Range - Most
Severe Severe
0102 Engine Intake Manifold Pressure 03 Shorted to High Source
03 Shorted to High Source 04 Shorted to Ground
04 Shorted to Ground 15 Above Normal Operating Range - Least

Severe
10 Abnormal Rate Of Change
16 Above Normal Operating Range - Moderately
0105 Engine Intake Manifold Temperature Severe
00 Above Normal Operational Range - Most 0190 Engine Speed

Severe
04 Shorted to Ground 08 Abnormal Sensor Frequency
15 Above Normal Operating Range - Least 15 Above Normal Operating Range - Least
Severe Severe
79033095 C Rev. 14-69

Engine ECM (SA 00) (Engine) Engine ECM (SA 00) (Engine)
(SPN) (SPN)
Failure Mode Identifier (FMI) Failure Mode Identifier (FMI)
For troubleshooting procedures, see procedure For troubleshooting procedures, see procedure
with same diagnostic code. with same diagnostic code.
SPN Component SPN Component
/ /
FMI FMI
0620 5 Volt DC Supply 0656 Engine Injector Cylinder 6
03 Shorted to High Source 05 Open Circuit
04 Shorted to Ground 06 Shorted to Ground
0626 Ether Injection Solenoid 0678 8 Volt DC Supply
05 Open Circuit 03 Shorted to High Source
Fo

0630 Configuration 0723 Engine Speed Sensor 2
r
02 Erratic, Intermittent, or Incorrect 08 Abnormal Sensor Frequency

in
0631 Machine Model 0729 Engine Inlet Air Heater 1

02 Erratic, Intermittent, or Incorrect 05 Open Circuit
te
0637 Engine Timing Sensor 06 Shorted to Ground

rn
13 Out of Calibration 1072 Engine Compression Brake Low/High Solenoid

0639 Controller Area Network 05 Open Circuit
al
09 Abnormal Update Rate 06 Shorted to Ground

0651 Engine Injector Cylinder 1 1073 Engine Compression Brake Medium/High
u
Solenoid
05 Open Circuit
05 Open Circuit
se
06 Shorted to Ground
0652 Engine Injector Cylinder 2
1079 5 Volt DC Supply
05 Open Circuit
on
03 Shorted to High Source

ly
05 Open Circuit
05 Open Circuit
05 Open Circuit
14-70 79033095 C Rev.

Machine ECM (SA 03) (Transmission) Machine ECM (SA 03) (Transmission)
(SPN) (SPN)
/ /
FMI FMI
0096 Fuel Level 0598 Inching Pedal Switch
03 Shorted to High Source 02 Erratic, Intermittent, or Incorrect
04 Shorted to Ground 07 Mechanical System Not Responding
0117 Brake Accumulator Pressure 14 Special Instructions
01 Below Normal Operational Range - Most 0617 Parking Brake Solenoid 2
Fo
Severe
0127 Transmission Oil Pressure
05 Open Circuit
01 Below Normal Operational Range - Most
r
Severe 06 Shorted to Ground

in
0161 Transmission Input Shaft Speed 0618 Parking Brake Solenoid 1
02 Erratic, Intermittent, or Incorrect 03 Shorted to High Source

te
0168 Battery Potential 05 Open Circuit

rn
01 Below Normal Operational Range - Most 06 Shorted to Ground

Severe
0625 Proprietary Network
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0177 Transmission Oil Temperature

02 Erratic, Intermittent or Incorrect
Severe 09 Abnormal Update Rate
u
03 Shorted to High Source 12 Malfunction

se
04 Shorted to Ground 0639 Controller Area Network

09 Abnormal Update Rate
14 Special Instructions
0677 Engine Starter Motor Relay
on
0191 Transmission Output Shaft Speed

Severe 05 Open Circuit
ly
12 Malfunction 06 Shorted to Ground

0473 Charge Pressure Sensor 0678 8 Volt DC Supply
03 Shorted to High Source 03 Shorted to High Source
0564 Differential Lock Solenoid 0684 Inching Pedal Position
03 Shorted to High Source 00 Above Normal Operational Range - Most
05 Open Circuit Severe
06 Shorted to Ground 01 Below Normal Operational Range - Most

Severe
0590 Engine ECM
08 Abnormal Sensor Frequency
12 Malfunction
79033095 C Rev. 14-71

(SPN) (SPN)
/ /
FMI FMI
0734 Transmission Clutch Solenoid 1 1873 Rear Hitch Position
03 Shorted to High Source 00 Above Normal Operational Range - Most
Severe
05 Open Circuit
06 Shorted to Ground Severe
0735 Transmission Clutch Solenoid 2 08 Abnormal Sensor Frequency
Fo
03 Shorted to High Source 12 Malfunction

05 Open Circuit 13 Out of Calibration
r
06 Shorted to Ground 1883 PTO Speed Sensor

in
0736 Transmission Clutch Solenoid 3 13 Out of Calibration

03 Shorted to High Source 2602 Hydraulic Oil Level Low
te
05 Open Circuit 14 Special Instructions

rn
06 Shorted to Ground 2613 Axle Lube Pressure Low

0737 Transmission Clutch Solenoid 4 01 Below Normal Operational Range - Most
al
Severe
18 Below Normal Operating Range - Moderately
u
06 Shorted to Ground 2833 Motion With Park Brake Engaged

se
0738 Transmission Clutch Solenoid 5 14 Special Instructions

03 Shorted to High Source 31 Unknown Condition Exists
05 Open Circuit
on
2858 Machine Data Configuration

06 Shorted to Ground 02 Erratic, Intermittent, or Incorrect
0739 Transmission Clutch Solenoid 6
ly
2905 Transmission Clutch Solenoid 7

05 Open Circuit 05 Open Circuit
0961 Clock Alignment Required 2906 Transmission Clutch Solenoid 8
14 Special Instructions 03 Shorted to High Source
1638 Hydraulic Oil Temperature 05 Open Circuit
00 Above Normal Operational Range - Most 06 Shorted to Ground
Severe
2910 PTO Clutch Solenoid
05 Open Circuit
1713 Implement Oil Filter Bypass
14-72 79033095 C Rev.

(SPN) (SPN)
/ /
FMI FMI
2924 Secondary Steering 13 Out of Calibration
14 Special Instructions 520387 Rear Hitch Lower Solenoid
3359 Transmission Oil Filter Bypass 03 Shorted to High Source
14 Special Instructions 05 Open Circuit
3454 Rear Fender PTO Switch 06 Shorted to Ground
Fo
02 Erratic, Intermittent, or Incorrect 13 Out of Calibration

3509 5 Volt DC Supply 520581 Park Brake Excessive Wear
r
03 Shorted to High Source 31 Unknown Condition Exists

in
04 Shorted to Ground 520674 Transmission Intermediate Shaft Speed

3513 10 Volt DC Supply Sensor
te

rn
04 Shorted to Ground 520706 Park Brake Is Not Engaged
3825 Transmission Output Shaft Speed 2 07 Mechanical System Not Responding

al
12 Malfunction 520726 Right Steering Solenoid
4056 Creeper Solenoid 03 Shorted to High Source

u

se
05 Open Circuit 06 Shorted to Ground
06 Shorted to Ground 13 Out of Calibration
520192 Steering System Malfunction 520727 Left Steering Solenoid

on
14 Special Instructions 03 Shorted to High Source
520256 Steering in Wrong Direction 05 Open Circuit

ly
14 Special Instructions 06 Shorted to Ground
520257 Uncommanded Steering Output 13 Out of Calibration
14 Special Instructions 520967 Machine Application Code
520258 No Steering Output Detected 02 Erratic, Intermittent, or Incorrect
14 Special Instructions 09 Abnormal Update Rate
520259 Excessive Steering Error 521004 Brake Charge Oil Filter Bypass Switch
14 Special Instructions 31 Unknown Condition Exists
520386 Rear Hitch Raise Solenoid 521409 Transmission Clutch Solenoid 9
79033095 C Rev. 14-73

(SPN) (SPN)
/ /
FMI FMI
521469 Steering Motor Speed Sensor 1 13 Out of Calibration
00 Above Normal Operational Range - Most 521473 Steering Wheel Position Sensor 3
Severe
01 Below Normal Operational Range - Most Severe
Severe
02 Erratic, Intermittent, or Incorrect Severe
Fo
08 Abnormal Sensor Frequency 02 Erratic, Intermittent, or Incorrect

521470 Steering Motor Speed Sensor 2 08 Abnormal Sensor Frequency
r
00 Above Normal Operational Range - Most 12 Malfunction

Severe
in
13 Out of Calibration
Severe 521475 Rear Fender Hitch Switch
te
02 Erratic, Intermittent, or Incorrect 02 Erratic, Intermittent, or Incorrect

rn
08 Abnormal Sensor Frequency 521476 Rear Hitch Steer Position Sensor
521471 Steering Wheel Position Sensor 1 00 Above Normal Operational Range - Most
al
Severe
Severe 01 Below Normal Operational Range - Most
Severe
u

Severe 08 Abnormal Sensor Frequency
se
08 Abnormal Sensor Frequency 13 Out of Calibration
12 Malfunction 521760 Secondary Steering Solenoid

on
13 Out of Calibration 03 Shorted to High Source
521472 Steering Wheel Position Sensor 2 05 Open Circuit

ly

Severe
Severe
12 Malfunction
14-74 79033095 C Rev.

Armrest ECM (SA 05) (Armrest) Armrest ECM (SA 05) (Armrest)
(SPN) (SPN)
/ /
FMI FMI
0069 Creeper Switch 1875 Rear Hitch Lever Sensor
02 Erratic, Intermittent or Incorrect 00 Above Normal Operational Range - Most
Severe
05 Open Circuit 03 Shorted to High Source
Fo
0601 Cruise Control Switch 04 Shorted to Ground

02 Erratic, Intermittent, or Incorrect 1894 PTO Switch
r

in
04 Shorted to Ground 03 Shorted to High Source

05 Open Circuit 04 Shorted to Ground
te

rn
19 Not Communicating 1919 Auxiliary Valve Control Sensor 1

0689 Differential Lock Switch 00 Above Normal Operational Range - Most
al
Severe
02 Erratic, Intermittent or Incorrect
u
se
1931 Auxiliary Valve Control Sensor 2

05 Open Circuit
0898 Hand Throttle Sensor Severe
on

Severe Severe
01 Below Normal Operational Range - Most 03 Shorted to High Source
Severe
ly
1231 Controller Area Network 2
1943 Auxiliary Valve Control Sensor 3
19 Not Communicating
1235 Controller Area Network 3 Severe
19 Not Communicating 01 Below Normal Operational Range - Most
1504 Operator Not Present Severe
31 Unknown Condition Exists 03 Shorted to High Source
1787 Maximum Power Switch 04 Shorted to Ground
03 Shorted to High Source 1955 Auxiliary Valve Control Sensor 4
04 Shorted to Ground 00 Above Normal Operational Range - Most

Severe
05 Open Circuit
Severe
79033095 C Rev. 14-75

Armrest ECM (SA 05) (Armrest) Armrest ECM (SA 05) (Armrest)
(SPN) (SPN)
/ /
FMI FMI
03 Shorted to High Source 3507 ECM Power Relay
1967 Auxiliary Valve Control Sensor 5 3510 DC Supply - 1.7 Volts
00 Above Normal Operational Range - Most 03 Shorted to High Source
Severe
Fo

Severe 3511 DC Supply - 3.3 Volts

r

in
1979 Auxiliary Valve Control Sensor 6 3646 Park Lever Switch
00 Above Normal Operational Range - Most 02 Erratic, Intermittent, or Incorrect

te
Severe
rn

al
04 Shorted to Ground 3652 Shift Up Switch
2825 Forward/Neutral/Reverse Lever Sensor 02 Erratic, Intermittent, or Incorrect

u
00 Above Normal Operational Range - Most 03 Shorted to High Source

se

01 Below Normal Operational Range - Most 05 Open Circuit
Severe
3653 Shift Down Switch
on
2832 Operator Not in Operating Station

31 Unknown Condition Exists
ly
2858 Machine Data Configuration

05 Open Circuit
2970 Constant Engine Speed A Switch
520193 One Touch Switch
05 Open Circuit
05 Open Circuit
2971 Constant Engine Speed B Switch
520194 Roading Lockout Switch
05 Open Circuit
14-76 79033095 C Rev.

Armrest ECM (SA 05) (Armrest) Steering ECM (SA 19) (Steering)
(SPN) (SPN)
/ /
FMI FMI
05 Open Circuit 0084 Wheel-Based Vehicle Speed
520196 High Slip 12 Malfunction
31 Unknown Condition Exists 0611 Steering Wheel Position Sensor
520197 AutoGuide Engage Switch 00 Above Normal Operational Range - Most
Severe
Fo
0612 Steering Wheel Position Redundant Sensor

r
05 Open Circuit 0613 Steering Wheel Speed Plausibility Check

in
521474 Rear Hitch Raise Switch Failure

02 Erratic, Intermittent, or Incorrect 14 Special Instructions
te
03 Shorted to High Source 0614 Steering Spool Valve

rn

Severe
05 Open Circuit
al
0615 Steering Controller Critical Failure

521893 Rear Hitch Lower Switch
u
0627 Power Supply

se

521894 PTO Disengage Switch 04 Shorted to Ground
on
1079 5 Volt DC Supply

Severe
05 Open Circuit
ly
1083 Articulation Angle Sensor

Severe
1084 Steering ECM Sensor 2
Severe
1807 Steering Wheel Angle
79033095 C Rev. 14-77

Lighting ECM (SA 55) (Lighting) (SA 162) (Aux Valve 2)
(SPN) (SPN)
/ /
FMI FMI
2055 Unknown Lighting ECM Address 0158 Keyswitch Battery Potential
02 Erratic, Intermittent, or Incorrect 00 Above Normal Operational Range - Most
Severe
(SA 161) (Ax Valve 1) 18 Below Normal Operating Range - Moderately
Severe
(SPN)
Failure Mode Identifier (FMI) 0628 Program Memory
Fo
12 Malfunction
with same diagnostic code. 0639 Controller Area Network
r
SPN Component 19 Not Communicating

/
in
FMI 0701 Auxiliary Valve Proportional Solenoid

0158 Keyswitch Battery Potential 05 Open Circuit
te

Severe
rn
0702 Auxiliary Valve Directional Solenoid

al
0628 Program Memory 06 Shorted to Ground

12 Malfunction
u
0639 Controller Area Network

se
0701 Auxiliary Valve Proportional Solenoid
on
05 Open Circuit
ly
0702 Auxiliary Valve Directional Solenoid

05 Open Circuit
14-78 79033095 C Rev.

(SA 163) (Aux Valve 3) (SA 164) (Aux Valve 4)
(SPN) (SPN)
/ /
FMI FMI
0158 Keyswitch Battery Potential 0158 Keyswitch Battery Potential
00 Above Normal Operational Range - Most 00 Above Normal Operational Range - Most
Severe Severe
18 Below Normal Operating Range - Moderately 18 Below Normal Operating Range - Moderately
Severe Severe
0628 Program Memory 0628 Program Memory
Fo
12 Malfunction 12 Malfunction
0639 Controller Area Network 0639 Controller Area Network
r
19 Not Communicating 19 Not Communicating

in
0701 Auxiliary Valve Proportional Solenoid 0701 Auxiliary Valve Proportional Solenoid
te

rn
0702 Auxiliary Valve Directional Solenoid 0702 Auxiliary Valve Directional Solenoid
al

u se
on
ly
79033095 C Rev. 14-79

(SA 165) (Aux Valve 5) (SA 166) (Aux Valve 6)
(SPN) (SPN)
/ /
FMI FMI
0158 Key switch Battery Potential 0158 Key Switch Battery Potential
00 Above Normal Operational Range - Most 00 Above Normal Operational Range - Most
Severe Severe
18 Below Normal Operating Range - Moderately 18 Below Normal Operating Range - Moderately
Severe Severe
0628 Program Memory 0628 Program Memory
Fo
12 Malfunction 12 Malfunction
0639 Controller Area Network 0639 Controller Area Network
r
19 Not Communicating 19 Not Communicating

in
0701 Auxiliary Valve Proportional Solenoid 0701 Auxiliary Valve Proportional Solenoid
te

rn
0702 Auxiliary Valve Directional Solenoid 0702 Auxiliary Valve Directional Solenoid
al

u se
on
ly
14-80 79033095 C Rev.

(SA 170) (Steer Hitch) (SA 208) (Front Lighting)
(SPN) (SPN)
/ /
FMI FMI
0158 Key Switch Battery Potential 2208 Front Lighting ECM Address
00 Above Normal Operational Range - Most 02 Erratic, Intermittent, or Incorrect
Severe
2354 Front Work Lights
0628 Program Memory 06 Shorted to Ground

Fo
12 Malfunction 2368 Left Turn Signal Lights

r
19 Not Communicating 06 Shorted to Ground

in
0701 Auxiliary Valve Proportional Solenoid 2370 Right Turn Signal Lights

te

rn
0702 Auxiliary Valve Directional Solenoid 2653 Headlamp Left Low Beam

al

2655 Headlamp Right Low Beam
u
05 Open Circuit
se
4011 Headlamp High Beam
05 Open Circuit
on
ly
79033095 C Rev. 14-81

(SA 209) (Roof Lighting)
(SPN)
with same diagnostic code.
SPN Component
/
FMI
0882 License Plate Lamp
05 Open Circuit
2209 Roof Lighting ECM Address
Fo
2362 Rear High Mounted Work Lights

05 Open Circuit
r
in
2368 Left Turn Signal Lights

05 Open Circuit
te
rn
2370 Right Turn Signal Lights

05 Open Circuit
al
2386 Rotating Beacon Light
u
05 Open Circuit
se
2873 Work Light Switch
on
2875 Hazard Light Switch

ly
3507 ECM Power Relay

3508 Main Power Relay
05 Open Circuit
3976 Dome Light
14-82 79033095 C Rev.

(SA 210) (Rear Lighting) (SA 210) (Rear Lighting)
(SPN) (SPN)
/ /FMI
FMI
2376 Stop Light
0046 Pneumatic Supply Pressure
05 Open Circuit
01 Below Normal Operational Range - Most 2392 Back Up Light/Alarm Horn

Severe
05 Open Circuit
Fo
2404 Running Lights
1083 Left Track Tension Sensor
05 Open Circuit
r

in

Severe
te

rn
1084 Right Track Tension Sensor
al

Severe
u

Severe
se

on
2210 Rear Lighting ECM Address

ly
2360 Rear Low Mounted Work Lights

05 Open Circuit
2368 Left Turn Signal Lights
05 Open Circuit
2370 Right Turn Signal Lights
05 Open Circuit
79033095 C Rev. 14-83

DIAGNOSTIC OPERATION
When a problem occurs with an Electronic control
module, a diagnostic code message is displayed on the
virtual display of the arm rest console to warn the operator
that a problem exists that will limit or prevent the operation
of the system. By pressing the escape assist with
troubleshooting. Control system is also designed to be
used with Electronic Technician (ET) service tool. Tool
can be used to perform several diagnostic functions and
programming functions.
Troubleshooting Procedures
These procedures are for diagnostic codes that
originate from electronic control modules that are
listed here:
• Engine ECM
Fo
• Machine ECM
• Armrest ECM
r
• Steering ECM
• Lighting ECM
in
Diagnostic codes can be viewed by using any of

the following systems:
te
• Arm Rest Virtual display

rn
• Electronic Diagnostics Tool (EDT)

See one of following references:
al
• Troubleshooting,
• Troubleshooting, Using Electronic Diagnostic Tool
u
(EDT) to Determine Diagnostic Codes

Following procedures may cause new diagnostic codes to
se
be logged. Therefore, before any procedures are

performed make a list of all active diagnostic codes to
determine system problems. Clear diagnostic codes that
were caused by procedure, when each procedure is
on
complete.
NOTE: Before performing a procedure, always check all
circuit breakers. Repair cause of any circuit
ly
breaker tripped.
14-84 79033095 C Rev.

FIG. 41: Codes for Failure Mode Identifier are defined by
SAE standards. Following list contains definitions.
Diagram that follows will help you understand use of FMI
with sensors.
Failure Mode Identifier and Message Center

Displays
FMI Description of Failure
00 Data Valid but Above Normal
Operational Range - Most Severe Level
01 Data Valid but Below Normal
Operational Range - Most Severe Level g00493694
02 Data Erratic, Intermittent or Incorrect FIG. 41
03 Voltage Above Normal or Shorted to

Fo
High Source
04 Voltage Below Normal or Shorted to
Ground
r
05 Current Below Normal or Open Circuit

in
06 Current Above Normal or Circuit

Shorted to Ground
te
07 Mechanical System Not Responding or

Out of Adjustment
rn
08 Abnormal Frequency, Pulse Width, or

Period
al

10 Abnormal Rate of Change
u
11 Root Cause Not Known

se
12 Bad Intelligent Device or Component

Malfunction
13 Out of Calibration
on
15 Data Valid but Above Normal Operating
Range - Least Severe Level
ly
16 Data Valid but Above Normal Operating

Range - Moderately Severe Level
17 Data Valid but Below Normal Operating
Range - Least Severe Level
18 Data Valid but Below Normal Operating
Range - Moderately Severe Level
31 An Unknown Condition Exists
79033095 C Rev. 14-85

Detailed FMI Explanation
FMI 00 - Data Valid But Above Normal Operational FMI 03 - Voltage Above Normal or Shorted to a Higher
Range - Most Severe Level. voltage than the Sensor Supply Voltage.
Every electronic control system sets a high limit for the Component or system voltage is higher than limit. FMI 03
expected operating range of signal. High limit includes most often relates to a signal circuit.
over range signals. This could be a high temperature. A Some of the components that could cause a FMI 03
sensor still operating but sending a signal above the diagnostic code are listed below.
expected limit will cause a FMI 00 code to be stored.
• Sensor or switch is faulty.
Some possible causes of a FMI 00 diagnostic code are
listed below. • Harness is damaged.
• Signal is above normal. • Electronic control has failed.
• Signal is shorted to + terminal of battery. Some of possible causes of a FMI 03 diagnostic code are
listed below.
• Sensor needs to be calibrated.
• A sensor that has failed and voltage output is high.
This is an example of a sensor that needs calibration. A
PWM signal at a duty cycle of 80 percent is a valid signal. • Any wiring harness that has a sensor signal wire
Fo
If PWM signal has a duty cycle of 81 percent, sensor is shorted to a high voltage. A high voltage is any
still working, but sensor signal is above expected signal voltage greater than sensor supply voltage.
limits. • A wiring harness that has an open circuit in sensor
r
signal wire will cause control to pull up. When this

occurs, input circuit is pulled up to the supply voltage.
in
FMI 01 - Data Valid But Below Normal Operational Range

- Most Severe Level. • A faulty control may also cause a FMI 03. This is very
unlikely.
te
Every electronic control system sets a low limit for

expected operating range of signal. Limit includes signals
rn
that are under lower limit. Low signal could be oil pressure FMI 04 - Voltage Below Normal or Shorted to Ground.
signal. Sensor is still working but sending a signal below
expected limit will cause a FMI 01 to be stored. Component or system voltage is lower than limit. FMI 04
al
most often relates to a signal circuit.

listed below. Some of components that could cause a FMI 04
diagnostic code are listed below.
u
• Signal is below normal range.

• Sensor or switch is faulty.
• Timing is retarded.
se
• Harness is damaged.
This is an example of a PWM sensor. This sensor is not
expected to generate a PWM signal below a duty cycle of • Electronic control has failed.
5 percent with zero air pressure. If sensor generates a Some possible causes of a FMI 04 diagnostic code are
on
signal with a duty cycle of 4 percent when engine is

listed below.
shutdown, sensor is still working but sending a signal
below the expected limit. • A sensor that has failed and voltage output is low.
ly
• Any wiring harness that has a sensor signal wire

shorted to ground.
FMI 02 - Data Erratic, Intermittent or Incorrect.
• A faulty control may also cause a FMI 04. This is very
Signal from a component is present. The control that unlikely.
reads diagnostic information can not read the signal
properly. Signal appears to be gone, is unstable or invalid.
Data can be correct or incorrect intermittently. Also,
FMI 05 - Current is Below Normal or Open Circuit.
condition relates to communication between controls.
This is an example of communication between controls. Current through a component or system is lower than
When monitoring system is looking for engine speed from limit. FMI 05 is most often related to a driver circuit.
engine ECM over CAT Data Link.
• There is a faulty connection. listed below.
• Signal is intermittent or erratic. • There is an open circuit or a poor harness
connection.
• Software has been changed.
• There is an open relay.
• Signal is noisy.
• A switch is in the open position.
• Signal is out of range.
14-86 79033095 C Rev.

FMI 06 - Current is Above Normal or Circuit is Shorted to FMI 10 - Abnormal Rate of Change.
Ground.
This relates to a signal that changes too fast. Rate of
Current through a component or system is higher than change is outside of expected limit.
limit. FMI 06 is most often related to a driver circuit. This
fault is very similar to FMI 04.
FMI 11 - Root Cause Not Known.
Some of possible causes of a FMI 06 diagnostic code are
listed below. Control identifies more than one FMI as being responsible
for a single failure.
• There is a short to ground in a harness connection.
• There is a shorted relay.
listed below.
• A faulty control may also cause a FMI 06. This is very
• There is a mechanical failure.
unlikely.
• There is damage to multiple circuits.
FMI 07 - Mechanical System Not Responding Properly.

Fo
FMI 12 - Bad Intelligent Device or Component

Control detects a signal sent to a mechanical system and
Malfunction.
response is not correct.
Control receives no response or response is incorrect.
r
listed below. Some possible causes of a FMI 12 diagnostic code are

listed below.
in
• Component responds improperly or is out of

adjustment. • There is a failure of an electronic control.
te
• Component is stuck in a position. • There is a failure on the data link.

• Component has failed. • There are one or more controls with mismatched
rn
software.
• Engine is shut down.
• Machine is being used improperly.
al
FMI 13 - Out of Calibration.

The electrical signal is not within limits for a specific
FMI 08 - Abnormal Signal Frequency, Pulse Width or
u
mechanical condition.
Period.
se
This occurs when signal is not in expected range. FMI 08

listed below.
can also relate to a faulty sensor.
• Calibration of a sensor is required.
listed below. • Data is out of range.
on
• Harness connections are intermittent or poor.

• Engine misfired. FMI 14 - Special Instructions.
ly
• Signal is noisy due to nearby interference. Displays any special instructions.

• There are loose mechanical devices.
FMI 15 - Data Valid but Above Normal Operating Range -
Least Severe Level.
FMI 09 - Abnormal Update Rate.
One or more Engine component temperatures is above
This relates to communications on data link. FMI 09
Normal Range. The sensor is still operating, but sending
occurs when a control is not able to get information from
a signal above the expected limit which will cause a FMI
another control.
15 code to be stored.
listed below.
FMI 16 - Data Valid but Above Normal Operating Range -
• Control module is not communicating on data link
Moderately Severe Level.
correctly.
One or more Engine component temperatures is above
• Rate of data transmission is abnormal.
Normal Range. Some possible causes of a FMI 16
• Data link has failed. diagnostic code are listed below.
• There is a mismatch of software.
79033095 C Rev. 14-87

• Signal is above normal.
• Signal is shorted to + terminal of battery.
• Sensor has failed.

- Least Severe Level.
One or more Engine or transmission lube pressures is
below Normal Range. The sensor is still operating, but
sending a signal below the expected limit which will cause
a FMI 18 code to be stored.

- Moderately Severe Level.
One or more Engine or Transmission lube pressures is
Fo
below Normal Range. Some possible causes of a FMI 18

diagnostic code are listed below.
• Signal is below normal.
r
• Signal sensor wire is shorted to Ground.

in
• Sensor has failed.

te
FMI 19 - Received Network Data in Error.

Conditions that are defined by software were not met, or
rn
Controller Area Networks are not communicating.

al
FMI 31 - Condition Exists.

A condition which prevents safe operation exists.
u
• Operator is not in operating

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MT835C / MT845C / MT855C / MT865C / MT875C

• Volume 1: Divisions 1-10 printed packet

© AGCO Corporation, 2013 All rights reserved.

Printing Batch Number

IMPLEMENT HYDRAULIC AND THREE-POINT HITCH SYSTEMS.....................................................................06

VIRTUAL TERMINAL .............................................................................................................................................09

HEATING VENTILATION AND AIR CONDITIONING...................................................................................................... 11

© AGCO Corporation, 2013 All rights reserved.

Divisions and Page Numbers .................................................................................................................... 1-1

Replacement Parts .......................................................................................................................................... 1-1

Signal Words ................................................................................................................................................... 1-3

General Hazard Information ............................................................................................................................ 1-5

Crushing Prevention and Cutting Prevention ............................................................................................ 1-7

Parking ...................................................................................................................................................... 1-8

Operator Station ........................................................................................................................................ 1-9

Fluid Precautions ..................................................................................................................................... 1-11

Burn Hazards .......................................................................................................................................... 1-12

79033095 C Rev. 01-i

INDEX ............................................................................................................................................................. 01-25

01-ii 79033095 C Rev.

WARNING: Some pictures in manual show

Divisions and Page Numbers

Service manual is separated into divisions. Refer to

Master Table of Contents.

alpha revision level indicator. Each division also has a

revision level. Pages are in numeric order within each

Measurements are given in metric units followed by

To receive prompt efficient service, always remember to

79033095 C Rev. 1-1

Safety precautions and warnings are provided in manual

hazard can be anticipated. Warnings in service manual

procedure, work method or operating technique not

Make sure machine will not be damaged or be made

procedures chosen. Information, specifications and

Specifications, torques, pressures, measurements,

adjustments, illustrations and other items can change at

with equivalent specifications including,

1-2 79033095 C Rev.

alerts and follow recommended precautions and safe

hazardous situation that, if not avoided, will

could result in DEATH OR SERIOUS

may result in MINOR INJURY.

79033095 C Rev. 1-3

Personal injury and death may result in precautions are FIG. 4

Words IMPORTANT and NOTE are not related to

IMPORTANT: Identifies special instructions or

result in damage to, or destruction of machine,

NOTE: Identifies points of particular interest for more

Right-hand and left-hand, as used in this manual, are

1-4 79033095 C Rev.

• Transmission control lever is in PARK position. FIG. 5

• Engine start switch is turned off and switch key is

• Machine has cooled down.

due to unexpected machine movement.

Know width of machine to maintain proper clearance

Wear a hard hat, protective glasses and other protective

Wearing loose clothing or not using correct safety