621d Manual de Serviços

621D Loader
Service Manual
6-42964
Table of Contents
Description Section No. Form No.
General Tab 1
Section Index - General 6-42730
Standard Torque Specifications 1001 8-71602
Fluids and Lubricants 1002 6-42981
Metric Conversion Chart 1003 7-52950
Loctite Product Chart 8-98902
Engines Tab 2
Section Index - Engines 6-42281
Engine and Radiator Removal and Installation 2000 6-44630
Engine and Radiator Removal and Installation P.I.N. JEE0135501 and Above 2000 6-49060
Stall Tests 2002 6-42991
For Engine Repair, See the Engine Service Manual 6-74500
Fuel System Tab 3

Section Index - Fuel System 6-42300
For Fuel System Repair, See the Engine Service Manual 6-74500
Electrical Tab 4
Section Index - Electrical 6-42311
Removal and Installation of Starter and Alternator 4001 6-44641
Electrical Specifications and Troubleshooting 4002 6-40782
Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above 4002 6-48930
Batteries 4003 6-42330
Information and Diagnostic Center 4005 6-42351
Alternator - 65 Ampere 4007 7-12260
Alternator - 45 Ampere 4008 6-42360
Steering Tab 5
Section Index - Steering 6-42370
Removal and Installation of Steering Components 5001 6-44650
Steering Specifications, Pressure Checks, and Troubleshooting 5002 6-43000
Steering Control Valve 5003 6-42390
Steering Priority Valve 5004 6-42400
Steering Cylinders 5005 6-44670
Center Pivot 5006 6-42420
Copyright © 2004 CNH Ameica LLC.

CNH America LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-44624 Issued August, 2001 Revised September, 2004
621D Loader
Service Manual
6-42964
Table of Contents
Auxiliary Steering Motor and Pump 5008 6-42430
Power Train Tab 6

Section Index - Power Train 6-44681
Removal and Installation of Power Train Components 6001 6-44690
Transmission Specifications, Pressure Checks, and Troubleshooting 6002 6-43010
Transmission 6003 6-47310
Front Axle 6004 6-45240
Rear Axle 6004 6-47320
Drive Shafts, Center Bearing, and Universal Joints 6005 6-44700
Wheels and Tires 6006 6-44710
Transmission Control Valve 6007 6-42500
Brakes Tab 7
Section Index - Brakes 6-42510
Removal and Installation of Brake Components 7001 6-44721
Hydraulic Brake Troubleshooting 7002 6-43021
Brake Accumulators 7004 6-42531
Parking Brake 7008 6-44970
NOTE: For parking brake and brake pedal adjustments, see Section 9001.
Hydraulics Tab 8
Section Index - Hydraulics 6-42550
Removal and Installation of Hydraulic Components 8001 6-44731
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 6-43031
Cleaning the Hydraulic System 8003 7-49640
Cylinders 8006 6-42591
Coupler Solenoid Locking Valve 8007 6-42600
Pilot Pressure Accumulator and Ride Control Accumulator 8013 6-42621
Mounted Equipment Tab 9

Section Index - Mounted Equipment 6-42640
Pedals and Levers 9001 6-43040
Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a
Refrigerant 9002 6-42650
Air Conditioner System Service 9003 6-42660

Removal and Installation of Air Conditioning Components For Systems with
9004 6-42671
HFC-134a Refrigerant
Bur 6-44624 Revised 9-04 Printed in U.S.A.

621D Loader
Service Manual
6-42964
Table of Contents
Loader 9006 6-44761
ROPS Cab and ROPS Canopy 9007 6-44770
Cab Glass Installation 9010 6-42710
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 6-43052
Electrical Schematic Foldouts and Hydraulic Schematic Foldout P.I.N. In Rear Pocket 6-49310
JEE0135501 and Above
NOTE: Case Corporation reserves the right to make improvements in design or

changes in specifications at any time without incurring any obligation to install
them on units previously sold.

SECTION INDEX
GENERAL
Section Title Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Loctite Product Chart
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright © 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42730 August, 2001
1001
Section
1001
STANDARD TORQUE SPECIFICATIONS
CASE CORPORATION
700 State Street
CASE CANADA CORPORATION

© 1999 Case Corporation
450 Sherman Avenue Printed in U.S.A.
Hamilton, ON L8N 4C4 CANADA Rac 8-71602 Revised May, 1999
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE ......................................................................................... 3
TORQUE SPECIFICATIONS - METRIC HARDWARE ........................................................................................... 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ............................................................................ 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ............................................................................ 6
NOTE: Case Corporation reserves the right to make improvements in design or

changes in specifications at any time without incurring any obligation to install
them on units previously sold.
Rac 8-71602 Revised 5-99 Printed in U.S.A

1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques are not
given. These torques apply to fasteners with both UNC and Grade 8 Bolts, Nuts, and Studs
UNF threads as received from suppliers dr y, or when
lubricated with engine oil. Not applicable if special graphities,
Molydisulfide greases, or other extreme pressure lubricants
are used.
Pound- Newton
Size Inches metres
Grade 5 Bolts, Nuts, and Studs 1/4 inch 144 to 180 16 to 20
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Pound- Newton
Size Inches metres Pound- Newton
1/4 inch 108 to 132 12 to 15 Size Feet metres
5/16 inch 204 to 252 23 to 28 7/16 inch 70 to 84 95 to 114
9/16 inch 160 to 192 217 to 260
Pound- Newton 5/8 inch 220 to 264 298 to 358
Size Feet metres 3/4 inch 380 to 456 515 to 618
1/2 inch 80 to 96 109 to 130 1.0 inch 900 to 1080 1220 to 1465
9/16 inch 110 to 132 149 to 179 1-1/8 inch 1280 to 1440 1736 to 1953
1.0 inch 580 to 696 787 to 944 NOTE: Use thick nuts with Grade 8 bolts.
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983

1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not given.
Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads as
received from supplier, plated or unplated, or when lubricated 10.9
with engine oil. These values do not apply if graphite or
Molydisulfide grease or oil is used.
Pound- Newton
Size Inches metres
Grade 8.8 Bolts, Nuts, and Studs M4 36 to 48 4 to 5
M5 84 to 96 9 to 11
8.8
M6 132 to 156 15 to 18
M8 324 to 384 37 to 43
Pound- Newton
Size Inches metres
M4 24 to 36 3 to 4 Pound- Newton
Size Feet metres
M5 60 to 72 7 to 8
M10 54 to 64 73 to 87
M6 96 to 108 11 to 12
M12 93 to 112 125 to 150
M8 228 to 276 26 to 31
M14 149 to 179 200 to 245
M10 456 to 540 52 to 61
M16 230 to 280 310 to 380
M20 450 to 540 610 to 730
Pound- Newton
Size Feet metres M24 780 to 940 1050 to 1275
M12 66 to 79 90 to 107 M30 1470 to 1770 2000 to 2400
M14 106 to 127 144 to 172 M36 2580 to 3090 3500 to 4200
M16 160 to 200 217 to 271

M20 320 to 380 434 to 515 Grade 12.9 Bolts, Nuts, and Studs
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500 12.9
M36 1600 to 1950 2175 to 2600

Usually the torque values specified for grade 10.9 fasteners
can be used satisfactorily on grade 12.9 fasteners.

1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton

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

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

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

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

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

1002
Section
1002
FLUIDS AND LUBRICANTS
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-42981 August, 2001 (Revised June, 2002)
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Model 621D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 621D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ......................................................................................... 15.1 litres (16 U.S. quarts)
Type of oil ..................................................... Case No. 1 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity........................................................................................................................... 36 litres (38 U.S. quarts)
Type of Coolant ................ Ethylene glycol and water mixed for lowest ambient temperature (at least 50/50 mix)
Fuel Tank
Capacity ...................................................................................................................... 189 litres (50 U.S. gallons)
Type of Fuel ............................................................................................ See Diesel fuel specifications on page 5
Hydraulic System
Hydraulic Reservoir Refill Capacity with Filter Change ................................................. 68.5 litres (72 U.S. quarts)
Total System Capacity........................................................................................................113.6 litres (30 gallons)
Type of Oil ...................................................................................................................... MS-1209 Hy-Tran® Ultra
Transmission
Refill Capacity with Filter Change ................................................................................. 19.9 litres (21 U.S. quarts)
Total System Capacity..............................................................................................27.7 litres (29.25 U.S. quarts)
Type of Oil ...................................................................................................................... MS-1209 Hy-Tran® Ultra
Axles
Capacity
Front..................................................................................................................................22.7 litres (24 quarts)
Rear ..................................................................................................................................24.6 litres (26 quarts)
Type of Lubricant.............................................................................................................................. SAE 80W140
Brake System
Type of Fluid (Same as Hydraulic System)............................................................... MS-1209 Hy-Tran® Ultra
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil.
CONVERSION FORMULAS
Imperial quart = litres x 0.879877
Imperial gallons = litres x 0.219969

1002-4
ENGINE OIL RECOMMENDATIONS

Case IH No. 1 Engine oil is recommended for use
in your Case engine. Case IH No. 1 Engine Oil will
lubricate your engine correctly under all operating
conditions.
If C ase No. 1 Multi-Viscosity or Single G rad e
Engine Oil is not available, use only oil meeting
API engine oil service category CH .
See the chart below for
r e c o m m e n d e d v i s c o s it y a t
ambient air temperature
ranges.
NOTE: Do not put performance
additives or other oil additive
products in the engine BP99J241
crankcase. The oil change

RH99K130
intervals given in this manual
are according to tests with Case
lubricants.
BS99M162

1002-5
DIESEL FUEL SYSTEM

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

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

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

1002-6
MAINTENANCE SCHEDULE
Model 621D
Instructions
AS REQUIRED
22 SERVICE THE AIR CLEANER IF THE AIR CLEANER WARNING LAMP ILLUMINATES................................... SEE OPERATORS MANUAL
30 REPLACE THE TRANSMISSION FILTER
IF THE TRANSMISSION FILTER RESTRICTION WARNING LAMP ILLUMINATES ......................................................... USE CASE FILTER
19 CHECK THE RADIATOR COOLANT LEVEL IF THE WARNING LAMP ILLUMINATES ...................................... SEE OPERATORS MANUAL
6.REPLACE THE HYDRAULIC FILTER IF THE HYDRAULIC FILTER WARNING LAMP ILLUMINATES............................... USE CASE FILTER
CHECK THE AIR CONDITIONING DRIVE TENSION (IF EQUIPPED) NOT SHOWN ...............................................ADJUST AS REQUIRED
EVERY 10 HOURS OF OPERATION OR EACH DAY - WHICHEVER OCCURS FIRST

16 CHECK THE ENGINE OIL LEVEL........................................................................................................................ SEE OPERATORS MANUAL
EVERY 50 HOURS OF OPERATION

1.CHECK THE COOLANT RESERVOIR FLUID LEVEL ................................................................................. ETHYLENE GLYCOL AND WATER
29 CHECK THE TRANSMISSION OIL LEVEL (ENGINE RUNNING AND OIL WARM)............................................ SEE OPERATORS MANUAL
5.CHECK THE HYDRAULIC RESERVOIR FLUID LEVEL ........................................................................................ SEE OPERATORS MANUAL
38.LUBRICATE THE BUCKET AND BELLCRANK PIVOT POINTS (10 FITTINGS) XT .................................. CASE MOLYDISULFIDE GREASE
39 LUBRICATE THE BELLCRANK AND BUCKET PIVOTS (6 FITTINGS) Z-BAR .......................................... CASE MOLYDISULFIDE GREASE

7.LUBRICATE THE STEERING CYLINDER PIVOTS - ROD AND CLOSED END (4 FITTINGS) ................... CASE MOLYDISULFIDE GREASE
40 LUBRICATE THE LOADER LIFT ARM AND CYLINDER PIVOTS (7 FITTINGS) Z-BAR............................ CASE MOLYDISULFIDE GREASE
26 LUBRICATE THE FRONT DRIVE SHAFT SUPPPORT BEARING (1 FITTING) ......................................... CASE MOLYDISULFIDE GREASE
8.LUBRICATE THE LOADER LIFT ARM AND CYLINDER PIVOTS (14 FITTINGS) XT .................................. CASE MOLYDISULFIDE GREASE

19 CHECK THE RADIATOR COOLANT LEVEL.............................................................................................. ETHYLENE GLYCOL AND WATER
2.CHANGE THE ENGINE OIL AND REPLACE THE ENGINE OIL FILTER.............................................................. SEE OPERATORS MANUAL
34 CHECK THE BATTERY FLUID LEVEL................................................................................................................. SEE OPERATORS MANUAL
36 CHECK THE TIRE CONDITION AND AIR PRESSURE....................................................................................... SEE OPERATORS MANUAL
12 CLEAN THE CAB AIR FILTERS (IF EQUIPPED) ................................................................................................. SEE OPERATORS MANUAL

3.REPLACE THE FUEL FILTER .............................................................................................................................................. USE CASE FILTER
33 DRAIN WATER AND SEDIMENT FROM THE FUEL TANK ................................................................................. SEE OPERATORS MANUAL
14 REPLACE THE IN-LINE FUEL FILTER ............................................................................................................................... USE CASE FILTER

21 CHECK THE ENGINE VALVE CLEARANCES ............................................................................................................SEE SERVICE MANUAL
6.REPLACE THE HYDRAULIC FILTER ................................................................................................................................... USE CASE FILTER
30 REPLACE THE TRANSMISSION OIL FILTER .................................................................................................................... USE CASE FILTER
28 CHANGE THE TRANSMISSION OIL.................................................................................................................... SEE OPERATORS MANUAL
23 CLEAN THE TRANSMISSION BREATHER ................................................................................................................CLEAN WITH SOLVENT
24 LUBRICATE THE UPPER AND LOWER CHASSIS PIVOTS (2 FITTINGS) ............................................... CASE MOLYDISULFIDE GREASE
31 CHANGE THE FRONT/REAR AXLE OIL ............................................................................................................. SEE OPERATORS MANUAL
EVERY 2000 HOURS OF OPERATION OR EACH YEAR - WHICHEVER OCCURS FIRST

4.CHANGE THE HYDRAULIC OIL ............................................................................................................................ SEE OPERATORS MANUAL
18 DRAIN, FLUSH AND REFILL THE ENGINE COOLING SYSTEM ............................................................. ETHYLENE GLYCOL AND WATER
22 REPLACE THE AIR CLEANER ELEMENTS .....................................................................................................................USE CASE FILTERS

1002-7
MAINTENANCE SCHEDULE
Model 621D
12
19
14 1
3 40
16
34
6 39
33 23 36
36
28
30
8
22 38
21 8
2
34
31 26 29 31 4
39 38
7 18
24
BS01B021
If you operate the machine in severe conditions, See your Operators manual for maintenance of
lubricate and service the machine more frequently. It safety related items and for detailed information of
is recommended that you see your Case dealer for the service items on this chart. Operators and
in fo rmatio n o n the Syste m G u ard L ub ricatio n service manuals are available for this machine from
Analysis System. your Case dealer.

1002-8
NOTES

Section
1003
1003
METRIC CONVERSION CHART
CASE CORPORATION
700 State Street
CASE CANADA CORPORATION

© 1997 Case Corporation
Hamilton, ON L8N 4C4 CANADA Bur 7-52950 June, 1997
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
Bur 7-52950 Issued 6-97 Printed in U.S.A

Template Name: SM_1_col Alt= to hide template information
Template Date: 1994_04_05 Alt+ to display template information
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

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

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

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

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

litre/min. 0.219 969 gallon/min. (Imperial)
Bur 7-52950 Issued 6-97 Printed in U.S.A.

1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

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

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

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

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact

LOCTITE PRODUCT CHART
Working Fixture/Full Cure
Similar Gap Strength Temperature (Steel/Steel) Time
Product Color Products (In Inches) (Steel/Steel) Range-Farenheit Primer Description
N/A Form a Gasket (works with oil, fuel or
#3 Dark Brown 24 hr
grease) Pliable
80 Yellow Fast N/A Weatherstrip Adhesive
123 Clear N/A N/A Parts Cleaner Fluid
220 Blue 290 0.003 57/143 in lbs -65 to +250 6 min/24 hrs 747 Wicking Threadlocker
221 Purple 222 0.005 75/44 in lbs -65 to +300 2 min/24 hrs 747 Low Strength Threadlocker
Low Strength Threadlocker
222 Purple 0.005 53/30 in lbs -65 to +300 20 min/24 hrs 764 (Small Screws)
225 Brown 222 0.010 45/25 in lbs -65 to +300 7 min/24 hrs 747 Low Strength Threadlocker
242 Blue 0.005 80/50 in lbs -65 to +300 10 min/24 hrs 764 Medium Strength Threadlocker
262 Red 271 0.005 160/190 in lbs -65 to +300 5 min/24 hrs 747 High Strength Threadlocker
270 Green 271 0.007 160/320 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
271 Red 262 0.007 160/320 in lbs -65 to +300 10 min/24 hrs 764 High Strength Threadlocker
272 Red 620 0.007 180/220 in lbs -65 to +450 30 min/24 hrs 764 High Temperature, High Strength
275 Green 277 0.010 210/300 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
277 Red 0.010 225/300 in lbs -65 to +300 60 min/24 hrs 764 High Strength Threadlocker
290 Green 0.003 85/350 in lbs -65 to +300 6 min/24 hrs 764 Wicking Threadlocker
*404 Clear 495 0.006 3200 psi -65 to +180 30 sec/24 hrs NA Instant Adhesive
*406 Clear 0.004 3200 psi -65 to +180 15 sec/24 hrs N/A Surface Insensitive Adhesive
*409 Clear 454 0.008 2500 psi -65 to +180 50 sec/24 hrs N/A Gel Instant Adhesive
*414 Clear 0.006 2500 psi -65 to +180 30 sec/24 hr N/A Instant Adhesive
*415 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals)
*416 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics)
*420 Clear 0.002 2500 psi -65 to +180 15 sec/24 hrs N/A Wicking Instant Adhesive
*422 Clear 454 0.020 2800 psi -65 to +180 60 sec/24 hrs N/A Gap Filling Instant Adhesive
*430 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
*445 White/Black 0.250 2000 psi -65 to +180 5 min/24 hrs N/A Fast Setting 2 Part Epoxy
Surface Insensitive Gen
*454 Clear 0.010 3200 psi -65 to +180 15 sec/24 hrs N/A Instant Adhesive
*495 Clear 0.004 2500 psi -65 to +180 20 sec/24 hrs N/A General Purpose Instant Adhesive
*496 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
504 Brt Orange 515 0.030 750 psi -65 to +300 90 min/24 hrs None Rigid Gasket Eliminator
509 Light Blue 0.020 750 psi -65 to +320 6 hr/72 hrs 764 Flange Sealant
510 Red 0.020 1000 psi -65 to +400 30 min/24 hrs 764 High Temperature, GAsket Eliminator
515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 515
Rac 8-98902 * Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity Printed in U.S.A.
LOCTITE PRODUCT CHART
Working Fixture/Full Cure
Similar Gap Strength Temperature (Steel/Steel) Time
Product Color Products (In Inches) (Steel/Steel) Range-Farenheit Primer Description
518 Red 515 0.030 500psi -65 to +300 1hr/24 hrs 764 Gasket Eliminator 518 for Aluminum
542 Brown 569 N/A 132/92 in lbs -65 to +300 2 hr/24 hrs 747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
545 Purple N/A 25/20 in lbs -65 to +300 4 hr/24 hrs 747
Sealant
549 Orange 504 0.020 2500 psi -65 to +300 2 hr/24 hrs 747 Instant Seal Plastic Gasket
554 Red 277 0.015 240/240 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Refrigerant Sealant
567 White 592 N/A 500 psi -65 to +400 4 hrs/24 hrs 764 Pipe Sealant for Stainless Steel
568 Orange 277 0.015 2500 psi -65 to +300 12 hrs/24 hrs 764 Plastic Gasket
569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant
570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hrs/72 hrs 764 Steam Sealant
571 Brown 592 0.015 40/20 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Pipe Sealant
572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs None Gasketing
592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon
593 Black 0.250 400 psi -95 to +400 30 min/24 hrs N/A RTV Silicone
601 Green 609 0.005 3000 psi -65 to +300 10 min/24 hrs 764 Current PIN #609
609 Green 0.005 3000 psi -65 to +300 10 min/24 hrs 764 General Purpose Retaining Compound
High Temperature Retaining
620 Green 640 0.015 3000 psi -65 to +450 30 min/24 hrs 747
Compound
635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 747 High Strength Retaining Compound
638 Green 680 0.015 4100 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747 High Temperature Retaining Compound
660 Silver 0.020 3000 psi -65 to +300 20 min/24 hrs 764 Quick Metal
675 Green 609 0.005 3000 psi -65 to +300 20 min/24 hrs 747 General Purpose Retaining Compound
680 Green 635 0.015 4000 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
706 Clear 755 N/A N/A N/A N/A N/A Cleaning Solvent
707 Amber N/A N/A N/A N/A N/A Activaltor for Structural Adhesives
736 Amber N/A N/A N/A N/A N/A Primer NF
738 Amber N/A N/A N/A N/A N/A Depend Activator
747 Yellow N/A N/A N/A N/A N/A N/A Primer T
751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives
755 Clear N/A N/A N/A N/A N/A Cleaning Solvent
764 Green N/A N/A N/A N/A N/A Primer N
767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant
Printed in U.S.A.
SECTION INDEX
ENGINES
Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

Engine and Radiator Removal and Installation P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . .2000
Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002
FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL
CASE CORPORATION
700 State Street
Hamilton, ON L7N 3M6 CANADA Bur 6-42281 February, 2003
Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
2000
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-44630 November, 2001
2000-2
TABLE OF CONTENTS
ENGINE . . . . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 16
RADIATOR . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 29
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 29
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 31
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Liters (38 Quarts)
Engine Oil
Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Liters (16 Quarts)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case No. 1 Engine Oil (SAE 15W-40
Hydraulic Reservoir
Refill Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Liters (18 Gallons)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS-1209 Hy-Tran Ultra®
SPECIAL TORQUES
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 to 298 Nm (180 to 220 lb-ft)
Engine Drive Shaft Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Radiator Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Counterweight Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693 to 780 Nm (510 to 575 lb-ft)
Counterweight Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955 to 1075 Nm (704 to 793 lb-ft)
Muffler Front Mounting Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 to 133 Nm (87 to 98 lb-ft)
Muffler Rear Mounting Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 39 Nm (25 to 28 lb-ft)
Turbocharger Elbow Clamp at Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 Nm (15 to 18 lb-ft)
Turbocharger Elbow Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 5.2 Nm (42.5 to 46 lb-inch)
Air Cleaner Hose Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Air Cleaner Inlet Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 4.5 Nm (32.4 to 39.6 lb-inch)
Hood Mounting Bolts at Cooling Frame Pivot Points . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 45 Nm (26.5 to 32.5 lb-ft)
Screen Hinge Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 33 Nm (19.8 to 24.4 lb-ft)
Coupler to Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)

2000-3
ENGINE
Removal STEP 5
STEP 1
Park machine on a level surface and lower bucket to
ground. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key 2
switch in ON position and move loader control lever 3
back and forth at least 30 times to release any
pressure from hydraulic circuit. Put key switch in OFF
position.
STEP 2 1
BD01F144
Using a flat blade screwdriver or other suitable tool,

disengage bottom clip (1) from hood prop (2) and pull
bottom of prop from stud (3). Repeat to remove top of
prop from hood; remove prop then close hood.
STEP 6
BD01F143
Put articulation lock in LOCKED position.
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4 BD01F145
Open screen.
STEP 7
BD01F258
Open and raise hood. Put master disconnect switch

in OFF position.
BD01F146
Remove cotter pin and three washers.

2000-4
STEP 8 STEP 11
6
5
4 7
BD01F148 BD01F154
Remove four bolts (4) securing hinges of screen to Remove lock nut (6) securing LH spring (7) to hood.
hood. Disconnect prop bar (5) from screen and Repeat to remove lock nut securing RH spring to
remove screen. hood. Disconnect springs from hood; it may be
necessary to raise hood to disconnect springs from
STEP 9 hood.
STEP 12
BD01F153
Connect a lifting strap to the hood handle and

connect lifting equipment to strap. Depress handle BD01F155
latch and let hood raise. At front RH side of hood, identify, tag, and disconnect
hood wiring harness connector from rear chassis
STEP 10 wiring harness connector.
STEP 13
Lower hood.
BD01F255
Take up all slack in strap connected to hood handle.

2000-5
STEP 14 STEP 17
BD01F150 BD01F158
Install two lifting eyes and connect lifting strap to Carefully raise and remove hood from loader. Lower
eyes. hood onto suitable platform and disconnect lifting
equipment.
STEP 15
STEP 18
BD01F156
Connect lifting equipment to the lifting straps. BD01D150
Tag and disconnect engine wiring harness connector

STEP 16 from air filter restriction switch.
STEP 19
BD01F151
Re mo ve tw o nu ts an d bo lts a nd fo ur w ashe rs
securing hood. BD01F159
Loosen clamp on air cleaner intake hose and remove

hose.

2000-6
STEP 20 STEP 23
BD01F160 BD01F167
Loosen clamp on turbocharger intake hose and Disconnect battery cable from RH battery positive
disconnect hose from turbocharger. post. Put a plastic cap over the positive post.
STEP 21 STEP 24
8
9
BD01F163 BD01F166
Loosen two bolts. Remove battery cover by sliding Support air cleaner assembly (9) and remove two
out from under bolts. Repeat this step to remove RH lock nuts, washers, bolts (8), and washers. Remove
battery cover. air cleaner and support as an assembly.
STEP 22 STEP 25
11
10
BD01F164 BD01F168
Disconnect battery cable from LH battery negative Remove four bolts (10) and washers securing drive
post. Put a plastic cap over the negative post. belt guard (11) to master disconnect switch mounting
bracket and belt guard bracket.

2000-7
STEP 26 STEP 29
BD01F169 BD01F173
Remove clamp securing elbow to muffler. Loosen clamp and remove tube from turbocharger.
STEP 27 STEP 30
13
12
12
BD01F232 BD01F174
At fron t o f en gin e, re move two b olts (12 ) an d Cut, remove, and discard tie strap securing RH rear
washers securing wiring harness clamps and muffler combination lamp wire. Identify, tag, and disconnect
mounting bracket (13). r e a r c h a s s i s w i r in g h a r n e s s c o n n e c t o r f r o m
combination lamp connector. Repeat this step for LH
STEP 28 rear combination lamp.
STEP 31
BD01F170
Support muffler and brackets and remove three bolts

and washers at rear of engine. Remove muffler and BD01F175
brackets as an assembly from engine. Connect lifting equipment to rear counterweight.

Take up all slack in lifting equipment.

2000-8
STEP 32 STEP 35
14 14
15
16 15
BD01F176 BD01F180
Remove two nuts (14) and washers and two bolts Connect lifting equipment to counterweight plate.
(15), washers, and nuts securing counterweight (16).
STEP 36
STEP 33
BD01F181
BD01F178 Remove counterweight plate from loader and place

P u ll c o u n t e r w e ig h t f r o m s t u d s a n d r o u te L H on pallet. Do not loose spacers.
combination lamp wiring harness and connector
through slot in rear chassis and cutout in STEP 37
counterweight plate if installed. Repeat for RH
combination lamp wiring harness and connector.
Remove counterweight (16) from loader and place
on pallet.
STEP 34
BD01F184
A Put a 37.8 liter (10 gallon) container below radiator

drain. Remove radiator cap. Remove cap and drain
coolant into container. Install cap after coolant has
drained. Install radiator cap.
BD01F179
If equipped with counterweight plate, use a pry bar

(A) and move plate away from rear chassis enough
to connect lifting straps to plate.

2000-9
STEP 38 STEP 41
BD01F186 BD01F189
Loosen two hose clamps. Remove bottom hose. Swing air conditioning condenser up to its upright
position.
STEP 39
STEP 42
17
19
20
17
BD01F185 18
Loosen two hose clamps. Remove upper hose. BD01F192
At top of cooling system frame, loosen two hose

STEP 40 clamps (17). Remove hose (18). Remove two nuts
(19) securing U-bolt and clamp (20). Remove U-bolt,
clamp, and spacer.
STEP 43
BD01F187
If loader is equipped with air conditioning, at top of

cooling system frame unlatch latch securing air
conditioning condenser.
BD01F190
Remove two nuts securing U-bolt holding top coolant

pipe. Remove U-bolt, clamp, and spacer. Remove
top coolant pipe from cooling system frame.

2000-10
STEP 44 STEP 46
23 24
22 25
21
BD01F197 BD01F200
If loader is equipped with air conditioning, identify, Remove nut (24) and washer from engine ground
tag, and disconnect the engine wiring harness stud. Disconnect secondary steering ground wire (if
connectors from air compressor clutch connector equipped) and five ground wires of the rear chassis
(21) an d high pressure switch connector (22). wiring harness from stud. Remove nut (25) and
Disconnect engine wiring harness connector from washer. Disconnect ground cables from engine
disconnect switch wiring harness connector (23). ground stud. Move cables away from engine.
STEP 45 STEP 47
26
BD01F198 BD01F202
Pull rubber boot (26) back from starter B+ terminal.

Remove the nut, lock washer, and flat washer from
B+ terminal. Identify, tag, and disconnect wires from
terminal.
BD01F199
If loader is equipped with a coolant heater, loosen

knurled nut and disconnect cable from element.

2000-11
STEP 48 STEP 51
BD01F204 BD01F210
Identify and tag wire connected to starter solenoid Route rear chassis wiring harness to front of engine
terminal. Pry the plastic cap from starter solenoid and pass to an assistant. Cut, remove, and discard
termin al. U sin g a Ph illips scre wdriver, lo ose n three tie straps then have assistant route harness to
terminal screw and disconnect wire from terminal. RH side of engine compartment and away from
engine. If equipped, move auxiliary steering wiring
STEP 49 harness away from engine.
STEP 52
28
27
29
BD01F207
Remove bolt (27), lock washer, and washer securing

harness clamps to engine. Top harness (28) is rear
BD01F196
chassis wiring harness; bottom harness (29) is
Put a 12.7 mm (1/2 inch) drive breaker bar or ratchet
engine wiring harness.
in bracket for automatic belt tensioner. Lift up on
breaker bar or ratchet to release drive belt tension
STEP 50 and remove belt.
BD01F205
Identify, tag, and disconnect the four connectors.

2000-12
STEP 53 STEP 56
BD01F211 BD01D194
If loader is equipped with air conditioning, support air Disconnect hose from fitting installed in engine oil
conditioning compressor and remove four bolts. pan. Install a plug in hose and a cap on fitting.
STEP 54 STEP 57
31 30
BD01F213 BD01D200
Install battery cover. Put air conditioning compressor At front of engine, remove six bolts (30) securing
on battery cover. drive shaft (31) to engine coupling. Use a pry bar to
move drive shaft away from engine coupling.
STEP 55
STEP 58
32
33
34
BD01F184
Put a 18.9 liter (5 gallon) container below engine oil BD01D208
d r a in . R e m o ve c a p a n d d r a in e n g in e o il in t o Disconnect engine wiring harness connector (32)

container. Install cap after oil has drained. f r o m t r a n s m i s s i o n w i r in g h a r n e s s b u l k h e a d
connector. Remove clamp (33) securing fuel supply
hose to engine flywhe el housing. Remove two
clamps (34) securing fuel return hose to engine.

2000-13
STEP 59 STEP 62
If equipped, disconnect ether start tube from intake
manifold. 38
STEP 60
37
41
42
39
40
BD01F225
Remove nut and washer securing ball joint (37) to

throttle lever (38 ). Remove two bolts (39) and
washers securing throttle bracket (40) to engine.
BD01F219
Move throttle bracket with throttle cable and ball joint
Expand clamp and disconnect heater hose from attached away from engine. Remove bolt (41) and
fitting. Plug heater hose and cap fitting. clamp securing fuel return hose (42).
STEP 61 STEP 63
35
36
BD01F221
BD01F217
Loosen clamp (35). Tag and disconnect fuel supply Connect a vacuum pump to hydraulic reservoir. If a
hose (36) from primer pump. Plug hose and cap vacuum pump is not available, drain the hydraulic oil
fitting to prevent intrusion of foreign matter into fuel (hydraulic reservoir holds 68.5 liters (18 gallons) of
system. oil). Turn on va cu um pump (if availab le). Tag,
disconnect, and plug hoses connected to brake
pump. Plug hoses securely and cap fittings. Turn off
vacuum pump.

2000-14
STEP 64 STEP 67
BD01F223 BD01F214
Tag and disconnect fuel return hose. Plug hose and Disconnect rear chassis wiring harness ether start
cap fitting. solenoid connector from engine wiring harness
connector.
STEP 65
STEP 68
44
45
43
BD01F226
Remove nut (43), washer, and bolt securing clamp BD01F229
(44) and engine oil pressure sender (45) to rear Connect lifting equipment to engine lifting brackets.
chassis. Remove these parts as an assembly and Take up all slack in lifting equipment.
secure to engine using suitable means.
STEP 69
STEP 66
BD01D206
BD01D219 At front of engine, remove nut, bolt, and two washers

Remove two nuts and remove belt guard bracket. securing both sides of engine to rear chassis.

2000-15
STEP 70 STEP 71
Slowly raise engine from rear chassis. Be sure all
harness c onnect ions and hoses hav e been
disconnected and out of the way. Remove engine
from machine.
BD01D181
At rear of rear chassis, between fuel tank mounting

plate and rear chassis, remove bolt and washer
securing rear of engine to rear chassis.

2000-16
Installation STEP 73
STEP 72 A
56 48
B
55
47
51
52 46
49
A
50
53
BC01D129
54
46. RUBBER ISOLATOR 50. BOLT
B 47. SPACER A. ENGINE
48. RUBBER ISOLATOR B. REAR CHASSIS
49. WASHER
58 57 If engine rear rubber isolators require replacement,
remove and discard isolators (46 and 48) and spacer
BC01D128
(47). Install new rubber isolators (46 and 48) and
51. RUBBER ISOLATOR 56. BOLT spacer (47) in rear chassis.
52. WASHER 57. WASHER
53. RUBBER ISOLATOR 58. NUT
54. WASHER A. ENGINE
STEP 74
55. WASHER B. REAR CHASSIS Slowly raise engine and move into position over rear
chassis. Be sure all harness connections and hoses
If engine front rubber isolators require replacement,
are out of the way then lower engine. Put washer
remove and discard isolators (51 and 53). Install new
(54) between front rubber isolator (53) and rear
rubber isolator (53), washer (52), then rubber isolator
chassis. Install washer (55), bolt (56), washer (57),
(51).
and nut (58) in engine front isolators. Lower engine
into position. Install washer (49) and bolt (50) in rear
isolator.
STEP 75
56
BD01D206
At front of engine, tighten two bolts (56) to a torque of

244 to 298 Nm (180 to 220 lb-ft).

2000-17
STEP 76 STEP 79
50
BD01D181 BD01D219
At rear of rear chassis, between fuel tank mounting Position belt guard bracket on rear chassis and
plate and rear chassis, tighten bolt (50) to a torque of secure using two nuts.
244 to 298 Nm (180 to 220 lb-ft).
STEP 80
STEP 77
44
45
43
BD01F226
BD01F229 Position engine oil pressure sender (45) and clamp

Disconnect lifting equipment from engine lifting (44) on tab of rear chassis. Install nut (43), washer,
brackets. and bolt to secure clamp and engine oil pressure
sender to rear chassis.
STEP 78
STEP 81
BD01F214
At right side of engine compartment, connect ether BD01F223
start solenoid connector to engine wiring harness Remove plug from hose and cap from fuel injection
connector. pump fitting. Connect fuel return hose to fuel injection
pump following tag installed during removal. Position
and tighten clamp. Remove and discard tag.

2000-18
STEP 82 STEP 84
35
36
BD01F221 BD01F217
Turn on vacuum pump conne cted to hydraulic Re mo ve p lug fr om ho se a n d ca p fro m fittin g.

reservoir. Remove caps from fittings and plugs from Connect fuel supply hose (36) to primer pump and
hoses. Connect hoses to brake pump following tags tighten clamp (35). Remove and discard tag installed
installed during removal. Remove and discard tags. during removal.
Turn off and disconnect vacuum pump from hydraulic
reservoir. STEP 85
STEP 83
38
37
41
42
39
40
BD01F219
Re mo ve p lug fr om ho se a n d ca p fro m fittin g.

BD01F225 Connect heater hose to fitting and position clamp on
Put fuel return hose (42) with clamp on engine and hose.
secure with bolt (41). Position throttle bracket(40)
with throttle cable and ball joint attached on engine. STEP 86
Install two washers and bolts (39) to secure throttle If equipped, connect ether start tube to intake
bracket to engine. Connect ball joint (37) to throttle manifold.
lever (38) and secure with nut and washer.

2000-19
STEP 87 STEP 90
32
33
34
BD01D208 BD01F211
Position fuel return hose and secure using two If loader is equipped with air conditioning, position
clamps (34). Position fuel supply hose and secure and support air conditioning compressor and install
using clamp (33). Connect engine wiring harness four bolts.
connector (32) to transmission wiring harness
bulkhead connector. STEP 91
STEP 88
31 30
BD01F196
Route drive belt on pulleys then put a 12.7 mm (1/2

BD01D200 inch) drive breaker bar or ratchet in bracket for
At front of engine, position drive shaft (31) on engine automatic belt tensioner. Lift up on breaker bar or
coupling. Install six bolts (30) to secure drive shaft ratchet and position drive belt then release belt
(31) to engine coupling. Tighten the six bolts to a tensioner to put tension on drive belt.
torque of 53 to 62 Nm (39 to 46 lb-ft).
STEP 92
STEP 89
BD01F210
BD01D194 Have an assistant route rear chassis wiring harness to

Remove plug from oil drain hose and cap from fitting LH front of engine. Position auxiliary steering wiring
installed in engine oil pan. Connect and tighten hose harness and install three tie straps to secure wiring
to fitting. harnesses.
2000-20
STEP 93 STEP 96
26
BD01F205 BD01F202
Connect connectors following tags installed during Connect wires to starter B+ terminal following tags
removal. Remove and discard tags. installed during removal. Install flat washer, lock
washer, and nut to secure wires. Position rubber boot
STEP 94 (26) over starter B+ terminal. Remove and discard
tags from wires.
STEP 97
28
27 24
25
29
BD01F207
Install bolt (27), lock washer, and washer to secure

harness clamps to engine. Top harness (28) is rear
chassis wiring harness; bottom harness (29) is BD01F200
engine wiring harness. Connect rear chassis wiring harness ground cable,
ground cable from disconnect switch, and ground
STEP 95 cable from rear chassis rear ground stud to engine
ground stud. Secure using nut (25) and washer.
Connect five ground wires of rear chassis wiring
harness and secondary steering (if equipped) ground
wire to engine ground stud. Secure using nut (24)
and washer.
BD01F204
Connect wire to starter solenoid terminal following

tag in sta lled du ring re mova l. U sing a P hillip s
screwdriver, tighten terminal screw. Install plastic cap
in terminal screw recess. Remove and discard tag.

2000-21
STEP 98 STEP 100
BD01F198 BD01F190
Insert top coolant pipe in cooling system frame.

Install spacer, clamp, and U-bolt then install two nuts.
Do not tighten nuts at this time.
STEP 101
17
19
BD01F199 20
If loader is equipped with a coolant heater, connect
cable to element and tighten knurled nut.
17
STEP 99 18
BD01F192
At top of cooling system frame, install spacer, clamp

(20), and U-bolt and secure using two nuts (19). Do
not tighten nuts at this time. Install hose (18).
23 Position clamps (17) and tighten clamps to a torque
22 of 10.1 to 11.3 Nm (90 to 100 lb-inch). Tighten four
nuts securing two U-bolts.
STEP 102
21
BD01F197
C o n n e ct e n g in e w irin g h a r n e ss c o n n e c to r t o
disconnect switch wiring harness connector (23). If
loader is equipped with air conditioning, connect the
engine wiring harness connectors to air compressor
clutch connector (21) and high pressure switch
con necto r (22 ) fo llowing ta gs installe d du rin g
removal. Remove and discard tags.
BD01F187
If equipped, lower air conditioning condenser into

position and secure using latch.

2000-22
STEP 103 STEP 106
BD01F185 BD01F180
Install upper hose. Position and tighten hose clamps. Install counterweight plate on spacers and studs.
Disconnect lifting equipment from counterweight
STEP 104 plate. Push counterweight plate towards front of
loader.
STEP 107
BD01F186
Install bottom hose. Position and tighten hose

clamps to a torque of 10.1 to 11.3 Nm (90 to 100 lb-
inch). BD01F177
STEP 105
BD01F178
Move counterweight into position at rear of loader.

BD01F181
Route LH combination lamp wiring harness and
If loader is equipped with counterweight plate, make connector through slot in counterweight plate (if
sure spa ce rs are installe d o n studs and move installed) and cutout in rear chassis. Repeat for RH
counterweight plate in position at rear of loader. combination lamp wiring harness and connector.

2000-23
STEP 108 STEP 111
14 14
15
16 15
BD01F176 BD01F170
Install two nuts (14) and washers and two bolts (15), Install and support muffler and brackets on engine
washers, and nuts. Tighten nuts to a torque of 693 to while connecting muffler to tube installed in Step 110.
780 Nm (510 to 575 lb-ft). Tighten bolts to a torque of Install three washers and bolts at rear of engine
955 to 1075 Nm (704 to 793 lb-ft). Disconnect lifting finger tight.
equipment from counterweight (16).
STEP 112
STEP 109
13
12
12
BD01F232
BD01F174 At front of engine, position wiring harness clamps on

Connect rear chassis wiring harness connector to muffler mounting bracket (13). Secure clamps and
combination lamp connector following tag installed muffler mounting bracket using two washers and
during removal. Install new tie strap to secure RH bolts (12). Tighten bolts to a torque of 118 to 133 Nm
rear combination lamp wire. Remove and discard (87 to 98 lb-ft). Tighten the three rear bolts installed
tags. Repeat this step for LH rear combination lamp. in Step 111 to a torque of 34 to 39 Nm (25 to 28 lb-ft).
STEP 110
BD01F173
Position tube on turbocharger. Do not tighten clamp

at this time.

2000-24
STEP 113 STEP 116
BD01F169 BD01F167
Position clamp securing elbow to muffler. Tighten Remove plastic cap installed over the RH battery
clamp to a torque of 20 to 25 Nm (15 to 18 lb-ft). positive post during removal. Connect battery cable
Tighten clamp securing opposite end of elbow to to RH battery positive post.
turbocharger to a torque of 4.8 to 5.2 Nm (42.5 to 46
lb-inch). STEP 117
STEP 114
11
10
BD01F164
Remove plastic cap installed over the LH battery

BD01F168 negative post during removal. Connect battery cable
Position drive belt guard (11) and secure using four to LH battery negative post.
washers and bolts (10) to master disconnect switch
mounting bracket and belt guard bracket. STEP 118
STEP 115
8
9
BD01F163
Install LH battery cover. Tighten two bolts. Repeat to

BD01F168 install RH battery cover.
Position air cleaner assembly (9) and support as an
assembly. Secure using two bolts (8), four washers,
and two lock nuts.

2000-25
STEP 119 STEP 122
BD01F160 BD01D242
C o n n e c t h o s e f r o m a ir c l e a n e r a s s e m b ly t o If removed, install bushings at hood pivot points on

turbocharger. Position clamp and tighten to a torque top of cooling frame.
of 10.1 to 11.3 Nm (90 to 100 in-inch).
STEP 123
STEP 120
BD01F158
BD01F159 Raise and move hood into position above loader.

Connect air cleaner hose between cooling frame and Slowly and carefully lower hood into position while
air cleaner inlet. Position clamp and tighten to a guiding hood pivot points into position with pivot
torque of 3.6 to 4.5 Nm (32.4 to 39.6 lb-inch). points on top of cooling frame.
STEP 121 STEP 124
BD01D150 BD01F151
Connect engine wiring harness connector to air filter Install two bolts, four washers, and two nuts to
restriction switch following tag installed during secure hood. Tighten bolts to a torque of 36 to 44 Nm
removal. Remove and discard tag. (26.5 to 32.5 lb-ft).

2000-26
STEP 125 STEP 127
BD01F156 BD01F154
Connect springs (7) to hood; it may be necessary to

raise hood to connect springs. Install lock nuts (6) to
secure LH and RH springs to hood.
STEP 128
BD01F149
Lower lifting equipment until strap connected to two

lifting eyes can be removed. Remove the two lifting
eyes from hood.
STEP 126 BD01F156
At front RH side of hood, connect hood wiring

harness connector to rear chassis wiring harness
connector following tag installed during removal.
Remove and discard tag.
STEP 129
Lower hood.
STEP 130
BD01F255
Take up all slack in strap connected to hood handle

and raise hood as shown.
BD01F153
Disconnect lifting strap from hood handle.

2000-27
STEP 131 STEP 134
5
4 2
3
1
BD01F148 BD01F144
Position screen on hood. Install four bolts (4) to Using a flat blade screwdriver or other suitable tool,
secure hinges of screen to hood. Tighten bolts to a disengage bottom clip (1) from hood prop (2) and
torque of 27 to 33 Nm (19.8 to 24.4 lb-ft). Connect push bottom of prop onto stud (3). Repeat to install
prop bar (5) to screen. top of prop to hood.
STEP 132 STEP 135
BD01F146 BD01F184
Install three washers and cotter pin. Check and make sure that drain caps are tight.
STEP 133 STEP 136

Install a new oil filter on engine. Fill engine with 15.1
liters (16 quarts) of Case No. 1 Engine Oil (SAE
15W-40).
STEP 137
If hydraulic reservoir was drained, fill reservoir with
68.5 liters (18 gallons) of MS-1209 Hy-Tran Ultra®
fluid.
STEP 138
Fill engine coolant system with a solution of 50%
BD01F145
Ethylene Glycol and 50% water. Cooling system
capacity is 36 liters (38 quarts). Install the radiator
Close screen and open hood.
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.

2000-28
STEP 139 STEP 140
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
a n d w a te r. W h e n th e c o o la n t is a t o p e r a ti n g
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
STEP 141
Lower and close hood.
STEP 142
Put articulation lock in OPERATING position.
BD01F259
Put master disconnect switch in ON position.

WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.

2000-29
RADIATOR
Removal STEP 148
STEP 143
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 144
BD01F234
BD01F143
STEP 145
Open and raise hood.
STEP 146 BD01F235
Remove two bolts and washers securing LH fender.

Remove LH fender.
STEP 149
BD01F258
Put master disconnect switch in OFF position.
STEP 147
Remove the hood (Steps 5 through 17). BD01F184
Put a 37.8 liter (10 gallon) container below radiator

drain. Remove radiator cap then remove cap and
drain coolant into container. Install cap after coolant
has drained. Install radiator cap.

2000-30
STEP 150 STEP 153
1 3
5 2 4
BD01F236 BD01F240
Loosen two hose clamps (1 and 2). Disconnect two Loosen two clamps securing radiator bottom hose.
hoses (3 and 4) from fuel cooler (5). Plug hoses and Remove bottom hose.
cap cooler ports to prevent entry of foreign matter
into fuel system. STEP 154
STEP 151 9 10
5
11
12
6
BD01D223
Remove radiator cap (9) and disconnect overflow

BD01F237 h o se ( 1 0 ) fr o m r a d ia to r. I n st a ll r a d ia to r ca p .
Support fuel cooler (5); remove two bolts (6) and Disconnect connector from coolant level sender (11).
washers. Remove fuel cooler. Remove screw (12) and install lifting eye.
STEP 152 STEP 155
13
7
14
7
8
BD01F192 BD01F238
If loader is equipped with air conditioning, at top of Remove two bolts (13) and lock washers on both
cooling system frame, unlatch latch securing air sides of radiator. Remove screw (14) and install
conditioning condenser. Swing condenser up to its lifting eye.
upright p ositio n. Loosen two ho se clamps (7).
Remove hose (8).

2000-31
STEP 156 Installation
STEP 158
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
STEP 159
BD01F239 15
Connect lifting equipment to lifting eyes. Take up all
slack in lifting equipment.
STEP 157
BD01D225
Install four lock washers and bolts (15) to secure

15 radiator to cooling frame.
STEP 160
BD01D225
Remove four bolts (15) and lock washers securing

radiator to cooling frame. Carefully and slowly raise
radiator from cooling frame and remove from loader.
BD01F239
Disconnect lifting equipment from lifting eyes.

2000-32
STEP 161 STEP 164
13
7
14
7
8
BD01F238 BD01F193
Remove lifting eye and install screw (14). Install two At top of cooling system frame, install hose (8).
lock washers and bolts (13) to secure radiator on Position hose clamps and tighten to a torque of 10.1
both sides. to 11.3 Nm (90 to 100 lb-inch).
STEP 162 STEP 165
9 10 5
11
12 6
BD01D223 BD01F237
Remove lifting eye and install screw (12). Connect Position and support fuel cooler (5) on radiator.
connector to coolant level sender (11). Remove Install two washers and bolts (6) to secure fuel
radiator cap (9) and connect overflow hose (10) to cooler.
radiator. Install radiator cap.
STEP 166
STEP 163
1 3
5 2 4
BD01F226
BD01F240 Remove plugs from hoses (3 and 4) and caps from

At bottom of radiator, install bottom radiator hose. fuel cooler (5) ports. Connect hoses to fuel cooler.
Position and tighten two hose clamps to a torque of Position two hose clamps (1 and 2) and tighten.
10.1 to 11.3 Nm (90 to 100 lb-inch).

2000-33
STEP 167 STEP 170
capacity is 36 liters (38 quarts). Install the radiator
the reservoir.
STEP 171
BD01F234
BD01F259
STEP 172
BD01F235
Install LH fender and secure using two washers and
bolts.
STEP 168
Install the hood (Steps 122 through 134). WARNING: Hot coolant can spray out if radiator cap
STEP 169 released. Scalding can result from fast removal of
radiator cap.
STEP 173
STEP 174
BD01F184
Check that coolant drain cap is tight.

2000-34
NOTES

Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION

P.I.N. JEE0135501 AND ABOVE
2000
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-49060 February, 2003
2000-2
TABLE OF CONTENTS
ENGINE . . . . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 16
RADIATOR . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 31
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 31
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 33
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 Liters (9 Gallons)
Engine Oil
Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Liters (11 Quarts)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case No. 1 Engine Oil (SAE 15W-40
Hydraulic Reservoir
Refill Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Liters (18 Gallons)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS-1209 Hy-Tran Ultra®
SPECIAL TORQUES
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 to 298 Nm (180 to 220 lb-ft)
Engine Drive Shaft Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Radiator Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Charge Air Tube Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Muffler Front Mounting Bracket to Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 118 to 133 Nm (87 to 98 lb-ft)
Muffler Rear Mounting Bracket to Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 68 to 77 Nm (50 to 56.5 lb-ft)
Muffler Mounting Brackets to Muffler Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 to 44 Nm (29 to 32 lb-ft)
Turbocharger Elbow Clamp at Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 Nm (15 to 18 lb-ft)
Turbocharger Elbow Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 5.2 Nm (42.5 to 46 lb-inch)
Air Cleaner Hose Clamps at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Air Cleaner Inlet and Outlet Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 4.5 Nm (32.9 to 39.6 lb-inch)
Hood Mounting Bolts at Cooling Frame Pivot Points . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 44 Nm (26.5 to 32.5 lb-ft)
Screen Hinge Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 33 Nm (19.8 to 24.4 lb-ft)
Coupler to Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Air Conditioning Compressor Mounting Bracket Mounting Bolts
M8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 44 Nm (25 to 32.5 lb-ft)
M10 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 to 87 Nm (49.4 to 64 lb-ft)

2000-3
ENGINE
Removal STEP 5
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in 2
ON position and move loader control lever back and 3
forth at least 30 times to release any pressure from 1
hydraulic circuit. Put key switch in OFF position.
STEP 2
BD01F144
1. CLIP
2. HOOD PROP
3. STUD
disengage bottom clip (1) from hood prop (2) and pull
bottom of prop from stud (3). Repeat to remove top of
prop from hood; remove prop then close hood.
STEP 6
BD01F143
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD01F145
Open screen.
STEP 7
BD01F258
Open and raise hood. Put master disconnect switch

in OFF position.
BD01F146
Remove cotter pin and three washers.

2000-4
STEP 8 STEP 11
5 6
4 7
BD01F148 BD01F154
4. BOLTS 5. PROP BAR 6. LOCK NUT 7. LH SPRING

Remove four bolts (4) securing hinges of screen to Remove lock nut (6) securing LH spring (7) to hood.
hood. Disconnect prop bar (5) from screen and Repeat to remove lock nut securing RH spring to
remove screen. hood. Disconnect springs from hood; it may be
necessary to raise hood to disconnect springs from
STEP 9 hood.
STEP 12
BS01F153
Connect a lifting strap to the hood handle and

connect lifting equipment to strap. Depress handle BD01F155
latch and let hood raise. At front RH side of hood, identify, tag, and disconnect
hood harness connector from rear chassis harness
STEP 10 connector.
STEP 13
Lower hood.
BD01F255

2000-5
STEP 14 STEP 17
BD01F150 BD01F158
Install two lifting eyes and connect lifting strap to Carefully raise and remove hood from loader. Lower
eyes. hood onto suitable platform and disconnect lifting
equipment.
STEP 15
STEP 18
BD01F156
Connect lifting equipment to the lifting straps. BD01D150
Tag and disconnect engine wiring harness connector

STEP 16 from air filter restriction switch.
BD01F151
Re mo ve tw o nu ts an d bo lts a nd fo ur w ashe rs
securing hood.

2000-6
STEP 19 STEP 22
9
8
13
14 10 8
15 11
10 12 BD01F167
11 11 Disconnect battery cable from RH battery positive
11 12
post. Put a plastic cap over the positive post.
STEP 23
BS02K106
8. BOLT 11. WASHER 14. WASHER 16

9. BATTERY COVER 12. BOLT 15. BATTERY COVER 19
10. LOCK NUT 13. BOLT
18
At LH battery cover, remove two bolts (8) and battery
cover (9). Remove two lock nuts (10), bolts (12), four 17 16
washers (11), bolt (13), and washer (14). Remove
battery cover (15).
20
21
STEP 20 27 20
Repeat Step 19 to remove RH battery covers. 22
STEP 21
18
23
24
25
26 25
BS02K105
BD01F164
16. CLAMP 22. TUBE
Disconnect battery cable from LH battery negative 17. INTAKE HOSE 23. HOSE
post. Put a plastic cap over the negative post. 18. CLAMP 24. LOCK NUT
19. HOSE 25. WASHER
20. CLAMP 26. BOLT
21. HOSE 27. AIR CLEANER
Loosen clamp (16) on air cleaner intake hose (17)
and remove intake hose.

2000-7
STEP 24 STEP 27
Loosen clamps (18 and 20) on crankcase hose (21)
and turbocharger intake hose (23). Disconnect hose
(21) from breather pipe. Disconnect hose (23) with
tube (22) attached from turbocharger. 38 40
STEP 25
Support air cleaner assembly (27) and remove two 31
lock nuts (24), bolts (26), four washers (25), and one
clamp holding battery B+ cable routed to relay plate.
Remove air cleaner (27) and associated parts as an 36
assembly. 39
32
STEP 26
38
28
29
33
30
37
34
29 35
28
BS02K107
31. CLAMP 36. FRONT BRACKET

BS02J049
32. BOLT 37. REAR BRACKET
28. BOLT 33. WASHER 38. MUFFLER
29. WASHER 34. BOLT 39. CLAMP
30. DRIVE BELT GUARD 35. WASHER 40. EXHAUST TUBE ELBOW
Remove four bolts (28) and washers (29) securing Remove clamp (31) securing exhaust tube elbow
drive belt guard (30) to master disconnect switch (40) to muffler (38).
mounting bracket and belt guard bracket.
STEP 28
At fron t o f en gine, re move two b olts (32 ) an d
washers (33) securing muffler front mounting bracket
(36).
STEP 29
Support muffler (38) and brackets (36 and 37) and
remove two bolts (34) and washers (35) at rear of
e n g in e . R e m o v e m u ff le r a n d b r a c k e t s a s a n
assembly from engine.
STEP 30
Loosen clamp (39) and remove exhaust tube elbow
(40) from turbocharger.

2000-8
STEP 31 STEP 34
Remove two bolts (52) and washers securing cable
41 clamps (53) to engine.
45 STEP 35
43 58
42
47 44
41 57
46
48
45
BS02K108
41. CLAMP 45. CLAMP

42. TUBE 46. TUBE 56
43. HOSE 47. HOSE
44. CLAMP 48. CLAMP
55 54
Loosen two clamps (41). Remove tube (42) and hose BS02J056
(43) as an assembly. 54. ACORN NUT 57. COVER

55. NUT 58. B+ STUD
STEP 32 56. WASHER
Loosen two clamps (45). Remove tube (46) and hose Remove acorn nut (54), nut (55), and washer (56)
(47) as an assembly. securing cover (57) to starter. Remove cover.
STEP 33 STEP 36
Remove nut and washer securing cables to starter
B+ stud (58). Identify, tag, and disconnect both
cables.
52
STEP 37
53
59 60
53 49 50 51 52
BS02K109 A
49. NUT 52. BOLT
61
50. GROUND CABLE 53. CABLE CLAMP BS02K110
51. GROUND CABLE 59. WIRE 61. STUD

Remove nut (49) and washer from stud installed in 60. NUT A. REAR CHASSIS HARNESS GROUND WIRE
engine block. Tag and disconnect two ground cables Identify and tag rear chassis harness wire (59)
(50 and 51) and one ground wire (A, Step 37) of rear connected to starter solenoid terminal. Disconnect
chassis harness from stud. rear chassis harness wire from terminal.
2000-9
STEP 38 STEP 41
Remove nut (60) and washer securing five ground Pull boot (65) away from alternator stud. Identify, tag,
wires of rear chassis harness and three ground wires and disconnect engine harness wire (66) from stud.
of engine harness to stud (61). Identify, tag, and
disconnect ground wires from stud. STEP 42
Identify, tag, and disconnect two connectors (67).
STEP 39
STEP 43
Remove bolt (68) and washer securing engine
62 harness clamp to engine.
STEP 44
72 75
73 73
74 71
70
69
BS02K111
62. CONNECTOR
Identify, tag, and disconnect rear chassis harness
connector (62) from grid heater temperature switch.
76
STEP 40 69 70
65 BS02K118
69. BOLT 73. WASHER

70. WASHER 74. CLAMP
66 71. NUT 75. FLYWHEEL HOUSING COVER
72. BOLT 76. CONNECTOR
Remove two bolts (69) and washers (70) securing
clamps of engine harness and rear chassis harness
67 to engine block. Top harness is rear chassis harness;
64 bottom harness is engine harness.
STEP 45
68 63 Remove two nuts (71) and bolts (72 ) and four
washers (73) securing two clamps (74) to flywheel
housing cover (75).
BS02J059 STEP 46
63. CONNECTOR 66. WIRE Route engine harness and rear chassis harness to
64. CONNECTOR 67. CONNECTOR front of engine and away from flywheel housing
65. BOOT 68. BOLT cover. Remove any hardware securing harness
Id e nt ify, ta g , a n d d isc o n ne c t e n g ine h ar n es s clamps to engine as necessary.
connector (63) from disconnect harness connector
(64). STEP 47
If necessary, identify, tag, and disconnect four
connectors (76).

2000-10
C
82
77 78
B
85
84
A
83
80 83
79
81
BS02K112
77. CONNECTOR 80. CONNECTOR 83. CONNECTOR A. ENGINE HARNESS

78. BOLT 81. WIRE 84. CONNECTOR B. ALTERNATOR
79. CONNECTOR 82. WIRE 85. CONNECTOR C. GRID HEATER
STEP 48 STEP 52
Identify, tag, and disconnect connector (77) from If equipped, identify, tag, and disconnect wire (82)
engine coolant temperature sender. from grid heater.
STEP 49 STEP 53
Remove two bolts (78) and washers securing engine Identify, tag, and disconnect connectors (83) from
harness clamps. fuel filter heaters.
STEP 50 STEP 54
If wheel loader is equipped with air conditioning, Identify, tag, and disconnect connector (84) from fuel
identify, tag, and disconnect connector (79) from air filter temperature switch.
conditioner compressor clutch. Identify. tag, and
disconnect connector (80) from air conditioning high STEP 55
pressure switch. I d e n ti fy a n d t a g c o n n e c t o r ( 8 5 ) . D is c o n n e c t
connector (85) from fuel injection pump fuel solenoid.
STEP 51
Identify, tag, and disconnect wire (81) from engine oil STEP 56
pressure switch. Ro u te en gin e ha rn e ss a w ay fro m e n gin e a n d
towards front of engine compartment.

2000-11
STEP 57 STEP 59
Insta ll b atte ry co vers on RH side. Suppo rt a ir
conditioning compressor (97) and remove bolt (96),
thre e w ash ers, a nd nut se cur in g co mpre ssor.
92 Remove compressor and place on RH battery cover.
93
STEP 60
91
89
88
90
87
86
BS92K113 BD01F184
86. BOLT 90. BRACKET Put a 37.8 liter (10 gallon) container below radiator
87. WASHER 91. CLAMP drain. Remove cap and drain coolant into container.
88. BOLT 92. HOSE Install cap after coolant has drained.
89. WASHER 93. HOSE
Remove two bolts (86 and 88) and washers (87 and STEP 61
89) securing bracket (90). Let bracket (90) with
clamp (91) and hoses (92 and 93) hang from air
conditioning compressor.
STEP 58
98
95 97
94 99
98
BS02J069
98. CLAMP
96
99. HOSE
Loosen two clamps (98). Disconnect and remove
bottom hose (99).
BS02K120
94. BOLT 96. BOLT

95. DRIVE BELT 97. AC COMPRESSOR
Loosen bolts (94 and 96). Move air conditioning
compressor (97) to put slack in drive belt (95) then
remove drive belt. Remove bolt (94), washers,
spacer, and nut.
2000-12
STEP 62 STEP 65
100
102
105 107
108 110
106 109
106
BS02K116
101
108.HOSE
104 103 109.ELBOW

110.ENGINE OIL PAN
100 Disconnect hose (108) from elbow (109) installed in
103 engine oil pan (110). Put a plug in hose and a cap on
fitting.
STEP 66
BS02K114
100.CLAMP 104.HOSE
101.BLEED LINE HOSE 105.PIPE
102.CLAMP 106.TIE STRAP
103.CLAMP 107.HOSE
Loosen two clamps (100) securing bleed line hose
(101). Disconnect bleed line hose (101) from fittings. 114
STEP 63 120
Loosen clamps (102 and 103). Disconnect and
remove hose (104) from engine and pipe (105). 113
Disconnect and remove pipe (105) with bleed line 117
hose (101) attached from hose (107). If necessary, 119
cut, remove, and discard tie straps (106) to separate 118 112
bleed line hose (101) from pipe (105). 111
STEP 64 116
115
BS02J070
111.NUT 116.WASHER
112.WASHER 117.U-BOLT
113.BALL JOINT 118.CLAMP
114.THROTTLE LEVER 119.THROTTLE CABLE
115.NUT 120.SUPPORT BRACKET
Remove nut (111) and washer (112) securing ball
joint (113) to throttle lever (114).
STEP 67
BD01F184 Remove two nuts (115) and washers (116), U-bolt
Put a 18.9 liter (5 gallon) container below engine oil (117), and clamp (118) securing throttle cable (119)
d r a in . R e m o ve c a p a n d d r a in e n g in e o il in t o to support bracket (120). Move throttle cable away
container. Install cap after oil has drained. from engine.

2000-13
STEP 68 STEP 70
121 122 125

132
126 131
133
BD01D326
131.CLAMP
132.FUEL SUPPLY HOSE
133.FITTING
123 124
At bottom center of fuel tank, loosen clamp (131).
BS02K115
Disconnect fuel supply hose (132) and remove
121.CLAMP 124.CLAMP clamp. Plug fuel supply hose and cap fuel tank fitting
122.FUEL SUPPLY HOSE 125.CLAMP (133). Tag fuel supply hose and remove from engine
123.BOLT 126.FUEL RETURN HOSE compartment.
Loosen clamp (121). Tag and disconnect fuel supply
hose (122) from priming pump. Plug hose and cap STEP 71
fitting. Remove bolt (123) and washer securing
clamp (124) holding in-line fuel filter to engine block.
Loosen clamp (125). Tag and disconnect fuel return 134
hose (126) from fuel injection pump. Plug hose and
cap fitting. 135
STEP 69
136
128
129 BD01D328
134.LOCK NUT
135.VENT COVER
136.VENT HOSE
130 127 Remove lock nut (134), washers, and bolt. Remove
vent cover (135) and breather valve installed in vent
hose (136). Route vent hose with breather valve
BD01D325
down to fuel tank.
127.DRAIN VALVE 129.FUEL RETURN HOSE
128.CLAMP 130.FITTING
Place a container large enough to hold fuel in fuel
tank under drain valve (127). Open drain valve (127)
and drain fuel tank. Close drain valve after fuel has
drained. Loosen clamp (128) and disconnect fuel
return hose (129). Remove clamp. Plug fuel return
hose and cap fuel tank fitting (130).

2000-14
STEP 72 STEP 74
146
145
144
A 144
143
BD01D330
A. FUEL LEVEL SENDER 143

Identify, tag, and disconnect wiring harness wires
142
from fuel level sender (A).
141
STEP 73
142
139
140
BS02J071
139.BOLT 143.WASHER
140.WASHER 144.WASHER
141.CLAMP 145.HOSE BRACKET
142.BOLT 146.FLYWHEEL HOUSING COVER
Remove bolt (139) and washer (140) securing fuel
138 return hose clamp (141) to flywheel housing cover
A (146). Remove two bolts (142), washers (143 and
144) holding hose bracket (145) to flywheel housing
BD01D332
cover. (Throttle cable and associated clamp and (if
used) air conditioning hoses and associated clamp
are also secured to hose bracket.) Move hose
137 bracket, hoses, and throttle cable away from engine.
137
STEP 75
Connect a vacuum pump to hydraulic reservoir. If a
vacuum pump is not available, drain the hydraulic oil
(hydraulic reservoir holds 68.5 liters (18 gallons) of
137 137 137 oil). Turn on vacuum pump (if available). At RH side,
front of engine, tag, disconnect, and plug hoses
137 connected to brake pump. Plug hoses securely and
cap fittings. Turn off vacuum pump.
BD01D327
137.BOLT
138.FUEL TANK PLATE
A. HYDRAULIC JACK
Position a hydraulic jack (A) under fuel tank plate
(138) to support fuel tank and plate. Jack must be at
center of plate and as far rearward as possible.
Loosen and remove six bolts (137) and washers.
With an assistant, slowly lower hydraulic jack and
carefully move fue l ta nk a nd plate fro m un der
machine.

2000-15
STEP 76 STEP 79
158
147 159
148
163
166
165
163
BD01D200
147.BOLT 148.DRIVE SHAFT

At front of engine, remove six bolts (147) securing 162
164
drive shaft (148) to engine coupling. Use a pry bar to
move drive shaft away from engine coupling.
STEP 77
Connect lifting equipment to engine lifting brackets.
Take up all slack in lifting equipment. 161
STEP 78 160
151
152 BS02K117
158.NUT 161.WASHER 164.BOLT

154
159.WASHER 162.WASHER 165.WASHER
160.BOLT 163.ENGINE MOUNT 166. BRACKET
157 At rear of rear chassis remove nut (158), washer
156 (159), bolt (16), and washer (161) securing engine.
STEP 80
Slowly raise engine from rear chassis. Check and be
sure all harness connections, hoses, and throttle
154 cable have been disconnected and are positioned
155 out of the way. Remove engine from machine.
153 STEP 81
Remove washers (153 and 162) from rear chassis
where engine was secured.
150 STEP 82
149 Remove engine mounts (154 and 163) from engine
brackets (157 and 166).
BS02J073
149.NUT 154.ENGINE MOUNT STEP 83

150.WASHER 155.BOLT If engine front brackets (157) require removal,
151.BOLT 156.WASHER remove four bolts (155) and washers (156); remove
152.WASHER 157. BRACKET brackets. If engin e re ar b racke ts(166) requ ire
153.WASHER removal, remove four bolts (164) and washers (165).
At front of engine, remove nut (149), washer (150), Remove brackets (166).
bolt (151), and washer (152) securing engine and
mounting brackets (157) to rear chassis.
2000-16
STEP 84 151
152
158
154
159
163 157
156
166
165
163 154
155
162 153
164
150
149
161
BS02J073
160
149.NUT 154.ENGINE MOUNT
150.WASHER 155.BOLT
151.BOLT 156.WASHER
BS02K117 152.WASHER 157. BRACKET
153.WASHER
158.NUT 161.WASHER 164.BOLT
159.WASHER 162.WASHER 165.WASHER If e n gin e fro nt mo un ting b ra ck ets (1 5 7) w er e
160.BOLT 163.ENGINE MOUNT 166. BRACKET removed, position and support bracket on engine
If e n g in e re a r m o u n tin g b ra c k e ts ( 1 6 6 ) w e r e and secure using four washers (156) and bolts (155).
removed, position and support bracket on engine. Tighten bolts securely. If necessary, install new
Install four washers (165) and bolts (164). Tighten engine mount (154) in bracket (157). Repeat this
bolts securely. If necessary, install new engine mount step to install remaining engine mounting bracket
(163) in engine mounting brackets. Repeat this step and engine mount as necessary.
to install remaining engine mounting bracket and
engine mount as necessary. STEP 86
Connect suitable lifting equipment to engine lifting
brackets. Slowly raise engine and move into position
over rear chassis. Be sure all harness connections
and hoses are out of the way then lower engine. Put
washers (162 and 153) between engine mounts (163
and 154) and rear chassis. Install washer (152), bolt
(151), washer (150), and nut (149) in engine front
mounts (154). Lower engine into position. Install
washer (161), bolt (160), washer (159), and nut (158)
in engine rear mounts (163).
STEP 87
Tighten four bolts (151 and 160) to a torque of 244 to
298 Nm (180 to 220 lb-ft).

2000-17
STEP 88 STEP 91
Disconnect lifting equipment from engine lifting
brackets. 146
STEP 89
145
147 144
148
144
143
143
BD01D200
142
147.BOLT 148.DRIVE SHAFT
141
At front of engine, position drive shaft (148) on
engine coupling. Put Loctite 242 on threads of six
142
139
bolts (147). Install six bolts (147) and tighten to a 140
torque of 53 to 62 Nm (39 to 46 lb-ft).
BS02J071
139.BOLT 143.WASHER
STEP 90 140.WASHER 144.WASHER
Turn on vacuum pump conne cted to hydraulic 141.CLAMP 145.HOSE BRACKET
reservoir. Remove caps from brake pump fittings and 142.BOLT 146.FLYWHEEL HOUSING COVER
plugs from brake pump hoses. Connect hoses to Position and support hose bracket (145) with throttle
brake pump following tags installed during removal. ca b le a n d a sso c iat ed cla mp a n d , if u se d , a ir
Remove and discard tags. Turn off and disconnect conditioning hoses and associated clamp on flywheel
vacuum pump from hydraulic reservoir. housing cover (146). Install four washers (144 and
143) and two bolts (142) to secure hose bracket.
Positio n fue l re tu rn h ose with cla mp (14 1) o n
flywheel housing cover and secure using washer
(140) and bolt (139).

2000-18
STEP 92 STEP 93
138 A
A
BD01D332 BD01D330
A. FUEL LEVEL SENDER
137 Connect wiring harness wires to fuel level sender (A)

137 following tags installed during removal. Remove and
discard tags.
STEP 94
137 137 137

134
137
135
BD01D327
137.BOLT
138.FUEL TANK PLATE
A. HYDRAULIC JACK
136
Put fuel tank and plate (138) on hydraulic jack (A)
and with an assistant, move into position beneath
loader. Make sure vent hose with breather installed is
BD01D328
routed up into engine compartment when fuel tank is
raised. Raise fuel tank and plate, align mounting 134.LOCK NUT
135.VENT COVER
holes, and secure using six washers and bolts (137).
136.VENT HOSE
Lower and remove hydraulic jack (A) from under fuel
tank plate. Rou te vent ho se (136 ) with b reathe r va lve u p
towards RH side of fan shroud. Put breather valve in
vent cover (135). Install washer and bolt, then
washer and lock nut (134) to secure vent cover and
breather valve.

2000-19
STEP 95 STEP 97
121 122 125

132
131 126
133
BD01D326
131.CLAMP
132.FUEL SUPPLY HOSE
133.FITTING
123 124
Route fuel supply hose (132) down from engine to
BS02K115
fuel tank. Remove plug from fuel supply hose and
cap from fuel tank fitting (133). Put clamp (131) on 121.CLAMP 124.CLAMP
hose (132). Connect fuel supply hose and tighten 122.FUEL SUPPLY HOSE 125.CLAMP
clamp to a torque of 3.4 Nm (30 lb-inch). 123.BOLT 126.FUEL RETURN HOSE
Put clamp (125) on fuel return hose (126). Remove
STEP 96 plug from fuel return hose (126) and cap from fuel
injection pump fitting. Connect fuel return hose to fuel
injection pump and tighten clamp (125) to a torque of
3.4 Nm (30 lb-inch). Position clamp (124) holding
128 in-line fuel filter and secure to engine block using
washer and bolt (123). Put clamp (121) on fuel
129 supply hose (122). Remove plug from fuel supply
hose (122) an d cap from priming pump fitting.
Connect fuel supply hose to priming pump and
tighten clamp (121) to a torqu e of 3.4 Nm (3 0
130 127 lb-inch).
BD01D325
127.DRAIN VALVE 129.FUEL RETURN HOSE

128.CLAMP 130.FITTING
Have an assistant route fuel return hose over to
fitting (130). Remove plug from hose and cap from
fitting. Put clamp (128) on fuel return hose. Connect
hose to fitting (130) and tighten clamp to a torque of
3.4 Nm (30 lb-inch). Check that drain valve (128) is
closed.

2000-20
STEP 98 STEP 101
100
102
105 107
106
114
106
120
101
113 103
104
117
119 118 100
112 103
111
116
115
BS02J070
BS02K114
111.NUT 116.WASHER
112.WASHER 117.U-BOLT 100.CLAMP 104.HOSE
113.BALL JOINT 118.CLAMP 101.BLEED LINE HOSE 105.PIPE
114.THROTTLE LEVER 119.THROTTLE CABLE 102.CLAMP 106.TIE STRAP
115.NUT 120.SUPPORT BRACKET 103.CLAMP 107.HOSE
Route throttle cable (119) up and over towards fuel Put clamp (102) on hose (107). Connect pipe (105)
injection pump. Put clamp (118), throttle cable (119), to hose (107). Position clamp (102) and tighten to a
and U-bolt (117) on support bracket (120) and secure torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). Put
using two washers (116) and nuts (115). clamps (103) on hose (104). Connect hose (104) to
pipe (105) and engine coolant outlet. Position clamps
STEP 99 (103) and tighten to a torque of 10.1 to 11.3 Nm (90
to 100 lb-inch).
Install ball joint (113) on throttle lever (114) and
secure using washer (112) and nut (111).
STEP 102
STEP 100 Put hose clamps (100) on bleed line hose (101) and
connect hose to fittings. Position clamps (100) and
tighten to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch). Install three tie straps (106) to secure bleed
line hose (101) to pipe (105).
108 110
109
BS02K116
108.HOSE
109.ELBOW
110.ENGINE OIL PAN
Remove plug from oil drain hose (108) and cap from
fitting (109) installed in engine oil pan (110). Connect
hose to fitting and tighten.

2000-21
STEP 103 STEP 105
Install drive belt (95). Take up slack in drive belt and
tighten bolts (96 and 94).
STEP 106
98
92
99 93
98
91
89
88
BS02J069
98. CLAMP 90
99. HOSE
87
Put clamps (98) on hose (99). Connect hose (99) 86
between bottom pipe and engine coolant inlet. BS92K113
Position clamps and tighten to a torque of 10.1 to 86. BOLT 90. BRACKET
11.3 Nm (90 to 100 lb-inch). 87. WASHER 91. CLAMP
88. BOLT 92. HOSE
STEP 104 89. WASHER 93. HOSE
Position and support bracket (90) with clamp (91)
and hoses (93 and 92) on engine block. Secure
bracket (90) using two bolts (88 and 86) and washers
95 97 (89 and 87).
94
STEP 107
R o u t e e n g in e h a rn e s s b r a n c h c o n t a in i n g a ir
conditioning compressor connectors (79 and 80) and
engine coolant temperature sender connector (77)
from front of engine compartment to RH side of
engine towards rear of engine compartment.
STEP 108
Connect connector (85) to fuel injection pump fuel
96 solenoid following tag installed during removal.
Remove and discard tag.
STEP 109
BS02K120 Connect connector (84) to fuel filter temperature
94. BOLT 96. BOLT switch following tag ins ta lled du rin g re mova l.
95. DRIVE BELT 97. AC COMPRESSOR Remove and discard tag.
Position and support air conditioning compressor
(97) on mounting bracket. Secure using bolt (96), STEP 110
th re e wa sh e rs, an d n u t. In sta ll b olt ( 94 ) , tw o Connect two connectors (83) to fuel filter heaters
washers, spacer, and nut. following tags installed during removal. Remove and
discard tag.

2000-22
C
82
77 78
B
85
84
A
83
80 83
79
81
BS02K112
77. CONNECTOR 80. CONNECTOR 83. CONNECTOR A. ENGINE HARNESS

78. BOLT 81. WIRE 84. CONNECTOR B. ALTERNATOR
79. CONNECTOR 82. WIRE 85. CONNECTOR C. GRID HEATER
STEP 111 STEP 114

If equipped, connect wire (82) to grid heater following Position engine harness clamps on engine and
tag installed during removal. Remove and discard secure using two bolts (78) and washers.
tag.
STEP 115
STEP 112 Connect connector (77) to engine coolant
Connect wire (81) to engine oil pressure switch temperature sender following tag installed during
following tag installed during removal. Remove and removal. Remove and discard tag.
discard tag.
STEP 113
If wheel loader is equipped with air conditioning,
connect connector (80) to air conditioning high
pre ssure switch fo llowing ta g installe d du rin g
removal. Connect connector (79) to air conditioning
compressor clutch following tag installed during
removal. Remove and discard tags.
2000-23
STEP 116 STEP 120
72 65
75
73
73
71 66
74
70
69
67
64
68 63
76
69 70
BS02J059
BS02K118
63. CONNECTOR 66. WIRE
69. BOLT 73. WASHER
64. CONNECTOR 67. CONNECTOR
70. WASHER 74. CLAMP
65. BOOT 68. BOLT
71. NUT 75. FLYWHEEL HOUSING COVER
72. BOLT 76. CONNECTOR Position engine harness clamp on engine block.
Connect four connectors (76) following tags installed Secure using bolt (68) and washer.
during removal. Remove and discard tags.
STEP 121
STEP 117 Connect two connectors (67) following tags installed
Position clamp (74) holding engine harness and rear during removal. Remove and discard tags.
chassis harness on flywheel housing cover (75).
Bottom harness is engine harness; top harness is STEP 122
rear chassis harness. Install bolt (72) and nut (71) Connect engine harness wire (66) to alternator stud
and two washers (73) to secure clamp. Repeat this following tag installed during removal. Remove and
step to install remaining clamp (74) on other side of discard tag. Push boot (65) on alternator stud.
flywheel housing cover (75).
STEP 123
STEP 118 Connect engine harness connector (63) to
Route engine harness and rear chassis harness to disconnect harness connector (64) following tags
rear of engine. installed during removal. Remove and discard tags.
STEP 119
P o s i t io n c la m p s o f e n g in e a n d r e a r c h a s s i s
harnesses on engine block. Top harness is rear
chassis harness; bottom harness is engine harness.
Install two bolts (69) and washers (70) to secure
clamps.

2000-24
STEP 124 STEP 127
58
62
57
56
55 54
BS02K111
BS02J056
62. CONNECTOR
54. ACORN NUT 57. COVER
Connect rear chassis harness connector (62) to grid 55. NUT 58. B+ STUD
heater temperature switch following tag installed 56. WASHER
during removal. Remove and discard tag.
Connect three cables to starter B+ stud (58) following
tags installed during removal. Install nut and washer
STEP 125 to secure cables. Remove and discard tags from
cables.
STEP 128
Put cover (57) on starter. Install washer (56), nut
(55), and acorn nut (54) to secure cover (57).
STEP 129
52
59 60
A 53
61
BS02K110
59. WIRE 61. STUD

60. NUT A. REAR CHASSIS HARNESS GROUND WIRE
Connect five ground wires of rear chassis harness
and three ground wires of engine harness to stud
(61) following tags installed during removal. Install
nut (60) and washer to secure ground wires. Remove
and discard tags.
STEP 126 53 49 50 51 52
Connect rear chassis harness wire (59) to starter BS02K109
solenoid terminal following tag installed during
49. NUT 52. BOLT
removal. Remove and discard tag. 50. GROUND CABLE 53. CABLE CLAMP
51. GROUND CABLE
Install cable clamps (53) and secure with bolt (52)
and washer.
2000-25
STEP 130 STEP 133
Connect ground wire of rear chassis harness and two
ground cables (51 and 50) to stud following tags
installed during removal. Install nut (49) and washer
to secure cables and wire. Remove and discard tags. 38 40
STEP 131
31
41
45 36
39
32
43
42 38
47 44
33
41 46
48 37
45
BS02K108 34
41. CLAMP 45. CLAMP
42. TUBE 46. TUBE
35
43. HOSE 47. HOSE
44. CLAMP 48. CLAMP
Install tube (46) and hose (47) as an assembly.
Tighten two clamps (45) to a torque of 10.1 to 11.3
Nm (90 to 100 lbs-inch).
BS02K107
STEP 132 31. CLAMP 36. FRONT BRACKET

Install tube (42) and hose (43) as an assembly. 32. BOLT 37. REAR BRACKET
33. WASHER 38. MUFFLER
Tighten two clamps (41) to a torque of 10.1 to 11.3
34. BOLT 39. CLAMP
Nm (90 to 100 lbs-inch).
35. WASHER 40. EXHAUST TUBE ELBOW
Put clamp (39) on exhaust tube elbow (40). Install
exhaust tube elbow and clamp on turbocharger. Do
not tighten clamp at this time.
STEP 134
Install and support muffler (38) and brackets (36 and
37) on engine while connecting muffler to exhaust
tube elbow (40). Install two washers (35) and bolts
(34) finger tight.
STEP 135
At front of engine, install two washers (33) and bolts
(32) to secure muffler front mounting bracket (36).
Tighten bolts (32) to a torque of 118 to 133 Nm (87 to
98 lb-ft). Tighten bolts (34) to a torque of 68 to 77 Nm
(50 to 56 lb-ft).

2000-26
STEP 136 STEP 138
Install clamp (31). Tighten clamp (31) to a torque of
20 to 25 Nm (15 to 18 lb-ft). Tighten clamp (39) to a 16
torque of 4.8 to 5.2 Nm (42.5 to 46 lb-ft). 19
18
STEP 137
17 16
28
29
20
21
30 27 20
22
29 18
28
24 23
25
26 25
BS02J049
28. BOLT
BS02K105
29. WASHER
30. DRIVE BELT GUARD 16. CLAMP 22. TUBE
17. INTAKE HOSE 23. HOSE
Position drive belt guard (30) and secure using four
18. CLAMP 24. LOCK NUT
washers (29) and bolts (28) to master disconnect
19. HOSE 25. WASHER
switch mounting bracket and belt guard bracket. 20. CLAMP 26. BOLT
Position air cleaner assembly (27) and support as an
assembly. Secure using two washers (25) and bolts
(26). Put clamp holding battery B+ cable routed to
relay plate on rear bolt then install two washers (25)
and lock nuts (24).
STEP 139
Connect turbocharger intake hose (23) attached to
tube (22) to turbocharger and crankcase hose (21) to
breather pipe. Position clamps (18 and 20) and
tighten. Tighten clamps (18) to a torque of 10.1 to
11.3 Nm (90 to 100 lb-inch).
STEP 140
Connect a ir clea ner intake hose (17) betwe en
cooling frame and air cleaner inlet. Position clamp
(16) and tighten to a torque of 3.6 to 4.5 Nm (32.4 to
39.6 lb-inch).

2000-27
STEP 141 STEP 143
9
8
13
14 10 8
15 11
BD01F167 10 12
11 11
Remove plastic cap installed over the positive post
11 12
during removal. Connect battery cable to RH battery
positive post.
BS02K106
STEP 142
8. BOLT 11. WASHER 14. WASHER
9. BATTERY COVER 12. BOLT 15. BATTERY COVER
10. LOCK NUT 13. BOLT
At LH battery, position battery cover (15). Install
wash er (14) and bolt (13), two bolts (12), four
washers (11), and two lock nuts (10). Install battery
cover (9) and secure using two bolts (8).
STEP 144
BD01F164
Remove plastic cap installed over the negative post

during removal. Connect battery cable to LH battery
negative post.
BD01D150
Connect engine wiring harness connector to air filter

restriction switch following tag installed during
removal. Remove and discard tag.

2000-28
STEP 145 STEP 148
BD01D242 BD01F156
If removed, install bushings at hood pivot points on

top of cooling frame.
STEP 146
BD01F150
Lower lifting equipment until strap connected to two

lifting eyes can be removed. Remove the two lifting
eyes from hood.
BD01F158
Raise and move hood into position above loader. STEP 149
Slowly and carefully lower hood into position while
guiding hood pivot points into position with pivot
points on top of cooling frame.
STEP 147
BD01F255
BD01F151
Install two bolts, four washers, and two nuts to

secure hood. Tighten bolts to a torque of 36 to 44 Nm
(26.5 to 32.5 lb-ft).

2000-29
STEP 150 STEP 153
BD01F154 BD01F153
6. LOCK NUT 7. SPRING Disconnect lifting strap from hood handle.

Connect springs (7) to hood; it may be necessary to
raise hood to connect springs. Install lock nuts (6) to STEP 154
secure LH and RH springs to hood.
STEP 151 5
BD01F148
4. BOLT 5. PROP BAR

Position screen on hood. Install four bolts (4) to
BD01F155 secure hinges of screen to hood. Tighten bolts to a
At front RH side of h ood, connect hood wiring torque of 27 to 33 Nm (19.8 to 24.4 lb-ft). Connect
harness connector to rear chassis wiring harness prop bar (5) to screen.
connector following tag installed during removal.
Remove and discard tag. STEP 155
STEP 152
Lower hood.
BD01F146
Install three washers and cotter pin.

2000-30
STEP 156 STEP 159
Install a new oil filter on engine. Fill engine with 10.5
liters (11 quarts) of Case No. 1 Engine Oil (SAE
15W-40).
STEP 160
If hydraulic reservoir was drained, fill reservoir with
68.5 liters (18 gallons) of MS-1209 Hy-Tran Ultra®
fluid.
STEP 161
BD01F145
capacity is 34.1 liters (9 gallons). Install the radiator
Close screen and open hood. cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
STEP 157
STEP 162
2
1 3
BD01F144
1. CLIP BD01F259
2. HOOD PROP Put master disconnect switch in ON position.
3. STUD
WARNING: Hot coolant can spray out if radiator cap
disengage bottom clip (1) from hood prop (2) and
push bottom of prop onto stud (3). Repeat to install
top of prop to hood.
radiator cap.
STEP 158 STEP 163

STEP 164
STEP 165
BD01F184M
Check and make sure that drain caps are tight.

2000-31
RADIATOR
Removal STEP 171
STEP 166
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 167
BD01F234
BD01F143
STEP 168
Open and raise hood.
STEP 169 BD01F235

Remove LH fender.
STEP 172
BD01F258
STEP 170
Remove the hood (Steps 5 through 17). BD01F184
Put a 37.8 liter (10 gallon) container below radiator

drain. Remove cap and drain coolant into container.
Install cap after coolant has drained.

2000-32
STEP 173 STEP 176
7
1
8
2
BD01F192 BD01F238
1. HOSE CLAMP 2. HOSE 7. BOLTS 8. SCREW

At top of cooling system frame, loosen two hose Remove two bolts (7) and lock washers on sides of
clamps (1). Remove hose (2). radiator. Remove screw (8) and install lifting eye.
STEP 174 STEP 177
BD01F240 BD01F239
Loosen two clamps securing radiator bottom hose. Connect lifting equipment to lifting eyes. Take up all
Remove bottom hose. slack in lifting equipment.
STEP 175 STEP 178
3 4
5
6
BD01D223 BD01D225
3. RADIATOR CAP 5. COOLANT LEVEL SENDER 9. BOLT

4. OVERFLOW HOSE 6. SCREW
Remove four bolts (9) and lock washers securing
Remove radiator cap (3) and disconnect overflow radiator to cooling frame. Carefully and slowly raise
h o s e ( 4 ) f r o m r a d i a t o r. I n s t a l l r a d i a t o r c a p . radiator from cooling frame and remove from loader.
Disconnect connector from coolant level sender (5).
Remove screw (6) and install lifting eye.

2000-33
STEP 179 7
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame. 8
STEP 180
9 BD01F238
7. BOLT 8. SCREW
Remove lifting eye and install screw (8). Install two
lock washers and bolts (7) to secure radiator on both
sides.
STEP 183
BD01D225
9. BOLTS
3 4
Install four lock washers and bolts (9) to secure
radiator to cooling frame.
STEP 181
5
6
BD01D223
3. RADIATOR CAP 5. COOLANT LEVEL SENDER

4. OVERFLOW HOSE 6. SCREW
Remove lifting eye and install screw (6). Connect
connector to coolant level sender (5). Remove
radiator cap (3) and connect overflow hose (4) to
BD01F239
radiator. Install radiator cap.
Disconnect lifting equipment from lifting eyes.

2000-34
STEP 184 STEP 186
BD01F240 BD01F234
At bottom of radiator, install bottom radiator hose.

Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
STEP 185
BD01F235
Install LH fender. Install two bolts and washers to

secure LH fender.
2 STEP 187
BD01F192BD01D188 Install the hood (Steps 140 through 152).
1. HOSE CLAMP 2. HOSE
STEP 188
At top of cooling system frame, install hose (2).
Position hose clamps (1) and tighten to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
BD01F184
Check that coolant drain cap is tight.
STEP 189
capacity is 34.1 liters (9 gallons). Install the radiator
the reservoir.

2000-35
STEP 190 WARNING: Hot coolant can spray out if radiator cap
radiator cap.
STEP 192
Lower a nd close hood. Put articulation lock in
OPERATING position.
BD01F259
STEP 191

2000-36
NOTES

2002
Section
2002
STALL TESTS
CASE CORPORATION Copyright © 2001 Case Corporation

Racine, WI 53404 U.S.A. Bur 6-42991 August, 2001 Revised September, 2004
2002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Procedure to Heat the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2002-3
SPECIFICATIONS
Low idle ............................................................................................................................................980 to 1020 rpm
Full throttle (no load)........................................................................................................................2220 to 2280 rpm
Temperature of the torque converter oil.......................................................................82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 51° to 79°C (125° to 175°F)
Stall Speeds
Torque converter..............................................................................................................................1940 to 2180 rpm
Hydraulic system .............................................................................................................................1715 to 2215 rpm
Torque converter and hydraulic system together.............................................................................1380 to 1800 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
Procedure to Heat the Oil Hydraulic System

1. Apply the parking brake.
Torque Converter
2. Start the engine and run at full throttle.
1. Sit in the seat.
3. Hold the bucket control lever in the ROLLBACK
2. Start the engine and run the engine at low idle. position and hold the lift control lever in the
3. To measure the oil temperature with the FLOAT position.
instrument cluster: 4. View the oil temperature by pressing the
A. Press the program switch. program switch, then press the up count switch
to function 008. Return the program switch to the
B. Press the up count switch to function 007. center (OFF) position.
C. Return the program switch to the OFF (center) 5. Continue holding until the temperature of the
position. hydraulic oil is 51° to 79°C (125° to 175°F).
4. Place the declutch switch in the OFF position.
Test No. 1 - Torque Converter and
5. Place the automatic switch in the manual mode
position. Hydraulic Stall Together
6. Release the parking brake. 1. Sit in the seat.
7. Move the transmission control lever to Forward 2. Start the engine and run the engine at low idle.
and turn the transmission control lever to 3rd 3. Press the brake pedal, and shift into Forward.
gear.
4. Make sure the parking brake is released (OFF).
8. Increase the engine speed to full throttle and run
the engine at this speed until the instrument 5. Run engine at low idle. Push the clutch cutout
cluster shows a temperature of 115°C (239°F). switch to OFF. Put the transmission in manual
mode. Push down and hold the brake pedal for
9. Decrease the engine speed to low idle and move the remainder of this procedure.
the transmission control lever to the Neutral
position. 6. Make sure that the transmission is in Forward
and turn the transmission control lever to third
10. Wait and allow the converter temperature to cool gear.
to 90°C (194°F).
7. Increase the engine speed to full throttle.
11. Repeat steps 4 through 9 (approximately three
times) until the temperature of the torque 8. Hold the bucket control lever in the ROLLBACK
converter oil is 82° to 104°C (180° to 220°F). position and raise the lift arms. The stall speed
must be read while the lift arms are in motion.

2002-4
9. Check the engine speed by pressing the Understanding the Results of Test
program switch, left side of the program/reset
switch. Press the up count switch until the
No. 2
display reads 01. Return the program switch to 1. If the engine speed was as specified, the engine,
the center (OFF) position. torque converter and transmission are probably
10. Release the bucket control lever. good.
11. Decrease the engine speed to low idle. 2. If the engine speed was more than specified, the
problem can be in the torque converter or the
12. Stop the engine. t r a n s m i s s i o n . S e e S e c t i o n 6 0 0 2 fo r
troubleshooting information.
Understanding the Results of Test 3. If the engine speed was less than specified, do
No. 1 Test No. 3.
1. If the engine speed was as specified, the engine,
torque converter, transmission and hydraulic Test No. 3 - Hydraulic Stall
system are probably good. 1. Start the engine and run at 1500 rpm.
2. If the engine speed was not as specified, do Test 2. Increase the engine speed to full throttle.
No. 2 and 3.
3. Hold the bucket control lever in the ROLLBACK
Test No. 2 - Torque Converter Stall position and raise the lift arms. The stall speed
must be read while the lift arms are in motion.
1. Sit in the seat.
4. Check the engine speed by pressing the
2. Start the engine and run the engine at low idle. program switch, left side of the program/reset
switch. Press the up count switch until the
3. Press the brake pedal, and shift into Forward.
display reads 01. Return the program switch to
4. Make sure the parking brake is released (OFF). the center (OFF) position.
5. Run the engine at low idle. 5. Release the bucket control lever.
6. Push down and hold the brake pedal for the 6. Decrease the engine speed to low idle.
remainder of this test.
7. Stop the engine.
7. Make sure that the transmission is in Forward
and turn the transmission control lever to third Understanding the Results of Test
gear.
No. 3
8. Increase the engine speed to full throttle.
1. If the engine speed was as specified, the engine
9. Check the engine speed by pressing the and hydraulic system are good.
program switch, left side of the program/reset
switch. Press the up count switch until the 2. If the engine speed was more than specified, a
display reads 01. Return the program switch to component in the hydraulic system is probably
the center (OFF) position. the cause. See Section 8002 for troubleshooting
information.
10. Decrease the engine speed to low idle.
3. If the engine speed was less than specified in all
11. Stop the engine. tests, the engine is probably the cause.

SECTION INDEX
FUEL SYSTEM
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL
CASE CORPORATION
700 State Street
SECTION INDEX
ELECTRICAL
Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Information and Diagnostic Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
Alternator - 65 Ampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4007
Alternator - 45 Ampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4008
CASE CORPORATION
700 State Street
Hamilton, ON L7N 3M6 CANADA Bur 6-42311 February, 2003
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-44641 August, 2001 (Revised February, 2003)
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.I.N. JEE0135501 AND ABOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4001-3
STARTER
P.I.N. JEE0135500 AND BELOW
Removal STEP 3
NOTE: The starter is located on the left side of the
engine, mounted to the engine flywheel housing.
2
STEP 1
1
4
BD01F160
1. HOSE CLAMP 3. ELECTRICAL CONNECTOR

Loosen hose clamp (1) and remove hose (2) from air
BD01F258
cleaner (4). Disconnect wiring harness connector
Put master disconnect switch in OFF position. from electrical connector (3) on air cleaner (4).
STEP 2 STEP 4
BD01F165
BD01F159
Loosen hose clamp and remove hose from top of air Loosen and remove bolts holding air cleaner bracket
cleaner. to frame. Remove air cleaner and bracket.

4001-4
STEP 5 STEP 7
2
3
1
BD01F201 BD01F204
1. BOOT 2. NUT 3. STARTER A. Insert a screwdriver into opening and loosen

and remove screw.
A. Slide boot (1) down to gain access to nut (2).
B. Tag and disconnect solenoid wire from starter.
B. Loosen and remove nut (2) from starter (3)
terminal.
STEP 8
C. Put identification tags on positive cables and
disconnect positive cables from starter (3).
STEP 6
BD01F208
Loosen and remove three bolts holding starter to

engine flywheel housing.
BD01F203
Remove starter from engine.
Open cover to gain access to screw.

4001-5
STEP 9
2
3
1
BD01F201
1. COVER 2. NUT 3. STARTER

BD01F208
A. Install positive cables and nut (2) on starter
Position and support starter on engine and install (3).
three bolts to secure starter to engine flywheel
housing. Tighten three bolts to a torque of 41 to 74 B. Tighten nut (2) to a torque of 22.5 to 29.4 Nm
Nm (30 to 54 lb-ft). (17 to 22 lb-ft).
C. Place boot (1) in position over nut (2).
STEP 10
STEP 12
BD01F204
Install solenoid wire and screw on starter. Tighten BD01F165

screw to a torque of 2.6 to 4.6 Nm (2 to 3.4 lb-ft). Put air cleaner in position and install bolts.

4001-6
STEP 13 STEP 15
2
1
4
BD01F160 BD01F259
1. HOSE CLAMP 3. ELECTRICAL CONNECTOR Put master disconnect switch in ON position.

A. Install hose (2) on air cleaner (4) and tighten
hose clamp (1).
B. Connect wiring harness connector to electrical
connector (3) on air cleaner (4).
STEP 14
BD01F159
Install hose on top of air cleaner and tighten hose

clamp.

4001-7
STARTER
Removal STEP 19
NOTE: The starter is located on the left side of the Remove nut and washer securing cables to starter
engine, mounted to the engine flywheel housing. B+ stud (5). Identify, tag, and disconnect the two
cables from B+ stud.
STEP 16
STEP 20
BD01F258

6
STEP 17
Remove air cleaner and bracket (Steps 2 through 4).
STEP 18
BS02K110
5 6. STARTER SOLENOID WIRE

Id entify and tag rear chassis harness wire (6)
connected to starter solenoid terminal. Disconnect
wire from terminal.
4 STEP 21
Support starter and remove bolts and washers
securing starter to engine. Remove starter.
3
2
1
BS02J056

2. NUT 5. B+ STUD
3. WASHER
Remove acorn nut (1), nut (2), and washer (3)
securing cover (4) to starter. Remove cover.

4001-8
STEP 22 5
Position and support starter on engine. Install
washers and bolts to secure starter. Tighten bolts to
a torque of 44 to 54 Nm (32 to 40 lb-ft).
STEP 23 4
3
2
1
BS02J056

2. NUT 5. B+ STUD
3. WASHER
Connect two cables to starter B+ stud (5) following
tags installed during removal. Install nut and washer
6 to secure cable terminals to B+ stud. Remove and
discard tags from cables.
STEP 25
Put cover (4) on starter. Install washer (3), nut (2),
BS02K110 and acorn nut (1) to secure cover.
6. STARTER SOLENOID WIRE
Connect rear chassis harness wire (6) to starter
STEP 26
solenoid terminal following tag installed during Install air cleaner bracket and air cleaner (Steps 12
removal. Remove and discard tag. through 14).
STEP 27
BD01F259

4001-9
ALTERNATOR
Removal Installation
STEP 28 STEP 35
Put master disconnect switch in OFF position and Install alternator (4), shield (3), washer (19) and bolt
remove drive belt guard. (18) on machine. Tighten bolt (18) to a torque of 60 to
104 Nm (42.5 to 76 lb-ft). Refer to illustration on
STEP 29 following page.
Use a wrench to move belt tensioner (2) and loosen
tension on drive belt (1). Refer to illustration on STEP 36
following page. Install washer (16), nut (14) and bolt (13). Tighten
bolt (13) to a torque of 60 to 104 Nm (42.5 to 76 lb-ft).
STEP 30
Remove drive belt (1). STEP 37
Use a wrench to move belt tensioner (2) until drive
STEP 31 belt (1) can be installed.
Remove boots (5 and 8), nuts (6 and 9), and lock
washers (7 and 10). Tag and disconnect wires (11 STEP 38
and 12) from alternator (4). Install drive belt (1).
STEP 32 STEP 39
Remove bolt (13), nut (14), and washer (16) from Install wire (12), lock washer (7) and nut (6) on
support bracket (17) and alternator (4). alternator D+ terminal. Tighten nut (6) to a torque of
3.5 to 3.9 Nm (2.6 to 2.9 lb-ft).
STEP 33
Loosen and remove bolt (18) and washer (19). STEP 40
Install boot (5).
STEP 34
Remove alternator (4) and shield (3) from machine. STEP 41
Install wire (11), lock washer (10) and nut (9) on
alternator B+ terminal. Tighten nut (9) to a torque of
15 to 27 Nm (11 to 20 lb-ft).
STEP 42
Install boot (8).
STEP 43
Put master disconnect switch in ON position and
install drive belt guard.

4001-10
7 10
6 9
5 8
12
11
17
14
16
2
4
13
18
19
20
15 21
BS01C136
1. FAN BELT 8. BOOT 15. BRACE

2. BELT TENSIONER 9. NUT 16. WASHER
3. SHIELD 10. LOCK WASHER 17. SUPPORT
4. ALTERNATOR 11. B+ WIRE 18. BOLT
5. BOOT (NOT SHOWN) 12. D+ WIRE 19. WASHER
6. NUT 13. BOLT 20. PULLEY
7. LOCK WASHER 14. NUT 21. BOLT
ALTERNATOR REMOVAL AND INSTALLATION ILLUSTRATION - P.I.N. JEE0135500 AND BELOW

4001-11
BS01E102
ALTERNATOR WITH AIR CONDITIONING DRIVE BELT INSTALLATION - P.I.N. JEE0135500 AND BELOW

4001-12
ALTERNATOR
Removal STEP 47
STEP 44
Put master disconnect switch in OFF position. 5
STEP 45 6
1
2
7
3
BS02J059
5. BOOT 7. CONNECTOR
6. WIRE
2 Pull boot (5) away from alternator stud. Identify, tag,

1 an d d is co nn e ct e ng ine h a rn ess w ir e (6 ) fr om
alternator stud.
STEP 48
Identify, tag, and disconnect two connectors (7).
STEP 49
BS02J049
1. BOLT 9
2. WASHER 8
3. DRIVE BELT GUARD
Remove four bolts (1) and washers (2) securing drive
belt guard to master disconnect switch mounting
bracket and belt guard bracket.
STEP 46
10
4 BS02K146
11
A
10
BS02K147
4. DRIVE BELT A. BREAKER BAR BS02K145
Put a 12.7 mm (1/2 inch) drive breaker bar or ratchet 8. BOLT 10. BOLT
(A) in bracket for automatic belt tensioner. Push 9. BRACE 11. ALTERNATOR
down on breaker bar or ratchet to release drive belt Remove bolt (8 ) securing bra ce (9) to engine.
tension and remove drive belt (4) from alternator Loosen bolt (10) and move alternator then remove
pulley. b o lt ( 1 0 ) a n d a s s o c ia te d h a r d w a r e . R e m o v e
alternator.
4001-13
Connect engine harness wire (6) to alternator stud
STEP 50 following tag installed during removal. Push boot (5)
over alternator terminal. Remove and discard tag.
11 STEP 53
4
10
A
BS02K145
9
8
BS02K147
4. DRIVE BELT A. BREAKER BAR

Put a 12.7 mm (1/2 inch) drive breaker bar or ratchet
(A) in bracket for automatic belt tensioner. Push
down on breaker bar or ratchet then position drive
belt (4) on alternator pulley. Release breaker bar or
10
ratchet to put tension on drive belt.
BS02K146
8. BOLT 10. BOLT STEP 54

9. BRACE 11. ALTERNATOR
Position and support alternator (11) on alternator 1
mounting bracket. Install bolt (10) and associated 2
hardware. Reposition alternator and install bolt (8) to
secure brace (9) to engine. Tighten bolt (10) to a
torque of 37 to 49 Nm (27 to 36 lb-ft). Tighten bolt (8) 3
to a torque of 20 to 28 Nm (15 to 21 lb-ft).
STEP 51
2
1
5
BS02J049
1. BOLT
7 2. WASHER
BS02J059 3. DRIVE BELT GUARD
5. BOOT 7. CONNECTOR Put belt guard bracket in position between master

6. WIRE disconnect switch mounting bracket and belt guard
bracket. Secure using four bolts (1) and washers (2).
Connect two connectors (7) following tags installed
STEP 55

4001-14
NOTES

4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-40782 March, 2001 (Revised June, 2002)
NOTES
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, ETHER START,
IGNITION SWITCH AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ether Start Temperature Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ether Start Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ether Start Relay No. 6 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ether Start Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Neutral Start Relay No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Accessory Relay No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Voltmeter Relay No. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,
SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Kick-down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FNR Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Back-up Alarm Relay No. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM/RESET SWITCH, PARK BRAKE
SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH . . . 46
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4002-4
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Program/Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Instrument Cluster (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL, PARKING BRAKE, AND
REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pilot Control Relay No. 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Parking Brake Relay No. 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Redundant Brake Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Relay Socket No. 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TROUBLESHOOTING BUCKET CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Detent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Bucket Control Valve Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Float Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Float Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL . . . . . . . . . . . . . . . 61
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ride Control Relay No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Horn Relay No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
A/C Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4002-5
A/C High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Compressor Clutch Lockout Relay No. 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET,
RADIOS AND SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Remote Radio or 24 Volt Radio (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Radio Power Converter (24 volts to 12 volts) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH, TURN SIGNAL/HI/LOW BEAM/
HORN SWITCH, AND FLASHER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Brake Lamps Relay No. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Turn Signal, Hi/Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS . . 81
LH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
LH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
RH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
LH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
RH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Five Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
High/Low Beam Relay No. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4002-6
NOTES

4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage............................................................................................................................................... 24 volts
Batteries
Specifications are the same for production battery and replacement battery.
Production Battery Case P/N ................................................................................................................... A176482
Replacement Battery Case P/N ............................................................................................................... A180406
Group Size .......................................................................................................................................................... 31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17°C (0°F) for 60 Seconds At 6.0 Volts .................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell ..................................................................................................................................................... 17
Approximate weight with electrolyte ..................................................................................... 25.9 kg (57.1 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 45 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20°C (68°F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20°C (68°F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20°C (68°F) .......................................... 3521 ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105°C (221°F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110 °C (230°F) .................................................. 133.9 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Setpoint ............................................................................................................................. 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Setpoint ............................................... 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Setpoint .................................. -6.4 kPa (Gauge) (-0.928 psig)
Brake Warning Pressure Switch (Normally Closed) Opening Setpoint ...................................... 117.2 Bar (1700 psi)
A/C High Pressure Switch (Normally Open) Closing Setpoint..................... 27.6 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch (Normally Closed) Opening Setpoint .................... 1.4 Bar (20 psi) (decreasing pressure)
Thermostat Switch
Contacts 2 to 3 close at initial turn of the switch. Contacts 1 to 2 close with thermal setting.
Engine Oil Pressure Switch (Normally Closed) Opening Setpoint ................................................... 0.69 Bar (10 psi)
Fuel Solenoid Resistance (pull in) At 20°C (68°F) (Nominal) ..................................................................... 1.1 ohms
Fuel Solenoid Resistance (hold in) At 20°C (68°F) (Nominal) ................................................................... 41.5 ohms
Brake Declutch Pressure Switch (Normally Closed) Opening Setpoint............................................. 24 Bar (350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing Setpoint ......................................... 62 Bar (900 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Setpoint....................................................... 4.1 Bar (60 psi)
Float Pressure Switch (Normally Open) Closing Setpoint ................................................................. 19 Bar (275 psi)
Secondary Steering Pressure Switch (Form C) Closing Setpoint ...................................................... 2.4 Bar (35 psi)
Ether Start Temperature Switch
Opens.................................................................................................................................. 13 ±3°C (55.4 ±5.4°F)
Closes ............................................................................................................................. 1.5 ±4.5°C (34.7 ±8.1°F)
Ether Start Solenoid DC Resistance At 25 °C (77°F) (Nominal)................................................................... 2.2 ohms
Parking Brake Solenoid DC Resistance At 20°C (68°F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20°C (68°F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20°C (68°F) (Nominal) ...................................... 27.4 ohms

4002-8
Ride Control Solenoid DC Resistance At 20°C (68°F) (Nominal) .............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20°C (68°F) (Nominal) ............................................................... 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20°C (68°F) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20°C (68°F) (Nominal)........................................................... 39.3 ohms
Float Solenoid DC Resistance At 20°C (68°F) (Nominal) .......................................................................... 39.7 ohms
Rollback Pressure Switch (Normally Closed) Opening Setpoint ........................................................ 6.2 Bar (90 psi)

4002-9
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

21C Bk - 1.0
Wire Size (mm 2) 0.8 mm 1.0 mm 2.0 mm 5.0 mm
Wire Color Bk = Black DU = Dark Blue S = Gray LG = Light Green K = Pink

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

Color, Size,
Wire Circuit Connector Cavity Connector Cavity
and Material
1 Alternator B+ R-13.0-SXL 153 Alternator B+ 1 149 Starter Power 1
14 Alternator D+ Or-1.0-SXL 94M Engine Trans 5 154 Alternator D+ 1
44 Brake Lt Input Signal T-1.0-SXL 159 Brake Lt Press Sw 2 21M Rear Cab 29
52 Fan Reverse Sol W-1.0-SXL 158 Fan Rev Sol Opt A 21M Rear Cab 27
57 Pin Engage Sol Pwr W-1.0-SXL 1 Cab-Frnt Chas U 107M Pin Engage Opt A
58 Ride Cntrl Sol Pwr W-1.0-SXL 1 Cab-Frnt Chas V SPL_A7 Ride Cntrl Sol Pwr SPL_A7
64 Horn Or-1.0-SXL 1 Cab-Frnt Chas N 147 Horn Pwr 1
0_A Ground Bk-1.0-SXL 125 LH Rear Comb Lt 5 SPL_E4 SPL_E4 1
0_AA Height-RTT Grnd Bk-1.0-SXL 10 Height Cntrl-RTT B SPL_A2 Splice A2 SPL_A2
0_AB Pin Engage Grnd Bk-1.0-SXL 107M Pin Engage Opt B SPL_A1 Splice A1 SPL_A1
0_AC Ride Cntrl Grnd Bk-1.0-SXL 5F Ride Control Opt 2 SPL_A1 Splice A1 SPL_A1
0_AD Horn Grnd Bk-1.0-SXL 146 Horn Grnd 1 SPL_A1 Splice A1 SPL_A1
0_AF RTD Grnd Bk-1.0-SXL 12F RTD B SPL_A2 Splice A2 SPL_A2
0_AG Lights Grnd RH Bk-1.0-SXL 8 Lights RH 1 SPL_A1 Splice A1 SPL_A1

0_AH Grnd Frnt Chas Bk-5.0-SXL 144 Grnd Rear Chas 1 143 Grnd Frnt Chas 1
0_AJ Grnd Cab Bk-2.0-SXL 145 Grnd Cab 1 SPL_A1 Splice A1 SPL_A1
0_AK Grnd Cab Bk-1.0-SXL 145 Grnd Cab 1 SPL_A2 Splice A2 SPL_A2
0_AL Lights Grnd LH Bk-1.0-SXL 6 Lights LH 1 SPL_A1 Splice A1 SPL_A1
0_AM RTD Grnd Bk-1.0-SXL 12M RTD B 200 RTD B
0_AN Sec Str Signal Grd Bk-1.0-SXL 131F Sec Str Pres Sw Opt B 180F Sec Str Mod Opt 5
0_AP Splice Bk-1.0-SXL SPL_A6 SPL_A6 SPL_A6 179F Float Solenoid 2
0_AQ Ground Bk-1.0-SXL 229M Diode Module C SPL_A6 SPL_A6 SPL_A6
0_AR Splice Bk-1.0-SXL SPL_A2 Splice A2 SPL_A2 SPL_A6 SPL_A6 SPL_A6
0_BA Signal Grnd Bk-1.0-SXL 150 Signal Grnd 1 SPL_B1 A
0_BB Ether Fuel Sol Grnd Bk-2.0-SXL 134 Fuel Solenoid C 151 Solenoid Grnd 1
0_BC Ether Fuel Sol Grnd Bk-1.0-SXL 97 Ether Temp Sw B 151 Solenoid Grnd 1
0_BD Air Filter Rest Sw Grnd Bk-1.0-SXL 117 Air Filter Res Sw B SPL_B1 A
0_BE Eng Cool Temp Ground Bk-1.0-SXL 138 Eng Cool Temp B SPL_B1 A

4002-10

21C Bk - 1.0


Color, Size,
and Material
0_BF Signal Ground Bk-1.0-SXL 94M Engine Trans 9 SPL_B1 A
0_BG Analog Ground Bk-1.0-SXL 94M Engine Trans 15 152 Analog Grnd 1
0_BH Signal Ground Bk-1.0-SXL 94M Engine Trans 11 SPL_B1 A
0_BJ Ground Bk-1.0-SXL 268 AC Diode Ground 1 265F Diode Module C
0_C Ground Bk-1.0-SXL 127 RH Rear Comb Lt 5 SPL_E4 SPL_E4 1
0_CA Sec Str Signal Grd Bk-1.0-SXL 90M Sec Str Mod 11 SPL_C1 1
0_CB Sec Str Signal Grd Bk-1.0-SXL 90M Sec Str Mod 12 SPL_C1 1
0_CC Sec Str Signal Grd Bk-1.0-SXL 180M Sec Str Mod Frnt Harn 5 SPL_C1 1
0_CD Sec Str Signal Grd Bk-1.0-SXL 177 Sec Str Mod Sig Grnd 1 SPL_C1 1
0_CE Sec Str Chassis Grnd Bk-1.0-SXL 90M Sec Str Mod 4 176 Sec Str Mod Chas Grnd 1
0_CF Sec Str Grnd Bk-1.0-SXL 264M Sec Str Sol Opt B SPL_C1 1
0_D Hood Ground Bk-2.0-SXL 164 Engine Grounds 1 SPL_E4 SPL_E4 1
0_DA AC Brk Lt Time Del Horn Grnd Bk-0.8-SXL 204F Relay Brake Lights 85 220F Ground Cab 1
0_DAB Signal Ground Bk-0.8-SXL 22F Cab Transmission 15 13F Cab-Pedestal 38
0_DAC Relay Grnd Bk-0.8-SXL 13F Cab Pedestal 53 222F Ground Cab 1
0-DAD Relay Grnd Bk-1.0-SXL 222F Ground Cab 1 SPL_D13 Ground 1
0_DAE Ground Bk-1.0-SXL 199F Trans Enable Sw 7 SPL_D13 Ground 1
0_DAF Switch Grnd Bk-1.0-SXL 210F Fan Reverser Sw 7 40F Pin Engage Sw 9
0_DAG Switch Grnd Bk-1.0-SXL 39F Return To Travel Sw 7 SPL_D13 Ground 1
0_DAH Switch Grnd Bk-1.0-SXL 39F Return To Travel Sw 1 39F Return To Travel Sw 7
0_DAJ Switch Grnd Bk-1.0-SXL 36F Detent Switch 7 39F Return To Travel Sw 1
0_DAK Switch Grnd Bk-1.0-SXL 36F Detent Switch 7 38F Declutch Switch 7
0_DAL Switch Grnd Bk-1.0-SXL 40F Pin Engage Sw 9 44F Ride Control Sw 7
0_DAM Switch Grnd Bk-1.0-SXL 44F Ride Control Sw 7 41F Trans Auto Sw 7
0_DAN Flasher Module Grnd Bk-0.8-SXL 62M Flasher Module 3 SPL_D14 Module Grnds 1
0_DAP Ground Bk-1.0-SXL 199F Trans Enable Sw 7 42F Beacon Sw 7
0_DAQ Flasher Module Grnd Bk-0.8-SXL 62M Flasher Module 4 SPL_D14 Module Grnds 1
0_DAR Blwr Wiper Seat Grnd Bk-1.0-SXL 35F Wiper and Washer Sw 1 218F Ground Cab 1
0_DAS Time Delay Mod Grnd Bk-0.8-SXL 63M Time Delay Module 3 SPL_D14 Module Grnds 1
0_DAT Brk Lt Time Del Horn Grnd Bk-0.8-SXL 220F Ground Cab 1 SPL_D14 Module Grnds 1
4002-11

21C Bk - 1.0


Color, Size,
and Material
0_DAU Analog Ground Bk-0.8-SXL 22F Cab Transmission 30 13F Cab-Pedestal 8
0_DAV Diag TECM Grnd Bk-0.8-SXL 108F Diagnostic Connector 3 221F Ground Cab 1
0_DAW Ground Bk-1.0-SXL 42F Beacon Sw 7 118F Back-up Alarm Dis Sw 7
0_DAX Beacon Wiper Diode Grnd Bk-0.8-SXL 206F Cab Floor Weld Stud 1 140M Diode Module C
0_DAY Switch Grnd Bk-1.0-SXL 210F Fan Reverser Sw 7 SPL_D13 Ground 1
0_DB Can Pilot Sol Grnd Bk-0.8-SXL 89M Pilot Pres Sol B 219F Ground Cab 1
0_DC Relay Grnd Bk-0.8-SXL 52F Ether Start Relay 85 49F Accessory Relay 85
0_DD Ride Cntrl Relay Sink Bk-0.8-SXL 19F TECM 57 50F Ride Control Relay 85
0_DE Relay Grnd Bk-0.8-SXL 48F Ignition Relay #2 85 47F Ignition Relay #1 85
0_DF Relay Grnd Bk-0.8-SXL 49F Accessory Relay 85 48F Ignition Relay #2 85
0_DG Relay Grnd Bk-0.8-SXL 52F Ether Start Relay 85 58F Volt Meter Relay 85
0_DH Relay Grnd Bk-0.8-SXL 58F Volt Meter Relay 85 54F Neutral Start Relay 85
0_DJ Relay Grnd Bk-0.8-SXL 54F Neutral Start Relay 85 222F Ground Cab 1
0_DK AC Brk Lt Time Del Horn Grnd Bk-0.8-SXL 203F Relay AC 85 204F Relay Brake Lights 85
0_DL Signal Ground Bk-0.8-SXL 22F Cab-Transmission 23 13F Cab-Pedestal 39
0_DM Speed Sensor Grounds Bk-0.8-SXL 19F TECM 3 22F Cab Transmission 11
0_DN Out Speed Sensor Grnd Bk-0.8-SXL 19F TECM 4 22F Cab Transmission 28
0_DP Diag TECM Grnd Bk-0.8-SXL 19F TECM 1 221F Ground Cab 1
0_DQ Diag TECM Grnd Bk-0.8-SXL 19F TECM 2 221F Ground Cab 1
0_DR Dome Court Work Lt Grnd Bk-1.0-SXL 24M Cab Roof E 223F Ground Cab 1
0_DS Dome Court Work Lt Grnd Bk-1.0-SXL 24M Cab Roof G 223F Ground Cab 1
0_DT Dome Court Work Lt Grnd Bk-1.0-SXL 23F Cab Roof B 223F Ground Cab 1
0_DU Beacon Wiper Diode Grnd Bk-1.0-SXL 23F Cab Roof C 206F Cab Floor Weld Stud 1
0_DV Beacon Wiper Diode Grnd Bk-0.8-SXL 206F Cab Floor Weld Stud 1 13F Cab-Pedestal 61
0_DW Ground Bk-0.8-SXL 45F Rear Wiper Sw 7 118F Back-up Alarm Dis Sw 7
0_DX Horn Ground Bk-0.8-SXL 13F Cab-Pedestal 41 220F Ground Cab 1
0_DY Blwr Wiper Seat Grnd Bk-1.0-SXL 28M Seat Comp Motor B 218F Ground Cab 1
0_DZ Blwr Wiper Seat Grnd Bk-2.0-SXL 29M Blower Motor 4 218F Ground Cab 1
0_E Fuel Redundant Br Cool Grnd Bk-1.0-SXL 160 Engine Grounds 1 171 Fuel Sender Grnd 1
0_F Frt Rear Wash Hot Grnd Bk-1.0-SXL 162 Engine Ground 1 3 Rear Washer 2
4002-12

21C Bk - 1.0


Color, Size,
and Material
0_G Frt Rear Wash Hot Grnd Bk-1.0-SXL 2 Front Washer 2 162 Engine Ground 1
0_GA Relay Ground Bk-2.0-SXL 93M Relay Box B SPL_G1 Splice G1 1
0_GB Starter Relay Ground Bk-2.0-SXL 132 Starter Relay 1 SPL_G1 Splice G1 1
0_GC Fuel Relay Ground Bk-2.0-SXL 173 Fuel Relay 1 SPL_G1 Splice G1 1
0_HA Signal Ground Bk-1.0-SXL 22M Cab Transmission 23 94F Eng-Trans 9
0_HB Signal Ground Bk-1.0-SXL 22M Cab Transmission 15 94F Eng-Trans 11
0_HC Analog Ground Bk-1.0-SXL 22M Cab Transmission 30 94F Eng-Trans 15
0_HD Speed Sense Grnd Bk-1.0-SXL 22M Cab Transmission 11 SPL_H2 Splice H2 Splice
0_HE Out Speed Grnd Bk-1.0-SXL 22M Cab Transmission 28 100 Out Speed Sens 1
0_HF Eng Speed Grnd Bk-0.8-BLD 101 Eng Speed Sense 2 SPL_H2 Splice H2 Splice
0_HG Int Speed Sig Bk-0.8-BLD 95 Int Speed Sense 1 SPL_H2 Splice H2 Splice
0_HH Turb Speed Grnd Bk-0.8-BLD 96 Turb Speed Sense 2 SPL_H2 Splice H2 Splice
0_J Hood Ground Bk-1.0-SXL 164 Engine Grounds 1 128F Rear-Hood C

0_JA Hood Ground Bk-1.0-SXL 128M Lic/Backup Alarm C SPL_J1 SPL_J1 1
0_JB Backup Alarm Grnd Bk-1.0-SXL 174 Backup Alarm Grnd 1 SPL_J1 SPL_J1 1
0_JC Lic Plate Lt Grnd Bk-1.0-SXL 168 Lic Plate Light B SPL_J1 SPL_J1 1
0_KD Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 39 13M Pedestal-Cab 39
0_KE Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 38 SPL_K1 SPL_K1 1
0_KF Horn High Low Beam Grnd Bk-0.8-SXL 187 High Low Beam 1 185 Horn Switch 1
0_KG Horn High Low Beam Grnd Bk-0.8-SXL 13M Pedestal-Cab 41 185 Horn Switch 1
0_KH Pilot Light Grnd Bk-0.8-SXL 71 Hazard Switch 7 37 Pilot Control Switch 7
0_KJ Pilot Light Grnd Bk-0.8-SXL 37 Pilot Control Switch 7 72 Parking Brake Switch 7
0_KK Pilot Light Grnd Bk-0.8-SXL 72 Parking Brake Switch 7 74 Up Down Count Switch 7
0_KL Pilot Light Grnd Bk-0.8-SXL 75 Program Reset Switch 7 74 Up Down Count Switch 7
0_KM Pilot Light Grnd Bk-0.8-SXL 13M Pedestal-Cab 53 75 Program Reset Switch 7
0_KN Front Wiper Grnd Bk-0.8-SXL 13M Pedestal-Cab 61 60 Front-Wiper Motor 1
0_KP Analog Grnd Bk-0.8-SXL 76 Instrument Cluster 8 13M Pedestal-Cab 8
0_KQ Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 37 SPL_K1 SPL_K1 1
0_KR Signal Grnd Bk-0.8-SXL 13M Pedestal-Cab 38 SPL_K1 SPL_K1 1
0_L Ground Bk-1.0-SXL 157 Redundant Brake Sw B SPL_E9 SPL_E9 1
4002-13

21C Bk - 1.0


Color, Size,
and Material
0_M Ground Bk-1.0-SXL 86 Redundant Brake Sw B SPL_E9 SPL_E9 1
0_MA Rear Wiper Mtr Grnd Bk-1.0-SXL 82M Rear Wiper Mtr 1 SPL_M6 Rear Wip Beacon Grnd 1
0_MB Dome Lt Grnd Bk-0.8-SXL 84F Dome Light B SPL_M5 Dome Courtesy Lt Grnd 1
0_MC Beacon Light Ground Bk-1.0-SXL 85F Beacon Light B SPL_M6 Rear Wip Beacon Grnd 1
0_MD Beacon-Rear Wiper Grnd Bk-1.0-SXL 23M Roof-Cab C SPL_M6 Rear Wip Beacon Grnd 1
0_ME LH Rear Work Lt Grnd Bk-1.0-SXL 83F LH Rear Work Lt B SPL_M3 Rear Work Lts Grnd 1
0_MF RH Rear Work Lt Grnd Bk-1.0-SXL 80F RH Rear Work Lt B SPL_M3 Rear Work Lts Grnd 1
0_MG Rear Work Light Grnd Bk-1.0-SXL 23M Roof-Cab B SPL_M3 Rear Work Lts Grnd 1
0_MH LH Frnt Work Lt Grnd Bk-1.0-SXL 79F LH Front Work Lt B SPL_M2 Frnt Work Lt Grnd 1
0_MJ RH Frnt Work Lt Grnd Bk-1.0-SXL 78F RH Front Work Lt B SPL_M2 Frnt Work Lt Grnd 1
0_MK Frnt Work Lt Grnd Bk-1.0-SXL 24F Roof-Cab G SPL_M2 Frnt Work Lt Grnd 1
0_ML Courtesy Lt Grnd Bk-0.8-SXL 77F Courtesy Lt B SPL_M5 Dome Courtesy Lt Grnd 1
0_MM Dome Lt Grnd Bk-0.8-SXL 84F Dome Light B 84F Dome Light C
0_MN Dome Courtesy Lt Grnd Bk-0.8-SXL 24F Roof-Cab E SPL_M5 Dome Courtesy Lt Grnd 1
0_N Brk Warn Pr Sw Bk-1.0-SXL 88 Brk Warn Pr Sw B SPL_E9 SPL_E9 1
0_NA Chas Grnd Blck Grnd Bk-62.0-SGR 232F Chas Grnd Blck Grnd 1 233F Chas Grnd Blck Grnd 1
0_NB Discon-Blck Grnd Bk-62.0-SGR 235F Discon-Blck Grnd 1 234F Discon-Blck Grnd 1
0_NC Disconnect Battery Bk-62.0-SGR 237F Disconnect Battery 1 236F Disconnect Battery 1
0_ND Chas Grnd-Sec Strg Mtr Bk-62.0-SGT 242F Chas Grnd-Sec Strg Mtr 1 243F Chas Grnd-Sec Strg Mtr 1
0_P Fuel Redundant Br Cool Grnd Bk-1.0-SXL 160 Engine Grounds 1 SPL_E9 SPL_E9 1
0_PA Left Spkr Ground Bk-0.8-SXL 114F 2 112M B
0_PB Right Spkr Ground Bk-0.8-SXL 114F 4 111M B
0_PC Radio Ground Bk-0.8-SXL 114F 3 110F 24/12V Converter B
0_PD Radio Ground Bk-1.0-SXL 247F Radio Ground 1 109M 24/12V Converter B
0_Q Park Str Fuel Relay Grnd Bk-1.0-SXL 87 Parking Brk Sol 2 165 Engine Ground 1
0_QA Left Spkr Ground Bk-0.8-SXL 114M 2 113 Radio 4
0_QB Right Spkr Ground Bk-0.8-SXL 114M 4 113 Radio 2
0_QC Radio Ground Bk-0.8-SXL 114M 3 113 Radio 5
0_RA Converter Ground Bk-5.0-SXL 251F Converter Ground 1 254F Converter Ground 1
0_RB Outlet Ground Bk-3.0-SXL 252F Outlet Ground 1 253F Power Outlet B
4002-14

21C Bk - 1.0


Color, Size,
and Material
0_S Cigar Lighter Grnd Bk-3.0-SXL 261F Cigar Lighter Grnd 1 259F Cigar Lighter 2
0_U Park Str Fuel Relay Grnd Bk-2.0-SXL 93F Rear-Fuel Str Rel B 165 Engine Ground 1
0_V Fuel Redundant Br Cool Grnd Bk-1.0-SXL 104 Cool Level Sensor B 160 Engine Grounds 1
0_VA Fuel Redundant Br Cool Grnd Y-0.8-SOLID 274F Cool Jmpr Rear Chsis B 275M Coolant Jmpr Coolant Sndr B
0_W Frt Rear Wash Hot Grnd Bk-1.0-SXL 136 Hyd Oil Temp Send B 162 Engine Ground 1
0_X Fan Rev Sol Grd Bk-1.0-SXL 158 Fan Rev Sol Opt B 163 Engine Ground 1
0_Y Engine Cab Grd Bk-13.0-SXL 161 Engine Ground 1 167 Engine Cab Grnd 1
12K_A Acc Power Or-1.0-SXL 49F Accessory Relay 86 18F Fuse Block M1
12K_B Acc Power Or-0.8-SXL 49F Accessory Relay 86 13F Cab-Pedestal 63
12K_C Ign Sw Acc Pwr Or-0.8-SXL 13M Pedestal-Cab 63 69 Ignition Switch 4
12P_A Acc Relay Or-1.0-SXL 49F Accessory Relay 87 18F Fuse Block L1
12P_B Acc Relay Or-1.0-SXL 18F Fuse Block N1 18F Fuse Block L1
12V_A 12V Pwr To Outlet R-3.0-SXL 257F 12V Pwr To Outlet 1 253F Power Outlet A
12V_B 12V Pwr To Fuse Blck R-5.0-SXL 258F 12V Pwr To Fuse Blck 1 18F Fuse Block 6
13C Fuel Sol Or-1.0-SXL 94M Engine Trans 1 139F Disc Harness A
13C_A Fuel Sol Or-1.0-SXL 94F Eng-Trans 1 22M Cab-Transmission 1
13C_B Fuel Sol Pwr Or-0.8-SXL 57F Engine Shutdown Relay 87 217M Engine Shutdown Jumper A
13C_C Fuel Sol Pwr Or-0.8-SXL 57F Engine Shutdown Relay 87 140M Diode Module D
13C_D Fuel Sol Pwr Or-0.8-SXL 22F Cab-Transmission 1 57F Engine Shutdown Relay 87
13C_E Fuel Sol Pwr Or-1.0-SXL 139M Disconnect-Engine A 231F Fuel Sol Disconnect 1
13D Delay Pwr (2 Way) Or-1.0-SXL 63M Time Delay Module 1 18F Fuse Block S1
13K Ignition Switch Pwr Or-0.8-SXL 13M Pedestal-Cab 56 69 Ignition Switch 3
13K_A Ignition Switch Pwr Or-1.0-SXL 48F Ignition Relay #2 86 47F Ignition Relay #1 86
13K_B Ignition Switch Pwr Or-1.0-SXL 48F Ignition Relay #2 86 57F Engine Shutdown Relay 30
13K_C Ignition Switch Pwr Or-1.0-SXL 58F Volt Meter Relay 86 57F Engine Shutdown Relay 30
13K_D Ignition Switch Pwr Or-0.8-SXL 57F Engine Shutdown Relay 30 217F Engine Shutdown Jumper A
13K_E Ignition Switch Pwr Or-0.8-SXL 58F Volt Meter Relay 86 SPL_D22 Ignition Switch 1
13K_F Ignition Switch Pwr Or-0.8-SXL 63M Time Delay Module 5 SPL_D22 Ignition Switch 1
13K_G Ignition Switch Pwr Or-0.8-SXL 13F Cab-Pedestal 56 SPL_D22 Ignition Switch 1
13M Fuel Sol Hold In Or-1.0-SXL 139F Disc Harness B 134 Fuel Solenoid A
4002-15

21C Bk - 1.0


Color, Size,
and Material
13M_A Fuel Sol Hold In Or-1.0-SXL 139M Disconnect-Engine B 230F Fuel Sol Disconnect 1
13P_A Ign Rel 1 Out Or-1.0-SXL 47F Ignition Relay #1 87 18F Fuse Block A1
13P_B Ign Rel 1 Out Or-1.0-SXL 47F Ignition Relay #1 87 18F Fuse Block P1
13R Ign Rel 2 Out (5 Way) Or-1.0-SXL 48F Ignition Relay #2 87 18F Fuse Block F1
13V Voltmeter Relay Out Or-1.0-SXL 58F Volt Meter Relay 87 18F Fuse Block V1
14 Alternator D+ LG-1.0-SXL 154 Alternator 1 94M Eng-Trans 5
14_A Alternator D+ LG-1.0-SXL 22M Cab-Transmission 2 94F Eng-Trans 5
14_B Alternator D+ LG-0.8-SXL 22F Cab-Transmission 2 215F Alternator Resistor 1
18A Rear Fld Lts Fuse Pwr Or-2.0-SXL 32F Light Switch B 18F Fuse Block A2’
18B High Beam LH Or-1.0-SXL 1 Cab-Frnt Chas G 6 Lights LH 3
18B_A High Beam LH Or-0.8-SXL 1F Cab-Frnt Chas G 18F Fuse Block B2’
18C High Beam RH Or-1.0-SXL 1 Cab-Frnt Chas Q 8 Lights RH 3
18C_A High Beam Fused Pwr Or-0.8-SXL 1F Cab-Frnt Chas Q 18F Fuse Block C2’
18C_B High Beam Fused Pwr Or-0.8-SXL 13F Cab-Pedestal 15 18F Fuse Block C2’
18C_C High Beam Telltale Or-0.8-SXL 76 Instrument Cluster 15 13M Pedestal-Cab 15
18D Low Beam LH Or-1.0-SXL 1 Cab-Frnt Chas O 6 Lights LH 2
18D_A Low Beam LH Or-0.8-SXL 1F Cab-Frnt Chas O 18F Fuse Block D2’
18E Low Beam RH Or-1.0-SXL 1 Cab-Frnt Chas P 8 Lights RH 2
18E_A Low Beam RH Or-0.8-SXL 1F Cab-Frnt Chas P 18F Fuse Block E2’
18F Position LH Or-1.0-SXL 1 Cab-Frnt Chas F 6 Lights LH 4
18F_A Left Tail Or-1.0-SXL 125 LH Rear Comb Lt 3 21M Rear-Cab 5
18F_D Left Tail Pos Or-0.8-SXL 21F Cab-Rear 5 18F Fuse Block F2’
18F_E Left Tail Pos Or-0.8-SXL 1F Cab-Frnt Chas F 18F Fuse Block F2’
18G Position RH Or-1.0-SXL 1 Cab-Frnt Chas E 8 Lights RH 4

18G_A Right Tail Or-1.0-SXL 127 RH Rear Comb Lt 3 SPL_E8 SPL_E8 1
18G_C Lic Plate Light Or-1.0-SXL 128F Rear-Hood A SPL_E8 SPL_E8 1
18G_D RH Tail Lic Lts Or-1.0-SXL 21M Rear-Cab 9 SPL_E8 SPL_E8 1
18G_E Lic Plate Light Or-1.0-SXL 168 Lic Plate Light A 128M Lic/Backup Alarm A
18G_F RH Tail Lic Lts Or-0.8-SXL 21F Cab-Rear 9 18F Fuse Block G2’
18G_G Position RH Or-0.8-SXL 1F Cab-Frnt Chas E 18F Fuse Block G2’
4002-16

21C Bk - 1.0


Color, Size,
and Material
18_H Radio Power Or-0.8-SXL 113 Radio 6 269 Radio Fuse Holder 2
19A Out Speed Power Or-1.0-SXL 22M Cab-Transmission 29 100 Out Speed Sens 3
19A_A Declutch Switch Or-1.0-SXL 4 Dec Press Sw A 21M Rear-Cab 30
19A_B FNR Switched Pwr Or-0.8-SXL 198 FNR Switch 5 197M FNR-Main Cab 1
19A_C Trans Ena Sw Pwr Or-0.8-SXL 197F Main Cab FNR 1 199F Trans Enable Sw 10
19A_D Trans Ena Sw Pwr Or-0.8-SXL 199F Trans Enable Sw 2 SPL_D15 1
19A_E Trans Ena Sw Pwr Or-0.8-SXL 199F Trans Enable Sw 2 199F Trans Enable Sw 10
19A_F FNR Switched Pwr Or-0.8-SXL 198 FNR Switch 8 198 FNR Switch 5
19A_G Trans Control Pwr Or-0.8-SXL 13M Pedestal-Cab 43 72 Parking Brake Switch 2
19A_H Trans Control Pwr Or-0.8-SXL 70 Transmission Shifter A 72 Parking Brake Switch 2
19A_K Cab Switched Pwr Or-0.8-SXL 19F TECM 45 SPL_D15 1
19A_L Cab Switched Pwr Or-0.8-SXL 108F Diagnostic Connector 1 SPL_D15 1
19A_M Cab Switched Pwr Or-0.8-SXL 22F Cab-Transmission 29 SPL_D15 1

19A_N Cab Switched Pwr Or-0.8-SXL 18F Fuse Block A2 SPL_D15 1
19A_P Cab Switched Pwr Or-0.8-SXL 53F Backup Alarm Relay 86 18F Fuse Block A2
19A_Q Cab Switched Pwr Or-0.8-SXL 41F Trans Auto Sw 2 SPL_D15 1
19A_R Cab Switched Pwr Or-0.8-SXL 38F Declutch Switch 2 SPL_D15 1
19A_S Cab Switched Pwr Or-0.8-SXL 13F Cab-Pedestal 43 SPL_D15 1
19A_T Cab Switched Pwr Or-0.8-SXL 21F Cab-Rear 30 SPL_D15 1
19A_U Cab Switched Pwr Or-0.8-SXL 20M Trans Kick-Down 1 SPL_D15 1
19B Turn Signal Power Or-0.8-SXL 13M Pedestal-Cab 66 67 Turn Signal Switch 1
19B_A Turn Signal Power Or-0.8-SXL 13F Cab-Pedestal 66 18F Fuse Block B2
19C Pilot Control Signal Or-0.8-SXL 13M Pedestal-Cab 68 37 Pilot Control Switch 2
19C_A Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 18F Fuse Block C2 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_B Ride Ctrl Fused Pwr Or-1.0-SXL 44F Ride Control Sw 2 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_C Ride Ctrl Fused Pwr Or-0.8-SXL 13F Cab-Pedestal 68 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_D Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 56F Pilot Control Relay 30 18F Fuse Block C2
19C_E Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 56F Pilot Control Relay 30 56F Pilot Control Relay 86
19D_A Parking Brake Rel Fused Pwr Or-1.0-SXL 55F Brake Lights Relay 30 18F Fuse Block D2
19D_B Parking Brake Rel Fused Pwr Or-1.0-SXL 55F Brake Lights Relay 30 55F Brake Lights Relay 86
4002-17

21C Bk - 1.0


Color, Size,
and Material
19E Ether Start Rel Fused Pwr Or-1.0-SXL 52F Ether Start Relay 30 18F Fuse Block E2
19F Eng Shtdwn Rel Fused Pwr Or-1.0-SXL 57F Engine Shutdown Relay 86 18F Fuse Block F2
19G Blower Switch Fused Pwr Or-2.0-SXL 30F Blower Switch 2 18F Fuse Block G2
19H Backup Alarm Rel Fuse Pwr Or-1.0-SXL 53F Backup Alarm Relay 30 18F Fuse Block H2
19J Frt Wip Wash Fused Pwr Or-0.8-SXL 13M Pedestal-Cab 60 61 Front-Wiper Motor C
19J_A Frt Wip Wash Fused Pwr Or-1.0-SXL 35F Wiper and Washer Sw 2 18F Fuse Block J2
19J_B Frt Wip Wash Fused Pwr Or-0.8-SXL 35F Wiper and Washer Sw 2 13F Cab-Pedestal 60
19K_A Rear Wip Wash Fused Pwr Or-1.0-SXL 18F Fuse Block K2 SPL_D23 Rear Wiper Pwr 1
19K_B Rear Wip Wash Fused Pwr Or-1.0-SXL 23F Cab-Roof F SPL_D23 Rear Wiper Pwr 1
19K_C Rear Wip Wash Fused Pwr Or-1.0-SXL 45F Rear Wiper Sw 3 SPL_D23 Rear Wiper Pwr 1
19K_D Rear Wip Wash Fused Pwr Or-0.8-SXL 45F Rear Wiper Sw 5 SPL_D23 Rear Wiper Pwr 1
19K_E Rear Wip Wshr Fused Pwr Or-1.0-SXL 23M Roof-Cab F 81M Rear Wiper Mtr C
19L Access To Fuse L (3 Way) Or-1.0-SXL 18F Fuse Block L2 18F Fuse Block 5
19L_A Radio Power Or-1.0-SXL 246M Radio Power A 109M 24/12V Converter A
19L_B Converter Pwr Ign Or-1.0-SXL 249M Converter Pwr Ign A 256F Converter Pwr Ign 1
19M_A Sec Str Accessory Or-0.8-SXL 1F Cab-Frnt Chas H 18F Fuse Block M2
19M_B Sec Str Accessory Or-1.0-SXL 180F Sec Str Mod Opt 1 1 Cab-Frnt Chas H
19M_C Sec Str Accessory Or-1.0-SXL 90M Sec Str Mod 7 180M Sec Str Mod-Frnt Harn 1
19N_A Access Seat Fused Pwr (3 Way) Or-1.0-SXL 28M Seat Comp Motor A 18F Fuse Block N2
19N_B Access Seat Fused Pwr (3 Way) Or-1.0-SXL 18F Fuse Block N2 18F Fuse Block 1
19P_A Fan Rev Pin Eng Fused Pwr Or-1.0-SXL 40F Pin Engage Sw 2 18F Fuse Block P2
19P_B Fan Rev Pin Eng Fused Pwr Or-1.0-SXL 210F Fan Reverser Sw 2 40F Pin Engage Sw 2
19R_A Sec Str Ignition Or-0.8-SXL 1F Cab-Frnt Chas J SPL_D25 SPL_D25 Splice
19R_B Sec Str Ignition Or-1.0-SXL 180F Sec Str Mod Opt 2 1 Cab-Frnt Chas J
19R_C Sec Str Ignition Or-1.0-SXL 90M Sec Str Mod 1 180M Sec Str Mod-Frnt Harn 2
19R_D Sec Strg Ignition Or-0.8-SXL SPL_D25 SPL_D25 Splice 262F Diode Module C
19R_E Cab Switched Pwr Or-0.8-SXL 216F Alternator Resistor 1 SPL_D25 SPL_D25 Splice
19R_F Sec Strg Ignition Or-0.8-SXL 262F Diode Module A 18F Fuse Block R2
19S Instr Cluster Fused Del Pwr Or-0.8-SXL 13F Cab-Pedestal 2 18F Fuse Block S2
19S_A Instr Cluster Fused Del Pwr Or-0.8-SXL 74 Up Down Count Switch 2 13M Pedestal-Cab 2
4002-18

21C Bk - 1.0


Color, Size,
and Material
19S_B Instr Cluster Fused Del Pwr Or-0.8-SXL 76 Instrument Cluster 2 74 Up Down Count Switch 2
19T_A Time Delay Fused Pwr Or-0.8-SXL 19F TECM 23 18F Fuse Block T2
19T_B Time Delay Fused Pwr Or-0.8-SXL 19F TECM 68 18F Fuse Block T2
19U_A Dome Lt Horn Fused Pwr Or-1.0-SXL 23F Cab-Roof D 18F Fuse Block U2
19U_B Dome Lt Horn Fused Pwr Or-1.0-SXL 51F Horn Relay 30 18F Fuse Block U2
19U_C Dome Lt Horn Fused Pwr Or-0.8-SXL 51F Horn Relay 86 51F Horn Relay 30
19U_D Dome Lt Fused Pwr Or-1.0-SXL 23M Roof-Cab D 84F Dome Light A
19V Cluster Main Fused Power Or-0.8-SXL 13F Cab-Pedestal 1 18F Fuse Block V2
19V_A Cluster Main Fused Pwr Or-0.8-SXL 76 Instrument Cluster 1 13M Pedestal-Cab 1
19W Cigarette Lighter Fused Pwr Or-1.0-SXL 18F Fuse Block W2 18F Fuse Block 16
19W_A Cigar Lighter Pwr Or-3.0-SXL 259F Cigar Lighter 1 260M Cigar Lighter Pwr A
19X Beacon Sw Fused Pwr Or-1.0-SXL 42F Beacon Sw 2 18F Fuse Block X2
19Z Frnt Flood Illum Fused Pwr Or-1.0-SXL 34F Light Switch C 18F Fuse Block Z2
1A_A Ign Prog Reset Sw Pwr R-0.8-SXL 13M Pedestal-Cab 62 69 Ignition Switch 1
1A_B Ign Prog Reset Sw Pwr R-0.8-SXL 75 Program Reset Switch 2 69 Ignition Switch 1
1A_C Ignition Switch Power R-0.8-SXL 13F Cab-Pedestal 62 SPL_D21 CB A Load 1
1A_D CB A Load R-0.8-SXL 214F Ign Sw Cir Brkr 1 SPL_D21 CB A Load 1
1A_E Time Delay Pwr R-0.8-SXL 63M Time Delay Module 2 SPL_D21 CB A Load 1
1B Hazard Switch Pwr R-0.8-SXL 13M Pedestal-Cab 65 71 Hazard Switch 2
1B_A Brake Lt Sw Pwr R-1.0-SXL 159 Brake Lt Pres Sw 1 21M Rear-Cab 28
1B_B Flasher Module Pwr R-0.8-SXL 62M Flasher Module 1 SPL_D19 CB B Load 1
1B_C Hazard Switch Power R-0.8-SXL 13F Cab-Pedestal 65 SPL_D19 CB B Load 1
1B_D CB B Load R-0.8-SXL 212F Flasher Cir Brkr 1 21F Cab-Rear 28
1B_E Brake Lt Relay Pwr R-0.8-SXL 204F Relay Brake Lights 30 SPL_D19 CB B Load 1
1B_F CB B Load R-0.8-SXL 212F Flasher Cir Brkr 1 SPL_D19 CB B Load 1
1_A B+ R-1.0-SXL 21M Rear-Cab 21 156 Fuel Str Rel B+ 1
1_B B+ R-13.0-SXL 156 Fuel Str Rel B+ 1 155 Cab Power B+ 1
1_C Starter Fuel Relay Pwr R-8.0-SXL 190 Jblock Relay 1 191 Jblock-Relay 1
1_D Starter Fuel Relay Pwr R-2.0-SXL 190 Jblock Relay 1 192 Jblock-Relay 1
1_E Power R-19.0-SGT 195 Jblock Pwr 1 196 Jblock Pwr 1
4002-19

21C Bk - 1.0


Color, Size,
and Material
1_F Starter Sol Pwr R-8.0-GPT 193 Starter Relay 1 194 Starter Signal 1
1_G Acc Relay Pwr R-3.0-SXL 49F Accessory Relay 30 SPL_D16 B+ Power 1
1_H High Beam Signal (2 Way) R-3.0-SXL 59F High/Low Beam 8 SPL_D16 B+ Power 1
1_J B+ Pwr R-3.0-SXL 228F Power Cab 1 SPL_D17 B+ Power 1
1_K B+ Pwr R-3.0-SXL 226F Power Cab 1 SPL_D16 B+ Power 1
1_L CB A Power R-3.0-SXL 213F Ign Sw Cir Brkr 1 SPL_D17 B+ Power 1
1_M CB B Power R-3.0-SXL 211F Flasher Cir Brkr 1 SPL_D17 B+ Power 1
1_N Light Sw Power R-3.0-SXL 33F Light Switch C 224F Power Cab 1
1_NA Battery Crossover R-62.0-SGR 239 Discon-Blck Grnd 1 238F Battery Crossover 1
1_NB Starter-Battery R-62.0-SGR 240F Starter-Battery 1 241F Starter-Battery 1
1_NC Starter-Sec Strg Mtr R-62.0-SGR 245F Starter-Sec Strg Mtr 1 244F Starter-Sec Strg Mtr 1
1_P Voltmeter Rel Pwr R-0.8-SXL 58F Volt Meter Relay 30 21F Cab-Rear 21
1_Q Dome Lt Horn Pwr R-1.0-SXL 18F Fuse Block U1 SPL_D16 B+ Power 1
1_R Cigar Lighter Pwr R-3.0-SXL 18F Fuse Block W1 227F Power Cab 1
1_S Ign Relay #1 Pwr R-3.0-SXL 47F Ignition Relay #1 30 SPL_D17 B+ Power 1
1_T Ign Relay #2 Pwr R-3.0-SXL 48F Ignition Relay #2 30 SPL_D17 B+ Power 1
1_U B+ Power (4 Way) R-3.0-SXL 18F Fuse Block Z1 225F Power Cab 1
1_V Converter 24V Pwr R-5.0-SXL 250F Converter 24V Pwr 1 255F Converter 24V Pwr 1
1_W Sec Strg Mtr B+ R-1.0-SXL 263F Sec Str Mtr 1 90M Sec Str Mod 3
1_X Radio Memory Power R-1.0-SXL 270F Radio Memory Power 1 269 Radio Fuse Holder 1
21C_A Fuel Relay Signal W-1.0-SXL 172 Fuel Relay 1 SPL_G2 Splice G2 1
21C_B Starter Relay Signal W-1.0-SXL 135 Starter Relay 1 SPL_G2 Splice G2 1
21C_C Starter Fuel Relay Signal W-1.0-SXL 93M Relay Box A SPL_G2 Splice G2 1
21C_D Starter Fuel Relay Signal W-1.0-SXL 93F Rear-Fuel Str Rel A 21M Rear-Cab 11
21C_E Starter Fuel Relay Signal W-0.8-SXL 54F Neutral Start Relay 87 21F Cab-Rear 11
21C_F Starter Fuel Relay Signal W-0.8-SXL 54F Neutral Start Relay 87 140M Diode Module E
21K Ign Sw Start Signal W-0.8-SXL 13M Pedestal-Cab 64 69 Ignition Switch 2
21K_A Ign Sw Start Signal W-0.8-SXL 54F Neutral Start Relay 30 13F Cab-Pedestal 64
23C Engine Shutdown Signal W-0.8-SXL 76 Instrument Cluster 23 13M Pedestal-Cab 23
23C_A Engine Shutdown Signal W-0.8-SXL 57F Engine Shutdown Relay 85 13F Cab-Pedestal 23
4002-20

21C Bk - 1.0


Color, Size,
and Material
23F Fuel Sol Pull In W-2.0-SXL 134 Fuel Solenoid B 133M Fuel Relay 1
23F_A Fuel Sol Pull In W-2.0-SXL 137 Fuel Relay 1 133F Fuel Solenoid 1
25A Eng Speed Sig W-0.8-BLD 22M Cab-Transmission 7 101 Eng Speed Sens 1
25A_A Eng Speed Sig LU-0.8-SXL 19F TECM 19 22F Cab-Transmission 7
25B Turb Speed Sig W-0.8-BLD 22M Cab-Transmission 8 96 Turb Speed Sens 1
25B_A Turb Speed Sig LU-0.8-SXL 19F TECM 41 22F Cab-Transmission 8
25C Int Speed Sig W-0.8-BLD 22M Cab-Transmission 9 95 Int Speed Sens 2
25C_A Int Speed Sig LU-0.8-SXL 19F TECM 42 22F Cab-Transmission 9
25D Output Speed Sig LU-1.0-SXL 22M Cab-Transmission 10 100 Out Speed Sens 2
25D_A Output Speed Sig LU-0.8-SXL 19F TECM 62 22F Cab-Transmission 10
25F Forward Signal LU-0.8-SXL 13M Pedestal-Cab 44 70 Transmission Shifter B
25F_A Forward Signal LU-0.8-SXL 19F TECM 43 13F Cab-Pedestal 44
25G Declutch Switch LU-1.0-SXL 4 Declutch Press Sw B 21M Rear-Cab 31

25G_A Declutch Switch LU-0.8-SXL 38F Declutch Switch 1 21F Cab-Rear 31
25G_B Declutch Switch LU-0.8-SXL 19F TECM 66 38F Declutch Switch 1
25H Trans Auto Signal LU-0.8-SXL 19F TECM 29 41F Trans Auto Sw 3
25J Trans Sol Valve Y6 LU-0.8-TXL 22M Cab-Transmission 21 102 Trans Control 6
25J_A Trans Sol Valve Y6 LU-0.8-SXL 19F TECM 51 22F Cab-Transmission 21
25K Trans Sol Valve Y1 LU-0.8-TXL 22M Cab-Transmission 16 102 Trans Control 1
25K_A Trans Sol Valve Y1 LU-0.8-SXL 19F TECM 56 22F Cab-Transmission 16
25L Trans Sol Valve Y2 LU-0.8-TXL 22M Cab-Transmission 17 102 Trans Control 2
25L_A Trans Sol Valve Y2 LU-0.8-SXL 19F TECM 10 22F Cab-Transmission 17
25M Trans Sol Valve Y3 LU-0.8-TXL 22M Cab-Transmission 18 102 Trans Control 3
25M_A Trans Sol Valve Y3 LU-0.8-SXL 19F TECM 32 22F Cab-Transmission 18

25N Trans Sol Valve Y4 LU-0.8-TXL 22M Cab-Transmission 19 102 Trans Control 4
25N_A Trans Sol Valve Y4 LU-0.8-SXL 19F TECM 55 22F Cab-Transmission 19
25P Trans Sol Valve Y5 LU-0.8-TXL 22M Cab-Transmission 20 102 Trans Control 5
25P_A Trans Sol Valve Y5 LU-0.8-SXL 19F TECM 9 22F Cab-Transmission 20
25R Reverse Signal LU-0.8-SXL 13M Pedestal-Cab 45 70 Transmission Shifter C
25R_A Reverse Signal LU-0.8-SXL 19F TECM 64 13F Cab-Pedestal 45
4002-21

21C Bk - 1.0


Color, Size,
and Material
25S Output Sw Power VPS1 LU-0.8-TXL 22M Cab-Transmission 22 102 Trans Control 7
25S_A Output Sw Power VPS1 LU-0.8-SXL 22F Cab-Transmission 22 SPL_D12 Common Power 1
25S_B Output Sw Power VPS1 LU-0.8-SXL 19F TECM 12 SPL_D12 Common Power 1
25S_C Output Sw Power VPS1 LU-0.8-SXL 19F TECM 13 SPL_D12 Common Power 1
25T_A Neutral Signal LU-0.8-SXL 92 Ether Switch 1 70 Transmission Shifter D
25T_B Neutral Signal LU-0.8-SXL 13M Pedestal-Cab 46 92 Ether Switch 1
25T_C Neutral Signal LU-0.8-SXL 13F Cab-Pedestal 46 SPL_D18 Neutral Signal 1
25T_D Neutral Signal LU-0.8-SXL 19F TECM 67 SPL_D18 Neutral Signal 1
25T_E Neutral Signal LU-0.8-SXL 54F Neutral Start Relay 86 SPL_D18 Neutral Signal 1
25W 3rd And 4th Gear Signal LU-0.8-SXL 13M Pedestal-Cab 48 183 Transmission Shifter B
25W_A 3rd And 4th Gear Signal LU-0.8-SXL 19F TECM 65 13F Cab-Pedestal 48
25Y Trans Kickdown Signal LU-0.8-SXL 13M Pedestal-Cab 50 183 Transmission Shifter D
25Y_A Trans Kickdown Signal LU-0.8-SXL 13F Cab-Pedestal 50 SPL_D11 Trans Kick Down Signal 1
25Y_B Trans Kickdown Sig LU-0.8-SXL 19F TECM 22 SPL_D11 Trans Kick Down Signal 1
25Y_C Trans Kickdown Signal LU-0.8-SXL 20M Trans Kick-Down 2 SPL_D11 Trans Kick Down Signal 1
25Z 1st And 4th Gear Signal LU-0.8-SXL 13M Pedestal-Cab 49 183 Transmission Shifter C
25Z_A 1st And 4th Gear Signal LU-0.8-SXL 19F TECM 63 13F Cab-Pedestal 49
26E Trans Enable Signal LU-0.8-SXL 19F TECM 31 199F Trans Enable Sw 3
26F_A FNR Forward Signal LU-0.8-SXL 198 FNR Switch 6 197M FNR-Main Cab 2
26F_B FNR Forward Signal LU-0.8-SXL 19F TECM 20 197F Main Cab FNR 2
26J FNR Switch Jumper LU-0.8-SXL 198 FNR Switch 2 198 FNR Switch 4
26N_A FNR Neutral Signal LU-0.8-SXL 198 FNR Switch 3 197M FNR-Main Cab 3
26N_B FNR Neutral Signal LU-0.8-SXL 19F TECM 44 197F Main Cab FNR 3
26R_A FNR Reverse Signal LU-0.8-SXL 198 FNR Switch 1 197M FNR-Main Cab 4
26R_B FNR Reverse Signal LU-0.8-SXL 19F TECM 30 197F Main Cab FNR 4
28C Ether Start Control W-0.8-SXL 13M Pedestal-Cab 52 182 Ether Switch 1
28C_A Ether Start Control W-0.8-SXL 52F Ether Start Relay 86 13F Cab-Pedestal 52
28P Ether Sol W-1.0-SXL 103 Ether Sol Opt A 21M Rear-Cab 1
28P_A Ether Sol W-0.8-SXL 52F Ether Start Relay 87 21F Cab-Rear 1
28T Ether Start Temp Sw W-1.0-SXL 97 Ether Temp Sw A 65M Eng-Rear (Ether Start) 1
4002-22

21C Bk - 1.0


Color, Size,
and Material
28T_A Ether Start Temp Sw W-1.0-SXL 103 Ether Sol Opt B 65F Rear-Eng (Ether Start) 1
31D Coolant Level Signal Y-1.0-SXL 104 Cool Level Sensor A 21M Rear-Cab 3
31D_A Coolant Level Signal Y-0.8-SXL 21F Cab-Rear 3 13F Cab-Pedestal 4
31D_B Coolant Level Signal Y-0.8-SXL 76 Instrument Cluster 4 13M Pedestal-Cab 4
31D_C Coolant Level Signal Y-0.8-SOLID 274F Coolant Jmpr Rear Chs A 275M Coolant Jmpr Coolant Sndr A
31F Air Filter Rest Sw Signal Y-1.0-SXL 94M Engine Trans 7 117 Air Filter Res Sw A
31F_A Air Filter Rest Sw Signal Y-1.0-SXL 22M Cab-Transmission 3 94F Eng-Trans 7
31F_B Air Filter Rest Sw Signal Y-0.8-SXL 22F Cab-Transmission 3 13F Cab-Pedestal 6
31F_C Air Filter Rest Sw Signal Y-0.8-SXL 76 Instrument Cluster 6 13M Pedestal-Cab 6
31H Hyd Oil Filter Rest Sw Signal Y-1.0-SXL 21M Rear-Cab 14 170 Hyd Oil Filter Res Sw 1
31H_A Hyd Filter Rest Sw Signal Y-0.8-SXL 21F Cab-Rear 14 13F Cab-Pedestal 7
31H_B Hyd Filter Rest Sw Signal Y-0.8-SXL 76 Instrument Cluster 7 13M Pedestal-Cab 7
31L Pilot Lockout Signal Y-0.8-SXL 76 Instrument Cluster 29 37 Pilot Control Switch 3
32F Trans Filter Maint Sw Y-1.0-SXL 22M Cab-Transmission 31 31 Filter Maint Sw 1
32F_A Trans Filter Maint Sw Y-0.8-SXL 19F TECM 17 22F Cab-Transmission 31
32J_A FNR Lt Signal Y-0.8-SXL 198 FNR Switch 7 197M FNR-Main Cab 5
32J_B Trans Enable Lt Sig Y-0.8-SXL 197F Main Cab FNR 5 199F Trans Enable Sw 9
32J_C Trans Enable Lt Sig Y-0.8-SXL 19F TECM 5 199F Trans Enable Sw 9
33P Low Brake Pres Warning Y-1.0-SXL 88 Brk Warn Pr Sw A 21M Rear-Cab 4
33P_A Low Brake Pres Warning Y-0.8-SXL 21F Cab-Rear 4 13F Cab-Pedestal 3
33P_B Low Brake Pres Warning Y-0.8-SXL 76 Instrument Cluster 3 13M Pedestal-Cab 3
33R_A Redundant Brake Sw Signal Y-1.0-SXL 157 Redundant Brake Sw A SPL_E10 SPL_E10 1
33R_B Redundant Brake Sw Signal Y-1.0-SXL 86 Redundant Brake Sw A SPL_E10 SPL_E10 1
33R_C Redundant Brake Sw Signal Y-1.0-SXL 21M Rear-Cab 15 SPL_E10 SPL_E10 1

33R_D Redundant Brake Sw Signal Y-0.8-SXL 21F Cab-Rear 15 13F Cab-Pedestal 28
33R_E Redundant Brake Sw Signal Y-0.8-SXL 76 Instrument Cluster 28 13M Pedestal-Cab 28
33U Parking Brake Signal Y-0.8-SXL 76 Instrument Cluster 9 72 Parking Brake Switch 3
35A_A Left Reverse K-1.0-SXL 125 LH Rear Comb Lt 4 SPL_E2 SPL_E2 1
35A_B Right Reverse K-1.0-SXL 127 RH Rear Comb Lt 4 SPL_E2 SPL_E2 1
35A_C Reverse Lights K-1.0-SXL 21M Rear-Cab 7 SPL_E2 SPL_E2 1
4002-23

21C Bk - 1.0


Color, Size,
and Material
35A_D Backup Alarm Relay Out Y-0.8-SXL 53F Backup Alarm Relay 87 21F Cab-Rear 7
35A_E Backup Alarm Relay Out Y-0.8-SXL 118F Backup Alarm Dis Sw 2 53F Backup Alarm Relay 87
35A_F Backup Alarm Relay Out Y-0.8-SXL 118F Backup Alarm Dis Sw 2 209M Backup Alarm Disa Jmp A
35C Backup Alarm Pull-Dwn Y-0.8-SXL 19F TECM 7 53F Backup Alarm Relay 85
35R_A Backup Alarm Sw Y-1.0-SXL 175 Backup Alarm 1 128M Lic/Backup Alarm B
35R_B Backup Alarm Sw Y-1.0-SXL 21M Rear-Cab 6 128F Rear-Hood B
35R_C Backup Alarm Sw Y-0.8-SXL 118F Backup Alarm Dis Sw 1 21F Cab-Rear 6
35R_D Backup Alarm Sw Y-0.8-SXL 118F Backup Alarm Dis Sw 1 209F Backup Alarm Disa Jmp A
35X_A Sec Str Low Pres Sig Y-1.0-SXL 131F Sec Str Pres Sw Opt C SPL_A4 SPL_A4 SPL_A4
35X_B Sec Str Low Pres Sig Y-1.0-SXL 1 Cab-Frnt Chas K SPL_A4 SPL_A4 SPL_A4
35X_C Sec Str Low Pres Sig Y-1.0-SXL 180F Sec Str Mod Opt 3 SPL_A4 SPL_A4 SPL_A4
35X_D Sec Str Low Pres Sig Y-1.0-SXL 90M Sec Str Mod 8 180M Sec Str Mod Frnt Harn 3
35X_E Sec Str Low Pres Sig Y-0.8-SXL 13F Cab-Pedestal 5 1 Cab-Frnt Chas K
35X_F Sec Str Low Pres Sig Y-0.8-SXL 76 Instrument Cluster 5 13M Pedestal-Cab 5
36C Eng Cool Temp Signal P-1.0-SXL 94M Engine Trans 13 138 Eng Cool Temp A
36C_A Eng Cool Temp Signal P-1.0-SXL 22M Cab-Transmission 4 94F Eng-Trans 13
36C_B Eng Cool Temp Signal P-0.8-SXL 22F Cab-Transmission 4 13F Cab-Pedestal 18
36C_C Eng Cool Temp Signal P-0.8-SXL 76 Instrument Cluster 18 13M Pedestal-Cab 18
36F Fuel Level Signal P-1.0-SXL 141 Fuel Sender 1 21M Rear-Cab 16
36F_A Fuel Level Signal P-0.8-SXL 21F Cab-Rear 16 13F Cab-Pedestal 19
36F_B Fuel Level Signal P-0.8-SXL 76 Instrument Cluster 19 13M Pedestal-Cab 19
36G Torque Conv Outpt Temp Signal P-1.0-SXL 22M Cab-Transmission 13 142 Torque Conv Temp Sender 1
36G_A Torque Conv Outpt Temp Signal P-1.0-SXL 19F TECM 49 22F Cab-Transmission 13
36H Hot Signal P-1.0-SXL 136 Hyd Oil Temp Send A 21M Rear-Cab 13
36H_A Hot Signal P-0.8-SXL 13F Cab-Pedestal 20 21F Cab-Rear 13
36H_B Hot Signal P-0.8-SXL 76 Instrument Cluster 20 13M Pedestal-Cab 20
36P Engine Oil Pressure Signal P-1.0-SXL 94M Engine Trans 6 148 Engine Oil Pressure Switch 1
36P_A Engine Oil Pressure Signal P-1.0-SXL 22M Cab-Transmission 6 94F Engine Trans 6
36P_B Engine Oil Pressure Signal P-0.8-SXL 22F Cab-Transmission 6 13F Cab-Pedestal 22
36P_C Engine Oil Pressure Signal P-0.8-SXL 76 Instrument Cluster 22 13M Pedestal-Cab 22
4002-24

21C Bk - 1.0


Color, Size,
and Material
36R_A Valve Body Temp Ret P-1.0-SXL 22M Cab-Transmission 12 SPL_H1 Splice H1 Splice
36R_B Valve Body Temp Ret P-1.0-SXL 31 Filter Maint Sw 2 SPL_H1 Splice H1 Splice
36R_C Valve Body Temp Ret P-0.8-SXL 102 Trans Control 9 SPL_H1 Splice H1 Splice
36R_D Valve Body Temp Ret P-1.0-SXL 142 Trq Conv Temp Sender 2 SPL_H1 Splice H1 Splice
36R_E Valve Body Temp Ret P-0.8-SXL 19F TECM 46 22F Cab-Transmission 12
36T Valve Body Temp Sig P-0.8-SXL 22M Cab-Transmission 5 102 Trans Control 8
36T_A Valve Body Temp Sig P-0.8-SXL 19F TECM 39 22F Cab-Transmission 5
37D Down Count Signal P-0.8-SXL 76 Instrument Cluster 27 74 Up Down Count Switch 1
37D_A Diagnostic Signal P-0.8-SXL 19F TECM 15 108F Diagnostic Connector 2
37E Diagnostic Signal P-0.8-SXL 19F TECM 18 108F Diagnostic Connector 4
37P Program Signal P-0.8-SXL 76 Instrument Cluster 24 75 Program Reset Switch 3
37R_A Reset Signal P-0.8-SXL 13M Pedestal-Cab 25 75 Program Reset Switch 1
37R_B Reset Signal P-0.8-SXL 76 Instrument Cluster 25 75 Program Reset Switch 1

37R_C Reset Signal P-0.8-SXL 63M Time Delay Module 4 13F Cab-Pedestal 25
37U Up Count Signal P-0.8-SXL 76 Instrument Cluster 26 74 Up Down Count Switch 3
41H High/Low Beam Relay Pwr K-2.0-SXL 59F High/Low Beam 4 18F Fuse Block C1’
41J_A Driving Light Sig K-2.0-SXL 33F Light Switch A 59F High/Low Beam 1
41J_B Driving Light Sig K-2.0-SXL 25F Light Switch A 33F Light Switch A
41L_A Low Beam Power K-2.0-SXL 59F High/Low Beam 3 18F Fuse Block E1’
41T_A Tail Lt Switched Pwr K-1.0-SXL 32F Light Switch C 18F Fuse Block G1’
41T_B Tail Lt Switched Pwr K-1.0-SXL 33F Light Switch B 32F Light Switch C
42C_A Front Flood Lts DU-1.0-SXL 24M Cab-Roof H 34F Light Switch A
42C_B LH Frnt Work Lt Pwr DU-1.0-SXL 79F LH Front Work Lt A SPL_M1 Frnt Work Lt Pwr 1
42C_C RH Frnt Work Lt Pwr DU-1.0-SXL 78F RH Front Work Lt A SPL_M1 Frnt Work Lt Pwr 1
42C_D Front Work Lts Pwr DU-1.0-SXL 24F Roof-Cab H SPL_M1 Frnt Work Lt Pwr 1
42R_A Work Light Telltale Sig Y-0.8-SXL 76 Instrument Cluster 12 13M Pedestal-Cab 12
42R_B Rear Work Light Pwr DU-0.8-SXL 23F Cab-Roof H 32F Light Switch A
42R_C Rear Work Light Pwr DU-0.8-SXL 13F Cab-Pedestal 12 32F Light Switch A
42R_D LH Rear Work Lt Pwr DU-1.0-SXL 83F LH Rear Work Lt A SPL_M4 Rear Work Lt Pwr 1
42R_E RH Rear Work Lt Pwr DU-1.0-SXL 80F RH Rear Work Lt A SPL_M4 Rear Work Lt Pwr 1
4002-25

21C Bk - 1.0


Color, Size,
and Material
42R_F Rear Work Light Pwr DU-1.0-SXL 23M Roof-Cab H SPL_M4 Rear Work Lt Pwr 1
44A_B Brake Lt Input Signal T-0.8-SXL 204F Relay Brake Lights 86 21F Cab-Rear 29
44_A Brake Light Signal T-1.0-SXL 125 LH Rear Comb Lt 1 SPL_E1 SPL_E1 1
44_B Brake Light Signal T-1.0-SXL 127 RH Rear Comb Lt 1 SPL_E1 SPL_E1 1
44_C Brake Light Signal T-1.0-SXL 21M Rear-Cab 8 SPL_E1 SPL_E1 1
44_D Brake Light Signal T-0.8-SXL 21F Cab-Rear 8 SPL_D9 Brake Lt Signal 1
44_E Brake Lt Relay Signal T-0.8-SXL 204F Relay Brake Lights 87 SPL_D9 Brake Lt Signal 1
44_F Brake Light Signal T-0.8-SXL 13F Cab-Pedestal 35 SPL_D9 Brake Lt Signal 1
44_G Brake Light Signal T-0.8-SXL 76 Instrument Cluster 35 13M Pedestal-Cab 35
45A Left Turn Switch Power N-0.8-SXL 13M Pedestal-Cab 69 66 Turn Signal Switch 1
45A_A Left Turn Switch Power N-0.8-SXL 62M Flasher Module 10 13F Cab-Pedestal 69
45B Right Turn Switch Power N-0.8-SXL 13M Pedestal-Cab 70 68 Turn Signal Switch 1
45B_A Right Turn Switch Power N-0.8-SXL 62M Flasher Module 9 13F Cab-Pedestal 70
45H Hazard Switch Power N-0.8-SXL 13M Pedestal-Cab 67 71 Hazard Switch 3
45H_A Hazard Switch Power N-0.8-SXL 62M Flasher Module 11 13F Cab-Pedestal 67
45L Left Turn Signal N-1.0-SXL 1 Cab-Frnt Chas A 6 Lights LH 5
45L_A Left Turn Signal N-1.0-SXL 125 LH Rear Comb Lt 2 21M Rear-Cab 10
45L_B Left Turn Signal N-0.8-SXL 21F Cab-Rear 10 SPL_D10 Left Turn Signal 1
45L_C Left Turn Signal N-0.8-SXL 1F Cab-Frnt Chas A SPL_D10 Left Turn Signal 1
45L_D Left Turn Signal N-0.8-SXL 62M Flasher Module 8 SPL_D10 Left Turn Signal 1
45L_E Left Turn Signal N-0.8-SXL 13F Cab-Pedestal 16 SPL_D10 Left Turn Signal 1
45L_F Left Turn Signal N-0.8-SXL 76 Instrument Cluster 16 13M Pedestal-Cab 16
45N_A Flasher Opp Side Cntrl N-0.8-SXL 64F Flasher Connector 1 62M Flasher Module 2
45N_B Flasher Opp Side Cntrl N-0.8-SXL 64M Flasher Connector 1 62M Flasher Module 12
45R Right Turn Signal N-1.0-SXL 1 Cab-Frnt Chas C 8 Lights RH 5
45R_A Right Turn Signal N-1.0-SXL 127 RH Rear Comb Lt 2 21M Rear-Cab 12
45R_B Right Turn Signal N-0.8-SXL 21F Cab-Rear 12 SPL_D20 Rt Turn Signal 1
45R_C Right Turn Signal N-0.8-SXL 13F Cab-Pedestal 17 SPL_D20 Rt Turn Signal 1
45R_D Right Turn Signal N-0.8-SXL 1F Cab-Frnt Chas C SPL_D20 Rt Turn Signal 1
45R_E Right Turn Signal N-0.8-SXL 62M Flasher Module 7 SPL_D20 Rt Turn Signal 1
4002-26

21C Bk - 1.0


Color, Size,
and Material
45R_F Right Turn Signal N-0.8-SXL 76 Instrument Cluster 17 13M Pedestal-Cab 17
46_A Beacon Switched Pwr K-0.8-SXL 23F Cab-Roof E 13F Cab-Pedestal 13
46_B Beacon Telltale K-0.8-SXL 76 Instrument Cluster 13 13M Pedestal-Cab 13
46_C Beacon Switched Pwr K-1.0-SXL 23F Cab-Roof E 42F Beacon Sw 3
46_D Beacon Switched Power K-1.0-SXL 23M Roof-Cab E 85F Beacon Light A
49_A Pilot Light S-0.8-SXL 13M Pedestal-Cab 51 71 Hazard Switch 8
49_B Pilot Light S-0.8-SXL 71 Hazard Switch 8 37 Pilot Control Switch 8
49_C Pilot Light S-0.8-SXL 37 Pilot Control Switch 8 72 Parking Brake Switch 8
49_D Pilot Light S-0.8-SXL 72 Parking Brake Switch 8 74 Up Down Count Switch 8
49_E Pilot Light S-0.8-SXL 74 Up Down Count Switch 8 75 Program Reset Switch 8
49_F Pilot Light Pwr S-0.8-SXL 13F Cab-Pedestal 51 SPL_D8 Pilot Lights 1
49_G Pilot Light S-0.8-SXL 199F Trans Enable Sw 8 SPL_D8 Pilot Lights 1
49_H Pilot Light S-0.8-SXL 210F Fan Reverser Sw 8 40F Pin Engage Sw 10
49_J Pilot Light S-0.8-SXL 34F Light Switch B SPL_D8 Pilot Lights 1
49_K Pilot Light S-1.0-SXL 39F Return To Travel Sw 8 34F Light Switch B
49_L Pilot Light S-0.8-SXL 45F Rear Wiper Sw 8 118F Backup Alarm Dis Sw 8
49_M Pilot Light S-1.0-SXL 39F Return To Travel Sw 8 36F Detent Switch 8
49_N Pilot Light S-1.0-SXL 36F Detent Switch 8 38F Declutch Switch 8
49_P Pilot Light S-1.0-SXL 40F Pin Engage Sw 10 44F Ride Control Sw 8
49_Q Pilot Light S-1.0-SXL 44F Ride Control Sw 8 41F Trans Auto Sw 8
49_R Pilot Light S-1.0-SXL 199F Trans Enable Sw 8 42F Beacon Sw 8
49_S Courtesy Pilot Lt S-1.0-SXL 24M Cab-Roof F SPL_D8 Pilot Lights 1
49_T Pilot Light S-1.0-SXL 42F Beacon Sw 8 118F Backup Alarm Dis Sw 8
49_U Pilot Light S-0.8-SXL 210F Fan Reverser Sw 8 SPL_D8 Pilot Lights 1
49_V Courtesy Pilot Lt S-0.8-SXL 24F Roof-Cab F 77F Courtesy Lt A
50G_A Can Ground Bk-0.8-SXL 13M Pedestal-Cab 34 SPL_K2 SPL_K2 1
50G_B Can Ground Bk-0_5-SXL SPL_K3 SPL_K3 1 SPL_K2 SPL_K2 1
50G_C Can Ground R-0_5-SXL SPL_K2 SPL_K2 1 SPL_K3 SPL_K3 1
50G_D Can Ground Bk-0.8-SXL 13F Cab-Pedestal 34 SPL_D6 Can Ground 1
50G_E Can Ground Bk-0_5-SXL SPL_D7 Can Ground 1 SPL_D6 Can Ground 1
4002-27

21C Bk - 1.0


Color, Size,
and Material
50G_F Can Ground R-0_5-SXL SPL_D7 Can Ground 1 SPL_D6 Can Ground 1
50G_G Can Pilot Sol Grnd Bk-0.8-SXL 219F Ground Cab 1 SPL_D7 Can Ground 1
50H Can H Y-0_5-SXL 76 Instrument Cluster 32 13M Pedestal-Cab 32
50H_A Can H Y-0_5-SXL 19F TECM 25 13F Cab-Pedestal 32
50L Can L G-0_5-SXL 76 Instrument Cluster 31 13M Pedestal-Cab 31
50L_A Can L G-0_5-SXL 13F Cab-Pedestal 31 SPL_D5 Can L 1
50L_B Can L G-0_5-SXL 19F TECM 26 SPL_D5 Can L 1
50L_C Can L G-0_5-SXL 19F TECM 27 SPL_D5 Can L 1
50T Can T Bk-0.8-SXL 76 Instrument Cluster 21 76 Instrument Cluster 33
51P_A Sec Str High Pres W-1.0-SXL 90M Sec Str Mod 9 180M Sec Str Mod Frnt Harn 4
51P_B Sec Str High Pres W-1.0-SXL 180F Sec Str Mod Opt 4 131F Sec Str Pres Sw Opt A
51_A Sec Str Mtr Rel W-1.0-SXL 90M Sec Str Mod 2 SPL_C2 1
51_B SPL_C2 W-1.0-SXL SPL_C2 1 181 Sec Str Mtr Relay 1

51_C Sec Strg Sol Pwr W-1.0-SXL 264M Sec Strg Sol Opt A SPL_C2 1
52C Parking Brake Signal W-0.8-SXL 76 Instrument Cluster 30 13M Pedestal-Cab 30
52C_A Parking Brake Signal W-0.8-SXL 55F Brake Lights Relay 85 13F Cab-Pedestal 30
52P Parking Brk Relay Out W-1.0-SXL 87 Parking Brk Sol 1 21M Rear-Cab 18
52P_A Parking Brk Relay Out W-0.8-SXL 19F TECM 21 55F Brake Lights Relay 87
52P_B Parking Brk Relay Out W-0.8-SXL 55F Brake Lights Relay 87 21F Cab-Rear 18
52_A Fan Reverse Sol W-0.8-SXL 210F Fan Reverser Sw 3 21F Cab-Rear 27
53B RTD Signal W-1.0-SXL 1 Cab-Frnt Chas M 12F RTD A
53B_A RTD Signal W-1.0-SXL 12M RTD A 200 RTD A
53B_B RTD Signal W-0.8-SXL 1F Cab-Frnt Chas M 17M RTD Height Cont RTT 3
53C Pilot Control Signal W-0.8-SXL 76 Instrument Cluster 36 13M Pedestal-Cab 36

53C_A Pilot Control Signal W-0.8-SXL 56F Pilot Control Relay 85 13F Cab-Pedestal 36
53P_A Pilot Control Signal W-0.8-SXL 56F Pilot Control Relay 87 89M Pilot Pres Sol A
53P_B Pilot Control Signal W-0.8-SXL 36F Detent Switch 2 56F Pilot Control Relay 87
53P_C Pilot Control Signal W-0.8-SXL 56F Pilot Control Relay 87 1F Cab-Frnt Chas B
53P_D Float Sol Power W-1.0-SXL 178M Float Switch A 1 Cab-Frnt Chas B
53S_A Float Sol Signal W-1.0-SXL 178M Float Switch B SPL_A5 SPL_A5 SPL_A5
4002-28

21C Bk - 1.0


Color, Size,
and Material
53S_B Float Sol Signal W-1.0-SXL 179F Float Solenoid 1 SPL_A5 SPL_A5 SPL_A5
53S_C Float Sw Signal W-1.0-SXL 202F Diode Module C SPL_A5 SPL_A5 SPL_A5
53S_D Float Sol Signal W-1.0-SXL 229M Diode Module B SPL_A5 SPL_A5 SPL_A5
53S_E Float Switch Signal W-1.0-SXL 273F Rollbck Jmpr Diode Mdl C 271M Frt Chassis Rollbck Jmpr C
54B Height-RTT Signal W-1.0-SXL 1 Cab-Frnt Chas L 10 Height Cntrl-RTT A
54B_A Height-RTT Signal W-0.8-SXL 1F Cab-Frnt Chas L SPL_D2 Height Cntrl-RTT Signal 1
54B_B RTT-Float Sw Load W-0.8-SXL 39F Return To Travel Sw 3 SPL_D2 Height Cntrl-RTT Signal 1
54B_C Height Cont Elec Mag W-0.8-SXL 17M RTD Height Cont RTT 2 SPL_D2 Height Cntrl-RTT Signal 1
55A RTT-Float Sw W-0.8-SXL 39F Return To Travel Sw 2 17M RTD Height Cont RTT 1
56_A Height-RTT Pwr W-1.0-SXL 10 Height Cntrl-RTT C SPL_A3 Splice A3 SPL_A3
56_B RTD Pwr W-1.0-SXL 12F RTD C SPL_A3 Splice A3 SPL_A3
56_C Prox Switch Pwr W-1.0-SXL 1 Cab-Frnt Chas T SPL_A3 Splice A3 SPL_A3
56_D RTD Pwr W-1.0-SXL 12M RTD C 200 RTD C

56_E Detent Switched Pwr W-0.8-SXL 17M RTD Height Cont RTT 6 SPL_D4 Detent Switched Pwr 1
56_F Detent Switched Pwr W-0.8-SXL 17M RTD Height Cont RTT 5 SPL_D4 Detent Switched Pwr 1
56_G Detent Switched Pwr W-0.8-SXL 17M RTD Height Cont RTT 4 SPL_D4 Detent Switched Pwr 1
56_H Detent Switched Pwr W-0.8-SXL 36F Detent Switch 3 SPL_D4 Detent Switched Pwr 1
56_J Prox Switch Pwr W-0.8-SXL 1F Cab-Frnt Chas T SPL_D4 Detent Switched Pwr 1
57_A Pin Engage Sol Pwr W-0.8-SXL 40F Pin Engage Sw 1 1F Cab-Frnt Chas U
58A_A Float Switch Signal W-1.0-SXL 272F Rollbck Jmpr Press Sw A 273F Rollbck Jmpr Diode Module A
58H_B Ride Cntl Signal W-0.8-SXL 19F TECM 8 50F Ride Control Relay 86
58S Ride Cntl Relay Pwr W-0.8-SXL 50F Ride Control Relay 30 44F Ride Control Sw 3
58_A Ride Cntrl Sol Pwr W-0.8-SXL 50F Ride Control Relay 87 1F Cab-Frnt Chas V
58_B Ride Cntrl Sol Pwr W-0.8-SXL 50F Ride Control Relay 87 44F Ride Control Sw 6
58_C Ride Cntrl Sol Pwr W-1.0-SXL SPL_A7 Ride Cntrl Sol Pwr SPL_A7 5F Ride Control Opt 1
58_D Ride Cntrl Sol Pwr W-1.0-SXL 202F Diode Module A SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_E Ride Cntrl Sol Pwr W-1.0-SXL 229M Diode Module A SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_F Float Switch Signal W-1.0-SXL 271M Frt Chs Rollbck Jmpr A 272F Rollbck Jmpr Press Sw B
61A AC High Pres Sw Or-1.0-SXL 94M Engine Trans 2 98 AC High Pres Sw A
61A_A AC High Pres Sw Or-1.0-SXL 22M Cab-Transmission 26 94F Eng-Trans 2
4002-29

21C Bk - 1.0


Color, Size,
and Material
61A_B AC Relay Pwr Or-0.8-SXL 203F Relay AC 30 22F Cab-Transmission 26
61A_C AC Relay Pwr Or-0.8-SXL 203F Relay AC 30 SPL_D3 AC Power 1
61A_D AC Thermostat Or-0.8-SXL 208F Thermostat Switch A SPL_D3 AC Power 1
61A_E AC Low Pres Sw Or-0.8-SXL 27M AC Low Pres Sw B SPL_D3 AC Power 1
61C AC Comp Clutch Or-1.0-SXL 94M Engine Trans 4 99 AC Comp Clutch 1
61C_A AC Comp Clutch Or-1.0-SXL 22M Cab-Transmission 25 94F Eng-Trans 4
61C_B AC Comp Clutch Or-0.8-SXL 203F Relay AC 87a 22F Cab-Transmission 25
61C_C Splice Or-1.0-SXL SPL_N1 Splice 1 265F Diode Module A
61C_D AC Compressor Clutch Or-1.0-SXL 267F AC Compressor Clutch 1 SPL_N1 Splice 1
61C_E AC Compressor Clutch Or-1.0-SXL 266M AC Compressor Clutch 1 SPL_N1 Splice 1
61R AC High Pres Sw Or-1.0-SXL 94M Engine Trans 3 98 AC High Pres Sw B
61R_A AC High Pres Sw Or-1.0-SXL 22M Cab-Transmission 27 94F Eng-Trans 3
61R_B AC Relay Signal Or-0.8-SXL 203F Relay AC 87 22F Cab-Transmission 27

61R_C AC Relay Signal Or-0.8-SXL 203F Relay AC 87 203F Relay AC 86
61R_D AC Relay Signal Or-0.8-SXL 203F Relay AC 87 SPL_D1 1
61R_E AC Low Pres Sw Or-0.8-SXL 27M AC Low Pres Sw A SPL_D1 1
61R_F AC Telltale Or-0.8-SXL 13F Cab-Pedestal 10 SPL_D1 1
61R_G AC Telltale Or-0.8-SXL 76 Instrument Cluster 10 13M Pedestal-Cab 10
61T AC Thermostat Pwr Or-1.0-SXL 30F Blower Switch 6 207F Thermostat Switch A
62H Blower High Speed Or-2.0-SXL 29M Blower Motor 3 30F Blower Switch 3
62L Blower Low Speed Or-1.0-SXL 29M Blower Motor 1 30F Blower Switch 5
62M Blower Medium Speed Or-2.0-SXL 29M Blower Motor 2 30F Blower Switch 4
63C Front Wiper Park Or-0.8-SXL 13M Pedestal-Cab 59 61 Front-Wiper Motor D
63C_A Front Wiper Park Or-0.8-SXL 35F Wiper and Washer Sw 4 13F Cab-Pedestal 59
63H Front Wiper High Speed Or-0.8-SXL 13M Pedestal-Cab 57 61 Front-Wiper Motor A
63H_A Front Wiper High Speed Or-0.8-SXL 35F Wiper and Washer Sw 5 13F Cab-Pedestal 57
63H_B Front Wiper High Speed Or-0.8-SXL 35F Wiper and Washer Sw 5 140M Diode Module B
63L Front Wiper Low Speed Or-0.8-SXL 13M Pedestal-Cab 58 61 Front-Wiper Motor B
63L_A Front Wiper Low Speed Or-0.8-SXL 35F Wiper and Washer Sw 6 13F Cab-Pedestal 58
63L_B Front Wiper Low Speed Or-0.8-SXL 35F Wiper and Washer Sw 6 140M Diode Module A
4002-30

21C Bk - 1.0


Color, Size,
and Material
63W Front Washer Pump Or-1.0-SXL 2 Front Washer 1 21M Rear-Cab 25
63W_A Front Washer Pump Or-0.8-SXL 35F Wiper and Washer Sw 3 21F Cab-Rear 25
64C Horn Control Or-0.8-SXL 13M Pedestal-Cab 42 184 Horn Switch 1
64C_A Horn Control Or-0.8-SXL 51F Horn Relay 85 13F Cab-Pedestal 42
64D High/Low Beam Signal Or-0.8-SXL 13M Pedestal-Cab 55 186 High Low Beam 1
64D_A Low Beam Signal (2 Way) Or-0.8-SXL 59F High/Low Beam 6 13F Cab-Pedestal 55
64A Horn Or-0.8-SXL 51F Horn Relay 87 1F Cab-Frnt Chas N
65C Radio Power Or-0.8-SXL 114F 6 110F 24/12V Converter A
65C_B Radio Power Or-0.8-SXL 114M 6 113 Radio Power 14
65L Left Spkr Signal Or-0.8-SXL 114F 1 112M A
65L_A Left Spkr Signal Or-0.8-SXL 114M 1 113 Radio 11
65R Right Spkr Signal Or-0.8-SXL 114F 5 111M A
65R_A Right Spkr Signal Or-0.8-SXL 114M 5 113 Radio 9

68C_A Rear Wiper Park Or-1.0-SXL 23F Cab-Roof A 45F Rear Wiper Sw 1
68C_B Rear Wiper Park Or-1.0-SXL 23M Roof-Cab A 81M Rear Wiper Mtr D
68L_A Rear Wiper Low Speed Or-1.0-SXL 23F Cab-Roof G 45F Rear Wiper Sw 2
68L_B Rear Wiper Low Speed Or-0.8-SXL 45F Rear Wiper Sw 2 140M Diode Module F
68L_C Rear Wiper Low Speed Or-1.0-SXL 23M Roof-Cab G 81M Rear Wiper Mtr B
68W Rear Washer Pump Or-1.0-SXL 3 Rear Washer 1 21M Rear-Cab 24
68W_A Rear Washer Pump Or-1.0-SXL 45F Rear Wiper Sw 6 21F Cab-Rear 24

4002-31
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
Check Points Reading Possible Cause of Bad Reading
2
Check the 10 ampere fuse at 3 4
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
5
6
1. This title is the number and component name on the Electrical Schematic.
2. This column shows the location of the check point.
3. This column shows the indication of the check.
4. This column shows the possible cause of a bad test indication.
5. The numbers in the parentheses show the number of the component on the Electrical Schematic.
6. This statement assumes that all other problems are solved at this point in the test.
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.
Co mpo ne nts can b e loc ate d o n th e Ele ctrica l
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters. Use the
following index to find the sheet a component is
located on.
COMPONENT COMPONENT SCHEMATIC

NUMBER SHEET
12 Volt Radio (Option) 95 6
Accessory Relay No. 3 16 1
Air Conditioning High Pressure Switch 87 5
Air Conditioning Low Pressure Switch 86 5
Air Filter Restriction Switch 44 3
Alternator 4 1
Back-up Alarm 37 2
Back-up Alarm Disable Switch 36 2
Back-up Alarm Relay No. 7 35 2
Batteries 1 1
Beacon Switch 99 4
Blower Motor 85 5
Blower Motor Speed Resistors with Thermal Fuse 84 5

4002-32

NUMBER SHEET
Blower Switch 83 5
Brake Declutch Pressure Switch 32 2
Brake Lamp Pressure Switch 101 4
Brake Lamps Relay No. 15 102 4
Brake Warning Pressure Switch 38 3
Bucket Control Valves Electromagnetic Detents 60 5
Cigar Lighter (Option) 91 6
Compressor Clutch 90 5
Compressor Clutch Lockout Relay No. 14 89 5
Coolant Level Sender 39 3
Courtesy Lamp 118 4
Declutch Switch 31 2
Detent Switch 59 5
Diagnostic Connector 28 2
Dome Lamp 117 4
Engine Coolant Temperature Sender 43 3
Engine Oil Pressure Switch 50 3
Engine Speed Sensor 20 2
Ether Start Relay No. 6 10 1
Ether Start Solenoid 9 1
Ether Start Switch 11 1
Ether Start Temperature Switch 8 1
FNR Switch 34 2
Fan Reverser Switch 55 5
Fan Reversing Solenoid 56 5
Filter Maintenance Switch 23 2
Five Position Rotary Lamp Switch 114 4
Flasher Module 105 4
Float Pressure Switch 64 5
Float Solenoid 65 5
Front Washer Pump Motor 76 5
Front Wiper Motor 74 5
Front Wiper and Washer Switch 75 5
Fuel Level Sender 40 3

4002-33

NUMBER SHEET
Fuel Relay 7 1
Fuel Shutoff Solenoid 3 1
Hazard Switch 103 4
Height Control/Return-To-Travel Proximity Switch 63 5
High/Low Beam Relay No. 13 115 4
Horn 81 5
Horn Relay No. 5 80 5
Hydraulic Filter Restriction Switch 42 3
Hydraulic Oil Temperature Sender 41 3
Ignition Relay No. 1 14 1
Ignition Switch 13 1
Instrument Cluster 47 3
Intermediate Speed Sensor 21 2
LH Front Combination Lamp 108 4
LH Front Work Lamp 112 4
LH Rear Combination Lamp 106 4
LH Rear Work Lamp 110 4
Left Speaker (Option 97 6
License Plate Lamp 116 4
Master Disconnect Switch 2 1
Neutral Start Relay No. 8 12 1
Output Speed Sensor 19 2
Parking Brake Relay No. 9 52 3
Parking Brake Solenoid 53 3
Parking Brake Switch 46 3
Pilot Control Relay No. 10 51 3
Pilot Control Switch 48 3
Pilot Pressure Solenoid 54 3
Pin Engage Solenoid (Option) 70 5
Pin Engage Switch (Option) 69 5
Power Converter (24 Volts to 12 Volts) (Option) 92 6
Power Outlet (Option) 93 6
Program/Reset Switch 45 3

4002-34

NUMBER SHEET
Relay Socket No. 11 58 1
RH Front Combination Lamp 109 4
RH Front Work Lamp 113 4
RH Rear Combination Lamp 107 4
RH Rear Work Lamp 111 4
Radio Power Converter (24 Volts to 12 Volts) (Option) 96 6
Rear Washer Pump Motor 78 5
Rear Wiper and Washer Switch 77 5
Rear Wiper Motor 79 5
Redundant Brake Pressure Switches 57 3
Remote Radio or 24 Volt Radio (Option) 94 6
Return-To-Dig Proximity Switch 62 5
Return-To-Travel/Float Switch 61 5
Ride Control Relay No. 4 72 5
Ride Control Solenoid 73 5
Ride Control Switch 71 5
Right Speaker (Option) 98 6
Rotating Beacon 100 4
Seat Compressor and Switch 82 5
Secondary Steering Module (Option) 66 5
Secondary Steering Motor (Option) 68 5
Secondary Steering Pressure Switch (Option) 67 5
Secondary Steering Solenoid (Option) 68A 5
Starter Motor 5 1
Starting Relay 6 1
Thermostat Switch 88 5
Time Delay Module 18 1
Torque Converter Output Temperature Sensor 24 2
Transmission Auto Switch 30 2
Transmission Electronic Control Module 26 2
Transmission Enable Switch 33 2
Transmission Kick-Down Switch 29 2
Transmission Shifter 27 2
Transmission Solenoid Valve and Temperature Sender 25 2

4002-35

NUMBER SHEET
Turbine Speed Sensor 22 2
Turn Signal, High/Low Beam, and Horn Switch 104 4
Up/Down Count Switch 49 3
Voltmeter Relay No. 12 17 1

4002-36
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING,

ALTERNATOR, ETHER START, IGNITION SWITCH AND RELAYS
11
13
7
6
4
10
12
1 14
8 3 5
1
9
BC00N140
1. BATTERIES 6. STARTER RELAY 11. ETHER START SWITCH
2. MASTER DISCONNECT SWITCH 7. FUEL RELAY 12. NEUTRAL START RELAY NO. 8
3. FUEL SHUTOFF SOLENOID 8. ETHER START TEMPERATURE SWITCH 13. IGNITION SWITCH
4. ALTERNATOR 9. ETHER START SOLENOID 14. IGNITION RELAY NO. 1
5. STARTER MOTOR 10. ETHER START RELAY NO. 6
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
1 – Batteries
NOTE: See Section 4003 and check the batteries.

4002-37
2 – Master Disconnect Switch

NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
Between terminals of master

Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.

Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
3 – Fuel Shutoff Solenoid

NOTE: Disconnect connector 134 from fuel shutoff solenoid (3).
Terminal for wire 0_BB to ground Continuity Bad ground circuit.
Between terminals A and C of fuel

40 to 44 ohms Bad fuel shutoff solenoid.
shutoff solenoid
Between terminals B and C of fuel

1 to 2 ohms Bad fuel shutoff solenoid.
shutoff solenoid
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the ON position.
24 volts Check wire 13M and circuits 13C and 13K, also check circuit to
Terminal for wire 13M to ground
batteries. Bad master disconnect switch (2) or ignition switch.
NOTE: Have another person hold the ignition switch in the START position.
24 volts Check circuit 23F. Bad fuel relay (7), neutral start relay (12), or
Terminal for wire 23F to ground
no neutral signal from transmission.
NOTE: If the readings are good, replace the fuel shutoff solenoid (3).
4 – Alternator
Between housing of alternator and

Continuity Bad ground connection.
ground
NOTE: Put the master disconnect switch in the ON position.
Between the positive terminal of 24 volts Check circuit to positive post of left battery.
alternator and ground
NOTE: Put the ignition switch in the ON position.
Between the positive terminal of

24 volts Check circuit to positive post of left battery.
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
Terminal for wire 14 to ground 20 volts
R. Check ignition relay No. 1, and 10 ampere circuit breaker A.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).

4002-38
5 – Starter Motor
Between housing of starter and

ground
Starter battery terminal to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starter relay (6). Also check wire 1_F between starter (5)
Terminal S to ground 24 volts
and starter relay (6).
NOTE: If the readings are good, see Section 4004 and repair the starter (5).
6 – Starter Relay
Terminal for wire 0_GB to ground Continuity Bad ground circuit.
Terminal for wire 1_C to ground 24 volts Check circuit to batteries.
Terminal for wire 21C_B to ground 24 volts Check neutral start relay (12), also check circuit 21C.
Terminal for wire 1_F to ground 24 volts Bad starter relay (6).
7 – Fuel Relay
Terminal for wire 0_GC to ground Continuity Bad ground circuit.
Terminal for wire 1_D to ground 24 volts Check wires 1_D and 1_E, also check circuit to batteries.
Terminal for wire 21C_A to ground 24 volts Check neutral start relay (12), also check circuit 21C.
Terminal for wire 23F_A to ground 24 volts Bad fuel relay (7).
8 – Ether Start Temperature Switch (Option)

NOTE: The ether start temperature switch opens at 13 ±3 °C (55 ±5 °F).
Terminal for wire 0_BC to ground Continuity Bad ground circuit.
NOTE: Disconnect the wires from the ether start temperature switch (8). Make sure the engine temperature is
below -3 °C (27 °F).
Between terminals A and B Continuity Bad ether start temperature switch (8).

4002-39
9 – Ether Start Solenoid (Option)

Terminal for wire 28T_A to ether

Continuity Bad 28T_A circuit.
start temperature switch
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Have another person push in
and hold the ether start switch (11). Make sure the engine temperature is below -3 °C (27 °F).
Terminal for wire 28P to ground 24 volts Check the ether start relay (10). Also check circuit 28P.
NOTE: If the readings are good, replace the ether start solenoid (9).
10 – Ether Start Relay No. 6 (Option)

Terminal for wire 0_DC to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Bad 10 ampere fuse E or bad ignition relay No. 1. Check wires

Terminal for wire 19E to ground 24 volts
19E and 13P_A.
NOTE: Have an assistant depress and hold ether start switch (11). Make sure engine temperature is below -3 °C
(27 °F) and transmission is in neutral.
Terminal for wire 28C_A to ground 24 volts Bad ether start switch (11), also check circuit 28C.
Terminal for wire 28P_A to ground 24 volts Bad ether start relay (10).
11 – Ether Start Switch (Option)

NOTE: Disconnect the wires from the ether start switch (11).
Between terminals of switch Open Circuit Bad ether start switch (11).
NOTE: Have an assistant depress and hold ether start switch (11).
Between terminals of switch Continuity Bad ether start switch (11).
NOTE: Put the master disconnect switch and the ignition switch in the ON position and transmission in neutral.
Terminal for wire 25T_B to ground 24 volts Check circuit 25T.

4002-40
12 – Neutral Start Relay No. 8

Terminal for wire 0_DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T_E to ground 24 volts Check circuit 25T.
Terminal for wire 21K_A to ground 24 volts Check circuit 21K_A and ignition switch.
Terminal for wire 21C_E to ground 24 volts Bad neutral start relay (12).
13 – Ignition Switch
Terminal for wire 1A to ground 24 volts Check circuit 1A to 10 ampere circuit breaker A.
NOTE: Disconnect the connector from the ignition switch (13). Turn the switch to ON.
Between Bat and Ign Continuity Bad ignition switch (13).
Between Bat and Acc Continuity Bad ignition switch (13).
NOTE: Hold the ignition switch (13) in the START position.
Between Bat and Starter Continuity Bad ignition switch (13).
NOTE: Put the switch in the Acc position.
14 – Ignition Relay No. 1

Terminal for wire 0_DE to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 1_S to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 13K_A to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13P to ground 24 volts Bad ignition relay No. 1 (14)

4002-41
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER

RELAY, AND TIME DELAY MODULE
18 15
16
17
BC00N140
15. IGNITION RELAY NO. 2 17. VOLTMETER RELAY NO. 12
16. ACCESSORY RELAY NO. 3 18. TIME DELAY MODULE

Terminal for wire 0 to ground Continuity Bad ground circuit.
Terminal for wire 1_T to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 13K to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13R to ground 24 volts Bad ignition relay No. 2 (15).

4002-42
16 – Accessory Relay No. 3

NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
Terminal for wire 1_G to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 12P_A to ground 24 volts Bad accessory relay (16).
17 – Voltmeter Relay No. 12

Terminal for wire 1_P to ground 24 volts Check circuit 1 to starter motor B+ stud.
NOTE: Turn ignition switch to the ON position.
Terminal for wire 13V to ground 24 volts Bad voltmeter relay (17).
18 – Time Delay Module

Terminal for wire 0_DAS to ground Continuity Bad ground circuit.
24 volts Bad 10 ampere circuit breaker A. Check wire 1_l to SPL_D17

Terminal for wire 1A_E to ground
and wire 1_J to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the program/reset switch
(45) in RESET position.
Terminal for wire 37R_C to ground 24 volts Bad program/reset switch (45), also check circuit 37R.
Terminal for wire 13K_F to ground 24 volts Bad ignition switch (13), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
Within 10 seconds of putting the 24 volts

ignition switch in the OFF position, Key OFF
Bad time delay module (18).
check terminal for wire 13D to 0 volt after 10
ground seconds
After 10 seconds of turning ignition

switch to the OFF position, check 0 volt Bad time delay module (18).
terminal for wire 13D to ground

4002-43
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND

SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR,
AND BACK-UP ALARM
,
27
32
25
24
37
29
23 26 30
33
28 31
20 34
35 36
21
22
19
BC00N140
19. OUTPUT SPEED SENSOR 29. TRANSMISSION KICK-DOWN SWITCH
20. ENGINE SPEED SENSOR 30. TRANSMISSION AUTO SWITCH
21. INTERMEDIATE SPEED SENSOR 31. DECLUTCH SWITCH
22. TURBINE SPEED SENSOR 32. BRAKE DECLUTCH PRESSURE SWITCH
23. FILTER MAINTENANCE SWITCH 33. TRANSMISSION ENABLE SWITCH
24. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 34. FNR SWITCH
25. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 35. BACK-UP ALARM RELAY NO. 7
26. TRANSMISSION ELECTRONIC CONTROL MODULE 36. BACK-UP ALARM DISABLE SWITCH
27. TRANSMISSION SHIFTER 37. BACK-UP ALARM
28. DIAGNOSTIC CONNECTOR

4002-44
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 19 through 34.
19 – Output Speed Sensor

20 – Engine Speed Sensor
21 – Intermediate Speed Sensor
22 – Turbine Speed Sensor
23 – Filter Maintenance Switch
24 – Torque Converter Output Temperature Sender
25 – Transmission Solenoid Valve and Temperature Sensors
26 – Transmission Electronic Control Module
27 – Transmission Shifter
28 – Diagnostic Connector
29 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
30 – Transmission Auto Switch
31 – Declutch Switch
32 – Brake Declutch Pressure Switch
33 – Transmission Enable Switch
34 – FNR Switch
35 – Back-up Alarm Relay No. 7

NOTE: Disconnect the transmission electronic control module (26) quick disconnect connector.
Terminal for wire 35C to terminal 7 of

Continuity Bad wire 35C.
quick disconnect connector
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
24 volts Bad fuse A, also check wires 19A_P, 13P_A, and ignition relay
Terminal for wire 19A_P to ground
No. 1 (14).
24 volts Bad fuse H, also check wires 19H and 13R and ignition relay
Terminal for wire 19H to ground
No. 2 (15).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A_D to ground 24 volts Bad back-up alarm relay (35).

4002-45
36 – Back-up Alarm Disable Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A_E to ground 24 volts Bad back-up alarm relay (35), also check circuit 35A_E.
NOTE: Wires 35A_F and 35R_D are connected together and switch is removed in North American models. The
wires are disconnected and the switch is installed in TUV road approved (Germany) models.
Bad back-up alarm disable switch (36). If machine is not a TUV

Terminal for wire 35R to ground 24 volts
model, check wires 35A_F and 35R_D.
37 – Back-up Alarm
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
Bad back-up alarm disable switch (36), also check wires

Terminal for wire 35R to ground 24 volts 35R_C and 35R_B. If machine is not a TUV model, check wires
35R_C and 35R_B.
NOTE: If the readings are good, replace the back-up alarm (37).

4002-46
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS,

PROGRAM/RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT
CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH
44 39
43
45
38 46
42 47
48
41
49
40
BC00N140
38. BRAKE WARNING PRESSURE SWITCH 44. AIR FILTER RESTRICTION SWITCH
39. COOLANT LEVEL SENDER 45. PROGRAM/RESET SWITCH
40. FUEL LEVEL SENDER 46. PARKING BRAKE SWITCH
41. HYDRAULIC OIL TEMPERATURE SENDER 47. INSTRUMENT CLUSTER
42. HYDRAULIC FILTER RESTRICTION SWITCH 48. PILOT CONTROL SWITCH
43. ENGINE COOLANT TEMPERATURE SENDER 49. UP/DOWN COUNT SWITCH

4002-47
38 – Brake Warning Pressure Switch

NOTE: Brake warning pressure switch opens at 117.2 bar (1700 psi).
Terminal B for wire 0 to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: Disconnect the wires from the brake warning pressure switch (38).
Between terminals A and B of the Continuity Bad brake warning pressure switch (38).
switch
NOTE: Start and run the engine at idle.
Bad brake warning pressure switch (38) or brake pressure is

Between terminals A and B of the
Open Circuit below 117.2 bar (1700 psi). Refer to Section 7002 to check
switch
brake pressure.
39 – Coolant Level Sender

Approximately
Terminal A for wire 31D to ground Check circuit 31D, also check the instrument cluster (47).
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender (39).
40 – Fuel Level Sender

Approximately
Terminal A for wire 36F to ground Check the instrument cluster (47).
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the wires
from the fuel level sender.
Between terminals of fuel level 33 to 240

Bad fuel level sender (40).
sender ohms

4002-48
41 – Hydraulic Oil Temperature Sender

NOTE: Disconnect the connector from the hydraulic oil temperature sender.
Between terminals of hydraulic oil 130 to 9500

ohms Replace hydraulic oil temperature sender (41).
temperature sender
Approximately
Terminal A for wire 36H to ground Check the instrument cluster (47).
5 volts
42 – Hydraulic Filter Restriction Switch

NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
Check between the housing of the

Bad ground connection between the hydraulic filter restriction
hydraulic filter restriction switch (42) Continuity
switch (42) and ground.
and ground
Approximately
Terminal A for wire 31H to ground. 11.5 volts Check the instrument cluster (47).
NOTE: If the readings are correct replace the hydraulic filter restriction switch (42).
43 – Engine Coolant Temperature Sender

Terminal for wire 0_BE to ground Continuity Bad ground circuit.
NOTE: Disconnect the connector from the engine coolant temperature sender.
Between terminals of engine coolant 130 to 9500

Replace engine coolant temperature sender.
temperature sender ohms
Approximately
Terminal A for wire 36C to ground Check the instrument cluster (47).
5 volts

4002-49
44 – Air Filter Restriction Switch

NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
Terminal for wire 0_BD to ground Continuity Bad ground circuit.
Approximately
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (44).
45 – Program/Reset Switch
Terminal for wire 0_KM to ground Continuity Bad ground circuit.
Terminal for wire 1A_B to ground 24 volts Check 10 ampere circuit breaker A. Also check circuit 1A.
NOTE: Press and hold the program/reset switch in the reset position.
Terminal for wire 37R to ground 24 volts Bad program/rest switch.
NOTE: Put the program/reset switch (45) in the program position.
Terminal for wire 37P to ground 24 volts Bad program/reset switch.
NOTE: Put the five position rotary lamp switch (114) in position 3, 4, or 5.
Bad rotary lamp switch. Also check fuse Z and circuit 49 and
Terminal for wire 49_E to ground 24 volts
19Z.
NOTE: If 24 volts between wire 49 and ground and program/reset switch is not illuminated, replace program/reset
switch.
46 – Parking Brake Switch

Terminal for wire 0_KJ to ground Continuity Bad ground circuit.
Terminal for wire 19A to ground 24 volts Check fuse A, also check circuit 19A.
NOTE: Apply parking brake switch (46).
Terminal for wire 33U to ground 24 volts Bad parking brake switch (46).
24 volts Bad rotary lamp switch. Also check fuse Z and circuits 49 and
Terminal for wire 49 to ground
19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.

4002-50
47 – Instrument Cluster
NOTE: Disconnect the connector from the instrument cluster.
Bad brake warning pressure switch (38). Also check circuit 33P
Connector terminal 3 to ground Continuity
and ground circuit at brake warning pressure switch.
Continuity Bad coolant level sender (39). Also check circuit 31D and
Connector terminal 4 to ground
ground circuit at coolant level sender.
Bad secondary steering pressure switch (67). Also check

circuit 35X and ground circuit at pressure switch.
Connector terminal 6 to ground Open Circuit Bad air filter restriction switch (44). Also check circuit 31F.
Connector terminal 7 to ground Open Circuit Bad hydraulic filter restriction switch. Also check circuit 31H.
Continuity Bad ground circuit. Check wires 0_KP, 0_DAV, 0_HC, and
0_BG.
130 to 9500 Bad engine coolant temperature sender (43). Also check circuit
Connector terminal 18 to ground ohms circuit 36C and ground circuit at sender.
Bad fuel level sender (40). Also check circuit 36F and ground
Connector terminal 19 to ground 33 to 240 ohms
circuit at sender.
130 to 9500 Bad hydraulic oil temperature sender (41). Also check circuit
ohms 36H and ground circuit at sender.
Connector terminal 21 to connector

Continuity Bad wire 50T.
terminal 33
237 to 243 Bad engine oil pressure switch (50). Also check circuit 36P and
ohms ground circuit.
Connector terminal 28 to ground Open Circuit Bad redundant brake switche(s) (57). Also check circuit 33R.
Connector terminal 31 to terminals

26 and 27 on the transmission Continuity Bad circuit 50L.
electronic control module (26)
Connector terminal 32 to terminal 25

on the transmission electronic Continuity Bad circuit 50H.
control module (26)
Check LH and RH stop lamps and circuit 44. Also check ground
circuit at lamps.
Connector terminal 37 to ground Continuity Bad ground circuit.
Connector terminal 1 to ground 24 volts Bad fuse V. Also check circuit 19V.
Connector terminal 2 to ground 24 volts Bad fuse S. Also check circuit 19S.
NOTE: Put the parking brake switch in the ON position.
Connector terminal 9 to ground 24 volts Bad parking brake switch. Also check fuse A and circuit 19A.

4002-51
47 – Instrument Cluster (Continued)

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

Connector terminal 10 to ground 24 volts
pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the five position rotary lamp switch in position four or five.
Check lamp switch and fuse A’. Also check circuits18A and
42R.
NOTE: Put the rotating beacon switch in the ON position.
Connector terminal 13 to ground 24 volts Check rotating beacon switch and fuse X. Also check circuit 46.
NOTE: Put the five position rotary lamp switch in position four or five. Put the high/low beam switch in HIGH
BEAM position.
Check high/low beam switch, high/low beam relay, five position

Connector terminal 15 to ground 24 volts rotary lamp switch, and fuse C’. Also check circuits 18C and
64D and wires 41H and 41J_A.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse B, turn signal switch, and flasher module. Also
Connector terminal 16 to ground off every 1-2 check wire 19B, circuit 45A to flasher module, and circuit 45L
seconds from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
Connector terminal 17 to ground off every 1-2 check wire 19B, circuit 45B to flasher module, and circuit 45R
NOTE: Put the program/reset switch in the PROGRAM position.
24 volts Bad program/reset switch. Also check wire 37P and wire 1A_B
to ignition switch.
NOTE: Press and hold the program/reset switch in the RESET position.
Bad program/reset switch. Also check wire 37R_B and wire

1A_B to ignition switch.
NOTE: Press and hold up/down count switch in UP position.
Fuse S, or up/down count switch, or time delay module bad.

Connector terminal 26 to ground 24 volts Also check wires 37U and wire 13D from time delay module to
fuse S, and circuit 19S.
NOTE: Press and hold up/down count switch in DOWN position.

Connector terminal 27 to ground 24 volts Also check wire 37D and wire 13D from time delay module to

4002-52

NOTE: Press pilot control switch to turn ON switch LED.
Bad pilot control switch or fuse C. Also check wire 31L and
circuit 19C.
Bad parking brake relay or fuse D. Also check circuits 52C and
19D.
Bad pilot control relay or fuse C. Also check circuits 53C and
19C.
48 – Pilot Control Switch

Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Terminal for wire 31L to ground 24 volts Bad pilot control switch (48).
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
24 volts Check five position rotary lamp switch (114) and fuse Z. Also
check circuit 49.
NOTE: If the readings are correct replace the pilot control switch (48).
49 – Up/down Count Switch

Check fuse S and time delay module. Also check circuits 19S
Terminal for wire 19S to ground 24 volts
and 13D from time delay module to fuse S.
NOTE: Press and hold the up/down switch in the DOWN COUNT position.
Terminal for wire 37D to ground 24 volts Bad up/down count switch.
NOTE: Press and hold the up/down switch in the UP COUNT position.
Terminal for wire 37U to ground 24 volts Bad up/down count switch.
Check five position rotary lamp switch (114) and fuse Z. Also
check circuit 49.

4002-53
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL,

PARKING BRAKE, AND REDUNDANT BRAKE SWITCHES
53
57
56
55
54
51
52
58
50
BC00N140
50. ENGINE OIL PRESSURE SWITCH 55. FAN REVERSER SWITCH (OPTION)
51. PILOT CONTROL RELAY NO. 10 56. FAN REVERSING SOLENOID (OPTION)
52. PARKING BRAKE RELAY NO. 9 57. REDUNDANT BRAKE SWITCHES
53. PARKING BRAKE SOLENOID 58. RELAY SOCKET NO. 11
54. PILOT PRESSURE SOLENOID

4002-54
50 – Engine Oil Pressure Switch

Between engine oil pressure switch

Continuity Bad engine oil pressure switch (50).
(50) terminals C and NC

Open Circuit Bad engine oil pressure switch (50).
(50) terminals C and NO
Between engine oil pressure switch 237 to 243

Bad ground connection or bad ground wire assembly.
(50) terminal NC and ground ohms
Between engine oil pressure switch 90 to 92 ohms Bad ground connection or bad ground wire assembly.
(50) terminal NO and ground
NOTE: Disconnect wire 36P from terminal C of engine oil pressure switch. Put master disconnect switch and
ignition switch in ON position.
Approximately
Terminal for wire 36P to ground Bad instrument cluster (47) or bad circuit 36P.
5 volts
NOTE: Start engine and operate at idle speed.

90 to 92 ohms Bad engine oil pressure switch.
terminal C and ground
51 – Pilot Control Relay No. 10

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(48) is OFF.
Terminal for wire 53C to ground 0 volt Bad instrument cluster (47). Also check circuit 53C.
Terminal for wire 53P to ground 24 volts Bad pilot control relay.
NOTE: Put the pilot control switch in ON position.
Terminal for wire 53C to ground 24 volts Bad instrument cluster (47). Also check circuit 53C.
52 – Parking Brake Relay No. 9

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (46) is OFF.
Terminal for wire 19D_B to ground 24 volts Bad fuse D, also check circuit 19D.
Terminal for wire 52P to ground 24 volts Bad parking brake relay.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (47). Also check wire 52C.

4002-55
53 – Parking Brake Solenoid

NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (52). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid (53).
54 – Pilot Pressure Solenoid

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (48) is OFF.
Terminal A for wire 53P to ground 24 volts Bad pilot control relay (51), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid (54).
55 – Fan Reversing Switch (Option)

Terminal for wire 0_DAF to ground Continuity Bad ground circuit.
Check fuse P, ignition relay No. 1, and wires 19P_A and

Terminal for wire 19P_B to ground 24 volts
13P_B.
NOTE: Put fan reversing switch in ON position (hold rocker in momentary position).
Terminal for wire 52_A to ground 24 volts Bad fan reversing switch.
NOTE: Put five position rotary lamp switch in position 3 or higher.
Check five position rotary lamp switch. If LEDs in fan reversing

Terminal for wire 49_U to ground 24 volts switch are not ON with 24 volts at check point, replace fan
reversing switch.

4002-56
56 – Fan Reversing Solenoid (Option)

NOTE: Disconnect wiring harness connector 158 from fan reversing solenoid.
Between pins A and B of fan

36 to 42 ohms Bad fan reversing solenoid.
reversing solenoid
Pin B of wiring harness connector Continuity Bad ground circuit.

158 to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON
position (hold rocker in momentary position).
Pin A of wiring harness connector

24 volts Bad fan reversing switch. Also check wire 52_A.
158 to ground
57 – Redundant Brake Pressure Switches

NOTE: Redundant brake switches close at 62 bar (900 psi).
Approximately
Terminal A for wire 33R to ground 11.5 volts Bad instrument cluster (47), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es) (57).
58 – Relay Socket No. 11

Bad instrument cluster (47). Also check circuit 23C to

Terminal for wire 23C_A to ground 0 volt
instrument cluster.
Terminal for wire 19F to ground 24 volts Bad fuse F. Also check circuit 19F to ignition relay No. 2 (15).
Terminal for wire 13K_B to ground 24 volts Check wire 13K_B to ignition relay No. 2 (15).
Check wires 13K_D and 13C_B and connectors 217F and

Terminal for wire 13C_D to ground 24 volts
217M.

4002-57
TROUBLESHOOTING BUCKET CONTROLS
63
62
65
64
60
59
61
BC00N140
59. DETENT SWITCH 63. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH
60. BUCKET CONTROL VALVES ELECTROMAGNETIC DETENTS 64. FLOAT PRESSURE SWITCH
61. RETURN TO TRAVEL/FLOAT SWITCH 65. FLOAT SOLENOID
62. RETURN TO DIG PROXIMITY SWITCH
59 – Detent Switch
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in
the OFF position.
Terminal for wire 53P_B to ground 24 volts Bad pilot control relay (51), also check circuit 53P_B.
NOTE: Put the detent switch (59) in the ON position.
Terminal for wire 56_H to ground 24 volts Bad detent switch (59).
Bad circuit 49_M. Also check five position rotary lamp switch
Terminal for wire 49_M to ground 24 volts (114). If detent switch illumination LED does not turn ON with
24 volts at check point, replace detent switch (59).

4002-58
60 – Bucket Control Valve Electromagnetic Detents

NOTE: Disconnect the wiring harness connector from the control valve electromagnetic detents connector.
Electromagnetic detents connector,

65 to 71 ohms Bad return-to-travel detent electromagnet.
between pins 1 and 6
Electromagnetic detents connector, 65 to 71 ohms Bad height control detent electromagnet.


65 to 71 ohms Bad return-to-dig control detent electromagnet.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (48) in OFF
position and detent switch (59) in ON position.
Wiring harness connector 17M, pin 4 Bad detent switch (59). Also check wires 53P_B, 56_G, and
24 volts
to ground 56_H.
Wiring harness connector 17M, pin 6

24 volts Bad detent switch (59). Also check wires 56_E and 56_H.
to ground
Wiring harness connector 17M, pin 5

24 volts Bad detent switch (59). Also check wires 56_F and 56_H.
to ground
61 – Return-To-Travel/Float Switch
Terminal for wire 0_DAG to ground Continuity Bad ground circuit.
Terminal for wire 0_DAH to ground Continuity Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch (61). Put the return-to-
travel/float switch (61) in FLOAT position.
Between switch terminals 1 and 2 Continuity Bad return-to-travel/float switch (61).
NOTE: Put the return-to-travel/float switch (61) in the TRAVEL position.
Bad return-to-travel detent electromagnet. Also check circuit

Pin 2 of connector 39F to ground 24 volts
55A.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch (61).
Put ignition switch in ON position. Put five position rotary lamp switch (114) in position 3 or higher.
Bad circuit 49_K. Also check five position rotary lamp switch
(114). If return-to-travel/float switch illumination LED is not ON
Terminal for wire 49_K to ground 24 volts
with 24 volts at check point, replace return-to-travel/float
switch.

4002-59
62 – Return-To-Dig Proximity Switch

NOTE: Disconnect the connector from the return-to-dig proximity switch (62). Put the master disconnect switch
and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position and the detent
switch (59) in the ON position.
Terminal B for wire 0_AM to ground Continuity Bad ground circuit.
Bad bucket control valve detent electromagnets (60) or detent

Terminal A for wire 53B_A to ground 24 volts
switch (59). Also check circuit 53B_A.
Terminal C for wire 56_D to ground 24 volts Bad detent switch (59), also check circuit 56.
NOTE: If the readings are good, replace the return-to-dig proximity switch (62).
63 – Height Control/Return-To-Travel Proximity Switch

NOTE: Disconnect the connector from the height control/return-to-travel proximity switch (63). Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position
and the detent switch (59) in the ON position.
Terminal B for wire 0_AA to ground Continuity Bad ground circuit.

Terminal A for wire 54B to ground 24 volts
switch (59). Also check circuit 54B.
Terminal C for wire 56_A to ground 24 volts Bad detent switch (59). Also check circuit 56.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch (63).
64 – Float Pressure Switch

NOTE: Disconnect the wiring harness connector 178M from the float pressure switch.
Between terminals of float pressure

Open Circuit Bad float pressure switch.
switch
NOTE: Start and run engine at idle speed. Put return-to-travel/float switch in FLOAT position. Put loader control
lever in FLOAT position.

Continuity Bad float pressure switch.
switch
NOTE: Shut down engine. Put ignition switch in ON position. Put pilot control switch in OFF position (switch LED
OFF).
Wiring harness connector 178M, pin 24 volts Bad pilot control relay. Also check wires 53P_C and 53P_D.
A and ground

4002-60
65 – Float Solenoid
NOTE: Disconnect the wiring harness connector 179F from the float solenoid.
Between terminals of float solenoid 37 to 43 ohms Bad float solenoid.
Wiring harness connector 179F pin 2

Continuity Bad ground circuit.
to ground

24 volts Bad float pressure switch. Also check wires 53S_A and 53S_B.
to ground

4002-61
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE

CONTROL
71
69 70
67
66
68A 73
72
68
BC00N140
66. SECONDARY STEERING MODULE (OPTION) 70. PIN ENGAGE SOLENOID (OPTION)
67. SECONDARY STEERING PRESSURE SWITCH (OPTION) 71. RIDE CONTROL SWITCH
68. SECONDARY STEERING MOTOR (OPTION) 72. RIDE CONTROL RELAY NO. 4
68A.SECONDARY STEERING SOLENOID (OPTION) 73. RIDE CONTROL SOLENOID
69. PIN ENGAGE SWITCH (OPTION)

4002-62
66 – Secondary Steering Module (Option)

NOTE: Disconnect the wiring harness connector 90M from the secondary steering module.
Bad relay on secondary steering motor (68) or bad secondary

Pin 2 of connector 90M to ground Continuity steering solenoid (68A). Also Check wires 51_A, 51_B, and
51_C and ground circuit connections (wires 0_ND and 0_CF).
Pin 4 of connector 90M to ground Continuity Bad ground circuit.
Bad secondary steering pressure switch (67). Also check wires

Pin 8 of connector 90M to ground Continuity
35X_D, 35X_C, and 35X_A.

Pin 9 of connector 90M to ground Open Circuit
51P_A and 51P_B.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector 90M to ground 24 volts Bad wire 1_W to secondary steering motor (68) B+ stud.
Pin 7 of connector 90M to ground 24 volts Bad fuse M or ignition switch. Also check circuits 19M and 12K.
Check fuse R, ignition relay No. 1, ignition switch, and diode

Pin 1 of connector 90M to ground 24 volts
module. Also check circuits 19R and 13P_B.
NOTE: Start and run engine at idle speed.
Pin 9 of connector 90M to ground Continuity Bad secondary steering pressure switch.
11 volts Check circuit 35X to instrument cluster. If circuit 35X okay,

Pin 8 of connector 90M to ground
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector 90M to secondary
steering module. Disconnect wire 51_B from secondary steering motor (68) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector 131F from secondary steering pressure switch (67). Apply a
ground to pin C of connector 131F.
Terminal for wire 51_B to ground 24 volts Bad secondary steering module.
67 – Secondary Steering Pressure Switch (Option)

NOTE: Disconnect wiring harness connector 131F from secondary steering pressure switch (67).
Pressure switch (67) pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin A to pin C Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin C Open Circuit Bad secondary steering pressure switch.

4002-63
68 – Secondary Steering Motor (Option)

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

ground terminal to ground
Bad secondary steering motor (68) relay coil or secondary

Terminal for wire 51_B to ground. 10 to 45 ohms steering solenoid (68A). Also check relay coil and solenoid
ground circuit.
NOTE: Put the master disconnect switch in ON position.
Terminal for red wire to ground 24 volts Check circuit to batteries.
NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO
NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is
associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect
wire 51_B from secondary steering motor relay.
Check fuses M and R, secondary steering module (66), and

secondary steering pressure switch (67). If 24 volts is obtained
the secondary steering motor is bad. If fuse M or R was
Terminal for wire 51_B to ground 24 volts replaced: if fuse M blows again, secondary steering module is
bad; if fuse R blows again, secondary steering module is bad
or secondary steering motor relay or secondary steering
solenoid is shorted.
68A – Secondary Steering Solenoid (Option)

NOTE: Disconnect connector 264M from secondary steering solenoid.
Between pins A and B of secondary

36 to 42 ohms Bad secondary steering solenoid.
steering solenoid
Between pin B of connector 264M

and ground
NOTE: Disconnect wire 51_B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately
to ON position.
Between pin A of connector 264M Check secondary steering module (66) and secondary steering
24 volts
and ground pressure switch (67).

4002-64
69 – Pin Engage Switch (Option)

Terminal for wire 0_DAL to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
24 volts Bad fuse P or ignition relay No. 2. Also check circuits 19P_A
Terminal for wire 19P_A to ground
and 13P_B.
Terminal for wire 57_A to ground 0 volt Bad pin engage switch.
NOTE: Put the pin engage switch (69) in the ON position.
Terminal for wire 57_A to ground 24 volts Bad pin engage switch.
Check the five position rotary lamp switch (114). Also check
Terminal for wire 49_P to ground 24 volts circuit 49. If LED in pin engage switch is not ON with 24 volts
at check point, replace pin engage switch.
70 – Pin Engage Solenoid (Option)

Terminal for wire 0_AB to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(69) in the ON position.
Terminal for wire 57 to ground 24 volts Bad pin engage switch (69), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (70).

4002-65
71 – Ride Control Switch

NOTE: Disconnect connector 44F from ride control switch (71).
Connector 44F pin 7 to ground Continuity Bad ground circuit.
Ride control switch terminal 6

Continuity Bad ride control switch.
(positive) to terminal 7 (negative)
NOTE: Connect connector 44F to ride control switch (71). Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Check fuse C and ignition relay No. 1. Also check circuits 19C
Terminal for wire 19C_B to ground 24 volts
and 13P_A.
Terminal for wire 58S to ground 0 volt Bad ride control switch.
NOTE: Put the ride control switch (71) in the ON position.
Terminal for wire 58S to ground 24 volts Bad ride control switch.
NOTE: Put the five position rotary light switch (114) in position 3 or higher.
Check five position rotary lamp switch (114). Also check circuit
Terminal for wire 49_P to ground 24 volts 49. If LED in ride control switch is not ON with 24 volts at check
point, replace ride control switch.
72 – Ride Control Relay No. 4

Terminal 85 for wire 0_DD to

Continuity Check wire 44F.
connector 19F pin 57
Terminal 86 for wire 58H_B to

Continuity Check wire 58H_B.
connector 19F pin 8
Terminal 87 for wire 58_B to ride Continuity Check wire 58_B

control switch (71) pin 6
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
Terminal for wire 58S to ground 24 volts Bad ride control switch. Also check wire 58S.
NOTE: If readings are normal, replace ride control relay (72).
73 – Ride Control Solenoid

NOTE: Disconnect connector 5F from ride control solenoid.
Between terminals 1 and 2 of ride

20 to 26 ohms Bad ride control solenoid.
control solenoid

4002-66
TROUBLESHOOTING WIPER/WASHER
74
79
75
77
78 76
BC00N140
74. FRONT WIPER MOTOR 77. REAR WIPER AND WASHER SWITCH
75. FRONT WIPER AND WASHER SWITCH 78. REAR WASHER PUMP MOTOR
76. FRONT WASHER PUMP MOTOR 79. REAR WIPER MOTOR

4002-67
74 – Front Wiper Motor

Terminal for wire 0_KN to ground Continuity Bad ground circuit.
NOTE: Make sure the front wiper and washer switch (75) is in the OFF position.
Between terminals B and D for wires

Continuity Bad front wiper motor.
63C and 63L
Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.
NOTE: Put the front wiper and washer switch (75) in the LOW position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63L to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (75) in the HIGH position.
Terminal for wire 63H to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L to ground 24 volts pulse Bad front wiper and washer switch (75).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (75).
NOTE: If the readings are good, replace the front wiper motor (74).

4002-68
75 – Front Wiper and Washer Switch

Terminal for wire 0_DAR to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch (75) is in the OFF position.
Terminal for wire 19J_A to ground 24 volts Check fuse J, also check circuit 19J.
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75)
Check fuse J, also check circuit 19J. Bad front rotary wiper and
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75).
Terminal for wire 63L_A to ground 24 volts pulse Bad front wiper and washer switch (75).
Terminal for wire 63C_A to ground 24 volts pulse Bad front wiper and washer switch (75).
76 – Front Washer Pump Motor

Terminal for wire 0_G to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (75).
24 volts Bad front wiper and washer switch (75), also check wires 63W
Terminal for wire 63W to ground
and 63W_A.
NOTE: If the readings are good, replace the front washer pump motor (76).

4002-69
77 – Rear Wiper and Washer Switch

Terminal for wire 0_DW to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position.
Terminal for wire 19K_D to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
Terminal for wire 19K_C to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Press and hold the rear wiper and washer switch (77) in the WASH position.
Terminal for wire 68W_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Put the five position rotary lamp switch in position 3 or higher.
Check rotary lamp switch and circuit 49. If LEDs in rear wiper
Terminal for wire 49_L to ground 24 volts and washer switch are not ON with 24 volts at check point,
replace rear wiper and washer switch.
78 – Rear Washer Pump Motor

Terminal for wire 0_F to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (77) in WASH position.
Bad rear wiper and washer switch (77) Also check wires
Terminal for wire 68W to ground 24 volts
68W_A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor (78).
79 – Rear Wiper Motor

Terminal for wire 0_MA to ground Continuity Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (77) is in the OFF position.
Between terminals for wires 68C_B

Continuity Bad rear wiper and washer switch (77).
and 68L_C
Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (77) in the ON position.
Terminal for wire 68L_C to ground 24 volts Bad rear wiper and washer switch (77).
Terminal for wire 68C_B to ground 0 volt Bad rear wiper and washer switch (77).
NOTE: If the readings are good, replace the rear wiper motor (79).

4002-70
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING
86
81
87
90
80 83
89 88
82
84
85
BC00N140
80. HORN RELAY NO. 5 86. A/C LOW PRESSURE SWITCH (IN CAB)
81. HORN 87. A/C HIGH PRESSURE SWITCH (IN REAR CHASSIS)
82. SEAT COMPRESSOR 88. THERMOSTAT SWITCH
83. BLOWER SWITCH 89. COMPRESSOR CLUTCH LOCKOUT RELAY NO. 14
84. SPEED RESISTOR 90. COMPRESSOR CLUTCH
85. BLOWER MOTOR
80 – Horn Relay No. 5

Terminal for wire 19U_B to ground 24 volts Check fuse U, also check wire 19U_B.
Terminal for wire 19U_C to ground 24 volts Check wire 19U_C.
Terminal for wire 64C_A to ground 24 volts Bad horn relay (80).
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64C_A to ground 0 volt Bad horn switch.
Terminal for wire 64_A to ground 24 volts Bad horn relay (80).

4002-71
81 – Horn
Terminal for wire 0_AD to ground Continuity Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn (81). Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (80). Also check wires 64 and 64_A.
NOTE: If the readings are good replace the horn (81).
82 – Seat Compressor and Switch (Option)

Terminal for wire 0_DY to ground Continuity Bad ground circuit.
Terminal for wire 19N_A at seat 24 volts Check fuse N and accessory relay (16). Also check wire 19N_A
switch and circuit 12P.
NOTE: Put the seat compressor (82) switch in the ON position.
Terminal for wire from seat switch at Bad seat switch, also check circuit from seat switch to
24 volts
compressor compressor.
NOTE: If the readings are good replace the seat compressor.
83 – Blower Switch
24 volts Check fuse G and ignition relay No. 2 (15). Also check circuits
Terminal for wire 19G to ground
19G and 13R.
NOTE: Turn the blower switch to LOW.
Terminal for wire 62L to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
NOTE: Turn the blower switch to MEDIUM.
Terminal for wire 62M to ground 24 volts Bad blower switch (83).
NOTE: Turn the blower switch to HIGH.
Terminal for wire 62H to ground 24 volts Bad blower switch (83).

4002-72
84 – Blower Motor Speed Resistors with Thermal Fuse

NOTE: Disconnect the wiring harness connector 29M from the blower motor (85).
Between terminals 1 and 2 of blower Approximately

Bad blower motor resistor.
motor connector 4.5 ohms

1.5 ohms Bad blower motor resistor.
motor connector
85 – Blower Motor
Terminals for wire 0_DZ to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (83) to
HIGH.
Terminal for wire 62H to ground 24 volts Check the blower switch (83).
NOTE: If the readings are correct and the blower motor (85) does not run, replace the blower motor (85). Turn the
blower switch (83) to LOW. If the blower motor (85) ran in HIGH but not in LOW or MEDIUM, check the blower
motor resistor (84).
86 – A/C Low Pressure Switch (In Cab)

NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (83) to HIGH and
the thermostat switch (88) to COLD.
Terminal B for wire 61A_E to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect the wiring harness connector 27M from the A/C low pressure switch (86).
Bad A/C low pressure switch (86), also check refrigerant

Between terminals of low pressure
Open Circuit charge level. (Pressure must be above 1.4 bar (20 psi) for
switch (86)
switch to open.)
87 – A/C High Pressure Switch (In Rear Chassis)

NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and the
thermostat switch (88) to COLD.
Terminal for wire 61A to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect wiring harness connector 98 from A/C high pressure switch (87).
Bad A/C high pressure switch (87), also check for excessive
Between terminals of A/C high
Open Circuit refrigerant pressure. (Switch closes at or above 27.6 bar (400
pressure switch (87)
psi)).

4002-73
88 – Thermostat Switch
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH.
Terminal for wire 61T to ground 24 volts Check the blower switch (83), also check wire 61T.
NOTE: Turn the thermostat switch (88) all the way to COLD.
Terminal for wire 61A_D to ground 24 volts Bad thermostat switch (88).
89 – Compressor Clutch Lockout Relay No. 14

Terminal for wire 0_DK to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and
Terminal for wire 61A_B to ground 24 volts Check thermostat switch (88), also check wire 61A_C.
Check A/C low pressure switch (86) and A/C high pressure
Terminal for wire 61R_D to ground 0 volt
switch (87).
Terminal for wire 61C_B to ground 24 volts Bad compressor clutch lockout relay (89).
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector 98 from A/C high pressure
switch. Connect a jumper wire between pins A and B of connector 98. Put ignition switch in ON position.
Check wires 61R_C and 61R_D. If air conditioning indicator on

Terminal for wire 61R_C to ground 24 volts instrument cluster (47) is not ON, check wires 61R_F and
61R_G to instrument cluster.
Terminal for wire 61C_B to ground 0 volt Bad compressor clutch lockout relay (89).
90 – Compressor Clutch
24 volts Check the compressor clutch lockout relay (89), also check
Terminals for wire 61C to ground
circuit 61C.

4002-74
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER

OUTLET, RADIOS AND SPEAKERS
97
98
94 92
95 93
96
91
BC00N140
91. CIGAR LIGHTER 94. REMOTE OR 24 VOLT RADIO 97. LEFT SPEAKER
92. POWER CONVERTER 95. 12 VOLT RADIO 98. RIGHT SPEAKER
93. POWER OUTLET 96. RADIO POWER CONVERTER
91 – Cigar Lighter (Option)

Terminal for wire 19W_A to ground 24 volts Check fuse W, also check circuit 19W.
Terminal for wire 0_S to ground Continuity Bad ground circuit.
NOTE: If the readings are good replace the cigar lighter (91).

4002-75
92 – Power Converter 24 volts to 12 volts (Option)

Terminal for wire 0_RA to ground Continuity Bad ground circuit.
Terminal for wire 1_V to ground 24 volts Check wire 1_V to cab power stud.
Terminal for wire 19L_B to ground 24 volts Bad fuse L, also check circuit 19L.
Terminal for wire 12V_B to ground 12 volts Bad power converter (92).
93 – Power Outlet (Option)

Terminal for wire 0_RB to ground Continuity Bad ground circuit.
Terminal for wire 12V_A to ground 12 volts Bad power converter (92), also check wire 12V_A.
NOTE: If the readings are good replace the power outlet (93).
94 – Remote Radio or 24 Volt Radio (Option)

Terminal in radio connector for wire

0_QC to ground
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on. Put balance control for RH
and LH speakers to center position.

24 volts Check fuse L, also check circuits 19L and 65C.
65C_A to ground
NOTE: Keep the ignition switch and radio ON. Disconnect wiring harness connectors at LH and RH speakers (97
and 98).
Pin A in wiring harness connector Voltage Bad circuit between the radio and the connector or bad radio
111M to ground (94).
95 – 12 Volt Radio Ready (Option)


0_QC to ground
Terminal in radio connector for wire Check fuse L, also check circuit 19L and 65C. Also check the
12 volts
65C_A to ground radio power converter (96).

4002-76
96 – Radio Power Converter (24 volts to 12 volts) (Option)

Terminal for wire 0_PD to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on.
Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (96).
97 – Left Speaker (Option)

NOTE: Disconnect connector from left speaker (97). Put master disconnect switch and ignition switch in ON
position. Turn radio (94) on. Put balance control for RH and LH speakers to center position.
Pin A in wiring harness connector Bad circuit between the left speaker (97) and the radio or a bad
Voltage
112M to ground radio (94).
Pin B in wiring harness connector

Continuity Bad circuit between the left speaker (97) and the radio (94).
112M to ground
NOTE: If the readings are good, replace the left speaker (97).
98 – Right Speaker (Option)

NOTE: Disconnect connector from right speaker (98). Put master disconnect switch and ignition switch in ON
Pin A in wiring harness connector Bad circuit between the right speaker (98) and the radio or a
Voltage
111M to ground bad radio (94).

Continuity Bad circuit between the right speaker (98) and the radio (94).
111M to ground
NOTE: If the readings are good, replace the right speaker (98).

4002-77
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD

SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER
MODULE
100
103
101
99 104
102
105
BC00N140
99. BEACON SWITCH 102. BRAKE LAMPS RELAY NO. 15 104. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH
100. ROTATING BEACON 103. HAZARD SWITCH 105. FLASHER MODULE
101. BRAKE LAMP PRESSURE
SWITCH
99 – Beacon Switch
Terminal for wire 0_DAP to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3 or
higher.
Check the five position rotary lamp switch (114), also check
Terminal for wire 49_R to ground 24 volts circuit 49. If LED in beacon switch is not ON with 24 volts at
check point, replace beacon switch.
Terminal for wire 19X to ground 24 volts Check fuse X, also check wire 19X.
NOTE: Put the beacon switch (99) in the ON position.
Terminal for wire 46_C to ground 24 volts Bad beacon switch (99).

4002-78
100 – Rotating Beacon

Bulb Continuity Bad bulb.
Terminal for wire 0_MC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and beacon switch (99) in ON position.
Bad circuit between the beacon (100) and the beacon switch
Terminal for wire 46_D to ground 24 volts
(99). Also check the beacon switch (99).
NOTE: If readings are good replace the rotating beacon (100).
101 – Brake Lamp Pressure Switch

NOTE: Put master disconnect switch in ON position.
Terminal for wire 1B_A to ground 24 volts Check circuit breaker B, also check wires 1B_A and 1B_D.
Terminal for wire 44 to ground 0 volt Bad brake lamp pressure switch (101).
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44 to ground 24 volts Bad brake lamp pressure switch (101).
102 – Brake Lamps Relay No. 15

Terminal for wire 0_DA to ground Continuity Bad ground circuit.
Terminal for wire 1B_E to ground 24 volts Check circuit breaker B and wires 1B_E and 1B_F.
Terminal for wire 44A_B to ground 0 volt Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 0 volt Bad brake lamps relay (102).
Terminal for wire 44A_B to ground 24 volts Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 24 volts Bad brake lamps relay (102).

4002-79
103 – Hazard Switch

Terminal for wire 0_KH to ground Continuity Bad ground circuit.
Terminal for wire 1B to ground 24 volts Check circuit breaker B. Also check wires 1B and 1B_F.
NOTE: Put hazard switch in ON position.
Bad hazard switch (103). If hazard switch LED is not ON with

24 volts at check point, replace hazard switch.
NOTE: Put five position rotary lamp switch (114) in position 3 or higher.
Terminal for wire 49_A to ground 24 volts 49 to lamp switch (114). If hazard switch LED is not ON with 24
volts at check point, replace hazard switch.
104 – Turn Signal, Hi/Low Beam, and Horn Switch

HORN SWITCH
Terminal for wire 0_KG to ground Continuity Bad ground circuit.
Check fuse U and horn relay (80). Also check wires 64C,
Terminal for wire 64C to ground 24 volts
64C_A, and 19U_C.
NOTE: If readings are good, replace the switch (104).
TURN SIGNAL
Check fuse B and ignition relay No. 1 (14). Also check wires
Terminal for wire 19B to ground 24 volts
19B and 19B_A.
NOTE: Move turn signal lever to RIGHT turn position.
Terminal for wire 45B to ground 24 volts Bad turn signal switch (104).
NOTE: Move turn signal lever to LEFT turn position.
Terminal for wire 45A to ground 24 volts Bad turn signal switch (104).
HI/LOW BEAM SWITCH
Terminal for wire 0_KF to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in OFF position. Hold Hi/Low beam lever in HIGH beam
position.
Terminal for wire 64D to ground Continuity Bad hi/low beam switch (104).

4002-80
105 – Flasher Module

NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
Terminal for wire 0_DAN to ground Continuity Bad ground circuit.
Terminal for wire 0_DAQ to ground Continuity Bad ground circuit.
Terminal for wire 45N_A to terminal

for wire 45N_B (North American Continuity Bad 45N circuit.
machines only)
Check flasher circuit breaker B. Also check wires 1B_B and

Terminal for wire 1B_B to ground 24 volts
1B_F.
NOTE: Put ignition switch in the ON position. Put the hazard switch (103) ON.
Terminal for wire 45H_A to ground 24 volts Bad hazard switch (103). Also check wires 45H_A and 45H.
Intermittent 24
Terminal for wire 45L_D to ground Bad flasher module (105).
volts
Intermittent 24
Terminal for wire 45R_E to ground Bad flasher module (105).
volts
NOTE: Put hazard switch (103) in OFF position. Put turn signal switch (104) in RIGHT turn position.
Bad turn signal switch (104) or fuse B. Also check wires 45B_A
Terminal for wire 45B_A to ground 24 volts
and 45B.
Intermittent 24
volts
NOTE: Put turn signal switch (104) in LEFT turn position.
24 volts Bad turn signal switch (104) or fuse B. Also check wires 45A_A
Terminal for wire 45A_A to ground
and 45A.
Intermittent 24
Terminal for wire 45L_D to ground volts Bad flasher module (105).

4002-81
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP

SWITCH, AND CAB LIGHTS
117 112
113
118
110 108
115
114
111 109
106
116
107
BC00N140
106. LH REAR COMBINATION LAMP 113. RH FRONT WORK LAMP
107. RH REAR COMBINATION LAMP 114. FIVE POSITION ROTARY LAMP SWITCH
108. LH FRONT COMBINATION LAMP 115. HIGH/LOW BEAM RELAY NO. 13
109. RH FRONT COMBINATION LAMP 116. LICENSE PLATE LAMP
110. LH REAR WORK LAMP 117. DOME LAMP
111. RH REAR WORK LAMP 118. COURTESY LAMP
112. LH FRONT WORK LAMP

4002-82
106 – LH Rear Combination Lamp

NOTE: Disconnect wiring harness connector 125 from LH rear combination lamp connector.
Combination lamp connector pin 1 to

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

pin 5

Continuity Bad tail lamp bulb.
pin 5

Continuity Bad reverse lamp bulb.
pin 5
NOTE: Connect wiring harness connector 125 to LH rear combination lamp connector.
Terminal for wire 0_A to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Check brake lamps relay (102). Also check circuit 44 to brake

Terminal for wire 44_A to ground 24 volts
lamps relay (102).
NOTE: Have assistant put transmission in reverse.
Check backup alarm relay (35). Also check circuit 35A to

Terminal for wire 35A_A to ground 24 volts
backup alarm relay (35).
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45L_A to ground
volts Also check circuit 45L to flasher module.
NOTE: Put five position rotary lamp switch (114) in position 2 or 3.
Check fuse F´ and lamp switch (114). Also check wires 18F_A
Terminal for wire 18F_A to ground 24 volts and 18F_D to fuse F’, and wire 41T_A from fuse F’ to lamp
switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp (106).

4002-83
107 – RH Rear Combination Lamp

NOTE: Disconnect wiring harness connector 127 from RH rear combination lamp connector.

pin 5

pin 5

pin 5

pin 5
NOTE: Connect wiring harness connector 127 to RH rear combination lamp connector.
Terminal for wire 0_C to ground Continuity Bad ground circuit.

Terminal for wire 44_B to ground 24 volts
lamps relay (102).

Terminal for wire 35A_B to ground 24 volts
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R_A to ground
volts Also check circuit 45R to flasher module.
Check fuse G´ and lamp switch (114). Also check wires 18G_A,
Terminal for wire 18G_A to ground 24 volts 18G_D, and 18G_F to fuse G’, and wire 41T_A from fuse G’ to
lamp switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp (107).

4002-84
108 – LH Front Combination Lamp

NOTE: Disconnect wiring harness connector 6 from LH front combination lamp connector.

Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 4 to Continuity Bad position lamp bulb.

pin 1

Continuity Bad low beam lamp bulb.
pin 1

Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector 6 to LH front combination lamp connector.
Terminal for wire 0_AL to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3.
Check fuse F’ and five position rotary lamp switch (114). Also
Terminal for wire 18F to ground 24 volts
check circuit 18F and wires 41T_A and 41T_B.
NOTE: Put high/low beam lever (104) in HIGH beam position.
Check fuse B’, high/low beam relay (115), five position rotary
Terminal for wire 18B to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18B and wire 41H.
NOTE: Put high/low beam lever (104) in LOW beam position.
Check fuse D’, high/low beam relay (115), five position rotary
Terminal for wire 18D to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18D and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Terminal for wire 45L to ground
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp (108).

4002-85
109 – RH Front Combination Lamp

NOTE: Disconnect wiring harness connector 8 from RH front combination lamp connector.

pin 1

pin 1

pin 1

pin 1
NOTE: Connect wiring harness connector 8 to RH front combination lamp connector.
Terminal for wire 0_AG to ground Continuity Bad ground circuit.
Check fuse G’ and five position rotary lamp switch (114). Also
Terminal for wire 18G to ground 24 volts
check circuit 18G and wires 41T_A and 41T_B.
Check fuse C’, high/low beam relay (115), five position rotary
Terminal for wire 18C to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18C and wire 41H.
Check fuse E’, high/low beam relay (115), five position rotary
Terminal for wire 18E to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18E and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R to ground
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp (109).
110 – LH Rear Work Lamp

NOTE: Disconnect wiring harness connector 83F from LH rear work lamp connector.
Flood lamp connector pin A to pin B Continuity Bad lamp bulb.
NOTE: Connect wiring harness connector 83F to LH rear work lamp connector.
Terminal for wire 0_ME to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse A´ and five position rotary lamp switch (114). Also
Terminal for wire 42R_D to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A’.

4002-86
111 – RH Rear Work Lamp

NOTE: Disconnect wiring harness connector 80F from RH rear work lamp connector.
NOTE: Connect wiring harness connector 80F to RH rear work lamp connector.
Terminal for wire 0_MF to ground Continuity Bad ground circuit.
Terminal for wire 42R_E to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A’.
112 – LH Front Work Lamp

NOTE: Disconnect wiring harness connector 79F from LH front work lamp connector.
NOTE: Connect wiring harness connector 79F to LH front work lamp connector.
Terminal for wire 0_MH to ground Continuity Bad ground circuit.
Check fuse Z and five position rotary lamp switch (114). Also
Terminal for wire 42C_B to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
113 – RH Front Work Lamp

NOTE: Disconnect wiring harness connector 78F from RH front work lamp connector.
NOTE: Connect wiring harness connector 78F to RH front work lamp connector.
Terminal for wire 0_MJ to ground Continuity Bad ground circuit.
Terminal for wire 42C_C to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.

4002-87
114 – Five Position Rotary Lamp Switch

Terminal for wire 1_N to ground 24 volts Check wire 1_N.
Terminal for wire 19Z to ground 24 volts Check fuse Z, also check circuit 19Z.
Terminal for wire 18A to ground 24 volts Check fuse A´, also check circuit 18A.
NOTE: Put the five position rotary lamp switch (114) in position 2.
Terminal for wire 41T to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 41J to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42R to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42C to ground 24 volts Bad five position rotary lamp switch (114).
115 – High/Low Beam Relay No. 13

NOTE: Put high/low beam lever in HIGH beam position.
Check high/low beam switch (104). Also check circuits 64D and
Terminal for wire 64D_A to ground Continuity
0_KF to and through the high/low beam switch.
Terminal for wire 1_H to ground 24 volts Check circuit 1_H.
NOTE: Put the 5 position rotary lamp switch (114) in position 3 or 4.
Bad five position rotary lamp switch (114). Also check wire
Terminal for wire 41J_A to ground 24 volts
41J_A.
NOTE: Put high/low beam lever in LOW beam position.
Terminal for wire 41L_A to ground 24 volts Bad high/low beam relay (115).
Terminal for wire 41H to ground 24 volts Bad high/low beam relay (115).

4002-88
116 – License Plate Lamp

Terminal for wire 0_JC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put the five position rotary lamp switch (114) in position 2.
Check fuse G’ and five 5 position rotary lamp switch (114). Also
Terminal for wire 18G_E to ground 24 volts
check circuit 18G.
117 – Dome Lamp

Terminal for wire 0_MB to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put dome lamp (118) switch in ON position.
Terminal for wire 19U_D to ground 24 volts Check fuse U, also check circuit 19U.
NOTE: If readings are good, replace dome lamp (118).
118 – Courtesy Lamp

Terminal for wire 0_ML to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 2 or
higher.
Check circuit 49, also check five position rotary lamp switch
Terminal for wire 49_V to ground 24 volts
(114).

4002-89
CONNECTORS
CONNECTOR 1 - FRONT CHASSIS HARNESS TO CONNECTOR 1F - MAIN CAB HARNESS TO
MAIN CAB HARNESS FRONT CHASSIS HARNESS
319148A1 291660A1
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT
A 45L N-1.0 Left Turn Signal A 45L_C N-0.8 Left Turn Signal
B 53P_D W-1.0 Float Solenoid Power B 53P_C W-0.8 Pilot Control Signal
C 45R N-1.0 Right Turn Signal C 45R_D N-0.8 Right Turn Signal
D None D None
E 18G Or-1.0 Position RH E 18G_G Or-0.8 Position RH
F 18F Or-1.0 Position LH F 18F_E Or-0.8 Left Tail Position
G 18B Or-1.0 High Beam LH G 18B_A Or-0.8 High Beam LH
H 19M_B Or-1.0 Secondary Steer Accessory H 19M_A Or-0.8 Secondary Steer Accessory
J 19R_B Or-1.0 Secondary Steer Ignition J 19R_A Or-0.8 Secondary Steer Ignition
K 35X_B Y-1.0 Secondary Steer Low Pres Sig K 35X_E Y-0.8 Secondary Steer Low Pres Sig
L 54B W-1.0 Height-RTT Signal L 54B_A W-0.8 Height-RTT Signal
M 53B W-1.0 RTD Signal M 53B_B W-0.8 RTD Signal
N 64 Or-1.0 Horn N 64A Or-0.8 Horn
O 18D Or-1.0 Low Beam LH O 18D_A Or-0.8 Low Beam LH
P 18E Or-1.0 Low Beam RH P 18E_A Or-0.8 Low Beam RH
Q 18C Or-1.0 High Beam RH Q 18C_A Or-0.8 High Beam Fused Pwr
R None R None
S None S None
T 56_C W-1.0 Prox Switch Pwr T 56_J W-0.8 Prox Switch Pwr
U 57 W-1.0 Pin Engage Sol Pwr U 57_A W-0.8 Pin Engage Sol Pwr
V 58 W-1.0 Ride Cntrl Sol Pwr V 58_A W-0.8 Ride Cntrl Sol Pwr
W None W None
X None X None

4002-90
CONNECTOR 2 - FRONT WASHER PUMP MOTOR CONNECTOR 5F - RIDE CONTROL SOLENOID TO
TO REAR CHASSIS HARNESS FRONT CHASSIS HARNESS
3227856R1 291718A1

1 63W Or-1.0 Front Washer Pump 1 58_C W-1.0 Ride Control Solenoid Power
2 0_G Bk-1.0 Front Rear Washer Hot Ground 2 0_AC Bk-1.0 Ride Control Ground
CONNECTOR 3 - REAR WASHER PUMP MOTOR CONNECTOR 6 - LH FRONT COMBINATION

TO REAR CHASSIS HARNESS LAMP TO FRONT CHASSIS HARNESS
225351C1
3227856R1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT 1 0_AL Bk-1.0 Lights Ground LH
1 68W Or-1.0 Rear Washer Pump 2 18D Or-1.0 Low Beam LH
2 0_F Bk-1.0 Front Rear Washer Hot Ground 3 18B Or-1.0 High Beam LH
4 18F Or-1.0 Position LH
CONNECTOR 4 - BRAKE DECLUTCH PRESSURE 5 45L N-1.0 Left Turn Signal

SWITCH TO REAR CHASSIS HARNESS 6 None
245482C1
CAV WIRE IDENT CIRCUIT

A 19A_A Or-1.0 Declutch Switch
B 25G LU-1.0 Declutch Switch

4002-91
CONNECTOR 8 - RH FRONT COMBINATION CONNECTOR 12F - RTD HARNESS FOR XT
LAMP TO FRONT CHASSIS HARNESS CHASSIS TO FRONT CHASSIS HARNESS
245485C1
225351C1
A 53B W-1.0 RTD Signal
1 0_AG Bk-1.0 Lights Ground RH
B 0_AF Bk-1.0 RTD Ground
2 18E Or-1.0 Low Beam RH
C 56_B W-1.0 RTD Power
3 18C Or-1.0 High Beam RH
4 18G Or-1.0 Position RH
5 45R N-1.0 Right Turn Signal CONNECTOR 12M - RTD HARNESS FOR XT
CHASSIS TO FRONT CHASSIS HARNESS
6 None
CONNECTOR 10 - HEIGHT CONTROL/RTT

PROXIMITY SWITCH TO FRONT CHASSIS
HARNESS
245484C1

A 53B_A W-1.0 RTD Signal
B 0_AM Bk-1.0 RTD Ground
C 56_D W-1.0 RTD Power
245484C1

A 54B W-1.0 Height/RTT Signal
B 0_AA Bk-1.0 Height/RTT Ground
C 56_A W-1.0 Height/RTT Power

4002-92
CONNECTOR 13F - MAIN CAB HARNESS TO CAV WIRE IDENT CIRCUIT
PEDESTAL HARNESS
33 None
34 50G_D Bk-0.8 CAN Ground
35 44_F T-0.8 Brake Light Signal
36 53C_A W-0.8 Pilot Control Signal
37 None
38 0_DAB Bk-0.8 Signal Ground
39 0_DL Bk-0.8 Signal Ground
40 0_DAA Bk-0.8 None
41 0_DX Bk-0.8 Horn Ground
42 64C_A Or-0.8 Horn Control
43 19A_S Or-0.8 Cab Switched Pwr
374972A1
44 25F_A LU-0.8 Forward Signal
CAV WIRE IDENT CIRCUIT 45 25R_A LU-0.8 Reverse Signal
1 19V Or-0.8 Cluster Main Fused Power 46 25T_C LU-0.8 Neutral Signal
2 19S Or-0.8 Instr Cluster Fused Del Power 47 None
3 33P_A Y-0.8 Low Brake Pres Warning 48 25W_A LU-0.8 3rd and 4th Gear Signal
4 31D_A Y-0.8 Coolant Level Signal 49 25Z_A LU-0.8 1st and 4th Gear Signal
5 35X_E Y-0.8 Sec Str Low Press Sig 50 25Y_A LU-0.8 Trans Kickdown Signal
6 31F_B Y-0.8 Air Filter Rest Sw Signal 51 49_F S-0.8 Pilot Light Power
7 31H_A Y-0.8 Hyd Filter Rest Sw Signal 52 28C_A W-0.8 Ether Start Control
8 0_DAU Bk-0.8 Analog Ground 53 0_DAC Bk-0.8 Relay Ground
9 None 54 None
10 61R_F Or-0.8 A/C Telltale 55 64D_A Or-0.8 High/Low Beam Signal
11 None 56 13K_G Or-0.8 Ignition Switch Pwr
12 42R_C DU 0.8 Rear Work Light Pwr 57 63H_A Or-0.8 Front Wiper High Speed
13 46_A K-0.8 Beacon Switched Pwr 58 63L_A Or-0.8 Front Wiper Low Speed
14 None 59 63C_A Or-0.8 Front Wiper Park
15 18C_B Or-0.8 High Beam Fused Pwr 60 19J_B Or-0.8 Frt Wip Wash Fused Pwr
16 45L_E N-0.8 Left Turn Signal 61 0_DV Bk-0.8 Beacon Wpr Diode Ground
17 45R_C N-0.8 Right Turn Signal 62 1A_C R-0.8 Ignition Switch Power
18 36C_B P-0.8 ECT Signal 63 12K_B Or-0.8 ACC Power
19 36F_A P-0.8 Fuel Level Signal 64 21K_A W-0.8 Ign Switch Start Signal
20 36H_A P-0.8 Hot Signal 65 1B_C R-0.8 Hazard Switch Power
21 None 66 19B-A Or-0.8 Turn Signal Power
22 36P_B P-0.8 EOP Signal 67 45H_A N-0.8 Hazard Switch Power
23 23C_A W-0.8 Engine Shutdown Signal 68 19C_C Or-0.8 Ride Control Fused Power
24 None 69 45A_A N-0.8 Left Turn Switch Power
25 37R_C P-0.8 Reset Signal 70 45B_A N-0.8 Right Turn Switch Power
26 None
27 None
28 33R_D Y-0.8 Red Brake Sw Signal
29 None
30 52C_A W-0.8 Parking Brake Signal
31 50L_A G-0.5 CAN L
32 50H_A Y-0.5 CAN H

4002-93
CONNECTOR 13M - PEDESTAL HARNESS TO CAV WIRE IDENT CIRCUIT
MAIN CAB HARNESS
34 50G_A Bk-0.8 CAN Ground
35 44_G T-0.8 Brake Light Signal
36 53C W-0.8 Pilot Control Signal
37 None
38 0_KR Bk-0.8 Signal Ground
39 0_KD Bk-0.8 Signal Ground
40 None
41 0_KG Bk-0.8 Horn Hi Lo Beam Ground
42 64C Or-0.8 Horn Control
43 19A_G Or-0.8 Trans Control Pwr
374971A1 44 25F LU-0.8 Forward Signal
CAV WIRE IDENT CIRCUIT 45 25R LU-0.8 Reverse Signal
1 19V_A Or-0.8 Cluster Main Fused Power 46 25T_B LU-0.8 Neutral Signal
2 19S_A Or-0.8 Instr Cluster Fused Del Power 47 None
3 33P_B Y-0.8 Low Brake Pres Warning 48 25W LU-0.8 3rd and 4th Gear Signal
4 31D_B Y-0.8 Coolant Level Signal 49 25Z LU-0.8 1st and 4th Gear Signal
5 35X_F Y-0.8 Sec Str Low Press Sig 50 25Y LU-0.8 Trans Kickdown Signal
6 31F_C Y-0.8 Air Filter Rest Sw Signal 51 49_A S-0.8 Pilot Light
7 31H_B Y-0.8 Hyd Filter Rest Sw Signal 52 28C W-0.8 Ether Start Control
8 0_KP Bk-0.8 Analog Ground 53 0_KM Bk-0.8 Pilot Light Ground
9 None 54 None
10 61R_G Or-0.8 A/C Telltale 55 64D Or-0.8 High/Low Beam Signal
11 None 56 13K Or-0.8 Ignition Switch Pwr
12 42R_A Y-0.8 Work Light Telltale Sig 57 63H Or-0.8 Front Wiper High Speed
13 46_B K-0.8 Beacon Telltale 58 63L Or-0.8 Front Wiper Low Speed
14 None 59 63C Or-0.8 Front Wiper Park
15 18C_C Or-0.8 High Beam Telltale 60 19J Or-0.8 Frt Wip Wash Fused Pwr
16 45L_F N-0.8 Left Turn Signal 61 0_KN Bk-0.8 Front Wiper Ground
17 45R_F N-0.8 Right Turn Signal 62 1A_A R-0.8 Ign Prog Reset Switch Power
18 36C_C P-0.8 ECT Signal 63 12K_C Or-0.8 Ign Switch ACC Power
19 36F_B P-0.8 Fuel Level Signal 64 21K W-0.8 Ign Switch Start Signal
20 36H_B P-0.8 Hot Signal 65 1B R-0.8 Hazard Switch Power
21 None 66 19B Or-0.8 Turn Signal Power
22 36P_C P-0.8 EOP Signal 67 45H N-0.8 Hazard Switch Power
23 23C W-0.8 Engine Shutdown Signal 68 19C Or-0.8 Pilot Control Signal
24 None 69 45A N-0.8 Left Turn Switch Power
25 37R_A P-0.8 Reset Signal 70 45B N-0.8 Right Turn Switch Power
26 None
27 None
28 33R_E Y-0.8 Red Brake Sw Signal
29 None
30 52C W-0.8 Parking Brake Signal
31 50L G-0.5 CAN L
32 50H Y-0.5 CAN H
33 None

4002-94
CONNECTOR 17M - BUCKET CONTROL VALVE
ELECTROMAGNETIC DETENTS TO MAIN CAB
HARNESS
225351C1

1 55A W-0.8 RTT Float Switch
2 54B_C W-0.8 Height Control Elec Mag
3 53B_B W-0.8 RTD Signal
4 56_G W-0.8 Detent Switched Power
5 56_F W-0.8 Detent Switched Power
6 56_E W-0.8 Detent Switched Power

4002-95
FUSE BLOCK 18F TO MAIN CAB HARNESS
232118A1

4002-96

19N_B Or-1.0
A1 13P_A Or-1.0 Ign Relay 1 Out (5 Way)* N2 Acces Seat Fused Pwr (3 Way)*
19N_A Or-1.0
B1 Ign Relay 1 (5 Way)
P2 19P_A Or-1.0 Fan Rev Pin Eng Fused Power
C1 Ign Relay 1 (5 Way)
R2 19R_A Or-0.8 Sec Str Ignition
D1 Ign Relay 1 (5 Way)
S2 19S Or-0.8 Instr Cluster Fused Del Power
E1 Ign Relay 1 (5 Way)
19T_A Or-0.8
T2 Time Delay Fused Power
F1 13R Or-1.0 Ign Relay 2 Out (5 Way)* 19T_B Or-0.8
G1 Ign Relay 2 (5 Way) 19U_A Or-1.0
U2 Dome Lt Horn Fused Power
19U_B Or-1.0
H1 Ign Relay 2 (5 Way)
V2 19V Or-0.8 Cluster Main Fused Power
J1 Ign Relay 2 (5 Way)
W2 19W Or-1.0 Cigarette Lighter Fused Power
K1 Ign Relay 2 (5 Way)
X2 19X Or-1.0 Beacon Sw Fused Power
12P_A Or-1.0
L1 ACC Relay
12P_B Or-1.0 Y2 None
M1 12K_A Or-1.0 ACC Power Z2 19Z Or-1.0 Frnt Flood Illum Fused Power
N1 12P_B Or-1.0 ACC Relay A2’ 18A Or-2.0 Rear Fld Lts Fuse Power
P1 13P_B Or-1.0 Ign Relay 1 Out (2 Way)* B2’ 18B_A Or-0.8 High Beam LH
R1 Ign Relay 1 (2 Way) 18C_A Or-0.8
C2’ High Beam Fused Power
S1 13D Or-1.0 Delay Power (2 Way)* 18C_B Or-0.8
D2’ 18D_A Or-0.8 Low Beam LH
T1 Time Delay Module (2 Way)
U1 1_Q R-1.0 Dome Light Horn Power E2’ 18E_A Or-0.8 Low Beam RH
18F_D Or-0.8
V1 13V Or-1.0 Voltmeter Relay Out F2’ Left Tail Pos
18F_E Or-0.8
W1 1_R R-3.0 Cigar Lighter Power
18G_F Or-0.8
G2’ Right Tail Pos Lic
X1 Power (4 Way) 18G_G Or-0.8
Y1 Power (4 Way) 1 19N_B Or-1.0 Acces Seat Fused Pwr (3 Way)*
Z1 1_U R-3.0 B+ Power (4 Way)* 2 None
A1’ Power (4 Way) 3 None
B1’ Hi Low Relay 13 (2 Way) 4 None
C1’ 41H K-2.0 High Beam Signal (2 Way)* 5 19L Or-1.0 Access to Fuse L (3 Way)*
D1’ Hi Low Relay 13 (2 Way) 6 None
E1’ 41L_A K-2.0 Low Beam Signal (2 Way)* 7 Access to Fuse N (3 Way)
F1’ Rotary Lamp Switch (2 Way) 8 None
G1’ 41T_A K-1.0 Tail Light Sw Power (2 Way)* 9 None
19A_N Or-0.8 10 None
A2 Cab Switched Power
19A_P Or-0.8
11 Access to Fuse L (3 Way)
B2 19B_A Or-0.8 Turn Signal Power
12 None
19C_A Or-1.0
C2 Pilot Ride Cntrl Fused Power 13 Access to Fuse N (3 Way)
19C_D Or-1.0
14 None
D2 19D_A Or-1.0 Park Brake Rel Fused Power
15 None
E2 19E Or-1.0 Ether Start Rel Fused Power
16 19W Or-1.0 Cigarette Lighter Fused Power
F2 19F Or-1.0 Eng Shutdown Rel Fused Pwr
G2 19G Or-2.0 Blower Switch Fused Power
18 None
H2 19H Or-1.0 Backup Alarm Rel Fuse Power
J2 19J_A Or-1.0 Front Wip Wash Fused Power
K2 19K_A Or-1.0 Rear Wip Wash Fused Power
L2 19L Or-1.0 Access to Fuse L (3 Way)*
M2 19M_A Or-0.8 Sec Str Accessory

4002-97
CONNECTOR 19F - TRANSMISSION CAV WIRE IDENT CIRCUIT
ELECTRONIC CONTROL MODULE TO MAIN CAB
HARNESS
44 26N_B LU-0.8 FNR Neutral Signal
45 19A_K Or-0.8 Cab Switched Power
1 0_DP Bk-0.8 Diag TECM Ground
46 36R_E P-0.8 Valve Body Temp Return
2 0_DQ Bk-0.8 Diag TECM Ground
47 None
3 0_DM Bk-0.8 Speed Sensor Ground
48 None
4 0_DN Bk-0.8 Out Speed Sensor Ground
49 36G_A P-1.0 TCO Temp Signal
5 32J_C Y-0.8 Trans Enable Lt Signal
50 None
6 None
51 25J_A LU-0.8 Trans Sol Valve Y6
7 35C Y-0.8 Backup Alarm Pull Down
52 None
8 58H_B W-0.8 Ride Cntl Sw Power VPS2
53 None
9 25P_A LU-0.8 Trans Sol Valve Y5
54 None
10 25L_A LU-0.8 Trans Sol Valve Y2
55 25N_A LU-0.8 Trans Sol Valve Y4
11 None
56 25K_A LU-0.8 Trans Sol Valve Y1
12 25S_B LU-0.8 Output Sw Power VPS1
57 0_DD Bk-0.8 Ride Control Relay Sink
13 25S_C LU-0.8 Output Sw Power VPS1
58 None
14 None
59 None
15 37D_A P-0.8 Diagnostic Signal
60 None
16 None
61 None
17 32F_A Y-0.8 Trans Filter Maint Switch
62 25D_A LU-0.8 Output Speed Signal
18 37E P-0.8 Diagnostic Signal
63 25Z_A LU-0.8 1st and 4th Gear Signal
19 25A_A LU-0.8 Engine Speed Signal
64 25R_A LU-0.8 Reverse Signal
20 26F_B LU-0.8 FNR Forward Signal
65 25W_A LU-0.8 3rd and 4th Gear Signal
21 52P_A W-0.8 Park Brake Relay Out
66 25G_B LU-0.8 Declutch Signal
22 25Y_B LU-0.8 Trans Kickdown Signal
67 25T_D LU-0.8 Neutral Signal
23 19T_A Or-0.8 Time Delay Fused Power
68 19T_B Or-0.8 Time Delay Fused Power
24 None
25 50H_A Y-0.5 CAN H
26 50L_B G-0.5 CAN L CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH TO MAIN CAB HARNESS
27 50L_C G-0.5 CAN L
28 None
29 25H LU-0.8 Trans Auto Signal
30 26R_B LU-0.8 FNR Reverse Signal
31 26E LU-0.8 Trans Enable Signal
32 25M_A LU-0.8 Trans Sol Valve Y3
33 None
34 None
35 None
36 None
222136A1
37 None
38 None
1 19A_U Or-0.8 Cab Switched Power
39 36T_A P-0.8 Valve Body Temp Signal
2 25Y_C LU-0.8 Trans Kickdown Signal
40 None
41 25B_A LU-0.8 Turb Speed Signal
42 25C_A LU-0.8 Int Speed Signal

4002-98
CONNECTOR 21F - CAB MAIN HARNESS TO CONNECTOR 21M - REAR CHASSIS HARNESS
REAR CHASSIS HARNESS TO CAB MAIN HARNESS
291661A1
374973A1
1 28P_A W-0.8 Ether Solenoid CAV WIRE IDENT CIRCUIT
2 None 1 28P W-1.0 Ether Solenoid
3 31D_A Y-0.8 Coolant Level Signal 2 None
4 33P_A Y-0.8 Low Brake Pres Warning 3 31D Y-1.0 Coolant Level Signal
5 18F_D Or-0.8 Left Tail Pos 4 33P Y-1.0 Low Brake Pres Warning
6 35R_C Y-0.8 Backup Alarm Switch 5 18F_A Or-1.0 Left Tail
7 35A_D Y-0.8 Backup Alarm Relay Out 6 35R_B Y-1.0 Backup Alarm Switch
8 44_D T-0.8 Brake Light Signal 7 35A_C K-1.0 Reverse Lights
9 18G_F Or-0.8 RH Tail Lic Lights 8 44_C T-1.0 Brake Light Signal
10 45L_B N-0.8 Left Turn Signal 9 18G_D Or-1.0 RH Tail Lic Lights
11 21C_E W-0.8 Starter Fuel Relay Signal 10 45L_A N-1.0 Left Turn Signal
12 45R_B N-0.8 Right Turn Signal 11 21C_D W-1.0 Starter Fuel Relay Signal
13 36H_A P-0.8 Hot Signal 12 45R_A N-1.0 Right Turn Signal
14 31H_A Y-0.8 Hyd Filter Rest Sw Signal 13 36H P-1.0 Hot Signal
15 33R_D Y-0.8 Red Brake Sw Signal 14 31H Y-1.0 Hyd Oil Filter Rest Sw Signal
16 36F_A P-0.8 Fuel Level Signal 15 33R_C Y-1.0 Red Brake Sw Signal
17 None 16 36F P-1.0 Fuel Level Signal
18 52P_B W-0.8 Park Brake Relay Out 17 None
19 None 18 52P W-1.0 Park Brake Relay Out
20 None 19 None
21 1_P R-0.8 Voltmeter Relay Power 20 None
22 None 21 1_A R-1.0 B+
23 None 22 None
24 68W_A Or-1.0 Rear Washer Pump 23 None
25 63W_A Or-0.8 Front Washer Pump 24 68W Or-1.0 Rear Washer Pump
26 None 25 63W Or-1.0 Front Washer Pump
27 52_A W-0.8 Fan Reverse Solenoid 26 None
28 1B_D R-0.8 CB B Load 27 52 W-1.0 Fan Reverse Solenoid
29 44A_B T-0.8 Brake Lt Input Signal 28 1B_A R-1.0 Brake Lt Sw Power
30 19A_T Or-0.8 Cab Switched Power 29 44 T-1.0 Brake Lt Input Signal
31 25G_A LU-0.8 Declutch Switch 30 19A_A Or-1.0 Declutch Switch

31 25G LU-1.0 Declutch Switch

4002-99
CONNECTOR 22F - CAB MAIN HARNESS TO CONNECTOR 22M - TRANSMISSION HARNESS
TRANSMISSION HARNESS TO CAB MAIN HARNESS
291661A1
373358A1
1 13C_D Or-0.8 Fuel Solenoid Power CAV WIRE IDENT CIRCUIT
2 14_B LG-0.8 Alternator D+ 1 13C_A Or-1.0 Fuel Solenoid
3 31F_B Y-0.8 Air Filter Rest Sw Signal 2 14_A LG-1.0 Alternator D+
4 36C_B P-0.8 ECT Signal 3 31F_A Y-1.0 Air Filter Rest Sw Signal
5 36T_A P-0.8 Valve Body Temp Signal 4 36C_A P-1.0 ECT Signal
6 36P_B P-0.8 EOP Signal 5 36T P-0.8 Valve Body Temp Signal
7 25A_A LU-0.8 Engine Speed Signal 6 36P_A P-1.0 EOP Signal
8 25B_A LU-0.8 Turb Speed Signal 7 25A W-0.8 Engine Speed Signal
9 25C_A LU-0.8 Int Speed Signal 8 25B W-0.8 Turb Speed Signal
10 25D_A LU-0.8 Output Speed Signal 9 25C W-0.8 Int Speed Signal
11 0_DM Bk-0.8 Speed Sensor Ground 10 25D LU-1.0 Output Speed Signal
12 36R_E P-0.8 Valve Body Temp Ret 11 0_HD Bk-1.0 Speed Sensor Ground
13 36G_A P-1.0 TCO Temp Signal 12 36R_A P-1.0 Valve Body Temp Ret
14 None 13 36G P-1.0 TCO Temp Signal
15 0_DAB Bk-0.8 Signal Ground 14 None
16 25K_A LU-0.8 Trans Solenoid Valve Y1 15 0_HB Bk-1.0 Signal Ground
17 25L_A LU-0.8 Trans Solenoid Valve Y2 16 25K LU-0.8 Trans Solenoid Valve Y1
18 25M_A LU-0.8 Trans Solenoid Valve Y3 17 25L LU-0.8 Trans Solenoid Valve Y2
19 25N_A LU-0.8 Trans Solenoid Valve Y4 18 25M LU-0.8 Trans Solenoid Valve Y3
20 25P_A LU-0.8 Trans Solenoid Valve Y5 19 25N LU-0.8 Trans Solenoid Valve Y4
21 25J_A LU-0.8 Trans Solenoid Valve Y6 20 25P LU-0.8 Trans Solenoid Valve Y5
22 25S_A LU-0.8 Output Sw Power VPS1 21 25J LU-0.8 Trans Solenoid Valve Y6
23 0_DL Bk-0.8 Signal Ground 22 25S LU-0.8 Output Sw Power VPS1
24 None 23 0_HA Bk-1.0 Signal Ground
25 61C_B Or-0.8 AC Comp Clutch 24 None
26 61A_B Or-0.8 AC Relay Power 25 61C_A Or-1.0 AC Comp Clutch
27 61R_B Or-0.8 AC Relay Signal 26 61A_A Or-1.0 AC High Pressure Switch
28 0_DN Bk-0.8 Out Speed Sensor Ground 27 61R_A Or-1.0 AC High Pressure Switch
29 19A_M Or-0.8 Cab Switched Power 28 0_HE Bk-1.0 Out Speed Ground
30 0_DAU Bk-0.8 Analog Ground 29 19A Or-1.0 Out Speed Power
31 32F_A Y-0.8 Trans Filter Maint Switch 30 0_HC Bk-1.0 Analog Ground
31 32F Y-1.0 Trans Filter Maint Switch

4002-100
CONNECTOR 23F - CAB MAIN HARNESS TO CAB CONNECTOR 24F - CAB ROOF HARNESS TO
ROOF HARNESS CAB MAIN HARNESS
3195530R1
3195530R1
A 68C_A Or-1.0 Rear Wiper Park A None
B 0_DT Bk-1.0 Dome Court Work Light Ground B None
C 0_DU Bk-1.0 Beacon Wiper Diode Ground C None
D 19U_A Or-1.0 Dome Light Horn Fused Power D None
46_A K-0.8 E 0_MN Bk-0.8 Dome Courtesy Light Ground

E Beacon Switched Power
46_C K-1.0 F 49_V S-0.8 Courtesy Pilot Light
F 19K_B Or-1.0 Rear Wiper Wash Fused Power G 0_MK Bk-1.0 Front Work Light Ground
G 68L_A Or-1.0 Rear Wiper Low Speed H 42C_D DU-1.0 Front Work Lights Power
H 42R_B DU-0.8 Rear Work Light Power
CONNECTOR 24M - CAB MAIN HARNESS TO

CONNECTOR 23M - CAB ROOF HARNESS TO CAB ROOF HARNESS
CAB MAIN HARNESS
245430C1
245430C1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A None
A 68C_B Or-1.0 Rear Wiper Park B None
B 0_MG Bk-1.0 Rear Work Light Ground C None
C 0_MD Bk-1.0 Beacon Rear Wiper Ground D None
D 19U_D Or-1.0 Dome Light Fused Power E 0_DR Bk-1.0 Dome Court Work Light Ground
E 46_D K-1.0 Beacon Switched Power F 49_S S-1.0 Courtesy Pilot Light
F 19K_E Or-1.0 Rear Wiper Wash Fused Power G 0_DS Bk-1.0 Dome Court Work Light Ground
G 68L_C Or-1.0 Rear Wiper Low Speed H 42C_A DU-1.0 Front Flood Lights
H 42R_F DU-1.0 Rear Work Light Power

4002-101
CONNECTOR 25F - FIVE POSITION ROTARY CONNECTOR 29M - BLOWER MOTOR TO CAB
LAMP SWITCH TO CAB MAIN HARNESS MAIN HARNESS
255058C1
631801C1
1 62L Or-1.0 Blower Low Speed
A 41J_B K-2.0 Driving Light Signal
2 62M Or-2.0 Blower Medium Speed
3 62H Or-2.0 Blower High Speed
CONNECTOR 27M - AC LOW PRESSURE SWITCH 4 0_DZ Bk-2.0 Blwr Wpr Seat Ground
TO CAB MAIN HARNESS
CONNECTOR 30F - BLOWER SWITCH TO CAB

MAIN HARNESS
245482C1

A 61R_E Or-0.8 AC Low Pressure Switch
B 61A_E Or-0.8 AC Low Pressure Switch
449797C1

CONNECTOR 28M - SEAT COMPRESSOR MOTOR 1 None
TO CAB MAIN HARNESS
2 19G Or-2.0 Blower Switch Fused Power
6 61T Or-1.0 AC Thermostat Power
245482C1

A 19N_A Or-1.0 Access Seat Fused Pwr (3 Way)
B 0_DY Bk-1.0 Blower Wpr Seat Ground

4002-102
CONNECTOR 31 - FILTER MAINTENANCE CONNECTOR 33F - FIVE POSITION ROTARY
SWITCH TO TRANSMISSION HARNESS LAMP SWITCH TO CAB MAIN HARNESS
266516C1
371614A1
1 32F Y-1.0 Trans Filt Maint Sw 41J_A K-2.0

A Driving Light Signal
41J_B K-2.0
2 36R_B P-1.0 Valve Body Temp Ret
B 41T_B K-1.0 Tail Light Switched Power
C 1_N R-3.0 Light Switch Power
CONNECTOR 32F - FIVE POSITION ROTARY
LAMP SWITCH TO CAB MAIN HARNESS
225287C1

42R_B DU-0.8 245423C1
A Rear Work Light Power
42R_C DU-0.8 CAV WIRE IDENT CIRCUIT
B 18A Or-2.0 Rear Fld Lts Fused Power A 42C_A DU-1.0 Front Flood Lights
41T_A K-1.0 49_J S-0.8
C Tail Light Switched Power B Pilot Light
41T_B K-1.0 49_K S-1.0
C 19Z Or-1.0 Front Flood Illum Fused Power

4002-103
CONNECTOR 35F - WIPER AND WASHER CONNECTOR 37 - PILOT CONTROL SWITCH TO
SWITCH TO CAB MAIN HARNESS PEDESTAL HARNESS
892136C1
382391A1
1 0_DAR Bk-1.0 Blower Wiper Seat Ground
1 None
19J_A Or-1.0
2 Front Wip Wash Fused Power 2 19C Or-0.8 Pilot Control Signal
19J_B Or-0.8
3 31L Y-0.8 Pilot Lockout Signal
3 63W_A Or-0.8 Front Washer Pump
4 None
4 63C_A Or-0.8 Front Wiper Park
5 None
63H_A Or-0.8
5 Front Wiper High Speed
63H_B Or-0.8 6 None
63L_A Or-0.8 0_KH Bk-0.8
6 Front Wiper Low Speed 7 Pilot Light Ground
63L_B Or-0.8 0_KJ Bk-0.8
49_B S-0.8
8 Pilot Light
49_C S-0.8
CONNECTOR 36F - DETENT SWITCH TO CAB 9 None
MAIN HARNESS
10 None
382391A1

1 None
2 53P_B W-0.8 Pilot Control Signal
3 56_H W-0.8 Detent Switched Power
4 None
5 None
6 None
0_DAJ Bk-1.0
7 Switch Ground
0_DAK Bk-1.0
49_M S-1.0
8 Pilot Light
49_N S-1.0
9 None
10 None

4002-104
CONNECTOR 38F - DECLUTCH SWITCH TO CAB CAV WIRE IDENT CIRCUIT
MAIN HARNESS
49_K S-1.0
8 Pilot Light
49_M S-1.0
9 None
10 None
CONNECTOR 40F - PIN ENGAGE SWITCH TO

CAB MAIN HARNESS
382391A1

25G_A LU-0.8
1 Declutch Switch
25G_B LU-0.8
2 19A_R Or-0.8 Cab Switched Power
3 None
4 None
382391A1
5 None
6 None
7 0_DAK Bk-1.0 Switch Ground 1 57_A W-0.8 Pin Engage Solenoid Power
19P_A Or-1.0
8 49_N S-1.0 Pilot Light 2 Fan Rev Pin Eng Fused Power
19P_B Or-1.0
9 None
3 None
10 None
4 None
5 None
CONNECTOR 39F - RETURN-TO-TRAVEL 6 None
SWITCH TO CAB MAIN HARNESS 7 None
8 None
0_DAF Bk-1.0
9 Switch Ground
0_DAL Bk-1.0
49_H S-0.8
10 Pilot Light
49_P S-1.0
382391A1

0_DAH Bk-1.0
1 Switch Ground
0_DAJ Bk-1.0
3 54B_B W-0.8 RTT Float Switch Load
4 None
5 None
6 None
0_DAG Bk-1.0
7 Switch Ground
0_DAH Bk-1.0

4002-105
CONNECTOR 41F - TRANSMISSION AUTO CAV WIRE IDENT CIRCUIT
SWITCH TO CAB MAIN HARNESS
49_R S-1.0
8 Pilot Light
49_T S-1.0
9 None
10 None
CONNECTOR 44F - RIDE CONTROL SWITCH TO

CAB MAIN HARNESS
382391A1

1 None
2 19A_Q Or-0.8 Cab Switched Power
4 None
5 None 382391A1
6 None CAV WIRE IDENT CIRCUIT

7 0_DAM Bk-1.0 Switch Ground 1 None
8 49_Q S-1.0 Pilot Light 2 19C_B Or-1.0 Ride Ctrl Fused Power
9 None 3 58S W-0.8 Ride Control Relay Power
10 None 4 None
5 None
6 58_B W-0.8 Ride Cntrl Sol Power
CONNECTOR 42F - BEACON SWITCH TO CAB
MAIN HARNESS 0_DAL Bk-1.0
7 Switch Ground
0_DAM Bk-1.0
49_P S-1.0
8 Pilot Light
49_Q S-1.0
9 None
10 None
382391A1

1 None
2 19X Or-1.0 Beacon Switch Fused Power
3 46_C K-1.0 Beacon Switched Power
4 None
5 None
6 None
0_DAP Bk-1.0
7 Ground
0_DAW Bk-1.0

4002-106
CONNECTOR 45F - REAR WIPER AND WASHER CONNECTOR 48F - IGNITION RELAY NO. 2 TO
SWITCH TO CAB MAIN HARNESS CAB MAIN HARNESS
382391A1
245731C1
1 68C_A Or-1.0 Rear Wiper Park
30 1_T R-3.0 Ign Relay No. 2 Power
68L_A Or-1.0
2 Rear Wiper Low Speed 0_DE Bk-0.8
68L_B Or-0.8 85 Relay Ground
0_DF Bk-0.8
3 19K_C Or-1.0 Rear Wip Wash Fused Power
13K_A Or-1.0
4 None 86 Ignition Switch Power
13K_B Or-1.0
5 19K_D Or-0.8 Rear Wip Wash Fused Power 87 13R Or-1.0 Ignition Relay 2 Out (5 Way)
6 68W_A Or-1.0 Rear Washer Pump 87A None
7 0_DW Bk-0.8 Ground
8 49_L S-0.8 Pilot Light
CONNECTOR 49F - ACCESSORY RELAY TO CAB
9 None
MAIN HARNESS
10 None
CONNECTOR 47F - IGNITION RELAY NO. 1 TO

CAB MAIN HARNESS
245731C1

30 1_G R-3.0 ACC Relay Power
0_DF Bk-0.8
245731C1
85 Relay Ground
0_DC Bk-0.8
CAV WIRE IDENT CIRCUIT 12K_A Or-1.0
86 ACC Power
30 1_S R-3.0 Ign Relay No. 1 Power 12K_B Or-0.8
87 12P_A Or-1.0 ACC Relay
85 0_DE Bk-0.8 Relay Ground
86 13K_A Or-1.0 Ignition Switch Power 87A None
13P_A Or-1.0
87 Ignition Relay 1 Out
13P_B Or-1.0
87A None

4002-107
CONNECTOR 50F - RIDE CONTROL RELAY TO CONNECTOR 52F - ETHER START RELAY TO
CAB MAIN HARNESS CAB MAIN HARNESS
245731C1 245731C1

30 58S W-0.8 Ride Control Relay Power 30 19E Or-1.0 Ether Start Relay Fused Power
85 0_DD Bk-0.8 Ride Control Relay Ground 0_DC Bk-0.8
85 Relay Ground
86 58H_B W-0.8 Ride Control Signal 0_DG Bk-0.8
58_A W-0.8 86 28C_A W-0.8 Ether Start Control

87 Ride Control Solenoid Power
58_B W-0.8 87 28P-A W-0.8 Ether Solenoid
87A None 87A None
CONNECTOR 51F - HORN RELAY TO CAB MAIN CONNECTOR 53F - BACKUP ALARM RELAY TO
HARNESS CAB MAIN HARNESS
245731C1
245731C1

19U_B Or-1.0 30 19H Or-1.0 Backup Alrm Rly Fuse Power
30 Dome Light Horn Fused Power
19U_C Or-0.8
86 19A_P Or-0.8 Cab Switched Power
86 19U_C Or-0.8 Dome Light Horn Fused Power
35A_E Y-0.8
87 64_A Or-0.8 Horn 87 Backup Alarm Relay Out
35A_D Y-0.8
87A None 87A None

4002-108
CONNECTOR 54F - NEUTRAL START RELAY TO CONNECTOR 56F - PILOT CONTROL RELAY TO
245731C1 245731C1

30 21K_A W-0.8 Ign Switch Start Signal 19C_D Or-1.0
30 Pilot Ride Control Fused Power
19C_E Or-1.0
0_DH Bk-0.8
85 Relay Ground
0_DJ Bk-0.8 85 53C_A W-0.8 Pilot Control Signal
86 25T_E LU-0.8 Neutral Signal 86 19C_E Or-1.0 Pilot Ride Control Fused Power
21C_E W-0.8 53P_A W-0.8
87 Starter Fuel Relay Signal
21C_F W-0.8 87 53P_B W-0.8 Pilot Control Signal
53P_C W-0.8
87A None
87A None
CONNECTOR 55F - PARKING BRAKE RELAY TO

CAB MAIN HARNESS CONNECTOR 57F - RELAY SOCKET N0. 11 TO
CAB MAIN HARNESS
245731C1
245731C1
19D_A Or-1.0
30 Park Brake Relay Fused Power 13K_B Or-1.0
19D_B Or-1.0
30 13K_C Or-1.0 Ignition Switch Power
85 52C_A W-0.8 Parking Brake Signal 13K_D Or-0.8
86 19D_B Or-1.0 Park Brake Relay Fused Power 85 23C_A W-0.8 Engine Shutdown Signal
52P_B W-0.8 86 19F Or-1.0 Engine Shtdwn Rly Fused Pwr
87 Park Brake Relay Out
52P_A W-0.8
13C_B Or-0.8
87A None 87 13C_C Or-0.8 Fuel Solenoid Power
13C_D Or-0.8
87A None

4002-109
CONNECTOR 58F - VOLTMETER RELAY TO CAB CONNECTOR 60 - FRONT WIPER MOTOR TO
MAIN HARNESS PEDESTAL HARNESS
245480C1
245731C1
CAV WIRE IDENT CIRCUIT 1 0_KN Bk-0.8 Front Wiper Ground
30 1_P R-0.8 Voltmeter Relay Power
0_DG Bk-0.8
85 Relay Ground
0_DH Bk-0.8 CONNECTOR 61 - FRONT WIPER MOTOR TO
13K_C Or-1.0 PEDESTAL HARNESS
86 Ignition Switch Power
13K_E Or-0.8
87 13V Or-1.0 Voltmeter Relay Out
87A None
CONNECTOR 59F - HIGH/LOW BEAM RELAY TO

CAB MAIN HARNESS
245715C1

A 63H Or-0.8 Front Wiper High Speed
B 63L Or-0.8 Front Wiper Low Speed
C 19J Or-0.8 Front Wiper Wash Fused Power
194791A1
D 63C Or-0.8 Front Wiper Park
1 41J_A K-2.0 High/Low Beam Signal
3 41L_A K-2.0 Low Beam Power
4 41H K-2.0 Hi/Low Beam Relay Power
6 64D_A Or-0.8 Low Beam Signal (2 Way)
8 1_H R-3.0 High Beam Signal (2 Way)

4002-110
CONNECTOR 62M - FLASHER MODULE TO CAB CONNECTOR 64F - FLASHER MODULE TO CAB
MAIN HARNESS MAIN HARNESS
225389C1 739070C1

1 1B_B R-0.8 Flasher Module Power 1 45N_A N-0.8 Flasher Opp Side Control
2 45N_A N-0.8 Flasher Opp Side Control
3 0_DAN Bk-0.8 Flasher Module Ground
CONNECTOR 64M - FLASHER MODULE TO CAB
4 0_DAQ Bk-0.8 Flasher Module Ground MAIN HARNESS
5 None
6 None
7 45R_E N-0.8 Right Turn Signal
8 45L_D N-0.8 Left Turn Signal
9 45B_A N-0.8 Right Turn Switch Power
10 45A_A N-0.8 Left Turn Switch Power
11 45H_A N-0.8 Hazard Switch Power
12 45N_B N-0.8 Flasher Opp Side Control
631801C1
CONNECTOR 63M - TIME DELAY MODULE TO
CAB MAIN HARNESS CAV WIRE IDENT CIRCUIT
CONNECTOR 65F - ETHER START SOLENOID TO

ETHER START TEMPERATURE SWITCH
225351C1

1 13D Or-1.0 Delay Power (2 Way)
2 1A_E R-0.8 Time Delay Power
3 0_DAS Bk 0.8 Time Delay Module Ground 245481C1
4 37R_C P-0.8 Reset Signal CAV WIRE IDENT CIRCUIT

5 13K_F Or-0.8 Ignition Switch Power 1 28T_A W-1.0 Ether Start Temp Switch
6 None

4002-111
CONNECTOR 65M - ETHER START CONNECTOR 68 - TURN SIGNAL SWITCH TO
TEMPERATURE SWITCH TO ETHER START PEDESTAL HARNESS
SOLENOID
1964527C1

245480C1
1 45B N-0.8 Right Turn Switch Power
1 28T W-1.0 Ether Start Temp Switch
CONNECTOR 69 - IGNITION SWITCH TO
PEDESTAL HARNESS
CONNECTOR 66 - TURN SIGNAL SWITCH TO
PEDESTAL HARNESS
1964527C1 225253C1
1 45A N-0.8 Left Turn Switch Power 1A_A R-0.8

1 Ign Prog Reset Sw Power
1A_B R-0.8
2 21K W-0.8 Ign Switch Start Signal
CONNECTOR 67 - TURN SIGNAL SWITCH TO 3 13K Or-0.8 Ignition Switch Power
PEDESTAL HARNESS 4 12K_C Or-0.8 Ign Switch Acc Power
5 None
6 None
1964527C1

1 19B Or-0.8 Turn Signal Power

4002-112
CONNECTOR 70 - TRANSMISSION SHIFTER TO CONNECTOR 72 - PARKING BRAKE SWITCH TO
PEDESTAL HARNESS PEDESTAL HARNESS
382391A1
245486C1
1 None
A 19A_H Or-0.8 Trans Control Power
19A_H Or-0.8
B 25F LU-0.8 Forward Signal 2 Trans Control Power
19A_G Or-0.8
C 25R LU-0.8 Reverse Signal
3 33U Y-0.8 Park Brake Signal
D 25T_A LU-0.8 Neutral Signal 4 None
5 None
CONNECTOR 71 - HAZARD SWITCH TO 6 None

PEDESTAL HARNESS 0_KJ Bk-0.8
7 Pilot Light Ground
0_KK Bk-0.8
49_C S-0.8
8 Pilot Light
49_D S-0.8
9 None
10 None
382391A1

1 None
2 1B R-0.8 Hazard Switch Power
3 45H N-0.8 Hazard Switch Power
4 None
5 None
6 None
7 0_KH Bk-0.8 Pilot Light Ground
49_A S-0.8
8 Pilot Light
49_B S-0.8
9 None
10 None

4002-113
CONNECTOR 74 - UP/DOWN COUNT SWITCH TO CONNECTOR 75 - PROGRAM/RESET SWITCH TO
382391A1 382391A1
1 37D P-0.8 Down Count Signal 37R_A P-0.8

1 Reset Signal
37R_B P-0.8
19S_A Or-0.8
2 Instr Cluster Fused Del Power 2 1A_B R-0.8 Ign Prog Reset Switch Power
19S_B Or-0.8
3 37U P-0.8 Up Count Signal 3 37P P-0.8 Program Signal
4 None 4 None
5 None 5 None
6 None 6 None
0_KK Bk-0.8 0_KL Bk-0.8

7 Pilot Light Ground 7 Pilot Light Ground
0_KL Bk-0.8 0_KM Bk-0.8
49_D S-0.8 8 49_E S-0.8 Pilot Light

8 Pilot Light
49_E S-0.8 9 None
9 None 10 None
10 None

4002-114
CONNECTOR 76 - INSTRUMENT CLUSTER TO CAV WIRE IDENT CIRCUIT
PEDESTAL HARNESS
33 50T Bk-0.8 CAN T
34 None
37 0_KQ Bk -0.8 Signal Ground
38 0_KE Bk-0.8 Signal Ground
40 None
CONNECTOR 77F - COURTESY LAMP TO CAB

282763A1
MAIN HARNESS
1 19V_A Or-0.8 Cluster Main Fused Power
2 19S_B Or-0.8 Instr Cluster Fused Del Power
3 33P_B Y-0.8 Low Brake Pres Warning
4 31D_B Y-0.8 Coolant Level Signal
5 35X_F Y-0.8 Sec Str Low Press Sig
6 31F_C Y-0.8 Air Filter Rest Sw Signal
7 31H_B Y-0.8 Hyd Filter Rest Sw Signal
8 0_KP Bk-0.8 Analog Ground
9 33U Y-0.8 Park Brake Signal 291729A1
10 61R_G Or-0.8 A/C Telltale CAV WIRE IDENT CIRCUIT
11 None A 49_V S-0.8 Courtesy Pilot Lamp
12 42R_A Y-0.8 Work Light Telltale Sig B 0_ML Bk-0.8 Courtesy Lamp Ground
13 46_B K-0.8 Beacon Telltale

14 None
CONNECTOR 78F - RH FRONT WORK LAMP TO
15 18C_C Or-0.8 High Beam Telltale CAB MAIN HARNESS
16 45L_F N-0.8 Left Turn Signal
17 45R_F N-0.8 Right Turn Signal
18 36C_C P-0.8 ECT Signal
19 36F_B P-0.8 Fuel Level Signal
20 36H_B P-0.8 Hot Signal
21 50T Bk-0.8 CAN T
22 36P_C P-0.8 EOP Signal
23 23C W-0.8 Engine Shutdown Signal
245483C1
24 37P P-0.8 Program Signal
25 37R_B P-0.8 Reset Signal
A 42C_C DU-1.0 RH Front Work Lamp Power
26 37U P-0.8 Up Count Signal
B 0_MJ Bk-1.0 RH Front Work Lamp Ground
27 37D P-0.8 Down Count Signal
31 50L G-0.5 CAN L
32 50H Y-0.5 CAN H

4002-115
CONNECTOR 79F - LH FRONT WORK LAMP TO CONNECTOR 81M - REAR WIPER MOTOR TO
245483C1

245715C1
A 42C_B DU-1.0 LH Front Work Lamp Power
B 0_MH Bk-1.0 LH Front Work Lamp Ground
A None
B 68L_C Or-1.0 Rear Wiper Low Speed
CONNECTOR 80F - RH REAR WORK LAMP TO C 19K_E Or-1.0 Rear Wpr Wash Fused Power
CAB MAIN HARNESS
D 68C_B Or-1.0 Rear Wiper Park
CONNECTOR 82M - REAR WIPER MOTOR TO

CAB MAIN HARNESS
245483C1

A 42R_E DU-1.0 RH Rear Work Lamp Power
B 0_MF Bk-1.0 RH Rear Work Lamp Ground
245480C1

1 0_MA Bk-1.0 Rear Wiper Motor Ground

4002-116
CONNECTOR 83F - LH REAR WORK LAMP TO CONNECTOR 85F - BEACON LAMP TO CAB MAIN
CAB MAIN HARNESS HARNESS
245483C1
CAV WIRE IDENT CIRCUIT 245426C1
A 42R_D DU-1.0 LH Rear Work Lamp Power CAV WIRE IDENT CIRCUIT
B 0_ME Bk-1.0 LH Rear Work Lamp Ground A 46_D K-1.0 Beacon Switched Power
B 0_MC Bk-1.0 Beacon Lamp Ground
CONNECTOR 84F - DOME LAMP TO CAB MAIN

HARNESS
CONNECTOR 86 - REDUNDANT BRAKE SWITCH
TO REAR CHASSIS HARNESS
245483C1
266516C1
A 33R_B Y-1.0 Redundant Brake Switch Sig
A 19U_D Or-1.0 Dome Lamp Fused Power
B 0_M Bk-1.0 Ground
0_MB Bk-0.8
B Dome Lamp Ground
0_MM Bk-0.8
C 0_MM Bk-0.8 Dome Lamp Ground CONNECTOR 87 - PARKING BRAKE SOLENOID
291718A1

1 52P W-1.0 Parking Brake Relay Out
2 0_Q Bk-1.0 Park Str Fuel Relay Ground

4002-117
CONNECTOR 88 - BRAKE PRESSURE WARNING CONNECTOR 90M - SECONDARY STEERING
SWITCH TO REAR CHASSIS HARNESS MODULE TO SECONDARY STEERING HARNESS
225389C1
222135A1
1 19R_C Or-1.0 Secondary Steering Ignition
A 33P Y-1.0 Low Brake Press Warning
2 51_A W-1.0 Secondary Steer Mtr Rel
B 0_N Bk-1.0 Brake Press Warning Switch
3 1_W R-1.0 Secondary Steer Module B+
4 0_CE Bk-1.0 Secondary Steer Chassis Grnd
CONNECTOR 89M - PILOT PRESSURE 5 None
SOLENOID TO CAB MAIN HARNESS 6 None
7 19M_C Or-1.0 Secondary Steer Accessory
8 35X_D Y-1.0 Secondary Steer Low Press Sig
9 51P_A W-1.0 Secondary Steer High Press
10 None
11 0_CA Bk-1.0 Secondary Steer Signal Grnd
12 0_CB Bk-1.0 Secondary Steer Signal Grnd
245482C1 CONNECTOR 92 - ETHER START SWITCH TO

PEDESTAL HARNESS
A 53P_A W-0.8 Pilot Control Signal
B 0_DB Bk-0.8 CAN Pilot Solenoid Ground
739070C1

25T_A LU-0.8
1 Neutral Signal
25T_B LU-0.8

4002-118
CONNECTOR 93F - REAR CHASSIS HARNESS CONNECTOR 94F - TRANSMISSION HARNESS
TO FUEL AND STARTER RELAY HARNESS TO ENGINE HARNESS
245483C1

A 21C_D W-1.0 Starter Fuel Relay Signal 291659A1
B 0_U Bk-2.0 Part Str Fuel Relay Ground CAV WIRE IDENT CIRCUIT
1 13C_A Or-1.0 Fuel Solenoid
2 61A_A Or-1.0 AC High Pressure Switch
CONNECTOR 93M - FUEL AND STARTER RELAY
HARNESS TO REAR CHASSIS HARNESS 3 61R-A Or-1.0 AC High Pressure Switch
4 61C_A Or-1.0 AC Comp Clutch
5 14_A LG-1.0 Alternator D+
6 36P_A P-1.0 EOP Sender
7 31F_A Y-1.0 Air Filter Rest Switch Signal
8 None
9 0_HA Bk-1.0 Signal Ground
10 None
11 0_HB Bk-1.0 Signal Ground
245482C1 12 None
CAV WIRE IDENT CIRCUIT 13 36C_A P-1.0 ECT Sender
A 21C_C W-1.0 Starter Fuel Relay Signal 14 None
B 0_GA Bk-2.0 Relay Ground 15 0_HC Bk-1.0 Analog Ground
16 None
17 None
18 None
19 None

4002-119
CONNECTOR 94M - ENGINE HARNESS TO CONNECTOR 95 - INTERMEDIATE SPEED
TRANSMISSION HARNESS SENSOR TO TRANSMISSION HARNESS
291718A1
373356A1
CAV WIRE IDENT CIRCUIT 1 0_HG Bk-0.8 Intermediate Speed Signal
1 13C Or-1.0 Fuel Solenoid 2 25C W-0.8 Intermediate Speed Signal
2 61A Or-1.0 AC High Pressure Switch
3 61R Or-1.0 AC High Pressure Switch
CONNECTOR 96 - TURBINE SPEED SENSOR TO
4 61C Or-1.0 AC Comp Clutch
TRANSMISSION HARNESS
5 14 LG-1.0 Alternator D+
6 36P P-1.0 EOP Sender
7 31F Y-1.0 Air Filter Rest Switch Signal
8 None
9 0_BF Bk-1.0 Signal Ground
10 None
11 0_BH Bk-1.0 Signal Ground
12 None
13 36C P-1.0 ECT Sender
14 None
291718A1
15 0_BG Bk-1.0 Analog Ground
16 None
1 25B W-0.8 Turbine Speed Signal
17 None
2 0_HH Bk-0.8 Turbine Speed Ground
18 None
19 None
CONNECTOR 97 - ETHER START TEMPERATURE
SWITCH TO ENGINE HARNESS
245483C1

A 28T W-1.0 Ether Start Temperature Switch
B 0_BC Bk-1.0 Ether Fuel Solenoid Ground

4002-120
CONNECTOR 98 - AC HIGH PRESSURE SWITCH CONNECTOR 101 - ENGINE SPEED SENSOR TO
TO ENGINE HARNESS TRANSMISSION HARNESS
245482C1

291718A1
A 61A Or-1.0 AC High Pressure Switch
B 61R Or-1.0 AC High Pressure Switch
1 25A W-0.8 Engine Speed Signal
2 0_HF Bk-0.8 Engine Speed Ground
CONNECTOR 99 - AC COMPRESSOR CLUTCH
TO ENGINE HARNESS CONNECTOR 102 - TRANSMISSION CONTROL
VALVE TO TRANSMISSION HARNESS
245480C1

1 61C Or-1.0 AC Compressor Clutch
371566A1

CONNECTOR 100 - OUTPUT SPEED SENSOR TO 1 25K LU-0.8 Trans Solenoid Valve Y1
2 25L LU-0.8 Trans Solenoid Valve Y2
3 25M LU-0.8 Trans Solenoid Valve Y3
4 25N LU-0.8 Trans Solenoid Valve Y4
5 25P LU-0.8 Trans Solenoid Valve Y5
6 25J LU-0.8 Trans Solenoid Valve Y6
7 25S LU-0.8 Output Sw Power VPS1
8 36T P-0.8 Valve Body Temp Signal
9 36R_C P-0.8 Valve Body Temp Ret
10 None
11 None
291719A1 12 None
CAV WIRE IDENT CIRCUIT 13 None
1 0_HE Bk-1.0 Output Speed Ground 14 None
2 25D LU-1.0 Output Speed Signal 15 None
3 19A Or-1.0 Output Speed Power 16 None

4002-121
CONNECTOR 103 - ETHER START SOLENOID TO CONNECTOR 108F - DIAGNOSTIC CONNECTOR
245483C1

291663A1
A 28P W-1.0 Ether Solenoid
B 28T_A W-1.0 Ether Start Temp Switch
1 19A_L Or-0.8 Cab Switched Power
CONNECTOR 104 - COOLANT LEVEL SENDER 3 0_DAV Bk-0.8 Diagnostic TECM Ground
5 None
6 None
CONNECTOR 109M - RADIO POWER

CONVERTER TO RADIO HARNESS
194788A1

A 31D Y-1.0 Coolant Level Signal
B 0_V Bk-1.0 Fuel Rdndnt Brake Cool Ground
CONNECTOR 107M - PIN ENGAGE SOLENOID TO

FRONT CHASSIS HARNESS
291730A1

A 19L_A Or-1.0 Radio Power
B 0_PD Bk-1.0 Radio Ground
245482C1

A 57 W-1.0 Pin Engage Solenoid Power
B 0_AB Bk-1.0 Pin Engage Ground

4002-122
CONNECTOR 110F - RADIO POWER CONNECTOR 113 - RADIO TO REMOTE RADIO
CONVERTER TO RADIO HARNESS ADAPTOR HARNESS
1 None
2 0_QB Bk-0.8 Right Speaker Ground
3 None
4 0_QA Bk-0.8 Left Speaker Ground
5 0_QC Bk-0.8 Radio Ground
6 18_ H Or-0.8 Radio Power
7 None
8 None
245426C1
9 65R_A Or-0.8 Right Speaker Signal
10 None
A 65C Or-0.8 Radio Power
11 65L_A Or-0.8 Left Speaker Signal
B 0_PC Bk-0.8 Radio Ground
12 None
13 None
CONNECTOR 111M - RIGHT SPEAKER TO RADIO 14 65C_B Or-0.8 Radio Power
HARNESS
CONNECTOR 114F - RADIO ADAPTOR TO RADIO

HARNESS
195552A1

A 65R Or-0.8 Right Speaker Signal
B 0_PB Bk-0.8 Right Speaker Ground
892136C1

CONNECTOR 112M - LEFT SPEAKER TO RADIO 1 65L Or-0.8 Left Speaker Signal
HARNESS
2 0_PA Bk-0.8 Left Speaker Ground
3 0_PC Bk-0.8 Radio Ground
4 0_PB Bk-0.8 Right Speaker Ground
5 65R Or-0.8 Right Speaker Signal
6 65C Or-0.8 Radio Power
195552A1

A 65L Or-0.8 Left Speaker Signal
B 0_PA Bk-0.8 Left Speaker Ground

4002-123
CONNECTOR 114M - RADIO ADAPTOR TO CONNECTOR 118F - BACKUP ALARM DISABLE
REMOTE RADIO ADAPTOR HARNESS SWITCH TO CAB MAIN HARNESS
449797C1 382391A1
1 65L_A Or-0.8 Left Speaker Signal 35R_C Y-0.8

1 Backup Alarm Switch
35R_D Y-0.8
2 0_QA Bk-0.8 Left Speaker Ground
35A_E Y-0.8
3 0_QC Bk-0.8 Radio Ground 2 Backup Alarm Relay Out
35A_F Y-0.8
4 0_QB Bk-0.8 Right Speaker Ground 3 None
5 65R_A Or-0.8 Right Speaker Signal 4 None
6 65C_B Or-0.8 Radio Power 5 None
6 None
0_DW Bk-0.8
CONNECTOR 117 - AIR FILTER RESTRICTION 7 Ground
0_DAW Bk-1.0
SWITCH TO ENGINE HARNESS
49_L S-0.8
8 Pilot Light
49_T S-1.0
9 None
10 None
CONNECTOR 125 - LH REAR COMBINATION

LAMP TO REAR CHASSIS HARNESS
291718A1

A 31F Y-1.0 Air Fltr Restriction Switch Signal
B 0_BD Bk-1.0 Air Fltr Restriction Switch Grnd
225351C1

1 44_A T-1.0 Brake Light Signal
2 45L_A N-1.0 Left Turn Signal
3 18F_A Or-1.0 Left Tail
4 35A_A K-1.0 Left Reverse
5 0_A Bk-1.0 Ground
6 None

4002-124
CONNECTOR 127 - RH REAR COMBINATION CONNECTOR 128M - HOOD HARNESS TO REAR
LAMP TO REAR CHASSIS HARNESS CHASSIS HARNESS
245484C1
225351C1
1 44_B T-1.0 Brake Light Signal A 18G_E Or-1.0 License Plate Light
2 45R_A N-1.0 Right Turn Signal B 35R_A Y-1.0 Backup Alarm Switch
3 18G_A Or-1.0 Right Tail C 0_JA Bk-1.0 Hood Ground
4 35A_B K-1.0 Right Reverse

5 0_C Bk-1.0 Ground CONNECTOR 131F - SECONDARY STEERING
6 None PRESSURE SWITCH TO FRONT CHASSIS
HARNESS
CONNECTOR 128F - REAR CHASSIS HARNESS

TO HOOD HARNESS
245485C1

A 51P_B W-1.0 Secondary Steer High Pressure
245485C1
B 0_AN Bk-1.0 Secondary Steer Signal Ground
C 35X_A Y-1.0 Secondary Steer Low Press Sig
A 18G_C Or-1.0 License Plate Light
B 35R_B Y-1.0 Backup Alarm Switch
C 0_J Bk-1.0 Hood Grounds CONNECTOR 133F - FUEL AND STARTER RELAY
HARNESS TO ENGINE HARNESS
245481C1

1 23F_A W-20 Fuel Solenoid Pull In

4002-125
CONNECTOR 133M - ENGINE HARNESS TO CONNECTOR 138 - ENGINE COOLANT
FUEL AND STARTER RELAY HARNESS TEMPERATURE SENDER TO ENGINE HARNESS
194788A1

245480C1
A 36C P-1.0 ECT Signal
CAV WIRE IDENT CIRCUIT B 0_BE Bk-1.0 ECT Ground
1 23F W-2.0 Fuel Solenoid Pull In
CONNECTOR 139F - ENGINE HARNESS TO

CONNECTOR 134 - FUEL SHUTOFF SOLENOID DISCONNECT HARNESS
HARNESS TO ENGINE HARNESS
245483C1

245484C1
A 13C Or-1.0 Fuel Solenoid
B 13M Or-1.0 Fuel Solenoid Hold In
A 13M Or-1.0 Fuel Solenoid Hold In
B 23F W-2.0 Fuel Solenoid Pull In
C 0_BB Bk-2.0 Ether Fuel Solenoid Ground CONNECTOR 139M - DISCONNECT HARNESS TO
ENGINE HARNESS
CONNECTOR 136 - HYDRAULIC OIL

TEMPERATURE SENDER TO REAR CHASSIS
HARNESS
245482C1

194788A1 A 13C_E Or-1.0 Fuel Solenoid Power
CAV WIRE IDENT CIRCUIT B 13M_A Or-1.0 Fuel Solenoid Hold In
A 36H P-1.0 Hot Signal
B 0_W Bk-1.0 Front Rear Wash Hot Ground

4002-126
CONNECTOR 140M - DIODE MODULE TO CAB CONNECTOR 157 - REDUNDANT BRAKE
MAIN HARNESS PRESSURE SWITCH TO REAR CHASSIS
HARNESS
245483C1
CAV WIRE IDENT CIRCUIT A 33R_A Y-1.0 Red Brake Switch Signal
A 63L_B Or-0.8 Front Wiper Low Speed B 0_L Bk-1.0 Ground
B 63H_B Or-0.8 Front Wiper High Speed

C 0_DAX Bk-0.8 Beacon Wiper Diode Ground CONNECTOR 158 - FAN REVERSING SOLENOID
D 13C_C Or-0.8 Fuel Solenoid Power TO REAR CHASSIS HARNESS
E 21C_F W-0.8 Starter Fuel Relay Signal
F 68L_B Or-0.8 Rear Wiper Low Speed
CONNECTOR 142 - TORQUE CONVERTER

OUTPUT TO TRANSMISSION HARNESS
225316C1

1 52 W-1.0 Fan Reversing Solenoid
2 0_X Bk-1.0 Fan Reversing Solenoid Ground
CONNECTOR 159 - BRAKE LAMP PRESSURE

SWITCH TO REAR CHASSIS HARNESS
291718A1

A 36G P-1.0 TCO Temperature Signal
B 36R_D P-1.0 Valve Body Temperature Ret
222136A1

A 1B_A R-1.0 Brake Lamp Switch Power
B 44 T-1.0 Brake Lamp Input Signal

4002-127
CONNECTOR 168 - LICENSE PLATE LAMP TO CONNECTOR 180F - FRONT CHASSIS HARNESS
HOOD HARNESS TO SECONDARY STEERING MODULE HARNESS
245482C1

225350C1
A 18G_E Or-1.0 License Plate Lamp
B 0_JC Bk-1.0 License Plate Lamp Ground
1 19M_B Or-1.0 Secondary Steering Accessory
2 19R_B Or-1.0 Secondary Steering Ignition
CONNECTOR 178M - FLOAT PRESSURE SWITCH 3 35X_C Y-1.0 Sec Steer Low Pressure Signal
TO FRONT CHASSIS HARNESS
4 51P_B W-1.0 Sec Steer High Pressure
5 0_AN Bk-1.0 Sec Steer Signal Ground
6 None
CONNECTOR 180M - SECONDARY STEERING

MODULE HARNESS TO FRONT CHASSIS
HARNESS
245482C1

A 53P_D W-1.0 Float Solenoid Power
B 53S_A W-1.0 Float Solenoid Signal
CONNECTOR 179F - FLOAT SOLENOID TO

225351C1

1 19M_C Or-1.0 Secondary Steering Accessory
3 35X_D Y-1.0 Sec Steer Low Pressure Signal
4 51P_A W-1.0 Sec Steer High Pressure
5 0_CC Bk-1.0 Sec Steer Signal Ground
6 None
291718A1

1 53S_B W-1.0 Float Solenoid Signal
2 0_AP Bk-1.0 Float Solenoid Ground

4002-128
CONNECTOR 182 - ETHER START SWITCH TO CONNECTOR 197F - CAB MAIN HARNESS TO
PEDESTAL HARNESS FNR HARNESS
739070C1
225350C1
1 28C W-0.8 Ether Start Control
1 19A_C Or-0.8 Transmission Enable Sw Power
CONNECTOR 183 - TRANSMISSION SHIFTER TO 3 26N_B LU-0.8 FNR Neutral Signal
PEDESTAL HARNESS 4 26R_B LU-0.8 FNR Reverse Signal
5 32J_B Y-0.8 Trans Enable LT Signal
6 None
CONNECTOR 197M - FNR HARNESS TO CAB

MAIN HARNESS
245487C1

A None
B 25W LU-0.8 3rd and 4th Gear Signal
C 25Z LU-0.8 1st and 4th Gear Signal
D 25Y LU-0.8 Transmission Kick Down Signal 225351C1

1 19A_B Or-0.8 FNR Switched Power
2 26F_A LU-0.8 FNR Forward Signal
3 26N_A LU-0.8 FNR Neutral Signal
4 26R_A LU-0.8 FNR Reverse Signal
5 32J_A Y-0.8 FNR LT Signal
6 None

4002-129
CONNECTOR 198 - FNR SWITCH TO FNR CAV WIRE IDENT CIRCUIT
HARNESS
49_G S-0.8
8 Pilot Light
49_R S-1.0
32J_B Y-0.8
9 Trans Enable LT Signal
32J_C Y-0.8
19A_C Or-0.8
10 None
19A_E Or-0.8
CONNECTOR 200 - RETURN-TO-DIG PROXIMITY

SWITCH TO RETURN-TO-DIG HARNESS FOR XT
CHASSIS
382391A1

2 26J LU-0.8 FNR Switch Jumper
19A_B Or-0.8
5 FNR Switched Power
19A_F Or-0.8
6 26F-A LU-0.8 FNR Forward Signal 245484C1
7 32J_A Y-0.8 FNR LT Signal CAV WIRE IDENT CIRCUIT
8 19A_F Or-0.8 FNR Switched Power A 53B_A W-1.0 RTD Signal
9 None B 0_AM Bk-1.0 RTD Ground
10 None C 56_D W-1.0 RTD Power
CONNECTOR 199F - TRANSMISSION ENABLE CONNECTOR 202F - DIODE MODULE TO FRONT

SWITCH TO CAB MAIN HARNESS CHASSIS
245485C1
382391A1 CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT A 58_D W-1.0 Ride Control Solenoid Power
1 None B None
19A_D Or-0.8 C 53S_C W-1.0 Float Switch Signal

2 Trans Enable Switched Power
19A_E Or-0.8
4 None
5 None
6 None
0_DAE Bk-1.0
7 Ground
0_DAP Bk-1.0

4002-130
CONNECTOR 203F - COMPRESSOR CLUTCH CONNECTOR 207F - THERMOSTAT SWITCH TO
LOCKOUT RELAY TO CAB MAIN HARNESS CAB MAIN HARNESS
A 61T Or-1.0 Beacon Wiper Diode Ground
CONNECTOR 208F - THERMOSTAT SWITCH TO

CAB MAIN HARNESS
A 61A_D Or-0.8 AC Thermostat
245731C1 CONNECTOR 209F - BACKUP ALARM DISABLE

CAV WIRE IDENT CIRCUIT JUMPER
61A_B Or-0.8
30 Relay Power
61A_C Or-0.8
85 0_DK Bk-0.8 AC BRK LT Time Del Horn Gnd
86 61R_C Or-0.8 AC Relay Signal
61R_B Or-0.8
61R_D Or-0.8
87A 61C_B Or-0.8 AC Comp Clutch
CONNECTOR 204F - BRAKE LAMPS RELAY TO 739070C1

A 35R_D Y-0.8 Backup Alarm Switch
CONNECTOR 209M - BACKUP ALARM DISABLE

JUMPER
245731C1

30 1B_E R-0.8 Brake Lamp Relay Power
0_DA Bk-0.8
85 AC BRK LT Time Del Horn Gnd
0_DK Bk-0.8
86 44A_B T-0.8 Brake LT Input Signal 631801C1
87 44_E T-0.8 Brake LT Relay Signal CAV WIRE IDENT CIRCUIT
87A None A 35A_F Y-0.8 Backup Alarm Relay Out

4002-131
CONNECTOR 210F - FAN REVERSER SWITCH TO CONNECTOR 216F - ALTERNATOR RESISTOR TO
199436A1
382391A1
CAV WIRE IDENT CIRCUIT 1 19R_E Or-0.8 Cab Switched Power
1 None
2 19P_B Or-1.0 Fan Rev Pin Engage Fused Pwr
CONNECTOR 217F - ENGINE SHUTDOWN
3 52_A W-0.8 Fan Reverse Solenoid
JUMPER
4 None
5 None
6 None
0_DAF Bk-1.0
7 Switch Ground
0_DAY Bk-1.0
49_H S-0.8
8 Pilot Light
49_U S-0.8
9 None
10 None
739070C1
CONNECTOR 215F - ALTERNATOR RESISTOR TO CAV WIRE IDENT CIRCUIT
CAB MAIN HARNESS
A 13K_D Or-0.8 Ignition Switch Power
CONNECTOR 217M - ENGINE SHUTDOWN

JUMPER
199436A1

1 14_B LG-0.8 Alternator D+
631801C1

A 13C_B Or-0.8 Fuel Solenoid Power

4002-132
CONNECTOR 229M - DIODE MODULE TO FRONT CONNECTOR 259F - CIGAR LIGHTER TO CIGAR
CHASSIS HARNESS LIGHTER HARNESS
245488C1 3227856R1

A 58_E W-1.0 Ride Control Solenoid Power 1 19W_A Or-3.0 Cigar Lighter Power
B 53S_D W-1.0 Float Solenoid Signal 2 0_S Bk-3.0 Cigar Lighter Ground
C 0_AQ Bk-1.0 Ground
D None
CONNECTOR 260M - FUSE BLOCK TERMINAL 16
E None TO CIGAR LIGHTER HARNESS
F None

TO RADIO HARNESS

TO CONVERTER HARNESS 276720A1

A 19L_B Or-1.0 Converter Power Ignition A 19W_A Or-3.0 Cigar Lighter Power
CONNECTOR 253F - POWER OUTLET TO CONNECTOR 262F - DIODE MODULE TO CAB

CONVERTER HARNESS MAIN CHASSIS HARNESS
245485C1

314908A1
A 19R_F Or-0.8 Secondary Steering Ignition
B None
A 12V_A R-3.0 12 V Power to Outlet
C 19R_D Or-0.8 Secondary Steering Ignition
B 0_RB Bk-3.0 Outlet Ground

4002-133
CONNECTOR 264M - SECONDARY STEERING CONNECTOR 267F - ENGINE HARNESS TO AIR
SOLENOID TO SECONDARY STEERING CONDITIONING DIODE HARNESS
HARNESS
245481C1
225316C1
CAV WIRE IDENT CIRCUIT 1 61C_D Or-1.0 AC Compressor Clutch
1 51_C W-1.0 Sec Steer Solenoid Power
2 0_CF Bk-1.0 Secondary Steering Ground
CONNECTOR 269 - RADIO FUSE HOLDER
(REMOTE RADIO ADAPTER HARNESS)
CONNECTOR 265F - AIR CONDITIONING DIODE CAV WIRE IDENT CIRCUIT
MODULE TO AIR CONDITIONING DIODE
1 1_X R-1.0 Radio Memory Power
HARNESS
2 18_H Or-0.8 Radio Memory Fused Power
CONNECTOR 270F - RADIO MEMORY POWER

245485C1 CONNECTOR 271M - FRONT CHASSIS

CAV WIRE IDENT CIRCUIT ROLLBACK JUMPER HARNESS
A 61C_C Or-1.0 AC Compressor Clutch
B None
C 0_BJ Bk-1.0 Ground
CONNECTOR 266M - AIR CONDITIONING DIODE

HARNESS TO AIR COMPRESSOR CLUTCH
245484C1

A 58_F W-1.0 Float Switch Signal
B None
C 53S_E W-1.0 Ride Control Solenoid Power
245480C1

1 61C_E Or-1.0 AC Compressor Clutch

4002-134
CONNECTOR 272F - ROLLBACK JUMPER CONNECTOR 274F - REAR CHASSIS COOLANT
PRESSURE SWITCH (ROLLBACK SWITCH JUMPER (COOLANT SENSOR JUMPER
JUMPER HARNESS) HARNESS)
A 31D_C Y-0.8 Coolant Level Signal
B 0_VA Y-0.8 Fuel Red Br Coolant Ground
CONNECTOR 275M - COOLANT JUMPER

COOLANT SENDER (COOLANT SENSOR
JUMPER HARNESS)
245483C1

A 58A_A W-1.0 Float Switch Signal
B 58_F W-1.0 Ride Control Solenoid Power
CONNECTOR 273F - ROLLBACK JUMPER DIODE

MODULE (ROLLBACK SWITCH JUMPER
HARNESS) 194788A1

245485C1

A 58A_A W-1.0 Ride Control Solenoid Power
B None
C 53S_E W-1.0 Float Switch Signal

4002-135
INDEX
Symbols Connector 117 ...................................................... 123
12 Volt Radio ..........................................................75 Connector 118F.................................................... 123
24 Volt Radio ..........................................................75 Connector 125 ...................................................... 123
Connector 127 ...................................................... 124
A Connector 128F.................................................... 124
A/C High Pressure Switch (In Rear Chassis) .........72 Connector 128M ...................................................124
A/C Low Pressure Switch (In Cab) .........................72 Connector 12F........................................................ 91
Accessory Relay No. 3 ...........................................42 Connector 12M....................................................... 91
Air Filter Restriction Switch.....................................49 Connector 131F.................................................... 124
Alarm Connector 133F.................................................... 124
Back-up ..............................................................45 Connector 133M ...................................................125
Back-up, Disable Switch ....................................45 Connector 134 ...................................................... 125
Back-up, Relay No. 7 .........................................44 Connector 136 ...................................................... 125
Alternator ................................................................37 Connector 138 ...................................................... 125
Connector 139F.................................................... 125
B Connector 139M ...................................................125
Back-up Alarm ........................................................45 Connector 13F........................................................ 92
Back-up Alarm Disable Switch ...............................45 Connector 13M....................................................... 93
Back-up Alarm Relay No. 7 ....................................44 Connector 140M ...................................................126
Batteries .................................................................36 Connector 142 ...................................................... 126
Beacon Switch ........................................................77 Connector 157 ...................................................... 126
Beacon, Rotating ....................................................78 Connector 158 ...................................................... 126
Blower Motor ..........................................................72 Connector 159 ...................................................... 126
Blower Motor Speed Resistors with Thermal Fuse 72 Connector 168 ...................................................... 127
Blower Switch .........................................................71 Connector 178M ...................................................127
Brake Lamp Pressure Switch .................................78 Connector 179F.................................................... 127
Brake Lamps Relay No. 15.....................................78 Connector 17M....................................................... 94
Brake Warning Pressure Switch .............................47 Connector 180F.................................................... 127
Bucket Control Valve Electromagnet Detents ........58 Connector 180M ...................................................127
Bulb Connector 182 ...................................................... 128
See Lamp ...........................................................78 Connector 183 ...................................................... 128
Connector 197F.................................................... 128
C Connector 197M ...................................................128
Cigar Lighter ...........................................................74 Connector 198 ...................................................... 129
Cluster, Instrument .....................................50, 51, 52 Connector 199F.................................................... 129
Compressor Clutch .................................................73 Connector 19F........................................................ 97
Compressor Clutch Lockout Relay No. 14 .............73 Connector 1F..........................................................89
Compressor, Seat...................................................71 Connector 2 ............................................................90
Connector 1 ............................................................89 Connector 200 ...................................................... 129
Connector 10 ..........................................................91 Connector 202F.................................................... 129
Connector 100 ......................................................120 Connector 203F.................................................... 130
Connector 107M ...................................................121 Connector 209M ...................................................130
Connector 108F....................................................121 Connector 20M....................................................... 97
Connector 109M ...................................................121 Connector 210F.................................................... 131
Connector 110F....................................................122 Connector 215F.................................................... 131
Connector 113 ......................................................122 Connector 217M ...................................................131
Connector 114F....................................................122 Connector 21F........................................................ 98
Connector 114M ...................................................123 Connector 21M....................................................... 98
Connector 229M ...................................................132
4002-136
Connector 22F........................................................99 Connector 6 ............................................................ 90
Connector 22M .......................................................99 Connector 60........................................................ 109
Connector 23F......................................................100 Connector 61........................................................ 109
Connector 23M .....................................................100 Connector 62M..................................................... 110
Connector 246M ...................................................132 Connector 63M..................................................... 110
Connector 24F......................................................100 Connector 64F...................................................... 110
Connector 253F....................................................132 Connector 65F...................................................... 110
Connector 259F....................................................132 Connector 65M..................................................... 111
Connector 260M ...................................................132 Connector 67........................................................ 111
Connector 262F....................................................132 Connector 68........................................................ 111
Connector 269 ......................................................133 Connector 74........................................................ 113
Connector 275M ...................................................134 Connector 8 ............................................................ 91
Connector 27M .....................................................101 Connector 80F...................................................... 115
Connector 3 ............................................................90 Connector 83F...................................................... 116
Connector 31 ........................................................102 Connector 85F...................................................... 116
Connector 35F......................................................103 Connector 89M..................................................... 117
Connector 37 ........................................................103 Connector 92........................................................ 117
Connector 4 ............................................................90 Connector 94F...................................................... 118
Connector 48F......................................................106 Connector, Diagnostic ............................................ 44
Connector 49F......................................................106 Converter, Radio Power (24 volts to 12 volts)........ 76
Connector 50F......................................................107 Coolant Level Sender .............................................47
Connector 51F......................................................107 Courtesy Lamp ....................................................... 88
Connector 52F......................................................107
Connector 53F......................................................107 D
Connector 54F......................................................108 Declutch Brake Switch ........................................... 44
Connector 55F......................................................108 Declutch Switch...................................................... 44
Connector 56F......................................................108 Detent Switch ......................................................... 57
Connector 57F......................................................108 Diagnostic Connector .............................................44
Connector 58F......................................................109 Dome Lamp ............................................................ 88
Connector 59F......................................................109
Connector 5F..........................................................90

4002-137
E License Plate .....................................................88
Engine Coolant Temperature Sender .....................48 Low Beam ....................................................84, 85
Engine Oil Pressure Switch ....................................54 Position ........................................................84, 85
Engine Speed Sensor.............................................44 Reverse........................................................82, 83
Ether Start Relay No. 6...........................................39 RH Front Combination .......................................85
Ether Start Solenoid ...............................................39 RH Front Work ................................................... 86
Ether Start Switch ...................................................39 RH Rear Combination ........................................ 83
Ether Start Temperature Switch .............................38 RH Rear Work.................................................... 86
Stop..............................................................82, 83
F Switch, Five Position Rotary .............................. 87
Fan Reversing Solenoid .........................................56 Tail ...............................................................82, 83
Fan Reversing Switch.............................................55 Turn..................................................82, 83, 84, 85
Filter Maintenance Switch ......................................44 Left Speaker ........................................................... 76
Five Position Rotary Lamp Switch ..........................87 LH Front Combination Lamp ..................................84
Flasher Module.......................................................80 LH Front Work Lamp ..............................................86
Float Pressure Switch.............................................59 LH Rear Combination Lamp ................................... 82
Float Solenoid.........................................................60 LH Rear Work Lamp............................................... 85
FNR Switch.............................................................44 License Plate Lamp ................................................ 88
Front Locating Components on the Schematic Posters .. 31
LH Work Lamp ...................................................86
RH Work Lamp...................................................86 M
Front LH Combination Lamp ..................................84 Master Disconnect Switch ...................................... 37
Front RH Combination Lamp ..................................85 Module
Front Washer Pump Motor .....................................68 Flasher ............................................................... 80
Front Wiper and Washer Switch .............................68 Secondary Steering............................................ 62
Front Wiper Motor...................................................67 Time Delay ......................................................... 42
Fuel Level Sender ..................................................47 Transmission Electronic Control ........................ 44
Fuel Relay ..............................................................38 Motor, Starter ......................................................... 38
Fuel Shutoff Solenoid .............................................37
Fuse Block 18F.......................................................95 N
Neutral Start Relay No. 8 .......................................40
H
Hazard Switch ........................................................79 O
Height Control/Return-To-Travel Proximity Switch .59 Outlet, Power..........................................................75
Hi/Low Beam Switch...............................................79 Output Speed Sensor ............................................. 44
High/Low Beam Relay No. 13 ................................87
Horn ........................................................................71 P
Horn Relay No. 5 ....................................................70 Parking Brake Relay No. 9 ..................................... 54
Horn Switch ............................................................79 Parking Brake Solenoid .......................................... 55
Hydraulic Filter Restriction Switch ..........................48 Parking Brake Switch ............................................. 49
Hydraulic Oil Temperature Sender .........................48 Pilot Control Relay No. 10 ...................................... 54
Pilot Control Switch ................................................ 52
I Pilot Pressure Solenoid .......................................... 55
Ignition Relay No. 1 ................................................40 Pin Engage Solenoid ..............................................64
Ignition Relay No. 2 ................................................41 Pin Engage Switch ................................................. 64
Ignition Switch ........................................................40 Power Converter (24 volts to 12 volts) ................... 75
Instrument Cluster ......................................50, 51, 52 Power Outlet........................................................... 75
Intermediate Speed Sensor....................................44 Program Reset Switch............................................ 49
Proximity Switch
L Height Control/Return-To-Travel........................ 59
Lamp Return-To-Dig .................................................... 59
Courtesy .............................................................88
Dome..................................................................88 R
High Beam ...................................................84, 85 Radio
LH Front Combination ........................................84 12 Volt ................................................................ 75
LH Rear Combination.........................................82 24 volt ................................................................ 75
LH Rear Work ....................................................85 Power Converter (24 volts to 12 volts) ...............76
4002-138
Remote...............................................................75 Transmission Solenoid Valve and Temperature 44
Rear Turbine Speed ................................................... 44
LH Combination Lamp .......................................82 Shifter, Transmission.............................................. 44
LH Work Lamp ...................................................85 Shutoff, Fuel Solenoid ............................................ 37
RH Combination Lamp .......................................83 Solenoid
RH Work Lamp...................................................86 Ether ..................................................................39
Rear Washer Pump Motor......................................69 Ether Start .......................................................... 39
Rear Wiper and Washer Switch .............................69 Fan Reversing....................................................56
Rear Wiper Motor ...................................................69 Float ................................................................... 60
Redundant Brake Pressure Switches .....................56 Fuel Shutoff........................................................ 37
Relay Parking Brake ....................................................55
Accessory, No. 3 ................................................42 Pilot Pressure..................................................... 55
Backup Alarm, No. 7 ..........................................44 Pin Engage ........................................................ 64
Brake Lamps No. 15 ..........................................78 Ride Control ....................................................... 65
Compressor Clutch Lockout No. 14 ...................73 Secondary Steering ........................................... 63
Ether Start No. 6 ................................................39 Speaker
Fuel ....................................................................38 Left ..................................................................... 76
High/Low Beam No. 13 ......................................87 Right................................................................... 76
Horn No. 5 ..........................................................70 Specifications ........................................................... 7
Ignition, No. 1 .....................................................40 Speed Resistors
Ignition, No. 2 .....................................................41 Blower Motor ...................................................... 72
Neutral Start No. 8 .............................................40 Start Relay.............................................................. 38
Parking Brake No. 9 ...........................................54 Starter Motor .......................................................... 38
Pilot Control No. 10 ............................................54 Steering
Ride Control No. 4..............................................65 Secondary, Module ............................................ 62
Start....................................................................38 Secondary, Motor...............................................63
Voltmeter, No. 12 ...............................................42 Secondary, Pressure Switch .............................. 62
Relay Socket No. 11 ...............................................56 Secondary, Solenoid .......................................... 63
Remote Radio.........................................................75 Switch ..................................................................... 73
Return-To-Dig Proximity Switch .............................59 A/C High Pressure (In Rear Chassis) ................ 72
Return-To-Travel/Float Switch................................58 A/C Low Pressure (In Cab) ................................ 72
RH Front Combination Lamp..................................85 Air Filter Restriction............................................ 49
RH Front Work Lamp..............................................86 Back-up Alarm Disable ...................................... 45
RH Rear Combination Lamp ..................................83 Beacon ............................................................... 77
RH Rear Work Lamp ..............................................86 Blower ................................................................ 71
Ride Control Relay No. 4 ........................................65 Brake Lamp Pressure ........................................78
Ride Control Solenoid.............................................65 Brake Warning Pressure .................................... 47
Ride Control Switch ................................................65 Declutch ............................................................. 44
Right Speaker.........................................................76 Declutch Brake................................................... 44
Rotating Beacon .....................................................78 Detent ................................................................ 57
Engine Oil Pressure ........................................... 54
S Ether Start .......................................................... 39
Seat Compressor and Switch .................................71 Ether Start Temperature .................................... 38
Secondary Steering Module ...................................62 Fan Reversing....................................................55
Secondary Steering Motor......................................63 Filter Maintenance .............................................44
Secondary Steering Pressure Switch .....................62 Five Position Rotary Lamp .................................87
Secondary Steering Solenoid .................................63 Float Pressure....................................................59
Sender FNR.................................................................... 44
Coolant Level .....................................................47 Front Wiper and Washer .................................... 68
Engine Coolant Temperature .............................48 Hazard ............................................................... 79
Fuel Level...........................................................47 Hi/Low Beam...................................................... 79
Hydraulic Oil Temperature .................................48 Horn ................................................................... 79
Torque Converter Output Temperature..............44 Hydraulic Filter Restriction .................................48
Sensor Ignition ............................................................... 40
Engine Speed.....................................................44 Master Disconnect .............................................37
Intermediate Speed ............................................44 Parking Brake ....................................................49
Output Speed .....................................................44 Pilot Control Switch ............................................ 52

4002-139
Pin Engage.........................................................64
Program Reset ...................................................49
Proximity, Height Control/Return-To-Travel .......59
Proximity, Return-To-Dig....................................59
Rear Wiper and Washer.....................................69
Redundant Brake Pressure ................................56
Return-To-Travel/Float .......................................58
Ride Control .......................................................65
Seat Compressor ...............................................71
Secondary Steering Pressure ............................62
Transmission Auto .............................................44
Transmission Enable..........................................44
Transmission Kick-down ....................................44
Turn Signal .........................................................79
Up/down Count ..................................................52
T
Thermal Fuse
Blower Motor ......................................................72
Thermostat .............................................................73
Thermostat Switch ..................................................73
Time Delay Module.................................................42
Torque Converter Output Temperature Sender .....44
Transmission Auto Switch ......................................44
Transmission Electronic Control Module ................44
Transmission Enable Switch ..................................44
Transmission Kick-down Switch .............................44
Transmission Shifter ...............................................44
Transmission Solenoid Valve and Temperature
Sensors .....................................................44
Turbine Speed Sensor............................................44
Turn Signal Switch..................................................79
U
Understanding the Troubleshooting Tables............31
Up/down Count Switch ...........................................52
V
Voltmeter Relay No. 12 ..........................................42
W
Wiper
Front Motor.........................................................67
Front Switch .......................................................68
Front Washer Pump Motor .................................68
Front Washer Switch ..........................................68
Rear Motor .........................................................69
Rear Switch ........................................................69
Rear Washer Pump Motor .................................69
Rear Washer Switch ..........................................69

4002-140

4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-48930 February, 2003
NOTES
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING BATTERIES, ENGINE FUEL SOLENOID, CHARGING, STARTING,
ALTERNATOR, FUEL FILTER HEATER, GRID HEATER, IGNITION SWITCH AND RELAYS . . . . . . . . . . . 36
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Filter Heater Relay No. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Filter Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
First Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Second Fuel Filter Heater (621D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Grid Heater Relay No. 15 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Grid Heater (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grid Heater Temperature Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grid Heater Controller (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Neutral Start Relay No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Accessory Relay No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Voltmeter Relay No. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,
SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Kick-down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FNR Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Back-up Alarm Relay No. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4002-4
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM/RESET SWITCH,
PARK BRAKE SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN
COUNT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Program/Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL, PARKING BRAKE, AND
REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pilot Control Relay No. 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parking Brake Relay No. 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Redundant Brake Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Relay Socket No. 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TROUBLESHOOTING BUCKET CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Detent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Bucket Control Valve Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Float Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Float Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL . . . . . . . . . . . . . . . 62
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Ride Control Relay No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Horn Relay No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4002-5
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
A/C Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
A/C High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Compressor Clutch Lockout Relay No. 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET,
RADIOS AND SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Remote Radio or 24 Volt Radio (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Radio Power Converter (24 volts to 12 volts) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH,
TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 78
Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Brake Lamps Relay No. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Turn Signal, Hi/Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH,
AND CAB LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
LH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
RH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
RH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
LH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
RH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Five Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
High/Low Beam Relay No. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4002-6
NOTES

4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage............................................................................................................................................... 24 volts
Batteries
Specifications are the same for production battery and replacement battery.
Production Battery Case P/N ................................................................................................................... A176482
Replacement Battery Case P/N ............................................................................................................... A180406
Group Size .......................................................................................................................................................... 31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17°C (0°F) for 60 Seconds At 6.0 Volts .................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell ..................................................................................................................................................... 17
Approximate weight with electrolyte ..................................................................................... 25.9 kg (57.1 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 45 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20°C (68°F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20°C (68°F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20°C (68°F) .......................................... 3521 ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105°C (221°F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110 °C (230°F) .................................................. 133.9 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Setpoint ............................................................................................................................. 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Setpoint ............................................... 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Setpoint .................................. -6.4 kPa (Gauge) (-0.928 psig)
Brake Warning Pressure Switch (Normally Closed) Opening Setpoint ...................................... 117.2 Bar (1700 psi)
A/C High Pressure Switch (Normally Open) Closing Setpoint..................... 27.6 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch (Normally Closed) Opening Setpoint .................... 1.4 Bar (20 psi) (decreasing pressure)
Thermostat Switch
Contacts 2 to 3 close at initial turn of the switch. Contacts 1 to 2 close with thermal setting.
Engine Oil Pressure Switch (Normally Closed) Opening Setpoint ................................................... 0.69 Bar (10 psi)
Fuel Solenoid Resistance At 20°C (68°F) (Nominal) ................................................................................ 12.7 Ohms
Brake Declutch Pressure Switch (Normally Closed) Opening Setpoint............................................. 24 Bar (350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing Setpoint ......................................... 62 Bar (900 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Setpoint....................................................... 4.1 Bar (60 psi)
Float Pressure Switch (Normally Open) Closing Setpoint ................................................................. 19 Bar (275 psi)
Secondary Steering Pressure Switch (Form C) Closing Setpoint ...................................................... 2.4 Bar (35 psi)
Fuel Filter Heater Switch
Opens.................................................................................................................................. 13 ±3°C (55.4 ±5.4°F)
Closes ............................................................................................................................. 1.5 ±4.5°C (34.7 ±8.1°F)
Fuel Filters Heater Resistance At 20 °C (68°F) (Nominal)............................................................................ 1.9 ohms
Grid Heater Temperature Sensor Resistance At:
80°C (176°F)................................................................................................................................ 304 to 342 ohms
20°C (68°F)............................................................................................................................ 2,262 to 2,760 ohms
-10°C (14°F) ........................................................................................................................ 8,244 to 10,661 ohms

4002-8
Parking Brake Solenoid DC Resistance At 20°C (68°F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20°C (68°F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20°C (68°F) (Nominal) ...................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20°C (68°F) (Nominal) .............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20°C (68°F) (Nominal) ............................................................... 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20°C (68°F) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20°C (68°F) (Nominal)........................................................... 39.3 ohms
Float Solenoid DC Resistance At 20°C (68°F) (Nominal) .......................................................................... 39.7 ohms
Rollback Pressure Switch (Normally Closed) Opening Setpoint ........................................................ 6.2 Bar (90 psi)

4002-9
ELECTRICAL WIRE IDENTIFICATION

21C Bk - 1.0


Color, Size,
and Material
1 Alternator B+ R-13.0-SXL 153 Alternator B+ 1 149 Starter Power 1
14 Alternator D+ LG-1.0-SXL 94M Engine Trans 5 154 Alternator 3
30 Alternator B+ R-1.0-SXL 153 Alternator B+ 1 154 Alternator 2
44 Brake Lt Input Signal T-1.0-SXL 159 Brake Lt Press Sw 2 21M Rear Cab 29
52 Fan Reverse Sol W-1.0-SXL 158 Fan Rev Sol Opt A 21M Rear Cab 27
57 Pin Engage Sol Pwr W-1.0-SXL 1 Cab-Frnt Chas U 107M Pin Engage Opt A
58 Ride Cntrl Sol Pwr W-1.0-SXL 1 Cab-Frnt Chas V SPL_A7 Ride Cntrl Sol Pwr SPL_A7
64 Horn Or-1.0-SXL 1 Cab-Frnt Chas N 147 Horn Pwr 1
0_A Ground Bk-1.0-SXL 125 LH Rear Comb Lt 5 SPL_E4 SPL_E4 1
0_AA Height-RTT Grnd Bk-1.0-SXL 10 Height Cntrl-RTT B SPL_A2 Splice A2 SPL_A2
0_AB Pin Engage Grnd Bk-1.0-SXL 107M Pin Engage Opt B SPL_A1 Splice A1 SPL_A1
0_AC Ride Cntrl Grnd Bk-1.0-SXL 5F Ride Control Opt 2 SPL_A1 Splice A1 SPL_A1
0_AD Horn Grnd Bk-1.0-SXL 146 Horn Grnd 1 SPL_A1 Splice A1 SPL_A1
0_AF RTD Grnd Bk-1.0-SXL 12F RTD B SPL_A2 Splice A2 SPL_A2
0_AG Lights Grnd RH Bk-1.0-SXL 8 Lights RH 1 SPL_A1 Splice A1 SPL_A1
0_AH Grnd Frnt Chas Bk-5.0-SXL 144 Grnd Rear Chas 1 143 Grnd Frnt Chas 1
0_AJ Grnd Cab Bk-2.0-SXL 145 Grnd Cab 1 SPL_A1 Splice A1 SPL_A1
0_AK Grnd Cab Bk-1.0-SXL 145 Grnd Cab 1 SPL_A2 Splice A2 SPL_A2
0_AL Lights Grnd LH Bk-1.0-SXL 6 Lights LH 1 SPL_A1 Splice A1 SPL_A1
0_AM RTD Grnd Bk-1.0-SXL 12M RTD B 200 RTD B
0_AN Sec Str Signal Grd Bk-1.0-SXL 131F Sec Str Pres Sw Opt B 180F Sec Str Mod Opt 5
0_AP Splice Bk-1.0-SXL SPL_A6 SPL_A6 SPL_A6 179F Float Solenoid 2
0_AQ Ground Bk-1.0-SXL 229M Diode Module C SPL_A6 SPL_A6 SPL_A6
0_AR Splice Bk-1.0-SXL SPL_A2 Splice A2 SPL_A2 SPL_A6 SPL_A6 SPL_A6
0_BA Signal Grnd Bk-1.0-SXL 150 Signal Grnd 1 SPL_B1 A
0_BC Grid Htr Temp Sensor Grnd Bk-1.0-SXL 290 Grid Htr Temperature Sw B 165 Engine Grnd 1
0_BD Air Filter Rest Sw Grnd Bk-1.0-SXL 117 Air Filter Res Sw B SPL_B1 A
0_BE Eng Cool Temp Ground Bk-1.0-SXL 138 Eng Cool Temp B SPL_B1 A
0_BF Signal Ground Bk-1.0-SXL 94M Engine Trans 9 SPL_B1 A

4002-10

21C Bk - 1.0


Color, Size,
and Material
0_BG Analog Ground Bk-1.0-SXL 94M Engine Trans 15 152 Analog Grnd 1
0_BH Signal Ground Bk-1.0-SXL 94M Engine Trans 11 SPL_B1 A
0_BJ Ground Bk-1.0-SXL 268 AC Diode Ground 1 265F Diode Module C
0-BK Fuel Filter Heater Grnd Bk-2.0-SXL 287 Fuel Filter Heater B 151 Solenoid Ground 1
0-BL Fuel Solenoid Grnd Bk-2.0-SXL 288 Fuel Filter Heater B 151 Solenoid Grnd 1
0-BM Fuel Solenoid Grnd Bk-1.0-SXL 289 Fuel Filter Temp Sw B 151 Solenoid Grnd 1
0_C Ground Bk-1.0-SXL 127 RH Rear Comb Lt 5 SPL_E4 SPL_E4 1
0_CA Sec Str Signal Grd Bk-1.0-SXL 90M Sec Str Mod 11 SPL_C1 1
0_CB Sec Str Signal Grd Bk-1.0-SXL 90M Sec Str Mod 12 SPL_C1 1
0_CC Sec Str Signal Grd Bk-1.0-SXL 180M Sec Str Mod Frnt Harn 5 SPL_C1 1
0_CD Sec Str Signal Grd Bk-1.0-SXL 177 Sec Str Mod Sig Grnd 1 SPL_C1 1
0_CE Sec Str Chassis Grnd Bk-1.0-SXL 90M Sec Str Mod 4 176 Sec Str Mod Chas Grnd 1
0_CF Sec Str Grnd Bk-1.0-SXL 264M Sec Str Sol Opt B SPL_C1 1
0_D Hood Ground Bk-2.0-SXL 164 Engine Grounds 1 SPL_E4 SPL_E4 1
0_DA AC Brk Lt Time Del Horn Grnd Bk-0.8-SXL 204F Relay Ac 85 220F Ground Cab 1
0_DAB Signal Ground Bk-0.8-SXL 22F Cab Transmission 15 13F Cab-Pedestal 38
0_DAC Relay Grnd Bk-0.8-SXL 13F Cab Pedestal 53 222F Ground Cab 1
0-DAD Relay Grnd Bk-1.0-SXL 222F Ground Cab 1 SPL_D13 Ground 1
0_DAE Ground Bk-1.0-SXL 199F Trans Enable Sw 7 SPL_D13 Ground 1
0_DAF Switch Grnd Bk-1.0-SXL 210F Fan Reverser Sw 7 40F Pin Engage Sw 9
0_DAG Switch Grnd Bk-1.0-SXL 39F Return To Travel Sw 7 SPL_D13 Ground 1
0_DAH Switch Grnd Bk-1.0-SXL 39F Return To Travel Sw 1 39F Return To Travel Sw 7
0_DAJ Switch Grnd Bk-1.0-SXL 36F Detent Switch 7 39F Return To Travel Sw 1
0_DAK Switch Grnd Bk-1.0-SXL 36F Detent Switch 7 38F Declutch Switch 7
0_DAL Switch Grnd Bk-1.0-SXL 40F Pin Engage Sw 9 44F Ride Control Sw 7
0_DAM Switch Grnd Bk-1.0-SXL 44F Ride Control Sw 7 41F Trans Auto Sw 7
0_DAN Flasher Module Grnd Bk-0.8-SXL 62M Flasher Module 3 SPL_D14 Module Grnds 1
0_DAP Ground Bk-1.0-SXL 199F Trans Enable Sw 7 42F Beacon Sw 7
0_DAQ Flasher Module Grnd Bk-0.8-SXL 62M Flasher Module 4 SPL_D14 Module Grnds 1
0_DAR Blwr Wiper Seat Grnd Bk-1.0-SXL 35F Wiper and Washer Sw 1 218F Ground Cab 1
0_DAS Time Delay Mod Grnd Bk-0.8-SXL 63M Time Delay Module 3 SPL_D14 Module Grnds 1

4002-11

21C Bk - 1.0


Color, Size,
and Material
0_DAT Brk Lt Time Del Horn Grnd Bk-0.8-SXL 220F Ground Cab 1 SPL_D14 Module Grnds 1
0_DAU Analog Ground Bk-0.8-SXL 22F Cab Transmission 30 13F Cab-Pedestal 8
0_DAV Diag TECM Grnd Bk-0.8-SXL 108F Diagnostic Connector 3 221F Ground Cab 1
0_DAW Ground Bk-1.0-SXL 42F Beacon Sw 7 118F Back-up Alarm Dis Sw 7
0_DAX Beacon Wiper Diode Grnd Bk-0.8-SXL 206F Cab Floor Weld Stud 1 140M Diode Module C
0_DAY Switch Grnd Bk-1.0-SXL 210F Fan Reverser Sw 7 SPL_D13 Ground 1
0_DB Can Pilot Sol Grnd Bk-0.8-SXL 89M Pilot Pres Sol B 219F Ground Cab 1
0-DBA Grid Heater Lamp Grnd Bk-0.8-SXL 13F Cab Pedestal 11 219F Ground Cab 1
0-DBB Ground Bk-0.8-SXL 201 Grid Htr Controller 8 202 Radio Ground 1
0_DC Ac Brk Lt Time Delay Horn Grnd Bk-0.8-SXL 204F Relay Brake Lamps 85 49F Accessory Relay 85
0_DD Ride Cntrl Relay Sink Bk-0.8-SXL 19F TECM 57 50F Ride Control Relay 85
0_DE Relay Grnd Bk-0.8-SXL 48F Ignition Relay #2 85 47F Ignition Relay #1 85
0_DF Relay Grnd Bk-0.8-SXL 49F Accessory Relay 85 48F Ignition Relay #2 85
0_DG Ac Brk Lt Time Delay Horn Grnd Bk-0.8-SXL 204F Relay Brake Lamps 85 58F Volt Meter Relay 85
0_DH Relay Grnd Bk-0.8-SXL 58F Volt Meter Relay 85 54F Neutral Start Relay 85
0_DJ Relay Grnd Bk-0.8-SXL 54F Neutral Start Relay 85 222F Ground Cab 1
0_DL Signal Ground Bk-0.8-SXL 22F Cab-Transmission 23 13F Cab-Pedestal 39
0_DM Speed Sensor Grounds Bk-0.8-SXL 19F TECM 3 22F Cab Transmission 11
0_DN Out Speed Sensor Grnd Bk-0.8-SXL 19F TECM 4 22F Cab Transmission 28
0_DP Diag TECM Grnd Bk-0.8-SXL 19F TECM 1 221F Ground Cab 1
0_DQ Diag TECM Grnd Bk-0.8-SXL 19F TECM 2 221F Ground Cab 1
0_DR Dome Court Work Lt Grnd Bk-1.0-SXL 24M Cab Roof E 223F Ground Cab 1
0_DS Dome Court Work Lt Grnd Bk-1.0-SXL 24M Cab Roof G 223F Ground Cab 1
0_DT Dome Court Work Lt Grnd Bk-1.0-SXL 23F Cab Roof B 223F Ground Cab 1
0_DU Beacon Wiper Diode Grnd Bk-1.0-SXL 23F Cab Roof C 206F Cab Floor Weld Stud 1
0_DV Beacon Wiper Diode Grnd Bk-0.8-SXL 206F Cab Floor Weld Stud 1 13F Cab-Pedestal 61
0_DW Ground Bk-0.8-SXL 45F Rear Wiper Sw 7 118F Back-up Alarm Dis Sw 7
0_DX Horn Ground Bk-0.8-SXL 13F Cab-Pedestal 41 220F Ground Cab 1
0_DY Blwr Wiper Seat Grnd Bk-1.0-SXL 28M Seat Comp Motor B 218F Ground Cab 1
0_DZ Blwr Wiper Seat Grnd Bk-2.0-SXL 29M Blower Motor 4 218F Ground Cab 1
0_E Fuel Redundant Br Cool Grnd Bk-1.0-SXL 160 Engine Grounds 1 171 Fuel Sender Grnd 1

4002-12

21C Bk - 1.0


Color, Size,
and Material
0_F Frt Rear Wash Hot Grnd Bk-1.0-SXL 162 Engine Ground 1 3 Rear Washer 2
0_G Frt Rear Wash Hot Grnd Bk-1.0-SXL 2 Front Washer 2 162 Engine Ground 1
0_HA Signal Ground Bk-1.0-SXL 22M Cab Transmission 23 94F Eng-Trans 9
0_HB Signal Ground Bk-1.0-SXL 22M Cab Transmission 15 94F Eng-Trans 11
0_HC Analog Ground Bk-1.0-SXL 22M Cab Transmission 30 94F Eng-Trans 15
0_HD Speed Sense Grnd Bk-1.0-SXL 22M Cab Transmission 11 SPL_H2 Splice H2 Splice
0_HE Out Speed Grnd Bk-1.0-SXL 22M Cab Transmission 28 100 Out Speed Sens 1
0_HF Eng Speed Grnd Bk-0.8-BLD 101 Eng Speed Sense 2 SPL_H2 Splice H2 Splice
0_HG Int Speed Sig Bk-0.8-BLD 95 Int Speed Sense 2 SPL_H2 Splice H2 Splice
0_HH Turb Speed Grnd Bk-0.8-BLD 96 Turb Speed Sense 2 SPL_H2 Splice H2 Splice
0_J Hood Ground Bk-1.0-SXL 164 Engine Grounds 1 128F Rear-Hood C
0_JA Hood Ground Bk-1.0-SXL 128M Lic/Backup Alarm C SPL_J1 SPL_J1 1
0_JB Backup Alarm Grnd Bk-1.0-SXL 174 Backup Alarm Grnd 1 SPL_J1 SPL_J1 1
0_JC Lic Plate Lt Grnd Bk-1.0-SXL 168 Lic Plate Light B SPL_J1 SPL_J1 1
0_KD Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 39 13M Pedestal-Cab 39
0_KE Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 38 SPL_K1 SPL_K1 1
0_KF Horn High Low Beam Grnd Bk-0.8-SXL 187 High Low Beam 1 185 Horn Switch 1
0_KG Horn High Low Beam Grnd Bk-0.8-SXL 13M Pedestal-Cab 41 185 Horn Switch 1
0_KH Pilot Light Grnd Bk-0.8-SXL 71 Hazard Switch 7 37 Pilot Control Switch 7
0_KJ Pilot Light Grnd Bk-0.8-SXL 37 Pilot Control Switch 7 72 Parking Brake Switch 7
0_KK Pilot Light Grnd Bk-0.8-SXL 72 Parking Brake Switch 7 74 Up Down Count Switch 7
0_KL Pilot Light Grnd Bk-0.8-SXL 75 Program Reset Switch 7 74 Up Down Count Switch 7
0_KM Pilot Light Grnd Bk-0.8-SXL 13M Pedestal-Cab 53 75 Program Reset Switch 7
0_KN Front Wiper Grnd Bk-0.8-SXL 13M Pedestal-Cab 61 60 Front-Wiper Motor 1
0_KP Analog Grnd Bk-0.8-SXL 76 Instrument Cluster 8 13M Pedestal-Cab 8
0_KQ Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 37 SPL_K1 SPL_K1 1
0_KR Signal Grnd Bk-0.8-SXL 13M Pedestal-Cab 38 SPL_K1 SPL_K1 1
0_L Ground Bk-1.0-SXL 157 Redundant Brake Sw B SPL_E9 SPL_E9 1
0_M Ground Bk-1.0-SXL 86 Redundant Brake Sw B SPL_E9 SPL_E9 1
0_MA Rear Wiper Mtr Grnd Bk-1.0-SXL 82M Rear Wiper Mtr 1 SPL_M6 Rear Wip Beacon Grnd 1
0_MB Dome Lt Grnd Bk-0.8-SXL 84F Dome Light B SPL_M5 Dome Courtesy Lt Grnd 1

4002-13

21C Bk - 1.0


Color, Size,
and Material
0_MC Beacon Light Ground Bk-1.0-SXL 85F Beacon Light B SPL_M6 Rear Wip Beacon Grnd 1
0_MD Beacon-Rear Wiper Grnd Bk-1.0-SXL 23M Roof-Cab C SPL_M6 Rear Wip Beacon Grnd 1
0_ME LH Rear Work Lt Grnd Bk-1.0-SXL 83F LH Rear Work Lt B SPL_M3 Rear Work Lts Grnd 1
0_MF RH Rear Work Lt Grnd Bk-1.0-SXL 80F RH Rear Work Lt B SPL_M3 Rear Work Lts Grnd 1
0_MG Rear Work Light Grnd Bk-1.0-SXL 23M Roof-Cab B SPL_M3 Rear Work Lts Grnd 1
0_MH LH Frnt Work Lt Grnd Bk-1.0-SXL 79F LH Front Work Lt B SPL_M2 Frnt Work Lt Grnd 1
0_MJ RH Frnt Work Lt Grnd Bk-1.0-SXL 78F RH Front Work Lt B SPL_M2 Frnt Work Lt Grnd 1
0_MK Frnt Work Lt Grnd Bk-1.0-SXL 24F Roof-Cab G SPL_M2 Frnt Work Lt Grnd 1
0_ML Courtesy Lt Grnd Bk-0.8-SXL 77F Courtesy Lt B SPL_M5 Dome Courtesy Lt Grnd 1
0_MM Dome Lt Grnd Bk-0.8-SXL 84F Dome Light B 84F Dome Light C
0_MN Dome Courtesy Lt Grnd Bk-0.8-SXL 24F Roof-Cab E SPL_M5 Dome Courtesy Lt Grnd 1
0_N Brk Warn Pr Sw Bk-1.0-SXL 88 Brk Warn Pr Sw B SPL_E9 SPL_E9 1
0_NA Chas Grnd Blck Grnd Bk-62.0-SGR 232F Chas Grnd Blck Grnd 1 233F Chas Grnd Blck Grnd 1
0_NB Discon-Blck Grnd Bk-62.0-SGR 235F Discon-Blck Grnd 1 234F Discon-Blck Grnd 1
0_NC Disconnect Battery Bk-62.0-SGR 237F Disconnect Battery 1 236F Disconnect Battery 1
0_ND Chas Grnd-Sec Strg Mtr Bk-62.0-SGT 242F Chas Grnd-Sec Strg Mtr 1 243F Chas Grnd-Sec Strg Mtr 1
0_P Fuel Redundant Br Cool Grnd Bk-1.0-SXL 160 Engine Grounds 1 SPL_E9 SPL_E9 1
0_PA Left Spkr Ground Bk-0.8-SXL 114F 2 112M B
0_PB Right Spkr Ground Bk-0.8-SXL 114F 4 111M B
0_PC Radio Ground Bk-0.8-SXL 114F 3 110F 24/12V Converter B
0_PD Radio Ground Bk-1.0-SXL 247F Radio Ground 1 109M 24/12V Converter B
0_Q Park Str Fuel Relay Grnd Bk-1.0-SXL 87 Parking Brk Sol 2 165 Engine Ground 1
0_QA Left Spkr Ground Bk-0.8-SXL 114M 2 113 Radio 4
0_QB Right Spkr Ground Bk-0.8-SXL 114M 4 113 Radio 2
0_QC Radio Ground Bk-0.8-SXL 114M 3 113 Radio 5
0_RA Converter Ground Bk-5.0-SXL 251F Converter Ground 1 254F Converter Ground 1
0_RB Outlet Ground Bk-3.0-SXL 252F Outlet Ground 1 253F Power Outlet B
0_S Cigar Lighter Grnd Bk-3.0-SXL 261F Cigar Lighter Grnd 1 259F Cigar Lighter 2
0_U Splice Bk-2.0-SXL SPL_G1 Splice G1 A 165 Engine Ground 1
0_UA Grid Heater Feedback Bk-2.0-SXL 276F Grid Heater Relay B SPL_G1 Splice G1 A
0_UB Starter Relay Ground Bk-2.0-SXL 132 Starter Relay 1 SPL_G1 Splice G1 A

4002-14

21C Bk - 1.0


Color, Size,
and Material
0_UC Grid Heater Feedback Bk-2.0-SXL 276M Relay Rear B 279M Grid Heater Relay 1
0_V Fuel Redundant Br Cool Grnd Bk-1.0-SXL 104 Cool Level Sensor B 160 Engine Grounds 1
0_VA Fuel Redundant Br Cool Grnd Y-0.8-SOLID 274F Cool Jmpr Rear Chsis B 275M Coolant Jmpr Coolant Sndr B
0_W Frt Rear Wash Hot Grnd Bk-1.0-SXL 136 Hyd Oil Temp Send B 162 Engine Ground 1
0_X Fan Rev Sol Grd Bk-1.0-SXL 158 Fan Rev Sol Opt B 163 Engine Ground 1
0_Y Engine Cab Grd Bk-13.0-SXL 161 Engine Ground 1 167 Engine Cab Grnd 1
12K_A Acc Power Or-1.0-SXL 49F Accessory Relay 86 18F Fuse Block M1
12K_B Acc Power Or-0.8-SXL 49F Accessory Relay 86 13F Cab-Pedestal 63
12K_C Ign Sw Acc Pwr Or-0.8-SXL 13M Pedestal-Cab 63 69 Ignition Switch 4
12P_A Acc Relay Or-1.0-SXL 49F Accessory Relay 87 18F Fuse Block L1
12P_B Acc Relay Or-1.0-SXL 18F Fuse Block N1 18F Fuse Block L1
12V_A 12V Pwr To Outlet R-3.0-SXL 257F 12V Pwr To Outlet 1 253F Power Outlet A
12V_B 12V Pwr To Fuse Blck R-5.0-SXL 258F 12V Pwr To Fuse Blck 1 18F Fuse Block 6
13C Fuel Sol Or-1.0-SXL 94M Engine Trans 1 SPL_B2 B+ Power A
13C_A Fuel Sol Or-1.0-SXL 94F Eng-Trans 1 22M Cab-Transmission 1
13C_B Fuel Sol Pwr Or-0.8-SXL 57F Engine Shutdown Relay 87 217M Engine Shutdown Jumper A
13C_C Fuel Sol Pwr Or-0.8-SXL 57F Engine Shutdown Relay 87 140M Diode Module D
13C_D Fuel Sol Pwr Or-0.8-SXL 22F Cab-Transmission 1 57F Engine Shutdown Relay 87
13C_E Fuel Sol Pwr Or-1.0-SXL 139M Disconnect-Engine A 231F Fuel Sol Disconnect 1
13C_F Disconnect Fuel Filter Heater Or-1.0-SXL SPL_B2 B+ Power A 139F Disconnect Harness A
13C_G Disconnect Fuel Filter Heater Or-1.0-SXL SPL_B2 B+ Power A 277F Engine Relay 4
13C_H Fuel Filter Heater Signal Power Or-1.0-SXL 280 Fuel Filter Heater Relay 86 277M Relay Engine 4
13D Delay Pwr (2 Way) Or-1.0-SXL 63M Time Delay Module 1 18F Fuse Block S1
13K Ignition Switch Pwr Or-0.8-SXL 13M Pedestal-Cab 56 69 Ignition Switch 3
13K_A Ignition Switch Pwr Or-1.0-SXL 48F Ignition Relay #2 86 47F Ignition Relay #1 86
13K_B Ignition Switch Pwr Or-1.0-SXL 48F Ignition Relay #2 86 57F Engine Shutdown Relay 30
13K_C Ignition Switch Pwr Or-1.0-SXL 58F Volt Meter Relay 86 57F Engine Shutdown Relay 30
13K_D Ignition Switch Pwr Or-0.8-SXL 57F Engine Shutdown Relay 30 217F Engine Shutdown Jumper A
13K_E Ignition Switch Pwr Or-0.8-SXL 58F Volt Meter Relay 86 SPL_D22 Ignition Switch 1
13K_F Ignition Switch Pwr Or-0.8-SXL 63M Time Delay Module 5 SPL_D22 Ignition Switch 1
13K_G Ignition Switch Pwr Or-0.8-SXL 13F Cab-Pedestal 56 SPL_D22 Ignition Switch 1

4002-15

21C Bk - 1.0


Color, Size,
and Material
13M Fuel Sol Hold In Or-1.0-SXL 139F Disc Harness B 133M Fuel Solenoid 1
13M_A Fuel Sol Hold In Or-1.0-SXL 139M Disconnect-Engine B 230F Fuel Sol Disconnect 1
13P_A Ign Rel 1 Out Or-1.0-SXL 47F Ignition Relay #1 87 18F Fuse Block A1
13P_B Ign Rel 1 Out Or-1.0-SXL 47F Ignition Relay #1 87 18F Fuse Block P1
13R Ign Rel 2 Out (5 Way) Or-1.0-SXL 48F Ignition Relay #2 87 18F Fuse Block F1
13V Voltmeter Relay Out Or-1.0-SXL 58F Volt Meter Relay 87 18F Fuse Block V1
14 Alternator D+ LG-1.0-SXL 154 Alternator 1 94M Eng-Trans 5
14_A Alternator D+ LG-1.0-SXL 22M Cab-Transmission 2 94F Eng-Trans 5
14_B Alternator D+ LG-0.8-SXL 22F Cab-Transmission 2 215F Alternator Resistor 1
14_C Alternator D+ LG-0.8-SXL 201 Grid Heater Controller 4 215F Alternator Resistor 1
18A Rear Fld Lts Fuse Pwr Or-2.0-SXL 32F Light Switch B 18F Fuse Block A2’
18B High Beam LH Or-1.0-SXL 1 Cab-Frnt Chas G 6 Lights LH 3
18B_A High Beam LH Or-0.8-SXL 1F Cab-Frnt Chas G 18F Fuse Block B2’
18C High Beam RH Or-1.0-SXL 1 Cab-Frnt Chas Q 8 Lights RH 3
18C_A High Beam Fused Pwr Or-0.8-SXL 1F Cab-Frnt Chas Q 18F Fuse Block C2’
18C_B High Beam Fused Pwr Or-0.8-SXL 13F Cab-Pedestal 15 18F Fuse Block C2’
18C_C High Beam Telltale Or-0.8-SXL 76 Instrument Cluster 15 13M Pedestal-Cab 15
18D Low Beam LH Or-1.0-SXL 1 Cab-Frnt Chas O 6 Lights LH 2
18D_A Low Beam LH Or-0.8-SXL 1F Cab-Frnt Chas O 18F Fuse Block D2’
18E Low Beam RH Or-1.0-SXL 1 Cab-Frnt Chas P 8 Lights RH 2
18E_A Low Beam RH Or-0.8-SXL 1F Cab-Frnt Chas P 18F Fuse Block E2’
18F Position LH Or-1.0-SXL 1 Cab-Frnt Chas F 6 Lights LH 4
18F_A Left Tail Or-1.0-SXL 125 LH Rear Comb Lt 3 21M Rear-Cab 5
18F_D Left Tail Pos Or-0.8-SXL 21F Cab-Rear 5 18F Fuse Block F2’
18F_E Left Tail Pos Or-0.8-SXL 1F Cab-Frnt Chas F 18F Fuse Block F2’
18G Position RH Or-1.0-SXL 1 Cab-Frnt Chas E 8 Lights RH 4
18G_A Right Tail Or-1.0-SXL 127 RH Rear Comb Lt 3 SPL_E8 SPL_E8 1
18G_C Lic Plate Light Or-1.0-SXL 128F Rear-Hood A SPL_E8 SPL_E8 1
18G_D RH Tail Lic Lts Or-1.0-SXL 21M Rear-Cab 9 SPL_E8 SPL_E8 1
18G_E Lic Plate Light Or-1.0-SXL 168 Lic Plate Light A 128M Lic/Backup Alarm A
18G_F RH Tail Lic Lts Or-0.8-SXL 21F Cab-Rear 9 18F Fuse Block G2’

4002-16

21C Bk - 1.0


Color, Size,
and Material
18G_G Position RH Or-0.8-SXL 1F Cab-Frnt Chas E 18F Fuse Block G2’
18L_C Indicator Lamp Or-0.8-SXL 201 Grid Heater Controller 1 13F Cab Pedestal 9
18L_D Grid Heater Lamp Bk-0.8-SXL 13M Pedestal Cab 9 97 Preheater Lamp 5
18_H Radio Power Or-0.8-SXL 113 Radio 6 269 Radio Fuse Holder 2
19A Out Speed Power Or-1.0-SXL 22M Cab-Transmission 29 100 Out Speed Sens 3
19A_A Declutch Switch Or-1.0-SXL 4 Dec Press Sw A 21M Rear-Cab 30
19A_B FNR Switched Pwr Or-0.8-SXL 198 FNR Switch 5 197M FNR-Main Cab 1
19A_C Trans Ena Sw Pwr Or-0.8-SXL 197F Main Cab FNR 1 199F Trans Enable Sw 10
19A_D Trans Ena Sw Pwr Or-0.8-SXL 199F Trans Enable Sw 2 SPL_D15 1
19A_E Trans Ena Sw Pwr Or-0.8-SXL 199F Trans Enable Sw 2 199F Trans Enable Sw 10
19A_F FNR Switched Pwr Or-0.8-SXL 198 FNR Switch 8 198 FNR Switch 5
19A_G Trans Control Pwr Or-0.8-SXL 13M Pedestal-Cab 43 72 Parking Brake Switch 2
19A_H Trans Control Pwr Or-0.8-SXL 70 Transmission Shifter A 72 Parking Brake Switch 2
19A_K Cab Switched Pwr Or-0.8-SXL 19F TECM 45 SPL_D15 1
19A_L Cab Switched Pwr Or-0.8-SXL 108F Diagnostic Connector 1 SPL_D15 1
19A_M Cab Switched Pwr Or-0.8-SXL 22F Cab-Transmission 29 SPL_D15 1
19A_N Cab Switched Pwr Or-0.8-SXL 18F Fuse Block A2 SPL_D15 1
19A_P Cab Switched Pwr Or-0.8-SXL 53F Backup Alarm Relay 86 18F Fuse Block A2
19A_Q Cab Switched Pwr Or-0.8-SXL 41F Trans Auto Sw 2 SPL_D15 1
19A_R Cab Switched Pwr Or-0.8-SXL 38F Declutch Switch 2 SPL_D15 1
19A_S Cab Switched Pwr Or-0.8-SXL 13F Cab-Pedestal 43 SPL_D15 1
19A_T Cab Switched Pwr Or-0.8-SXL 21F Cab-Rear 30 SPL_D15 1
19A_U Cab Switched Pwr Or-0.8-SXL 20M Trans Kick-Down 1 SPL_D15 1
19B Turn Signal Power Or-0.8-SXL 13M Pedestal-Cab 66 67 Turn Signal Switch 1
19B_A Turn Signal Power Or-0.8-SXL 13F Cab-Pedestal 66 18F Fuse Block B2
19C Pilot Control Signal Or-0.8-SXL 13M Pedestal-Cab 68 37 Pilot Control Switch 2
19C_A Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 18F Fuse Block C2 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_B Ride Ctrl Fused Pwr Or-1.0-SXL 44F Ride Control Sw 2 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_C Ride Ctrl Fused Pwr Or-0.8-SXL 13F Cab-Pedestal 68 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_D Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 56F Pilot Control Relay 30 18F Fuse Block C2
19C_E Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 56F Pilot Control Relay 30 56F Pilot Control Relay 86

4002-17

21C Bk - 1.0


Color, Size,
and Material
19D_A Parking Brake Rel Fused Pwr Or-1.0-SXL 55F Brake Lights Relay 30 18F Fuse Block D2
19D_B Parking Brake Rel Fused Pwr Or-1.0-SXL 55F Brake Lights Relay 30 55F Brake Lights Relay 86
19E Switched Power Or-1.0-SXL 201 Grid Heater Controller 7 18F Fuse Block E2
19F Eng Shtdwn Rel Fused Pwr Or-1.0-SXL 57F Engine Shutdown Relay 86 18F Fuse Block F2
19G Blower Switch Fused Pwr Or-2.0-SXL 30F Blower Switch 2 18F Fuse Block G2
19H Backup Alarm Rel Fuse Pwr Or-1.0-SXL 53F Backup Alarm Relay 30 18F Fuse Block H2
19J Frt Wip Wash Fused Pwr Or-0.8-SXL 13M Pedestal-Cab 60 61 Front-Wiper Motor C
19J_A Frt Wip Wash Fused Pwr Or-1.0-SXL 35F Wiper and Washer Sw 2 18F Fuse Block J2
19J_B Frt Wip Wash Fused Pwr Or-0.8-SXL 35F Wiper and Washer Sw 2 13F Cab-Pedestal 60
19K_A Rear Wip Wash Fused Pwr Or-1.0-SXL 18F Fuse Block K2 SPL_D23 Rear Wiper Pwr 1
19K_B Rear Wip Wash Fused Pwr Or-1.0-SXL 23F Cab-Roof F SPL_D23 Rear Wiper Pwr 1
19K_C Rear Wip Wash Fused Pwr Or-1.0-SXL 45F Rear Wiper Sw 3 SPL_D23 Rear Wiper Pwr 1
19K_D Rear Wip Wash Fused Pwr Or-0.8-SXL 45F Rear Wiper Sw 5 SPL_D23 Rear Wiper Pwr 1
19K_E Rear Wip Wshr Fused Pwr Or-1.0-SXL 23M Roof-Cab F 81M Rear Wiper Mtr C
19L Access To Fuse L (3 Way) Or-1.0-SXL 18F Fuse Block L2 18F Fuse Block 5
19L_A Radio Power Or-1.0-SXL 246M Radio Power A 109M 24/12V Converter A
19L_B Converter Pwr Ign Or-1.0-SXL 249M Converter Pwr Ign A 256F Converter Pwr Ign 1
19M_A Sec Str Accessory Or-0.8-SXL 1F Cab-Frnt Chas H 18F Fuse Block M2
19M_B Sec Str Accessory Or-1.0-SXL 180F Sec Str Mod Opt 1 1 Cab-Frnt Chas H
19M_C Sec Str Accessory Or-1.0-SXL 90M Sec Str Mod 7 180M Sec Str Mod-Frnt Harn 1
19N_A Access Seat Fused Pwr (3 Way) Or-1.0-SXL 28M Seat Comp Motor A 18F Fuse Block N2
19N_B Access Seat Fused Pwr (3 Way) Or-1.0-SXL 18F Fuse Block N2 18F Fuse Block 1
19P_A Fan Rev Pin Eng Fused Pwr Or-1.0-SXL 40F Pin Engage Sw 2 18F Fuse Block P2
19P_B Fan Rev Pin Eng Fused Pwr Or-1.0-SXL 210F Fan Reverser Sw 2 40F Pin Engage Sw 2
19R_A Sec Str Ignition Or-0.8-SXL 1F Cab-Frnt Chas J SPL_D25 SPL_D25 Splice
19R_B Sec Str Ignition Or-1.0-SXL 180F Sec Str Mod Opt 2 1 Cab-Frnt Chas J
19R_C Sec Str Ignition Or-1.0-SXL 90M Sec Str Mod 1 180M Sec Str Mod-Frnt Harn 2
19R_D Sec Strg Ignition Or-0.8-SXL SPL_D25 SPL_D25 Splice 262F Diode Module C
19R_E Cab Switched Pwr Or-0.8-SXL 216F Alternator Resistor 1 SPL_D25 SPL_D25 Splice
19R_F Sec Strg Ignition Or-0.8-SXL 262F Diode Module A 18F Fuse Block R2
19S Instr Cluster Fused Del Pwr Or-0.8-SXL 13F Cab-Pedestal 2 18F Fuse Block S2

4002-18

21C Bk - 1.0


Color, Size,
and Material
19S_A Instr Cluster Fused Del Pwr Or-0.8-SXL 74 Up Down Count Switch 2 13M Pedestal-Cab 2
19S_B Instr Cluster Fused Del Pwr Or-0.8-SXL 76 Instrument Cluster 2 74 Up Down Count Switch 2
19T_A Time Delay Fused Pwr Or-0.8-SXL 19F TECM 23 18F Fuse Block T2
19T_B Time Delay Fused Pwr Or-0.8-SXL 19F TECM 68 18F Fuse Block T2
19U_A Dome Lt Horn Fused Pwr Or-1.0-SXL 23F Cab-Roof D 18F Fuse Block U2
19U_B Dome Lt Horn Fused Pwr Or-1.0-SXL 51F Horn Relay 30 18F Fuse Block U2
19U_C Dome Lt Horn Fused Pwr Or-0.8-SXL 51F Horn Relay 86 51F Horn Relay 30
19U_D Dome Lt Fused Pwr Or-1.0-SXL 23M Roof-Cab D 84F Dome Light A
19V Cluster Main Fused Power Or-0.8-SXL 13F Cab-Pedestal 1 18F Fuse Block V2
19V_A Cluster Main Fused Pwr Or-0.8-SXL 76 Instrument Cluster 1 13M Pedestal-Cab 1
19W Cigarette Lighter Fused Pwr Or-1.0-SXL 18F Fuse Block W2 18F Fuse Block 16
19W_A Cigar Lighter Pwr Or-3.0-SXL 259F Cigar Lighter 1 260M Cigar Lighter Pwr A
19X Beacon Sw Fused Pwr Or-1.0-SXL 42F Beacon Sw 2 18F Fuse Block X2
19Z Frnt Flood Illum Fused Pwr Or-1.0-SXL 34F Light Switch C 18F Fuse Block Z2
1A_A Ign Prog Reset Sw Pwr R-0.8-SXL 13M Pedestal-Cab 62 69 Ignition Switch 1
1A_B Ign Prog Reset Sw Pwr R-0.8-SXL 75 Program Reset Switch 2 69 Ignition Switch 1
1A_C Ignition Switch Power R-0.8-SXL 13F Cab-Pedestal 62 SPL_D21 CB A Load 1
1A_D CB A Load R-0.8-SXL 214F Ign Sw Cir Brkr 1 SPL_D21 CB A Load 1
1A_E Time Delay Pwr R-0.8-SXL 63M Time Delay Module 2 SPL_D21 CB A Load 1
1B Hazard Switch Pwr R-0.8-SXL 13M Pedestal-Cab 65 71 Hazard Switch 2
1B_A Brake Lt Sw Pwr R-1.0-SXL 159 Brake Lt Pres Sw 1 21M Rear-Cab 28
1B_B Flasher Module Pwr R-0.8-SXL 62M Flasher Module 1 SPL_D19 CB B Load 1
1B_C Hazard Switch Power R-0.8-SXL 13F Cab-Pedestal 65 SPL_D19 CB B Load 1
1B_D CB B Load R-0.8-SXL 212F Flasher Cir Brkr 1 21F Cab-Rear 28
1B_E Brake Lt Relay Pwr R-0.8-SXL 204F Relay Brake Lights 30 SPL_D19 CB B Load 1
1B_F CB B Load R-0.8-SXL 212F Flasher Cir Brkr 1 SPL_D19 CB B Load 1
1Y Fuel Filter Heater Relay Power R-8.0-SXL 283 Fuel Filter Heater Fuse 1 278 J Block Power 1
1Y_A Fuel Filter Heater Relay Power R-8.0-SXL 281 Fuel Filter Heater Fuse 1 280 Fuel Filter Heater Relay 87
1Y_B Fuel Filter Heater Power R-2.0-SXL 277F Engine Relay 2 287 Fuel Filter Heater A
1Y_C Fuel Filter Heater Power R-2.0-SXL 277F Engine Relay 1 288 Fuel Filter Heater A
1Y_D Fuel Filter Heater Power R-2.0-SXL 277M Relay Engine 2 280 Fuel Filter Heater Relay 30

4002-19

21C Bk - 1.0


Color, Size,
and Material
1Y_E Fuel Filter Heater Power R-2.0-SXL 280 Fuel Filter Heater Relay 30 277M Relay Engine 1
1Z Grid Heater Power R-19.0-SGT 137 Grid Heater Relay 1 285 Grid Heater 1
1_A B+ R-1.0-SXL 21M Rear-Cab 21 156 Fuel Str Rel B+ 1
1_B B+ R-13.0-SXL 156 Fuel Str Rel B+ 1 155 Cab Power B+ 1
1_C Grid Heater Relay Pwr R-8.0-SXL 190 Jblock Power 1 191 Jblock-Relay 1
1_D Grid Heater Relay Pwr R-19.0-SGT 284 Jblock Power 1 282 Grid Heater Fuse 1
1_DA Grid Heater Relay Pwr R-19.0-SGT 189 Jblock Power 1 192 Jblock Relay 1
1_E Starter Battery R-62.0-SGR 240F Starter Battery 1 195 Jblock Power 1
1_F Starter Sol Pwr R-8.0-GPT 193 Starter Relay 1 194 Starter Signal 1
1_G Acc Relay Pwr R-3.0-SXL 49F Accessory Relay 30 SPL_D16 B+ Power 1
1_H High Beam Signal (2 Way) R-3.0-SXL 59F High/Low Beam 8 SPL_D16 B+ Power 1
1_J B+ Pwr R-3.0-SXL 228F Power Cab 1 SPL_D17 B+ Power 1
1_K B+ Pwr R-3.0-SXL 226F Power Cab 1 SPL_D16 B+ Power 1
1_L CB A Power R-3.0-SXL 213F Ign Sw Cir Brkr 1 SPL_D17 B+ Power 1
1_M CB B Power R-3.0-SXL 211F Flasher Cir Brkr 1 SPL_D17 B+ Power 1
1_N Light Sw Power R-3.0-SXL 33F Light Switch C 224F Power Cab 1
1_NA Battery Crossover R-62.0-SGR 239 Discon-Blck Grnd 1 238F Battery Crossover 1
1_NB Starter-Battery R-62.0-SGR 240F Starter-Battery 1 241F Starter-Battery 1
1_NC Starter-Sec Strg Mtr R-62.0-SGR 245F Starter-Sec Strg Mtr 1 244F Starter-Sec Strg Mtr 1
1_P Voltmeter Rel Pwr R-0.8-SXL 58F Volt Meter Relay 30 21F Cab-Rear 21
1_Q Dome Lt Horn Pwr R-1.0-SXL 18F Fuse Block U1 SPL_D16 B+ Power 1
1_R Cigar Lighter Pwr R-3.0-SXL 18F Fuse Block W1 227F Power Cab 1
1_S Ign Relay #1 Pwr R-3.0-SXL 47F Ignition Relay #1 30 SPL_D17 B+ Power 1
1_T Ign Relay #2 Pwr R-3.0-SXL 48F Ignition Relay #2 30 SPL_D17 B+ Power 1
1_U B+ Power (4 Way) R-3.0-SXL 18F Fuse Block Z1 225F Power Cab 1
1_V Converter 24V Pwr R-5.0-SXL 250F Converter 24V Pwr 1 255F Converter 24V Pwr 1
1_W Sec Strg Mtr B+ R-1.0-SXL 263F Sec Str Mtr 1 90M Sec Str Mod 3
1_X Radio Memory Power R-1.0-SXL 270F Radio Memory Power 1 269 Radio Fuse Holder 1
21C_D Starter Fuel Relay Signal W-1.0-SXL 135 Starter Relay 1 21M Rear-Cab 11
21C_E Starter Fuel Relay Signal W-0.8-SXL 54F Neutral Start Relay 87 21F Cab-Rear 11
21C_F Starter Fuel Relay Signal W-0.8-SXL 54F Neutral Start Relay 87 140M Diode Module E

4002-20

21C Bk - 1.0


Color, Size,
and Material
21C_G Cranking Power W-0.8-SXL 201 Grid Heater Controller 5 54F Neutral Start Relay 87
21K Ign Sw Start Signal W-0.8-SXL 13M Pedestal-Cab 64 69 Ignition Switch 2
21K_A Ign Sw Start Signal W-0.8-SXL 54F Neutral Start Relay 30 13F Cab-Pedestal 64
23C Engine Shutdown Signal W-0.8-SXL 76 Instrument Cluster 23 13M Pedestal-Cab 23
23C_A Engine Shutdown Signal W-0.8-SXL 57F Engine Shutdown Relay 85 13F Cab-Pedestal 23
25A Eng Speed Sig W-0.8-BLD 22M Cab-Transmission 7 101 Eng Speed Sens 1
25A_A Eng Speed Sig LU-0.8-SXL 19F TECM 19 22F Cab-Transmission 7
25B Turb Speed Sig W-0.8-BLD 22M Cab-Transmission 8 96 Turb Speed Sens 1
25B_A Turb Speed Sig LU-0.8-SXL 19F TECM 41 22F Cab-Transmission 8
25C Int Speed Sig W-0.8-BLD 22M Cab-Transmission 9 95 Int Speed Sens 1
25C_A Int Speed Sig LU-0.8-SXL 19F TECM 42 22F Cab-Transmission 9
25D Output Speed Sig LU-1.0-SXL 22M Cab-Transmission 10 100 Out Speed Sens 2
25D_A Output Speed Sig LU-0.8-SXL 19F TECM 62 22F Cab-Transmission 10
25F Forward Signal LU-0.8-SXL 13M Pedestal-Cab 44 70 Transmission Shifter B
25F_A Forward Signal LU-0.8-SXL 19F TECM 43 13F Cab-Pedestal 44
25G Declutch Switch LU-1.0-SXL 4 Declutch Press Sw B 21M Rear-Cab 31
25G_A Declutch Switch LU-0.8-SXL 38F Declutch Switch 1 21F Cab-Rear 31
25G_B Declutch Switch LU-0.8-SXL 19F TECM 66 38F Declutch Switch 1
25H Trans Auto Signal LU-0.8-SXL 19F TECM 29 41F Trans Auto Sw 3
25J Trans Sol Valve Y6 LU-0.8-TXL 22M Cab-Transmission 21 102 Trans Control 6
25J_A Trans Sol Valve Y6 LU-0.8-SXL 19F TECM 51 22F Cab-Transmission 21
25K Trans Sol Valve Y1 LU-0.8-TXL 22M Cab-Transmission 16 102 Trans Control 1
25K_A Trans Sol Valve Y1 LU-0.8-SXL 19F TECM 56 22F Cab-Transmission 16
25L Trans Sol Valve Y2 LU-0.8-TXL 22M Cab-Transmission 17 102 Trans Control 2
25L_A Trans Sol Valve Y2 LU-0.8-SXL 19F TECM 10 22F Cab-Transmission 17
25M Trans Sol Valve Y3 LU-0.8-TXL 22M Cab-Transmission 18 102 Trans Control 3
25M_A Trans Sol Valve Y3 LU-0.8-SXL 19F TECM 32 22F Cab-Transmission 18
25N Trans Sol Valve Y4 LU-0.8-TXL 22M Cab-Transmission 19 102 Trans Control 4
25N_A Trans Sol Valve Y4 LU-0.8-SXL 19F TECM 55 22F Cab-Transmission 19
25P Trans Sol Valve Y5 LU-0.8-TXL 22M Cab-Transmission 20 102 Trans Control 5
25P_A Trans Sol Valve Y5 LU-0.8-SXL 19F TECM 9 22F Cab-Transmission 20

4002-21

21C Bk - 1.0


Color, Size,
and Material
25R Reverse Signal LU-0.8-SXL 13M Pedestal-Cab 45 70 Transmission Shifter C
25R_A Reverse Signal LU-0.8-SXL 19F TECM 64 13F Cab-Pedestal 45
25S Output Sw Power VPS1 LU-0.8-TXL 22M Cab-Transmission 22 102 Trans Control 7
25S_A Output Sw Power VPS1 LU-0.8-SXL 22F Cab-Transmission 22 SPL_D12 Common Power 1
25S_B Output Sw Power VPS1 LU-0.8-SXL 19F TECM 12 SPL_D12 Common Power 1
25S_C Output Sw Power VPS1 LU-0.8-SXL 19F TECM 13 SPL_D12 Common Power 1
25T_A Neutral Signal LU-0.8-SXL 92 Ether Switch 1 70 Transmission Shifter D
25T_B Neutral Signal LU-0.8-SXL 13M Pedestal-Cab 46 92 Ether Switch 1
25T_C Neutral Signal LU-0.8-SXL 13F Cab-Pedestal 46 SPL_D18 Neutral Signal 1
25T_D Neutral Signal LU-0.8-SXL 19F TECM 67 SPL_D18 Neutral Signal 1
25T_E Neutral Signal LU-0.8-SXL 54F Neutral Start Relay 86 SPL_D18 Neutral Signal 1
25W 3rd And 4th Gear Signal LU-0.8-SXL 13M Pedestal-Cab 48 183 Transmission Shifter B
25W_A 3rd And 4th Gear Signal LU-0.8-SXL 19F TECM 65 13F Cab-Pedestal 48
25Y Trans Kickdown Signal LU-0.8-SXL 13M Pedestal-Cab 50 183 Transmission Shifter D
25Y_A Trans Kickdown Signal LU-0.8-SXL 13F Cab-Pedestal 50 SPL_D11 Trans Kick Down Signal 1
25Y_B Trans Kickdown Sig LU-0.8-SXL 19F TECM 22 SPL_D11 Trans Kick Down Signal 1
25Y_C Trans Kickdown Signal LU-0.8-SXL 20M Trans Kick-Down 2 SPL_D11 Trans Kick Down Signal 1
25Z 1st And 4th Gear Signal LU-0.8-SXL 13M Pedestal-Cab 49 183 Transmission Shifter C
25Z_A 1st And 4th Gear Signal LU-0.8-SXL 19F TECM 63 13F Cab-Pedestal 49
26E Trans Enable Signal LU-0.8-SXL 19F TECM 31 199F Trans Enable Sw 3
26F_A FNR Forward Signal LU-0.8-SXL 198 FNR Switch 6 197M FNR-Main Cab 2
26F_B FNR Forward Signal LU-0.8-SXL 19F TECM 20 197F Main Cab FNR 2
26J FNR Switch Jumper LU-0.8-SXL 198 FNR Switch 2 198 FNR Switch 4
26N_A FNR Neutral Signal LU-0.8-SXL 198 FNR Switch 3 197M FNR-Main Cab 3
26N_B FNR Neutral Signal LU-0.8-SXL 19F TECM 44 197F Main Cab FNR 3
26R_A FNR Reverse Signal LU-0.8-SXL 198 FNR Switch 1 197M FNR-Main Cab 4
26R_B FNR Reverse Signal LU-0.8-SXL 19F TECM 30 197F Main Cab FNR 4
28C Ether Start Control W-0.8-SXL 13M Pedestal Cab 52 182 Ether Switch 1
28GC Grid Heater Signal W-0.8-SXL SPL_D26 B+ Power 1 201 Grid Heater Controller 6
28GC_A Grid Heater Signal W-0.8-SXL SPL_D26 B+ Power 1 21F Cab Rear 20
28GC_B Grid Heater Signal W-1.0-SXL 276F Relay Rear A 21M Rear Cab 20

4002-22

21C Bk - 1.0


Color, Size,
and Material
28GC_C Grid Heater Signal W-1.0-SXL 276M Relay Rear A 279M Grid Heater Relay 2
28GP Feedback of Grid Heater W-1.0-SXL 201 Grid Heater Controller 3 SPL_D26 B+ Power 1
31D Coolant Level Signal Y-1.0-SXL 104 Cool Level Sensor A 21M Rear-Cab 3
31D_A Coolant Level Signal Y-0.8-SXL 21F Cab-Rear 3 13F Cab-Pedestal 4
31D_B Coolant Level Signal Y-0.8-SXL 76 Instrument Cluster 4 13M Pedestal-Cab 4
31D_C Coolant Level Signal Y-0.8-SOLID 274F Coolant Jmpr Rear Chs A 275M Coolant Jmpr Coolant Sndr A
31F Air Filter Rest Sw Signal Y-1.0-SXL 94M Engine Trans 7 117 Air Filter Res Sw A
31F_A Air Filter Rest Sw Signal Y-1.0-SXL 22M Cab-Transmission 3 94F Eng-Trans 7
31F_B Air Filter Rest Sw Signal Y-0.8-SXL 22F Cab-Transmission 3 13F Cab-Pedestal 6
31F_C Air Filter Rest Sw Signal Y-0.8-SXL 76 Instrument Cluster 6 13M Pedestal-Cab 6
31H Hyd Oil Filter Rest Sw Signal Y-1.0-SXL 21M Rear-Cab 14 170 Hyd Oil Filter Res Sw 1
31H_A Hyd Filter Rest Sw Signal Y-0.8-SXL 21F Cab-Rear 14 13F Cab-Pedestal 7
31H_B Hyd Filter Rest Sw Signal Y-0.8-SXL 76 Instrument Cluster 7 13M Pedestal-Cab 7
31L Pilot Lockout Signal Y-0.8-SXL 76 Instrument Cluster 29 37 Pilot Control Switch 3
31T Temperature Sender Signal Y-0.8-SXL 201 Grid Heater Controller 10 21F Cab Rear 22
31T_A Grid Htr Temp Sender Signal Y-1.0-SXL 21M Rear Cab 22 290 Grid Heater Temperature Sw A
31U Fuel Filter Heater Signal W-1.0-SXL 289 Fuel Filter Temp Switch A 277F Engine Relay 3
31U_X Fuel Filter Heater Signal W-1.0-SXL 277M Relay Engine 3 280 Fuel Filter Heater Relay 85
31Y_B Grid Heater Lamp Ground Y-0.9-SXL 13M Pedestal Cab 11 97 Preheater Lamp 4
32F Trans Filter Maint Sw Y-1.0-SXL 22M Cab-Transmission 31 31 Filter Maint Sw 1
32F_A Trans Filter Maint Sw Y-0.8-SXL 19F TECM 17 22F Cab-Transmission 31
32J_A FNR Lt Signal Y-0.8-SXL 198 FNR Switch 7 197M FNR-Main Cab 5
32J_B Trans Enable Lt Sig Y-0.8-SXL 197F Main Cab FNR 5 199F Trans Enable Sw 9
32J_C Trans Enable Lt Sig Y-0.8-SXL 19F TECM 5 199F Trans Enable Sw 9
33P Low Brake Pres Warning Y-1.0-SXL 88 Brk Warn Pr Sw A 21M Rear-Cab 4
33P_A Low Brake Pres Warning Y-0.8-SXL 21F Cab-Rear 4 13F Cab-Pedestal 3
33P_B Low Brake Pres Warning Y-0.8-SXL 76 Instrument Cluster 3 13M Pedestal-Cab 3
33R_A Redundant Brake Sw Signal Y-1.0-SXL 157 Redundant Brake Sw A SPL_E10 SPL_E10 1
33R_B Redundant Brake Sw Signal Y-1.0-SXL 86 Redundant Brake Sw A SPL_E10 SPL_E10 1
33R_C Redundant Brake Sw Signal Y-1.0-SXL 21M Rear-Cab 15 SPL_E10 SPL_E10 1
33R_D Redundant Brake Sw Signal Y-0.8-SXL 21F Cab-Rear 15 13F Cab-Pedestal 28

4002-23

21C Bk - 1.0


Color, Size,
and Material
33R_E Redundant Brake Sw Signal Y-0.8-SXL 76 Instrument Cluster 28 13M Pedestal-Cab 28
33U Parking Brake Signal Y-0.8-SXL 76 Instrument Cluster 9 72 Parking Brake Switch 3
35A_A Left Reverse K-1.0-SXL 125 LH Rear Comb Lt 4 SPL_E2 SPL_E2 1
35A_B Right Reverse K-1.0-SXL 127 RH Rear Comb Lt 4 SPL_E2 SPL_E2 1
35A_C Reverse Lights K-1.0-SXL 21M Rear-Cab 7 SPL_E2 SPL_E2 1
35A_D Backup Alarm Relay Out Y-0.8-SXL 53F Backup Alarm Relay 87 21F Cab-Rear 7
35A_E Backup Alarm Relay Out Y-0.8-SXL 118F Backup Alarm Dis Sw 2 53F Backup Alarm Relay 87
35A_F Backup Alarm Relay Out Y-0.8-SXL 118F Backup Alarm Dis Sw 2 209M Backup Alarm Disa Jmp A
35C Backup Alarm Pull-Dwn Y-0.8-SXL 19F TECM 7 53F Backup Alarm Relay 85
35R_A Backup Alarm Sw Y-1.0-SXL 175 Backup Alarm 1 128M Lic/Backup Alarm B
35R_B Backup Alarm Sw Y-1.0-SXL 21M Rear-Cab 6 128F Rear-Hood B
35R_C Backup Alarm Sw Y-0.8-SXL 118F Backup Alarm Dis Sw 1 21F Cab-Rear 6
35R_D Backup Alarm Sw Y-0.8-SXL 118F Backup Alarm Dis Sw 1 209F Backup Alarm Disa Jmp A
35X_A Sec Str Low Pres Sig Y-1.0-SXL 131F Sec Str Pres Sw Opt C SPL_A4 SPL_A4 SPL_A4
35X_B Sec Str Low Pres Sig Y-1.0-SXL 1 Cab-Frnt Chas K SPL_A4 SPL_A4 SPL_A4
35X_C Sec Str Low Pres Sig Y-1.0-SXL 180F Sec Str Mod Opt 3 SPL_A4 SPL_A4 SPL_A4
35X_D Sec Str Low Pres Sig Y-1.0-SXL 90M Sec Str Mod 8 180M Sec Str Mod Frnt Harn 3
35X_E Sec Str Low Pres Sig Y-0.8-SXL 13F Cab-Pedestal 5 1 Cab-Frnt Chas K
35X_F Sec Str Low Pres Sig Y-0.8-SXL 76 Instrument Cluster 5 13M Pedestal-Cab 5
36C Eng Cool Temp Signal P-1.0-SXL 94M Engine Trans 13 138 Eng Cool Temp A
36C_A Eng Cool Temp Signal P-1.0-SXL 22M Cab-Transmission 4 94F Eng-Trans 13
36C_B Eng Cool Temp Signal P-0.8-SXL 22F Cab-Transmission 4 13F Cab-Pedestal 18
36C_C Eng Cool Temp Signal P-0.8-SXL 76 Instrument Cluster 18 13M Pedestal-Cab 18
36F Fuel Level Signal P-1.0-SXL 141 Fuel Sender 1 21M Rear-Cab 16
36F_A Fuel Level Signal P-0.8-SXL 21F Cab-Rear 16 13F Cab-Pedestal 19
36F_B Fuel Level Signal P-0.8-SXL 76 Instrument Cluster 19 13M Pedestal-Cab 19
36G Torque Conv Outpt Temp Signal P-1.0-SXL 22M Cab-Transmission 13 142 Torque Conv Temp Sender 1
36G_A Torque Conv Outpt Temp Signal P-1.0-SXL 19F TECM 49 22F Cab-Transmission 13
36H Hot Signal P-1.0-SXL 136 Hyd Oil Temp Send A 21M Rear-Cab 13
36H_A Hot Signal P-0.8-SXL 13F Cab-Pedestal 20 21F Cab-Rear 13
36H_B Hot Signal P-0.8-SXL 76 Instrument Cluster 20 13M Pedestal-Cab 20

4002-24

21C Bk - 1.0


Color, Size,
and Material
36P Engine Oil Pressure Signal P-1.0-SXL 94M Engine Trans 6 148 Engine Oil Pressure Switch 1
36P_A Engine Oil Pressure Signal P-1.0-SXL 22M Cab-Transmission 6 94F Engine Trans 6
36P_B Engine Oil Pressure Signal P-0.8-SXL 22F Cab-Transmission 6 13F Cab-Pedestal 22
36P_C Engine Oil Pressure Signal P-0.8-SXL 76 Instrument Cluster 22 13M Pedestal-Cab 22
36R_A Valve Body Temp Ret P-1.0-SXL 22M Cab-Transmission 12 SPL_H1 Splice H1 Splice
36R_B Valve Body Temp Ret P-1.0-SXL 31 Filter Maint Sw 2 SPL_H1 Splice H1 Splice
36R_C Valve Body Temp Ret P-0.8-SXL 102 Trans Control 9 SPL_H1 Splice H1 Splice
36R_D Valve Body Temp Ret P-1.0-SXL 142 Trq Conv Temp Sender 2 SPL_H1 Splice H1 Splice
36R_E Valve Body Temp Ret P-0.8-SXL 19F TECM 46 22F Cab-Transmission 12
36T Valve Body Temp Sig P-0.8-SXL 22M Cab-Transmission 5 102 Trans Control 8
36T_A Valve Body Temp Sig P-0.8-SXL 19F TECM 39 22F Cab-Transmission 5
37D Down Count Signal P-0.8-SXL 76 Instrument Cluster 27 74 Up Down Count Switch 1
37D_A Diagnostic Signal P-0.8-SXL 19F TECM 15 108F Diagnostic Connector 2
37E Diagnostic Signal P-0.8-SXL 19F TECM 18 108F Diagnostic Connector 4
37P Program Signal P-0.8-SXL 76 Instrument Cluster 24 75 Program Reset Switch 3
37R_A Reset Signal P-0.8-SXL 13M Pedestal-Cab 25 75 Program Reset Switch 1
37R_B Reset Signal P-0.8-SXL 76 Instrument Cluster 25 75 Program Reset Switch 1
37R_C Reset Signal P-0.8-SXL 63M Time Delay Module 4 13F Cab-Pedestal 25
37U Up Count Signal P-0.8-SXL 76 Instrument Cluster 26 74 Up Down Count Switch 3
41H High/Low Beam Relay Pwr K-2.0-SXL 59F High/Low Beam 4 18F Fuse Block C1’
41J_A Driving Light Sig K-2.0-SXL 33F Light Switch A 59F High/Low Beam 1
41J_B Driving Light Sig K-2.0-SXL 25F Light Switch A 33F Light Switch A
41L_A Low Beam Sig (2-Way) K-2.0-SXL 18F Fuse Block E1’ 59F High/Low Beam 3
41T_A Tail Lt Switched Pwr K-1.0-SXL 32F Light Switch C 18F Fuse Block G1’
41T_B Tail Lt Switched Pwr K-1.0-SXL 33F Light Switch B 32F Light Switch C
42C_A Front Flood Lts DU-1.0-SXL 24M Cab-Roof H 34F Light Switch A
42C_B LH Frnt Work Lt Pwr DU-1.0-SXL 79F LH Front Work Lt A SPL_M1 Frnt Work Lt Pwr 1
42C_C RH Frnt Work Lt Pwr DU-1.0-SXL 78F RH Front Work Lt A SPL_M1 Frnt Work Lt Pwr 1
42C_D Front Work Lts Pwr DU-1.0-SXL 24F Roof-Cab H SPL_M1 Frnt Work Lt Pwr 1
42R_A Work Light Telltale Sig Y-0.8-SXL 76 Instrument Cluster 12 13M Pedestal-Cab 12
42R_B Rear Work Light Pwr DU-0.8-SXL 23F Cab-Roof H 32F Light Switch A

4002-25

21C Bk - 1.0


Color, Size,
and Material
42R_C Rear Work Light Pwr DU-0.8-SXL 13F Cab-Pedestal 12 32F Light Switch A
42R_D LH Rear Work Lt Pwr DU-1.0-SXL 83F LH Rear Work Lt A SPL_M4 Rear Work Lt Pwr 1
42R_E RH Rear Work Lt Pwr DU-1.0-SXL 80F RH Rear Work Lt A SPL_M4 Rear Work Lt Pwr 1
42R_F Rear Work Light Pwr DU-1.0-SXL 23M Roof-Cab H SPL_M4 Rear Work Lt Pwr 1
44A_B Brake Lt Input Signal T-0.8-SXL 204F Relay Brake Lights 86 21F Cab-Rear 29
44_A Brake Light Signal T-1.0-SXL 125 LH Rear Comb Lt 1 SPL_E1 SPL_E1 1
44_B Brake Light Signal T-1.0-SXL 127 RH Rear Comb Lt 1 SPL_E1 SPL_E1 1
44_C Brake Light Signal T-1.0-SXL 21M Rear-Cab 8 SPL_E1 SPL_E1 1
44_D Brake Light Signal T-0.8-SXL 21F Cab-Rear 8 SPL_D9 Brake Lt Signal 1
44_E Brake Lt Relay Signal T-0.8-SXL 204F Relay Brake Lights 87 SPL_D9 Brake Lt Signal 1
44_F Brake Light Signal T-0.8-SXL 13F Cab-Pedestal 35 SPL_D9 Brake Lt Signal 1
44_G Brake Light Signal T-0.8-SXL 76 Instrument Cluster 35 13M Pedestal-Cab 35
45A Left Turn Switch Power N-0.8-SXL 13M Pedestal-Cab 69 66 Turn Signal Switch 1
45A_A Left Turn Switch Power N-0.8-SXL 62M Flasher Module 10 13F Cab-Pedestal 69
45B Right Turn Switch Power N-0.8-SXL 13M Pedestal-Cab 70 68 Turn Signal Switch 1
45B_A Right Turn Switch Power N-0.8-SXL 62M Flasher Module 9 13F Cab-Pedestal 70
45H Hazard Switch Power N-0.8-SXL 13M Pedestal-Cab 67 71 Hazard Switch 3
45H_A Hazard Switch Power N-0.8-SXL 62M Flasher Module 11 13F Cab-Pedestal 67
45L Left Turn Signal N-1.0-SXL 1 Cab-Frnt Chas A 6 Lights LH 5
45L_A Left Turn Signal N-1.0-SXL 125 LH Rear Comb Lt 2 21M Rear-Cab 10
45L_B Left Turn Signal N-0.8-SXL 21F Cab-Rear 10 SPL_D10 Left Turn Signal 1
45L_C Left Turn Signal N-0.8-SXL 1F Cab-Frnt Chas A SPL_D10 Left Turn Signal 1
45L_D Left Turn Signal N-0.8-SXL 62M Flasher Module 8 SPL_D10 Left Turn Signal 1
45L_E Left Turn Signal N-0.8-SXL 13F Cab-Pedestal 16 SPL_D10 Left Turn Signal 1
45L_F Left Turn Signal N-0.8-SXL 76 Instrument Cluster 16 13M Pedestal-Cab 16
45N_A Flasher Opp Side Cntrl N-0.8-SXL 64F Flasher Connector 1 62M Flasher Module 2
45N_B Flasher Opp Side Cntrl N-0.8-SXL 64M Flasher Connector 1 62M Flasher Module 12
45R Right Turn Signal N-1.0-SXL 1 Cab-Frnt Chas C 8 Lights RH 5
45R_A Right Turn Signal N-1.0-SXL 127 RH Rear Comb Lt 2 21M Rear-Cab 12
45R_B Right Turn Signal N-0.8-SXL 21F Cab-Rear 12 SPL_D20 Rt Turn Signal 1
45R_C Right Turn Signal N-0.8-SXL 13F Cab-Pedestal 17 SPL_D20 Rt Turn Signal 1

4002-26

21C Bk - 1.0


Color, Size,
and Material
45R_D Right Turn Signal N-0.8-SXL 1F Cab-Frnt Chas C SPL_D20 Rt Turn Signal 1
45R_E Right Turn Signal N-0.8-SXL 62M Flasher Module 7 SPL_D20 Rt Turn Signal 1
45R_F Right Turn Signal N-0.8-SXL 76 Instrument Cluster 17 13M Pedestal-Cab 17
46_A Beacon Switched Pwr K-0.8-SXL 23F Cab-Roof E 13F Cab-Pedestal 13
46_B Beacon Telltale K-0.8-SXL 76 Instrument Cluster 13 13M Pedestal-Cab 13
46_C Beacon Switched Pwr K-1.0-SXL 23F Cab-Roof E 42F Beacon Sw 3
46_D Beacon Switched Power K-1.0-SXL 23M Roof-Cab E 85F Beacon Light A
49_A Pilot Light S-0.8-SXL 13M Pedestal-Cab 51 71 Hazard Switch 8
49_B Pilot Light S-0.8-SXL 71 Hazard Switch 8 37 Pilot Control Switch 8
49_C Pilot Light S-0.8-SXL 37 Pilot Control Switch 8 72 Parking Brake Switch 8
49_D Pilot Light S-0.8-SXL 72 Parking Brake Switch 8 74 Up Down Count Switch 8
49_E Pilot Light S-0.8-SXL 74 Up Down Count Switch 8 75 Program Reset Switch 8
49_F Pilot Light Pwr S-0.8-SXL 13F Cab-Pedestal 51 SPL_D8 Pilot Lights 1
49_G Pilot Light S-0.8-SXL 199F Trans Enable Sw 8 SPL_D8 Pilot Lights 1
49_H Pilot Light S-0.8-SXL 210F Fan Reverser Sw 8 40F Pin Engage Sw 10
49_J Pilot Light S-0.8-SXL 34F Light Switch B SPL_D8 Pilot Lights 1
49_K Pilot Light S-1.0-SXL 39F Return To Travel Sw 8 34F Light Switch B
49_L Pilot Light S-0.8-SXL 45F Rear Wiper Sw 8 118F Backup Alarm Dis Sw 8
49_M Pilot Light S-1.0-SXL 39F Return To Travel Sw 8 36F Detent Switch 8
49_N Pilot Light S-1.0-SXL 36F Detent Switch 8 38F Declutch Switch 8
49_P Pilot Light S-1.0-SXL 40F Pin Engage Sw 10 44F Ride Control Sw 8
49_Q Pilot Light S-1.0-SXL 44F Ride Control Sw 8 41F Trans Auto Sw 8
49_R Pilot Light S-1.0-SXL 199F Trans Enable Sw 8 42F Beacon Sw 8
49_S Courtesy Pilot Lt S-1.0-SXL 24M Cab-Roof F SPL_D8 Pilot Lights 1
49_T Pilot Light S-1.0-SXL 42F Beacon Sw 8 118F Backup Alarm Dis Sw 8
49_U Pilot Light S-0.8-SXL 210F Fan Reverser Sw 8 SPL_D8 Pilot Lights 1
49_V Courtesy Pilot Lt S-0.8-SXL 24F Roof-Cab F 77F Courtesy Lt A
50G_A Can Ground Bk-0.8-SXL 13M Pedestal-Cab 34 SPL_K2 SPL_K2 1
50G_B Can Ground Bk-0_5-SXL SPL_K3 SPL_K3 1 SPL_K2 SPL_K2 1
50G_C Can Ground R-0_5-SXL SPL_K2 SPL_K2 1 SPL_K3 SPL_K3 1
50G_D Can Ground Bk-0.8-SXL 13F Cab-Pedestal 34 SPL_D6 Can Ground 1

4002-27

21C Bk - 1.0


Color, Size,
and Material
50G_E Can Ground Bk-0_5-SXL SPL_D7 Can Ground 1 SPL_D6 Can Ground 1
50G_F Can Ground R-0_5-SXL SPL_D7 Can Ground 1 SPL_D6 Can Ground 1
50G_G Can Pilot Sol Grnd Bk-0.8-SXL 219F Ground Cab 1 SPL_D7 Can Ground 1
50H Can H Y-0_5-SXL 76 Instrument Cluster 32 13M Pedestal-Cab 32
50H_A Can H Y-0_5-SXL 19F TECM 25 13F Cab-Pedestal 32
50L Can L G-0_5-SXL 76 Instrument Cluster 31 13M Pedestal-Cab 31
50L_A Can L G-0_5-SXL 13F Cab-Pedestal 31 SPL_D5 Can L 1
50L_B Can L G-0_5-SXL 19F TECM 26 SPL_D5 Can L 1
50L_C Can L G-0_5-SXL 19F TECM 27 SPL_D5 Can L 1
50T Can T Bk-0.8-SXL 76 Instrument Cluster 21 76 Instrument Cluster 33
51P_A Sec Str High Pres W-1.0-SXL 90M Sec Str Mod 9 180M Sec Str Mod Frnt Harn 4
51P_B Sec Str High Pres W-1.0-SXL 180F Sec Str Mod Opt 4 131F Sec Str Pres Sw Opt A
51_A Sec Str Mtr Rel W-1.0-SXL 90M Sec Str Mod 2 SPL_C2 1
51_B SPL_C2 W-1.0-SXL SPL_C2 1 181 Sec Str Mtr Relay 1
51_C Sec Strg Sol Pwr W-1.0-SXL 264M Sec Strg Sol Opt A SPL_C2 1
52C Parking Brake Signal W-0.8-SXL 76 Instrument Cluster 30 13M Pedestal-Cab 30
52C_A Parking Brake Signal W-0.8-SXL 55F Brake Lights Relay 85 13F Cab-Pedestal 30
52P Parking Brk Relay Out W-1.0-SXL 87 Parking Brk Sol 1 21M Rear-Cab 18
52P_A Parking Brk Relay Out W-0.8-SXL 19F TECM 21 55F Brake Lights Relay 87
52P_B Parking Brk Relay Out W-0.8-SXL 55F Brake Lights Relay 87 21F Cab-Rear 18
52_A Fan Reverse Sol W-0.8-SXL 210F Fan Reverser Sw 3 21F Cab-Rear 27
53B RTD Signal W-1.0-SXL 1 Cab-Frnt Chas M 12F RTD A
53B_A RTD Signal W-1.0-SXL 12M RTD A 200 RTD A
53B_B RTD Signal W-0.8-SXL 1F Cab-Frnt Chas M 17M RTD Height Cont RTT 3
53C Pilot Control Signal W-0.8-SXL 76 Instrument Cluster 36 13M Pedestal-Cab 36
53C_A Pilot Control Signal W-0.8-SXL 56F Pilot Control Relay 85 13F Cab-Pedestal 36
53P_A Pilot Control Signal W-0.8-SXL 56F Pilot Control Relay 87 89M Pilot Pres Sol A
53P_B Pilot Control Signal W-0.8-SXL 36F Detent Switch 2 56F Pilot Control Relay 87
53P_C Pilot Control Signal W-0.8-SXL 56F Pilot Control Relay 87 1F Cab-Frnt Chas B
53P_D Float Sol Power W-1.0-SXL 178M Float Switch A 1 Cab-Frnt Chas B
53S_A Float Sol Signal W-1.0-SXL 178M Float Switch B SPL_A5 SPL_A5 SPL_A5

4002-28

21C Bk - 1.0


Color, Size,
and Material
53S_B Float Sol Signal W-1.0-SXL 179F Float Solenoid 1 SPL_A5 SPL_A5 SPL_A5
53S_C Float Sw Signal W-1.0-SXL 202F Diode Module C SPL_A5 SPL_A5 SPL_A5
53S_D Float Sol Signal W-1.0-SXL 229M Diode Module B SPL_A5 SPL_A5 SPL_A5
53S_E Float Switch Signal W-1.0-SXL 273F Rollbck Jmpr Diode Mdl C 271M Frt Chassis Rollbck Jmpr C
54B Height-RTT Signal W-1.0-SXL 1 Cab-Frnt Chas L 10 Height Cntrl-RTT A
54B_A Height-RTT Signal W-0.8-SXL 1F Cab-Frnt Chas L SPL_D2 Height Cntrl-RTT Signal 1
54B_B RTT-Float Sw Load W-0.8-SXL 39F Return To Travel Sw 3 SPL_D2 Height Cntrl-RTT Signal 1
54B_C Height Cont Elec Mag W-0.8-SXL 17M RTD Height Cont RTT 2 SPL_D2 Height Cntrl-RTT Signal 1
55A RTT-Float Sw W-0.8-SXL 39F Return To Travel Sw 2 17M RTD Height Cont RTT 1
56_A Height-RTT Pwr W-1.0-SXL 10 Height Cntrl-RTT C SPL_A3 Splice A3 SPL_A3
56_B RTD Pwr W-1.0-SXL 12F RTD C SPL_A3 Splice A3 SPL_A3
56_C Prox Switch Pwr W-1.0-SXL 1 Cab-Frnt Chas T SPL_A3 Splice A3 SPL_A3
56_D RTD Pwr W-1.0-SXL 12M RTD C 200 RTD C
56_E Detent Switched Pwr W-0.8-SXL 17M RTD Height Cont RTT 6 SPL_D4 Detent Switched Pwr 1
56_F Detent Switched Pwr W-0.8-SXL 17M RTD Height Cont RTT 5 SPL_D4 Detent Switched Pwr 1
56_G Detent Switched Pwr W-0.8-SXL 17M RTD Height Cont RTT 4 SPL_D4 Detent Switched Pwr 1
56_H Detent Switched Pwr W-0.8-SXL 36F Detent Switch 3 SPL_D4 Detent Switched Pwr 1
56_J Prox Switch Pwr W-0.8-SXL 1F Cab-Frnt Chas T SPL_D4 Detent Switched Pwr 1
57_A Pin Engage Sol Pwr W-0.8-SXL 40F Pin Engage Sw 1 1F Cab-Frnt Chas U
58A_A Float Switch Signal W-1.0-SXL 272F Rollbck Jmpr Press Sw A 273F Rollbck Jmpr Diode Module A
58H_B Ride Cntl Sw Pwr VPS2 W-0.8-SXL 19F TECM 8 50F Ride Control Relay 86
58S Ride Cntl Relay Pwr W-0.8-SXL 50F Ride Control Relay 30 44F Ride Control Sw 3
58_A Ride Cntrl Sol Pwr W-0.8-SXL 50F Ride Control Relay 87 1F Cab-Frnt Chas V
58_B Ride Cntrl Sol Pwr W-0.8-SXL 50F Ride Control Relay 87 44F Ride Control Sw 6
58_C Ride Cntrl Sol Pwr W-1.0-SXL 5F Ride Control Opt 1 SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_D Ride Cntrl Sol Pwr W-1.0-SXL 202F Diode Module A SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_E Ride Cntrl Sol Pwr W-1.0-SXL 229M Diode Module A SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_F Float Switch Signal W-1.0-SXL 271M Frt Chs Rollbck Jmpr A 272F Rollbck Jmpr Press Sw B
61A AC High Pres Sw Or-1.0-SXL 94M Engine Trans 2 98 AC High Pres Sw A
61A_A AC High Pres Sw Or-1.0-SXL 22M Cab-Transmission 26 94F Eng-Trans 2
61A_B AC Relay Pwr Or-0.8-SXL 203F Relay AC 30 22F Cab-Transmission 26

4002-29

21C Bk - 1.0


Color, Size,
and Material
61A_C AC Relay Pwr Or-0.8-SXL 203F Relay AC 30 SPL_D3 AC Power 1
61A_D AC Thermostat Or-0.8-SXL 208F Thermostat Switch 1 A SPL_D3 AC Power 1
61A_E AC Low Pres Sw Or-0.8-SXL 27M AC Low Pres Sw B SPL_D3 AC Power 1
61C AC Comp Clutch Or-1.0-SXL 94M Engine Trans 4 99 AC Comp Clutch 1
61C_A AC Comp Clutch Or-1.0-SXL 22M Cab-Transmission 25 94F Eng-Trans 4
61C_B AC Comp Clutch Or-0.8-SXL 203F Relay AC 87a 22F Cab-Transmission 25
61C_C Splice Or-1.0-SXL SPL_N1 Splice 1 265F Diode Module C
61C_D AC Compressor Clutch Or-1.0-SXL 267F AC Compressor Clutch 1 SPL_N1 Splice 1
61C_E AC Compressor Clutch Or-1.0-SXL 266M AC Compressor Clutch 1 SPL_N1 Splice 1
61R AC High Pres Sw Or-1.0-SXL 94M Engine Trans 3 98 AC High Pres Sw B
61R_A AC High Pres Sw Or-1.0-SXL 22M Cab-Transmission 27 94F Eng-Trans 3
61R_B AC Relay Signal Or-0.8-SXL 203F Relay AC 87 22F Cab-Transmission 27
61R_C AC Relay Signal Or-0.8-SXL 203F Relay AC 87 203F Relay AC 86
61R_D AC Relay Signal Or-0.8-SXL 203F Relay AC 87 SPL_D1 1
61R_E AC Low Pres Sw Or-0.8-SXL 27M AC Low Pres Sw A SPL_D1 1
61R_F AC Telltale Or-0.8-SXL 13F Cab-Pedestal 10 SPL_D1 1
61R_G AC Telltale Or-0.8-SXL 76 Instrument Cluster 10 13M Pedestal-Cab 10
61T AC Thermostat Pwr Or-1.0-SXL 30F Blower Switch 6 207F Thermostat Switch A
62H Blower High Speed Or-2.0-SXL 29M Blower Motor 3 30F Blower Switch 3
62L Blower Low Speed Or-1.0-SXL 29M Blower Motor 1 30F Blower Switch 5
62M Blower Medium Speed Or-2.0-SXL 29M Blower Motor 2 30F Blower Switch 4
63C Front Wiper Park Or-0.8-SXL 13M Pedestal-Cab 59 61 Front-Wiper Motor D
63C_A Front Wiper Park Or-0.8-SXL 35F Wiper and Washer Sw 4 13F Cab-Pedestal 59
63H Front Wiper High Speed Or-0.8-SXL 13M Pedestal-Cab 57 61 Front-Wiper Motor A
63H_A Front Wiper High Speed Or-0.8-SXL 35F Wiper and Washer Sw 5 13F Cab-Pedestal 57
63H_B Front Wiper High Speed Or-0.8-SXL 35F Wiper and Washer Sw 5 140M Diode Module B
63L Front Wiper Low Speed Or-0.8-SXL 13M Pedestal-Cab 58 61 Front-Wiper Motor B
63L_A Front Wiper Low Speed Or-0.8-SXL 35F Wiper and Washer Sw 6 13F Cab-Pedestal 58
63L_B Front Wiper Low Speed Or-0.8-SXL 35F Wiper and Washer Sw 6 140M Diode Module A
63W Front Washer Pump Or-1.0-SXL 2 Front Washer 1 21M Rear-Cab 25
63W_A Front Washer Pump Or-0.8-SXL 35F Wiper and Washer Sw 3 21F Cab-Rear 25

4002-30

21C Bk - 1.0


Color, Size,
and Material
64C Horn Control Or-0.8-SXL 13M Pedestal-Cab 42 184 Horn Switch 1
64C_A Horn Control Or-0.8-SXL 51F Horn Relay 85 13F Cab-Pedestal 42
64D High/Low Beam Signal Or-0.8-SXL 13M Pedestal-Cab 55 186 High Low Beam 1
64D_A Low Beam Signal (2 Way) Or-0.8-SXL 59F High/Low Beam 6 13F Cab-Pedestal 55
64A Horn Or-0.8-SXL 51F Horn Relay 87 1F Cab-Frnt Chas N
65C Radio Power Or-0.8-SXL 114F Radio Radio Adapter 6 110F 24/12V Converter A
65C_B Radio Power Or-0.8-SXL 114M Radio Adapter Radio 6 113 Radio 14
65L Left Spkr Signal Or-0.8-SXL 114F Radio Radio Adapter 1 112M Left Speaker A
65L_A Left Spkr Signal Or-0.8-SXL 114M Radio Adapter Radio 1 113 Radio 11
65R Right Spkr Signal Or-0.8-SXL 114F Radio Radio Adapter 5 111M Right Speaker A
65R_A Right Spkr Signal Or-0.8-SXL 114M Radio Adapter Radio 5 113 Radio 9
68C_A Rear Wiper Park Or-1.0-SXL 23F Cab-Roof A 45F Rear Wiper Sw 1
68C_B Rear Wiper Park Or-1.0-SXL 23M Roof-Cab A 81M Rear Wiper Mtr D
68L_A Rear Wiper Low Speed Or-1.0-SXL 23F Cab-Roof G 45F Rear Wiper Sw 2
68L_B Rear Wiper Low Speed Or-0.8-SXL 45F Rear Wiper Sw 2 140M Diode Module F
68L_C Rear Wiper Low Speed Or-1.0-SXL 23M Roof-Cab G 81M Rear Wiper Mtr B
68W Rear Washer Pump Or-1.0-SXL 3 Rear Washer 1 21M Rear-Cab 24
68W_A Rear Washer Pump Or-1.0-SXL 45F Rear Wiper Sw 6 21F Cab-Rear 24

4002-31
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
2
Check the 10 ampere fuse at 3 4
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
5
6
1. This title is the number and component name on the Electrical Schematic.
2. This column shows the location of the check point.
3. This column shows the indication of the check.
4. This column shows the possible cause of a bad test indication.
5. The numbers in the parentheses show the number of the component on the Electrical Schematic.
6. This statement assumes that all other problems are solved at this point in the test.
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.
Co mpo ne nts can b e loc ate d o n th e Ele ctrica l
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters. Use the
following index to find the sheet a component is
located on.

NUMBER SHEET
12 Volt Radio (Option) 95 6
Accessory Relay No. 3 16 1
Air Conditioning High Pressure Switch 87 5
Air Conditioning Low Pressure Switch 86 5
Air Filter Restriction Switch 44 3
Alternator 4 1
Back-up Alarm 37 2
Back-up Alarm Disable Switch 36 2
Back-up Alarm Relay No. 7 35 2
Batteries 1 1
Beacon Switch 99 4
Blower Motor 85 5
Blower Motor Speed Resistors with Thermal Fuse 84 5

4002-32

NUMBER SHEET
Blower Switch 83 5
Brake Declutch Pressure Switch 32 2
Brake Lamp Pressure Switch 101 4
Brake Lamps Relay No. 6 102 4
Brake Warning Pressure Switch 38 3
Bucket Control Valves Electromagnetic Detents 60 5
Cigar Lighter (Option) 91 6
Compressor Clutch 90 5
Compressor Clutch Lockout Relay No. 14 89 5
Coolant Level Sender 39 3
Courtesy Lamp 118 4
Declutch Switch 31 2
Detent Switch 59 5
Diagnostic Connector 28 2
Dome Lamp 117 4
Engine Coolant Temperature Sender 43 3
Engine Fuel Solenoid 3 1
Engine Oil Pressure Switch 50 3
Engine Speed Sensor 20 2
FNR Switch 34 2
Fan Reverser Switch 55 5
Fan Reversing Solenoid 56 5
Filter Maintenance Switch 23 2
First Fuel Filter Heater 9 1
Five Position Rotary Lamp Switch 114 4
Flasher Module 105 4
Float Pressure Switch 64 5
Float Solenoid 65 5
Front Washer Pump Motor 76 5
Front Wiper Motor 74 5
Front Wiper and Washer Switch 75 5
Fuel Filter Heater Relay No. 16 7 1
Fuel Filter Heater Switch 8 1
Fuel Level Sender 40 3

4002-33

NUMBER SHEET
Grid Heater (Option) 11A 1
Grid Heater Controller (Option) 11C 1
Grid Heater Relay No. 15 (Option) 11 1
Grid Heater Temperature Sensor (Option) 11B 1
Hazard Switch 103 4
Height Control/Return-To-Travel Proximity Switch 63 5
High/Low Beam Relay No. 13 115 4
Horn 81 5
Horn Relay No. 5 80 5
Hydraulic Filter Restriction Switch 42 3
Hydraulic Oil Temperature Sender 41 3
Ignition Switch 13 1
Instrument Cluster 47 3
Intermediate Speed Sensor 21 2
LH Front Combination Lamp 108 4
LH Front Work Lamp 112 4
LH Rear Combination Lamp 106 4
LH Rear Work Lamp 110 4
Left Speaker (Option 97 6
License Plate Lamp 116 4
Master Disconnect Switch 2 1
Neutral Start Relay No. 8 12 1
Output Speed Sensor 19 2
Parking Brake Relay No. 9 52 3
Parking Brake Solenoid 53 3
Parking Brake Switch 46 3
Pilot Control Relay No. 10 51 3
Pilot Control Switch 48 3
Pilot Pressure Solenoid 54 3
Pin Engage Solenoid (Option) 70 5
Pin Engage Switch (Option) 69 5
Power Converter (24 Volts to 12 Volts) (Option) 92 6

4002-34

NUMBER SHEET
Power Outlet (Option) 93 6
Program/Reset Switch 45 3
Relay Socket No. 11 58 1
RH Front Combination Lamp 109 4
RH Front Work Lamp 113 4
RH Rear Combination Lamp 107 4
RH Rear Work Lamp 111 4
Radio Power Converter (24 Volts to 12 Volts) (Option) 96 6
Rear Washer Pump Motor 78 5
Rear Wiper and Washer Switch 77 5
Rear Wiper Motor 79 5
Redundant Brake Pressure Switches 57 3
Remote Radio or 24 Volt Radio (Option) 94 6
Return-To-Dig Proximity Switch 62 5
Return-To-Travel/Float Switch 61 5
Ride Control Relay No. 4 72 5
Ride Control Solenoid 73 5
Ride Control Switch 71 5
Right Speaker (Option) 98 6
Rotating Beacon 100 4
Seat Compressor and Switch 82 5
Secondary Fuel Filter Heater 10 1
Secondary Steering Module (Option) 66 5
Secondary Steering Motor (Option) 68 5
Secondary Steering Pressure Switch (Option) 67 5
Secondary Steering Solenoid (Option) 68A 5
Starter Motor 5 1
Starting Relay 6 1
Thermostat Switch 88 5
Time Delay Module 18 1
Torque Converter Output Temperature Sensor 24 2
Transmission Auto Switch 30 2
Transmission Electronic Control Module 26 2
Transmission Enable Switch 33 2

4002-35

NUMBER SHEET
Transmission Kick-Down Switch 29 2
Transmission Shifter 27 2
Transmission Solenoid Valve and Temperature Sender 25 2
Turbine Speed Sensor 22 2
Turn Signal, High/Low Beam, and Horn Switch 104 4
Up/Down Count Switch 49 3
Voltmeter Relay No. 12 17 1

4002-36
TROUBLESHOOTING BATTERIES, ENGINE FUEL SOLENOID, CHARGING,

STARTING, ALTERNATOR, FUEL FILTER HEATER, GRID HEATER,
IGNITION SWITCH AND RELAYS
13
7
11
5
4 6
11C
12
14
1
11A
3 11B
1
8 9 10
BC00N140
1. BATTERIES 7. FUEL FILTER HEATER RELAY NO. 16 11B.GRID HEATER TEMPERATURE
2. MASTER DISCONNECT SWITCH 8. FUEL FILTER HEATER SWITCH SENSOR (OPTION)
3. ENGINE FUEL SOLENOID 9. FIRST FUEL HEATER 11C.GRID HEATER CONTROLLER
4. ALTERNATOR 10. SECOND FUEL FILTER HEATER (621D ONLY) (OPTION)
5. STARTER MOTOR 11. GRID HEATER RELAY NO. 15 (OPTION) 12. NEUTRAL START RELAY NO. 8
6. STARTING RELAY 11A.GRID HEATER (OPTION) 13. IGNITION SWITCH
14. IGNITION RELAY NO. 1
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
1 – Batteries
NOTE: See Section 4003 and check the batteries.

4002-37
2 – Master Disconnect Switch

NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.

Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.

Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
3 – Engine Fuel Solenoid

NOTE: Disconnect connector 133M from fuel solenoid (3).
Between housing of fuel solenoid

and ground
12.7 ohms at
Between terminal 1 of fuel solenoid 20°C (68°F) Bad fuel solenoid.
and ground (Nominal)
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the ON position.
Check wire 13M and circuits 13C and 13K, also check circuit to
Terminal for wire 13M to ground 24 volts batteries. Bad master disconnect switch (2) or ignition switch
(13).
NOTE: If the readings are good, replace the fuel solenoid (3).
4 – Alternator
Between housing of alternator and

ground
Between the B+ terminal of Check circuit to positive post of left battery. Bad master
24 volts
alternator and ground disconnect switch.
Between terminal for wire 30 and 24 volts Bad wire 30.

ground
Between the B+ terminal of

24 volts Check circuit to positive post of left battery.
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
Terminal for wire 14 to ground 20 volts R. Check ignition relay No. 1, and 12.5 ampere circuit breaker
A.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).

4002-38
5 – Starter Motor
Between housing of starter and

ground
Starter B+ stud to ground 24 volts Check circuit to batteries.
Bad starting relay (6). Also check wire 1_F between starter (5)
Terminal S to ground 24 volts
and starting relay (6).
NOTE: If the readings are good, see Section 4004 and repair the starter (5).
6 – Starting Relay
Terminal for wire 0_UB to ground Continuity Bad ground circuit.
Terminal for wire 1_C to ground 24 volts Check circuit to batteries.
Terminal for wire 21C_D to ground 24 volts Check neutral start relay (12), also check circuit 21C.
Terminal for wire 1_F to ground 24 volts Bad starting relay (6).
7 – Fuel Filter Heater Relay No. 16

NOTE: Make sure engine temperature is below -3 °C (27 °F).
Terminal for wire 31U_X to ground Continuity Bad ground circuit or bad fuel filter heater switch (8).
Check 40 ampere fuse, also check circuit 1Y and circuit to

Terminal for wire 1Y_A to ground 24 volts
batteries.
Terminal for wire 13C_H to ground 24 volts Check ignition switch (13), also check circuits 13C and 13K.
Terminal for wires 1Y_D and 1Y_E 24 volts Bad fuel filter relay (7).
to ground

4002-39
8 – Fuel Filter Heater Switch

NOTE: The fuel filter heater switch opens at 13 ±3 °C (55 ±5 °F) and closes at 1.5 ±4 °C (34 ±8 °F).
Terminal for wire 0_BM to ground Continuity Bad ground circuit.
NOTE: Disconnect the connector from the fuel filter heater switch (8). Make sure the engine temperature is below
-3 °C (27 °F).
Between terminals A and B of fuel

Continuity Bad fuel filter heater switch (8).
filter heater switch (8)
9 – First Fuel Filter Heater

Terminal for wire 0_BL to ground Continuity Bad ground circuit.
NOTE: Disconnect connector 288 from first fuel filter heater.
Between terminals A and B of first

1.9 ohms Bad first fuel filter heater.
fuel filter heater
NOTE: If the readings are good, check circuit 1Y between first fuel filter heater connector 288 and fuel filter
heater relay connector 280.
10 – Second Fuel Filter Heater (621D Only)

Terminal for wire 0_BK to ground Continuity Bad ground circuit.
NOTE: Disconnect connector 287 from second fuel filter heater.
Between terminals A and B of

1.9 ohms Bad second fuel filter heater.
second fuel filter heater
NOTE: If the readings are good, check circuit 1Y between second fuel filter heater connector 287 and fuel filter
heater relay connector 280.
11 – Grid Heater Relay No. 15 (Option)

Terminal for wire 0_UC to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 1_DA to ground 24 volts Bad 150 ampere fuse. Check wires 1_DA and 1_D.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make
sure engine temperature is below -3 °C (27 °F).
Terminal for wire 28GC_C to ground 24 volts Bad grid heater controller (11C), also check circuit 28GC.
Terminal for wire 1Z to ground 24 volts Bad grid heater relay (11).

4002-40
11A – Grid Heater (Option)

Grid heater terminal B to ground Continuity Bad ground circuit.
NOTE: Disconnect terminal for wire 1Z from grid heater.
Between terminals of grid heater Resistance If an open or short circuit is obtained, replace the grid heater.
11B – Grid Heater Temperature Sensor (Option)

Terminal for wire 0_BC to ground Continuity Bad ground circuit.
NOTE: Disconnect connector 290 from grid heater temperature sensor.
2.26 to 2.76 K
Between terminals A and B of grid
ohms at 20°C Bad grid heater temperature sensor.
heater temperature sensor
(68°F)
NOTE: Resistance of grid heater temperature sensor decreases as temperature increases and increases as
temperature decreases.
11C – Grid Heater Controller (Option)

NOTE: Disconnect connector 201 from the grid heater controller.
Bad preheater lamp. Also check wires 18L_C, 18L_D, 31Y_B,

and 0_DBA.
110 to 140 Bad grid heater relay (11). Also check circuit 28GC, and wires
ohms 28GP, 0_UC, 0_UA, and 0_U.
110 to 140 Bad grid heater relay (11). Also check circuit 28GC, and wires
Connector terminal 6 to ground ohms 0_UC, 0_UA, and 0_U.
Connector terminal 8 to ground Continuity Bad ground circuit. Check wire 0_DBB.
2.26 to 2.76 K
Bad grid heater temperature sensor (11B). Also check circuit
Connector terminal 10 to ground ohms at 20°C
31T and wire 0_BC.
(68°F)
NOTE: Put master disconnect switch in ON position and ignition switch in ON position.
20 volts Bad fuse R. Check 75 ohms resistor and diode module. Check
ignition relay No. 1 (14) and 12.5 ampere circuit breaker A.
24 volts Bad fuse E. Check wire 19E. Also check ignition relay (14) and
12.5 ampere circuit breaker A.
NOTE: Have an assistant put transmission in neutral and ignition switch in START position.
Bad neutral start relay (12). Also check ignition switch (13) and
wire 21C_G.
NOTE: If all readings are good, replace the grid heater controller.

4002-41
12 – Neutral Start Relay No. 8

Terminal for wire 0_DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T_E to ground 24 volts Check circuit 25T.
Terminal for wire 21K_A to ground 24 volts Check circuit 21K_A and ignition switch.
Terminal for wire 21C_E to ground 24 volts Bad neutral start relay (12).
13 – Ignition Switch
Terminal for wire 1A to ground 24 volts Check circuit 1A to 12.5 ampere circuit breaker A.
NOTE: Disconnect the connector from the ignition switch (13). Turn the switch to ON.
NOTE: Hold the ignition switch (13) in the START position.
Between Bat and Starter Continuity Bad ignition switch (13).
NOTE: Put the switch in the Acc position.

Terminal for wire 0_DE to ground Continuity Bad ground circuit.
Terminal for wire 1_S to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 13K_A to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13P to ground 24 volts Bad ignition relay No. 1 (14)

4002-42
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER

RELAY, AND TIME DELAY MODULE
18 15
16
17
BC00N140
15. IGNITION RELAY NO. 2 17. VOLTMETER RELAY NO. 12
16. ACCESSORY RELAY NO. 3 18. TIME DELAY MODULE

Terminal for wire 1_T to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 13R to ground 24 volts Bad ignition relay No. 2 (15).

4002-43
16 – Accessory Relay No. 3

NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
Terminal for wire 1_G to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 12P_A to ground 24 volts Bad accessory relay (16).
17 – Voltmeter Relay No. 12

Terminal for wire 1_P to ground 24 volts Check circuit 1 to starter motor B+ stud.
NOTE: Turn ignition switch to the ON position.
Terminal for wire 13V to ground 24 volts Bad voltmeter relay (17).
18 – Time Delay Module

Terminal for wire 0_DAS to ground Continuity Bad ground circuit.
24 volts Bad 12.5 ampere circuit breaker A. Check wire 1_l to SPL_D17
Terminal for wire 1A_E to ground
and wire 1_J to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the program/reset switch
(45) in RESET position.
Terminal for wire 37R_C to ground 24 volts Bad program/reset switch (45), also check circuit 37R.
Terminal for wire 13K_F to ground 24 volts Bad ignition switch (13), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
Within 10 seconds of putting the 24 volts

ignition switch in the OFF position, Key OFF
Bad time delay module (18).
check terminal for wire 13D to 0 volt after 10
ground seconds
After 10 seconds of turning ignition

switch to the OFF position, check 0 volt Bad time delay module (18).
terminal for wire 13D to ground

4002-44
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND

SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR,
AND BACK-UP ALARM
,
27
32
25
24
37
29
23 26 30
33
28 31
20 34
35 36
21
22
19
BC00N140
19. OUTPUT SPEED SENSOR 29. TRANSMISSION KICK-DOWN SWITCH
20. ENGINE SPEED SENSOR 30. TRANSMISSION AUTO SWITCH
21. INTERMEDIATE SPEED SENSOR 31. DECLUTCH SWITCH
22. TURBINE SPEED SENSOR 32. BRAKE DECLUTCH PRESSURE SWITCH
23. FILTER MAINTENANCE SWITCH 33. TRANSMISSION ENABLE SWITCH
24. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 34. FNR SWITCH
25. TRANSMISSION SOLENOID VALVE AND TEMPERATURE 35. BACK-UP ALARM RELAY NO. 7
SENSORS
26. TRANSMISSION ELECTRONIC CONTROL MODULE 36. BACK-UP ALARM DISABLE SWITCH
27. TRANSMISSION SHIFTER 37. BACK-UP ALARM
28. DIAGNOSTIC CONNECTOR

4002-45
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 19 through 34.
19 – Output Speed Sensor

20 – Engine Speed Sensor
21 – Intermediate Speed Sensor
22 – Turbine Speed Sensor
23 – Filter Maintenance Switch
24 – Torque Converter Output Temperature Sender
25 – Transmission Solenoid Valve and Temperature Sensors
26 – Transmission Electronic Control Module
27 – Transmission Shifter
28 – Diagnostic Connector
29 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
30 – Transmission Auto Switch
31 – Declutch Switch
32 – Brake Declutch Pressure Switch
33 – Transmission Enable Switch
34 – FNR Switch
35 – Back-up Alarm Relay No. 7

NOTE: Disconnect the transmission electronic control module (26) quick disconnect connector.
Terminal for wire 35C to terminal 7 of

Continuity Bad wire 35C.
quick disconnect connector
24 volts Bad fuse A, also check wires 19A_P, 13P_A, and ignition relay
Terminal for wire 19A_P to ground
No. 1 (14).
24 volts Bad fuse H, also check wires 19H and 13R and ignition relay
Terminal for wire 19H to ground
No. 2 (15).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A_D to ground 24 volts Bad back-up alarm relay (35).

4002-46
36 – Back-up Alarm Disable Switch

position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A_E to ground 24 volts Bad back-up alarm relay (35), also check circuit 35A_E.
NOTE: Wires 35A_F and 35R_D are connected together and switch is removed in North American models. The
wires are disconnected and the switch is installed in TUV road approved (Germany) models.
Bad back-up alarm disable switch (36). If machine is not a TUV

Terminal for wire 35R to ground 24 volts
model, check wires 35A_F and 35R_D.
37 – Back-up Alarm
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
Bad back-up alarm disable switch (36), also check wires

Terminal for wire 35R to ground 24 volts 35R_C and 35R_B. If machine is not a TUV model, check wires
35R_C and 35R_B.
NOTE: If the readings are good, replace the back-up alarm (37).

4002-47
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS,

PROGRAM/RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT
CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH
44 39
43
45
38 46
42 47
48
41
49
40
BC00N140
38. BRAKE WARNING PRESSURE SWITCH 44. AIR FILTER RESTRICTION SWITCH
39. COOLANT LEVEL SENDER 45. PROGRAM/RESET SWITCH
40. FUEL LEVEL SENDER 46. PARKING BRAKE SWITCH
41. HYDRAULIC OIL TEMPERATURE SENDER 47. INSTRUMENT CLUSTER
42. HYDRAULIC FILTER RESTRICTION SWITCH 48. PILOT CONTROL SWITCH
43. ENGINE COOLANT TEMPERATURE 49. UP/DOWN COUNT SWITCH
SENDER

4002-48
38 – Brake Warning Pressure Switch

NOTE: Brake warning pressure switch opens at 117.2 bar (1700 psi).
Terminal B for wire 0 to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: Disconnect the wires from the brake warning pressure switch (38).
Between terminals A and B of the Continuity Bad brake warning pressure switch (38).
switch
NOTE: Start and run the engine at idle.
Bad brake warning pressure switch (38) or brake pressure is

Between terminals A and B of the
Open Circuit below 117.2 bar (1700 psi). Refer to Section 7002 to check
switch
brake pressure.
39 – Coolant Level Sender

Approximately
Terminal A for wire 31D to ground Check circuit 31D, also check the instrument cluster (47).
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender (39).
40 – Fuel Level Sender

Approximately
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the
wires from the fuel level sender.
Between terminals of fuel level 33 to 240

Bad fuel level sender (40).
sender ohms

4002-49
41 – Hydraulic Oil Temperature Sender

NOTE: Disconnect the connector from the hydraulic oil temperature sender.
Between terminals of hydraulic oil 130 to 9500

ohms Replace hydraulic oil temperature sender (41).
temperature sender
Approximately
Terminal A for wire 36H to ground Check the instrument cluster (47).
5 volts
42 – Hydraulic Filter Restriction Switch

NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
Check between the housing of the

Bad ground connection between the hydraulic filter restriction
hydraulic filter restriction switch (42) Continuity
switch (42) and ground.
and ground
Approximately
Terminal A for wire 31H to ground. 11.5 volts Check the instrument cluster (47).
NOTE: If the readings are correct replace the hydraulic filter restriction switch (42).
43 – Engine Coolant Temperature Sender

Terminal for wire 0_BE to ground Continuity Bad ground circuit.
NOTE: Disconnect the connector from the engine coolant temperature sender.
Between terminals of engine coolant 130 to 9500

Replace engine coolant temperature sender.
temperature sender ohms
Approximately
Terminal A for wire 36C to ground Check the instrument cluster (47).
5 volts

4002-50
44 – Air Filter Restriction Switch

NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
Terminal for wire 0_BD to ground Continuity Bad ground circuit.
Approximately
Terminal for wire 31F to ground Check the instrument cluster (47).
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (44).
45 – Program/Reset Switch
Terminal for wire 0_KM to ground Continuity Bad ground circuit.
Terminal for wire 1A_B to ground 24 volts Check 12.5 ampere circuit breaker A. Also check circuit 1A.
NOTE: Press and hold the program/reset switch in the reset position.
Terminal for wire 37R to ground 24 volts Bad program/rest switch.
NOTE: Put the program/reset switch (45) in the program position.
Terminal for wire 37P to ground 24 volts Bad program/reset switch.
Bad rotary lamp switch. Also check fuse Z and circuit 49 and
Terminal for wire 49_E to ground 24 volts
19Z.
NOTE: If 24 volts between wire 49 and ground and program/reset switch is not illuminated, replace program/reset
switch.
46 – Parking Brake Switch

Terminal for wire 0_KJ to ground Continuity Bad ground circuit.
Terminal for wire 19A to ground 24 volts Check fuse A, also check circuit 19A.
NOTE: Apply parking brake switch (46).
Terminal for wire 33U to ground 24 volts Bad parking brake switch (46).
24 volts Bad rotary lamp switch. Also check fuse Z and circuits 49 and
19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.

4002-51
47 – Instrument Cluster
NOTE: Disconnect the connector from the instrument cluster.
Bad brake warning pressure switch (38). Also check circuit 33P
and ground circuit at brake warning pressure switch.
Continuity Bad coolant level sender (39). Also check circuit 31D and
ground circuit at coolant level sender.
Bad secondary steering pressure switch (67). Also check

circuit 35X and ground circuit at pressure switch.
Connector terminal 6 to ground Open Circuit Bad air filter restriction switch (44). Also check circuit 31F.
Connector terminal 7 to ground Open Circuit Bad hydraulic filter restriction switch. Also check circuit 31H.
Continuity Bad ground circuit. Check wires 0_KP, 0_DAV, 0_HC, and
0_BG.
130 to 9500 Bad engine coolant temperature sender (43). Also check circuit
Connector terminal 18 to ground ohms circuit 36C and ground circuit at sender.
Bad fuel level sender (40). Also check circuit 36F and ground
Connector terminal 19 to ground 33 to 240 ohms
circuit at sender.
130 to 9500 Bad hydraulic oil temperature sender (41). Also check circuit
ohms 36H and ground circuit at sender.
Connector terminal 21 to connector

Continuity Bad wire 50T.
terminal 33
237 to 243 Bad engine oil pressure switch (50). Also check circuit 36P and
ohms ground circuit.
Connector terminal 28 to ground Open Circuit Bad redundant brake switche(s) (57). Also check circuit 33R.
Connector terminal 31 to terminals

26 and 27 on the transmission Continuity Bad circuit 50L.
electronic control module (26)
Connector terminal 32 to terminal 25

on the transmission electronic Continuity Bad circuit 50H.
control module (26)
Check LH and RH stop lamps and circuit 44. Also check ground
circuit at lamps.
Connector terminal 1 to ground 24 volts Bad fuse V. Also check circuit 19V.
Connector terminal 2 to ground 24 volts Bad fuse S. Also check circuit 19S.
Connector terminal 9 to ground 24 volts Bad parking brake switch. Also check fuse A and circuit 19A.

4002-52

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the five position rotary lamp switch in position four or five.
Check lamp switch and fuse A’. Also check circuits18A and
42R.
NOTE: Put the rotating beacon switch in the ON position.
Connector terminal 13 to ground 24 volts Check rotating beacon switch and fuse X. Also check circuit 46.
NOTE: Put the five position rotary lamp switch in position four or five. Put the high/low beam switch in HIGH
BEAM position.
Check high/low beam switch, high/low beam relay, five position

Connector terminal 15 to ground 24 volts rotary lamp switch, and fuse C’. Also check circuits 18C and
64D and wires 41H and 41J_A.
NOTE: Put the turn signal switch in the LEFT TURN position.
Connector terminal 16 to ground off every 1-2 check wire 19B, circuit 45A to flasher module, and circuit 45L
NOTE: Put the turn signal switch in the RIGHT TURN position.
Connector terminal 17 to ground off every 1-2 check wire 19B, circuit 45B to flasher module, and circuit 45R
NOTE: Put the program/reset switch in the PROGRAM position.
24 volts Bad program/reset switch. Also check wire 37P and wire 1A_B
to ignition switch.
NOTE: Press and hold the program/reset switch in the RESET position.
Bad program/reset switch. Also check wire 37R_B and wire

1A_B to ignition switch.
NOTE: Press and hold up/down count switch in UP position.

Connector terminal 26 to ground 24 volts Also check wires 37U and wire 13D from time delay module to
NOTE: Press and hold up/down count switch in DOWN position.

Connector terminal 27 to ground 24 volts Also check wire 37D and wire 13D from time delay module to

4002-53

Bad pilot control switch or fuse C. Also check wire 31L and
circuit 19C.
Bad parking brake relay or fuse D. Also check circuits 52C and
19D.
Bad pilot control relay or fuse C. Also check circuits 53C and
19C.
48 – Pilot Control Switch

Terminal for wire 31L to ground 24 volts Bad pilot control switch (48).
24 volts Check five position rotary lamp switch (114) and fuse Z. Also
check circuit 49.
NOTE: If the readings are correct replace the pilot control switch (48).
49 – Up/down Count Switch

Check fuse S and time delay module. Also check circuits 19S
Terminal for wire 19S to ground 24 volts
and 13D from time delay module to fuse S.
NOTE: Press and hold the up/down switch in the DOWN COUNT position.
Terminal for wire 37D to ground 24 volts Bad up/down count switch.
NOTE: Press and hold the up/down switch in the UP COUNT position.
Terminal for wire 37U to ground 24 volts Bad up/down count switch.
Check five position rotary lamp switch (114) and fuse Z. Also
check circuit 49.

4002-54
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL,

PARKING BRAKE, AND REDUNDANT BRAKE SWITCHES
53
57
56
55
54
51
52
58
50
BC00N140
50. ENGINE OIL PRESSURE SWITCH 55. FAN REVERSER SWITCH (OPTION)
51. PILOT CONTROL RELAY NO. 10 56. FAN REVERSING SOLENOID (OPTION)
52. PARKING BRAKE RELAY NO. 9 57. REDUNDANT BRAKE SWITCHES
53. PARKING BRAKE SOLENOID 58. RELAY SOCKET NO. 11
54. PILOT PRESSURE SOLENOID

4002-55
50 – Engine Oil Pressure Switch


Continuity Bad engine oil pressure switch (50).
(50) terminals C and NC

Open Circuit Bad engine oil pressure switch (50).
(50) terminals C and NO
Between engine oil pressure switch 237 to 243

Bad ground connection or bad ground wire assembly.
(50) terminal NC and ground ohms
Between engine oil pressure switch 90 to 92 ohms Bad ground connection or bad ground wire assembly.
(50) terminal NO and ground
NOTE: Disconnect wire 36P from terminal C of engine oil pressure switch. Put master disconnect switch and
ignition switch in ON position.
Approximately
Terminal for wire 36P to ground Bad instrument cluster (47) or bad circuit 36P.
5 volts
NOTE: Start engine and operate at idle speed.

90 to 92 ohms Bad engine oil pressure switch.
terminal C and ground
51 – Pilot Control Relay No. 10

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(48) is OFF.
Terminal for wire 53P to ground 24 volts Bad pilot control relay.
NOTE: Put the pilot control switch in ON position.
Terminal for wire 53C to ground 24 volts Bad instrument cluster (47). Also check circuit 53C.
52 – Parking Brake Relay No. 9

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (46) is OFF.
Terminal for wire 19D_B to ground 24 volts Bad fuse D, also check circuit 19D.
Terminal for wire 52P to ground 24 volts Bad parking brake relay.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (47). Also check wire 52C.

4002-56
53 – Parking Brake Solenoid

NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (52). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid (53).
54 – Pilot Pressure Solenoid

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (48) is OFF.
Terminal A for wire 53P to ground 24 volts Bad pilot control relay (51), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid (54).
55 – Fan Reversing Switch (Option)

Terminal for wire 0_DAF to ground Continuity Bad ground circuit.
Check fuse P, ignition relay No. 1, and wires 19P_A and

Terminal for wire 19P_B to ground 24 volts
13P_B.
NOTE: Put fan reversing switch in ON position (hold rocker in momentary position).
Terminal for wire 52_A to ground 24 volts Bad fan reversing switch.
NOTE: Put five position rotary lamp switch in position 3 or higher.
Check five position rotary lamp switch. If LEDs in fan reversing

Terminal for wire 49_U to ground 24 volts switch are not ON with 24 volts at check point, replace fan
reversing switch.

4002-57
56 – Fan Reversing Solenoid (Option)

NOTE: Disconnect wiring harness connector 158 from fan reversing solenoid.
Between pins 1and 2 of fan

36 to 42 ohms Bad fan reversing solenoid.
reversing solenoid
Pin 2 of wiring harness connector Continuity Bad ground circuit.

158 to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in
ON position (hold rocker in momentary position).
Pin 1 of wiring harness connector

24 volts Bad fan reversing switch. Also check wire 52_A.
158 to ground
57 – Redundant Brake Pressure Switches

NOTE: Redundant brake switches close at 62 bar (900 psi).
Approximately
Terminal A for wire 33R to ground 11.5 volts Bad instrument cluster (47), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es) (57).
58 – Relay Socket No. 11

Bad instrument cluster (47). Also check circuit 23C to

Terminal for wire 23C_A to ground 0 volt
instrument cluster.
Terminal for wire 19F to ground 24 volts Bad fuse F. Also check circuit 19F to ignition relay No. 2 (15).
Terminal for wire 13K_B to ground 24 volts Check wire 13K_B to ignition relay No. 2 (15).
Check wires 13K_D and 13C_B and connectors 217F and

Terminal for wire 13C_D to ground 24 volts
217M.

4002-58
TROUBLESHOOTING BUCKET CONTROLS
63
62
65
64
60
59
61
BC00N140
59. DETENT SWITCH 63. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY
SWITCH
60. BUCKET CONTROL VALVES ELECTROMAGNETIC DETENTS 64. FLOAT PRESSURE SWITCH
61. RETURN TO TRAVEL/FLOAT SWITCH 65. FLOAT SOLENOID
62. RETURN TO DIG PROXIMITY SWITCH

4002-59
59 – Detent Switch
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in
the OFF position.
Terminal for wire 53P_B to ground 24 volts Bad pilot control relay (51), also check circuit 53P_B.
NOTE: Put the detent switch (59) in the ON position.
Terminal for wire 56_H to ground 24 volts Bad detent switch (59).
Bad circuit 49_M. Also check five position rotary lamp switch
Terminal for wire 49_M to ground 24 volts (114). If detent switch illumination LED does not turn ON with
24 volts at check point, replace detent switch (59).
60 – Bucket Control Valve Electromagnetic Detents

NOTE: Disconnect the wiring harness connector from the control valve electromagnetic detents connector.
Electromagnetic detents connector, 65 to 71 ohms Bad return-to-travel detent electromagnet.


65 to 71 ohms Bad height control detent electromagnet.

65 to 71 ohms Bad return-to-dig control detent electromagnet.
Wiring harness connector 17M, pin 4 Bad detent switch (59). Also check wires 53P_B, 56_G, and
24 volts
to ground 56_H.
Wiring harness connector 17M, pin 6 24 volts Bad detent switch (59). Also check wires 56_E and 56_H.
to ground
Wiring harness connector 17M, pin 5 24 volts Bad detent switch (59). Also check wires 56_F and 56_H.
to ground

4002-60
61 – Return-To-Travel/Float Switch
Terminal for wire 0_DAG to ground Continuity Bad ground circuit.
Terminal for wire 0_DAH to ground Continuity Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch (61). Put the return-to-
travel/float switch (61) in FLOAT position.
NOTE: Put the return-to-travel/float switch (61) in the TRAVEL position.
Bad return-to-travel detent electromagnet. Also check circuit

Pin 2 of connector 39F to ground 24 volts
55A.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch (61).
Put ignition switch in ON position. Put five position rotary lamp switch (114) in position 3 or higher.
Bad circuit 49_K. Also check five position rotary lamp switch
(114). If return-to-travel/float switch illumination LED is not ON
Terminal for wire 49_K to ground 24 volts
with 24 volts at check point, replace return-to-travel/float
switch.
62 – Return-To-Dig Proximity Switch

NOTE: Disconnect the connector from the return-to-dig proximity switch (62). Put the master disconnect switch
and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position and the detent
switch (59) in the ON position.
Terminal B for wire 0_AM to ground Continuity Bad ground circuit.

Terminal A for wire 53B_A to ground 24 volts
switch (59). Also check circuit 53B_A.
Terminal C for wire 56_D to ground 24 volts Bad detent switch (59), also check circuit 56.
NOTE: If the readings are good, replace the return-to-dig proximity switch (62).

4002-61
63 – Height Control/Return-To-Travel Proximity Switch

NOTE: Disconnect the connector from the height control/return-to-travel proximity switch (63). Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position
and the detent switch (59) in the ON position.
Terminal B for wire 0_AA to ground Continuity Bad ground circuit.

Terminal A for wire 54B to ground 24 volts
switch (59). Also check circuit 54B.
Terminal C for wire 56_A to ground 24 volts Bad detent switch (59). Also check circuit 56.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch (63).
64 – Float Pressure Switch

NOTE: Disconnect the wiring harness connector 178M from the float pressure switch.

Open Circuit Bad float pressure switch.
switch

Continuity Bad float pressure switch.
switch
NOTE: Shut down engine. Put ignition switch in ON position. Put pilot control switch in OFF position (switch LED
OFF).
Wiring harness connector 178M, pin

24 volts Bad pilot control relay. Also check wires 53P_C and 53P_D.
A and ground
65 – Float Solenoid
NOTE: Disconnect the wiring harness connector 179F from the float solenoid.
Between terminals of float solenoid 37 to 43 ohms Bad float solenoid.

to ground
Wiring harness connector 179F pin 1 24 volts Bad float pressure switch. Also check wires 53S_A and 53S_B.
to ground

4002-62
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE

CONTROL
71
69 70
67
66
68A 73
72
68
BC00N140
66. SECONDARY STEERING MODULE (OPTION) 70. PIN ENGAGE SOLENOID (OPTION)
67. SECONDARY STEERING PRESSURE SWITCH (OPTION) 71. RIDE CONTROL SWITCH
68. SECONDARY STEERING MOTOR (OPTION) 72. RIDE CONTROL RELAY NO. 4
68A.SECONDARY STEERING SOLENOID (OPTION) 73. RIDE CONTROL SOLENOID
69. PIN ENGAGE SWITCH (OPTION)

4002-63
66 – Secondary Steering Module (Option)

NOTE: Disconnect the wiring harness connector 90M from the secondary steering module.
Bad relay on secondary steering motor (68) or bad secondary

Pin 2 of connector 90M to ground Continuity steering solenoid (68A). Also Check wires 51_A, 51_B, and
51_C and ground circuit connections (wires 0_ND and 0_CF).

Pin 8 of connector 90M to ground Continuity
35X_D, 35X_C, and 35X_A.

Pin 9 of connector 90M to ground Open Circuit
51P_A and 51P_B.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector 90M to ground 24 volts Bad wire 1_W to secondary steering motor (68) B+ stud.
Pin 7 of connector 90M to ground 24 volts Bad fuse M or ignition switch. Also check circuits 19M and 12K.
Check fuse R, ignition relay No. 1, ignition switch, and diode

Pin 1 of connector 90M to ground 24 volts
module. Also check circuits 19R and 13P_B.
Pin 9 of connector 90M to ground Continuity Bad secondary steering pressure switch.
11 volts Check circuit 35X to instrument cluster. If circuit 35X okay,

Pin 8 of connector 90M to ground
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector 90M to secondary
steering module. Disconnect wire 51_B from secondary steering motor (68) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector 131F from secondary steering pressure switch (67). Apply a
ground to pin C of connector 131F.
Terminal for wire 51_B to ground 24 volts Bad secondary steering module.
67 – Secondary Steering Pressure Switch (Option)

NOTE: Disconnect wiring harness connector 131F from secondary steering pressure switch (67).
Pressure switch (67) pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin A to pin C Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin C Open Circuit Bad secondary steering pressure switch.

4002-64
68 – Secondary Steering Motor (Option)

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

ground terminal to ground
Bad secondary steering motor (68) relay coil or secondary

Terminal for wire 51_B to ground. 10 to 45 ohms steering solenoid (68A). Also check relay coil and solenoid
ground circuit.
NOTE: Put the master disconnect switch in ON position.
Terminal for red wire to ground 24 volts Check circuit to batteries.
NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO
NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is
associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect
wire 51_B from secondary steering motor relay.
Check fuses M and R, secondary steering module (66), and

secondary steering pressure switch (67). If 24 volts is obtained
the secondary steering motor is bad. If fuse M or R was
Terminal for wire 51_B to ground 24 volts replaced: if fuse M blows again, secondary steering module is
bad; if fuse R blows again, secondary steering module is bad
or secondary steering motor relay or secondary steering
solenoid is shorted.
68A – Secondary Steering Solenoid (Option)

NOTE: Disconnect connector 264M from secondary steering solenoid.
Between pins A and B of secondary

36 to 42 ohms Bad secondary steering solenoid.
steering solenoid
Between pin B of connector 264M

and ground
NOTE: Disconnect wire 51_B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position.
Between pin A of connector 264M Check secondary steering module (66) and secondary steering
24 volts
and ground pressure switch (67).

4002-65
69 – Pin Engage Switch (Option)

Terminal for wire 0_DAL to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
24 volts Bad fuse P or ignition relay No. 2. Also check circuits 19P_A
Terminal for wire 19P_A to ground
and 13P_B.
Terminal for wire 57_A to ground 0 volt Bad pin engage switch.
NOTE: Put the pin engage switch (69) in the ON position.
Terminal for wire 57_A to ground 24 volts Bad pin engage switch.
Check the five position rotary lamp switch (114). Also check
Terminal for wire 49_P to ground 24 volts circuit 49. If LED in pin engage switch is not ON with 24 volts
at check point, replace pin engage switch.
70 – Pin Engage Solenoid (Option)

Terminal for wire 0_AB to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(69) in the ON position.
Terminal for wire 57 to ground 24 volts Bad pin engage switch (69), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (70).

4002-66
71 – Ride Control Switch

NOTE: Disconnect connector 44F from ride control switch (71).
Ride control switch terminal 6

Continuity Bad ride control switch.
(positive) to terminal 7 (negative)
NOTE: Connect connector 44F to ride control switch (71). Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Check fuse C and ignition relay No. 1. Also check circuits 19C
Terminal for wire 19C_B to ground 24 volts
and 13P_A.
Terminal for wire 58S to ground 0 volt Bad ride control switch.
NOTE: Put the ride control switch (71) in the ON position.
Terminal for wire 58S to ground 24 volts Bad ride control switch.
NOTE: Put the five position rotary light switch (114) in position 3 or higher.
Terminal for wire 49_P to ground 24 volts 49. If LED in ride control switch is not ON with 24 volts at check
point, replace ride control switch.
72 – Ride Control Relay No. 4

Terminal 85 for wire 0_DD to

Continuity Check wire 44F.
connector 19F pin 57
Terminal 86 for wire 58H_B to

Continuity Check wire 58H_B.
connector 19F pin 8
Terminal 87 for wire 58_B to ride Continuity Check wire 58_B

control switch (71) pin 6
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
Terminal for wire 58S to ground 24 volts Bad ride control switch. Also check wire 58S.
NOTE: If readings are normal, replace ride control relay (72).
73 – Ride Control Solenoid

NOTE: Disconnect connector 5F from ride control solenoid.
Between terminals 1 and 2 of ride

20 to 26 ohms Bad ride control solenoid.
control solenoid

4002-67
TROUBLESHOOTING WIPER/WASHER
74
79
75
77
78 76
BC00N140
74. FRONT WIPER MOTOR 77. REAR WIPER AND WASHER SWITCH
75. FRONT WIPER AND WASHER SWITCH 78. REAR WASHER PUMP MOTOR
76. FRONT WASHER PUMP MOTOR 79. REAR WIPER MOTOR

4002-68
74 – Front Wiper Motor

Terminal for wire 0_KN to ground Continuity Bad ground circuit.
NOTE: Make sure the front wiper and washer switch (75) is in the OFF position.
Between terminals B and D for wires

Continuity Bad front wiper motor.
63C and 63L
Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75).
Terminal for wire 63L to ground 24 volts pulse Bad front wiper and washer switch (75).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (75).
NOTE: If the readings are good, replace the front wiper motor (74).

4002-69
75 – Front Wiper and Washer Switch

Terminal for wire 0_DAR to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch (75) is in the OFF position.
Terminal for wire 19J_A to ground 24 volts Check fuse J, also check circuit 19J.
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75)
Check fuse J, also check circuit 19J. Bad front rotary wiper and
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75).
Terminal for wire 63L_A to ground 24 volts pulse Bad front wiper and washer switch (75).
Terminal for wire 63C_A to ground 24 volts pulse Bad front wiper and washer switch (75).
76 – Front Washer Pump Motor

Terminal for wire 0_G to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (75).
24 volts Bad front wiper and washer switch (75), also check wires 63W
Terminal for wire 63W to ground
and 63W_A.
NOTE: If the readings are good, replace the front washer pump motor (76).

4002-70
77 – Rear Wiper and Washer Switch

Terminal for wire 0_DW to ground Continuity Bad ground circuit.
Terminal for wire 19K_D to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
Terminal for wire 19K_C to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Press and hold the rear wiper and washer switch (77) in the WASH position.
Terminal for wire 68W_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Put the five position rotary lamp switch in position 3 or higher.
Check rotary lamp switch and circuit 49. If LEDs in rear wiper
Terminal for wire 49_L to ground 24 volts and washer switch are not ON with 24 volts at check point,
replace rear wiper and washer switch.
78 – Rear Washer Pump Motor

Terminal for wire 0_F to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (77) in WASH position.
Bad rear wiper and washer switch (77) Also check wires
Terminal for wire 68W to ground 24 volts
68W_A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor (78).
79 – Rear Wiper Motor

Terminal for wire 0_MA to ground Continuity Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (77) is in the OFF position.
Between terminals for wires 68C_B

Continuity Bad rear wiper and washer switch (77).
and 68L_C
Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (77) in the ON position.
Terminal for wire 68L_C to ground 24 volts Bad rear wiper and washer switch (77).
Terminal for wire 68C_B to ground 0 volt Bad rear wiper and washer switch (77).
NOTE: If the readings are good, replace the rear wiper motor (79).

4002-71
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING
86
81
87
90
80 83
89 88
82
84
85
BC00N140
80. HORN RELAY NO. 5 86. A/C LOW PRESSURE SWITCH (IN CAB)
81. HORN 87. A/C HIGH PRESSURE SWITCH (IN REAR CHASSIS)
82. SEAT COMPRESSOR 88. THERMOSTAT SWITCH
83. BLOWER SWITCH 89. COMPRESSOR CLUTCH LOCKOUT RELAY NO. 14
84. SPEED RESISTOR 90. COMPRESSOR CLUTCH
85. BLOWER MOTOR
80 – Horn Relay No. 5

Terminal for wire 19U_B to ground 24 volts Check fuse U, also check wire 19U_B.
Terminal for wire 19U_C to ground 24 volts Check wire 19U_C.
Terminal for wire 64C_A to ground 24 volts Bad horn relay (80).
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64C_A to ground 0 volt Bad horn switch.
Terminal for wire 64_A to ground 24 volts Bad horn relay (80).

4002-72
81 – Horn
Terminal for wire 0_AD to ground Continuity Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn (81). Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (80). Also check wires 64 and 64_A.
NOTE: If the readings are good replace the horn (81).
82 – Seat Compressor and Switch (Option)

Terminal for wire 0_DY to ground Continuity Bad ground circuit.
Terminal for wire 19N_A at seat 24 volts Check fuse N and accessory relay (16). Also check wire 19N_A
switch and circuit 12P.
NOTE: Put the seat compressor (82) switch in the ON position.
Terminal for wire from seat switch at Bad seat switch, also check circuit from seat switch to
24 volts
compressor compressor.
NOTE: If the readings are good replace the seat compressor.
83 – Blower Switch
24 volts Check fuse G and ignition relay No. 2 (15). Also check circuits
Terminal for wire 19G to ground
19G and 13R.
NOTE: Turn the blower switch to LOW.
Terminal for wire 62L to ground 24 volts Bad blower switch (83).
NOTE: Turn the blower switch to MEDIUM.
Terminal for wire 62M to ground 24 volts Bad blower switch (83).
NOTE: Turn the blower switch to HIGH.
Terminal for wire 62H to ground 24 volts Bad blower switch (83).

4002-73
84 – Blower Motor Speed Resistors with Thermal Fuse

NOTE: Disconnect the wiring harness connector 29M from the blower motor (85).

Bad blower motor resistor.
motor connector 4.5 ohms

1.5 ohms Bad blower motor resistor.
motor connector
85 – Blower Motor
Terminals for wire 0_DZ to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (83) to
HIGH.
Terminal for wire 62H to ground 24 volts Check the blower switch (83).
NOTE: If the readings are correct and the blower motor (85) does not run, replace the blower motor (85). Turn
the blower switch (83) to LOW. If the blower motor (85) ran in HIGH but not in LOW or MEDIUM, check the blower
motor resistor (84).
86 – A/C Low Pressure Switch (In Cab)

NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (83) to HIGH and
the thermostat switch (88) to COLD.
Terminal B for wire 61A_E to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect the wiring harness connector 27M from the A/C low pressure switch (86).
Bad A/C low pressure switch (86), also check refrigerant

Between terminals of low pressure
Open Circuit charge level. (Pressure must be above 1.4 bar (20 psi) for
switch (86)
switch to open.)
87 – A/C High Pressure Switch (In Rear Chassis)

NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and the
Terminal for wire 61A to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect wiring harness connector 98 from A/C high pressure switch (87).
Bad A/C high pressure switch (87), also check for excessive
Between terminals of A/C high
Open Circuit refrigerant pressure. (Switch closes at or above 27.6 bar (400
pressure switch (87)
psi)).

4002-74
88 – Thermostat Switch
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH.
Terminal for wire 61T to ground 24 volts Check the blower switch (83), also check wire 61T.
NOTE: Turn the thermostat switch (88) all the way to COLD.
Terminal for wire 61A_D to ground 24 volts Bad thermostat switch (88).
89 – Compressor Clutch Lockout Relay No. 14

Terminal for wire 0_DA to ground Continuity Bad ground circuit.
Terminal for wire 61A_B to ground 24 volts Check thermostat switch (88), also check wire 61A_C.
Check A/C low pressure switch (86) and A/C high pressure
Terminal for wire 61R_D to ground 0 volt
switch (87).
Terminal for wire 61C_B to ground 24 volts Bad compressor clutch lockout relay (89).
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector 98 from A/C high pressure
switch. Connect a jumper wire between pins A and B of connector 98. Put ignition switch in ON position.
Check wires 61R_C and 61R_D. If air conditioning indicator on

Terminal for wire 61R_C to ground 24 volts instrument cluster (47) is not ON, check wires 61R_F and
61R_G to instrument cluster.
Terminal for wire 61C_B to ground 0 volt Bad compressor clutch lockout relay (89).
90 – Compressor Clutch
24 volts Check the compressor clutch lockout relay (89), also check
Terminals for wire 61C to ground
circuit 61C.

4002-75
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER

OUTLET, RADIOS AND SPEAKERS
97
98
94 92
95 93
96
91
BC00N140
91. CIGAR LIGHTER 94. REMOTE OR 24 VOLT RADIO 97. LEFT SPEAKER
92. POWER CONVERTER 95. 12 VOLT RADIO 98. RIGHT SPEAKER
93. POWER OUTLET 96. RADIO POWER CONVERTER
91 – Cigar Lighter (Option)

Terminal for wire 19W_A to ground 24 volts Check fuse W, also check circuit 19W.
Terminal for wire 0_S to ground Continuity Bad ground circuit.
NOTE: If the readings are good replace the cigar lighter (91).

4002-76
92 – Power Converter 24 volts to 12 volts (Option)

Terminal for wire 0_RA to ground Continuity Bad ground circuit.
Terminal for wire 1_V to ground 24 volts Check wire 1_V to cab power stud.
Terminal for wire 19L_B to ground 24 volts Bad fuse L, also check circuit 19L.
Terminal for wire 12V_B to ground 12 volts Bad power converter (92).
93 – Power Outlet (Option)

Terminal for wire 0_RB to ground Continuity Bad ground circuit.
Terminal for wire 12V_A to ground 12 volts Bad power converter (92), also check wire 12V_A.
NOTE: If the readings are good replace the power outlet (93).
94 – Remote Radio or 24 Volt Radio (Option)


0_QC to ground
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on. Put balance control for RH
and LH speakers to center position.

24 volts Check fuse L, also check circuits 19L and 65C.
65C_A to ground
NOTE: Keep the ignition switch and radio ON. Disconnect wiring harness connectors at LH and RH speakers (97
and 98).
95 – 12 Volt Radio Ready (Option)


0_QC to ground
Terminal in radio connector for wire Check fuse L, also check circuit 19L and 65C. Also check the
12 volts
65C_A to ground radio power converter (96).

4002-77
96 – Radio Power Converter (24 volts to 12 volts) (Option)

Terminal for wire 0_PD to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on.
Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (96).
97 – Left Speaker (Option)

NOTE: Disconnect connector from left speaker (97). Put master disconnect switch and ignition switch in ON
Pin A in wiring harness connector Bad circuit between the left speaker (97) and the radio or a bad
Voltage
112M to ground radio (94).

Continuity Bad circuit between the left speaker (97) and the radio (94).
112M to ground
NOTE: If the readings are good, replace the left speaker (97).
98 – Right Speaker (Option)

NOTE: Disconnect connector from right speaker (98). Put master disconnect switch and ignition switch in ON
Pin A in wiring harness connector Bad circuit between the right speaker (98) and the radio or a
Voltage
111M to ground bad radio (94).

Continuity Bad circuit between the right speaker (98) and the radio (94).
111M to ground
NOTE: If the readings are good, replace the right speaker (98).

4002-78
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD

SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER
MODULE
100
103
101
99 104
102
105
BC00N140
99. BEACON SWITCH 102. BRAKE LAMPS RELAY NO. 6 104. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH
100. ROTATING BEACON 103. HAZARD SWITCH 105. FLASHER MODULE
101. BRAKE LAMP PRESSURE
SWITCH
99 – Beacon Switch
Terminal for wire 0_DAP to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3 or
higher.
Check the five position rotary lamp switch (114), also check
Terminal for wire 49_R to ground 24 volts circuit 49. If LED in beacon switch is not ON with 24 volts at
check point, replace beacon switch.
Terminal for wire 19X to ground 24 volts Check fuse X, also check wire 19X.
NOTE: Put the beacon switch (99) in the ON position.
Terminal for wire 46_C to ground 24 volts Bad beacon switch (99).

4002-79
100 – Rotating Beacon

Terminal for wire 0_MC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and beacon switch (99) in ON position.
Bad circuit between the beacon (100) and the beacon switch
Terminal for wire 46_D to ground 24 volts
(99). Also check the beacon switch (99).
NOTE: If readings are good replace the rotating beacon (100).
101 – Brake Lamp Pressure Switch

Terminal for wire 1B_A to ground 24 volts Check circuit breaker B, also check wires 1B_A and 1B_D.
Terminal for wire 44 to ground 0 volt Bad brake lamp pressure switch (101).
Terminal for wire 44 to ground 24 volts Bad brake lamp pressure switch (101).
102 – Brake Lamps Relay No. 6

Terminal for wire 0_DC to ground Continuity Bad ground circuit.
Terminal for wire 1B_E to ground 24 volts Check circuit breaker B and wires 1B_E and 1B_F.
Terminal for wire 44A_B to ground 0 volt Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 0 volt Bad brake lamps relay (102).
Terminal for wire 44A_B to ground 24 volts Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 24 volts Bad brake lamps relay (102).

4002-80
103 – Hazard Switch

Terminal for wire 0_KH to ground Continuity Bad ground circuit.
Terminal for wire 1B to ground 24 volts Check circuit breaker B. Also check wires 1B and 1B_F.
NOTE: Put hazard switch in ON position.
Bad hazard switch (103). If hazard switch LED is not ON with

24 volts at check point, replace hazard switch.
NOTE: Put five position rotary lamp switch (114) in position 3 or higher.
Terminal for wire 49_A to ground 24 volts 49 to lamp switch (114). If hazard switch LED is not ON with 24
volts at check point, replace hazard switch.
104 – Turn Signal, Hi/Low Beam, and Horn Switch

HORN SWITCH
Terminal for wire 0_KG to ground Continuity Bad ground circuit.
Check fuse U and horn relay (80). Also check wires 64C,
Terminal for wire 64C to ground 24 volts
64C_A, and 19U_C.
NOTE: If readings are good, replace the switch (104).
TURN SIGNAL
Check fuse B and ignition relay No. 1 (14). Also check wires
Terminal for wire 19B to ground 24 volts
19B and 19B_A.
NOTE: Move turn signal lever to RIGHT turn position.
Terminal for wire 45B to ground 24 volts Bad turn signal switch (104).
NOTE: Move turn signal lever to LEFT turn position.
Terminal for wire 45A to ground 24 volts Bad turn signal switch (104).
HI/LOW BEAM SWITCH
Terminal for wire 0_KF to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in OFF position. Hold Hi/Low beam lever in HIGH beam
position.
Terminal for wire 64D to ground Continuity Bad hi/low beam switch (104).

4002-81
105 – Flasher Module

NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
Terminal for wire 0_DAN to ground Continuity Bad ground circuit.
Terminal for wire 0_DAQ to ground Continuity Bad ground circuit.
Terminal for wire 45N_A to terminal

for wire 45N_B (North American Continuity Bad 45N circuit.
machines only)
Check flasher circuit breaker B. Also check wires 1B_B and

Terminal for wire 1B_B to ground 24 volts
1B_F.
NOTE: Put ignition switch in the ON position. Put the hazard switch (103) ON.
Terminal for wire 45H_A to ground 24 volts Bad hazard switch (103). Also check wires 45H_A and 45H.
Intermittent 24
Terminal for wire 45L_D to ground Bad flasher module (105).
volts
Intermittent 24
volts
NOTE: Put hazard switch (103) in OFF position. Put turn signal switch (104) in RIGHT turn position.
Bad turn signal switch (104) or fuse B. Also check wires 45B_A
Terminal for wire 45B_A to ground 24 volts
and 45B.
Intermittent 24
volts
NOTE: Put turn signal switch (104) in LEFT turn position.
24 volts Bad turn signal switch (104) or fuse B. Also check wires 45A_A
Terminal for wire 45A_A to ground
and 45A.
Intermittent 24
Terminal for wire 45L_D to ground volts Bad flasher module (105).

4002-82
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP

SWITCH, AND CAB LIGHTS
117 112
113
118
110 108
115
114
111 109
106
116
107
BC00N140
106. LH REAR COMBINATION LAMP 113. RH FRONT WORK LAMP
107. RH REAR COMBINATION LAMP 114. FIVE POSITION ROTARY LAMP SWITCH
108. LH FRONT COMBINATION LAMP 115. HIGH/LOW BEAM RELAY NO. 13
109. RH FRONT COMBINATION LAMP 116. LICENSE PLATE LAMP
110. LH REAR WORK LAMP 117. DOME LAMP
111. RH REAR WORK LAMP 118. COURTESY LAMP
112. LH FRONT WORK LAMP

4002-83
106 – LH Rear Combination Lamp

NOTE: Disconnect wiring harness connector 125 from LH rear combination lamp connector.

pin 5

pin 5

pin 5

pin 5
NOTE: Connect wiring harness connector 125 to LH rear combination lamp connector.
Terminal for wire 0_A to ground Continuity Bad ground circuit.

Terminal for wire 44_A to ground 24 volts
lamps relay (102).

Terminal for wire 35A_A to ground 24 volts
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Terminal for wire 45L_A to ground
Check fuse F´ and lamp switch (114). Also check wires 18F_A
Terminal for wire 18F_A to ground 24 volts and 18F_D to fuse F’, and wire 41T_A from fuse F’ to lamp
switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp (106).

4002-84
107 – RH Rear Combination Lamp

NOTE: Disconnect wiring harness connector 127 from RH rear combination lamp connector.

pin 5

pin 5

pin 5

pin 5
NOTE: Connect wiring harness connector 127 to RH rear combination lamp connector.
Terminal for wire 0_C to ground Continuity Bad ground circuit.

Terminal for wire 44_B to ground 24 volts
lamps relay (102).

Terminal for wire 35A_B to ground 24 volts
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R_A to ground
Check fuse G´ and lamp switch (114). Also check wires 18G_A,
Terminal for wire 18G_A to ground 24 volts 18G_D, and 18G_F to fuse G’, and wire 41T_A from fuse G’ to
lamp switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp (107).

4002-85
108 – LH Front Combination Lamp

NOTE: Disconnect wiring harness connector 6 from LH front combination lamp connector.

pin 1

pin 1

pin 1

pin 1
NOTE: Connect wiring harness connector 6 to LH front combination lamp connector.
Terminal for wire 0_AL to ground Continuity Bad ground circuit.
Check fuse F’ and five position rotary lamp switch (114). Also
Terminal for wire 18F to ground 24 volts
check circuit 18F and wires 41T_A and 41T_B.
Check fuse B’, high/low beam relay (115), five position rotary
Terminal for wire 18B to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18B and wire 41H.
Check fuse D’, high/low beam relay (115), five position rotary
Terminal for wire 18D to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18D and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Terminal for wire 45L to ground
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp (108).

4002-86
109 – RH Front Combination Lamp

NOTE: Disconnect wiring harness connector 8 from RH front combination lamp connector.

pin 1

pin 1

pin 1

pin 1
NOTE: Connect wiring harness connector 8 to RH front combination lamp connector.
Terminal for wire 0_AG to ground Continuity Bad ground circuit.
Check fuse G’ and five position rotary lamp switch (114). Also
Terminal for wire 18G to ground 24 volts
check circuit 18G and wires 41T_A and 41T_B.
Check fuse C’, high/low beam relay (115), five position rotary
Terminal for wire 18C to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18C and wire 41H.
Check fuse E’, high/low beam relay (115), five position rotary
Terminal for wire 18E to ground 24 volts lamp switch (114), and high/low beam switch (104). Also check
circuit 18E and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R to ground
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp (109).
110 – LH Rear Work Lamp

NOTE: Disconnect wiring harness connector 83F from LH rear work lamp connector.
NOTE: Connect wiring harness connector 83F to LH rear work lamp connector.
Terminal for wire 0_ME to ground Continuity Bad ground circuit.
Terminal for wire 42R_D to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A’.

4002-87
111 – RH Rear Work Lamp

NOTE: Disconnect wiring harness connector 80F from RH rear work lamp connector.
NOTE: Connect wiring harness connector 80F to RH rear work lamp connector.
Terminal for wire 0_MF to ground Continuity Bad ground circuit.
Terminal for wire 42R_E to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A’.
112 – LH Front Work Lamp

NOTE: Disconnect wiring harness connector 79F from LH front work lamp connector.
NOTE: Connect wiring harness connector 79F to LH front work lamp connector.
Terminal for wire 0_MH to ground Continuity Bad ground circuit.
Terminal for wire 42C_B to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
113 – RH Front Work Lamp

NOTE: Disconnect wiring harness connector 78F from RH front work lamp connector.
NOTE: Connect wiring harness connector 78F to RH front work lamp connector.
Terminal for wire 0_MJ to ground Continuity Bad ground circuit.
Terminal for wire 42C_C to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.

4002-88
114 – Five Position Rotary Lamp Switch

Terminal for wire 1_N to ground 24 volts Check wire 1_N.
Terminal for wire 19Z to ground 24 volts Check fuse Z, also check circuit 19Z.
Terminal for wire 18A to ground 24 volts Check fuse A´, also check circuit 18A.
Terminal for wire 41J to ground 24 volts Bad five position rotary lamp switch (114).
115 – High/Low Beam Relay No. 13

Check high/low beam switch (104). Also check circuits 64D and
Terminal for wire 64D_A to ground Continuity
0_KF to and through the high/low beam switch.
Terminal for wire 1_H to ground 24 volts Check circuit 1_H.
NOTE: Put the 5 position rotary lamp switch (114) in position 3 or 4.
Bad five position rotary lamp switch (114). Also check wire
Terminal for wire 41J_A to ground 24 volts
41J_A.
NOTE: Put high/low beam lever in LOW beam position.
Terminal for wire 41L_A to ground 24 volts Bad high/low beam relay (115).
Terminal for wire 41H to ground 24 volts Bad high/low beam relay (115).

4002-89
116 – License Plate Lamp

Terminal for wire 0_JC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put the five position rotary lamp switch (114) in position 2.
Check fuse G’ and five 5 position rotary lamp switch (114). Also
Terminal for wire 18G_E to ground 24 volts
check circuit 18G.
117 – Dome Lamp

Terminal for wire 0_MB to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put dome lamp (118) switch in ON position.
Terminal for wire 19U_D to ground 24 volts Check fuse U, also check circuit 19U.
NOTE: If readings are good, replace dome lamp (118).
118 – Courtesy Lamp

Terminal for wire 0_ML to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 2 or
higher.
Check circuit 49, also check five position rotary lamp switch
Terminal for wire 49_V to ground 24 volts
(114).

4002-90
CONNECTORS
CONNECTOR 1 - FRONT CHASSIS HARNESS TO CONNECTOR 1F - MAIN CAB HARNESS TO
MAIN CAB HARNESS FRONT CHASSIS HARNESS
319148A1 291660A1
A 45L N-1.0 Left Turn Signal A 45L_C N-0.8 Left Turn Signal
B 53P_D W-1.0 Float Solenoid Power B 53P_C W-0.8 Pilot Control Signal
C 45R N-1.0 Right Turn Signal C 45R_D N-0.8 Right Turn Signal
D None D None
E 18G Or-1.0 Position RH E 18G_G Or-0.8 Position RH
F 18F Or-1.0 Position LH F 18F_E Or-0.8 Left Tail Position
G 18B Or-1.0 High Beam LH G 18B_A Or-0.8 High Beam LH
H 19M_B Or-1.0 Secondary Steer Accessory H 19M_A Or-0.8 Secondary Steer Accessory
J 19R_B Or-1.0 Secondary Steer Ignition J 19R_A Or-0.8 Secondary Steer Ignition
K 35X_B Y-1.0 Secondary Steer Low Pres Sig K 35X_E Y-0.8 Secondary Steer Low Pres Sig
L 54B W-1.0 Height-RTT Signal L 54B_A W-0.8 Height-RTT Signal
M 53B W-1.0 RTD Signal M 53B_B W-0.8 RTD Signal
N 64 Or-1.0 Horn N 64A Or-0.8 Horn
O 18D Or-1.0 Low Beam LH O 18D_A Or-0.8 Low Beam LH
P 18E Or-1.0 Low Beam RH P 18E_A Or-0.8 Low Beam RH
Q 18C Or-1.0 High Beam RH Q 18C_A Or-0.8 High Beam Fused Pwr
R None R None
S None S None
T 56_C W-1.0 Prox Switch Pwr T 56_J W-0.8 Prox Switch Pwr
U 57 W-1.0 Pin Engage Sol Pwr U 57_A W-0.8 Pin Engage Sol Pwr
V 58 W-1.0 Ride Cntrl Sol Pwr V 58_A W-0.8 Ride Cntrl Sol Pwr
W None W None
X None X None

4002-91
CONNECTOR 2 - FRONT WASHER PUMP MOTOR CONNECTOR 5F - RIDE CONTROL SOLENOID TO
TO REAR CHASSIS HARNESS FRONT CHASSIS HARNESS
3227856R1 291718A1

1 63W Or-1.0 Front Washer Pump 1 58_C W-1.0 Ride Control Solenoid Power
2 0_G Bk-1.0 Front Rear Washer Hot Ground 2 0_AC Bk-1.0 Ride Control Ground
CONNECTOR 3 - REAR WASHER PUMP MOTOR CONNECTOR 6 - LH FRONT COMBINATION

TO REAR CHASSIS HARNESS LAMP TO FRONT CHASSIS HARNESS
225351C1
3227856R1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT 1 0_AL Bk-1.0 Lights Ground LH
1 68W Or-1.0 Rear Washer Pump 2 18D Or-1.0 Low Beam LH
2 0_F Bk-1.0 Front Rear Washer Hot Ground 3 18B Or-1.0 High Beam LH
4 18F Or-1.0 Position LH
CONNECTOR 4 - BRAKE DECLUTCH PRESSURE 5 45L N-1.0 Left Turn Signal

SWITCH TO REAR CHASSIS HARNESS 6 None
245482C1

A 19A_A Or-1.0 Declutch Switch
B 25G LU-1.0 Declutch Switch

4002-92
CONNECTOR 8 - RH FRONT COMBINATION CONNECTOR 12F - RTD HARNESS FOR XT
LAMP TO FRONT CHASSIS HARNESS CHASSIS TO FRONT CHASSIS HARNESS
245485C1
225351C1
A 53B W-1.0 RTD Signal
1 0_AG Bk-1.0 Lights Ground RH
B 0_AF Bk-1.0 RTD Ground
2 18E Or-1.0 Low Beam RH
C 56_B W-1.0 RTD Power
3 18C Or-1.0 High Beam RH
4 18G Or-1.0 Position RH
5 45R N-1.0 Right Turn Signal CONNECTOR 12M - RTD HARNESS FOR XT
CHASSIS TO FRONT CHASSIS HARNESS
6 None
CONNECTOR 10 - HEIGHT CONTROL/RTT

PROXIMITY SWITCH TO FRONT CHASSIS
HARNESS
245484C1

245484C1

A 54B W-1.0 Height/RTT Signal
B 0_AA Bk-1.0 Height/RTT Ground
C 56_A W-1.0 Height/RTT Power

4002-93
CONNECTOR 13F - MAIN CAB HARNESS TO CAV WIRE IDENT CIRCUIT
PEDESTAL HARNESS
33 None
34 50G_D Bk-0.8 CAN Ground
35 44_F T-0.8 Brake Light Signal
37 None
38 0_DAB Bk-0.8 Signal Ground
39 0_DL Bk-0.8 Signal Ground
40 0_DAA Bk-0.8 None
41 0_DX Bk-0.8 Horn Ground
43 19A_S Or-0.8 Cab Switched Pwr
374972A1
CAV WIRE IDENT CIRCUIT 45 25R_A LU-0.8 Reverse Signal
1 19V Or-0.8 Cluster Main Fused Power 46 25T_C LU-0.8 Neutral Signal
2 19S Or-0.8 Instr Cluster Fused Del Power 47 None
3 33P_A Y-0.8 Low Brake Pres Warning 48 25W_A LU-0.8 3rd and 4th Gear Signal
4 31D_A Y-0.8 Coolant Level Signal 49 25Z_A LU-0.8 1st and 4th Gear Signal
5 35X_E Y-0.8 Sec Str Low Press Sig 50 25Y_A LU-0.8 Trans Kickdown Signal
6 31F_B Y-0.8 Air Filter Rest Sw Signal 51 49_F S-0.8 Pilot Light Power
7 31H_A Y-0.8 Hyd Filter Rest Sw Signal 52 28C_A W-0.8 None
8 0_DAU Bk-0.8 Analog Ground 53 0_DAC Bk-0.8 Relay Ground
9 18L_C Or-0.8 Grid Heater Lamp 54 None
10 61R_F Or-0.8 A/C Telltale 55 64D_A Or-0.8 High/Low Beam Signal
11 0_DBA Bk-0.8 Grid Heater Lamp Ground 56 13K_G Or-0.8 Ignition Switch Pwr
12 42R_C DU 0.8 Rear Work Light Pwr 57 63H_A Or-0.8 Front Wiper High Speed
13 46_A K-0.8 Beacon Switched Pwr 58 63L_A Or-0.8 Front Wiper Low Speed
14 None 59 63C_A Or-0.8 Front Wiper Park
15 18C_B Or-0.8 High Beam Fused Pwr 60 19J_B Or-0.8 Frt Wip Wash Fused Pwr
16 45L_E N-0.8 Left Turn Signal 61 0_DV Bk-0.8 Beacon Wpr Diode Ground
17 45R_C N-0.8 Right Turn Signal 62 1A_C R-0.8 Ignition Switch Power
18 36C_B P-0.8 ECT Signal 63 12K_B Or-0.8 ACC Power
19 36F_A P-0.8 Fuel Level Signal 64 21K_A W-0.8 Ign Switch Start Signal
20 36H_A P-0.8 Hot Signal 65 1B_C R-0.8 Hazard Switch Power
21 None 66 19B-A Or-0.8 Turn Signal Power
22 36P_B P-0.8 EOP Signal 67 45H_A N-0.8 Hazard Switch Power
23 23C_A W-0.8 Engine Shutdown Signal 68 19C_C Or-0.8 Ride Control Fused Power
24 None 69 45A_A N-0.8 Left Turn Switch Power
25 37R_C P-0.8 Reset Signal 70 45B_A N-0.8 Right Turn Switch Power
26 None
27 None
28 33R_D Y-0.8 Red Brake Sw Signal
29 None
31 50L_A G-0.5 CAN L
32 50H_A Y-0.5 CAN H

4002-94
CONNECTOR 13M - PEDESTAL HARNESS TO CAV WIRE IDENT CIRCUIT
MAIN CAB HARNESS
34 50G_A Bk-0.8 CAN Ground
37 None
38 0_KR Bk-0.8 Signal Ground
40 None
41 0_KG Bk-0.8 Horn Hi Lo Beam Ground
42 64C Or-0.8 Horn Control
43 19A_G Or-0.8 Trans Control Pwr
374971A1 44 25F LU-0.8 Forward Signal
CAV WIRE IDENT CIRCUIT 45 25R LU-0.8 Reverse Signal
1 19V_A Or-0.8 Cluster Main Fused Power 46 25T_B LU-0.8 Neutral Signal
2 19S_A Or-0.8 Instr Cluster Fused Del Power 47 None
3 33P_B Y-0.8 Low Brake Pres Warning 48 25W LU-0.8 3rd and 4th Gear Signal
4 31D_B Y-0.8 Coolant Level Signal 49 25Z LU-0.8 1st and 4th Gear Signal
5 35X_F Y-0.8 Sec Str Low Press Sig 50 25Y LU-0.8 Trans Kickdown Signal
6 31F_C Y-0.8 Air Filter Rest Sw Signal 51 49_A S-0.8 Pilot Light
7 31H_B Y-0.8 Hyd Filter Rest Sw Signal 52 None
8 0_KP Bk-0.8 Analog Ground 53 0_KM Bk-0.8 Pilot Light Ground
9 18L_D Bk-0.8 Grid Heater Lamp 54 None
10 61R_G Or-0.8 A/C Telltale 55 64D Or-0.8 High/Low Beam Signal
11 31Y_B Y-0.8 Grid Heater Lamp Ground 56 13K Or-0.8 Ignition Switch Pwr
12 42R_A Y-0.8 Work Light Telltale Sig 57 63H Or-0.8 Front Wiper High Speed
13 46_B K-0.8 Beacon Telltale 58 63L Or-0.8 Front Wiper Low Speed
14 None 59 63C Or-0.8 Front Wiper Park
15 18C_C Or-0.8 High Beam Telltale 60 19J Or-0.8 Frt Wip Wash Fused Pwr
16 45L_F N-0.8 Left Turn Signal 61 0_KN Bk-0.8 Front Wiper Ground
17 45R_F N-0.8 Right Turn Signal 62 1A_A R-0.8 Ign Prog Reset Switch Power
18 36C_C P-0.8 ECT Signal 63 12K_C Or-0.8 Ign Switch ACC Power
19 36F_B P-0.8 Fuel Level Signal 64 21K W-0.8 Ign Switch Start Signal
20 36H_B P-0.8 Hot Signal 65 1B R-0.8 Hazard Switch Power
21 None 66 19B Or-0.8 Turn Signal Power
22 36P_C P-0.8 EOP Signal 67 45H N-0.8 Hazard Switch Power
23 23C W-0.8 Engine Shutdown Signal 68 19C Or-0.8 Pilot Control Signal
24 None 69 45A N-0.8 Left Turn Switch Power
25 37R_A P-0.8 Reset Signal 70 45B N-0.8 Right Turn Switch Power
26 None
27 None
29 None
31 50L G-0.5 CAN L
32 50H Y-0.5 CAN H
33 None

4002-95
CONNECTOR 17M - BUCKET CONTROL VALVE
ELECTROMAGNETIC DETENTS TO MAIN CAB
HARNESS
225351C1

2 54B_C W-0.8 Height Control Elec Mag
3 53B_B W-0.8 RTD Signal
4 56_G W-0.8 Detent Switched Power
5 56_F W-0.8 Detent Switched Power
6 56_E W-0.8 Detent Switched Power

4002-96
FUSE BLOCK 18F TO MAIN CAB HARNESS
232118A1

4002-97

19N_B Or-1.0
A1 13P_A Or-1.0 Ign Relay 1 Out (5 Way)* N2 Acces Seat Fused Pwr (3 Way)*
19N_A Or-1.0
B1 Ign Relay 1 (5 Way)
P2 19P_A Or-1.0 Fan Rev Pin Eng Fused Power
C1 Ign Relay 1 (5 Way)
R2 19R_A Or-0.8 Sec Str Ignition
D1 Ign Relay 1 (5 Way)
S2 19S Or-0.8 Instr Cluster Fused Del Power
E1 Ign Relay 1 (5 Way)
19T_A Or-0.8
T2 Time Delay Fused Power
F1 13R Or-1.0 Ign Relay 2 Out (5 Way)* 19T_B Or-0.8
G1 Ign Relay 2 (5 Way) 19U_A Or-1.0
U2 Dome Lt Horn Fused Power
19U_B Or-1.0
H1 Ign Relay 2 (5 Way)
V2 19V Or-0.8 Cluster Main Fused Power
J1 Ign Relay 2 (5 Way)
W2 19W Or-1.0 Cigarette Lighter Fused Power
K1 Ign Relay 2 (5 Way)
X2 19X Or-1.0 Beacon Sw Fused Power
12P_A Or-1.0
L1 ACC Relay
12P_B Or-1.0 Y2 None
M1 12K_A Or-1.0 ACC Power Z2 19Z Or-1.0 Frnt Flood Illum Fused Power
N1 12P_B Or-1.0 ACC Relay A2’ 18A Or-2.0 Rear Fld Lts Fuse Power
P1 13P_B Or-1.0 Ign Relay 1 Out (2 Way)* B2’ 18B_A Or-0.8 High Beam LH
R1 Ign Relay 1 (2 Way) 18C_A Or-0.8
C2’ High Beam Fused Power
S1 13D Or-1.0 Delay Power (2 Way)* 18C_B Or-0.8
D2’ 18D_A Or-0.8 Low Beam LH
T1 Time Delay Module (2 Way)
U1 1_Q R-1.0 Dome Light Horn Power E2’ 18E_A Or-0.8 Low Beam RH
18F_D Or-0.8
V1 13V Or-1.0 Voltmeter Relay Out F2’ Left Tail Pos
18F_E Or-0.8
W1 1_R R-3.0 Cigar Lighter Power
18G_F Or-0.8
G2’ Right Tail Pos Lic
X1 Power (4 Way) 18G_G Or-0.8
Y1 Power (4 Way) 1 19N_B Or-1.0 Acces Seat Fused Pwr (3 Way)*
Z1 1_U R-3.0 B+ Power (4 Way)* 2 None
A1’ Power (4 Way) 3 None
B1’ Hi Low Relay 13 (2 Way) 4 None
C1’ 41H K-2.0 High Beam Signal (2 Way)* 5 19L Or-1.0 Access to Fuse L (3 Way)*
D1’ Hi Low Relay 13 (2 Way) 6 None
E1’ 41L_A K-2.0 Low Beam Signal (2 Way)* 7 Access to Fuse N (3 Way)
F1’ Rotary Lamp Switch (2 Way) 8 None
G1’ 41T_A K-1.0 Tail Light Sw Power (2 Way)* 9 None
19A_N Or-0.8 10 None
A2 Cab Switched Power
19A_P Or-0.8
B2 19B_A Or-0.8 Turn Signal Power
12 None
19C_A Or-1.0
C2 Pilot Ride Cntrl Fused Power 13 Access to Fuse N (3 Way)
19C_D Or-1.0
14 None
D2 19D_A Or-1.0 Park Brake Rel Fused Power
15 None
E2 19E Or-1.0 Ether Start Rel Fused Power
16 19W Or-1.0 Cigarette Lighter Fused Power
F2 19F Or-1.0 Eng Shutdown Rel Fused Pwr
G2 19G Or-2.0 Blower Switch Fused Power
18 None
H2 19H Or-1.0 Backup Alarm Rel Fuse Power
J2 19J_A Or-1.0 Front Wip Wash Fused Power
K2 19K_A Or-1.0 Rear Wip Wash Fused Power
L2 19L Or-1.0 Access to Fuse L (3 Way)*
M2 19M_A Or-0.8 Sec Str Accessory

4002-98
CONNECTOR 19F - TRANSMISSION CAV WIRE IDENT CIRCUIT
ELECTRONIC CONTROL MODULE TO MAIN CAB
HARNESS
45 19A_K Or-0.8 Cab Switched Power
1 0_DP Bk-0.8 Diag TECM Ground
46 36R_E P-0.8 Valve Body Temp Return
2 0_DQ Bk-0.8 Diag TECM Ground
47 None
3 0_DM Bk-0.8 Speed Sensor Ground
48 None
4 0_DN Bk-0.8 Out Speed Sensor Ground
49 36G_A P-1.0 TCO Temp Signal
5 32J_C Y-0.8 Trans Enable Lt Signal
50 None
6 None
51 25J_A LU-0.8 Trans Sol Valve Y6
52 None
8 58H_B W-0.8 Ride Cntl Sw Power VPS2
53 None
9 25P_A LU-0.8 Trans Sol Valve Y5
54 None
10 25L_A LU-0.8 Trans Sol Valve Y2
55 25N_A LU-0.8 Trans Sol Valve Y4
11 None
56 25K_A LU-0.8 Trans Sol Valve Y1
12 25S_B LU-0.8 Output Sw Power VPS1
57 0_DD Bk-0.8 Ride Control Relay Sink
13 25S_C LU-0.8 Output Sw Power VPS1
58 None
14 None
59 None
60 None
16 None
61 None
17 32F_A Y-0.8 Trans Filter Maint Switch
62 25D_A LU-0.8 Output Speed Signal
63 25Z_A LU-0.8 1st and 4th Gear Signal
19 25A_A LU-0.8 Engine Speed Signal
64 25R_A LU-0.8 Reverse Signal
65 25W_A LU-0.8 3rd and 4th Gear Signal
21 52P_A W-0.8 Park Brake Relay Out
66 25G_B LU-0.8 Declutch Signal
22 25Y_B LU-0.8 Trans Kickdown Signal
67 25T_D LU-0.8 Neutral Signal
23 19T_A Or-0.8 Time Delay Fused Power
68 19T_B Or-0.8 Time Delay Fused Power
24 None
25 50H_A Y-0.5 CAN H
26 50L_B G-0.5 CAN L CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH TO MAIN CAB HARNESS
27 50L_C G-0.5 CAN L
28 None
32 25M_A LU-0.8 Trans Sol Valve Y3
33 None
34 None
35 None
36 None
222136A1
37 None
38 None
1 19A_U Or-0.8 Cab Switched Power
39 36T_A P-0.8 Valve Body Temp Signal
2 25Y_C LU-0.8 Trans Kickdown Signal
40 None
41 25B_A LU-0.8 Turb Speed Signal
42 25C_A LU-0.8 Int Speed Signal

4002-99
CONNECTOR 21F - CAB MAIN HARNESS TO CONNECTOR 21M - REAR CHASSIS HARNESS
291661A1
374973A1
2 None 1 None
3 31D_A Y-0.8 Coolant Level Signal 2 None
4 33P_A Y-0.8 Low Brake Pres Warning 3 31D Y-1.0 Coolant Level Signal
5 18F_D Or-0.8 Left Tail Pos 4 33P Y-1.0 Low Brake Pres Warning
6 35R_C Y-0.8 Backup Alarm Switch 5 18F_A Or-1.0 Left Tail
7 35A_D Y-0.8 Backup Alarm Relay Out 6 35R_B Y-1.0 Backup Alarm Switch
8 44_D T-0.8 Brake Light Signal 7 35A_C K-1.0 Reverse Lights
9 18G_F Or-0.8 RH Tail Lic Lights 8 44_C T-1.0 Brake Light Signal
10 45L_B N-0.8 Left Turn Signal 9 18G_D Or-1.0 RH Tail Lic Lights
11 21C_E W-0.8 Starter Fuel Relay Signal 10 45L_A N-1.0 Left Turn Signal
12 45R_B N-0.8 Right Turn Signal 11 21C_D W-1.0 Starter Fuel Relay Signal
13 36H_A P-0.8 Hot Signal 12 45R_A N-1.0 Right Turn Signal
14 31H_A Y-0.8 Hyd Filter Rest Sw Signal 13 36H P-1.0 Hot Signal
15 33R_D Y-0.8 Red Brake Sw Signal 14 31H Y-1.0 Hyd Oil Filter Rest Sw Signal
16 36F_A P-0.8 Fuel Level Signal 15 33R_C Y-1.0 Red Brake Sw Signal
17 None 16 36F P-1.0 Fuel Level Signal
18 52P_B W-0.8 Park Brake Relay Out 17 None
19 None 18 52P W-1.0 Park Brake Relay Out
20 28GC_A W-0.8 Grid Heater Signal 19 None
21 1_P R-0.8 Voltmeter Relay Power 20 28GC_B W-1.0 Grid Heater Signal
22 31T Y-0.8 Grid Heater Temp Sndr Signal 21 1_A R-1.0 B+
23 None 22 31T_A Y-1.0 Grid Heater Temp Sndr Signal
24 68W_A Or-1.0 Rear Washer Pump 23 None
25 63W_A Or-0.8 Front Washer Pump 24 68W Or-1.0 Rear Washer Pump
26 None 25 63W Or-1.0 Front Washer Pump
27 52_A W-0.8 Fan Reverse Solenoid 26 None
28 1B_D R-0.8 CB B Load 27 52 W-1.0 Fan Reverse Solenoid
29 44A_B T-0.8 Brake Lt Input Signal 28 1B_A R-1.0 Brake Lt Sw Power
30 19A_T Or-0.8 Cab Switched Power 29 44 T-1.0 Brake Lt Input Signal
31 25G_A LU-0.8 Declutch Switch 30 19A_A Or-1.0 Declutch Switch

31 25G LU-1.0 Declutch Switch

4002-100
CONNECTOR 22F - CAB MAIN HARNESS TO CONNECTOR 22M - TRANSMISSION HARNESS
TRANSMISSION HARNESS TO CAB MAIN HARNESS
291661A1
373358A1
1 13C_D Or-0.8 Fuel Solenoid Power CAV WIRE IDENT CIRCUIT
2 14_B LG-0.8 Alternator D+ 1 13C_A Or-1.0 Fuel Solenoid
3 31F_B Y-0.8 Air Filter Rest Sw Signal 2 14_A LG-1.0 Alternator D+
4 36C_B P-0.8 ECT Signal 3 31F_A Y-1.0 Air Filter Rest Sw Signal
5 36T_A P-0.8 Valve Body Temp Signal 4 36C_A P-1.0 ECT Signal
6 36P_B P-0.8 EOP Signal 5 36T P-0.8 Valve Body Temp Signal
7 25A_A LU-0.8 Engine Speed Signal 6 36P_A P-1.0 EOP Signal
8 25B_A LU-0.8 Turb Speed Signal 7 25A W-0.8 Engine Speed Signal
9 25C_A LU-0.8 Int Speed Signal 8 25B W-0.8 Turb Speed Signal
10 25D_A LU-0.8 Output Speed Signal 9 25C W-0.8 Int Speed Signal
11 0_DM Bk-0.8 Speed Sensor Ground 10 25D LU-1.0 Output Speed Signal
12 36R_E P-0.8 Valve Body Temp Ret 11 0_HD Bk-1.0 Speed Sensor Ground
13 36G_A P-1.0 TCO Temp Signal 12 36R_A P-1.0 Valve Body Temp Ret
14 None 13 36G P-1.0 TCO Temp Signal
15 0_DAB Bk-0.8 Signal Ground 14 None
16 25K_A LU-0.8 Trans Solenoid Valve Y1 15 0_HB Bk-1.0 Signal Ground
17 25L_A LU-0.8 Trans Solenoid Valve Y2 16 25K LU-0.8 Trans Solenoid Valve Y1
18 25M_A LU-0.8 Trans Solenoid Valve Y3 17 25L LU-0.8 Trans Solenoid Valve Y2
19 25N_A LU-0.8 Trans Solenoid Valve Y4 18 25M LU-0.8 Trans Solenoid Valve Y3
20 25P_A LU-0.8 Trans Solenoid Valve Y5 19 25N LU-0.8 Trans Solenoid Valve Y4
21 25J_A LU-0.8 Trans Solenoid Valve Y6 20 25P LU-0.8 Trans Solenoid Valve Y5
22 25S_A LU-0.8 Output Sw Power VPS1 21 25J LU-0.8 Trans Solenoid Valve Y6
23 0_DL Bk-0.8 Signal Ground 22 25S LU-0.8 Output Sw Power VPS1
24 None 23 0_HA Bk-1.0 Signal Ground
25 61C_B Or-0.8 AC Comp Clutch 24 None
26 61A_B Or-0.8 AC Relay Power 25 61C_A Or-1.0 AC Comp Clutch
27 61R_B Or-0.8 AC Relay Signal 26 61A_A Or-1.0 AC High Pressure Switch
28 0_DN Bk-0.8 Out Speed Sensor Ground 27 61R_A Or-1.0 AC High Pressure Switch
29 19A_M Or-0.8 Cab Switched Power 28 0_HE Bk-1.0 Out Speed Ground
30 0_DAU Bk-0.8 Analog Ground 29 19A Or-1.0 Out Speed Power
31 32F_A Y-0.8 Trans Filter Maint Switch 30 0_HC Bk-1.0 Analog Ground
31 32F Y-1.0 Trans Filter Maint Switch

4002-101
CONNECTOR 23F - CAB MAIN HARNESS TO CONNECTOR 24F - CAB ROOF HARNESS TO
CAB ROOF HARNESS CAB MAIN HARNESS
3195530R1
3195530R1
A 68C_A Or-1.0 Rear Wiper Park A None
B 0_DT Bk-1.0 Dome Court Work Light Ground B None
C 0_DU Bk-1.0 Beacon Wiper Diode Ground C None
D 19U_A Or-1.0 Dome Light Horn Fused Power D None
46_A K-0.8 E 0_MN Bk-0.8 Dome Courtesy Light Ground

E Beacon Switched Power
46_C K-1.0 F 49_V S-0.8 Courtesy Pilot Light
F 19K_B Or-1.0 Rear Wiper Wash Fused Power G 0_MK Bk-1.0 Front Work Light Ground
G 68L_A Or-1.0 Rear Wiper Low Speed H 42C_D DU-1.0 Front Work Lights Power
H 42R_B DU-0.8 Rear Work Light Power
CONNECTOR 24M - CAB MAIN HARNESS TO

CONNECTOR 23M - CAB ROOF HARNESS TO CAB ROOF HARNESS
CAB MAIN HARNESS
245430C1

CAV WIRE IDENT CIRCUIT A None
A 68C_B Or-1.0 Rear Wiper Park B None
B 0_MG Bk-1.0 Rear Work Light Ground C None
C 0_MD Bk-1.0 Beacon Rear Wiper Ground D None
D 19U_D Or-1.0 Dome Light Fused Power E 0_DR Bk-1.0 Dome Court Work Light Ground
E 46_D K-1.0 Beacon Switched Power F 49_S S-1.0 Courtesy Pilot Light
F 19K_E Or-1.0 Rear Wiper Wash Fused Power G 0_DS Bk-1.0 Dome Court Work Light Ground
G 68L_C Or-1.0 Rear Wiper Low Speed H 42C_A DU-1.0 Front Flood Lights
H 42R_F DU-1.0 Rear Work Light Power

4002-102
CONNECTOR 25F - FIVE POSITION ROTARY CONNECTOR 29M - BLOWER MOTOR TO CAB
LAMP SWITCH TO CAB MAIN HARNESS MAIN HARNESS
255058C1
631801C1
A 41J_B K-2.0 Driving Light Signal
CONNECTOR 27M - AC LOW PRESSURE 4 0_DZ Bk-2.0 Blwr Wpr Seat Ground
CONNECTOR 30F - BLOWER SWITCH TO CAB

MAIN HARNESS
245482C1

A 61R_E Or-0.8 AC Low Pressure Switch
B 61A_E Or-0.8 AC Low Pressure Switch
449797C1

CONNECTOR 28M - SEAT COMPRESSOR 1 None
MOTOR TO CAB MAIN HARNESS
2 19G Or-2.0 Blower Switch Fused Power
6 61T Or-1.0 AC Thermostat Power
245482C1

A 19N_A Or-1.0 Access Seat Fused Pwr (3 Way)
B 0_DY Bk-1.0 Blower Wpr Seat Ground

4002-103
CONNECTOR 31 - FILTER MAINTENANCE CONNECTOR 33F - FIVE POSITION ROTARY
SWITCH TO TRANSMISSION HARNESS LAMP SWITCH TO CAB MAIN HARNESS
266516C1
371614A1
1 32F Y-1.0 Trans Filt Maint Sw 41J_A K-2.0

A Driving Light Signal
41J_B K-2.0
2 36R_B P-1.0 Valve Body Temp Ret
B 41T_B K-1.0 Tail Light Switched Power
C 1_N R-3.0 Light Switch Power
225287C1

42R_B DU-0.8 245423C1
A Rear Work Light Power
42R_C DU-0.8 CAV WIRE IDENT CIRCUIT
B 18A Or-2.0 Rear Fld Lts Fused Power A 42C_A DU-1.0 Front Flood Lights
41T_A K-1.0 49_J S-0.8
C Tail Light Switched Power B Pilot Light
41T_B K-1.0 49_K S-1.0
C 19Z Or-1.0 Front Flood Illum Fused Power

4002-104
CONNECTOR 35F - WIPER AND WASHER CONNECTOR 37 - PILOT CONTROL SWITCH TO
SWITCH TO CAB MAIN HARNESS PEDESTAL HARNESS
892136C1
382391A1
1 0_DAR Bk-1.0 Blower Wiper Seat Ground
1 None
19J_A Or-1.0
2 Front Wip Wash Fused Power 2 19C Or-0.8 Pilot Control Signal
19J_B Or-0.8
3 63W_A Or-0.8 Front Washer Pump
4 None
4 63C_A Or-0.8 Front Wiper Park
5 None
63H_A Or-0.8
5 Front Wiper High Speed
63H_B Or-0.8 6 None
63L_A Or-0.8 0_KH Bk-0.8
6 Front Wiper Low Speed 7 Pilot Light Ground
63L_B Or-0.8 0_KJ Bk-0.8
49_B S-0.8
8 Pilot Light
49_C S-0.8
CONNECTOR 36F - DETENT SWITCH TO CAB 9 None
MAIN HARNESS
10 None
382391A1

1 None
2 53P_B W-0.8 Pilot Control Signal
3 56_H W-0.8 Detent Switched Power
4 None
5 None
6 None
0_DAJ Bk-1.0
7 Switch Ground
0_DAK Bk-1.0
49_M S-1.0
8 Pilot Light
49_N S-1.0
9 None
10 None

4002-105
CONNECTOR 38F - DECLUTCH SWITCH TO CAB CAV WIRE IDENT CIRCUIT
MAIN HARNESS
49_K S-1.0
8 Pilot Light
49_M S-1.0
9 None
10 None
CONNECTOR 40F - PIN ENGAGE SWITCH TO

CAB MAIN HARNESS
382391A1

25G_A LU-0.8
1 Declutch Switch
25G_B LU-0.8
2 19A_R Or-0.8 Cab Switched Power
3 None
4 None
382391A1
5 None
6 None
7 0_DAK Bk-1.0 Switch Ground 1 57_A W-0.8 Pin Engage Solenoid Power
19P_A Or-1.0
8 49_N S-1.0 Pilot Light 2 Fan Rev Pin Eng Fused Power
19P_B Or-1.0
9 None
3 None
10 None
4 None
5 None
CONNECTOR 39F - RETURN-TO-TRAVEL 6 None
SWITCH TO CAB MAIN HARNESS 7 None
8 None
0_DAF Bk-1.0
9 Switch Ground
0_DAL Bk-1.0
49_H S-0.8
10 Pilot Light
49_P S-1.0
382391A1

0_DAH Bk-1.0
1 Switch Ground
0_DAJ Bk-1.0
3 54B_B W-0.8 RTT Float Switch Load
4 None
5 None
6 None
0_DAG Bk-1.0
7 Switch Ground
0_DAH Bk-1.0

4002-106
CONNECTOR 41F - TRANSMISSION AUTO CAV WIRE IDENT CIRCUIT
49_R S-1.0
8 Pilot Light
49_T S-1.0
9 None
10 None
CONNECTOR 44F - RIDE CONTROL SWITCH TO

CAB MAIN HARNESS
382391A1

1 None
2 19A_Q Or-0.8 Cab Switched Power
4 None
5 None 382391A1

7 0_DAM Bk-1.0 Switch Ground 1 None
8 49_Q S-1.0 Pilot Light 2 19C_B Or-1.0 Ride Ctrl Fused Power
9 None 3 58S W-0.8 Ride Control Relay Power
10 None 4 None
5 None
6 58_B W-0.8 Ride Cntrl Sol Power
CONNECTOR 42F - BEACON SWITCH TO CAB
MAIN HARNESS 0_DAL Bk-1.0
7 Switch Ground
0_DAM Bk-1.0
49_P S-1.0
8 Pilot Light
49_Q S-1.0
9 None
10 None
382391A1

1 None
2 19X Or-1.0 Beacon Switch Fused Power
3 46_C K-1.0 Beacon Switched Power
4 None
5 None
6 None
0_DAP Bk-1.0
7 Ground
0_DAW Bk-1.0

4002-107
CONNECTOR 45F - REAR WIPER AND WASHER CONNECTOR 48F - IGNITION RELAY NO. 2 TO
SWITCH TO CAB MAIN HARNESS CAB MAIN HARNESS
382391A1
245731C1
1 68C_A Or-1.0 Rear Wiper Park
30 1_T R-3.0 Ign Relay No. 2 Power
68L_A Or-1.0
2 Rear Wiper Low Speed 0_DE Bk-0.8
68L_B Or-0.8 85 Relay Ground
0_DF Bk-0.8
3 19K_C Or-1.0 Rear Wip Wash Fused Power
13K_A Or-1.0
4 None 86 Ignition Switch Power
13K_B Or-1.0
5 19K_D Or-0.8 Rear Wip Wash Fused Power 87 13R Or-1.0 Ignition Relay 2 Out (5 Way)
6 68W_A Or-1.0 Rear Washer Pump 87A None
7 0_DW Bk-0.8 Ground
8 49_L S-0.8 Pilot Light
CONNECTOR 49F - ACCESSORY RELAY TO CAB
9 None
MAIN HARNESS
10 None
CONNECTOR 47F - IGNITION RELAY NO. 1 TO

CAB MAIN HARNESS
245731C1

30 1_G R-3.0 ACC Relay Power
0_DF Bk-0.8
245731C1
85 Relay Ground
0_DC Bk-0.8
CAV WIRE IDENT CIRCUIT 12K_A Or-1.0
86 ACC Power
30 1_S R-3.0 Ign Relay No. 1 Power 12K_B Or-0.8
87 12P_A Or-1.0 ACC Relay
85 0_DE Bk-0.8 Relay Ground
86 13K_A Or-1.0 Ignition Switch Power 87A None
13P_A Or-1.0
87 Ignition Relay 1 Out
13P_B Or-1.0
87A None

4002-108
CONNECTOR 50F - RIDE CONTROL RELAY TO CONNECTOR 53F - BACKUP ALARM RELAY TO
245731C1 245731C1

30 58S W-0.8 Ride Control Relay Power 30 19H Or-1.0 Backup Alrm Rly Fuse Power
85 0_DD Bk-0.8 Ride Control Relay Ground 85 35C Y-0.8 Backup Alarm Pull Down
86 58H_B W-0.8 Ride Control Signal 86 19A_P Or-0.8 Cab Switched Power
58_A W-0.8 35A_E Y-0.8
87 Ride Control Solenoid Power 87 Backup Alarm Relay Out
58_B W-0.8 35A_D Y-0.8
87A None 87A None
CONNECTOR 51F - HORN RELAY TO CAB MAIN CONNECTOR 54F - NEUTRAL START RELAY TO
HARNESS CAB MAIN HARNESS
245731C1
245731C1

19U_B Or-1.0 30 21K_A W-0.8 Ign Switch Start Signal
30 Dome Light Horn Fused Power
19U_C Or-0.8
0_DH Bk-0.8
85 64C_A Or-0.8 Horn Control 85 Relay Ground
0_DJ Bk-0.8
86 19U_C Or-0.8 Dome Light Horn Fused Power 86 25T_E LU-0.8 Neutral Signal
87 64_A Or-0.8 Horn 21C_E W-0.8
87A None 87 21C_F W-0.8 Starter Fuel Relay Signal
21C_G W-0.8
87A None

4002-109
CONNECTOR 55F - PARKING BRAKE RELAY TO CONNECTOR 57F - RELAY SOCKET N0. 11 TO
245731C1
245731C1
13K_B Or-1.0
19D_A Or-1.0
30 Park Brake Relay Fused Power 30 13K_C Or-1.0 Ignition Switch Power
19D_B Or-1.0
13K_D Or-0.8
85 23C_A W-0.8 Engine Shutdown Signal
86 19D_B Or-1.0 Park Brake Relay Fused Power
86 19F Or-1.0 Engine Shtdwn Rly Fused Pwr
52P_B W-0.8
87 Park Brake Relay Out 13C_B Or-0.8
52P_A W-0.8
87 13C_C Or-0.8 Fuel Solenoid Power
87A None 13C_D Or-0.8
87A None
CONNECTOR 56F - PILOT CONTROL RELAY TO

CAB MAIN HARNESS CONNECTOR 58F - VOLTMETER RELAY TO CAB
MAIN HARNESS
245731C1
19C_D Or-1.0 CAV WIRE IDENT CIRCUIT

30 Pilot Ride Control Fused Power
19C_E Or-1.0
30 1_P R-0.8 Voltmeter Relay Power
0_DG Bk-0.8
85 Relay Ground
86 19C_E Or-1.0 Pilot Ride Control Fused Power 0_DH Bk-0.8
53P_A W-0.8 13K_C Or-1.0
86 Ignition Switch Power
87 53P_B W-0.8 Pilot Control Signal 13K_E Or-0.8
53P_C W-0.8
87 13V Or-1.0 Voltmeter Relay Out
87A None
87A None

4002-110
CONNECTOR 59F - HIGH/LOW BEAM RELAY TO CONNECTOR 61 - FRONT WIPER MOTOR TO
CAB MAIN HARNESS PEDESTAL HARNESS
194791A1

245715C1
1 41J_A K-2.0 High/Low Beam Signal
3 41L_A K-2.0 Low Beam Power
A 63H Or-0.8 Front Wiper High Speed
4 41H K-2.0 Hi/Low Beam Relay Power
B 63L Or-0.8 Front Wiper Low Speed
6 64D_A Or-0.8 Low Beam Signal (2 Way)
C 19J Or-0.8 Front Wiper Wash Fused Power
8 1_H R-3.0 High Beam Signal (2 Way)
D 63C Or-0.8 Front Wiper Park
CONNECTOR 60 - FRONT WIPER MOTOR TO

CONNECTOR 62M - FLASHER MODULE TO CAB
PEDESTAL HARNESS
MAIN HARNESS
245480C1
225389C1
1 0_KN Bk-0.8 Front Wiper Ground
1 1B_B R-0.8 Flasher Module Power
3 0_DAN Bk-0.8 Flasher Module Ground
4 0_DAQ Bk-0.8 Flasher Module Ground
5 None
6 None
7 45R_E N-0.8 Right Turn Signal
8 45L_D N-0.8 Left Turn Signal
9 45B_A N-0.8 Right Turn Switch Power
10 45A_A N-0.8 Left Turn Switch Power
11 45H_A N-0.8 Hazard Switch Power

4002-111
CONNECTOR 63M - TIME DELAY MODULE TO CONNECTOR 64M - FLASHER MODULE TO CAB
CAB MAIN HARNESS MAIN HARNESS
225351C1
631801C1
1 13D Or-1.0 Delay Power (2 Way) CAV WIRE IDENT CIRCUIT
2 1A_E R-0.8 Time Delay Power 1 45N_B N-0.8 Flasher Opp Side Control
3 0_DAS Bk 0.8 Time Delay Module Ground

4 37R_C P-0.8 Reset Signal CONNECTOR 66 - TURN SIGNAL SWITCH TO
5 13K_F Or-0.8 Ignition Switch Power PEDESTAL HARNESS
6 None
CONNECTOR 64F - FLASHER MODULE TO CAB

MAIN HARNESS
1964527C1

1 45A N-0.8 Left Turn Switch Power
CONNECTOR 67 - TURN SIGNAL SWITCH TO

739070C1
PEDESTAL HARNESS
1964527C1

1 19B Or-0.8 Turn Signal Power

4002-112
CONNECTOR 68 - TURN SIGNAL SWITCH TO CONNECTOR 70 - TRANSMISSION SHIFTER TO
1964527C1

245486C1
1 45B N-0.8 Right Turn Switch Power
A 19A_H Or-0.8 Trans Control Power
CONNECTOR 69 - IGNITION SWITCH TO B 25F LU-0.8 Forward Signal

PEDESTAL HARNESS C 25R LU-0.8 Reverse Signal
D 25T_A LU-0.8 Neutral Signal
CONNECTOR 71 - HAZARD SWITCH TO

PEDESTAL HARNESS
225253C1

1A_A R-0.8
1 Ign Prog Reset Sw Power
1A_B R-0.8
2 21K W-0.8 Ign Switch Start Signal 382391A1
3 13K Or-0.8 Ignition Switch Power CAV WIRE IDENT CIRCUIT
4 12K_C Or-0.8 Ign Switch Acc Power
1 None
5 None 2 1B R-0.8 Hazard Switch Power
6 None
3 45H N-0.8 Hazard Switch Power
4 None
5 None
6 None
7 0_KH Bk-0.8 Pilot Light Ground
49_A S-0.8
8 Pilot Light
49_B S-0.8
9 None
10 None

4002-113
CONNECTOR 72 - PARKING BRAKE SWITCH TO CONNECTOR 74 - UP/DOWN COUNT SWITCH TO
382391A1 382391A1

1 None 1 37D P-0.8 Down Count Signal
19A_H Or-0.8 19S_A Or-0.8
2 Trans Control Power 2 Instr Cluster Fused Del Power
19A_G Or-0.8 19S_B Or-0.8
3 33U Y-0.8 Park Brake Signal 3 37U P-0.8 Up Count Signal
4 None 4 None
5 None 5 None
6 None 6 None
0_KJ Bk-0.8 0_KK Bk-0.8
7 Pilot Light Ground 7 Pilot Light Ground
0_KK Bk-0.8 0_KL Bk-0.8
49_C S-0.8 49_D S-0.8
8 Pilot Light 8 Pilot Light
49_D S-0.8 49_E S-0.8
9 None 9 None
10 None 10 None

4002-114
CONNECTOR 75 - PROGRAM/RESET SWITCH TO CAV WIRE IDENT CIRCUIT
PEDESTAL HARNESS
8 0_KP Bk-0.8 Analog Ground
9 33U Y-0.8 Park Brake Signal
10 61R_G Or-0.8 A/C Telltale
11 None
12 42R_A Y-0.8 Work Light Telltale Sig
13 46_B K-0.8 Beacon Telltale
14 None
15 18C_C Or-0.8 High Beam Telltale
16 45L_F N-0.8 Left Turn Signal
382391A1 17 45R_F N-0.8 Right Turn Signal
CAV WIRE IDENT CIRCUIT 18 36C_C P-0.8 ECT Signal
37R_A P-0.8 19 36F_B P-0.8 Fuel Level Signal

1 Reset Signal
37R_B P-0.8 20 36H_B P-0.8 Hot Signal
2 1A_B R-0.8 Ign Prog Reset Switch Power 21 50T Bk-0.8 CAN T
3 37P P-0.8 Program Signal 22 36P_C P-0.8 EOP Signal
4 None 23 23C W-0.8 Engine Shutdown Signal
5 None 24 37P P-0.8 Program Signal
6 None 25 37R_B P-0.8 Reset Signal
0_KL Bk-0.8 26 37U P-0.8 Up Count Signal
7 Pilot Light Ground
0_KM Bk-0.8
27 37D P-0.8 Down Count Signal
8 49_E S-0.8 Pilot Light
9 None
10 None
31 50L G-0.5 CAN L
CONNECTOR 76 - INSTRUMENT CLUSTER TO 32 50H Y-0.5 CAN H
PEDESTAL HARNESS 33 50T Bk-0.8 CAN T
34 None
37 0_KQ Bk -0.8 Signal Ground
38 0_KE Bk-0.8 Signal Ground
40 None
282763A1

1 19V_A Or-0.8 Cluster Main Fused Power
2 19S_B Or-0.8 Instr Cluster Fused Del Power
3 33P_B Y-0.8 Low Brake Pres Warning
4 31D_B Y-0.8 Coolant Level Signal
5 35X_F Y-0.8 Sec Str Low Press Sig
6 31F_C Y-0.8 Air Filter Rest Sw Signal
7 31H_B Y-0.8 Hyd Filter Rest Sw Signal

4002-115
CONNECTOR 77F - COURTESY LAMP TO CAB CONNECTOR 80F - RH REAR WORK LAMP TO
MAIN HARNESS CAB MAIN HARNESS
245483C1

291729A1 A 42R_E DU-1.0 RH Rear Work Lamp Power
CAV WIRE IDENT CIRCUIT B 0_MF Bk-1.0 RH Rear Work Lamp Ground
A 49_V S-0.8 Courtesy Pilot Lamp
B 0_ML Bk-0.8 Courtesy Lamp Ground
CAB MAIN HARNESS
CONNECTOR 78F - RH FRONT WORK LAMP TO
CAB MAIN HARNESS
245715C1
245483C1
A None
A 42C_C DU-1.0 RH Front Work Lamp Power
B 68L_C Or-1.0 Rear Wiper Low Speed
B 0_MJ Bk-1.0 RH Front Work Lamp Ground
C 19K_E Or-1.0 Rear Wpr Wash Fused Power
D 68C_B Or-1.0 Rear Wiper Park
CONNECTOR 79F - LH FRONT WORK LAMP TO
CAB MAIN HARNESS
CAB MAIN HARNESS
245483C1

A 42C_B DU-1.0 LH Front Work Lamp Power
245480C1
B 0_MH Bk-1.0 LH Front Work Lamp Ground
1 0_MA Bk-1.0 Rear Wiper Motor Ground

4002-116
CONNECTOR 83F - LH REAR WORK LAMP TO CONNECTOR 85F - BEACON LAMP TO CAB
CAB MAIN HARNESS MAIN HARNESS
245483C1
A 42R_D DU-1.0 LH Rear Work Lamp Power CAV WIRE IDENT CIRCUIT
B 0_ME Bk-1.0 LH Rear Work Lamp Ground A 46_D K-1.0 Beacon Switched Power
B 0_MC Bk-1.0 Beacon Lamp Ground
CONNECTOR 84F - DOME LAMP TO CAB MAIN

HARNESS
CONNECTOR 86 - REDUNDANT BRAKE SWITCH
245483C1
266516C1
A 33R_B Y-1.0 Redundant Brake Switch Sig
A 19U_D Or-1.0 Dome Lamp Fused Power
B 0_M Bk-1.0 Ground
0_MB Bk-0.8
B Dome Lamp Ground
0_MM Bk-0.8
C 0_MM Bk-0.8 Dome Lamp Ground CONNECTOR 87 - PARKING BRAKE SOLENOID
291718A1

1 52P W-1.0 Parking Brake Relay Out
2 0_Q Bk-1.0 Park Str Fuel Relay Ground

4002-117
CONNECTOR 88 - BRAKE PRESSURE WARNING CONNECTOR 90M - SECONDARY STEERING
SWITCH TO REAR CHASSIS HARNESS MODULE TO SECONDARY STEERING HARNESS
225389C1
222135A1
A 33P Y-1.0 Low Brake Press Warning
2 51_A W-1.0 Secondary Steer Mtr Rel
B 0_N Bk-1.0 Brake Press Warning Switch
3 1_W R-1.0 Secondary Steer Module B+
4 0_CE Bk-1.0 Secondary Steer Chassis Grnd
CONNECTOR 89M - PILOT PRESSURE 5 None
SOLENOID TO CAB MAIN HARNESS 6 None
7 19M_C Or-1.0 Secondary Steer Accessory
8 35X_D Y-1.0 Secondary Steer Low Press Sig
9 51P_A W-1.0 Secondary Steer High Press
10 None
11 0_CA Bk-1.0 Secondary Steer Signal Grnd
12 0_CB Bk-1.0 Secondary Steer Signal Grnd
245482C1 CONNECTOR 92 - ETHER START SWITCH TO

PEDESTAL HARNESS
A 53P_A W-0.8 Pilot Control Signal
B 0_DB Bk-0.8 CAN Pilot Solenoid Ground
739070C1

25T_A LU-0.8
1 Neutral Signal
25T_B LU-0.8

4002-118
CONNECTOR 94F - TRANSMISSION HARNESS CONNECTOR 94M - ENGINE HARNESS TO
291659A1
373356A1
1 13C_A Or-1.0 Fuel Solenoid CAV WIRE IDENT CIRCUIT
2 61A_A Or-1.0 AC High Pressure Switch 1 13C Or-1.0 Fuel Solenoid
3 61R-A Or-1.0 AC High Pressure Switch 2 61A Or-1.0 AC High Pressure Switch
4 61C_A Or-1.0 AC Comp Clutch 3 61R Or-1.0 AC High Pressure Switch
5 14_A LG-1.0 Alternator D+ 4 61C Or-1.0 AC Comp Clutch
6 36P_A P-1.0 EOP Sender 5 14 LG-1.0 Alternator D+
7 31F_A Y-1.0 Air Filter Rest Switch Signal 6 36P P-1.0 EOP Sender
8 None 7 31F Y-1.0 Air Filter Rest Switch Signal
9 0_HA Bk-1.0 Signal Ground 8 None
10 None 9 0_BF Bk-1.0 Signal Ground
11 0_HB Bk-1.0 Signal Ground 10 None
12 None 11 0_BH Bk-1.0 Signal Ground
13 36C_A P-1.0 ECT Sender 12 None
14 None 13 36C P-1.0 ECT Sender
15 0_HC Bk-1.0 Analog Ground 14 None
16 None 15 0_BG Bk-1.0 Analog Ground
17 None 16 None
18 None 17 None
19 None 18 None
19 None

4002-119
CONNECTOR 95 - INTERMEDIATE SPEED CONNECTOR 97 - PREHEATER LIGHT TO
SENSOR TO TRANSMISSION HARNESS PEDESTAL HARNESS
245781C1
291718A1
A None
1 25C W-0.8 Intermediate Speed Signal
B None
2 0_HG Bk-0.8 Intermediate Speed Signal
C None
D 31Y_B Y-0.8 Lamp Signal
CONNECTOR 96 - TURBINE SPEED SENSOR TO E 18L_D Bk-0.8 Lamp Ground
F None
CONNECTOR 98 - AC HIGH PRESSURE SWITCH

TO ENGINE HARNESS
291718A1

1 25B W-0.8 Turbine Speed Signal 245482C1
2 0_HH Bk-0.8 Turbine Speed Ground CAV WIRE IDENT CIRCUIT

A 61A Or-1.0 AC High Pressure Switch
B 61R Or-1.0 AC High Pressure Switch

4002-120
CONNECTOR 99 - AC COMPRESSOR CLUTCH CONNECTOR 101 - ENGINE SPEED SENSOR TO
245480C1
CAV WIRE IDENT CIRCUIT 291718A1
1 61C Or-1.0 AC Compressor Clutch CAV WIRE IDENT CIRCUIT

1 25A W-0.8 Engine Speed Signal
2 0_HF Bk-0.8 Engine Speed Ground
CONNECTOR 100 - OUTPUT SPEED SENSOR TO
CONNECTOR 102 - TRANSMISSION CONTROL
VALVE TO TRANSMISSION HARNESS
291719A1

1 0_HE Bk-1.0 Output Speed Ground 371566A1
2 25D LU-1.0 Output Speed Signal CAV WIRE IDENT CIRCUIT

3 19A Or-1.0 Output Speed Power 1 25K LU-0.8 Trans Solenoid Valve Y1
2 25L LU-0.8 Trans Solenoid Valve Y2
3 25M LU-0.8 Trans Solenoid Valve Y3
4 25N LU-0.8 Trans Solenoid Valve Y4
5 25P LU-0.8 Trans Solenoid Valve Y5
6 25J LU-0.8 Trans Solenoid Valve Y6
7 25S LU-0.8 Output Sw Power VPS1
8 36T P-0.8 Valve Body Temp Signal
9 36R_C P-0.8 Valve Body Temp Ret
10 None
11 None
12 None
13 None
14 None
15 None
16 None

4002-121
CONNECTOR 104 - COOLANT LEVEL SENDER CAV WIRE IDENT CIRCUIT
5 None
6 None
CONNECTOR 109M - RADIO POWER

CONVERTER TO RADIO HARNESS
194788A1

A 31D Y-1.0 Coolant Level Signal
B 0_V Bk-1.0 Fuel Rdndnt Brake Cool Ground
CONNECTOR 107M - PIN ENGAGE SOLENOID TO

291730A1

B 0_PD Bk-1.0 Radio Ground
CONNECTOR 110F - RADIO POWER

245482C1 CONVERTER TO RADIO HARNESS
A 57 W-1.0 Pin Engage Solenoid Power
B 0_AB Bk-1.0 Pin Engage Ground
CONNECTOR 108F - DIAGNOSTIC CONNECTOR

TO CAB MAIN HARNESS
245426C1

A 65C Or-0.8 Radio Power
B 0_PC Bk-0.8 Radio Ground
291663A1

1 19A_L Or-0.8 Cab Switched Power
3 0_DAV Bk-0.8 Diagnostic TECM Ground

4002-122
CONNECTOR 111M - RIGHT SPEAKER TO RADIO CONNECTOR 114F - RADIO ADAPTOR TO RADIO
HARNESS HARNESS
195552A1
A 65R Or-0.8 Right Speaker Signal CAV WIRE IDENT CIRCUIT

B 0_PB Bk-0.8 Right Speaker Ground 1 65L Or-0.8 Left Speaker Signal
2 0_PA Bk-0.8 Left Speaker Ground
CONNECTOR 112M - LEFT SPEAKER TO RADIO 3 0_PC Bk-0.8 Radio Ground

HARNESS 4 0_PB Bk-0.8 Right Speaker Ground
5 65R Or-0.8 Right Speaker Signal
6 65C Or-0.8 Radio Power
CONNECTOR 114M - RADIO ADAPTOR TO

REMOTE RADIO ADAPTOR HARNESS
195552A1

A 65L Or-0.8 Left Speaker Signal
B 0_PA Bk-0.8 Left Speaker Ground
CONNECTOR 113 - RADIO TO REMOTE RADIO

ADAPTOR HARNESS
2 0_QB Bk-0.8 Right Speaker Ground 1 65L_A Or-0.8 Left Speaker Signal
3 None 2 0_QA Bk-0.8 Left Speaker Ground
4 0_QA Bk-0.8 Left Speaker Ground 3 0_QC Bk-0.8 Radio Ground
5 0_QC Bk-0.8 Radio Ground 4 0_QB Bk-0.8 Right Speaker Ground
6 18_ H Or-0.8 Radio Power 5 65R_A Or-0.8 Right Speaker Signal
7 None 6 65C_B Or-0.8 Radio Power
8 None
9 65R_A Or-0.8 Right Speaker Signal
10 None
11 65L_A Or-0.8 Left Speaker Signal
12 None
13 None
14 65C_B Or-0.8 Radio Power

4002-123
CONNECTOR 117 - AIR FILTER RESTRICTION CONNECTOR 125 - LH REAR COMBINATION
SWITCH TO ENGINE HARNESS LAMP TO REAR CHASSIS HARNESS
225351C1
291718A1
CAV WIRE IDENT CIRCUIT 1 44_A T-1.0 Brake Light Signal

2 45L_A N-1.0 Left Turn Signal
A 31F Y-1.0 Air Fltr Restriction Switch Signal
B 0_BD Bk-1.0 Air Fltr Restriction Switch Grnd 3 18F_A Or-1.0 Left Tail
4 35A_A K-1.0 Left Reverse
5 0_A Bk-1.0 Ground
CONNECTOR 118F - BACKUP ALARM DISABLE 6 None
CONNECTOR 127 - RH REAR COMBINATION

LAMP TO REAR CHASSIS HARNESS
382391A1

35R_C Y-0.8
1 Backup Alarm Switch 225351C1
35R_D Y-0.8
35A_E Y-0.8
2 Backup Alarm Relay Out
35A_F Y-0.8 1 44_B T-1.0 Brake Light Signal
3 None 2 45R_A N-1.0 Right Turn Signal
4 None 3 18G_A Or-1.0 Right Tail
5 None 4 35A_B K-1.0 Right Reverse
6 None 5 0_C Bk-1.0 Ground
0_DW Bk-0.8 6 None
7 Ground
0_DAW Bk-1.0
49_L S-0.8
8 Pilot Light
49_T S-1.0
9 None
10 None

4002-124
CONNECTOR 128F - REAR CHASSIS HARNESS CONNECTOR 131F - SECONDARY STEERING
TO HOOD HARNESS PRESSURE SWITCH TO FRONT CHASSIS
HARNESS
245485C1
245485C1
A 18G_C Or-1.0 License Plate Light
A 51P_B W-1.0 Secondary Steer High Pressure
B 35R_B Y-1.0 Backup Alarm Switch
B 0_AN Bk-1.0 Secondary Steer Signal Ground
C 0_J Bk-1.0 Hood Grounds
C 35X_A Y-1.0 Secondary Steer Low Press Sig
CONNECTOR 128M - HOOD HARNESS TO REAR

CHASSIS HARNESS CONNECTOR 133M - ENGINE HARNESS TO
FUEL SOLENOID
245484C1
A 18G_E Or-1.0 License Plate Light CAV WIRE IDENT CIRCUIT

B 35R_A Y-1.0 Backup Alarm Switch 1 13M Or-1.0 Fuel Solenoid Hold In
C 0_JA Bk-1.0 Hood Ground
CONNECTOR 136 - HYDRAULIC OIL

TEMPERATURE SENDER TO REAR CHASSIS
HARNESS
194788A1

A 36H P-1.0 Hot Signal
B 0_W Bk-1.0 Front Rear Wash Hot Ground

4002-125
CONNECTOR 138 - ENGINE COOLANT CONNECTOR 140M - DIODE MODULE TO CAB
TEMPERATURE SENDER TO ENGINE HARNESS MAIN HARNESS
194788A1

A 36C P-1.0 ECT Signal
245488C1
B 0_BE Bk-1.0 ECT Ground
A 63L_B Or-0.8 Front Wiper Low Speed
CONNECTOR 139F - ENGINE HARNESS TO B 63H_B Or-0.8 Front Wiper High Speed
DISCONNECT HARNESS
C 0_DAX Bk-0.8 Beacon Wiper Diode Ground
D 13C_C Or-0.8 Fuel Solenoid Power
E 21C_F W-0.8 Starter Fuel Relay Signal
F 68L_B Or-0.8 Rear Wiper Low Speed
CONNECTOR 142 - TORQUE CONVERTER

OUTPUT TO TRANSMISSION HARNESS
245483C1

A 13C Or-1.0 Fuel Solenoid
B 13M Or-1.0 Fuel Solenoid Hold In
CONNECTOR 139M - DISCONNECT HARNESS

TO ENGINE HARNESS
291718A1

A 36G P-1.0 TCO Temperature Signal
B 36R_D P-1.0 Valve Body Temperature Ret
245482C1

A 13C_E Or-1.0 Fuel Solenoid Power
B 13M_A Or-1.0 Fuel Solenoid Hold In

4002-126
CONNECTOR 154 - ALTERNATOR TO ENGINE CONNECTOR 159 - BRAKE LAMP PRESSURE
HARNESS SWITCH TO REAR CHASSIS HARNESS
1 None
2 30 R-1.0 Battery Sensing
3 14 LG-1.0 Ignition Power
4 None
5 None
CONNECTOR 157 - REDUNDANT BRAKE

PRESSURE SWITCH TO REAR CHASSIS 222136A1
HARNESS
A 1B_A R-1.0 Brake Lamp Switch Power
B 44 T-1.0 Brake Lamp Input Signal
CONNECTOR 168 - LICENSE PLATE LAMP TO

HOOD HARNESS
245483C1

A 33R_A Y-1.0 Red Brake Switch Signal
B 0_L Bk-1.0 Ground
CONNECTOR 158 - FAN REVERSING SOLENOID

TO REAR CHASSIS HARNESS 245482C1

A 18G_E Or-1.0 License Plate Lamp
B 0_JC Bk-1.0 License Plate Lamp Ground
CONNECTOR 178M - FLOAT PRESSURE SWITCH

TO FRONT CHASSIS HARNESS
225316C1

1 52 W-1.0 Fan Reversing Solenoid
2 0_X Bk-1.0 Fan Reversing Solenoid Ground
245482C1

A 53P_D W-1.0 Float Solenoid Power
B 53S_A W-1.0 Float Solenoid Signal

4002-127
CONNECTOR 179F - FLOAT SOLENOID TO CONNECTOR 180M - SECONDARY STEERING
FRONT CHASSIS HARNESS MODULE HARNESS TO FRONT CHASSIS
HARNESS
225351C1
291718A1
1 19M_C Or-1.0 Secondary Steering Accessory
1 53S_B W-1.0 Float Solenoid Signal
2 0_AP Bk-1.0 Float Solenoid Ground
3 35X_D Y-1.0 Sec Steer Low Pressure Signal
4 51P_A W-1.0 Sec Steer High Pressure
CONNECTOR 180F - FRONT CHASSIS HARNESS 5 0_CC Bk-1.0 Sec Steer Signal Ground
TO SECONDARY STEERING MODULE HARNESS
6 None
CONNECTOR 182 - ETHER START SWITCH TO

PEDESTAL HARNESS
225350C1

1 19M_B Or-1.0 Secondary Steering Accessory
2 19R_B Or-1.0 Secondary Steering Ignition 739070C1
3 35X_C Y-1.0 Sec Steer Low Pressure Signal CAV WIRE IDENT CIRCUIT
4 51P_B W-1.0 Sec Steer High Pressure 1 28C W-0.8 Ether Start Control
5 0_AN Bk-1.0 Sec Steer Signal Ground
6 None

4002-128
CONNECTOR 183 - TRANSMISSION SHIFTER TO CONNECTOR 197M - FNR HARNESS TO CAB
PEDESTAL HARNESS MAIN HARNESS
245487C1 225351C1
A None 1 19A_B Or-0.8 FNR Switched Power
B 25W LU-0.8 3rd and 4th Gear Signal 2 26F_A LU-0.8 FNR Forward Signal
C 25Z LU-0.8 1st and 4th Gear Signal 3 26N_A LU-0.8 FNR Neutral Signal
D 25Y LU-0.8 Transmission Kick Down Signal 4 26R_A LU-0.8 FNR Reverse Signal
6 None
CONNECTOR 197F - CAB MAIN HARNESS TO
FNR HARNESS
CONNECTOR 198 - FNR SWITCH TO FNR
HARNESS
225350C1

382391A1
1 19A_C Or-0.8 Transmission Enable Sw Power
5 32J_B Y-0.8 Trans Enable LT Signal
6 None
19A_B Or-0.8
5 FNR Switched Power
19A_F Or-0.8
6 26F-A LU-0.8 FNR Forward Signal
8 19A_F Or-0.8 FNR Switched Power
9 None
10 None

4002-129
CONNECTOR 199F - TRANSMISSION ENABLE CONNECTOR 201 - GRID HEATER CONTROLLER
SWITCH TO CAB MAIN HARNESS TO MAIN CAB HARNESS
1 18L_C Or-0.8 Indicator Light
2 None
3 28GP W-1.0 Feedback of Grid Heater
4 14_C LG-0.8 Alternator D+
5 21C_G W-0.8 Cranking Power
6 28GC W-0.8 Grid Heater Signal
7 19E Or-1.0 Switched Power
382391A1
8 0_DBB Bk-0.8 Ground
9 None
1 None 10 31T Y-0.8 Grid Heater Temp Sndr Signal
19A_D Or-0.8
2 Trans Enable Switched Power
19A_E Or-0.8
CONNECTOR 202F - DIODE MODULE TO FRONT
CHASSIS HARNESS
4 None
5 None
6 None
0_DAE Bk-1.0
7 Ground
0_DAP Bk-1.0
49_G S-0.8
8 Pilot Light
49_R S-1.0
32J_B Y-0.8
9 Trans Enable LT Signal
32J_C Y-0.8
245485C1
19A_C Or-0.8
10 None
19A_E Or-0.8 CAV WIRE IDENT CIRCUIT
A 58_D W-1.0 Ride Control Solenoid Power
B None
CONNECTOR 200 - RETURN-TO-DIG PROXIMITY
SWITCH TO RETURN-TO-DIG HARNESS FOR XT C 53S_C W-1.0 Float Switch Signal
CHASSIS
245484C1


4002-130
CONNECTOR 203F - COMPRESSOR CLUTCH CONNECTOR 207F - THERMOSTAT SWITCH TO
LOCKOUT RELAY TO CAB MAIN HARNESS CAB MAIN HARNESS
A 61T Or-1.0 Beacon Wiper Diode Ground
CONNECTOR 208F - THERMOSTAT SWITCH TO

CAB MAIN HARNESS
A 61A_D Or-0.8 AC Thermostat
245731C1 CONNECTOR 209F - BACKUP ALARM DISABLE

CAV WIRE IDENT CIRCUIT JUMPER
61A_B Or-0.8
30 Relay Power
61A_C Or-0.8
85 0_DA Bk-0.8 AC BRK LT Time Del Horn Gnd
61R_B Or-0.8
61R_D Or-0.8
87A 61C_B Or-0.8 AC Comp Clutch
CONNECTOR 204F - BRAKE LAMPS RELAY TO 739070C1

A 35R_D Y-0.8 Backup Alarm Switch
CONNECTOR 209M - BACKUP ALARM DISABLE

JUMPER
245731C1

30 1B_E R-0.8 Brake Lamp Relay Power
0_DC Bk-0.8
85 AC BRK LT Time Del Horn Gnd
0_DG Bk-0.8
86 44A_B T-0.8 Brake LT Input Signal 631801C1
87 44_E T-0.8 Brake LT Relay Signal CAV WIRE IDENT CIRCUIT
87A None A 35A_F Y-0.8 Backup Alarm Relay Out

4002-131
CONNECTOR 210F - FAN REVERSER SWITCH CONNECTOR 216F - ALTERNATOR RESISTOR
TO CAB MAIN HARNESS TO CAB MAIN HARNESS
199436A1
382391A1
CAV WIRE IDENT CIRCUIT 1 19R_E Or-0.8 Cab Switched Power
1 None
2 19P_B Or-1.0 Fan Rev Pin Engage Fused Pwr
CONNECTOR 217F - ENGINE SHUTDOWN
3 52_A W-0.8 Fan Reverse Solenoid
JUMPER
4 None
5 None
6 None
0_DAF Bk-1.0
7 Switch Ground
0_DAY Bk-1.0
49_H S-0.8
8 Pilot Light
49_U S-0.8
9 None
10 None
739070C1
CONNECTOR 215F - ALTERNATOR RESISTOR CAV WIRE IDENT CIRCUIT
TO CAB MAIN HARNESS
A 13K_D Or-0.8 Ignition Switch Power
CONNECTOR 217M - ENGINE SHUTDOWN

JUMPER
199436A1

14_B LG-0.8
1 Alternator D+
14_C LG-0.8
631801C1

A 13C_B Or-0.8 Fuel Solenoid Power

4002-132
CONNECTOR 229M - DIODE MODULE TO FRONT CONNECTOR 259F - CIGAR LIGHTER TO CIGAR
CHASSIS HARNESS LIGHTER HARNESS
245488C1 3227856R1

A 58_E W-1.0 Ride Control Solenoid Power 1 19W_A Or-3.0 Cigar Lighter Power
B 53S_D W-1.0 Float Solenoid Signal 2 0_S Bk-3.0 Cigar Lighter Ground
C 0_AQ Bk-1.0 Ground
D None
E None TO CIGAR LIGHTER HARNESS
F None

TO RADIO HARNESS

TO CONVERTER HARNESS 276720A1

A 19L_B Or-1.0 Converter Power Ignition A 19W_A Or-3.0 Cigar Lighter Power
CONNECTOR 253F - POWER OUTLET TO CONNECTOR 262F - DIODE MODULE TO CAB

CONVERTER HARNESS MAIN CHASSIS HARNESS
245485C1

314908A1
A 19R_F Or-0.8 Secondary Steering Ignition
B None
A 12V_A R-3.0 12 V Power to Outlet
C 19R_D Or-0.8 Secondary Steering Ignition
B 0_RB Bk-3.0 Outlet Ground

4002-133
CONNECTOR 264M - SECONDARY STEERING CONNECTOR 267F - ENGINE HARNESS TO AIR
SOLENOID TO SECONDARY STEERING CONDITIONING DIODE HARNESS
HARNESS
245481C1
225316C1
CAV WIRE IDENT CIRCUIT 1 61C_D Or-1.0 AC Compressor Clutch
1 51_C W-1.0 Sec Steer Solenoid Power
2 0_CF Bk-1.0 Secondary Steering Ground
CONNECTOR 269 - RADIO FUSE HOLDER
CONNECTOR 265F - AIR CONDITIONING DIODE CAV WIRE IDENT CIRCUIT
MODULE TO AIR CONDITIONING DIODE
HARNESS
2 18_H Or-0.8 Radio Memory Fused Power
CONNECTOR 270F - RADIO MEMORY POWER

245485C1 CONNECTOR 271M - FRONT CHASSIS

CAV WIRE IDENT CIRCUIT ROLLBACK JUMPER HARNESS
A 0_BJ Bk-1.0 Ground
B None
C 61C_C Or-1.0 AC Compressor Clutch
CONNECTOR 266M - AIR CONDITIONING DIODE

HARNESS TO AIR COMPRESSOR CLUTCH
245484C1

A 58_F W-1.0 Float Switch Signal
B None
C 53S_E W-1.0 Ride Control Solenoid Power
245480C1

1 61C_E Or-1.0 AC Compressor Clutch

4002-134
CONNECTOR 272F - ROLLBACK JUMPER CONNECTOR 275M - COOLANT JUMPER
PRESSURE SWITCH (ROLLBACK SWITCH COOLANT SENDER (COOLANT SENSOR
JUMPER HARNESS) JUMPER HARNESS)
194788A1
245483C1
A 58A_A W-1.0 Float Switch Signal
B 58_F W-1.0 Ride Control Solenoid Power
CONNECTOR 276F - REAR CHASSIS HARNESS

CONNECTOR 273F - ROLLBACK JUMPER DIODE
TO RELAY HARNESS
MODULE (ROLLBACK SWITCH JUMPER
HARNESS)
245483C1

245485C1
A 28GC_B W-1.0 Grid Heater Signal
B 0_UA Bk-2.0 Grid Heater Feedback
A 58A_A W-1.0 Ride Control Solenoid Power
B None
C 53S_E W-1.0 Float Switch Signal CONNECTOR 276M - RELAY HARNESS TO REAR
CHASSIS HARNESS
CONNECTOR 274F - REAR CHASSIS COOLANT

JUMPER (COOLANT SENSOR JUMPER
HARNESS)
245482C1

A 28GC_C W-1.0 Grid Heater Signal
B 0_UC Bk-2.0 Grid Heater Feedback

4002-135
CONNECTOR 277F - ENGINE HARNESS TO CONNECTOR 280 - FUEL FILTER HEATER
RELAY HARNESS RELAY TO RELAY HARNESS
1 1Y_C R-2.0 Fuel Filter Heater Power
2 1Y_B R-2.0 Fuel Filter Heater Power
3 31U W-1.0 Fuel Filter Heater Signal
4 13C_G Or-1.0 Fuel Filter Heater Signal Power
CONNECTOR 277M - RELAY HARNESS TO

ENGINE HARNESS
245731C1

1Y_E R-2.0
30 Fuel Filter Heater Power
1Y_D R-2.0
85 31U_X W-1.0 Fuel Filter Heater Signal
86 13C_H Or-1.0 Fuel Filter Heater Signal Power
87 1Y_A R-8.0 Fuel Filter Relay Power
87A None
239451A1
CONNECTOR 287 - SECOND FUEL FILTER
HEATER TO ENGINE HARNESS
1 1Y_E R-2.0 Fuel Filter Heater Power
2 1Y_D R-2.0 Fuel Filter Heater Power
3 31U_X W-1.0 Fuel Filter Heater Signal
4 13C_H Or-1.0 Fuel Filter Heater Signal Power
CONNECTOR 279M - GRID HEATER RELAY TO

RELAY HARNESS
182069A1

A 1Y_B R-2.0 Fuel Filter Heater Power
B 0_BK Bk-2.0 Fuel Filter Heater Ground
3227856R1

1 0_UC Bk-2.0 Grid Heater Ground
2 28GC_C W-1.0 Grid Heater Ground

4002-136
CONNECTOR 288 - FIRST FUEL FILTER HEATER CONNECTOR 291 - FUEL FILTER
TO ENGINE HARNESS TEMPERATURE SWITCH TO ENGINE HARNESS
(621D ONLY)
182069A1
CAV WIRE IDENT CIRCUIT 371614A1
A 1Y_C R-2.0 Fuel Filter Heater Power CAV WIRE IDENT CIRCUIT
B 0_BC Bk-2.0 Fuel Solenoid Ground A 31U W-1.0 Fuel Filter Heater Signal
B 0_BM Bk-1.0 Signal Ground
CONNECTOR 289 - FUEL FILTER

TEMPERATURE SWITCH TO ENGINE HARNESS
(521D ONLY)
256340A1

A 31U W-1.0 Fuel Filter Heater Signal
B 0_BM Bk-1.0 Fuel Solenoid Ground
CONNECTOR 290 - GRID HEATER

TEMPERATURE SENSOR TO REAR CHASSIS
HARNESS
A 31T_A Y-1.0 Grid Heater Temp Snsr Signal
B 0_BC Bk-1.0 Grid Heater Temp Snsr Ground

4002-137
INDEX
Symbols Connector 118F.................................................... 123
Connector 128F.................................................... 124
A Connector 128M ...................................................124
A/C High Pressure Switch (In Rear Chassis) .........73 Connector 12F........................................................ 92
A/C Low Pressure Switch (In Cab) .........................73 Connector 12M....................................................... 92
Accessory Relay No. 3 ...........................................43 Connector 131F.................................................... 124
Air Filter Restriction Switch.....................................50 Connector 133M ...................................................124
Alarm Connector 136 ...................................................... 124
Back-up ..............................................................46 Connector 138 ...................................................... 125
Back-up, Disable Switch ....................................46 Connector 139F.................................................... 125
Back-up, Relay No. 7 .........................................45 Connector 139M ...................................................125
Alternator ................................................................37 Connector 13F........................................................ 93
Connector 13M....................................................... 94
B Connector 140M ...................................................125
Back-up Alarm ........................................................46 Connector 142 ...................................................... 125
Back-up Alarm Disable Switch ...............................46 Connector 154 ...................................................... 126
Back-up Alarm Relay No. 7 ....................................45 Connector 157 ...................................................... 126
Batteries .................................................................36 Connector 158 ...................................................... 126
Beacon Switch ........................................................78 Connector 159 ...................................................... 126
Beacon, Rotating ....................................................79 Connector 168 ...................................................... 126
Blower Motor ..........................................................73 Connector 178M ...................................................126
Blower Motor Speed Resistors with Thermal Fuse 73 Connector 179F.................................................... 127
Blower Switch .........................................................72 Connector 17M....................................................... 95
Brake Lamp Pressure Switch .................................79 Connector 180F.................................................... 127
Brake Lamps Relay No. 6.......................................79 Connector 180M ...................................................127
Brake Warning Pressure Switch .............................48 Connector 182 ...................................................... 127
Bucket Control Valve Electromagnet Detents ........59 Connector 183 ...................................................... 128
Bulb Connector 197F.................................................... 128
See Lamp ...........................................................79 Connector 197M ...................................................128
Connector 198 ...................................................... 128
C Connector 199F.................................................... 129
Cigar Lighter ...........................................................75 Connector 19F........................................................ 98
Cluster, Instrument .....................................51, 52, 53 Connector 1F..........................................................90
Compressor Clutch .................................................74 Connector 2 ............................................................91
Compressor Clutch Lockout Relay No. 14 .............74 Connector 200 ...................................................... 129
Compressor, Seat...................................................72 Connector 201 ...................................................... 129
Connector 1 ............................................................90 Connector 202F.................................................... 129
Connector 10 ..........................................................92 Connector 203F.................................................... 130
Connector 107M ...................................................121 Connector 209M ...................................................130
Connector 108F....................................................121 Connector 20M....................................................... 98
Connector 110F....................................................121 Connector 215F.................................................... 131
Connector 114F....................................................122 Connector 21F........................................................ 99
Connector 114M ...................................................122 Connector 21M....................................................... 99
Connector 22F...................................................... 100
4002-138
Connector 246M ...................................................132 Connector 55F...................................................... 109
Connector 25F......................................................102 Connector 5F.......................................................... 91
Connector 260M ...................................................132 Connector 6 ............................................................ 91
Connector 265F....................................................133 Connector 62M..................................................... 110
Connector 266M ...................................................133 Connector 63M..................................................... 111
Connector 269 ......................................................133 Connector 64M..................................................... 111
Connector 279M ...................................................135 Connector 77F...................................................... 115
Connector 280 ......................................................135 Connector 79F...................................................... 115
Connector 287 ......................................................136 Connector 8 ............................................................ 92
Connector 289 ......................................................136 Connector 81M..................................................... 115
Connector 3 ............................................................91 Connector 86........................................................ 116
Connector 4 ............................................................91 Connector 98........................................................ 119
Connector 41F......................................................106 Connector, Diagnostic ............................................ 45
Connector 42F......................................................106 Controller
Connector 44F......................................................106 Grid Heater ........................................................ 40
Connector 45F......................................................107 Converter, Radio Power (24 volts to 12 volts)........ 77
Connector 47F......................................................107 Coolant Level Sender .............................................48
Connector 48F......................................................107 Courtesy Lamp ....................................................... 89
Connector 49F......................................................107
Connector 50F......................................................108

4002-139
D Horn Relay No. 5 .................................................... 71
Declutch Brake Switch............................................45 Horn Switch ............................................................80
Declutch Switch ......................................................45 Hydraulic Filter Restriction Switch .......................... 49
Detent Switch .........................................................59 Hydraulic Oil Temperature Sender ......................... 49
Diagnostic Connector .............................................45
Dome Lamp ............................................................89 I
Ignition Relay No. 1 ................................................ 41
E Ignition Relay No. 2 ................................................ 42
Engine Coolant Temperature Sender .....................49 Ignition Switch ........................................................ 41
Engine Fuel Solenoid .............................................37 Instrument Cluster ...................................... 51, 52, 53
Engine Oil Pressure Switch ....................................55 Intermediate Speed Sensor.................................... 45
Engine Speed Sensor.............................................45
Ether Start Solenoid ...............................................39 L
Lamp
F Courtesy............................................................. 89
Fan Reversing Solenoid .........................................57 Dome .................................................................89
Fan Reversing Switch.............................................56 High Beam ...................................................85, 86
Filter Maintenance Switch ......................................45 LH Front Combination ........................................ 85
First Fuel Filter Heater ............................................39 LH Rear Combination......................................... 83
Five Position Rotary Lamp Switch ..........................88 LH Rear Work .................................................... 86
Flasher Module.......................................................81 License Plate .....................................................89
Float Pressure Switch.............................................61 Low Beam ....................................................85, 86
Float Solenoid.........................................................61 Position ........................................................85, 86
FNR Switch.............................................................45 Reverse........................................................83, 84
Front RH Front Combination .......................................86
LH Work Lamp ...................................................87 RH Front Work ................................................... 87
RH Work Lamp...................................................87 RH Rear Combination ........................................ 84
Front LH Combination Lamp ..................................85 RH Rear Work.................................................... 87
Front RH Combination Lamp ..................................86 Stop..............................................................83, 84
Front Washer Pump Motor .....................................69 Switch, Five Position Rotary .............................. 88
Front Wiper and Washer Switch .............................69 Tail ...............................................................83, 84
Front Wiper Motor...................................................68 Turn..................................................83, 84, 85, 86
Fuel Filter Left Speaker ........................................................... 77
Heater, First .......................................................39 LH Front Combination Lamp ..................................85
Heater, Second (621D Only) ..............................39 LH Front Work Lamp ..............................................87
Fuel Filter Heater Relay No. 16 ..............................38 LH Rear Combination Lamp ................................... 83
Fuel Filter Heater Switch ........................................39 LH Rear Work Lamp............................................... 86
Fuel Level Sender ..................................................48 License Plate Lamp ................................................ 89
Fuel Solenoid, Engine ............................................37 Locating Components on the Schematic Posters .. 31
Fuse Block 18F.......................................................96
M
G Master Disconnect Switch ...................................... 37
Grid Heater .............................................................40 Module
Grid Heater Controller ............................................40 Flasher ............................................................... 81
Grid Heater Relay No. 15 .......................................39 Secondary Steering............................................ 63
Grid Heater Temperature Sensor ...........................40 Time Delay ......................................................... 43
Transmission Electronic Control ........................ 45
H Motor, Starter ......................................................... 38
Hazard Switch ........................................................80
Heater N
First Fuel Filter ...................................................39 Neutral Start Relay No. 8 .......................................41
Grid ....................................................................40
Second Fuel Filter (621D Only)..........................39 O
Height Control/Return-To-Travel Proximity Switch .61 Outlet, Power..........................................................76
Hi/Low Beam Switch...............................................80 Output Speed Sensor ............................................. 45
High/Low Beam Relay No. 13 ................................88
Horn ........................................................................72
4002-140
P Ride Control Relay No. 4........................................66
Parking Brake Relay No. 9 .....................................55 Ride Control Solenoid ............................................ 66
Parking Brake Solenoid ..........................................56 Ride Control Switch ................................................ 66
Parking Brake Switch .............................................50 Right Speaker......................................................... 77
Pilot Control Relay No. 10 ......................................55 Rotating Beacon..................................................... 79
Pilot Control Switch ................................................53
Pilot Pressure Solenoid ..........................................56 S
Pin Engage Solenoid ..............................................65 Seat Compressor and Switch .................................72
Pin Engage Switch .................................................65 Second Fuel Filter Heater (621D Only) .................. 39
Power Converter (24 volts to 12 volts) ...................76 Secondary Steering Module ................................... 63
Power Outlet...........................................................76 Secondary Steering Motor...................................... 64
Program Reset Switch............................................50 Secondary Steering Pressure Switch .....................63
Proximity Switch Secondary Steering Solenoid .................................64
Height Control/Return-To-Travel ........................61 Sender
Return-To-Dig ....................................................60 Coolant Level ..................................................... 48
Engine Coolant Temperature ............................. 49
R Fuel Level .......................................................... 48
Radio Hydraulic Oil Temperature .................................49
12 Volt ................................................................76 Torque Converter Output Temperature ............. 45
24 volt.................................................................76 Sensor
Power Converter (24 volts to 12 volts) ...............77 Engine Speed ....................................................45
Remote...............................................................76 Grid Heater, Temperature .................................. 40
Rear Intermediate Speed............................................ 45
LH Combination Lamp .......................................83 Output Speed ..................................................... 45
LH Work Lamp ...................................................86 Transmission Solenoid Valve and Temperature 45
RH Combination Lamp .......................................84 Turbine Speed ................................................... 45
RH Work Lamp...................................................87 Shifter, Transmission.............................................. 45
Rear Washer Pump Motor......................................70 Solenoid
Rear Wiper and Washer Switch .............................70 Engine, Fuel ....................................................... 37
Rear Wiper Motor ...................................................70 Ether ..................................................................39
Redundant Brake Pressure Switches .....................57 Fan Reversing....................................................57
Relay Float ................................................................... 61
Accessory, No. 3 ................................................43 Parking Brake ....................................................56
Backup Alarm, No. 7 ..........................................45 Pilot Pressure..................................................... 56
Brake Lamps No. 6 ............................................79 Pin Engage ........................................................ 65
Compressor Clutch Lockout No. 14 ...................74 Ride Control ....................................................... 66
Grid Heater No. 15 .............................................39 Secondary Steering ........................................... 64
High/Low Beam No. 13 ......................................88 Speaker
Horn No. 5 ..........................................................71 Left ..................................................................... 77
Ignition, No. 1 .....................................................41 Right................................................................... 77
Ignition, No. 2 .....................................................42 Specifications ........................................................... 7
Neutral Start No. 8 .............................................41 Speed Resistors
Parking Brake No. 9 ...........................................55 Blower Motor ...................................................... 73
Pilot Control No. 10 ............................................55 Starter Motor .......................................................... 38
Ride Control No. 4..............................................66 Starting Relay......................................................... 38
Starting ...............................................................38 Steering
Voltmeter, No. 12 ...............................................43 Secondary, Module ............................................ 63
Relay No. 16 Secondary, Motor...............................................64
Fuel Filter Heater ...............................................38 Secondary, Pressure Switch .............................. 63
Relay Socket No. 11 ...............................................57 Secondary, Solenoid .......................................... 64
Remote Radio.........................................................76 Switch ..................................................................... 74
Return-To-Dig Proximity Switch .............................60 A/C High Pressure (In Rear Chassis) ................ 73
Return-To-Travel/Float Switch................................60 A/C Low Pressure (In Cab) ................................ 73
RH Front Combination Lamp..................................86 Air Filter Restriction............................................ 50
RH Front Work Lamp..............................................87 Back-up Alarm Disable ...................................... 46
RH Rear Combination Lamp ..................................84 Beacon ............................................................... 78
RH Rear Work Lamp ..............................................87 Blower ................................................................ 72

4002-141
Brake Lamp Pressure ........................................79 U
Brake Warning Pressure ....................................48 Understanding the Troubleshooting Tables ........... 31
Declutch .............................................................45 Up/down Count Switch ........................................... 53
Declutch Brake ...................................................45
Detent.................................................................59 V
Engine Oil Pressure ...........................................55 Voltmeter Relay No. 12 .......................................... 43
Fan Reversing ....................................................56
Filter Maintenance..............................................45 W
Five Position Rotary Lamp .................................88 Wiper
Float Pressure ....................................................61 Front Motor......................................................... 68
FNR ....................................................................45 Front Switch ....................................................... 69
Front Wiper and Washer ....................................69 Front Washer Pump Motor................................. 69
Fuel Filter Heater ...............................................39 Front Washer Switch.......................................... 69
Hazard................................................................80 Rear Motor ......................................................... 70
Hi/Low Beam ......................................................80 Rear Switch........................................................ 70
Horn ...................................................................80 Rear Washer Pump Motor ................................. 70
Hydraulic Filter Restriction .................................49 Rear Washer Switch .......................................... 70
Ignition................................................................41
Master Disconnect .............................................37
Parking Brake.....................................................50
Pilot Control Switch ............................................53
Pin Engage.........................................................65
Program Reset ...................................................50
Proximity, Height Control/Return-To-Travel .......61
Proximity, Return-To-Dig....................................60
Rear Wiper and Washer.....................................70
Redundant Brake Pressure ................................57
Return-To-Travel/Float .......................................60
Ride Control .......................................................66
Seat Compressor ...............................................72
Secondary Steering Pressure ............................63
Transmission Auto .............................................45
Transmission Enable..........................................45
Transmission Kick-down ....................................45
Turn Signal .........................................................80
Up/down Count ..................................................53
T
Temperature Sensor
Grid Heater.........................................................40
Thermal Fuse
Blower Motor ......................................................73
Thermostat .............................................................74
Thermostat Switch ..................................................74
Time Delay Module.................................................43
Torque Converter Output Temperature Sender .....45
Transmission Auto Switch ......................................45
Transmission Electronic Control Module ................45
Transmission Enable Switch ..................................45
Transmission Kick-down Switch .............................45
Transmission Shifter ...............................................45
Transmission Solenoid Valve and Temperature
Sensors .....................................................45
Turbine Speed Sensor............................................45
Turn Signal Switch..................................................80

4002-142
NOTES

Section
4003
4003
BATTERIES
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-42330 August, 2001
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4003-3
SAFETY RULES
Never try to charge the battery if the electrolyte in the Battery acid causes severe burns. Batteries contain
! battery is frozen. sulfuric acid. Avoid contact with skin, eyes, or clothing.
47-83A Antidote: EXTERNAL-Flush with water. INTERNAL-
Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physi-
Never cause sparks to occur or smoke near batteries
cian immediately. Eyes: Flush with water for 15 min-
! that are charging or have been recently charged.
13-8A
utes and get prompt medical attention.
! Batteries produce explosive gases. Keep sparks,
Disconnect the ground cable first when the battery flame, and cigarettes away. Ventilate when charging or
cables are disconnected from the battery. using in enclosed area. Always shield eyes when work-
ing near batteries.
! Connect the ground cable last when the battery cables
are connected to the battery. Keep out of reach of children.
47-55A
D-47-53A
SPECIAL TOOLS
B795328M
The CAS-10147 tester is used to do the Capacity

(Load) Test. This tool is first used on page 4003-7.

4003-4
MAINTENANCE
Electrolyte Level NOTE: Add water only. DO NOT add electrolyte.
If the battery is a maintenance free battery, check Inspecting and Cleaning a Battery
the level of the electrolyte every 1000 hours of
operation or six months, whichever occurs first. For If damage causes an electrolyte leak, replace the
all other batteries, check the level of the electrolyte battery.
every 250 hours of operation.
Inspect the battery at regular intervals for dirt,
NOTE: Before checking the electrolyte level in the corrosion, and damage. Electrolyte and dirt on the
battery, the battery must have been idle for at least top of the battery can cause the battery to discharge
16 hours. During charging the level of the liquid may by making a passage for the current to flow.
raise.
If the battery must be cleaned, remove the battery
Check the level of the electrolyte more often from the battery carrier and clean the battery, cable
during hot weather. The use of a large amount of terminals, and the battery carrier. When available,
water by the battery can be caused by high battery use Case Battery Saver and Cleaner according to
temperature or a voltage regulator setting that is too the instructions on the container. Case Battery Saver
high. Keep the electrolyte level above the top of the and Cleaner also helps prevent corrosion. If Case
plates in the battery at all times to prevent damage to Battery Saver and Cleaner is not available, use
the battery. baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
If the level of the electrolyte is low, add distilled
water or other clean water until the electrolyte is just Install the battery in the machine and make sure
below the cell well bottom, approximztely 5 mm (3/16 the fasteners are tight. Apply Case Battery Saver and
inch).Do not add more water than is needed. Too Cleaner or Urethane Seal Coat to the cable terminals
much water can cause bad performance, a short to prevent corrosion. See the Parts Counter Catalog.
service life, and corrosion around the battery. DO NOT apply grease.

4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See page 4003-4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check B790863J
A hydrometer is used to check the specific gravity 1. TEMPERATURE IN F° 2. TEMPERATURE IN C°

(weight) of the electrolyte. The specific gravity is an 4. Make a record of the corrected specific gravity
indication of the level of charge for each cell. reading for each cell.
Hydrometers are made to show the co rrect 5. If the difference between the high reading and
sp e c ific g r a vi ty w h e n t he te m p e ra t ur e of t h e the low reading is 0.050 or more, charge the
electrolyte is 26.7°C (80°F). battery and check the specific gravity again. If
When you check the specific gravity, you must after charging, the difference is still 0.050 or
know the temperature of the electrolyte. If your more, install a new battery.
hydrometer does not have a thermometer, get a 6. The corrected specific gravity reading shows the
the rmo me ter to c he ck the tem pe ra tur e o f th e level of charge for the cell. The level of charge
electrolyte. The thermometer must indicate a high must be at least 75% in each of the cells. In
temperature of at least 52°C (120°F). maintenance free batteries the level of charge is
1. Remove enough electrolyte from a cell so that at least 75% if the corrected specific gravity
the float is free in the tube. reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
NOTE: If the specific gravity cannot be checked specific gravity reading is 1.230 or higher.
without first adding water to the cell, the battery must
be tilted to the left and right to about a 30° angle to 7. If the difference between the high reading and
mix the water and acid. Next the battery must be the low reading is less than 0.050, and the level
charged for 15 minutes at 15 to 25 amperes to of charge is at least 75% in all of the cells, do the
further mix the water with the electrolyte. Then check Capacity (Load) Test.
the specific gravity. 8. If the difference between the high reading and
2. Read the float. the low reading is less than 0.050, but the level of
charge is less than 75% in any of the cells,
3. Read the thermometer. If the reading is above charge the battery and check the specific gravity
26.7°C (80°F) add specific gravity points to the again. If after charging:
reading for specific gravity. If the reading is below
26.7°C (80°F) subtract specific gravity points from A. The level of charge is less than 75% in any of
the reading for specific gravity. See the following the cells, discard the battery.
illustration and add or subtract specific gravity B. The level of charge is at least 75% in all of the
points as needed. cells, do the Capacity (Load) Test.

4003-6
Capacity (Load) Test 4. Apply a 15 ampere load to the battery for 15

seconds. Wait at least three minutes before
This test can be done using a variable load tester applying the load again.
s u c h a s th e S u n E le c tr ic VAT- 3 3 . O th e r te s t
equipment can be used. Connect the test equipment 5. Check and make a record of the temperature of
according to the instructions of the manufacturer of the electrolyte.
the equipment. 6. Find the correct load for this test in Specifications
1. The level of charge of the battery must be at in Section 4002.
least 75%. Do the Specific Gravity Check in this NOTE: The correct load is half of the cold cranking amperes at
section. -17°C (0°F).
2. Prepare the tester (Sun Electric VAT-33 shown) 7. Turn the load control knob until the ammeter
for the test. indicates the specified load. Keep the load for 15
A. Select the voltmeter range that will measure 1 seconds and read the voltmeter. Turn the load
to 18 volts. control knob to OFF.
B. Make sure the load control knob is in the OFF 8. Compare the test reading and the temperature of
position. the electrolyte to the chart below.
TEMPERATURE OF MINIMUM
C. Select the ammeter range that will measure 0
ELECTROLYTE VOLTAGE
to 1000 amperes.
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . . 9.6
D. Move the volt lead switch to the INT. position. 16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
3. Connect the tester to the battery as shown. 10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
2 -7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
-18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
1 B. If the test result is less than the voltage
shown, discard the battery.
B790499J
1. LOAD CONTROL KNOB

2. AMMETER CLAMP (TIP OF ARROW
AWAY FROM BATTERY)
NOTE: Never apply a load for longer than 15
seconds. After each 15 seconds, turn the load control
knob to OFF for at least one minute.

4003-7
CHARGING A BATTERY
Before you charge the battery, check the level of 1. Too much gas causes the electrolyte to flow from
the electrolyte. the cells.
It is difficult to give an e xa ct cha rgin g rate 2. The temperature of the electrolyte rises above
because of the following variable conditions: (1) 52°C (125° F).
temperature of the electrolyte, (2) level of charge,
NOTE: For the best charge, use the slow charging
and (3) condition of the battery. Use the charging
rates.
guide for the correct charging rate and time.
The battery is fully charged when, over a three
Se e Sp ecifica tio ns in Se ctio n 4 002 for th e
hour period at a low charging rate, no cell is giving
reserve capacity of the battery in this machine.
too much gas, and the specific gravity does not
The charging rate must be decreased if: change.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve

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

80 Minutes or Less

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

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

*Initial rate for standard taper charger
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.

4003-8
CHARGING GUIDE FOR BATTERIES OTHER THAN

MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve

Capacity under Specifications Slow Charge Fast Charge

80 Minutes or Less

7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes

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

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

1. Remove the caps from the battery. 4. Connect a battery charger to the battery.
2. Fill each cell to the top of the separators with 5. Charge the battery at 30 amperes until the
ele ctro ly te . Th is will p er mit the vo lu me of s p e cif ic g ra v it y is 1 .2 5 0 o r m o r e a n d t h e
electrolyte to increase when heated by charging temperature of the electrolyte is at least 15.5°C
the battery. (60° F).
3. Install the caps on the battery. If the battery in 6. If necessary, fill each cell with electrolyte until the
your machine must have nonspill caps, install the electrolyte is just below split ring at the bottom of
nonspill caps. See Specifications in Section 4002 the cell opening.
to find if the battery in your machine must have
nonspill caps.

Section
4005
INFORMATION AND DIAGNOSTIC CENTER
4005
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-42351 August, 2001 (Revised November, 2001)
4005-2
TABLE OF CONTENTS
INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stop Master Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Caution Master Indicator (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Beacon Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Work Light Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pilot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Coolant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Secondary Steering Indicator (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Conditioning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WARNING DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Non-Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Requested Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Actual Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission Mode (Automatic or Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SETTINGS, DIAGNOSTICS, AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Programming the Information Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Manual Scrolling Gauge Displays (01, 02, or 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Automatically Scrolling Gauge Displays (03 or 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Individual Function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Testing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting Display Center Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Voltmeter at Key ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4005-3
Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Park Brake Information Center Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pilot Lockout Information Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Work Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air Conditioning Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Requested Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operational Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Actual Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Line Shift Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hourmeter Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tachometer Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Service Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Movement Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Beacon Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Left Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Right Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Caution and Warning Master Indicator Lights Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnostic Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Park Brake Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Redundant Brake Pressure Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service Brake Foot Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pilot Lockout Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Display Location 047 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Display Location Numbers (048 and 049) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Minimum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maximum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gear Range Read Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reset Diagnostic Stack for Locations 071 through 090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Display Location Numbers (056 - 060) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service Interval Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ZF Transmission ECM Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ZF Transmission ECM Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Information Center Software Revision Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LED Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LCD Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Internal Information Center Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Display Location Number 097 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Entry Code for Accessing Test Mode Locations 100 to 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Vehicle Identification Numbers (VINS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Display Location Numbers 104 - 113 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instrument Cluster (Information Center) Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instrument Cluster (Information Center) Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Instrument Cluster (Information Center) Date Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display Location Numbers 117 - 120 Reserved for Supplier Information . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display Location Numbers 121 -129 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display Location Numbers 131 - 139 Reserved for Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . . 28
Display Location Numbers 141 - 170 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Temporary Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4005-4
Display Location Numbers 191 - 196 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Display Location Number 197 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Display Location Number 198 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Display Location Number 199 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4005-5

The information and diagnostic center monitors a number of functions and can be tailored to fit the operator’s
preferences, refer to Figure 1. The information center not only monitors machine functions, it warns the operator
when caution is needed due to a possible malfunction and when immediate action is needed due to a possible
critical malfunction. When the machine is started, the information and diagnostic center will perform the following
self-test:
6 7 8
5 9 10
4 11
3 12
2 13
1
20
14
19
15
18 16
17
RD98K316
1. BEACON INDICATOR 11. HYDRAULIC OIL FILTER INDICATOR
2. WORK LIGHT INDICATOR 12. AIR FILTER INDICATOR
3. PILOT CONTROL INDICATOR 13. TRANSMISSION OIL FILTER INDICATOR
4. LOW COOLANT INDICATOR 14. TRANSMISSION OIL TEMPERATURE GAUGE
5. BRAKE PRESSURE INDICATOR 15. HYDRAULIC OIL TEMPERATURE GAUGE
6. STOP MASTER INDICATOR 16. VOLTMETER GAUGE
7. CAUTION MASTER INDICATOR 17. FUEL LEVEL GAUGE
8. SECONDARY STEERING INDICATOR 18. ENGINE OIL PRESSURE
9. PARKING BRAKE INDICATOR 19. ENGINE COOLANT TEMPERATURE GAUGE
10. AIR-CONDITIONING INDICATOR 20. SERVICE INDICATOR ICON
FIGURE 1. INFORMATION CENTER
Self-Test
IMPORTANT: During operation, if the stop master 3. All LED’s (Light Emitting Diodes) will illuminate
indicator (on the front console) flashes, and the for 2 - 3 seconds.
warning alarm is continuous, stop the machine, stop
4. Six bar graphs will energize for 2 - 3 seconds.
the engine, and find the problem.
5. The warning alarm will sound for 2 - 3 seconds.
1. Turn the ignition (key) switch to the ON position.
6. If there is an open circuit between a sensor and
2. The information center will automatically check
the information center, the LED will flash and the
each monitored system.
warning alarm will sound for 5 seconds.

4005-6
7. If there were no faults detected during the check, Caution Master Indicator (Yellow)
all monitored systems will return to normal
operation. When the caution master indicator illuminates:
8. If only some of the LEDs illuminate, replace the 1. The warning alarm sounds for three seconds.
information center. 2. The indicator turns yellow and one or more of the
9. If the LEDs illuminate, but the warning alarm following conditions exist:
does not sound, replace the information center. A. Parking brake engaged when shifting into
forward or reverse.
10. If the warning alarm sounds but the LEDs do not
illuminate, replace the information center. B. High engine coolant temperature.
11. If the warning alarm does not sound and the C. High hydraulic oil temperature.
LEDs do not illuminate on the information center, D. High transmission oil temperature.
do the following steps to test the power circuit: E. High or low air conditioning pressure.
F. Air filter restriction.
Power Circuit Test
G. Transmission filter restriction.
A. Check the 7.5 amp fuse V. If the fuse is bad,
replace the fuse and repeat Self-Test steps 1 H. Hydraulic filter restriction.
through 7. If the fuse is good, do the next step. I. Alternator malfunction.
B. Check wire 19V for continuity. Repair/replace J. Low fuel.
the wire as required. If continuity is found do
the next step. Beacon Indicator
C. Check wire 13V for continuity. Repair/replace The beacon indicator illuminates when the Beacon (if
the wire as required. If continuity is found, do equipped) is in the ON position.
the next step.
Work Light Indicator
D. Check the voltmeter relay #12 for proper
operation, see Section 4002. If voltmeter The work light indicator illuminates when the work
operates properly, do the next step. lights are ON.
E. If no faults are found in Power Circuit Test Pilot Control

steps A through D, then remove and replace
The Pilot Control indicator illuminates when the pilot
the information center.
lockout is actuated.
Indicators and Gauges Low Coolant Indicator

Stop Master Indicator (Red) The low coolant indicator illuminates when the
engine coolant is low.
IMPORTANT: Failure to follow these procedures may
result in injury and/or damage to the machine. 1. The warning alarm sounds continuously.
When the stop master indicator illuminates: 2. The stop master indicator will be red.
1. Stop the machine immediately. 3. Stop the engine and add coolant to the radiator.
2. Turn OFF the engine. Brake Pressure Indicator

3. The warning alarm sounds continuously and one The brake pressure indicator illuminates when the
or more of the following conditions exist: brake system pressure is too low.
A. Low engine oil pressure. 1. The warning alarm sounds continuously.
B. Low brake pressure. 2. The stop master indicator will be red.
C. Low steering pressure. 3. Stop the engine and correct the problem.
D. Low engine coolant level.
E. High engine coolant temperature.
F. High hydraulic oil temperature.
G. High transmission oil temperature.

4005-7
Secondary Steering Indicator (If 3. Replace the transmission oil filter(s) as required.
equipped) Transmission Oil Temperature Gauge
The secondary steering indicator illuminates when The transmission oil temperature gauge is shown as
the primary steering system pressure is too low. an indicator bar with a green, yellow or red zone.
1. The warning alarm sounds continuously. Green Zone:
2. The stop master indicator will be red. Indicates normal operating temperature, 20 ° to 120°
C (68° to 248° F).
3. Stop the engine and correct the problem.
Yellow Zone:
Parking Brake Indicator
1. Transmission oil temperature is too low, 20 ° C or
The parking brake indicator illuminates when the below (68° F or below), or it has increased, 120°
parking brake is applied. If the transmission is shifted to 125° C (248° to 257° F).
into FORWARD or REVERSE when the parking
brake is applied: 2. The indicator bars flash.
1. The warning alarm sounds for 3 seconds. 3. The warning alarm sounds for 3 seconds.
2. The caution master indicator turns yellow. 4. The yellow caution master indicator turns on.
3. Disengage the parking brake before shifting the Red Zone:

machine. NOTE: The machine must not be operated when the
temperature is in the red zone.
Air Conditioning Indicator
1. Transmission oil temperature continues to
The air conditioning indicator illuminates when the air
increase, 125° C and above (257° F and above).
conditioner has stopped due to refrigerant pressures
that are too high or too low. 2. The indicator bar flashes.
1. The warning alarm sounds for 3 seconds. 3. The warning alarm sounds continuously.
2. The caution master indicator turns yellow. 4. The red stop master indicator turns on.
3. Service the air conditioning system, or the 5. Stop the machine.
outside air temperature is too cool for the system
6. Shift the transmission into NEUTRAL.
to work.
7. Run the engine at half throttle until the
Air Filter Indicator transmission cools.
The air filter indicator illuminates when the air filter is 8. If the transmission oil temperature does not
restricted. return to normal operating temperature, run the
1. The warning alarm sounds for 3 seconds. engine at idle speed and check the transmission
oil level.
2. The caution master indicator turns yellow.
9. Correct the problem before continuing to operate
3. Replace or clean the air filter as required. the machine.
Hydraulic Oil Filter Indicator Hydraulic Oil Temperature Gauge
The hydraulic oil filter indicator illuminates when the The hydraulic oil temperature gauge is shown as an
hydraulic filters are restricted. indicator bar with a green, yellow, or red zone.
1. The warning alarm sounds for 3 seconds. Green Zone:
2. The caution master indicator turns yellow. Indicates normal operating temperature, 20 ° to 105°
3. Replace the hydraulic oil filters as required. C (68° to 221° F).
Transmission Oil Filter Indicator Yellow Zone:
The transmission oil filter indicator illuminates when 1. Hydraulic oil temperature has decreased, 20° C
the transmission filter(s) are restricted. or below (68 ° F or below), or it has increased
105° to 110° C (221° to 230° F).
1. The warning alarm sounds for 3 seconds.
2. The indicator bars flash.
2. The caution master indicator turns yellow.
4005-8
3. The warning alarm sounds for 3 seconds. 2. The warning alarm sounds for 3 seconds.
4. The yellow caution master indicator turns on. 3. The yellow caution master indicator turns on.
Red Zone: Engine Oil Pressure Gauge
NOTE: The machine must not be operated when the The engine oil pressure gauge is shown as an
temperature is in the red zone. indicator bar with a green or red zone.
1. Hydraulic oil temperature continues to increase Green Zone:
110° C and above (230° F and above).
Indicates normal operating pressure, 110 kPa (16
2. The indicator bar flashes. psi) and over.
3. The warning alarm sounds continuously. Red Zone:
4. The red stop master indicator turns on. NOTE: The machine must not be operated when the
5. Stop the machine and correct the problem. oil pressure is in the red zone.
1. Engine oil pressure decreased to less than 70
Voltmeter Gauge
kPa (less than 10 psi).
The voltmeter gauge is shown as an indicator bar
2. The indicator bar flashes.
with a green or yellow zone.
3. The warning alarm sounds continuously.
Green Zone:
4. The red stop master indicator turns on.
Indicates normal operating range:
5. Stop the machine and correct the problem.
A. 26 to 32 volts above low idle = normal
operating range. Engine Coolant Temperature
B. 18 to 24 volts stopped or at low idle = low to The engine coolant temperature gauge is shown as
normal battery charge. an indicator bar with a green, yellow, or red zone.
C. 18 to 24 volts at above low idle = problem in Green Zone:
charging system.
Indicates normal operating temperature, 20 ° to 105°
Yellow Zone: C (68° to 221° F).
Voltage has increased or decreased: Yellow Zone:
A. 0 to 18 volts stopped or at low idle = very low 1. Engine coolant temperature has decreased 20°
battery charge. C or below (68° or below), or increased 105° to
B. 32 volts and above = problem in charging 110° C (221° to 230° F).
system (overcharging). 2. The indicator bars flash.
1. The indicator bars flash. 3. The warning alarm sounds for 3 seconds.
2. The warning alarm sounds for 3 seconds. 4. The yellow caution master indicator turns on.
3. The yellow caution master indicator turns on. Red Zone:
4. Stop the machine and correct the problem. NOTE: The machine must not be operated when the
temperature is in the red zone.
Fuel Level Gauge
1. Engine coolant temperature continues to
The fuel level gauge is shown as an indicator bar increase, 110° C or above (230° F or above).
with a green or yellow zone.
Green Zone:
Indicates normal operating range, 5 percent and
above.
Yellow Zone:
The tank is almost empty, 5 percent and below.
1. The indicator bars flash.

4005-9
2. The indicator bar flashes. Service Indicator Icon
3. The warning alarm sounds continuously. When a fault code is written, the service indicator
4. The red stop master indicator turns on. icon (a manual with a wrench) will be displayed on
5. Stop the machine and correct the problem.

4005-10
WARNING DISPLAYS
Critical Warning Displays

IMPORTANT: Failure to follow these procedures may result in injury and/or damage to the machine.
The following table is a listing of critical warning displays that may appear on the information center and the
corrective action required. When a fault occurs, a continuous warning alarm will sound, the STOP indicator will be
RED, and the Display indicator will be illuminated. When this occurs bring the machine safely to a stop and
shutdown the engine to help avoid expensive repairs
.
DISPLAY DESCRIPTION CORRECTIVE ACTION

1. Check low idle specifications.
ENGINE OIL Low engine oil
2. Change engine oil and filter.
PRESSURE pressure.
3. Change operating procedures.
1. Bring the machine to a safe stop and shut the engine
BRAKE PRESSURE Low brake pressure. OFF immediately.
2. Check brake system for proper charging and leaks.
STEERING OFF immediately.
Low steering pressure.
PRESSURE 2. Check the hydraulic fluid level.
3. Check hydraulic system and steering system for leaks.
OFF immediately.
COOLANT LEVEL Low coolant level.
2. Check the coolant level.
3. Check the engine cooling system for leaks.
OFF immediately.
COOLANT High engine coolant
2. Check the coolant levels after allowing the engine and
TEMPERATURE temperature.
coolant to cool down.
3. Clean the radiator.
HYDRAULIC OIL High hydraulic oil OFF immediately.
TEMPERATURE temperature. 2. Check the hydraulic fluid level.
3. Clean the cooler.
OFF immediately.
TRANSMISSION OIL High transmission oil 2. Check the transmission fluid level.
TEMPERATURE temperature. 3. Clean the cooler.
4. Check transmission for leaks.
5. Select lower gear.

4005-11
Non-Critical Warning Displays

The following table is a listing of warning displays that may appear on the information center and the corrective
action required. When a fault occurs, a warning alarm will sound for three seconds, the CAUTION indicator will be
YELLOW, and the display indicator will be illuminated. When this occurs, do the corrective action and return the
machine to service. If the noncritical warning display continues, shutdown the machine and perform repairs.
DISPLAY DESCRIPTION CORRECTIVE ACTION

Parking brake engaged and Release the parking brake and depress the
PARKING BRAKE
shifts from Forward to Reverse. service brake.
COOLANT High engine coolant 1. Idle machine and monitor temperature.
TEMPERATURE temperature. 2. Clean radiator.
HYDRAULIC 1. Idle machine and monitor temperature.
High hydraulic temperature.
TEMPERATURE 2. Clean the cooler.
1. Idle machine and monitor temperature.
TRANSMISSION
High transmission temperature. 2. Clean the cooler.
TEMPERATURE
3. Use a lower gear.
1. Turn air conditioning OFF.
High or low air conditioning
AIR CONDITIONING 2. Low outside temperature.
pressure.
3. Servicing required.
1. Clean air filter.
AIR FILTER High air filter restriction.
2. Replace primary and secondary filters.
TRANSMISSION
Transmission filter restriction. Replace transmission filter.
FILTER
HYDRAULIC FILTER Hydraulic filter restriction. Replace hydraulic filter.
1. Check electrical system.
ALTERNATOR Alternator malfunction. 2. Voltages are out of range.
3. Change operating procedure.
FUEL Low fuel. Fill fuel tank within the next hour.

4005-12

Many of the machine functions can be displayed on the Programmable Information Center. It can be programmed
to display all functions, or only the functions important to the operator. The following functions can be displayed on
the Information Center, refer to Figure 2:
2
4
1
RD98K316
1. DIRECTION (F-N-R) 4. REQUESTED GEAR (1, 2, 3, 4)
2. TRANSMISSION DISPLAY 5. ACTUAL GEAR BARS
3. DISPLAY CENTER 6. TRANSMISSION MODE (A OR BLANK)
FIGURE 2. INFORMATION CENTER AND TRANSMISSION DISPLAY
Hourmeter Engine Coolant Temperature

The hourmeter displays the accumulated running Displays the engine coolant temperature in Celsius
time of the engine in hours and tenths of an hour with with the engine coolant temperature bar graph
an “hour glass” symbol. flashing. See page 8 for a detailed description of the
bar graph function.
Tachometer
Engine Oil Pressure
The ta ch omete r d isp la ys the en gine sp ee d in
revolutions per minute along with a “r/min” symbol. Displays the engine oil pressure in kilopascals (kPa)
with the engine oil pressure bar graph flashing. See
Speedometer page 8 for a detailed description of the bar graph
function.
The speedometer displays the ground speed in
either kilometers per hour (km/h) or miles per hour Fuel Level
(mph) along with either a “km/h” or “mph” symbol.
Displays the fuel level in percent remaining in the
tank with the fuel level bar graph flashing. See page
8 for a detailed description of the bar graph function.

4005-13
Transmission Oil Temperature Transmission Display

Displays the transmission oil temperature in Celsius The Transmission Display shows the status of the
with the transmission oil temperature bar graph transmission control. The display center contains the
flashing. See page 7 for a detailed description of the following information, refer to Figure 2:
bar graph function.
Direction Selected
Hydraulic Oil Temperature Shown at the top of the display center:
Displays the hydraulic oil temperature in Celsius with F Forward

the hydraulic oil temperature bar graph flashing. See
N Neutral
page 7 for a detailed description of the bar graph
function. R Reverse
F Flashing forward not engaged.
Voltmeter
Flashing set control lever to neutral
Displays the electrical system voltage level in volts N
position.
with the voltmeter bar graph flashing. See page 8 for
a detailed description of the bar graph function. R Flashing reverse not engaged.
Requested Gear
Th e gea r positio n on sh ift lever, sh own in the
center of the gear symbol:
1 1st gear
2 2nd gear
3 3rd gear
4 4th gear
Actual Gear
Shown with bars to the right of the gear symbol. The
number of bars indicates the gear the transmission is
actually in.
Transmission Mode (Automatic or
Manual)
Shown in the lower left of the display center:
A Automatic Mode
No symbol will be displayed when
transmission is in Manual Mode.

4005-14
SETTINGS, DIAGNOSTICS, AND FAULT CODES
3 4 5 6
2
1
RD98K316
1. INFORMATION CENTER 3. UP COUNT 5. PROGRAM
2. DISPLAY CENTER 4. DOWN COUNT 6. RESET
FIGURE 3. INFORMATION CENTER
Programming the Information 1. Turn the machine OFF.

Center 2. Turn the key to the RUN position.
NOTE: The machine must be OFF prior to 3. Press the program/reset switch to program.
programming the information center. 4. Press the up/down count switch to up count
Two switches are used during the programming of program location 010.
the information center: the up/down count switch and 5. Center the program/reset switch to OFF.
th e program/reset switch. The se sw itch es are
located on the right hand side of the information 6. Note the gauge display setting that is displayed,
center, refer to Figure 3. 01, 02, 03, 04, or 05. If the desired setting has
already been selected go to step 7.
For an up count press the left side of the up/down
count switch. For a down count press the right side of 7. Press the up/down count switch to up count to
the up/down count switch. The center position is OFF choose one of the following gauge disp lay
or NEUTRAL. settings:
For programming pres s the left s ide of t he

program/reset switch. For resetting press the right
side of the program/reset switch. The center position
is OFF or NEUTRAL.
To program the information center do the following
steps:

4005-15
Individual Function Display
Manually scrolls through Hourmeter,
01
Tachometer, and Speedometer (km/h). Do the following steps to display any individual
function, at anytime, regardless of the gauge display
02 Manually scrolls through Hourmeter, that was programmed:
Tachometer, and Speedometer (mph).
1. Press the program/reset switch to program.
Automatically scrolls through Hourmeter
(at start-up), Tachometer (in 1st, 2nd and 2. Press the up/down count switch to up count and
03 select one of the following individual functions:
3rd gears), and Speedometer (km/h in 4th
gear).
000 Hourmeter
Automatically scrolls through Hourmeter
001 Tachometer
(at start-up), Tachometer (in 1st, 2nd and
04
3rd gears), and Speedometer (mph in 4th 002 Speedometer (mph)
gear).
003 Speedometer (km/h)
Manually scrolls through Hourmeter,
004 Engine Oil Temperature
Tachometer, and Speedometer (mph),
Speedometer (km/h), Engine Oil 005 Engine Oil Pressure
Temperature (Celsius), Engine Oil
05 Pressure, Fuel Level, Transmission Oil 006 Fuel Level
Temperature (Celsius), Hydraulic Oil 007 Transmission Oil Temperature
Temperature (Celsius), and Voltmeter.
008 Hydraulic Oil Temperature
NOTE: 05 is the factory installed setting.
009 Voltmeter
8. Press the program/reset switch to reset
momentarily.
3. Put the program/reset switch in the OFF (center)
9. If the Information Center does not function
position.
properly, do the programming steps again.
4. If one of the individual functions (004 through
10. If the Information Center continues to
009) is selected, the corresponding bar graph will
malfunction replace the instrument panel.
flash indicating that this individual function is
Manual Scrolling Gauge Displays (01, 02, being displayed.
or 05 5. The individual function selected will be shown on
If the Information Center has been programmed to
display one of the manual scrolling displays (01, 02, Testing the Park Brake
or 05) press the up/down count switch to up count
and scroll through the gauge displays. Do the following steps to test the parking brake:
1. Press the up count switch one time to display the NOTE: The Transmission Control Module will
Tachometer. disconnect the transmission if any gear other than
3rd is used.
2. Press the up count switch again to display the
Speedometer (km/h). 1. Turn the machine ON.
3. Press the up count switch again to display the 2. Make sure the transmission is in the manual shift
Hourmeter. mode, the gear selector is in 3rd neutral gear,
and the park brake switch is ON.
Automatically Scrolling Gauge Displays
3. Set the park brake calibration as follows:
(03 or 04)
A. Press the program/reset switch to program.
If the Information Center has been programmed with
one of the automatic scrolling displays the gauge B. Press the up/down count switch to up count
display will automatically scroll through after starting until the display reads 011.
the machine. The up/down count switch has no effect C. Put the program/reset switch in the OFF
on the display. (center) position.

4005-16
D. Press the up/down count switch to up count If this occurs, the code in the 3rd and 4th
once, so the display reads 01. spaces will be a Clutch Calibration Main Code
09 through 14 and indicate what process the
E. Shift the transmission selector into 3rd forward
calibration was in when it was aborted
and slowly increase the engine rpm.
The 1st and 2nd spaces will produce the
F. The park brake should hold the machine at full
Clutch Calibration Sub Code, which is the
throttle.
code that informs the operator of the reason
G. To exit the test mode, press the program/reset the process was aborted.
switch to reset.
K. After completing the Clutch Calibration
Transmission Clutch Calibration procedure, turn the machine OFF for 15
Clutch Calibration ensures the most optimum shifting seconds. This sets the calibration in the
of the transmission. Before doing the following controller.
transmission clutch calibration procedures make
CLUTCH CALIBRATION MAIN CODES
sure of the following:
1. The machine is running and the transmission oil Main Code Meaning
is warm. Clutch Calibration Mode was not
2. Engine low idle speed is correct. 00 initiated because one of the
requirements was not met.
3. The transmission is in neutral.
01 Adjusting 1st gear.
4. The park brake is applied.
02 Adjusting 2nd gear.
5. If steps 1 through 4 have been accomplished,
calibrate the transmission clutches as follows: 03 Adjusting 3rd gear.
A. Put the transmission in the manual shift mode 04 Adjusting 4th gear.
and the gear selector in 3rd gear neutral.
05 Adjusting Forward gear.
B. Press the program/reset switch to program.
06 Adjusting Reverse gear.
C. Press the up/down count switch to up count
until the display reads 011. 07 Clutch Calibration Completed.
D. Put the program/reset switch in the OFF Operator aborted calibration
08
(center) position. procedure.
E. Press the up/down count switch to up count 09 Aborted while adjusting 1st gear.
twice, so the display reads 02.
10 Aborted while adjusting 2nd gear.
F. 2 00 00 will begin to flash in the display center.
11 Aborted while adjusting 3rd gear.
G. After one second, the Clutch Calibration Main
Code status will be displayed in the 3rd and 12 Aborted while adjusting 4th gear.
4th spaces (2 XX 00, the XX represents the
Aborted while adjusting Forward
3rd and 4th spaces). 13
gear.
H. The Modulation Cycle Number will be
Aborted while adjusting Reverse
displayed in the 1st and 2nd spaces (2 00 XX, 14
gear.
the XX represents the 1st and 2nd spaces).
I. During Clutch Calibration, the Clutch
Calibration Main Code will change from 01 to
07 as the process is completed. Code 07 CLUTCH CALIBRATION SUB CODES
in dic ates tha t th e calib ratio n p rocess is
Sub Code Meaning
complete and the information center will return
to normal working status. 00 Calibration in process.
J. If any of the Clutch Calibration parameters are 01 Fault present.
incorrect, the display center will stop flashing
and display a code in the 1st, 2nd, 3rd, and 02 Shift lever not in neutral.
4th spaces.

4005-17
2. Press the up/down count switch to up count until
03 Park brake not applied.
the display reads 015.
04 Output speed not 0 kph/mph.
3. The alarm will begin to sound intermittently.
05 Low transmission oil temperature. 4. Place the program/reset switch in the OFF
06 High transmission oil temperature. (center) position.
07 Low engine RPM. 5. The Information Center will display 00 and sound
the alarm, when the machine is being checked,
08 High engine RPM. while all systems are normal. If there is a fault in
the system that would cause the alarm to sound,
Setting Display Center Lighting the Information Center will display 01 while the
alarm is being checked. The alarm will sound
Do the following procedures to set the brightness intermittently.
of the display lighting:
Coolant Level Check
Do the following procedures to check the coolant
level indicator light and the coolant level switch.
the display reads 012 (for working lights OFF) or
013 (for working lights ON). 1. Press the program/reset switch to program.
3. Place the program/reset switch in the OFF 2. Press the up/down count switch to up count until
(center) position. the display reads 016.
4. Increase the brightness by pressing the up/down 3. The coolant light will flash intermittently.
count switch to the up count position.
4. Place the program/reset switch in the OFF
5. Decrease the brightness by pressing the (center) position.
up/down count switch to the down count position.
5. The Information Center will display 00, when the
NOTE: The brightness can be varied between 001 machine is being checked, if the coolant level is
and 100, with 100 being the brightest. The factory set normal. If the coolant level is low, the Information
brightness is 070 for working lights OFF and 020 for Center will display 01 while the coolant level
working lights ON. switch is being checked. The coolant light will
flash intermittently on the Information Center.
6. Press the program/reset switch to reset
(m o m e n ta r ily, 0 . 2 5 s e c o n d s) to e n te r t h e
selected brightness setting. Brake Pressure
Do the following procedures to check the brake
Voltmeter at Key ON Position pressure indicator light and the brake pressure
switch.
Do the following procedures to read the system
voltage at the key ON position. 1. Press the program/reset switch to program.
1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until
the display reads 017. The brake pressure light
will flash intermittently.
(center) position.
(center) position.
4. The system voltage is displayed at the key ON
machine is being checked, if the brake pressure
position.
is normal. If the brake pressure is low, the
5. Press the program/reset switch to reset to exit Information Center will display 00 while the brake
the monitoring mode. pressure switch is being checked. The brake
pressure light will flash intermittently on the
Alarm Check Information Center.
Do the following procedures to check the audible

alarm system.
4005-18
Secondary Steering Pressure Switch 4. The Information Center will display 00, when the
Information Center is not activating the pilot
Do the following procedures to check the secondary lockout relay. The Information Center will display
steering pressure indicator light and the secondary 01 when it is activating the pilot lockout relay.
steering switch. The pilot lockout light will flash intermittently on
5. Press the program/reset switch to program. the Information Center.

Hydraulic Filter Restriction Switch Check
the display reads 018. The secondary steering
pressure light will flash intermittently. Do the following procedures to check the hydraulic
filter restriction indicator light and the hydraulic filter
restriction switch.
(center) position.
machine is being checked, if the secondary 2. Press the up/down count switch to up count until
steering switch is not activated. If the secondary the display reads 021. The h y d ra u lic filte r
steering switch is activated, the Information restriction indicator light will flash intermittently.
Cente r will displa y 00 while th e secondary
steering switch is being checked. The secondary
(center) position.
steering light will flash intermittently on the
Information Center. 4. The Information Center will display 01, when the
machine is being checked, if the hydraulic filter
Park Brake Information Center Output r e s t r i c t i o n s w i t c h is n o t a c t iva te d . I f t h e
Check hydraulic filter restriction switch is activated, the
Information Center will display 00 while the
Do the following procedures to check the park brake h y d r a u lic fil te r re st r ic tio n s w it ch is bein g
indicator light and the status of the signal that the c h e c k e d . Th e h y d r a u l i c f i l t e r r e s t r i c t i o n
Information Center is sending to the park brake relay indicator light will flash intermittently on the
(to engage or disengage). Information Center.
Air Filter Restriction Switch Check
the display reads 019. The park brake light will Do the following procedures to check the air filter
flash intermittently. restriction indicator light and the air filter restriction
switch.
(center) position. 1. Press the program/reset switch to program.
4. The Information Center will display 00, when the 2. Press the up/down count switch to up count until
Information Center is not activating the park the display reads 022. The air filter restriction
brake relay. The Information Center will display indicator light will flash intermittently.
01 when it is activating the park brake relay. The 3. Place the program/reset switch in the OFF
park brake light will flash intermittently on the (center) position.
Information Center.
Pilot Lockout Information Output Check ma ch in e is b e ing ch ec ke d , if th e a ir filte r
restriction switch is not activated. If the air filter
Do the following procedures to check the pilot lockout restriction switch is activated, the Information
indicator light and the status of the signal that the C e n te r w il l d i s p la y 0 0 w h ile th e a ir f i lt e r
Information Center is sending to the pilot lockout restriction switch is being checked. The air filter
relay (to engage or disengage). restriction indicator light will flash intermittently
1. Press the program/reset switch to program. on the Information Center.
2. Press the up/down count switch to up count until Work Lights Check
the display reads 020. The pilot lockout light will
flash intermittently. Do the following procedures to check the work lights
indicator light and the work light electrical signal
3. Place the program/reset switch in the OFF coming into the Information Center.
(center) position.
4005-19
2. Press the up/down count switch to up count until 4. The Information Center will display 00, when the
the display reads 023. The work lights indicator machine is being checked, if the transmission
light will flash intermittently. filter restriction switch is not activated. If the
transmission filter restriction switch is activated,
the Information Center will display 01 while the
(center) position.
transmission filter restriction switch is being
4. The Information Center will display 00 when the checked. The transmission filter restriction
work lights are OFF and 01 when the work lights indicator light will flash intermittently on the
are ON. The work lights ind icator lig ht will Information Center.
continue to flash intermittently and the numbers
on the display will change in accordance with the High Beam Check
status of the work lights. Do the following procedures to check the high beam
indicator light and the high beam switch.
Air Conditioning Switch Check
Do th e fo llow in g p ro c ed u r es to ch e ck th e a ir
conditioning indicator light and the air conditioning
the display reads 027. The high beam indicator
high/low pressure switch.
light will flash intermittently.
2. Press the up/down count switch to up count until (center) position.
the display reads 025. The a ir con ditioning
4. The Information Center will display 00 when the
indicator light will flash intermittently.
high beam lights are OFF and 01 when the high
3. Place the program/reset switch in the OFF beam lights are ON. The high beam indicator
(center) position. light will continue to flash intermittently and the
numbers on the display w ill change in
accordance with the status of the high beam
machine is being checked, if the air conditioning
lights.
high/low pressure switch is not activated. If the
air conditioning high/low pressure switch is
activated, the Information Center will display 01 Requested Gear Check
while the air conditioning high/low pressure Do the following procedures to check that the gear
switch is being checked. The air conditioning being requested by the shifter is the same gear that
indicator light will flash intermittently on the the Information Center is reading.
Information Center.
Transmission Filter Restriction Switch 2. Press the up/down count switch to up count until
Check the display reads 028. The “F, N or R” indicator in
the transmission display will flash intermittently.
Do the follow ing procedures to check the
transmission filter restriction indicator light and the 3. Place the program/reset switch in the OFF
transmission filter restriction switch. (center) position.
1. Press the program/reset switch to program. 4. Place the gear shifter in all positions and verify
that the code in each position corresponds to the
codes in the table below
the display reads 026. The transmission filter :
restriction indicator light will flash intermittently. Forward 1- Neutral 1- Reverse 1-

3. Place the program/reset switch in the OFF Code 101 Code 201 Code 301
(center) position. Forward 2- Neutral 2- Reverse 2-
Code 102 Code 202 Code 302
Forward 3- Neutral 3- Reverse 3-
Code 103 Code 203 Code 303
Forward 4- Neutral 4-
Code 104 Code 204

4005-20
Operational Indicator Status 3. Press the up/down count switch to up count until
the display reads 031. The drive line shift status
Do the following procedures to check the status of bars flash intermittently.
the operational indicator.
1. Press the program/reset switch to program. (center) position.
2. Press the up/down count switch to up count until 5. The Information Center will read 000.
the display reads 029. The operational indicator
flashes intermittently. 6. Shift the shift lever.
3. Place the program/reset switch in the OFF 7. The Information Center will read 001 while the
(center) position. shift is being made.
4. The Information Center will read 00. 8. The Information Center will read 000 if the
transmission does not engage the drive line or
Actual Gear Check 010 if the transmission does engage the drive
line; 010 also indicates the transmission is in
Do the following procedures to check that the gear Normal Mode.
engaged in the transmission is the same gear that
the Information Center is reading. 9. The Information Center will read 110 if the
transmission is in Substitute Clutch Control
1. With the engine running put the transmission in Mode.
manual mode and release the parking brake.
10. The Information Center will read 210 if the
2. Press the program/reset switch to program. transmission is in Limp Home Mode.
3. Press the up/down count switch to up count until 11. The Information Center will read 300 if the
the display reads 030. The bars that outline the transmission is in Shutdown Mode.
large gear in the transmission display will flash
intermittently. 12. The Information Center will read 400 if the
transmission is in TECM Shutdown Mode.
(center) position. Hourmeter Indicator Status
5. Place the gear selector in all positions and verify Do the following procedures to check the status of
that the code in each position corresponds to the the hourmeter indicator.
codes in the table below.
: 1. Press the program/reset switch to program.
Forward 1- Neutral 1- Reverse 1- 2. Press the up/down count switch to up count until
Code 101 Code 201 Code 301 the display reads 032. The hourmeter indicator
Forward 2- Neutral 2- Reverse 2- flashes intermittently.
Code 102 Code 202 Code 302 3. Place the program/reset switch in the OFF
Forward 3- Neutral 3- Reverse 3- (center) position.
Code 103 Code 203 Code 303 4. The Information Center will read 00.
Forward 4- Neutral 4-
Code 104 Code 204 Tachometer Indicator Status
Limp Home Limp Home Limp Home Do the following procedures to check the status of
Mode - 115 Mode - 215 Mode - 315 the tachometer indicator.
Drive Line Shift Status 2. Press the up/down count switch to up count until
Do the following procedures to check the drive line the display reads 033. The tachometer indicator
shift status. flashes intermittently.
1. With the engine running, release the parking 3. Place the program/reset switch in the OFF
brake. (center) position.
2. Press the program/reset switch to program. 4. The Information Center will read 00.

4005-21
Service Indicator Status 4. The Information Center will read 00 if the left turn
indicator is OFF or 01 if the left turn indicator is
Do the following procedures to check the status of ON.
the service indicator.
1. Press the program/reset switch to program. Right Turn Indicator Status
2. Press the up/down count switch to up count until Do the following procedures to check the status of
the display reads 034. The service indicator the right turn indicator.
flashes intermittently.
(center) position.
the display reads 038. The right turn indicator
4. The Information Center will read 00 if the service flashes intermittently.
indicator is OFF or 01 if the service indicator is
ON.
(center) position.
Movement Indicator Status 4. The Information Center will read 00 if the right
turn in dicator is OFF or 01 if the righ t tu rn
Do the following procedures to check the status of indicator is ON.
the movement indicator.
1. Press the program/reset switch to program. Caution and Warning Master Indicator
2. Press the up/down count switch to up count until Lights Status
th e d isp l a y re a d s 0 3 5 . Th e K p h a n d M p h Do the following procedures to ensure that the
indicators flash intermittently. caution and warning lights are working correctly.
3. Place the program/reset switch in the OFF 1. Press the program/reset switch to program.
(center) position.
4. The Information Center will read 00. the display reads 039 (Critical Master Light Red).
Beacon Status
(center) position.
Do the following procedures to check the status of
the beacon.
indicator is OFF under normal operation, or 01 if
1. Press the program/reset switch to program. the indicator is ON under normal operation
2. Press the up/down count switch to up count until 5. Press the program/reset switch to program.
the display reads 036. The beacon indicator
the display reads 041 (Caution Master Light
3. Place the program/reset switch in the OFF Yellow).
(center) position.
4. The Information Center will read 00 if the beacon (center) position.
is OFF or 01 if the beacon is ON.
indicator is OFF under normal operation, or 01 if
Left Turn Indicator Status the indicator is ON under normal operation
Do the following procedures to check the status of
the left turn indicator. Diagnostic Indicator Status
1. Press the program/reset switch to program. Do the following procedures to check the status of
the diagnostic indicator.
the display reads 037. The left turn indicator 1. Press the program/reset switch to program.
3. Place the program/reset switch in the OFF the display reads 040. The diagnostic indicator
(center) position. flashes intermittently.
(center) position.
4005-22
4. The Information Center will read 00. 4. The Information Center will display 00, when the
machine is being checked, if the brake pressure
Master Reset is normal and there is nothing wrong with the
c i r c u i t . I f t h e b r a k e p r e s s u r e i s l o w, t h e
Do the following procedure to reset the Information Information Center will display 01 while the
Center to the values set at the factory for the Gauge re du n da nt br ak e p re ss ure s witch is b ein g
Display, Information Center lighting for work lights off checked. The brake light will flash intermittently
and on, minimum gear selection in automatic mode, on the Information Center.
maximum gear selection, and declutch modulation
selection.
Service Brake Foot Switch Check
Do the following procedures to check the service
2. Press the up/down count switch to up count until brake foot switch.
(center) position.
the display reads 045. The park brake light
4. Press the up/down count switch to up count flashes intermittently.
twice to change the readings from 00 to 01.
5. Press the program/reset switch momentarily (center) position.
(0.25 second) to reset.
4. The Information Center will read 00 when the
switch is open (service brakes are not applied)
Park Brake Switch Check and 01 when the switch is closed (service brakes
Do the following procedures to check the park brake are applied).
switch and the s tatus of the signal that the
Information Center is receiving from the park brake Pilot Lockout Switch Check
switch (to engage or disengage).
Do the following procedures to check the pilot lockout
1. Press the program/reset switch to program. indicator light and the status of the signal that the
Information Center is receiving from the pilot lockout
switch (to engage or disengage).
the display reads 043. The park brake light will
flash intermittently. 1. Press the program/reset switch to program.
(center) position. the display reads 046. The park brake light will
flash intermittently.
Information Center is not receiving a signal from 3. Place the program/reset switch in the OFF
the park brake switch to engage the park brake. (center) position.
The Information Center will display 01 when it is
receiving a signal from the park brake switch to
Information Center is not receiving a signal from
engage the park brake.
the switch to engage the pilot lockout. The
5. Cycle the park brake switch to ensure it is Information Center will display 01 when it is
working in both directions. receiving a signal from the switch to disable the
loader hydraulic controls.
Redundant Brake Pressure Switch Check 5. Cycle the switch to ensure it is working in both
Do the following procedures to check the redundant directions.
brake pressure switch.
Display Location 047
Do the following procedures to check display location
047.
the display reads 044. The brake light will flash
intermittently. 1. Press the program/reset switch to program.
(center) position. the display reads 047. The pilot lockout light
4005-23
3. Place the program/reset switch in the OFF 5. If you want a different maximum gear selection,
(center) position. press the up/down count switch to up count until
the desired number is displayed.
4. The Information Center will read 00 if the circuit
is closed or 01 if there is a circuit malfunction. 6. Press the program/reset switch momentarily
(0.25 seconds) to reset.
Display Location Numbers (048 and 049)
Reserved for Future Use Gear Range Read Only
Do the following procedures to read the gear range.
Minimum Gear Selection
D o t h e f o l lo w in g p r o c e d u r e s t o p r o g r a m th e
transmission for the lowest gear possible in the 2. Press the up/down count switch to up count until
automatic mode. the display reads 052. The operational indicator
will flash intermittently.
NOTE: The 1st or 2nd gear can be selected. The
gear that is selected will be the gear that the 3. Place the program/reset switch in the OFF
transmission is in when the machine begins to move. (center) position.
The factory minimum gear setting is 1. 4. The Information Center will read 1 or 2 (gears).
1. Press the program/reset switch to program. 5. Press the program/reset switch to program.
2. Press the up/down count switch to up count until 6. Press the up/down count switch to up count until
the display reads 050. the display reads 053. The operational indicator
3. Place the program/reset switch in the OFF will flash intermittently.
(center) position. 7. Place the program/reset switch in the OFF
4. Read the number (1 or 2) shown on the (center) position.
Information Center. If this is the desired gear 8. The Information Center will read 2, 3, or 4
selection, press the program/reset switch to (gears).
either program or reset.
5. If you want the other minimum gear selection, Reset Diagnostic Stack for Locations 071
press the up/down count switch to up count. through 090
6. Press the program/reset switch momentarily Do the following procedure to remove all diagnostic
(0.25 seconds) to reset. codes from field number locations 071 through 090.
Maximum Gear Selection
D o t h e f o l lo w in g p r o c e d u r e s t o p r o g r a m th e the display reads 055. The service indicator will
transmission for the highest gear possible in the flash intermittently.
manual or automatic mode.
NOTE: The 2nd, 3rd, or 4th gear can be selected. (center) position.
The gear that is selected will be the highest
attainable gear that the transmission will be able to 4. Press the up/down count switch to up count until
reach. The factory maximum gear setting is 4. the display reads 21.
1. Press the program/reset switch to program. 5. Press the program/reset switch to reset. If there
are diagnostic codes in field number locations
2. Press the up/down count switch to up count until 071 through 090 they will be removed, unless the
the display reads 051. condition still exists.
(center) position.
4. Read the number (2, 3, or 4) shown on the
Information Center. If this is the desired gear
selection, press the program/reset switch to
either program or reset.

4005-24
Display Location Numbers (056 - 060) 1. To view the fault codes and the hours they
Reserved for Future Use occurred do the following:
Service Interval Hours
B. Press the up/down count switch to up count
Field number locations 61 through 70 are service until the display reads the desired location
interval hour settings. The service interval hours (071 - 090).
accumulate until they are reset. Once they are reset,
C. Place the program/reset switch in the OFF
they begin accumulating hours independent from the
(center) position.
machine hours until they are reset again. Do the
following procedures to view or reset the service D. Read any fault codes in the chosen location.
interval hours.
NOTE: A complete list of fault codes can be
NOTE: If the operator wanted location 061 to found in the Fault Code Table in this section.
indicate when the engine oil should be changed,
E. Press the program/reset switch to program.
location 061 would be reset to begin accumulating
hours for the next oil change. The operator could F. Press the up/down count switch to up count
then go into location 061 and monitor accumulating one time to advance to the next location.
hours. When location 061 reaches the engine oil
G. Place the program/reset switch in the OFF
change interval, the operator would change the oil
(center) position.
and reset location 061 again.
H. Read the hours that the previous fault code
1. To view the service hour interval locations do the
occurred at.
following:
NOTE: The hour location will always follow the fault
code location.
NOTE: Example: Location 072 will display the hours
until the display reads the desired location
on the machine when the fault code in location 071
(061 - 070).
was written. Location 074 will display the hours on
C. Place the program/reset switch in the OFF the machine when the fault code in location 073 was
(center) position. written.
D. Read the accumulated hours in the chosen 2. To monitor a particular location without going into
location. the programming mode do the following:
2. To reset the service interval hours do the A. Press the program/reset switch to program.
following:
A. Press the program/reset switch to program. until the location to be monitored is displayed.
B. Press the up/down count switch to up count C. Place the program/reset switch in the OFF
until the display reads the desired location (center) position.
(061 - 070).
D. Press the program/reset switch to program
C. Place the program/reset switch in the OFF and wait 5 seconds. The numbers on the
(center) position. display will change.
D. Press the up/down count switch to down count E. Place the program/reset switch in the OFF
and hold it for 3 seconds. The service interval (center) position.
hours in the chosen location will reset to 0.
F. Within 3 seconds, press the program/reset
switch to reset once.
Fault Code Status
G. With the machine in normal operating mode
Field number locations 071 through 090 display fault press the program/reset switch to reset to
cod es a nd th e h our s the fa ults occu rred . Th e display the hours accumulated in the selected
Infor matio n C en ter co ntinu ous ly mo nitors th e lo c a t io n . L o c a t i o n 0 0 0 ( h o u r m e t e r ) is
machine’s condition and records any fault codes; programmed into the Information Center from
however, it will only record a duplicate code once the factory.
every hour. When a fault code is written, the service
indicator icon (a manual with a wrench) will be
displayed on the Information Center.

4005-25
H. To reset a programmed location back to 000 1. Press the program/reset switch to program.
(h o u r m e te r - fa c to r y se t tin g ), h o ld t h e
program/reset switch to reset for 5 seconds.
When it is reset, the operator can view the
hour meter at any time during normal 3. Place the program/reset switch in the OFF
operating conditions by pressing the reset (center) position.
switch.
4. The Information Center will display the LED duty
cycle in units of 0.01 percent.
ZF Transmission ECM Part Number (1st
part) LCD Duty Cycle
Do the following to display the first part of the Do the following to display the LCD duty cycle.
transmission ECM ZF part number.
2. Press the up/down count switch to up count until the display reads 095.
3. Place the program/reset switch in the OFF (center) position.
(center) position.
4. The Information Center will display the LCD duty
4. The Information Center will display the first part cycle in units of 0.01 percent.
of the ZF Tra ns mis sion EC M p a rt n u mbe r
(6009#, # is a digit from 0 to 9).
Internal Information Center Temperature
ZF Transmission ECM Part Number (2nd Do the following to display the internal temperature of
part) the Information Center.
Do the following to display the second part of the 1. Press the program/reset switch to program.
transmission ECM ZF part number. 2. Press the up/down count switch to up count until
1. Press the program/reset switch to program. the display reads 096.
2. Press the up/down count switch to up count until 3. Place the program/reset switch in the OFF
the display reads 092. (center) position.
3. Place the program/reset switch in the OFF 4. The Information Center’s internal temperature
(center) position. will be displayed in degrees Celsius.
4. The Information Center will display the second Display Location Number 097 Reserved
part of the ZF Transmission ECM part number
for Future Use
(#####, # is a digit from 0 to 9).
Information Center Software Revision Entry Code for Accessing Test Mode
Number Locations 100 to 199
Do the following to access test mode locations 100 to
Do the following to display the Information Center
199.
software revision number.
2. Press the up/down count switch to down count
until the display reads 098.
(center) position.
(center) position.
4. The Information Center will display the software
revision number.
LED Duty Cycle 6. Press the up/down count switch one time so that
Do the following to display the LED duty cycle. the display reads 099.

4005-26
7. Place the program/reset switch in the OFF 16. Place the program/reset switch in the OFF
(center) position. (center) position.
8. Press the up/down count switch to up count until 17. Press the up/down count switch to up count until
the display reads 21. the display reads 010. This sends the VINS data
to the TECM.
18. Press the up/down switch until the display reads
10. Press the up/down count switch to up count past
000. This locks locations 100 and 101.
location 099.
NOTE: In location 102, 000 means locations 100
NOTE: When locations 098 and 099 are reset at 21,
and 101 are the same and locked; 001 means
the Information Center will scroll past location 099.
reprogram locations 100 and 101 only; 101 means
Once location 100 or higher is reached, locations 098
reprogram TECM; and 1-- in the third position means
and 099 are automatically reset to 000. If only one of
VIN data stored in locations 100 and 101 are
the locations is set at 21, and the user leaves the
different.
range of 098-099, locations 098 and 099 are
automatically reset to 000. 19. Press the program/reset switch to program.
Vehicle Identification Numbers (VINS) the display reads 103.
Do the following to view and change the vehicle NOTE: In location 103, 0-- in the third position
identification numbers. means no data received from TECM once location
1. Access test mode locations 100 to 199. 102 is set at 010; 1-- in the third position means data
received from TECM once location 102 is set at 010;
2. Press the program/reset switch to program. 100 means VINS data are identical; 101 means VINS
3. Press the up/down count switch to up count until data different; 110 means VINS data reprogrammed;
the display reads 102. and 111 means VINS data not present as received.
4. Place the program/reset switch in the OFF 21. Place the program/reset switch in the OFF
(center) position. (center) position. When the TECM has been
reprogrammed, 110 will be displayed. If 110 is
5. Use the up/down count switch to change the not displayed, press program/reset switch to
display to read 001. This allows changes to reset and turn ignition switch OFF. Wait 15
locations 100 and 101. seconds and repeat procedure (from Step 1) until
6. Press the program/reset switch to program. 110 is displayed. If 110 is displayed continue with
Step 22.
until the display reads 101. 22. Press the reset button momentarily.
8. Place the program/reset switch in the OFF 23. Turn off and restart the machine.
(center) position.
Display Location Numbers 104 - 113
9. Use the up/down count switch to change the
vehicle identification number: if a 521D machine Reserved for Future Use
enter 52101; if a 621D machine enter 62101.
Instrument Cluster (Information Center)
Part Number (1st part)
(center) position.
D o th e fo llo win g t o e nt er t he firs t p a r t o f th e
instrument cluster (Information Center) part number.
until the display reads 100.
(center) position. 2. Press the up/down count switch to down count
until the display reads 114. The service indicator
13. Use the up/down count switch to change the
vehicle identification number: if a 521D machine
enter 52101; if a 621D machine enter 62101. 3. Place the program/reset switch in the OFF
(center) position.
4. Use the up/down count switch to enter the first
part of the instrument cluster part number from
the parts catalog.
4005-27
Instrument Cluster (Information Center) 1. If your tire and calibration number are listed in
Part Number (2nd part) the table below go to step 3. Do the following to
calculate a calibration number:
Do the following to enter the second part of the
instrument cluster (Information Center) part number. A. Obtain the tire revolution/km (obtainable from
most manufacturers).
B. If the tire revolution/km is not available,
2. Press the up/down count switch to down count measure the distance the tire travels (in
until the display reads 115. The service indicator meters) in 10 revolutions. Divide that number
flashes intermittently. into 1000. Multiply the answer by 10. This is
3. Place the program/reset switch in the OFF how many revolutions your tire makes in a km.
(center) position. 2. Multiply the tire revolution/km by the axle ratio.
4. Use the up/down count switch to enter the Th e a n sw e r will b e t he n ew sp e ed o me te r
sec ond pa rt o f th e ins trume nt cluste r p art calibration number.
number from the parts catalog.
CALIBRATION NUMBER
NOTE: The part number may contain the letter A
followed by a number, to show revision level. Using
the up/down count switch, enter the A as 0 (zero)
followed by the number, (A1 = 01, A2 = 02).
TIRE REV/KM
MACHINE/TIRE
AXLE RATIO
Instrument Cluster (Information Center)
Date Code
Do the following to display the instrument cluster
date code.
521D w/15.5 x 25 L2, L3, 19.20 260 4992
1. Press the program/reset switch to program. XTLA, XHA
2. Press the up/down count switch to down count 521D w/17.5 x 25 L2, L3,
until the display reads 116. The service indicator 19.20 246 4723
XTLA, XHA
621D w/17.5 x 25 L2, L3,
3. Place the program/reset switch in the OFF 20.36 246 5009
XTLA, XHA or 20.5 x 25
(center) position.
XLD 70
4. The Information center will display the date code.
621D w/20.5 x 25 L2, L3,
Read the date code as follows: the first two 20.36 222 4520
XTLA, XHA
numbers = year, next three numbers = day.
Reserved for Supplier Information 4. Press the up/down count switch to up count until
Display Location Numbers 121 -129 5. Place the program/reset switch in the OFF
Reserved for Future Use (center) position.
6. Use the up/down count switch to enter the
Speedometer Calibration calibration number from the table.
Do the following to reset the speed ometer
calibration.
NOTE: If a dealer or customer changes tire sizes,
the speedometer calibration will have to be changed
to match the Information Center and transmission
ECM to the new tire size.
NOTE: A calibration number is required to perform
this function.

4005-28
Display Location Numbers 131 - 139 2. To monitor a particular location without going into
Reserved for Speedometer Calibration the programming mode do the following:
Reserved for Future Use B. Press the up/down count switch to up count
until the location to be monitored is displayed.
Temporary Fault Code Status
C. Place the program/reset switch in the OFF
Field number locations 171 through 190 display (center) position.
temporary fault codes and the hours the faults
oc curred. These tem porary fault codes will D. Press the program/reset switch to program
automatically be erased when the Information Center and wait 5 seconds. The numbers on the
is turned off. The Information Center monitors the display will change.
machine’s condition and records any fault codes into E. Place the program/reset switch in the OFF
the short-term resettable memory once every 3 (center) position.
minutes. This will enable a technician to quickly
check conditions to verify if a problem was resolved F. Within 3 seconds, press the program/reset
or still exists after maintenance. When a fault code is switch to reset once.
written, the service indicator icon (a manual with a G. With the machine in normal operating mode
wrench) will be displayed on the Information Center. press the program/reset switch to reset to
1. To view the temporary fault codes and the hours display the hours accumulated in the selected
they occurred do the following: lo ca t ion . ( L o ca t ion 0 0 0 ( h o u r me te r ) is
programmed into the Information Center from
A. Press the program/reset switch to program. the factory.
B. Press the up/down count switch to up count H. To reset a programmed location back to 000
until the display reads the desired location (h o u r m e te r - fa c to r y se t tin g ), h o ld t h e
(171 - 190). program/reset switch to reset for 5 seconds.
C. Place the program/reset switch in the OFF When it is reset, the operator can view the
(center) position. hour meter at any time during normal
operating conditions by pressing the reset
D. Read any fault codes in the chosen location. switch.
NOTE: A complete list of fault codes can be Display Location Numbers 191 - 196
found in the Fault Code Table in this section.
Reserved for Future Use
E. Press the program/reset switch to program.
Display Location Number 197 Reserved
F. Press the up/down count switch to up count for Manufacturing Data
one time to advance to the next location.
Display Location Number 198 Reserved
G. Place the program/reset switch in the OFF
(center) position. for Future Use
H. Read the hours that the previous fault code Display Location Number 199 Reserved
occurred at. for Manufacturing Data
NOTE: The hour location will always follow the fault NOTE: To exit the upper range of display location
code location. numbers (100-199) press the program/reset switch to
reset.
NOTE: Example: Location 172 will display the hours
on the machine when the fault code in location 171
was written. Location 174 will display the hours on
the machine when the fault code in location 173 was
written.

4005-29
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS
DISPLAY
LOCATION DEFINITION STATUS
NUMBER
000 Engine Hours
001 Engine Tachometer
002 Speedometer in Miles Per Hour
003 Speedometer in Kilometers Per Hour
004 Engine Coolant Temperature in Degrees Celsius
005 Engine Oil Pressure in Kilopascals
006 Fuel Level in Percent of Fuel in Tank
007 Transmission Oil Temperature in Degrees Celsius
008 Hydraulic Oil Temperature in Degrees Celsius
009 Voltmeter Reading (Continuous)
010 Gauge Display Selection
011 Parking Brake Test / Clutch Calibration
012 Information Center Light Setting - Work Lights Off
013 Information Center Light Setting - Work Lights On
014 Voltmeter Reading at Key-on
015 Alarm Status 00 = Off, 01 = On
00 = Normal Level
016 Coolant Level Status
01 = Low Level
00 = Switch Closed
017 Brake Pressure Switch Status 01 = Switch Opened
(Open = Normal Pressure)
00 = Switch Closed
018 Steering Pressure Switch Status 01 = Switch Opened
019 Parking Brake Status 00 = Off, 01 = On
020 Pilot Lockout Status 00 = Off, 01 = On
00 = Switch Closed
021 Hydraulic Filter Restriction Switch Status 01 = Switch Opened
(Open = Filter is OK)
00 = Switch Closed
022 Air Filter Restriction Switch Status 01 = Switch Opened
(Open = Filter is OK)
023 Present Work Lights Status 00 = Off, 01 = On
024 Present Fog Lights Status 00 = Off, 01 = On

4005-30
DISPLAY
NUMBER
00 = Switch Open
025 Air Conditioning High/Low Pressure Switch Status 01 = Switch Closed
00 = Filter Acceptable
01 = Filter Restricted
026 Transmission Filter Restriction Indicator Status 02 = Filter Fault
03 = Not Available
(Open - Filter is OK)
027 High Beam Lights Status 00 = Off, 01 = On
101 = F1, 102 = F2, 103 = F3,
104 = F4, 201 = N1, 202 = N2,
203 = N3, 204 = N4, 301 = R1,
028 Requested Gear and FNR Status
302 = R2, 303 = R3, 304 = R4
401 = Request to move shifter
to N
029 Status of Transmission Operation Indicator - In

00 = Always
Transmission Display
101 = F1, 102 = F2, 103 = F3,
104 = F4, 115 = Limp Home,
200 = Neutral or Declutch
030 Actual Gear Status 201 = N1, 202 = N2, 203 = N3,
204 = N4, 215 = Limp Home,
301 = R1, 302 = R2, 303 = R3,
315 = Limp Home
First Digit =
000 = Shift Not In Process
001 = Shift In Process
Second Digit =
001 = Driveline Not Engaged
Shift Status
010 = Driveline Engaged
031 Driveline Status
Operational Mode Third Digit = Mode Control
010 = Normal
110 = Substitute Clutch control
210 = Limp Home Mode
300 = Transmission Shutdown
400 = T.E.C.M. Shutdown
032 Hourmeter Status 00 - Always
033 Tachometer Status 00 - Always
Current Status of Service Indicator for Normal Operating
034 00 = Off, 01 = On
Mode (Book with the wrench)
035 Movement indicator Status 00 - Always
036 Beacon Status 00 = Off, 01 = On
037 Left Turn Indicator Status 00 = Off, 01 = On
038 Right Turn Indicator Status 00 = Off, 01 = On

4005-31
DISPLAY
NUMBER
039 Current Status Master Indicator (Red) 00 = Off, 01 = On
Current Status of Diagnostic Indicator (Book without the
040 00 - Always
wrench - Operators Manual)
041 Current Status Master Indicator (Yellow) 00 = Off, 01 = On
042 Master Reset - Reset Information Center to Factory Setting
00 = Switch Open
043 01 = Switch Closed
Park Brake Switch Status
(Closed = engaged Parking
Brake)
00 = Switch Closed
044 Redundant Brake Pressure Switch Status 01 = Switch Open
(Closed = Normal Operation)
00 = Switch Open
045 Service Brake Foot Switch Status 01 = Switch Closed
(Closed = Actuated)
00 = Switch Open
01 = Switch Closed
046 Pilot Lockout Switch Status
(Closed = Loader Controls
Locked)
00 = Switch Closed
047 Seat Switch Status 01 = Switch Open
(open = unoccupied)
050 Minimum Gear Selection Range - 1st and 2nd gear
051 Maximum Gear Selection Range - 2nd, 3rd and 4th gear
052 Minimum Gear Read Only
053 Maximum Gear Read Only
Range = 0 to 99
Default = 0
055 Reset Diagnostic Stack, 071 to 090 to zero Set to “21” and then exit this
location 055 to reset diagnostic
stack 071 -099 to zero
061 - 070 Service Hour interval Selection #1 - 10
071,073,
075,077,
079,081, Fault Code #1 Through Fault Code #10
083,085,
087, 089
072, 074, Hour Code #1 Through Hour Code #10. Hour Codes Follow
076, 078, Fault Codes Respectively.
080, 082,
084, 086, I.e.: Hour Code #1 (072) Corresponds with Fault Code #1
088, 090 (071)

4005-32
DISPLAY
NUMBER
1st Portion Of Transmission Electronic Control Module

091 ZF part number
(ECM) Part Number (5 digits from 0-9)
2nd Portion Of Transmission ECM Part Number (5 digits
092 ZF part number
from 0-9)
093 Cluster Software Revision Number 1 - 21
094 Light Emitting Diode (LED) Duty Cycle In units of 0.01%
095 Liquid Crystal Display (LCD) Duty Cycle In units of 0.01%
096 Internal Cluster Temperature In units of deg C
Set to “21” to enter Test Mode
098 Entry Code for Accessing Test Mode Locations 100 to 199
locations (Range = 0 to 99)
Set to “21” to enter Test Mode
099 Entry Code for Accessing Test Mode Locations 100 to 199
locations (Range = 0 to 99)
521D = 52101
100-101 Vehicle Identification Number (VINS)
621D = 62101
000 = Locations 100 and 101
are the same and locked
001 = Reprogram Locations
102 Allows Changing Locations 100 and 101 100 and 101 only
010 = Reprogram TECM
1-- = Locations 100 and 101 are
different
0-- = No data received from
TECM once location 102 is sent
as 010
103 1-- = Data received from TECM
Reprogramming Status
once location 102 is sent as 010
100 = VINS identical
101 = VINS different
110 = VINS reprogrammed
114 Cluster Part Number
115 Cluster Part Number
116 Cluster Date Code
130 Speedometer Calibration
171 - 190 Temporary Fault Code Status

4005-33
FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
Engine coolant temperature is 110° C (230° F)

12110
or greater
Engine coolant temperature sensor short
12900
circuit measuring less than 50 ohms.
Troubleshoot electrical circuits.
Engine coolant temperature sensor open
circuit measuring greater than 10,000 ohms
12901
with hydraulic oil temperature at 40° C (104°
F) or more.
Low engine coolant level - This code will not 1. A critical stop function warning has occurred.
13000 be generated if the engine coolant 2. Red stop indicator comes on and continuous
temperature is below 20° C (68° F). buzzer sounds.
3. Stop machine and perform required service on
Engine oil pressure is measured below 70 kPa
21070 the critical area.
(10 psi)
Engine oil pressure sensor short circuit Troubleshoot electrical circuits.
21900
measuring less than 16 ohms.
NOTE: Fault code 21900 is possible during cold
Engine oil pressure sensor open circuit engine start-up. After machine warm up, verify
21901
measuring more than 270 ohms. proper operation.
Fuel level sender short circuit measuring less
33900
than 16 ohms.
Fuel level sender open circuit measuring more Troubleshoot electrical circuits.
33901
than 270 ohms.
34000 Short circuit in fuel solenoid circuit.
1. A caution level warning has occurred.
2. Yellow caution indicator comes on and buzzer
35000 High air filter restriction. sounds for 3 seconds.
3. Perform required service on the cautioned area.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
Transmission temperature measured above buzzer sounds.
42125
125° C (257° F) 3. Stop machine and perform required service on
the critical area.
High transmission filter restriction when the 2. Yellow caution indicator comes on and buzzer
45000
transmission oil is above 20° C (68° F). sounds for 3 seconds.
1. Check the cables from TCU to shift lever.
46017 Gear range fault error 2. Check signal combinations of shift lever
positions for gear range.
1. Check the cables from TCU to shift lever.
46018 Logical error at direction select signal 2. Check signal combinations of shift lever
positions F-N-R.
1. Check the cables from the electronic boxes to
46020 Logical fault at park brake status the status switches.
2. Check signals of the status switches.

4005-34
1. Check the cables from the TCU to the FNR

switch.
46021 Logical error at FNR switch 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
46023 Short circuit to ground at ride control 1. Check the cables from the TCU to the ride
control relay.
46024 Short circuit to battery voltage at ride control 2. Check the connectors from the TCU to the ride
control relay.
46025 Open circuit at ride control 3. Check the ride control relay.
Short circuit to battery voltage or open circuit 1. Check the connectors.
46037
at temperature sensor 2. Check the temperature sensor.
46038 Short circuit to ground at temperature sensor
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
46039
at converter output temperature sensor 2. Check the connectors.
3. Check the temperature sensor.
46040 Short circuit to ground at converter output
temperature sensor
46049
at engine speed sensor 2. Check the connectors.
46050 3. Check the speed sensor.
Short circuit to ground at engine speed sensor
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.
46051 Logical error at engine speed sensor input
NOTE: This fault code is reset after power up of the
TCU. It is also reset if the signal is above zero
speed threshold.
Short circuit to battery voltage or open circuit
46052 1. Check the cables from TCU to the sensor.
at turbine speed sensor input
Short circuit to ground at turbine speed sensor 3. Check the speed sensor.
46053
input
46054 Logical error at turbine speed sensor input 3. Check the speed sensor.
TCU.
Short circuit to battery voltage or open circuit
46055 1. Check the cables from TCU to the sensor.
at intermediate speed sensor input
Short circuit to ground at intermediate speed 3. Check the speed sensor.
46056
input
Logical error at intermediate speed sensor 3. Check the speed sensor.
46057
input
TCU.

4005-35
46058
at output speed sensor 2. Check the connectors.
46059 3. Check the speed sensor.
Short circuit to ground at output speed sensor
46060 Logical error at output speed sensor 3. Check the speed sensor.
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the connector connected to the output
Output speed zero, does not match other speed.
46062
speeds. 3. Check the cable from the TCU to the sensor.
TCU.
1. Check the cluster controller.
46064 Invalid gear range restriction (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
46065 Invalid declutch modulation selection (CAN)
46089 Invalid test mode signal (CAN) 1. Check the cluster controller.
2. Check wire of CAN-Bus.
46090 Invalid park brake status (CAN) 3. Check the cable to the cluster controller.
46091 Invalid shift quality selection (CAN)

4005-36
46113 Short circuit to battery voltage at clutch K1

46114 Short circuit to ground at clutch K1
46115 Open circuit at clutch K1
1. Check the cable from the TCU to the
46120 Short circuit to ground at clutch K3 transmission control valve.
46121 Open circuit at clutch K3 2. Check the connectors from the TCU to the
transmission control valve.
46129 Short circuit to battery voltage at clutch K4 3. Check the regulator resistance.
4. Check internal wire harness of the transmission
control valve.
46132 Short circuit to battery voltage at clutch KV
46133 Short circuit to ground at clutch KV
46134 Open circuit at clutch KV
46135 Short circuit to battery voltage at clutch KR
46136 Short circuit to ground at clutch KR
46137 Open circuit at clutch KR
46145 Short circuit to ground at backup alarm relay 1. Check the cable from the TCU to the backup.
alarm relay.
Short circuit to battery voltage at backup alarm 2. Check the connectors from the backup alarm
46146
relay relay to TCU.
3. Check the resistance of backup alarm relay
46147 Open circuit at backup alarm relay circuit.
1. Check pressure at clutch K1.
2. Check main pressure in the system.
46177 Slippage at clutch K1 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
5. Replace clutch.
5. Replace clutch.

4005-37

5. Replace clutch.
1. Check pressure at clutch KV.
46181 Slippage at clutch KV 3. Check signal at internal speed sensor.
5. Replace clutch.
1. Check pressure at clutch KR.
46182 Slippage at clutch KR 3. Check signal at internal speed sensor.
5. Replace clutch.
buzzer sounds.
3. Stop machine and perform required service on
46183 Oil temperature at valve body is above limit the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
Engine speed is measured above 5,000 rpm 1. Check engine speed sensor
46185
for 0.2 seconds
1. Check oil filter.
2. Check wiring from TCU to filter maintenance
TCU sensed a voltage at oil filter maintenance switch.
46186
switch out of the allowed range (dirty filter) 3. Check filter maintenance switch (measure
resistance).
buzzer sounds.
Oil temperature at converter output is above 3. Stop machine and perform required service on
46195
limit the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
Short circuit to ground at transmission enable
46196
switch indicator circuit 1. Check the cable from the TCU to the
transmission enable switch.
Short circuit to battery voltage at transmission 2. Check the connectors from the transmission
46197
enable switch indicator circuit enable switch to the TCU.
Open circuit at transmission enable switch 3. Check the transmission enable switch.
46198
indicator circuit
Short circuit to battery voltage at power supply
46209 1. Check cables from the TCU to the sensors.
for sensors
2. Check the connectors from the TCU to the
46210 Short circuit to ground at power supply for sensors.
sensors

4005-38
46211 Low voltage at battery 1. Check batteries.

2. Check B+ wires from batteries to TCU.
46212 High voltage at battery 3. Check voltage at TCU connector pin 45.
46213 Error at switch 1 for solenoid power supply 1. Check fuse A2.
2. Check cable from control valve to TCU.
46214 3. Check connectors from control valve to TCU.
Error at switch 2 for solenoid power supply
4. Replace TCU.
Short circuit to battery voltage at display 1. Check the cable from TCU to the display.
46227
output 2. Check the connectors at the display.
46228 3. Change display.
Short circuit to ground at display output
1. Check the cluster controller.
46229 Error at communication on CAN 2. Check the wire of the CAN-Bus.
3. Check cable to cluster controller.
46230 Undefined VIN request via CAN.
46241 General EEPROM fault Replace the TCU.
Reprogram the correct configuration for the
46242 Current ID not set or corrupt
vehicle.
46243 Application error (ZF internal) Replace the TCU.
46245 Clutch calibration fault Check the clutch.
46246 Clutch adjustment data lost Do the transmission clutch calibration procedure.
1. Clear the codes.
CAN interface failure where no signals are 2. Restart the machine.
47000
received over one second of time 3. Monitor machine operation and diagnostics.
47001 Engine speed is missing 1. Verify corresponding function is displayed on
the information center and is working properly:
47002 Output shaft speed is missing
A. Engine rpm - run engine LO to HI and verify
display shows rpm.
B. Output shaft speed - drive unit with mph/kph
d is pl ay e d an d ve r if y th a t it is w o rk in g
properly.
C. Transmission oil temperature - display
temperature values on information center
47011 Transmission oil temperature is missing an d ru n ma chine to ve rify tha t the
temperature changes with machine
operation.
4. If operation is satisfactory, clear fault codes and
continue to monitor.
5. If there are problems during operation,
troubleshoot the appropriate electrical circuits.

4005-39
1. Check the function/operation of the

tra nsm iss io n filter r estr ictio n b y g oing to
program count location 026.
Transmission filter restriction information is 2. Read filter restriction status: 00 = filter
47012
missing acceptable, 01 = filter restricted, 02 = filter fault.
3. If filter restricted, 01, replace filter.
4. If 00 or 02, clear fault codes and monitor
machine performance and diagnostic codes.
47013 Current VINS is outside of the range 1. Reprogram VINS.
2. Verify program count location reads 110 or 100.
47014 3. Clear codes and monitor machine performance
Result code (11)
and continue to operate.
Low steering pressure has been detected after
51000 a normal operating pressure has been 1. A critical stop function warning has occurred.
reached since start up. 2. Red stop indicator comes on and continuous
buzzer sounds.
Low brake pressure (1700 PSI / 11721 kPa) 3. Stop machine and perform required service on
61000 has been detected after a normal operating the critical area.
pressure has been reached since start up.
1700 PSI (11,721 kPa) Brake pressure switch
61900 has not cycled within 50 hours of operation 1. Turn machine off.
time. 2. Pump service brake 30 full strokes.
3. Start machine and verify proper operation and
900 PSI (6250 kPa) Redundant brake no diagnostic codes.
61901 pressure switch has not cycled within 100 4. Operate machine and monitor performance.
hours of operation time.
64000 Park brake solenoid output short circuit. 1. Check park brake for proper operation.
2. Do park brake test, see section 7008.
3. Adjust/repair park brake as required.
Park brake switch has not cycled within 50
66900 4. Clear diagnostic codes and monitor machine
hours of operation time.
performance.
1. Verify full pedal actuation and return, make sure
debris does not obstruct pedal travel.
Service brake foot switch has not cycled within 2. Clear codes.
66901
50 hours of operation. 3. Verify proper machine operation.
4. If code reappears, check brake light switch and
troubleshoot electrical circuits.
Hydraulic oil temperature is 110° C (230° F) or buzzer sounds.
72110
greater. 3. Stop machine and perform required service on
the critical area.
Hydraulic oil temperature sensor short circuit
72900
measuring less than 50 ohms.
Hydraulic oil temperature sensor open circuit
measuring greater than 10,000 ohms with the Troubleshoot electrical circuits.
72901
engine coolant temperature at 90° C (194° F)
or more.
74000 Pilot pressure solenoid output short circuit.

4005-40
High hydraulic filter restriction when the

75000 1. A caution level warning has occurred.
hydraulic oil is above 20° C (68° F).
2. Yellow caution indicator comes on and buzzer
84018 System voltage is below 18 volts. sounds for 3 seconds.
84032 System voltage is above 32 volts.
1. Operate the machine to verify all functions and
monitoring systems are working properly (no
yellow or red warnings, normal operation).
2. Monitor cluster performance during machine
operational check (no new diagnostic codes, no
erratic behavior, flashing icons, etc.).
86010 Corrupt engine hours, data lost 3. If all systems and operations are normal, clear
d ia g n o s t ic co d e s a n d c o n t in u e ma c h in e
operation.
4. Monitor machine for recurrence of fault codes.
5. Repeated codes may be an indication of a
pending cluster failure.
1. Reprogram correct tire calibration number for
the machine.
Corrupt tire calibration numbers, data lost – 2. Verify proper machine operation and machine
86020 The calibration number will default back to the travel speed to displayed speed.
number used at cluster shipment 3. Continue machine operation and monitor for
recurring fault codes.

4005-41
86040 Information Center program memory error

86050 Information Center RAM failure
Information Center Reset – This code is
generated if the Information Center Program
“goes astray”. The Information Center is reset.
86060 This code will also be generated if there is a
brief intermittent open between the time the
engine is shut off and the Information Center
shuts off.
86070 Open range setting
86071 Brightness setting
1. Operate the machine to verify all functions and
86072 Machine ID monitoring systems are working properly (no
yellow or red warnings, normal operation).
86073 Machine info
2. Monitor cluster performance during machine
86075 Cluster date code operational check (no new diagnostic codes, no
erratic behavior, flashing icons, etc.).
86076 Cluster reserved 3. If all systems and operations are normal, clear
86077 Calibration number d ia g n o s t ic co d e s a n d c o n t in u e ma c h in e
operation.
86078 Shift quality 4. Monitor machine for recurrence of fault codes.
86079 5. Repeated codes may be an indication of a
Requested Gmin
pending cluster failure.
86080 Requested Gmax
86081 Declutch modulation
86082 Creep setting
86083 Service hours
86084 Diagnostics stack pointer (internal to software)
86085 Diagnostics stack contents
86086 Digital input states (internal to software)
Engine hour time stamps for digital input
86087
states (internal to software)
Air Conditioning high or low pressure 2. Yellow caution indicator comes on and buzzer
91000
indication sounds for 3 seconds.

4005-42
NOTES

4005-43
INDEX
A 056 through 060 ................................................ 24
Actual Gear Check ................................................20 071 through 090 ................................................ 23
Air Conditioning Indicator ........................................7 097 .................................................................... 25
Air Conditioning Switch Check ..............................19 100 through 199 ................................................ 25
Air Filter Indicator ....................................................7 104 through 113 ................................................ 26
Air Filter Restriction Switch Check ........................18 117 through 120 ................................................ 27
Alarm Check ..........................................................17 121 through 129 ................................................ 27
Automatic Scrolling Gauge Displays .....................15 131 through 139 ................................................ 28
140 through 170 ................................................ 28
B 191 through 196 ................................................ 28
Beacon Indicator ......................................................6 197 .................................................................... 28
Beacon Status .......................................................21 198 .................................................................... 28
Brake 199 .................................................................... 28
Park, Information Center Output Check ............18 Display Location Numbers and Descriptions ......... 29
Park, Testing .....................................................15 Displays
Parking Brake Indicator .......................................7 Gauge, Automatic Scrolling ............................... 15
Brake Pressure ......................................................17 Gauge, Manual Scrolling ................................... 15
Brake Pressure Indicator .........................................6 Individual Function ............................................ 15
Drive Line Shift Status ........................................... 20
C Duty Cycle, LCD .................................................... 25
Calibration Duty Cycle, LED .................................................... 25
Transmission Clutch ..........................................16
Caution and Warning Master Indicator Lights .......21 E
Caution Master Indicator (Yellow) ...........................6 Engine
Check Coolant Temperature ...........................................8
Actual Gear .......................................................20 Oil Pressure Gauge .............................................8
Air Conditioning Switch .....................................19 Engine Coolant Temperature ............................8, 12
Alarm .................................................................17 Engine Oil Pressure ..............................................12
Coolant Level ....................................................17 Engine Oil Pressure Gauge .....................................8
High Beam ........................................................19 Entry Code
Park Brake Switch .............................................22 Test Mode Locations 100 to 199 ....................... 25
Requested Gear ................................................19
Switch, Pilot Lockout .........................................22 F
Switch, Redundant Brake Pressure ..................22 Fault Code Status .................................................. 24
Switch, Service Brake Foot ...............................22 Fault Codes ........................................................... 33
Work Lights .......................................................18 Filter
Clutch Indicator, Air Filter ...............................................7
Calibration, Transmission ..................................16 Indicator, Hydraulic Oil ........................................7
Control Indicator, Transmission Oil ..................................7
Pilot .....................................................................6 Restriction Switch, Air
Coolant Restriction Switch, Air Filter .......................... 18
Engine Temperature ............................................8 Restriction Switch, Hydraulic ............................. 18
Indicator, Low ......................................................6 Restriction Switch, Transmission ...................... 19
Coolant Level Check .............................................17 Fuel
Critical Warning Displays .......................................10 Gauge, Level .......................................................8
Fuel Level Gauge ....................................................8
D Fuel Lever ............................................................. 12
Diagnostic Center ....................................................5
Diagnostic Indicator Status ....................................21 G
Display Center Gauge
Lighting, Setting ................................................17 Engine Oil Pressure ............................................8
Display Location Fuel Level ...........................................................8
047 ....................................................................22 Hydraulic Oil Temperature ...................................7
048 and 049 ......................................................23 Transmission Oil Temperature ............................7
Voltmeter .............................................................8
4005-44
Gauges and Indicators ............................................6 L
Gear LCD Duty Cycle ..................................................... 25
Check, Actual ....................................................20 LED Duty Cycle ..................................................... 25
Check, Requested .............................................19 Left Turn Indicator Status ...................................... 21
Gear Range Read Only .........................................23 Level
Gear Selection Coolant, Check ................................................. 17
Maximum ...........................................................23 Lighting, Setting Display Center ............................ 17
Minimum ............................................................23 Lights
Work ..................................................................18
H Low Coolant Indicator .............................................. 6
High Beam Check ..................................................19
Hourmeter ..............................................................12 M
Hourmeter Indicator Status ....................................20 Manual Scrolling Gauge Displays ......................... 15
Hours Master Reset ......................................................... 22
Service Interval .................................................24 Maximum Gear Selection ...................................... 23
Hydraulic Filter Restriction Switch Check ..............18 Minimum Gear Selection ....................................... 23
Hydraulic Oil Filter Indicator ....................................7 Movement Indicator Status .................................... 21
Hydraulic Oil Temperature .....................................13
Hydraulic Oil Temperature Gauge ...........................7 N
Non-Critical Warning Displays ............................... 11
I
Indicator O
Air Conditioning ...................................................7 Oil
Air Filter ...............................................................7 Pressure Gauge, Engine ..................................... 8
Beacon ................................................................6 Operational Indicator Status .................................. 20
Brake Pressure ...................................................6
Caution and Warning Master, Status Lights ......21 P
Caution Master (Yellow) ......................................6 Park Brake
Diagnostic, Status .............................................21 Information Center Output Check .....................18
Hourmeter, Status .............................................20 Testing ............................................................... 15
Hydraulic Oil Filter ...............................................7 Park Brake Switch Check ...................................... 22
Icon, Service .......................................................9 Parking Brake Indicator ........................................... 7
Left Turn, Status ................................................21 Pilot Control .............................................................6
Low Coolant ........................................................6 Pilot Lockout
Movement, Status .............................................21 Information Output Check .................................18
Operational, Status ...........................................20 Pilot Lockout Switch Check ................................... 22
Parking Brake ......................................................7 Power Circuit Test ................................................... 6
Right Turn, Status .............................................21 Pressure
Secondary Steering .............................................7 Brake Indicator .................................................... 6
Service, Status ..................................................21 Pressure, Brake ..................................................... 17
Stop Master (Red) ...............................................6 Programming Information Center ..........................14
Tachometer, Status ...........................................20 Programming, Information Center ......................... 14
Transmission Oil Filter .........................................7
Work Light ...........................................................6 R
Indicators and Gauges ............................................6 Redundant Brake Pressure Switch Check ............ 22
Individual Function Display ....................................15 Requested Gear Check ......................................... 19
Information and Diagnostic Center ....................5, 12 Reset Diagnostic Stack for Display Locations .......23
Information Center ...................................................5 Reset, Master ........................................................ 22
Internal Temperature .........................................25 Right Turn Indicator Status .................................... 21
Software Revision Number ...............................25
Instrument Cluster S
Date Code .........................................................27
Secondary Steering Indicator .................................. 7
Part Number (1st part) ......................................26
Secondary Steering Pressure Switch .................... 18
Part Number 2nd part) ......................................27
Self-Test .................................................................. 5
Internal Information Center Temperature ..............25
Service Brake Foot Switch Check ......................... 22
Service Indicator Icon .............................................. 9
Service Indicator Status ........................................21
4005-45
Service Interval Hours ...........................................24 V
Setting Display Center Lighting .............................17 Vehicle Idenification Numbers (VINS) ................... 26
Settings, Diagnostics, and Fault Codes .................14 VINS ...................................................................... 26
Software Voltmeter ............................................................... 13
Revision Number, Information Center ...............25 Voltmeter Gauge .....................................................8
Speedometer .........................................................12 Voltmeter, Key ON ................................................ 17
Speedometer Calibration .......................................27
Status W
Beacon ..............................................................21 Work Light Indicator ................................................6
Caution and Warning Master Indicator Lights ...21 Work Lights Check ................................................ 18
Diagnostic Indicator ...........................................21
Drive Line Shift ..................................................20 Z
Fault Code .........................................................24 ZF Transmission
Fault Code, Temporary ......................................28 See Transmission ............................................. 25
Hourmeter Indicator ..........................................20
Left Turn Indicator .............................................21
Movement Indicator ...........................................21
Right Turn Indicator ...........................................21
Service Indicator ...............................................21
Tachometer Indicator .........................................20
Steering
Secondary Indicator ............................................7
Secondary Pressure Switch ..............................18
Stop Master Indicator (Red) ....................................6
Switch
Park Brake, Check ............................................22
Pilot Lockout ......................................................22
Pressure, Secondary Steering ..........................18
Redundant Brake Pressure ...............................22
Restriction, Hydraulic Filter ...............................18
Restriction,Transmission Filter ..........................19
Service Brake Foot ............................................22
T
Tachometer ...........................................................12
Tachometer Indicator Status .................................20
Temperature
Engine Coolant ....................................................8
Internal Information Center ...............................25
Temporary Fault Code Status ...............................28
Test
Power Circuit .......................................................6
Self-Test ..............................................................5
Test Mode Locations 100 to 199 ...........................25
Testing Park Brake ................................................15
Transmission
ZF Transmission
ECM Part Number (1st part) .........................25
ECM Part Number (2nd part) ........................25
Transmission Clutch Calibration ............................16
Transmission Display ............................................13
Transmission Filter Restriction Switch Check .......19
Transmission Oil Filter Indicator ..............................7
Transmission Oil Temperature ..............................13
Transmission Oil Temperature Gauge ....................7

4005-46
NOTES

Section
4007
ALTERNATOR
4007
CASE CORPORATION
700 State Street
CASE CANADA CORPORATION © 1999 Case Corporation

January, 1999
Hamilton, ON L8N 4C4 CANADA Bur 7-12260
4007-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................... 2
SPECIAL TORQUES .................................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................ 3
GENERAL INSPECTION AND TESTING ......................................................................................................................... 4
ALTERNATOR DISASSEMBLY, TESTING, AND ASSEMBLY ............................................................................................. 5

Disassembly and Testing .......................................................................................................................................... 5
Assembly ................................................................................................................................................................ 8
SPECIFICATIONS
Case part number .............................................................................................................................................................1964860C1
Manufacturer ................................................................................................................................................................ Robert Bosch
Robert Bosch part number .......................................................................................................................................... 0 120 468 054
Output ....................................................................................................................................... 28 volts at 65 amperes at full throttle
Resistance of rotor winding .............................................................................................................................................. 8 to 9 ohms
Resistance of stator winding ...................................................................................................................................0.18 to 0.21 ohms
Minimum brush length, outside housing ................................................................................................................... 7 mm (0.27 inch)
SPECIAL TORQUES
Alternator mounting nuts and bolts ................................................................................................................ 100 Nm (74 pound-feet)
Pulley retaining nut ........................................................................................................................ 60 to 70 Nm (44 to 52 pound-feet)
Alternator housing screw........................................................................................................................4 to 5 Nm (3 to 4 pound-feet)

4007-3
SPECIAL TOOLS
CAS-1375 PULLEY NUT TOOL AMMETER
CARBON PILE (100 WATT, 1 OHM)

VARIABLE RESISTOR
CAS-1559 DIGITAL MULTIMETER

CAS-10344 CHARGING SYSTEM ANALYZER
51L7

4007-4
GENERAL INSPECTION AND TESTING

1. Park the machine on a level surface and lower D. Connect the positive voltmeter lead of the
the attachments to the floor. tester (9) to the positive battery post (10)
of the other battery.
2. Apply the parking brake and stop the engine.
E. Fasten the ammeter clamp of the tester
3. Make sure all of the controls are in the (11) around the negative battery cable (4).
NEUTRAL position. The po int of the a rrow on the ammeter
clamp must be toward the battery.
4. Make sure that the batteries are fully charged
and that all wiring harness leads are connected. 2 6 7 9
4
5. Turn all accessories OFF.
11 12
6. Make sure there is no oil or grease on the
alternator drive belt and the alternator drive belt
is tight.
7. If the alternator still does not operate correctly,

troubleshoot the alternator, refer to Section 4002. 5 3 8 10
8. Make sure the parking brake is applied. 1
B871240J
9. Make sure the master disconnect switch is in the 1. 12 VOLT BATTERY
ON position. 2. NEGATIVE LOAD LEAD OF TESTER
3. NEGATIVE BATTERY POST
10. Adjust the controls for the tester as follows: 4. NEGATIVE BATTERY CABLE
5. TO MASTER DISCONNECT SWITCH
A. Move the load control to the OFF position. 6. NEGATIVE VOLTMETER LEAD OF TESTER
7. POSITIVE LOAD LEAD OF TESTER
B. Select the volt range that will measure 24 8. POSITIVE BATTERY POST
volts. 9. POSITIVE VOLTMETER LEAD OF TESTER
10. POSITIVE BATTERY POST
C. Select the ampere range that will measure 11. AMMETER CLAMP
100 amperes. 12. JUMPER CABLE
D. Put the volt lead selector in the EXT. Figure 1. TESTER CONNECTIONS
position.
11. Connect the tester to the batteries (1), refer to 12. Start the engine and run the engine at full
Figure 1, as follows: throttle.
A. Connect the negative load lead of the NOTE: Do not apply a load to the battery for more than
tester (2) to the negative battery post (3) of 15 seconds at one time. After 15 seconds, turn the load
the 12 volt battery (1) that is connected to control to the OFF position for 60 seconds before
the master disconnect switch (5). applying the load again.
B. Connect the negative voltmeter lead of the 13. Adjust the load control of the tester to get the
tester (6) to the same negative battery post maximum amm eter indication. Read the
(3). ammeter and voltmeter. Make a record of the
ammeter and the voltmeter indications.
C. Connect the positive load lead of the tester
(7) to the positive battery post (8) of the 14. Turn the load control to the OFF position.
same battery.
15. Decrease the engine speed and stop the engine.

4007-5
16. The ammeter indication in step 13 must not be B. If the ammeter and voltmeter indications
l e s s th a n 6 5 a m p e r e s a n d t h e v o l t m e t e r were n ot co rrect, the p roblem is in th e
indication must be 25 to 29 volts. alternator or voltage regulator. If a new
voltage regulator and brush assembly are
A. If the ammeter and voltmeter indications available, replace the voltage regulator
were correct, the alternator and voltage and brush assembly and repeat the test.
regulator are good.
C. If the alternator still does not operate
correctly, disassemble the alternator and
repair as necessary.
ALTERNATOR DISASSEMBLY, TESTING, AND ASSEMBLY
Disassembly and Testing 3. Remove the pulley (3), refer to Figure 3.
1. Place the alternator on a clean bench. 4. Remove the fan (4).
2. Use the pulley nut tool (1), wrench (2), and 5. Remove the nuts (5), washers (6), nuts (7),
socket (3), and remove the retaining nut (4) and washers (8), and plastic washers (9) that hold
washer (5) from the alternator drive pulley (6), the housings together.
refer to Figure 2.
6. Remove the two screws (10) and washers (11)
3 that hold the brush holder and voltage regulator
2 5 (12) to the alternator. Remove the brush holder
and voltage regulator (12).
7. Disconnect the capacitor (18) from the alternator.

1
8. Remove the screw (16) and washer (17) that
hold the capacitor (18) to the rear housing (21).
Remove the capacitor (18).
9. Put marks on the front housing (20) and rear

housing (21) so they can be correctly assembled.
4 10. Remove the four housing screws (19) that hold

the front and rear housings (20 and 21) together.
6 11. Separate the front housing (20) from the rear

housing (21). Put a mark on the stator coil (44)
44L7 so it can be correctly assembled.
1. PULLEY NUT TOOL
2. WRENCH 12. Remove the four screws (22) that hold the rotor
3. SOCKET (24) in the front housing (20).
4. RETAINING NUT
5. WASHER 13. Remove the rotor (24) from the front housing
6. ALTERNATOR PULLEY (20).
Figure 2. RETAINING NUT REMOVAL

4007-6
4
20 1
22
23
2
3
27
28
19
24
25
36
37
44 39
26
38
34 42
32 43
33
31
30 41
40
29
16 35
14 9 21
18 7
13 8
15 5
17 6
10
11 12
45L7
1. RETAINING NUT 13. SPRING 25. REAR BEARING 37. RECTIFIER BRIDGE
2. WASHER 14. BRUSH 26. SNAP RING 38. INSULATOR
3. PULLEY 15. DUST SEAL 27. FRONT BEARING 39. D+ TERMINAL
4. FAN 16. SCREW 28. BEARING RETAINING PLATE 40. B+ TERMINAL
5. NUT 17. WASHER 29. NUT 41. DUST SEAL
6. WASHER 18. CAPACITOR 30. WASHER 42. TERMINAL
7. NUT 19. HOUSING SCREW 31. NUT 43. BUSHING
8. WASHER 20. FRONT HOUSING 32. WASHER 44. STATOR COIL
9. PLASTIC WASHER 21. REAR HOUSING 33. FIBER WASHER
10. SCREW 22. SCREW 34. FIBER SPACER
11. WASHER 23. SPACER 35. INSULATOR
12. BRUSH HOLDER AND 24. ROTOR 36. RECTIFIER SCREW
VOLTAGE REGULATOR
Figure 3. ALTERNATOR ASSEMBLY

4007-7
14. Check the rotor shaft for damage. Make sure that 24. Install a new brush (14) and spring (13) in the
the coils are not loose on the shaft. Check the brush holder and voltage regulator (12). Solder
slip rings for too much wear or deep grooves. lead to terminal using rosin-cored solder. Clamp
The slip rings can be cleaned by using fine 400 rubber tube in terminal next to the solder point.
grit sand paper. Te st fo r e a s y m o v e m e n t o f b r u s h e s a ft e r
installation. Brushes will project 14 mm (0.55
15. Connect one of the test leads from an ohmmeter inch) from holder.
to the rotor shaft (ground). Connect the other test
lead to one of the slip rings. There must not be 25. Remove the nuts (29), washers (30), nuts (31),
any electrical connection between the slip ring washers (32) and fiber washers (33) from the
and the rotor shaft. The ohmmeter reading must rectifier bridge terminals.
not be low or zero ohms. If the ohmmeter reading
is low or zero ohms, replace the rotor assembly. 26. Remove the insulator (35) from the B+ terminal
Repeat this test on the other slip ring. (40).
16. Connect an ohmmeter between the two slip 27. Remove the rectifier screws (36) that hold the
rings. The reading on the ohmmeter must be 8 to rectifier bridge (37) to the rear housing (21).
9 ohms. If the reading on the ohmmeter is high, Remove the rectifier bridge (37) from the rear
there is a break in the rotor coil and the rotor housing (21).
assembly will have to be replaced.
28. Remove the insulator (35) from the B+ terminal
17. Remove the rear bearing (25) from the rotor (24) (40).
using a bearing puller.
29. Remove the insulator (38) from the D+ terminal
18. Remove the front bearing (27) and spacer (23) (39).
by using a bearing puller and hydraulic press.
30. Unsolder the stator coil (44) at the connections to
19. Remove the bearing retaining plate (28). the rectifier bridge (37). Remove the stator coil
(44).
20. Check the capacitor (18) for continuity between
th e mo u ntin g ta b an d th e lea d . If the r e is NOTE: Bend phase lead-out wires as little as possible.
continuity, the capacitor (18) is bad. Check the
capacitor (18) by connecting an ohmmeter 31. Test the positive diodes in the rectifier bridge
b e t w e e n t h e mo u n ti n g ta b a n d l e a d . T h e (37). Connect the negative lead of the ohmmeter
ohmmeter will initially show movement and then to the output B+ terminal (40). Connect the
return to indicating no continuity as the capacitor positive lead of the ohmmeter to one of the leads
(18) is charged. Discharge the capacitor (18) by for the positive diodes. The positive diodes are
grounding the lead to the tab before installation. the seven diodes closest to the B+ terminal (40).
21. Check for continuity between each brush (14) 32. Reverse the ohmmeter leads. Read the
and the brush terminal. If there is no continuity, ohmmeter. There must be a high reading and a
replace the brushes (14). low rea ding . If the read ings are the same,
replace the rectifier bridge (37). Repeat this step
22. Measure the length of the brush (14) projecting for the other six diodes.
from the brush holder and voltage regulator (12).
Replace the brushes if the length is 7 mm (0.27 NOTE: D+ terminal (39) must be installed on a new
inch) or less. rectifier bridge (37).
23. Use a soldering iron to disconnect the brush 33. Check the negative diodes in the rectifier bridge
lead. Remove the brush (14) and the spring (13) (37). Connect the negative lead of the ohmmeter
from the brush holder and voltage regulator (12). to the surface of the diode plate that is not
p a in te d . C o n n e ct t h e p o sit ive lea d o f t h e
NOTE: When soldering leads to the terminals, the ohmmeter to one of the leads for the negative
solder must not flow into copper leads. diodes. The negative diodes are the seven
diodes on the side of the rectifier bridge (37)
opposite the B+ terminal (40).

4007-8
34. Reverse the ohmmeter leads. Read the 12. Assemble the front housing (20) and rear
ohmmeter. There must be a high reading and a housing (21), making sure the reference marks
low rea ding . If the read ings are the same, align.
replace the rectifier bridge (37). Repeat this step
for the other six diodes. 13. Install the four housing screws (19) that hold the
housing halves together. Do not tighten the
NOTE: D+ terminal (39) must be installed on a new housing screws (19).
rectifier bridge (37).
14. Put three 0.2 mm (0.008 inch) feeler gauges
35. Measure the resistance of the stator windings by between the stator coil (44) and rotor (24). This
connecting the ohmmeter across the leads. The will correctly position the rotor (24) in relation to
resistance in each coil should be 0.18 to 0.21 th e stato r, and align the drive end bearing
ohms. hou sing w ith the collector ring en d shie ld.
Alternate tightening the two housing screws (19)
36. Check the stator coil (44) for short circuit. opposite of each other until the four housing
Co n ne c t o ne le a d of th e oh mme te r to th e sc r e ws (1 9 ) t h a t h o ld th e h o us in g ha lv e s
housing of the stator coil (44). Connect the other together are tightened to a torque of 4 to 5 Nm (3
lead to each of the four leads from the stator coil to 4 p oun d-fe et). Remo ve the th ree fe eler
(44). If the ohmmeter moves there is a short gauges.
circuit in the stator coil (44). Install a new stator
coil (44). 15. Install the capacitor (18). Install and tighten the
sc re w ( 1 6 ) a nd w as h e r (1 7 ) th a t ho ld th e
Assembly capacitor (18) to the rear housing (21).
1. Solder the stator coil (44), at the connections, to 16. Connect the capacitor terminal to the alternator.
the rectifier bridge (37), refer to Figure 3.
17. Check the dust seal (15) on the brush holder and
2. Install the insulator (38) on the D+ terminal (39). v o l t a g e r e g u l a t o r ( 1 2 ) t o m a k e s u r e i t is
positioned correctly.
3. Install the insulator (35) on the B+ terminal (40).
Check the dust seal (41) and make sure it is in 18. Install the brush holder and voltage regulator
place. (12). Make sure the rectifier bridge contact spring
is in contact with the brush holder and voltage
4. Align the rectifier bridge (37) in the rear housing regulator (12). Make sure the dust seal (15) is in
(21) and install the rectifier screws (36) that hold contact with the housing.
the rectifier bridge (37) to the housing.
19. Install and tighten the two screws (10) and
5. Install the insulator (35) on the B+ terminal (40). washers (11) that hold the brush holder and
voltage regulator (12) to the alternator.
6. Install the fiber washers (33), washers (32), nuts
(31), washers (30), and nuts (29) on the rectifier 20. Install plastic washers (9), washers (8), nuts (7),
bridge terminals. washers (6) and nuts (5).
7. Install the bearing retaining plate (28). 21. Install the fan (4).
8. Install a new front bearing (27) on the rotor shaft 22. Install the pulley (3).
if it has been removed. Install the front bearing
(27) and spacer (23) with a hydraulic press. 23. Install the retaining nut (1) and washer (2) on the
front of the alternator.
9. Install a new rear bearing (25) on the rotor shaft
if it has been has been removed. Install the rear 24. Use the pulley nut tool (1), wrench (2), and
bearing (25) using a hydraulic press. socket (3) to tighten the retaining nut (4) and
washer (5), refer to Figure 2. Tighten retaining
10. Install the rotor (24) in the front housing (20). nut (4) to a torque of 60-70 Nm (44 to 52 pound-
feet).
11. Install and tighten the four screws (22) that hold
the rotor (24) in the front housing (20).

Section
4008
ALTERNATOR - 45 AMPERE
4008
CASE CORPORATION
700 State Street
4008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
45 Ampere Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection of the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection and Testing of the Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection and Testing of the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection and Replacement of the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4008-3
SPECIFICATIONS
45 Ampere Alternator
Rated output ........................................................................................................................... 28 volts at 45 amperes
Resistance of rotor ............................................................................................................................. 8.1 to 9.9 ohms
Maximum runout for slip rings ....................................................................................................0.05mm (0.002 inch)
Minimum diameter of slip rings.................................................................................................. 26.8 mm (1.055 inch)
Resistance of stator........................................................................................................................ 0.20 to 0.24 ohms
Minimum length of brushes ...............................................................................................................7mm (0.27 inch)
Torque nut for pulley ..............................................................................................60 to 73 Nm (45 to 54 pound-feet)

4008-4
ALTERNATOR
Disassembly STEP 3
STEP 1
B523411M
Remove the retainer and the pulley from the shaft.

B518007M
Fasten the pulley of the alternator in a vise that has STEP 4

soft jaws. Loosen and remove the nut and washer.
STEP 2
B523413M
Remove the fan from the shaft.
B523405M STEP 5
Hit the face of the pulley softly with a hammer to
loosen the retainer in the pulley.
B8971201M
Loosen and remove the screws and flat washers that

fasten the voltage regulator and brush holder to the
housing.

4008-5
STEP 6 STEP 9
B8971204M B8971213M
Remove the voltage regulator and brush holder. Loosen and remove the nut, flat washer, and fiber
washers from the D+ terminal.
STEP 7
STEP 10
B8971207M
Disconnect the lead for the capacitor. B8971216M
Loosen and remove the nut, flat washer, and fiber

STEP 8 washers from the B+ terminal.
STEP 11
B8971210M
Loosen and remove the screw and remove the

capacitor. B8971219M
Make an alignment mark on the cover, the stator, and

the housing.

4008-6
STEP 12 STEP 15
B8971222M B8971301M
Loosen and remove the screws that fasten the cover, Remove the rotor from the cover.
stator, and housing together.
STEP 16
STEP 13
B8971304M
B8971231M 1. SCREWS
Remove the cover and rotor from the stator and
Loosen and remove the screws that fasten the
housing. The cover can be difficult to remove. Use a
rectifier bridge to the housing.
soft hammer as required to remove the cover.
STEP 17
STEP 14
B8971307M
B8971508M
Remove the housing.
Loosen and remove the screws that fasten the
bearing retainer to the cover. The rotor now can be
removed.

4008-7
STEP 18 STEP 20
B8971310M B8971319M
Remove the insulator from the B+ terminal. Remove the shield from the housing.
STEP 19
B8971313M
Remove the insulator from the D+ terminal.

4008-8
Inspection of the Brushes STEP 23
STEP 21
B9064418M
Measure the length of each brush. If one brush is

B9064411M
less than 7 mm (0.27 inch) long replace both brushes
Use an ohmmeter and check the continuity from or the voltage regulator and brush holder.
each terminal and brush. If the reading is not zero,
replace the brush or voltage regulator and brush STEP 24
holder.
STEP 22
B9064421M
To replace the brushes, use a soldering iron to

remove the original brushes. Install the springs and
B9064414M
new brushes and use rosin core solder to solder the
Remove the shield. leads to the terminals. Before soldering the terminal
shown, open the sleeve for the brush lead and then
crimp the sleeve.
STEP 25
B9064414M
Install the shield.

4008-9
Inspection and Testing of the Rotor STEP 28
STEP 26
B9064433M
Use a dial indicator and measure the runout of each

B9064405M
slip ring. If the runout is more than 0.05 mm (0.002
Touch the leads of the ohmmeter to the slip rings. inch) a new rotor must be used or use a lathe to
The reading must be as specified, see below. If the remove enough material until the runout is less than
reading is not as specified, a new rotor must be specified.
installed.
45 Ampere Alternator . . . . . . . . . . . . 8.1to 9.9ohms STEP 29
STEP 27
B9064436M
Measure the diameter of the slip ring. The diameter

must not be less than 26.8 mm (1.055 inch).
B9064407M
Touch the leads to each slip ring and the shaft. If a

reading shows continuity, a new rotor must be
installed.

4008-10
Inspection and Testing of the STEP 33

Stator
STEP 30
Look for burned insulation on the coils of the stator.
This is an indication of a short circuit. Install a new
stator.
STEP 31
B9064502M
Use a high watt soldering iron and rosin core solder

to solder the leads of the stator to the rectifier bridge.
Testing the Capacitor

STEP 34
B9064319M
Touch the leads of the ohmmeter to each lead from

the stator and the common connection. The readings
must be as specified, see below. If the readings are
not as specified, a new stator must be installed.
45 Ampere Alternator . . . . . . . . . 0.20 to 0.24 ohms
STEP 32
B9064424M
Touch the leads of the ohmmeter to the capacitor as

shown. The reading will initially approach zero ohms,
then gradually increase to an open circuit as the
capacitor is charged. If there is no indication of
resistance, a new capacitor must be installed. The
capacitor is used to reduce radio noise.
STEP 35
B9064322M
Touch the terminal to the bracket to discharge the
Touch the leads of the ohmmeter to each lead from condenser.
th e s ta t o r a n d t he fr a me . If a re a d in g sh o w s
continuity, a new stator must be installed.

4008-11
Testing the Rectifier Bridge Inspection and Replacement of the

Bearings
STEP 36
STEP 38
B9064402M
Touch the leads of the ohmmeter to a positive diode B8971402M

and the heat sink as shown. Then reverse the leads. Inspect the bearings on the rotor. If the bearings are
There must be a high reading and a low or zero damaged, use the following procedure to replace the
reading. Then test the other two positive diodes. If a bearings.
positive diode did not have readings as specified, the
positive diode is bad and a new rectifier bridge must
be installed.
STEP 37
B8971426M
1. Use a suitable support between the front bearing

and the bearing retainer on the rotor shaft and
press the rotor shaft out of the front bearing and
the spacer.
B9064332M
Touch the leads of the ohmmeter to a negative diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero
reading. Then test the other two negative diodes. If a
negative diode did not have readings as specified,
the negative diode is bad and a new rectifier bridge
must be installed.
NOTE: If the tester you are using has a diode test
function, use the tester according to the instructions
of the manufacturer to check the positive and
negative diodes.
B8971429M
2. Remove the bearing retainer.

4008-12
B8971432M B8971504M
3. Use a suitable support between the rear bearing 6. Press the spacer onto the rotor shaft until the
and the slip ring on the other end of the rotor spacer stops moving.
shaft and press the rotor shaft out of the rear
bearing.
B8971505M
7. Press the new rear bearing onto the other end of

B8971429M the rotor shaft.
4. Install the bearing retainer on the rotor shaft.
B8971435M
5. Press the new front bearing onto the rotor shaft

until the front bearing stops moving.

4008-13
18
20
21
23 22
24 22
23
16
24 22
17
23 19
9
21 10
11
23
26 12
27 13
7
7 15 14
1
2
3
5
6
8
4
BS01B125
1. NUT 8. COVER 15. STATOR 22. FLAT WASHER

2. WASHER 9. SPACER 16. SCREW 23. NUT
3. RETAINER 10. FRONT BEARING 17. RECTIFIER BRIDGE 24. LOCK WASHER
4. SCREW 11. BEARING RETAINER 18. INSULATOR 25. BRUSH
5. PULLEY 12. KEY 19. SHIELD 26. VOLTAGE REGULATOR
6. FAN 13. ROTOR 20. HOUSING AND BRUSH HOLDER
7. SCREW 14. REAR BEARING 21. FIBER WASHER 27. CAPACITOR
45 AMPERE ALTERNATOR

4008-14
Assembly STEP 42
STEP 39
B8971601M
Install the housing on the rectifier bridge.

B8971316M
Install a new shield in the housing. STEP 43
STEP 40
B8971304M
1. SCREWS
B8971313M
Install and tighten the screws that fasten the rectifier
Install the insulator on the D+ terminal.
bridge to the housing.
STEP 41 STEP 44
B8971310M
B8971604M
Install the insulator on the B+ terminal.
Install the fiber washers, flat washer, and nut on the
B+ terminal.

4008-15
STEP 45 STEP 48
B8971607M B8971301M
Check for a short circuit between the terminal and Install the rotor in the cover.
the housing. If there is continuity, the insulator is bad.
STEP 49
STEP 46
B8971508M
B8971610M Install and tighten the screws that fasten the bearing
Install the fiber washers, flat washer, and nut on the retainer and rotor to the cover.
D+ terminal.
STEP 50
STEP 47
B8971231M
B8971613M Make sure the marks are in alignment and install the
Check for a short circuit between the terminal and cover and rotor in the stator and housing.
the housing. If there is continuity, the insulator is bad.

4008-16
STEP 51 STEP 54
B8971222M B8971622M
Install and tighten the screws evenly that fasten the Install the voltage regulator and the brush holder. Be
housing, stator, and cover. careful not to damage the brushes.
STEP 52 STEP 55
B8971616M B8971625M
Install the capacitor and tighten the screw. Install the screws and flat washers and tighten the
screws.
STEP 53
STEP 56
B8971619M
Connect the lead to the terminal. B523413M
Install the fan.

4008-17
STEP 57 STEP 59
B523418M B518009M
Install the pulley and the retainer. Fasten the pulley in a vise with soft jaws. Tighten the
nut to a torque of 60 to 73 Nm (45 to 54 pound-feet).
STEP 58
B523407M
Install the washer and start the nut onto the shaft.

4008-18
NOTES

SECTION INDEX
STEERING
Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001

Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5003
Steering Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5004
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005
Center Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006
Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5008
CASE CORPORATION
700 State Street
5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING

COMPONENTS
CASE CORPORATION
700 State Street
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5001-3
NOTES

5001-4
STEERING CONTROL VALVE
1. Remove the left, right, and front cab skirts, 1. Put the seals (8) and base plate (11) in position
located under the cab or canopy. on the steering control valve (5). Install the bolts
(9) and lock washers (10) that fasten the base
2. Remove all dirt and grease from the steering
plate (11) to the steering control valve (5). Refer
co ntr ol v alve ( 5) a nd th e ar ea a ro un d th e
to the illustration on page 5.
steering control valve (5), refer to the illustration
on page 5. 2. Put the base plate (11) and steering control valve
(5) assembly in position on the bottom of the
3. Remove the fill cap for the hydraulic reservoir.
pedestal (12). Make sure that the notch in the
4. Fasten identification tags to the hoses at the steering column shaft (6) on the steering control
steering control valve (5). valve (5) is aligned with the hole in the coupling
(2).
5. Disconnect the hoses from the fittings in the
steering control valve (5). 3. Install the bolts (7), washers (3), and steering
isolator mounts (4) that fasten the base plate
6. Cap or plug the fittings and hoses.
(10) and steering control valve (5) assembly to
7. Turn the steering wheel as required for access to the bottom of the pedestal (12).
the cap screw (1) that holds the steering column
4. Turn the steering wheel as required for access to
shaft (6) of the steering control valve (5) in the
the hole for the cap screw (1) that holds the
coupling (2).
steering column shaft (6) of the steering control
8. Remove the cap screw (1) that holds the steering valve (5) in the coupling (2).
column shaft (6) of the steering control valve (5)
5. Install the cap screw (1) that holds the steering
in the coupling (2).
column shaft (6) of the steering control valve (5)
9. Hold the steering control valve (5) in position and in the coupling (2).
remove the bolts (7), washers (3), and steering
6. Connect the hoses to the fittings in the steering
isolator mounts (4) that fasten the base plate
control valve (5).
(11) and steering control valve (5) to the bottom
of the pedestal (12). 7. Install the fill cap on the hydraulic reservoir.
10. Remove the steering control valve (5) and base 8. Start the engine and turn the machine all the way
plate (11) from the machine. to the left and right several times to remove any
air in the circuits.
11. Remove the bolts (9) and lock washers (10) that
fasten the base plate (11) to the steering control 9. Stop the engine and check for leaks.
valve (5).
10. Check the fluid level in the hydraulic reservoir.
12. Remove the base plate (11) and seals (8) from Add oil as re qu ir ed. S ee Section 10 02 for
the steering control valve (5). specifications.

5001-5
12
2
10
8
4
4
4
11
3
8
4
3
7
7 6
BS01C107
1. CAP SCREW 4. STEERING ISOLATOR MOUNT 7. BOLT 10. LOCK WASHER

2. COUPLING 5. STEERING CONTROL VALVE 8. SEAL 11. BASE PLATE
3. WASHER 6. STEERING COLUMN SHAFT 9. BOLT 12. PEDESTAL
STEERING CONTROL VALVE ILLUSTRATION

5001-6
PRIORITY VALVE
1. Remove all dirt and grease from the priority valve 1. Start the vacuum pump.
(3) and the area around the priority valve (3),
2. Install the bolt (8), washer (6), and lock nut (7), to
refer to the illustration on page 7.
fasten the priority valve (3) to the bracket (4).
2. Remove the fill cap for the hydraulic reservoir. Refer to the illustration on page 7.
3. Connect a vacuum pump to the hydraulic 3. Connect the hose (1) to the elbow in the side of
reservoir. the priority valve (3).
4. Start the vacuum pump. 4. Connect the hose (10) to the elbow in the side of
the priority valve (3).
5. Tag and disconnect the hose (9) from the priority
valve (3). 5. Connect the hose (5) to the top of the priority
valve (3).
6. Plug the hose (9).
6. Connect the hose (2) to the top of the priority
valve (3).
valve (3).
7. Connect the hose (9) to the bottom of the priority
valve (3).
8. Stop the vacuum pump.
valve (3).
9. Disconnect the vacuum pump from the hydraulic
reservoir.
11. Tag and disconnect the hose (10) from the
10. Install the fill cap on the hydraulic reservoir.
priority valve (3).
11. Start the engine and run at low idle for 30
seconds. Stop the engine and check for leaks.
12. Check to make sure the priority valve works
valve (3).
correctly. See Section 5002.
13. Check the fluid level in the hydraulic reservoir.
15. Loosen and remove the locknut (7), washer (6) Add oil as re qu ir ed. S ee Section 10 02 for
and bolt (8) which fasten the priority valve (3) to specifications.
the bracket (4).
16. Stop the vacuum pump.

5001-7
1
8 10
7
6
4
3
9 4
11
13
14
12
17
15 16 18
BS01C105
1. HOSE 7. LOCKNUT 13. AUXILIARY STEERING PRESSURE FITTING

2. HOSE 8. BOLT 14. HOSE TO LOADER CONTROL VALVE
3. PRIORITY VALVE 9. HOSE 15. HOSE TO PRIORITY VALVE
4. BRACKET 10. HOSE 16. HOSE TO PRIORITY VALVE
5. HOSE 11. STEERING CONTROL VALVE 17. HOSE TO PRIORITY VALVE
6. WASHER 12. SOLENOID VALVE 18. HOSE TO LOADER CONTROL VALVE
PRIORITY VALVE ILLUSTRATION

5001-8
AUXILIARY STEERING PUMP AND MOTOR
1. Remove the fill cap for the hydraulic reservoir. 1. Install the auxiliary steering pump and motor (2).
Install the nuts (4), bolts (5) and flat washers.
2. Connect a vacuum pump to the hydraulic
Tighten the bolts. Refer to the illustration on
reservoir.
page 9.
3. Start the vacuum pump.
4. Tag and disconnect the hose (1) from the fitting
3. Connect the hose (1) to the fitting (9) on the
(9) on the auxiliary steering pump and motor (2)
auxiliary steering pump and motor (2).
and in sta ll a plu g in the h ose, refer to th e
illustration on page 9. 4. Connect the hose (3) to the elbow (8) on the
auxiliary steering pump and motor (2).
5. Tag and disconnect the hose (3) from the elbow
(8) on the auxiliary steering pump and motor (2) 5. Stop the vacuum pump. Install the fill cap in the
and install a plug in the hose (3). hydraulic reservoir.
6. Stop the vacuum pump. 6. Connect the ground wire to the rear chassis (7).
7. Turn the master disconnect switch to the OFF 7. Connect the electrical wires to the auxiliary
position. steering pump and motor (2).
8. Tag and disconnect the electrical wires from the 8. Place the master disconnect switch in the ON
auxiliary steering pump and motor (2). position.
9. Tag and disconnect the ground wire from the 9. Start and run the engine at low idle, loosen the
rear chassis (7). hose at the pressure switch to bleed out air in the
line.
10. Remove the nuts (4), bolts (5) and washers (6)
that hold the auxiliary steering pump and motor 10. Stop the engine.
(2).
11. Disconnect the wire from the fuel shutoff
11. Remove the auxiliary steering pump and motor solenoid on the fuel injection pump.
(2).
12. Actuate the starter for 3 to 5 seconds to actuate
the auxiliary steering pump and motor.
13. Turn the steering wheel all the way to the left and
to the right to make su re that the auxiliary
steering pump and motor works correctly. Turn
the key switch to OFF.
14. Connect the wire to the fuel shutoff solenoid.

5001-9
5
6 7
4
5
6
1
4
2
8
3
BS01C106
1. HOSE 4. NUT 7. REAR CHASSIS

2. AUXILIARY STEERING PUMP AND MOTOR 5. BOLT 8. ELBOW
3. HOSE 6. WASHER 9. FITTING
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

5001-10
STEERING CYLINDER
1. Loosen the fill cap for the hydraulic reservoir to 1. Put the steering cylinder (1) into position in the
release pressure in the reservoir, then tighten the machine. Make sure that the washer (15) is
fill cap. installed between the steering cylinder (1) and
the rear frame. Refer to the illustration on page
2. Disconnect the hoses (13,14,16 and 17) for the
11.
steering cylinder (1), refer to the illustration on
page 11. NOTE: Use a washer (15) on top and bottom of the
steering cylinder (1) if possible. If only one washer
3. Install plugs in hoses 16 and 17.
(15) is used, place the washer (15) on the bottom of
4. Remove the grease hose (11) from the tube end the steering cylinder (1).
of the steering cylinder (1).
2. Make sure the washers (6) are in position
5. Loosen and remove the locknut (4) that holds the between the steering cylinder (1) and the front
pin (2) to the steering cylinder (1). frame of the machine.
6. Remove the bolt (3). 3. Install the pivot pin (7) to fasten the rear of the
steering cylinder (1) to the machine frame. Install
7. Remove the pin (2).
the spacer (10), washer (9) and bolt (8) to fasten
8. Remove the washers (6). the pivot pin (7).
9. Remove the bolt (8), washer (9) and spacer (10) 4. Tighten the bolt (8).
that hold the pivot pin (7) at the rear of the
5. Install the pin (2) in the front of the steering
steering cylinder (1).
cylinder (1). Make sure that the washers (6) are
10. Use an acceptable driver and drive the pivot pin in the correct position.
(7) out of the steering cylinder (1).
6. Install the bolt (3) and locknut (4) in the steering
11. Remove the washer(s) (15) from between the cylinder (1) and pin (2). Tighten the locknut (4).
steering cylinder (1) and the rear frame of the
NOTE: The bolt (3) should turn freely in the hole
machine.
after tightening.
12. Remove the steering cylinder (1).
7. Connect the hoses (13,14,16 and 17) to the
hydraulic cylinders.
8. Connect the grease hose (11) to the base end of
the steering cylinder (1).
9. Tighten the fill cap for the hydraulic reservoir.
10. Start the engine.
11. Turn the steering wheel all the way to the right
and then to the left several times.
12. Stop the engine. Check the hydraulic oil level.
See Section 1002 for specifications.

5001-11
8
9
7 10
13 15
8
14
15 1
9
11 3
13 14
10
7 6
16
12
15
12 17 4
4 5 2
18
6 3
2
5
BS01G020
1. STEERING CYLINDER 7. PIVOT PIN 13. HOSE

2. PIN 8. BOLT 14. HOSE
3. BOLT 9. WASHER 15. WASHER
4. LOCKNUT 10. SPACER 16. HOSE
5. GREASE FITTING 11. GREASE HOSE 17. HOSE
6. WASHER 12. TEE FITTING 18. STEERING CONTROL VALVE
STEERING CYLINDER ILLUSTRATION

5001-12
NOTES

5002
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS, AND

TROUBLESHOOTING
CASE CORPORATION
700 State Street
5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNDERSTANDING THE RESULTS OF THE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Auxiliary steering pump
Minimum flow ............................................................................................. 24 .6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
Steering relief valve
Pressure setting .................................................................................................239 to 243 bar (3465 to 3523 psi)
Location of steering relief valve......................................................................................in the loader control valve

5002-3
SPECIAL TOOLS
B785789 B009638
OEM-1239 (CAS-10280) FLOWMETER CAS-1804 PRESSURE TEST FITTING KIT
B797157
CAS-1808 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included 3. Do the main hydraulic pump test. See Section
in the hydraulic schematic. Refer to the rear pocket of 8002. If the main pump is bad, repair or replace
this manual. the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir 4. Test the steering cylinders for leakage, refer to
is correct. Visually inspect the steering system instructions on page 10. If a steering cylinder is
for leakage and damage. leaking, repair or replace the steering cylinder.
2. Do the steering relief valve pressure test. Refer
to page 7. If the pressure is above or below
specifications, adjust the steering relief valve in
the loader control valve.

5002-4
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
1. CAS- 10280 Flowmeter
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1
BB830300
1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as
1 in illustration above.
7. Make sure that the parking brake is applied and
the bucket is on the floor.
BD00M030
8. Make sure that the oil is at operating
1. ARTICULATION LOCK temperature.
1. Install articulation lock. 9. Make sure that the load valve for the flowmeter is
open (zero pressure).
NOTE: When performing this pressure check,
always be sure the articulation lock is in place, 10. Start and run the engine.
especially when working in the articulation joint 11. Stop the engine and turn the key back to the On
areas. position.
2. Loosen and remove the outlet hose of the 12. Turn the steering wheel, this will activate the
Auxiliary Steering Pump from the Steering auxiliary steering pump.
Priority Valve.
13. Turn the load valve on the flowmeter towards
3. Install a plug into the hose. CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet 14. Read the flowmeter and ammeter gauges and
fitting on the Steering Priority Valve. record the readings.
5. Install the outlet hose of the flowmeter in the 15. The flowmeter reading must not be less than
hydraulic reservoir and hold in place with wire. 24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.

5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST
Test Equipment
1. A 24 volt battery that is fully charged. 2
1
NOTE: A 24 volt battery system (two 12 volt
batteries in a series) is used for this test. A 12 volt
battery system will cause damage to the auxiliary 4
steering motor. 3
2. A remote starter switch.
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
5
System Tester.
B790852
Test Procedure 1. REMOTE STARTER SWITCH
1. Remove the connector that is between the 2. TESTER
3. AUXILIARY STEERING MOTOR
te rmin als o n the m ag n e tic sw itch a n d th e
4. AMMETER CLAMP
auxiliary steering motor.
5. 24 VOLT BATTERY SYSTEM
2. Remove the auxiliary steering motor from the
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt 8
6 7
battery system (5) as illustrated in Figure 3.
5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
6. Turn the load control (8) until the voltmeter (7)
indicates 24 volts. Refer to figure 4. Look at the
ammeter (6) in the tester. Make a record of the
ammeter indication. B795328
7. Hold the tachometer against the armature shaft. 6. AMMETER

7. VOLTMETER
Look at the tachometer. Make a record of the
8. LOAD CONTROL
indication.
8. Release the button on the remote starter switch
(1).

5002-6
UNDERSTANDING THE RESULTS OF THE TEST

1. If the ammeter indication in step 6 was 30 4. If the armature did not turn, and the ammeter
amperes or less and the tachometer indication in indication was zero amperes, possible causes
ste p 7 wa s 6 9 50 r /min ( rp m) or mo re , th e include the following:
auxiliary steering motor is good.
A. An open field coil.
2. If the armature speed was less than 6950 r/min
B. An open armature coil. After the motor is
(rpm) and the ammeter indication was higher
disassembled, look at the commutator on the
than 30 amperes, possible causes include the
armature. If the commutator is badly burned,
following:
the armature coil is probably open.
A. Damaged bearings.
C. Broken brush springs or worn brush springs.
B. Loose pole shoes.
5. If the armature speed was less than 6950 r/min
C. A short circuit in the armature coil. The (rpm) and the ammeter indication was less than
arm at ure coil m ust be c hec ked on an 3 0 a mp e r e s, p o ss ib le c a us e s in clu d e t h e
armature tester after the motor is following:
disassembled.
A. Bad connections between the brushes and the
D. A ground connection in the field coil. field coil.
3. If the armature did not turn and the ammeter B. Dirty commutator.
indication was higher than 30 amperes, possible
6. If the armature speed was 6950 r/min (rpm) or
causes include the following:
more and the ammeter indication was more than
A. The motor terminal is in contact with the field 30 amperes, there is probably a short circuit in
frame. the field coil. A short circuit in the field coil is
difficult to find. It is recommended that a new
B. A damaged bearing that will not let the
field frame assembly be installed.
armature turn.

5002-7
STEERING RELIEF VALVE

NOTE: The pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002
Testing and Adjusting the Pump Differential Pressure.
Pressure Setting Test
1
1
BD00M048
1. SAFETY LINK
BD00M048
1. SAFETY LINK
3. Remove the safety link (1) and lower the loader
arms to the ground.
1. Install the safety link (1) and lower the loader
arms slowly, until the safety link is supporting the 4. Stop the engine.
loader arms.
1
BD00M030
BD00M041 1. ARTICULATION LOCK

1. COVER PLATE
5. Install articulation lock (1).
2. Remove the cover plate (1) to gain access to the IMPORTANT: When performing the following
loader control valve. pressure check and adjustment, the articulation lock
must be installed. Use caution when working in or
near the articulation area.

5002-8
6. Make sure that the temperature of the hydraulic
oil is at least 52° C (125° F).
7. To measure the temperature of the oil using the
instrument panel:
A. Press the program switch (left side of the
program/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
1
position.
2
9. Start and run the engine at full throttle. BD00N018
10. Lower the lift arms and hold the control lever in 1. LOADER CONTROL VALVE
the FLOAT position. 2. PUMP PRESSURE TEST PORT
11. Hold the bucket control lever in the rollback 15. Remove the dust cap from the test port (2).
position. 16. Connect a 345 bar (5000 psi) pressure gauge to
12. Continue holding until the specified temperature the test port (2) on the front of the loader control
of the oil is reached. valve (1).
13. Stop the engine. NOTE: Make sure when you connect the pressure
gauge that you do so in a manner that you can read
14. Remove the cap on the hydraulic reservoir to the pressure gauge while sitting in the operators
release any pressure in the hydraulic system. seat.
17. Start the engine and operate the machine at full
throttle.
18. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
19. Continue holding the steering wheel, and read
the pressure gauge.
20. The pressure gauge must indicate 239 to 243
bar (3465 to 3523 psi). If the pressure is not
correct, adjust the steering relief valve.

5002-9
Pressure Setting Adjustment
1
1
BD00M048
1. SAFETY LINK
BD00M048
1. SAFETY LINK
3. Remove the safety link (1), and lower the loader
arms to the ground.
1. Install the safety link (1) before adjusting the
steering relief valve. 4. If the pressure gauge is still connected, repeat
steps 17 through 20 in the Pressure Setting Test
Proc edure. If the pressure gauge is not
connected, do the entire Pressure Setting Test
Procedure.
5. If necessary, adjust the relief valve again until the
relief valve is within the specified range.
6. Stop the engine before removing the pressure
gauge.
BS01A046
1. LOADER CONTROL VALVE

2. STEERING RELIEF VALVE
2. Turn the adjusting screw clockwise to increase

the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.
NOTE: 1/4 turn of the adjusting screw will change
the pressure by approximately 35 bar (500 psi).

5002-10
STEERING CYLINDER LEAK TEST

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

Section
5003
5003
CASE CORPORATION
700 State Street
5003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 6

5003-3
SPECIFICATIONS
Manufacturer ..................................................................................................................................................... Eaton
Special Torques
Cap screws for end cap ............................................................................................ 33.9 NM (300 pound-inches)
SPECIAL TOOLS
Retaining ring pliers.......................................................................................................... Eaton part number 600610
Splined shaft end tool, #600604 ........................................................................................... Eaton part number 8063
Order Special Tools from:

Eaton Corporation, Hydraulics Division, 15151 Highway 5, Eden Prairie, MN 55344
Disassembly
1. Clean the port area of the steering control valve 7. Hold the gerotor star and drive shaft (6), with
housing before disconnecting the hydraulic lines. your hand. Protect both the gerotor star and
hand with a shop towel while turning.
2. Drain the oil, and plug the ports. Clean the
exterior of the steering control valve housing. 8. Turn the tool clockwise or counter-clockwise to
Protect the machines surfaces during repair. compress the centering spring (12).
3. Put the steering control valve in a vise so that the 9. Hold the drive shaft (6) stationary.
end cap (2) is up, refer to Figure 1.
10. Remove the centering spring (12), spool (9) and
sleeve (8), ball checks (10), pin (11), drive shaft
(6), bearing race (14), retaining ring (18) and
needle thrust bearing (13). Use retaining ring
3 pliers. (See Special Tools).
11. Remove the back-up washer (15), seal ring (16),
2 and O-ring (17).
12. Carefully pry the dust seal (19) from the steering
control valve housing (7), using a small blade
screwdriver. Do not damage the dust seal (19).
NOTE: If the steering control valve housing (7) has
anti-cavitation valves, find the anti-cavitation valves
1 in the steering control valve housing (7).
GS98K501 13. To disassemble these valves, insert soda straws

(3) in each end of the threaded holes, refer to
1. VISE 3. ANTI-CAVITATION
2. END CAP VALVES Figure 3. Remove the steering control valve
housing from the vise and tilt it until the port face
FIGURE 1. STEERING CONTROL VALVE-END CAP UP
(4) is upward. Continue turning until the roll pins
4. Remove the seven cap screws (1), end cap (2), (2) and ball checks (1) slide through the straws
O-ring (3), gerotor (4), O-ring (3), spacer plate (3).
(5), and O-ring (3), refer to Figure 2.
5. Remove the gerotor star from gerotor (4).
6. Using a splined shaft end no. 8063 tool (refer to
Special Tools), start the tool on the splined end
of the spool (9).

5003-4
14
18 13
14
16 7
17
15
19
6
8 10
11
1
2 9
10
12
3
4
21
3
5
20 3
GS98K502
1. CAP SCREW 8. SLEEVE 15. BACKUP WASHER

2. END CAP 9. SPOOL 16. SEAL RING
3. O-RING 10. BALL CHECK 17. O-RING
4. GEROTOR 11. PIN 18. RETAINING RING
5. SPACER PLATE 12. CENTERING SPRING 19. DUST SEAL
6. DRIVE SHAFT 13. NEEDLE THRUST BEARING 20. BALL CHECK
7. STEERING CONTROL HOUSING 14. BEARING RACE 21. ROLL PIN
FIGURE 2. STEERING CONTROL VALVE - EXPLODED VIEW

5003-5
3
4
5
2
3
GS98K530
1. BALL CHECK 4. PORT FACE

2. ROLL PIN 5. ANTI-CAVITATION VALVES
3. SODA STRAW
FIGURE 3. ANTI-CAVITATION VALVE - DISASSEMBLY
Inspection 3. If the spool (9) and sleeve (8) or the bore in the
housing of the steering control valve (7) is
1. Clean all parts in cleaning solvent and air dry on damaged or worn, use a new steering control
paper towels. Do not use cloths to wipe parts dry, valve.
as it may leave lint on the parts.
4. Inspect the cap screws (1), pin (11), ball check
2. Check all machined surfaces for wear or (10), backup washer (15), seal ring (16), O-ring
damage. If there are rough places on the ends of (17), needle thrust bearing (13) and bearing race
the gerotor star or gerotor (4), steering control (14). Use new parts as required.
valve housing (7), end cap (2), or spacer plate
(5), use 600 grit emery cloth to smooth the 5. If your steering control valve has anti-cavitation
surfaces, refer to Figure 2. Place the emery cloth valves, inspect the ball checks (20) and roll pins
on a flat surface. If the emery cloth is new, rub a (21) for damage or wear. Use new parts as
piece of steel across the emery cloth six times to required.
remove the sharp pieces of grit. Make sure that
the part is held flat on the emery cloth. Rub each
part across the cloth six times. Check to see if
the rough places are removed. Use this method
until all rough places are removed. Clean the
parts in cleaning solvent to remove any grit.

5003-6
Assembly 3. Lubricate the spool (3) with clean hydraulic fluid

and slide it into the sleeve (2), along with the ball
NOTE: Use new seals (3), (16), and (19) when check (5), refer to Figure 5.
reassembling the steering control valve.
4. Install the drive shaft (1) and pin (4).
IMPORTANT: Lubricate the new seals with a
petroleum jelly. Lubricate machined surfaces with 5. Install the centering spring (6). Position one end
clean hydraulic fluid. of the centering spring (6) in slotted end of spool
(3) and sleeve (2). Compress the centering
1. Use a soda straw (3) as a guide tool, refer to spring (6) by turning it counter-clockwise to
Figu re 4. Drop the stra w (3) in to th e engage the free end of the spring.
anti-cavitation valve (5) to the bottom of the bore.
Drop the ball check (2) through the straw (3). Pull 6. Install the bearing race (8) and retaining ring (7),
the straw (3) out and use the same procedure in onto the spool (3), using retaining ring pliers.
the second ball seat. 7. Lubricate, using petroleum jelly, the ID of the
dust seal (19) that is mounted in the steering
control valve housing (7), refer to Figure 2.
2 8. Lubricate, using petroleum jelly, the needle thrust
bearing (13), second bearing race (14), backup
3 washer (15), seal ring (16) and O-ring (17).
1 Position each part onto the spool (9). The needle
th ru st b ea rin g (1 3) g oe s b e twe e n t he tw o
4 bearing races (14), and must be centered around
the retaining ring (18).
9. Lubricate, using clean hydraulic fluid, the spool
(9) and sleeve (8) assembly and slide it into the
steering control valve housing (7), as follows:
IMPORTANT: Do not damage the dust or shaft seals.
A. Protecting the gerotor star and hand with shop
towels, hold the gerotor star and splined end
of drive shaft (6) to keep it from turning.
5 B. Insert the splined shaft end No. 8063 (see
Special Tools this section), into the steering
control valve housing (7), and start it onto the
GS98K504 splined end of the spool (9). Turn the tool
1. ROLL PIN 4. PORT FACE clockwise or counter-clockwise to compress
2. BALL CHECK 5. ANTI-CAVITATION the centering spring (12).
3. SODA STRAW VALVES
NOTE: If the unit is positioned horizontally, keep the
FIGURE 4. OPTIONAL ANTI-CAVITATION VALVES ASSEMBLY
pin horizontal. If the tension on the pin is released
2. Use a small light and check each bore to make before the assembly is fully engaged, the pin can
sure each ball check (2) is in the correct place. drop and lockup can occur if the pin is not horizontal.
Add the roll pin (1) in each.

5003-7
5
1
5 3
2
1
6 6
8
7
2 6 8
1 7
4 3
5
GS98K505
1. DRIVE SHAFT 5. BALL CHECK

2. SLEEVE 6. CENTERING SPRING
3. SPOOL 7. RETAINING RING
4. PIN 8. BEARING RACE
FIGURE 5. SPOOL AND SLEEVE ASSEMBLY

5003-8
10. Compressing the centering spring (12), carefully 15. Install the spacer plate (5), O-ring (3), and align
in se r t th e a s se m b le d b e a r in g r a c e s ( 1 4 ), th e h o le s in th e sp a ce r p la te (5 ) w ith th e
retaining ring (18), needle thrust bearing (13), threaded holes in the housing (7).
backup washer (15), seal ring (16) and O-ring
16. Lubricate a new O-ring (3) and install into the
(17).
groove of the spacer plate (5).
11. Release the centering spring (12) tension.
17. Install the gerotor (4) and align the screw holes.
12. Remove the gerotor star.
18. Lubricate a new O-ring (3) and install into the
13. Remove the splined shaft end No. 8063 tool. groove in the gerotor ring (4).
14. Lubricate new O-rings (3) and install in the 19. Install the end cap (2) and seven cap screws (1).
groove of the steering control valve housing (7). Pre-tighten the cap screws in a criss-cross
pattern to 17 Nm (150 pound-inch), and finally, in
a criss-cross pattern, tighten cap screws (1) to
33 .9 N m (3 0 0 po u nd -in ch ). Se e SP ECIA L
TORQUES in this section.

Section
5004
5004
STEERING PRIORITY VALVE
CASE CORPORATION
700 State Street
5004-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ....... 2
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
SPECIAL TORQUES
Spool Orifice Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 to 9.6 Nm (65 to 85 lb-inch).
Plugs and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 to 54.2 Nm (25 to 40 lb-ft).
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 to 9.5 Nm (72 to 84 lb-inch).

5004-3
STEERING PRIORITY VALVE
Disassembly STEP 4
Remove plug (5). Remove and discard O-ring (6)
STEP 1 from plug.
Put the steering priority valve in a soft jawed vise.
STEP 5
STEP 2 Remove spring (7).
Remove adapter (1). Remove and discard O-ring (2)
from adapter. STEP 6
Remove spool (8).
STEP 3
Remove relief valve (3). Remove and discard O-ring STEP 7
(4) from relief valve. Remove plug (9). Remove and discard O-ring (10)
from plug.
3 4 11
1 2
10 9
7 8
BS01E129
1. ADAPTER 7. SPRING
2. O-RING 8. SPOOL
3. RELIEF VALVE 9. PLUG
4. O-RING 10. O-RING
5. PLUG 11. HOUSING
6. O-RING

5004-4
Cleaning and Inspection Assembly

STEP 8 STEP 12
Clean all parts in cleaning solvent. Immerse housing Install new O-ring (10) on plug (9). Install plug and
(11) in cleaning solvent and agitate cleaning solvent. O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
WEAR EYE PROTECTION WHEN USING (25 to 40 lb-ft).
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of valve housing and to STEP 13
ensure that all orifices and bores are clear. Install spool (8) and spring (7),
STEP 9 STEP 14
Insp ect spo ol (8) a nd ho using b ore s for d ee p Install new O-ring (6) on plug (5). Install plug and
scratches, gouges, and other damage. Replace O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
steering priority valve if any of these conditions are (25 to 40 lb-ft).
seen.
STEP 15
STEP 10
Install new O-ring (4) on relief valve (3). Install relief
Check that orifice screws in each end of spool (8) are valve and O-ring. Tighten relief valve to a torque of
fr e e a n d c le a r o f fo r e ig n m a tt e r. W E AR EY E 33.9 to 54.2 Nm (25 to 40 lb-ft).
PROTECTION WHEN USING COMPRESSED AIR.
If n e c e ss a r y, r e m o ve o ri fic e s c re w s a n d u s e
STEP 16
compressed air to remove foreign matter from interior
of spool (8) and orifice screws. Install orifice screws Install new O-ring (2) on adapter (1). Install adapter
in spool (8) ends. Tighten screws to a torque of 7.3 to and O-ring. Tighten adapter to a torque of 8.1 to 9.5
9.6 Nm (65 to 85 lb-inch). Nm (72 to 84 lb-inch).
STEP 11
Check spring (7) for cracks, breaks, or signs of
permanent set. Replace if any of these conditions are
seen.
3 4 11
1 2
10 9
7 8
BS01E129
1. ADAPTER 4. O-RING 7. SPRING 10. O-RING

2. O-RING 5. PLUG 8. SPOOL 11. HOUSING
3. RELIEF VALVE 6. O-RING 9. PLUG

Section
5005
STEERING CYLINDERS
5005
CASE CORPORATION
700 State Street
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 5

5005-3
SPECIFICATIONS
Torque for piston cap screw...........................................................................585 to 720 Nm (431 to 531 pound-feet)
Torque for gland.............................................................................................339 to 475 Nm (250 to 350 pound-feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten the tube (1) in a vise. Be careful not to 1. Discard the O-ring (6), backup ring (7), seal (4),
damage the tube (1). Refer to the illustration on seal (5), wiper (9), and guide (8) from the gland
page 4. (3). Refer to the illustration on page 4.
2. Loosen and remove the gland (3) from the tube 2. Discard the seal (12), backup ring (13), and wear
(1). ring (14) that were removed from the piston (11).
3. Pull the piston (11) straight out of the tube (1). 3. Clean all parts in cleaning solvent.
4. Fasten the yoke on the piston rod (10) in the vise 4. Check to be sure that the piston rod (10) is
and put a support below the piston rod (10) near straight. If the piston rod (10) is bent, install a
the piston (11). Use a shop cloth between the new piston rod (10).
suppo rt and the pisto n rod (10) to prevent
5. Inspect the inside of the tube (1) for deep
damage to the piston rod (10).
grooves and other damage . If there is any
5. Loosen and remove the bolt (15) and hardened damage to the tube (1), a new tube (1) must be
washer (16) that hold the piston (11). used.
6. Remove the piston (11) from the piston rod (10). 6. Remove small scratches on the piston rod (10) or
inside the tube (1) with emery cloth of medium
7. Remove the seal (12), backup ring (13), and
grit. Use the emery cloth with a rotary motion.
wear ring (14) from the piston (11).
7. Inspect the bushings (2) and replace as required.
8. Remove the gland (3) from the piston rod (10).
9. Remove the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland
(3).

5005-4
10
9
4
5
3
7
6
8
14
11
12
13
16
15
1
17
BS01B202
1. TUBE 7. BACKUP RING 13. BACKUP RING

2. BUSHING 8. GUIDE 14. WEAR RING
3. GLAND 9. WIPER 15. BOLT
4. SEAL 10. PISTON ROD 16. HARDENED WASHER
5. SEAL 11. PISTON 17. GREASE FITTING
6. O-RING 12. SEAL
STEERING CYLINDER ILLUSTRATION

5005-5
Assembly 12. Install a new backup ring (13) on the piston (11).
1. Install the seal (4) in the gland (3). The seal (4) 13. Install a new seal (12) over the backup ring (13).
must be installed so that the lips of the seal (4) 14. Clean the threads on the end of the piston rod
are toward the small end of the gland (3). The (10) and the threads of the bolt (15) using Loctite
seal (4) can be difficult to install. Use tools that cleaning solvent. Allow to dry. Apply Loctite 242
will n o t da ma ge th e s ea l (4 ). R efe r to th e to the piston rod threads 1/4 inch from the open
illustration on page 4. end of the piston rod so that there is 1/2 inch of
2. Install the seal (5) in the gland (3). Loctite 242 on the piston rod threads. DO NOT
apply Loctite to the first 1/4 inch of the piston rod
3. Install the guide (8) in the gland (3). threads.
4. Install the wiper (9) in the gland (3). 15. Install the bolt (15) and hardened washer (16) in
5. Install the O-ring (6) on the gland (3). The O-ring the piston (11).
(6) must be toward the small end of the gland (3). 16. Install the piston (11) on the piston rod (10) and
6. Install the backup ring (7) on the gland (3). The start the bolt (15) into the piston rod (10).
backup ring (7) must be toward the large end of 17. Tighten the bolt (15) according to torque
the gland (3). If the backup ring (7) is not flat on specifications listed on page 2.
both sides, the side that is not flat must be
toward the O-ring (6). 18. Fasten the tube (1) in the vise. Be careful not to
damage the tube (1).
7. Fasten the yoke on the piston rod (10) in the vise.
19. Apply petroleum jelly to the O-ring (6) and
8. Lubricate the piston rod (10) and the bore in the backup ring (7) on the gland (3) and to the
gland (3) with clean hydraulic oil. sealing surface in the tube (1).
NOTE: If a new gland (3) is being installed, write the 20. Lubricate the piston (11) and the inside of the
part number of the cylinder on the gland (3). tube (1) with clean hydraulic oil.
9. Push the gland (3) onto the piston rod (10). If 21. Push the piston (11) straight into the tube (1). Be
necessary, use a soft hammer to drive the gland careful not to damage the wear ring (14) and seal
(3) onto the piston rod (10). (12) on the piston (11).
10. Put the support below and near the end of the 22. When the piston (11) is in the smooth part of the
piston rod (10). Put a cloth between the support tube (1), start the gland (3) into the tube (1).
and the piston rod (10) to prevent damage to the
piston rod (10). 23. Tighten the gland (3) to 339 to 475 Nm (250 to
350 pound-feet).
11. Install a new wear ring (14) on the piston (11).

5005-6
NOTES

Section
5006
CENTER PIVOT
5006
CASE CORPORATION
700 State Street
5006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin.......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for the lower pin plate .......................................................................................124 Nm (91 pound-feet)
M12 bolts screws for the lower pin plate .....................................................128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals .......................................................................................... Case IH molydisulfide grease
Steering cylinder rod eyes........................................................................................ Case IH molydisulfide grease
FLUIDS
Hydraulic system reservoir ..............................................................................................MS-1209, Hy-Tran® Ultra
SPECIAL TOOLS
CAS-10219 ...................................................................................................................... Hand pump (hydraulic ram)
CAS-10512 ...................................................................................................................................... 10 ton ram (long)
CAS-10592 .......................................................................................................... Puller set, includes 24827 leg ends
CAS-10600 ............................................................................... Bearing cup and seal puller, includes 24850 adapter
CAS-10193 ............................................................................................................................. Vacuum pump (12 volt)
CAS-1960 .................................................................................. *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS-10592)

5006-4
CENTER PIVOT
Disassembly 19. Disconnect the supply hose.
1. Remove all dirt and grease from the area of the 20. Install a cap on the hose and a plug in the fitting.
center pivot. Park the machine on a level surface. 21. Stop the vacuum pump.
2. Lower the bucket until the bucket is flat on the 22. Loosen and remove the self-locking nut and bolt
floor. that hold the pivot pin for the steering cylinder
3. Stop the engine and apply the parking brake. rod eye.
4. Remove the covers from both sides of the 23. Remove the pivot pin from the rear frame and the
machine. steering cylinder rod eye.
5. Disconnect the front wiring harness from the cab 24. Remove the washer from the rear frame. Move
floor. the steering cylinder out of the way.
6. Remove any tie straps that fasten the front wiring 25. Repeat steps 22, 23 and 24 for the other steering
harness to the chassis near the center pivot. cylinder.
7. Loosen and remove the nut and washer that 26. Loosen and remove the Ferry head screws and
fasten the chassis ground wire and cab ground retainers that fasten the drive shaft to the front
wire to the studs. yoke. Move the drive shaft out of the way.
8. Loosen and remove the bolt, lock washer, and 27. Place two stands below and in contact with the
nut that fasten the clamp on the front wiring front frame.
harness to the bracket on the rear frame. Move 28. Install blocks between the rear axle and the rear
the front wiring harness out of the way. frame on both sides of the machine to prevent
9. Loosen and remove the fill plug for the hydraulic the rear frame from tipping.
reservoir. 29. Put a jack in contact with both sides of the rear
10. Connect a vacuum pump to the hydraulic frame near the center pivot area. Use another
reservoir. Start the vacuum pump. jack at the rear of the machine to prevent the rear
frame from tipping.
11. Disconnect the brake hose from the backside of
front brake line bracket. 30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
12. Install a plug in the tube and a cap on the fitting. the rear chassis (5), refer to Figure 1.
13. Disconnect the hoses for the steering cylinder. 31. Use a prybar to remove the upper pivot pin (4).
14. Install caps on the fittings and plugs in the hoses. 32. Loosen and remove the bolts (1) and hardened
15. Loosen and remove the bolts, lock washers, and washers (2) that fasten the lower pin plate (15) to
self-locking nuts that fasten the mounting bracket the lower pivot pin (10).
for the hoses to the bracket on the front frame. 33. Loosen and remove the cap screws (1) and
16. Loosen and remove the bolts, flat washers, and washers (2) that fasten the lower pin plate (15) to
self-locking nuts that fasten the bracket for the the bottom of the rear chassis (5).
hoses to the rear frame. 34. Use the ram and hand pump to remove the lower
17. Disconnect the return hose. pivot pin (10).
18. Install the cap on the hose and a plug in the 35. Install the puller on the bottom spacer (14), see
fitting. Special Tools in this section.

5006-5
1
2 3
4
5
1
6 2
7
5 9
10
6
5
5 A
16 11
12
6
8
8
13
6 2
15
14 1
2 2
1 A
1
BS01B225
1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

2. WASHER 6. SEAL 10. LOWER PIVOT PIN 14. BOTTOM SPACER
3. SPACER 7. BEARING RETAINER 11. LOWER BEARING SPACER 15. LOWER PIN PLATE
4. UPPER PIVOT PIN 8. SHIM 12. LOWER PIVOT BEARING 16. FRONT CHASSIS
FIGURE 1. CENTER PIVOT ASSEMBLY

5006-6
36. Remove the bottom spacer (14). Assembly
37. Release the parking brake. 1. Pack the bearing cones with grease. See
38. Use prybars to turn the left rear wheel backwards Specifications in this section. Be careful not to
and the right rear wheel forward to move the front mix the bearing cones.
of the rear frame to the left for access to the 2. Lubricate the bore in the top pivot with grease.
bearings. Install blocks under the wheels to See Specifications in this section for the correct
prevent the rear frame from moving. grease.
39. Apply the parking brake. 3. Install a bearing cup in the top pivot, refer to
40. Hold the bearing retainer (13) in place and Figure 2.
loosen and remove the bolts (1) and washers (2) 4. Install the bearing driver and plate.
that fasten the bearing retainer (13) and shims
(8) to the bottom of the rear pivot.
41. Remove the bearing retainer (13) and shims (8).
42. Remove the lower bearing spacer (11) from the
top of the lower pivot.
43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot.
44. Remove the bearing retainer (7) and shims (8).
45. Use the puller to remove the seal (6) from the top
of the bottom pivot.
46. Use the puller to remove the seal (6) from the B1423A88J
bottom of the top pivot. FIGURE 2.
47. Use an acceptable driver, the hydraulic ram, and 5. Tighten a nut on the screw until the bearing cup
the h an d pu mp to r emo ve th e u pp e r p iv ot is seated in the bore of the top pivot. Remove the
bearing (9) from the top pivot. See Special Tools bearing driver and plate from the top pivot.
in this section. 6. Install a bearing cone, spacer, the other bearing
NOTE: The spacers are matched to the bearing cone, and the remaining bearing cup in the top
sets. Do not mix the spacers. Do not use the old pivot, refer to Figure 3.
spacers if new bearing sets are being installed. 7. Install the bearing driver and plate.
48. Use an acceptable driver, the hydraulic ram, and 8. Tighten a nut on the screw until the bearing cup
the hand pump to remove the lower pivot bearing is sea ted a ga in st the spa ce r. R emo ve th e
(12) from the bottom pivot. See Special Tools in bearing driver and plate from the top pivot.
this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out
of each bearing retainer (7 and 13).
B1424A88J
FIGURE 3.

5006-7
9. Put the bearing retainer (7) in place on the upper 17. Fill the other seal (6) for the top pivot with grease.
pivot bearing (9), refer to Figure 1. See Specifications in this section for the correct
grease.
10. Install the bearing driver and plate, refer to
Figure 4. 18. Use an acceptable driver to install the seal (6) in
the bottom of the top pivot, refer to Figure 6.
11. Tighten a nut on the screw until the bearing
retainer (7) is tight against the upper pivot 19. The bottom of the seal (6) must be even with the
bearing (9). bottom of the top pivot.
B1425A88J B1430A88J
FIGURE 4. FIGURE 6.
12. Measure the gap between the bearing retainer 20. Apply grease to the upper pivot pin (4).
(7) and the top pivot. Make a record of the
21. Install the upper pivot pin (4) in the top pivot.
measurement. Subtract 0.0762 to 0.1016 mm
(0.003 to 0.004 inch) from the measurement, 22. Lubricate the top pivot until grease is forced out
refer to Figure 4. Select shims (8) equal to that of the seal (6). See Specifications in this section.
value.
23. Rotate the upper pivot pin (4) to check the
13. Remove the bearing driver, plate, and bearing bearing assembly. The upper pivot pin (4) must
retainer (7) from the top pivot. rotate smoothly, but not easily. Leave the upper
pivot pin (4) in place to keep dirt out of the upper
14. Install the shims (8) and the bearing retainer (7).
pivot bearing (9).
15. Install the washers (2) and bolts (1). Tighten the
24. Lubricate the bore for the bottom pivot with
bolts (1) to 124 Nm (92 pound-feet).
grease. Install a bearing cup in the bottom pivot.
16. Install the seal (6) in the bearing retainer (7). The
top of the seal (6) must be even with the top of
Figure 7.
the bearing retainer (7), refer to Figure 5.
B1426A88J
B1427A88J
FIGURE 5.
FIGURE 7.

5006-8
26. Tighten a nut on the screw until the bearing cup 35. Measure the gap between the bearing retainer
is seated in the bore in the bottom pivot. (13) and the bottom pivot. Make a record of the
27. Remove the bearing driver and plate from the
(0.003 to 0.004 inch) from the measurement.
bottom pivot.
Select shims (8) equal to that value.
28. Install a bearing cone, spacer, the other bearing
36. Remove the bearing driver, plate and bearing
cone, and the remaining bearing cup in the
retainer (13) from the bottom pivot.
bottom pivot.
37. Install the shims (8), the bearing retainer (13),
washers (2) and bolts (1).
Figure 8.
38. Tighten the bolts (1) to 124 Nm (92 pound-feet).
39. Fill the seal (6) for the bearing retainer (13) with
grease. See Specifications in this section for the
correct grease.
40. Install the seal (6) in the bearing retainer (13).
The bottom of the seal (6) must be even with the
bottom of the bearing retainer (13). Be careful
not to damage seal (6), refer to Figure 10.
B1428A88J
FIGURE 8.
30. Tighten a nut on the screw until the bottom
bearing cup is seated against the spacer.
31. Remove the bearing driver and plate from the
bottom pivot.
32. Put the bearing retainer (13) in place on the
B1430A88J
lower pivot bearing (12).
FIGURE 10.
41. Install the other seal (6) in the bottom pivot, refer
Figure 9.
to Figure 11. The top of the seal (6) must be even
with the top of the bottom pivot.
B1429A88J
FIGURE 9.
B1426A88J
34. Tighten a nut on the screw until the bearing FIGURE 11.
retainer (13) is tight against the lower pivot 42. Install the lower bearing spacer (11) and the
bearing (12). bottom spacer (14).

5006-9
43. Apply grease to the lower pivot pin (10). See 46. Rotate the lower pivot pin (10) to check the
Specifications in this section. bearing assembly. The lower pivot pin (10) must
rotate smoothly, but not easily.
44. Install the lower pivot pin (10) in the bottom pivot.
47. Remove the lower pivot pin (10) and the upper
45. Hold the bottom spacer (14) in place and
pivot pin (4).
lubricate the bottom pivot until grease is forced
out of the seal (6). 48. Remove the bottom spacer (14).
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 20. Remove the blocks from the rear axle.
2. Move the rear frame into alignment with the front 21. Remove the stands from the front frame.
frame.
22. Put the drive shaft in position on the front yoke.
3. Move the steering cylinders as required to move
23. Install new Ferry head screws that fasten the
the rear frame into alignment with the front
drive shaft to the front yoke.
frame.
24. Tighten the Ferry head screws to 61 to 81 Nm
(45 to 60 pound-feet).
5. Apply grease to the upper pivot pin (4), refer to
25. Put the steering cylinder rod eye in position in the
Figure 1.
frame. Install the washer between the steering
6. Install the upper pivot pin (4), spacer (3), washer cylinder rod eye and the rear frame.
(2) and bolt (1). Be careful not to damage the
26. Align the hole in the pivot pin with the holes in the
seal (6).
steering cylinder rod eye, and install the pivot
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184 pin.
pound-feet).
27. Install the bolt and self-locking nut that hold the
8. Apply grease to the lower pivot pin (10). pivot pin.
9. Install the lower pivot pin (10) in the frames. Be 28. Repeat steps 25, 26 and 27 for the other steering
careful not to damage the seal (6). cylinder.
10. Use the ram and hand pump to install the bottom 29. Start the vacuum pump.
spacer (14). See Special Tools in this section.
30. Connect the return hose.
11. Install the lower pin plate (15), three inner bolts
31. Connect the supply hose.
(1), and washers (2) that fasten the lower pin
plate (15) to the lower pivot pin (10). 32. Put the bracket for the hoses in position on the
rear frame. Install the bolts, flat washers, and
12. Tighten the bolts (1) to 69 Nm (51 pound-feet).
self-locking nuts that fasten the bracket to the
13. Measure the gap between the lower pin plate rear frame.
(15) and the bottom pivot. Make a record of the
33. Put the bracket for the hoses in position on the
front frame.
(0.003 to 0.004 inch) from the measurement.
Select shims equal to that value. 34. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the front frame.
14. Loosen the bolts (1) that fasten the lower pin
plate (15) to the lower pivot pin (10). 35. Connect the hoses for the steering cylinders.
15. Start the six outer bolts (1) into the lower pin 36. Connect the brake hose for the front brakes at
plate (15) and the bottom pivot. the front bracket.
16. Install the shims (8). 37. Stop the vacuum pump.
17. Tighten the six outer bolts (1) to 128 to 136 Nm 38. Connect the front wiring harness to the rear
(94 to 100 pound-feet). wiring harness.
18. Tighten the three inner bolts (1) to 124 Nm (92
pound-feet).
19. Remove the jacks from the rear frame.
5006-10
39. Put the clamp on the wiring harness in position 43. Check the fluid level in the hydraulic reservoir.
on the bracket. Install the bolt, lock washer, and Add oil as required. See Specifications in this
nut that fasten the clamp on the wiring harness to section.
the bracket.
44. Install the fill plug on the hydraulic reservoir.
40. Put the ground wire in position on the stud. Install
45. Bleed air from the front axle bleed screws. Refer
the washer and nut that fasten the ground wire to
to Section 7002 for complete brake bleeding
the stud.
instructions.
41. Install a tie strap to fasten the wiring harness to
46. Lubricate the pivot pins for the steering cylinder
the tube.
rod eyes.
42. Disconnect the vacuum pump from the hydraulic
47. Install the covers on both sides of the machine.
reservoir.

Section
5008
AUXILIARY STEERING MOTOR AND PUMP
5008
CASE CORPORATION
700 State Street
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5008-3
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor .......................................................................................................................................................... 24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)

5008-4
AUXILIARY STEERING MOTOR AND PUMP
Disassembly Assembly
NOTE: Refer to Section 5001 for removal and 1. Lubricate all parts with clean hydraulic oil before
installation of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (8) and motor (1) are ring (3) on the plate (17). Refer to the illustration
replaced as units and are not serviced. Refer to the on page 5.
illustration on page 5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1).
4. Lubricate and install new O-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup ring 8. Install a new gasket (13) on the pump assembly.
(5) from the end plate (21).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to 348
pound-inches).
9. Remove and discard the O-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
NOTE: The only serviceable items on the pump
assembly are the seals (6), backup rings (5), O-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.

5008-5
10 8
9
11
12 16
13
3 17
4 14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
1. MOTOR 7. O-RING 13. GASKET 19. DRIVEN GEAR

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

5008-6
NOTES

SECTION INDEX
POWER TRAIN
Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
Transmission Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
CASE CORPORATION
700 State Street
Hamilton, ON L7N 3M6 CANADA Bur 6-44681 June, 2002
6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN

COMPONENTS
CASE CORPORATION
700 State Street
6001-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... .................... 2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... ................... 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... ................... 3
Transmission Mounting . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... ................... 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 10
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 16
Front Axle Mounting . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 19
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 21
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 24
SPECIAL TORQUES
RH and LH Mounting Brackets to Transmission Mounting Bolts . . . . . . . . . . . . . . 481 to 590 Nm (355 to 435 lb-ft)
Top Mounting Bracket to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 251 to 319 Nm (185 to 235 lb-ft)
Transmission Mounting Brackets to Chassis Mounting Bolts . . . . . . . . . . . . . . . . 890 to 1000 Nm (655 to 735 lb-ft)
Engine Drive Shaft to Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 41 Nm (25 to 30 lb-ft)
Transmission Fill Tube Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 33 Nm (12 to 24 lb-ft)
Rear Drive Shaft to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft)
Center Drive Shaft to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft)
Front Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845 to 950 Nm (625 to 700 lb-ft)
Wheel Bolts
Preliminary Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Nm (150 lb-ft)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 to 720 Nm (475 to 530 lb-ft)
Center Bearing Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 to 128 Nm (73 to 94 lb-ft)
Front Drive Shaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft).
Pivot Pin Caps Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 to 280 Nm (185 to 205 lb-ft)
Rear Drive Shaft to Rear Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 to 81 Nm (45 to 60 lb-ft)

6001-3
TRANSMISSION
Removal STEP 4
STEP 1 7
Refer to Section 9007 and remove ROPS cab or 4
ROPS canopy.
STEP 2 6
9
5
8
BD01F278
1
Remove four bolts (4) and washers. Remove two split
flanges (5). Disconnect tube assembly (6) with
suction hose (7) attached from hydraulic pump.
Remove and discard O-ring face seal from flange
head of tube assembly. Tag and disconnect case
drain hose (8) from fitting (9). Remove and discard
BD01D321
O-rin g fa ce se al fro m fitting . Plu g h os e, tub e
P u t a 3 7 . 8 l it e r ( 1 0 g a l lo n ) c o n t a in e r u n d e r assembly, and pump port and cap fitting to prevent
transmission drain plug (1). Remove drain plug and intrusion of foreign matter into hydraulic system.
drain transmission oil. Install drain plug after oil has
drained.
STEP 5
STEP 3
10 11
8
2 BD01D304
3 Loosen clamp (10). Disconnect suction hose (7) from
BD01F278
hydraulic reservoir and remove with tube assembly
Identify, tag, and disconnect pump load sensing hose (6) attached from machine. Disconnect case drain
(2). Remove and discard O-ring face seal from fitting hose (8) from fitting (11); remove hose (8). Remove
(3). Plug hose and cap fitting to prevent entry of and discard O-ring face seal from fitting. Plug hoses
foreign matter into hydraulic system. and cap fittings to prevent entry of foreign matter into
hydraulic system.

6001-4
STEP 6 STEP 8
13
19
14 20
12
BD01F279 BD01D315
Remove four bolts (12) and washers. Remove two Disconnect transmission wiring harness connector
split flanges (13). Disconnect pump pressure hose (19) from control valve connector. Remove socket
(14) from hydraulic pump. Remove and discard head bolt securing wiring harness clamp (20). Move
O-ring face seal from flange head of hose (14). Plug wiring harness away from transmission.
hose and pump port.
STEP 9
STEP 7
17 15
21
18
16 BD01D317
BD01D306 Just above where clamp (20) was installed, tag and
Identify, tag, and disconnect brake pump pressure disconnect transmission wiring harness connector
hose (15) and brake to hydraulic reservoir hose (16). (21) from torque converter output sender. Move
Position hoses away from transmission. Remove and wiring harness away from transmission.
discard O-ring face seals from fittings (17 and 18).
Plug hoses and cap fittings to prevent entry of foreign STEP 10
matter into hydraulic system.
22
23
BD01D310
Remove two socket head bolts securing transmission

wiring harness clamps (22 and 23).

6001-5
STEP 11 STEP 14
24
25
26 30
31
BD01D312 BD01F281
Identify, tag, and disconnect transmission wiring Remove two bolts (30) and washers securing hose
harness connectors from engine speed sensor (24), retainer (31) to front of rear chassis. Move hose
intermediate speed sensor (25), and turbine speed retainer towards front of machine.
sensor (26). Move transmission wiring harness away
from transmission. STEP 15
STEP 12 32
33
27
33
BD01F286
Connect lifting equipment to hydraulic pump (32).

BD01D316 Take up all slack in lifting equipment. Remove two
Remove socket head bolt securing wiring harness bolts (33) and washers securing pump to
c la m p ( 2 7 ) . M o v e w ir in g h a r n e s s a w a y f r o m transmission. Pull hydraulic pump from transmission
transmission. and remove from loader. Remove and discard O-ring
from pump.
STEP 13
28
29
BD01D314
Identify, tag, and disconnect transmission wiring

harness connectors from filter maintenance switch
(28 ) a nd ou tp ut sp eed se nso r (2 9). Mo ve
transmission wiring harness away from transmission.

6001-6
STEP 16 STEP 18
34 43
35
36
42
44
37
38
BD01F287 BD01D324
At front of transmission, identify, tag, and disconnect Remove two bolts (42) securing hose bracket (43) to
parking brake hose (34) from parking brake (35). transmission. Remove bracket from transmission and
Plug hose and cap fitting to prevent entry of foreign lay on rear axle brake hose (44).
matter into hydraulic system. Move hose away from
transmission. Remove four bolts (36) and two straps STEP 19
(37) securing center drive shaft (38) to transmission
output flange. Disconnect center drive shaft from
transmission.
STEP 17
46
39 45
BD01D322
Remove two bolts (45). Remove fill tube (46), with

41 cap and oil gauge assembled, two seals, and metal
40 strainer. Discard seals.
BD01D323 STEP 20
Remove four bolts (39) and two straps (40) securing
rear drive shaft (41) to transmission output flange.
Disconnect rear drive shaft from transmission. 48
47
BD01D318
Identify, tag, and disconnect cooler hose (47) from

fitting (48) installed in LH side of transmission. Install
a plug in hose. Remove and discard O-ring face seal
from fitting (48).

6001-7
STEP 21 STEP 24
56
56
48
BD01D339 BD01D343
Remove fitting (48). Remove and discard O-ring from Connect lifting equipment to transmission lifting eyes
fitting. Install a plug in transmission port. (56). Take up all slack in lifting equipment.
STEP 22 STEP 25
58 57
49
59
60
50 60
61
BD01D340 BD01D342
Repeat Steps 20 and 21 to disconnect cooler hose In area between rear of transmission and front of
(49) and remove fitting (50). engine, remove four bolts (57) and two straps (58).
Discard bolts (57) and straps (58). Use pry bar to
STEP 23 disconnect engine drive shaft (59) from transmission.
Using 3/4 inch drive socket, extensions, and impact
55 wrench, remove four bolts (60) and washers securing
transmission to top mounting bracket (61).
53
53
54 51
51
52 52
BD01F290
Remove fo ur bolts (5 1) and washe rs securin g

mounting brackets (52), spacers (53), parking brake
accumulator (54), and brake accumulators (55) to
rear chassis. Move assembled parts away from
transmission.

6001-8
STEP 26 STEP 28
64
65
62
63
BD01D337 BD01D345
Loosen two bolts (62) securing RH and LH mounting Slowly and carefully raise transmission from loader
brackets (63) to transmission. Remove bolts (64) and while checking that all hoses, electrical connectors,
washers (65) securing RH and LH mounting brackets and wires have been disconnected and nothing
(63) to rear chassis. interferes with transmission removal. Remove
transmission from loader.
STEP 27
STEP 29
67 66
63
62 61
BD01D344
Raise transmission just enough to enable removal of BD01D361
RH and LH mounting brackets (63). Remove two If top mounting bracket (61) requires removal,
b o lt s ( 6 2 ) a n d w a s h e r s s e cu ri n g R H a n d L H remove bolt (66) and washer (67) then remove
mounting brackets (63) to transmission. Remove RH bracket.
and LH mounting brackets.

6001-9
Transmission Mounting
64 66 64
65 67
C
B 65
68
68
ISOLATOR 62
INSTALLATION
66
62
67
63
68
64
61
65
60
62
60 68
62
63
BS01E012
60. BOLT 66. BOLT

61. TOP MOUNTING BRACKET 67. WASHER
62. BOLT 68. ISOLATOR
63. MOUNTING BRACKET A. REAR CHASSIS TRUNNION
64. BOLT B. BRACKET (61 OR 63)
65. WASHER C. SMALLER PIECE ON TOP

6001-10
STEP 30
C he c k is ola t o rs ( 6 8 ) fo r d e te r io ra tio n , te a r s,
deformation, or other damage. Replace as
necessary: refer to Page 9.
STEP 31 63
67 66 62
BD01D344
Ins tall R H a nd L H mou n tin g br ac ket s (6 3 ) o n

transmission using two washers and bolts (62). Do
not tighten bolts.
61 STEP 34
BD01D361
If top mounting bracket (61) was removed, put

bracket on rear chassis trunnion and secure using
washer (67) and bolt (66). Do not tighten bolt. 64
STEP 32 65
62
63
BD01D337
Loosely install washers (65) and bolts (64) to secure

RH and LH mounting brackets (63) to rear chassis.
Tighten bolts (62) securing RH and LH mounting
brackets to transmission to a torque of 481 to 590
Nm (355 to 435 lb-ft).
BD01D345
Move transmission into position above loader. Slowly

lower transmission into loader.

6001-11
STEP 35 STEP 37
NOTE: In this step, new straps (58) and bolts (57)
must be installed whenever these parts are removed.
Bolts have a nylon patch to maintain torque which
requires new bolts.
58 57 56
56
66
59
60
BD01D343
Disconnect lifting equipment from transmission lifting

60 eyes (56).
61
BD01D342
STEP 38
Using 3/4 inch drive socket, extensions, and impact
55
wrench, install four washers and bolts (60) to secure
top mounting bracket (61) to transmission. Then
tighten bolts (60) to a torque of 251 to 319 Nm (185
to 235 lb-ft). If bracket (61) had been removed,
tighten bolt (66) to a torque of 890 to 1000 Nm (655
to 735 lb-ft). Connect engine drive shaft (59) to 53
53
transmission. Install two new straps (58) and four 51
new bolts (57). Tighten bolts (57) to a torque of 34 to
54
41 Nm (25 to 30 lb-ft).
51
52 52
STEP 36
BD01F290
Mo v e m o u nt in g b r a ck e ts ( 5 2 ), p a r kin g b ra k e
accumulator (54), and brake accumulators (55) into
position. Secure to rear chassis using two spacers
(53), washers, and bolts (51).
64
STEP 39
49
BD01D337
Tighten bolts (64) securing RH and LH mounting

brackets to a torque of 890 to 1000 Nm (655 to 735
lb-ft).
50
BD01D340
Install new O-ring on fitting (50) and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose (49) to fitting following tag
installed during removal. Remove and discard tag.

6001-12
STEP 40 STEP 43
48
47
39
41
40
BD01D318 BD01D323
Install new O-ring on fitting (48) and install fitting in Connect rear drive shaft (41) to transmission then
transmission. Install new O-ring face seal in fitting install two straps (40) and four bolts (39). Tighten
then connect cooler hose (47) to fitting following tag bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).
installed during removal. Remove and discard tag.
STEP 44
STEP 41
34
35
36
46
37
45 38
BD01F287
BD01D322 Connect center drive shaft (38) to transmission and

Position fill tube (46), two new seals, and metal install two straps (37) and four bolts (36). Tighten
strainer on transmission; metal strainer is installed bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).
between seals. Secure using two bolts (45). Tighten Connect parking brake hose (34) to parking brake
bolts to a torque of 17 to 33 Nm (12 to 24 lb-ft). (35) following tag installed during removal. Remove
and discard tag.
STEP 42
43
42
44
BD01D324
Position hose bracket (43) with rear axle brake hose

(44) on transmission. Install two bolts (42) to secure
hose bracket to transmission.

6001-13
STEP 45 STEP 48
33 32
27
33
BD01F286 BD01D316
Install new O-ring on hydraulic pump (32) flange. Install socket head bolt to secure wiring harness
Move pump into position and install in transmission. clamp (27).
Install two washers and bolts (33) to secure pump to
transmission. Disconnect lifting equipment from STEP 49
pump.
STEP 46 24
25
26
30 BD01D312
31 Connect transmission wiring harness connectors to
turbine speed sensor (26), intermediate speed
BD01F281 sensor (25), and engine speed sensor (24) following
Position hose retainer (31) on front of rear chassis tags installed during removal. Remove and discard
and secure using two washers and bolts (30). tags.
STEP 47 STEP 50
28
22
29
23
BD01D314 BD01D310
Connect transmission wiring harness connectors to Install two socket head bolts to secure transmission
output speed sensor (29) and filter maintenance wiring harness clamps (23 and 22).
switch (28) following tags installed during removal.
Remove and discard tags.

6001-14
STEP 51 STEP 54
13
21
14
12
BD01D317 BD01F279
Connect transmission wiring harness connector (21) At hydraulic pump, remove plug from pump pressure
to torque converter output sender following tag hose (14) and pump port. Install a new O-ring face
installed during removal. Remove and discard tag. seal in flange head of hose (14). Position pump
pressure hose (14) on pump port and secure using
STEP 52 two split flanges (13) and four washers and bolts
(12).
STEP 55
10 11
19 8
20
BD01D315 7
Install socket head bolt to secure wiring harness
clamp (20). Connect transmission wiring harness
connector (19) to control valve connector. BD01D304
Remove plugs from hoses and caps from fittings.

STEP 53 Install new O-ring face seal in fitting (11). Connect
hydraulic pump case drain hose (8) to fitting (11).
17 15 Position suction hose (7) between reservoir port and
hydraulic pump inlet port. Connect suction hose (7)
to hydraulic reservoir. Tighten clamp (10).
18
16
BD01D306
At brake valve, install new O-ring face seals in fittings

(18 and 17). Connect brake to hydraulic reservoir
hose (16) and brake pump pressure hose (15)
following tags installed during removal. Remove and
discard tags.

6001-15
STEP 56 STEP 58
7
4
6 1
9
5
8
BD01F278 BD01D321
At hydraulic pump, remove plug from hose (8), tube Check that transmission drain plug (1) is tight.
assembly (6), and pump port and cap from fitting (9).
Install new O-ring face seal in fitting (9). Connect STEP 59
pump case drain hose (8) to fitting (9) following tag
installed during removal. Install new O-ring face seal
in flange head of tube assembly (6). Position tube
assembly (6) with hose (7) on hydraulic pump port.
Install two split flanges (5) and secure using four
washers and bolts (4).
STEP 57
BS00M474A
Fill transmission with MS-1209 Hy-Tran® Ultra oil

until oil level is up to the arrow.
STEP 60
Refer to Section 9007 and install ROPS cab or ROPS
2 canopy.
3
BD01F278
STEP 61
Remove cap from fitting (3) and plug from hose (2).
Instal a new O-ring face seal on fitting (3). Connect Start and run engine at idle speed with transmission
hose to fitting following tag installed during removal. in neutral. If transmission oil level is at or below
Remove and discard tag from hose. bottom of crosshatch region, put articulation lock in
LOCKED position and add MS-1209 Hy-Tran® Ultra
oil until oil level is up to crosshatch region. Shut down
engine and put articulation lock in OPERATING
position.

6001-16
FRONT AXLE
Removal STEP 65
STEP 62 2
1
3
1 2 1
BD01F292
Remove four bolts (1) and two straps (2) securing

BD01F143
front drive shaft (3) to front axle.
Park machine on level surface. Have assistant put
articulation lock in LOCKED position. STEP 66
STEP 63 4
8
5
3
7
9
5 6
BD01F291
Remove clamp securing lubrication hose (4) to

BD00M048
machine and nut securing opposite end of hose (4).
Raise bucket and have assistant install safety link. Remove four bolts (5) and two straps (6) securing
L o w e r lo a d e r a r ms slo w ly u n til s a fe t y lin k is center drive shaft (7) to front drive shaft (3). Use a
supporting loader arms. pry bar to separate drive shafts. While supporting
center bearing (9) and front drive shaft (3), remove
four nuts and bolts (8) and eight washers. Lower
STEP 64
center bearing and front drive shaft from mounting
Stop engine. Actuate brake pedal several times to plate and remove from machine.
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.

6001-17
STEP 67 STEP 70
10
11
BD01F293 BD01F297
Dis co nn e ct br a ke h os e (1 0 ) fr o m e lbo w (11 ). Use an acceptable jack to hold front axle.

Remove and discard O-ring face seal from elbow.
STEP 71
STEP 68
13 12
BD01F295
BD01F298 Remove 12 bolts (12) and washers from front wheels

(13). Remove both wheels from front axle.
STEP 72
14
BD01D392
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine. BD01F296
Remove eight nuts (17) bolts (14), and 16 washers

STEP 69 (15 and 16) securing front axle to machine.
Repeat Step 68 to raise other front axle tire from
ground. STEP 73
Carefully lower front axle and remove from under
machine.

6001-18
Front Axle Mounting
14
14
15 15
15
18
16
16
17
17
BS01D131
14. BOLT 17. NUT

15. WASHER 18. FRONT AXLE
16. WASHER

6001-19
STEP 74
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 75
14
BD01F297
Remove jack from front axle.
STEP 78
BD01F296
Install eight washers (15), bolts (14), washers (16),

and nuts (17) to secure front axle to machine.
Tighten bolts to a torque of 845 to 950 Nm (625 to
700 lb-ft).
STEP 76
13 12
BD01F298
BD01F295
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 79
Repeat Step 78 to remove other jack stand from
under machine.
B0987A88
Install both wheels (13) on front axle and secure

using 10 washers and bolts (12). Tighten bolts to a
preliminary torque of 203 Nm (150 lb-ft) in sequence
indicated; then tighten to a torque of 640 to 720 Nm
(475 to 530 lb-ft) in same sequence.
6001-20
STEP 80 STEP 82
1
3
10
11
1 2 1
BD01F293 BD01F292
Install a new O-ring face seal in elbow (11). Connect Secure drive shaft (3) to front axle using two straps
brake hose (10) to elbow. (2) and four bolts (1). Tighten bolts (1) to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 81
STEP 83
4 If necessary, fill axle with gear lubricant specified in
8 Section 1002.
5 STEP 84
3 Refer to Section 7002 and bleed brakes.
7
9 STEP 85
5 6
BD01F291
Position and support center bearing (9) and front

drive shaft (3) and install eight washers and four bolts
(8) and nuts. Tighten bolts (8) to a torque of 99 to 128
Nm (73 to 94 lb-ft). Install two straps (6) and four
bolts (5). Tighten bolts (5) to a torque of 61 to 81 Nm
(45 to 60 lb-ft). Secure lubrication hose (4 ) to
machine using clamp; secure opposite end of hose
using nut.
BD00M048
Start eng ine and raise b ucket. Have assistant

remove safety link. Lower bucket to ground and stop
engine.
STEP 86

6001-21
REAR AXLE
Removal STEP 91
STEP 87
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any
pressure from hydraulic circuit.
5 4
STEP 88
BD01F301
Disconnect brake hose (4) from elbow (5). Remove

and discard O-ring face seal from elbow.
STEP 92
BD00F143
STEP 89
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting. BD01F299
Using an acceptable hydraulic jack, raise one tire

STEP 90 from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP 93
3
1 2
BD01F303
Remove four bolts (1) and two straps (2). Use a pry
bar to disconnect rear drive shaft (3) from rear axle.
BD01F302
Use an acceptable jack to hold rear axle.

6001-22
STEP 94 STEP 95
8
6
10
A A
9
10
12
BD01F295 BD01D363
Remove 12 bolts (6) and washers (7) from rear At front of trunnion (9), remove two Allen head bolts
wheels (8). Remove both wheels from rear axle. (10) and washers (11). Remove front cap (12): if
necessary use two M12 by 32 mm (1.25 inches) bolts
in puller holes (A); tighten bolts evenly to pull cap
from axle and trunnion. Remove and discard O-ring
(15) from cap. Repeat this step at rear of trunnion
except remove and retain shim(s) (14) after removal
of rear cap (13). Remove pivot shaft (16) using
acceptable sleeve or rod if necessary.
STEP 96
Carefully lower rear axle and remove through side of
machine.
STEP 97
Remove and discard two seals (17) from rear axle
pivot point.

6001-23
Rear Axle Mounting
10
9 11
12
17
15
10
11
14 7
16
11
10 15 18
17
13 6
11
10
BS01D131
6. BOLT 11. WASHER 15. O-RING

7. WASHER 12. FRONT CAP 16. PIVOT PIN
9. TRUNNION 13. REAR CAP 17. SEAL
10. BOLT 14. SHIM(S) 18. REAR AXLE

6001-24
NOTE: If shim(s) (14) have been lost or pivot pin
(16) has been replaced, do Step 98 to determine
required shim(s) otherwise go to Step 99. A
STEP 98
10 9 10
9
16
12
13
BD01D482A
A
B
BS01E091A
Install pivot pin (16) and caps (12 and 13) in trunnion
(9) without rear axle or shim(s). Install washers (11)
a n d b o lt s (1 0 ) . Tig h t e n b o l ts se cu re ly. P u s h
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (13) and trunnion. Select shims from the
following:
BD01D499
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm Clean front (A) and rear (B) pivot area of rear axle
(0.059 inch). where seals (17) will be installed.
MEASURED SHIM(S) REQUIRED STEP 100

GAP (mm) (mm)
0.07 to 0.55 None A
0.56 to 1.09 0.50
17
1.10 to 1.59 1.0
12
1.60 to 2.09 1.50
13
2.10 to 2.59 0.50 plus 1.50
2.60 to 3.02 1.0 plus 1.50
15
BS01E092
Lubricate two new seals (17) and new O-rings (15)

using Case Molydisulfide Grease. Install seals,
smooth side out, into front and rear of axle housing
(A) until flush with housing or recessed 2.0 mm
(0.079 inch). Install an O-ring in each cap (12 and
13).
STEP 101
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.

6001-25
STEP 102 STEP 104
Remove hydraulic jack supporting rear axle and jack
14 stands supporting loader.
A 12 10
10 13
STEP 105
16 9
9
BS01E091 5 4
Lubricate pivot pin (16) using Case Molydisulfide
Grease. At rear of trunnion (9), install pivot pin into
trunnion and axle (A). Install shim pack (14), rear cap
(13) with O-ring installed, and two washers and bolts BD01F301
(10). At front of trunnion install front cap (12) with Install a new O-ring face seal in elbow (5). Connect
O-ring installed, and two washers and bolts (10). brake hose (4) to elbow.
Tighten bolts (10) to a torque of 251 to 280 Nm (185
to 205 lb-ft).
STEP 106
STEP 103
8 3
6
1 2
BD01F303
Connect rear drive shaft (3) to rear axle. Install two

BD01F295
straps (2) and four bolts (1). Tighten bolts to a torque
of 61 to 81 Nm (45 to 60 lb-ft).
STEP 107
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 108
Refer to Section 7002 and bleed brakes.
STEP 109
B0987A88
Install both wheels (8) on front axle and secure using
1 2 w a sh e rs a n d b o lts ( 6 ) . Tig h te n b o l ts t o a
preliminary torque of 203 Nm (150 lb-ft) in sequence
indicated; then tighten to a torque of 640 to 720 Nm
(475 to 530 lb-ft) in same sequence.

6001-26
NOTES

6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING
CASE CORPORATION
700 State Street
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHART FOR RECORDING Pressure READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONSUMPTION TEST PROCEEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20

6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure ....................................................................................................... 8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure ........................................................................................................ 2.5 bar (36 psi) minimum
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm)
621D...................................................................................................................................52 L/min (14 U.S. gpm)
Transmission oil operating temperature .........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)

6002-4
4 1
3 2
5 12
9
6
11
14
13 7
10
BS01A190
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. PLUG
FIGURE 1. COMPONENT LOCATIONS SYSTEMS

6002-5
BS01B049
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. DRIVE SHAFT
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6
2 2
2
2
1 3
4
BS01A191
3. OUTPUT FLANGE CONVERTER
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
SIDE
2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG
FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

6002-7
1
2
3
10
6
7
BS01A192
1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR
2. BREATHER 7. OIL DRAIN PLUG
3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE
4. FILTER HEAD 9. TRANSMISSION CASE
5. FILTER 10. PARKING BRAKE
FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

6002-8
2
1
1
7 3
4 4
BS01B048
1. LIFTING LUGS 5. OUTPUT FLANGE REAR
2. POWER TAKE OFF 6. FILTER
3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD
4. TRANSMISSION SUSPENSION BORES
FIGURE 5. COMPONENT LOCATIONS REAR VIEW

6002-9
TRANSMISSION OPERATION
General A. Determines which clutches to engage in the

transmission.
The transmissions for the D series equipment is
equipped with a Transmission ECM (Electronic B. Protects the engine and transmission turbine
Control Module). This module controls modulation from overspeed conditions during
and shifting that were normally associated with downloading.
hydraulically modulated transmissions, providing C. Receives speed information from the engine
smoother shifts and enhanced clutch life. speed sensor, the turbine speed sensor, the
Th e Transmission EC M relies on sig nals from intermediate clutch speed sensor and the
several solenoids that are incorporated into the transmission output speed sensor. These
design. These solenoids measure the speed of speed sensors are checked to determine if
several components, as well as other sensors that normal sensor operation is present. The data
measure temperature. These solenoids and sensors is also used to control modulation during
are further defined in the following paragraphs. shifting and to determine the appropriate shift
patterns.
In a d d it io n , t h e t r a n s m is s io n in c o r p o r a t e s a
two-piece transmission case for ease of transmission D. Detects system failures and determines the
maintenance, helical cut gears that help reduce appropriate alternative actions.
noise, and all external hoses have been eliminated E. Provides various diagnostic messages to the
(all oil passages are internal). Information Center.
F. Provides other information to the information
Transmission ECM center, which in turn displays engine speed,
Mod u la tion a nd sh iftin g a re co ntr olled b y th e wheel speed, gear shift selection, and actual
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e gear selection.
(Transmission ECM). This module replaces the oil G. Provides a method to calibrate the
and springs that are found in hydraulically modulated transmission clutch control.
transmissions.
H. Establishes clutch modulation pressure during
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h transmission shifts.
engagement, providing smoother shifts and
enhanced clutch life, whether the transmission is set Transmission Sensor Data Collection.
to the automatic or manual shift mode.
T h e Tr a n s m i s s i o n E C M c o l l e c t s a n d u s e s
The Transmission ECM also informs the Information information from four sensors to accurately shift the
Center, by the use of diagnostic codes, of any transmission and determine if any clutches are
transmission error and the hours of operation that the slipping. These sensors are:
error occurred.
Engine (Speed) Sensor - monitors engine speed to
Electrical Shift Solenoids determine the load on the engine for shift points and
sends the engine rpm to the Transmission ECM,
Electrical Shift Solenoids control the modulation of which sends the information to the tachometer in the
the clutches, eliminating the need for a modulation Information Center.
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows: Turbine (Speed) Sensor - assists the engine speed
sen so r in d ete rmin ing the lo ad go ing in to th e
A. A temperature sensor relays the oil transmission and helps determine shift points.
temperature to the Transmission ECM.
Intermediate (Shaft Speed) Sensor - determines
B. The Transmission ECM times the rate the differential gear speed in the transmission to check
solenoid energizes and de-energizes. for clutch slippage.
C. As the transmission changes gears, there is Output (Speed) Sensor - monitors transmission
reduced hesitation from one gear to the next. output shaft speed to help determine the load on the
Transmission ECM Tasks transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM
The Transmission ECM performs a variety of tasks in which sends the information to the speedometer in
the overall system. The Transmission ECM: the Information Center.

6002-10
Th e t r a n s m is s io n E C M a ls o r e v ie w s v o l ta g e If the Transmission ECM generates a code, the
in for mation from th e shifter an d tra ns miss io n w r e n ch o v e r t h e se r v i c e m a n u a l i c o n w i l l b e
solenoids to determine if there are any short circuits displayed on the Information Center.
or open circuits in the system.
Automatic Problem Modes Transmission Clutch Calibration
If the Transmission ECM detects an error condition in The Transmission ECM has the capability to find the
the transmission system, it will generate a service optimal adjustment of the clutch filling parameters for
code in the Information Center and will enter one of each individual transmission, providing the ability to
three modes: individually adjust the optimum fill time for the
individual transmission in the machine. Clutch Filling
A. Clutch Modulation Substitute Mode Parameter Calibration is performed on each machine
B. Limp-Home Mode at the plant and should be repeated at the first 250
C. Transmission/Transmission ECM Shutdown hours of use and every 1000 hours thereafter.
Mode
Gear Selections
Clutch Modulation Substitute Mode
The transmission in all D Series models provides 4
In this mode, the transmission clutch modulation is
f o r w a r d a n d 3 r e v e r s e g e a r s e le c t i o n s . T h e
time dependant rather than load dependant. The
transmission ratios were designed to give optimized
transmission will go into the Clutch Modulation
speed and torque for each gear selection. The torque
Substitute Mode if any of the four speed sensors fail.
converter is a single stage torque converter (one
If the ou tp ut sp eed sen sor is working an d th e locking unit in the torque converter).
transmission is in gear, the shift points in Automatic
mode will be speed dependant but the modulation Automatic/Manual Modes
will be a predetermined amount of time.
The automatic/manual switch is located on the right
If the output speed sensor is not working and the control panel. The transmission is in automatic mode
transmission is in gear, the shift points will be load when the top of the automatic/manual switch is
d e p e n d a n t b u t t h e m o d u la t io n w i ll s ti ll b e a de pr ess ed . The Tra ns mis sio n Displa y Ce nte r
predetermined amount of time. indicates when the machine is in the automatic
If the transmission is shifted from neutral into a mode.
direction in the Clutch Modulation Substitute Mode in
automatic, the transmission will shift into 4th gear
and shift down until it gets the correct output speed
from the turbine.
Limp-Home Mode
In this mode, the transmission will go into second
gear, forward or reverse, no matter what gear is
selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
gears unt il an operable gear is f ound. T he
transmission will go into the Limp Home Mode if
there is a fault on one clutch, a fault on one clutch
valve, or a fault on more than one speed sensor. RD98K308
FIGURE 6. AUTO/MANUAL TRANSMISSION SWITCH
Transmission/Transmission ECM Shutdown
Mode Upshifting in Automatic Mode
In this mode, the Transmission ECM has detected a Upshifting is determined by machine speed and the
severe failure that disables control of the torque on the transmission.
transmission. The transmission will go into Shutdown
The transmission will shift from first or second gear
Mode if there is a fault on more than one clutch, a
up to the highest gear selected as the accelerator is
fault on the solenoid power supply, or invalid voltage.
depressed, machine speed increases, and required
In this mode, the Transmission ECM will shut off all
torque is reduced.
so lenoid valves and the power supply and the
transmission shifts into and stays in neutral.

6002-11
If the machine speed is increasing, but the operator
is not depressing the accelerator (such as when
going down a hill), the transmission will not upshift.
As the operator depresses the accelerator and the 1
torque on the transm ission is lowered, the
transmission will upshift.
Downshifting in Automatic Mode
Downshifting is determined directly by machine
speed and transmission torque. The transmission will
downshift to first or second gear as machine speed
decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
BS00M472
and the machine speed decreases, as the torque 1. DOWNSHIFT BUTTON/SINGLE LEVER CONFIGURATION
re q u ir e me n t in c re a s e s, t h e tr a n sm is sio n wi ll
FIGURE 7
downshift into third, then second, and down to first
gear, if necessary.
Upshifting in Manual Mode 1
In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.
Downshifting in Manual Mode 1. DOWNSHIFT BUTTON/TWO LEVER CONFIGURATION
409
The transmission can be downshifted in the manual FIGURE 8

mode without reducing engine speed or machine
speed.
Automatic Mode
In the Automatic Mode, the downshift button only
If 1st gear is selected from 3rd or 4th gear, the
shifts down. The downshift button allows the operator
transmission will downshift into 2nd gear for 1.2
to downshift through the entire range of gears. This is
seconds and then will shift into 1st gear.
useful in long haul applications or roading.
Downshift Button Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then
The downshift button is located on front of the from 3rd to 2nd, and then from 2nd to 1st.
joystick control lever in machines with a single lever
configuration, and on top of the control tower in The transmission will automatically downshift and
machines with a two lever configuration. then upshift, as needed, to the last gear that was
selected with the downshift button.
With the number of different ways the downshift
button functions, the operator can tailor the use of Example: If the downshift button was used to shift
the machine to the application at hand. from 4th to 3rd gear, the transmission will
automatically shift from 3rd down and then back up
to 3rd again. It will not shift into 4th until the
transmission has been returned to the full range
automatic mode.

6002-12
The transmis sion will r et ur n to the fu ll range Brake Pedal Transmission
automatic mode when:
Declutch
A. Another gear is selected.
A transmission declutch feature concentrates more
B. The shifter is moved into neutral and then into engine power on the loader when digging in heavy or
forward or reverse. tough conditions, providing smoother stops and
C. The autoshift switch is recycled. starts. Total disconnection of the transmission from
the engine is prevented. This feature will function in
Manual Mode 1st, 2nd, or 3rd gear only. It will not function in 4th
gear.
In the manual mode, the downshift button toggles
between 1st and 2nd gear. The manual mode is
useful in short haul operations. In this mode, the
downshift button functions in two ways in 1st and 2nd
gear.
When the operator is in 2nd gear and pushes the
downshift button, the transmission instantly shifts into
1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
If the machine is in 2nd gear and the downshift
button is pushed, the transmission instantly shifts
into 1st gear. When the operator shuttles the shifter,
the transmission upshifts back into 2nd gear. RD98K308
Cold Start Protection System FIGURE 9. TRANSMISSION DECLUTCH SWITCH

When the transmission declutch switch is in the on
The transmission has a cold start protection system.
p o s i ti o n a n d th e b r a k e p e d a l is p u s h e d , th e
When the transmission sump temperature is minus
Transmission ECM reduces the pressure to the
10° C (14° F), the Transmission ECM will keep the
transmission forward or reverse clutch.
transmission in neutral.
T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y
When the transmission sump temperature warms up
disconnect the clutch from the engine, but gradually
to minus 10° C (14°F) (within approximately one
reduces the forward or reverse clutch pressure down
minute), the machine will operate in all gears.
to a lower level.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.

6002-13
NOTES

6002-14
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter - Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
60 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
63 Behind the Converter Temperature 100° C, Short Time 120° C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16” - 12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16” - 12 UNF-2B
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter n Turbine M18x1.5
34 Speed Sensor n Output and Speedometer
47 Inductive Transmitter n Central Gear Train M18x1.5
48 Inductive Transmitter n Engine M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
NOTE: See Figure 10 for Measuring Point, Transmitter, Sensor and Connection locations.

6002-15
BC01B047
FIGURE 10. MEASURING POINTS AND CONNECTIONS

6002-16
CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:
TEST POINTS
Shift P V R 1 2 3 4 5 6
LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE
V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN
R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT

6002-17
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
9. Charge pump worn. B. Check that torque converter installation is

correct.
10. Oil supply flange not sealing correctly.
Machine Stops or Hesitates While
Some Pressures Low Shifting - Intermittent
Possible causes include:
Possible causes include:
1. Circuit isolation does not correct low pressure.
1. Check orifice and O-ring. (See Section 6007 for
A. Control valve or gasket. replacing.)
B. Channel plate or gasket. 2. Check for foreign material plugging orifices or
sticking valves.
2. Circuit isolation corrects low pressure.
3. Check for reduced pressure at test pressure
A. Clutch shaft or seals.
points.
B. Clutch drum or piston.
4. See Electrical Troubleshooting in this Section for
electrical system problem.

6002-18
CONVERTER OUT PRESSURE CHECK
Test Equipment Required 2. Apply the parking brakes.
0 to 28 bar (400 psi) gauge with hose long enough to 3. Install the pressure gauge.
take readings in the cab and CAS-2324 Special 4. Heat the oil to an operating temperature of 80 to
Adapter. 100° C (176 to 212° F).
5. While in the cab, put the transmission in
Test Procedure NEUTRAL. Run the engine at full throttle. Record
1. Block the machine tires. the r ead in g in the cha rt on p ag e 60 02 .1 6.
Pressure must be a minimum of 2.5 bar (36 psi).
LUBRICATION PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 6002.16. Pressure
must be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to

100° C (176 to 212° F).
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter. 4. Remove the filter and install the CAS-2702
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
2. Apply the parking brakes. Put the transmission in NEUTRAL and record the
flow measurement. The correct flow for 521D
machines is 52 L/min (14 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEEDURE

1. Block the machine tires. 6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1
2. Apply the parking brakes.
L/min (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 ° F).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line L/min (2 U.S. gpm).
to cooler) in series.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).

6002-19
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

6002-20
ERROR CODES
In case of possible errors in the system, a wrench appears on the display, combined with indication of the error
number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION

Shifter Wire Shifter Tower Shifter Shroud Harness Harness
Function Shifter Trans. ECM #
Color Connector Connector Wire # ped/cab #
power B+ red/black A A 19A 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-2) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Transmission ECM Transmission Transmission Transmission Trans/Cab
Clutch # Wire #
Function ECM Pin # Valve Valve Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12

Section
6003
6003
TRANSMISSION
CASE CORPORATION
700 State Street
Hamilton, ON L7N 3M6 CANADA Bur 6-47310 June, 2002
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6003-3
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
CAS2807 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL CAS2869 TRANSMISSION
INSTALLATION TOOL OUTPUT SHAFT SEAL
CAS2803 TRANSMISSION INSTALLATION TOOL
TORQUE CONVERTER SEAL (521D AND 621 MODELS
INSTALLATION TOOL ONLY)
BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT
CAS2802 ALIGNMENT
CAS2799 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2796 NESTING MOUNTING BRACKETS
PLATE
CAS2868 CLUTCH
SPRING COMPRESSOR
(521D AND 621 MODELS
CAS2800 CLUTCH CAS2797 LIFTING ONLY)
ASSEMBLY HOLDING EYEBOLT SET
CAS2798 GEAR KNOB SET
PULLER COLLET SET
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
SPECIAL TORQUES
Oil pipes
Studs .............................................................................................................................................. 9 Nm (80 lb-in)
Socket head screw ..................................................................................................................... 23 Nm (204 lb-in)
Screw plug .................................................................................................................................... 51 Nm (38 lb-ft)
Clutch K1, K2, K3, K4 Stud ............................................................................................................ 17 Nm (150 lb-in)
Plugs................................................................................................................................................ 25 Nm (221 lb-in)
Output shaft
Output shaft screws (apply Loctite 243 to threads) .................................................................... 23 Nm (204 lb-in)
Housing cover screws (apply Loctite 574 to threads)................................................................. 46 Nm (407 lb-in)
Output flange screws ................................................................................................................. 34 Nm (301 lb-in)
Oil feed housing and transmission pump
Transmission pump screws ........................................................................................................ 46 Nm (407 lb-in)
Oil feed housing screws ............................................................................................................. 25 Nm (221 lb-in)
Engine connection and converter
Input shaft screws ....................................................................................................................... 115 Nm (85 lb-ft)
Converter housing screws............................................................................................................. 68 Nm (50 lb-ft)
Cover........................................................................................................................................... 23 Nm (204 lb-in)
Converter cover.......................................................................................................................... 46 Nm (407 lb-in)
Input flange ................................................................................................................................. 34 Nm (301 lb-in)

6003-4
SPECIAL TORQUES (CONTINUED)

Duct plate
Screws ....................................................................................................................................... 25 Nm (221 lb-in)
Screw plug ................................................................................................................................. 30 Nm (265 lb-in)
Hydraulic control unit ....................................................................................................................... 9.5 Nm (84 lb-in)
Filter
Filter head screws ...................................................................................................................... 25 Nm (221 lb-in)
Oil distribution cover screws ...................................................................................................... 25 Nm (221 lb-in)
Speed sensor and inductive transmitter
Speed sensor screw................................................................................................................... 23 Nm (204 lb-in)
Inductive transmitter ................................................................................................................... 30 Nm (265 lb-in)
Cover plate ................................................................................................................................. 23 Nm (204 lb-in)
Screw plug ................................................................................................................................ 140 Nm (103 lb-ft)
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.5 to 2.7 mm (0.098 to 0.106 in)
Clutch K1, K2,K3 plate clearance........................................................................... 2.1 to 2.3 mm (0.083 to 0.090 in)
Clutch K4 Plate Clearance ..................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)
NOTE: The J I Case Company reserves the right to make improvements in design or changes in specifications at
any time without incurring any obligation to install them on units previously sold.

6003-5
DISASSEMBLY
STEP 1 STEP 4
GD98M833 GD98M837
Fasten transmission on an assembly stand using R e m o v e tw o s o c k e t h e a d s cr e w s a n d i n s ta l l

CAS2801 transmission mounting brackets. CAS2885 transmission valve adjustment tool set.
Remove remaining 21 socket head screws securing
STEP 2 control valve. Loosen and remove hex rods (part of
CAS2885) from studs then remove control valve.
STEP 5
GD98M835
Remove and discard oil filter.
STEP 3 GD98M838
Remove both gaskets and the intermediate plate.
STEP 6
GD98M836
Remove hex head screws securing filter head.

Remove filter head from transmission. GD98M839
Remove socket head screws and hex nuts. Remove

duct plate. Remove flat gasket.

6003-6
STEP 7 STEP 10
GD98M844
GD98M847
Be nd loc k p late a wa y fr om he x h e ad sc re ws.
U sin g p r o p er siz e r o d, p r e ss in p u t sh a ft a n d
Remove two hex head screws, lock plate, and
converter from cover.
washer. Remove input flange from shaft.
STEP 11
STEP 8
GD98M845 GD98M848
Pu t alig n me n t ma rk s on co n ve r te r co ve r a n d Remove retaining ring then remove bearing.
housing to aid in assembly. Remove 12 nuts and
hex head screws. STEP 12
STEP 9
GD98M849
Rem ove f our hex head sc rews and rem ov e

GD98M846
diaphragm and input shaft.
C o n n e c t s u i t a b l e l if t i n g e q u ip m e n t t o s h a f t.
R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m
transmission and place in hydraulic press.

6003-7
STEP 13 STEP 16
GD98M853
GD98M850
Put input shaft and diaphragm in vise as shown. Remove the socket head screws for removal of the
Remove 12 hex head screws to separate transmission pump.
diaphragm and input shaft.
STEP 17
STEP 14
GD98M854
GD98M851 Apply a bearing separator on the splines shoulder of

Remove the inductive transmitter. the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
STEP 15 NOTE: If traces of wear should be encountered in
the pump housing or the cam disk, the complete
pump has to be replaced.
STEP 18
GD98M852
Remo ve the h ex head scre ws and remo ve the

converter housing.
GD98M855
Se p ar at e th e tra n smiss ion p u mp fr om st ato r.

Separate the cam plate from pump.
6003-8
STEP 19 STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
Remove the hex head screws and remove the oil

feed housing. Remove the flat gasket.
STEP 20 GD98M862
Remo ve the spe ed se nso r and bo th in ductive

transmitters.
STEP 25
GD98M860
Remove the hex head screws, cover, and flat gasket.
STEP 21
GD98M863
Remove the hex nuts and the two covers.
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22 GD98M864
Pry the shaft seal out of the housing bore. Install CAS2802 alignment dowel set.
NOTE: The following steps describe the common
removal of all clutches.
6003-9
STEP 27 STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
BK00D029
Install CAS2800 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install CAS2797 lifting eyebolt set and lifting device
to transmission cover. GD98M867
Remove the socket head screws and remove the

STEP 28 output shaft and both oil baffle plates.
STEP 32
BK00D028
Separate the cover along with clutches from the

transmission housing, using lifting device. GD98M872
STEP 29 Remove clutch K2.
STEP 33
BK00D026
Place clutch disc carriers onto CAS2796 nesting

GD98M873
plate.
Remove clutch K1 while lifting clutch K4.

6003-10
STEP 34 STEP 37
GD98M877
GD98M874
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
GD98M875
GD98M878
Remove clutch K4 while lifting input shaft slightly.
Remove the rectangular ring and separate ball
STEP 36 bearing from the shaft.
NOTE: The following steps are for the disassembly
of the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
GD98M876
Remove clutches KV and KR together with input

shaft.
GD98M979
Remove the sealing ring. Pull the tapered roller

bearing from the shaft. Remove the opposite tapered
roller bearing.
6003-11
STEP 40 STEP 43
GD98M881 BK00D020
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
GD98M882 BK00D019
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
GD98M885
BK00D018 Remove piston from clutch pack holder. Remove and

Preload compression spring using CAS2799 clutch discard the O-rings from piston.
pack holder and spring compressor tool.

6003-12
STEP 46 STEP 48
GD98M886 GD98M889
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 47 NOTE: The following steps are for disassembly of

clutch K3. Disassembly of clutches K1 and K2 is
similar
STEP 49
GD98M887
GD98M890
Remove the rectangular ring. Pull the tapered roller

bearing from the shaft.
STEP 50
GD98M888
Press the idler gear from the shaft using a bearing

separator. Remove released needle bearing.
GD98M892
Remove the thrust washer, thrust bearing, and thrust

washer.

6003-13
STEP 51 STEP 54
GD98M893 BK00D018
Remove the idler gear. Preload compression spring using CAS2799 clutch
STEP 52
STEP 55
GD98M894
Remove the needle bearings and thrust bearing. BKOOD020
Remove the snap ring.

STEP 53
STEP 56
GD98M895
Remove the snap ring and remove the clutch disc BK00D019
pack. Remove the compression spring.

6003-14
STEP 57 STEP 59
BS00G001 GD98M800
Remove the sealing ring. Remove bearing using Remove and discard two sealing rings. Pull two
bearing puller. Tap assembly until piston drops out of bearings from shaft using bearing puller. Remove the
the clutch pack carrier. Then, remove and discard snap ring and separate the clutch disc carrier from
O-rings from piston. the shaft.
STEP 58 STEP 60
BK00D022 GD98M801
Remove the clutch disc carrier from the shaft. Remove the snap ring and remove the clutch disc
pack.
NOTE: The following steps are for the disassembly
of the clutch K4.
STEP 61
BK00D018
Preload compression spring using CAS2799 clutch


6003-15
STEP 62 NOTE: The following two steps are for disassembly
of the input shaft.
NOTE: A snap ring is used to lock turbine shaft in
input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.
STEP 64
BK00D020
STEP 63
GD98M803
If turbine shaft is to be removed from input shaft, use

proper size diameter sleeve or rod and press turbine
shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Remove the compression spring.

6003-16
ASSEMBLY
NOTE: The following steps are for the reassembly of STEP 69
the oil pipes.
STEP 66
3 GD98M607
Install a new O-ring on plug. Tighten the plug to a

torque of 51 Nm (38 lb-ft).
1
STEP 70
GD98M603
Install suction tube (1), pressure pipes (2), and

lubrication pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 lb-in)
STEP 68
GD98M608
Install all bearing outer races in housing bores.
STEP 71
GD98M605
Tilt the cover 180 degrees. Install the suction tubes

and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be GD98M609
slightly below the housing plane face.
Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the
housing plane face.
6003-17
STEP 72 STEP 75
GD98M610 BK00D019
Install the studs. Tighten the studs to a torque of 9

Nm (80 lb-in).
NOTE: The following steps are for the assembly of
clutches KV and KR, starting with assembly of the
clutch disc carrier.
STEP 73
BK00D018
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring
using CAS2 799 clutch pack h older and spring
compressor tool.
STEP 76
GD98M612
Check that drain hole is clear and free of foreign

matter. Install both O-rings in recesses of the piston
and apply oil.
STEP 74
BK00D020
Install the snap ring.

NOTE: The following steps are for the KV and KR
clutch disc packs. The disc stacking of clutches KV
and KR is identical.
GD98M613
Install piston in clutch disc carrier.

6003-18
STEP 77 STEP 79
GD98M617
Install end shim and snap ring.

225B
1. PLATE CARRIER STEP 80
2. PISTON
3. OUTER PLATE - ONE-SIDED COATED
4. INNER PLATES
5. OUTER PLATES - COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
A RUNNING CLEARANCE 2.5 TO 2.7 MM (0.098 TO 0.106
IN)
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above.
Install outer plates (3) with steel faced side facing
piston and end shim (7).
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To GD98M618
ensure correct adjustment, do not apply oil to clutch Adjust running clearance to 2.5 to 2.7 mm (0.098 to
discs until after adjustment is completed. 0 . 1 0 6 in ) . P r e s s d o w n o n t h e e n d s h i m w it h
approximately 10 kg (20 lb). Measure and record
STEP 78 dimension (A) from carrier face to end shim using
depth gauge as shown.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
GD98M616
Install the clutch disc pack.

6003-19
STEP 81 STEP 84
GD98M619 GD98M621
Use tools to lift the end shim against snap ring Apply Loctite 243 to stud. Tighten stud to a torque of
(upward) until contact is obtained. Measure and 17 Nm (150 lb-in).
record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this STEP 85
measurement from the measurement of Step 80. The
difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.75 mm (0.19 in)
Difference = Running . . . . . . . . . . . 2.50 mm (0.10 in)
Clearance
Required running clearance is 2.5 to 2.7 mm (0.098
to 0.106 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 82
GD98M622
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as Install ball bearing until contact is obtained. Secure
determined in Step 81. using snap ring.
STEP 83 STEP 86
GD98M620 GD98M623
Install idler gear to align and engage all inner discs, Install needle bearing.
then remove idler gear.

6003-20
STEP 87 STEP 90
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Install gear and shaft into heated bore.
Press the idler gear against the shoulder.
STEP 91
STEP 88
BK00D024
GD98M625 Heat bearing.

Secure idler gear using snap ring.
STEP 92
STEP 89
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BK00D023
Use heat gun to heat assembled clutch disc carrier

inner bore.
BK00D025
In st a ll h e at e d b ea r in g o n s ha f t a g a in st sh a ft
shoulder.

6003-21
STEP 93 STEP 96
Check operation of the clutch using compressed air.
NOTE: The following steps are for assembly of
clutch K1, K2, and K3.
STEP 94
GD98M632

matter. Install both O-rings in recesses of piston and
apply oil.
STEP 97
GD98M630
Press bearing against shoulder of shaft. Apply

Loctite 243 to the stud and install the stud. Tighten
the stud to a torque of 17 Nm (150 lb-in).
STEP 95
GD98M633
Install piston in clutch disc carrier.
STEP 98
GD98M631
Install the clutch disc carrier until contact is obtained.
GD98M634
Install the compression spring and spring cup.

6003-22
STEP 99 STEP 101
BK00D019
232A
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 2.1 TO 2.3 MM (0.083 TO 0.090
IN)
Install clutch disc plates in K1, K2, and K3 clutch disc

carriers in position and sequence shown above.
BK00D018 Install outer plate (3) with steel faced side facing
Install compression spring and two spring cups in piston.
clutch disc carrier. Preload compression spring NOTE: Snap rings of different thickness are
using CAS27 99 clutch pack h older and spring available for adjustment of the running clearance. To
compressor tool. ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed.
STEP 100
STEP 102
BK00D020
Install the snap ring. GD98M636
NOTE: The following steps are for K1, K2 and K3 Install the clutch disc pack.
clutches. The assembly of clutches K1, K2, and K3 is
identical.

6003-23
STEP 103 STEP 105
GD98M637 GD98M639
Install the end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 104 record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this
measurement from the measurement of Step 104.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running . . . . . . . . . . . .2.1 mm (0.08 in)
Clearance
GD98M638
STEP 106
Adjust running clearance for K1, K2, and K3 to 2.1 to Remove clutch disc pack, apply oil to discs, and
2.3 mm (0.083 to 0.090 in). Press down on the end install clutch disc pack, end shim, and snap ring as
shim with approximately 10 kg (20 lb). Measure and determined in Step 105.
record dimension (A) from carrier face to end shim
using depth gauge as shown. STEP 107
Example
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)
3
2
1
GD98M640
Install the thrust washer (1), thrust bearing (2), and

thrust washer (3).
NOTE: Install the thrust washer (1) with the chamfer
facing the thrust bearing.

6003-24
STEP 108 STEP 111
GD98M641 BK00D024
Install both needle bearings. Heat bearing.
STEP 109 STEP 112

SM121A
GD98M642
Install idler gear until all inner discs are engaged.
STEP 110
BK00D025
1 Place heated bearing on the shaft.
2 STEP 113
3
GD98M643
Install the thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
NOTE: Ensure the thrust washer (1) is overlapping
with the chaff collar to accommodate all the inner
discs.

6003-25
NOTE: The following steps are for assembly of STEP 116
clutch K4.
STEP 114
SM121A
GD98M649
Apply Loctite 243 to the stud and install the stud.

Tighten the stud to a torque of 17 Nm (150 lb-in).
STEP 117
GD98M647
Heat the gear to about 120° C (248° F) and install

until seated in position.
STEP 115
GD98M650

matter. Install both O-rings in recesses of the piston
and apply oil.
STEP 118
GD98M648
Install retaining ring to secure gear.
GD98M651
Install piston in clutch disc carrier. Be sure piston

bottoms out.

6003-26
STEP 119 STEP 121
BK00D019 BS02C131
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer
plate (3) with steel faced side facing piston.
NOTE: Snap rings of different thickness are
BK00D018 available for adjustment of the running clearance. To
Install compression spring and two spring cups in ensure correct adjustment, do not apply oil to clutch
clutch disc carrier. Preload compression spring discs until after adjustment is completed.
using CAS27 99 clutch pack h older and spring
compressor tool. STEP 122
STEP 120
GD98M653
Install clutch disc pack.

BK00D020
Install snap ring.

NOTE: The following steps are for installing the
clutch disc pack in clutch K4.

6003-27
STEP 123 STEP 125
GD98M654 GD98M656
Install end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 124 record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this
measurement from the measurement of Step 124.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
GD98M655
STEP 126
Adjust running clearance to 1.2 to 1.4 mm (0.047 to Remove clutch disc pack, apply oil to discs, and
0 . 0 5 5 in ) . P r e s s d o w n o n t h e e n d s h i m w it h install clutch disc pack, end shim, and snap ring as
approximately 10 kg (20 lb). Measure and record determined in Step 125.
dimension (A) from carrier face to end shim using
depth gauge as shown. STEP 127
Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.

6003-28
STEP 128 STEP 131
GD98M658 GD98M661
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1). Install the thrust washer (1) with
NOTE: Upper and lower thrust washers are the
the chamfer facing the thrust bearing.
same thickness.
STEP 132
STEP 129
GD98M662
GD98M659
Install the assembled clutch disc carrier until all the
Install both needle bearings.
inner discs are engaged.
STEP 130 STEP 133
GD98M660
GD98M663
Install the idler gear.
Install snap ring to secure clutch disc carrier.

6003-29
STEP 134 STEP 138
SM121A
BK00D024
Heat bearing.
STEP 135
WARNING: Always wear heat protective GD98M666
gloves to prevent burning your hand when Heat gear to about 120° C (248° F) and install on
handling heated parts. input shaft until contact is obtained.
SM121A
STEP 139
BK00D025
Install heated bearing on the shaft shoulder. GD98M667
Secure gear with snap ring.

STEP 136
Repeat Steps 134 and 135 to install bearing on STEP 140
opposite end of shaft.
STEP 137
NOTE: The following steps are for the reassembly of
the input shaft.
GD98M668
Install snap ring into recess of turbine shaft.

6003-30
STEP 141 STEP 144
GD98M669 GD98M672
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 NOTE: The following steps are for the installation of
the output shaft and clutches. All clutches have a
WARNING: Always wear heat protective common installation.
handling heated parts. STEP 145
SM121A
K1 K4
AN KR
AB
K3 K2
KV
GD98M673
BK00D024 Install bearing outer races into housing cover until

Heat bearings and install on turbine shaft until contact is obtained.
bearings are against shoulder.
STEP 146
STEP 143
BK00F003
GD98M671 Install the clutches onto CAS2796 nesting plate.

Install bearing then install rectangular ring.

6003-31
STEP 147 STEP 150
BK00D029 GD98M681
Using CAS2797 lifting eye bolt set and acceptable Install the sealing rings and insert rings in their
lif tin g e q u ip m e n t , in s ta ll h o u s in g c o v e r o n t o respective grooves. Apply grease to the sealing rings
clutches. Install CAS2800 clutch assembly holding and align the rings centrally.
knob set to secure clutch shafts to cover.
STEP 151
STEP 148
KR
KV
K4
K2
K1 K3
GD98M692
GD98M679 Install both the O-rings into the annular groove of the
The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
AN
KV KR
K2 K4
K3 K1
AB
GD98M866
The above shows the position of the single clutches

and the input and output clutches.

6003-32
STEP 153 STEP 156
GD98M683 GD98M686
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover rear bearings on output shaft until contact with
and clutches into the gear box housing. shoulder of output shaft is made.
STEP 154 STEP 157

Remove CAS2800 clutch assembly holding knob set.
STEP 155
GD98M688
Install the screening plate.
GD98M685 STEP 158

Separate the housing cover from the gearbox, using
a lifting device.
NOTE: The following steps are for the reassembly of
the output shaft.
GD98M689
Install the output shaft.

6003-33
STEP 159 STEP 162
GD98M690 GD98M697
Apply Loctite 243 to the socket head screws and Heat the output flange to about 90° C (194° F). Apply
install the screws. Tighten the screws to a torque of Loctite 574 to the contact area and assemble the
23 Nm (204 lb-in). flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 lb-in).
STEP 160 Bend corner of lock plate over hex head screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
the oil feed housing and transmission pump.
STEP 164
GD98M691
Install rectangular rings in grooves of clutch shafts.

Apply grease to rings and align rings.
STEP 161
GD98M702
Install two alignment studs and install the gasket.
GD98M696
Position shaft seal with sealing lip facing oil chamber.

Apply grease to sealing lip. Use CAS286 9
transmission output shaft seal installation tool to
install seal.

6003-34
STEP 165 STEP 168
GD98M703 GD98M706
Install the oil feed housing with washers and hex Install transmission pump.
head screws. Screw the hex head screws in only
until contact is obtained, do not tighten. STEP 169
STEP 166
GD98M707
Apply grease to new O-rings. Install the O-rings on

GD98M704 the socket head screws.
Install the two alignment screws and install the stator
shaft. STEP 170
STEP 167
GD98M708
Secure the transmission pump with the socket head

GD98M705 screws. Tighten screws to a torque of 46 Nm (407
Apply oil and install the O-ring. lb-in).

6003-35
STEP 171 STEP 173
GD98M709 GD98M712
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of screws. Tighten the screws to a torque of 68 Nm (50
25 Nm (221 lb-in). lb-ft).
STEP 172 STEP 174
GD98M711 GD98M713
Position the gasket and cover. Secure the cover with P u t i n p u t s h a ft in a v i se a s s h o w n . P o s it io n

the hex head screws. Tighten the screws to a torque diaphragm on input shaft and secure using 12 hex
of 23 Nm (204 lb-in). head screws. Tighten screws to a torque of 115 Nm
(85 lb-ft).
the engine connection and converter. STEP 175
GD98M714
Position diaphragm and input shaft on converter.

Apply Loctite 262 to threads of hex head screws.
Install screws and tighten to a torque of 115 Nm (85
lb-ft).
6003-36
STEP 176 STEP 178
GD98M715 GD98M718
Position converter cover on converter housing. Make

sure alignment marks made during removal of cover
are aligned. Install input flange, two hex head
screws, lock plate, and washer. Pull cover against
housing by tightening two hex head bolts evenly.
STEP 179
GD98M716
Position converter. Check and ensure that impulse

disk of converter is centered on the bore for the
inductive transmitter.
STEP 177
GD98M719
Secure converter cover using 12 hex head screws

and nuts. Tighten screws to a torque of 46 Nm (407
lb-in).
GD98M717
Position converter cover as shown. Install bearing

against shoulder in cover. Secure using retaining
ring.

6003-37
STEP 180 NOTE: The following steps are for installation of
transmission control valve.
STEP 183
GD98M720
Tighten input flange hex head screws to a torque of

34 Nm (301 lb-in). Lock screws by bending corners
258
of lock plate over screws.
Install CAS2885 transmission valve adjustment tool
STEP 181 set. Be sure hex rods (part of tool set) are not
installed on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 lb-in).
STEP 185
GD98M724
Install new sealing rings and both plugs in duct plate.
STEP 182
GD98M727
Install control valve on duct plate and CAS2885

studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 lb-in). Remove
CAS2885 transmission valve adjustment tool set.
Install remaining two socket head screws. Tighten
screws to a torque of 9.5 Nm (84 lb-in).
NOTE: The following steps are for the installation of
GD98M725
the filter.
Install the gasket and place the duct plate against
shoulder. Install socket head screws and hex nuts.
Tighten to a torque of 25 Nm (221 lb-in).

6003-38
STEP 186 STEP 189
GD98M729 GD98M735
Install new O-rings in recesses of oil filter head. Apply grease to the new O-ring and install the speed
Position filter head on transmission and secure using sensor with the socket head screw. Tighten the
two socket head screws. Tighten screws to a torque screw to a torque of 23 Nm (204 lb-in).
of 25 Nm (221 lb-in).
STEP 190
STEP 187
GD98M736
GD98M730 With new O-rings, install the inductive transmitters.

Install a new transmission filter. Tighten to a torque of 30 Nm (265 lb-in).
STEP 188 STEP 191

Install the breather.
STEP 192
GD98M733
Install new O-rings in oil distribution covers. Install GD98M737

the two oil distribution covers on the housing with hex
Install the gasket and the cover plate. Tighten to a
nuts and flat washers. Tighten to a torque of 25 Nm
torque of 23 Nm (204 lb-in). With a new O-ring, install
(221 lb-in).
the screw plug. Tighten to a torque of 140 Nm (103
lb-ft).
Section
6004
6004
FRONT AXLE
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-45240 June, 2002
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIFFERENTIAL CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DRIVE PINION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BRAKE TUBES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE TUBES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIFFERENTIAL CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Determine Shim Thickness for Correct Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6004-3
SPECIFICATIONS
Lubricant Capacity........................................................................................................22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ...................................... 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim .........................................................................4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play ............................................................................................................1.00 mm (0.04 inch)
Drive Pinion Rolling Torque ................................................................................... 1.1 to 2.3 Nm (9.7 to 20.3 lb-inch)
Seal Caps Depth in Differential Housing .................................................................1.5 to 2.5 mm (0.06 to 0.10 inch)
Differential Carrier Disc Clearance .............................................................................................. 0.40 mm (0.02 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing....................................................................................390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier........................................................................ 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve and Fitting ....................................................................................................................... 130 Nm (96 lb-ft)
Axle Housing Connector for Brake Tube ........................................................................................190 Nm (140 lb-ft)
Nut Securing Brake Tube to Connector.............................................................................................. 70 Nm (52 lb-ft)
Brake Tube Fitting to Wheel End Fitting ............................................................................................. 80 Nm (60 lb-ft)
Breather Plug......................................................................................................................................70 Nm (52 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads).............................................................700 Nm (516 lb-ft)
Bolts Securing Differential Ring Gear .............................................................................................250 Nm (185 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ......................................280 Nm (207 lb-ft)
Differential Carrier Mounting Bolts..................................................................................................250 Nm (185 lb-ft)
SPECIAL TOOLS
Brake housing seal installer. . . . . . . . . . . . CAS2880 Step plate set (includes 8061, 8067,
Differential bearing cone puller collet set. . CAS2871 and 8073) . . . . . . . . . . . . . . . . . . . . . . . .OEM4288
Differential bearing preload wrench . . . . . . CAS2851 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8061
Brake housing inner bearing cup installer . CAS2877 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8067
Brake housing outer bearing cup installer . CAS2878 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8073
Wear ring installer adapter . . . . . . . . . . . . CAS2875 Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2876
Pinion depth gauge set . . . . . . . . . . . . . . . CAS2872 Planetary Gear Puller . . . . . . . . . . . . . . . . . CAS2848
Puller body and screw . . . . . . . . . . . . . . . . CAS2882 Brake Housing Puller Bridge . . . . . . . . . . . CAS2850
Support bracket . . . . . . . . . . . . . . . . . . . . . CAS2883 Pressure Ring Installer . . . . . . . . . . . . . . . . CAS2860
Slide hammer puller adapter . . . . . . . . . CAS10846-3 Holding Bracket . . . . . . . . . . . . . . . . . . . . CAS2847
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252 Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2848
Replacer . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2297 Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4175
Dial indicator with magnetic base . . . . . CAS10066A Puller Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
Heat gun . . . . . . . . . . . . . . . . . . . . . . . . . CAS10810 Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8065
Engine stand . . . . . . . . . . . . . . . . . . . . . . . OEM4135 Holding Wrench . . . . . . . . . . . . . . . . . . . . CAS1579A
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6484 Pinion Inner Bearing Cup Installer . . . . . CAS2293-1
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6177 Pinion Outer Bearing Cup Installer . . . . . CAS2293-2
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6492 Pinion Seal Installer . . . . . . . . . . . . . . . . . . CAS2288
Alignment Studs . . . . . . . . . . . . . . . . . . . . CAS2861 Pinion Seal Installer . . . . . . . . . . . . . . . . . . CAS2299
Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4054

6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

6004-6
LUBRICATION
4 4
5
5 6
4 4
6
3 2
2 3
2 1 1
2
BS00M069 BS00M070
1. OIL DRAIN HOLE (AXLE HOUSING) 3. PLUG 5. BREATHER

2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER 6. DIPSTICK AND OIL FILL
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 70 Nm (52 lb-ft).

6004-7
WHEEL END AND BRAKE
Disassembly STEP 3
NOTE: Tools and axle shown in the following
photographs may appear slightly different than the
tools and axle you may have. The use of the tools
and disassembly/assembly of axle is the same
regardless of appearance.
STEP 1
BD00M238
Using two pry bars, remove cover from output shaft.

Remove and discard O-ring from cover.
STEP 4
BD00M235
Fasten axle on a stand.
STEP 2
BD00M239
Remove pin from lock nut using OEM4252 slide

hammer and CAS10846-3 adapter.
STEP 5
BD00M236
BD00M240
Remove lock nut using CAS2883 support bracket

BD00M237 and CAS2876 socket and nuts.
Remove drain plugs and drain oil from axle housing.
6004-8
STEP 6 STEP 9
BD00M241 BD00M244
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP 10
STEP 7
BD00M245
BD00M242 Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
Remove and discard O-ring from axle housing wheel
end. STEP 11
STEP 8
BD00M246
Using OEM4054 pulling attachment, remove the

BD00M243
planetary carrier.
Pull the stub shaft out of the sun gear shaft. Be
careful not to lose shim(s) that may be installed in
sun gear shaft.

6004-9
STEP 12 STEP 15
BD00M247 BD00M250
Remove retaining ring. Put alignment marks on planetary ring gear and
brake housing to aid in assembly. Using suitable
STEP 13 puller, remove planetary ring gea r fro m bra ke
housing.
STEP 16
BD00M248
Using CAS2848 planetary gear puller and step plate

8061, remove planetary gear and outer bearing from BD00M251
planetary carrier shaft. Using a suitable puller, Remove and discard two O-rings from planetary ring
remove the inner bearing from carrier shaft. gear.
STEP 14 STEP 17
Repeat Steps 12 and 13 to remove the remaining
three retaining rings, planetary gears, and six
bearings.
BD00M252
Remove and discard O-ring from brake housing port.

6004-10
STEP 18 STEP 21
BD00M253 BD00M256
Remove the brake disc pack from brake housing. W E A R FA C E P R O T E C T I O N W H E N U S I N G

COMPRESSED AIR. Apply compressed air to brake
STEP 19 ho using por t to pus h br ake pis to n fro m bra ke
housing.
STEP 22
BD00M254
Using suitable tool, push the three pins down until

pins are even with top surface of shim.
BD00M257
STEP 20 Remove the support shim from the brake piston.
STEP 23
BD00M255

BD00M258
Remove three pins from support shim.

6004-11
STEP 24 STEP 27
BD00M262
BD00M259
Lift and remove the piston from the brake housing.
Put support shim in a press and compress Belleville
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
BD00M263
BD00M260
Remove seven Belleville washers from each pin.
STEP 26
BS00M072
1. BRAKE HOUSING 5. U-RING

2. GUIDE RING 6. SUPPORT RING
3. SUPPORT RING 7. WHEEL END SHAFT
BD00M261 4. U-RING
Using a press, remove four gripping rings from each
Remove the guide ring (2), support rings (3 and 6),
pin.
and U-rings (4 and 5) from the grooves of the brake
housing.

6004-12
STEP 29 STEP 32
BD01F102A BD00M267
Using the CAS2850 brake housing puller bridge and Remove the face seal from the brake housing.
8073 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the
STEP 30 wheel end shaft.
STEP 34
BD00M265
Use acceptable lifting equipment and lift the brake

housing from the wheel end shaft. BD00M269
Remove and discard the face seal metal ring from

STEP 31 the wheel end shaft.
BD00M266
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.

6004-13

IMPORTANT: Do not use compressed air to dry
bearings. Allow bearings to air dry. STEP 40
STEP 35
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FA C E
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 36
I n s p e c t b e a r i n g r o l l e r s f o r p i t t i n g , s c o r in g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
d a m a g e . C h e c k a s s o c ia te d b e a r in g c u p s f o r BD00M271
scratches, grooves, or cracks. Check bearings for Install a new face seal metal ring on the wheel end
rough spots or binding by holding bearing and shaft.
rotating. If bearing binds or action is not smooth,
replace the bearing. STEP 41
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires
replacement, the associated part must also be
replaced.
STEP 38
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks, BD01F107
chipping, or other damage. Replace the part if any of
these conditions are seen. Check planetary carrier
sh a f t sp lin e s f o r b r ok e n , c ra c ke d , o r t w ist e d
condition. Replace if necessary.
STEP 39
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD01F105
Install CAS2875 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using CAS2860
pressure ring installer.

6004-14
STEP 42 STEP 45
SM121A
BD00M275
A A
BD00M273 A 1
Heat the wheel end shaft outer bearing to 100° C
(212° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel 2
end shaft until the bearing is against the shoulder on
the wheel end shaft.
STEP 43
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
BD00M274 STEP 46
Using CAS2877 inner bearing cup installer, press the
inner bearing cup into the brake housing until seated
against the shoulder in the brake housing.
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
BD00M276
Use acceptable lifting equipment and install the

brake housing on the wheel end shaft.

6004-15
STEP 47 STEP 48
SM121A
BD00M278
BD00M277
Heat the wheel end shaft inner bearing to 100° C

gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the bearing cup
in the brake housing.
BS00M072
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION

4. U-RING
Install the support rings and U-rings in the grooves of
the brake housing.

6004-16
STEP 49 STEP 51
A B
BD00M279 BD00M282
1. GRIPPING RINGS
Clean the groove of the brake housing with cleaning
solvent. Install the guide ring in the groove. Make Press the gripping rings on the pins. Ends of gripping
sure the ends (A) of the guide ring are facing up rings must be 180° opposite from each other.
towards the top (B) of the brake housing and the
guide ring is installed completely in its groove in the STEP 52
brake housing. Apply Loctite 415 to ID of guide ring
to secure guide ring in its groove.
STEP 50
BD00M283
5 4
BD00M280
3
Apply oil on the sliding surface of the piston, support
rings, U-rings and guide ring. Carefully install piston
A
in the brake housing. 2
BS00M074
1. PIN 4. SUPPORT SHIM

2. GRIPPING RINGS 5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
Install the Belleville springs on the pins. Make sure
dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

6004-17
STEP 53 STEP 56
BD00M284 BD00M287
Put the assembled pins into the support shim and

install the snap ring. A
STEP 54
BS00M075
1. BRAKE HOUSING 4. SUPPORT SHIM

2. SNAP RING 5. PISTON
3. PIN A. 4.5 TO 5.0 MM (0.18 TO 0.20
BD00M285 INCH)
Put the assembled support shim in the piston. Install the three pins (3) in the support shim (4) to
lock the snap ring (2). Dimension (A) between top of
STEP 55 pins (3) and top of support shim (4) must be 4.5 to
5.0 mm (0.18 to 0.20 inch).
STEP 57
BD00M286
Install the snap ring to secure the support shim.

1
BD00M288
1. SPLINE
If removed, drive the stop bolt into the planetary

carrier until contact. Then coat the spline with Loctite
No. 767 antiseize lubricant.
6004-18
STEP 58 STEP 61
BD00M289
BD00M251
Install the planet carrier into the spline of the wheel Apply grease to new O-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
BD00M253
BD00M291
Apply oil to the clutch discs. Install the outer and
Install two alignment studs in the brake housing.
inner clutch discs alternately starting with an outer
Pos ition the plan eta ry r in g g ea r o n th e b ra ke
clutch disc.
housing. Make sure alignment marks made during
disassembly are aligned. Press planetary ring gear
STEP 60 into brake housing.
BD00M290
Install a new O-ring in the brake housing port.

6004-19
STEP 63 STEP 65
WARNING: Always wear heat protective WARNING: Always wear heat protective
gloves to prevent burning your hand when gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
BD00M292 BD00M294
Heat the planetary gears inner bearings to 100° C Heat the planetary gears outer bearings to 100° C
(212° F) in a bearing oven. Wearing heat resistant (212° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
BD00M293 BD00M295
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear
shafts.

6004-20
Sun Gear Shaft End Play Adjustment STEP 69
STEP 67
BD00M298
Install the sun gear shaft in the stub shaft. Make sure
BD00M296 the stub shaft is installed all the way into the sun gear
Using two M18 bolts of suitable length, secure shaft.
p la n e t a r y r in g g e a r to b r a k e h o u s in g . Th e n ,
d e te r min e di me n si on A, f ro m t h e fa c e of t h e STEP 70
planetary carrier stop bolt to the mounting face of the
planetary ring gear.
Example:
Dimension A . . . . . . . . . . . . . 36.00 mm (1.42 inch)
STEP 68
BD00M299
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
Example:
Dimension B . . . . . . . . . . . . . . 32.80 mm (1.29 inch)
BD00M297 STEP 71
Install the stub shaft in the spline of the axle bevel Subtract dimension B from dimension A. Then
gear. Make sure the stub shaft is installed all the way subtract 1 mm (0.04 inch) from the difference. The
into the axle bevel gear. difference is the required shim size.
Example:
Dimension A + 36.00 mm (1.42 inch)
Dimension B − 32.80 mm (1.29 inch)
Difference 3.20 mm (0.13 inch)
Required end play − 1.00 mm (0.04 inch)
Difference = shim
2.20 mm (0.09 inch)
size

6004-21
STEP 72 STEP 75
BD00M245 BD00M300
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
BD00M244
Install the shim set (size as determined in Step 71

above) into the sun gear shaft with grease. BD00M301
Install the lock nu t by ha nd a nd tig hten usin g

STEP 74 CAS2883 support bracket and CAS2876 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 77
BD00M242
Apply grease to a new O-ring and install O-ring in

brake port. Use acceptable lifting equipment and
install the assembled wheel end o nto the axle
housing. BD00M302
Install the slotted pin into the wheel end lock nut.

6004-22
STEP 78 STEP 79
BD00M303 BD00M304
1. O-RING
Install the cover into the wheel end.
Install a new O-ring on the wheel end cover.

6004-23
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 High Pressure Test
PSI) PRESSURE IN THE FOLLOWING STEPS. If
the maximum pressure of 100 bar (1450 psi) is
STEP 81
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings Operate the hand pump to increase pressure to 100
adjustment changes, the wheel end must be bar (1450 psi) maximum. Close connection to hand
removed and disassembled and the gripping rings pump using the shutoff valve. During a 5 minute
adjusted to the correct dimension (Step 52). period, pressure shall not drop more than 2 bar (29
psi).
STEP 80
Low Pressure Test
STEP 82
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BD00M305
Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
Case MS-1209 Hy-Tran® Ultra. Build up pressure in
the axle internal brake lines then bleed air from the
lines. After air is bled, actuate the brakes a minimum
of 10 times by operating the hand pump.

6004-24
DIFFERENTIAL CARRIER DISASSEMBLY

STEP 83 STEP 85
BD00M306 BD00M241
Fasten the axle to a stand. Use acceptable lifting equipment to hold wheel end in
place. Remove the bolts and washers.
STEP 84
STEP 86
BD00M307
BD00M242
Carefully pull the wheel end from the axle housing.

end.
BD00M308
Remove drain plugs and drain oil from axle.

6004-25
STEP 87 STEP 91
BD00M243
BD00M314
Pull the stub shaft out of the sun gear shaft. Be Mount differential carrier in OEM4135 engine stand
careful not to lose shim(s) that may be installed in using one CAS2847 holding bracket.
sun gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BD00M315
Drive out the roll pins from the bearing caps.
STEP 93
BD00M312
Put alignment marks on the differential carrier and

axle housing. Remove 15 bolts securing differential
carrier.
STEP 90
Connect lifting equipment to flange and remove the
differential carrier from axle housing.
BD01F072
Remove both adjusting nuts using CAS2851 wrench.

6004-26
STEP 94 STEP 96
BD00M317 BD00M319
Heat the differential carrier using a hot air blower. Remove both bearing cups.
NOTE: Bolts are installed with Loctite.
STEP 97
STEP 95
IMPORTANT: Do not use an air ratchet or wrench to
remove bolts.
1
BD00M320
Use acceptable lifting equipment and remove the

differential from the differential carrier.
BD00M318
1. ALIGNMENT MARK
M a k e a li g n m e n t m a r k s o n b e a r in g c a p s a n d
differential housing to aid in assembly. Remove four
bolts then remove both bearing caps.

6004-27
DIFFERENTIAL DISASSEMBLY
STEP 98 STEP 101
BD01F059
BD00M324
Remove the bearing from the differential housing
Remove the housing cover from the differential
using CAS2848 puller, OEM4175 pulling attachment,
housing.
1103 puller legs, and 8065 step plate.
STEP 99 STEP 102
BD01F075 BD00M325
Remove the bearing from the housing cover using Remove all parts from the differential housing.
CAS2871 collet set, CAS2882 puller body, and 8067
step plate. STEP 103
STEP 100
BD00M326
BD00M323 Press the ring gear from the differential housing.

Place the differential in a press to prevent it from
turning. Remove the bolts.

6004-28
DRIVE PINION DISASSEMBLY

STEP 104 STEP 107
Heat lock nut securing flange with a hot air blower to
loosen Loctite.
STEP 105
BD00M330
Remove the shaft seal from the axle drive housing.
STEP 108
BD01F091 Using a rubber hammer remove the drive pinion from
Install CAS1579A holding wrench on input flange. the axle drive housing. Remove the pinion outer
Hold flange using holding wrench and remove lock bearing.
nut and washer. Remove holding tool from flange.
STEP 109
STEP 106 Remove the spacer ring and inner bearing from the
drive pinion.
STEP 110
BD00M329
Remove the input flange from the drive pinion.
BD00M333
If necessary drive out both bearing cups from the

differential carrier.

6004-29
BRAKE TUBES REMOVAL

STEP 111 STEP 114
BD00M334 BD00M337
Remove the plug with the breather installed from the Loosen the fitting on the opposite end of the brake
axle housing. tube then remove the brake tube from the axle
housing.
STEP 112
STEP 115
BD00M335
Remove the nut securing the brake tube to the axle BD00M338
housing. Remove the vent valve from the fitting.
STEP 113 STEP 116
BD00M336 BD00M339
Loosen and remove the connector from the axle. Remove the fitting. Remove and discard O-ring and
rectangular ring from fitting.
NOTE: Do Steps 112 to 116 on other wheel end.

6004-30
BRAKE TUBES INSTALLATION

STEP 117 STEP 119
1 2
3
4
BD00M340 BD00M342
1. VENT VALVE
Install a new O-ring on the connector. Install the
2. FITTING
3. O-RING
connector in the axle and tighten to a torque of 190
4. RECTANGULAR RING Nm (140 lb-ft).
Install new O-ring and rectangular ring on fitting. STEP 120

Install and tighten vent valve in fitting.
STEP 118
BD00M343
1. O-RING
Install a new O-ring in the groove of the brake tube

BD00M341
fitting.
Install the assembled vent valve and fitting in the
axle. Tighten the fitting to a torque of 130 Nm (96
lb-ft).

6004-31
STEP 121 STEP 123
3
2
BD00M344 BD00M346
1. BRAKE TUBE 3. CONNECTOR Connect fitting on opposite end of brake tube to

2. FITTING fitting installed in wheel end. Tightening brake tube
fitting to a torque of 80 Nm (60 lb-ft).
Install th e bra ke tube (1) in the axle ho using,
inserting the fitting (2) through the connector (3). NOTE: Do Steps 117 to 123 on other wheel end.
STEP 122 STEP 124

1
2
BD00M347
1. O-RING
2. PLUG
BD00M345
3. BREATHER
Install the nut to secure the brake tube fitting. Tighten Remove and discard O-ring (1) from plug (2) and
the nut to a torque of 70 Nm (52 lb-ft). install a new O-ring. Install breather (3) in plug.
STEP 125
MD00M348
Install the plug in axle housing. Tighten plug to a

torque of 70 Nm (52 lb-ft)

6004-32
DIFFERENTIAL CARRIER ASSEMBLY

NOTE: The ring gear and the drive pinion are a STEP 128
matched gear set and cannot be serviced separately.
Determine Shim Thickness for

Correct Tooth Contact Pattern
NOTE: Make the following measurements at
maximum accuracy. Inaccurate measurements will
result in a faulty tooth contact pattern causing
disassembly of the drive pinion and differential.
STEP 126
Install the CAS2872 pinion depth gauge set on the
BD00M350
Determine dimension C (bearing width).

STEP 127
Dimension C (Example) . . . . 33.50 mm (1.319 inch)
STEP 129
BD00M349
Determine dimension B (gap between the measuring

shaft and the measuring pin) using a thickness
gauge. 1. 148.00 MM (+0.05 MM)
BD00M351
Dimension B (Example) . . . . . 1.00 mm (0.039 inch)

Read dimension D (dimension for pinion).
Example A.:
Dimension D (Example) . . . . 148.05 mm (5.83 inch)
181.75 mm
Dimension A (tool constant) Example B:
------(7.155 inch)
+ 1.00 mm 33.50 mm
Dimension B (gap) Dimension C
------(0.039 inch) ------(1.319 inch)
182.75 mm + 148.05 mm
Results in Dimension X Dimension D
-----(7.195 inch) ------(5.829 inch)
181.55 mm
Results in Dimension Y
-----(7.148 inch)
STEP 130
Su btr ac t dime ns io n Y fr om dime ns io n X. Th e
difference is the required shim thickness.
Example C:
Dimension X 182.75 mm (7.195 inch)
Dimension Y − 181.55 mm (7.148 inch)
Difference = Shim 1.20 mm (0.047)

6004-33
Install Drive Pinion STEP 133

WARNING: Always wear insulated gloves or
STEP 131 mittens when handling frozen parts.
BD00M352
Install the shim set determined in Step 130 in the

BD01F062
bearing bore on the differential carrier.
Freeze new outer bearing cup in dry ice for several
hours. Install bearing cup in differential carrier using
STEP 132 CAS2293-2.
mittens when handling frozen parts. STEP 134
BD01F065
BD01F062 Press the inner bearing on the drive pinion shaft

Freeze new inner bearing cup in dry ice for several using CAS2297.
CAS2293-1.

6004-34
Drive Pinion Bearing Rolling STEP 137

Torque Adjustment
STEP 135
BD01F101
Using CAS2882 puller tube, press the dust shield on

the input flange.
BD00M356
STEP 138
Install an 8.90 mm (0.35 inch) thick spacer on the
pinion shaft.
STEP 136
SM121A
BD00M359
Install the input flange on the pinion shaft.
STEP 139
BD00M357
Heat the pinion shaft outer bearing to 100° C (212°

F) in a bearing oven. Wearing heat resistance gloves
or mittens, install the bearing on the pinion shaft until
contact.
BD00M360
Put the washer in place on the pinion shaft.

6004-35
STEP 140 STEP 143
BD01F091 BD01F066
Install CAS1579A holding wrench on input flange. Using the CAS2288 and CAS2299 p inion sea l
Hold flange using holding tool and tighten nut to a installers, install the shaft seal with the seal lip down.
torque of 700 Nm (516 lb-ft). Remove CAS1579A.
NOTE: Just before installation, wet the outer
NOTE: When tightening rotate the pinion shaft in diameter of the shaft seal with a solution of 50%
both directions several times. water and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 141
STEP 144
BD00M362
Check the rolling torque of the drive pinion bearing. BD01F091
The rolling torque should be 1.1 to 2.3 Nm (9.7 to Install the input flange. Install CAS1579A holding
20.3 lb-inch). If rolling torque is too low, install a wrench on input flange. Apply Loctite No. 262, on the
thinner spacer (Step 135); if rolling torque is too high, threads of the locknut. Install the washer and locknut
install a thicker spacer (Step 135). by hand. Hold flange using holding tool and tighten
nut to a torque of 700 Nm (516 lb-ft). Remove
STEP 142 CAS1579A.
Remove the nut and input yoke from the drive pinion
shaft.

6004-36
DIFFERENTIAL ASSEMBLY
STEP 145 STEP 146
BD00M365 BD00M366
1. GROOVE
Install the retaining ring in the groove in the bottom of

the differential housing.
STEP 147
A
BS00M077
1. DIFFERENTIAL HOUSING
2. SEAL CAPS
A. 1.5 TO 2.5 MM (0.06 TO 0.10 INCH)
Install the seal caps. Seal caps must be installed to

depth A. BD00M367
1. GROOVES
NOTE: Be sure to apply oil to all parts before
In s t a ll th e d r iv in g p in s i n t h e g r o o ve s o f t h e
assembly.
differential housing.

6004-37
STEP 148 STEP 152
BD00M368 BD00M371
Install both thrust washers in the differential housing. Install the axle bevel gear. Make sure axle bevel gear
splines mate with splines of all inner clutch discs.
STEP 149- LIMITED SLIP DIFFERENTIAL
STEP 153
BD00M369
Starting with an outer clutch disc install alternately BD00M372

the outer and inner clutch discs. Thickness of disc Assemble the differential spider and install into the
pack must be the same on both sides. differential housing.
STEP 150- OPEN DIFFERENTIAL STEP 154

Install four outer clutch discs in differential housing.
Thickness of disc pack must be the same on both
sides.
STEP 151
BD00M373
Install the second axle bevel gear.
BD00M370
Install the pressure ring in the differential housing.

6004-38
STEP 155 Determine Disc Clearance
STEP 159
BD00M374
Install the second pressure ring in the differential

BD00M377
housing.
Determine dimension A, from mounting face of the
STEP 156- LIMITED SLIP DIFFERENTIAL differential housing to face of the outer clutch disc.
Dimension A (Example). . . . . . 15.60 mm (0.61 inch)
STEP 160
BD00M375
Starting with an inner clutch disc, install alternately

the inner and outer clutch disc. Thickness of disc
BD00M378
pack must be the same on both sides.
Determine dimension B, from contact surface of the
outer clutch disc to mounting face of the housing
STEP 157- OPEN DIFFERENTIAL
cover.
Install four outer clutch discs. Thickness of disc pack
Dimension B (Example). . . . . . 15.20 mm (0.60 inch)
must be the same on both sides.
Example B:
15.60 mm
STEP 158 Dimension A
-------(0.62 inch)
+ 15.20 mm
Dimension B
-------(0.60 inch)
= 0.40 mm
Difference = Disc clearance
------(0.02 inch)
NOTE: If required disc clearance of 0.040 mm (0.02
inch) is not obtained, install new outer clutch discs of
thickness necessary to obtain 0.040 mm (0.002 inch)
disc clearance. Difference in thickness between left
and right disc pack must not exceed 0.1 mm (0.004
inch). Outer clutch discs are available in following
thicknesses: 2.1 mm (0.083 inch), 2.2 mm (0.087
inch), 2.3 mm (0.090 inch), 2.4 mm (0.094 inch), and
BD00M376 2.5 mm (0.098 inch).
Install the driving pin in the differential housing.
6004-39
STEP 161 STEP 163
SM121A
BD00M379
Install the thrust washer with grease in the recess of

the housing cover.
STEP 162 BD00M381
Heat the ring gear to 100° C (212° F) in a bearing

oven. Wearing heat resistance gloves or mittens,
install the ring gear on the differential.
STEP 164
BD00M380
Put the housing cover on the differential housing.
BD00M382

turning. Install new bolts and tighten bolts to a torque
of 250 Nm (185 lb-ft).

6004-40
STEP 165 STEP 168
BD00M383 BD00M385
Press both bearings on the differential. Install both bearing caps. Apply Loctite No. 262 to
threads of bolts. Install the bolts and washers.
STEP 166 Tighten the bolts to a torque of 280 Nm (207 lb-ft).
STEP 169
BD00M320

differential into the differential carrier. BD01F072
Use CAS2851 wrench to tighten the two adjusting

STEP 167 nuts evenly until there is light pressure against the
bearings on each side of the differential.
BD00M384
Install both bearing cups and install adjusting nuts.

6004-41
Adjust Backlash and Bearing STEP 175

Preload
STEP 170
BD00M388
Apply marking ink on several teeth of the ring gear

and rotate it in both directions. Compare the obtained
tooth contact pattern with the examples on pages 4
BD01F061
and 5.
Place CAS10066A dial indicator right-angled at the
outer diameter of the tooth flank (ring gear). Adjust NOTE: If the tooth contact pattern differs, the wrong
the pinion to ring gear backlash to the low side of shim size was selected in Step 130. Remove
specifications (see numbers etched on the outer differential and repeat Steps 126 though 130.
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to STEP 176
or further away from the pinion.
STEP 171
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.
STEP 172
Tighten the bearing adjusting nut slowly until firm
contact is made with the bearing.
NOTE: As the adjusting nut makes firm contact with BD00M389
the bearing, the adjusting nut will immediately begin Install pins to secure both adjusting nuts.
to turn with more effort.
STEP 177
STEP 173 Apply sealing compound (Three Bond Type 1215) to
To adjust the differential bearing preload, note the differential mounting surface on axle housing. Install
position of the adjusting nut. Now tighten the nut two two CAS2861 alignment studs in axle housing to aid
additional notches. installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
STEP 174 housing then remove alignment studs.
When the bearing preload is adjusted the backlash
may increase slightly. Check pinion backlash to
confirm that it is within specifications. If within
specifications, install the adjusting nut locking roll
pins. If backlash is outside of specified range, repeat
Step 170 through 174 again.

6004-42
STEP 178 STEP 181
BD00M391 BD00M242
Using new bolts, secure the differential carrier to the Apply grease to a new O-ring and install O-ring in
axle housing. Tighten bolts to a torque of 250 Nm brake port. Position the wheel end on the axle
(185 lb-ft). housing.
STEP 179 STEP 182
BD00M392 BD00M394
Install the stub shaft into the spline of the differential Install the washers and bolts on the wheel end.
bevel gear. Tighten the bolts to a torque of 390 Nm (288 lb-ft)
NOTE: Repeat Steps 179 through 182 for the other
STEP 180 wheel end.
NOTE: Refer to Section 1002 of this service manual
for proper lubricant.
BD00M393
Install the thrust washer removed at disassembly.

Use grease to keep it in the sun gear.

Section
6004
6004
REAR AXLE
CASE CORPORATION
700 State Street
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIFFERENTIAL CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DRIVE PINION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PIVOT PIN BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE TUBES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BRAKE TUBES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIFFERENTIAL CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Determine Shim Thickness for Correct Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Open Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Limited Slip Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6004-3
SPECIFICATIONS
Lubricant Capacity........................................................................................................22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ...................................... 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim .........................................................................4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play ....................................................................................0.5 to 2.0 mm (0.020 to 0.079 inch)
Drive Pinion Rolling Torque ...................................................................................... 1.1 to 4.5 Nm (9.7 to 40 lb-inch)
Differential Carrier Bevel Gear End Play .......................................................... Zero to 0.15 mm (zero to 0.006 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing....................................................................................390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier........................................................................ 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve Fitting ............................................................................................................................140 Nm (103 lb-ft)
Vent Valve...........................................................................................................................................80 Nm (59 lb-ft)
Axle Housing Connector for Brake Tube ........................................................................................140 Nm (103 lb-ft)
Nut Securing Brake Tube to Connector..........................................................................................140 Nm (103 lb-ft)
Brake Tube Fitting to Wheel End Fitting ............................................................................................. 80 Nm (60 lb-ft)
Breather Plug..................................................................................................................................140 Nm (103 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads).............................................................600 Nm (442 lb-ft)
Bolts Securing Differential Ring Gear
M12 Bolts ..................................................................................................................................... 120 Nm (88 lb-ft)
M16 Bolts ...................................................................................................................................300 Nm (221 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ......................................185 Nm (136 lb-ft)
Differential Carrier Mounting Bolts (Apply Loctite 262 to Threads) ................................................390 Nm (288 lb-ft)
SPECIAL TOOLS
Brake housing seal installer. . . . . . . . . . . . CAS2880 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8061
Differential bearing cone puller collet set. . CAS2871 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8067
Brake housing inner bearing cup installer . CAS2877 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8073
Brake housing outer bearing cup installer . CAS2878 Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2876
Wear ring installer adapter . . . . . . . . . . . . CAS2875 Planetary Gear Puller . . . . . . . . . . . . . . . . . CAS2848
Pinion depth gauge set . . . . . . . . . . . . . . CAS(*TBS) Brake Housing Puller Bridge . . . . . . . . . . . CAS2850
Support bracket . . . . . . . . . . . . . . . . . . . . . CAS2883 Pressure Ring Installer . . . . . . . . . . . . . . . . CAS2860
Slide hammer puller adapter . . . . . . . . . CAS10846-3 Holding Bracket . . . . . . . . . . . . . . . . . . . . CAS2847
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252 Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2848
Replacer . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2297 Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4175
Dial indicator with magnetic base . . . . . CAS10066A Puller Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
Heat gun . . . . . . . . . . . . . . . . . . . . . . . . . CAS10810 Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8065
Engine stand . . . . . . . . . . . . . . . . . . . . . . . OEM4135 Holding Wrench . . . . . . . . . . . . . . . . . . . . CAS1579A
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6484 Pinion Inner Bearing Cup Installer . . . . . CAS2293-1
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6177 Pinion Outer Bearing Cup Installer . . . . . .CAS(*TBS)
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6492 Pinion Seal Installer . . . . . . . . . . . . . . . . .CAS(*TBS)
Alignment Studs . . . . . . . . . . . . . . . . . . . . CAS2861 Pinion Seal Installer . . . . . . . . . . . . . . . . .CAS(*TBS)
Step plate set (includes 8061, 8067, Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4054
and 8073) . . . . . . . . . . . . . . . . . . . . . . . OEM4288
*TBS: To Be Supplied

6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

6004-6
LUBRICATION
6
5
4
2
3
1
2
BS02D084
1. OIL DRAIN PLUG (AXLE HOUSING) 4. OIL DIPSTICK

2. OIL DRAIN PLUG (OUTPUTS) 5. BRAKE BLEEDER
3. OIL FILL PLUG 6. BLEEDER
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD02D001 BS02D085
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 70 Nm (52 lb-ft).

6004-7
WHEEL END AND BRAKE
Disassembly STEP 3
NOTE: Tools and axle shown in the following
photographs may appear slightly different than the
tools and axle you may have. The use of the tools
and disassembly/assembly of axle is the same
regardless of appearance.
STEP 1
BD02D005
Using two pry bars, remove cover from output shaft.

Remove and discard O-ring from cover.
STEP 4
BD02D002
Fasten axle on a stand.
STEP 2
BD02D006
Remove pin from lock nut using OEM4252 slide

hammer and CAS10846-3 adapter.
STEP 5
BD02D003
BD02D007
Remove lock nut using CAS2883 support bracket

BD02D004 and CAS2876 socket and nuts.
Remove drain plugs and drain oil from axle housing.
6004-8
STEP 6 STEP 9
BD02D008 BD02D011
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP 10
STEP 7
BD02D012
BD02D009 Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
end. STEP 11
STEP 8
BD02D013
Using two pry bars, remove ring gear from brake

BD02D010
housing.
Pull the stub shaft out of the sun gear shaft. Be
careful not to lose shim(s) that may be installed in
sun gear shaft.

6004-9
STEP 12 STEP 15
BD02D014 BD02D017
Remove and discard O-rings from ring gear. Using CAS2848 planetary gear puller and step plate
8061, remove planetary gear and outer bearing from
STEP 13 planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.
STEP 16
Repeat Steps 14 and 15 to remove the remaining
two re ta in ing ring s, pla neta ry gea rs, a nd fo ur
bearings.
STEP 17
BD02D015
Using OEM4054 pulling attachment, remove the

planetary carrier.
STEP 14
BD02D018
Remove and discard O-ring from brake housing port.
BD02D016
Remove retaining ring.

6004-10
STEP 18 STEP 21
BD02D019 BD02D022
Remove the brake disc pack from brake housing. W E A R FA C E P R O T E C T I O N W H E N U S I N G

COMPRESSED AIR. Apply compressed air to brake
STEP 19 ho using por t to pus h br ake pis to n fro m bra ke
housing.
STEP 22
BD02D020
Using suitable tool, push the three pins down until

pins are even with top surface of shim.
BD02D023
STEP 20 Remove the support shim from the brake piston.
STEP 23
BD02D021

BD00M258
Remove three pins from support shim.

6004-11
STEP 24 STEP 27
BD02D024
BD00M259
Lift and remove the piston from the brake housing.
Put support shim in a press and compress Belleville
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
BD02D025
BD00M260
Remove seven Belleville washers from each pin.
STEP 26
BS02D086

BD00M261 4. U-RING
Using a press, remove four gripping rings from each
Remove the guide ring (2), support rings (3 and 6),
pin.
and U-rings (4 and 5) from the grooves of the brake
housing.

6004-12
STEP 29 STEP 32
BD02D026 BD02D029
Using the CAS2850 brake housing puller bridge and Remove the face seal from the brake housing.
8073 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the
STEP 30 wheel end shaft.
STEP 34
BD02D027
Use acceptable lifting equipment and lift the brake

housing from the wheel end shaft. BD02D030
Remove and discard the face seal metal ring from

STEP 31 the wheel end shaft.
BD02D028
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.

6004-13

IMPORTANT: Do not use compressed air to dry
bearings. Allow bearings to air dry. STEP 40
STEP 35
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FA C E
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 36
I n s p e c t b e a r i n g r o l l e r s f o r p i t t i n g , s c o r in g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
d a m a g e . C h e c k a s s o c ia te d b e a r in g c u p s f o r BD02D031
scratches, grooves, or cracks. Check bearings for Apply Loctite 574 to inside diameter of a new face
rough spots or binding by holding bearing and seal metal ring. Install face seal metal ring on wheel
rotating. If bearing binds or action is not smooth, end shaft.
replace the bearing.
STEP 41
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires
replacement, the associated part must also be
replaced.
STEP 38
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of BD01F107
these conditions are seen. Check planetary carrier
sh a f t sp lin e s f o r b r ok e n , c ra c ke d , o r t w ist e d
condition. Replace if necessary.
STEP 39
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD01F105
Install CAS2875 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using CAS2860
pressure ring installer.

6004-14
STEP 42 STEP 45
SM121A
BD02D034
A A
BD02D032
A 1
Heat the wheel end shaft outer bearing to 100° C
gloves or mittens, install the bearing on the wheel 2
end shaft until the bearing is against the shoulder on
the wheel end shaft.
STEP 43
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
BD02D033 STEP 46
Using CAS2877 inner bearing cup installer, press the
inner bearing cup into the brake housing until seated
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
BD02D027

brake housing on the wheel end shaft.

6004-15
STEP 47 STEP 48
SM121A
BD02D025
BD02D035
Heat the wheel end shaft inner bearing to 100° C

gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the bearing cup
BS02D086
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION

4. U-RING
Install the support rings and U-rings in the grooves of
the brake housing.

6004-16
STEP 49 STEP 51
A B
BD02D036 BD00M282
1. GRIPPING RINGS
Clean the groove of the brake housing with cleaning
solvent. Install the guide ring in the groove. Make Press the four gripping rings on the pins. Ends of
sure the ends (A) of the guide ring are facing up gripping rings must be 180° opposite from each
towards the top (B) of the brake housing and the other.
guide ring is installed completely in its groove in the
brake housing. Apply Loctite 415 to ID of guide ring STEP 52
to secure guide ring in its groove.
STEP 50
BD00M283
5 4
BD02D037
Apply oil on the sliding surface of the piston, support

3
rings, U-rings and guide ring. Carefully install piston
A
2
BS00M074
1. PIN 4. SUPPORT SHIM

2. GRIPPING RINGS 5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
Install the Belleville springs on the pins. Make sure
dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

6004-17
STEP 53 STEP 56
BD00M259 BD02D020
Put the assembled pins into the support shim and

install the snap ring.
STEP 54
BS02D087
1. BRAKE HOUSING 4. SUPPORT SHIM

2. SNAP RING 5. PISTON
3. PIN A. 4.5 TO 5.0 MM (0.18 TO 0.20
BD02D038 INCH)
Put the assembled support shim in the piston. Install the three pins (3) in the support shim (4) to
lock the snap ring (2). Dimension (A) between top of
STEP 55 pins (3) and top of support shim (4) must be 4.5 to
5.0 mm (0.18 to 0.20 inch).
STEP 57
BD02D039
Install the snap ring to secure the support shim.

1
BD02D040
1. SPLINE
If removed, drive the stop bolt into the planetary

carrier until contact. Then coat the spline with Loctite
No. 767 antiseize lubricant.
6004-18
STEP 58 STEP 61
BD02D041
BD02D014
Install the planet carrier into the spline of the wheel Apply grease to new O-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
BD02D042
BD02D044
Apply oil to the clutch discs. Install the outer and
Install two alignment studs in the brake housing.
inner clutch discs alternately starting with an outer
Pos ition the plan eta ry r in g g ea r o n th e b ra ke
clutch disc.
housing. Make sure alignment marks made during
disassembly are aligned. Press planetary ring gear
STEP 60 into brake housing.
BD02D043
Install a new O-ring in the brake housing port.

6004-19
STEP 63 STEP 65
WARNING: Always wear heat protective WARNING: Always wear heat protective
gloves to prevent burning your hand when gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
BD02D045 BD02D047
Heat the planetary gears inner bearings to 100° C Heat the planetary gears outer bearings to 100° C
(212° F) in a bearing oven. Wearing heat resistant (212° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
BD02D046 BD02D048
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear
shafts.

6004-20
Sun Gear Shaft End Play Adjustment STEP 69
STEP 67
BD02D051
Install the sun gear shaft in the stub shaft. Make sure
BD02D049 the stub shaft is installed all the way into the sun gear
Using two M18 bolts of suitable length, secure shaft.
p la n e t a r y r in g g e a r to b r a k e h o u s in g . Th e n ,
d e te r min e di me n si on A, f ro m t h e fa c e of t h e STEP 70
planetary carrier stop bolt to the mounting face of the
planetary ring gear.
Example:
Dimension A . . . . . . . . . . . . . 35.60 mm (1.40 inch)
STEP 68
BD02D052
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
Example:
Dimension B . . . . . . . . . . . . . . 31.40 mm (1.24 inch)
BD02D050 STEP 71
Install the stub shaft in the spline of the axle bevel Subtract dimension B from dimension A. Then
gear. Make sure the stub shaft is installed all the way subtract 1 mm (0.04 inch) from the difference. The
into the axle bevel gear. difference is the required shim size.
Example:
Dimension A + 35.60 mm (1.40 inch)
Dimension B − 31.40 mm (1.24 inch)
Difference 4.20 mm (0.16 inch)
Required end play − 1.00 mm (0.04 inch)
Difference = shim
3.20 mm (0.12 inch)
size

6004-21
STEP 72 STEP 75
BD02D012 BD02D154
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
BD02D011
Install the shim set (size as determined in Step 71

above) into the sun gear shaft with grease. BD02D155
Install the lock nu t by ha nd a nd tig hten usin g

STEP 74 CAS2883 support bracket and CAS2876 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 77
BD02D009
Apply grease to a new O-ring and install O-ring in

brake port. Use acceptable lifting equipment and
install the assembled wheel end o nto the axle
housing. BD02D156
Install a new slotted pin into the wheel end lock nut.

6004-22
STEP 78 STEP 79
BD00M303 BD02D153
1. O-RING
Install the cover into the wheel end.
Install a new O-ring on the wheel end cover.

6004-23
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 High Pressure Test
PSI) PRESSURE IN THE FOLLOWING STEPS. If
the maximum pressure of 100 bar (1450 psi) is
STEP 81
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings Operate the hand pump to increase pressure to 100
adjustment changes, the wheel end must be bar (1450 psi) maximum. Close connection to hand
removed and disassembled and the gripping rings pump using the shutoff valve. During a 5 minute
adjusted to the correct dimension (Step 52). period, pressure shall not drop more than 2 bar (29
psi).
STEP 80
Low Pressure Test
STEP 82
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BD02D157
Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
Case MS-1209 Hy-Tran® Ultra. Build up pressure in
the axle internal brake lines then bleed air from the
lines. After air is bled, actuate the brakes a minimum
of 10 times by operating the hand pump.

6004-24
DIFFERENTIAL CARRIER DISASSEMBLY

STEP 83 STEP 85
BD02D002 BD02D008
Fasten the axle to a stand. Use acceptable lifting equipment to hold wheel end in
place. Remove the bolts and washers.
STEP 84
STEP 86
BD02D003
BD02D054
Carefully pull the wheel end from the axle housing.

end.
BD02D004
Remove drain plugs and drain oil from axle.

6004-25
STEP 87 STEP 91
BD02D010
BD02D057
Pull the stub shaft out of the sun gear shaft. Be Mount differential carrier in OEM4135 engine stand
careful not to lose shim(s) that may be installed in using one CAS2847 holding bracket.
sun gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BD02D058
Drive out the roll pins from the bearing caps.
STEP 93
BD02D055
Remove 15 bolts securing differential carrier.
STEP 90
BD02F158
Remove both adjusting nuts.
BD02D056
Connect lifting equipment to flange and remove the

differential carrier from axle housing.

6004-26
STEP 94 STEP 96
BD02D059 BD02D061
Heat the differential carrier using a hot air blower. Remove both bearing cups.
NOTE: Bolts are installed with Loctite.
STEP 97
STEP 95
IMPORTANT: Do not use an air ratchet or wrench to
remove bolts.
1
BD02D062
Remove the differential from the differential carrier.
BD02D060
1. ALIGNMENT MARK
M a k e a li g n m e n t m a r k s o n b e a r in g c a p s a n d
differential housing to aid in assembly. Remove four
bolts then remove both bearing caps.

6004-27
DIFFERENTIAL DISASSEMBLY
STEP 98 STEP 101
BD01F059
BD02D064
Remove the bearing from the differential housing
Remove the differential cage half and remove all
using CAS2848 puller, OEM4175 pulling attachment,
parts from the differential housing.
1103 puller legs, and 8065 step plate.
STEP 102
STEP 99
Repeat Step 98 to remove the bearing from the
housing cover.
STEP 100
BD02D065
Press the ring gear from the differential cage.
BD02D063

turning. Remove the bolts.

6004-28
DRIVE PINION DISASSEMBLY

STEP 103 STEP 106
Heat nut securing flange with a hot air blower to
loosen Loctite.
STEP 104
BD02D067
Remove the shaft seal from the differential carrier.
STEP 107
BD01F091 Put the differential carrier in a press. Press the drive
Install CAS1579A holding wrench on input flange. pinion from the differential carrier. Remove the pinion
Hold flange using holding wrench and remove nut outer bearing.
and washer. Remove holding tool from flange.
STEP 108
STEP 105 Remove the spacer ring and inner bearing from the
drive pinion.
STEP 109
BD02D066
Remove the input flange from the drive pinion.
BD02D068
If necessary drive out both bearing cups from the


6004-29
PIVOT PIN BUSHINGS

STEP 110 STEP 112
A
A
1 1 2
BD01D482
BD01D495
A
A
2
1 2
BD01D499
BD01D499
1. DIFFERENTIAL CARRIER PIVOT PIN BUSHING
2. AXLE HOUSING PIVOT PIN BUSHING 1. DIFFERENTIAL CARRIER PIVOT PIN BUSHING
A. THRUST SURFACE 2. AXLE HOUSING PIVOT PIN BUSHING
A. GROOVE
Inspect pivot pin bushings in differential carrier and
axle housing for cracks, breaks, deformation, or
other damage. Check oil splash grooves for scoring WARNING: Always wear insulated gloves

or chipping. Check for scoring on thrust surface (A). or mittens when handling frozen parts.
If bushing (1 or 2) requires replacement, do Steps
111 and 112.
Freeze new bushing in dry ice for several hours.
STEP 111 Install bushing in axle housing or differential carrier
with groove (A) on circumference of bushing facing
center of housing or carrier. Install bushing against
shoulder in housing or carrier.
BD01D491
Put axle housing or differential carrier in hydraulic

press. Make sure housing or carrier is properly
supported. Using a 66.6 mm (2.625 inches) diameter
by suitable length rod, press bushing out of housing
or carrier.
6004-30
BRAKE TUBES REMOVAL

STEP 113 STEP 116
BD02D069 BD02D072
Remove the plug with the breather installed from the Loosen the fitting on the opposite end of the brake
axle housing. tube then remove the brake tube from the axle
housing.
STEP 114
STEP 117
BD02D070
Remove the nut securing the brake tube to the axle BD02D073
housing. Remove the vent valve from the fitting.
STEP 115 STEP 118
BD02D071 BD02D074
Loosen and remove the connector from the axle. Remove the fitting. Remove and discard O-ring and
rectangular ring from fitting.
NOTE: Do Steps 114 to 118 on other wheel end.

6004-31
BRAKE TUBES INSTALLATION

STEP 119 STEP 121
1 2
3
4
BD00M340 BD02D116
1. VENT VALVE
Tighten the vent valve to a torque of 80 Nm (59 lb-ft).
2. FITTING
3. O-RING
4. RECTANGULAR RING STEP 122
Install new O-ring and rectangular ring on fitting.
Install and tighten vent valve in fitting.
STEP 120
BD02D117
Install a new O-ring on the connector. Install the

connector in the axle and tighten to a torque of 140
Nm (103 lb-ft).
BD02D115
STEP 123
Install the assembled vent valve and fitting in the
axle. Tighten the fitting to a torque of 140 Nm (103
lb-ft).
BD00M343
1. O-RING
Install a new O-ring in the groove of the brake tube

fitting.

6004-32
STEP 124 STEP 126
2
1
3
BD02D118 BD02D120
1. BRAKE TUBE 3. CONNECTOR Connect fitting on opposite end of brake tube to

2. FITTING fitting installed in wheel end. Tighten brake tube
fitting to a torque of 80 Nm (60 lb-ft).
Install th e bra ke tube (1) in the axle ho using,
inserting the fitting (2) through the connector (3). NOTE: Do Steps 119 to 126 on other wheel end.
STEP 125 STEP 127

1
2
BD00M347
1. O-RING
2. PLUG
BD02D119
3. BREATHER
Install the nut to secure the brake tube fitting. Tighten Remove and discard O-ring (1) from plug (2) and
the nut to a torque of 140 Nm (103 lb-ft). install a new O-ring. Install breather (3) in plug.
STEP 128
BD02D121
Install the plug in axle housing. Tighten plug to a

torque of 140 Nm (103 lb-ft)

6004-33
DIFFERENTIAL CARRIER ASSEMBLY

NOTE: The ring gear and the drive pinion are a STEP 131
matched gear set and cannot be serviced separately.
Determine Shim Thickness for

Correct Tooth Contact Pattern
NOTE: Make the following measurements at
maximum accuracy. Inaccurate measurements will
result in a faulty tooth contact pattern causing
disassembly of the drive pinion and differential.
STEP 129
Install the CAS(*TBS) pinion depth gauge set on the
BD02D122
Determine dimension C (bearing width).

STEP 130
Dimension C (Example) . . . . 33.65 mm (1.325 inch)
STEP 132
BD01F076
Determine dimension B (gap between the measuring

shaft and the measuring pin) using a thickness
gauge. 1. 138.00 MM (+/-0 MM)
BD02D123
Dimension B (Example) . . . . . . 1.00 mm (0.039 inch)

Read dimension D (dimension for pinion).
Example A:
Dimension D (Example) . . . 138.00 mm (5.433 inch)
171.75 mm
Dimension A (tool constant) Example B:
------(6.762 inch)
+ 1.00 mm 33.65 mm
Dimension B (gap) Dimension C
------(0.039 inch) ------(1.325 inch)
172.75 mm + 138.00 mm
Results in Dimension X Dimension D
-----(6.801 inch) ------(5.433 inch)
171.65 mm
Results in Dimension Y
-----(6.758 inch)
STEP 133
Su btr ac t dime ns io n Y fr om dime ns io n X. Th e
difference is the required shim thickness.
Example C:
Dimension X 172.75 mm (6.801 inch)
Dimension Y − 171.65 mm (6.758 inch)
*TBS: To Be Supplied Difference = Shim 1.10 mm (0.043 in)

6004-34
Install Drive Pinion STEP 136

STEP 134 mittens when handling frozen parts.
BD02D124
Install the shim set determined in Step 133 in the

BD01F062
bearing bore on the differential carrier.
Freeze new outer bearing cup in dry ice for several
STEP 135 CAS(*TBS).
mittens when handling frozen parts. STEP 137
BD02D125
BD01F064 Press the inner bearing on drive pinion shaft using

Freeze new inner bearing cup in dry ice for several suitable size slee ve p re ssing on inne r race of
hours. Install bearing cup in differential carrier using bearing.
CAS2293-1.

6004-35
Drive Pinion Bearing Rolling STEP 140

Torque Adjustment
STEP 138
BD02D128
Using CAS(*TBS) puller tube, press the dust shield

on the input flange.
BD02D126
STEP 141
Install an 16.90 mm (0.665 inch) thick spacer on the
pinion shaft.
STEP 139
SM121A
BD02D129
Install the input flange on the pinion shaft.
STEP 142
BD02D127
Install the assembled pinion shaft in the differential

carrier. Heat the pinion shaft outer bearing to 100° C
(212° F) in a bearing oven. Wearing heat resistance
gloves or mittens, install the bearing on the pinion
shaft until contact.
BD02D130
Put the washer in place on the pinion shaft.
6004-36
STEP 143 STEP 146
BD01F091 BD02D132
Install CAS1579A holding wrench on input flange. Using the CAS(*TBS) and CAS(*TBS) pinion seal
Hold flange using holding tool and tighten nut to a installers, install the shaft seal with the seal lip down.
torque of 600 Nm (442 lb-ft). Remove CAS1579A.
NOTE: Just before installation, wet the outer
NOTE: When tightening rotate the pinion shaft in diameter of the shaft seal with a solution of 50%
both directions several times. water and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 144
STEP 147
BD02D131
Check the rolling torque of the drive pinion bearing. BD01F091
The rolling torque should be 1.1 to 4.5 Nm (9.7 to 40 Install the input flange. Install CAS1579A holding
lb-inch). If rolling torque is too low, install a thinner wrench on input flange. Apply Loctite No. 262, on the
spacer (Step 138); if rolling torque is too high, install threads of the locknut. Install the washer and locknut
a thicker spacer (Step 138). by hand. Hold flange using holding tool and tighten
nut to a torque of 600 Nm (442 lb-ft). Remove
STEP 145 CAS1579A.
Remove the nut and input yoke from the drive pinion
shaft.
6004-37
DIFFERENTIAL ASSEMBLY
STEP 148 Open Differential Assembly
STEP 149
BD02D133
Install two slotted pins (2 and 3)in each of the four

blind holes in the differential cage half (1). Install BD02D134
slotted pins so that slots are 180° from center of Using suitable size sleeve press the ring gear (4)
differential cage and slots of pins are 180° offset to onto the slo tted pins until rin g gear is a gainst
each other.
8 3
2
7
8 7
6 13
11 10
14
5 1
9
4
7 8
7
12
8
BS01D140
1. DIFFERENTIAL CAGE HALF 5. THRUST WASHER 9. SHAFT 13. BOLT

2. SLOTTED PIN 6. BEVEL GEAR 10. BEVEL GEAR 14. BOLT
3. SLOTTED PIN 7. BEVEL GEAR 11. THRUST WASHER
4. RING GEAR 8. THRUST WASHER 12. DIFFERENTIAL CAGE HALF
STEP 150 STEP 152

Install thrust washer (5) then bevel gear (6) in Install shaft (9) with bevel gears (7) and thrust
differential cage half (1). washers (8) on differential cage half (1). Check that
teeth of bevel gears (7 and 6) mesh.
STEP 151
Install bevel gears (7) and thrust washers (8) on shaft STEP 153
(9). Install and mesh bevel gear (10) with gears (7) and
install thrust w asher (11 ) o n gea r (1 0). Install
differential cage half (12). Go to Step 163.
6004-38
Limited Slip Differential Assembly STEP 157
STEP 154 10
7 9
7 11
5
8
1
6
BD02D137
6 Install assembled shafts (11) with gears (9) and

BD02D135
thrust washers (10) in differential cage (1) making
Install the thrust washer (5), coated surface to clutch sure gear teeth mesh. Check that tabs on thrust
discs, and outer and inner clutch discs (6 and 7) on washers (10) are positioned as shown above.
bevel gears (8) in the sequence shown above.
STEP 158
STEP 155
1 A
BD02D138
BD02D142
Carefully assemble the differential cage halves.
Put the bevel gear (8) with installed parts (5 through Make sure the manufacturers markings (A) on both
7) in the differential cage half (1). halves are aligned.
STEP 156 STEP 159
8
1
BD02D139
BD02D136
Put the other bevel gear (8) with installed parts (5 Secure the differential cage halves together using
through 7) in differential cage half (12). two bolts.

6004-39
13
2
6
10 6
9 8
10
11 3
9 14
8
7 5 4
7 11 7 1
7
5
9 9
10
6 10
12 6
BS01D141
1. DIFFERENTIAL CAGE HALF 5. THRUST WASHER 9. BEVEL GEAR 13. BOLT

2. SLOTTED PIN 6. SEPARATOR PLATE 10. THRUST WASHER 14. BOLT
3. SLOTTED PIN 7. FRICTION PLATE 11. SHAFT
4. RING GEAR 8. BEVEL GEAR 12. DIFFERENTIAL CAGE HALF
STEP 160 STEP 161

After obtaining the required end play, disassemble
the differential. Install the adjusted clutch pack that
was in the differential cage half (12) in the other
12 differential cage half (1). Repeat Step 160 to check
the end play. After both clutch packs have been
adjusted, go to Step 162.
STEP 162
BD02D140
Check the end play (zero to 0.15 mm (0.006 inch)) of

th e b evel gear (8). Do this by mounting a dia l
indicator as shown set to indicate from the top
separator plate through one of the top holes in
differential cage half (12). Zero the dial indicator.
Using screwdrivers or other suitable tools inserted in
holes in side of cage half, move the bevel gear up.
Record the dial indicator reading. Dial indicator BD02D141
sho u ld in d ica te z ero to 0.1 5 mm (0.0 06 inch ) After adjustment is completed, separate the cage
(required end play). halves, and remove the parts. Keep clutch packs
If required end play of zero to 0.15 mm (0.006 inch) together and identify which side they are installed.
is not obtained, install new outer clutch discs of Ap ply o il to all pa rts. Do Step s 1 5 4 to 15 8 to
thickness necessary to obtain required end play. assemble the differential, then go to Step 163.

6004-40
STEP 163 STEP 166
BD02D143 BD02D146
Put the differential in a press to prevent it from Install both bearing cups and adjusting nuts.
turning. Apply Loctite 262 to threads of bolts (13 and
14). Tighten M16 bolts (13), to a torque of 300 Nm STEP 167
(221 lb-ft); tighten M12 bolts (14) to a torque of 120
Nm (88 lb-ft).
STEP 164
BD02D147
Position bearing brackets; make sure threads of

bearing brackets and adjusting nuts are not crossed.
Put Loctite 262 on threads of four bolts. Install bolts
BD02D144 and tighten to a torque of 185 Nm (136 lb-ft).
Using proper size sleeve pushing on inner race of
bearing, press bearing on differential housing until STEP 168
bearing is against housing. Repeat to install other Using a spanner wrench, tighten the two adjusting
bearing. nuts evenly until there is a light pressure against the
bearings on each side of the differential.
STEP 165
BD02D145
Install differential in differential carrier.

6004-41
Adjust Backlash and Bearing STEP 174

Preload
STEP 169
BD02D149
Apply marking ink on several teeth of the ring gear

and rotate it in both directions. Compare the obtained
tooth contact pattern with the examples on pages 4
BD02D148
and 5.
Place CAS10066A dial indicator right-angled at the
outer diameter of the tooth flank (ring gear). Adjust NOTE: If the tooth contact pattern differs, the wrong
the pinion to ring gear backlash to the low side of shim size was selected in Step 133. Remove
specifications (see numbers etched on the outer differential and repeat Steps 129 though 133.
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to STEP 175
or further away from the pinion.
STEP 170
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.
STEP 171
Tighten the bearing adjusting nut slowly until firm
contact is made with the bearing.
NOTE: As the adjusting nut makes firm contact with BD02D150
the bearing, the adjusting nut will immediately begin Install pins to secure both adjusting nuts.
to turn with more effort.
STEP 176
STEP 172 Apply sealing compound (Three Bond Type 1215) to
To adjust the differential bearing preload, note the differential mounting surface on axle housing. Install
position of the adjusting nut. Now tighten the nut two two CAS2861 alignment studs in axle housing to aid
additional notches. installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
STEP 173 housing then remove alignment studs.
When the bearing preload is adjusted the backlash
may increase slightly. Check pinion backlash to
confirm that it is within specifications as marked on
the ring gear. If within specifications, install the
adjusting nut locking roll pins. If backlash is outside
of specified range, repeat Step 169 through 173
again.

6004-42
STEP 177 STEP 180
BD02D151 BD02D054
Using new bolts, secure the differential carrier to the Apply grease to a new O-ring and install O-ring in
axle housing. Tighten bolts to a torque of 390 Nm brake port. Position the wheel end on the axle
(288 lb-ft). housing.
STEP 178 STEP 181
BD02D050 BD02D154
Install the stub shaft into the spline of the differential Install the washers and bolts on the wheel end.
bevel gear. Tighten the bolts to a torque of 390 Nm (288 lb-ft)
NOTE: Repeat Steps 178 through 181 for the other
STEP 179 wheel end.
NOTE: Refer to Section 1002 of this service manual
for proper lubricant.
BD02D011
Install the thrust washer removed at disassembly.

Use grease to keep it in the sun gear.

Section
6005
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS
6005
CASE CORPORATION
700 State Street
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts ................................................................................................. 53 to 62 Nm (39 to 46 lb ft)
Engine Drive Shaft to Coupler Bolts ................................................................................. 53 to 62 Nm (39 to 46 lb ft)
Engine Drive Shaft to Transmission Bolts ........................................................................ 34 to 41 Nm (25 to 30 lb ft)
Center, Rear and Front Drive Shaft Bolts ......................................................................... 61 to 81 Nm (45 to 60 lb ft)
Carrier Bearing Bolts ...................................................................................................... 99 to 128 Nm (73 to 94 lb ft)
Lock Nut for Yoke on Front Drive Shaft .................................................................... 339 to 375 Nm (250 to 275 lb ft)
FRONT DRIVE SHAFT
Removal STEP 4
Use an acceptable puller and remove the yoke from
STEP 1 the end of the front drive shaft.
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD01F291
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP 2
BD01F292

the front drive shaft to the front axle.
STEP 8
Use a prybar to disengage the front drive shaft from
BD01D715 the front axle and remove the front drive shaft from
Remove the lock nut that fastens the yoke to the front the machine.
drive shaft.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.
STEP 3
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.

6005-4
FRONT DRIVE SHAFT
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD01D715
Install the lock nut and washer which fastens the

yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 lb ft).
STEP 15
Tighten the set screws, that secures the center
bearing to the front drive shaft, alternately until they
stop turning and the hex head socket wrench starts
to spring.
BD01F292
STEP 16
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
61 to 81 Nm (45 to 60 lb ft).
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed, BD01F291
make sure the yoke being installed is 90° to the yoke Install the bolts and straps that fasten the front drive
on the other end of the front drive shaft. shaft to the center drive shaft. Tighten the bolts to a
torque of 61 to 81 Nm (45 to 60 lb ft).

6005-5
CENTER BEARING
Removal STEP 20
Make an alignment mark on the yoke and the front
STEP 17 drive shaft to be sure that the yoke is installed
correctly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD01F291
STEP 23
Loosen and remove the bolts and straps that fasten Loosen the set screws that secure the center bearing
the center drive shaft to the front drive shaft. to the front drive shaft.
STEP 18 STEP 24
BD01D715 BD01D715
Loosen and remove the lubrication hose from the Loosen and remove the bolts, washers and nuts that
center bearing fasten the bearing housing to the front frame.
STEP 19 STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD01D715
Loosen and remove the lock nut that fastens the
yoke to the front drive shaft.
6005-6
CENTER BEARING
NOTE: The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is
cracked, a new center bearing and bearing housing
must be used.
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
BD01D715
fitting is at the top.
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
STEP 28
of 339 to 375 Nm (250 to 275 lb ft).
STEP 32
BD01D715
Install the bolts, washers and nuts that fasten the

bearing housing to the front frame. Tighten the bolts
BD01F291
to a torque of 99 to 128 Nm (73 to 94 lb ft).
Install the straps and bolts that fasten the center
drive shaft to the yoke on the front drive shaft.
STEP 29
Tighten the bolts to a torque of 61 to 81 Nm (45 to 60
Apply antiseize compound to the splines on the front lb ft).
drive shaft.
STEP 33
STEP 30
Install the lubrication hose into the fitting on the
Install the yoke to the front drive shaft, making sure bearing housing.
the alignment marks made during removal are
aligned.
STEP 34
L ub r ic a te th e c en te r b ea r ing w ith t he g r ea s e
specified in Section 1002.

6005-7
CENTER DRIVE SHAFT
STEP 35 STEP 39
BD01F291 BD01F289
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 61
to 81 Nm (45 to 60 lb ft).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD01F291
Install the bolts and straps that fasten the center

drive shaft to the yoke of the front drive shaft. Tighten
BD01F289
the bolts to a torque of 61 to 81 Nm (45 to 60 lb ft).
the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the
machine.

6005-8
REAR DRIVE SHAFT
STEP 41 STEP 45
BD01D323 BD01F304
Loosen and remove the bolts and straps that fasten Hold the rear drive shaft into position and install the
the rear drive shaft to the transmission. bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 61 to 81 Nm
STEP 42 (45 to 60 lb ft).
Use a prybar to disengage the rear drive shaft from
the transmission. STEP 46
STEP 43
BD01D323
Install the bolts and straps that fasten the rear drive
BD01F304
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 61 to 81 Nm (45 to 60 lb ft).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.

6005-9
ENGINE DRIVE SHAFT
STEP 47 STEP 50
BD01D342 BD01D342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the
the engine drive shaft to the transmission. transmission and install new straps and bolts.
Tighten the bolts to a torque of 34 to 41 Nm (25 to 30
IMPORTANT: The bolts and straps that fasten the
lb ft).
engine drive shaft to the transmission must be
replaced when removed.
STEP 51
STEP 48
BD01D199
Install the six bolts that fasten the engine drive shaft
BD01D199
to the engine. Tighten the bolts to a torque of 53 to
Loosen and remove the six bolts that fasten the
62 Nm (39 to 46 lb ft)
engine drive shaft to the engine.
STEP 49
Remove the engine drive shaft from the machine.

6005-10
UNIVERSAL JOINTS
NOTE: The bearing race and journal that make up
STEP 52 the universal joint are not serviced separately. If the
Remove the drive shaft from the machine. bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 53
STEP 55
Clean the slots in the yoke of the drive shaft.
2
1
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
BD01F304
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.
STEP 54
Remove the universal joint from the drive shaft.

Section
6006
WHEELS AND TIRES
6006
CASE CORPORATION
700 State Street
6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIRE PRESSURE 621D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6006-3
WHEELS AND BOLTS
General Information Torque Specification

The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 298 Nm (220 pound-feet)
hours of operation until the wheel bolts stay tight: in the sequence shown in Figure 1. Then a final
torque of 640 to 720 Nm (475 to 530 pound-feet) in
A. If the machine is new.
the same sequence.
B. If a wheel has been removed and installed.
TIRE PRESSURE 621D

15.5 x 25 L2 ...................................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
15.5 x R25 XTLA TL ......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
15.5 x R25 XHA TL........................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 XTLA TL ......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 XHA TL........................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5 x R25 XTLA TL ........................................ Front,2.07 - 2.75 bar (30 - 40 psi), Rear 1.72 - 3.10 bar (25 - 45 psi)
Suggest: Front, 2.75 bar (40 psi), Rear, 2.07 bar (30 psi)
20.5 x R25 XHA TL.......................................... Front,2.07 - 2.75 bar (30 - 40 psi), Rear 1.72 - 3.10 bar (25 - 45 psi)
Suggest: Front, 2.75 bar (40 psi), Rear, 2.07 bar (30 psi)
20.5 x R25 XLD 70 .........................................Front, 2.07 - 2.75 bar (30 - 40 psi), Rear, 1.72 - 2.41 bar (25 - 35 psi)

6006-4
CHANGING TIRES
1. Have a qualified tire mechanic service the split
The split rim wheels used on this machine rim wheels used on this machine.
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and 2. The correct tire equipment, especially a tire
stand at the front or rear of the tire. inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
When inflating a tire off the machine, put death.
th e w he el in a tire inflatio n c ag e. Th e IMPORTANT: When installing a Michelin tire,
retaining ring and rim can come off with lubricate the tire with a tire mounting lubricant and
enough force to result in death to a person inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
in front of the rim. sure that the tire is seated on the rim. Then decrease
48-44 the pressure to the specified pressure.
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and 4. Tighten the wheel bolts to 298 Nm (220
axle flange are clean and free of dirt and grease. pound-feet) in the sequence shown in Figure 1.
Th e n tig h te n t he wh e e l b o lts in th e sa m e
2. Install the wheel, hardened washers and wheel
s e q u e n c e t o 6 4 0 to 7 2 0 N m ( 4 7 5 t o 5 3 0
bolts.
pound-feet).
3. Use a hand wrench (not an impact) to tighten the
w h e e l b o lts to p u ll th e w h e e l a g a in s t t h e
planetary housing. DO NOT use an impact
wrench to tighten the wheel bolts.
1
10 8
6 12
4 3
11 5
7 9
2
B0987A88
FIGURE 1. WHEEL BOLT TORQUE SEQUENCE

Section
6007
TRANSMISSION CONTROL VALVE
6007
CASE CORPORATION
700 State Street
6007-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
INPUT/OUTPUT SHAFT SEAL CAS2869
INSTALLATION TOOL TRANSMISSION
OUTPUT SHAFT SEAL
CAS2803 TRANSMISSION INSTALLATION TOOL
TORQUE CONVERTER SEAL (621 MODEL ONLY)
INSTALLATION TOOL
BS02C093 THRU 096
CAS40075 TRANSMISSION TOOL KIT
SPECIAL TORQUES
Screws Securing End Housings to Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Screws Securing Pressure Regulator Locating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Screws Securing Covers to End Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Valve Housing Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in)
Screws Securing Distribution Plate to Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm (84 lb-in)

6007-3
DISASSEMBLY
STEP 1 STEP 3
To a i d in a s s e m b ly, p u t a l ig n m e n t m a r k s o n Remove distribution plate (2), housing gasket (3),
transmission control valve (7, figure 1), distribution valve plate (4), and housing gasket (5). Discard
plate (2), and valve plate (4). housing gaskets (3 and 5).
STEP 2 STEP 4
Remove 18 screws (1) securing distribution plate (2) Remove six filter screens (6) from valve plate (4).
to transmission control valve (7).
5
4
3
2
BS98J157
1. SCREW 4. VALVE PLATE 7. TRANSMISSION CONTROL VALVE

2. DISTRIBUTION PLATE 5. HOUSING GASKET
3. HOUSING GASKET 6. FILTER SCREEN
FIGURE 1. TRANSMISSION CONTROL VALVE PLATES AND GASKETS

6007-4
STEP 5 STEP 13
To aid in assembly, put alignment marks on covers Remove two screws (13) from opposite corners of
(3 and 6, figure 2), end housings (14), and valve end housing (14).
housing (27). Put alignment marks on wiring harness
(8) connector and cover (3). STEP 14
STEP 6
Remove clamp (1) securing wiring harness (8)
connector to cover (3).
STEP 7
Remove 14 screws (2) securing cover (3) to end
housing (14).
STEP 8
Remove cover (3) and gasket (4). Discard gasket (4).
BS02C114
STEP 9 Install CAS2885 transmission valve adjustment tool
Remove 14 screws (5) securing cover (6) to end set in holes where screws (13) were removed.
housing (14). Tighten hex rods of CAS2885 down against end
housing. Remove remaining 16 screws from end
STEP 10 housing (14). Loosen CAS2885 hex rods uniformly to
Remove cover (6) and gasket (7). Discard gasket (7). release spring tension. Remove end housing and
gasket (15). Discard gasket. Remove CAS2885
STEP 11 studs.
STEP 15
BS02C113
Disconnect wiring harness (8) connectors from six

BS02C115
pressure regulators (11). Remove wiring harness
from housings (14 and 27) by carefully routing Remove three pistons (16 and 18), springs (17 and
h ar ne s s a n d co n n ec to rs th ro u g h op e n ing s in 19), spring (20), and piston (21) from valve housing
housings. (27).
STEP 12 STEP 16
Remove three screws (9) and locating plates (10) Repeat Steps 12 through 14 for other side of valve
securing three pressure regulators (11) to end housing (27).
housing (14). Remove pressure regulators (11).
Remove and discard O-ring (12) from pressure
regulators.
NOTE: End housings (14) are under spring pressure.
Use CAS2885 transmission valve adjustment tool set to
hold springs down.

6007-5
1 4
21
20
18
19
9
23
25
26 22
11
10
12
18
19 15
14
13
14 10 9 7
15
5
16 27
17 13
24 11
17 12
16
6
BS01B099
1. CLAMP 7. GASKET 13. SCREW 19. SPRING 25. PLUG

2. SCREW 8. WIRING HARNESS 14. END HOUSING 20. SPRING 26. O-RING
3. COVER 9. SCREW 15. GASKET 21. PISTON 27. VALVE HOUSING
4. GASKET 10. LOCATING PLATE 16. PISTON 22. PISTON
5. SCREW 11. PRESSURE REGULATOR 17. SPRING 23. SPRING
6. COVER 12. O-RING 18. PISTON 24. ORIFICE
FIGURE 2. TRANSMISSION CONTROL VALVE

6007-6
STEP 17 STEP 18
BS02C1163 BS02C117
Remove three pistons (16 and 18), springs (17 and Remove six orifices (24) from valve housing (27).
19), piston (22), and spring (23) from valve housing
(27). STEP 19
Remove eight plugs (25). Remove and discard O-
ring (26) from plugs.

6007-7
INSPECTION
STEP 20 STEP 25
Clean all metal parts in cleaning solvent. Check pressure regulators (11) for cracks, breaks, or
o th er d a ma g e . C h e ck c on n e ct or c o nt ac ts fo r
STEP 21 looseness or signs of corrosion. Replace a pressure
Immerse end housings (14,figure 2), valve housing regulator if any of these conditions are seen. Check
(27), valve plate (4, Figure 1), and distribution plate resistance of pressure regulators using a multimeter.
(2) in cleaning solvent and agitate cleaning solvent. Replace a pressure regulator if resistance is not 17
WEAR EYE PROTECTION WHEN USING to 21 ohms.
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of housings and plates STEP 26
and to ensure that all bores are clear of foreign Check wiring harness (8) connectors for signs of
matter. breaks, cracks, or other damage. Check contacts for
foreign matter or corrosion. Check harness wiring for
STEP 22 signs of broken or cracked insulation and broken or
WEAR EYE PROTECTION WHEN USING frayed wiring at connection to connectors. Replace
COMPRESSED AIR. Use compressed air to ensure wiring harness if any of these conditions are seen.
that orifices (24, figure 2) are clear of foreign matter.
STEP 27
STEP 23 Check springs (17, 19, 20, and 23, figure 2) for
Check filter screens (6, figure 1) for blockage, rips, or cracks, breaks, distortion, or signs of permanent set.
tears. Replace if any of these conditions are seen. Replace a spring if any of these conditions are seen.
STEP 24 STEP 28
Inspect the plates (2 and 4, figure 1), housings (14 Inspect pistons (16, 18, 21 and 22, figure 2) for
and 27, figure 2) and covers (3 and 6) for corrosion, cracks, breaks, chipping, grooves, or other damage.
cracks, breaks, chipping or other damage. Check Replace if any of these conditions are seen.
bores in housings for deep scratches, gouges, and
other damage. Replace a housing or cover if any of
the above conditions are seen.

6007-8
1 4
21
20
18
19
9
23
25
26 22
11
10
12
18
19 15
14
13
14 10 9 7
15
5
16 27
17 13
24 11
17 12
16
6
BS01B099
1. CLAMP 7. GASKET 13. SCREW 19. SPRING 25. PLUG

2. SCREW 8. WIRING HARNESS 14. END HOUSING 20. SPRING 26. O-RING
3. COVER 9. SCREW 15. GASKET 21. PISTON 27. VALVE HOUSING
4. GASKET 10. LOCATING PLATE 16. PISTON 22. PISTON
5. SCREW 11. PRESSURE REGULATOR 17. SPRING 23. SPRING
6. COVER 12. O-RING 18. PISTON 24. ORIFICE
FIGURE 3. TRANSMISSION CONTROL VALVE

6007-9
ASSEMBLY
NOTE: Apply clean Case No. 1 engine oil (15W-40) STEP 31
to pistons (16, 18, 21, and 22, figure 3) and springs
(17, 19, 20, and 23), orifices (24), new O-rings (12
and 26), and filter screens (6, figure 4) before
assembly.
STEP 29
BS02C118
Push down on pistons (16) to compress springs (17)

and use 5.0 mm (0.197 inch) diameter pins to hold
pistons in position. Install pins in locations shown
above.
BS02C117 STEP 32
Install six orifices (24, figure 3) with concave side
facing up. Install orifices until contact with shoulder in
valve housing (27) is made.
STEP 30 15
A
BS02C119
BS02C115
Install springs (17 and 19) and piston (21) in valve

housing (27) bores then install pistons (16 and 18)
and spring (20).
BS02C120
Install gasket (15) and end housing (14) on valve

housing (27). Make sure 15 mm (0.6 inch) diameter
recess (A) in end housing is facing spring (20). Install
CAS2885 transmission valve adjustment tool set to
secure end housing. Remove three pins installed in
Step 31 above. Install 16 screws (13) then remove
adjustment tool set and install remaining two screws
(13). Tighten screws (13) to a torque of 5.5 Nm (48
lb-in).

6007-10
STEP 33 STEP 36
BS02C121 BS02C123
Install a new O-ring (12) lubricated with clean Case Do Step 33 to install remaining pressure regulators
No. 1 engine oil (15W-40) on pressure regulators (11) except make sure pressure regulators are
(11). Install pressure regulators and locating plates positioned as shown above.
(10). Make sure pressure regulators are positioned
as shown above. Locating plates (10) are installed STEP 37
with the nose (bump) down. Install screws (9) and
tighten to a torque of 5.5 Nm (48 lb-in).
4
STEP 34
BS02C125
Install wiring harness (8) by routing harness and

connectors through openings in housings (14 and
27 ). C on nect h arne ss con ne cto rs to p ressu re
BS02C116 regulators (11). Install gasket (4). Insert wiring
At opposite side of valve housing (27), install springs harness multi-pin circular connector in its hole in
(17, 19, and 23) and pistons (16, 18, and 22) in valve cover (3) making sure marks made in Step 5 are
housing (27) bores. aligned. Secure connector to cover using clamp (1).
STEP 35 STEP 38
Install 14 screws (2) to secure cover (3) to end
housing (14). Tighten screws to a torque of 5.5 Nm
(48 lb-in).
STEP 39
A Install gasket (7) and cover (6).
STEP 40
Install 14 screws (5) to secure cover (6). Tighten
screws to a torque of 5.5 Nm (48 lb-in).
BS02C122
Repeat Steps 31 and 32 except when installing end

housing (14), make sure 19 mm (0.75 inch) diameter
recess (A) faces large piston as shown above.

6007-11
STEP 41 STEP 42
BS02C127 BS02C128
Install a new O-ring (26) on eight plugs (25). Install Install two studs in transmission control valve (7,
eight plugs and tighten to a torque of 6 Nm (53 lb-in). Figure 4) then install housing gasket (5).
5
4
3
2
6
BS98J157
1. SCREW 4. VALVE PLATE 7. TRANSMISSION CONTROL VALVE

2. DISTRIBUTION PLATE 5. HOUSING GASKET
3. HOUSING GASKET 6. FILTER SCREEN
FIGURE 4. TRANSMISSION CONTROL VALVE PLATES AND GASKETS

6007-12
STEP 43 STEP 44
BS02C129 BS02C130
Install six filter screens (6) flush in bores of valve Install housing gasket (3) then distribution plate (2).
plate (4). Screens must be facing upward toward Make sure marks made in Step 1 are aligned. Install
distribution plate (2). Make sure marks made in Step 18 screws (1) and tighten evenly to a torque of 9.5
1 are aligned. Nm (84 lb-in).
STEP 45
Refer to Section 6003 and install transmission
control valve.

SECTION INDEX
BRAKES
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

Hydraulic Brake Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008
CASE CORPORATION
700 State Street
7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-44721 November, 2001 (Revised February, 2003)
7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 3
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS ...................................... 4
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . ...................................... 4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................... 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................... 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS ...................................... 6
P.I.N. JEE0135501 AND ABOVE. . . . . . . . . . . . . . . . . . . . . . ...................................... 6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................... 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................... 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 8

7001-3
BRAKE VALVE
Removal 10. Connect a vacuum pump to the hydraulic

reservoir. Start the vacuum pump
1. Park the machine on a level surface and lower
the loader bucket to the floor. Stop the engine. 11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
2. Put blocks on both sides of each tire to prevent
machine movement. 12. Stop the vacuum pump and remove.
3. Make sure the brake accumulators are 13. Remove the mounting bolts (2), washers (3),
completely discharged. Push down and release brake valve plate (4) and the brake valve (1).
the brake pedals at least 30 times.
4. Turn the master disconnect switch to the OFF
Installation
position. 1. Install the brake valve (1), brake valve plate (4),
5. Remove the cab skirts located under the cab or washers (3) and mounting bolts (2). Refer to the
canopy. illustration below.
6. To release the pressure on the parking brake 2. Connect a vacuum pump to the hydraulic
accumulator, the line at the accumulator must be reservoir. Start the vacuum pump.
SLOWLY cracked open. A pan will be needed to 3. Remove the plugs from the hydraulic lines and
catch the hydraulic oil. connect the hydraulic lines to the brake valve (1).
7. Connect a drain hose to the quick disconnect 4. Stop the vacuum pump and remove.
couplings in each brake circuit to release any 5. Connect all of the electrical connections.
pressure in the brake circuit.
6. Turn the master disconnect switch to the ON
8. Clean the brake valve (1) and lines, refer to the position.
illustration below.
7. Bleed the brake system. See Section 7002.
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake 8. Install the cab skirts.
valve (1). 9. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
BS01C126
1. BRAKE ACCUMULATOR 3. WASHERS

CHARGING VALVE 4. BRAKE VALVE PLATE
2. MOUNTING BOLTS 5. BRAKE PEDAL
BRAKE ACCUMULATOR CHARGING VALVE ILLUSTRATION

7001-4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

1. Park the machine on a level surface and lower 1. Put the brake accumulators (1) on the brake
the loader bucket to the floor. Stop the engine. accumulator mounting brackets (12 and 13).
Refer to the illustration on page 5.
machine movement. 2. Install the clamps (8), washers (7) and nuts (6).
Install the clamps (8) using the reference marks
3. Make sure the service brake accumulators (1)
made during removal. Tighten the nuts (6).
and the parking brake a ccumulator (2) are
completely discharged. Push down and release 3. Install the spacer (11), accumulator brackets (12
the brake pedal at least 30 times, refer to the and 13), washers (10) and bolts (9). Tighten the
illustration on page 5. bolts (9).
4. To release the pressure on the parking brake 4. Install the parking brake accumulator (2) on the
accumulator, the line at the accumulator must be brackets (12 and 13).
SLOWLY cracked open. A pan will be needed to
5. Install the clamps (5), washers (4) and nuts (3).
catch the hydraulic oil.
Tighten the nuts (3).
5. Remove the left cab skirt located under the cab
or canopy.
reservoir and start the pump.
6. Connect a drain hose to the quick disconnect
7. Connect the lines for both brake accumulators
couplings in each brake circuit to release any
(1) and the parking brake accumulator (2).
pressure in the brake circuit.
8. Stop the vacuum pump and remove.
7. Place the master disconnect switch in the OFF
position. 9. Install the left cab skirt.
8. Clean the brake accumulators (1), parking brake 10. Turn the master disconnect switch to the ON
accumulator (2) and lines. position.
9. Put identification tags on all lines that are 11. Bleed the brake system. See Section 7002.
connected to the brake accumulators (1) and
12. Refer to Section 7008 and perform the Parking
parking brake accumulator (2).
Brake Test Procedure.
13. Check the hydraulic reservoir oil level and add oil
reservoir. Start the vacuum pump.
11. Disconnect hoses from both brake accumulators
(1) and parking brake accumulator (2).
12. Install plugs or caps on each line.
14. Remove the nut (3), washer (4) and clamps (5).
15. Remove the parking brake accumulator (2).
16. Loosen and remove the bolts (9), washers (10),
accumulator brackets (12 and 13) and spacer
(11).
17. Put an identification mark on the brake
accumulators (1) for reference where the clamps
(8) are to be installed during installation.
18. Remove the nut (6), washer (7) and clamps (8).
19. Remove the brake accumulators (1).

7001-5
8 1 8
13 5
8
3
1
4 2
4 10
3
9
6
7
11
12 5
10
9
BS01G023
1. BRAKE ACCUMULATOR 8. CLAMP

2. PARKING BRAKE ACCUMULATOR 9. BOLT (4)
3. NUT 10. WASHER (4)
4. WASHER 11. SPACER
5. CLAMP 12. FRONT ACCUMULATOR BRACKET
6. NUT 13. REAR ACCUMULATOR BRACKET
7. WASHER
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION - P.I.N. JEE0135500 AND BELOW

7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

1. Park the machine on a level surface and lower 1. Position and support the brake accumulators (1)
the loader bucket to the floor. Stop the engine. on the rear mounting bracket (10). Loosely install
washers (6 and 5) and bolts (4) to secure the
accumulators to the rear mounting bracket (10).
machine movement.
Refer to the illustration on page 7.
3. Make sure the service brake accumulators (1)
2. Move the front mounting bracket (9) in front of
and the parking brake a ccumulator (2) are
the brake accumulators (1) and loosely install
completely discharged. Push down and release
washers (6 and 5) and bolts (4).
the brake pedal at least 30 times. Refer to the
illustration on page 7. 3. Install washers (8) and bolts (7) to secure front
mounting bracket (9) to chassis. Tighten bolts
4. Remove the left cab skirt located under the cab
securely.
or canopy.
4. Tighten eight bolts (4) securely.
5. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any 5. Install the parking brake accumulator (2) on front
pressure in the brake circuit. mounting bracket (9).
6. Turn the master disconnect switch to OFF. 6. Install and tighten nut (3).
7. Clean the brake accumulators (1), parking brake 7. Connect a vacuum pump to the hydraulic
accumulator (2), and lines. reservoir and start the pump.
8. Put identification tags on all lines that are 8. Connect the lines for both brake accumulators
connected to the brake accumulators (1) and (1) and the parking brake accumulator (2).
parking brake accumulator (2).
10. Install the left cab skirt.
11. Turn the master disconnect switch to the ON
10. Disconnect the lines from both brake
position.
accumulators (1) and parking brake accumulator
(2). 12. Bleed the brake system. See Section 7002.
11. Install plugs or caps on each line. 13. Refer to Section 7008 and perform the Parking
Brake Test Procedure.
13. Remove the nut (3) holding the parking brake
accumulator (2).
14. Remove the parking brake accumulator (2).
15. Remove the bolts (4) and washers (5 and 6)
securing the brake accumulators to the front
mounting bracket (9).
16. Remove bolts (7) and washers (8) holding the
front mounting bracket (9) to the chassis.
17. Move the front mounting bracket (9) towards the
fr o n t o f th e lo a d er a n d r e mo v e t h e b r a k e
accumulators (1).

7001-7
3 9
4 2
6
1
8 1
7
4
10
6
5
BS02K144
1. BRAKE ACCUMULATOR 6. WASHER

2. PARKING BRAKE ACCUMULATOR 7. BOLT
3. NUT 8. WASHER
4. BOLT 9. FRONT MOUNTING BRACKET
5. WASHER 10. REAR MOUNTING BRACKET
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION - P.I.N. JEE0135501 AND ABOVE

7001-8
BRAKE PUMP
1. Park the machine on a level surface and lower 1. Install the brake pump (1), mounting bolts (2)
the loader bucket to the floor. Stop the engine. and lock washers (3). Refer to the illustration
below.
machine movement. 2. Tighten the mounting bolts (2).
3. Raise the engine hood and turn the master 3. Connect a vacuum pump to the hydraulic
disconnect switch to the OFF position. reservoir. Start the vacuum pump.
4. Clean the brake pump (1) and lines, refer to the 4. Remove the plugs or caps and connect the lines
illustration below. to the brake pump (1).
5. Put identification tags on all lines that are 5. Turn the master disconnect switch to the ON
connected to the brake pump (1). position.
6. Connect a vacuum pump to the hydraulic 6. Bleed the brake system. See Section 7002.
7. Disconnect the lines from the brake pump (1) as required. See Section 1002 for the correct oil.
and put plugs or caps on each line.
9. Remove the mounting bolts (2) and lock washers
(3) from the brake pump (1) and remove the
brake pump (1).
7 6
1
3
2
4
5
9
8
7
BS01C125
1. BRAKE PUMP 4. GEAR 7. O-RING

2. MOUNTING BOLT 5. SPACER 8. ELBOW
3. LOCK WASHER 6. GASKET 9. HOSE
BRAKE PUMP ILLUSTRATION - P.I.N. JEE0135500 AND BELOW
7001-9
3
1
4
5
2 4
8
12
11
9
7
11 6
12
10
BS02K143
1. BRAKE PUMP 7. NUT

2. BOLT 8. GEAR
3. WASHER 9. PRESSURE HOSE
4. GASKET 10. SUCTION HOSE
5. SPACER 11. ELBOW
6. COTTER PIN 12. O-RING
BRAKE PUMP ILLUSTRATION - P.I.N. JEE0135501 AND ABOVE

7001-10
NOTES

7002
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING
CASE CORPORATION
700 State Street
7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7002-3
SPECIFICATIONS
Brake pump output ....................................................................................................................30.8 L/min at 172 bar
(8.14 gpm at 2500 psi at 2200 rpm)
Accumulator nitrogen charge pressure...........................................................................53 to 57 bar (775 to 825 psi)

Accumulator valve cut in pressure......................................................................... 147 to 167 bar (2130 to 2422 psi)
Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2842 psi)
Brake warning pressure switch............................................................................................ 117 bar (1697 psi) falling
141 bar (2045 psi) rising
Brake redundant pressure switch .......................................................................................................62 bar (900 psi)
Brake light pressure switch..................................................................................................................4.1 bar (60 psi)
Modulation pressure front brake cylinders..................................................................90 to 97 bar (1305 to 1407 psi)
Modulation pressure rear brake cylinders ..................................................................87 to 94 bar (1260 to 1363 psi)
SPECIAL TOOL
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.

7002-4
20 14
25 17
18 24
15
6
3
1
5 21
15
19
14 20
16
10
23 13
8 12
22 26 7
11
BC01E035
1. FRONT BRAKES 10. OIL COOLER (OPTIONAL) 19. BRAKE LIGHT PRESSURE SWITCH
2. REAR BRAKES 11. HYDRAULIC FILTER 20. REDUNDANT BRAKE PRESSURE SWITCH
3. PARKING BRAKE 12. BY-PASS WARNING SWITCH 21. FROM COUPLER LOCKING VALVE (OPTIONAL)
4. FRONT AXLE TEST PORT 13. FILTER BY-PASS 22. NOT USED WITH OPTIONAL FAN REVERSER
5. REAR AXLE TEST PORT 14. BRAKE ACCUMULATOR 23. REVERSE FLOW CHECK VALVE (RIDE CONTROL ONLY)
6. PARKING BRAKE SOLENOID 15. BRAKE ACCUMULATOR TEST PORT 24. BRAKE AND ACCUMULATOR CHARGING VALVE
7. BRAKE PUMP 16. FAN REVERSER (OPTIONAL) 25. PARKING BRAKE ACCUMULATOR
8. BREATHER 17. BRAKE WARNING PRESSURE SWITCH 26. FAN VALVE (STANDARD)
9. RESERVOIR 18. PARKING BRAKE ACCUMULATOR DIAGNOSTIC FITTING (NOT USED ON P.I.N. JEE0135501 AND ABOVE)
621D BRAKE ILLUSTRATION

7002-5
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in 6. With the engine running at high idle, push and
the hydraulic schematic. Refer to the rear pocket of release the brake pedal rapidly while reading the
this manual. drop in pressure on the gauges. The pressure
drops ma y not be equal, but as the lowest
1. Make sure the oil level in the hydraulic reservoir
pressure reaches 147 to 167 bar (2130 to 2422
is correct. Remove all pressure from the brake
psi), the system pressure must start to increase.
system by pushing and releasing the brake pedal
This is the valve cut in pressure.
many times with the engine stopped, until there
is no pressure on the pedal. NOTE: The brake cut-in and cut-out pressures of the
brake system charge valve are factory preset and are
2. Install two 207 bar (3000 psi) pressure gauges to
not adjustable.
both front and rear hydraulic brake accumulator
lines.The test ports for the accumulators are NOTE: If the pressure on one of the pressure
located behind the left cab skirt. gauges is lower than specified, the problem can be a
bad accumulator valve.
NOTE: On units P.I.N. JEE0135500 and below,
there are three accumulators and test ports located 7. Stop the engine. Push and release the brake
behind the cab skirt. The accumulator and test port several times while reading the pressure on the
closest to the outside of the machine is for the gauges. Each push and release of the pedal will
parking brake. The accumulator in the middle is for resu lt in a sligh t drop in p ressu re, bu t not
the rear brakes, with the test port being in the upper necessarily equal on the two gauges. As the
position. The accumulator to the back is for the front lowest pressure reaches 110 to 124 bar (1600 to
brakes, with the test port located in the lower 1800 psi) the brake warning lamp and alarm
position. Refer to the illustration on page 9. On units buzzer must actuate. If the warning lamp and
P.I.N. JEE0135501 and above, there are three alarm buzzer fail to work, test the low brake
accumulators and two test ports located behind the pressure warning switches and electrical circuit.
cab skirt. The accumulator and test port located to If the warning lamp and alarm buzzer actuate at
the outside of the loader is for the rear brakes. The a higher or lower pressure than specified, test
accumulator and test port to the inside of the loader the low brake pressure warning switches and
is for the front brakes. The small bottle type replace as needed.
accumulator is for the parking brake. Refer to the
8. Continue to slowly push and release the brake
pedal several times until the gauge pressure
3. Make sure that the hoses on the pressure sudd enly drop s to zero. The last pressu re
gauges are long enough so the gauges can be reading before the drop to zero is the nitrogen
read while sitting in the operators seat. charge pressure in the accumulator. Test the
pressure in both accumulators. If the pressure is
NOTE: The gauges can not be connected if
below 53 to 57 bar (775 to 825 psi), charge or
hydraulic pressure remains in the system.
replace the accumulator(s) (see page 6).
4. Start the engine. Run the engine at low idle while
NOTE: Cold temperature can cause a drop in
re ad ing th e p re ssu re g au g es . Th e a lar ms
pressure.
(buzzer, master warning light and brake pressure
warning light) should shut off when the
accumulator with the lowest pressure reaches
126 to 140 bar (1825 to 2025 psi).
5. After the alarms stop, run the machine at high
idle to finish charging the accumulators. The
pressure must increase on both gauges until 190
to 196 bar (2755 to 2842 psi) is reached. This is
the accumulator valve cut-out pressure. It is
normal for the pressure to drop slightly once the
cut-out pressure is reached.

7002-6
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following: E
C
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
F
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
D B A
4. Turn the stem out of valve F until the stem stops.
94L95
5. Remove the cap screws and guard from the NITROGEN CHARGING KIT
accumulator.
8. Make sure that valve D is open.
6. Remove the cap from the accumulator valve
9. Turn the stem into valve F and read the pressure
stem.
gauge E.
7. Connect valve F to the accumulator valve stem.
10. The pressure must be 48 to 58.6 bar (700 to 850
psi). If the p ressure is to o low, cha rge th e
accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 5. If the pressure increases above 57 bar (825 psi),
according to the instructions in Checking the quickly open and close valve D and read gauge
Nitrogen Charge in the Accumulator. Keep the E. If the pressure is still too high, close valve A
nitrogen charging kit connected to the accumulator. (turn counterclockwise) a small amount and
quickly open and close valve D. The pressure
1. Close (turn counterclockwise) valve A and open
shown on gauge E is the charge pressure.
valve B. Close valves C and D.
6. Connect valve F to the accumulator valve stem.
2. Turn the stem out of valve F until the stem stops
Turn the stem into valve F until the stem stops
moving. Disco nn ect va lve F fr om th e
moving and open valve D to c harge the
accumulator valve stem.
accumulator.
3. Connect the nitrogen charging kit to a dry
7. After the accumulator stops charging, turn the
nitrogen tank.
stem out of valve F until the stem stops moving.
4. Slowly turn valve A clockwise and read gauge E
8. Close valve B and disconnect the nitrogen
until the pressure is 53 to 57 bar (775 to 825 psi).
charging kit from the accumulator valve stem.
Stop turning valve A.
9. Install the cap on the accumulator valve stem.
Ins tall the guard and cap screws on the
accumulator.

7002-7
BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir. 5. Locate connector at end of engine harness wire
Add fluid to the reservoir if necessary. (1) and disconnect connector from fuel injector
pump fuel solenoid connector.
NOTE: The fuel solenoid is located behind the fuel
injection pump near the fuel lines.
6. Loosen the pressure side fitting (4) on the brake
pump. The pressure side is the top fitting on the
brake pump. Refer to the illustration on page 11
or 12.
7. Turn the engine over until a few drops of oil leak
past the pressure side fitting.
1 8. Tighten the hose fitting and connect the fuel
solenoid connector to the engine harness wire
BD00M048
(1) connector.
1. SAFETY LINK 9. Start the engine.
10. Keep the engine speed at low idle until both
2. Raise loader arms and install the safety link (1) brake accumulators are fully charged.
for safe access to the front axle bleed screws.
NOTE: This will be approximately 30 seconds after
3. Apply the parking brake. the low brake pressure light goes out.
4. Stop the engine. 11. Stop the engine.
12. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
1 pumps).
13. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
NOTE: Attach a hose to the bleed screws to prevent
spilling any fluids.
14. Start the engine and run at low idle.
15. Push the brake pedal all the way down and
slowly release for one cycle.
16. Close all four wheel end bleed screws.
BD01E139
P.I.N. JEE0135500 AND BELOW 17. Fully depress the brake pedal three times in 5
second cycles.
18. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
19. Open the bleed screw on the right front axle.
Repeat step 18.
1 20. Open the bleed screw on the left rear axle.
Repeat step 18.
21. Open the bleed screw on the right rear axle.
BS02K112 Repeat step 18.
22. Tighten all bleed screws, caps and plugs.
1. FUEL SOLENOID WIRE
23. Check the hydraulic fluid and add as necessary.
7002-8
BRAKE MODULATION PRESSURE CHECK
Testing the Brake Modulation Adjusting the Brake Modulation

Pressure Pressure
1. Make sure the hydraulic accumulator cut-in and NOTE: The adjusting bolt to adjust the modulation
cut-out pressures are correct. Refer to page 5 of pressure is located in the cab, under the brake pedal.
this section.
2. Stop the engine. Pump the brake pedal until
there is no pressure in the brake system.
2
1
1 2
BD00N012
1. FRONT AXLE TEST PORT BD00N121

2. REAR AXLE TEST PORT
1. TAMPER RESISTANT COVER
3. Connect two 207 bar (3000 psi) pressure gauges 2. ADJUSTING BOLT
to the front axle test port (1) and the rear axle 1. Remove the tamper resistant cover (1).
test port (2).
NOTE: This is a tamper resistant cover and it will be
NOTE: These test ports are located behind the left necessary to install a new cover after the modulation
cab skirt near the brake valve. The test port closest pressure is adjusted.
to the front of the machine is for the front brakes and
the test port for the rear brakes is towards the rear. 2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
4. Install two 207 bar (3000 psi) pressure gauges to
the accumulator test ports (3 and 4). Refer to the NOTE: The rear brake modulation pressure cannot
illustration on page 9. be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 10 in the Testing the
6. Operate the machine at low idle and watch the Brake Modulation Pressure procedure.
pressure gauges on the brake accumulators until
the gauges rise above 170 bar (2645 psi). 4. Repeat these steps until the brake modulation
pressure is within the specified range.
7. Apply and hold the brakes for 10 to 15 seconds.
8. Make a note of the pressure on the gauges for
the front and rear axles.
9. The front axle brake pressure should read 90 to
97 bar (1305 to 1407 psi). This is the modulation
pressure for the front axle.
10. The rear axle brake pressure should read 87 to
94 bar (1260 to 1363 psi).
11. If the pressures are not within the specified
r a n g e , i t w i ll b e n e c e s s a r y t o a d ju s t t h e
modulation pressures.

7002-9
CHECKING THE BRAKE SYSTEM

1. Check the level of the hydraulic fluid in the 6. Start the engine and let idle until both the front
reservoir, add as needed. a nd r ea r ac cu mu lato r s ( 5 an d 6 ) a r e fully
charged. The accumulators are fully charged at
190 to 196 bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal (8) down slowly, allowing
for full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal (8) down. The
1 low brake pressure light should activate when
the pressure reaches 110 to 124 bar (1600 to
1800 psi). After the low brake pressure light
BD00M030
activates, press the brake pedal eight more
times.
1. ARTICULATION LOCK
2. Install the articulation lock (1) before doing this 10. Record the readings on the pressure gauges.
test. The pressure gauges should read at or above 52
to 58 bar (750 to 850 psi).
3. Remove the left side cab skirt to gain access to
the brake accumulators (5 and 6). Refer to the 11. If the pressures are at or above 52 to 58 bar (750
illustration below. to 850 psi), the test is complete.
4. Pump the brake pedal (8) until there is no 12. If the pressures are not within the required
hydraul ic pressu re in the brake system specifications, then the brake system must be
(approximately 20 pumps). bled.
5. Connect two 207 bar (3000 psi) pressure gauges 13. After bleeding the brake system, perform the
to the test ports (3 and 4). brake system check again.
6
8
5
2
4
7 3
BC01E040
1. PARKING BRAKE ACCUMULATOR 5. FRONT BRAKE ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR TEST PORT 6. REAR BRAKE ACCUMULATOR
3. FRONT BRAKE ACCUMULATOR TEST PORT 7. BRAKE AND ACCUMULATOR CHARGING VALVE
4. REAR BRAKE ACCUMULATOR TEST PORT 8. BRAKE PEDAL
BRAKE SYSTEM COMPONENTS - P.I.N. JEE0135500 AND BELOW

7002-10
BS02M025
1. PARKING BRAKE ACCUMULATOR 5. FRONT BRAKE ACCUMULATOR

2. NOT USED 6. REAR BRAKE ACCUMULATOR
3. FRONT BRAKE ACCUMULATOR TEST PORT 7. BRAKE AND ACCUMULATOR CHARGING VALVE
4. REAR BRAKE ACCUMULATOR TEST PORT 8. BRAKE PEDAL
BRAKE SYSTEM COMPONENTS - P.I.N. JEE0135501 AND ABOVE

7002-11
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as 3. Measure the flow at 0 bar (0 psi). Record the flow
shown below for units P.I.N. JEE0135500 and reading. Slowly close the load valve on the
below or as shown on page 12 for units P.I.N. flowmeter and read the flow at 170 bar (2500
JEE0135501 and above. psi). Record the flow reading.
2. Make sure the load control of the flowmeter is 4. Divide the flow reading at 170 bar (2500 psi) by
open. Start the engine. Run the engine at full the reading at 0 bar (0 psi). Multiply the result by
th ro ttle . M ak e su r e th e oil is a t o p e ra tin g 100. This is the percent efficiency of the pump. If
temperature. the efficiency of the pump is less than 85%,
repair or replace the pump.
11
9
12
NOTE
8
10
6 7
12 12
5
4
3
12
2
12 1
BS01B007
1. FROM HYDRAULIC RESERVOIR 5. BRAKE PUMP 9. FILTER INLET MANIFOLD

2. ELBOW 6. FLOWMETER INLET HOSE 10. FILTER
3. PLUG 7. CAS-10280 FLOWMETER 11. FILTER TO RESERVOIR HOSE
4. TO ACCUMULATOR VALVE 8. FLOWMETER OUTLET HOSE 12. O-RING
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
BRAKE PUMP OUTPUT TEST - P.I.N. JEE0135500 AND BELOW

7002-12
11
9
12 NOTE
8
10
5 6 7
1
2 12
3 4
BS02M026
1. FROM HYDRAULIC RESERVOIR 5. BRAKE PUMP 9. FILTER INLET MANIFOLD

2. ELBOW 6. FLOWMETER INLET HOSE 10. FILTER
3. PLUG 7. CAS-10280 FLOWMETER 11. FILTER TO RESERVOIR HOSE
4. TO ACCUMULATOR VALVE 8. FLOWMETER OUTLET HOSE 12. O-RING
BRAKE PUMP OUTPUT TEST - P.I.N. JEE0135501 AND ABOVE

Section
7004
7004
BRAKE ACCUMULATORS
CASE CORPORATION
700 State Street
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 3
BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
PARKING BRAKE ACCUMULATOR P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6

7004-3
SPECIAL TOOL
94L95
CAS-10899 NITROGEN CHARGING KIT
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C E
D B A
94L95
NITROGEN CHARGING KIT
NOTE: The parking brake accumulator used on 6. Connect valve F to the valve stem on the
P.I.N. JEE0135501 and above is not rechargeable accumulator.
nor repairable.
7. Turn the T-handle inward on valve F to engage
1. Use the CAS-10899 nitrogen charging kit to the pin in the valve stem.
discharge the accumulator, refer to illustration
8. Open valve D and check the charge pressure on
above. The tool must be disconnected from the
gauge E.
nitrogen tank.
9. To discharge the accumulator, partially open
2. Close valves B, C and D.
valve B. The accumulator charge will bleed down
3. Adjust the regulator A to the minimum pressure through the regulator.
setting by turning the knob counterclockwise.
10. Once the accumulator is fully discharged,
4. Turn the T-handle on valve F fully out. disconnect valve F from the valve stem.
5. Remove the guard (2) and valve assembly cap 11. The accumulator can now be disassembled.
(9) from the accumulator, refer to Figure 2.

7004-4
BRAKE ACCUMULATORS
NOTE: See Section 7001 for the proper procedure 1. Fasten the body (1) in a vise. Be careful not to
to remove the accumulator. damage the body (1). Refer to the illustration on
page 5.
WA R N I N G : D O N O T a t t e m p t t o
disassemble any accumulator until the 2. Install a new wear ring (9), O-ring (11) and
nitrogen charge is properly discharged. backup ring (10) on the piston (5).
SM386 3. Lubricate the bore of the body (1) and the piston
(5) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (5) into the body (1), round
damage the body (1), refer to the illustration on surface first. Then push the piston (5) farther into
page 5. the body (1).
2. Remove the screws (3) and guard (2) from the
NOTE: The piston (5) must be installed squarely and
body (1).
slowly into the body (1). Once the piston (5) is started
3. Remove the pressure valve (4) and the elbow (8) straight into the bore of the body (1), use a hammer
from the body (1). and wood block to gently tap the piston into the
4. Remove and discard the O-ring (7) from the polished area of the bore. Keep force on the piston
elbow (8). (5) while tapping into the bore or damage may occur
to the O-ring.
5. Loosen and remove the gland (6) from the body
(1). 5. Install new seals (12) on the gland (6).
6. Remove the piston (5) from the body (1). 6. Lubricate the seals (12) with clean oil and start
7. Remove and discard the wear ring (9), O-ring the gland (6) into the body (1).
(11) and the backup ring (10) from the piston (5). 7. Tighten the gland (6).
8. Remove the seals (12) from the gland (6).
8. Install a new O-ring (7) on the elbow(8).
Inspection 9. Install the elbow (8) on the body (1).
1. Clean body (1), gland (6) and piston (5) in 10. Install the pressure valve (4) in the elbow (8).
cleaning solvent, refer to the illustration on page 11. Install the guard (2), screws (3) in the body (1).
5.
12. Charge the accumulator with dry nitrogen
2. Inspect the piston (5) for cracks, burrs or other according to instructions in Section 7002.
damage.
3. Inspect the bore of the body (1) for scratches or
scoring using a light.
NOTE: Minor scratches or scoring in the bore of the
body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (4) and replace as
needed.

7004-5
12 6 9 10 11 4
5
3
7
1 8
BS01B223
1. BODY 4. PRESSURE VALVE 7. O-RING 10. BACKUP RING

2. GUARD 5. PISTON 8. ELBOW 11. O-RING
3. SCREW 6. GLAND 9. WEAR RING 12. SEALS (2)
BRAKE ACCUMULATOR

7004-6
PARKING BRAKE ACCUMULATOR

NOTE: The parking brake accumulator used on Assembly
P.I.N. JEE0135501 and above is not rechargeable
nor repairable. 1. Fasten the body (1) in a vise. Be careful not to
damage the body (1). Refer to the illustration on
Disassembly page 7.
2. Install a new wear ring (8), O-ring (10) and
NOTE: See Section 7001 for the proper procedure
backup ring (9) on the piston (5).
to remove the accumulator.
3. Lubricate the bore of the body (1) and the piston
WA R N I N G : D O N O T a t t e m p t t o (5) with clean oil.
disassemble any accumulator until the
nitrogen charge is properly discharged. 4. Start the piston (5) into the body (1), round
SM386 surface first. Then push the piston (5) farther into
the body (1).
1. Fasten the body (1) in a vise. Be careful not to NOTE: The piston (5) must be installed squarely and
damage the body (1), refer to the illustration on slowly into the body (1). Once the piston (5) is started
page 7. straight into the bore of the body (1), use a hammer
and wood block to gently tap the piston into the
polished area of the bore. Keep force on the piston
body (1).
(5) while tapping into the bore or damage may occur
3. Remove the pressure valve (4) from the to the O-ring.
body (1).
5. Install new seals (11) on the gland (6).
4. Remove and discard the O-ring (7) from the
pressure valve (4). 6. Lubricate the seals (11) with clean oil and start
the gland (6) into the body (1).
5. Loosen and remove the gland (6) from the body
(1). 7. Tighten the gland (6).
6. Remove the piston (5) from the body (1). 8. Install a new O-ring (7) on the pressure valve (4).
7. Remove and discard the wear ring (8), O-ring 9. Install the pressure valve (4) on the body (1).
(10) and the backup ring (9) from the piston (5).
10. Install the guard (2), screws (3) in the body (1).
8. Remove the seals (11) from the gland (6).
11. Charge the accumulator with dry nitrogen
Inspection according to instructions in Section 7002.
1. Clean body (1), gland (6) and piston (5) in WA R N I N G : U s e o n l y n i t r o g e n w h e n

cleaning solvent, refer to the illustration on page charging the accumulator. DO NOT use air
7. or oxygen that will cause an explosion.
SM115A
2. Inspect the piston (5) for cracks, burrs or other
damage.
needed.

7004-7
11 6 8 9 10 3
5
2
4
3
1
BS01B224
1. BODY 4. PRESSURE VALVE 7. O-RING 10. O-RING

2. GUARD 5. PISTON 8. WEAR RING 11. SEALS (2)
3. SCREW 6. GLAND 9. BACKUP RING
PARKING BRAKE ACCUMULATOR - P.I.N. JEE0135500 AND BELOW

7004-8
NOTES

Section
7008
PARKING BRAKE
7008
CASE CORPORATION
700 State Street
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7008-3
PARKING BRAKE
Removal and Disassembly STEP 6
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wh eel ch ocks on each wheel to prevent
machine movement.
STEP 3
BD01F287
Loosen and remove the parking brake hose. Cap and

plug the hose and fitting.
STEP 7
BD01F143
Install the articulation lock.
STEP 4
BD01F289
Loosen and remove the cover from the parking

brake.
STEP 8
BD01D136
Place the master disconnect switch in the OFF

position.
STEP 5
With the engine in the OFF position, pump the brake
pedal at least 30 times to discharge the
accumulators.
BD01D347
Loosen the jam nut that secures the center post.

7008-4
STEP 9 Inspection
STEP 12
Clean and inspect all parts for wear and damage.
Inspect the brake disc for wear and damage.
Replace all parts that are worn or damaged.
Assembly and Installation

STEP 13
BD01D347
Turn the center post counterclockwise until the brake
pads are loose.
STEP 10
BD01D350
Install the two brake pads in the parking brake

assembly.
STEP 14
Install the parking brake assembly on the brake disc.
BD01D348
Loosen and remove the two bolts holding the parking STEP 15
brake to the transmission. Remove the parking
brake.
NOTE: The photo above shows the drive shaft
removed, it is not necessary to remove the drive
shaft.
STEP 11
BD01D348
Install the two bolts holding the parking brake to the

transmission. Tighten the two bolts.
NOTE: The photo above shows the drive shaft
removed, it is not necessary to remove the drive
shaft.
BD01D351
Remove the two brake pads from the parking brake
assembly.
7008-5
STEP 16 STEP 19
BD01F287 BD01F287
Remove the plugs and caps and install the hose onto If the parking brake cover has been installed, remove
the fitting on the parking brake. the cover.
STEP 17 STEP 20
Start the machine and run the engine at low idle with
the bucket resting on the ground.
IMPORTANT: It will be necessary to have an
assistant help for this procedure. An operator must
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.
STEP 18
1
Disengage the parking brake. 2
NOTE: Hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is
BD01D347
turned off, the service brakes applied and the
1. JAM NUT
transmission is put into gear.
2. CENTER POST
A. Place the parking brake rocker switch in the Loosen the jam nut (1) that secures the center post
OFF position. (2).
B. Apply the service brake and put the machine
into gear. STEP 21
C. The parking brake light on the cluster will turn
off at this time.
D. Place the transmission back into neutral
before proceeding.
BD01D347
Turn the center post clockwise until both brake pads

contact the brake disc, then turn the center post
counterclockwise one turn.

7008-6
STEP 22 STEP 26
BD01D347 BD01F143
Tighten the jam nut to secure the center post. Remove the articulation lock.
STEP 23 STEP 27
BD01F287 BD01D140
Install the cover on the parking brake. Place the ma ster d isconn ect switch to the O N
position.
STEP 24
Perform the Pa rking Brake Test Procedu re as
described in this section.
STEP 25
Re fe r to Se ctio n 70 02 fo r Bleed in g th e Bra ke
System.

7008-7
PARKING BRAKE TEST PROCEDURE

STEP 28 STEP 36
While testing, the machine must be on a clear level Shift the gear selector into third gear forward and
surface with the bucket in the travel position. slowly increase the engine speed to wide open
throttle.
STEP 29
Start the machine and run the engine at low idle in STEP 37
third gear neutral. Verify that the machine does not move.
STEP 30 STEP 38
Place the Transmission-Auto switch to the manual Reduce the engine speed to low idle and return the
position, transmission neutral.
STEP 31 STEP 39
Place the Parking Brake switch in the ON position. Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
STEP 32 throttle.
Press the Program switch on the instrument cluster.
STEP 40
STEP 33 Verify that the machine does not move.
Press the Up Count switch until the display reads
011. STEP 41
Reduce the engine speed to low idle and return the
STEP 34 transmission to neutral.
Return the Program switch to the OFF position.
STEP 42
STEP 35 Press the Reset switch on the instrument cluster to
Press the UP Count switch until the display reads 01. exit the test mode.
This mode will allow the transmission to engage
while the parking brake is applied. STEP 43
If any machine movement was detected, the parking
brake must be adjusted.

7008-8
NOTES

SECTION INDEX
HYDRAULICS
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Pilot Pressure Accumulator and Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
CASE CORPORATION
700 State Street
8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS

Racine, WI 53404 U.S.A. Bur 6-44731 Issued November, 2001 Revised September, 2004
8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Bur 6-44731 Issued 11-01 Revised 9-04 Printed in U.S.A.

8001-3
LOADER CONTROL VALVE
Removal STEP 6
Loosen the filler cap on the reservoir to release the
STEP 1 air pressure in the reservoir.
Park the machine on a level surface.
STEP 7
STEP 2 Drain the hydraulic reservoir.
STEP 8
BD00M048
Raise the lift arms and install the safety link on the lift
arm cylinder. BD00M041
Loosen and remove the bolts and washers that

STEP 3 fasten the access cover plate for the loader control
Stop the engine and apply the parking brake. valve. Remove the cover plate.
IMPORTANT: Pump the brake repeatedly to be sure

the brake accumulators have no hydraulic pressure,
then move the loader control valve back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 4
BD01D138

position.
STEP 5
Release the pressure in the ride control accumulator
with the manual bleeder valve at the rear of the front
chassis.
8001-4
9
5
REAR OF MACHINE
10
11
4
12
8
1
BS01D179
1. LOADER CONTROL VALVE 5. PRESSURE SWITCH FITTING 9. PILOT LIFT LEFT

2. PILOT ACCUMULATOR HOSE 6. FLOAT SWITCH 10. PILOT TILT LEFT
3. PILOT PRESSURE HOSE 7. AUXILIARY HOSE (OPTIONAL) 11. PILOT LIFT RIGHT
4. CHECK VALVE 8. AUXILIARY HOSE (OPTIONAL) 12. PILOT TILT RIGHT
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION
STEP 9 STEP 10
Disconnect the hoses (2,3, (7 anf 8 if equipped) Install a plug in each hose and a cap on each fitting.
9,10,11, and 12) from the remote control valve(s) at
the loader control valve (1) one at a time and fasten
an identification tag to each hose. Refer to the
illustration above.

8001-5
STEP 11 STEP 12
1
2 2
4
3 1 3
4
5
6
BD01D376 BD01D381
1. VALVE RETURN HOSE 1. ROD END TILT TUBE

2. RIDE CONTROL TANK HOSE 2. HEAD END TILT TUBE
3. ACCUMULATOR DRAIN HOSE 3. HEAD END LIFT TUBE
4. PUMP LOAD SENSING HOSE 4. ROD END LIFT TUBE
5. STEERING LOAD SENSING HOSE
A. Tag and disconnect the rod end tilt tube (1)
6. STEERING PRESSURE HOSE
from the loader control valve and install a plug
7. PUMP PRESSURE HOSE (NOT SHOWN)
in the tube and a cap on the fitting.
A. Tag and disconnect the valve return hose (1)
at the loader control valve and install a plug in B. Tag and disconnect the head end tilt tube (2)
the hose and a cap on the fitting. from the loader control valve and install a plug
B. Tag and disconnect the pump pressure hose
(7) and install a plug in the hose and a cap on C. Tag and disconnect the head end lift tube (3)
the fitting. from the loader control valve and install a plug
NOTE: The pump pressure hose (7) will be
connected to a elbow at the bottom of the loader D. Tag and disconnect the rod end lift tube (4)
control valve. from the loader control valve and install a plug
C. Tag and disconnect the ride control tank hose
E. Tag and disconnect any auxiliary spool tubes
(2) and install a plug in the hose and a cap on
if equipped.
the fitting.
D. Tag and disconnect the accumulator drain STEP 13
hose (3) and install a plug in the hose and a
cap on the fitting.
E. Tag and disconnect the pump load sensing
cap on the fitting.
F. Tag and disconnect the steering load sensing
cap on the fitting.
G. Tag and disconnect the steering pressure
cap on the fitting.
BS01D190
Loosen and remove the three bolts and washers that
hold the loader control valve to the valve mounting
plate.
8001-6
STEP 14 B. Connect the head end lift tube (3) to the
Use proper lifting device to lift and remove the loader loader control valve.
control valve. C. Connect the head end tilt tube (2) to the
loader control valve.
Installation D. Connect the rod end tilt tube (1) to the loader
control valve.
STEP 15
STEP 17
4
3 1
5
6
BD01D376
1. VALVE RETURN HOSE

2. RIDE CONTROL TANK HOSE
BS01D190
3. ACCUMULATOR DRAIN HOSE
A. Install and align the loader control valve with 4. PUMP LOAD SENSING HOSE
the valve mounting plate. 5. STEERING LOAD SENSING HOSE
6. STEERING PRESSURE HOSE
B. Install the bolts and washers that fasten the
7. PUMP PRESSURE HOSE (NOT SHOWN)
loader control valve to the valve mounting
plate. Tighten the bolts. A. Connect the steering pressure hose (6) to the
IMPORTANT: Before installing the fittings or
connecting the tubes to the fittings, install new B. Connect the steering load sensing hose (5) to
O-rings on the fittings. the loader control valve.
C. Connect the pump load sensing hose (4) to
STEP 16 the loader control valve.
D. Connect the accumulator drain hose (3) to the
1 loader control valve.
2 E. Connect the ride control tank hose (2) to the
loader control valve/
F. Connect the pump pressure hose (7) to the
bottom of the loader control valve.
3 4 G. Connect the valve return hose (1) to the

BD01D381
1. ROD END TILT TUBE

2. HEAD END TILT TUBE
3. HEAD END LIFT TUBE
4. ROD END LIFT TUBE
A. Connect the rod end lift tube (4) to the loader
control valve.

8001-7
9 5
REAR OF MACHINE 10
4
11
12
BS01D179
1. LOADER CONTROL VALVE 5. PRESSURE SWITCH FITTING 9. PILOT LIFT LEFT

2. PILOT ACCUMULATOR HOSE 6. FLOAT SWITCH 10. PILOT TILT LEFT
3. PILOT PRESSURE HOSE 7. AUXILIARY HOSE (OPTIONAL) 11. PILOT LIFT RIGHT
4. CHECK VALVE 8. AUXILIARY HOSE (OPTIONAL) 12. PILOT TILT RIGHT
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION
STEP 18 STEP 19
Connect the lines (2, 3, (7 and 8 if equipped) 9, 10, Fill the hydraulic reservoir with oil. Refer to Section
11, and 12) from the remote control valve to the 1002 for the correct oil.
l o ad e r c o n t r o l val ve ( 1 ) . R e fer to t h e a b ove
illustration.

8001-8
STEP 20 STEP 22
Start the engine and run at half throttle.
STEP 23
Slowly and completely extend and r etract all
cylinders at least 10 times to remove any air from the
circuits.
STEP 24
Stop the engine and check for leaks.
STEP 25
Install the access cover on the front of the machine.
BD01D138
Place the master disconnect switch in the ON STEP 26

position.
Check the level of the hydraulic oil and add hydraulic
oil as required.
STEP 21
BD00M048
Raise the loader arms and remove the safety link.

8001-9
REMOTE CONTROL VALVE
Removal STEP 34
Unlatch and open the window on the right hand side.
STEP 27
Park the machine on a level surface and lower the STEP 35
bucket to the floor. Stop the engine and apply the
parking brake. 1 1 1
1
IMPORTANT: Pump the brake repeatedly to be sure
the brake accumulators have no hydraulic pressure,
then move the loader control lever back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 28
BD01D271
A. Loosen the top four screws (1).

B. Loosen and remove the remaining six screws
holding the access panel to the ROPS cab or
canopy.
STEP 36
Remove the access panel.
BD01D138 STEP 37
position.
STEP 29
fasten the right skirt panel under the right side of the
ROPS cab or ROPS canopy. Remove the right skirt
panel.
STEP 30
Loosen the filler cap on the reservoir to release any
air in the reservoir.
BD01D390
STEP 31 Disconnect the wire from the solenoid and loosen
Drain the hydraulic reservoir. and remove the lock-out solenoid to gain access to
the hydraulic hoses.
STEP 32
Unlatch and open the right hand side access door. STEP 38
Put identification tags on each hose and disconnect
STEP 33 one at a time from the remote control valve. Install
Lift the access door up and remove the access door plugs in the hoses and caps on the fittings.
from the pins.
STEP 39
Tag and disconnect the electrical connectors for the
remote control valve.
8001-10
STEP 43
Install new O-rings on the adapters for the remote
control valve.
STEP 44
BD01D720
Loosen and remove the two screws and washers

holding the hydraulic control tower cover. Remove
the cover.
STEP 41
BD01D722
Install the remote control valve and screws in the

hydraulic control tower and tighten the screws.
STEP 45
Connect the electrical connectors for the remote
control valve.
STEP 46
BD01D722
Loosen and remove the four screws that fasten the

remote control valve to the hydraulic control tower.
STEP 42
Remove the remote control valve from the hydraulic
control tower.
BD01D720
Install the cover over the remote control valve and

install the two screws and washers.
STEP 47
Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 12 through 14 as necessary.
STEP 48
Fill the hydraulic reservoir. See Section 1002 for the
correct hydraulic oil.

8001-11
STEP 49 STEP 54
BD01D136 BD01D271
Place the master disconnect switch in the ON Position the access panel on the ROPS cab or the
position. ROPS canopy and install and tighten the screws.
STEP 50 STEP 55
Start the engine and run the engine at low idle. Close the right hand window.
STEP 51 STEP 56
Check to see that the remote control valve works Install the access door on the pins and close the
correctly. access door.
STEP 52 STEP 57
Check for hydraulic oil leakage at the remote control Install the right skirt panel under the ROPS cab or
valve. the ROPS canopy and tighten the bolts.
STEP 53
Check the level of hydraulic oil in the reservoir and
add as required.

8001-12
2
1
BS01D180
1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE

JOYSTICK AND 2 LEVER HOSE ILLUSTRATION

8001-13
2
2
1 2 2 1
BS01D178
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3 LEVER HOSE ILLUSTRATION JOYSTICK AND 1 LEVER HOSE ILLUSTRATION

8001-14
2
2
1 2 2 1
BS01D177
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
2 LEVER HOSE ILLUSTRATION JOYSTICK HOSE ILLUSTRATION

8001-15
HYDRAULIC PUMP
Removal STEP 61
STEP 58
Park the machine on a level surface and lower the
parking brake.
STEP 59
4 3
1
2
BD01F278
1. BOLTS (4) 3. SUCTION HOSE

2. CASE DRAIN HOSE 4. HYDRAULIC PUMP
A. Loosen and remove the four bolts (1)
c onn ec tin g the s uc tio n h os e (3 ) to th e
hydraulic pump (4).
B. Tag and disconnect the case drain hose (2)
BD01D138 from the top of the hydraulic pump (4).
position. C. Plug all lines and cap all fittings.
STEP 60 STEP 62
Drain the hydraulic reservoir then refer to Section
9007 and remove the ROPS cab or ROPS canopy.
BD01F281
Loosen and remove the two bolts holding the bracket

for the hydraulic hoses. Slide the bracket up to gain
enough clearance for the hydraulic pump to be
removed.

8001-16
STEP 63 STEP 65
3 1
BD01F279 BD01F285
1. BOLTS (4) Use proper lifting device to strap and support the
2. PRESSURE HOSE hydraulic pump.
3. HYDRAULIC PUMP
Loosen and remove the two bolts that fasten the
A. Loosen and remove the four bolts (1) hydraulic pump to the transmission.
connecting the pressure hose (2) to the
hydraulic pump (3).
STEP 66
B. Plug all lines and cap all fittings.
Remove the hydraulic pump from the machine.
STEP 64 STEP 67
Remove and discard the O-ring from the hydraulic
pump.
2
1
BD01F277
1. LOAD SENSING HOSE

2. HYDRAULIC PUMP
Tag and disconnect the load sensing hose (1) from
the hydraulic pump (2). Plug the hose and cap the
fitting.

8001-17
STEP 68
Use proper lifting device to lift and suppor t the
hydraulic pump. Lubricate and install a new O-ring on
the hydraulic pump.
STEP 69
2
1
3
BD01F279
1. BOLTS (4)
2. PRESSURE HOSE
3. HYDRAULIC PUMP
A. Connect the pressure hose (2) to the hydraulic
pump (3) with the four bolts (1). Tighten the
bolts.
BD01F285
Install the hydraulic pump on the transmission. STEP 72

Install the two bolts that fasten the hydraulic pump to
the transmission. Tighten the two bolts to a torque of
335 to 375 Nm (245 to 275 lb ft). 1
STEP 70
3 4
2 2
BD01F278
1. BOLTS (4) 3. SUCTION HOSE

2. CASE DRAIN HOSE 4. HYDRAULIC PUMP
1 A. Connect the suction hose (3) to the hydraulic
pump (4) with the four bolts (1). Tighten the
bolts.
BD01F277
B. Connect the case drain hose (2) to the
1. LOAD SENSING HOSE
2. HYDRAULIC PUMP
hydraulic pump (4).
Install the load sensing hose (1) to the hydraulic

pump (2).

8001-18
STEP 73 STEP 76
BD01F281 BD01D136
Install the bracket holding the hydraulic hoses. Place the master disconnect switch in the ON
Tighten the bolts. position.
STEP 74 STEP 77
See Section 9007 for installing the ROPS cab or Start the engine and run the engine at low idle for two
ROPS canopy. minutes.
NOTE: If any unusual vibration is heard coming from
STEP 75 the pump, stop the machine immediately and check
Fill the hydraulic reservoir with hydraulic oil. See for obstructions in the pump suction line.
Section 1002 for correct oil type.
STEP 78
Stop the engine and check for hydraulic oil leakage at
the hydraulic pump.
STEP 79
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.

8001-19
LIFT CYLINDERS
Removal STEP 85
STEP 80
parking brake.
STEP 81
Pump the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, then move
the loader control lever back and forth several times
to release any hydraulic pressure in the pilot control
circuit.
BD01D709
STEP 82 Loosen and remove the bolt, washer and spacer that
Relieve the pressure in the ride control accumulator hold the pivot pin for the yoke.
with the manual bleeder valve located at the rear of
the front chassis. STEP 86
STEP 83
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 84
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 87
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.

8001-20
STEP 91
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 92
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 89
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 93
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 90
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.

8001-21
STEP 94 STEP 97
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 98
STEP 95
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 99
STEP 96 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 100
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 101
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the
hydraulic reservoir.

8001-22
BUCKET CYLINDER - Z-BAR LOADER
Removal STEP 106
STEP 102
parking brake.
STEP 103
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 104
BD01D695

mounting bracket to the machine. Remove the
mounting bracket.
STEP 107
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 105
BD01D697

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
BD01D696

target bar to the mounting bracket. Remove the
target bar.

8001-23
STEP 108 STEP 111
BD01D699 BD01D701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 112
STEP 109
BD01D704
BD01D700 Remove the pivot pin from the head end of the bucket
Use acceptable equipment to hold the bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
STEP 110 replaced.
STEP 113
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD01D706
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.

8001-24
STEP 114
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 115
BD01D699
Connect the hoses to each side of the bucket

cylinder.
STEP 119
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 116 STEP 120

Install the pivot pin and stop the engine.
STEP 121
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 117 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect
the grease line to the pivot pin.

8001-25
STEP 122 STEP 125
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 123 STEP 126

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 127
Start and run the engine at low idle.
STEP 128
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 129
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 130
target bar.
and add as required. Tighten the filler cap on the
STEP 124 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.

8001-26
BUCKET CYLINDERS - XT LOADER
Removal STEP 134

Disconnect the hoses from the elbows at both ports
STEP 131 of the bucket cylinders. Install a plug in the tube and
Lower the bucket to the floor. With the engine a cap on the elbow.
stopped, move the bucket control lever to release any
pressure in the bucket circuit. STEP 135
Remove the roll pin (1) from the yoke (2). Remove
NOTE: Steps 132 and 133 apply only to the left hand
the pivot pin (3). Refer to the illustration on page 28.
bucket cylinder. For the right hand bucket cylinder go
to step 134.
STEP 136
STEP 132 Loosen and remove the nuts (4) and washers (5) at
the top and bottom of the cylinder bellcrank.
2 STEP 137
3 Remove the inner bellcrank (6) from the pivot pins
(7).
STEP 138
5 Remove the nut (8) and the grease line (9) from the
1 bucket cylinder (10).
4 STEP 139
6 Fasten acceptable lifting equipment to the bucket
BS01C084
cylinder (10) and remove the bucket cylinder (10)
from the machine.
1. BUCKET CYLINDER (LEFT HAND SIDE)
2. PROXIMITY SWITCH MOUNTING BRACKET
3. TARGET MOUNTING BRACKET
4. PROXIMITY SWITCH GUARD
5. PROXIMITY SWITCH
6. TARGET BAR
Disconnect the Return-to-Dig proximity switch (5)
and remove with the mounting bracket (2) as an
assembly.
STEP 133
Remove the Return-to Dig target bar (6) with the
mounting bracket (3) from the yoke of the bucket
cylinder (1).

8001-27
10 9
3
1
5
10
7
4
7
5
4
BS01C085
1. ROLL PIN 6. INNER BELLCRANK

2. YOKE 7. PIVOT PIN
3. PIVOT PIN 8. NUT
4. NUT 9. GREASE LINE
5. WASHER 10. BUCKET CYLINDER
XT LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION

8001-28

Install the Return-to Dig target bar and proximity
STEP 140 switch assembly. Connect the proximity switch
Use acceptable lifting equipment to install the bucket connector to the wiring harness connector. This step
cylinder (10) closed end on the pivot pins (7). Refer applies only to the left hand bucket cylinder.
STEP 147
STEP 141 Remove the plugs and caps and connect the hoses
Install the grease line (9) and the nut (8) on the to the elbows at the cylinder ports.
bucket cylinder (10).
STEP 148
STEP 142 Start the engine and run the engine at low idle.
Install the inner bellcrank (6) on the pivot pins (7).
STEP 149
STEP 143 SLOWLY, extend and retract the piston rod three
Install the washers (5) and nuts (4) on the retaining times to remove any air from the bucket cylinder (10).
bolts. Tighten the nuts (4).
STEP 150
STEP 144 Lubricate the pivot pins with molydisulfide grease.
Align and install the pivot pin (3) in the yoke (2).
STEP 151
STEP 145 Check the level of the hydraulic oil in the hydraulic
Install the roll pin (1) in the yoke (2) and pivot pin (3). reservoir and add as required. See Section 1002 for
the correct hydraulic oil.

8001-29
OIL COOLER
Removal STEP 157
STEP 152
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 153
BD01D234
Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
STEP 158
BD01D138

position.
STEP 154
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil
cooler.
STEP 155
Loosen the filler cap on the hydraulic reservoir to BD01D231
release the air pressure in the reservoir. Disconnect the hose from the bottom of the oil cooler.
Install a plug in the hose and a cap on the fitting.
STEP 156
Drain the hydraulic reservoir.

8001-30
STEP 161
Place the oil cooler in position in the cooling frame.
STEP 162
BD01D234
BD01D231
BD01D231

fasten the oil cooler to the cooling frame.
STEP 160
Remove the oil cooler from the machine. BD01D234
Install the bolts and washers that fasten the oil cooler
to the cooling frame
STEP 163
BD01D231
Connect the hose to the bottom of the oil cooler.

8001-31
STEP 164 STEP 166
BD01D234 BD01D136
Connect the hose to the top of the oil cooler. Place the master disconnect switch in the ON
position.
STEP 165
Fill the hydraulic reservoir with hydraulic oil. See STEP 167
Section 1002 for the correct hydraulic oil. Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 168
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
STEP 169
and add hydraulic oil as required.

8001-32
RIDE CONTROL ACCUMULATOR
Removal STEP 175
STEP 170
parking brake.
STEP 171
With the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have
no hydraulic pressure, the move the loader control
lever back and forth several times to release any
hydraulic pressure in the pilot control circuit.
BD01D716
STEP 172 Loosen and remove the nuts and washers from the
Relieve the pressure in the ride control accumulator U-bolt. Remove the U-bolt.
with the manual bleeder valve located at the rear of
the front chassis. STEP 176
STEP 173
release any air in the reservoir.
STEP 174
BD01D717

accumulator bracket to the front frame.
STEP 177
Remove the ride control accumulator from the
BD01D717 machine.
Disconnect the hose from the elbow at the bottom of
the ride control accumulator. Install a plug in the hose
and a cap on the fitting.
NOTE: The above photo shows the center drive
shaft removed and was done for photographic
reasons only.

8001-33
STEP 178
Place the ride control accumulator in position on the
front frame.
STEP 179
BD01D717
Remove the caps and plugs and install the hose on

t h e e l b ow a t t h e b o t t o m o f t h e r i d e c o n t r o l
accumulator.
STEP 182
BD01D717
Refer to Section 8002 Testing the Ride Control for
Install the two bolts that fasten the accumulator the proper charging of the accumulator to check for
bracket to the front frame. Tighten the bolts. leaks.
STEP 180 STEP 183

BD01D716
Install the U-bolt, washers and nuts. Tighten the nuts.

8001-34
RIDE CONTROL VALVE
Removal STEP 189

STEP 184 release any air in the reservoir.
Park the machine on a level surface and apply the
parking brake. STEP 190
STEP 185
BD01D138

BD00M048
position.
Raise the loader arms and install the safety link.
STEP 191
STEP 186
BD01G005
BD00M041
Disconnect the electrical connector on top of the ride
Remove the access cover. control valve.
STEP 187 STEP 192

With the engine NOT running, pump the brake Tag and disconnect the accumulator bleed hose (4)
repeatedly to be sure the brake accumulators have from the elbow (5) at the ride control valve (3). Install
no hydraulic pressure, then move the loader control a plug in the hose and a cap on the fitting. Refer to
lever back and forth several times to release any the illustration on page 35.
STEP 193
STEP 188 Tag and disconnect the ride control tank hose (6)
Relieve the pressure in the ride control accumulator from the adapter (14). Install a plug in the hose and a
with the manual bleeder valve located at the rear of cap on the fitting.
the front chassis.

8001-35
STEP 194 STEP 196
Tag and disconnect the ride control accumulator Loosen and remove the four bolts (12) and washers
hose (10) from the elbow (11). Install a plug in the (13) that fasten the ride control valve (3) to the ride
hose and a cap on the fitting. control bracket (2).
STEP 195 STEP 197

Tag and disconnect the ride control head tube (8) Remove the ride control valve from the machine.
from the fitting (9). Install a plug in the hose and a
cap on the fitting. STEP 198
Remove and discard all O-rings.
15 13
5 12
9
7
6 8
11
14
10
BS01G019
1. FRONT FRAME (LEFT SIDE) 6. RIDE CONTROL TANK HOSE 11. ELBOW
2. RIDE CONTROL BRACKET 7. ELBOW 12. BOLT (4)
3. RIDE CONTROL VALVE 8. RIDE CONTROL HEAD TUBE 13. WASHER (4)
4. ACCUMULATOR BLEED HOSE 9. FITTING 14. ADAPTER
5. ELBOW 10. RIDE CONTROL ACCUMULATOR HOSE 15. RIDE CONTROL ACCUMULATOR
RIDE CONTROL VALVE ILLUSTRATION

8001-36
STEP 199
Install the ride control valve (3) in position on the
front frame (1). Refer to the illustration on page 35.
STEP 200
Install the washers (13) and bolts (12) through the
ride control bracket (2) and into the ride control valve
(3). Tighten the bolts (12).
STEP 201
Lubricate and install new O-rings to all necessary
fittings. BD01D136
Place the master disconnect switch in the ON

STEP 202 position.
Connect the ride control head tube (8) to the fitting
(9) at the ride control valve (3). STEP 208
Start and run the engine at low idle for two minutes.
STEP 203
Connect the ride control accumulator hose (10) to the STEP 209
elbow (11) at the ride control valve (3). Stop the engine and check for hydraulic oil leakage at
the ride control valve.
STEP 204
Connect the ride control tank hose (6) to the adapter STEP 210
(14) at the ride control valve (3).
STEP 205
Connect the accumulator bleed hose (4) to the elbow
(5) at the ride control valve (3).
STEP 206
BD00M041
Install the access cover.
BD01G005
Connect the electrical connector to the ride control

valve.

8001-37
STEP 211 STEP 212
STEP 213
Refer to Section 8002 and perform the Ride Control
Test Procedure.
BD00M048
Raise the loader arms and remove the safety link.

8001-38
FAN REVERSING VALVE
Removal STEP 218
STEP 214 5
bucket to the ground. Stop the engine and apply the 4
parking brake.
STEP 215
3
With the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have
no hydraulic pressure, then move the loader control
2
lever back and forth several times to release any 1 5 5
BD01D360
STEP 216 1. FAN FORWARD HOSE

Loosen the filler cap on the hydraulic reservoir to 2. FAN REVERSE HOSE
release any air in the reservoir. 3. FAN VALVE RETURN HOSE
4. FAN VALVE SUPPLY HOSE
5. NUTS
STEP 217 6. WASHERS (NOT SHOWN)
7. BOLTS (NOT SHOWN)
A. Tag and disconnect the fan forward hose (1)
from the fan reversing valve. Install a plug in
the hose and a cap on the fitting.
B. Tag and disconnect the fan reverse hose (2)
from the fan reversing valve. Install a plug in
the hose and a cap on the fitting.
C. Tag and disconnect the fan valve return hose
(3) from the fan reversing valve. Install a plug
in the hose and a cap on the fitting.
D. Tag and disconnect the fan valve supply hose
BD01D359 (4) from the fan reversing valve. Install a plug
Disconnect the electrical connector for the fan in the hose and a cap on the fitting.
reversing valve.
E. Loosen and remove the nuts (5), washers (6)
and bolts (7).
STEP 219
Remove the fan reversing valve from the machine.
STEP 220
Remove and discard all O-rings from the fittings.

8001-39
STEP 221
Place the fan reversing valve into position on the
machine.
STEP 222
Lubricate and install new O-rings in the fittings.
STEP 223
5
BD01D359
4
Connect the electrical connector for the fan reversing
valve.
3 STEP 225
Check the level of the hydraulic oil in the reservoir.
2
STEP 226
1 5 5
Start the engine and run the engine at low idle for two
BD01D360
minutes.
1. FAN FORWARD HOSE
2. FAN REVERSE HOSE STEP 227
3. FAN VALVE RETURN HOSE Stop the engine and check for hydraulic oil leakage at
4. FAN VALVE SUPPLY HOSE the fan reversing valve.
5. NUTS
6. WASHERS (NOT SHOWN)
STEP 228
7. BOLTS (NOT SHOWN)
A. Install the bolts (7), washers (6) and nuts (5).
Tighten the nuts (5).
reservoir.
B. Connect the fan valve supply hose (4) to the
fitting on the fan reversing valve.
C. Connect the fan valve return hose (3) to the
elbow on the fan reversing valve.
D. Connect the fan reverse hose (2) to the fitting
on the fan reversing valve.
E. Connect the fan forward hose (1) to the fitting
on the fan reversing valve.

8001-40
NOTES

8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
621D HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
621D HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8002-3
SPECIFICATIONS
Pump Output ...............................................................................................174 to 178 L/min at 2000 rpm at 138 bar
(46 to 47 gpm at 2000 rpm at 2000 psi)
Main relief valve pressure settings
621D (Z-Bar/XT) ................................................................................................248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A and B port (Z-Bar) ......................................................................................................290 bar (4206 psi)
Bucket A port (XT) .....................................................................................................................183 bar (2654 psi)
Bucket B port (XT) .....................................................................................................................290 bar (4206 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Accumulator pressure .................................................................................................................... See Section 7002

8002-4
SPECIAL TOOLS
633L95 B877168V
CAS-1904 PRESSURE FITTING KIT CAS-1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS-1906 PRESSURE FITTING KIT CAS-10090 HAND PUMP
B785789M B877558M
CAS-10280 FLOWMETER CAS-1804 PRESSURE FITTING KIT

8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
No specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits

Replace the hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated See Page 7. Do the flowmeter tests of the
No hydraulic pump.
oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 8 and check the pressure setting of
Adjust the main relief valve. See page 8 in
the main relief valve in the loader control No this section.
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.

8002-6
Problem in a Single Loader Circuit

Star t and r un the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 10. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of contr ol valve and c heck for wo r n o r
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 7. Do the Primary Pump Output

Test.
Problem in the Ride Control

Lift ar ms rapidly and continuously sink See the Ride Control Test Procedure page
towards the ground. No 11 in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.

8002-7
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE

NOTE: The Pump Differential Pressure must be set before attempting any other tests.
Pressure Check STEP 3
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil.
A. Start the engine and run at full throttle.
B. Lower the loader bucket to the ground and
hold the lift control lever in the FLOAT position.
1
C. Roll the bucket back against the stops and
hold.
D. View the oil temperature by pressing the
program switch, then press the up count BD00N020
switch to function 008. Return the program

switch to the center (OFF) position.
STEP 2
BD00N017
1. TEST PORT (LOAD SENSE)

1 2. TEST PORT (PUMP PRESSURE)
BD00M041 Connect two 69 bar (1000 psi) test gauges to the test
1. COVER PLATE ports (1) and (2) located on the loader control valve.
Remove the cover plate to gain access to the loader STEP 4

control valve. Start the engine and run at low idle.
STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
The pressure on test por t (1) should read
approximately 29 bar (420 psi). The pressure on test
port (2) should read approximately 51 bar (740 psi).
NOTE: These readings may vary from one machine
to another. The important value is the difference
between the two readings.

8002-8
STEP 7 Adjusting the Main Hydraulic
Subtract the reading of the test port (1) from the Pump
reading of the test port (2).
STEP 10
STEP 8
Turn the pump adjusting screw closest to the pump.
The difference between the two readings should be Turn the screw clockwise to increase the differential
22 + 2.8 bar (320 + 40 psi). pressure. Turning the screw counterclockwise will
decrease the differential pressure.
STEP 9
NOTE: One turn of the adjustment screw will change
If this reading is more or less than that specified, it
the pressure approximately 16 bar (230 psi).
will be necessary to adjust the pump.
7 NOTE
4
5
2
BS01A308
1. TEE 4. LOADER CONTROL VALVE INLET HOSE 7. FILTER INLET MANIFOLD

2. LOADER CONTROL VALVE 5. CAS-10280 FLOWMETER 8. FILTER
3. FLOWMETER INLET HOSE 6. FLOWMETER OUTLET HOSE 9. FILTER TO RESERVOIR
HOSE

8002-9
TESTING AND ADJUSTING THE MAIN RELIEF VALVE

NOTE: The Pump Differential Pressure must be set before attempting any other tests. Refer to page 7 of this
section.
STEP 1
1
BD00M041
Remove the cover plate to gain access to the loader

BD00M030
control valve.
1. ARTICULATION LOCK
STEP 4
Install the articulation lock (1).
STEP 2
2
1
BD00N017

2. TEST PORT
BD00M048
Stop the engine and install a 345 bar (5000 psi)
1. SAFETY LINK
pressure gauge to the test port (2) on the front of the
Raise the loader arms and install the safety link (1). loader control valve (1).

8002-10
STEP 5 Adjustment
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil. STEP 10
A. Start the engine and run at full throttle.
B. Lower the loader bucket to the ground and
hold the lift control lever in the FLOAT position.
C. Roll the bucket back against the stops and
hold.
D. View the oil temperature by pressing the
program switch, then press the up count
switch to function 008. Return the program
switch to the center (OFF) position.
STEP 6
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
STEP 7
Operate the machine at full throttle. Tilt the bucket to
a full rollback position and hold while observing the
pressure gauge. 2
STEP 8
1
The pressure should read between 248 and 252 bar
(3596 to 3654 psi).
BS01A046

STEP 9
2. RELIEF VALVE ADJUSTMENT
If the pressure is not within the specifications, it will
be necessary to adjust the main relief valve. With the engine running and the loader on the
ground, loosen the jam nut and turn the adjustment
s c r e w ( 2 ) c l o c k w i s e fo r h i g h e r p r e s s u r e o r
counterclockwise for lower pressure.
NOTE: 1/4 turn of the adjusting screw changes the
pressure setting approximately 35 bar (500 psi).
STEP 11
Repeat the Pressure Check Procedure.
STEP 12
If the pressure is not within the specifications, repeat
steps 10 and 11 until pressure is within the required
range.
STEP 13
Stop the engine before removing the pressure
gauge.

8002-11
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Connect the hand pump to the disconnected line that
STEP 1 goes to the loader control valve.
Circuit relief valves are located as shown below.
STEP 4
6 Make sure that the hand pump is full of hydraulic oil
5 1 5 and that the temperature of the oil is approximately
1
21°C (70°F).
STEP 5
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
4 4 be sure of the reading.
STEP 6
Compare the reading to the specifications on Page 3.
STEP 7
If the pressure is not correct, adjust the circuit relief
valve.
3 Adjustment
3 1
1 STEP 1
2 Loosen the lock nut. Turn the adjustment screw
clockwis e to increase the pressure or
counterclockwise to decrease the pressure.
BS01A046
1. CIRCUIT RELIEF VALVE STEP 2

2. MAIN RELIEF VALVE Check the pressure again. Repeat the adjustment as
3. BUCKET SPOOL
necessary.
4. LIFT SPOOL
5. AUXILIARY SPOOL
6. LOADER CONTROL VALVE Leak Test
Remove the cover at the front of the machine. Test for internal leakage by raising the lift arms to the
top and shutting the engine off.
STEP 2
A. Turn the key to the “RUN” position and
Lower the bucket to the floor. Shut off the engine. disengage the controller lock-out switch.
Find an easy place to disconnect the line for the
circuit to be tested. B. Wait for the buzzer to stop.
C. Repeatedly put the lift control lever into the
“FLOAT” position and back to neutral. The
system must allow a minimum of 10
actuations into float and still cause the lift
arms to come down.
D. If 10 full actuations cannot be made, an
internal hydraulic leak exists.

8002-12
TESTING THE RIDE CONTROL

STEP 1 STEP 8
Verify that the manual ride control accumulator Accelerate the machine to at least 5 km/hr (3 mph).
bleeder valve is closed. At 5km/hr (3 mph) the lift arms should raise a visible
amount, 102mm to 635mm (4 to 12 inches)
NOTE: The bleeder valve is located on the left wall
depending on bucket and coupler weight. This is an
of the front chassis immediately behind the ride
indication that the ride control is functioning. As the
control accumulator. If this valve is left open, the lift
machine continues to travel there should be visible
arms will rapidly and continuously sink. Ride control
c y l i n d e r m ove m e n t i n r e s p o n s e t o t h e r o a d
will not function in this state because the ride control
conditions.
accumulator cannot charge.
NOTE: With an empty bucket, cylinder travel will not
STEP 2 exceed 25mm (1 inch).
Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/hr (3 mph) STEP 9
for 30 seconds and stop. With the machine traveling over 5 km/hr (3 mph)
check the indicator light on the ride control rocker
STEP 3 switch, it should be illuminated.
Start the engine.
STEP 10
STEP 4 Slow the machine down and observe the indicator
Activate the ride control. Press down on the symbol light. The indicator light should go out when the
side of the switch to activate. The indicator light WILL machine slows below 5 km/hr (3 mph).
NOT illuminate at this time.
STEP 11
NOTE: The ride control switch is located in the bank
Stop the machine.
of rocker switches to the right of the operator’s seat. It
is in the center row, second switch from the front.
STEP 12
STEP 5 De-activate the ride control with the rocker switch.
Repeat steps 5, 6 and 7.
Raise the lift arms to near the top of their travel.
STEP 13
STEP 6
Accelerate the machine to at least 5 km/hr (3 mph).
Rapidly dump the bucket until it hits the dump stops.
This time there should be no visible raising of the
This will create a down force on the liftarms and they
liftarms and the light should remain off. The quality of
should drop visibly. Repeat this process 2 or 3 times
the ride should be noticeably worse with the ride
if necessary.
control de-activated.
NOTE: The oil displaced from the lift cylinders is
used to charge the ride control accumulator. STEP 14
Stop the machine.
STEP 7
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the liftarms or the bucket on
their stops.

8002-13
621D HYDRAULIC COMPONENT LOCATIONS
6 20
14 3
15
13 2
1 4
9 11
5 10
16
12
4
18
19
7 8
17
BC00N140
1.RIDE CONTROL VALVE (OPTIONAL) 11. STEERING PRESSURE DIAGNOSTIC COUPLER
2.RIDE CONTROL ACCUMULATOR 12. BRAKE ACCUMULATORS
3.RIDE CONTROL ACCUMULATOR BLEEDER VALVE 13. BRAKE AND ACCUMULATOR CHARGING VALVE
4.LIFT CYLINDERS 14. BRAKE WARNING PRESSURE SWITCH
5.BUCKET CYLINDER (TILT CYLINDER) 15. BRAKE LIGHT PRESSURE SWITCH
6.STEERING CONTROL VALVE 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
7.STEERING CYLINDERS 17. REAR BRAKE CYLINDERS
8.AUXILIARY STEERING PUMP AND MOTOR (OPTION - 18. FRONT BRAKE CYLINDERS
NORTH AMERICAN MODELS) 19. PARKING BRAKE CYLINDER
9. AUXILIARY STEERING PRIORITY VALVE (OPTION - 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC
NORTH AMERICAN MODELS) COUPLERS
10. AUXILIARY STEERING PRESSURE SWITCH
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

8002-14
621D HYDRAULIC COMPONENT LOCATIONS
39
42 23 31
22 40
41
35 38
25 37
36
26 34
30 33
29
25
21
32
27
28
24
BC00N140
21. FAN DRIVE MOTOR 32. PILOT PRESSURE ACCUMULATOR

22. FAN REVERSING VALVE (OPTIONAL) 33. PILOT PRESSURE DIAGNOSTIC COUPLER
23. FAN VALVE (STANDARD) 34. FLOAT SWITCH
24. BRAKE HYDRAULIC PUMP 35. CONTROLLER
25. COUPLER LOCKING VALVE 36. LOADER CONTROL VALVE
26. COUPLER LOCKING CYLINDERS 37. PUMP PRESSURE DIAGNOSTIC COUPLER
27. IMPLEMENT HYDRAULIC PUMP 38. LOAD SENSING DIAGNOSTIC COUPLER
28. HYDRAULIC FILTER 39. BRAKE PRESSURE SWITCH (2)
29. HYDRAULIC RESERVOIR 40. AUXILIARY STEERING LOAD SENSE SOLENOID VALVE (OPTIONAL)
30. HYDRAULIC RESERVOIR BREATHER 41. PARKING BRAKE ACCUMULATOR
31. HYDRAULIC COOLER 42. PARKING BRAKE ACCUMULATOR DIAGNOSTIC COUPLER
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM
CASE CORPORATION
700 STATE STREET
RACINE, WI 53404 U.S.A.
3350 SOUTH SERVICE ROAD Bur 7-49640 Printed in U.S.A.
BURLINGTON, ON L7N 3M6 CANADA Issued May 1995
8003-2
TABLE OF CONTENTS
PORTABLE FILTER ..................................................................................................................................................... 3
GENERAL INFORMATION ............................................................................................................................................ 4
TYPES OF CONTAMINATION ....................................................................................................................................... 4
CLEANING THE HYDRAULIC SYSTEM .......................................................................................................................... 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM .................................................................................................... 7
NOTE: The Case Corporation reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install them on units
previously sold.

8003-3
SPECIAL TOOLS
806128
The part number for the Fitting Kit is CAS-10508.
806127
The part number for the Portable Filter is CAS-10162A.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major cause of 1. Cylinder rod seals leak.
the malfunction of hydraulic components. Contamination is
any foreign material in the hydraulic oil. Contamination can 2. Control valve spools do not return to neutral.
enter the hydraulic system in several ways.
3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line.
4. Hydraulic oil becomes too hot.
2. When you disassemble a component.
5. Pump gears, housing, and other parts wear rapidly.
3. From normal wear of the hydraulic components.
6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals.
7. Quick failure of components that have been repaired.
5. From a damaged component in the hydraulic system.
8. Cycle times are slow; machine does not have enough
All hydraulic systems operate with some contamination. power.
The design of the components in this hydraulic system
per mits efficient operation with a small amount of If your machine has any of these problems, check the
contamination. An increase in this amount of contamination hydraulic oil for contamination. See Types of Contamination
can cause problems in the hydraulic system. The following list below. If you find contamination, use the Portable Filter to
includes some of these problems. clean the hydraulic system.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic and 3. Visible contamination is foreign material that can be
visible. found by sight, touch, or odor. Visible contamination can
cause a sudden failure of components. Examples of
1. Microscopic contamination occurs when very fine visible contamination:
particles of foreign material are in suspension in the
hydraulic oil. a. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. Microscopic b. Air in the oil.
contamination can be found by identification of the
following problems or by testing in a laboratory. Examples c. The oil is dark and thick.
of the problems:
d. The oil has the odor of burned oil.
a. Cylinder rod seal leak.
e. Water in the oil. See page 7.
b. Control valve spools do not return to NEUTRAL.
c. The hydraulic system has a high operating

temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. See the fitting kit shown on page 3. Install the valve in the
following steps: hole for the drain plug. Make sure that the valve is closed.
a. Remove all the hydraulic oil from the inlet and outlet 9. Stop the vacuum pump.
hoses for the portable filter.
10. Connect the inlet hose for the portable filter to the valve
b. Remove the filter element from the portable filter. that is installed in the hole for the drain plug.
c. Remove all hydraulic oil from the portable filter. 11. Disconnect the vacuum pump from the filler cap opening
on the hydraulic reservoir.
d. Clean the inside of the housing for the filter
element. 12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is microscopic
or visible. See Types of Contamination on page 4. 13. Open the valve that is installed in the hole for the drain
plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON position.
a. Check the maintenance schedule for the machine to Start and run the engine at 1500 rpm (r/min).
lear n if the hydraulic oil must be changed. If
needed, change the hydraulic oil. See Section 1002 15. Run the portable filter for 10 minutes.
for specifications. Change the hydraulic filter.
16. Continue to run the portable filter. Increase the engine
b. Do steps 6 through 38. s p e e d t o f u l l t h r o t t l e. H e a t t h e o i l t o o p e r a t i n g
temperature by doing the following steps:
4. If the contamination is visible:
a. Hold the bucket control lever in the ROLLBACK
a. Change the hydraulic oil and hydraulic filter. See position for 15 seconds.
Section 1002 for oil specifications.
b. Return the bucket control lever to NEUTRAL for 30
b. Do steps 5 through 38. seconds.
5. Check the amount of contamination in the hydraulic c. Repeat steps 17a through 18b until the oil in the
system by doing the following steps: hydraulic system is at operating temperature.
a. Disassemble one cylinder in two different circuits. 17. Continue to run the engine at full throttle. Continue to run
Check for damage to seals, scoring of the cylinder the portable filter.
wall, etc. Repair the cylinders as necessary.
18. Operate each hydraulic circuit to completely extend and
b. If, in your judgment, the damage to the cylinders retract the cylinders. Continue to operate each hydraulic
was caused by severe contamination and is not the circuit two times, one after the other, for 45 minutes.
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders, 19. Decrease the engine speed to low idle.
hydraulic reservoir, etc. in the hydraulic system.
20. Continue to run the portable filter for 10 minutes.
6. Connect a vacuum pump to the hydraulic reservoir air
breather hose. Start the vacuum pump. 21. Stop the portable filter.
7. Loosen and remove the drain plug from the reservoir. 22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.

8003-6
24. Close the valve that is installed in the hole for the drain 30. Stop the vacuum pump. Disconnect the vacuum pump
plug. from the hydraulic reservoir.
25. Disconnect the inlet hose for the portable filter from the 31. Remove the hydraulic filter element from the machine.
valve.
32. Install a new hydraulic filter element on the machine.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir. 33. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
34. Start the engine. Check for oil leakage around the new
28. Remove the valve from the hole for the drain plug. hydraulic filter.
29. Install the drain plug. 35. Stop the engine.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 9. Move each control lever in both directions to release
pressure in the hydraulic circuits.
2. Completely retract the cylinders of all attachments on the
machine. 10. Disconnect the line from the rod end and closed end of
each cylinder.
WARNING: If retracting the cylinder rods 11. Be sure all control levers are in the NEUTRAL position.
causes the attachment to be raised, block
! the attachment in place before proceeding to
the next step!
12. Start the engine and run the engine at low idle.
39-4 IMPORTANT: C h e ck t h e o i l l eve l i n t h e hy d r a u l i c

reser voir frequently while doing step 14. Have another
NOTE: Any attachment or part of an attachment that is person hold a container under the hydraulic lines while
raised must be supported with acceptable equipment to you do step 14.
prevent the attachment from falling.
13. Slowly move each control lever in both directions until oil
3. Loosen and remove the filler cap from the reservoir. begins to flow from the open line. Hold the control lever in
place until clean oil flows from the open line.
4. Drain the hydraulic oil from the reservoir.
a. The reservoir holds approximately 15 U.S. gallons
(56.8 litres) of hydraulic oil. NOTE: Any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
b. Have available acceptable equipment to drain the prevent the attachment from falling.
hydraulic oil.
15. Connect the line to the CLOSED end of each cylinder.
c. Remove the drain plug from the bottom of the
reservoir. 16. Start the engine and run the engine at low idle.
5. Remove the hydraulic oil filter from the machine. 17. Slowly and completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out of the
6. Install a new hydraulic oil filter on the machine. rod end of the cylinder.
7. Install the drain plug in the bottom of the reservoir. 18. Support the loader frame so that the loader frame will
stay in the RAISED position.
8. Fill the hydraulic reservoir with 14.4 U.S. gallons (54.5
litres) of Case TCH Fluid. 19. Stop the engine.
20. Connect the lines to the rod end of the cylinders.
21. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
22. Install the filler cap for the reservoir.

8006
Section
8006
CYLINDERS

8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BUCKET CYLINDERS FOR XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Z-BAR AND XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder - XT and Z-Bar.......................................................................................................75.7 kg (167 pounds)
Bucket Cylinder - Z-Bar Models................................................................................................. 75.6 kg (167 pounds)
Bucket Cylinder - XT Models ........................................................................................................73 kg (160 pounds)
SPECIAL TORQUES
Screw in Gland Z-Bar Bucket Cylinder ..........................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland XT Bucket Cylinder...............................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland for Lift Cylinders XT and Z-Bar Models ................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders XT and Z-Bar Models ...............................1780 to 2180 Nm (1312 to 1607 pound-feet)
Piston Bolt for Z-Bar Bucket Cylinder ....................................................3310 to 3850 Nm (2440 to 2838 pound-feet)
Piston Bolt for XT Bucket Cylinder.........................................................1780 to 2180 Nm (1312 to 1607 pound-feet)
Lock Screw for all Cylinders .............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039

8006-4
LIFT CYLINDER
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 1. Do
3. Check to be sure that the piston rod is straight. If
not damage the tube (1).
the piston rod is not straight, replace it with a new
3. Loosen and remove the self-tapping screw (12). piston rod.
4. Use a spanner wrench to loosen and remove the 4. Illuminate the inside of the tube for deep grooves
gland (4) out of the tube (1). and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Pull the piston rod (13) straight out of the tube (1)
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
6. Fasten the piston rod eye or yoke in a vise and
Use the emery cloth with a rotary motion.
put a support under the piston rod (13) near the
piston (15). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (13) to prevent damage to the yoke and the tube. Replace as required.
piston rod (13).
7. Inspect the gland for rust. Clean and remove rust
7. Use a torque multiplier, CAS-1039, to loosen and as necessary.
remove the bolt (14) that fastens the piston (15)
8. Inspect the gland end of the tube for sharp edges
to the piston rod (13).
that will cut the gland O-ring and remove as
8. Remove the piston (15) from the piston rod (13). necessary.
9. Remove the gland (4) from the piston rod (13). 9. Inspect the piston for damage and wear. If the
piston is damaged or worn, replace it with a new
10. Remove the seal (16), ring (17)and the wear ring
piston.
(18) from the piston (15).
11. Remove the O-ring (10), ring (9), O-ring (11),
wiper (5), seal (6), seal (7), and bushing (8) from
the gland (4).

8006-5
13
5
6
7
4
8
11
9
10
15
17
16
18
14
1
3
2
2
3
BS03B200
1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL

2. BUSHING 7. BUFFER SEAL 12. SCREW (NOT SHOWN) 17. RING
3. WIPER 8. BUSHING 13. ROD 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT
5. WIPER 10. O-RING 15. PISTON
FIGURE 1. LIFT CYLINDER

8006-6
Assembly 15. Install the bolt (14) into the piston rod (13).
Tighten the bolt (14) to a torque of 1780 to 2180
NOTE: If a new gland is being used, put the part Nm ( 1 3 12 t o 1 6 0 7 p o un d - fe e t) . A to r q u e
number of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (14).
Figure 1. 16. Install a new wear ring (18) in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (15), refer to Figure 1.
to be installed so that the lips of the seal (6) are 17. Install a new ring (17) in the other groove on the
toward the bushing (8). The seal (6) can be outside of the piston (15).
difficult to install.
18. Install a new seal (16) on the top of the ring (17).
3. Install the seal (7) in the gland (4). The side of
the seal (7) with the groove must be toward the 19. Fasten the tube (1) in an acceptable repair stand
bushing (8). or other holding equipment. Be careful to prevent
damage to the tube (1).
4. Install a new wiper (5) in the gland (4). The lips of
the wiper (5) must be toward the outside end of 20. Lubricate the inside of the tube (1) and the piston
the gland (4). (15) with clean oil.
5. Install a new O-ring (11) in the groove on the OD 21. Push the piston (15) straight into the tube (1).
of the gland (4). 22. When the piston (15) is in the smooth part of the
6. Install a new ring (9) in the groove on the OD of tube (1), start the gland (4) into the tube (1).
the gland (4). If both sides of the ring (9) are not 23. Lubricate the O-rings (10 and 11) on the gland
flat, the side that is not flat must be toward the (4) with clean oil.
small end of the gland (4).
24. Turn the gland (4) into the tube (1). Tighten the
7. Install a new O-ring (10) next to the ring (9) in the gland (4) to a torque of 135 to 542 Nm (100 to
groove on the outside of the gland (4). The 400 pound-feet).
O-ring (10) must be toward the small end of the
gland. 25. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise. A. Tighten the gland to a torque of 135 to 542
Nm (100 to 400 pound-feet).
9. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (13). Make B. Install and tighten the lock screw (12) to a
sure that the piston rod (13) is clean. torque of 2.3 Nm (20 inch-pounds).
10. Lubricate the bore of the gland (4) and the piston C. If, after tightening the gland, the lock screw
rod (13) with clean oil. (12) holes are not aligned, a new hole for the
lock screw (12) must be drilled. See Step 27.
11. Push the gland (4) onto the piston rod (13). If
necessary, use a soft hammer to drive the gland 26. If a new gland (4) or a new tube (1) are being
(4) onto the piston rod (13). assembled:
12. Put a support below and near the end of the A. Tighten the gland (4) to 135 to 542 Nm (100 to
piston rod (13). Use a shop cloth between the 400 pound-feet).
suppor t and the piston rod (13) to prevent B. Use a No. 27 drill bit and drill a hole half in the
damage to the piston rod (13). gland (4) and half in the tube (1). Drill to a
13. Start the piston (15) onto the piston rod (13). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a hole for the gland
14. Clean the threads on the end of the piston rod wrench.
and the threads of the piston bolt using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242 C. Install and tighten the lock screw (12) to a
to the piston rod threads 1/4 inch from the open torque of 2.3 Nm (20 inch-pounds).
end of the piston rod so that there is 1/2 inch of 27. If the hoses were removed with the cylinder,
Loctite 242 on the piston rod threads. DO NOT install new O-rings, if equipped, on the hose
apply Loctite to the first 1/4 inch of the piston rod fittings. Lubricate O-rings with clean oil. Install
threads. the hoses.

8006-7
BUCKET CYLINDERS Z-BAR MODELS
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 2. Do
not damage the tube (1).
3. Loosen and remove the locking screw (12) from piston rod.
the gland (4) and tube (1).
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) out of the tube (1). tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1). inside the tube with emery cloth of medium grit.
6. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (12) near the 6. Inspect the bushings in the piston rod eye or
piston (17). Put a shop cloth between the support yoke and the tube. Replace as required.
and the piston rod (12) to prevent damage to the
7. Inspect the gland for rust and clean and remove
piston rod (12).
rust as necessary.
7. Use a torque multiplier, CAS-1039 to loosen and
remove the bolt (15) that fastens the piston (17)
to the piston rod (12).
necessary.
8. Remove the piston (17) from the piston rod (12).
9. Inspect the piston for damage and wear. If the
9. Remove the gland (4) from the piston rod (12). piston is damaged or worn, replace it with a new
piston.
10. Remove the seal (18), backup ring (19) and wear
ring (20) from the piston (17).
11. Remove the O-ring (11), backup ring (10), wiper
(5), seal (6), seal (7) and bushing (8) from the
gland (4).

8006-8
BC03G289
1. TUBE 6. SEAL 11. O-RING 16. PISTON

2. BUSHING 7. SEAL 12. PISTON ROD 17. SEAL
3. SCREW (NOT SHOWN) 8. BUSHING 13. BUSHING 18. BACKUP RING
4. GLAND 9. O-RING 14. WIPER 19. WEAR RING
5. WIPER 10. BACKUP RING 15. BOLT AND WASHER
FIGURE 2. BUCKET CYLINDER Z-BAR MODELS

8006-9
Assembly 16. Install the bolt (15) into the piston rod (12).
Tighten the bolt (15) to a torque of 3310 to 3850
NOTE: If a new gland is being used, put the part Nm ( 2 4 4 0 t o 2 8 3 8 p o un d - fe e t) . A to r q u e
number of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (15).
Figure 2. 17. Install a new wear ring (20) in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (17), refer to Figure 2.
to be installed so that the lips of the seal (6) are 18. Install a new backup ring (19) in the other groove
toward the bushing (8). The wide seal (6) can be on the outside of the piston (17).
difficult to install.
19. Install a new seal (18) on the top of the backup
3. Install the seal (7) in the gland (4). The side of ring (19).
the seal (7) with the groove must be toward the
bushing (8). 20. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
4. Install a new wiper (5) in the gland (4). The lips of damage to the tube (1).
the wiper (5) must be toward the outside end of
the gland (4). 21. Lubricate the inside of the tube (1) and the piston
(17) with clean oil.
5. Install a new O-ring (9) in the groove on the
gland (4). 22. Push the piston (17) straight into the tube (1).
6. Install a new backup ring (10) in the groove on 23. When the piston (17) is in the smooth part of the
the OD of the gland (4). If both sides of the tube (1), start the gland (4) into the tube (1).
backup ring (10) are not flat, the side that is not 24. Lubricate the O-rings (9 and 11) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
25. Turn the gland (4) into the tube (1). Tighten the
7. Install a new O-ring (11) next to the backup ring gland (4) to a torque of 407 +/- 68 Nm (300 +/- 50
(10) in the groove on the outside of the gland (4). pound-feet).
The O-ring (11) must be toward the small end of
the gland. 26. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise. A. Tighten the gland to a torque of 135 to 542
Nm (100 to 400 pound-feet).
9. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (12). Make B. Install and tighten the lock screw (3) to a
sure that the piston rod (12) is clean. torque of 2.3 Nm (20 inch-pounds).
10. Lubricate the bore of the gland (4) and the piston C. If, after tightening the gland, the lock screw (3)
rod (12) with clean oil. holes are not aligned, a new hole for the lock
screw (3) must be drilled. See Step 27.
11. Push the gland (4) onto the piston rod (12). If
necessary, use a soft hammer to drive the gland 27. If a new gland (4) or a new tube (1) are being
(4) onto the piston rod (12). assembled:
12. Put a support below and near the end of the A. Tighten the gland (4) to a torque of 135 to 542
piston rod (12). Use a shop cloth between the Nm (100 to 400 pound-feet).
suppor t and the piston rod (12) to prevent B. Use a No. 27 drill bit and drill a hole half in the
damage to the piston rod (12). gland (4) and half in the tube (1). Drill to a
13. Start the piston (17) onto the piston rod (12). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a hole for the gland
14. Put the washer (16) on the bolt (15). wrench.
15. Clean the threads on the end of the piston rod C. Install and tighten the lock screw (3) to a
and the threads of the piston bolt using Loctite torque of 2.3 Nm (20 inch-pounds).
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open 28. If the hoses were removed with the cylinder,
end of the piston rod so that there is 1/2 inch of install new O-rings, if equipped, on the hose
Loctite 242 on the piston rod threads. DO NOT fittings. Lubricate O-rings with clean oil. Install
apply Loctite to the first 1/4 inch of the piston rod the hoses.
threads.
8006-10
BUCKET CYLINDERS FOR XT MODELS
2. Fasten the cylinder in a vise or other holding free cloths for cleaning and drying.
equipment. Be careful to prevent damage to the
tube (1), refer to Figure 3.
3. Loosen and remove the lock screw (3) from the piston rod.
gland (4) and tube (1).
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) from the tube (1). tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1). inside the tube with emery cloth of medium grit.
6. Fasten the rod yoke in a vise and put a support
below the piston rod (12) near the piston (13). 6. Inspect the bushings in the piston rod eye or
Use a shop cloth between the support and the yoke and the tube. Replace as required.
piston rod (12) to prevent damage to the piston
7. Inspect the gland for rust and clean and remove
rod (12).
rust as necessary.
7. Use a torque multiplier, CAS-1039, to loosen and
remove the piston bolt (17) that secures the
piston (13).
necessary.
8. Remove the piston (13) from the piston rod (12).
9. Inspect the piston for damage and wear. If the
9. Remove the gland (4) from the piston rod (12). piston is damaged or worn, replace it with a new
piston.
10. Remove the backup ring (14), piston seal (15)
and wear ring (16) from the piston (13).
11. Remove the wiper (5), seal (7), seal (8) and the
bushing (6) from the gland (4).
NOTE: Use care not to scratch the ID of gland when
removing seals.
12. Remove the O-ring (10) and backup ring (11)
from the OD of gland (4).

8006-11
12
5
7
8
9 13
11 3
10 14
15
16
17
6
19
2 1
2
19
18
BS03B202
1. TUBE 6. BUSHING 11. BACKUP RING 16. WEAR RING

2. BUSHING 7. ROD SEAL 12. PISTON ROD 17. BOLT
3. SCREW 8. BUFFER SEAL 13. PISTON 18. GREASE FITTING
4. GLAND 9. O-RING 14. BACKUP RING 19. WIPER
5. WIPER 10. O-RING 15. SEAL
FIGURE 3. BUCKET CYLINDER FOR XT MODELS

8006-12
Assembly 15. Install the piston bolt (17). Tighten the piston bolt
(17) to a torque of 1780 ti 2180 Nm (1312 to
NOTE: If a new gland (4) is being installed, put the 1607 pound-feet). A torque multiplier can be
part number of the cylinder on the new gland (4). used to help tighten the piston bolt (17).
1. Install the bushing (6) in the gland (4), refer to 16. Install a new wear ring (16) in the groove on the
Figure 3. outer end of the piston (13).
2. Install the seal (8). The seal (8) must be installed 17. Install the piston backup ring (14) into the
with the seal lips toward the small end of the remaining groove in the piston (13).
gland (4). The seal (8) can be difficult to install.
18. Install a new piston seal (15) on top of the
3. Install the seal (7). The seal (7) must be installed backup ring (14).
with the lips toward the small end of the gland (4)
also. 19. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the
4. Install a new wiper (5) in the gland (4). The lips of tube (1).
the wiper (5) must be toward the large end of the
gland (4). 20. Lubricate the inside of the tube (1) and the piston
(13) with clean oil.
5. Install a new O-ring (9) in the groove of the gland
(4). 21. Push the piston (13) straight into the tube (1).
6. Install a new backup ring (11) in the groove on 22. When the piston (13) is in the smooth part of the
the outside of the gland (4). If both sides of the tube (1), start the gland (4) into the tube (1).
backup ring (11) are not flat, the side that is not 23. Lubricate the O-ring (9 and 10) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
24. Tighten the gland (4) into the tube (1). Tighten
7. Install the O-ring (10) on the gland (4). The the gland to a torque of 135 to 542 Nm (100 to
O-ring (10) must be toward the small end of the 400 pound-feet).
gland (4).
25. If the original parts are being assembled:
8. Fasten the piston rod yoke in the vise.
A. Tighten the gland to a torque of 135 to 542
9. Remove any marks and sharpen edges on the Nm (100 to 400 pound-feet).
chamfer at the end of the piston rod (12).
B. Install and tighten the lock screw (3) to a
10. Lubricate the bore of the gland (4) and the piston torque of 2.3 Nm (20 inch-pounds).
rod (12) with clean oil.
C. If, after tightening the gland, the lock screw (3)
11. Push the gland (4) onto the piston rod (12). If holes are not aligned, a new hole for the lock
necessary, use a soft hammer to drive the gland screw (3) must be drilled. See Step 27.
(4) onto the piston rod (12).
26. If a new gland (4) or a new tube (1) are being
12. Put a support below and near the end of the assembled:
piston rod (12). Use a shop cloth between the
suppor t and the piston rod (12) to prevent A. Tighten the gland (4) to 135 to 542 Nm (100 to
damage to the rod. 400 pound-feet).
13. Put the piston (13) on the end of the piston rod B. Use a No. 27 drill bit and drill a hole half in the
(12). gland (4) and half in the tube (1). Drill to a
depth of 11 mm (7/16 inch). Do not drill within
14. Clean the threads on the end of the piston rod 13 mm (1/2 inch) of a hole for the gland
and the threads of the piston bolt using Loctite wrench.
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open C. Install and tighten the lock screw (3) to a
end of the piston rod so that there is 1/2 inch of torque of 2.3 Nm (20 inch-pounds).
Loctite 242 on the piston rod threads. DO NOT 27. If the hoses were removed with the cylinder,
apply Loctite to the first 1/4 inch of the piston rod install new O-rings, if equipped, on the hose
threads. fittings. Lubricate the O-rings with clean oil.
Install the hoses.

8006-13
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS

Z-BAR AND XT MODELS
Disassembly
1. Put the piston tube (4) in a press, refer to Figure
4.
2. Use an acceptable driver to press the wipers (1)
3
and bushings (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
1
(4).
4
Assembly
1. Use an acceptable driver to press a new bushing
2
(2) into the tube (4) until the bushing (2) is
centered in the tube (4). 1
2. Use an acceptable driver to install the wipers (1) 2
in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
BS01C003
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
FIGURE 4. BUSHING AND WIPER REMOVAL AND
REPLACEMENT LIFT CYLINDERS
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS
Disassembly
1. Put the piston tube (4) in a press, refer to Figure 3
5.
and bushing (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
(4). 1 4
Assembly 2
1. Use an acceptable driver to press new bushings
(2) into the tube (4). Refer to Figure 5.
2. Use an acceptable driver to install the wipers (1)
in the tube (4). The lips of the wipers (1) must be 2
toward the outside of the bore. 1
BS01C002
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
REPLACEMENT XT BUCKET CYLINDERS

8006-14
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS
Disassembly
1
1. Put the piston rod eye (3) in a press, refer to
Figure 6.
2 3
and bushing (2) out of the piston rod eye (3). 2
3. Put the tube (4) in a press.
1
4. Use an acceptable driver to press the bushings
(2) out of the tube (4).
5. Clean the bore for the bushings (2) in the piston
rod eye (3) and the tube (4).
4
Assembly
2
(2) into the piston rod eye (3). Refer to Figure 6.
2. Use an acceptable driver to install the wipers (1)
in the piston rod eye (3). The lips of the wipers
(1) must be towards the outside of the bore.
2
(2) into the tube (4).
BS01C004
1. WIPER 3. PISTON ROD EYE

2. BUSHING 4. TUBE
REPLACEMENT Z-BAR BUCKET CYLINDER

Section
8007
COUPLER SOLENOID LOCKING VALVE
8007
CASE CORPORATION
700 State Street
8007-2
TABLE OF CONTENTS
COUPLER SOLENOID LOCKING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3

8007-3
COUPLER SOLENOID LOCKING VALVE
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3). 1
STEP 3
Remove valve cartridge (3) from valve housing (7).
2
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
Cleaning and Inspection

STEP 5
Immerse valve cartridge (3) and valve housing (7) in
3
cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to
4
ensure that all passage ways and bores are clear.
6
STEP 6 5
Check valve cartridge for (3) for cracks, breaks, 6
chipping, or other damage. Replace if any of these 6
conditions are seen.
5
6
STEP 7
Check bores in valve housing (7) for deep scratches,
6
5
gouges, and other damage. Replace valve if any of
these conditions are seen.
7 6
STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly GS98J818
1. NUT 5. O-RING
STEP 9
2. SOLENOID 6. BACKUP RING
Install new O-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. O-RING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
8007-4
NOTES

Section
8013
8013
PILOT PRESSURE ACCUMULATOR AND RIDE
CONTROL ACCUMULATOR
CASE CORPORATION
700 State Street
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PILOT PRESSURE ACCUMULATOR P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ............................ 17.2 +/- 1.7 bar (250 +/- 25 psi) at 21° C (70°F)
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure
P.I.N. JEE0135500 and Below ...................................................................................................207 bar (3000 psi)
P.I.N. JEE0135501 and Above ................................................................................................. 248 bar (3600 psi)
Pilot Pressure Accumulator Dry Nitrogen Pressure......................... 13.8 +/- 1.7 bar (200 +/- 25 psi) at 21° C (70° F)
Pilot Pressure Accumulator Fluid Capacity ............................................................................ 95 liters (59.5 cu. inch)
Pilot Pressure Accumulator Maximum Operating Pressure ...........................................................207 bar (3000 psi)
SPECIAL TORQUES
Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)
SPECIAL TOOLS
94L95 B786441M
CAS-10899 NITROGEN ACCUMULATOR CHARGING KIT CAS-1456 GLAND WRENCH

8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C E
D B A
94L95
CAS-10899 NITROGEN CHARGING KIT
NOTE: The pilot pressure accumulator used on 7. Turn the T-handle inward on valve F to engage
P.I.N. JEE0135501 and above is not repairable nor the pin in the valve stem.
rechargeable.
8. Open valve D and check the charge pressure on
1. Use the CAS-10899 Nitrogen Charging Kit to gauge E.
d i s c h a r g e t h e a c c u m u l a t o r, r e f e r t o t h e
9. To discharge the accumulator, partially open
illustration above. The tool must be disconnected
valve B. The accumulator charge will bleed down
from the nitrogen tank.
through the regulator.
2. Close valves B, C and D.
10. Once the accumulator is fully discharged,
3. Adjust the regulator A to the minimum pressure disconnect valve F from the valve stem.
setting by turning the knob counterclockwise.
11. The accumulator can now be disassembled.
4. Turn the T-handle on valve F fully out.
5. Remove the guard and valve assembly cap from
the accumulator.
6. Connect valve F to the valve stem on the
accumulator.

8013-5
NOTES

8013-6
RIDE CONTROL ACCUMULATOR
NOTE: Refer to Section 8001 for the proper 1. Fasten the body (1) in a vise. Be careful not to
procedure for the removal of the ride control damage the body (1). Refer to the illustration on
accumulator. page 7.
WA R N I N G : D O N O T a t t e m p t t o 2. Install a new wear ring (8), O-ring (10) and

disassemble any accumulator until the backup ring (9) on the piston (5).
nitrogen charge is properly discharged. 3. Lubricate the bore of the body (1) and the piston
SM386 (5) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (5) into the body (1), round
damage the body (1), refer to the illustration on surface first. Then push the piston (5) farther into
page 7. the body (1).
NOTE: The piston (5) must be installed squarely and
body (1).
slowly into the body (1). Once the piston (5) is started
3. Remove the pressure valve (4) from the straight into the bore of the body (1), use a hammer
body (1). and wood block to gently tap the piston into the
4. Remove and discard the O-ring (7) from the polished area of the bore. Keep force on the piston
pressure valve (4). (5) while tapping into the bore or damage may occur
to the O-ring.
5. Loosen and remove the cap (12) from the body
(1). 5. Install and tighten the cap (12) into the body (1).
6. Loosen and remove the gland (6) from the body 6. Install new seals (11) on the gland (6).
(1).
7. Lubricate the seals (11) with clean oil and start
7. Remove the piston (5) from the body (1). the gland (6) into the body (1).
8. Remove and discard the wear ring (8), O-ring
8. Tighten the gland (6).
(10) and the backup ring (9) from the piston (5).
9. Remove the seals (11) from the gland (6). 9. Install a new O-ring (7) on the pressure valve (4).
10. Install the pressure valve (4) in the body (1).
Inspection 11. Install the guard (2), screws (3) in the body (1).
1. Clean body (1), gland (6), cap (12) and piston (5) 12. Charge the accumulator with dry nitrogen
in cleaning solvent, refer to the illustration on according to instructions on page 10.
page 7.
damage.
needed.

8013-7
11 8 9 10 3
12
6 5
7 2
4
3
1
BS01B224
1. BODY 5. PISTON 9. BACKUP RING

2. GUARD 6. GLAND 10. O-RING
3. SCREW 7. O-RING 11. SEALS (2)
4. PRESSURE VALVE 8. WEAR RING 12. CAP
RIDE CONTROL ACCUMULATOR ILLUSTRATION

8013-8
PILOT PRESSURE ACCUMULATOR

NOTE: The pilot pressure accumulator used on Assembly
P.I.N. JEE0135501 and above is not repairable nor
rechargeable. 1. Fasten the body (1) in a vise. Be careful not to
damage the body (1). Refer to the illustration on
Disassembly page 9.
2. Install a new wear ring (8), O-ring (10) and
NOTE: See Section 8001 for the proper procedure
backup ring (9) on the piston (5).
to remove the accumulator.
3. Lubricate the bore of the body (1) and the piston
WA R N I N G : D O N O T a t t e m p t t o (5) with clean oil.
disassemble any accumulator until the
nitrogen charge is properly discharged. 4. Start the piston (5) into the body (1), round
SM386 surface first. Then push the piston (5) farther into
the body (1).
1. Fasten the body (1) in a vise. Be careful not to NOTE: The piston (5) must be installed squarely and
damage the body (1), refer to the illustration on slowly into the body (1). Once the piston (5) is started
page 9. straight into the bore of the body (1), use a hammer
and wood block to gently tap the piston into the
polished area of the bore. Keep force on the piston
body (1).
(5) while tapping into the bore or damage may occur
3. Remove the pressure valve (4) from the to the O-ring.
body (1).
5. Install the cap (12) in the body (1).
4. Remove and discard the O-ring (7) from the
pressure valve (4). 6. Install new seals (11) on the gland (6).
5. Loosen and remove the cap (12) from the body 7. Lubricate the seals (11) with clean oil and start
(1). the gland (6) into the body (1).
6. Loosen and remove the gland (6) from the body 8. Tighten the gland (6).
(1).
9. Install a new O-ring (7) on the pressure valve (4).
7. Remove the piston (5) from the body (1).
10. Install the pressure valve (4) in the body (1).
8. Remove and discard the wear ring (9), O-ring
(10) and the backup ring (9) from the piston (5). 11. Install the guard (2), screws (3) in the body (1).
9. Remove the seals (11) from the gland (6). 12. Charge the accumulator with dry nitrogen
according to instructions on page 10.
Inspection
WA R N I N G : U s e o n l y n i t r o g e n w h e n
1. Clean body (1), gland (6), cap (12) and piston (5) charging the accumulator. DO NOT use air
in cleaning solvent, refer to the illustration on

or oxygen that will cause an explosion.
page 9. SM115A

damage.
needed.

8013-9
11 9 10 3
6 8
5 12
2
7
4
3
1
BS01B224
1. BODY 5. PISTON 9. BACKUP RING

2. GUARD 6. GLAND 10. O-RING
3. SCREW 7. O-RING 11. SEALS (2)
4. PRESSURE VALVE 8. WEAR RING 12. CAP
PILOT PRESSURE ACCUMULATOR ILLUSTRATION - P.I.N. JEE0135500 AND BELOW

8013-10
CHARGING THE ACCUMULATOR WITH NITROGEN
5 4
3 2
GS98N801
1. TO NITROGEN TANK 4. VALVE D

2. VALVE A 5. TO ACCUMULATOR
3. VALVE B 6. VALVE C
NITROGEN CHARGING KIT CAS-10899
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.

8013-11
1. Close the shutoff valve A by turning it all the way 10. Install the charging hose fitting onto the
to the le ft ( cou nterc loc kwise), re fe r to th e accumulator pressure valve (4), refer to the
illustration on page 10. illustrations on pages 7 and 9.
2. Open valve B by turning it out all the way to the 11. Tighten the needle valve by turning it clockwise.
left (counterclockwise). Slowly open the gauge valve D and observe the
re ad in g o n the ga ug e. Th is rea d in g is th e
3. Close valve C by turning it all the way to the right
nitrogen pressure level inside the accumulator,
(clockwise).
refer to illustration on page 10.
4. Close the gauge valve D by turning it all the way
12. Open the shutoff valve A on the nitrogen supply
to the right (clockwise).
tank. While observing the pressure on the gauge,
5. Connect the charging hose to the nitrogen supply slightly op en the nee dle valve on th e
tank. accumulator charge hose. By regulating the
needle valve, fill the accumulator to 31 bar (450
6. SLOWLY turn valve A clockwise while watching
psi). Close the needle valve. Close the shutoff
the high pressure gauge. Stop turning valve A
valve A on the nitrogen supply tank.
when the needle on the gauge reaches 31 bar
(450 psi). 13. Close valve B by turning to the right (clockwise).
After a few minutes, check the accumulator for
NOTE: If the needle goes over the needed pressure,
leakage.
quickly open and close valve D and check the
pressure setting again. 14. Back off the needle valve on the accumulator
end of the charging hose by turning it
The charging kit is now ready to be installed on the
counterclockwise the maximum amount. This will
accumulator.
p r e v e n t n it r o g e n f r o m e s c a p in g f r o m th e
7. Remove the two cap screws (3) and the accumulator as the hose is removed. Remove
protection bracket (2) from the body (1) on the t h e c h a r g in g h o s e f r o m t h e a c c u m u l a to r
accumulator, refer to the illustrations on pages 7 pressure valve (4), refer to the illustrations on
and 9. pages 7 and 9.
8. Remove the valve cap from the pressure valve 15. Install the valve cap onto the pressure valve (4)
(4) on the accumulator. on the accumulator.
9. Back off the needle valve on the accumulator 16. Install the protection bracket (2) over the
end of the charging hose by turning it pressure valve (4) and secure it with cap screws
counterclockwise to the maximum amount. This (3).
pr ev en ts n itro ge n fro m e sca p in g fro m th e
17. Remove the charging hose from the nitrogen
accumulator when the charging hose is attached
supply tank, refer to the illustration on page 10.
to the accumulator gas charging valve, refer to
the illustration on page 10.

8013-12
NOTES

SECTION INDEX
MOUNTED EQUIPMENT
Pedals and Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001

Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning Components for Systems with HFC134a Refrigerant . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
ROPS Cab and ROPS Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
CASE CORPORATION
700 State Street
9001
Section
9001
PEDALS AND LEVERS
CASE CORPORATION
700 State Street
9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCELERATOR PEDAL AND CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

9001-3
SPECIFICATIONS
Engine speeds
Low idle - 621D Z-Bar and XT............................................................................................. 920 to 980 r/min (rpm)
High idle - 621D Z-Bar and XT ........................................................................................ 2160 to 2260 r/min (rpm)
Brake light pressure switch..................................................................................................................4.1 bar (60 psi)
Brake warning pressure switch............................................................................................. 141 bar (2045 psi) rising

117 bar (1697 psi) falling
Parking brake adjustment
Adjusting screw - M16 ................................................................................................................0.5 mm to 1.5 mm
Adjusting screw - M20 ................................................................................................................1.0 mm to 3.0 mm

9001-4
ACCELERATOR PEDAL AND CABLE ADJUSTMENT

1. Disconnect the ball joint (8) from the cable (4) at 4. Make sure that the ball joint (3) at the end of
the throttle lever (10) on the fuel injection pump, cable (4) is turned all the way onto cable (4).
5. Have another person push the accelerator pedal
2. Check the engine speed by pressing the program (2) all the way against the stop bolt (1).
switch, left side of the program/reset switch.
6. Move the rear cable clamp (6) and cable (4) so
Press the up count switch until the display reads
that the throttle lever (10) on the fuel injection
01. Return the program switch to the center
pump contacts the high idle stop, and make a
(OFF) position. If the engine speeds are not
mark for the position of the rear cable clamp (6).
equal to the specifications in this section, adjust
the stop bolts on the fuel injection pump as 7. Have the other person release the accelerator
required. pedal (2).
NOTE: Adjustment of the high idle must be done by 8. Move the rear cable clamp (6) and cable (4)
an authorized Case service person. forward 2 mm (0.07 inches) and tighten the rear
cable clamp (6).
3. Adjust the stop bolt (1) for the accelerator pedal
(2) so that the dimension from the top of the floor 9. Check to see that the high and low idle engine
plate to the top of the stop bolt (1) is 68 mm (2.7 speeds are as specified in this section.
inches).

9001-5
7
6
10
9 8
BS01E003
1. STOP BOLT 6. REAR CABLE CLAMP

2. ACCELERATOR PEDAL 7. SPRING
3. BALL JOINT 8. BALL JOINT AT THROTTLE ARM
4. CABLE 9. THROTTLE BRACKET
5. CABLE CLAMP 10. THROTTLE ARM
ACCELERATOR PEDAL AND CABLE ADJUSTMENT

9001-6
PARKING BRAKE
Checking the Parking Brake 5. Release the lock nut (2) and turn the adjusting
screw (3) clockwise until the two brake pads (4)
1. Park the machine on a level surface. make contact with the brake disc (5).
2. The transmission must be in manual shift mode 6. Turn the adjusting screw (3) counter clockwise
and the gear select must be in 3rd gear. and set the clearance, this should be 1/2 of one
NOTE: The Transmission Control Module will turn, refer to the table below.
disconnect the transmission if any other gear is used. A dj u st in g
Type Clearance (mm) Revolutions
Screw
3. Press the program switch. Min. 0.5 1/4
Small M16 (size 8) Rated Clearance 1.0 1/2
4. Press the up count switch until the display reads
Max 1.5 3/4
011. Min. 1.0 2/5
Large M20 (size 10) Rated Clearance 2.0 4/5
5. Press the program switch back to the center
Max 3.0 1 1/5
position.
6. Press the up count switch once. 7. Hold the adjusting screw (3) in position and lock
with the lock nut (2).
7. Make sure the transmission selector is in 3rd
neutral and the parking brake switch is on and in 8. Install the cover (1).
manual mode.
9. Perform the Checking the Parking Brake
8. Shift the transmission selector into 3rd gear procedure again.
FORWARD and slowly increase engine rpm.
10. If the parking brake is still out of adjustment, see
9. The parking brake should hold the machine at full section 7008 and replace the brake shoes on the
throttle. parking brake.
10. If the machine begins to move, decrease the
engine speed and stop the engine. See Adjusting
the Parking Brake in this section.
6
11. Press the reset switch to exit the test mode. 1
Adjusting the Parking Brake
1. Park the machine on a level surface.
2. Start the engine and run at low idle with the
service brakes engaged and the bucket resting
on the ground throughout this procedure.
3. Release the parking brake.
NOTE: Hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is 3
4 4
turned off, the service brakes are applied, and the 2
transmission is put into gear.
5
A. Set the parking brake rocker switch to the off
position. BS01D198
B. With the service brakes applied, put the 1. COVER 4. BRAKE PADS
machine into gear. 2. LOCK NUT 5. BRAKE DISC
3. ADJUSTING SCREW 6. PARKING BRAKE
C. The parking brake light on the cluster will turn
PARKING BRAKE ILLUSTRATION
off at this time.
D. Put the transmission back into neutral before
proceeding.
4. Remove the cover (1), refer to the illustration on
this page.
9001-7
BRAKE PEDAL
2
11
3
4
10 1
11
2
11
3
5
7
6
8 4
BS00N109
1. BRAKE PEDAL 5. FRONT BRAKE TEST PORT 9. PIN

2. BRAKE MODULATION PRESSURE ADJUSTING BOLT 6. REAR BRAKE TEST PORT 10. E-RING
3. TAMPER RESISTANT COVER 7. BRAKE WARNING PRESSURE SWITCH 11. BASE
4. BRAKE AND ACCUMULATOR CHARGING VALVE 8. BRAKE LIGHT PRESSURE SWITCH
BRAKE PEDAL

9001-8
NOTES

9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM

CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CASE CORPORATION
700 State Street
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE

THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if
when removed from a system during servicing.
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
Liquid refrigerant getting into the eyes can cause
combustible gas.
se rio u s in jur y. D o th e fo llow ing if yo u g et
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

9002-4
299L7C A22094
BELT TENSION TOOL CAS-10808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3

9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
con ta in s five major co mp on ents: comp ressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. e va p o r a t o r me t e r s r e fr ig e ra n t f lo w b a s e d o n
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and
pressure gas. The compressor then compresses the flowing through the evaporator fins. The combination
refrigerant and sends it in the form of a high pressure of increased heat and decreased pressure causes
gas to the condenser. The air flow through the the air flow through the evaporator fins to become
condenser then removes t he heat from the very cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
No Check Page 8
Compressor Runs
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13

9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.

ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Re mo ve the compresso r for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch b e t w e e n t h e f r o n t p la t e a n d p u l le y
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
co m p re s so r c loc k wis e . Co m p re s so r
rotation should be smooth and not require
much effort.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment Us e a str aig ht ed g e to ch ec k p u lle y
alignment. Adjust the compressor
mounting bracket if needed.

9002-9
Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (10 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
sw itc h t erm in a ls . If co n tin u ity is n ot
present when switch is on maximum cold,
replace switch.

9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure
hoses (small line) must be warmer than the low pressure
hose (large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

run the compre ssor fo r five minutes to make
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
re fr ig e ra n t, th e r e is a r e st ric tio n in th e s ys te m,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control
s w i t c h s h o u l d in t e r r u p t t h e c u r r e n t f l o w t o t h e
compressor. Check for current at the control switch
te rm in a ls a s on pr e vio u s pa g e . If c u rr e nt is n ot
interrupted then replace the control switch.

9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks.
Replace all hoses that have damage.
1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. U se
instructions from manufacturer of leak
Leak Finding Check finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion
valve for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.

9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fin s th at have b end s or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s . I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
wate r dra in s freely from th e
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
1. See Section 9004 for access to the

evaporator/heater core.
2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing will pull a ir o nly throu gh th e
evaporator/heater core and not around
the evaporator/heater core.
Filters 1. Make sure the filters are clean.

9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigeran t charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
C o n n e c t th e ma n if o l d g a u g e s e t in t o t h e a ir
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best used to judge
e va c u a tio n e ff e ct iv e ne s s . A va c u u m r e a d in g
indicates a system malfunction. For this reason, it is
nece ssary to use a compo und gau ge tha t w ill
indicate both pressure and vacuum.

9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH

AIR LOUVER (BEHIND
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings 5. Measurements taken 15 minutes after startup.
taken in low relative humidity. Adjust the chart
according to local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25

9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1
WARNING: Always wear safety goggles
when working with liquid refrigerant. Liquid
r e f r ig e r a n t i n y o u r e y e s c o u l d c a u s e
blindness. SM105A
Make sure the charging station manifold gauge

valves are in the closed position.
STEP 3
BD01D251
Clean the external surfaces of the compressor and 1

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
2
WARNING: Do not steam clean any air

conditioning system parts while the system is
charged. The heat will cause the refrigerant
BD00N030
to rise to a pressure that could cause the
system to explode. SM104A 6. A/C TEMPERATURE CONTROL
7. BLOWER FAN SWITCH
Start the engine and run at 1500 RPM maximum
STEP 2
sp ee d . O pe ra te the a ir co nd itio n er sys tem at
maximum cooling setting and blower speed for 15
minutes with the cab door open. Observe the test
gauges and check the chart on page 13 against the
gauge readings.
BD01D273
Connect the hoses from the test gauges to the

service ports by turning the knurled knobs on the
depressors.
Connect the hose from the low pressure gauge to the
port on the suction hose.
Connect the hose from the high pressure gauge to
the port on the discharge hose.

9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.

9002-17
HIGH HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
recla im a nd recharge refrigera nt un til gauge
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.

9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart
Temperature °F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)

9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.

9002-20
LOW LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm - not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream
9003.
from or at the point of the restriction

9002-21
Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.

9002-22
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

9002-23
HIGH HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.

9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the fre ezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day. 3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.

9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.

9002-26
TUBE CONNECTIONS TORQUE CHART
TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.

Section
9003
9003
AIR CONDITIONER SYSTEM SERVICE
CASE CORPORATION
700 State Street
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

9003-4
SAFETY PROCEDURES


4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable and easiest conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC’s) which are
harmful to the Earth’s ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.
se rio u s in jur y. D o th e fo llo w ing if yo u ge t

9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

R e co v e re d re f rig e r a n t p a ss e s th r o u g h a n o il STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD01D251
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD01D273
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the p ort o n the discha rge h ose . Turn in valve
depressor.

9003-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
comp ress or d isch ar ge p re ssure ba ck into th e
separator.
BD01D273
Remove the hoses from the service ports and install

the caps.

9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you vacuu m pump. A vacuum pump is the only
remove the air and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer’s
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
STEP 12
BD01D273
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed A22115
after the system has been opened for maintenance. Press the Charge key. “Program” and “Charge” will
Air enters the system when the system is opened. Air appear on the display.
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not
pull a sufficient vacuum to remove air and moisture.

9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on
will flash once indicating the programmed data has the display. Vacuum will appear on the display and
been accepted. after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
W h e n th e p ro g r a mme d tim e h a s e la p se d , a n
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
le a k - f r e e s y s te m w il l l e a c h r e fr ig e r a n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114 STEP 17
Fully open the low and high pressure valves.
STEP 15
A22113
Press the charge key to begin refrigerant charging.

“Automatic” and “Charge” will appear on the display.
A22107 The display shows the programmed amount and
Open the red (vapor) and blue (liquid) valves on the counts down to zero as charging proceeds. When
tank. charging is completed, the display shows “CPL”.

9003-9
STEP 18 STEP 20
A22114 A22117
Completely close the high and low pressure manifold Observe the pressure gauge readings to determine
valves. that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
ATTENTION: Check the OEM equipment manual
and pressure variations.
before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if STEP 21
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the BD01D273
compressor, the air conditioner control or blower Stop the engine, close any open valves and carefully
switch must be turned to the OFF position and then remove the manifold gauge hoses.
to the ON position.
STEP 22
BD01D251
Install the caps on the service ports on the suction

and discharge hoses.

9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER (BEHIND

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position (full
9. Measurements taken 15 minutes after start-up.
clockwise) and all louvers open.
4. Cab temperature control set to maximum cooling
(full counterclockwise).

Section
9004
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
COMPONENTS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CASE CORPORATION
700 State Street
9004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPRESSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXPANSION VALVE AND EVAPORATOR/HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

9004-3
SAFETY PROCEDURES


4. Always reclaim refrigerant from the system if you
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC’s) which are
harmful to the earth’s ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.
se rio u s in jur y. D o th e fo llow ing if yo u g et

9004-4
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

9004-5
COMPRESSOR REMOVAL
P.I.N. JEE0135500 and Below STEP 4
STEP 1
BD01D189
Remove the fan belt.

BD01D138
Place the master disconnect switch in the OFF STEP 5

position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD01D184
Disconnect the low pressure line from the suction

port and the high pressure line from the discharge
p o r t o n t h e c o m p r e s s o r. I m m e d i a t e ly in s t a l l
protective caps on the open ports and lines.
STEP 6
BD01D165
Remove the four bolts and washers holding the drive

belt guard. Remove the guard.
BD01D191
Disconnect the compressor clutch wire from the

engine harness assembly.
9004-6
STEP 7 STEP 11
BD01D193 BD01D165
Loosen and remove the four compressor mounting Remove the four bolts and washers holding the drive
bolts. belt guard. Remove the guard.
STEP 8 STEP 12
Remove the compressor from the machine. Identify, tag, and disconnect the low pressure hose
from the compressor suction port and the high
P.I.N. JEE0135501 and Above pressure hose from the discharge port. Immediately
install plugs and caps in the hoses and on the ports.
STEP 9
STEP 13
Identify, tag, and disconnect the engine harness
connector from the compressor clutch connector.
STEP 14
2 4
1
BD01D138

position.
STEP 10
Discharge the air conditioning system according to 3
BS02J067
1. BOLT 3. BOLT
Loosen bolts (1 and 3). Move compressor (4) to put
slack in drive belt (102) then remove drive belt.
STEP 15
Remove bolt (1), two washers, spacer, and nut.
Support compressor (4) and remove bolt (3), three
washers, and nut securing compressor. Remove
compressor from engine.
9004-7
COMPRESSOR INSTALLATION
P.I.N. JEE0135500 and Below STEP 19
STEP 16
Position and support the compressor on the engine.
STEP 17
BD01D184
Slowly remove the protective cap, install a new

O-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
BD01D193
new compressors have internal pressure when
Install the four bolts to secure the compressor. shipped.
STEP 18 STEP 20
BD01D191
BD01D184
Connect the compressor clutch wire to the engine Carefully remove the protective cap, install a new
harness assembly. O-ring, and connect the low pressure line to the
suction port on the compressor.

9004-8
STEP 21 P.I.N. JEE0135501 and Above
STEP 25
2 4
1
BD01D189
Install the belt.
STEP 22 3
BS02J067
1. BOLT 3. BOLT
Position and support compressor (4) on mounting
bracket. Secure using bolt (3), three washers, and
nut. Install bolt (1), two washers, spacer, and nut.
STEP 26
Install drive belt (2). Move compressor (4) to take up
slack in drive belt then tighten bolts (1 and 3).
BD01D165 STEP 27
Install d rive b elt g ua rd a nd secu re u sin g fou r Co nne ct the e ng in e ha rne ss con ne ctor to th e
washers and bolts. compressor clutch connector following tags installed
STEP 23
Charge the air conditioning system according to the STEP 28
instructions in Section 9003. IMPORTANT: In this step, use caution when
removing cap as new compressors have internal
STEP 24 pressure when shipped.
Slowly remove protective cap from compressor
discharge port. Following tags installed during
removal, install a new O-ring and connect high
pressure hose to compressor discharge port. Repeat
this step to connect low pressure hose to compressor
suction port. Remove and discard tags.
BD01D136
Place the master disco nnect switch in the ON

position.

9004-9
STEP 29 STEP 31
BD01D165 BD01D136
Install drive b elt g ua rd a nd secu re u sin g fou r Place the master d isco nnect switch in the ON
washers and bolts. position.
STEP 30
Charge the air conditioning system according to the
instructions in Section 9003.

9004-10
EXPANSION VALVE AND EVAPORATOR/HEATER CORE
Removal STEP 36
STEP 32
bucket to the floor.
STEP 33
STEP 34
BD01D396
Remove the four bolts that fasten the operator’s seat.
STEP 37
BD01D138
Place the master disconnect in the OFF position.
STEP 35
BD01D397
Remove the two bolts that fasten the strap to the

plate.
STEP 38
BD01D395
Disconnect the wiring harness from the operator’s

seat (if equipped with air seat option).
BD01D398
Remove the three screws and plate.

9004-11
STEP 39 STEP 42
BD01D399 BD01D402
Fold the rubber mat over to gain access to the cover Remove the screws holding the valve cover plate
plate and remove the screws holding the cover plate. and remove the plate.
STEP 40 STEP 43
BD01D400 BD01D403
Remove the six screws and remove the back panel. Remove and discard the insulation tape from the
fittings and the expansion valve.
STEP 41
STEP 44
3
1
BD01D401 4
Remove the back screw holding the cover plate and DS01D183
remove the cover plate.
5. LIQUID TUBE 7. FITTINGS
6. SUCTION TUBE 8. EXPANSION VALVE
Disconnect the liquid tube (1), suction tube (2) and
the fittings (3) from the expansion valve (3). Cap and
plug all fittings and tubes.

9004-12
Remo ve th e expa nsion valve from the
evaporator/heater core. STEP 49
Install the evaporator/heater core in position in the
STEP 46 machine.
Remove and discard the O-rings from the openings
in the expansion valve. STEP 50
STEP 47
BD01D265
C o n n e c t t h e h o s e s a n d h o s e c la m p s t o t h e
BD01D265 evaporator/heater core.
Remove the hose clamps and the hoses from the
evaporator/heater core. STEP 51
Lubricate new O-rings for the expansion valve with
STEP 48 clean refrigerant oil.
Re mo v e th e ev a po r at or /h ea te r co r e fro m th e
machine. STEP 52
Install th e new O-rin gs in the ope nin gs of th e
expansion valve.
STEP 53
3
1
4
BS01D183
1. LIQUID TUBE 3. FITTINGS

2. SUCTION TUBE 4. EXPANSION VALVE
Connect the fittings (3) of the evaporator/heater core
to the expansion valve (4).
Connect the liquid (1) and the suction tube (2) to the
expansion valve (4).
9004-13
STEP 54 STEP 58
BD01D403 BD01D398
Install new insulation tape around the fittings and the Fold the rubber mat back into place and install the
expansion valve. metal plate and screws.
STEP 55 STEP 59
BD01D402 BD01D397
Install the valve cover plate. Install the strap.
STEP 56 STEP 60
Install the cover for the evaporator/heater core.
STEP 57
BD01D396
Place the operator’s seat in position and install and

tighten the four bolts.
BD01D400
Position the back panel in place and install the

screws.

9004-14
STEP 61 STEP 63
BD01D395 BD01D136
Connect the wiring connector to the operator’s seat Place the master d isco nnect switch in the O N
(if equipped with air seat option). position.
STEP 62

9004-15
CONTROL VALVE
STEP 64 STEP 68
Park the machine on a level surface and lower the Make sure the control knob is in the OFF position.
bucket to the ground.
STEP 69
STEP 65
1
2
4 3
BD01D266
BD01D138 1. CONTROL VALVE 3. FRONT H0SE AND CLAMP

Place the master disconnect switch in the OFF 2. HEATER CABLE 4. REAR HOSE AND CLAMP
position. A. Install a new control valve (1).
B. Install the rear hose and clamp (4) on the
STEP 66
control valve (1).
Open the access panel on the right side of the
machine. C. Install the front hose and clamp (3) on the
control valve (1).
STEP 67 D. Install the heater cable (2) on the heater cable
clip.
1
STEP 70
2 Close the access panel door.
STEP 71
4 3
BD01D266
1. CONTROL VALVE 3. FRONT HOSE AND CLAMP

2. HEATER CABLE 4. REAR HOSE AND CLAMP
A. Remove the heater cable (2) from the heater
cable clip.
B. Remove the front clamp and hose (3) from the
BD01D136
control valve (1).
Place the master d isco nnect switch in the ON
C. Remove the rear clamp and hose (4) from the position.
control valve (1).
D. Remove the control valve (1).
9004-16
CONDENSER
Removal STEP 77
STEP 72
bucket to the ground.
STEP 73
BS01D181
Fa s t e n i d e n t if ic a ti o n t a g s o n th e h o s e s a n d
disconnect the hoses from the condenser.
STEP 78
Install plugs in the hoses and caps on the fittings.
BD01D136
Place the master disconnect switch in the OFF STEP 79

position.
STEP 74
STEP 75
BD01D142
1. COVER 2. CONDENSER
BS01D182
Open the cover (1) to gain access to the condenser
(2). L oo s e n a n d re mo v e th e b o lts th a t fa st en th e
condenser to the brackets.
STEP 76
STEP 80
The condenser is connected to brackets which pivot
on the cooling frame. Pivot the condenser to gain Remove the condenser.
access to the mounting bolts and the hoses.

9004-17
CONDENSER
STEP 81
Inspect the condition of the seals on the condenser.
If the seals are bad, replace the seals.
STEP 82
Put the condenser in position on the brackets.
STEP 83
BS01D181
A. Remove the plugs from the hoses and the

caps from the fittings.
B. Install new O-rings and connect the hoses to
the fittings
STEP 85
Pivot the condenser down and close the cover.
STEP 86
STEP 87
BS01D182
Install the bolts that fasten the condenser to the

brackets.
BD01D136
Place the master d isco nnect switch in the ON

position.

9004-18
NOTES

9006
Section
9006
LOADER

Racine, WI 53404 U.S.A. Bur 6-44761 Issued November, 2001 Revised September, 2004
9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR AND XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RETURN TO DIG ADJUSTMENT (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVING THE LOADER FRAME (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLING THE LOADER FRAME (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVING THE LOADER FRAME (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLING THE LOADER FRAME (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth ........................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining 3 5
pin (1) for the tooth point (2) out of the tooth
4
shank (3), refer to the illustration on this page.. 2 1
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank
(3).
4. Install the retaining pin (1) into the tooth point (2)
7
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
6
8 10
a hammer to hit the retaining pin (1) until the 3
retaining pin (1) is even with the outside of the
tooth shank (3).
2 1
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth. 9
NOTE: If wear of the bolt or nut makes removal 7
difficult, the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. RETAINING RING 6. BOLT
(7). 2. TOOTH POINT 7. CUTTING EDGE
3. TOOTH SHANK 8. PLOW BOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
9006-4
RETURN TO DIG ADJUSTMENT (Z-BAR MODELS)
6
1
3
4
5
BS01C083
1. TARGET MOUNTING BRACKET 3. TARGET BAR 5. PROXIMITY SWITCH

2. BUCKET CYLINDER 4. PROXIMITY SWITCH MOUNTING BRACKET 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION Z-BAR MODELS
IMPORTANT: Before adjusting the return-to-dig, 7. Loosen the bolts holding the target bar (3) to the
make sure that the target bar on the bucket linkage is target mounting bracket (1). Slide the target bar
not damaged. Slowly roll back and dump the bucket (3) towards the proximity switch (5) until the face
and make sure that the target bar stays the same of the proximity switch (5) is completely covered.
distance from the switch. The switch mounting 8. Align the target bar (3) parallel to the tilt cylinder
bracket protects the switch. Make sure the target bar (2) and tighten the bolts.
cannot touch the switch when the bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the lift NOT start the engine.
arms until they are approximately horizontal and
dump the bucket. Lower the bucket until the 10. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine. 11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1).
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Slide the target bar (3) slowly away from the
mounting bracket (1) parallel to the tilt cylinder proximity switch (5), until the control lever returns
(2). Tighten the bolts, refer to the illustration on to the center position. Tighten the bolts holding
this page. the target bar (3).
4. Loosen the bolts holding the proximity switch 13. Check to make sure that the 3.5 to 5.0 mm (1/8
mounting bracket (4) to the tilt cylinder (2). to 3/16 inch) gap is still maintained.
Position the proximity switch (5) parallel to the 14. Start the engine.
target bar (3) and tighten the bolts. 15. Place the detent switch in the ON position and
5. Adjust the proximity switch (5) out towards the place the return to travel/float detent switch to the
target bar (3), until an air gap of 3.5 to 5.0 mm TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude 17. Place the loader control lever in the ROLLBACK
past the proximity switch guard (6). position, and verify that the electromagnet holds
6. Start the engine, position the bucket to the it in that position until the end of the target bar (3)
correct digging angle and stop the engine. passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.
9006-5
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

(Z-BAR AND XT MODELS)
5
6
3
2
1
BS01C081
1. TARGET MOUNTING PLATE 3. PROXIMITY SWITCH 5. RETURN TO TRAVEL TARGET

2. HEIGHT CONTROL TARGET 4. LIFT ARM 6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR AND XT MODELS
1. Park the machine on a level surface. 5. Position the return to travel target (5) opposite
the proximity switch (3) and tighten it to the target
2. Start the engine and apply the parking brake.
mounting plate (1).
3. Lower the lift arms and place the bucket flat on
6. Adjust the proximity switch (3) out towards the
the ground.
return to travel target (5) until an air gap of 3.5 to
4. Stop the engine. 5.0 mm (1/8 to 3/16 inch) is obtained.
NOTE: To avoid damge to the proximity switch (3), it 7. Lock the proximity switch (3) in this position with
must be adjusted back to clear everything on the lift the jam nut. Torque the jam nut to 6 to 7.5 Nm
arm as it passes. Refer to the illustration on this (4.5 to 5.5 pound-feet).
page.
WARNING: Raised equipment on the machine

without an operator can cause injury or death.
Before you leave the operators compar tment,
! a l way s s u p p o r t o r l ow e r t h e e q u i p m e n t
( backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105

9006-6
2
A
B
1
BS01C082
1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
621D Z-BAR 44 mm (1.7 inches) 380 mm (15 inches) 38 mm (1.4 inches) 3302 mm (130 inches)
621D XT 78 mm (3 inches) 496 mm (19.5 inches) 54 mm (2.1 inches) 3302 mm (130 inches)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR XT MODELS
8. Refer to the table and the illustration on this 14. Place the loader control lever in the raise position
page. Position the height control target (1) on the and verify that the electromagnet holds it in that
target mounting plate (3) using the table above. position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
NOTE: The higher the height control target (1) is
positioned in its slot in the target mounting plate (3),
the lower the lift arms will stop as they are raised. 15. With the lift arms still raised, place the loader
control lever in the lower position and verify that
9. Tighten the height control target (1).
the electromagnet holds it in that position until
10. Position the return to travel target (2) using the the return to travel target (5) passes in front of
table above. the proximity switch (3). Refer to the illustration
on page 5.
NOTE: The higher the return to travel target (2) is
positioned in its slot in the target mounting plate (3), 16. Repeat steps 8 through 15 until the desired
the lower the lift arms will stop as they are lowered. heights are reached.
11. Check to make sure the proximity switch (3) and 17. Lower the bucket to the ground and stop the
all of the mounting bolts are tight. Refer to the engine.
13. Place the detent switch in the ON position, and
set the return to travel/float detent switch to the
return to travel position.

9006-7
RETURN TO DIG ADJUSTMENT (XT MODELS)
2
3
5
1
4
6
BS01C084
1. BUCKET CYLINDER (LEFT HAND SIDE) 3. TARGET MOUNTING BRACKET 5. PROXIMITY SWITCH
2. PROXIMITY SWITCH MOUNTING BRACKET 4. PROXIMITY SWITCH GUARD 6. TARGET BAR
RETURN TO DIG ADJUSTMENT ILLUSTRATION XT MODELS
IMPORTANT: Before adjusting the return-to-dig, 8. Loosen the bolts holding the target bar (6) to the
make sure that the target bar on the bucket linkage is target mounting bracket (3). Slide the target bar
not damaged. Slowly roll back and dump the bucket (6) away from the proximity switch (5) until the
and make sure that the target bar stays the same face of the proximity switch (5) is completely
distance from the switch. The switch mounting uncovered.
bracket protects the switch. Make sure the target bar 9. Align the target bar (6) parallel to the bucket
cannot touch the switch when the bucket is dumped. cylinder (1) and tighten the bolts.
1. Park the machine on a level surface. Raise the lift 10. Turn the ignition switch to the ON position. Do
arms until they are approximately horizontal and NOT start the engine.
dump the bucket. Lower the bucket until the
bucket edge is on the ground. 11. Place the bucket control lever in the ROLLBACK
position.
2. Apply the parking brake and stop the engine.
12. Loosen the bolts holding the target bar (6) to the
3. Loosen the bolts holding the target mounting target mounting bracket (3).
bracket (3) to the bucket cylinder clevis. Align the
target mounting bracket (3) parallel to the bucket 13. Slide the target bar (6) slowly towards the
cylinder (1) and tighten the bolts. Refer to the proximity switch (5), until the bucket control lever
illustration on this page. returns to the center position. Tighten the bolts
holding the targe bar (6).
4. Loosen the bolts holding the target bar (6) to the
target mounting bracket (3). Align the target bar 14. Check to make sure that the 3.5 to 5.0 mm (1/8
(6) parallel to the bucket cylinder (1) and tighten to 3/16 inch) gap is still maintained.
the bolts. 15. Start the engine.
5. Loosen the bolts holding the proximity switch 16. Place the detent switch in the ON position and
mounting bracket (2) to the bucket cylinder (1). set the return to travel/float detent switch to the
Position the proximity switch (5) face parallel to return to travel position.
the target bar (6) and tighten the bolts. 17. Raise the lift arms to approximately the
6. Adjust the proximity switch (5) out towards the horizontal position and put the bucket in the fully
target bar (6) until an air gap of 3.5 to 5.0 mm dumped position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 18. Place the loader control lever in the ROLLBACK
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). position and verify that the electromagnet holds it
NOTE: The proximity switch (5) must not protrude in that position until the end of the target bar (6)
past the proximity switch guard (4). passes in front of the proximity switch (5).
7. Start the engine, position the bucket to the 19. Lower the lift arms to the ground and verify that
correct digging angle and stop the engine. the bucket is at the correct digging angle.

9006-8
REMOVING THE LOADER FRAME (Z-BAR MODELS)

1. Park the machine on a level surface and apply 17. Loosen and remove the bolt (19), flat washer
the parking brake. Roll the bucket all the way (20) and spacer (21) that fasten the pivot pin (9
forward and lower the bucket to the floor. Stop or 10) to the front frame.
the engine.
18. Raise the loader frame slightly. Use an
2. Loosen the filler plug in the reservoir to release acceptable driver and drive the pivot pin (9 or 10)
the air in the reservoir. out of the front frame. Do not lose the washers
(18) and wipers (22) between the front frame and
3. Fasten a chain hoist to the crossmember (1) of
the loader frame (2).
the loader frame (2), refer to the illustration on
page 9.
4. Loosen and remove the bolt (12), flat washer
(13), and spacer (14) that fasten the pivot pin (3)
to the piston rod yoke of the right lift cylinder (4).
5. Use an acceptable driver and drive the pivot pin
(3) out of the piston rod yoke of the right lift
cylinder (4). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (4 or
6). BD01G009
19. Remove the proximity switch cover. Left-hand

8. Raise the lift cylinder (4 or 6) slightly and remove side of the machine only.
the driver.
9. Repeat steps 7 and 8 for the other lift cylinder (4
or 6).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (15), flat washer 1
(16), and spacer (17) that fasten the pivot pin (7)
for the piston rod eye of the bucket cylinder (8) to
the bellcrank (11).
2
12. Use an acceptable driver and drive the pivot pin
(7) out of the piston rod eye of the bucket cylinder
(8).
BD01G010
13. Raise the bucket cylinder (8) and use a chain or 1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH
other acceptable holding equipment to hold the
20. Disconnect the electrical connector (1), remove
bucket cylinder (8) in place.
the lock nut from the proximity switch (2) and
14. If the machine is equipped with auxiliary r emove the p rox i mit y swi tc h ( 2 ) fr om th e
hydraulics, disconnect the two hoses from the machine. Left-hand side of the machine only.
tubes at the bracket on the right side of the
21. Repeat Steps 17 and 18 for the other pivot pin (9
loader frame (2). Install caps on the hoses and
or 10).
plugs in the tube fittings.
22. Raise the loader frame (2) out of the front frame.
15. If the machine is equipped with front lamps,
Carefully move the machine out of the loader
loosen and remove the cap screws and lock
frame (2).
washers that fasten the lamp brackets to the front
frame. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (2).

9006-9
10
18 8
20 18 22
16
17 15
19 9 6 7
2
1 11
21
5
5 4
14
12 5
3
13
23
BS01G022
1. CROSSMEMBER 7. PIVOT PIN 13. WASHER 19. BOLT

2. LOADER FRAME 8. BUCKET CYLINDER 14. SPACER 20. WASHER
3. PIVOT PIN 9. PIVOT PIN 15. BOLT 21. SPACER
4. LIFT CYLINDER 10. PIVOT PIN 16. WASHER 22. WIPER
5. PIVOT PIN 11. BELLCRANK 17. SPACER 23. DUMP LINK
6. LIFT CYLINDER 12. BOLT 18. WASHER
LOADER FRAME - Z-BAR AND XR MODELS ILLUSTRATION

9006-10
INSTALLING THE LOADER FRAME (Z-BAR MODELS)

1. Apply antiseize compound to the inner bores and 17. Disconnect the chain hoist from the bucket
outer bores for the pivot pins of the front frame , cylinder (8).
18. Fasten the chain hoist to one of the lift cylinders
2. Move the machine into alignment with the loader (4 or 6).
frame (2).
19. Raise the piston rod yoke of the lift cylinder (4 or
3. Lower the loader frame (2) into alignment with 6) so the piston rod yoke is aligned with the
the front frame. loader frame (2).
4. Apply antiseize compound to the pivot pins (9 20. Install a driver in the piston rod yoke and the
and 10) that fasten the loader frame (2) to the loader frame (2).
front frame.
21. Repeat Steps 18, 19, and 20 for the other lift
5. Start the pivot pins (9 and 10) into the front cylinder (4 or 6).
frame. Install the washers (18) and new wipers
22. Disconnect the chain hoist from the lift cylinder (4
(22) between the loader frame (2) and the front
or 6).
frame.
23. Start the engine. Raise the loader frame and roll
6. Install the pivot pins (9 and 10) all the way.
the bucket all the way forward. Lower the bucket
7. Install the bolt (19), washer (20) and spacer (21) to the floor. Stop the engine.
that fasten the pivot pins (9 and 10). Tighten the
24. Fasten the chain hoist to the crossmember (1) of
bolt.
8. Install the proximity switch and cover. Left-hand
25. Start the engine and run the engine at low idle.
side of the machine only.
26. Have another person help you at this time. Move
9. Disconnect the chain hoist from the loader frame
the lift control lever as required to align the piston
(2).
rod yoke of one of the lift cylinders (4 or 6) with
10. If the machine is equipped with front lamps, hold the loader frame (2).
the front lamps in place and install the cap
screws and lock washers that fasten the front IMPORTANT: D o n o t u s e yo u r f i n g e r s t o
lamps to the front frame. Tighten the cap screws. check the alignment of the cylinder rod.
11. If the machine is equipped with auxiliary
! Personal injury can be the result.
48-88
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the 27. Remove the driver and install the pivot pin (3).
hoses to the tubes.
28. Install the bolt (12), washer (13), and spacer(14)
12. Connect the chain hoist to the bucket cylinder (8) that fasten the pivot pin (3). Tighten the bolt.
and lower the bucket cylinder (8).
13. Start the engine and run the engine at low idle. cylinder (4 or 6). Stop the engine.
14. Have another person help you at this time. Move 30. Lubricate the pivot pins with molydisulfide
the bucket control lever as required to align the grease.
piston rod eye of the bucket cylinder (8) with the
bellcrank (11). Stop the engine. 31. Disconnect the chain hoist from the
crossmember (1) of the loader frame (2).
IMPORTANT: D o n o t u s e yo u r f i n g e r s t o 32. Tighten the filler plug in the reservoir.
c heck the alignment of the c ylinder rod.
! Personal injury can be the result.
33. If the machine is equipped with auxiliary
48-88
hydraulics, start the engine and run the engine at
low idle.
15. Install the pivot pin (7) in the bellcrank (11) and
34. Slowly extend and retract the clam cylinders four
the piston rod eye of the bucket cylinder (8).
times to remove air from the auxiliary circuit.
16. Install the bolt (15), washer (16), and spacer (17)
35. Stop the engine, check the level of the oil in the
that fasten the pivot pin (7). Tighten the bolt.
reservoir, and check for leaks. Add oil to the
reservoir as required.

9006-11
REMOVING THE LOADER FRAME (XT MODELS)

1. Remove all dirt and grease from the hose and 13. Disconnect the hoses to the bucket cylinders.
tube connections for the bucket cylinders and Disconnect the hoses from the tubes at the
clam cylinder, if equipped. bucket cylinders.
2. With the engine running at low idle, roll the 14. Install a cap on each hose and a plug in each
bucket all the way forward and lower the loader tube.
frame until the bucket is on the floor.
15. If equipped, disconnect the clam hydraulic
3. Stop the engine and apply the parking brake. connections, the auxiliary hydraulic connections,
and the coupler connections as necessary. Plug
4. Loosen the filler plug in the reservoir to release
and cap lines as needed.
the air in the reservoir.
16. Disconnect the wiring harnesses.
5. Loosen and remove the bolt (7), washer (8), and
spacer (9) that fasten the pivot pin (1) to the 17. Connect the chain hoist to the loader frame (3).
piston rod yoke of the lift cylinder (2 or 10), refer
18. Loosen and remove the bolt (11), washer (12),
and spacer (13) that fasten the loader frame (3),
6. Use an acceptable driver and drive the pivot pin pivot pin (4) and anchor link pivot pin (5) to the
(1) out of the piston rod yoke of the lift cylinder (2 machine frame.
or 10). Do not remove the driver.
19. Raise the loader frame (3) slightly. Use an
7. Repeat Steps 5 and 6 for the other lift cylinder (2 acceptable driver and drive both the pivot pins (4
or 10). and 5) from the loader frame (3) and anchor link
(6).
8. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor. 20. Do not lose the washers (14) between the front
Fasten the chain hoist to a lift cylinder (2 or 10). frame and the loader frame (3).
9. Raise the lift cylinder (2 or 10) slightly and 21. If equipped, remove the proximity switch cover
remove the driver. and the proximity switch from the left-hand side
of the machine.
10. Repeat Steps 8 and 9 for the other lift cylinder (2
or 10). 22. Repeat Steps 18 and 19 on the opposite side of
the machine.
23. Raise the loader frame from the machine. Be
12. Move the bucket control lever to the ROLLBACK
sure all the necessary hydraulic lines, wiring etc.
position and the lift control lever to the LOWER
are properly disconnected.
position to relieve any pressure in the circuits.
24. Carefully move the machine out of the loader
frame.

9006-12
14
15
12
11 4 14
13 5 3
9
1
BS01G021
1. PIVOT PIN 6. ANCHOR LINK 11. BOLT

2. LIFT CYLINDER 7. BOLT 12. WASHER
3. LOADER FRAME 8. WASHER 13. SPACER
4. PIVOT PIN 9. SPACER 14. WASHER
5. PIVOT PIN 10. LIFT CYLINDER (NOT SHOWN) 15. WIPER
LOADER FRAME - XT MODELS ILLUSTRATION

9006-13
INSTALLING THE LOADER FRAME (XT MODELS)

1. Apply antiseize compound to the inner bores and 16. Disconnect the chain hoist from the lift cylinder (2
outer bores of the front frame. or 10).
2. Move the machine into alignment with the loader 17. Start the engine. Raise the loader frame (3) and
frame (3), refer to the illustration on page 12. roll the bucket all the way forward. Lower the
bucket to the floor. Stop the engine.
3. Lower the loader frame (3) into alignment with
the machine frame. 18. Fasten the chain hoist to the crossmember of the
loader frame (3).
4. Apply antiseize compound to the pivot pins (4)
and (5) that fasten the loader frame (3) to the 19. Start the engine and run the engine at low idle.
machine frame.
20. Have another person help you at this time. Move
5. Start the loader frame pivot pin (4), washer (14) the lift control lever as required to align the piston
and wiper (15). rod yoke of one of the lift cylinders (2 or 10) with
6. Install the loader frame pivot pin (4) and anchor
link pivot pin (5) on one side of the machine. IMPORTANT: D o n o t u s e yo u r f i n g e r s t o
7. Repeat Steps 5 and 6 for the opposite side of the check the alignment of the cylinder rod.
machine. ! Personal injury can be the result.
48-88
8. Install the bolt (11), washer (12) and spacer (13)
that secure the pivot pins (4 and 5) to the 21. Remove the driver and install the pivot pin (1).
machine on each side of the machine. Tighten 22. Install the bolt (7), washer (8), and spacer (9)
the bolt. that fasten the pivot pin (1). Tighten the cap bolt.
9. Disconnect the chain hoist from the loader frame 23. Repeat Steps 20, 21, and 22 for the other lift
(3). cylinder (2 or 10). Stop the engine.
10. If the machine is equipped with auxiliary 24. Lubricate the pivot pins with molydisulfide
hy d r a u l i c s , c l a m hy d r a u l i c s , o r c o u p l e r grease.
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses and make 25. Disconnect the chain hoist from the
the necessary connections. crossmember of the loader frame (3).
11. Connect the hoses and tubing to the bucket 26. Start the engine and run the engine at low idle.
cylinders. 27. Slowly extend and retract the cylinders four times
12. Fasten the chain hoist to one of the lift cylinders to remove air from the hydraulic circuit.
(2 or 10). 28. If equipped with auxiliary hydraulics, slowly
13. Raise the piston rod yoke of the lift cylinder (2 or extend and retract the clam cylinders four times
10) so the piston rod yoke is aligned with the to remove air from the auxiliary circuit.
loader frame (3). 29. Stop the engine, check the level of the oil in the
14. Install a driver in the piston rod yoke and the reservoir, and check for oil leaks. Add oil to the
loader frame (3). reservoir as required.
cylinder (2 or 10).

9006-14
BS01C089
1. BUCKET CYLINDER 2. CONTROL VALVE
BUCKET CYLINDER HYDRAULIC CIRCUIT - Z-BAR MODELS

9006-15
BS01C086
1. BUCKET CYLINDER 2. CONTROL VALVE
BUCKET CYLINDER HYDRAULIC CIRCUIT - XT MODELS

9006-16
B1445A88J
1. LEFT LIFT CYLINDER 2. RIGHT LIFT CYLINDER 3. CONTROL VALVE
LIFT CYLINDER HYDRAULIC CIRCUIT - Z-BAR AND XT MODELS

Section
9007
ROPS CAB AND ROPS CANOPY
9007
CASE CORPORATION
700 State Street
9007-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................... 2
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY . . . . . . . . . . . . ......................... 3
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY ......................... 3
ROPS CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................... 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................... 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TORQUES
ROPS Cab and ROPS Canopy Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 to 854 Nm (570 to 630 lb-ft)
Operators Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 to 87 Nm (54 to 64 lb-ft)
Top Step Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 61 Nm (40 to 45 lb-ft)

9007-3
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY

If the machine has rolled over or the ROPS cab or After an accident, check for damage to the ROPS
ROPS canopy has been in some type of accident cab or ROPS canopy, the operators seat, the seat
(such as hitting an overhead object during transport), belt, and all accessories, wiring, etc., in the ROPS
you must replace the ROPS cab or ROPS canopy to cab or ROPS canopy. Before operating the machine
get as much protection as you had originally. again, all damaged parts must be replaced.
Do not weld or try to straighten a ROPS cab or ROPS
canopy.
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that
will make the total weight of the machine
1. Check the torque on the ROPS cab or ROPS more than the weight shown in the maximum
canopy mounting bolts; torque should be 773 to gross vehicle weight section of the ROPS
854 Nm (570 to 630 lb-ft). If necessary, tighten serial number plate. 47-26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
sh o u ld b e 7 3 to 8 7 N m ( 54 to 6 4 lb- ft ). If cutting will make the ROPS weaker and
necessary, tighten the bolts to the correct torque. decrease your protection. Replace the
Replace parts that are worn or damaged. ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
WARNING: Grade 8 hardware is used to ROPS. 47-25
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
parts catalog. 47-27A

9007-4
ROPS CAB AND ROPS CANOPY
Removal STEP 5
NOTE: Procedures and photos in following steps
cover in detail removal and installation of ROPS cab.
Removal and installation of ROPS canopy is similar
to removal and installation of ROPS cab.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position. BD01F258
Put battery disconnect switch in OFF position. Close

STEP 2 hood.
STEP 6
BD01F143

BD01F184
STEP 3 Put a 75.7 liter (18 gallon) container below hydraulic
Slowly loosen the filler cap for hydraulic reservoir to oil drain. remove cap and drain hydraulic oil into
release air pressure in hydraulic reservoir. container. Install cap after oil has drained.
STEP 4 STEP 7
Open hood.
BD01F184
If machine is equipped with a heater, put a 37.8 liter

(10 gallon) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.

9007-5
STEP 8 STEP 10
BD01F262 BD01F263
Remove skirting under each side and front of cab. Remo ve two nuts and bolts and four washers.
Remove mud flap from rear fender and bracket.
STEP 9
STEP 11
2
2
1
BD01F234
BD01F264
Remove two nuts (1) and bolts, and four washers

securing LH fender to top step. Connect lifting
equipment to LH fender. Remove two bolts (2) and
washers securing fender to rear chassis. Remove
fe nder from loader. Install nuts (1), bolts, a nd
washers to secure step to bracket. Repeat Steps 10
and 11 to remove RH fender from loader.
STEP 12
BD01F235

Remove LH fender. Repeat this step to remove RH
fender.
BD01D261
At RH rear, bottom of cab, disconnect ground strap

from rear chassis.

9007-6
STEP 13 STEP 16
6
5 5
7
8
8
9
BD01D262 BD01D265
Tag and disconnect transmission wiring harness If machine is equipped with a heater, open side
connector from bulkhead connector. access door to gain access to heater hoses (6 and
7). Compress two clamps (5) and disconnect hoses.
STEP 14 Remove clamps (5 and 8) from hoses. Pull hoses
down from cab; grommets (9) may dislodge from cab
when hoses are pulled down.
STEP 17
11 13
3
10
BD01D263
If machine is equipped with windshield washers, 12

identify, tag, and disconnect front (3) and rear (4)
windshield washer nozzle hoses from supply hoses.
BD01D267
STEP 15 Pull boot (10) back from B+ power stud. Tag and
disconnect wire from stud. Tag and disconnect two
wires from ground stud (11). Tag and disconnect rear
chassis wiring harness connector (12) and front
wirin g h a rn es s co n ne cto r ( 13 ) fr om bu lkhe a d
connectors.
BD01D264
If machine is equipped with a heater, cut, remove,

and discard two tie straps.

9007-7
STEP 18 STEP 20
17
16
BD01D271 BD01D390
Open RH window then remove access panel.
STEP 19
17
16
BC01D272
Remove solenoid valve (16) from remote valve body

14 15 (17). Move solenoid valve away from valve body and
BD01D269
hose connections. Identify, tag, and disconnect
Using suitable tool push up on hose mounting hoses from remote valve body. Plug hoses and cap
grommet (14) from bottom of cab. Remove both valve fittings to prevent entry of foreign matter into
halves of grommet (14 and 15) from cab and hoses. hydraulic system.
STEP 21
BD01D275
Cut, remove, and discard tie strap.

9007-8
STEP 22 STEP 25
19
18
20 27
BD01D277 BD01D286
Cut, remove, and discard tie strap (18). Disconnect Remove three screws, washers, and seal channel
throttle cable (19) from pedal assembly (20). Move cover (27).
throttle cable away from cab.
STEP 26
STEP 23
21 BD01D288
BD01D279 Raise floor mat up and away from brake pedal to gain
Identify, tag, and disconnect hoses from steering access to mounting hardware.
control valve (21). Plug hoses and cap steering
control valve fittings to prevent entry of foreign matter STEP 27
into hydraulic system.
STEP 24
22 25
23
24 BD01D287
26 Remove hardware securing brake valve to cab floor.

Let brake valve hang down from cab.
BD01D285
If machine is equipped with two brake pedals,

remove retaining ring (22) securing pin (23) to brake
pedal (24). Remove pin. Remove two bolts (25),
pedal and shaft (26), pivot assembly, and block.
Remove pedal (24) cover pad.

9007-9
STEP 28 STEP 30
31
29
BD01D284 BD01D293
If machine has a ROPS cab and is equipped with air Remove two bolts (31) and washers. Remove pod
conditioning, refer to Section 9002 and discharge air (29) from cab.
conditioning system. At left rear bottom of cab,
d i s c o n n e c t t w o h o s e s f r o m a ir c o n d i t i o n i n g STEP 31
evaporator tubes. Remove and discard O-rings from
evaporator tubes. Plug tubes and cap hoses to
prevent entry of foreign matter.
STEP 29
28 29
BD01D297
28 Install two lifting eyes in threaded holes at top front of
cab.
BD01D291
30
29
28
BD01D282
At top rear of cab, remove hardware securing LH

flood light (28) to pod (29). Disconnect flood light
connector (30) from wiring harness connector and
remove flood light. Repeat this step to remove RH
flood light.

9007-10
STEP 32 STEP 34
BD01D389 BD01F272
Remove four nuts (34), washers (35), bolts (36), and

washers (37) securing cab to rear chassis.
STEP 35
BD01D298
Connect lifting equipment to cab at lifting eyes

installed in Step 31 and at rear top LH and RH rails.
Take up all slack in lifting equipment.
BD01D300
STEP 33 Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all hoses,
tubes, and wires are disconnected and free. Check
that brake valve with hoses attached is free and clear
of cab. Remove the ROPS cab or ROPS canopy from
the machine. Lower cab or canopy onto wooden
33 blocks to prevent damaging cab or canopy.
32
BD01F274
At LH and RH bottom rear of cab, loosen two bolts

(32) and remove cover plate (33) to gain access to
cab rear mounting hardware.

9007-11
33 39
34
35
38
32
37
36
BS01D195
32. BOLT 36. BOLT

33. COVER PLATE 37. WASHER
34. NUT 38. RUBBER MOUNT
35. WASHER 39. ROPS CANOPY

9007-12
STEP 36
Check rubber mounts (38) for deterioration, tears,
deforma tion , or oth er d ama ge; replace rub ber
mounts as necessary.
STEP 37
BD01F272
Install four washers (37), bolts (36), washers (35),

and nuts (34) to secure cab to rear chassis. Tighten
bolts to a torque of 773 to 854 Nm (570 to 630 lb-ft)
STEP 39
BD01D300
33
41
40
32
BD01F274
At LH and RH bottom rear of cab, install cover plate

BD01D388
(33) and tighten two bolts (32).
Position cab over rear chassis then put wood blocks
under brake valve (41). Slowly lower cab onto rear STEP 40
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve. Route
front windshield washer hose (40) towards RH of rear
chassis.
BD01D298
Disconnect lifting equipment from cab.

9007-13
STEP 41 STEP 44
BD01D297 BD01D284
Remove two lifting eyes installed in Step 31 in If machine has a ROPS cab and is equipped with air
threaded holes at top front of cab. conditioning, remove plugs from tubes and caps from
hoses at left rear bottom of cab. Install new O-rings in
STEP 42 air conditioning evaporator tubes. Connect two hoses
to evaporator tubes. Refer to Section 9002 and
charge air conditioning system.
STEP 45
31
29
BD01D293
Position and support pod (29). Secure pod using two

washers and bolts (31).
STEP 43 BD01D287
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
STEP 46
30
29
28
BD01D282
At top rear of cab, connect flood light connector (30)

to wiring harness connector. Insert flood light (28)
stud through hole in pod (29) and secure flood light
using nut. Repeat this step to install RH flood light.
BD01D288
Position floor mat.

9007-14
STEP 47 STEP 50
19
18
27 20
BD01D286 BD01D277
Install seal channel cover (27) and secure with three Connect throttle cable (19) to pedal assembly (20).
washers and screws. Install new tie strap (18) to secure front windshield
washer hose to throttle cable.
STEP 48
STEP 51
22 25
23
24
26
BD01D285
If machine is equipped with two brake pedals, install BD01D275
pedal (24) cover pad. Position pedal and shaft (26), Position hoses as shown and install new tie strap.
pivot assembly, and block; secure with two bolts (25). NOTE: If machine has a joystick controller, go to
Install pin (23) through brake pedal (24) and pedal Step 52; if machine has a two-lever controller, go to
shaft crank. Install retaining ring (22) to secure shaft. Step 53; if a joystick and one-lever controller go to
Step 54; if a three-lever controller go to Step 55; If a
STEP 49 joystick and two-lever controller go to Step 56.
NOTE: Except for pilot pressure and pilot tank
hoses, hose ends are color coded.
21
BD01D279
Remove plugs from hoses and caps from fittings.

Co n n ec t h o se s to ste er ing c o ntr o l va lve (2 1 )
following tags installed during removal. Remove and
discard tags.

9007-15
STEP 52 STEP 53
D
E
E F
C
B C
B
F
A A D
A D
C B C
A
B D
F E
E F BS01D177A
BS01D177B A. ORANGE-BLACK D. GREEN-BLACK

A. ORANGE-BLACK D GREEN-BLACK B. YELLOW-BLACK E. PILOT PRESSURE HOSE
B. YELLOW-BLACK E PILOT PRESSURE HOSE C. RED-BLACK F. PILOT TANK HOSE
C. RED-BLACK F PILOT TANK HOSE Remove plugs from hoses and caps from fittings.
Remove plugs from hoses and caps from fittings. Connect hoses to two-lever controller and install in
Connect hoses to joystick controller and install in hose mounting grommet halves as shown above. Go
hose mounting grommet halves as shown above. Go to Step 57.
to Step 57.

9007-16
STEP 54 STEP 55
E F
H G
D
G B C
B A D
C
E F
A H D
A
C
B
A C
H
B D G
E F
BS01D178A
A. ORANGE-BLACK E. YELLOW-WHITE
E G H F B. YELLOW-BLACK F. RED-WHITE
BS01D178B C. RED-BLACK G. PILOT PRESSURE HOSE
D. GREEN-BLACK H. PILOT TANK HOSE
A. ORANGE-BLACK E. YELLOW-WHITE
B. YELLOW-BLACK F. RED-WHITE Remove plugs from hoses and caps from fittings.
C. RED-BLACK G. PILOT PRESSURE HOSE Connect hoses to three-lever controller and install in
D. GREEN-BLACK H. PILOT TANK HOSE hose mounting grommet halves as shown above. Go
Remove plugs from hoses and caps from fittings. to Step 57.
Connect hoses to joystick and one-lever controller
and install in hose mounting grommet halves as
shown above. Go to Step 57.

9007-17
STEP 56 STEP 58
G H
E F
I
14 15
C
D BD01D269
J Install both halves of hose mounting grommet (14

B and 15).
A
C STEP 59
A D
B
E F
I J
G H
BS01D180
A. ORANGE-BLACK F. RED-WHITE
B. YELLOW-BLACK G. ORANGE-WHITE
C. RED-BLACK H. GREEN-WHITE
D. GREEN-BLACK I. PILOT PRESSURE HOSE
E. YELLOW-WHITE J. PILOT TANK HOSE
BD01D271
Remove plugs from hoses and caps from fittings. Install access panel then close RH cab door.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as STEP 60
shown above. Go to Step 57.
STEP 57
11 13
10
12
17
16 BD01D267
Connect rear chassis wiring harness connector (12)

and front wiring harness connector (13) to bulkhead
BD01D390 connectors following tags installed during removal.
Install solenoid valve (16) in valve body (17). Connect two wires to ground stud (11) following tags
installed during removal. Connect wire to B+ power
stud following tag installed during removal and
position boot (10) over stud. Remove and discard
tags.

9007-18
STEP 61 STEP 64
6
7
BD01D264A BD01D262
If machine is equipped with a heater, install two Connect transmission wiring harness connector to
grommets (9) (if dislodged during removal) and bulkhead connector following tag installed during
heater hoses (6 and 7) up into cab. removal. Remove and discard tag.
STEP 62 STEP 65
6
5
5
7
8
8
9
BD01D265 BD01D261
Make sure grommets (9) are installed completely in At RH rear, bottom of cab, connect ground strap to
cab holes. Install clamps (8 an d 5) o n ho ses. rear chassis.
Connect hoses (6 and 7) and position clamps (8 and
5) as shown. STEP 66
STEP 63
2
2
4
1
3
BD01F264
Using suitable lifting equipment, move LH fender into

BD01D263 position on loader. Remove two nuts (1), bolts, and
If machine is equipped with windshield washers, washers used to secure step to bracket. Install two
connect front (3) and rear (4) windshield washer washers and bolts (2) to secure fender to rear
nozzle hoses to supply hoses following tags installed chassis. Install two nuts (1) and bolts, and four
during removal. Install two new tie straps. Remove washers to secure LH fender to steps and bracket.
and discard tags.

9007-19
STEP 67 STEP 69
BD01F263 BD01F262
Position mud flap between bracket and fender. Install skirting under each side and front of cab.
Secure using two nuts and bolts and four washers.
Repeat Steps 66 and 67 to install RH fender on STEP 70
loader.
STEP 68
BD01F184M
Check that hydraulic oil drain cap is tig ht. Fill

hydraulic reservoir with 68.5 liters (18 gallons) of
BD01F234 MS-1209 Hy-Tran Ultra® fluid.
STEP 71
BD01F235
Install LH fender and secure with two bolts and

washers. Repeat this step to install RH fender. BD01F184
If machine is equipped with a heater and coolant was

drained, check that coolant drain cap is tight.

9007-20
STEP 72 STEP 75
If coolant was drained, fill engine coolant system with Start engine and run engine at low idle. Run engine
a solution of 50% Ethylene Glycol and 50% water. at operating temperature for approximately five
Cooling system capacity is 36 liters (9.5 gallons). minutes to completely mix Ethylene Glycol and water.
Install radiator cap. Fill coolant reservoir up to FULL When coolant is at operating temperature, stop
mark on reservoir. engine. When engine has cooled, check coolant level
at reservoir.
STEP 73 WARNING: Hot coolant can spray out if radiator cap
Open hood. is removed. To remove radiator cap: let system cool,
STEP 74 released. Scalding can result from fast removal of
radiator cap.
STEP 76
STEP 77
BD01F259
Put battery disconnect switch in ON position. Close

hood.

Section
9010
CAB GLASS INSTALLATION
9010
CASE CORPORATION
700 State Street
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and 5. Clean the new glass section. Apply a 25 mm (1
the silicone sealant from the window frame inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must 3. For front glass installations install a glass spacer
be installed within 5 minutes. If the glass is not 12 mm (1/2 inch) from each corner on bottom
installed within the 5 minute period, the adhesive edge of each glass section, refer to Figure 3.
must be removed and applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
ad he sive (3 45 -1 35 ) to the p rim ed su rfac e
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at each
tape into the gap. end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with th e glass sectio ns d uring this
process. Refer to Figure 2 for forming tool
template.

9010-4
9. Remove all the silicone from the forming tool
1 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the inside
joint by carefully sliding the forming tool down the
length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3 13. Remove the inside joint masking tape.
4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges
3.
smooth.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM 120°
(1/2 INCH) R
120°
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE

9010-5
2
1
3
4
2
1
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
9010-6
NOTES

FUSE X BEACON 7.5A
FUSE Y NONE
10A FUSE L RADIO 7.5A
FUSE Z FRONT FLOOD LAMPS & ILLUMINATION
FUSE A' REAR FLOOD LAMPS 10A FUSE M SECONDARY STEERING 7.5A
5A FUSE N SEAT COMPRESSOR 10A
FUSE B' HIGH BEAM LEFT
5A FUSE P COUPLER/FAN REVERSER 7.5A
FUSE C' HIGH BEAM RIGHT
5A FUSE R SECONDARY STEERING 7.5A
FUSE D' LOW BEAM LEFT
5A FUSE S INSTRUMENT CLUSTER 5A
FUSE E' LOW BEAM RIGHT
5A FUSE T TRANSMISSION CONTROL 7.5A
FUSE F' TAIL LAMPS LEFT
5A FUSE U DOME LAMP AND HORN 7.5A
FUSE G' TAIL LAMPS RIGHT
FUSE V VOLTMETER 7.5A
SHEET 4 - 42F (99) 19X Or-1.0 X2 X1 FUSE W CIGARETTE LIGHTER 15A
SHEET 4 - 34F (114) 19Z Or-1.0 Y2 Y1
SHEET 4 - 32F (144) 18A Or-2.0 Z2 Z1 1_U R-3.0 19L Or-1.0 12P_A Or-1.0
SHEET 4 - 1F CAB FRONT 18B_A Or-0.8 A2' A1' SHEET 5 - 1F CAB FRONT CHASSIS 19M_A Or-0.8 L2 L1 12P_B Or-1.0
SHEET 4 - 1F CAB FRONT 18C_A Or-0.8 B2' B1' SHEET 5 - 28M (82) 19N_A Or-1.0 M2 M1 12K_A Or-1.0
SHEET 3 - 13F CAB PEDESTAL 18C_B Or-0.8 C2' C1' 41H K-2.0 SHEET 4 - 59F (115) 19N_B Or-1.0 N2 N1 12P_B Or-1.0
SHEET 4 - 1F CAB FRONT 18D_A Or-0.8 D2' D1' SHEET 5 - 40F (69) 19P_A Or-1.0 P2 P1 13P_B Or-1.0
SHEET 4 - 1F CAB FRONT 18E_A Or-0.8 E2' E1' 41L_A K-2.0 SHEET 4 - 59F (115) 19R_F Or-0.8 R2 R1
SHEET 4 - 21F CAB REAR 18F_D Or-0.8 F2' F1 ' SHEET 3 - 13F CAB PEDESTAL 19S Or-0.8 S2 S1 13D Or-1.0
SHEET 4 - 1F CAB FRONT 18F_E Or-0.8 G2' G1' 41T_A K-1.0 SHEET 4 - 32F (114) SHEET 2 - 19F (26) 19T_A Or-0.8 T2 T1
SHEET 4 - 21F CAB REAR 18G_F Or-0.8 SHEET 2 - 19F (26) 19T_B Or-0.8 U2 U1 1_Q R-1.0
SHEET 4 - 1F CAB FRONT 18G_G Or-0.8 18F 18F SHEET 4 - 23F CAB ROOF 19U_A Or-1.0 V2 V1 13V Or-1.0
SHEET 5 - 51F (80) 19U_B Or-1.0 W2 W1 1_R R-3.0
SHEET 3 - 13F CAB PEDESTAL 19V Or-0.8
19W Or-1.0 18F 18F
SHEET 5 - 244F (68) 1_NC R-62 1_B R-13.0

1_A R-1.0
245F 156 FUSE A TRANSMISSION CONTROL 7.5A
241F
FUSE B FLASHER MODULE 5A
1_NB R-62
CRANKING FUSE C RIDE AND PILOT CONTROL 5A
195 19N_B Or-1.0 FUSE D PARKING BRAKE 5A
MOTOR
1_E R-19
B+ STUD 12V_B R-5.0 FUSE E ETHER START 10A
SHEET 6 - 258F (92)
246M 260M FUSE F ENGINE SHUTDOWN 5A
194
14 LG-1.0 154
6 A 5 4 3 2 1
FUSE G BLOWER SWITCH 15A
12 A 11 10 9 8 7
B S FUSE H BACKUP ALARM 5A
149 18
249M 17 A 16 15 14 13
18F FUSE J FRONT WIPER & WASHER MOTOR 10A

D+ 153 M 18F 18F 18F 18F 18F
FUSE K REAR WIPER & WASHER MOTOR 10A
4 R + 1 R-13.0
19W_A Or-3.0 SHEET 6 - 259F (91)
−
5 M 19L_B Or-1.0 SHEET 6 - 256F (92)

240F 155 225F 19L_A Or-1.0 SHEET 6 - 109M (96) SHEET 2 - TO SPL_D15 19A_N Or-0.8
POS 1_NB R-62 227F SHEET 2 - 35F (35) 19A_P Or-0.8
193 196 1_R R-3.0 SHEET 4 - 13F CAB PEDESTAL 19B_A Or-0.8 A2 A1 13P_A Or-1.0
30 1_F R-8.0 SHEET 5 SPL_D24 19C_A Or-1.0 B2 B1
NEG 1_NA R-62 250F CAB B+ 270F SHEET 3 - 56F (51) 19C_D Or-1.0 C2 C1
191 190
87 1_C R-8.0 1 239F JUNCTION 1_X R-1.0 SHEET 6 - 269 RADIO SHEET 3 - 55F (52) 19D_A Or-1.0 D2 D1
BLOCK MEMORY FUSE 1_H R-3.0 SHEET 4 - 59F (115) 30 30 19E Or-1.0 19E Or-1.0 E2 E1
6 RELAY BOX 226F SPL_D16 87 87 28P_A W-0.8 19F Or-1.0 F2 F1 13R Or-1.0
86
135
21C_B W-1.0 JUNCTION 1 1_K R-3.0 1_G R-3.0 87a 87A 0_DG Bk-0.8 SHEET 5 - 30F (83) 19G Or-2.0 G2 G1
BLOCK 85 85 0_DC Bk-0.8 SHEET 2 - 53F (35) 19H Or-1.0 H2 H1
85
132 0_GB Bk-2.0 238F 86 86 28C_A W-0.8 SHEET 5 - 35F (75) 19J_A Or-1.0 J2 J1
POS 1_NA R-62 224F 228F 1_J R-3.0 SHEET 5 SPL_D23 19K_A Or-1.0 K2 K1
52F
1_D R-2.0 18F 18F
NEG 0_NC Bk-62 1_N R-3.0 SHEET 4 - 33F (114) 10
23F_A W-2.0
1 1 23F W-2.0 30 30
137 237F
30 133F 133M 1_V R-5.0 SHEET 6 - 255F (92) 87 87 12P_A Or-1.0
192 FUEL AND STARTER ENGINE 87a 87A 0_DC Bk-0.8
87
RELAYS HARNESS HARNESS 85 85 0_DF Bk-0.8
0_P Bk-1.0 SHEET 3 - SPL_E9 86 86 12K_A Or-1.0
7 16 12K_B Or-0.8
0_E Bk-1.0 SHEET 3 - 104 (39) 172 SPL_G1 49F
REAR ENGINE 86 21C_A W-1.0 28P W-1.0 1 1
160 0_V Bk-1.0 SHEET 3 - 171 (40) 21C_C W-1.0 A A 21C_D W-1.0 11 11
BLOCK GROUND 85
173 0_GC Bk-2.0 0_GA Bk-2.0 B B 1_A R-1.0 21 21
STUD(–) SPL_G2 93M 93F
21M 21F 30 30 1_P R-0.8
0_G Bk-1.0 SHEET 5 - 2 (76) FUEL AND STARTER REAR A A 87 87 13V Or-1.0
13C Or-1.0 13M Or-1.0 9 REAR CAB
RELAYS HARNESS CHASSIS 28T_A W-1.0 B B 87a 87A 0_DG Bk-0.8
0_F Bk-1.0 SHEET 5 - 3 (78) A B 139F ENGINE HARNESS CHASSIS MAIN 0_DH Bk-0.8
A B
HARNESS 103 85 85
162 0_W Bk-1.0 SHEET 3 - 136 (41) 139M DISCONNECT HARNESS HARNESS HARNESS 86 86 13K_E Or-0.8
2.2 ohms at 25°C (77°F)
58F 13K_C Or-1.0
65F REAR CHASSIS HARNESS
13M_A Or-1.0
1
13C_E Or-1.0
REAR CHASSIS HARNESS 0_X Bk-1.0 SHEET 5 - 158 (56) 17
opens 13±3°C (55.4±5.4°F) 1 65M ENGINE HARNESS
163 closes 1.5±4.5°C (34.7±8.1°F)
A B C 134
A B C
30 30 1_T R-3.0
0_J Bk-1.0 SHEET 4 - 128F REAR HOOD 87 87 13R Or-1.0
B B 262F
A A 8 87a 87A 0_DF Bk-0.8 13K_C Or-1.0
164 0_D Bk-2.0 SHEET 4 - SPL_E4 A A 85 85 0_DE Bk-0.8
97 B B 86 86 13K_B Or-1.0 217F 217M
231F 230F 236F 235F
19R_D Or-0.8 C C 13K_A Or-1.0 13K_D Or-0.8 AA
3 28T W-1.0 48F SEE NOTE 4
0_U Bk-2.0 DIODE 13C_B Or-0.8
41.5 ohms 1.1 ohm 75 OHMS MODULE 15 30
165 0_Q Bk-1.0 SHEET 3 - 87 (53) 2 at 20°C (68°F) at 20°C (68°F) 87 13C_C Or-0.8 SHEET 5 - 140M DIODE
RESISTOR
AIR CONDITIONING 0_BJ Bk-1.0 SHEET 5 - 265F AIR CONDITIONING DIODE MODULE HOLD PULL-IN 1_M R-3.0
58 87A MODULE
215F 216F SHEET 4 - 211F FLASHER 85
DIODE HARNESS 268 SPL_D25 CIRCUIT BREAKER B 86 23C_A W-0.8 SHEET 3 - 13F CAB
19R_E Or-0.8 PEDESTAL
SPL_D17 57F 19F Or-1.0
0_BB Bk-2.0 19R_A Or-0.8 SHEET 5 - 1F CAB-FRONT
CHASSIS 1_S R-3.0
151 0_BC Bk-1.0
13C Or-1.0 1 1 13C_A Or-1.0 1 1 13C_D Or-0.8 13C_D Or-0.8
14 LG-1.0 5 5 14_A LG-1.0 2 2 14_B LG-0.8
ENGINE HARNESS 0_BG Bk-1.0 0_BG Bk-1.0 15 15 0_HC Bk-1.0 30 30 0_DAU Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 1_L R-3.0 30 30
152 0_BF Bk-1.0 9 9 0_HA Bk-1.0 23 23 87 87
0_BH Bk-1.0 11 11 0_HB Bk-1.0 15 15 0_DL Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 87a 87A 13P_A Or-1.0
213F IGNITION SWITCH 85 85
SHEET 3 - 138 (43) 0_BE Bk-1.0 SPL_B1
0_BA Bk-1.0 94M 94F 22M 22F 0_DAB Bk-0.8 SHEET 3 - 13F CAB PEDESTAL CIRCUIT 86 86
BREAKER A 21K_A W-0.8
150 SHEET 3 - 117 (44) 0_BD Bk-1.0 ENGINE TRANSMISSION TRANSMISSION CAB MAIN 47F
12.5 AMP 21C_F W-0.8 SHEET 5 - 140M DIODE
SECONDARY STEERING HARNESS HARNESS HARNESS HARNESS 214F 14 30 30 MODULE
MODULE HARNESS 0_CD Bk-1.0 SHEET 5 - SPL_C1 87 87 21C_E W-0.8
177 1A_D R-0.8 87a 87A 0_DH Bk-0.8
85 85 0_DJ Bk-0.8
13D Or-1.0 86 86 25T_E LU-0.8
SPL_D21
0_DZ Bk-2.0 SHEET 5 - 29M (85) 63M TIME DELAY MODULE 1A_E R-0.8
1 DELAY POWER-2-WAY 1
54F
CAB 0_DY Bk-1.0 SHEET 5 - 28M (82) 2 TIME DELAY POWER 2 0_DAS Bk-0.8 SHEET 4 - SPL_D14 12
REAR CHASSIS FRONT ENGINE GROUND SHEET 5 - 35F (75)
3 TIME DELAY MODULE GROUND 3
0_NB Bk-62 218F 0_DAR Bk-1.0 4 RESET SIGNAL 4 37R_C P-0.8 SHEET 3 - 13F CAB
GROUND WELD BLOCK GROUND SPL_D18
STUD (−) 234F JUNCTION 5 IGNITION SWITCH POWER 5 PEDESTAL
0_NA Bk-62 STUD (−) 6 NONE 6 SHEET 2 - 19F (26) 25T_D LU-0.8
BLOCK (–) 50G_G Bk-0.8 SHEET 2 - SPL_D7
13K_F Or-0.8
232F 233F 63M SPL_D22
0_DB Bk-0.8 SHEET 3 - 89M (54) 18
1 REAR
REAR CHASSIS 0_Y Bk-13.0 0_Y Bk-13.0 CHASSIS 219F
HARNESS 167 HARNESS
161 13
1A_C R-0.8
13K_G Or-0.8
REAR CHASSIS 0_DX Bk-0.8 SHEET 4 - 13F CAB PEDESTAL
GROUND WELD SHEET 3 - 75 (45) 1A_B R-0.8 5
SHEET 5 - SPL_A1 0_AJ Bk-2.0 0_DA Bk-0.8 SHEET 4 - 204F (102) 1 BAT
STUD (−) 0_CE Bk-1.0 SHEET 5 - 90M (66) FRONT 3 IGN
CHASSIS 220F 0_DAT Bk-0.8 SHEET 4 - SPL_D14 2 ST
176 HARNESS
SHEET 5 - SPL_A2 0_AK Bk-1.0 145 4 ACC
2 6
0_DQ Bk-0.8 SHEET 2 - 19F (26)
69
CAB 0_DP Bk-0.8 SHEET 2 - 19F (26)
UPPER PEDESTAL CAB GROUND REAR CHASSIS REAR CHASSIS SHEET 6 - 254F (92) 0_RA Bk-5.0 HARNESS
GROUND GROUND WELD 221F 0_DAV Bk-0.8 SHEET 2 - 108F (28) 12K_C Or-0.8 63 63 12K_B Or-0.8
WELD STUD (−) GROUND WELD 251F 21K W-0.8 64 64 21K_A W-0.8
SCREW (−) BRAIDED_STRAP_2 BRAIDED STRAP STUD (−) STUD (−) 0_ND Bk-62 SHEET 5 - 242F (68) CONVERTER 13K Or-0.8 56 56
HARNESS 0_DAD Bk-1.0 SHEET 5 SPL_D13 1A_A R-0.8 62 62
CAB STUD REAR 243F 52 52 28C_A W-0.8
CHASSIS SHEET 6 - 253F (93) 0_RB Bk-3.0 0_DJ Bk-0.8 11 25T_C LU-0.8
1 3 4 46 46
STUD 222F 0_DAC Bk-0.8 SHEET 3 - 13F CAB PEDESTAL
252F
182 13M 13F
1 28C W-0.8
LOWER PEDESTAL CAB GROUND REAR CHASSIS FRONT CHASSIS PEDESTAL CAB MAIN
0_DAX Bk-0.8 SHEET 5 - 140M DIODE MODULE GROUND WELD CIGAR 0_DS Bk-1.0 SHEET 4 - 24M CAB ROOF 92 HARNESS HARNESS
GROUND WELD STUD (−) GROUND WELD 1 25T_B LU-0.8
SCREW (−) 0_DU Bk-1.0 SHEET 4 - 23F CAB ROOF STUD (−) 0_AH Bk-5.0 STUD (−) SHEET 6 - 259F (91) 0_S Bk-3.0 LIGHTER 0_DR Bk-1.0 SHEET 4 - 24M CAB ROOF 25T_A LU-0.8 SHEET 2 - 70 (27)
261F HARNESS 0_DT Bk-1.0 SHEET 4 - 23F CAB ROOF
206F 0_DV Bk-0.8 SHEET 5 - 13F CAB PEDESTAL 144 143 223F
2 5
CONVERTER 0_PD Bk-1.0 SHEET 6 - 109M (92)

HARNESS
247F
SHEET 1 - POWER CONTROL AND DISTRIBUTION

COMPONENTS
1. Batteries 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) 105. Flasher Module 117. Dome Lamp
2. Master Disconnect Switch 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 118. Courtesy Lamp
3. Fuel Shutoff Solenoid 15. Ignition Relay - Number 2 27. Transmission Shifter 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 107. Right-Hand Rear Combination Lamp
4. Alternator 16. Accessory Relay - Number 3 28. Diagnostic Connector 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 108. Left-Hand Front Combination Lamp
5. Starter Motor 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 109. Right-Hand Front Combination Lamp
6. Starting Relay 18. Time Delay Module 30. Transmission Auto Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 110. Left-Hand Rear Work Lamp
7. Fuel Relay 19. Output Speed Sensor 31. Declutch Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 111. Right-Hand Rear Work Lamp
8. Ether Start Temperature Switch 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 112. Left-Hand Front Work Lamp
9. Ether Start Solenoid 21. Intermediate Speed Sensor 33. Transmission Enable Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 113. Right-Hand Front Work Lamp
10. Ether Start Relay - Number 6 22. Turbine Speed Sensor 34. FNR Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 15 114. Five Position Rotary Lamp Switch
11. Ether Start Switch 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 115. High/Low Beam Relay - Number 13
12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch 116. License Plate Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
1 5 6 1 4 7 10 1 4 1 4 1
1. WIRE NUMBER 23F_A W-2.0 4 10 14 1. LEVER RELEASED 1. VACUUM SWITCH 1. SINGLE POLE, 1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER,
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1 2. Resistors part of ground wire assembly.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0
D+ 3. 64M and 64F connected for North American machines, opposite side steady ON.
B B 2 2
R + 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 93M 93F 7 9
− 5. HAND OPERATED 5. LAMP 3. DOUBLE POLE, MANUAL RESET 64M and 64F disconnected for European machines, opposite side OFF.
3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 XXXX XXXX
11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
15
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE,
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN R = RED Y = YELLOW
1.
2.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
6.
7.
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
11.
12.
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION
CONNECTION POINT ON SCHEMATIC
9. RESISTOR ELECTRICAL SCHEMATIC
3 6 9 12 10. DIODE 3 3 3
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION

3. CIRCUIT CONNECTED 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED) A 11. LIGHT EMITTING DIODE 621D Z-BAR, 621D XR, and 621D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER 12A. MOMENTARY CONTACT T Additional copies of this Hydraulic and Electrical Schematic can be ordered through
5. MALE CONNECTOR 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Technical Publications Distribution System. The Part Number is 6-43052
BC02D008
FUSE X BEACON 7.5A
FUSE Y NONE
10A FUSE L RADIO 7.5A
FUSE Z FRONT FLOOD LAMPS & ILLUMINATION
FUSE A' REAR FLOOD LAMPS 10A FUSE M SECONDARY STEERING 7.5A
5A FUSE N SEAT COMPRESSOR 10A
241F FUSE B' HIGH BEAM LEFT
1_NB R-62 5A FUSE P COUPLER/FAN REVERSER 7.5A
FUSE C' HIGH BEAM RIGHT
CRANKING 5A FUSE R SECONDARY STEERING 7.5A
14 LG-1.0 30 R-1.0 FUSE D' LOW BEAM LEFT
MOTOR 5A FUSE S INSTRUMENT CLUSTER 5A
154 FUSE E' LOW BEAM RIGHT
5 4 3 2 1 B+ STUD FUSE T TRANSMISSION CONTROL 7.5A
FUSE F' TAIL LAMPS LEFT 5A
5 4 3 2 1 194 5A FUSE U DOME LAMP AND HORN 7.5A
FUSE G' TAIL LAMPS RIGHT
FUSE V VOLTMETER 7.5A
B S SHEET 4 - 42F (99) FUSE W CIGARETTE LIGHTER 15A
149 19X Or-1.0 X2 X1
15 SHEET 4 - 34F (114) 19Z Or-1.0 Y2 Y1

L BS M SHEET 4 - 32F (144) 18A Or-2.0 Z2 Z1 1_U R-3.0 19L Or-1.0 12P_A Or-1.0
4 W G DFM SHEET 4 - 1F CAB FRONT 18B_A Or-0.8 A2' A1' SHEET 5 - 1F CAB FRONT CHASSIS 19M_A Or-0.8 L2 L1 12P_B Or-1.0
B- B1+ SHEET 4 - 1F CAB FRONT 18C_A Or-0.8 B2' B1' SHEET 5 - 28M (82) 19N_A Or-1.0 M2 M1 12K_A Or-1.0
SHEET 3 - 13F CAB PEDESTAL 18C_B Or-0.8 C2' C1' 41H K-2.0 SHEET 4 - 59F (115) 19N_B Or-1.0 N2 N1 12P_B Or-1.0
1 R-13.0
5 M SHEET 4 - 1F CAB FRONT 18D_A Or-0.8 D2' D1' SHEET 5 - 40F (69) 19P_A Or-1.0 P2 P1 13P_B Or-1.0
153 SHEET 4 - 1F CAB FRONT 18E_A Or-0.8 E2' E1' 41L_A K-2.0 SHEET 4 - 59F (115) 19R_F Or-0.8 R2 R1
SHEET 4 - 21F CAB REAR 18F_D Or-0.8 F2' F1 ' SHEET 3 - 13F CAB PEDESTAL 19S Or-0.8 S2 S1 13D Or-1.0
SHEET 4 - 1F CAB FRONT 18F_E Or-0.8 G2' G1' 41T_A K-1.0 SHEET 4 - 32F (114) SHEET 2 - 19F (26) 19T_A Or-0.8 T2 T1
SHEET 4 - 21F CAB REAR 18G_F Or-0.8 SHEET 2 - 19F (26) 19T_B Or-0.8 U2 U1 1_Q R-1.0
SHEET 4 - 1F CAB FRONT 18G_G Or-0.8 18F 18F SHEET 4 - 23F CAB ROOF 19U_A Or-1.0 V2 V1 13V Or-1.0
SHEET 5 - 51F (80) 19U_B Or-1.0 W2 W1 1_R R-3.0
SHEET 3 - 13F CAB PEDESTAL 19V Or-0.8
19W Or-1.0 18F 18F
RELAY ENGINE 1.9 OHMS AT 20°C (68°F)
HARNESS HARNESS
277M 277F 1 Y_C R-2.0 A A
0_BL BK-2.0 B B 9 FUSE A TRANSMISSION CONTROL 7.5A
30 30 1 Y_E R-2.0 1 1
87 87 1 Y_D R-2.0 2 2 288 FUSE B FLASHER MODULE 5A
7 87a 87A 31U_X W-1.0 3 3 31U W-1.0 FUSE C RIDE AND PILOT CONTROL 5A
85 85 13C_H OR-1.0 4 4
86 86 1 Y_B R-2.0 A A 19N_B Or-1.0 FUSE D PARKING BRAKE 5A
0_BK BK-2.0 B B
NOTE 5 10
280 12V_B R-5.0 FUSE E GRID HEATER CONTROLLER (NOTE 7) 5A
287 SHEET 6 - 258F (92)
NOTE 7 246M 260M FUSE F ENGINE SHUTDOWN 5A
1_B R-13.0
31C_G OR-1.0 1.9 OHMS AT 20°C (68°F) 6 A 5 4 3 2 1
FUSE G BLOWER SWITCH 15A
12 A 11 10 9 8 7
1Y_A R-8.0 1_Y R-8.0 18 17 A 16 15 14 13 FUSE H BACKUP ALARM 5A
249M
281 40A 283 18F FUSE J FRONT WIPER & WASHER MOTOR 10A
18F 18F 18F 18F 18F
NOTE 7 FUSE K REAR WIPER & WASHER MOTOR 10A
19W_A Or-3.0 SHEET 6 - 259F (91)
1_A R-1.0
19L_B Or-1.0 SHEET 6 - 256F (92)
193 1_E R-62
30 1_F R-8.0 240F 155 225F 19L_A Or-1.0 SHEET 6 - 109M (96) SHEET 2 - TO SPL_D15 19A_N Or-0.8
191 POS 1_NB R-62 227F SHEET 2 - 35F (35) 19A_P Or-0.8
289 87 1_C R-8.0 1_R R-3.0 SHEET 4 - 13F CAB PEDESTAL 19B_A Or-0.8 A2 A1 13P_A Or-1.0
A A 6 SHEET 5 SPL_D24 19C_A Or-1.0 B2 B1
B B 8 135 NEG 1_NA R-62 250F CAB B+ 270F SHEET 3 - 56F (51) 19C_D Or-1.0 C2 C1
86 21C_D W-1.0 156 JUNCTION 1_X R-1.0 SHEET 6 - 269 RADIO SHEET 3 - 55F (52) 19D_A Or-1.0 D2
278 195 239F D1
+ 3°C (55.4 _
OPENS AT 13_ + 5.4°F) 132 BLOCK MEMORY FUSE 1_H R-3.0 SHEET 4 - 59F (115) 19E Or-1.0 E2 E1
85 0_UB Bk-2.0 226F SPL_D16 19F Or-1.0 13R Or-1.0
+ 4.5°C (34.7_
CLOSES AT 1.5_ + 8.1°F) 245F 1
F2 F1
100 A AT 22V 11A 1_K R-3.0 1_G R-3.0 SHEET 5 - 30F (83) 19G Or-2.0 G2 G1
190 SHEET 2 - 53F (35) 19H Or-1.0 H2 H1
1 1Z R-19 1 A B RELAY BOX 284 238F SHEET 5 - 35F (75) 19J_A Or-1.0 J2 J1
NOTE 6 224F 228F
2
285 286 JUNCTION POS 1_NA R-62 1_J R-3.0 SHEET 5 SPL_D23 19K_A Or-1.0 K2 K1
0_ BM Bk-1.0 291 137 BLOCK

30
18F 18F
ENGINE HARNESS 0_ BL Bk-2.0 NOTE 7 NEG 0_NC Bk-62 1_N R-3.0 SHEET 4 - 33F (114)
192 1_DA R-19 237F 30 30
151 0_ BK Bk-2.0 87
1_V R-5.0 SHEET 6 - 255F (92) 87 87 12P_A Or-1.0
11 189 150A 282 87a 87A 0_DC Bk-0.8 SHEET 4 - 204F (102)
1_NC R-62
86 2 28GC_C W-1.0 85 85 0_DF Bk-0.8
0_P Bk-1.0 SHEET 3 - SPL_E9 28GC_B W-1.0 SHEET 5 - 244F (68) 86 86 12K_A Or-1.0
A A 19 19
16 12K_B Or-0.8
0_E Bk-1.0 SHEET 3 - 104 (39) 85 1 0_UC Bk-2.0 0_UA Bk-2.0 B B 20 20 28GC_A W-0.8 49F
REAR ENGINE 279M 276M 276F SPL_G1 1 1
160 0_V Bk-1.0 SHEET 3 - 171 (40) 21C_D W-1.0 11 11 21C_E W-0.8
BLOCK GROUND RELAY HARNESS REAR 1_A R-1.0 21 21 1_P R-0.8
NOTE 7
STUD(–) 13C Or-1.0 CHASSIS HARNESS 31T_A Y-1.0 22 22
23 23
31T Y-0.8
30 30 1_P R-0.8
0_G Bk-1.0 SHEET 5 - 2 (76) 13M Or-1.0
26 26 87 87 13V Or-1.0
SPL_B2 87a 87A 0_DG Bk-0.8 SHEET 4 - 202F (102)
0_F Bk-1.0 SHEET 5 - 3 (78) A B 139F ENGINE HARNESS 21M 21F 85 85 0_DH Bk-0.8
162 NOTE 7 A B 139M DISCONNECT HARNESS 1 133M 86 86 13K_E Or-0.8
0_W Bk-1.0 SHEET 3 - 136 (41) REAR CAB
1
CHASSIS MAIN 58F 13K_C Or-1.0
13M_A Or-1.0
HARNESS HARNESS
13C_E Or-1.0
REAR CHASSIS HARNESS 0_X Bk-1.0 SHEET 5 - 158 (56) 12.7 OHMS 17
AT 20°C (68°F) 3
163
30 30 1_T R-3.0
0_J Bk-1.0 SHEET 4 - 128F REAR HOOD 87 87 13R Or-1.0
262F 87a 87A 0_DF Bk-0.8
164 A A
13K_C Or-1.0
0_D Bk-2.0 SHEET 4 - SPL_E4 85 85 0_DE Bk-0.8
75 OHMS B B 86 86 13K_B Or-1.0 217F 217M
0_BC Bk-1.0 231F 230F 236F 235F RESISTOR 19R_D Or-0.8 C C 13K_A Or-1.0 13K_D Or-0.8 AA
48F SEE NOTE 4
0_U Bk-2.0 11B DIODE
15 13C_B Or-0.8
215F 216F MODULE 30 30
165 0_Q Bk-1.0 SHEET 3 - 87 (53) 2 SPL_D25 87 87 13C_C Or-0.8 SHEET 5 - 140M DIODE
A A 19R_E Or-0.8 87a 87A MODULE
AIR CONDITIONING 0_BJ Bk-1.0 SHEET 5 - 265F AIR CONDITIONING DIODE MODULE 0_BC Bk-1.0 B B 19R_A Or-0.8 SHEET 5 - 1F CAB-FRONT 1_M R-3.0 SHEET 4 - 211F FLASHER 85 85
DIODE HARNESS 268 CC
CHASSIS CIRCUIT BREAKER B 86 86 23C_A W-0.8 SHEET 3 - 13F CAB
290 2.26-2.76K OHMS 14_C LG-0.8 57F PEDESTAL
SPL_D17 19F Or-1.0
AT 20°C (68°F) 1_S R-3.0 58
13C Or-1.0 1 1 13C_A Or-1.0 1 1 13C_D Or-0.8 13C_D Or-0.8
14 LG-1.0 5 5 14_A LG-1.0 2 2 14_B LG-0.8
ENGINE HARNESS 0_BG Bk-1.0 0_BG Bk-1.0 15 15 0_HC Bk-1.0 30 30 0_DAU Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 1_L R-3.0 30 30
152 0_BF Bk-1.0 9 9 0_HA Bk-1.0 23 23 87 87
0_BH Bk-1.0 11 11 0_HB Bk-1.0 15 15 0_DL Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 87a 87A 13P_A Or-1.0
213F IGNITION SWITCH 85 85
SHEET 3 - 138 (43) 0_BE Bk-1.0 SPL_B1
0_BA Bk-1.0 94M 94F 22M 22F 0_DAB Bk-0.8 SHEET 3 - 13F CAB PEDESTAL CIRCUIT 86 86
BREAKER A 21K_A W-0.8
150 SHEET 3 - 117 (44) 0_BD Bk-1.0 ENGINE TRANSMISSION TRANSMISSION CAB MAIN 47F 21C_F W-0.8 SHEET 5 - 140M DIODE
SECONDARY STEERING 214F 12.5 AMP 14
HARNESS HARNESS HARNESS HARNESS 30 30 21C_G W-0.8 MODULE
MODULE HARNESS 0_CD Bk-1.0 SHEET 5 - SPL_C1 87 87 21C_E W-0.8
177 1A_D R-0.8 87a 87A 0_DH Bk-0.8
85 85 0_DJ Bk-0.8
13D Or-1.0 86 86 25T_E LU-0.8
SPL_D21
0_DZ Bk-2.0 SHEET 5 - 29M (85) 63M TIME DELAY MODULE 1A_E R-0.8 SPL_D18
1 DELAY POWER-2-WAY 1
54F
CAB 0_DY Bk-1.0 SHEET 5 - 28M (82) 2 TIME DELAY POWER 2 0_DAS Bk-0.8 SHEET 4 - SPL_D14 12
REAR CHASSIS FRONT ENGINE GROUND SHEET 5 - 35F (75)
3 TIME DELAY MODULE GROUND 3
0_NB Bk-62 218F 0_DAR Bk-1.0 4 RESET SIGNAL 4 37R_C P-0.8 SHEET 3 - 13F CAB
GROUND WELD BLOCK GROUND
STUD (-) 234F JUNCTION 5 IGNITION SWITCH POWER 5 PEDESTAL SHEET 2 - 19F (26) 25T_D LU-0.8
0_NA Bk-62 STUD (-) 6 NONE 6
BLOCK (–) 50G_G Bk-0.8 SHEET 2 - SPL_D7
13K_F Or-0.8
232F 233F 63M SPL_D22
0_DB Bk-0.8 SHEET 3 - 89M (54) 18
1 REAR
REAR CHASSIS 0_Y Bk-13.0 0_Y Bk-13.0 CHASSIS 219F 0_DBA Bk-0.8
HARNESS 167 HARNESS
161
REAR CHASSIS 0_DX Bk-0.8 SHEET 4 - 13F CAB PEDESTAL
GROUND WELD SHEET 3 - 75 (45) 1A_B R-0.8 5
1A_C R-0.8
13K_G Or-0.8
SHEET 5 - SPL_A1 0_AJ Bk-2.0 0_DA Bk-0.8 SHEET 5 - 203F (89) 1 BAT
STUD (-) 0_CE Bk-1.0 SHEET 5 - 90M (66) FRONT 3 IGN
CHASSIS 220F 0_DAT Bk-0.8 SHEET 4 - SPL_D14
PREHEATER 2 ST 13
176 HARNESS
SHEET 5 - SPL_A2 0_AK Bk-1.0 145 LIGHT
4 ACC
2 6
0_DQ Bk-0.8 SHEET 2 - 19F (26)
69
CAB 0_DP Bk-0.8 SHEET 2 - 19F (26) 13M 13F
UPPER PEDESTAL REAR CHASSIS HARNESS 1 2 3 4 5 6
CAB GROUND REAR CHASSIS SHEET 6 - 254F (92) 0_RA Bk-5.0
GROUND GROUND WELD 221F 0_DAV Bk-0.8 SHEET 2 - 108F (28) A B C D E F 97 12K_C Or-0.8 63 63 12K_B Or-0.8
WELD STUD (-) GROUND WELD 251F 21K W-0.8 64 64 21K_A W-0.8
SCREW (-) BRAIDED_STRAP_2 BRAIDED STRAP STUD (-) STUD (-) 0_ND Bk-62 SHEET 5 - 242F (68) CONVERTER 13K Or-0.8 56 56
HARNESS 0_DAD Bk-1.0 SHEET 5 SPL_D13 182 1A_A R-0.8 62 62
CAB STUD REAR 243F 1 28C W-0.8 52 52
CHASSIS SHEET 6 - 253F (93) 0_RB Bk-3.0 0_DJ Bk-0.8 25T_C LU-0.8
1 3 4 92 46 46
STUD 222F 0_DAC Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 1 25T_B LU-0.8
252F
25T_A LU-0.8 SHEET 2 - 70 (27)
FRONT CHASSIS 18L_D Bk-0.8 9 9 18L_C Or-0.8
LOWER PEDESTAL CAB GROUND REAR CHASSIS 31Y_B Y-0.8 11 11 0_DBA Bk-0.8
GROUND 0_DAX Bk-0.8 SHEET 5 - 140M DIODE MODULE GROUND WELD CIGAR 0_DS Bk-1.0 SHEET 4 - 24M CAB ROOF
WELD STUD (-) GROUND WELD
SCREW (-) 0_DU Bk-1.0 SHEET 4 - 23F CAB ROOF STUD (-) SHEET 6 - 259F (91) 0_S Bk-3.0 LIGHTER 0_DR Bk-1.0 SHEET 4 - 24M CAB ROOF PEDESTAL CAB MAIN
STUD (-) 0_AH Bk-5.0 GRID HEATER CONTROLLER 201
HARNESS HARNESS HARNESS
0_DV Bk-0.8 SHEET 5 - 13F CAB PEDESTAL 144 143 261F 223F 0_DT Bk-1.0 SHEET 4 - 23F CAB ROOF 1 INDICATOR LIGHT 1
206F
2 NONE 2
2 5 3 FEED BACK OF GH 3 28GP W-1.0
4 ALTERNATOR D+ 4 14_C LG-0.8 SPL_D26
CONVERTER 5 CRANKING POWER 5 21C_G W-0.8
0_PD Bk-1.0 SHEET 6 - 109M (92) 11C 6 GRID HEATER ON SIGNAL 6 28GC W-0.8
HARNESS
247F 7 SWITCHED POWER 7 19E Or-1.0
8 GROUND 8 0_DBB Bk-0.8
202 9 NONE 9
10 TEMP SENDER SIGNAL 10
SHEET 1 - POWER CONTROL AND DISTRIBUTION

COMPONENTS
1. Batteries 11B. Grid Heater Temperature Sensor (Option) 22. Turbine Speed Sensor 34. FNR Switch 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 114. Five Position Rotary Lamp
2. Master Disconnect Switch 11C. Grid Heater Controller (Option) 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch
3. Engine Fuel Solenoid 12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) Switch 115. High/Low Beam Relay -
4. Alternator 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 105. Flasher Module Number 13
5. Starter Motor 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 116. License Plate Lamp
6. Starting Relay 15. Ignition Relay - Number 2 27. Transmission Shifter 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 107. Right-Hand Rear Combination Lamp 117. Dome Lamp
7. Fuel Filter Heater Relay - Number 16 16. Accessory Relay - Number 3 28. Diagnostic Connector 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 108. Left-Hand Front Combination Lamp 118. Courtesy Lamp
8. Fuel Filter Heater Switch 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 109. Right-Hand Front Combination Lamp
9. First Fuel Filter Heater 18. Time Delay Module 30. Transmission Auto Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 110. Left-Hand Rear Work Lamp
10. Second Fuel Filter Heater 19. Output Speed Sensor 31. Declutch Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 111. Right-Hand Rear Work Lamp
11. Grid Heater Relay - Number 15 (Option) 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 112. Left-Hand Front Work Lamp
11A. Grid Heater (Option) 21. Intermediate Speed Sensor 33. Transmission Enable Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 6 113. Right-Hand Front Work Lamp
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
1. WIRE NUMBER 10
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. 64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER, 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
9 R
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 - 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET 5. Used only on 621D.
21M 21F
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15 6. On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE, 7. Used only when grid heater option installed.
LG = LIGHT GREEN 1. SPLICE IDENTIFICATION 6. FEMALE CONNECTOR 11. SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION 9. RESISTOR
R = RED Y = YELLOW
2. CIRCUIT CROSSING (NOT 7. CONNECTOR IDENTIFICATION 12. CONNECTION POINT ON SCHEMATIC 3 6 9 12 10. DIODE 3 3 3 ELECTRICAL SCHEMATIC P.I.N. JEE0135501 AND ABOVE
CONNECTED) 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED)
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION 3. CIRCUIT CONNECTED 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER
A 11.
12A.
LIGHT EMITTING DIODE
MOMENTARY CONTACT T 621D Z-BAR, 621D XR, and 621D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49310
BC02M130
19A_E Or-0.8
19A_C Or-0.8
P/N 409725A1 10 10 10 0_DAE Bk-1.0 SHEET 5 - SPL_D13
7 7 7 0_DAP Bk-1.0 SHEET 4 - 42F (99)
8 8 8 49_G S-0.8 SHEET 4 - SPL_D8
2.5K ohm 1 1 49_R S-1.0 SHEET 4 - 42F (99)
resistor 6 6 0_DAW Bk-1.0 SHEET 4 - 42F (99)
33 5 33 5
4 4 32J_C Y-0.8 10 0_DW Bk-0.8 SHEET 5 - 45F (77)
Used in place of 9 9 9 32J_B Y-0.8 7 7
transmission enable switch 3 3 3 26E LU-0.8 8 8 49_L S-0.8 SHEET 5 - 45F (77)
before Serial Number JEE0133334 2 2 2 19A_D Or-0.8 9
19A_E Or-0.8 6 49_T S-1.0 SHEET 4 - 42F (99)
199F 199F 36 5
1 1 35R_C Y-0.8
4
P/N 409726A1 JOYSTICK CONTROLLER SINGLE AXIS CONTROLLER 32J_A Y-0.8 3 3 35R_D Y-0.8
5 5 19A_F Or-0.8 5 5 32J_B Y-0.8 2 2 35A_F Y-0.8 AA NOTE 1
7 7
6 R 6 8 8 6 6 209M 209F
Or-0.8 1 N 1 5 5 19A_B Or-0.8 1 1 19A_C Or-0.8 118F 35A_E Y-0.8
34 2 34 N Y 2 4 4 26J LU-0.8 2 2 26F_B LU-0.8
4 K 4 9 4 4 26R_B LU-0.8
3
F
P 3 34 6 6 26F_A LU-0.8 3 3 26N_B LU-0.8
Used in place of FNR switch 1 1 26R_A LU-0.8 19H Or-1.0 SHEET 1 - 18F FUSE BLOCK
before Serial Number JEE0133334 10 197M 197F
3 3 26N_A LU-0.8 FNR CAB MAIN 35A_E Y-0.8
2 2 30 30
HARNESS HARNESS
87 87 35A_D Y-0.8 SHEET 4 - 21F CAB REAR
198
35 87a 87A
25 SPL_D12 85 85 35C Y-0.8
25S_A LU-0.8 25S_A LU-0.8 25S_C LU-0.8 86 86
25S_B LU-0.8 19A_P Or-0.8 SHEET 1 - 18F FUSE BLOCK
53F
CLUTCH FORWARD REVERSE NEUTRAL 26
102 TRANSMISSION CONTROL 19F 19F
NUMBER 1 2 3 4 1 2 3 1 2 3 4 19F TECM 19F TECM
1 TRANSMISSION SOLENOID VALVE Y1 K4 1 25K LU-0.8 25K LU-0.8 16 16 25K_A LU-0.8 56 56 TRANSMISSION SOLENOID VALVE Y1 1 DIAGNOSTIC TECM GROUND 1 0_DP Bk-0.8 SHEET 1 - 221F GROUND CAB
2 TRANSMISSION SOLENOID VALVE Y2 KR 2 25L LU-0.8 25L LU-0.8 17 17 25L_A LU-0.8 10 10 TRANSMISSION SOLENOID VALVE Y2 2 DIAGNOSTIC TECM GROUND 2 0_DQ Bk-0.8 SHEET 1 - 221F GROUND CAB
3 TRANSMISSION SOLENOID VALVE Y3 K1 3 25M LU-0.8 25M LU-0.8 18 18 25M_A LU-0.8 32 32 TRANSMISSION SOLENOID VALVE Y3 5 TRANSMISSION ENABLE LAMP SIGNAL 5 32J_C Y-0.8
4 TRANSMISSION SOLENOID VALVE Y4 K3 4 25N LU-0.8 25N LU-0.8 19 19 25N_A LU-0.8 55 55 TRANSMISSION SOLENOID VALVE Y4 6 NONE 6
5 TRANSMISSION SOLENOID VALVE Y5 KV 5 25P LU-0.8 25P LU-0.8 20 20 25P_A LU-0.8 9 9 TRANSMISSION SOLENOID VALVE Y5 7 BACKUP ALARM PULL-DOWN 7 35C Y-0.8
6 TRANSMISSION SOLENOID VALVE Y6 K2 6 25J LU-0.8 25J LU-0.8 21 21 25J_A LU-0.8 51 51 TRANSMISSION SOLENOID VALVE Y6 8 RIDE CONTROL SWITCHED POWER VPS2 8 58H_B W-0.8 SHEET 5 - 50F (72)
7 OUTPUT SWITCHED POWER VPSI 7 25S LU-0.8 25S LU-0.8 22 22 39 39 VALVE BODY TEMPERATURE SENDER 11 NONE 11 0_DAV Bk-0.8 SHEET 1 - 221F GROUND CAB
8 VALVE BODY TEMPERATURE SIGNAL 8 36T P-0.8 36T P-0.8 5 5 36T_A P-0.8 17 17 TRANSMISSION FILTER MAINTENANCE SWITCH 12 OUTPUT SWITCHED POWER VPS1 12
9 VALVE BODY TEMPERATURE RETURN 9 36R_C P-0.8 32F Y-1.0 31 31 32F_A Y-0.8 4 4 OUTPUT SPEED SENSOR GROUND 13 OUTPUT SWITCHED POWER VPS2 13 3
10 NONE 10 0_HE Bk-1.0 28 28 0_DN Bk-0.8 62 62 OUTPUT SPEED SIGNAL 14 NONE 14 5 28
11 NONE 11 25D LU-1.0 10 10 25D_A LU-0.8 46 46 TEMPERATURE/FILTER RETURN 15 DIAGNOSTIC SIGNAL 15 37D_A P-0.8 37D_A P-0.8 2 10
12 NONE 12 19A Or-1.0 29 29 19A_M Or-0.8 49 49 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 16 NONE 16 6 7 7 0_DAM Bk-1.0 SHEET 5 - 44F (71) 174
13 NONE 13 24 24 19 19 ENGINE SPEED SIGNAL 18 DIAGNOSTIC SIGNAL 18 37E P-0.8 37E P-0.8 4 8 8 49_Q S-1.0 SHEET 5 - 44F (71) SHEET 4 - SPL_J1 0_JB Bk-1.0
14 NONE 14 36R_A P-1.0 12 12 36R_E P-0.8 3 3 SPEED SENSOR GROUND 20 FNR FORWARD SIGNAL 20 26F_B LU-0.8 1 9 37
15 NONE 15 36G P-1.0 13 13 36G_A P-1.0 42 42 INTERMEDIATE SPEED 21 PARKING BRAKE RELAY OUT 21 52P_A W-0.8 SHEET 3 - 55F (52) 6
35R_A Y-1.0
108F BB
16 NONE 16 14 14 41 41 TURBINE SPEED SIGNAL 22 TRANSMISSION KICKDOWN SIGNAL 22 25Y_B LU-0.8 5
✱ MODULATED AND CURRENT CONTROLLED 102 25A W-0.8 7 7 25A_A LU-0.8 23 TIME DELAY FUSED POWER 23 19T_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 4 128F 128M 175
0_DM Bk-0.8
19A_D Or-0.8
0_HD Bk-1.0 11 11 24 NONE 24 1
REAR HOOD
25C W-0.8 9 9 25C_A LU-0.8 25 CONTROLLER AREA NETWORK H 25 50H_A Y-0.5 SHEET 3 - 13F CAB PEDESTAL 3 3 25H LU-0.8 26 26
25B W-0.8 8 8 25B_A LU-0.8 26 CONTROLLER AREA NETWORK L 26 50L_B G-0.5 30 2 2 19A_Q Or-0.8 23 23 CHASSIS HARNESS
27 CONTROLLER AREA NETWORK L 27 50L_C G-0.5 50L_A G-0.5 SHEET 3 - 13F CAB 22 22 HARNESS
22M 22F 41F
28 NONE 28 SPL_D5 PEDESTAL 20 20
TRANSMISSION CAB MAIN 29 TRANSMISSION AUTO SIGNAL 29 25H LU-0.8 19 19
11 32F Y-1.0 HARNESS HARNESS 30 FNR REVERSE SIGNAL 30 26R_B LU-0.8 17 17
23 22 36R_B P-1.0 36R_A P-1.0 31 TRANSMISSION ENABLE SIGNAL 31 26E LU-0.8 2 2
510 OHMS 31 SPL_H1 33 NONE 33
SPL_D15 6 6 35R_B Y-1.0
34 NONE 34 19A_L Or-0.8 19A_T Or-0.8 30 30 19A_A Or-1.0 AA
35 NONE 35 31 31 25G LU-1.0 BB 32
36 NONE 36 SHEET 3 - 13F CAB PEDESTAL 19A_S Or-0.8
4
37 NONE 37 21F 21M
22 36R_D P-1.0 38 NONE SHEET 1 - 18F FUSE BLOCK 19A_N Or-0.8 Normally Closed
24 11 36G P-1.0
38
CAB REAR CHASSIS Opens at 24.1 bar (350 psi)
40 NONE 40
MAIN HARNESS
19A_M Or-0.8
142 43 FORWARD SIGNAL 43 25F_A LU-0.8
44 FNR NEUTRAL SIGNAL 44 26N_B LU-0.8 HARNESS
3521 ohms at 20°C (68°F)
45 CAB SWITCHED POWER 45 19A_K Or-0.8 19A_K Or-0.8
11 0_HE Bk-1.0 47 NONE 47
19 22 25D LU-1.0 48 NONE 48
33 19A Or-1.0 50 NONE 50 10
100 52 NONE 52 7 7 0_DAK Bk-1.0 SHEET 5 - 36F (54)
53 NONE 53 8 8 49_N S-1.0 SHEET 5 - 36F (54)
54 NONE 54 9
11 25A W-0.8 57 RIDE CONTROL RELAY SINK 0_DD Bk-0.8 SHEET 5 - 50F (72)
20 22 0_HF Bk-0.8 SPL_H2
57
31
6
58 NONE 58 5
101 59 NONE 59 1 1 25G_A LU-0.8
60 NONE 60 4 25G_B LU-0.8
61 NONE 61 3 3
63 1ST AND 4TH GEAR SIGNAL 63 25Z_A LU-0.8 2 2 19A_R Or-0.8
11 0_HG Bk-0.8 64 REVERSE SIGNAL 64 25R_A LU-0.8
21 22 25C W-0.8 65 3RD AND 4TH GEAR SIGNAL 65 25W_A LU-0.8 38F
95 66 DECLUTCH SWITCH 66 25G_B LU-0.8
67 NEUTRAL SIGNAL 67 25T_D LU-0.8 SHEET 1 - SPL_D18
68 TIME DELAY FUSED POWER 68 19T_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
22 0_HH Bk-0.8 29
22 11 25B W-0.8
96
2 1
2 1 20M
SPL_D11
25Y_C LU-0.8 19A_U Or-0.8
183
FORWARD REVERSE NEUTRAL Bk A A
183 TRANSMISSION SHIFTER G B B 25W LU-0.8
1 2 3 4 1 2 3 4 1 2 3 4 U C C 25Z LU-0.8 25W LU-0.8 48 48 25W_A LU-0.8
A NONE D D 25Y LU-0.8 25Z LU-0.8 49 49 25Z_A LU-0.8
B THIRD AND FOURTH GEAR SIGNAL 25Y LU-0.8 50 50 25Y_A LU-0.8
C FIRST AND FOURTH GEAR SIGNAL 70 24 24
D TRANSMISSION KICKDOWN SIGNAL R A A 19A_H Or-0.8 SHEET 3 - 72 (46) 47 47
✱ INDICATES HIGH (24 VOLTS) Y B B 25F LU-0.8 25F LU-0.8 44 44 25F_A LU-0.8
K C C 25R LU-0.8 25R LU-0.8 45 45 25R_A LU-0.8
S D D 25T_A LU-0.8 SHEET 1 - 92 (11) 27 27
FORWARD REVERSE NEUTRAL 33 33
70 TRANSMISSION SHIFTER
1 2 3 4 1 2 3 4 1 2 3 4 SPL_K2 37 37 SPL_D6 50G_E Bk-0.5 SPL_D7
A TRANSMISSION CONTROL POWER 27 50G_C R-0.5 50G_A Bk-0.8 34 34 50G_D Bk-0.8 50G_G Bk-0.8 SHEET 1 - 219F GROUND CAB
B FORWARD SIGNAL 50G_F R-0.5
C REVERSE SIGNAL SPL_K3 50G_B Bk-0.5 13M 13F
D NEUTRAL SIGNAL PEDESTAL CAB MAIN LOCATED NEAR TECM
✱ INDICATES HIGH (24 VOLTS) HARNESS HARNESS CONNECTOR 19F
LOCATED NEAR INSTRUMENT
CLUSTER CONNECTOR 76
SHEET 2 - TRANSMISSION CONTROLS

COMPONENTS
1 5 6 1 4 7 10 1 4 1 4 1
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0
B B 2 2
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 93M 93F 7 9
3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 XXXX XXXX
11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
15
1.
2.
6.
7.
FEMALE CONNECTOR
11.
12.
3 6 9 12 10. DIODE 3 3 3

3. CIRCUIT CONNECTED 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED) A 11. LIGHT EMITTING DIODE 621D Z-BAR, 621D XR, and 621D XT WHEEL LOADERS
BC02009
19A_E Or-0.8
19A_C Or-0.8
10 10 0_DAE Bk-1.0 SHEET 5 - SPL_D13
7 7 0_DAP Bk-1.0 SHEET 4 - 42F (99)
8 8 49_G S-0.8 SHEET 4 - SPL_D8
1 49_R S-1.0 SHEET 4 - 42F (99)
6 0_DAW Bk-1.0 SHEET 4 - 42F (99)
33 5
4 32J_C Y-0.8 10 0_DW Bk-0.8 SHEET 5 - 45F (77)
9 9 32J_B Y-0.8 7 7
3 3 26E LU-0.8 8 8 49_L S-0.8 SHEET 5 - 45F (77)
2 2 19A_D Or-0.8 9
19A_E Or-0.8 6 49_T S-1.0 SHEET 4 - 42F (99)
199F 36 5
1 1 35R_C Y-0.8
4
JOYSTICK CONTROLLER SINGLE AXIS CONTROLLER 32J_A Y-0.8 3 3 35R_D Y-0.8
5 19A_F Or-0.8 5 5 32J_B Y-0.8 2 2 35A_F Y-0.8 AA NOTE 1
7 7
R 6 8 8 6 6 209M 209F
N 1 5 5 19A_B Or-0.8 1 1 19A_C Or-0.8 118F 35A_E Y-0.8
34 N Y 2 4 4 26J LU-0.8 2 2 26F_B LU-0.8
K 4 9 4 4 26R_B LU-0.8
F
P 3 34 6 6 26F_A LU-0.8 3 3 26N_B LU-0.8
1 1 26R_A LU-0.8 19H Or-1.0 SHEET 1 - 18F FUSE BLOCK
10 197M 197F
3 3 26N_A LU-0.8 FNR CAB MAIN 35A_E Y-0.8
2 2 30 30
HARNESS HARNESS
87 87 35A_D Y-0.8 SHEET 4 - 21F CAB REAR
198
35 87a 87A
25 SPL_D12 85 85 35C Y-0.8
25S_A LU-0.8 25S_A LU-0.8 25S_C LU-0.8 86 86
25S_B LU-0.8 19A_P Or-0.8 SHEET 1 - 18F FUSE BLOCK
53F
CLUTCH FORWARD REVERSE NEUTRAL 26
102 TRANSMISSION CONTROL 19F 19F
NUMBER 1 2 3 4 1 2 3 1 2 3 4 19F TECM 19F TECM
1 TRANSMISSION SOLENOID VALVE Y1 K4 1 25K LU-0.8 25K LU-0.8 16 16 25K_A LU-0.8 56 56 TRANSMISSION SOLENOID VALVE Y1 1 DIAGNOSTIC TECM GROUND 1 0_DP Bk-0.8 SHEET 1 - 221F GROUND CAB
2 TRANSMISSION SOLENOID VALVE Y2 KR 2 25L LU-0.8 25L LU-0.8 17 17 25L_A LU-0.8 10 10 TRANSMISSION SOLENOID VALVE Y2 2 DIAGNOSTIC TECM GROUND 2 0_DQ Bk-0.8 SHEET 1 - 221F GROUND CAB
3 TRANSMISSION SOLENOID VALVE Y3 K1 3 25M LU-0.8 25M LU-0.8 18 18 25M_A LU-0.8 32 32 TRANSMISSION SOLENOID VALVE Y3 5 TRANSMISSION ENABLE LAMP SIGNAL 5 32J_C Y-0.8
4 TRANSMISSION SOLENOID VALVE Y4 K3 4 25N LU-0.8 25N LU-0.8 19 19 25N_A LU-0.8 55 55 TRANSMISSION SOLENOID VALVE Y4 6 NONE 6
5 TRANSMISSION SOLENOID VALVE Y5 KV 5 25P LU-0.8 25P LU-0.8 20 20 25P_A LU-0.8 9 9 TRANSMISSION SOLENOID VALVE Y5 7 BACKUP ALARM PULL-DOWN 7 35C Y-0.8
6 TRANSMISSION SOLENOID VALVE Y6 K2 6 25J LU-0.8 25J LU-0.8 21 21 25J_A LU-0.8 51 51 TRANSMISSION SOLENOID VALVE Y6 8 RIDE CONTROL SWITCHED POWER VPS2 8 58H_B W-0.8 SHEET 5 - 50F (72)
7 OUTPUT SWITCHED POWER VPSI 7 25S LU-0.8 25S LU-0.8 22 22 39 39 VALVE BODY TEMPERATURE SENDER 11 NONE 11 0_DAV Bk-0.8 SHEET 1 - 221F GROUND CAB
8 VALVE BODY TEMPERATURE SIGNAL 8 36T P-0.8 36T P-0.8 5 5 36T_A P-0.8 17 17 TRANSMISSION FILTER MAINTENANCE SWITCH 12 OUTPUT SWITCHED POWER VPS1 12
9 VALVE BODY TEMPERATURE RETURN 9 36R_C P-0.8 32F Y-1.0 31 31 32F_A Y-0.8 4 4 OUTPUT SPEED SENSOR GROUND 13 OUTPUT SWITCHED POWER VPS2 13 3
10 NONE 10 0_HE Bk-1.0 28 28 0_DN Bk-0.8 62 62 OUTPUT SPEED SIGNAL 14 NONE 14 5 28
11 NONE 11 25D LU-1.0 10 10 25D_A LU-0.8 46 46 TEMPERATURE/FILTER RETURN 15 DIAGNOSTIC SIGNAL 15 37D_A P-0.8 37D_A P-0.8 2 10
12 NONE 12 19A Or-1.0 29 29 19A_M Or-0.8 49 49 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 16 NONE 16 6 7 7 0_DAM Bk-1.0 SHEET 5 - 44F (71) 174
13 NONE 13 24 24 19 19 ENGINE SPEED SIGNAL 18 DIAGNOSTIC SIGNAL 18 37E P-0.8 37E P-0.8 4 8 8 49_Q S-1.0 SHEET 5 - 44F (71) SHEET 4 - SPL_J1 0_JB Bk-1.0
14 NONE 14 36R_A P-1.0 12 12 36R_E P-0.8 3 3 SPEED SENSOR GROUND 20 FNR FORWARD SIGNAL 20 26F_B LU-0.8 1 9 37
15 NONE 15 36G P-1.0 13 13 36G_A P-1.0 42 42 INTERMEDIATE SPEED 21 PARKING BRAKE RELAY OUT 21 52P_A W-0.8 SHEET 3 - 55F (52) 6
35R_A Y-1.0
108F BB
16 NONE 16 14 14 41 41 TURBINE SPEED SIGNAL 22 TRANSMISSION KICKDOWN SIGNAL 22 25Y_B LU-0.8 5
Q MODULATED AND CURRENT CONTROLLED 102 25A W-0.8 7 7 25A_A LU-0.8 23 TIME DELAY FUSED POWER 23 19T_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 4 128F 128M 175
0_DM Bk-0.8
19A_D Or-0.8
0_HD Bk-1.0 11 11 24 NONE 24 1
REAR HOOD
25C W-0.8 9 9 25C_A LU-0.8 25 CONTROLLER AREA NETWORK H 25 50H_A Y-0.5 SHEET 3 - 13F CAB PEDESTAL 3 3 25H LU-0.8 26 26
25B W-0.8 8 8 25B_A LU-0.8 26 CONTROLLER AREA NETWORK L 26 50L_B G-0.5 30 2 2 19A_Q Or-0.8 23 23 CHASSIS HARNESS
27 CONTROLLER AREA NETWORK L 27 50L_C G-0.5 50L_A G-0.5 SHEET 3 - 13F CAB 22 22 HARNESS
22M 22F 41F
28 NONE 28 SPL_D5 PEDESTAL 20 20
TRANSMISSION CAB MAIN 29 TRANSMISSION AUTO SIGNAL 29 25H LU-0.8 19 19
11 32F Y-1.0 HARNESS HARNESS 30 FNR REVERSE SIGNAL 30 26R_B LU-0.8 17 17
23 22 36R_B P-1.0 36R_A P-1.0 31 TRANSMISSION ENABLE SIGNAL 31 26E LU-0.8 2 2
510 OHMS 31 SPL_H1 33 NONE 33
SPL_D15 6 6 35R_B Y-1.0
34 NONE 34 19A_L Or-0.8 19A_T Or-0.8 30 30 19A_A Or-1.0 AA
35 NONE 35 31 31 25G LU-1.0 BB 32
36 NONE 36 SHEET 3 - 13F CAB PEDESTAL 19A_S Or-0.8
4
37 NONE 37 21F 21M
22 36R_D P-1.0 38 NONE SHEET 1 - 18F FUSE BLOCK 19A_N Or-0.8 Normally Closed
24 11 36G P-1.0
38
CAB REAR CHASSIS Opens at 24.1 bar (350 psi)
40 NONE 40
MAIN HARNESS
19A_M Or-0.8
142 43 FORWARD SIGNAL 43 25F_A LU-0.8
44 FNR NEUTRAL SIGNAL 44 26N_B LU-0.8 HARNESS
3521 ohms at 20°C (68°F)
45 CAB SWITCHED POWER 45 19A_K Or-0.8 19A_K Or-0.8
11 0_HE Bk-1.0 47 NONE 47
19 22 25D LU-1.0 48 NONE 48
33 19A Or-1.0 50 NONE 50 10
100 52 NONE 52 7 7 0_DAK Bk-1.0 SHEET 5 - 36F (54)
53 NONE 53 8 8 49_N S-1.0 SHEET 5 - 36F (54)
54 NONE 54 9
11 25A W-0.8 57 RIDE CONTROL RELAY SINK 0_DD Bk-0.8 SHEET 5 - 50F (72)
20 22 0_HF Bk-0.8 SPL_H2
57
31
6
58 NONE 58 5
101 59 NONE 59 1 1 25G_A LU-0.8
60 NONE 60 4 25G_B LU-0.8
61 NONE 61 3 3
63 1ST AND 4TH GEAR SIGNAL 63 25Z_A LU-0.8 2 2 19A_R Or-0.8
22 0_HG Bk-0.8 64 REVERSE SIGNAL 64 25R_A LU-0.8
21 11 25C W-0.8 65 3RD AND 4TH GEAR SIGNAL 65 25W_A LU-0.8 38F
95 66 DECLUTCH SWITCH 66 25G_B LU-0.8
67 NEUTRAL SIGNAL 67 25T_D LU-0.8 SHEET 1 - SPL_D18
68 TIME DELAY FUSED POWER 68 19T_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
22 0_HH Bk-0.8 29
22 11 25B W-0.8
96
2 1
2 1 20M
SPL_D11
25Y_C LU-0.8 19A_U Or-0.8
183
FORWARD REVERSE NEUTRAL Bk A A
183 TRANSMISSION SHIFTER G B B 25W LU-0.8
1 2 3 4 1 2 3 4 1 2 3 4 U C C 25Z LU-0.8 25W LU-0.8 48 48 25W_A LU-0.8
A NONE D D 25Y LU-0.8 25Z LU-0.8 49 49 25Z_A LU-0.8
B THIRD AND FOURTH GEAR SIGNAL 25Y LU-0.8 50 50 25Y_A LU-0.8
C FIRST AND FOURTH GEAR SIGNAL 70 24 24
D TRANSMISSION KICKDOWN SIGNAL R A A 19A_H Or-0.8 SHEET 3 - 72 (46) 47 47
Q INDICATES HIGH (24 VOLTS) Y B B 25F LU-0.8 25F LU-0.8 44 44 25F_A LU-0.8
K C C 25R LU-0.8 25R LU-0.8 45 45 25R_A LU-0.8
S D D 25T_A LU-0.8 SHEET 1 - 92 27 27
FORWARD REVERSE NEUTRAL 33 33
70 TRANSMISSION SHIFTER
1 2 3 4 1 2 3 4 1 2 3 4 SPL_K2 37 37 SPL_D6 50G_E Bk-0.5 SPL_D7
A TRANSMISSION CONTROL POWER 27 50G_C R-0.5 50G_A Bk-0.8 34 34 50G_D Bk-0.8 50G_G Bk-0.8 SHEET 1 - 219F GROUND CAB
B FORWARD SIGNAL 50G_F R-0.5
C REVERSE SIGNAL SPL_K3 50G_B Bk-0.5 13M 13F
D NEUTRAL SIGNAL PEDESTAL CAB MAIN LOCATED NEAR TECM
Q INDICATES HIGH (24 VOLTS) HARNESS HARNESS CONNECTOR 19F
LOCATED NEAR INSTRUMENT
CLUSTER CONNECTOR 76
SHEET 2 - TRANSMISSION CONTROLS

COMPONENTS
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. WIRE NUMBER 10
0_GA Bk-2.0 B B 2 2
9 R
21M 21F
R = RED Y = YELLOW
A 11.
12A.
BC02M131
Normally Open
Closes at 62 bar (900 psi)
AA 33R_A Y-1.0
57 BB 0_L Bk-1.0
157
Normally Open
AA 33R_B Y-1.0 SPL_E10

57 BB 0_M Bk-1.0
86
SPL_E9
SHEET 1 - 160 ENGINE GROUND 0_P Bk-1.0

Normally Closed
Opens at 117.2 bar (1700 psi)
BB 0_N Bk-1.0 33R_C Y-1.0 15 15 33R_D Y-0.8
38 AA 33P Y-1.0 33P Y-1.0 4 4 33P_A Y-0.8
88 31D Y-1.0 3 3 31D_A Y-0.8
36H P-1.0 13 13 36H_A P-0.8
31D_C Y-0.8 AA 36F P-1.0 16 16 36F_A P-0.8
0_VA Y-0.8 BB 0_V Bk-1.0 SHEET 1 - 160 ENGINE GROUND 31H Y-1.0 14 14 31H_A Y-0.8
274F 104 AA 36H P-1.0 52P W-1.0 18 18 52P_B W-0.8
41 BB 0_W Bk-1.0 SHEET 1 - 162 ENGINE GROUND
21M 21F
136
36F P-1.0 REAR CAB
3521 ohms at 20°C (68°F)
141 CHASSIS MAIN
S HARNESS HARNESS
40 G 1 0_E Bk-1.0 SHEET 1 - 160 ENGINE GROUND

275M
A B 171
A B 31H Y-1.0
33 to 240 ohms
SHEET 1 - 165 ENGINE GROUND 0_Q Bk-1.0 52P W-1.0
39 170 2 1 87
2 1
Normally Open
42 Closes at 2.8 bar (40 psi) 53
40.3 ohms at 20°C (68°F)

47
76 INSTRUMENT CLUSTER
1 CLUSTER MAIN FUSED POWER 1 19V_A Or-0.8 19V_A Or-0.8 1 1 19V Or-0.8 SHEET 1 - 18F FUSE BLOCK 19D_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
2 INSTRUMENT CLUSTER FUSED DELAYED POWER 2 19S_B Or-0.8 29 29 30 30 19D_B Or-1.0
3 LOW BRAKE PRESSURE WARNING 3 33P_B Y-0.8 33P_B Y-0.8 3 3 33P_A Y-0.8 87 87 52P_B W-0.8
4 COOLANT LEVEL SIGNAL 4 31D_B Y-0.8 31D_B Y-0.8 4 4 31D_A Y-0.8 52 87a 87A 52P_A W-0.8 SHEET 2 - 19F (26)
5 SECONDARY STEERING LOW PRESSURE SIGNAL 5 35X_F Y-0.8 35X_F Y-0.8 5 5 35X_E Y-0.8 SHEET 5 - 1F CAB FRONT CHASSIS 85 85 52C_A W-0.8
6 AIR FILTER RESTRICTION SWITCH SIGNAL 6 31F_C Y-0.8 31F_C Y-0.8 6 6 31F_B Y-0.8 86 86
7 HYDRAULIC FILTER RESTRICTION SWITCH SIGNAL 7 31H_B Y-0.8 31H_B Y-0.8 7 7 31H_A Y-0.8 55F
8 ANALOG GROUND 8 0_KP Bk-0.8 0_KP Bk-0.8 8 8 0_DAU Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
9 PARKING BRAKE SIGNAL 9 33U Y-0.8 9 9
10 AIR CONDITIONING TELLTALE 10 61R_G Or-0.8 61R_G Or-0.8 10 10 61R_F Or-0.8 SHEET 5 - SPL_D1
11 NONE 11 11 11
12 WORK LAMP TELLTALE SIGNAL 12 42R_A Y-0.8 42R_A Y-0.8 12 12 42R_C DU-0.8 SHEET 4 - 32F (114)
13 BEACON TELLTALE 13 46_B K-0.8 46_B K-0.8 13 13 46_A K-0.8 SHEET 4 - 23F CAB ROOF
14 NONE 14 14 14
15 HIGH BEAM TELLTALE 15 18C_C Or-0.8 18C_C Or-0.8 15 15 18C_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
16 LEFT TURN SIGNAL 16 45L_F N-0.8 45L_F N-0.8 16 16 45L_E N-0.8 SHEET 4 - SPL_D10
17 RIGHT TURN SIGNAL 17 45R_F N-0.8 45R_F N-0.8 17 17 45R_C N-0.8 SHEET 4 - SPL_D20
18 ENGINE COOLANT TEMPERATURE SIGNAL 18 36C_C P-0.8 36C_C P-0.8 18 18 36C_B P-0.8
19 FUEL LEVEL SIGNAL 19 36F_B P-0.8 36F_B P-0.8 19 19 36F_A P-0.8 19C_D Or-1.0 SHEET 1 - 18F FUSE BLOCK
20 HYDRAULIC OIL TEMPERATURE SIGNAL 20 36H_B P-0.8 36H_B P-0.8 20 20 36H_A P-0.8 19C_E Or-1.0
21 CONTROLLER AREA NETWORK T 21 50T Bk-0.8 21 21 30 30 53P_C W-0.8 SHEET 5 - 1F CAB FRONT CHASSIS
22 ENGINE OIL PRESSURE SIGNAL 22 36P_C P-0.8 36P_C P-0.8 22 22 36P_B P-0.8 87 87 53P_B W-0.8 SHEET 5 - 36F (59)
23 ENGINE SHUTDOWN SIGNAL 23 23C W-0.8 23C W-0.8 23 23 23C_A W-0.8 SHEET 1 - 57F (58) 51 87a 87A 53P_A W-0.8
24 PROGRAM SIGNAL 24 37P P-0.8 33R_E Y-0.8 28 28 33R_D Y-0.8 85 85 53C_A W-0.8
25 RESET SIGNAL 25 37R_B P-0.8 52C W-0.8 30 30 52C_A W-0.8 86 86 19C_E Or-1.0
26 UP COUNT SIGNAL 26 37U P-0.8 50L G-0.5 31 31 50L_A G-0.5 SHEET 2 - SPL_D5 56F
27 DOWN COUNT SIGNAL 27 37D P-0.8 50H Y-0.5 32 32 50H_A Y-0.5 SHEET 2 - 19F (26) 0_DB Bk-0.8 SHEET 1 - 219F GROUND CAB
28 REDUNDANT BRAKE SWITCH SIGNAL 28 33R_E Y-0.8 54 54
29 PILOT LOCKOUT SIGNAL 29 31L Y-0.8 26 26
30 PARKING BRAKE SIGNAL 30 52C W-0.8 44_G T-0.8 35 35 44_F T-0.8 SHEET 4 - SPL_D9 A B 89M
31 CONTROLLER AREA NETWORK L 31 50L G-0.5 53C W-0.8 36 36 53C_A W-0.8 A B
32 CONTROLLER AREA NETWORK H 32 50H Y-0.5 0_KR Bk-0.8 38 38 0_DAB Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
33 CONTROLLER AREA NETWORK T 33 50T Bk-0.8 0_KM Bk-0.8 53 53 0_DAC Bk-0.8 SHEET 1 - 222F RELAY GROUND
34 NONE 34 0_KD Bk-0.8 39 39 0_DL Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION 54
35 BRAKE LAMP SIGNAL 35 44_G T-0.8 37R_A P-0.8 25 25 37R_C P-0.8 SHEET 1 - 63M (18)
36 PILOT CONTROL SIGNAL 36 53C W-0.8 19S_A Or-0.8 2 2 19S Or-0.8 SHEET 1 - 18F FUSE BLOCK
37 SIGNAL GROUND 37 0_KQ Bk-0.8 0_KQ Bk-0.8 SPL_K1 19C Or-0.8 68 68 19C_C Or-0.8 SHEET 5 - SPL_D24 29.9 ohms at 20°C (68°F) Joystick
38 SIGNAL GROUND 38 0_KE Bk-0.8 0_KE Bk-0.8 19A_G Or-0.8 43 43 19A_S Or-0.8 SHEET 2 - SPL_D15 27.4 ohms at 20°C (68°F) Single Axis
39 SIGNAL GROUND 39 0_KD Bk-0.8 40 40
40 NONE 40
76 6 13M 13F
7 7 0_KM Bk-0.8 PEDESTAL CAB MAIN
8 8 0_KL Bk-0.8 HARNESS HARNESS
10 49_E S-0.8
4
45 9 6 0_KL Bk-0.8
1 1 37R_A P-0.8 7 7 0_KK Bk-0.8 3521 ohms at 20°C (68°F)
5 37R_B P-0.8 8 8 49_E S-0.8 BB 0_BE Bk-1.0 SHEET1 - SPL_B1
3 3 37P P-0.8 4 49_D S-0.8 43 AA 36C P-1.0
2 2 1A_B R-0.8 SHEET 1 - 69 (13) 10
49 5 138
75
1 1 37D P-0.8
9
3 3 37U P-0.8
2 2 19S_A Or-0.8 36C_B P-0.8 4 4 36C_A P-1.0 13 13
74 31F_B Y-0.8 3 3 31F_A Y-1.0 7 7 31F Y-1.0 0_BD Bk-1.0 SHEET1 - SPL_B1
36P_B P-0.8 6 6 36P_A P-1.0 6 6 36P P-1.0
19S_B Or-0.8
22F 22M 94F 94M
117 A B
CAB MAIN TRANSMISSION TRANSMISSION ENGINE 148 A B
HARNESS HARNESS HARNESS HARNESS COMMON
Normally Closed
9 0_KK Bk-0.8 50 Opens at 0.69 bar (10 psi) 44
7 7 0_KJ Bk-0.8
8 8 49_D S-0.8 NORMALLY NORMALLY
5 49_C S-0.8 OPEN CLOSED Normally Open
6 Closes at − 0.06 bar (− 0.928 psi)
46 10
4
1
3 3 33U Y-0.8 91 OHM RESISTOR 240 OHM RESISTOR
2 2 19A_H Or-0.8 SHEET 2 - 70 (27) YELLOW WIRE BLACK WIRE
19A_G Or-0.8 (NOTE 2) (NOTE 2)
72
ENGINE GROUND
10 0_KJ Bk-0.8
7 7 0_KH Bk-0.8 SHEET 4 - 71 (103)
8 8 49_C S-0.8
1 49_B S-0.8 SHEET 4 - 71 (103)
9
48 5
6
4
3 3 31L Y-0.8
2 2 19C Or-0.8
37
SHEET 3 - INSTRUMENT CLUSTER

COMPONENTS
1 5 6 1 4 7 10 1 4 1 4 1
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET 3. 64M and 64F connected for North American machines, opposite side steady ON.
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
9 R 64M and 64F disconnected for European machines, opposite side OFF.
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 − 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET
21M 21F 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
XXXX XXXX 15
1.
2.
6.
7.
FEMALE CONNECTOR
11.
12.
3 6 9 12 10. DIODE 3 3 3

3. CIRCUIT CONNECTED 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED) A 11. LIGHT EMITTING DIODE 621D Z-BAR, 621D XR, and 621D XT WHEEL LOADER
BC02D010
Normally Open
AA 33R_A Y-1.0
57 BB 0_L Bk-1.0
157
Normally Open
AA 33R_B Y-1.0 SPL_E10

57 BB 0_M Bk-1.0
86
SPL_E9
SHEET 1 - 160 ENGINE GROUND 0_P Bk-1.0

Normally Closed
BB 0_N Bk-1.0 33R_C Y-1.0 15 15 33R_D Y-0.8
38 AA 33P Y-1.0 33P Y-1.0 4 4 33P_A Y-0.8
88 31D Y-1.0 3 3 31D_A Y-0.8
36H P-1.0 13 13 36H_A P-0.8
31D_C Y-0.8 AA 36F P-1.0 16 16 36F_A P-0.8
0_VA Y-0.8 BB 0_V Bk-1.0 SHEET 1 - 160 ENGINE GROUND 31H Y-1.0 14 14 31H_A Y-0.8
274F 104 AA 36H P-1.0 52P W-1.0 18 18 52P_B W-0.8
41 BB 0_W Bk-1.0 SHEET 1 - 162 ENGINE GROUND
21M 21F
136
36F P-1.0 REAR CAB
3521 ohms at 20°C (68°F)
141 CHASSIS MAIN
S HARNESS HARNESS
40 G 1 0_E Bk-1.0 SHEET 1 - 160 ENGINE GROUND

275M
A B 171
A B 31H Y-1.0
33 to 240 ohms
SHEET 1 - 165 ENGINE GROUND 0_Q Bk-1.0 52P W-1.0
39 170 2 1 87
2 1
Normally Open
42 Closes at 2.8 bar (40 psi) 53
40.3 ohms at 20°C (68°F)

47
76 INSTRUMENT CLUSTER
1 CLUSTER MAIN FUSED POWER 1 19V_A Or-0.8 19V_A Or-0.8 1 1 19V Or-0.8 SHEET 1 - 18F FUSE BLOCK 19D_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
2 INSTRUMENT CLUSTER FUSED DELAYED POWER 2 19S_B Or-0.8 29 29 30 30 19D_B Or-1.0
3 LOW BRAKE PRESSURE WARNING 3 33P_B Y-0.8 33P_B Y-0.8 3 3 33P_A Y-0.8 87 87 52P_B W-0.8
4 COOLANT LEVEL SIGNAL 4 31D_B Y-0.8 31D_B Y-0.8 4 4 31D_A Y-0.8 52 87a 87A 52P_A W-0.8 SHEET 2 - 19F (26)
5 SECONDARY STEERING LOW PRESSURE SIGNAL 5 35X_F Y-0.8 35X_F Y-0.8 5 5 35X_E Y-0.8 SHEET 5 - 1F CAB FRONT CHASSIS 85 85 52C_A W-0.8
6 AIR FILTER RESTRICTION SWITCH SIGNAL 6 31F_C Y-0.8 31F_C Y-0.8 6 6 31F_B Y-0.8 86 86
7 HYDRAULIC FILTER RESTRICTION SWITCH SIGNAL 7 31H_B Y-0.8 31H_B Y-0.8 7 7 31H_A Y-0.8 55F
8 ANALOG GROUND 8 0_KP Bk-0.8 0_KP Bk-0.8 8 8 0_DAU Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
9 PARKING BRAKE SIGNAL 9 33U Y-0.8 9 9
10 AIR CONDITIONING TELLTALE 10 61R_G Or-0.8 61R_G Or-0.8 10 10 61R_F Or-0.8 SHEET 5 - SPL_D1
11 NONE 11 11 11
12 WORK LAMP TELLTALE SIGNAL 12 42R_A Y-0.8 42R_A Y-0.8 12 12 42R_C DU-0.8 SHEET 4 - 32F (114)
13 BEACON TELLTALE 13 46_B K-0.8 46_B K-0.8 13 13 46_A K-0.8 SHEET 4 - 23F CAB ROOF
14 NONE 14 14 14
15 HIGH BEAM TELLTALE 15 18C_C Or-0.8 18C_C Or-0.8 15 15 18C_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
16 LEFT TURN SIGNAL 16 45L_F N-0.8 45L_F N-0.8 16 16 45L_E N-0.8 SHEET 4 - SPL_D10
17 RIGHT TURN SIGNAL 17 45R_F N-0.8 45R_F N-0.8 17 17 45R_C N-0.8 SHEET 4 - SPL_D20
18 ENGINE COOLANT TEMPERATURE SIGNAL 18 36C_C P-0.8 36C_C P-0.8 18 18 36C_B P-0.8
19 FUEL LEVEL SIGNAL 19 36F_B P-0.8 36F_B P-0.8 19 19 36F_A P-0.8 19C_D Or-1.0 SHEET 1 - 18F FUSE BLOCK
20 HYDRAULIC OIL TEMPERATURE SIGNAL 20 36H_B P-0.8 36H_B P-0.8 20 20 36H_A P-0.8 19C_E Or-1.0
21 CONTROLLER AREA NETWORK T 21 50T Bk-0.8 21 21 30 30 53P_C W-0.8 SHEET 5 - 1F CAB FRONT CHASSIS
22 ENGINE OIL PRESSURE SIGNAL 22 36P_C P-0.8 36P_C P-0.8 22 22 36P_B P-0.8 87 87 53P_B W-0.8 SHEET 5 - 36F (59)
23 ENGINE SHUTDOWN SIGNAL 23 23C W-0.8 23C W-0.8 23 23 23C_A W-0.8 SHEET 1 - 57F (58) 51 87a 87A 53P_A W-0.8
24 PROGRAM SIGNAL 24 37P P-0.8 33R_E Y-0.8 28 28 33R_D Y-0.8 85 85 53C_A W-0.8
25 RESET SIGNAL 25 37R_B P-0.8 52C W-0.8 30 30 52C_A W-0.8 86 86 19C_E Or-1.0
26 UP COUNT SIGNAL 26 37U P-0.8 50L G-0.5 31 31 50L_A G-0.5 SHEET 2 - SPL_D5 56F
27 DOWN COUNT SIGNAL 27 37D P-0.8 50H Y-0.5 32 32 50H_A Y-0.5 SHEET 2 - 19F (26) 0_DB Bk-0.8 SHEET 1 - 219F GROUND CAB
28 REDUNDANT BRAKE SWITCH SIGNAL 28 33R_E Y-0.8 54 54
29 PILOT LOCKOUT SIGNAL 29 31L Y-0.8 26 26
30 PARKING BRAKE SIGNAL 30 52C W-0.8 44_G T-0.8 35 35 44_F T-0.8 SHEET 4 - SPL_D9 A B 89M
31 CONTROLLER AREA NETWORK L 31 50L G-0.5 53C W-0.8 36 36 53C_A W-0.8 A B
32 CONTROLLER AREA NETWORK H 32 50H Y-0.5 0_KR Bk-0.8 38 38 0_DAB Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
33 CONTROLLER AREA NETWORK T 33 50T Bk-0.8 0_KM Bk-0.8 53 53 0_DAC Bk-0.8 SHEET 1 - 222F RELAY GROUND
34 NONE 34 0_KD Bk-0.8 39 39 0_DL Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION 54
35 BRAKE LAMP SIGNAL 35 44_G T-0.8 37R_A P-0.8 25 25 37R_C P-0.8 SHEET 1 - 63M (18)
36 PILOT CONTROL SIGNAL 36 53C W-0.8 19S_A Or-0.8 2 2 19S Or-0.8 SHEET 1 - 18F FUSE BLOCK
37 SIGNAL GROUND 37 0_KQ Bk-0.8 0_KQ Bk-0.8 SPL_K1 19C Or-0.8 68 68 19C_C Or-0.8 SHEET 5 - SPL_D24 29.9 ohms at 20°C (68°F) Joystick
38 SIGNAL GROUND 38 0_KE Bk-0.8 0_KE Bk-0.8 19A_G Or-0.8 43 43 19A_S Or-0.8 SHEET 2 - SPL_D15 27.4 ohms at 20°C (68°F) Single Axis
39 SIGNAL GROUND 39 0_KD Bk-0.8 40 40
40 NONE 40
76 6 13M 13F
7 7 0_KM Bk-0.8 PEDESTAL CAB MAIN
8 8 0_KL Bk-0.8 HARNESS HARNESS
10 49_E S-0.8
4
45 9 6 0_KL Bk-0.8
1 1 37R_A P-0.8 7 7 0_KK Bk-0.8 3521 ohms at 20°C (68°F)
5 37R_B P-0.8 8 8 49_E S-0.8 BB 0_BE Bk-1.0 SHEET 1 - SPL_B1
3 3 37P P-0.8 4 49_D S-0.8 43 AA 36C P-1.0
2 2 1A_B R-0.8 SHEET 1 - 69 (13) 10
49 5 138
75
1 1 37D P-0.8
9
3 3 37U P-0.8
2 2 19S_A Or-0.8 36C_B P-0.8 4 4 36C_A P-1.0 13 13
74 31F_B Y-0.8 3 3 31F_A Y-1.0 7 7 31F Y-1.0 0_BD Bk-1.0 SHEET 1 - SPL_B1
36P_B P-0.8 6 6 36P_A P-1.0 6 6 36P P-1.0
19S_B Or-0.8
22F 22M 94F 94M
117 1 2
CAB MAIN TRANSMISSION TRANSMISSION ENGINE 148 A B
HARNESS HARNESS HARNESS HARNESS COMMON
Normally Closed
9 0_KK Bk-0.8 50 Opens at 0.69 bar (10 psi) 44
7 7 0_KJ Bk-0.8
8 8 49_D S-0.8 NORMALLY NORMALLY
5 49_C S-0.8 OPEN CLOSED Normally Open
6 Closes at - 0.06 bar (- 0.928 psi)
46 10
4
1
3 3 33U Y-0.8 91 OHM RESISTOR 240 OHM RESISTOR
2 2 19A_H Or-0.8 SHEET 2 - 70 (27) YELLOW WIRE BLACK WIRE
19A_G Or-0.8 (NOTE 2) (NOTE 2)
72
ENGINE GROUND
10 0_KJ Bk-0.8
7 7 0_KH Bk-0.8 SHEET 4 - 71 (103)
8 8 49_C S-0.8
1 49_B S-0.8 SHEET 4 - 71 (103)
9
48 5
6
4
3 3 31L Y-0.8
2 2 19C Or-0.8
37
SHEET 3 - INSTRUMENT CLUSTER

COMPONENTS
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. WIRE NUMBER 10
0_GA Bk-2.0 B B 2 2
9 R
21M 21F
R = RED Y = YELLOW
A 11.
12A.
BC02M132
185
31 1 0_KG Bk-0.8
H 45 1 64C Or-0.8
184
2 1 45B N-0.8
R 68
104 5 1 19B Or-0.8
67
L 1 1 45A N-0.8
66
B 1 0_KF Bk-0.8
187
A 1 64D Or-0.8
186
6
7 7 0_KH Bk-0.8 SHEET 3 - 37 (48)
8 8 49_B S-0.8 SHEET 3 - 37 (48)
9 49_A S-0.8
4
103 5
1
10
3 3 45H N-0.8
2 2 1B R-0.8
0_KG Bk-0.8
71
49_A S-0.8
64D Or-0.8
64C Or-0.8
19B Or-0.8
45H N-0.8
45A N-0.8
45B N-0.8
1B R-0.8
106 107
65 67 51 55 69 66 70 42 41 13M PEDESTAL HARNESS
STOP TURN TAIL REVERSE STOP TURN TAIL REVERSE 65 67 51 55 69 66 70 42 41 13F CAB MAIN HARNESS
18G_C Or-1.0 A A 18G_E Or-1.0 AA

116
64D_A Or-0.8
45H_A N-0.8
0_J Bk-1.0 0_JC Bk-1.0
45A_A N-0.8
45B_A N-0.8
C C 0_JA Bk-1.0 BB
1B_C R-0.8
49_F S-0.8
SPL_J1 168
128F 128M
REAR HOOD 10 0_DAW Bk-1.0 SHEET 2 - 118F (36)
0_JB Bk-1.0 SHEET 2 - 174 (37) 0_DAP Bk-1.0 SHEET 2 - 199F (33)
CHASSIS HARNESS 7 7
HARNESS 8 8 49_R S-1.0 SHEET 2 - 199F (33)
0_DX Bk-0.8 SHEET 1 - 220F GROUND CAB 9 49_T S-1.0 SHEET 2 - 118F (36)
6
SHEET 5 - 51F (80)
99 5
1 6 2 3 4 5 1 6 2 3 4 5 64C_A Or-0.8
1 6 2 3 4 5 125 1 6 2 3 4 5 127 4
SHEET 1 - 164 ENGINE GROUND 19B_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 1
3 3 46_C K-1.0
18G_A Or-1.0
2 2 19X Or-1.0 SHEET 1 - 18F FUSE BLOCK

45R_A N-1.0
35A_B K-1.0
0_C Bk-1.0
44_B T-1.O
1B_E R-0.8 42F

30 30
SPL_D9
87 87 44_E T-0.8 44_F T-0.8 SHEET 3 - 13F CAB PEDESTAL
102 87a 87A 0_DK Bk-0.8 SHEET 5 - 203F (89)
85 85 0_DA Bk-0.8 SHEET 1 - 220F GROUND CAB
86 86
0_A Bk-1.0 0_D Bk-2.0 SHEET 1 - 164 ENGINE 204F
SPL_E4 GROUND
1B_E R-0.8
18G_A Or-1.0 SPL_E8 SHEET 1 - SPL_D17 1_M R-3.0
SPL_E2 SHEET 2 - 53F (35) 211F SHEET 1 - 18F FUSE BLOCK 41L_A K-2.0 3 3 56b
35A_A K-1.0 35A_C K-1.0 35A_C K-1.0 7 7 35A_D Y-08
SHEET 1 - 18F FUSE BLOCK FLASHER SHEET 1 - 18F FUSE BLOCK 41H K-2.0 4 4
56a
18F_A Or-1.0 18F_A Or-1.0 5 5 18F_D Or-0.8
18G_D Or-1.0 9 9 18G_F Or-0.8 SHEET 1 - 18F FUSE BLOCK CIRCUIT 41J_A K-2.0 1 1 56 115
BREAKER B SHEET 1 - SPL_D16 30
45R_A N-1.0 12 12 45R_B N-0.8 1_H R-3.0 8 8
S
45L_A N-1.0 45L_A N-1.0 10 10 45L_B N-0.8 12.5 AMPERES 212F 64D_A Or-0.8 6 6
44_A T-1.0 44_C T-1.0 8 8 44_D T-0.8 59F
SPL_E1 1B_A R-1.0 28 28 1B_D R-0.8 1B_F R-0.8
44 T-1.0 29 29 44A_B T-0.8 SPL_D19
21M 21F
1B_B R-0.8
REAR CAB
49_U S-0.8 SHEET 5 - 210F (55)
CHASSIS MAIN
HARNESS HARNESS 49_G S-0.8 SHEET 2 - 199F (33)
49_F S-0.8 49_S S-1.0
1 2 SPL_D8
1 2 159
0_MA Bk-1.0 SHEET 5 - 82M (77)
101
1_N R-3.0 SHEET 1 - 224F POWER CAB
SHEET 1 - 206F CAB FLOOR WELD STUD 0_DU Bk-1.0 SPL_M6
0_DAS Bk-0.8 SHEET 1 - 63M (18) 49_K S-1.0 SHEET 5 - 39F (61) 46_A K-0.8 0_MD Bk-1.0 0_MC Bk-1.0
SHEET 3 - 13F CAB PEDESTAL C C BB
Normally Open SPL_D14 42C_A DU-1.0 46_C K-1.0 E E 46_D K-1.0 46_D K-1.0 AA
M 100
Closes at 4.1 bar (60 psi) 105 0_DAT Bk-0.8 SHEET 1 - 220F GROUND CAB 42R_B DU-0.8 H H 42R_F DU-1.0
19Z Or-1.0 SHEET 1 - 18F FUSE BLOCK 85F
SHEET 1 - 223F GROUND CAB 0_DT Bk-1.0 B B 0_MG Bk-1.0
19U_A Or-1.0 19U_D Or-1.0
41T_B K-1.0
41T_B K-1.0
41T_A K-1.0 SHEET 1 - 18F FUSE BLOCK SHEET 1 - 18F FUSE BLOCK
41J_B K-2.0
D D
62M FLASHER MODULE SPL_M4
49_J S-0.8
1B_B R-0.8 42R_E DU-1.0 AA
1 FLASHER MODULE POWER 1
42R_B DU-0.8 23F 23M 0_MF Bk-1.0 BB 111
2 FLASHER OPP SIDE CONTROL 2 45N_A N-0.8 SPL_M3
3 FLASHER MODULE GROUND 3 0_DAN Bk-0.8 CAB CAB 80F
4 FLASHER MODULE GROUND 4 0_DAQ Bk-0.8 42R_C DU-0.8 SHEET 1 - 13F CAB PEDESTAL MAIN ROOF
5 NONE 5 HARNESS HARNESS
6 6 18A Or-2.0 SHEET 1 - 18F FUSE BLOCK 42R_D DU-1.0 AA
NONE SPL_D20 0_ME Bk-1.0 BB 110
7 RIGHT-HAND TURN SIGNAL 7 45R_E N-0.8 45R_C N-0.8 SHEET 3 - 13F CAB PEDESTAL 25F A B A C 33F B A C 34F C A B 32F
8 LEFT-HAND TURN SIGNAL 8 45L_D N-0.8 45L_E N-0.8 SHEET 3 - 13F CAB PEDESTAL A B A C B A C C A B 83F
9 RIGHT-HAND TURN SWITCH POWER 9 45B_A N-0.8 SPL_D10
10 LEFT-HAND TURN SWITCH POWER 10 45A_A N-0.8
11 HAZARD SWITCH POWER 11 45H_A N-0.8 HD TL F4 B1 IL F1 B3 F3 F2 B2 LAMPS 1
12 FLASHER OPP SIDE CONTROL 12 45N_B N-0.8 1 1 45N_A N-0.8 SWITCH 19U_D Or-1.0 AA
2 3 4 2 3 4 2 3 4 POSITION 0_MB Bk-0.8 BB
POSITION DRIVE FLOOD ILLUMINATION
62M 64M 64F 1 5 1 5 1 5 AND TAIL CC 117
NOTE 3 1 OFF OFF OFF OFF 0_MM Bk-0.8 2
84F
2 ON OFF OFF OFF
114 3 ON ON OFF ON
4 ON ON ON ON A A
SPL_M5
5 ON OFF ON ON B B 0_ML Bk-0.8 BB
C C 49_V S-0.8 AA 118
D D
77F
SHEET 1 - 223F GROUND CAB 0_DR Bk-1.0 E E 0_MN Bk-0.8
49_S S-1.0 F F 49_V S-0.8 SPL_M2
SHEET 1 - 223F GROUND CAB 0_DS Bk-1.0 G G 0_MK Bk-1.0 0_MJ Bk-1.0 BB
42C_A DU-1.0 H H 42C_D DU-1.0 42C_C DU-1.0 AA 113
108 109 SPL_M1
78F
24M 24F
HIGH LOW HIGH LOW CAB CAB
MAIN ROOF 42C_B DU-1.0 AA
BEAM POSITION BEAM TURN BEAM POSITION BEAM TURN
0_MH Bk-1.0 BB 112
HARNESS HARNESS
79F
3 6 4 2 5 1 3 6 4 2 5 1
3 6 4 2 5 1 6 3 6 4 2 5 1 8
0_AL Bk-1.0 SHEET 5 - SPL_A1 0_AG Bk-1.0 SHEET 5 - SPL_A1
SHEET 1 - 18F FUSE BLOCK 18B_A Or-0.8 G G 18B Or-1.0

SHEET 1 - 18F FUSE BLOCK 18F_E Or-0.8 F F 18F Or-1.0
SHEET 1 - 18F FUSE BLOCK 18D_A Or-0.8 O O 18D Or-1.0
45L_C N-0.8 A A 45L N-1.0
SHEET 1 - 18F FUSE BLOCK 18C_A Or-0.8 Q Q 18C Or-1.0
SHEET 1 - 18F FUSE BLOCK 18G_G Or-0.8 E E 18G Or-1.0
SHEET 1 - 18F FUSE BLOCK 18E_A Or-0.8 P P 18E Or-1.0
45R_D N-0.8 C C 45R N-1.0
1F 1
CAB MAIN FRONT
HARNESS CHASSIS
HARNESS
SHEET 4 - LIGHTING
COMPONENTS
1 5 6 1 4 7 10 1 4 1 4 1
3. WIRE SIZE 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
1 2 3
0_GA Bk-2.0
B B 2 2
Bk = BLACK LU = LIGHT BLUE S = GRAY 93M 93F 7 9
2 3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
XXXX XXXX 15
1.
2.
6.
7.
FEMALE CONNECTOR
11.
12.
3 6 9 12 10. DIODE 3 3 3

BC01D011
185
31 1 0_KG Bk-0.8
H 45 1 64C Or-0.8
184
2 1 45B N-0.8
R 68
104 5 1 19B Or-0.8
67
L 1 1 45A N-0.8
66
B 1 0_KF Bk-0.8
187
A 1 64D Or-0.8
186
6
7 7 0_KH Bk-0.8 SHEET 3 - 37 (48)
8 8 49_B S-0.8 SHEET 3 - 37 (48)
9 49_A S-0.8
4
103 5
1
10
3 3 45H N-0.8
2 2 1B R-0.8
0_KG Bk-0.8
71
49_A S-0.8
64D Or-0.8
64C Or-0.8
19B Or-0.8
45H N-0.8
45A N-0.8
45B N-0.8
1B R-0.8
106 107
65 67 51 55 69 66 70 42 41 13M PEDESTAL HARNESS
STOP TURN TAIL REVERSE STOP TURN TAIL REVERSE 65 67 51 55 69 66 70 42 41 13F CAB MAIN HARNESS
18G_C Or-1.0 A A 18G_E Or-1.0 AA

116
64D_A Or-0.8
45H_A N-0.8
0_J Bk-1.0 0_JC Bk-1.0
45A_A N-0.8
45B_A N-0.8
C C 0_JA Bk-1.0 BB
1B_C R-0.8
49_F S-0.8
SPL_J1 168
128F 128M
REAR HOOD 10 0_DAW Bk-1.0 SHEET 2 - 118F (36)
0_JB Bk-1.0 SHEET 2 - 174 (37) 0_DAP Bk-1.0 SHEET 2 - 199F (33)
CHASSIS HARNESS 7 7
HARNESS 8 8 49_R S-1.0 SHEET 2 - 199F (33)
0_DX Bk-0.8 SHEET 1 - 220F GROUND CAB 9 49_T S-1.0 SHEET 2 - 118F (36)
6
SHEET 5 - 51F (80)
99 5
1 6 2 3 4 5 1 6 2 3 4 5 64C_A Or-0.8
1 6 2 3 4 5 125 1 6 2 3 4 5 127 4
SHEET 1 - 164 ENGINE GROUND 19B_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 1
3 3 46_C K-1.0
18G_A Or-1.0
2 2 19X Or-1.0 SHEET 1 - 18F FUSE BLOCK

45R_A N-1.0
35A_B K-1.0
0_C Bk-1.0
1B_E R-0.8
44_B T-1.0
42F
30 30
SPL_D9
87 87 44_E T-0.8 44_F T-0.8 SHEET 3 - 13F CAB PEDESTAL
102 87a 87A 0_DG Bk-0.8 SHEET 1 - 58F (17)
85 85 0_DC Bk-0.8 SHEET 1 - 49F (16)
86 86
0_A Bk-1.0 0_D Bk-2.0 SHEET 1 - 164 ENGINE 204F
SPL_E4 GROUND
1B_E R-0.8
18G_A Or-1.0 SPL_E8 SHEET 1 - SPL_D17 1_M R-3.0
SPL_E2 SHEET 2 - 53F (35) 211F SHEET 1 - 18F FUSE BLOCK 41L_A K-2.0 3 3 56b
35A_A K-1.0 35A_C K-1.0 35A_C K-1.0 7 7 35A_D Y-08
SHEET 1 - 18F FUSE BLOCK FLASHER SHEET 1 - 18F FUSE BLOCK 41H K-2.0 4 4
56a
18F_A Or-1.0 18F_A Or-1.0 5 5 18F_D Or-0.8
18G_D Or-1.0 9 9 18G_F Or-0.8 SHEET 1 - 18F FUSE BLOCK CIRCUIT 41J_A K-2.0 1 1 56 115
BREAKER B SHEET 1 - SPL_D16 30
45R_A N-1.0 12 12 45R_B N-0.8 1_H R-3.0 8 8
S
45L_A N-1.0 45L_A N-1.0 10 10 45L_B N-0.8 12.5 AMPERES 212F 64D_A Or-0.8 6 6
44_A T-1.0 44_C T-1.0 8 8 44_D T-0.8 59F
SPL_E1 1B_A R-1.0 28 28 1B_D R-0.8 1B_F R-0.8
44 T-1.0 29 29 44A_B T-0.8 SPL_D19
21M 21F
1B_B R-0.8
REAR CAB
49_U S-0.8 SHEET 5 - 210F (55)
CHASSIS MAIN
HARNESS HARNESS 49_G S-0.8 SHEET 2 - 199F (33)
49_F S-0.8 49_S S-1.0
1 2 SPL_D8
1 2 159
0_MA Bk-1.0 SHEET 5 - 82M (77)
101
1_N R-3.0 SHEET 1 - 224F POWER CAB
SHEET 1 - 206F CAB FLOOR WELD STUD 0_DU Bk-1.0 SPL_M6
0_DAS Bk-0.8 SHEET 1 - 63M (18) 49_K S-1.0 SHEET 5 - 39F (61) 46_A K-0.8 0_MD Bk-1.0 0_MC Bk-1.0
SHEET 3 - 13F CAB PEDESTAL C C BB
Normally Open SPL_D14 42C_A DU-1.0 46_C K-1.0 E E 46_D K-1.0 46_D K-1.0 AA
M 100
Closes at 4.1 bar (60 psi) 105 0_DAT Bk-0.8 SHEET 1 - 220F GROUND CAB 42R_B DU-0.8 H H 42R_F DU-1.0
19Z Or-1.0 SHEET 1 - 18F FUSE BLOCK 85F
SHEET 1 - 223F GROUND CAB 0_DT Bk-1.0 B B 0_MG Bk-1.0
19U_A Or-1.0 19U_D Or-1.0
41T_B K-1.0
41T_B K-1.0
41T_A K-1.0 SHEET 1 - 18F FUSE BLOCK SHEET 1 - 18F FUSE BLOCK
41J_B K-2.0
D D
62M FLASHER MODULE SPL_M4
49_J S-0.8
1B_B R-0.8 42R_E DU-1.0 AA
1 FLASHER MODULE POWER 1
42R_B DU-0.8 23F 23M 0_MF Bk-1.0 BB 111
2 FLASHER OPP SIDE CONTROL 2 45N_A N-0.8 SPL_M3
3 FLASHER MODULE GROUND 3 0_DAN Bk-0.8 CAB CAB 80F
4 FLASHER MODULE GROUND 4 0_DAQ Bk-0.8 42R_C DU-0.8 SHEET 3 - 13F CAB PEDESTAL MAIN ROOF
5 NONE 5 HARNESS HARNESS
6 6 18A Or-2.0 SHEET 1 - 18F FUSE BLOCK 42R_D DU-1.0 AA
NONE SPL_D20 0_ME Bk-1.0 BB 110
7 RIGHT-HAND TURN SIGNAL 7 45R_E N-0.8 45R_C N-0.8 SHEET 3 - 13F CAB PEDESTAL 25F A B A C 33F B A C 34F C A B 32F
8 LEFT-HAND TURN SIGNAL 8 45L_D N-0.8 45L_E N-0.8 SHEET 3 - 13F CAB PEDESTAL A B A C B A C C A B 83F
9 RIGHT-HAND TURN SWITCH POWER 9 45B_A N-0.8 SPL_D10
10 LEFT-HAND TURN SWITCH POWER 10 45A_A N-0.8
11 HAZARD SWITCH POWER 11 45H_A N-0.8 HD TL F4 B1 IL F1 B3 F3 F2 B2 LAMPS 1
12 FLASHER OPP SIDE CONTROL 12 45N_B N-0.8 1 1 45N_A N-0.8 SWITCH 19U_D Or-1.0 AA
2 3 4 2 3 4 2 3 4 POSITION 0_MB Bk-0.8 BB
POSITION DRIVE FLOOD ILLUMINATION
62M 64M 64F 1 5 1 5 1 5 AND TAIL CC 117
NOTE 3 1 OFF OFF OFF OFF 0_MM Bk-0.8 2
84F
2 ON OFF OFF OFF
114 3 ON ON OFF ON
4 ON ON ON ON A A
SPL_M5
5 ON OFF ON ON B B 0_ML Bk-0.8 BB
C C 49_V S-0.8 AA 118
D D
77F
SHEET 1 - 223F GROUND CAB 0_DR Bk-1.0 E E 0_MN Bk-0.8
49_S S-1.0 F F 49_V S-0.8 SPL_M2
SHEET 1 - 223F GROUND CAB 0_DS Bk-1.0 G G 0_MK Bk-1.0 0_MJ Bk-1.0 BB
42C_A DU-1.0 H H 42C_D DU-1.0 42C_C DU-1.0 AA 113
108 109 SPL_M1
78F
24M 24F
HIGH LOW HIGH LOW CAB CAB
MAIN ROOF 42C_B DU-1.0 AA
BEAM POSITION BEAM TURN BEAM POSITION BEAM TURN
0_MH Bk-1.0 BB 112
HARNESS HARNESS
79F
3 6 4 2 5 1 3 6 4 2 5 1
3 6 4 2 5 1 6 3 6 4 2 5 1 8
0_AL Bk-1.0 SHEET 5 - SPL_A1 0_AG Bk-1.0 SHEET 5 - SPL_A1
SHEET 1 - 18F FUSE BLOCK 18B_A Or-0.8 G G 18B Or-1.0

SHEET 1 - 18F FUSE BLOCK 18F_E Or-0.8 F F 18F Or-1.0
SHEET 1 - 18F FUSE BLOCK 18D_A Or-0.8 O O 18D Or-1.0
45L_C N-0.8 A A 45L N-1.0
SHEET 1 - 18F FUSE BLOCK 18C_A Or-0.8 Q Q 18C Or-1.0
SHEET 1 - 18F FUSE BLOCK 18G_G Or-0.8 E E 18G Or-1.0
SHEET 1 - 18F FUSE BLOCK 18E_A Or-0.8 P P 18E Or-1.0
45R_D N-0.8 C C 45R N-1.0
1F 1
CAB MAIN FRONT
HARNESS CHASSIS
HARNESS
SHEET 4 - LIGHTING
COMPONENTS
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. WIRE NUMBER 10
0_GA Bk-2.0 B B 2 2
9 R
21M 21F
R = RED Y = YELLOW
A 11.
12A.
BC02M133
58S W-0.8
30 30 58_A W-0.8
61R_B Or-0.8 27 27 61R_A Or-1.0 3 3 61R Or-1.0 BB Normally Open 87 87 58_B W-0.8
61A_B Or-0.8 61A_B Or-0.8 26 26 61A_A Or-1.0 2 2 61A Or-1.0 AA 87 Closes at 27.6 bar (400 psi)
61A_C Or-0.8
72 87a 87A
61C_B Or-0.8 25 25 61C_A Or-1.0 4 4 61C Or-1.0 85 85 0_DD Bk-0.8 SHEET 2 - 19F (26)
61R_B Or-0.8 8 8 98
30 30 86 86 58H_B W-0.8 SHEET 2 - 19F (26)
87 87 61R_C Or-0.8 22F 22M 10 10
89 87a 87A 61R_D Or-0.8 12 12 50F
CAB TRANSMISSION
85 85 61C_B Or-0.8 MAIN HARNESS 14 14
86 86 0_DK Bk-0.8 SHEET 4 - 204F (102) 16 16 SHEET 1 - 18F FUSE BLOCK 19U_B Or-1.0
HARNESS 17 17 19U_C Or-0.8 30 30
61R_C Or-0.8 61C_D Or-1.0 1_W R-1.0
203F 18 18 10 0_DAM Bk-1.0 SHEET 2 - 41F (30) 64A_A Or-0.8 87 87
19 19 99 267F
7 7 0_DAL Bk-1.0 87A 87a 80 51_B W-1.0 1_NC R-50 SHEET 1 - 245F (5) B+ STUD
ENGINE AIR CONDITIONING 8 8 49_Q S-1.0 SHEET 2 - 41F (30) SHEET 4 - 13F CAB PEDESTAL 64C_A Or-0.8 85 85
94F 94M HARNESS DIODE HARNESS 19U_C Or-0.8 86 86
DIODE 9 49_P S-1.0 181 253F 244F
TRANSMISSION ENGINE 5
MODULE 51F
HARNESS HARNESS SPL_N1 265F 71 6 6 58_B W-0.8
61C_E Or-1.0 61C_C Or-1.0 A A 4
B B 1
266M 0_BJ Bk-1.0 C C 3 3 58S W-0.8
2 2 19C_B Or-1.0 19C_C Or-0.8 SHEET 3 - 13F CAB PEDESTAL 242F
44F SPL_D24 19C_A Or-1.0 SHEET 1 - 18F FUSE BLOCK M 68
SHEET 1 - 268 REAR ENGINE BLOCK
1 1 19G Or-2.0 SHEET 1 - 18F FUSE BLOCK GROUND STUD 147
B
2 2 61T Or-1.0
C 64 Or-1.0
6 6
83 L
5 5 62L Or-1.0 1 1 W 1
207F AIR CONDITIONING DIODE HARNESS 81
M USED ONLY ON LOADERS WITH BOTH 10 10 49_P S-1.0 0_AD Bk-1.0 0_ND Bk-62 SHEET 1 - 243F REAR CHASSIS GROUND STUD
4 4 62M Or-2.0 2 2 R 2 2 A 61T Or-1.0 3 49_H S-0.8
H
3 3 62H Or-2.0 3 3 Bk 3 88 90 AIR CONDITIONING AND TAPE DECK 146
8
30F 4 4 N N 1 A 61A_D Or-0.8 7
29M 4 3 208F 6 0_AJ Bk-2.0 SHEET 1 - 145 GROUND CAB
84 69 5
SHEET 1 - 218F GROUND CAB 0_DZ Bk-2.0 SPL_D3 61A_C Or-0.8 1 1 57_A W-0.8
M 0_AL Bk-1.0 SHEET 4 - 6 (108)
9 9 0_DAL Bk-1.0
4 0_DAF Bk-1.0 0_AG Bk-1.0 SHEET 4 - 8 (109)
BB 61A_E Or-0.8 2 2 19P_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
85 86 AA 61R_E Or-0.8 61R_D Or-0.8
40F 19P_B Or-1.0 SPL_A1
27M SPL_D1
SPL_C2
Normally Closed 0_AB Bk-1.0 BB 51_C W-1.0 AA
61R_F Or-0.8 SHEET 3 - 13F CAB PEDESTAL 57 W-1.0 AA 70 28.8 ohms at 20°C (68°F)
0_CF Bk-1.0 BB 68A 39.3 ohms at 20°C (68°F)
10 0_DAY Bk-1.0 107M 264M
7 7 0_DAF Bk-1.0
8 8 49_H S-0.8
9 49_U S-0.8 SHEET 4 - SPL_D8
6
55 5 0_AC Bk-1.0 2 2
73 22.7 ohms at 20°C (68°F)
BB 0_X Bk-1.0 SHEET 1 - 163 ENGINE GROUND 58_C W-1.0 1 1 66
56 1 1
AA 52 W-1.0 4 5F
158 3 3 52_A W-0.8
19P_B Or-1.0 64A_A Or-0.8 N N 64 Or-1.0 90M SECONDARY STEERING MODULE
2 2 19R_C Or-1.0
39.3 ohms at 20°C (68°F) X X 1 1 SECONDARY STEERING IGNITION
210F 57_A W-0.8 U U 57 W-1.0 51_A W-1.0 2 2 SECONDARY STEERING MOTOR RELEASE
27 27 52_A W-0.8 W W 1_W R-1.0 3 3 SECONDARY STEERING MODULE B+
1 1 68W Or-1.0 24 24 68W_A Or-1.0 D D SPL_A7 SHEET 1 - 176 REAR CHASSIS GROUND STUD 0_CE Bk-1.0 4 4 SECONDARY STEERING CHASSIS GROUND
78 M
2 2 0_F Bk-1.0 SHEET 1 - 162 ENGINE GROUND 25 25 63W_A Or-0.8 SHEET 2 - 199F (33) 0_DAE Bk-1.0 58_A W-0.8 V V 58 W-1.0 5 5 NONE
63W Or-1.0 SPL_D13 SHEET 1 - 18F FUSE BLOCK 19M_A Or-0.8 H H 19M_B Or-1.0 19M_B Or-1.0 1 1 19M_C Or-1.0 6 6 NONE
3 21M 21F SHEET 1 - 222F GROUND CAB 0_DAD Bk-1.0 SHEET 1 - SPL_D25 19R_A Or-0.8 J J 19R_B Or-1.0 19R_B Or-1.0 2 2 7 7 SECONDARY STEERING ACCESSORY
REAR CAB SHEET 3 - 13F CAB PEDESTAL 35X_E Y-0.8 K K 35X_B Y-1.0 35X_C Y-1.0 3 3 35X_D Y-1.0 8 8 SECONDARY STEERING LOW PRESSURE SIGNAL
1 1 S S SPL_A4 51P_B W-1.0 4 4 51P_A W-1.0 9 9 SECONDARY STEERING HIGH PRESSURE
76 M
2 2 0_G Bk-1.0 SHEET 1 - 162 ENGINE GROUND
CHASSIS MAIN 10 0_DAH Bk-1.0 R R 54B W-1.0 AA C 0_AN Bk-1.0 5 5 0_CC Bk-1.0 0_CA Bk-1.0 10 10 NONE
HARNESS HARNESS 7 7 0_DAG Bk-1.0 54B_A W-0.8 54B W-1.0 0_AA Bk-1.0
2 L L BB − 63 6 6 SPL_C1 11 11 SECONDARY STEERING SIGNAL GROUND
8 8 49_K S-1.0 SHEET 4 - 34F (114) 56_J W-0.8 T T 56_C W-1.0 56_A W-1.0 CC + 0_CB Bk-1.0 12 12 SECONDARY STEERING SIGNAL GROUND
9 49_M S-1.0 53B_B W-0.8 180F 180M
M M 53B W-1.0 SPL_A3 10 90M
6 53P_C W-0.8 B B 53P_D W-1.0 FRONT SECONDARY
61 NORMALLY
56_B W-1.0
5 0_DAH Bk-1.0 CHASSIS STEERING
0_DW Bk-0.8 SHEET 2 - 118F (36) 1 1 0_DAJ Bk-1.0 1F 1 CLOSED
54B_A W-0.8 HARNESS MODULE
7 7 49_L S-0.8 SHEET 2 - 118F (36) 4 CAB FRONT 0_CD Bk-1.0 SHEET 1 - 177 REAR ENGINE BLOCK GROUND STUD
8 8 3 3 54B_B W-0.8 SPL_D2 HARNESS
SPL_D23 54B_C W-0.8 MAIN CHASSIS
5 5 19K_D Or-0.8 19K_A Or-1.0 SHEET 1 - 18F FUSE BLOCK 2 2 55A W-0.8 HARNESS HARNESS
10 39F
9
77 6 6 68W_A Or-1.0 SHEET 3 - 56F (51) 51P_B W-1.0 A A N.O.
1 1 68C_A Or-1.0 0_AN Bk-1.0 B B COM
67 Closes at 2.4 bar (35 psi)
4 19K_B Or-1.0 F F 19K_E Or-1.0 35X_A Y-1.0 C C
0_AA Bk-1.0
19K_C Or-1.0 68C_A Or-1.0 68C_B Or-1.0 N.C.
3 3 A A 10 0_DAJ Bk-1.0
2 2 68L_A Or-1.0 68L_A Or-1.0 G G 68L_C Or-1.0 7 7 0_DAK Bk-1.0 SHEET 2 - 38F (31) 131F
45F 68L_B Or-0.8 8 8 49_M S-1.0
23F 23M 9 49_N S-1.0 SHEET 2 - 38F (31)
CAB ROOF 6
MAIN HARNESS 59 5 53B W-1.0 A A 53B_A W-1.0 AA C
HARNESS 4 0_AF Bk-1.0 0_AF Bk-1.0 B B 0_AM Bk-1.0 BB − 62
1 SPL_A2 56_B W-1.0 C C 56_D W-1.0 CC +
81M 56_H W-0.8 SPL_D4
3 3 12F 12M 200
A A 2 2 53P_B W-0.8 SHEET 3 - 56F (51) 0_AK Bk-1.0 SHEET 1 - 145 GROUND CAB
B B 68L_C Or-1.0 XT MODELS: NORMALLY CLOSED
79 M 36F RETURN-TO-DIG HARNESS Z-BAR MODELS: NORMALLY OPEN
C C 19K_E Or-1.0 FOR XT CHASSIS
D D 68C_B Or-1.0
0_AR Bk-1.0
1 1 0_MA Bk-1.0 SHEET 4 - SPL_M6
82M
RETURN-TO-DIG 3 3 53B_B W-0.8
F F 68L_B Or-0.8 4 4 56_G W-0.8
A A 63L_B Or-0.8 2 2 54B_C W-0.8
DIODE C C 0_DAX Bk-0.8 SHEET 1 - 206F CAB FLOOR WELD STUD
60 HEIGHT CONTROL
5 5 56_F W-0.8 58_E W-1.0 AA
MODULE B B 63H_B Or-0.8 RETURN-TO-TRAVEL 1 1 55A W-0.8 53S_D W-1.0 BB
D D 13C_C Or-0.8 SHEET 1 - 57F (58) 6 6 56_E W-0.8 0_AQ Bk-1.0 0_AQ Bk-1.0 CC DIODE
E E 21C_F W-0.8 SHEET 1 - 54F (12) 17M SPL_A6 DD MODULE
140M 75 68.2 ohms - Joystick EE
MOMENTARY 305 ohms - Single Axis F F
PARK INTERMITTENT LOW HIGH 0_AP Bk-1.0 2 2
35F WIPER AND WASHER SWITCH PUSH 65 229M 64A
SHEET 1 - 218F GROUND CAB 0_DAR Bk-1.0 53S_B W-1.0 1 1
SHEET 1 - 18F FUSE BLOCK 19J_A Or-1.0 1 1 BLOWER WIPER SEAT GROUND
19J_B Or-0.8 2 2 FRONT WIPER WASHER FUSED POWER 24V 24V 24V 24V 24V 179F ROLLBACK PRESSURE
63W_A Or-0.8 3 3 FRONT WASHER PUMP 24V 39.7 ohms at 20°C (68°F) 58_D W-1.0 AA 58_F W-1.0 BB
61 SWITCH (OPTION)
63C_A Or-0.8 4 4 FRONT WIPER PARK 24V PULSE 53S_D W-1.0 BB 58A_A W-1.0 AA
A A 63H Or-0.8 57 57 63H_A Or-0.8 63H_A Or-0.8 5 5 FRONT WIPER HIGH SPEED 24V 53S_C W-1.0 53S_C W-1.0 CC Normally Closed
B B 63L Or-0.8 58 58 63L_A Or-0.8 63L_A Or-0.8 6 6 FRONT WIPER LOW SPEED 24V PULSE 24V 272F 6.2 bar (90 psi)
74 M SPL_A5
C C 19J Or-0.8 60 60 19J_B Or-0.8 63H_B Or-0.8 202F 271M
63L_B Or-0.8 35F PINS 4 AND 6 ARE CONNECTED INTERNALLY
D D 63C Or-0.8 59 59 63C_A Or-0.8
61 61 0_DV Bk-0.8 SHEET 1 - 206F CAB GROUND WELD STUD BY THE LIMIT SWITCH INSIDE MOTOR 58A_A W-1.0 AA DIODE
1 1 0_KN Bk-0.8 BB
53S_E W-1.0 C C MODULE
60 13M 13F
PEDESTAL CAB 53S_A W-1.0 BB 273F
53P_D W-1.0 AA 64
HARNESS MAIN
HARNESS 178M ROLLBACK PRESSURE SWITCH
Normally Open JUMPER HARNESS FOR XT CHASSIS
SHEET 5 - MACHINE CONTROLS

RADIO MEMORY
AFTER S/N JEE0133334
1 1_X R-1.0 SHEET 1 - 270F CAB B+ J-BLOCK 94 95

2 18_H Or-0.8
96
Fuse H 7.5 A 92
18_H Or-0.8 6 6
8 8
SHEET 1 - 246M ON 18F FUSE BLOCK CONTACT 5 19L_A Or-1.0 AA AA 65C Or-0.8 6 6 65C_B Or-0.8 14 14 SHEET 1 - 250F CAB B+ J BLOCK 1_V R-5.0 24V IGN 19L_B Or-1.0 SHEET 1 - 249M ON 18F FUSE BLOCK CONTACT 11
24V/12V
SHEET 1 - 247F CAB GROUND J-BLOCK 0_PD Bk-1.0 BB BB 0_PC Bk-0.8 3 3 0_QC Bk-0.8 5 5
255F 256F
CONVERTER
109M 110F 2 2 0_QA Bk-0.8 4 4
REMOTE
1 1 65L_A Or-0.8 11 11
24V
4 4 0_QB Bk-0.8 2 2 TOP CAB
A 5 5 65R_A Or-0.8 9 9
REMOTE 254F 258F
RADIO GROUND
7 7 12V_B R-5.0 SHEET 1 - 18F FUSE BLOCK CONTACT 6
114F 114M WELD STUD 0_RA Bk-5.0 GND 12V 12V_A R-30
10 10 SHEET 1 - 251F CAB GROUND J BLOCK
BB 0_PA Bk-0.8
97 AA 65L Or-0.8
3 3
257F BB 0_DY Bk-1.0 SHEET 1 - 218F GROUND CAB
12 12 1 1 19W_A Or-3.0 SHEET 1 - 260M ON 18F FUSE BLOCK CONTACT 16 AA 19N_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
112M 13 13 91 2 2 0_S Bk-3.0 SHEET 1 - 261F CAB GROUND J-BLOCK
TAPE DECK 82 28M
1 1
AA 259F
BB 0_PB Bk-0.8 113 SHEET 1 - 252F OUTLET GROUND (CAB GROUND WELD STUD) 0_RB Bk-3.0 BB 93
98 AA 65R Or-0.8
B C 253F
111M CIGAR LIGHTER OPTION
1. 24V REMOTE RADIO (ALL CIRCUITS SHOWN INCLUDING BOX B BUT EXCLUDING BOXES A AND C (109M CONNECTED TO 110F)) AIR SEAT OPTION
2. 24V REMOTE RADIO WITH TAPE DECK (ALL CIRCUITS SHOWN INCLUDING BOXES B AND C BUT EXCLUDING BOX A (109M CONNECTED TO 110F)) 24 VOLT - 12 VOLT POWER CONVERTER OPTION
3. 24V RADIO READY (ALL CIRCUITS SHOWN EXCLUDING BOXES A, B, AND C (109M CONNECTED TO 110F))
4. 12V RADIO READY (ALL CIRCUITS SHOWN INCLUDING BOX A BUT EXCLUDING BOXES B AND C)
RADIO OPTIONS
SHEET 6 - OPTIONS
COMPONENTS
1 5 6 1 4 7 10 1 4 1 4 1
3. WIRE SIZE 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
1 2 3
0_GA Bk-2.0
B B 2 2
Bk = BLACK LU = LIGHT BLUE S = GRAY 93M 93F 7 9
2 3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
XXXX XXXX 15
1.
2.
6.
7.
FEMALE CONNECTOR
11.
12.
3 6 9 12 10. DIODE 3 3 3

BC02D012
58S W-0.8
30 30 58_A W-0.8
61R_B Or-0.8 27 27 61R_A Or-1.0 3 3 61R Or-1.0 BB Normally Open 87 87 58_B W-0.8
61A_B Or-0.8 61A_B Or-0.8 26 26 61A_A Or-1.0 2 2 61A Or-1.0 AA 87 Closes at 27.6 bar (400 psi)
61A_C Or-0.8
72 87a 87A
61C_B Or-0.8 25 25 61C_A Or-1.0 4 4 61C Or-1.0 85 85 0_DD Bk-0.8 SHEET 2 - 19F (26)
61R_B Or-0.8 8 8 98
30 30 86 86 58H_B W-0.8 SHEET 2 - 19F (26)
87 87 61R_C Or-0.8 22F 22M 10 10
89 87a 87A 61R_D Or-0.8 12 12 50F
CAB TRANSMISSION
85 85 61C_B Or-0.8 MAIN HARNESS 14 14
86 86 0_DA Bk-0.8 SHEET 1 - 220F 16 16 SHEET 1 - 18F FUSE BLOCK 19U_B Or-1.0
HARNESS 17 17 19U_C Or-0.8 30 30
61R_C Or-0.8 61C_D Or-1.0 1_W R-1.0
203F 18 18 10 0_DAM Bk-1.0 SHEET 2 - 41F (30) 64A_A Or-0.8 87 87
19 19 99 267F
7 7 0_DAL Bk-1.0 87A 87a 80 51_B W-1.0 1_NC R-50 SHEET 1 - 245F RELAY BOX
ENGINE AIR CONDITIONING 8 8 49_Q S-1.0 SHEET 2 - 41F (30) SHEET 4 - 13F CAB PEDESTAL 64C_A Or-0.8 85 85
94F 94M JUNCTION BLOCK
HARNESS DIODE HARNESS 9 49_P S-1.0 19U_C Or-0.8 86 86
TRANSMISSION ENGINE DIODE 181 263F 244F
MODULE 5 51F
HARNESS HARNESS SPL_N1 265F 71 6 6 58_B W-0.8
61C_E Or-1.0 61C_C Or-1.0 C C 4
B B 1
266M 0_BJ Bk-1.0 A A 3 3 58S W-0.8
2 2 19C_B Or-1.0 19C_C Or-0.8 SHEET 3 - 13F CAB PEDESTAL 242F
44F SPL_D24 19C_A Or-1.0 SHEET 1 - 18F FUSE BLOCK M 68
SHEET 1 - 268 REAR ENGINE BLOCK
1 1 19G Or-2.0 SHEET 1 - 18F FUSE BLOCK GROUND STUD 147
B
2 2 61T Or-1.0
C 64 Or-1.0
6 6
83 L
5 5 62L Or-1.0 1 1 W 1
207F AIR CONDITIONING DIODE HARNESS 81
M USED ONLY ON LOADERS WITH BOTH 10 10 49_P S-1.0 0_AD Bk-1.0 0_ND Bk-62 SHEET 1 - 243F REAR CHASSIS GROUND STUD
4 4 62M Or-2.0 2 2 R 2 2 A 61T Or-1.0 3 49_H S-0.8
H
3 3 62H Or-2.0 3 3 Bk 3 88 90 AIR CONDITIONING AND TAPE DECK 146
8
30F 4 4 N N 1 A 61A_D Or-0.8 7
29M 4 3 208F 6 0_AJ Bk-2.0 SHEET 1 - 145 GROUND CAB
84 69 5
SHEET 1 - 218F GROUND CAB 0_DZ Bk-2.0 SPL_D3 61A_C Or-0.8 1 1 57_A W-0.8
M 0_AL Bk-1.0 SHEET 4 - 6 (108)
9 9 0_DAL Bk-1.0
4 0_DAF Bk-1.0 0_AG Bk-1.0 SHEET 4 - 8 (109)
BB 61A_E Or-0.8 2 2 19P_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
85 86 AA 61R_E Or-0.8 61R_D Or-0.8
40F 19P_B Or-1.0 SPL_A1
27M SPL_D1
SPL_C2
Normally Closed 0_AB Bk-1.0 BB 51_C W-1.0 AA
61R_F Or-0.8 SHEET 3 - 13F CAB PEDESTAL 57 W-1.0 AA 70 28.8 ohms at 20°C (68°F)
0_CF Bk-1.0 BB 68A 39.3 ohms at 20°C (68°F)
10 0_DAY Bk-1.0 107M 264M
7 7 0_DAF Bk-1.0
8 8 49_H S-0.8
9 49_U S-0.8 SHEET 4 - SPL_D8
6
55 5 0_AC Bk-1.0 2 2
73 22.7 ohms at 20°C (68°F)
22 0_X Bk-1.0 SHEET 1 - 163 ENGINE GROUND 58_C W-1.0 1 1 66
56 1 1
11 52 W-1.0 4 5F
158 3 3 52_A W-0.8
19P_B Or-1.0 64A_A Or-0.8 N N 64 Or-1.0 90M SECONDARY STEERING MODULE
2 2 19R_C Or-1.0
39.3 ohms at 20°C (68°F) X X 1 1 SECONDARY STEERING IGNITION
210F 57_A W-0.8 U U 57 W-1.0 51_A W-1.0 2 2 SECONDARY STEERING MOTOR RELEASE
27 27 52_A W-0.8 W W 1_W R-1.0 3 3 SECONDARY STEERING MODULE B+
1 1 68W Or-1.0 24 24 68W_A Or-1.0 D D SPL_A7 SHEET 1 - 176 REAR CHASSIS GROUND STUD 0_CE Bk-1.0 4 4 SECONDARY STEERING CHASSIS GROUND
78 M
2 2 0_F Bk-1.0 SHEET 1 - 162 ENGINE GROUND 25 25 63W_A Or-0.8 SHEET 2 - 199F (33) 0_DAE Bk-1.0 58_A W-0.8 V V 58 W-1.0 5 5 NONE
63W Or-1.0 SPL_D13 SHEET 1 - 18F FUSE BLOCK 19M_A Or-0.8 H H 19M_B Or-1.0 19M_B Or-1.0 1 1 19M_C Or-1.0 6 6 NONE
3 21M 21F SHEET 1 - 222F GROUND CAB 0_DAD Bk-1.0 SHEET 1 - SPL_D25 19R_A Or-0.8 J J 19R_B Or-1.0 19R_B Or-1.0 2 2 7 7 SECONDARY STEERING ACCESSORY
REAR CAB SHEET 3 - 13F CAB PEDESTAL 35X_E Y-0.8 K K 35X_B Y-1.0 35X_C Y-1.0 3 3 35X_D Y-1.0 8 8 SECONDARY STEERING LOW PRESSURE SIGNAL
1 1 S S SPL_A4 51P_B W-1.0 4 4 51P_A W-1.0 9 9 SECONDARY STEERING HIGH PRESSURE
76 M
2 2 0_G Bk-1.0 SHEET 1 - 162 ENGINE GROUND
CHASSIS MAIN 10 0_DAH Bk-1.0 R R 54B W-1.0 AA C 0_AN Bk-1.0 5 5 0_CC Bk-1.0 0_CA Bk-1.0 10 10 NONE
HARNESS HARNESS 7 7 0_DAG Bk-1.0 54B_A W-0.8 54B W-1.0 0_AA Bk-1.0
2 L L BB - 63 6 6 SPL_C1 11 11 SECONDARY STEERING SIGNAL GROUND
8 8 49_K S-1.0 SHEET 4 - 34F (114) 56_J W-0.8 T T 56_C W-1.0 56_A W-1.0 CC + 0_CB Bk-1.0 12 12 SECONDARY STEERING SIGNAL GROUND
9 49_M S-1.0 53B_B W-0.8 180F 180M
M M 53B W-1.0 SPL_A3 10 90M
6 53P_C W-0.8 B B 53P_D W-1.0 FRONT SECONDARY
61 NORMALLY
56_B W-1.0
5 0_DAH Bk-1.0 CHASSIS STEERING
0_DW Bk-0.8 SHEET 2 - 118F (36) 1 1 0_DAJ Bk-1.0 1F 1 CLOSED
54B_A W-0.8 HARNESS MODULE
7 7 49_L S-0.8 SHEET 2 - 118F (36) 4 CAB FRONT 0_CD Bk-1.0 SHEET 1 - 177 REAR ENGINE BLOCK GROUND STUD
8 8 3 3 54B_B W-0.8 SPL_D2 HARNESS
SPL_D23 54B_C W-0.8 MAIN CHASSIS
5 5 19K_D Or-0.8 19K_A Or-1.0 SHEET 1 - 18F FUSE BLOCK 2 2 55A W-0.8 HARNESS HARNESS
10 39F
9
77 6 6 68W_A Or-1.0 SHEET 3 - 56F (51) 51P_B W-1.0 A A N.O.
1 1 68C_A Or-1.0 0_AN Bk-1.0 B B COM
67 Closes at 2.4 bar (35 psi)
4 19K_B Or-1.0 F F 19K_E Or-1.0 35X_A Y-1.0 C C
0_AA Bk-1.0
19K_C Or-1.0 68C_A Or-1.0 68C_B Or-1.0 N.C.
3 3 A A 10 0_DAJ Bk-1.0
2 2 68L_A Or-1.0 68L_A Or-1.0 G G 68L_C Or-1.0 7 7 0_DAK Bk-1.0 SHEET 2 - 38F (31) 131F
45F 68L_B Or-0.8 8 8 49_M S-1.0
23F 23M 9 49_N S-1.0 SHEET 2 - 38F (31)
CAB ROOF 6
MAIN HARNESS 59 5 53B W-1.0 A A 53B_A W-1.0 AA C
HARNESS 4 0_AF Bk-1.0 0_AF Bk-1.0 B B 0_AM Bk-1.0 BB - 62
1 SPL_A2 56_B W-1.0 C C 56_D W-1.0 CC +
81M 56_H W-0.8 SPL_D4
3 3 12F 12M 200
A A 2 2 53P_B W-0.8 SHEET 3 - 56F (51) 0_AK Bk-1.0 SHEET 1 - 145 GROUND CAB
B B 68L_C Or-1.0 XT MODELS: NORMALLY CLOSED
79 M 36F RETURN-TO-DIG HARNESS Z-BAR MODELS: NORMALLY OPEN
C C 19K_E Or-1.0 FOR XT CHASSIS
D D 68C_B Or-1.0
0_AR Bk-1.0
1 1 0_MA Bk-1.0 SHEET 4 - SPL_M6
82M
RETURN-TO-DIG 3 3 53B_B W-0.8
F F 68L_B Or-0.8 4 4 56_G W-0.8
A A 63L_B Or-0.8 2 2 54B_C W-0.8
DIODE C C 0_DAX Bk-0.8 SHEET 1 - 206F CAB FLOOR WELD STUD
60 HEIGHT CONTROL
5 5 56_F W-0.8 58_E W-1.0 AA
MODULE B B 63H_B Or-0.8 RETURN-TO-TRAVEL 1 1 55A W-0.8 53S_D W-1.0 BB
D D 13C_C Or-0.8 SHEET 1 - 57F (58) 6 6 56_E W-0.8 0_AQ Bk-1.0 0_AQ Bk-1.0 CC DIODE
E E 21C_F W-0.8 SHEET 1 - 54F (12) 17M SPL_A6 DD MODULE
140M 75 68.2 ohms - Joystick EE
MOMENTARY 305 ohms - Single Axis F F
PARK INTERMITTENT LOW HIGH 0_AP Bk-1.0 2 2
35F WIPER AND WASHER SWITCH PUSH 65 229M 64A
SHEET 1 - 218F GROUND CAB 0_DAR Bk-1.0 53S_B W-1.0 1 1
SHEET 1 - 18F FUSE BLOCK 19J_A Or-1.0 1 1 BLOWER WIPER SEAT GROUND
19J_B Or-0.8 2 2 FRONT WIPER WASHER FUSED POWER 24V 24V 24V 24V 24V 179F
63W_A Or-0.8 3 3 FRONT WASHER PUMP 24V 39.7 ohms at 20°C (68°F) 58_D W-1.0 AA 58_F W-1.0 BB
61 63C_A Or-0.8 4 4 FRONT WIPER PARK 24V PULSE 53S_D W-1.0 BB 58A_A W-1.0 AA
A A 63H Or-0.8 57 57 63H_A Or-0.8 63H_A Or-0.8 5 5 FRONT WIPER HIGH SPEED 24V 53S_C W-1.0 53S_C W-1.0 CC Normally Closed
B B 63L Or-0.8 58 58 63L_A Or-0.8 63L_A Or-0.8 6 6 FRONT WIPER LOW SPEED 24V PULSE 24V 272F Opens at 6.2 bar (90 psi)
74 M SPL_A5
C C 19J Or-0.8 60 60 19J_B Or-0.8 63H_B Or-0.8 202F 271M
63L_B Or-0.8 35F PINS 4 AND 6 ARE CONNECTED INTERNALLY
D D 63C Or-0.8 59 59 63C_A Or-0.8
61 61 0_DV Bk-0.8 SHEET 1 - 206F CAB GROUND WELD STUD BY THE LIMIT SWITCH INSIDE MOTOR 58A_A W-1.0 AA DIODE
1 1 0_KN Bk-0.8 BB
53S_E W-1.0 C C MODULE
60 13M 13F
PEDESTAL CAB 53S_A W-1.0 BB 273F
53P_D W-1.0 AA 64
HARNESS MAIN
HARNESS 178M ROLLBACK PRESSURE SWITCH
Normally Open JUMPER HARNESS FOR XT CHASSIS
SHEET 5 - MACHINE CONTROLS

RADIO MEMORY
AFTER S/N JEE0133334
1 1_X R-1.0 SHEET 1 - 270F CAB B+ J-BLOCK 94 95

2 18_H Or-0.8
96
Fuse H 7.5 A 92
18_H Or-0.8 6 6
8 8
SHEET 1 - 246M ON 18F FUSE BLOCK CONTACT 5 19L_A Or-1.0 AA AA 65C Or-0.8 6 6 65C_B Or-0.8 14 14 SHEET 1 - 250F CAB B+ J BLOCK 1_V R-5.0 24V IGN 19L_B Or-1.0 SHEET 1 - 249M ON 18F FUSE BLOCK CONTACT 11
24V/12V
SHEET 1 - 247F CAB GROUND J-BLOCK 0_PD Bk-1.0 BB BB 0_PC Bk-0.8 3 3 0_QC Bk-0.8 5 5
255F 256F
CONVERTER
109M 110F 2 2 0_QA Bk-0.8 4 4
REMOTE
1 1 65L_A Or-0.8 11 11
24V
4 4 0_QB Bk-0.8 2 2 TOP CAB
A 5 5 65R_A Or-0.8 9 9
REMOTE 254F 258F
RADIO GROUND
7 7 12V_B R-5.0 SHEET 1 - 18F FUSE BLOCK CONTACT 6
114F 114M WELD STUD 0_RA Bk-5.0 GND 12V 12V_A R-30
10 10 SHEET 1 - 251F CAB GROUND J BLOCK
BB 0_PA Bk-0.8
97 AA 65L Or-0.8
3 3
257F BB 0_DY Bk-1.0 SHEET 1 - 218F GROUND CAB
12 12 1 1 19W_A Or-3.0 SHEET 1 - 260M ON 18F FUSE BLOCK CONTACT 16 AA 19N_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
112M 13 13 91 2 2 0_S Bk-3.0 SHEET 1 - 261F CAB GROUND J-BLOCK
TAPE DECK 82 28M
1 1
AA 259F
BB 0_PB Bk-0.8 113 SHEET 1 - 252F OUTLET GROUND (CAB GROUND WELD STUD) 0_RB Bk-3.0 BB 93
98 AA 65R Or-0.8
B C 253F
111M CIGAR LIGHTER OPTION
1. 24V REMOTE RADIO (ALL CIRCUITS SHOWN INCLUDING BOX B BUT EXCLUDING BOXES A AND C (109M CONNECTED TO 110F)) AIR SEAT OPTION
2. 24V REMOTE RADIO WITH TAPE DECK (ALL CIRCUITS SHOWN INCLUDING BOXES B AND C BUT EXCLUDING BOX A (109M CONNECTED TO 110F)) 24 VOLT - 12 VOLT POWER CONVERTER OPTION
3. 24V RADIO READY (ALL CIRCUITS SHOWN EXCLUDING BOXES A, B, AND C (109M CONNECTED TO 110F))
4. 12V RADIO READY (ALL CIRCUITS SHOWN INCLUDING BOX A BUT EXCLUDING BOXES B AND C)
RADIO OPTIONS
SHEET 6 - OPTIONS
COMPONENTS
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. WIRE NUMBER 10
0_GA Bk-2.0 B B 2 2
9 R
21M 21F
R = RED Y = YELLOW
A 11.
12A.
BC02M134
41 12
14
39
42 6
16
19 13 L
S3 S1 DS2
P
40
LS
BR3 7
P
18 R
T
33
20
BR1 32
17 T Pst P
LOCK
SX UNLOCK
241 BAR
(3495 PSI) 25
45 BAR 30 BAR
(653 PSI) (435 PSI)
36 LS
BR2
38 26
20
DS1 S2 T N 250 BAR 11 10

16 XT MODELS (3626 PSI)
15
39
XT MODELS 0.7 L/min

12
XY
5
XZ
Z-BAR and
NOTE 3 XR MODELS
XT MODELS
b1 a1
290 BAR
(4206 PSI) A1
XY XY
XZ XZ
B1 5
Z-BAR and XR MODELS

M1 TANK
NOTE 1
193
Z-BAR and
21 BAR XR MODELS
31 (2800 PSI)
35 a2
M1 TANK
136
BAR A2
136
M2 (1975 PSI) BAR 1 6-8 BAR 4
(1975 PSI) b2 (87-116 PSI) B2
IN
23 P
M2
IN
22 2
T
3
b3 a3
34
290 BAR
(4206 PSI) A3
290 BAR B3
(4206 PSI)
4 1
SOLENOID
28 27 B X
2 VALVE A B
P T
NOTE 2 b4 a4 2
SEQUENCE
1 Y
290 BAR VALVE
(4206 PSI) A4
2
9 LS EF CF 290 BAR B4
(4206 PSI)
X Z1 Y X2
24 PP X1
LOGIC
240 BAR 1 VALVE
(3481 PSI) S2 S1 MP
MA MX 3
30 37 RELIEF
VALVE
8 T P
S L1 L
A T
M
29
43 43
COMPONENTS NOTES HYDRAULIC SYMBOLS

1. RIDE CONTROL VALVE (OPTION) 5. BUCKET CYLINDER (XT MODELS) 9. AUXILIARY STEERING PRIORITY VALVE 15. BRAKE LIGHT PRESSURE SWITCH DISPLACEMENT: 14 CC/REV (0.85 CU IN./REV) 32. PILOT PRESSURE ACCUMULATOR 38. LOAD SENSING PRESSURE DIAGNOSTIC
2. RIDE CONTROL ACCUMULATOR (OPTION) BORE: 104.80 MM (4.125 IN) (OPTION - NORTH AMERICAN MODELS) 4.1 BAR (60 PSI) PRECHARGE: 13.8 BAR (200 PSI) COUPLER 1. CHECK AND RELIEF VALVES NOT USED WITH
25. COUPLER LOCKING VALVE (OPTION)
PRECHARGE: 14.5 BAR (250 PSI) ROD: 57.20 MM (2.25 IN) RELIEF PRESSURE: 240.3 BAR (3481 PSI) 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER (2) 26. COUPLER LOCKING CYLINDERS (2) (OPTION) CAPACITY: 0.95 LITRE (58 CU IN.) 39. REDUNDANT BRAKE PRESSURE SWITCH FAN REVERSER. PRESSURE
CAPACITY: 3.78 LITRES (231 CU IN.) STROKE: 954.30 MM (37.57 IN) 10. AUXILIARY STEERING PRESSURE SWITCH 17. REAR BRAKE CYLINDERS 27. IMPLEMENT HYDRAULIC PUMP 33. PILOT PRESSURE DIAGNOSTIC COUPLER (2) 2. REVERSE FLOW CHECK VALVE (OPTION) COMPONENT
6. STEERING CONTROL VALVE CROSSING LINES CHECK VALVE FILTER OR SCREEN
3. RIDE CONTROL ACCUMULATOR BLEEDER VALVE 2.4 BAR (35 PSI) MODULATION PRESSURE: 84 +7 BAR (1218 +101 PSI) DISPLACEMENT: 90 CC/REV (5.49 CU IN./REV) 34. FLOAT SWITCH - CLOSES AT 24 BAR (350 PSI) CLOSES AT 62 BAR (900 PSI) USED ONLY WITH RIDE CONTROL.
4. LIFT CYLINDERS) DISPLACEMENT: 590 CC/REV (36 CU IN./REV) 11. STEERING PRESSURE DIAGNOSTIC COUPLER 18. FRONT BRAKE CYLINDERS CUTOFF: 280 BAR (4061 PSI) 35. CONTROLLER WITH TWO SPOOL LOADER VALVE 40. AUXILIARY STEERING LOAD SENSE RETURN
3. Z-BAR AND XR MODELS - 290 BAR (4206 PSI)
BORE: 114.30 MM (4.50 IN) 1.6:1 FLOW AMPLIFICATION 12. BRAKE ACCUMULATORS (2) MODULATION PRESSURE: 90 +7 BAR (1305 +101 PSI) DELTA: 22 BAR (319 PSI) TWO LEVER OR JOYSTICK CONTROLLER SOLENOID VALVE (OPTION - NORTH
ROD: 63.50 MM (2.50 IN) 7. STEERING CYLINDERS (2) PRECHARGE: 55 ±1.7 BAR (800 ±25 PSI) 19. PARKING BRAKE CYLINDER 28. HYDRAULIC FILTER ASSEMBLY 35. CONTROLLER WITH THREE SPOOL LOADER VALVE AMERICAN MODELS) XT MODELS - 183 BAR (2654 PSI) LOAD SENSE
STROKE: 787.70 MM (31.01 IN) BORE: 69.9 MM (2.75 IN) CAPACITY: 1.90 LITRE (116 CU IN.) 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC FITTINGS (2) BYPASS VALVE: 3.4 BAR (50 PSI) THREE LEVER OR JOYSTICK WITH ONE LEVER CONTROLLER 41. PARKING BRAKE ACCUMULATOR
ROD: 38.10 MM (1.50 IN) PILOT PRESSURE LINE CONNECTION RESTRICTOR OIL COOLER
5. BUCKET CYLINDER (Z-BAR MODELS) 13. BRAKE VALVE AND ACCUMULATOR CHARGING VALVE 21. FAN DRIVE MOTOR WARNING SWITCH: 2.7 BAR (40 PSI) 35. CONTROLLER WITH FOUR SPOOL LOADER VALVE PRECHARGE: 97 BAR (1407 PSI)
BORE: 127.00 MM (5.00 IN) STROKE: 462.50 MM (18.21 IN) CUT-IN: 157 +10 BAR (2277 +145 PSI) DISPLACEMENT: 14 CC/REV (0.85 CU IN./REV) 29. HYDRAULIC RESERVOIR JOYSTICK WITH TWO LEVER CONTROLLER CAPACITY: 0.5 LITRE (31 CU IN.)
ROD: 76.20 MM (3.00 IN) 8. AUXILIARY STEERING MOTOR AND PUMP CUT-OUT: 193 ±3 BAR (2800 ± 43 PSI) 22. FAN REVERSING VALVE (OPTION) TOTAL VOLUMN: 83.3 LITRES (22 U.S. GALLONS) 36. LOADER CONTROL VALVE 42. PARKING BRAKE ACCUMULATOR HYDRAULIC SCHEMATIC
STROKE: 619.80 MM (24.40 IN) (OPTION - NORTH AMERICAN MODELS) 14. BRAKE WARNING PRESSURE SWITCH RELIEF SETTING: 170 BAR (2466 PSI) OIL CAPACITY: 56.8 LITRES (15 U.S. GALLONS) TWO SPOOL (STANDARD) PRESSURE DIAGNOSTIC COUPLER
DISPLACEMENT: 11 CC/REV (0.671 CU IN./REV) 141 BAR (2045 PSI) RISING 23. FAN VALVE (STANDARD) 30. HYDRAULIC RESERVOIR BREATHER THREE SPOOL (OPTION) 43. 100 MESH STRAINER (2) 621D Z-BAR, 621D XR, and 621D XT WHEEL LOADERS
117 BAR (1697 PSI) FALLING RELIEF SETTING: 136 BAR (1975 PSI) 20 MICRON BREATHER FOUR SPOOL (OPTION) Additional copies of this Hydraulic and Electrical Schematic can be ordered through
24. BRAKE HYDRAULIC PUMP 31. HYDRAULIC COOLER (OPTION) 37. PUMP PRESSURE DIAGNOSTIC COUPLER Technical Publications Distribution System. The Part Number is 6-43052
BC02D013
41 12
14
39
16 6
19 13 L
S3 S1 DS2
P
40
LS
BR3 7
P
18 R
T
33
20
BR1 32
17 T Pst P
LOCK
SX UNLOCK
241 BAR
(3495 PSI) 25
45 BAR 30 BAR
(653 PSI) (435 PSI)
36 LS
BR2
38 26
20
DS1 S2 T N 250 BAR 11 10

16 XT MODELS (3626 PSI)
15
39
XT MODELS 0.7 L/min

12
XY
5
XZ
Z-BAR and
NOTE 3 XR MODELS
XT MODELS
b1 a1
290 BAR
(4206 PSI) A1
XY XY
XZ XZ
B1 5
Z-BAR and XR MODELS

M1 TANK
NOTE 1
193
Z-BAR and
21 BAR XR MODELS
31 (2800 PSI)
35 a2
M1 TANK
136
BAR A2
136
M2 (1975 PSI) BAR 1 6-8 BAR 4
(1975 PSI) b2 (87-116 PSI) B2
IN
23 P
M2
IN
22 2
T
3
b3 a3
34
290 BAR
(4206 PSI) A3
290 BAR B3
(4206 PSI)
4 1
SOLENOID
28 27 B X
2 VALVE A B
P T
NOTE 2 b4 a4 2
SEQUENCE
1 Y
290 BAR VALVE
(4206 PSI) A4
2
9 LS EF CF 290 BAR B4
(4206 PSI)
X Z1 Y X2
24 PP X1
LOGIC
240 BAR 1 VALVE
(3481 PSI) S2 S1 MP
MA MX 3
30 37 RELIEF
VALVE
8 T P
S L1 L
A T
M
29
42 42
COMPONENTS NOTES HYDRAULIC SYMBOLS

1. RIDE CONTROL VALVE (OPTION) 5. BUCKET CYLINDER (XT MODELS) 9. AUXILIARY STEERING PRIORITY VALVE 15. BRAKE LIGHT PRESSURE SWITCH DISPLACEMENT: 14 CC/REV (0.85 CU IN./REV) 32. PILOT PRESSURE ACCUMULATOR 38. LOAD SENSING PRESSURE DIAGNOSTIC
2. RIDE CONTROL ACCUMULATOR (OPTION) BORE: 104.80 MM (4.125 IN) (OPTION - NORTH AMERICAN MODELS) 4.1 BAR (60 PSI) PRECHARGE: 13.8 BAR (200 PSI) COUPLER 1. CHECK AND RELIEF VALVES NOT USED WITH
25. COUPLER LOCKING VALVE (OPTION)
PRECHARGE: 14.5 BAR (250 PSI) ROD: 57.20 MM (2.25 IN) RELIEF PRESSURE: 240.3 BAR (3481 PSI) 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER (2) 26. COUPLER LOCKING CYLINDERS (2) (OPTION) CAPACITY: 0.95 LITRE (58 CU IN.) 39. REDUNDANT BRAKE PRESSURE SWITCH FAN REVERSER. PRESSURE
CAPACITY: 3.78 LITRES (231 CU IN.) STROKE: 954.30 MM (37.57 IN) 10. AUXILIARY STEERING PRESSURE SWITCH 17. REAR BRAKE CYLINDERS 27. IMPLEMENT HYDRAULIC PUMP 33. PILOT PRESSURE DIAGNOSTIC COUPLER (2) 2. REVERSE FLOW CHECK VALVE (OPTION) COMPONENT
6. STEERING CONTROL VALVE CROSSING LINES CHECK VALVE FILTER OR SCREEN
3. RIDE CONTROL ACCUMULATOR BLEEDER VALVE 2.4 BAR (35 PSI) MODULATION PRESSURE: 84 +7 BAR (1218 +101 PSI) DISPLACEMENT: 90 CC/REV (5.49 CU IN./REV) 34. FLOAT SWITCH - CLOSES AT 24 BAR (350 PSI) CLOSES AT 62 BAR (900 PSI) USED ONLY WITH RIDE CONTROL.
4. LIFT CYLINDERS) DISPLACEMENT: 590 CC/REV (36 CU IN./REV) 11. STEERING PRESSURE DIAGNOSTIC COUPLER 18. FRONT BRAKE CYLINDERS CUTOFF: 280 BAR (4061 PSI) 35. CONTROLLER WITH TWO SPOOL LOADER VALVE 40. AUXILIARY STEERING LOAD SENSE RETURN
3. Z-BAR AND XR MODELS - 290 BAR (4206 PSI)
BORE: 114.30 MM (4.50 IN) 1.6:1 FLOW AMPLIFICATION 12. BRAKE ACCUMULATORS (2) MODULATION PRESSURE: 90 +7 BAR (1305 +101 PSI) DELTA: 22 BAR (319 PSI) TWO LEVER OR JOYSTICK CONTROLLER SOLENOID VALVE (OPTION - NORTH
ROD: 63.50 MM (2.50 IN) 7. STEERING CYLINDERS (2) PRECHARGE: 55 ±1.7 BAR (800 ±25 PSI) 19. PARKING BRAKE CYLINDER 28. HYDRAULIC FILTER ASSEMBLY 35. CONTROLLER WITH THREE SPOOL LOADER VALVE AMERICAN MODELS) XT MODELS - 183 BAR (2654 PSI) LOAD SENSE
STROKE: 787.70 MM (31.01 IN) BORE: 69.9 MM (2.75 IN) CAPACITY: 3.0 LITRE (183 CU IN.) 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC FITTINGS (2) BYPASS VALVE: 3.4 BAR (50 PSI) THREE LEVER OR JOYSTICK WITH ONE LEVER CONTROLLER 41. PARKING BRAKE ACCUMULATOR
ROD: 38.10 MM (1.50 IN) PILOT PRESSURE LINE CONNECTION RESTRICTOR OIL COOLER
5. BUCKET CYLINDER (Z-BAR MODELS) 13. BRAKE VALVE AND ACCUMULATOR CHARGING VALVE 21. FAN DRIVE MOTOR WARNING SWITCH: 2.7 BAR (40 PSI) 35. CONTROLLER WITH FOUR SPOOL LOADER VALVE PRECHARGE: 97 BAR (1407 PSI)
BORE: 127.00 MM (5.00 IN) STROKE: 462.50 MM (18.21 IN) CUT-IN: 157 +10 BAR (2277 +145 PSI) DISPLACEMENT: 14 CC/REV (0.85 CU IN./REV) 29. HYDRAULIC RESERVOIR JOYSTICK WITH TWO LEVER CONTROLLER CAPACITY: 0.16 LITRE (9.8 CU IN.)
ROD: 76.20 MM (3.00 IN) 8. AUXILIARY STEERING MOTOR AND PUMP CUT-OUT: 193 ±3 BAR (2800 ± 43 PSI) 22. FAN REVERSING VALVE (OPTION) TOTAL VOLUMN: 83.3 LITRES (22 U.S. GALLONS) 36. LOADER CONTROL VALVE 42. 100 MESH STRAINER (2) HYDRAULIC SCHEMATIC P.I.N. JEE0135501 AND ABOVE
STROKE: 619.80 MM (24.40 IN) (OPTION - NORTH AMERICAN MODELS) 14. BRAKE WARNING PRESSURE SWITCH RELIEF SETTING: 170 BAR (2466 PSI) OIL CAPACITY: 56.8 LITRES (15 U.S. GALLONS) TWO SPOOL (STANDARD)
DISPLACEMENT: 11 CC/REV (0.671 CU IN./REV) 141 BAR (2045 PSI) RISING 23. FAN VALVE (STANDARD) 30. HYDRAULIC RESERVOIR BREATHER THREE SPOOL (OPTION) 621D Z-BAR, 621D XR, and 621D XT WHEEL LOADERS
117 BAR (1697 PSI) FALLING RELIEF SETTING: 136 BAR (1975 PSI) 20 MICRON BREATHER FOUR SPOOL (OPTION) Additional copies of this Hydraulic and Electrical Schematic can be ordered through
24. BRAKE HYDRAULIC PUMP 31. HYDRAULIC COOLER (OPTION) 37. PUMP PRESSURE DIAGNOSTIC COUPLER Technical Publications Distribution System. The Part Number is 6-49310
BC02M135

621d Manual de Serviços

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621d Manual de Serviços

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621D Loader

Fuel System Tab 3

Copyright © 2004 CNH Ameica LLC.

Power Train Tab 6

Mounted Equipment Tab 9

Air Conditioner System Service 9003 6-42660

Bur 6-44624 Revised 9-04 Printed in U.S.A.

NOTE: Case Corporation reserves the right to make improvements in design or

Copyright © 2004 CNH Ameica LLC.

Section Title Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

STANDARD TORQUE SPECIFICATIONS

CASE CANADA CORPORATION

TORQUE SPECIFICATIONS - METRIC HARDWARE ........................................................................................... 4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ............................................................................ 5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ............................................................................ 6

NOTE: Case Corporation reserves the right to make improvements in design or

Rac 8-71602 Revised 5-99 Printed in U.S.A

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Rac 8-71602 Revised 5-99 Printed in U.S.A

TORQUE SPECIFICATIONS - METRIC HARDWARE

M12 66 to 79 90 to 107 M30 1470 to 1770 2000 to 2400

M16 160 to 200 217 to 271

M36 1600 to 1950 2175 to 2600

Rac 8-71602 Revised 5-99 Printed in U.S.A

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton

Split Flange Mounting Bolts

Rac 8-71602 Revised 5-99 Printed in U.S.A

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

Rac 8-71602 Revised 5-99 Printed in U.S.A

FLUIDS AND LUBRICANTS

Bur 6-42981 Revised 6-02 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Bur 6-42981 Revised 6-02 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS

crankcase. The oil change

Bur 6-42981 Revised 6-02 Printed in U.S.A.

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

Bur 6-42981 Revised 6-02 Printed in U.S.A.

EVERY 10 HOURS OF OPERATION OR EACH DAY - WHICHEVER OCCURS FIRST

EVERY 50 HOURS OF OPERATION

EVERY 100 HOURS OF OPERATION

EVERY 250 HOURS OF OPERATION

EVERY 500 HOURS OF OPERATION

EVERY 1000 HOURS OF OPERATION

EVERY 2000 HOURS OF OPERATION OR EACH YEAR - WHICHEVER OCCURS FIRST

Bur 6-42981 Revised 6-02 Printed in U.S.A.

Bur 6-42981 Revised 6-02 Printed in U.S.A.

Bur 6-42981 Revised 6-02 Printed in U.S.A.

METRIC CONVERSION CHART

CASE CANADA CORPORATION

Bur 7-52950 Issued 6-97 Printed in U.S.A

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.