Forw tm2123

Technical manual
Forwarders
TM 2123
TECHNICAL MANUAL
Forwarders TM2123
tm2123 14AUG03 (ENGLISH)
For complete service information also see:

8100D operator‘s Manual . . . . . . . . . . . . . . . F064833
Deere engine 6081 HTJ 03 Manual . . . . . . . CTM 86
Fuel system Manual for 4,5 and 6.8 l diesel
engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM 331
Fuel system Manual for 8,1l diesel
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM 255
TMC Workshop . . . . . . . . . . . . . . . . . . . . . . . F064497
Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F062701
Timbermatic 700 / 900 . . . . . . . . . . . . . . . . . . F065312
LCS Technical manual . . . . . . . . . . . . . . . . . F061919
Worldwide Construction
And Forestry Division
Litho in Finland
Introduction
Foreword
This manual is written for an experienced technician.

Essential tools required in performing certain service work
are identified in this manual and are recommended for
use.
Live with safety: Read the safety messages in the

introduction of this manual and the cautions presented
throughout the text of the manual.
: This is the safety-alert symbol. When you see this

symbol on the machine or in this manual, be alert to the
potential for personal injury.
This technical manual is concise guide for specific

machine type. This is on-the-job guide containing only the
vital information needed for diagnosis, analysis, testing,
and repair.
Fundamental service information is available from other

sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type
of failures and their causes.
OUTJ003,0000344 –19–22JAN01–1/1
Serial Numbers
This Manual covers the following range of Forwarders

serial numbers:
• WJ810D0001405...
• WJ1010D003505...
• WJ1110D001125...
• WJ1410D000475...
• WJ1710D000375...
JK11466,0000003 –19–14AUG03–1/1
Timberjack Contact Information
Please, contact our web site: www.Timberjack.com.
EL62757,000015B –19–19APR02–1/1
tm2123 (14AUG03) Forwarders Technical Manual

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Introduction
Technical Information Feedback Form
We need your help to continually improve our Technical

manuals please FAX or mail your comments, ideas and
improvements on this comment sheet.
SEND TO: Timberjack Oy

P.O. Box 474
FIN-33101 Tampere
Finland
Attn: Publications Supervisor
FAX NUMBER: +358 205 84 6160
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EL62757,000015C –19–19APR02–1/1

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Introduction

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Contents
00
SECTION 00—General Information Group 1650—LCS- Loader Control System
Group 0010—Safety features Group 1660—Alternator
Group 0020—General Specifications Group 1680—Starter Motor
Group 0030—Torque Values
Group 0040—Fluids and Lubricants SECTION 17—Frames
01
Group 0050—Transporting and Towing Group 1710—Frame installation
Group 0060—Inspection and Procedures Group 1720—Frame Hinge
Group 1740—Operational Checks
SECTION 01—Wheels
Group 0110—Wheels Service SECTION 18—Cabin
Group 1810—Cabin Environment 02
SECTION 02—Power Train Group 1820— Cabin Service

Group 0210—Theory of Operation
Group 0220—Transfer case SECTION 19—Heating and Air Conditioning System
Group 0230—Drive shaft Group 1910—General
Group 0240—Axles / Bogie Group 1920—Air Conditioning / Heater Components 03
Group 0250—Brakes Group 1930—Diagnosing Air Conditioning / Heater
System
SECTION 03—Hydraulic systems
SECTION 37 —Booms
Group 0310—General
Group 3710—Forwarder Booms
Group 0320—Drive Hydraulics Service 04
Group 3720—Boom Parts Removal and Installation
Group 0325—Checking and Adjusting Drive
Group 3730—Booms Removal and installation
Hydraulics
Group 3740—Diagnostic Information
Group 0330—Work Hydraulics
Group 3750—Boom overall maintenance
Group 0335—Work Hydraulics Service
Group 0340—Work Hydraulics Checking and
Adjusting SECTION 38—Decking Blade 05
Group 0350—Hydraulic Cylinders Group 3810—Theory of Operation
Group 0360—Hydraulic Schematics Group 3820—Service
Group 0380—Appendix Manuals SECTION 40—Grapple
16
Group 4020—Removal and Installation
SECTION 04—Engine Group 4030—Grapple Service
Group 0410—Engine mounting and dismounting Group 4040—Grapple Rotator
Group 0420—Engine Group 4050—Diagnostics
SECTION 05—Engine Auxiliary system SECTION 45—Tool Drawings 17

Group 0510—Auxiliary Systems Group 4510—Dealer Fabricated Tools
SECTION 16—Electrical-System SECTION 80—Optional Equipments

Group 1610—Main Electrical System Group 8010— Engine Preheater; EbenSprächer
Group 1620—Electrical Schematics Group 8020—1410 and 1710D Decking Blade 18
Group 1630—Electrical Sensors
Group 1640—Control Systems Continued on next page
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 19
COPYRIGHT  2003
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
tm2123 (14AUG03) i Forwarders Technical Manual

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Contents
00
Group 8030—Fire Extinguisher
01
02
03
04
05
16
17
18
19
tm2123 (14AUG03) ii Forwarders Technical Manual

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38
40
45
80
INDX
tm2123 (14AUG03) iii Forwarders Technical Manual

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Contents
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38
40
45
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INDX
tm2123 (14AUG03) iv Forwarders Technical Manual

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00
Section 00
General Information
Contents
Page Page
Group 0010—Safety features Service Recommendations for O-Ring

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0010-1 Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0030-8
Decals and Signs . . . . . . . . . . . . . . . . . . . . .00-0010-2 Service Recommendations for Flat Face
Forwarders Safety Features . . . . . . . . . . . . .00-0010-7 O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0030-10
Recognize Safety Information . . . . . . . . . . . .00-0010-7 Service Recommendations For Inch
Understand Signal Words . . . . . . . . . . . . . . .00-0010-8 Series Four Bolt Flange Fittings. . . . . . . .00-0030-11
Replace Safety Signs . . . . . . . . . . . . . . . . . .00-0010-8 Service Recommendations for Metric
Maintain Safety Cabin . . . . . . . . . . . . . . . . . .00-0010-9 Series Four Bolt Flange Fitting . . . . . . . .00-0030-12
Park Machine Safely . . . . . . . . . . . . . . . . . .00-0010-10 Metric Flanged Head . . . . . . . . . . . . . . . . . .00-0030-13
Support Machine Properly . . . . . . . . . . . . . .00-0010-11 O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0030-14
Securing the Service Position . . . . . . . . . . .00-0010-12 SAE Code 61 and 62 Flanges. . . . . . . . . . .00-0030-15
Use Proper Lifting Equipment . . . . . . . . . . .00-0010-13 Tapered Pipe Treads (NPTF and NPT) . . . .00-0030-16
Remove Paint Before Welding or Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . .00-0030-17
Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0010-13
Welding Cautions . . . . . . . . . . . . . . . . . . . .00-0010-14 Group 0040—Fluids and Lubricants
Attach Do not Operate Tag . . . . . . . . . . . . .00-0010-15 Recommended Lubricants and Fluids . . . . . .00-0040-1
Illuminate Work Area Safely . . . . . . . . . . . .00-0010-16 Fluid and Lubricant Capacities . . . . . . . . . . .00-0040-2
Using the Xenon Worklamp. . . . . . . . . . . . .00-0010-16 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-4
Driving and Service . . . . . . . . . . . . . . . . . . .00-0010-17 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-7
Use of Radio-transmitters . . . . . . . . . . . . . .00-0010-17 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-8
Prepare for Emergencies. . . . . . . . . . . . . . .00-0010-18 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-9
Handle Fluids Safely—Avoid Fires . . . . . . .00-0010-18 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-9
Handle Chemical Products Safely . . . . . . . .00-0010-19 Brake fluid. . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-9
Dispose of waste properly . . . . . . . . . . . . . .00-0010-19 Cab lift pump. . . . . . . . . . . . . . . . . . . . . . . .00-0040-10
Avoid High-Pressure Fluids . . . . . . . . . . . . .00-0010-20 Lubricant Storage . . . . . . . . . . . . . . . . . . . .00-0040-10
Wear Protective Clothing. . . . . . . . . . . . . . .00-0010-21 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-10
Group 0020—General Specifications Group 0050—Transporting and Towing

Timberjack Tools For Forwarders . . . . . . . . .00-0020-1 Transporting the Machine . . . . . . . . . . . . . . .00-0050-1
Use Proper Tools . . . . . . . . . . . . . . . . . . . . .00-0020-1 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0050-2
General Component Locator . . . . . . . . . . . . .00-0020-2 Stowing a Disabled Boom . . . . . . . . . . . . . . .00-0050-6
Machine Dimensions . . . . . . . . . . . . . . . . . . .00-0020-3
Power Unit Specifications . . . . . . . . . . . . . . .00-0020-9 Group 0060—Inspection and Procedures
Power Train Specifications . . . . . . . . . . . . .00-0020-10 Machine Operational Checkout . . . . . . . . . . .00-0060-1
Hydraulic System Specifications . . . . . . . . .00-0020-12 Machine Condition and Cleanliness. . . . . . . .00-0060-1
Tires Specifications . . . . . . . . . . . . . . . . . . .00-0020-18 Engine Operation . . . . . . . . . . . . . . . . . . . . .00-0060-2
Boom Specifications . . . . . . . . . . . . . . . . . .00-0020-21 Brake Systems . . . . . . . . . . . . . . . . . . . . . . .00-0060-3
Rotator GV12-2 . . . . . . . . . . . . . . . . . . . . . .00-0020-31 Steering System . . . . . . . . . . . . . . . . . . . . . .00-0060-5
Grapple Specifications. . . . . . . . . . . . . . . . .00-0020-32 Driving Checks . . . . . . . . . . . . . . . . . . . . . . .00-0060-6
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . .00-0060-9
Group 0030—Torque Values Wheels and Tires . . . . . . . . . . . . . . . . . . . .00-0060-10
Tightening Torque for Bolted Joints. . . . . . . .00-0030-1 Cab Components . . . . . . . . . . . . . . . . . . . .00-0060-11
Unified Inch Bolt and Cap Screw Torque Accessories. . . . . . . . . . . . . . . . . . . . . . . . .00-0060-16
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0030-5 Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0060-23
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0030-7 Continued on next page
tm2123 (14AUG03) 00-1 Forwarders Technical Manual

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Contents
00
Page
Operational Checkout Record Sheet . . . . . .00-0060-27

Troubleshooting Techniques . . . . . . . . . . . .00-0060-30

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Group 0010
Safety features
00
General 0010
1
Comply with instructions in this manual and also your

company’s regulations.
Should there be any information or instructions in this

manual that are not in compliance with local laws and
regulations in force in the country or region where this
equipment is operated, the local laws and regulations
must take precedence.
This machine should not be operated or maintained by

personnel other than those who have been thoroughly
trained.
As the maintainer ensure that you become familiar with all

occupational safety regulations pertaining to forest
machinery as well as all safety instructions pertaining to
this equipment. Observe the instructions provided in this
manual and on all hazard and information decals on the
machine.
OUTJ003,00004A0 –19–15FEB01–1/1
tm2123 (14AUG03) 00-0010-1 Forwarders Technical Manual

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Safety features
00
0010 Decals and Signs
2
–UN–09APR03
T189423
810D Decals and Signs
A—Punched serial number on

the front frame, on the
right side of the machine.
Continued on next page EL62757,00001E5 –19–22APR02–1/5

081403
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Safety features
00
0010
3
–UN–11NOV02
T161525
A—Pressed manufacturing
number, on the front
frame, on the right side of
the machine (optional)

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Safety features
00
0010
4
–UN–30JAN03
T164794
A—Punched serial number on

the front frame, on the
right side of the machine.

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Safety features
00
0010
5
–UN–19MAR03
T160263
A—Serial number B—Behind the front frame, on

On the front frame, on the the left side
right side of the machine
(optional)

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Safety features
00
0010
6
–UN–16MAR03
T152784
1710D Decals and signs
A—Serial number B—Behind the front frame, on

On the front frame, on the the left side
right side of the machine
(optional)
EL62757,00001E5 –19–22APR02–5/5

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Safety features
00
Forwarders Safety Features 0010
7
–UN–30JAN03
T164793
Forwarders Safety
1—Secondary exit. The 4—Seat safety switch. No 7—Frame brake. Locks the 9—Emergency stop Stops the
right-hand cap window can function can be engaged horizontal hinge of the machine and engages the
be used as a secondary before somebody sits on machine. parking brake.
exit from the cab. the seat. 8—Hand-held fire 10—Stairs, anti-slips on the
2—ROPS. Integrated rollover 5—Safety signs. Warn and extinguishers and fire steps, handrails. Help to
and operator protective give safety information for extinguisher system (opt.) climb into the machine.
structures fully enclose the operator.
and protect the operator 6—Back-up alarm (opt). Allerts
3—Central warning light and bystanders when machine
alarms (+buzzer).Alarm is reversing.
when malfunctions occur.
Please remember, the Operator is the key to

preventing accidents.
OUTJ003,00005CF –19–10MAY01–1/1
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol

–UN–28AUG00
on your machine or in this manual, be alert to the

potential for personal injury.
Follow recommended precautions and safe operating

T133555
practices.
DX,ALERT –19–29SEP98–1/1

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Safety features
00
0010 Understand Signal Words
8
A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
Replace Safety Signs
Carefully study all of the safety messages that are in this

manual and on the machine.
More specific measures are illustrated with pictographs

which may also be attached to the machine in locations
–UN–23AUG88
pertinent to their respective message.
Keep safety signs in good condition. Repair or replace

damaged signs.
TS201
DX,SIGNS1 –19–04JUN90–1/1

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Safety features
00
Maintain Safety Cabin 0010
9
Cabin is safety tested according to international ROPS,

FOPS and OPS standards.
Do not operate the machine with the door open or any of

the safety covers or protective devices removed.
It is important to keep the operator protective structure in

place (doors, screens, windows, windshield, etc.) to
minimize hazards from whipping or intruding objects.
The protection offered by ROPS, FOPS and OPS will be

impaired if cabin
• is subjected to structural damage

• is involved in an overturn incident
• is in any way altered by welding, bending, drilling, or
cutting
To maintain ROPS, FOPS and OPS protection, replace

damaged cabin parts immediately. A damaged structure
should be replaced, not reused.
Do not attach any parts on the cabin by welding nor drill

any holes on it because it is a safety cabin. It is forbidden
to modify the window fastening.
AK12300,000010A –19–05NOV01–1/1

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Safety features
00
0010 Park Machine Safely
10
Before working on the machine:
1. Park machine on a level surface.
2. Lower decking blade to the ground.
–UN–24MAY89
3. Secure boom and grapple in woodbunk.
TS230
CAUTION: Prevent unexpected machine
movement and possible injury. Connect frame
locking pin to both frames before working in
frame hinge pivot area.
4. Install frame locking pin before working in frame hinge

pivot area.
5. Engage park brake.
6. Run engine at 1/2 speed for 2 minutes before stopping

to avoid damage to turbocharger.
7. Turn key switch OFF. Remove key from switch. (If

maintenance must be performed with engine running,
DO NOT leave machine unattended.)
8. Attach a “Do Not Operate” tag to the key switch.
IMPORTANT: The mechanic, and foreman must be

familiar with the safety rules and
regulations provided in this technical
manual and in the decals of the
machine, as well as with those related
to national road traffic and occupational
safety.
All safety rules and regulations in effect

pertaining to the machine and
workplace must be obeyed.
DX,PARK –19–04JUN90–1/1

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Safety features
00
Support Machine Properly 0010
11
Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment. If left in a raised position,
hydraulically supported devices can settle or leak down.
–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When working underneath raised equipment, always

ensure that the equipment is supported on rigid blocks,
jack stands or other stable support.
Do not use jacks, the dozer blade, grapple attachment, or

boom to hold the machine in a raised position.
Install the frame lock to prevent accidental articulation of

the machine.
OUTJ003,00005A9 –19–09MAY01–1/1

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Safety features
00
0010 Securing the Service Position
12
Before dismantling parts subjected to load, hydraulic

cylinders, stays, wheels, etc., they must be supported and
relieved so as to eliminate the risk of injury.
–UN–06JUN01
Having raised the cab to its full height, always lock the
safety support in place. Do not use any middle position.
Make sure that nobody comes close to the cab when
raising or lowering it.
T139371
CAUTION: When lowering cab, its lowering
speed may accelerate when the cab is appr. 5
centimeters from the fastening studs. Make
sure that nobody comes too close to the cab
when lowering it.
CAUTION: The use of engine hoods and belly

pans may have been facilitated by means of lift
supports. Should these supports become
defective, the cover may unexpectedly come
down. Do not go under these parts when
lifting/lowering them or before they are properly
secured in the uppermost position.
Before disconnecting any load-bearing parts, secure the
–UN–19MAR02
vertical hinge of the machine.
Likewise, also secure the horizontal hinge, if necessary,

as applicable under the circumstances.
T152685
If the machine breaks down in difficult terrain, and cannot 1
be moved prior to being repaired, take extra care to fully
immobilize the machine and all rotating or moving parts. 1—Frame lock
Install the frame lock (1) to prevent accidental articulation

of the machine.
Read the manual carefully and follow the maintenance

procedures provided.
NOTE: The operator and serviceman are responsible for

safety on and around the machine.
EL62757,000016A –19–19APR02–1/1

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Safety features
00
Use Proper Lifting Equipment 0010
13
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and

installation of components in the manual.
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.
Remove paint before welding or heating:
TS220
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is ventilated to carry toxic

fumes and dust away.
DX,PAINT –19–03MAR93–1/1

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Safety features
00
0010 Welding Cautions
14
Before you start arc welding the machine, do the following
Ensure that the area to be repaired is cleaned of debris

and combustible material. Have a charged fire
–UN–20MAR02
extinguisher available and know how to use it.
1. The first actions

a. turn the main switch off
T152800
b. disconnect the wire (1) between the battery and the
frame.
c. disconnect central unit wires of the automatic fire Disconnect battery cable
extinguishing system (Not in model 1010D) (A) and
the tripping of the extinguisher (F).
d. disconnect ECU’s cable
e. disconnect Hub’s cables (5 cables)
2. Grounding
a. Connect the ground wire as close to the welding
point as possible.
b. The welding current must never pass through
bearings, joints, electrical equipment, or hydraulic
systems.
–UN–01OCT02
3. The parts that must never be welded:
• boom fastening bolts
• control valves
• hydraulic pipes
T159874
4. The parts that must not be welded without the ECU cables
manufacturer’s instructions:
• castings
• cylinder loops.
5. The points and components to which it is

forbidden to attach other parts by welding:
• castings
• boom ends
• cylinder fastening lugs
• corners of box girders
6. Welding.
–UN–13SEP02
T159362
Hub in cab
Continued on next page OUTJ003,00004AF –19–15FEB01–1/2

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PN=22
Safety features
00
Weld inside, if possible, in facilities reserved for this 0010
15
purpose where the temperature is at least 10 degrees
centigrade. If welding in other places, pay attention to
local regulations and to circumstances as well as to the
environment before you start welding.
The welder must possess adequate skills and the
permits required.
7. Assessment of damage.
In case a component or structure has been damaged
as a result of an accident, excessive load, or fatigue, it
is first necessary to determine whether the structure
requires reinforcements or is ordinary repair sufficient.
8. Instructions.
Before you start welding you can also contact the
manufacturer who has detailed instructions for each
case.
Possibility of major damage is reduced by regularly
cleaning and checking the machine and the boom.
OUTJ003,00004AF –19–15FEB01–2/2
Attach Do not Operate Tag
If the machine becomes disabled, attach a warning tag to

the armrest controls. If the machine should not be started,
remove the ignition key and, as applicable, turn the main
switch to ’OFF’.
Before undertaking any maintenance or repair work,

obtain permission. DO NOT perform any maintenance
work without authorization.
Consult the manufacturer’s instruction manual and follow

recommended procedures.
–19–22APR91
T7447AO
OUTJ003,0000740 –19–01AUG01–1/1

081403
PN=23
Safety features
00
0010 Illuminate Work Area Safely
16
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1
Using the Xenon Worklamp
When using the lamp, please notice the following: • Allow the bulb cool off.
• Wear safety goggles and gloves when exchanging
• Avoid looking directly into the intensive light bulb.
• The lens may occasionally be cleaned
• No aggressive or abrasive cleaners may be used CAUTION: The glass body of the Xenon bulb
is filled with various gasses and metal
IMPORTANT: Do not wash the lens with liquid gasses under pressure (danger of
substances while switched on or splintering).
while the lens is still warm, as the
lens might crack. • Never touch the glass bulb of the Xenon lamp, touch
the bulb at its base only.
• Use a clean cloth and alcohol to remove any
Safety instructions for replacing the Xenon bulb fingerprints from the glass bulb.
• The Xenon lamp has to be operated only in the
Please observe the following safety instructions when closed work lamp.
replacing the Xenon bulb:
IMPORTANT: If a Xenon bulb breaks in a closed
• Always switch off the headlamp before exchanging room (workshop), the room is to be
bulbs and disconnect from the power supply. aired and everyone must leave the
• Never insert foreign objects of fingers into the bulb room for 20 minutes to exclude any
holder. danger to health due to escaped gas.
• The electrician connection between headlamp and
lamp ballast is under high voltage and must not be • Dispose of used Xenon bulbs as hazardous waste.
disconnected.
• The ballast unit must never be operated without a
bulb, as dangerous voltage spark-over, which leads
to damage, may occur at the bulb holder.
EL62757,0000050 –54–16SEP02–1/1

081403
PN=24
Safety features
00
Driving and Service 0010
17
The machine may only be used or repaired by personnel

who have received training that is approved by
Timberjack.
–UN–20MAR02
IMPORTANT: Do not let an untrained person operate
the machine.
• Carry no passengers. The vehicle is provided and
T152788
approved with seating for the operator only.
• Use the handrails and steps provided when mounting
and dismounting from the machine. Do not climb onto
the machine in any other fashion.
• The machine must not be operated by anyone under
the influence of alcohol or drugs.
• Avoid operating the machine if you are tired or ill, as
there is a greater risk of accident. Take sufficient breaks
and observe local regulations on working hours.
EL62757,000015F –19–19APR02–1/1
Use of Radio-transmitters
IMPORTANT: Any use of equipment containing a

radio transmitter (e.g., telephone,
communications radio) that has an
antenna inside the cab is strictly
prohibited.
Such equipment must be permanently installed in a proper

manner with an antenna on a suitable grounded plate
outside the cab.
Never mount an antenna inside the cabin because it may

cause malfunction in electrical devices!
CAUTION: Never use a headset when there is

thunder or lightening. Observe the danger of an
outer antenna so that it does not come into
contact with power lines.
EL62757,000005B –19–24SEP01–1/1

081403
PN=25
Safety features
00
0010 Prepare for Emergencies
18
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
–UN–23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 –19–03MAR93–1/1
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1

081403
PN=26
Safety features
00
Handle Chemical Products Safely 0010
19
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
See your authorized dealer for MSDS’s on chemical

products used with your machine.
TX,05,DH2500 –19–02OCT92–1/1
Dispose of waste properly
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with equipment include such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into TS1133
any water source.
Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your authorized dealer.
EL62757,0000160 –19–19APR02–1/1

081403
PN=27
Safety features
00
0010 Avoid High-Pressure Fluids
20
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source.
CED,TX14740,7088 –19–30JUN00–1/1

081403
PN=28
Safety features
00
Wear Protective Clothing 0010
21
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Safety face shield, glasses, or goggles should always be
used as protection from pressurized fluid spray, flying
debris, and other airborne matter when working with tools,
power tools, welding equipment, and corrosive or
dangerous chemicals.
Wear protective clothing as required by the job. Use a

rubber apron and rubber gloves when working with
corrosives and wear heavy work gloves and safety shoes
when handling large heavy or sharp objects and cables.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
OUTJ003,00005AA –19–09MAY01–1/1

081403
PN=29
Safety features
00
0010
22

081403
PN=30
Group 0020
General Specifications
00
Timberjack Tools For Forwarders 0020
1
1710D Base Machine
• forwarder Base Machine Notes F612884

Middle joint pivot pin nut tool Boom F617763
1710D Boom
• Lifting boom cylinder tool F0617763

• Jib boom cylinder piston tool F057655
• Jib boom cylinder cover tool F038312
• Extension boom cylinder tool F061007
• Pivot nut spanner, d=80 F055827
• Pivot nut spanner, d=100 Engine F055828
JK11466,0000014 –19–01NOV02–1/1
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use power tools only to loosen threaded parts and

fasteners.
–UN–08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Make sure that jack stands and lifting equipment are in

good condition and of adequate capacity. Repair or
replace worn or damaged tools, including lifting
equipment, before initiating repair work on your machine.
Use only service parts meeting manufacturer’s

specifications.
OUTJ003,00005AB –19–09MAY01–1/1

081403
PN=31
00
0020 General Component Locator
2
–UN–06JUN01
T139393
Example of general component locator (1110)
1—Engine Compartment/Hood 6—Boom Control Valve and 9—Rear Frame or Carrier 12—Frame Brake
2—Air Intake Hydraulic Tank Frame 13—Front Axle Bogie
3—Exhaust 7—Boom 10—Rear Axle Bogie 14—Front Frame or Power
4—Cab 8—Stakes 11—Frame Joint Frame
5—Work Lights
JK11466,000009E –19–31JAN03–1/1

081403
PN=32
00
Machine Dimensions 0020
3
–UN–09APR03
T189400
810D dimensions
Continued on next page 0010-3 –19–04FEB03–1/6

081403
PN=33
00
0020
4
–UN–11NOV02
T161526
1010D Dimensions
–UN–11NOV02
T161527
Width of 1010D

081403
PN=34
00
0020
5
–UN–19JUL01
T144170
1010D 4-wheel Long Frame Machine Dimensions
A—2600 mm (8 ft. 6 in.) D—2200 mm (7 ft. 3 in.) G—2000 mm (6 ft. 7 in.) I—Min. 2680 mm (8 ft. 10 in.)
B—3700 mm (12 ft. 4 in.) E—1500 mm (4 ft. 11 in.) H—9000 mm (29 ft. 6 in.) Max. 3480 mm (11 ft. 5 in.)
C—30.4° F.—3300 mm (12 ft. 10 in.)

081403
PN=35
00
0020
6
–UN–30JAN03
T164796
1110D dimensions

081403
PN=36
00
0020
7
–UN–03OCT02
T160088
1410D dimensions

081403
PN=37
00
0020
8
–UN–05MAR02
T151638
1710D Dimensions
Forwarders Weights and Dimensions
Forwarders Weights and dimensions

810D 1010D 1110D 1410D 1710D
Weight 10400-11500 kg 12000 kg 14900 kg (32849 lbs) 17000 kg (37478 lb)
4-wheeled According to 11000kg 12700 - 14000 kg 16500kg (36376 lbs) 18500 kg (40785 lbs)
6-wheeled equipment (27998 - 30864lb) max. 19500 kg(42990
8-wheeled 14600 - 15900 kg lbs
(32197 - 35053lb)
Overall Length 8640 mm 9045 mm 9825mm (32ft.) min.9295 mm(30.5 ft. 10100 mm (33 ft.)
Short frame 9300 mm max.10495 mm(34.4
Long Frame ft.)
Wheelbase 4543mm / 4243 mm 4800 mm(189 in.) 5000 mm(16 ft.) 5250 mm(17.2 ft) 5150 mm (16 ft 10 in.)
6-wheeled 5850 mm (19.2 ft.
8-wheeled
Minimum Width 2520 mm 2680 mm 2700 mm(8.9ft.) 2750 mm(9ft). 2680 mm (8 ft 10 in.)
4-wheeled 2859 mm 600-tires
Maximum Width 2670mm(8.75 ft) 3480 mm(11 ft. 5 in.) 2880mm (9ft.) 2930 mm(9.6ft) 2990 mm( 9.8 ft.
6-wheeled 700-tires
Maximum Height 3700 mm 3831mm 3700 mm(12ft) 3900 mm(12.8ft.) 3900mm(12.8 ft.
Ground Clearance 595 mm 636 mm 605 mm (2ft). 605 mm.(1.98 ft) 750 mm( 2.5ft )
0010-3 –19–04FEB03–6/6

081403
PN=38
00
Power Unit Specifications 0020
9
See All Power Unit Specifications
Deere Engine 6081 HTJ 03 Manual CTM 86
OUTJ003,00004B4 –19–15FEB01–1/1

081403
PN=39
00
0020 Power Train Specifications
10
Transfer Case Specifications
Transfer case 810D 1010D 1110D 1410D 1710D

Model NAF LOK 86 NAF LOK 124 NAF LOK 124 NAF LOK 87 NAF LOK 96
Type Mechanical/hydraulic with high/low gear select and rear axle drive disengage
Oil Capacity 4.5 L (4.75 qt)
Axles/Bogies Specifications
Axles / Bogies specifications

810D 1010D 1110D 1410D 1710D
Axles/Bogies Type Bogie axles with portal 4-wheeled: single Bogie axles with High-walker, full gear balanced heavy
type bogie beams rigid axle in front and portal type bogie duty bogie axle with portal type bogie in
including balancing units. rear beams including front and rear
Similar axles in front and 6-wheeled: single balancing units.
rear rigid front and Similar axles in
high-walker, full gear front and rear in
bogie axle with portal 8-wheels. Hub
type bogie beams on planetaries in
the rear 6-wheel front
axle.
Axles/Bogies Model NAF LOK 36 NAF LOK 115 NAF LOK 116 NAF LOK 101 6-w NAF LOK 53 6-w
Front NAF LOK 117 NAF LOK 100 8-w NAF LOK 103 8-w
NAF LOK 102* 8-w NAF LOK 104*
*Heavy duty Axles 8-w
*Heavy duty Axles
Axles/Bogies Model Rear NAF LOK 37 NAF LOK 128 6-w NAF LOK 131 NAF LOK 118 NAF LOK 103 8-w
NAF LOK 115 4-w NAF LOK 114* NAF LOK 104*
*Heavy duty Axles 8-w
*Heavy duty Axles
Flange to Flange Length 2190 mm ( 86.22 in.)
Weight 1750 kg ( 3858 lb)
Differential Oil Capacity Rear12 L (3.1 gal) 28 L (7.4 gal) Rear12 L(3.1 gal) 14 L (3.7 gal)
Front 8-wheel 12 L (3.1 Front 8-wheel 12 L
gal) (3.1 gal)
Bogie Housing Oil Front 8-wheel 50L (13.21 50.0 L (13.21 gal) 52 L(13.7 gal) 65 L(17 gal)
Capacity gal)
Rear 52 L(13.7 gal)
Continued on next page OUTJ003,00004B5 –19–15FEB01–1/2

081403
PN=40
00
Brakes Specifications 0020
11
Brakes Specification
Brakes 810D 1010D 1110D 1410D 1710D
Service and Working brake type Hydraulically Foot-pedal Hydraulically Foot-pedal operated,
actuated, Oil operated, actuated, Oil imersed hydraulically activated, oil
imersed multiple hydraulically multiple disc brakes. immeresed, multiple disc,
disc brakes. activated, oil Identical in both inboard
Identical in both immeresed, axles Spring actuated
axles Spring multiple disc parking and
actuated parking brakes, inboard emergency brakes in
and emergency front and rear
brakes in front and bogies.According to
rear ISO 11169
bogies.According to
ISO 11169
Parking brake pressure 4.0 MPa (588 psi)
Service brake pressure 7.0 MPa (1029 psi)
Accumulators Type Welded diaphragm, nitrogen precharge pressure
Accumulators Precharge 6.5 MPa (945 psi)
Parking Brake Pressure Switch Normally closed 2.0 MPa (294 psi)
W41A
Work Brake Pressure Switches Normally closed 10.0 MPa (1470 psi)
W37A
Parking Brake Solenoid Y41 Voltage 24 volts
Work Brake Solenoid Y41W Voltage 24 volts
OUTJ003,00004B5 –19–15FEB01–2/2

081403
PN=41
00
0020 Hydraulic System Specifications
12
Hydrostatic System Pressures
Hydrostatic System Pressures

810D 1010D 1110D 1410D 1710D
Charge Pressure 2.8-3.2Mpa 3 MPa ± 0.2Mpa(435 ±29 psi) 2.8-3.2Mpa 2.8-3.2Mpa 2.8-3.2Mpa
(406-464psi) (406-464psi) (406-464psi) (406-464psi)
Supply Pressure 3.0 ± 0.2MPa (435 ± 29 psi)
Drive Pressure 45 + 0.5Mpa 41.0 ± 0.5 MPa (5976 ±72 psi) 45 + 0.5Mpa 45 + 0.5Mpa 43 + 0.5Mpa
(6526 +72.5 psi) (6526 +72.5 psi) (6526 +72.5 psi) (6234 +72 psi)
Hydrostatic Drive Pump
Hydrostatic Drive Pump

Hydrostatic drive pump 810D 1010D 1110D 1410D 1710D
Hydrostatic Drive Pump Model Rexroth Rexroth AA4VG90HDDT2 Rexroth Rexroth Rexroth
AA4VG71 AA4VG125 AA4VG140 AA4VG180
Hydrostatic Drive Pump Type Reversible, variable displacement, swashplate/axial piston
Hydrostatic Drive Pump Location Mounted on engine flex coupling
Control Type Proportional Pilot operated hydraulic Proportional electronic control
electronic control control
Displacement 71 cm3 per 90 cm3per revolution 125 cm3 (7.63 in3) 140 cm3 180 cm3 per
revolution per revolution revolution revolution
Flow Rate at 1850 rpm 130 L /min 165 L /min 230 L /min 260 L /min 330 L /min
Drive Pressure Relief Setting 41 ± 0.5 MPa 41 ± 0.5 MPa (5946 ± 72.5 45 MPa 45 MPa 43 MPa
(Pressure Cut-off Valve) (5946 ± 72.5 psi) psi)
Drive pressure 48 Mpa 44 Mpa 48 Mpa 48 Mpa 46 Mpa
(Pressure relief valves)
Maximum Drive System Pressure 43 ± 0.5 MPa (6235 ± 72.5
(High Pressure Relief valves) psi)
Through Drive Type SAE ’C’ (1 [frac14]" 14T - 12/24P) with SAE ’C’, 2-bolt flange
Filtration Spin-on filter (10 micron filter)
Filtration Bypass Pressure Integral by-pass valve in pump at 350 kPa (50 psi)
Input Shaft Splined Shaft, SAE 1 3/8 in. 21 tooth, 16/32 SAE 1 3/4 13 T 8/16 DP SAE 21/4 17 T
pitch 8/16 DP
Charge Pump Displacement 19.6 cm3/rev 28.3 cm3/rev 39.8 cm3/rev
Charge Pump Pressure Relief 3.0 ± 0.2 MPa (435 ± 30 psi)
Setting @ 1600 RPM
Charge Pressure Warning Switch Closed below 1.0 MPa (147
W82A psi) activating warning
indicator light
Continued on next page OUTJ003,00004BA –19–15FEB01–1/6

081403
PN=42
00
Hydrostatic Drive Motor 0020
13
Hydrostatic Motor 810D 1010D 1110D 1410D 1710D
Model Rexroth AA6VM107 Rexroth AA6VM160HDXD Rexroth Rexroth Rexroth
AA6VM160 AA6VM160 AA6VM200
Hydrostatic Drive Motor Type Bent Axis, variable displacement, axial piston, with loop flushing valve
Hydrostatic Drive Motor Mounted on transfer case
Location
Control Type Hydraulic Pilot Pressure with Constant Pressure Control
3
Maximum Displacement 107cm /rev (6.5 160 cm3/rev (9.76 in3/rev) 160 cm3/rev 160 cm3/rev 200 cm3/rev
in3/rev) (9.76 in3/rev) (9.76 in3/rev)
Rotation Direction Reversible
Output Shaft Type SAE Splined
Mounting Flange SAE 4 bolt
Weight 64 kg (141 lb)
Hydrostatic Cooling
810D 1010D 1110D 1410D 1710D

Hydrostatic Cooling Flow from drive pump
and motor case drains
to oil cooler equipped
with thermal by-pass
valve
Maximum System Warning activated at
Temperature 80°C (176°F)
Oil Cooler Type Tube type, located on
left side of radiator
assembly
Oil Cooler Size .213 m2 (2.29 ft2)
Thermal Valve Located on oil cooler
Location
Thermostat Closed 49°C (120°F)
Thermostat Open 63°C (145°F)
Pressure Relief 449 kPa (65 psi)
Valve Open

081403
PN=43
00
0020 Hydraulic System Specifications
14
810D 1010D 1110D 1410D 1710D
Hydraulic System 180 L (47.6 gal)
Capacity
System Pressure 24 MPa ( 3480 psi) 24 MPa ( 3480 psi) 24 MPa ( 3480 24 MPa ( 3480 psi) 24 MPa ( 3480 psi)
psi)
Main Pressure 28.0 MPa (4061 psi)
Relief
Differential Load 2.5 MPa (435 psi)
Sense Pressure
Pilot Pressure 3.5 MPa (507 psi)
Boom and Steering 25 MPa (3625 psi)
Functions,
Maximum Working
Pressure
Differential Locks 3.5 MPa (507 psi) 3.5 MPa (507 psi) 3.5 MPa (507 3.5 MPa (507 psi) 3.5 MPa (507 psi)
and High/Low Gear psi)
Pressure, Rear
wheel drive
disconnect pressure
Frame Brake 25 MPa (3625psi) 25 MPa (3625psi) 25 MPa 25 MPa (3625psi) 25 MPa (3625psi)
Pressure (3625psi)
Grapple Close 19 MPa (2755 psi) 19 MPa (2755 psi) 19 MPa (2755 19 MPa (2755 psi) 19 MPa (2755 psi)
psi)
Grapple Open 17 MPa (2465 psi) 17 MPa (2465 psi) 17 MPa (2465 17 MPa (2465 psi) 17 MPa (2465 psi)
psi)
Orifice - Load 0.7 mm
Sense Signal (LS
Port boom Control
Valve)

081403
PN=44
00
Work Pump Specifications 0020
15
Machine Model 810D 1010D 1110D 1410D 1710D
Work Pump Type Variable, swashplate design, axial piston rotary group
Work Pump Model Rexroth A10VO 74 Rexroth A10VO100DFLR RexrothA10VO140
Work Pump Location Mounted on auxiliary pad of hydrostatic drive pump
Maximum Displacement 74 cm3 per rev. (4.5 in3 per 100 cm3 per rev. (6.10 in3 per 140 cm3 per rev. (8.54 in3 per rev.)
rev.) rev.)
Maximum Speed 2000 rpm
Maximum Flow 145 L/min. 200 L/min. ( 39.6 US gpm) 260L 280 L / min.( 55.5 US gpm)
Mounting Flange SAE 2-bolt
Shaft Rotation Direction Right Hand, Clockwise as viewed from driveshaft
Pressure Port Type SAE at side1 1/4” SAE at rear, fixing thread UNC1 SAE 1 1/4” at side
1/4”
Suction Port Type SAE 2 ” at side, fixing thread SAE 2 1/2” at rear, fixing thread SAE 2 1/2” at side, fixing thread UNC
UNC UNC
Case Drain Port Type 7/8 UNF-2B 1 1/16 - 12 UN-2B
Shaft, Drive End 1 1/4", SAE-C 14-tooth Spline
Factory Compensator 24 MPa (3480 psi)
Pressure Setting
Pressure Control Load Sensing, Differential Pressure
Function
Factory Differential 2.5 Mpa(363 psi)
Pressure Control Setting
Load Sensing, Differential 2.5 MPa (363 psi)
Pressure
Oil Capacity 1.6 L (0.42 gal) 2.2 L(0.58 gal) 3.0 L (0.79 gal)
Dry Weight 33 kg (73 lbs) 45 Kg (99 lbs) 60 Kg(132lbs)

081403
PN=45
00
0020 Hydraulic Tank and Filter Specifications
16
Hydraulic System Capasity 110 L 135 L (36.9 gal) 140 L ( 36.9 gal) 140 L 180 L
Maximum Tank Fill 85 L 113 L ( gal)
Minimum Tank Fill 82 L ( 21.6 gal)
Pressure Filter Location On bracket near hydraulic tank
Pressure Filter Restriction Indicator Pressure Warning light activated at 0,80 Mpa (1168 psi)
Switch
Return Filter Location In hydraulic tank
Return Filter Size 10 micron
Return Filter By-pass 0.15 MPa ( psi)
Return Filter Restriction Indicator Pressure TMC alarm activated Warning light activated at 0,13 Mpa (18 psi)
Switch at 0.13 MPa (18 psi)
Hydraulic Oil Temperature Indicator Sensor TMC alarm activated TMC alarm activated at 70°C (158°F)
at 70°C (158°F)
Hydraulic Oil Level Indicator Sensor TMC alarm activated Warning light activated when level in tank
when level in tank drops below 62 L (16.4 gal)
drops below 62 L
(16.4 gal)
Breather / Relief Valve Maximum Reservoir 0.02 MPa (3.0 psi)
Pressure
Steering and Decking Blade Cylinders

Cylinders Bore Diameter / Rod 80 mm / 50mm 100 mm / 63 mm
Stroke Length 370 mm 360 mm(1 ft 2 in.) 460 mm
Retracted Length 295 mm 665 mm(2 ft 2 in.) 765 mm
Extended Length 665 mm 1025 mm (3 ft 4 in.) 1225 mm
Weight Approximately 38 kg (85 lb) Approximately 45 kg
Decking blade Cylinders
Machine Model 1010D 1110D 1410D 1710D

Cylinders Bore Diameter / Rod 100 / 63 mm
Stroke Length 360 mm(1 ft 2 in.)
Retracted Length 665 mm(2 ft 2 in.)
Extended Length 1025 mm (3 ft 4 in.)
Weight 38 kg

081403
PN=46
00
Auxiliary Valve Specifications 0020
17
Auxiliary Valve Location Front frame
Parking Brake Pressure Regulator Valve Adjustable, factory set at 3.0 MPa (435 psi) Adjustable,
CB1 factory set at
6.0 MPa
Auxiliary Functions Pressure Regulator Adjustable, factory set at 3.0 MPa (435 psi)
Valve CP3
Frame Brake Pressure Reducing Valve 21 MPa
Frame Brake Pressure Restrictor Orifice 1.0 mm
8 (Diameter)
Work Pump Stroke Solenoid Y208 1.2 mm
Pressure Restrictor Orifice(Diameter)
All Solenoids 27 volts
Solenoid Y33F Front Differential Lock
Solenoid Y33B Rear Differential Lock
Solenoid Y39 Rear Wheel Drive Disengage
Solenoid Y45 Low Gear Select
Solenoid Y46 High Gear Select
Solenoid Y65 Frame Brake
Solenoid Y41 Parking Brake
OUTJ003,00004BA –19–15FEB01–6/6

081403
PN=47
00
0020 Tires Specifications
18
810D Tire sizes and pressures
810D Tire pressures

6-wheeled FRONT Pressure (kPa) (psi) min REAR Pressure (kPa) (psi)
SIZE / max SIZE min / max
700/40x22.5/16 PR 250 ... 290 kPa 700/40x22.5/16 PR 310 ... 360 kPa
(36 ... 42 psi) (45 ... 52 psi)
650/45x22.5 PR 300 ... 350 kPa 650/45x22.5 PR 380 ... 440 kPa
600/50x22.5/16 PR (43,5 ... 51 psi) 600/50x22.5/16 PR (55 ... 64 psi)
Check tire pressures visually every day. If in doubt, use a

pressure gauge to check the pressure.
1010D Tire pressures

FRONT Pressure (kPa) REAR Pressure (kPa) (psi) min / max
SIZE (psi) min / max SIZE
6-wheeled 600/65-34 14 PR 200...230 600/55-26.5 16 PR 400...460
(29...46) (58...67)
700/55-34 14 PR 180...210 700/50-26.5 16 PR 350...400
(26...30) (51...58)
28L-26 16 PR 190...220
(28...32)
23.1 - 26 160 (23) 600 x 26.5 min 360 (52)
Firestone Firestone
28L - 26 140 (20) 700 x 26.5 min 330 (48)
Firestone Firestone
4-wheeled Front Pressure (kPa) (psi) min Rear Pressure (kPa) (psi) min
600/65-34 14 PR 170 600/55-26.5 16 PR 340
(25) (49)
700/55-34 14 PR 150 700/50-26.5 16 PR 310
(22) (45)
23.1 - 26 160 (23) 23.1 - 26 330 (48)
Firestone Firestone
28L - 26 140 (20) 28L - 26 300 (43.5)
Firestone Firestone
66/43 - 26 125 (18) 66/43 - 26 200 (29)
Firestone Firestone
Continued on next page EL62757,000014A –19–18APR02–1/3

081403
PN=48
00
1110D Tire sizes and pressures 0020
19
Front Pressure min / max Rear Pressure min / max
8-wheeled 700/50-26.5 16 PR 270...310 kpa 700/50-26.5 16 PR 400...460 kpa
Nokian 39...44,9 psi Nokian 58...66,7 psi
800/40-26.5 20 PR 250...290 kpa 800/40-26.5 20 PR 350...400 kpa
Nokian 36...42 psi Nokian 50,7...58 psi
6-wheeled Front Pressure (kPa) (psi) min Rear Pressure (kPa) (psi) min
700/55-34 14 PR 200...230 kpa 700/50-26.5 16 PR 400...460 kpa
Nokian 29...33 psi 58...66,7 psi
800/40-26.5 20 PR 350...400 kpa
50,7...58 psi

8-wheel
FRONT PRESSURE REAR PRESSURE
SIZE
710/45-26.5 20PR 300..350 kpa 710/45-26.5 20PR 500... 550
Nokian (43,5...50,8 psi) Nokian 72,5...79,8 psi)
800/40-26.5 20PR 300..350 800/40-26.5 20PR 450... 500
700/50-26.5 20PR 300...350 700/50-26.5 20PR 500...550
6-wheel
700/55-34 14PR 220...230 710/45-26.5 20PR 500...550
Nokian 31,9...33,4 psi) 72,5...79,8 psi)
800/40-26.5 20PR 450...500
65,3...72,5 psi)
700/50-26.5 20PR 500...550
Nokian 72,5...79,8 psi)

pressure gauge to check the pressure.
Continued on next page EL62757,000014A –19–18APR02–2/3

081403
PN=49
00
0020 1710D Tire pressures
20 8-wheel
FRONT PRESSURE REAR PRESSURE
(kPa) (kPa)
650/55-26.5/20 300... (44 psi) 650/55-26.5/20 500... (73 psi)
Nokian 350 (51 psi) 750/50-26.5/20 550 (80 psi)
Nokian
6-WHEEL
23.1-34/16 230...(33 psi) 650/55-26.5/20 500... (73 psi)
Nokian 250 (36 psi) 550 (80 psi)
700/70-34/16 220...(32 psi) 750/50-26.5/20 500... (73 psi)
Nokian 250 (36 psi) 550 (80 psi)
NOTE: When operating with heavy loads in harsh, rugged

terrain, it is good to use maximum tire pressures.
NOTE: When operating with heavy loads in harsh, rugged

terrain, it is good to use maximum tire pressures.
Running a tire with too low pressure can lead to
immediate tire failure.
NOTE: Too low pressure can lead to sidewall damage

and rim chafing, possible even to rim slippage.
NOTE: Min.pressures must be found in wheels even in

cold winter days (cold weather reduces the tire
pressures about 10 kPa / 10°C).
EL62757,000014A –19–18APR02–3/3

081403
PN=50
00
Boom Specifications 0020
21
1010D Boom CF5
CF5
CF510 CF585 CF572
Gross lifting moment 91 kNm 91 kNm 91 kNm
Net lifting moment 59 kNm 65 kNm 68 kNm
Maximum reach 10 010 mm 8450 mm 7200 mm
Stroke of extension boom 4200 mm 2650 mm 1400 mm
Gross slewing moment of booms 24,4 kNm 24,4 kNm 24,4 kNm
Slewing angle of booms 380° 380° 380°
Weight without oil 1460 kg 1355 kg 1225 kg
1010D Grapple
Grapple Loglift FX25 Loglift FX35 Hultdins SG 260 Hultdins 360

Grapple closing pressure (21,5 12 kN (2698 lbf) 11 kN (2473 lbf) 13 kN (2923 lbf) 16,5 kN (3709 lbf)
MPa) (3118 psi)
Weight 160 kg (352 lb) 170 kg (375 lb) 154 kg (340 lb) 216 kg (476 lb)

081403
PN=51
00
0020
22
–UN–30JAN03
T161844
CF510Continued on next page OUTJ003,00004B7 –19–15FEB01–2/11

081403
PN=52
00
0020
23
–UN–30JAN03
T161842
CF85 Continued on next page OUTJ003,00004B7 –19–15FEB01–3/11

081403
PN=53
00
0020
24
–UN–30JAN03
T161843
CF572Continued on next page OUTJ003,00004B7 –19–15FEB01–4/11

081403
PN=54
00
1410D Boom CF7 0020
25
CF7
CF772 CF785 CF10
Gross lifting moment 125,4 kNm 125,4 kNm 125,4 kNm
Net lifting moment 90,3 kNm 86,7 kNm 77,6 kNm
Maximum reach 7200 mm 8500 mm 10 000 mm
Stroke of extension boom 1390 mm 2450 mm 4200 mm
Gross slewing moment of booms 32,6 kNm 32,6 kNm 32,6 kNm
Slewing angle of booms 380° 380° 380°
Weight without oil 1610 kg 1660 kg 1750 kg

081403
PN=55
00
0020
26
–UN–08OCT02
T159871
all
–UN–02OCT02
T160022
Foot

081403
PN=56
00
0020
27
–UN–08OCT02
T160023
Models

081403
PN=57
00
0020
28
–UN–08OCT02
T159872
Boom CF5 Range
1410D Grapple
1410D Grapple
Grapple Loglift FX25 Loglift FX35 Hultdins SG Hultdins SG Hultdins 360
260 360S
Grapple closing 12kN 11 kN 13 kN 16,6 kN 16,5 kN
pressure (21,5
MPa)
Weight 230 kg 240 kg 235 kg 432 kg 310 kg

081403
PN=58
00
1710D Boom CF885 0020
29
Boom CF885
Boom CF885
Gross lifting moment 151,8 kNm (111 961 lb-ft)
Net lifting moment 100 kNm (73 760 lb-ft)
Maximum reach 8500 mm (27,9 ft)
Stroke of extension boom 2170 mm (7,1 ft)
Gross slewing moment of booms 41 kNm (30240 lb-ft)
Slewing angle of booms 380°
Weight without oil 2030 kg (4475 lbs)

081403
PN=59
00
0020
30
–UN–19FEB02
T151621
Boom CF885

081403
PN=60
00
1710D Grapple 0020
31
1710D Grapple
Grapple Loglift FX35 Loglift FX40 Hultdins SG 360 Hultdins SG 360S Hultdins 420
Grapple closing 11 kN 16 kN 16,5 kN 16,6 kN 16 kN
pressure (21,5 2473 lbf 3597 lbf 3709 lbf 3732 lbf 3597 lbf
MPa)
Weight 170 kg 250 kg 248 kg 370 kg 276 kg
375 lbs 551 lbs 547 lbs 816 lbs 608 lbs
OUTJ003,00004B7 –19–15FEB01–11/11
Rotator GV12-2
Rotator GV12–2
Rotator GV12–2
Slewing angle Unlimited
Slewing moment (21,5 MPa) (3118 psi) 1,9 kNm (1400 lb-ft)
Weight 58 kg (128 lbs)
Rotator Servicing
Stator Screws 120 N•m (90 lb-ft)
Rotator Base Screws 50 N•m (35 lb-ft)
Cleaning the Rotator Magnetic Plug
Magnetic Plug 20 N•m (15 lb-ft)
JK11466,000009F –19–03FEB03–1/1

081403
PN=61
00
0020 Grapple Specifications
32
–UN–13JUN01
T142833
Supergrip SG 260 Grapple
Supergrip SG 260 Grapple Specifications
Item Measurement Specification
Gripping Area, tip-to-tip Cross Sectional Area 0.26 m2 (2.80 ft2)
Maximum Gripping Width (B) Width 1525 mm (60 in.)
Minimum Gripping Diameter Diameter 90 mm (3.5 in.)
Maximum Load Weight 3,500 kg (7,700 lb)
Grapple Weight Weight 168 kg (370 lb)
Height, Arms Closed Height 550 mm (21.5 ft)
Height, Arms Down (A) Height 867 mm (34 in.)
Overall Grapple Width (C) Width 430 mm (17 in.)
Maximum Working Pressure Pressure 21 MPa (3050 psi)
Maximum Intermittent Pressure Pressure 23 MPa (3300 psi)
Continued on next page JK11466,00000A3 –19–06FEB03–1/4

081403
PN=62
00
0020
33
–UN–13JUN01
T142833
Supergrip SG 360 Grapple
Supergrip SG 360 Grapple Specifications
Gripping Area, tip-to-tip Cross Sectional Area 0.36 m2 (3.87 ft2)
Maximum Gripping Width (B) Width 1870 mm (73.6 in.)
Minimum Gripping Diameter Diameter 110 mm (4.3 in.)
Maximum Load Weight 5000 kg (11,000 lb)
Height, Arms Closed Height 627 mm (24.5 in.)
Height, Arms Down (A) Height 962 mm (38 in.)
Overall Grapple Width (C) Width 510 mm (20 in.)
Maximum Intermittent Pressure Pressure 23 MPa (3300 psi)

081403
PN=63
00
0020
34
–UN–13JUN01
T142834
Loglift GF25 Grapple
Loglift GF25 Grapple Specifications
Grapple Height (A) Height 860 mm (34 in.)
Grapple Height, Arms Closed Height 535 mm (21 in.)
Grapple Width (B) Width 412 mm (16 in.)
Gripping Area (C) Cross Sectional Area .25 m2 (2.69 ft2)
Minimum Log Diameter Diameter 90 mm (3.5 in.)
Maximum Grapple Width Width 1490 mm (59 in.)
Maximum Load Weight Weight 4000 kg (8800 lb)
Jaw Closing Force @ 20 MPa Force 11.3 kN (2,540 lb-force)

081403
PN=64
00
0020
35
–UN–13JUN01
T142834
Loglift GF35 Grapple
Loglift GF35 Grapple Specifications
Grapple Height (A) Height 920 mm (36 in.)
Grapple Height, Arms Closed Height 570 mm (22.5 in.)
Grapple Width (B) Width 412 mm (16 in.)
Gripping Area (C) Cross Sectional Area .35 m2 (3.76 ft2)
Minimum Log Diameter Diameter 108 mm (4.25 in.)
Maximum Grapple Width Width 1575 mm (62 in.)
Maximum Load Weight Weight 4000 kg (8800 lb)
Jaw Closing Force @ 20 MPa Force 10.5 kN (2,360 lb-force)
JK11466,00000A3 –19–06FEB03–4/4

081403
PN=65
00
0020
36

081403
PN=66
Group 0030
Torque Values
00
Tightening Torque for Bolted Joints 0030
1
When the machine is new, check all bolted joints daily,

especially those between the boom and the frame and
those between the axles and the frame. Keep tightening
until the bolts maintain their tightness. Check the hose
joints, too. During ordinary operation, the joints should be
frequently checked in addition to scheduled maintenance.
Expander pivot pin joints of the new machine must be

tightened after first working day.
810D Tightening Torques
810D
JOINT QTY SIZE GRADE TORQUE
Nm
Wheel bolts 8 M22x1.5 550
( 405 lb -f t)
Cab fastenings 4 M16 100
( 74 l b -f t )
Joints between axles and frame
Horizontal bolts 4 M24 x 580 8.8 950
(700 lb -f t)
Vertical bolts 8 M24 x 240 12.9 950
( 700 lb -f t)
1010D Tightening Torques
1010D
Nm
Wheel bolts 550
( 405 lb -f t)
Cab fastenings 100
( 74 l b -f t )
Cab base fastenings 170
( 125 lb -f t)
Horizontal bolts M24 x 580 10.9 950
(700 lb -f t)
Vertical bolts M24 x 240 12.9 950
( 700 lb -f t)
Continued on next page AK12300,0000058 –19–12OCT01–1/4

081403
PN=67
Torque Values
00
0030 1110D Tightening Torque
2
1110D
JOINT TORQUE
Nm
Wheel bolts 550
( 405 lb -f t)
Horizontal bolts 950
(700 lb -f t)
Vertical bolts 950
( 700 lb -f t)

081403
PN=68
Torque Values
00
1410D Tightening Torques 0030
3
1410D
Nm
Wheel bolts 550
( 405 lb -f t)
Cab fastenings 100
( 74 l b -f t )
Cab base fastenings 170
( 125 lb -f t)
Horizontal bolts 950
(700 lb -f t)
Vertical bolts 950
( 700 lb -f t)
BOOM
Fastening 8 M24x100 12.9 1120
( 826 lb -f t)
Base, support plate 6 M10x25 8.8 49
( 36 lb -f t)
M12x40 12.9 137
( 101 lb -f t)
Slewing cylinder 4x12 M12x70 12.9 110
( 81 l b -f t )
Main boom cylinder 2 M65x2 1890
( 1394 lb -f t)
Outer boom cylinder 2 M65x2 1890
( 1394 lb -f t)
Extension boom
cylinder
2 M40x2 440
( 325 lb -f t)
2 M20x1.5 200
(147,5 lb -f t)

081403
PN=69
Torque Values
00
0030 1710D Tightening Torques
4
Tightening torque for bolted joints
Joint Qty Size Grade Torque Nm Torque lb-ft
Wheel nuts 64 M22 8.8 550 ( 405 lb -f t)
Axle mounts 4 M27 x 520 12.9 1250 922
Bolts for rear axle mount 2 M27 x 220 12.9 800 590
Bolts for rear axle mount 2 M27 x 180 8.8 800 590
Nuts for front axle mount 8 M27 800 590
Bearing support 2 M16 x 30 8.8 200 148
Drive shafts 16 1/2"UNF x 51 10.9 118 87
Horizontal bearing, center hinge 40 M20 x 90 12.9 500 369
Vertical bearings, center hinge 2 M75 x 2 610 450
Frame brake 6 M24 x 60 12.9 750 553
Engine mount, engine block, front 8 5/8"UNC x 64 10.9 90 66
Engine mount, engine block, rear 8 5/8"UNC x 38 8.8 90 66
Engine mount, dampers 4 M20 x 90 8.8 150 111
Damper mount, frame 8 M16 x 35 8.8 150 111
Hydraulic motor / gearbox 5 M20 x 50 8.8 385 284
Engine cooling fan 6 3/8"UNC x 50 8.8 40 30
Engine flywheel, flex coupling 8 3/8"UNC x 38 12.9 49 36
Locking screw, flex coupling hub 1 8.8 295 218
Pump mount flange, flywheel 12 3/8"UNC x 38 8.8 49 36
housing
Working pump 4 M20 x 45 8.8 300 221
Driving pump 4 M20 x 40 8.8 300 221
Boom valve mount, boom 4 M16 x 60 8.8 222 164
Locking screws, boom pillar pivot 2 M16 x 40 8.8 222 164
Tightening torque for bolted joints, boom

Joint Qty Size Grade Torque Nm Torque lb-ft
Slew bearing cover, boom pillar 6 M10 x 25 8.8 49 36
Slew bearing cover, slew housing 8 M12 x 40 12.9 137 101
Slewing cylinder, piston 16 M12 x 60 8.8 85 63
Slewing cylinder 48 M12 x 70 12.9 110 81
Main boom ram 1 M98 x 6 2000 1475
Outer boom ram 1 M65 x 2 1890 1394
Extension ram 1 180 133
Expander-axle, boom pillar 2 M30 x 2 8.8 600 443
Expander-axle, main boom 2 M30 x 2 8.8 600 443
Expander-axle, rotator link 2 M20 x 1,5 8.8 400 295
AK12300,0000058 –19–12OCT01–4/4

081403
PN=70
Torque Values
00
Unified Inch Bolt and Cap Screw Torque Values 0030
5
–UN–27SEP99
TORQ1A
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Unified Inch Bolt and Cap Screw Torque Values, 1 of 2

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c b c b c
Size Lubricated Dry N•m (lb-ft) Lubricated Dry Lubricated Dry N•m (lb-ft) Lubricatedb Dryc N•m
N•m N•m N•m N•m (lb-ft) N•m (lb-ft) (lb-ft)
(lb-ft) (lb-ft) (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
(11.5)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 170 (125) 215 (160) 240 (175) 305 (225)
(100)
3/4 120 (88) 150 (110) 190 240 300 (220) 380 (280) 425 (315) 540 (400)
(140) (175)
7/8 190 (140) 240 (175) 190 240 490 (360) 615 (455) 690 (510) 870 (640)
(140) (175)
1 285 (210) 360 (265) 285 360 730 (540) 920 (680) 1030 (760) 1300 (960)
(210) (265)
1-1/8 400 (300) 510 (375) 400 510 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
(300) (375)
1-1/4 570 (420) 725 (535) 570 725 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
(420) (535)
1-3/8 750 (550) 950 (700) 750 950 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
(550) (700)
1-1/2 990 (730) 1250 (930) 990 1250 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
(730) (930)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6 in.) long. Grade 1 applies for hex cap screws over 152 mm (6 in.) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
Continued on next page DX,TORQ1 –19–01OCT99–1/2

081403
PN=71
Torque Values
00
0030 DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
6 procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If
higher grade fasteners are used, these should only be tightened to
the strength of the original.
DX,TORQ1 –19–01OCT99–2/2

081403
PN=72
Torque Values
00
Metric Bolt and Cap Screw Torque Values 0030
7
–UN–07SEP99
TORQ2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Metric Bolt and Cap Screw Torque Values, 1 of 2

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a b a b a b
Size Lubricated Dry N•m Lubricated Dry N•m Lubricated Dry N•m Lubricateda Dryb N•m
N•m (lb-ft) (lb-ft) N•m (lb-ft) (lb-ft) N•m (lb-ft) (lb-ft) N•m (lb-ft) (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.
DX,TORQ2 –19–01OCT99–1/1

081403
PN=73
Torque Values
00
0030 Service Recommendations for O-Ring Boss
8
Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
–UN–18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 –19–29SEP99–1/2

081403
PN=74
Torque Values
00
Angle Fitting 0030
9
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
–UN–18OCT88
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
Straight Fitting or Special Nut Torque Chart

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N•m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.
04T,90,K66 –19–29SEP99–2/2

081403
PN=75
Torque Values
00
0030 Service Recommendations for Flat Face
10
O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces. They must be free

of dirt or defects.
–UN–18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using
T6243AD
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum

jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand pressing joint

together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the

chart per dash size stamped on the fitting. Do not allow
hoses to twist when tightening fittings.
Flat Face O-Ring Seal Fitting Torque

FLAT FACE O-RING SEAL FITTING TORQUE
Thread Size
Nominal Tube O.D. Dash Size in. Swivel Nut Bulkhead Nut
mm in. N•m lb-ft N•m lb-ft
6.35 0.250 -4 9/16-18 16 12 5.0 3.5
9.52 0.375 -6 11/16-16 24 18 9.0 6.5
12.70 0.500 -8 13/16-16 50 37 17.0 12.5
15.88 0.625 -10 1-14 69 51 17.0 12.5
19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5
22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5
25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5
31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5
38.10 1.500 -24 2-12 217 160 17.0 12.5
NOTE: Torque tolerance is +15 -20%.
04T,90,K67 –19–29SEP99–1/1

081403
PN=76
Torque Values
00
Service Recommendations For Inch Series Four Bolt Flange Fittings 0030
11
–UN–01MAR90
T6890BB
Flange Fittings
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches Four Bolt Flange Fittings Torque
cause leaks. Roughness causes seal wear. TORQUE CHART
Out-of-flat causes seal extrusion. If defects cannot N•m lb-ft
be polished out, replace component. Nominal Cap Screw
Flange Size
2. Install O-ring (and backup washer if required) into Size Min Max Min Max
groove using petroleum jelly to hold it in place. 1/2 5/16-18 20 31 15 23
UNC
3. Split flange: Loosely assemble split flange (B) 3/4 3/8-16 UNC 28 54 21 40
halves. Make sure split is centrally located and 1 3/8-16 UNC 37 54 27 40
perpendicular to port. Hand tighten cap screws to
1-1/4 7/16-14 47 85 35 63
hold parts in place. Do not pinch O-ring (C). UNC
1-1/2 1/2-13 UNC 62 131 46 97
4. Single piece flange (D): Place hydraulic line in
2 1/2-13 UNC 73 131 54 97
center of flange and install cap screws. Flange
must be centrally located on port. Hand tighten cap 2-1/2 1/2-13 UNC 107 131 79 97
screws to hold flange in place. Do not pinch O-ring. 3 5/8-11 UNC 158 264 117 195
3-1/2 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 4 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
5 5/8-11 UNC 158 264 117 195
screws. Tighten all cap screws as specified in the
chart below.
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 –19–01AUG94–1/1

081403
PN=77
Torque Values
00
0030 Service Recommendations for Metric Series Four Bolt Flange Fitting
12
–UN–01MAR90
T6890BB
Metric Series Four Bolt Flange Fitting
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
Torque Chart
3. Split flange: Loosely assemble split flange (B) TORQUE CHARTa
halves. Make sure split is centrally located and Threadb N•m lb-ft
perpendicular to the port. Hand tighten cap screws M6 12 9
to hold parts in place. Do not pinch O-ring (C).
M8 30 22
M10 57 42
4. Single piece flange (D): Place hydraulic line in
center of flange and install four cap screws. Flange M12 95 70
must be centrally located on port. Hand tighten cap M14 157 116
screws to hold flange in place. Do not pinch O-ring. M16 217 160
M18 334 246
5. After components are properly positioned and cap
M20 421 318
screws are hand tightened, tighten one cap screw,
a
Tolerance ± 10%. The torques given are enough for the given
size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 –19–29SEP99–1/1

081403
PN=78
Torque Values
00
Metric Flanged Head 0030
13
Metric Flanged Head, Tightening Torque Values for Class 10.9
Nominal Thread Diameter Tightening Torque Values for Class 10.9
M5 7 - 8 N•m 5 - 6 lb-ft
M6 12 - 15 N•m 9 - 11 lb-ft
M8 32 - 38 N•m 23 - 26 lb-ft
M10 60 - 70 N•m 45 - 50 lb-ft
M12 110 - -125 N•m 80 - 90 lb-ft
M14 170 - 190 N•m 125 - 140 lb-ft
M16 265 - 300 N•m 195 - 220 lb-ft
M20 515 - 575 N•m 380 - 425 lb-ft
M22 665 - 745 N•m 490 - 550 lb-ft
M24 840 - 950 N•m 620 - 700 lb-ft
1. Torque values shown are based on Zinc Phosphate or

oil coating.
2. The torque values listed develop clamping forces that
are based on material proof loads for the different
class fasteners. The clamping forces developed are 85
+ 5% of proof loads.
3. All the torque values in N•m or lb-ft are rounded to the
nearest multiple of 5, or in some cases, to the nearest
whole number to be in line with graduations on torque
wrenches and dials.
CAUTION: Use only metric tools on metric

hardware and imperial tools on imperial
hardware to assure correct torque readings,
and to prevent damage to tools and hardware
as well as possible injury.
OUTJ003,00004BC –19–16FEB01–1/1

081403
PN=79
Torque Values
00
0030 O-ring Fittings
14
NOTE: All O-Rings must have a light coat of system fluid

before tightening to the torque in the following
chart.
Ref: SAE J1453 June ’94
O-ring Fittings, O-ring Face Seal End

Nominal SAE Dash Thread Size Swivel Nut Torque
No.
4 9/16 - 18 14 - 16 N•m 10 - 12 lb-ft
6 11/16 - 16 24 - 27 N•m 18 - 20 lb-ft
8 13/16 - 16 43 - 47 N•m 32 - 35 lb-ft
10 1 - 14 60 - 68 N•m 46 - 50 lb-ft
12 1-3/16 - 12 90 - 95 N•m 65 - 70 lb-ft
14 1-3/16 - 12 90 - 95 N•m 65 - 70 lb-ft
16 1-7/16 - 12 125 - 135 N•m 92 - 100 lb-ft
20 1-11/16 - 12 170 - 190 N•m 125 - 140 lb-ft
24 2 - 12 200 - 225 N•m 150 - 165 lb-ft
O-ring Fittings, O-Ring Boss End

Nominal SAE Dash Thread Size Straight Fitting or Locknut Torque
No.
4 7/16 - 20 20 - 22 N•m 14 - 16 lb-ft
6 9/16 - 18 33 - 35 N•m 24 - 26 lb-ft
8 3/4 - 16 68 - 78 N•m 50 - 60 lb-ft
10 7/8 - 14 98 - 110 N•m 72 - 80 lb-ft
12 1-1/16 - 12 170 - 183 N•m 125 - 135 lb-ft
14 1-3/16 - 12 215 - 245 N•m 160 - 180 lb-ft
16 1-5/16 - 12 270 - 300 N•m 200 - 220 lb-ft
20 1-5/8 - 12 285 - 380 N•m 210 - 280 lb-ft
24 1-7/8 - 12 370 - 490 N•m 270 - 360 lb-ft
OUTJ003,00004BD –19–16FEB01–1/1

081403
PN=80
Torque Values
00
SAE Code 61 and 62 Flanges 0030
15
NOTE: For both one piece and split flanges turn the bolts
until mating parts are in full contact. Tighten one
bolt, then the opposite, followed by the remaining
two before applying torque.
Ref: SAE J518 June ’93
SAE Code 61, Standard Pressure Series Flanges

Flange Dash Flange Size Bolt Thread Flange Bolt Torque
Number
8 1/2 5/16 - 18 15 - 19 N•m 20 - 25 lb-ft
12 3/4 3/8 - 16 21 - 30 N•m 28 - 40 lb-ft
16 1 3/8 - 16 27 - 36 N•m 37 - 48 lb-ft
20 1-1/4 7/16 - 14 35 - 46 N•m 48 - 62 lb-ft
24 1-1/2 1/2 - 13 46 - 59 N•m 62 - 79 lb-ft
32 2 1/2 - 13 54 - 67 N•m 73 - 90 lb-ft
40 2-1/2 1/2 - 13 79 - 92 N•m 107 - 124 lb-ft
48 3 5/8 - 11 138 - 150 N•m 186 - 203 lb-ft
SAE Code 62, High Pressure Series Flanges

Flange Dash Flange Size Bolt Thread Flange Bolt Torque
Number
8 1/2 5/16 - 18 15 - 19 N•m 20 - 25 lb-ft
12 3/4 3/8 - 16 25 - 34 N•m 34 - 45 lb-ft
16 1 7/16 - 14 42 - 50 N•m 56 - 68 lb-ft
20 1-1/4 1/2 - 13 63 - 75 N•m 85 - 102 lb-ft
24 1-1/2 5/8 - 11 117 - 134 N•m 158 - 181 lb-ft
32 2 3/4 - 10 271 - 294 N•m 200 - 217 lb-ft
OUTJ003,00004BE –19–16FEB01–1/1

081403
PN=81
Torque Values
00
0030 Tapered Pipe Treads (NPTF and NPT)
16
NOTE: Apply LOCTITE to the treads before installing.
Tapered Pipe Treads (NPTF and NPT)

Dash Number Pipe Thread Size Tapered Pipe Treads (NPTF and NPT) Torque
02 1/8 — 27 15 N•m 20 lb-ft
04 1/4 — 18 18 N•m 25 lb-ft
06 3/8 — 18 26 N•m 35 lb-ft
08 1/2 — 14 33 N•m 45 lb-ft
10 3/4 — 14 44 N•m 60 lb-ft
16 1 — 11-1/2 55 N•m 75 lb-ft
20 1-1/4 — 11-1/2 70 N•m 95 lb-ft
24 1-1/2 — 11-1/2 81 N•m 110 lb-ft
32 2 — 11-1/2 96 N•m 130 lb-ft
LOCTITE is a trademark of Loctite Corp. OUTJ003,00004BF –19–16FEB01–1/1

081403
PN=82
Torque Values
00
Flare Fittings 0030
17
1. Check flare and seat for defects that might cause

leakage and lubricate the connection with system fluid.
2. Install hoses without twist.
3. When a torque wrench cannot be used, tighten until
seats bottom. Using two wrenches to prevent twisting,
rotate the nut the number of hex flats or equivalent
shown below.
37° Flare Fittings

Tube Dash Tube O.D. (in.) Thread Size Torque N•m Torque lb-ft No. of Flats - No. of Flats -
Number New Fitting Reassembled
Fitting
03 3/16 3/8 — 24 4-5 5-7 2-1/2 1
04 1/4 7/16 — 20 9 - 10 12 - 14 2-1/2 1
05 5/16 1/2 — 12 15 - 17 20 - 23 2-1/2 1
06 3/8 9/16 — 18 20 - 22 27 - 30 2 1
08 1/2 3/4 — 16 30 - 33 41 - 45 2 1
10 5/8 7/8 — 14 40 - 44 54 - 60 1-1/2 to 2 1
12 3/4 1 - 1/16 — 12 70 - 77 95 - 104 1 3/4
14 7/8 1 - 3/16 — 12 82 - 90 111 - 122 1 3/4
16 1 1 - 5/16 — 12 90 - 99 122 - 134 3/4 3/4
20 1 1/4 1 - 5/8 — 12 120 - 132 163 - 179 3/4 3/4
24 1 1/2 1 - 7/8 — 12 131 - 144 178 - 195 1/2 1/2
32 2 2 - 1/2 — 12 300 - 330 407 - 447 1/2 1/2
OUTJ003,00004C0 –19–16FEB01–1/1

081403
PN=83
Torque Values
00
0030
18

081403
PN=84
Group 0040
Fluids and Lubricants
00
Recommended Lubricants and Fluids 0040
1
General instructions for checking oil levels and fill-ups:
• The machine must stand on level ground when you

check any of the oil levels
• Check the oil level in the morning for that is when the
oil is cold and it has seeped down into the lower parts
of the component.
• Renew the oil while the engine is warm. Thus it is
easier to remove the old oil
• To even the pressure at the oil space, open a plug
located above the oil level (e.g. filling plug) before
opening the drain plug.
• Avoid direct contact with oil, particularly heated oil.
NOTE: Oil on the skin should be washed off immediately.
Basic rules when changing oil and filters, checking

hydraulic pressures, repairing etc.
• Clean thoroughly the area around the components to be

opened to ensure that no dirt enters the system.
• Keep the hydraulic hoses plugged as well as the filters
in their packs until they are installed to the machine.
• Plug removed components
• Ensure that all parts are clean before assembly
EL62757,000014E –19–18APR02–1/1

081403
PN=85
00
0040 Fluid and Lubricant Capacities
2
Capacities
Fluids and lubricants 810D 1010D 1110D 1410D 1710D
Liters (Gallons) Liters (Gallons) Liters (Gallons) Liters (Gallons) Liters (Gallons)
Engine oil + filter 13,5(3.6) 13,5(3.6) 25 (6.6) 25 (6.6) 28.5(7.5)
Coolant 21 (5.5) 21 (5.5) 27(7) 27.5 (7.3) 27 (7.1)
High/low gear 3.5 4,5 (1.2) 4.5 (1.2) 4.5 (1.2) 4.8 (1.3)
Differential single axle 11 28 (7.4) 30(7.9)
Differential; rear- 6-wheeled 12 (3.1) 11(2.2)
Differential; front - 6-wheeled 27 (7.1) 32 (8.5)
Differential; front - 8-wheeled 12(3.2) 12 (3.1) 14 (3.7)
Differential; rear 12 (3.1) 14 (3.7)
Hub gearings / each 4 (1) 4(1)
Hub gearings - 6-wheeled 2 x 4 (2x1.05) 2 x 5 (2 x 1.3)
Bogie housing; front - 50(13)
8-wheeled/each
Bogie housing rear /each 52 (13.7)
Bogie housing/each 52 (13.7) 50 (13) 52 (13.7) 65 (17.2)
Boom slew housing 5 7(1.8) 7(1.8) 9.5 (2.5) 15 (4.0)
Hydraulic fluid - max. level 78 136 (36) 150 (36.9) 150 (36.9) 220 (58.1)
Hydraulic fluid - min. level 72 (19) 79 (20.9) 79 (20.9) 175 (46.2)
Fuel tank 110 180 (47.5) 165 (43.5) 165 (43.5) 190(50.2)
Windshield washer fluid tank 5 5 (1.3) 2x5 (2x1.3) 2x5 (2x1.3) 15 (4.0)
Cab lift 0,8(0.2) 0,8(0.2) 0.8 (0.2) 0.8 (0.2) 0.8 (0.2)
Driving brake oil level (ATF oil) 0.4(0.1) 0.4(0.1) 0.4(0.1) 0.5 (0.1) 0.5 (0.1)
Air conditioner system 1.4kg 1.5 kg(3.3 lbt) 1.5 kg(3.3 lbt) 1.5 kg(3.3 lbt)
Air Conditioner Compressor 0.5dl (0.13) 0.5dl (0.13) 0.5dl (0.13) 0.5dl (0.13)
(PAG Oil)

081403
PN=86
00
The filling capacities given are guidelines only. Having 0040
3
changed the oil it is always necessary to check the final
correct oil level through the check opening or by means of
the oil dipstick.
The drain hoses are located on the underpan under the
–UN–05MAR02
engine. The hose clamps have been numbered:
1. Hydraulic oil; hydraulic tank

2. The drainage of the hydraulic suction hose.
T152229
3. Engine oil; draining.
4. Fuel tank; draining
Hoses
Fluid leaks under pressure may not be visible.
Pressure can be maintained in a hydraulic system long

after the power source and pump have been shut down.
Lower the implements to the ground and relieve trapped
pressure before performing maintenance work on
components.
• Do not disconnect any hoses before making sure that

all pressure has been eliminated.
• Do not fill up the oil tanks or fuel tank if the engine is
running.
• Do not modify any pressure adjustments without a
permission from the manufacturer.
• Use extreme caution when draining hot fluids from the
machine. Splashing hot fluid can cause serious burns.
• Open the expansion tank cap slowly if the cooling
system is hot. This allows the pressure to even out.
OUTJ003,00004B9 –19–15FEB01–2/2

081403
PN=87
00
0040 Diesel Fuel
4
Recommended quality requirements for diesel fuel:
❒ Cetane number of 40 minimum. Cetane number

greater than 50 is preferred, especially for
temperatures below -20°C (-4 °F).
❒ When operating in cold circumstances use fuel that is
suitable for winter operation and has a cloud point
appearing at a lower level than the operating
temperatures.
❒ Sulfur content:
• Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
• The period for changing the engine oil must be
reduced by half if diesel fuel containing more than
0.5% sulphur is used.
• Do not use diesel fuel with sulfur content greater
than 1.0%.
NOTE: Do not use diesel fuel with sulfur content greater

than 1.0%.
IMPORTANT: Use only pure fuel. DO NOT mix used

engine oil or any other type of lubricant
with diesel fuel.
Bio-diesel fuels
Bio-diesel fuels may be used ONLY if the fuel properties

meet DIN 51606 or equivalent specification.
Continued on next page EL62757,0000151 –19–18APR02–1/3

081403
PN=88
00
Handling And Storing Diesel Fuel 0040
5
CAUTION: Handle fuel carefully. Do not fill the

fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or
–UN–23AUG88
service the fuel system.
• Fill the fuel tank at the end of each day’s operation to

prevent water condensation and freezing during cold
TS202
weather.
• Keep all storage tanks as full as practicable to minimize
condensation..
• Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering.
• Monitor water content of the fuel regularly.
• Fuel filter may require more frequent replacement due
to premature plugging.
• When fuel is stored for an extended period or if there is
a slow turnover of fuel, add a fuel conditioner to
stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
Monitoring the quality of the fuel
DIESELSCAN is a John Deere fuel sampling program

help you monitor the quality of your fuel source.
It verifies fuel type, cleanliness, water content, suitability

for cold weather operation, and if fuel is within ASTM
specifications.
Check with your John Deere dealer for availability of

DIESELSCAN kits.
Minimizing the Effect of Cold Weather on Diesel

Engines
❒ Use Grade No. 1-D Fuel When temperatures fall below

5°C (40°F),
❒ Coolant Heaters Engine block heaters (coolant) if
equipped.
❒ Use Seasonal Viscosity Oil and Proper Coolant
Concentration
❒ Use Winterfronts
DIESELSCAN is a trademark of Deere & Company Continued on next page EL62757,0000151 –19–18APR02–2/3

081403
PN=89
00
0040
6
NOTE: If winterfronts are used, they should never totally
close off the grill frontal area. Approximately 25%
area in the center of the grill should remain open
at all times.
EL62757,0000151 –19–18APR02–3/3

081403
PN=90
00
Engine Oil 0040
7
Capacity
NOTE: Consult your Timberjack service for use and

availability of John Deere engine oils.
1. ENGINE BREAK-IN OIL

New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
during the first 250 hours of operation:
❒ API CE
–UN–10OCT97
❒ ACEA E1
Use oil viscosity based on the expected air

temperature range during the period between oil
TS1661
changes.
2. 500 hour service interval is achieved by using a

diesel engine oil meeting one of the following
classifications:
• John Deere PLUS-50
• ACEA E4
• ACEA E5
Reduce the service interval by 50%:
• If diesel fuel with sulfur content greater than 0.5% is

used
• If oil with lower classification than recommended is
used
3. Service interval is 250 hours while using a diesel

engine oil meeting one of the following
classifications:
• ACEA E3
• API CH-4
• API CI-4
PLUS-50 is a registered trademark of Deere & Company. Continued on next page EL62757,0000152 –19–18APR02–1/2

081403
PN=91
00
0040
8
IMPORTANT: All allowed oil grades are specified
here. Using any other types of oils is
prohibited.
NOTE: Use only original John Deere oil filters.
EL62757,0000152 –19–18APR02–2/2
Coolant
The engine cooling system is filled to provide year-round

protection against corrosion and cylinder liner pitting, and
winter freeze protection to -37°C (-34°F).
Use a coolant mixture consisting of 50 percent of water

and 50 percent of antifreeze in the system all year round.
The antifreeze must consist of ethylene glycol or
propylene glycol and that complies with grade ASTM4985
or ASTM5345.
Coolant chart
Antifreeze, in percents Freezing point of volume, °C (°F)
40 -24 (-11)
50 -37 (-34)
The anti-freezing ability will be reduced if the content of

glycol is greater than 60%.
If it is necessary to add coolant to the system make sure

that the new coolant is similar to the original. Allow the
engine to cool down before adding new coolant.
Check the coolant concentration before the ambient

temperature drops below 0°C (32°F).
EL62757,0000153 –19–18APR02–1/1

081403
PN=92
00
Hydraulic oil 0040
9
If you use mineral oil:
Comply with SH 68 (SMR classification) in summer.

Comply with SHS 32 (SMR classification) in winter.
Comply with SHS 46 (SMR classification) for year-round usage.
If you use synthetic biodegradeable oil:
Neste Biohydrauli SE 46
IMPORTANT: Do not mix different types of oils as this

will cause degradation of their
properties when mixed. When in doubt,
contact the manufacturer. Abuse will
result in the revocation of the warranty.
EL62757,0000155 –19–18APR02–1/1
Gear oil
Use hypoid oil that complies with the classification: API

GL-5 or MIL-L-2105 B or D.
The following viscosity categories can be used:
• SAE 90
• SAE 85W/90
• SAE 80W/90
• SAE 75W/90
EL62757,0000157 –19–18APR02–1/1
Brake fluid
Use ATF-oil.
EL62757,0000156 –19–18APR02–1/1

081403
PN=93
00
0040 Cab lift pump
10
Factory has filled the pump with Biohydr. 15 oil.
NOTE: Don’t mix oils together.
If the pump is emptied, it can also be filled with ATF-oil.
EL62757,0000158 –19–18APR02–1/1
Lubricant Storage
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST –19–18MAR96–1/1
Grease
IMPORTANT: Contact Timberjack service about

availability of John Deere greases.
Apply lithium grease, some examples:
• Neste Yleisrasva EP 2
• Esso Beacon EP2
• Shell Retinax LX Lithium
• Mobilgrease
• Castrol LM Grease
• Texaco Molytex Grease EP 2
NOTE: Use enough grease!
NOTE: Don’t mix different type of grease together.
EL62757,0000154 –19–18APR02–1/1

081403
PN=94
Group 0050
Transporting and Towing
00
Transporting the Machine 0050
1
–UN–08NOV02
T161471
Forwarder on Trailer
NOTE: Use a steering locking bar and the binding possible. Similarly, when positioning the machine and
points in the frame (see figure). the boom bear in mind the maximum axle loads
permitted for the truck or trailer as well as the
BInding maximum width and height.
Make sure that the tracks, fuel container, and other If necessary, the values must be checked by
loose items on the load area of the machine are measuring before transporting. Ensure that the
properly secured for the transport (use heavy-duty machine or Boom will not move during the transport.
hold-down straps, for instance).
The machine must be secured by at least two chains
Positioning (you can use a ratchet tensioner, for example). It is
good to utilize any support provided by, for instance,
When positioning the forwarder onto the trailer, ensure the fenders of the truck or trailer if the tires of the
that the machine is laterally as well centered as machine can be positioned against these
Continued on next page EL62757,000021B –19–28NOV02–1/2

081403
PN=95
00
0050
2
–UN–20FEB03
T165710
Holes for tracks
Minilevers tightening to prevent the tensioners from coming loose

during the transport. In addition, when securing the
Clamp the minilevers to the extreme position with chains make sure that they will not damage the
rubber loops situated on outer side of control panels. forwarder.
Chains Highway code
The chains secured to the front frame and rear frame Finally, fit clearance lights as stipulated by local laws.
must provide longitudinal support for the machine both
fore and aft, as well as lateral support at suitable NOTE: When travelling on public roads, all regulatory
angles. Make sure that the chains are not twisted after requirements must be met in full.
EL62757,000021B –19–28NOV02–2/2
Towing
As a result of a machine failure it may be necessary to

tow the machine when it comes to a halt on a public road
or if you have to transfer the machine to proper repair
facilities.
The machine cannot be towed unless some or all of the

following actions are taken:
1. Release the parking brake.

2. Release the driving power transmission system
3. Release the work brake.
4. Release the steering.

081403
PN=96
00
0050
CAUTION: Once the above steps have been 3
taken, the machine cannot be properly
controlled anymore. Therefore, it is of utmost
importance to ensure that nobody is placed in
jeopardy during the towing process or during
installation work. Make sure that no outsider
–UN–18JUL01
enters the risk zone around the machine.
NOTE: We strongly recommend you use a rigid towing

linkage for towing. Make sure that the machine is
T144065
adequately supported before anybody embarks on
repairing the machine. Brake cylinder locations
NOTE: Use low towing speed 2 km/h (1.24 mph)
How to Release the Parking Brake
1. Open the underpan.

2. Remove the cover at the end of the brake cylinder.
–UN–13JUN01
3. Screw down the release screw (under the cover) to
release the brake.
4. Repeat the procedure for each brake cylinder.
5. After towing, the release screws must be removed.
T142813
There are four brake cylinders in all. Two of these are for
the front axle and two for the rear axle. Brake cylinder
1—Brake cylinders
2—Brake cylinder cover
3—Release screw of the brakes
EL62757,0000194 –19–21APR02–2/6
How to Disengage the Power Transmission System

(bypass function)
1. Lift up the cabin

2. Turn the screw of shock pressure valves (1) of the
drive pump to such an extent that the valve cartridge is
–UN–05MAR02
released and free oil circulation is possible.
NOTE: When towing short distances (< 20 m /65 ft)),

release the power transmission system. Otherwise
T152219
release the drive shafts.
Once towing is over the valves need to be closed again. Drive pump, Drive pressure relief valves
Torque to 200 ± 10 Nm (148 ± 7,4 lb-ft)

081403
PN=97
00
0050 How to Release the Work Brake
4
1. Lift up the cabin.

2. Disconnect the solenoid valve Y41W coupler of the
work brake
–UN–08OCT02
NOTE: Re-connect the connector after towing
Disconnecting the Steering Cylinders
T159878
In 1010D do the following
Solenoid valve Y41W

IMPORTANT: Secure all loose parts and the valve
housing against dirt
1. Remove the pressure relief valves (1)

2. Replace the valves by plugs (2) (F030959).
3. After towing, insert the pressure relief valves again with
their seals
EL62757,0000194 –19–21APR02–4/6
–UN–13JUN01
T142817
1010D Steering valve

081403
PN=98
00
The steering valve block Y66 is located in the boom valve. 0050
5
In models 810D, 1110D, 1410D and 1710D do the

following
1. Open the relief valve plug and remove the spring (1)
and cartridge (2)
2. Install the plug with gasket and tighten.
3. After towing, install the spring and cartridge
–UN–05MAR02
T152221
810D, 1110D, 1410D and 1710D Y66 valve block and steering
valve
EL62757,0000194 –19–21APR02–6/6

081403
PN=99
00
0050 Stowing a Disabled Boom
6
–UN–10APR03
T189514
810D Boom control valve and spool section
EL62757,0000195 –19–21APR02–1/3
If the engine is stopped with the boom in an extended

position it may be necessary to manually retract and stow
the boom before the forwarder can be towed.
The boom hydraulics are released by by-passing the port

reliefs in the boom control valve and the boom is
maneuvered using a second forwarder or a suitable lifting
device.
1—Boom swing
2—Jib boom
–UN–03JUL02
3—Grapple open / closed

4—Extension
5—Grapple rotation
6—Main boom
T157015
7—Steering
1010D Boom control valve

081403
PN=100
00
0050
CAUTION: If the boom is stopped in a raised 7
position it must be completely supported in that
position before the hydraulics are released.
If the boom load is not completely disabled, oil

might be pressurized and the oil flow is heavy
–UN–13JUN01
at the beginning.
Failure to follow proper safety precautions may

lead to personal injury or damage to the
T142817
machine.
1010D Boom control valve section
Securely block the wheels. Support the boom using blocks
or a second machine. Each boom function is controlled
from its spool section on the Boom valve. Each spool
must be by-passed in order to move the boom in that
direction.
At each spool section:
1. Remove the pressure relief valves. Open the relief

valve plug and remove the spring (1) and cartridge (2).
2. Replace the valves with by-pass plugs. Install the plug
with gasket and tighten.
3. Maneuver the boom using a second forwarder boom or
suitable lifting device.
4. Replace the valves.
NOTE: Do not mix the valves after they have been

removed. Replace the valves as originally
installed.
For example, to raise or lower the main boom:
–UN–05MAR02
1. Support the boom in position carefully. There must not
be any pressure in a cylinder when a relief valve plug
is opened.
T152221
2. By-pass the sixth spool section.
3. Lift or lower the main boom using a suitable lifting
device
4. Replace the pressure relief valves
NOTE: Secure all loose parts and the valve housing

against dirt.
EL62757,0000195 –19–21APR02–3/3

081403
PN=101
00
0050
8

081403
PN=102
Group 0060
Inspection and Procedures
00
Machine Operational Checkout 0060
1
This procedure is designed so the technician can make a

quick check of the operation of the machine. Most of the
checks can be made while the technician is seated in the
operator’s seat.
NOTE: This procedure is specially for model 1010D but it

can be applied in most parts also in other
forwarder models.
A location will be required that is level and has adequate

space to complete the driving checks and to work the
machine.
The engine and all other major components must be at

operating temperature for some checks.
Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, loose linkage,
etc.) before doing the checkout.
Most checks require no special tools or gauges. Always

start in the left column and read completely, following this
sequence from left to right. Read each check completely
before performing.
Perform the Operational Checks before installing any test

equipment. Use this sheet to record the results. Bold face
numbers on the record sheet correspond to the item
numbers in this group.
OUTJ003,000058F –19–12APR01–1/1
1 Machine Condition and Cleanliness
– – –1/1

081403
PN=103
00
0060 Machine Condition and The machine should be kept clean, especially in the winter. OK: Go to next check.
2 Cleanliness
Snow, dirt and slash should be removed. NOT OK: Remove snow,
dirt and slash before it
freezes.
When using a power

washer, do not aim the
stream at the joint
between the pedestal and
the boom base.
– – –1/1
Decals Condition Decals and safety warning labels should be readable and in good condition. OK: Go to next check.
NOT OK: Replace any

damaged decals.
– – –1/1
2 Engine Operation
– – –1/1
Parking Brake Start NOTE: A circuit prevents the engine from starting unless OK: Go to next check.
Prevent the Parking Brake Switch is ON.
Parking Brake Switch on dashboard OFF.
Turn Ignition key to START.
LOOK/LISTEN: Engine must not start.

T140609 –UN–21JUL01
– – –1/1

081403
PN=104
00
Ignition Switch OK: Go to next check. 0060
3
T152192 –UN–05MAR02
1110D Startlock
P—Vacuum pump (opt. eq.)
STOP—Engine turn-off
I—Power on
II— Empty
START—Starting.
In positions Start and II the load on the working hydraulic pump is relieved
making it easier for the engine to run
Ignition Switch OFF.
Parking Brake Switch ON.
Turn Ignition Switch to Position I (RUN). Gauge Lights switch ON.
LOOK: The Gauge Lights should be lit, indicating current for the accessories is
available through the Ignition Switch.
Turn Ignition Switch to Position II (GLOW).
LOOK: Glow Indicator light on dashboard should be illuminated.
Turn Ignition Switch to Position III (START).
LISTEN: Starter motor should operate.
Release Ignition key.
LOOK: Ignition key switch should return to Position I (RUN).
NOTE: Shut off engine before proceeding to next check.
– – –1/1
3 Brake Systems
– – –1/1

081403
PN=105
00
0060 Parking Brake Operation Start engine. OK: Go to next check.
4
Parking Brake switch ON. NOT OK: See for
procedures to diagnose
LOOK: Park brake indicator light at the switch must be the Parking Brake
on.(1010D Engage Circuit.
For procedures to
diagnose the Parking
T140609 –UN–21JUL01
Brake Indicator Light
1010D Parking Brake
Circuit.
Indicator Light
NOTE: The parking Brake switch should release the OK: Go to next check.
Parking Brake.
NOT OK: For procedures
Parking Brake switch OFF. to diagnose the Parking
Brake Engage Circuit.
Select Forward Drive Direction. Slowly press drive pedal.
LOOK: Machine should move forward.

T140609 –UN–21JUL01
NOTE: The Parking Brake should engage automatically OK: Go to next check.
when the engine is turned off.
NOT OK: For procedures
Parking Brake Switch OFF. to diagnose the Parking
Brake Engage Circuit.
Turn Ignition key to OFF to stop engine.
Start engine.
T140609 –UN–21JUL01
LOOK: Parking Brake indicator light at the switch should
be illuminated.
– – –1/1
Work Brake Operation NOTE: The Work Brakes are engaged automatically when the Parking Brakes are OK: Go to next check.
released. The Work Brakes are released when the drive pedal is pressed.
NOT OK: See Section
Stop machine on a slope. Engage the Parking Brake. 02, for procedures to
diagnose the Work Brake
Disengage the parking brake. Do not press the driving brake. Engage Circuit.
LOOK/FEEL: The machine should not roll down slope. Work brakes should be Remedy possible
engaged. hydraulic or mechanical
problems.
– – –1/1

081403
PN=106
00
Service Brake Operation OK: Go on to next check. 0060
5
NOT OK: Diagnose the
Service Brake hydraulics.
T141541 –UN–13AUG01
Brake Pedals
1—Brake Pedals
Turn seat to face forward.
Start engine.
Drive forward slowly.
Press forward facing brake pedal.
LOOK/FEEL: Machine should slow to stop.
Drive Direction Select Switch to Neutral. Engage parking brake. Turn seat to face rear
of machine.
Release the parking brake.
Drive forward slowly.
Press rear facing brake pedal.
LOOK/FEEL: Machine should slow to stop.
– – –1/1
4 Steering System
– – –1/1

081403
PN=107
00
0060 Steering Operation 1—Steering Control Lever OK: Go on to next check.
6
NOTE: It is not necessary for the machine to be moving NOT OK: Remedy
to check the steering. possible Steering System
hydraulic or mechanical
Start engine. Release Parking Brakes. problems.
Push steering control lever on armrest to the right. See Section 03, for more
information on the
T141542 –UN–21JUL01
1010D Steering Control LOOK/FEEL: The machine should articulate to the right. Steering hydraulics.
Lever
Push steering control lever on armrest to the left.
LOOK/FEEL: The machine should articulate to the left.
NOTE: The machine should turn in the direction the

steering lever is moved whether the seat is facing
forward or towards the rear of the machine. Check the
steering with the seat in both positions.
– – –1/1
5 Driving Checks
– – –1/1
Low Gear Select 1—High Gear Select Switch OK: Go on to next check.
NOTE: Low Gear should be automatically selected when NOT OK: See Section
drive is engaged. 16, for procedures to
diagnose the Low Gear
Start engine. Select electrical Circuits.
Parking Brake OFF. Remedy possible

T140626 –UN–21JUL01
Transfer Case hydraulic
Select Forward Drive Direction. or mechanical problems.
1010D High Gear Select
Switch
LOOK: Indicator light at High Gear Select Switch should See Section 02, Group
not be illuminated.(1010D) 0220, for more
information on the
In other models High gear selection symbol should not Transfer Case hydraulics.
show on TMC screen
Drive the machine forward a short distance to confirm

Low Gear has been selected.
LOOK: Ground speed in Low Gear should be

approximately 0 — 8 km/h (0 — 5 mph).
– – –1/1

081403
PN=108
00
High Gear Select 1—High Gear Select Switch OK: Go on to next check 0060
7
Start engine. NOT OK: See Section
16, for procedures to
IMPORTANT: The machine must be stationary and diagnose the High Gear
the parking brake engaged before changing transfer Select electrical Circuits.
case gear range.
See Section 16 for
Press the High Gear Select Button on the armrest. procedures to diagnose
T140626 –UN–21JUL01
the High Gear Select
1010D High Gear Select
Switch LOOK: Indicator light at High Gear Select Switch should Indicator Light electrical
be illuminated. Circuit.
Parking Brake OFF. Remedy possible

Transfer Case hydraulic
Select Forward Drive Direction. or mechanical problems.
Drive the machine forward a short distance to confirm See Section 02 Group
High Gear has been selected. 0220, for more
information on the
LOOK: Ground speed in High Gear should be Transfer Case hydraulics.
approximately 0 — 22 km/h (0 — 13 mph).
(See the NAF LOK
NOTE: Shut off engine before proceeding to next check. Repair Manual for
procedures to service the
Transfer Case.)
– – –1/1

081403
PN=109
00
0060 Differential Locks 1—Differential Lock Buttons OK: Go on to next check.
8
NOTE: This check must be conducted on grass or a NOT OK: See Section
loose gravel surface. 16, for procedures to
diagnose the Differential
Start engine. Release parking brake. Lock electrical Circuits.
Select Forward Drive Direction. Remedy possible

Differential Lock hydraulic
T140641 –UN–13AUG01
Press and hold Front Differential Lock Button. or mechanical problems.
Press drive pedal. When machine begins to move, See Section 02, for more
release the Front Differential Lock Button. information on the
Differential Lock
LOOK: Front Differential Lock should be engaged. The hydraulics.
indicator light at the button should be lit.
Drive forward at low speed. Use the steering lever to

turn the machine to the right.
LOOK: The left hand wheels should skid in the gravel, if

the Differential Lock is properly engaged.
Use the brake pedal to bring the machine to a stop.
LOOK: When the machine stops, the Front Differential

Lock should be released. The indicator light at the button
should go out.
Repeat the test to check the Rear Differential Lock.
NOTE: Shut off the engine before proceeding to the next

check.
– – –1/1

081403
PN=110
00
Rear Wheel Drive NOTE: The Rear Wheel Drive is automatically engaged OK: Go on to next check. 0060
Engage when the machine is in Low Gear. 9
NOT OK: Remedy
The Rear Wheel Drive is automatically disengaged when possible Transfer Case
the machine is in High Gear. hydraulic or mechanical
problems.
When the machine is in High Gear, the Rear Wheel
Drive can be manually engaged using the Rear Wheel See Section 02, Group
T140627 –UN–21JUL01
Drive Switch on the dashboard. 0220, for more
information on the
1010D Rear Wheel Drive
Support machine with wheels off ground. Transfer Case hydraulics.
Engage Switch
Start engine. (See the NAF LOK
manual for procedures to
Press the High Gear Select Button on the armrest. service the Transfer
Case.)
LOOK: The indicator light at the High Gear Select button
should be illuminated.
Select Forward Drive Direction.
Press drive pedal slowly.
LOOK: Rear Wheel Drive should be disengaged. The

front wheels should turn. The rear wheels should not
turn.
Apply brakes to stop wheels.
Press the Rear Wheel Drive Engage switch to ON.
LOOK: The indicator light at the Rear Wheel Drive

Engage switch should be illuminated.
Press drive pedal slowly.
LOOK: Rear Wheel Drive should be engaged. Both front

and rear wheels should turn.
– – –1/1
6 Drive Train
– – –1/1

081403
PN=111
00
0060 Drive Shafts Start engine. Drive machine slowly. OK: Go on to next check.
10
LISTEN/FEEL: Drive shafts should not produce any unusual chattering noise or NOT OK: Inspect
vibration. driveshafts and universal
joints. Inspect carrier
NOTE: Shut off engine before proceeding to next check. bearings.
OK: Go on to next check.
NOT OK: See group

0230, for procedures to
service driveshafts and
universal joints.
T141545 –UN–08JUN01
Drive Shaft and Universal Joint
CAUTION: Engage parking brakes and block wheels securely to prevent

machine movement before working under machine. Failure to observe
proper safety precautions can lead to severe personal injury.
Remove access covers on front and rear frames to inspect driveshafts and universal
joints.
LOOK: Driveshafts should be in good condition.
Universal joints should be properly lubricated.
Joint components should be fit together properly.
Mounting screws should be secure.
Yokes should be aligned on driveshaft.
Carrier bearings should be properly lubricated and in good condition.
Carrier bearing seals should be in good condition.
– – –1/1
7 Wheels and Tires
– – –1/1

081403
PN=112
00
Wheel Rims Inspect the wheel rims. OK: Go on to next check. 0060
11
LOOK: Wheel rims should be in good condition. NOT OK: Replace
damaged wheel rims.
The wheel rims should have no cuts and dents.
T141546 –UN–08JUN01
Wheel Rims
– – –1/1
Wheel Nuts Wheel nuts should be Tightened to specified torque. OK: Go on to next check.
NOT OK: Tighten or

replace wheel nuts.
T141546 –UN–08JUN01
– – –1/1
Tire Pressure Tires should be in good condition. OK: Go on to next check.
Use gauge to check tire pressure. NOT OK: Add air to tires.
Replace tires if required.
See Repair Manual, Section 01, Group 0112, for table showing correct tire pressures.
– – –1/1
8 Cab Components
– – –1/1

081403
PN=113
00
0060 Condition and
12 Cleanliness
T156559 –UN–25JUN02
Cab Component Locator 1010D
1—Brake Pedal
2—Drive Pedal
3—Instrument Box (Includes Fuses, Relays and HUB Module
4—Dashboard/Instrument Panel
5—24 V Socket
6—Ignition Switch
7—Dashboard Switches
8—Indicator Lights
9—Gauges
10—Emergency Stop Button
11—Engine Throttle Adjustment
12—Heater/Air Conditioner Unit
13—Heater/AC Controls
14—Dome Light
15—Central Warning Light
16—Speaker
17—AM/FM Radio
18—Exterior Light Switches
19—Operator’s Seat (Includes SEAT Module on seat back)
20—Fire Extinguisher
21—Left Armrest Control Panel
22—Right Armrest Control Panel
– – –1/3

081403
PN=114
00
0060
13
T152190 –UN–12SEP02
810D, 1110D ,1410D and 1710D Cab Component Locator
–19– –2/3

081403
PN=115
00
0060 1—Front dashboard OK: Go on to next check.
14 2—Signal lights
3—TMC-display NOT OK: Clean cab.
4—Left control panel Remove any accumulated
5—Right control panel refuse.
6—Drive pedal
7—Brake pedal Replace Operator’s
8—Heater/AC controls Manual in cab.
9—Warning lamps
10—Light switch Replace any damaged
11—Engine preheater decals.
12—Control unit for fire extinguisher system
13—Radio Repair or replace any
damages or missing
*) if equipped control knobs, etc.
Check condition of cab. Repair or replace any

damaged interior
LOOK: Cab should be clean. components.
Operator’s Manual should be stowed in cab.
Decals and warning labels should be readable and in good condition.
Controls should be in good condition.
Cab interior panels should be secure and in good condition.
Seat should be in good condition.
–19– –3/3
Door and Door Latch Unlatch door. OK: Go on to next check.
Inspect door seals. NOT OK: Repair or

replace door latch.
LOOK: Door handle must work freely. Door seals must not be damaged.
Replace damaged door
Close door. seals as required.
LOOK: Door must close securely. Latch must hold door closed. Door seals must
contact door opening and prevent air entry.
– – –1/1
Door Gas Cylinder Unlatch door. OK: Go on to next check.
LOOK: Door gas cylinder should hold door open. NOT OK: See Repair
Manual for procedure to
repair or replace door gas
cylinder.
– – –1/1

081403
PN=116
00
Operator’s Seat Inspect seat condition. OK: Go on to next check. 0060
15
LOOK: Seat upholstery should not have cuts and tears NOT OK: Repair seat as
or indications of excessive wear. required.
Check seat position and height adjustments.
FEEL: Seat adjustments should work freely and lock in

T141550 –UN–21JUL01
all positions.
Check armrest position adjustments.
FEEL: Seat armrest adjustments should work freely and

lock in all positions.
Check seat rotation.
FEEL: Seat should rotate freely to face the front or the

rear of the machine.
Turn seat to face forward. OK: Go on to next check.
Check the Seat Direction Limit Switch located on the seat pedestal. NOT OK: Repair or
replace switch as
LOOK: Switch should be in open position. required
Turn the seat to face the rear.
LOOK: Switch should contact stop, tripping the switch to the closed position.
– – –1/1
Seat Belt Sit in seat and secure seat belt across lap. OK: Go on to next check.
LOOK/FEEL: Belt must adjust snugly. Latch must hold belt securely. NOT OK: Tighten any
loose attaching hardware.
Unlatch buckle.
Replace the entire seat
LOOK/FEEL: The seat belt must release when the buckle is unlatched. belt assembly if any
component does not
Carefully examine the buckle, webbing and attaching hardware. operate properly, or if it is
damaged, worn or
LOOK: Buckle must work smoothly and not show indications of wear. Webbing must deteriorated.
not be cut or frayed or show indications of wear. Attaching hardware must be in place
and secure.
NOTE: The seat belt must be replaced every 3 years from the date on the decal.
– – –1/1
Windows Check condition of window material and seals. OK: Go on to next check.
LOOK: Window material should be in good condition and not show any scratches, NOT OK: Replace
hazing or indications of wear. Window seals should be in good condition and not allow windows or seals as
any flow of air or water into the cab. required.
– – –1/1

081403
PN=117
00
0060 Service Decal Inspect service decal. OK: Go on to next check.
16
LOOK: Service decal must be legible. NOT OK: Replace
service decal.
– – –1/1
9 Accessories
– – –1/1
Dome Light Ignition switch ON. OK: Go on to next check.
Dome Light switch ON. NOT OK: Replace bulb.
T164090 –UN–16JAN03
LOOK: Dome light on cab ceiling should be illuminated.
– – –1/1

081403
PN=118
00
Windscreen Open hood. OK: Go on to next check. 0060
Wiper/washers 17
Check level in washer fluid tanks. NOT OK: Fill washer fluid
tanks.
LOOK: Washer fluid tanks should be full.
T141558 –UN–21JUL01
Ignition switch ON. OK: Go on to next check.
Front Windscreen Washer Switch ON. NOT OK: Diagnose Front

Windscreen Washer
LOOK: Washer pump should operate. Washer fluid circuit.
should spray on front windscreen.
Replace Washer pump as
required.
T140715 –UN–21JUL01
Check condition of front wiper blade. OK: Go on to next check.
LOOK: Wiper blade should not have cuts or show NOT OK: Replace wiper
indications of wear. blade as required.
NOTE: Operating the wiper on a dry windscreen can Diagnose Front

damage the window material. Use windscreen washer Windscreen Washer
before running wiper. Circuits.
T140713 –UN–21JUL01
Ignition switch ON.
Front Wiper Switch to ON.
LOOK: Front windscreen wiper should operate at normal

speed.
Ignition switch ON. OK: Go on to next check.
Rear Windscreen Washer Switch ON. NOT OK: Diagnose Rear

Windscreen Washer
LOOK: Washer pump should operate. Washer fluid circuit.
should spray on rear windscreen.
Replace Washer pump as
required.
T140722 –UN–21JUL01
– – –1/2

081403
PN=119
00
0060 Check condition of rear wiper blade. OK: Go on to next check.
18
LOOK: Wiper blade should not have cuts or show NOT OK: Replace wiper
indications of wear. blade as required.
NOTE: Operating the wiper on a dry windscreen can Diagnose Rear

damage the window material. Use windscreen washer Windscreen Washer
before running wiper. Circuits.
T140717 –UN–21JUL01
Ignition switch ON.
Rear Wiper Switch ON.
LOOK: Rear windscreen wiper should operate at normal

speed.
–19– –2/2

081403
PN=120
00
Intermittent Windscreen NOTE: Operating the wiper on a dry windscreen can OK: Go on to next check. 0060
Wiper Button damage the window material. Use windscreen washer 19
before running wiper. NOT OK: Diagnose
Intermittent Wiper
Ignition switch ON. Circuits.
Press the Intermittent Windscreen Wiper Button on the

right armrest once.
T140713 –UN–21JUL01
LOOK: Front and rear windscreen wipers should operate
once.
Wait 10 seconds and press the Intermittent Windscreen

Wiper Button on the right armrest a second time.
LOOK: Front and rear windscreen wipers should operate

intermittently with a 10 second delay between passes.
NOTE: The delay between pressing the button the first

time and the second time will set the delay for the
intermittent wiper operation. You have up to 30 seconds
to press the button the second time.
Press the Front Windscreen Wiper switch on the

dashboard to ON.
LOOK: The front windscreen wipers should operate at

full speed. The rear windscreen wipers should continue
to operate intermittently.
Press the Front Windscreen Wiper switch on the

dashboard to OFF.
LOOK: The front windscreen wiper should resume

intermittent operation.
Press the Rear Windscreen Wiper switch on the

dashboard to ON.
LOOK: The rear windscreen wipers should operate at full

speed. The front windscreen wipers should continue to
operate intermittently.
Press the Rear Windscreen Wiper switch on the

dashboard to OFF.
LOOK: The rear windscreen wiper should resume

intermittent operation.
Press the Intermittent Windscreen Wiper Button on the

right armrest a third time.
LOOK: Both windscreen wipers should stop.
– – –1/1

081403
PN=121
00
0060 Horn Ignition switch ON. OK: Go on to next check.
20
Horn Switch ON. NOT OK: Diagnose Horn
circuit.
LISTEN: Horn should sound.
T140724 –UN–21JUL01
– – –1/1
AC/Heater Blower 1—AC/Heater Blower Switch OK: Go on to next check.

Operation
NOTE: See Section 9031, Group 10, for detailed NOT OK: Diagnose
operational checkout of AC/Heater system. AC/Heater Blower
circuits.
T141559 –UN–08JUN01
Ignition switch ON.
AC/Heater Blower Switch to LOW.
LISTEN/FEEL: Blower should operate at low speed.
AC/Heater Blower Switch to MEDIUM.
LISTEN/FEEL: Blower should operate at medium speed.
AC/Heater Blower Switch to HIGH.
LISTEN/FEEL: Blower should operate at high speed.
– – –1/1
Air Conditioner 1—AC/Heater Blower Switch OK: Go on to next check.

Operation 2—AC Switch
3—Heater Switch NOT OK: Diagnose Air
Conditioner Thermostat
NOTE: See Section 9031, Group 10, for detailed circuits.
operational checkout of AC/Heater system.
Start engine.
T141560 –UN–21JUL01
Cab Heater switch to OFF.
AC switch to cool.
FEEL: After a few minutes, cool air should flow from air
vents in cab.
– – –1/1

081403
PN=122
00
Heater Operation 1—AC/Heater Blower Switch OK: Go on to next check. 0060
2—AC Switch 21
3—Heater Switch NOT OK: (See Section
19 for procedures to
NOTE: See Section 9031, Group 10, for detailed service the cab heater
operational checkout of AC/Heater system. system and components.)
Start engine.
T141560 –UN–21JUL01
AC Switch to OFF.
Cab Heater Switch to WARM.
FEEL: After a few minutes, warm air should flow from air
vents in cab.
– – –1/1

081403
PN=123
00
0060 Work Lights
22
T156800 –UN–28JUN02
1010D cab lights
1. Loader lights (opt.eq

2. Work spot light; front
3. Work spot light; left side
4. Work spot light; right side
5. Work spot light; rear
T164083 –UN–16JAN03
1—Work light, boom (opt.eq.)

2—Work spot light; bottom corner of cab, (opt.eq.)
3—Work spot light; rear
4—Work spot light; right side
5—Work spot light; left side
6—Work spot light; forward
7—Cab light
8—Service light under the cab
NOTE: If the engine is not running, any electrical system

operated will drain the batteries.
T164082 –UN–16JAN03
Ignition switch ON.
Front Work Lights Switch ON.
LOOK: Front work lights should be illuminated.
Left Work Lights Switch ON.
NOTE: The front work lights are the outside pair of lights
mounted on the cab roof facing forward.
LOOK: Left work lights should be illuminated.
Right Work Lights Switch ON.
LOOK: Right work lights should be illuminated.
Rear Work Lights Switch ON.
LOOK: Rear work lights should be illuminated.
– – –1/2

081403
PN=124
00
Front Work Lights Switch ON. OK: Go on to next check. 0060
23
LOOK: Front work lights should be illuminated. NOT OK: Replace lights
as required.
Track Lights Switch ON.
Diagnose Work Lights
LOOK: Track lights should be illuminated. and Track Lights Circuits.
NOTE: The track lights are the inside pair of lights

mounted on the cab roof facing forward.
NOTE: If engine is running, shut off engine before

proceeding to next check.
–19– –2/2
Radio main switch ON. OK: Go on to next check.
Press Power switch on Radio. NOT OK: Diagnose

Radio Circuits.
LOOK/LISTEN: Radio should operate. Radio indicator
lights should be lit. Sound should be heard at both
speakers.
T140708 –UN–21JUL01
Turn main switch OFF, then back ON.
LOOK: Radio memory should maintain station locations.
– – –1/1
10 Frames
– – –1/1
Condition and NOTE: The machine should be kept clean, especially in the winter. OK: Go on to next check.
Cleanliness
Inspect the machine for cleanliness. NOT OK: Remove snow,
LOOK: There should be no snow, dirt and slash on the machine. freezes.
NOTE: When using a power washer, do not aim the stream at the joint between the
pedestal and the boom base.
– – –1/1

081403
PN=125
00
0060 Frame Joint Inspect the frame joint. OK: Go on to next check.
24
LOOK: Frame joint should be in good condition and NOT OK: Lubricate frame
properly lubricated. joint and pins. Tighten
fasteners.
LOOK: Pins should be in good condition and properly
lubricated. fasteners should be tight.
T141594 –UN–21JUL01
LOOK: Bearing seals should be in good condition and
properly lubricated.
1—Hinge Pins OK: Go on to next check.

2—Steer Cylinder Pins
NOT OK: Lubricate pins
Start engine. and bearings.
Use the Steering Lever to articulate the machine left and

right.
T141595 –UN–21JUL01
LOOK/FEEL: Frame joint hinge pins and bearings should
operate smoothly.
1—Frame Joint Bearings OK: Go on to next check.
Start engine. NOT OK: Lubricate

bearings.
Drive machine slowly over uneven surface.
Damage to the main
LOOK: Rear frame should roll relative to front frame, tapered roller bearings
keeping all wheels in firm contact with the ground. will require the complete
T141596 –UN–21JUL01
Bearings should operate smoothly. removal and disassembly
of the frame joint.
– – –1/1

081403
PN=126
00
Panels and Covers Open hood. OK: Go on to next check. 0060
25
LOOK: Hood should be in good conditions with no dents NOT OK: Repair or
or damage. Latches and hinges should operate replace latches. Repair or
smoothly. The pneumatic cylinder should be in place and replace pneumatic
operate smoothly to slow movement of hood. cylinder. Repair or
replace seal on air intake
Close hood. cap.
T141597 –UN–21JUL01
LOOK: The pneumatic cylinder should operate smoothly Replace hood, grill or
to slow movement of hood. Hood should fit properly. Air screen, if necessary.
cleaner rubber bellows should fit properly, making a
proper seal with the hood. Latches should hold hood
securely.
Remove front grill.
LOOK: The grill should be clean and in good condition.

The screen behind the grill should be clean and
undamaged. Fasteners should hold grill securely.

CAUTION: Apply parking brake and securely
block wheels to prevent machine movement NOT OK: Repair or
before working under machine. Failure to replace safety hook.
observe proper safety precautions can result Repair or replace
in personal injury. pneumatic cylinder.
Replace belly pan if
Open the front frame belly pan. damaged.
T141598 –UN–21JUL01
LOOK: Belly pan should be undamaged. Safety hook
should be in place and stop belly pan from dropping
more than a few inches. The pneumatic cylinder should
operate smoothly to slow movement of belly pan.
Close belly pan.
LOOK: Fasteners should be tight and hold belly pan

securely.

block wheels to prevent machine movement NOT OK: Tighten
before working under machine. Failure to fasteners. Replace
observe proper safety precautions can result covers, if missing or
in personal injury. damaged.
Inspect front frame drive shaft access covers.
T141599 –UN–21JUL01
LOOK: Covers should be in place and undamaged.
Fasteners should be tight.
Inspect panels on front frame at hinge and on either side OK: Go on to next check.
of cab.
NOT OK: Tighten
LOOK: Panels should be in place and undamaged. fasteners. Replace
Fasteners should be tight. panels, if missing or
damaged.
T141600 –UN–21JUL01
– – –1/2

081403
PN=127
00
0060 1—Frame Joint Access Cover OK: Go on to next check.
26 2—Rear driveshaft Access Cover
3—Rear Frame Belly Pan NOT OK: Tighten
fasteners. Replace
covers, if missing or
CAUTION: Apply parking brake and securely damaged.
block wheels to prevent machine movement
before working under machine. Failure to
observe proper safety precautions can result
T141601 –UN–21JUL01
in personal injury.
Inspect covers on boom pedestal and on the underside

of the rear frame.

Inspect covers on the cab. OK: Go on to next check.
LOOK: Covers should be in place and undamaged. NOT OK: Tighten

Fasteners should be tight. fasteners. Replace
damaged.
T141602 –UN–21JUL01
–19– –2/2

081403
PN=128
00
Operational Checkout Record Sheet 0060
27
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
X9811
Protect hands and body from high pressure
fluids. High-Pressure Fluids
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable medical source.
IMPORTANT: Any hydraulic leaks must be repaired

immediately.
Install frame lock bar when working in

articulation area.
OWNER DATE
HOURS
PIN
TECHNICIAN

OK NOT OK COMMENTS
1. Machine Condition and Cleanliness
Machine Condition and Cleanliness ❒ ❒
Decals Condition ❒ ❒
Continued on next page OUTJ003,000058E –19–12APR01–1/3

081403
PN=129
00
0060 2. Engine Operation
28
Parking Brake Start Prevent ❒ ❒
Ignition Switch ❒ ❒
Throttle ❒ ❒
3.Indicators
Alternator/Battery Charge Warning Light ❒ ❒
Brake Pressure Warning Light ❒ ❒
Parking Brake ❒ ❒
Direction Indicators ❒ ❒
Direction Indicators, Trailer ❒ ❒
Beeper and Warning Lamp on the roof, (TMC ❒ ❒
sows what is wrong)
Fire Alarm lamp (red) ❒ ❒
4. Brake Systems
Parking Brake Operation ❒ ❒
Work Brake Operation ❒ ❒
Service Brake Operation ❒ ❒
5. Steering System
Steering Operation ❒ ❒
6. Driving Checks
Low Gear Select ❒ ❒
High Gear Select ❒ ❒
Differential Locks ❒ ❒
Rear Wheel Drive Engage ❒ ❒
7. Drive Train
Drive Shafts ❒ ❒
8. Wheels and Tires
Wheel Rims ❒ ❒
Wheel Nuts ❒ ❒
Tire Pressure ❒ ❒
9. Cab Components
Condition and Cleanliness ❒ ❒
Door and Door Latch ❒ ❒
Door Gas Cylinder ❒ ❒
Operator’s Seat ❒ ❒
Seat Belt ❒ ❒
Windows ❒ ❒
Service Decal ❒ ❒
10. Accessories
Dome Light ❒ ❒
Gauge Lights ❒ ❒
Continued on next page OUTJ003,000058E –19–12APR01–2/3

081403
PN=130
00
2. Engine Operation 0060
29
Windscreen Wiper/washers ❒ ❒
Horn ❒ ❒
AC/Heater Blower Operation ❒ ❒
AC Operation ❒ ❒
Heater Operation ❒ ❒
Work Lights ❒ ❒
Radio ❒ ❒
OK NOT OK COMMENTS
11. Frames
Frame Joint ❒ ❒
Panels and Covers ❒ ❒
Cleanliness ❒ ❒
Cleanliness ❒ ❒
2. boom
Cleanliness
Load Bearing Structures ❒ ❒
Hoses and Fittings ❒ ❒
Cylinders Rod Seals ❒ ❒
Boom and Cylinder Pins ❒ ❒
Extension Boom Wear Pads ❒ ❒
Extension Boom Chains ❒ ❒
boom Fasteners ❒ ❒
Slew Housing Oil Level ❒ ❒
Boom Cylinder Internal Seals ❒ ❒
boom Slew ❒ ❒
Main Boom Up / Down ❒ ❒
Jib Boom Up / Down ❒ ❒
Extension Boom Extend/Retract ❒ ❒
Frame Brake ❒ ❒
3.forwarder head
GrappleLink ❒ ❒
Grapple Frame and Delimbing Blades ❒ ❒
Cylinder Rod Seals ❒ ❒
Grapple Rotate Motor ❒ ❒
GrappleRotate ❒ ❒
OUTJ003,000058E –19–12APR01–3/3

081403
PN=131
00
0060 Troubleshooting Techniques
30
The troubleshooting sections describe some problems that

can be experienced with the various components or
systems. While every effort has been made to list the
most likely sources of problems, no guarantee of
completeness is offered. Some causes produce more than
one symptom or problem. The possible causes are
arranged from the simplest , most likely to occur to the
more complex, least likely to occur. In every instance a
systematic approach to diagnostics is essential.
• Ensure that the correct operating procedure is being

followed.
• Identify the problem as completely as possible.
• Check the simplest and obvious causes first.
• The solutions to most problems are simpler and less
costly if acted on as soon as a problem is noted.
It may be necessary to periodically check or adjust certain

systems or components. See the Operator’s Manual for
more information.
OUTJ003,00004C8 –19–19FEB01–1/1

081403
PN=132
Section 01
Wheels
Contents 01
Page
Group 0110—Wheels Service

Service Tires Safely . . . . . . . . . . . . . . . . . . .01-0110-1
Service Equipment and Tools . . . . . . . . . . . .01-0110-1
Wheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-2
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3
Wheel Inspection. . . . . . . . . . . . . . . . . . . . . .01-0110-3
Tire Removal and Installation . . . . . . . . . . . .01-0110-4
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . .01-0110-5
Anti-Slip and Bogie Tracks Fitting . . . . . . . . .01-0110-6

081403
PN=1
Contents
01

081403
PN=2
Group 0110
Wheels Service
Service Tires Safely
Explosive separation of a tire and rim parts can cause

serious injury or death.
01
Do not attempt to mount a tire unless you have the proper 0110
equipment and experience to perform the job. 1
Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension

hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.
–UN–23AUG88
TS211
DX,RIM –19–24AUG90–1/1
Service Equipment and Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.
SERVICEGARD is a trademark of Deere & Company. OUTJ003,0000543 –19–13MAR01–1/3
20-Ton Service Jack
To raise unit to install floor stand.
OUTJ003,0000543 –19–13MAR01–2/3
20-Ton Floor Stand
To support unit while removing and installing wheels.
OUTJ003,0000543 –19–13MAR01–3/3

081403
PN=135
Wheels Service
Wheel Removal
CAUTION: The wheel assembly is heavy.

Always use proper equipment to handle the
01 wheel assembly.
0110
2
Always support the machine properly. Do not
use cinder blocks or props that may collapse
under continuous load. Failure to follow proper
safety precautions may lead to risk of personal
injury and equipment damage.
1. Loosen wheel cap screws before lifting machine off

ground.
2. Raise axle housing using a 20-ton capacity service

jack.
3. Put a 20-ton floor stand under axle housing.
OUTJ003,0000545 –19–13MAR01–1/2
4. Put wheel lift under wheel. Fasten safety chain around

upper portion of tire.
5. Remove retaining cap screws and pull wheel assembly

away from machine.
1—Wheel Lift
2—Safety Chain
–UN–27JUN01
T141917
OUTJ003,0000545 –19–13MAR01–2/2

081403
PN=136
Wheels Service
Wheel Installation
1. Cap screws, washers, and tapped holes must be clean

and free of foreign material.
01
IMPORTANT: Start cap screws by hand to prevent 0110
thread damage. 3
2. Install wheel using wheel lift. Guide wheel over three

special studs. Install three cap screws and washers.
Remove studs. Install remaining cap screws and
washers. Tighten cap screws.
3. Remove shop stands and lower equipment to ground.
4. Tight wheel nuts to specified torque. See Group 0030

for specific torques
OUTJ003,0000547 –19–13MAR01–1/1
Wheel Inspection
Inspect wheel rims for cuts and dents. Replace damaged

rims.
Wheel nuts should be tightened to specified torque.See

Group 0030 for specific torques
OUTJ003,00003A3 –19–30JAN01–1/1

081403
PN=137
Wheels Service
Tire Removal and Installation
CAUTION: Explosive separation of a tire and

rim parts can cause serious injury or death.
01
0110 Do not attempt to mount a tire unless you have
4
the proper equipment and experience to
perform the job.
Always maintain the correct tire pressure. Do

not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire
assembly. The heat can cause an increase in air
pressure resulting in a tire explosion. Welding
can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and

extension hose long enough to allow you to
stand to one side and NOT in front of or over
the tire assembly. Use a safety cage if available.
–UN–23AUG88
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
TS211
NOTE: The tire can be removed without removing the
wheel.
1. Before attempting any demounting operation, always

completely deflate tire by removing valve core from
valve stem.
2. If tire is flat, check for a plugged valve stem by running

a wire through it. Inspect parts for wear or damage;
replace as necessary.
3. Make sure all parts are clean and free of paint, rust,
oil, grease, dirt or other foreign material before
assembly.
4. Install valve core in valve stem.
Continued on next page OUTJ003,0000546 –19–13MAR01–1/2

081403
PN=138
Wheels Service
5. Apply soap on bead of tire and mount tire on rim.
6. Clear area of personnel.
7. Connect pressure regulating valve to valve stem and

01
stand to one side of tire. DO NOT stand in front of tire 0110
–UN–27JUN01
when inflating. 5
8. Inflate tire until side flanges of tire slides out against

the rim. Adjust tire pressure. See group 0030 for
T141919
recommended tire pressures.
9. Apply grease to cover threads. Install cap and cover. Tire Inflation
1—Tire Bead
OUTJ003,0000546 –19–13MAR01–2/2
Tire Pressure

gauge to confirm the pressure.
NOTE: See group 0030 for Proper tire pressures
• Use maximum tire pressure with chains and tracks.

• Use maximum tire pressure when operating with heavy
loads in harsh, rugged terrain. Low tire pressure can
lead to immediate tire failure.
• Low tire pressure can lead to side wall damage and rim
chafing or possible rim slippage.
• Cold weather can reduce tire pressures by 10 kPa (1.5
psi) per 10°C below normal operating temperature.
Even in cold weather, minimum tire pressures must be
maintained.
OUTJ003,00003A5 –19–30JAN01–1/1

081403
PN=139
Wheels Service
Anti-Slip and Bogie Tracks Fitting
• Choose fairly smooth ground when fitting the anti-slip.

• Ensure that the anti-slips are in good condition.
• Turn them the right way.
01
0110 • Lay the anti-slip out in front of the wheel, (fig 1 or 2)
–UN–02MAY02
6 • Tie a 1.5 meter (5 ft) long piece of rope, or something
similar, to the anti-slip and place it over the tire as
illustrated.
• Carefully move the machine. If needed stop the
T152224
machine and adjust the anti-slip. Continue until the ends
of the anti-slip lie near each other, and connect the
ends together with the coupling links.
–UN–05MAR02
T152223
Continued on next page AK12300,000005D –19–15OCT01–1/3

081403
PN=140
Wheels Service
IMPORTANT: When using chains and tracks ensure

that they do not collide machine
structures under any driving
circumstances. Original equipment
delivered from Timberjack suits the
01
machine. 0110
7
Bogie tracks fitting
Useful tool: A chain or cable about 5,5 m (18 ft) long.
1. Lay the bogie track on the ground with track plates (fig
1).
2. Secure the chain or cable to the first track plate (fig 1
and 2).
3. Then lay the chain over both bogie wheels, and wedge
it under the front bogie wheel (fig 1 and 2).
4. Drive forward slowly, watching the chain all the time to
make sure it stays in the centre of the wheel and does
not slide off (fig 3).
–UN–05MAR02
5. Drive forward until one track plate lies free behind the
rear bogie wheel (fig 4).
6. Fit the chains (fig 5) to the links between the second
and third track links on each side of the joint. Make
T152225
sure the chains are the same length on both sides.
Make sure you tighten both sides equally, otherwise
the track will be unbalanced.
A—Fitting chain
B—Extra chain
–UN–05MAR02
T152226
Continued on next page AK12300,000005D –19–15OCT01–2/3

081403
PN=141
Wheels Service
7. Reverse the machine carefully until the joint is midway

between the wheels. The track is now stretched and
the chain 1 in the middle should be slack. If the track
needs to be tightened more, shorten these, reverse
and fit a suitable track lock.
01
0110
8 CAUTION: Make sure no-one is nearby when
you tighten the tracks.
8. Fit the track lock with the loop on the inside against the
tire.
9. Then drive forward until the tensioning chains are
slack. Remove them.
10. Drive the machine forward and back a couple of
times. Check the track tension (fig 8). Dimension A
should be 50 — 100 mm (2 — 4 in).
NOTE: Do not over-tighten the tracks.
NOTE: If the tensioning chains do not pull the track

together enough: Fit an extra chain between the
ends and then drive forward again. This will now
hold the track together so that the tensioning
chains can be tightened more (fig 5).
Positioning of track lock (fig 9) (Nut must face

tire).
–UN–05MAR02
T152227
AK12300,000005D –19–15OCT01–3/3

081403
PN=142
Section 02
Power Train
Contents
Page

Power Train Overall Description . . . . . . . . . .02-0210-1 02
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . .02-0210-2
Prepare Machine for Maintenance. . . . . . . . .02-0210-3
Group 0220—Transfer case

Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0220-1
Transfer Case Operation . . . . . . . . . . . . . . . .02-0220-2
Operating Power Transmission . . . . . . . . . . .02-0220-3
Transfer Case Removal and installation . . . .02-0220-4
Checking High / Low Gear Oil. . . . . . . . . . .02-0220-15
Changing High / Low Gear Oil . . . . . . . . . .02-0220-17
Group 0230—Drive shaft

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0230-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0230-2
Drive Shaft General. . . . . . . . . . . . . . . . . . . .02-0230-3
Bearing Drive Shafts . . . . . . . . . . . . . . . . . .02-0230-10
Diagnose Drive Lines . . . . . . . . . . . . . . . . .02-0230-11
Universals . . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-12
Group 0240—Axles / Bogie

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0240-2
Bogie axle general . . . . . . . . . . . . . . . . . . . .02-0240-3
Bogie Axle Removal and Installation . . . . . .02-0240-4
Axle Removal and Installation . . . . . . . . . .02-0240-11
Bleeding the Differential Lock . . . . . . . . . . .02-0240-17
Checking Differential Oil . . . . . . . . . . . . . . .02-0240-18
Change Bogie Axle Differential Oil . . . . . . .02-0240-19
Change Single Axle Differential Oil . . . . . . .02-0240-21
Checking Bogie Housings Oil . . . . . . . . . . .02-0240-22
Changing Bogie Housings Oil . . . . . . . . . . .02-0240-23
Check Single Axle Wheel Ends ( Hub
gear) Oil . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-24
Change Single Axle Wheel Ends Oil . . . . . .02-0240-24
Bogie Bearing Grease Points . . . . . . . . . . .02-0240-25
Group 0250—Brakes
Description . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-2
1010D Checking and Adjusting . . . . . . . . . . .02-0250-8
Checking and Adjusting (810D,1110D,1410D
and 1710D) . . . . . . . . . . . . . . . . . . . . . . .02-0250-14

081403
PN=1
Contents
02

081403
PN=2
Group 0210
Theory of Operation
Power Train Overall Description
02
0210
1
–UN–21JUN01
T139408
Power Train Component Locator
1—Engine 5—Hydrostatic Drive Motor 8—Driveshaft, Transfer Case 10—Driveshaft, Frame Joint
2—Hydrostatic Drive Pump 6—Transfer Case to Front Axle 11—Driveshaft, Frame Joint to
3—Hydraulic Work Pump 7—Front Axle Bogie (in 1010D 9—Driveshaft, Transfer Case Rear Axle
4—Hydrostatic Drive Lines also a single axle) To Frame Joint 12—Rear Axle Bogie
The power train consists of the transfer case, drive of the operator’s seat. The transfer case also includes
shafts and bogie or a single axle in the front and a a feature which can disconnect the rear wheel drive.
bogie axle in the rear.
The transfer case is connected to the front axle by one
Power is provided to the transfer case by the driveshaft and to the rear axle by a series of three
hydrostatic drive system. The engine operates at a drive shafts.
constant speed turning the drive pump. The drive
pump supplies a flow of oil to turn the drive motor Two brake cylinders are mounted on each bogie. Each
mounted on the transfer case. The displacement of the brake cylinder consists of a parking brake (spring
pump is varied to control the speed of the drive motor. applied and hydraulically released) and a service/work
The direction of the machine, forward or reverse, is brake (hydraulically applied and spring released).
determined by the direction of flow between the drive
pump and motor. See Section 03, for more information The forwarder has four-wheel bogie mounted on the
on the Hydrostatic Drive System. front frame and two wheel single axle on the rear
frame. The bogie is equipped with differential lock
The transfer case provides a high and a low gear which may be engaged to improve traction on soft
which can be selected by a switch on the right armrest terrain.
OUTJ003,0000461 –19–08FEB01–1/1

081403
PN=145
Theory of Operation
Drive Coupling
02
0210
2
–UN–20JUL01
T139409
1010D Drive Coupling
1—Coupling Assembly 4—Screw 7—Washer 10—Washer

2—Splined Flange 5—Adapter Plate 8—Screw 11—Screw
3—Splined Adapter 6—Screw 9—Hydrostatic Drive Pump 12—Work Pump
The drive coupling transmits the power from the hydrostatic drive pump input shaft and a splined flange
engine to the drive and working pumps. The coupling mounted to the engine flywheel.
consists of a splined adapter attached to the
OUTJ003,0000462 –19–08FEB01–1/1

081403
PN=146
Theory of Operation
Prepare Machine for Maintenance
Before performing maintenance procedures given in the

following chapters and before leaving the operators seat,
park the machine as described below unless another
position is specified in the procedure.
1. Park machine on a level surface.
2. Lower decking blade to ground.

02
3. Secure boom and grapple in woodbunk. 0210
3
CAUTION: Prevent unexpected machine

movement and possible injury. Connect frame
locking pin to both frames before working in
frame hinge pivot area.
4. Install frame locking pin before working in frame hinge

pivot area.
Continued on next page TX,50,FF3180 –19–02MAR95–1/2

081403
PN=147
Theory of Operation
5. Engage park brake.
6. Run engine at 1/2 speed for 2 minutes before stopping

to avoid damage to turbocharger.
7. Turn key switch OFF. Remove key from switch. (If
–UN–06JUN01
maintenance must be performed with engine running,
DO NOT leave machine unattended.)
8. Attach a “Do Not Operate” tag to the key switch.
T139371
02
0210 The operator and serviceman are responsible for safety
4
on and around the machine.
IMPORTANT: The operator, mechanic, and foreman

must be familiar with the safety rules
and regulations provided in this service
manual and in the decals of the
machine, as well as with those related
to national road traffic and occupational
safety.
All safety rules and regulations in effect

pertaining to the machine and
workplace must be obeyed.
1—Frame lock
–UN–19MAR02
T152685
1
TX,50,FF3180 –19–02MAR95–2/2

081403
PN=148
Group 0220
Transfer case
Other Material
Number Name Use
N/A (U.S.) Loctite 242 Used to secure bolts retaining

Mounting rubber pads to transfer
case.
N/A (U.S.) Loctite 242 Used to secure bolts retaining drive

shafts to transfer case yokes.
02
0220
JK11466,0000076 –19–03JAN03–1/1 1

081403
PN=149
Transfer case
Transfer Case Operation
02
0220
2
–UN–20JUL01
T139410
1010D Transfer Case with Hydrostatic Drive Motor
The transfer case is unsynchronized and located at the seat. The switch operates a solenoid on the auxiliary
back of the front frame. The power generated by the valve which hydraulically operates the shifter mounted
hydraulic motor is distributed by the high/low transfer on the front face of the transfer case. The high / low
case (through the drive shafts) to the front and rear range shift circuit is linked to the brake and drive
axels. If the high gear is activated the rear-wheel drive direction circuits and this prevents a gear change from
is automatically disengaged. being made when the machine is moving.
Transfer case is equipped with clutch, which enables With the low gear range selected, the rear axle drive is
front wheel drive disengaging. always automatically engaged. The rear axle drive
disengages when the high gear range is selected. A
The hydrostatic motor is mounted on the input flange override switch on the dashboard allows the operator
of the transfer case and the power is transmitted to engage the rear axle drive with high gear selected.
through a splined coupling. It is possible to engage the rear wheel drive while the
forwarder is in motion, but not if the wheels are
The operator has control of the high / low range shift spinning.
through a switch on the right armrest of the operator’s
JK11466,0000041 –19–12DEC02–1/1

081403
PN=150
Transfer case
Operating Power Transmission
02
0220
3
–UN–07FEB03
T152540
General Power Transmission
The hydrostatic-mechanical power transmission can be The hydrostatic section consists of a hydraulic motor
divided into two main parts: mechanical and connected to the high/low transfer case and of a
hydrostatic part. hydraulic pump connected to the diesel engine.
The mechanical part consists of the high/low transfer

case, drive shafts, differentials, and bogies.
EL62757,00001B7 –19–21APR02–1/1

081403
PN=151
Transfer case
Transfer Case Removal and installation
02
0220
4
–UN–22AUG01
T139411
An Example of Transfer Case Mounting and Hoses
1—Hydrostatic Drive Motor 5—Screw 8—Shifter Valve 10—Rear Wheel Drive

2—Locknut 6—Mounting Bracket or Lug 9—High/low Gear Selection Disengage Line
3—Screw 7—Transfer Case Lines 11—Auxiliary Valve
4—Sleeve
Removal hydraulic component in order to

prevent contamination of the
IMPORTANT: To prevent machine damage when hydraulic and hydrostatic systems.
servicing the machine, use correct
fuels and lubricants. See Group Failure to follow these procedures
0040, Fuels and Lubricants. may lead to equipment damage.
Cleanliness procedures must be

observed when working on any
Continued on next page JK11466,000006C –19–20DEC02–1/17

081403
PN=152
Transfer case
02
0220
5
–UN–04JUN03
T191692
1710D Transfer case mounting and hoses
1—Auxiliary valve 4—Fitting 6—High / Low gear selection 7—Fitting

2—Hydrostatic drive motor 5—Fitting lines 8—Fitting
3—Transfer case

081403
PN=153
Transfer case
Failure to observe proper safety precautions

CAUTION: Ensure that the engine is stopped
may lead to situations with risk of personal
and the main switch is in the ’OFF’ position.
injury.
Remove handle from the main switch before
disconnecting any hydraulic components.
1. Tilt the cab. See group 1820 for specific instructions
Securely block the wheels to prevent
machine movement before disconnecting the
drive shafts.
02
0220
6 Continued on next page JK11466,000006C –19–20DEC02–3/17

081403
PN=154
Transfer case
–UN–13JUN01
T142899
02
0220
(1) 1010D main switch 7
–UN–08NOV02
T160624
Draining the 1010D hydraulic tank
–UN–05MAR02
T152229
Draning the 810D, 1110D-1710D hydraulic tank

081403
PN=155
Transfer case
2. Drain the hydraulic tank through the drain hose (1.)

You can use vacuum pump (optional Equipment) to
draining the hydraulic tank
NOTE: Dispose of waste properly
3. Tag and disconnect all hoses from the hydraulic tank.

Disconnect the level and temperature sensors.
4. If necessary for clearance, dismount the hydraulic

02 pressure filter bracket. Leave the hoses and wires
0220 connected and move the filter assembly aside.
8
5. Remove the bolts mounting the boom control valve
–UN–11APR03
bracket to the tank. Swing the valve off to the right side
of the machine to get clearance to remove the tank.
NOTE: The cover and valve remain assembled on the
T189555
bracket. The hoses remain connected to the
valve.
810D Hydraulic oil filling
6. Remove the frame cover plate.
CAUTION: Proper safety precautions must be

taken when using any lifting devices.
Failure to follow these procedures may lead to

personal injury and equipment damage.
–UN–30JAN03
7. Remove the bolts mounting the tank on the frame.
Remove the tank.
T164081
3—Switch for hydraulic pump
4—Quick coupler
5—Switch for vacuum pump 1110D, 1410D and 1710D switches and quick-couplers

081403
PN=156
Transfer case
NOTE: It is recommended that the hydrostatic motor and

transfer case be removed from the frame as an
assembly. In some instances, it may be easier to
remove the hydrostatic motor from the transfer
case before removal from the frame.
–UN–07JUN01
8. Clean the area of gearbox well. Tag and disconnect
the high/low gear selection hoses from the transfer
case. Disconnect the rear wheel drive disengage hose
from the transfer case.
T139043
02
9. If required, the oil can be drained from the transfer 0220
Transfer Case, Hoses 9
case through the drain plug prior to removal of the
assembly from the frame.
JK11466,000006C –19–20DEC02–6/17
10. Tag and disconnect the hoses from the hydrostatic

drive motor.
–UN–07JUN01
T139044
Hydrostatic Drive Motor, Hoses
JK11466,000006C –19–20DEC02–7/17
11. Disconnect the front drive shaft and the frame pivot
drive shaft from the transfer case. Access the drive
shafts by removing the covers on the underside of the
front frame.
–UN–07JUN01
1—Front Drive Shaft

2—Frame Pivot Drive Shaft
T139045
Transfer Case, Drive Shafts


081403
PN=157
Transfer case
12. Remove the vertical mounting bolts.
NOTE: The Mounting rubber pads remain on the transfer

case.
CAUTION: The transfer case and motor

assembly is heavy. Use appropriate support,
slings and lifting devices to prevent personal
injury or equipment damage when lifting the
assembly.
–UN–07JUN01
02
0220
10 13. Lift the transfer case assembly clear of the frame.
T139046
Transfer Case, Mounts
JK11466,000006C –19–20DEC02–9/17
14. To remove the hydrostatic motor from the transfer

case, remove the four socket head capscrews and
slide the motor rearward 75 mm (3") to clear the
spline. When the bolts are removed, ensure that the
motor is adequately supported at all times to prevent
damage to the spline and seals.
–UN–07JUN01
T139047
Transfer Case, Hydrostatic Motor Removal

081403
PN=158
Transfer case
Installation
1. Replace O-ring on motor.
Attach the hydrostatic motor to the transfer case with

the four socket head capscrews. Tighten the screws to
–UN–07JUN01
the specified torque.
T139047
02
0220
Transfer Case, Hydrostatic Motor 11
Installation
JK11466,000006C –19–20DEC02–11/17
2. If the Mounting rubber pads had been removed from

the transfer case, re-install using LOCTITE 242 and
tighten the bolts to the specified torque.
3. Replace the transfer case assembly in the frame.

Install the mounting bolts and tighten the bolts to the
specified torque.
–UN–07JUN01
T139046
Transfer Case Mounting Rubber pads
LOCTITE is a trademark of Loctite Corp. JK11466,000006C –19–20DEC02–12/17
4. Connect the front drive shaft and the frame pivot drive
shaft to the transfer case. Use LOCTITE 242 and
tighten the bolts to the specified torque. See Section
02, Group 0230, for procedures to install drive shafts.
–UN–07JUN01
1—Front Drive Shaft

2—Frame Pivot Drive Shaft
T139045
LOCTITE is a trademark of Loctite Corp. Transfer Case, Drive Shafts


081403
PN=159
Transfer case
5. Connect the hoses to the transfer case.
1—High/low Gear Selection Hose to Auxiliary Valve

Port A4
2—High/low Gear Selection Hose to Auxiliary Valve
Port B4
–UN–07JUN01
3—Rear Wheel Drive Disengage Hose to Auxiliary
Valve Port A3
T139049
02
0220
12 Transfer Case, Hoses
JK11466,000006C –19–20DEC02–14/17
6. Connect the hoses to the hydrostatic motor.
7. Install the hydraulic tank weldment. Install the mounting

bolts and torque to the specified torque.
1—Drive Pressure Hose
–UN–07JUN01
3—Case Drain Hose
T139050
Hydrostatic Drive Motor, Hoses

081403
PN=160
Transfer case
8. Install the frame cover plates.
9. Install the boom control valve bracket assembly.
10. Connect the return lines to the valve bank on the

hydraulic tank.
–UN–07JUN01
T139042
02
0220
Frame Cover Plate 13

081403
PN=161
Transfer case
11. Connect the work pump suction line, charge pump

inlet line and drain hose at the tank.
12. Install the hydraulic pressure filter bracket.
13. Fill the hydraulic tank.
NOTE: Do not mix different type of oils. See group 0040,

for recommended hydraulic fluids.
02 During the fill upp, open the vent tap of hte

0220 hydraulic tank.
14
Add oil through the hydraulic fill-up pump (3) (optional

equipment) to add oil to the tank. The quick coupler
(4) is mounted in away that the new oil enters the
–UN–07JUN01
system through the filter. Also a manual pump can be
used.
14. Bleed the air from the hydraulics system. See group
T139053
0310 for the procedures.
1010 D Hydraulic Tank, Inlets and Sensors
Bleed the air from the hydrostatic drive system. See
Operators Manual F064826 page 5-2-2, for the 1—Drain Hose
procedures. 2—Work Pump Suction Line
3—Drive Pump Inlet Line
15. Operate all hydraulic functions on the machine, then 4—Hydraulic Oil Temperature Sensor
5—Hydraulic Oil Level Sensor
re-check the level in the tank.
6—Valve Bank
16. Do a short test drive.
17. Check transfer case for leaks and that all are properly
on place.
18. Stop the engine and check for leaks and that
everything are properly in condition
JK11466,000006C –19–20DEC02–17/17

081403
PN=162
Transfer case
Checking High / Low Gear Oil
02
0220
15
–UN–07APR03
T189349
810D High / Low gear oil checking
JK11466,000006A –19–20DEC02–1/3
1—Dipstick
2—Filling plug
–UN–13JUN01
T142882
1010D (1410D) High / Low gear oil checking
Continued on next page JK11466,000006A –19–20DEC02–2/3

081403
PN=163
Transfer case
The dipstick (1) is in model 1010D under the hydraulic oil

tank, at the rear edge. In models 1410D and 1710D the
dipstic is located between the hydraulic tank and the fuel
tank
1. Lower decking blade to the ground and secure grapple

to rear frame.
2. Engage park brake. Turn key switch OFF.
3. In models 1110D, 1410D and 1710D for prevent
–UN–16JAN03
02
0220 unexpected machine movement install frame locking
16
bar before working in frame pivot area
T164069
4. Check oil level on dipstick. Oil level must be at the
“FULL” notch except In models 1110D and 1710D oil
level should stay between “MIN” and “MAX” marks 1110D High / Low gear oil checking
5. If necessary, remove fill plug and add oil. See group

0040, Fuels and Lubricants, for recommended Transfer
3
Case Oil.
NOTE: To vent transfer case while adding oil, pull up

dipstick.
6. Install fill plug.
1—Dipstick
2 and 3—Filling plug
–UN–20MAR02
T152824
1710D High / Low gear oil checking
JK11466,000006A –19–20DEC02–3/3

081403
PN=164
Transfer case
Changing High / Low Gear Oil
NOTE: To even the pressure at the oil space, open the

filling plug before opening the drain plug.
Before the oil change, let the machine stand still for at
least 30 minutes to make sure that all impurities of the oil
sink to the bottom.
1. Lower decking blade to the ground and secure grapple

to rear frame. 02
0220
17
2. Engage park brake. Turn key switch OFF.
3. In models 810D, 1110D, 1410D and 1710D install

frame locking bar before working in frame pivot area..
JK11466,0000005 –19–30DEC02–1/7
4. To access the bottom of the transfer case, remove the

cover on the underside of the front frame.
1—Transfer Case Access Cover
–UN–13JUN01
T142916
Transfer Case Access Cover
Continued on next page JK11466,0000005 –19–30DEC02–2/7

081403
PN=165
Transfer case
5.
1—Dipstick
2—Filling plug
3—Drain plug
02
0220
18
–UN–07APR03
T189349
810D Changing High / Low gear oil

081403
PN=166
Transfer case
1—Dipstick
2—Filler Plug
–UN–13JUN01
T142915
02
0220
1010D High / Low Gear Box 19
–UN–13JUN01
T142882
High / Low Gear Box Fill

081403
PN=167
Transfer case
02
0220
20
–UN–16JAN03
T164068
1—Dipstick 2—Filling plug

081403
PN=168
Transfer case
Remove the drain plug and drain the high /low gear oil
(transfer case)into a suitable container.
02
0220
21
–UN–06FEB03
T165055
–UN–20MAR02
T152824

081403
PN=169
Transfer case
NOTE: Dispose of waste properly.
6. After draining, install the plug and replace the access

cover.
7. Remove fill plug and add oil. See group 0040, Fuels
and Lubricants, for recommended Transfer Case Oil.
NOTE: To vent transfer case while adding oil, pull up

dipstick.
02
0220 8. Check oil level on dipstick. Oil level must be at the
22
FULL notch.
–UN–20MAR02
9. Install fill plug.
NOTE: Any time plugs are removed, the o-ring seals

should be replaced.
T152797
1—Drain plug
1410D and 1710D Transfer Case Drain plug
3—Fill plug
–UN–20MAR02
T152824
LOK96
JK11466,0000005 –19–30DEC02–7/7

081403
PN=170
Group 0230
Drive shaft
Essential Tools

European Microfiche Tool Catalog (MTC).
02
0230
SERVICEGARD is a trademark of Deere & Company OUTJ003,0000372 –19–25JAN01–1/4 1
Driver, Drive Shaft Bearing Cups . . . . . . . . . . TA0909#1
Used to install Bearing Cups on frame during Frame

Hinge Drive Shaft Installation.
–UN–18JUN01
T138937
TA0909#1 - Driver, Drive Shaft Bearing Cups
OUTJ003,0000372 –19–25JAN01–2/4
Driver, Drive Shaft Bearing Cone . . . . . . . . . . TA0909#2
Used to install Bearing Cone on drive shaft during Frame

–UN–18JUN01
T138939
TA0909#2 - Driver, Drive Shaft Bearing Cone
Continued on next page OUTJ003,0000372 –19–25JAN01–3/4

081403
PN=171
Drive shaft
Driver, Drive Shaft Seals. . . . . . . . . . . . . . . . TA0909#3
Used to install Drive Shaft Seals during Frame Hinge

Drive Shaft Installation.
–UN–18JUN01
T138944
02
0230
2 TA0909#3 - Driver, Drive Shaft Seals
OUTJ003,0000372 –19–25JAN01–4/4
Other Material
Number Name Use
N/A (U.S.) Loctite 242 Used to secure driveshaft universal

joint mounting bolts.
N/A (U.S.) Loctite Nitromethane Solvent used to clean hardened

adhesive.
N/A (U.S.) Acetone Alternative solvent used to clean

hardened adhesive.
N/A (U.S.) Loctite 380 Used to secure drive shaft seal

during Frame Hinge Drive Shaft
Installation.
OUTJ003,0000374 –19–25JAN01–1/1

081403
PN=172
Drive shaft
Drive Shaft General
02
0230
3
–UN–21JUN01
T139413
Genaral Drive Shaft Locator
1—Front Shaft 2—Frame Pivot Drive Shaft 3—Frame Joint Bearing Drive 4—Rear Drive Shaft
Shaft
Power is transmitted from the transfer case to the front shaft with universal joints both ends. This shaft
and rear axles through drive (cardan) shafts. The front operates through the full range of articulation and
axle is connected by a single drive shaft with a frame pivot. Power through the frame pivot is through
universal joint each end. a bearing mounted shaft inside the pivot. The final
drive shaft to the rear axle is a one piece unit with
The rear axle is connected by a series of three drive universal joints both ends.The yokes on each end of
shafts. Power to the frame joint is through a short drive the driveshaft must be in line.
Continued on next page JK11466,0000077 –19–03JAN03–1/8

081403
PN=173
Drive shaft
02
0230
4
–UN–04JUN03
T191680
810D Driveshaft component general view

081403
PN=174
Drive shaft
1—Front drive shaft 2—Frame pivot drive shaft 3—Frame joint bearing drive 4—Rear drive shaft
shaft
02
0230
5

081403
PN=175
Drive shaft
02
0230
6
–UN–04JUN03
T191681
1010D Cardan shaft

081403
PN=176
Drive shaft
shaft
02
0230
7

081403
PN=177
Drive shaft
02
0230
8
–UN–04JUN03
T191695
1410D Dive shaft component general view

081403
PN=178
Drive shaft
shaft
JK11466,0000077 –19–03JAN03–7/8
02
0230
9
–UN–21JUN01
T139414
1010D Front Drive Shaft, Frame Pivot Drive Shaft, Rear Drive Shaft
1—Screw 4—Screw 7—Dust Cap 10—Universal Joint

2—Universal Joint 5—Yoke 8—Drive Shaft 11—Screw
3—Seal 6—Seal 9—Screw
NOTE: The Front Drive Shaft, Frame Pivot Drive Shaft

and Rear Drive Shaft are similar in
configuration.
JK11466,0000077 –19–03JAN03–8/8

081403
PN=179
Drive shaft
Bearing Drive Shafts
02
0230
10
–UN–21JUN01
T139415
1010D Frame Joint Bearing Drive Shaft
1—Cotter Pin 3—Washer 5—Bearing Seal 6—Drive Shaft

2—Slotted Nut 4—Coupling Yoke
When installing a driveline the female spline must be to release any wind-up torque load between
towards the front of the machine to risk of reduce shaft the axles and the transfer case.
damage.
NOTE: Prior to disconnecting universal joints or drive

shafts, lift the axle off the ground momentarily
JK11466,0000069 –19–20DEC02–1/1

081403
PN=180
Drive shaft
Diagnose Drive Lines
Symptom Problem Solution
Driveline emitting a chattering Faulty universal joint Locate faulty joint and replace.
noise
Faulty carrier bearing Locate faulty bearing and replace.
Driveline causing machine Faulty universal joint Locate faulty joint cross and yokes
vibration and replace. 02
0230
11
Loose connector bolts at the Replace and or tighten connector
coupling yokes bolts to specified torque.
Damaged drive shaft Replace complete drive shaft

assembly.
Misaligned universal joint yokes Align universal joint yokes so they

are parallel on drive shaft assembly.
OUTJ003,000046B –19–08FEB01–1/1

081403
PN=181
Drive shaft
Universals
To assemble a joint to a yoke:
1. Insert the lower key and pilot of one bearing into the
keyway and pilot of the yoke.
–UN–18JUN01
2. Insert the upper key and pilot of the opposite bearing
into the yoke.
T138927
02 Since this is a precision product, the fit tends to be
0230 tight and some compression of the seals and/or thrust
12 Universal Joint, Drive Shaft, Clamp
washers may be required to seat the second bearing.
This can be done with a ’C’ clamp, a tap with a soft
hammer or hand pressure.
NOTE: Do not use the mounting bolts to seat the

bearings.
3. Once the bearings are properly seated, insert the bolts.
–UN–18JUN01
Use LOCTITE 242 and tighten bolts to specified
torque.
NOTE: When installing drive shafts, align the drive shaft
T138928
grease fittings so they can all be accessed without
moving the machine more than once. Universal Joint, Mallet
LOCTITE is a trademark of Loctite Corp. OUTJ003,000036D –19–25JAN01–1/1

081403
PN=182
Group 0240
Axles / Bogie
Essential Tools

02
0240
SERVICEGARD is a trademark of Deere & Company JK11466,0000003 –19–30DEC02–1/4 1
Front Frame Support . . . . . . . . . . . . . . . . . . . TA9002
Support placed under back end of front frame during

bogie removal and installation.
–UN–19JUN01
T139887
TA9002 - Front Frame Support
JK11466,0000003 –19–30DEC02–2/4
Axle Stand . . . . . . . . . . . . . . . . . . . . . . . . . . TA0899
Support placed under each bogie housing during bogie

removal and installation.
–UN–19JUN01
T139888

081403
PN=183
Axles / Bogie
Axle Mounting Bolt Installation Tool. . . F603762/F603764
Used to torque long horizontal axle mounting bolts during

Bogie Removal and Installation procedures.
–UN–19JUN01
T139889
02
0240
2 Axle Mounting Bolt Installation Tool
JK11466,0000003 –19–30DEC02–4/4
Other Material
Number Name Use
N/A (U.S.) Never-Seez Anti seize compound applied to

mounting bolts during bogie
installation.
JK11466,0000003 –19–30DEC02–1/1

081403
PN=184
Axles / Bogie
Bogie axle general
02
0240
3
–UN–21JUN01
T139421
Front Bogie Axle
1—Wheel Rims 3—Multi-disk Brakes 5—Driveshaft Coupling 6—Differential

2—Bogie Housing 4—Brake Actuating Cylinders
Axles / Bogies specifications

810D 1010D 1110D 1410D 1710D
Axles/Bogies Model Front NAF LOK 36 NAF LOK 115 NAF LOK 116 NAF LOK 101 6-w NAF LOK 53 6-w
NAF LOK 117 NAF LOK 100 8-w NAF LOK 103 8-w
NAF LOK 102* 8-w NAF LOK 104* 8-w
*Heavy duty Axles *Heavy duty Axles
Axles/Bogies Model Rear NAF LOK 37 NAF LOK 128 6-w NAF LOK 131 NAF LOK 118 NAF LOK 103 8-w
NAF LOK 115 4-w NAF LOK 114* NAF LOK 104* 8-w
*Heavy duty Axles *Heavy duty Axles
NOTE: See page 0020-14 for more information about 1010D bogie axles
bogie axles. For detailed repair instructions
see NAF LOK manuals enclosed. 4-wheeled: single rigid axle in front and rear
810D bogie axles 6-wheeled: single rigid front and high-walker, full gear
bogie axle with portal type bogie beams on the rear.
Bogie axles with portal type bogie beams including On 4-wheel: Heavy duty planetaries mounted outboard
balancing units. Similar axles in front and rear. Power in front and rear. On 6-wheel Heavy duty planetaries
transmission through gears in bogie beams. mounted outboard in front and inboard in rear.
Hydraulically operated mechanical differential lock in Differentials are hypoid type, hydraulically operated
front and rear. Disconnection of rear axle with high mechanical differential locks in front and rear.
range. Disconnection of the rear-wheel drive in high range

081403
PN=185
Axles / Bogie
1110D bogie axles portal type bogie beams in front and rear.Heavy duty
planetaries mounted inboard in front and
Bogie axles with portal type bogie beams including rear.Differentials are hypoid type, hydraulically
balancing units. Similar axles in front and rear on 8 operated mechanical differential locks in front and rear.
wheels. Hub planetaries in 6-wheel front axle. Power The bogie axle incorporates the differential with
transmission through gears in bogie beams. hydraulic lock, two hydraulic driven multi disc brake
Hydraulically operated mechanical differential lock in units with the brake cylinders and two bogie housings
front and rear. Disconnection of rear axle with high connected to the differential with special balancing
range. units.
02 1410D and 1710D bogie axles

0240
4
The 8-wheeler 1410D and 1710D is equipped with two
similar high-walker, full gear balanced bogie axles with
JK11466,0000001 –19–30DEC02–2/2
Bogie Axle Removal and Installation
CAUTION: Securely block the wheels to prevent

the machine from moving during this
procedure.
Install frame lock bar to prevent accidental

articulation.
Use appropriate safety precautions when using

any lifting devices.
Failure to observe safety precautions can lead

to risk of severe personal injury.
–UN–05APR02
IMPORTANT: Use caution when handling the bogie to
avoid damage to the brake lines.
T153335
Removal
Jack underneath boogie
1. Lift machine up. Position supports under the front
frame. Position axle stand under each bogie housing.

081403
PN=186
Axles / Bogie
See section 45, for Frame Supports Tool Drawings.
1—Front Frame Support, TA0898

2—Axle Stand, TA0899
–UN–19JUN01
T138910
02
0240
Front Frame and Axle Supports 5

081403
PN=187
Axles / Bogie
IMPORTANT: Cleanliness procedures must be

hydraulic component in order to
prevent contamination of the hydraulic
and hydrostatic systems.
–UN–18JUN01
Failure to follow these procedures may
lead to equipment damage.
Disconnect the brake hoses and differential lock hose.
T138911
02 Cap the hoses and plug the ports.
0240
6 Front Bogie, Brake and Differential Lock Hoses
2. Loosen wheel bolts.
3. Fit the steering interlock to ensure that articulation

does not move.
4. Lift machine up and place supports under front frame.

Leave the area of bottom plate free.
5. Remove the front wheels and tires.
6. Remove the axle access cover from underside of

frame.
7. Tilt the cab to the service position.
NOTE: To remove the right hand bogie mounting bolts, it

may be necessary to tilt the cab farther than
normal. Disconnect the attachment pins from the
lift cylinder and the safety support. Using
appropriate slings and lifting devices, tilt the cab
to an angle of 60 degrees. Securely block the cab
in this position.
8. Disconnect drive shaft from the yoke of differential.

081403
PN=188
Axles / Bogie
See Section 02, Group 0230, for procedures to remove

the driveshafts.
9. Mark all hydraulic hoses of brake cylinders to ensure

that it is possible to reconnect hoses to right
connections.
–UN–18JUN01
10. Disconnect all hydraulic hoses from brake cylinders
and differential lock.
T138914
02
0240
Differential, Drive Shaft 7
JK11466,0000003 –19–30DEC02–4/10
11. Loosen but do not yet remove the four top capscrews.
The capscrews on the right hand side of the vehicle
are set in wells in the fuel tank weldment. The tool
used will require an extension approximately 450 mm
(18 in.) in length.
–UN–18JUN01
12. Remove the two long mounting bolts (one on each
side). Note the locations of any shims used.
13. Remove the four vertical mounting bolts.
T138915
14. Place the jack under axle. Raise it to relieve the
loading on the bogie mounting bolts. Axle Mounting Section View

15. Use the jack to lower the bogie to ground. Remove

the bogie from under the frame.
Installation
1. Clean mounting surfaces and threads of mounting bolts

well

081403
PN=189
Axles / Bogie
2. Use a jack to raise the bogie into position and align the
mounting holes.
3. Place the bogie under the front frame.Lift the axle up

on to its place .
–UN–19JUN01
T138910
02
0240
8 Front Frame and Axle Supports
JK11466,0000003 –19–30DEC02–6/10
4. Apply NEVER-SEEZ anti-seize compound to the

mounting bolts.
5. Install the two vertical mounting bolts with lock washers

at both ends. Position any shims used. Install the nuts
hand tight but do not torque at this time.
–UN–18JUN01
6. Tighten the four vertical mounting bolts to specified
torque.
T138915
Axle Mounting Section View
NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page JK11466,0000003 –19–30DEC02–7/10

081403
PN=190
Axles / Bogie
Tighten the two horizontal mounting bolts to specified

torque.
NOTE: A special tool (F603762/F603764) is available to

tighten the long horizontal bolts. See section 45,
for Tool Drawings.
–UN–18JUN01
7. Connect the driveshaft to the yoke of axle differential.
Be sure that both yokes of drive shaft are in same
angle. See Section 02, Group 0230, for procedures to
T138918
install the driveshafts. 02
0240
Axle Mounting Bolt Installation Tool 9
8. Install the axle access cover on the underside of the
frame.
9. Connect hydraulic hoses to brake cylinders and

differential lock.

081403
PN=191
Axles / Bogie
10. Bleed the air from the Differential Lock. See Section
02, Group 0200, for the procedures.
11. Start the machine and bleed the air from the brake
system.
–UN–18JUN01
See Section 10, Group 1060, for procedures to bleed
the Service/Work Brakes.
See Section 11, Group 1160, for procedures to bleed
T138914
02 the Parking Brakes.
0240
10 Differential, Drive Shaft
12. Lower machine to ground and remove the steering
interlock.
13. Check differential and bogie oil level. Add if

necessary. See oil specifications from operators’
manual chapter 6.4.8
14. Drive a short test drive.
15. Stop the engine and check for leaks and that
everything are properly in condition.
16. Install bottom plate
JK11466,0000003 –19–30DEC02–9/10

–UN–18JUN01

Connect the brake hoses and differential lock hose.

T138911
17. If the cab was tilted beyond the normal raised

position, connect the attachment pins to the lift Front Bogie, Brake and Diff Lock Hoses
cylinder and the safety support.
18. Lower the cab.
JK11466,0000003 –19–30DEC02–10/10

081403
PN=192
Axles / Bogie
Axle Removal and Installation
02
0240
11
–UN–19JUL01
T144163
Rear Axle
General Failure to observe safety precautions can

lead to risk of severe personal injury.
NOTE: See page 0240-3 for more information about
bogie axles. For detailed repair instructions IMPORTANT: Use caution when handling the bogie
see NAF LOK manuals enclosed. to avoid damage to the brake lines.
Removal
CAUTION: Securely block the front wheels to
prevent the machine from moving during
1. Loosen wheel bolts.
this procedure.
2. Fit the steering interlock to ensure that articulation
Install frame lock bar to prevent accidental
does not move.
articulation.
Use appropriate safety precautions when

using any lifting devices.

081403
PN=193
Axles / Bogie
3. Lift machine up and place supports under rear frame.

Leave the area of bottom plate free.
02
0240
12
–UN–12DEC02
T153617
Jack underneath axle
JK11466,0000003 –19–30DEC02–2/9
See section 45, for Axle Stand Tool Drawings.
4. Remove rear wheels and tires.

–UN–18JUN01

T138920

Rear Frame and Axle Supports
5. Remove bottom plate.

081403
PN=194
Axles / Bogie
6. Disconnect the brake hoses and differential lock hose.
7. Mark all hydraulic hoses of brake cylinders to ensure

that all hoses can be reconnected to right place.
8. Disconnect all hydraulic hoses from brake cylinders

and differential lock.
9. Remove the axle access cover from underside of

frame.
02
10. Disconnect drive shaft from the yoke of differential. 0240
13
See Section 02, Group 0230, for procedures to
remove the driveshafts.
–UN–29AUG01
11. Loosen axle mounting bolts..
12. Place the jack under the axle. Raise it to relieve the
T145097
loading on the bogie mounting bolts. Weight of axle is
640 kg. Be sure that the jack can carry that weight.
Rear Axle, Brake and diff Lock Hoses
13. Loosen but do not yet remove the four top capscrews.
JK11466,0000003 –19–30DEC02–4/9
Access the bolts by removing the four caps on the top

surface of the rear frame.
14. Remove the two long capscrews (one on each side).

Note the locations of any shims used.
–UN–18JUN01
15. Remove the four top capscrews .

16. Use the jack to lower the axle Remove the axle from T138924
under the frame. Rear Frame, Axle Mounting Exploded View
Installation
1. Clean mounting surfaces and the threads of mounting

bolts well.

081403
PN=195
Axles / Bogie
2. Place the bogie under the rear frame. Use a jack to

raise the bogie into position and align the mounting
holes.
–UN–18JUN01
T138920
02
0240
14 Rear Frame and Axle Supports
JK11466,0000003 –19–30DEC02–6/9
3. Apply NEVER-SEEZ anti-seize compound to the

mounting bolts.
4. Lift the axle up to its place.
5. Loosely insert the four vertical mounting bolts.
–UN–18JUN01
6. Install the two horizontal mounting bolts with lock
washers at both ends. Position any shims used. Install
the nuts hand tight but do not torque at this time.
T138924
7. Tighten the four vertical mounting bolts to specified
torque. Rear Frame, Axle Mounting Exploded View
NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page JK11466,0000003 –19–30DEC02–7/9

081403
PN=196
Axles / Bogie
8. Tighten the two horizontal mounting bolts to specified

torque.
NOTE: A special tool (F603762/F603764) is available to

tighten the long horizontal bolts. See section 45,
for Tool Drawings.
–UN–18JUN01
T138918
02
0240
Axle Mounting Bolt Installation Tool 15

081403
PN=197
Axles / Bogie
9. Connect hydraulic hoses to brake cylinders and

differential lock.
10. Connect drive shaft to the yoke of differential. Be sure

that both yokes in drive shaft are at same angle.for
procedures to install the driveshafts. See Section 02,
Group 0230
11. Install the wheels and tires. Tighten the wheel nuts to
specified torque.
02
0240 12. Check hub oil levels.
16
13. Lower machine to the ground and remove steering
–UN–29AUG01
interlock.
14. Check differential oil level. Add if necessary.
T145097
15. Bleed the air from the Differential Lock.
16. Start the machine and bleed brake system. See group Rear axle, Brake and Differential lock hoses
0250 for procedures to bleed the brakes.
17. Drive a short test drive. Check that brakes are

working well.
18. Stop the engine and check that all are properly in
condition.
19. Install the axle access cover on the underside of the

frame.
JK11466,0000003 –19–30DEC02–9/9

081403
PN=198
Axles / Bogie
Bleeding the Differential Lock
CAUTION: Securely block the rear wheels to

prevent the machine from moving during this
procedure.
–UN–18JUN01
Failure to observe safety precautions can lead
to risk of severe personal injury.
NOTE: Bleed the differential lock any time the differential
T138925
02
lock hose is disconnected. This procedure 0240
requires two people. Bogie, Diff Lock Hose 17
1. With the engine running, loosen the fitting between the 1—Differential Lock Hose
differential lock hose and the axle.
2. Press and hold the differential lock switch on the

operators seat RH control panel.
3. When air is purged from hose, tighten the fitting.
JK11466,0000004 –19–30DEC02–1/1

081403
PN=199
Axles / Bogie
Checking Differential Oil
NOTE: The differential is similar on the single axle and

the bogie axle
The oil levels in the differential and both bogie

housings must be checked separately.
1. To access the dipstick and filler plugs on the rear axle,

remove the service covers on top of the rear frame.
02
0240 2. To access the dipstick and filler plugs on the front axle,
18
tilt the cab to the service position..
–UN–21JUN01
3. Check the oil level in the differential gear on the
dipstick.
T142883
4. If required, add oil through one of the filler plugs on top
of the axle. Alternatively, add oil through the level plug
on the differential. See group 0040, for recommended Differentials oil level checking
axle oil.

should be replaced.
1—Differential Oil Level Dipstick

2—Filler Plugs
–UN–21JUN01
3—Level Plug
T142884
Differential, Oil Filler Plug
JK11466,0000005 –19–30DEC02–1/1

081403
PN=200
Axles / Bogie
Change Bogie Axle Differential Oil
NOTE: Change the oil while it is warm.
1. Park the machine on a level surface. Engage the

parking brake. Install the frame lock.
2. To access the dipstick and filler plugs on the rear axle,

remove the service covers on top of the rear frame.
3. Clean the area around the plugs. 02

0240
19
4. Lift the dipstick or remove one of the filler plugs to vent
–UN–02DEC02
the differential.
5. Remove drain plug. Drain oil into suitable container.
T162345
NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.
6. Clean and install the drain plug.
NOTE: Any time plugs are removed, the o-ring seals or

copper washers should be replaced.
7. Add new oil through one of the filler plugs on top of the
–UN–15JUN01
axle. Alternatively, add oil through the level plug on the
differential. See group 0040, Fluids and Lubricants, for
recommended axle differential oil.
T142920
8. Check oil level on dipstick. Install the filler plug.
NOTE: Any time plugs are removed, the o-ring seals or

copper washers should be replaced. 1—Differential Oil Level Dipstick
2—Filler Plugs
3—Level Plug
Capacities Axle model Litres (US gallons)
4—Drain Plug
Differentials (in 4-wheeled NAF LOK 115) 28 l (7.4 gal)each
(in 6-wheeled NAF LOK 128)

Differentials, rear (NAF LOK 131) 11 l (2.9 gal)
Differentials, (NAF LOK 116 or 117) 12 l (3.1 gal)
front, 8-wheel
Continued on next page OUTJ003,00006B9 –19–16MAY01–1/2

081403
PN=201
Axles / Bogie

(NAF LOK 114 Heavy
Duty)
Differentials, front (in 6-wheeled NAF LOK 12 l (3.1 gal)
101)
(in 8-wheeled NAF LOK
100)
102HD)
02 Capacities Axle model Litres (US gallons)

0240
20
(NAF LOK 104 Heavy
Duty)
53)
103)
104HD)
OUTJ003,00006B9 –19–16MAY01–2/2

081403
PN=202
Axles / Bogie
Change Single Axle Differential Oil
02
0240
21
–UN–02DEC02
T162344
Single Axle Differential Plugs
1—Dipstick 3—Differential Level Port 4—Axle Beam Drain Ports 5—Differential Drain Port
2—Axle Beam Fill Ports
NOTE: Change the oil while it is warm. 7. Remove drain plugs from the differential and both
axle beams. Drain oil into suitable container.
parking brake. Install the frame lock. NOTE: See group 0040 Fluids and Lubricants for
recomended axle differential oil
2. To access the dipstick and filler plugs on the rear
axle, remove the service covers on top of the rear See NAF LOK manuals enclosed for detailed
frame. service and repair instructions for single and
bogie axles
3. To access the dipstick and filler plugs on the front
axle, tilt the cab to the service position. NOTE: Dispose of waste properly. Do not dump oil on
4. Open the bellypan to access the underside of the
differential. 8. Clean and install the drain plugs.
5. Clean the area around the plugs.
6. Lift the dipstick or remove the differential filler plug

to vent the differential.
Continued on next page OUTJ003,00006F7 –19–17JUL01–1/2

081403
PN=203
Axles / Bogie
NOTE: Any time plugs are removed, the o-ring seals 10. Check oil level on dipstick. Install the filler plug.
or copper washers should be replaced.
9. Add new oil through one of the filler plugs on top of or copper washers should be replaced.
the axle beams. Alternatively, add oil through the
level plug on the differential. See group 0040,
Fluids and Lubricants, for recommended axle
differential oil.

02 Differentials (in 4-wheeled NAF LOK 115) 28 l (7.4 gal)each
0240 (in 6-wheeled NAF LOK 128)
22
Capacities Single Axle model Litres (US gallons) Capacities Axle model Litres (US
Differentials, (NAF LOK 116 or 117) 30 l (8 gal) gallons)
front, 6-wheel Differentials, front (in 6-wheeled NAF LOK 32 l (8.45 gal)
53)
Capacities Axle model Litres (US
gallons)
101)
OUTJ003,00006F7 –19–17JUL01–2/2
Checking Bogie Housings Oil
2. Remove the filler plug to vent the bogie housing.
–UN–21JUN01
3. Remove the inspection plug. The oil level must be up
to the inspection port. T142885
NOTE: The oil levels in the differential and both bogie

housings must be checked separately.
4. If necessary, add oil to the bogie housing through the 1—Filler Plug
filler port. 2—Inspection Plug
See group 0040 for recomended oil types and

capasities
NOTE: Any time a plug is removed, replace the O-ring

seal or copper washer.
JK11466,0000005 –19–30DEC02–1/1

081403
PN=204
Axles / Bogie
Changing Bogie Housings Oil
NOTE: Before changing the bogie housing oil, let the

machine stand for 30 minutes to allow impurities
to settle to the bottom.
–UN–13JUN01
2. Remove the filler plug to vent the bogie housing.
T142919
3. Remove the inspection plug. 02
0240
Bogie Housing, Filler Plug, Inspection Plug, Drain Plug 23
4. Remove the drain plug. Drain a sample of oil into a
suitable container.
1—Filler Plug
2—Inspection Plug
Specification 3—Drain Plug
Bogie Housing Oil Sample—
Volume..................................................................................... 5 L (5.3 qt.)
Check the condition of the oil. If the oil is clear, add new
oil.
NOTE: The oil sample taken from the bogie housing is

not reusable.
If the oil is cloudy, replace all the oil in the bogie housing.

5. Install the drain plug. Add oil to the bogie housing

through the filler port until the oil level is up to the
inspection port.
6. Install the filler and inspection plugs.
NOTE: Any time plugs are removed, the O-ring seals

should be replaced.
7. Repeat the procedure at each bogie.
OUTJ003,00006B8 –19–16MAY01–1/1

081403
PN=205
Axles / Bogie
Check Single Axle Wheel Ends ( Hub gear)

Oil
NOTE: Although oil can pass from the differential to the

wheel ends, it is necessary to check the oil level
in the differential and each wheel end separately.
1. Position the wheel end so that the drain port (1) is on

the horizontal centerline of the axle.
02 2. Remove the drain plug. The oil level must be up to the

0240
drain port.
24
3. Add oil, if necessary, through the fill port (2).
4. Install the drain plug.
NOTE: Any time a plug is removed, replace the O-ring
–UN–19JUL01
seal or copper washer.
1—Drain Plug
2—Fill Plug
T144162
JK11466,0000005 –19–30DEC02–1/1
Change Single Axle Wheel Ends Oil
NOTE: Although oil can pass from the differential to the

wheel ends, it is necessary to change the oil level
in the differential and each wheel end separately.
–UN–19JUL01
Change the oil while it is warm.
1. Position the wheel end with the drain plug at the

bottom.
T144165

Wheel End - Drain Position
3. Remove the filler plug to vent the wheel end.
1—Drain Plug
2—Filler Plug
4. Remove drain plug. Drain oil into suitable container.

Continued on next page OUTJ003,00006F8 –19–17JUL01–1/2

081403
PN=206
Axles / Bogie
5. Position the wheel end with the drain plug on the

horizontal centerline of the axle.
6. Add new oil through the filler port until the level is at
the drain plug.
–UN–19JUL01
7. Clean and install the drain plug and the filler plug.
NOTE: Any time plugs are removed, the O-ring seals or

copper washers should be replaced.
T144166
02
8. Repeat the procedure at each wheel end. 0240
Wheel End - Fill Position 25
1—Drain Plug
2—Filler Plug
OUTJ003,00006F8 –19–17JUL01–2/2
Bogie Bearing Grease Points
Each bogie housing has ten grease fittings on each side

of the housing which must be greased to properly
lubricate the bogie bearings.
–UN–11JUN03
Cover the grease fittings with white plastic caps.
See group 0040 page 7 for recomended gease for bogie

bearing.
T192055
Bogie Housing Grease Points
–UN–11JUN03
T192056
Bogie Housing Grease Points on side
JK11466,0000007 –19–30DEC02–1/1

081403
PN=207
Axles / Bogie
02
0240
26

081403
PN=208
Group 0250
Brakes
02
0250
1

081403
PN=209
Brakes
Description
02
0250
2
–UN–10JUN03
T191927
1110D Front brake system,. hoses, fittings and components

Continued on next page OUTJ003,0000466 –19–08FEB01–1/7

081403
PN=210
Brakes
1—Auxiliary valve 3—Valve 4—Elbow fitting 5—Pipe

2—Hose guard
02
0250
3

081403
PN=211
Brakes
02
0250
4
–UN–10JUN03
T191926
1110D Rear brake system, hoses, f ittings and components

081403
PN=212
Brakes
1—Auxiliary valve 5—Pressuren switch 9—Plug 12—Hose

2—Brake valve 6—Braket 10—ATF Brake oil tank 13—Pipe
3—Cap screw 7—Check valve 11—Cotter pin 14—Clip
4—Pressuren switch 8—Hydraulic accumulator
OUTJ003,0000466 –19–08FEB01–4/7
02
0250
5
–UN–21JUN01
T139416
Axle, Brake Cylinders, Brake Disks
Each bogie has two brake disc assemblies inside the is operated by the parking brake system,. Brake
axle housing, one for each wheel set. Each brake Hydraulics, for more information.
assembly is actuated by a brake cylinder located on
the axle beam housing. The service/work portion of the brake cylinder is
hydraulically applied and spring released. This cylinder
Each brake cylinder is comprised of a parking brake is operated by the work brake system and by the
cylinder assembly and a service/work brake assembly. service brake system.
The parking brake portion of the brake cylinder is

spring applied and hydraulically released. This cylinder

081403
PN=213
Brakes
02
0250
6
–UN–21JUN01
T139417
Parking Brake Cylinder Assembly (Spring Applied and Hydraulically Released)
1—Gasket 7—Two M6 Screws with 10—Piston 15—Bleed Screw Cover

2—Parking Brake Housing Washers 11—Guide Ring 16—Parking Brake Bleed
3—O-ring 8—Four M8 Screws with 12—Ring Screw
4—Spacer Washers 13—Guide Ring 17—Parking Brake Cylinder
5—Protective Cap 9—Spring Discs 14—Ring
6—Emergency Brake Release
Bolt

081403
PN=214
Brakes
02
0250
7
–UN–21JUN01
T139418
Service/Work Brake Cylinder Assembly (Hydraulically Applied and Spring Released)
1—Jam Nut 5—Service/Work Brake Bleed 8—Ring 12—Ring

2—Service/Work Brake Screw 9—Guide Ring 13—Guide Ring
Adjusting Screw 6—Service/Work Brake 10—Clamping Bolt 14—Ring
3—O-ring Cylinder 11—Pin 15—Wedge
4—Bleed Screw Cover 7—O-ring
OUTJ003,0000466 –19–08FEB01–7/7

081403
PN=215
Brakes
1010D Checking and Adjusting
CAUTION: Do not disconnect any brake system

hose joints before all pressure has been
released from the accumulators.
Pressurized fluid in brake lines can cause

personal injury.
IMPORTANT: Clean the brake cylinder and immediate

02
0250 area before disassembly. Cover the
8 housing opening immediately after
removing the cylinder to prevent
contamination of the differential.
1010D Parking Brake Pressure
1. Connect a 0...6 MPa (0...870 psi)pressure transducer

to the measuring point (112)
2. Set the engine rpm’s to aprox. 1600.
3. Check the pressure at measuring point (112). The

pressure should be 4,0 ± 0,1 MPa (580 ± 14,5 psi).
4. If necessary, adjust the pressure through adjusting

screw (114).
Continued on next page JK11466,00000D4 –19–07MAY03–1/7

081403
PN=216
Brakes
02
0250
9
–UN–11NOV02
T161523
1010D Checking parking brake pressure
a—To brake fluid container c—To T-connector d—To rear pedal e—To front pedal
b—To brake valve
Checking the 1010D Drive Brake (pedal brake) 2. Connect a pressure transducers (0 ... 60 MPa)
pressure (0...8702 psi) to measuring points (303) and (304).
1. Connect a pressure transducers (0 ... 60 MPa) 3. Disengage the parking brake

(0...8702 psi) to measuring points (303) and (304)
4. Check the pressures at measuring points (303) and
2. Press smoothly the brake pedal fully down. (304). Pressures should be 7 ± 0,5 MPa (1015 ±
72,5 psi).
3. The pressures at measuring points (303) and (304)
should increase from 0 to 7 ± 0,5 MPa (0 to 1015 ± The pressures cannot be adjusted.
72,5 psi).
The pressures cannot be adjusted.
Checking the 1010D Service Brake Pressure
1. Start the engine

081403
PN=217
Brakes
1010D Mechanical Adjustment of Brakes
IMPORTANT: Before maintenance, park the machine

on an even ground and make sure that
it cannot start moving.
–UN–08OCT02
If brake or brake cylinder components have been
replaced, every step (1 ... 12) of the procedure must be
taken. Should you wish to check whether there is need for
any adjustments as a result of ordinary wear, start with
T159878
02 step 10 with steps 1 and 2.
0250
10 Electronic connector Y41W of the brake valve
1. Remove the connector Y41W of the brake valve
2. Remove the protective cover (2).
Take out the loose release screw (3) that is under the
cover. (In the illustration the screw has been screwed
to the release position.)
–UN–04APR02
3. Open the four bigger socket-head screws (5) (width
across flats 8 mm) and remove the cylinder.
NOTE: Do not open the two smaller socket-head screws
T153523
(width across flats 6 mm).
1010D Brake valve sectional view
4. Take hold of the piston (6). Loosen the lock nut (4).
1—Adjusting sscrew
5. Fully open the adjusting screw (1). Clean the thread 2—Protective cover
3—Release screw
and the lock nut (4).
4—Lock nut
5—Socket-head screws(4 pcs)
6. Unscrew the lock nut (4) to the very end of the 6—Piston
adjustment screw thread. Apply Loctite 242 to the 7—O-ring
threat of the screw. 8—Release screw hole
NOTE: If locking fluid gets to other parts than the

adjusting screw and the lock nut, it must be wiped
away.
7. Put the adjusting screw (1) in its place and turn

clockwise, until there is an obvious resistance (8 ... 15
Nm). Then take hold of the piston (6) and unscrew the
adjusting screw (1) by 3 1/2 turns.
8. Holding the piston (6), tighten the lock nut (4) to about
40 Nm.

081403
PN=218
Brakes
9. Put the cylinder back to its place (check that the o-ring
(7) is proper and firmly in its place). Tighten the four
screws (5).
10. Make sure that the cylinder has been correctly

adjusted by taking a measurement through the
release screw hole (8) with, for example, a sliding
transducer.
a. Release the parking brake

02
b. Place the sliding transducer against the adjusting 0250
11
screw (1) through the hole and check the reading.
c. Put on the parking brake and take the

measurement again.
The reading must not deviate more than 5,25 mm

(0,2 in) from the first one. If the difference is
bigger, readjust the cylinder.
11. Put the protective cover back (2) to its place (check
the O-ring and its proper position).
12. Mount the connector (Y41W) of the brake valve.
❒ Adjust all cylinders in the same way.

❒ Check the functioning of the parking brake by
putting it on when driving at a very low speed.
❒ If necessary, bleed air from the parking brake
cylinders.
When bleeding, the engine must be running and
parking brake must be released.
Bleeding the brake Cylinders
1. Start the engine
2. Disengage parking brake.

081403
PN=219
Brakes
3. Vent air from parking brake through the vent screws:

RB2, RB3, RB4 and RB5
1—Perking Brake Cylinder Bleed Screw
–UN–06JUN01
T139066
02
0250
12 Vent screw RB2 and RB3
–UN–06JUN01
T139067
Vent screw RB4 and RB5
–UN–06JUN01
T139068
Brake cylinder

081403
PN=220
Brakes
4. Vent air from work brake system through the vent

screws: RB6, RB7, RB8 and RB9.
5. Stop the engine
NOTE: Two people are needed for bleeding of the brake
–UN–06JUN01
pedal.
NOTE: Do not start the diesel engine.
T139063
NOTE: Check that there is sufficient brake fluid in the 02
fluid bottle (3) 0250
13
1—Service Brake Cylinder Bleed Screw
–UN–06JUN01
T139064
–UN–06JUN01
T139065

081403
PN=221
Brakes
Filling the brake pedal circuit
If needed, the brake pedal circuit is filled as followed:
1. Connect an external pump to a T-connector (1) near

the shuttle valve.
2. Pump oil until the oil level starts to rise in the brake
fluid container.
–UN–08NOV02
02 3. Repeat the procedure in another brake pedal.
0250
14
4. After filling both of the pedal fluid circuits, open the
bleed screw RB1 and bleed as an ordinary fluid circuit
T161494
brake.
RB1
JK11466,00000D4 –19–07MAY03–7/7
Checking and Adjusting (810D,1110D,1410D

and 1710D)
IMPORTANT: Before you start the servicing work, the

machine has to be parked on a level
surface.
–UN–04APR02
Checking the brakes
You can check that the cylinders are correctly adjusted by
T153524
taking measurements through the release screw aperture
(8), for example using a slide calliper.
810D, 1110D, 1410D and 1710D Brake adjusting
1. Release the parking brake

2. Insert the calliper (A) through the aperture and take a
measurement at the adjusting screw (B)
3. Make a note of the measurement.
4. Reconnect the parking brake and repeat the
measurement.
The difference between the two measurements must
not exceed 5,25 mm (0.2 inc).
If the difference is greater than this, the cylinder should
be adjusted.
Continued on next page EL62757,00001A7 –19–21APR02–1/10

081403
PN=222
Brakes
Mechanical adjustment of brakes
1. Disconnect electrical contact Y41W, from the work

brake valve.
2. Remove the protective cover (2). Note the loose
release screw (3) under the cover
–UN–08OCT02
3. Open the larger Allen screws (5) (4 screws, key size 8
mm) and remove the cylinder.
NOTE: The smaller Allen screws (2 screws, key size 6
T159878
mm) should not be loosened 02
0250
Work brake electrical contact Y41w 15
4. Loosen the locking nut (4). Hold the piston (6) in
position.
5. Fully open the adjusting screw (1). Clean the thread
and the locking nut (4).
6. Turn the locking nut (4) to the end of the adjusting
screw. Lock the adjusting screw thread (1) by applying
locking fluid (Loctite 242).
–UN–04APR02
NOTE: If the locking fluid comes into contact with other
areas than the adjusting screw and the locking
nut, the excess fluid should be cleaned away.
T153523
7. Insert the adjusting screw (1) and turn it clockwise until
a significant resistance is felt (8...15 Nm) (5,9...11 Brake adjusting
lb-ft). Turn the adjusting screw (1) 3 1/2 turns
counterclockwise while holding the piston (6) in 1—Adjusting sscrew
position. 2—Protective cover
3—Release screw
8. Tighten the locking nut (4) to approx. 40 Nm (29.5 lb-ft)
4—Lock nut
while holding the piston (6) in position. 5—Socket-head screws(4 pcs)
9. Reinstall the cylinder. Ensure that the O ring (7) is in 6—Piston
good condition and is correctly positioned. Tighten the 7—O-ring
four screws (5). 8—Release screw hole
10. Fit the protective cover (2). Check that the O ring is in
good condition and is correctly positioned
11. Connect the electrical contact Y41W to the brake
valve. Adjust all the cylinders in the same way

081403
PN=223
Brakes
Brake Charging Pressure
CAUTION: Do not ever disconnect any brake

system hose joints before all pressure has been
eliminated from pressure accumulators.
Connect a pressure sensor (0...30 MPa) (0...4351 psi) to

pressure measuring points (307) and (301).
–UN–20FEB03
NOTE: The pressure is the same with that of the
02
0250 pressure accumulators
16
1. Turn the start key to I position and wait until you hear
T165711
the TMC signal. Start the engine.
2. Disengage the parking brake and wait until the Accumulators
pressure has risen to 15,0...16,0 MPa (2175...2320
psi). 301—Measure point
3. Engage and disengage the parking brake a number of 307—Measure point
times.
The pressure reading measured from measuring points
(307) and (301) should drop
The charging system of the pressure accumulators should

be activated as soon as the pressure drops to 13,0 ...
14,5 MPa (1885...2103 psi), and disengaged when the
pressure has risen to 16,0 MPa (2320 psi).
EL62757,00001A7 –19–21APR02–3/10
Checking the Work Brake
1. Connect a pressure sensor (0...30 MPa) (0...4351 psi)

to measuring points (305) and (304).
2. Start the engine
3. Disengage the parking brake. Symbol ’P’ on the TMC
–UN–13OCT02
display will be replaced by ’S’.

4. Make sure that the maximum pressure reading from
the pressure measuring points (305) and (304) are 9.5
... 10.0 MPa (1377...1450 psi).
T152794
NOTE: The pressures cannot be adjusted.

Measuring points 304 and 305

081403
PN=224
Brakes
Checking the Drive Brake (Brake Pedal)
1. Connect a pressure sensor (0...30 MPa) (0...4351 psi)

to measuring points (305) and (304)
2. Start the engine and keep engaged the parking brake
3. Press the brake pedal and ensure that the pressure
–UN–13OCT02
reading from the (305) and (304) rises to 9.5 ... 10.0
MPa (1377...1450 psi).
NOTE: The pressures cannot be adjusted.
T152794
02
Bleeding Air from Brake System 0250
Measuring points 304 and 305 17
CAUTION: With the engine running, the brake

system pressure is in models 1010D, 1410D and
1710D 10 MPa (1450 psi) and 810D and 1110D 7
Mpa (1015 psi). Use extreme caution when
opening the vent screws to bleed air from the
system.
As necessary, eliminate air from the brake system as

follows:
1. Start the engine
2. In model 1010D Disengage parking brake
Release parking brake (See the symbol on TMC

display).

081403
PN=225
Brakes
3. Vent air from parking brake through the vent screws:

RB2, RB3, RB4 and RB5
1—Perking Brake Cylinder Bleed Screw
–UN–06JUN01
T139066
02
0250
18
–UN–06JUN01
T139067
–UN–06JUN01
T139068

081403
PN=226
Brakes
4. Vent air from work brake system through the vent

screws: RB6, RB7, RB8 and RB9.
5. Stop the engine
Bleeding the brake cylinders
–UN–06JUN01
1. Start the diesel engine.
2. Release the parking brake (see the symbol on TMC
display).
T139063
3. Bleed the work brake cylinders through vent screws 02
RB6, RB7, RB8 and RB9 0250
19
1—Service Brake Cylinder Bleed Screw
–UN–06JUN01
T139064
–UN–06JUN01
T139065
Service brake bleed screw

081403
PN=227
Brakes
4. Bleed the parking brake cylinders through vent screws

RB2, RB3, RB4 and RB5.
Bleeding the brake pedal
If necessary, the brake pedal circuit can be bled as
–UN–06JUN01
follows:

pedal.
T139066
02
0250 NOTE: Do not start the diesel engine.
20 Brake cylinders in rear bogie
NOTE: Check that there is sufficient brake fluid in the
fluid bottle (3)
The process is the same as for a normal fluid brake
1—Vent screw of parking brake cylinder
–UN–06JUN01
T139067
Brake cylinders in front bogie
–UN–06JUN01
T139068

081403
PN=228
Brakes
3—ATF tank
1—Bleed screw
02
0250
21
–UN–20MAR02
T152820
ATF brake oil tank
–UN–01OCT02
T159877
Brake valve bleeding screw

081403
PN=229
Brakes
1. Press the pedal several times,

2. Keep the pedal pressed and open the bleed screw (1).
3. Close the bleed screw and release the pedal.
4. Repeat until no air comes out with fluid.
5. Do the same procedure for the other brake pedal.
6. Check that air is properly removed from both of the
brake pedals by driving the machine when the brake is
on.

02 pedal.
0250
22
NOTE: Do not start the diesel engine.
–UN–01SEP02
NOTE: Check that there is sufficient brake fluid in the
fluid bottle (3)
1—1710D Bleed screw
T152783
1710D Brake valve bleeding screw
EL62757,00001A7 –19–21APR02–10/10

081403
PN=230
Section 03
Hydraulic systems
Contents
Page Page
Group 0310—General 1010D Bleeding Work Hydraulic System . . .03-0330-10

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0310-1 810D,1110D and 1410D Bleeding Work
Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0310-1 Hydraulic System. . . . . . . . . . . . . . . . . . .03-0330-12
Drive Hydraulic System . . . . . . . . . . . . . . . . .03-0310-2 1710D Bleeding Work Hydraulic System . . .03-0330-14
Work Hydraulic System . . . . . . . . . . . . . . . . .03-0310-5
Hydraulic Oil Cooling. . . . . . . . . . . . . . . . . .03-0310-10 Group 0335—Work Hydraulics Service
Control of Transmission . . . . . . . . . . . . . . .03-0310-11 Work Pump Removal and Installation . . . . . .03-0335-1 03
Conversion Table for Pressures . . . . . . . . .03-0310-12 Work Pump Service . . . . . . . . . . . . . . . . . . .03-0335-6
Boom Control Valve . . . . . . . . . . . . . . . . . .03-0310-13 Auxiliary Valve Removal and Installation . . .03-0335-26
Thermostat valve. . . . . . . . . . . . . . . . . . . . .03-0310-15 Boom Control Valve Removal and
Hydraulic Pressure Filter . . . . . . . . . . . . . . .03-0310-16 Installation . . . . . . . . . . . . . . . . . . . . . . . .03-0335-31
Service Accumulator Systems Safely . . . . .03-0310-16 Boom Control Valve Disassembly and
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .03-0335-35
Group 0320—Drive Hydraulics Service Thermostat Valve Removal and
Hydrostatic Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . .03-0335-40
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . .03-0320-1 Hydraulic Pressure Filter Replacement . . . .03-0335-41
Essential Tools. . . . . . . . . . . . . . . . . . . . . . .03-0320-1 Hydraulic Return Filter Replacement . . . . . .03-0335-42
Service Equipment . . . . . . . . . . . . . . . . . . . .03-0320-2 Hydraulic Tank Removal and installation . . .03-0335-48
Renew the pressure filter . . . . . . . . . . . . . . .03-0320-3
Hydrostatic Drive Motor Group 0340—Work Hydraulics Checking and
Removal and Installation . . . . . . . . . . . . . .03-0320-5 Adjusting
Servicing Drive Motor . . . . . . . . . . . . . . . . . .03-0320-6 Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0340-1
Hydrostatic Drive Pump Adjusting 1010D Pressures . . . . . . . . . . . . .03-0340-1
Removal and Installation . . . . . . . . . . . . .03-0320-12 Adjustment of Pressure Difference . . . . . . . .03-0340-6
Drive Shaft Seal Replacement . . . . . . . . .03-0320-13 Adjusting the Maximum Pressure . . . . . . . . .03-0340-6
Bleeding the Drive Hydraulics . . . . . . . . . . .03-0320-49 Adjusting the Boom Pressure . . . . . . . . . . . .03-0340-7
Hydrostatic Drive Pump Adjusting Auxiliary Functions. . . . . . . . . . . . .03-0340-9
Start-up Procedure . . . . . . . . . . . . . . . . .03-0320-55 Adjusting Frame Brake . . . . . . . . . . . . . . . .03-0340-10
Adjusting Proportional Decking Blade . . . . .03-0340-10
Group 0325—Checking and Adjusting Drive Hydraulic Function Cycle Times . . . . . . . . .03-0340-11
Hydraulics Adjustment
1010D Checking and Adjusting . . . . . . . . . .03-0325-1 Motor Start of Control Point
Charge pressure (810D supply pressure) . . .03-0325-8 Adjustment . . . . . . . . . . . . . . . . . . . . . .03-0340-12
Pressure Cut-Off Valve Setting of The Hose Inspection and Replacement . . . . . . .03-0340-14
Drive Pump . . . . . . . . . . . . . . . . . . . . . . . .03-0325-9 1010D Direction Selection Solenoids
Pressure Cut-Off Setting for the Drive Inspection and Replacement . . . . . . . . . .03-0340-15
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0325-10
1710D Checking and adjusting drive Group 0350—Hydraulic Cylinders
motors pressure cut-off settings . . . . . . . .03-0325-11 Cylinder Service . . . . . . . . . . . . . . . . . . . . . .03-0350-1
1410D and 1710D Checking the function Cylinder Seals Replacement . . . . . . . . . . . . .03-0350-1
of hydrostatic flushing valve. . . . . . . . . . .03-0325-14 Cylinder Internal Seal Leak Test . . . . . . . . . .03-0350-4
Lifting Boom Cylinder Service . . . . . . . . . . . .03-0350-5
Group 0330—Work Hydraulics Extension Cylinder Service . . . . . . . . . . . . . .03-0350-8
Work Pump Theory of operation . . . . . . . . . .03-0330-1 Outer Boom Cylinder Servicing . . . . . . . . . .03-0350-12
Work Pump Start-up Procedure. . . . . . . . . . .03-0330-4
Valves General . . . . . . . . . . . . . . . . . . . . . . .03-0330-6 Continued on next page

081403
PN=1
Contents
Page
Grapple Cylinder Servicing - Supergrip SG

260/360 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-13
Grapple Cylinder Servicing - Loglift
GF25/GF35 . . . . . . . . . . . . . . . . . . . . . . .03-0350-18
Group 0360—Hydraulic Schematics

Hydraulic Diagram Symbols . . . . . . . . . . . . .03-0360-1
Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-6
810D Boom Hydraulics . . . . . . . . . . . . . . . . .03-0360-8
1010D Hydraulic Diagrams . . . . . . . . . . . . .03-0360-20
03
Diagnose Work Hydraulics . . . . . . . . . . . . . .03-0370-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . .03-0370-1
Cab Tilt System. . . . . . . . . . . . . . . . . . . . . . .03-0370-3
Diagnose Drive Hydraulics . . . . . . . . . . . . . .03-0370-5
Diagnose Hydraulic/ Hydrostatic Cooling
System . . . . . . . . . . . . . . . . . . . . . . . . . .03-0370-13
Diagnose Cab Tilt Hydraulics . . . . . . . . . . .03-0370-13
Diagnose Brake Hydraulics . . . . . . . . . . . . .03-0370-14
Troubleshooting. . . . . . . . . . . . . . . . . . . . . .03-0370-15
Work Hydraulic Checkout Record Sheet . . .03-0370-16
Hydrostatic System Checkout Record
Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0370-17
Group 0380—Appendix Manuals

Rexroth Drive Motors . . . . . . . . . . . . . . . . . .03-0380-1
Rexroth Drive Pumps . . . . . . . . . . . . . . . . . .03-0380-1
Rexroth Hydraulic Work Pumps. . . . . . . . . . .03-0380-1
VOAC / Parker Boom Control Valves . . . . . .03-0380-1

081403
PN=2
Group 0310
General
Essential Tools

SERVICEGARD is a trademark of Deere & Company OUTJ003,0000310 –19–18JAN01–1/2
Air Bleed Hose

03
To bleed air from test fittings on Hydrostatic Drive Pump. 0310
1
OUTJ003,0000310 –19–18JAN01–2/2
Other Material
Number Name Use
N/A (U.S.) Loctite 275 Used to install cylinder piston.
Number Name Use
N/A (U.S.) Loctite 270 Used to secure cylinder piston during

Grapple Cylinder Servicing
(Supergrip SG 260/360) procedure.
N/A (U.S.) Loctite 242 Used to secure cylinder piston during

Grapple Cylinder Servicing (Loglift
GF25/GF35) procedure.
OUTJ003,000034C –19–22JAN01–1/1

081403
PN=233
General
Drive Hydraulic System
03
0310
2
–UN–20JUL01
T138185
1110D Hydrostatic Drive Pump and Motor
1—Hydrostatic Drive Pump 2—Work Pump 3—Hydrostatic Drive Motor
IMPORTANT: Cleanliness procedures must be drive, the direction of flow is reversed. The transfer
observed when working on any case mechanically provides a high and low range of
hydraulic component in order to operation.
hydraulic and hydrostatic systems. Some oil leaves the loop through the pump and motor
Failure to follow these procedures case drains, lubricating the main bearings at the same
may lead to equipment damage. time. This oil passes through a cooler and returns to
the reservoir.
A hydrostatic drive is a closed loop system between a
variable displacement piston pump and a variable Fresh oil is brought into the loop by a charge pump
displacement piston motor. The pump is coupled to the which is built into the hydrostatic drive pump. The oil is
engine. The motor is mounted on the transfer case. Oil filtered before entering the system through a check
is fed from the pump to the motor and back to the valve.
pump again.
The work pump is driven off the auxiliary pad of the
In operation, the engine speed is constant. To change hydrostatic pump. This second pump supplies flow for
the speed of the machine, the flow of the oil is steering, decking blade and loader operations.
increased or decreased. To change direction on the
Continued on next page EL62757,00001C2 –19–22APR02–1/3

081403
PN=234
General
03
0310
3
–UN–10JUN03
T191671
General view of hydrostatic drive pump components(1110D illustrated)
1—Hydraulic motor 2—Hydraulic tank 3—Hydraulic pump


081403
PN=235
General
The main components of the system are a hydraulic The direction of rotation and speed of the motor
pump and a hydraulic motor. These components make depend on the direction and magnitude of the flow
up a closed loop circuit in which the oil flowing from generated by the pump.
the pump to the motor will return to the pump from the
motor. Both the pump and the motor are of the The motor displacement is adjusted by turning the
variable displacement piston type. motor shaft while the plate stays in place.
The direction of rotation of the pump shaft is always The pump and motor angles are interdependent. If the
the same. The displacement of the pump is regulated machine stands still, the pump angle is zero and the
by means of two electrically controlled proportional motor angle at its maximum. When the machine starts
valves. One of the valves adjusts the pump plate in off, the pump angle begins to increase. When the
one direction and the other valve in the opposite pump angle reaches its maximum, the motor angle
direction. This system alters the direction and amount begins to decrease. If you drive at full speed, the
of oil flow generated by the pump, which, in turn, pump angle is at its maximum and the motor angle at
changes the direction of rotation of the motor (driving its minimum.
direction and speed) accordingly. In addition to the
03
0310 control current of the proportional valve, the amount of
4 flow generated by the pump can also be changed by
adjusting the speed of the diesel engine.
EL62757,00001C2 –19–22APR02–3/3

081403
PN=236
General
Work Hydraulic System
03
0310
5
–UN–13AUG01
T138111
1110D Hydraulic System Component Locator
1—Decking Blade Valve 6—Brake Pressure 9—Hydrostatic Drive Motor 13—Steering Cylinder
2—Hydrostatic Drive Pump Accumulator 10—Hydraulic Pressure Filter 14—Hydraulic Tank
3—Hydraulic Work Pump 7—Auxiliary Valve 11—Transfer Case 15—Hydraulic Return Filter
4—Direction Selection Valve 8—Brake Valve 12—Cab Tilt Hand Pump 16—Boom Control Valve
5—Cab Tilt Cylinder
The working hydraulics is the supply system for • Grapple

operation of the following: • Frame steering
• Drive brakes
• Boom • Frame brake
Continued on next page OUTJ003,00002A5 –19–09JAN01–1/5

081403
PN=237
General
• high/low gear shift • Differential lock

• All wheel drive off
03
0310
6

081403
PN=238
General
03
0310
7
–UN–22AUG01
T138112
An example of Work Hydraulic System
1—Work Pump 4—Brake Valve 6—Hydraulic Tank 7—Hydraulic Pressure Filter

3—Auxiliary Valve 5—boom Control Valve
The working hydraulics consists of the following • Working pump

components: • Auxiliary valve block

081403
PN=239
General
• Boom control valve • Auxiliary valve block

• Brake valve • Main distribution valve block
• Hydraulic tank plus the hoses and fittings connecting • Boom control valve
these components • Working pump displacement control unit
• There can also be optional equipment in the working
hydraulic system In the auxiliary valve, measuring point is used for
testing the pilot pressure of the boom control valve.
The working pump is mounted onto the diesel engine. Tank pressure of the boom control valve can be
Hydrostatic pump is mounted behind the working pump measured from the measuring point on the boom
with the pump shaft mechanically connected to the valve. Working pump LS-pressure can be measured
working pump shaft bushing. Propulsion of the two from the LS-measuring point on the pump and supply
pumps is provided by the diesel engine. pressure from the measuring point on the main
distribution valve block.
Case drain from the hydraulic pump is directed to the
hydraulic tank through a 10-micron return filters. Normally the brake circuit would demand automatic
charging of the brake accumulators as soon as the
03
0310 The hydraulic system is load sensing, i.e., it senses pump starts turning. However, to reduce resistance at
8 how much pressure is required when a particular start-up, particularly in cold weather, a solenoid valve
function is activated. The pump supplies only the (Y44) in the brake valve is energized when the ignition
amount of fluid required in each situation, and no fluid key is turned to ”start” position. When this valve is
is circulated by the pump when all functions are at open, the flow in the load sense line from the brake
rest. circuit is directed to tank. Without load sensing
pressure at the pressure compensator the pump will
During normal operation the flow from the pump and de-stroke; thereby, preventing charging while the
the pressure in the system will vary as the demand engine is cranking. The Y44 solenoid valve will stay
changes. When the system is not demanding power, energized controlled by TMC after the engine starts as
the load sense control will operate in stand-by mode. long as parking brake switch is in the ON position.
Also solenoid valve (Y44B) on boom valve works on a
Typically, the differential pressure is that between the similar way than a solenoid valve Y44.
pressure inlet and any service port of the proportionally
controlled boom control valve. The factory setting of The boom and steering functions are operated by
the differential load sense pressure is 2.5 MPa (363 means of the boom control valve that is a sectional,
psi). load sensing and pressure compensated directional
valve.
If the load pressure exceeds the system pressure
setting of 24.0 MPa, the pressure cut-off valve Manually controlled joysticks are used to electrically
de-strokes the pump until the correct maximum operate the control valve spool solenoids. These
pressure is re-established. solenoids, in turn, control the pilot flow to operate the
main valve spools.
The load sense signal to control the displacement of
the working pump is sensed from the boom control The pilot flow is obtained from the main flow through
valve and the brake valve, The LS-hose directs the the pressure reducing valve. The pressure of the pilot
signal to the load sensing control valve on the pump. flow is reduced to 3.5 MPa before being directed
through the pilot control valves.
There are measuring points for measuring and
adjusting pressures in the following components:

081403
PN=240
General
The boom and steering functions are connected to the solenoids correspond to the boom and steering
boom control valve sections, A and B ports, as shown functions):
in the table below (electrical connections at the
OUTJ003,00002A5 –19–09JAN01–5/5
03
0310
9

081403
PN=241
General
Hydraulic Oil Cooling
03
0310
10
–UN–20JUL01
T138163
An example of hydraulic Oil Cooling System

Continued on next page OUTJ003,00002B7 –19–10JAN01–1/2

081403
PN=242
General
1—Drive Motor Case Drain 3—thermostat valve 4—Oil Cooler 5—Hydraulic Tank Return
2—Drive Pump Case Drain
Oil from the drive pump and motor case drains goes to Oil from the drive pump and motor case drains is the
the thermostat valve. The thermostat valve directs the only oil sent to the cooler. Oil from the work pump
oil to the oil cooler or the hydraulic tank depending on case drain, valve and implement return lines is
the oil temperature. The thermostat valve is located on returned directly to the hydraulic tank.
the oil cooler, on the left side of the radiator assembly.
See thermostat valve, in this section, for information on

the operation of the thermostat valve.
03
0310
11
OUTJ003,00002B7 –19–10JAN01–2/2
Control of Transmission
TMC controls electrically hydrostatic transmission:
• To adjust the speed of the diesel engine and the angle

of the hydraulic pump as dictated by the signal coming
from the accelerator pedal
• The electronic control system monitors the speed of the
diesel engine. If the engine speed drops as a result of
additional loading, the pump angle will be reduced by
the electronic system. In other words, the gear ratio of
the power transmission is adjusted by the electronic
system which ensures that the power needed to operate
the machine is always smaller than the power
generated by the engine
• When the machine stops, the work brake is
automatically engaged by the system.
The control of transmission is part of the Total Machine

Control System. (see Instructions for use TMC enclosed).
EL62757,00001C1 –19–22APR02–1/1

081403
PN=243
General
Conversion Table for Pressures

psi MPa bar kPa kg/cm2
psi 1 0.006895 0.06895 6,895 0.07031
MPa 145 1 10 1000 10.20
bar 14.50 0.1 1 100 1.02
kPa 0.145 0.001 0.01 1 0.0102
kg/cm2 14.22 0.09807 0.9807 98.07 1
03
0310
12
OUTJ003,0000744 –19–08AUG01–1/1

081403
PN=244
General
Boom Control Valve
Boom Control Valve Specifications
810D 1010D 1110D 1410D 1710D

Boom Control Valve block number 7
Main Relief Valve 26 MPa (3100 psi)
Jib Port Reliefs (2) 23.0 MPa (3100 psi)
Grapple Close Port Relief 25 MPa (2625 psi)
Grapple Open Port Relief 25 MPa (2625 psi)
Extension Boom Port Reliefs (2) 25 MPa (2625 psi)
Grapple Rotator Port Reliefs (2) 25 MPa (2625 psi)
Main Boom Port Relief (A port only) 25 MPa (2625 psi)
Steering Section Port Reliefs (2) 25 MPa (2625 psi)
Return Counter Pressure Valve 5 Mpa (73 psi) 03
0310
Load Sense Signal Pressure Restrictor 0.7 mm
13
Orifice
Pilot Pressure Regulator Valve 3.5 MPa (508 psi)
Slew Section Pilot Restrictors (2) 1.2 / 1.2 mm 1.2 mm 1.0 / 1.0 mm
Jib Section Pilot Restrictors (2) 0.8 / 0.8 mm 0.6 mm A 1.0 / B 0.6 mm
Grapple Open/Close Section Pilot 1.0 /1.0 mm 0.8 / 0.8 mm 1.5/1.5 mm
Restrictors (2)
Extension Boom Section Pilot Restrictors (2) 1.0 /1.0 mm 0.8/0.8 mm 1.0 mm
Grapple Rotator Section Pilot Restrictors (2) 1.0 /1.0 mm 1.2 / 1.2 mm 1.0/1.0 mm
Main Boom Raise Function Pilot Restrictor 1.0 /1.0 mm 0.8 / 0.8 mm 1.0 / 1.0mm
Main Boom Lower Function Pilot Restrictor 1.2 / 1.2 mm
Steering Section Pilot Restrictors (2) steering pilot restrictors are in separate pilotvalve block
Slew port feed reduction setting 22.5 MPa 21.5 Mpa (3118 psi)
Grapple open port feed reduction setting 17 Mpa (2465 psi)
Grapple close port feed reduction setting 19 Mpa (2577 psi)
Steering port feed reduction setting 21.5 Mpa
All Solenoids 27 volts
Solenoid Y66L Steering Left
Solenoid Y66R Steering Right
Solenoid Y409 Grapple Rotate Counterclockwise
Solenoid Y416 Grapple Open
Solenoid Y417 Grapple Close
Solenoid Y418 Boom Extension out
Solenoid Y419 Boom Extension in
Solenoid Y420 Main Boom up
Solenoid Y421 Main Boom down
Solenoid Y422 Outer Boom up
Continued on next page OUTJ003,00002AA –19–10JAN01–1/2

081403
PN=245
General
Solenoid Y423 Outer Boom down

Solenoid Y424 Boom Slew Counterclockwise
Solenoid Y425 Boom Slew Clockwise
The boom control valve is a modular valve composed port in the main boom section are equipped with port
of seven work (spool) sections, an inlet and an outlet relief and anti-cavitation check valves. The port reliefs
section assembled into a single valve bank. are pre-set at 23.0 MPa (3100 psi) and non-adjustable.
The A and B ports in the slew section are equipped
NOTE: Port relief cartridges are used on all valve with anti-cavitation check valves .
sections except Slew section A and B ports
and Main Boom section B port. The grapple open/close section includes two
adjustable pressure reliefs. The grapple open pressure
The Grapple Open/close section includes two is adjusted to 16 MPa (2,320 psi). The GrappleClose
pressure relief adjustment screws. pressure is adjusted to 19 MPa (2,755 psi).
03 Hydraulic fluid from the pump is supplied through the All spool sections are operated by hydraulic flow
0310 inlet port P1 and distributed through connecting oil directed through the pilot solenoid valves. These
14 galleries in the individual valve sections. The inlet valves are electro-hydraulic, proportionally controlled,
section is equipped with a main relief valve to protect with spring centering to neutral position. To obtain to
the pump and inlet side of the valve. The relief valve is the required pilot flow to each section as needed, a
non-adjustable and set at 23.0 MPa (3100 psi). restrictor plate of varying size is used with each
solenoid valve.
The load sensing signal system consists of the
interconnected shuttle valves. These shuttle valves Internal pilot pressure supply is built into the outlet
compare the load signal from the seven spool sections section. The pilot regulator valve works as both a
and the dominating signal is transmitted to the LS port pressure regulator and a pressure relief valve in the
in the inlet section and through an externally pilot circuit. For safety reason the regulator cartridge is
connected restrictor to the compensator on the work also equipped with a separate safety valve function
pump. Load sense signal pressure can be checked at that prevents the maximum permissible regulated
the MC2 test port. pressure from being exceeded. A check valve prevents
pilot oil from leaking back to the pump, enabling the
Each spool section is equipped with a double-acting pressure in the pilot supply circuit to be maintained in
spool that is blocked in neutral. The spools are the event of a temporary fall in pump pressure, e.g.
designed for their specific functions and not during a rapid lowering movement.
interchangeable.
A coarse filter with by-pass function is provided in the
The slew and the main boom spool sections are internal pilot pressure supply. The filter protects the
equipped with a pressure compensator with check pilot circuit from dirt, especially during start-up of the
valve function in the spool inlet. A restrictor is installed system.
in the load sensing line to the compensator. The
remaining spool sections are equipped with a load-hold A non-adjustable counter pressure valve, ahead of exit
check valve in the spool inlet. port T3, is provided to maintain a positive pressure of
.5 MPa (73 psi) in the control valve main tank return. A
The A and B ports in the Outer , extension boom, separate port, TP, provides tank return of the pilot
grapple rotator and steering sections as well as the A flow.
OUTJ003,00002AA –19–10JAN01–2/2

081403
PN=246
General
Thermostat valve
Theory of operation
The thermostat valve directs hot oil from the drive pump
and motor case drains to the oil cooler depending on the
oil temperature. The valve includes a by-pass in case flow
through the oil cooler is restricted.
The thermostat valve is located on the left side of the

radiator assembly.
03
0310
15
OUTJ003,00002AE –19–10JAN01–1/2
When the oil temperature is below 49°C (120°F). the

thermostat remains closed and the oil flow is directed to
the hydraulic tank from the bottom port.
At oil temperatures between 49°C (120°F) and 63°C

(145°F) the thermostat starts to open and a portion of the
oil flow is directed to the cooler from the top port and then
returned to the hydraulic tank.
At pressures below 449 kPa (65 psi) and temperatures

above 63°C (145°F) the thermostat is fully open and all
the oil flow is directed to the cooler and then returned to
the hydraulic tank.
At pressures above 449 kPa (65 psi) and temperatures

above 63°C (145°F) the thermostat will remain partially
closed, diverting a portion of the flow directly to the tank.
1—Thermostat –UN–13AUG01
2—Pressure Relief Spring
3—Cooler Port
4—Inlet Port
T141865
5—Tank Port
OUTJ003,00002AE –19–10JAN01–2/2

081403
PN=247
General
Hydraulic Pressure Filter
A Hydraulic Pressure Filter is installed after the work

pump. The 50 micron filter is cleanable; there should be
no need to replace it. The filter should be cleaned in the
event of hydraulic system contamination or pump damage.
The filter restriction pressure switch is set to close at 800

kPa (116 psi) activating an indicator light in the cab. This
warning will indicate a clogged filter before the filter is
by-passed.
1—Hydraulic Pressure Filter
–UN–13AUG01
03
0310
16
T144418
1010D Hydraulic Pressure Filter
JK11466,000005E –19–17DEC02–1/1
Service Accumulator Systems Safely
Escaping fluid or gas from pressurized hydraulic

accumulator systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch
near a pressurized accumulator or pressurized line.
–UN–23AUG88
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting. TS281
Accumulators cannot be repaired.
DX,WW,ACCLA –19–15APR03–1/1

081403
PN=248
Group 0320
Drive Hydraulics Service
General
IMPORTANT: See Group 0030 for tightening torques.

See also enclosed NAF and Rexroth
manuals for detailed service
instructions


03
Use an air hose and wire brush to remove any loose dirt 0320
and debris from the outside of the motor before starting 1
any work.
Plug all ports to prevent contamination.
JK11466,0000078 –19–03JAN03–1/1
Essential Tools

Drive motor
Driver, Drive Shaft Seal . . . . . . . . . . . Part Number N/A
Used to press fit Drive Shaft Seal on Hydrostatic Drive

Motor.
OUTJ003,0000313 –19–18JAN01–2/8
Drive Pump

081403
PN=249
Driver, Drive Shaft Seal . . . . . . . . . . . Part Number N/A
Used to press fit Drive Shaft Seal on Hydrostatic Drive

Pump.
OUTJ003,0000313 –19–18JAN01–4/8
Spring Preloading Cylinder . . . . . . . . . Part number N/A
Used to preload spring while installing retaining rings on

Hydrostatic Drive Pump Control Piston
OUTJ003,0000313 –19–18JAN01–5/8
Rotary Group Assembly Tool . . . . . . . . Part Number N/A

03
0320 Used to position cylinder during installation of Rotary
2 Group in Hydrostatic Drive Pump housing.
OUTJ003,0000313 –19–18JAN01–6/8
Connecting Hose
Used to connect Ports X1 and X2 during Mechanical

Centering of Hydrostatic Drive Pump procedure.
OUTJ003,0000313 –19–18JAN01–7/8
OUTJ003,0000313 –19–18JAN01–8/8
Service Equipment
Drive Motor

Gauge 5.0 MPa (1000 psi)
Used to measure hydraulic pressures at test ports.

081403
PN=250
NOTE: See Section 00, group 0020 for all specifications
Drive Pump

Two Gauges 60 MPa (9000 psi)

03
To measure hydraulic pressure at test port. 0320
3
OUTJ003,0000314 –19–18JAN01–4/6
Gauge 5.0 MPa (1000 psi)
To measure hydraulic pressure at test port.
OUTJ003,0000314 –19–18JAN01–5/6
OUTJ003,0000314 –19–18JAN01–6/6
Renew the pressure filter
–UN–08NOV02
T161497
1010D Pressure filter

081403
PN=251
1—Pressure filter
–UN–22SEP02
03
0320
4
T159654
810D, 1110D and 1410D Pressure filter
EL62757,0000117 –19–10APR02–2/3
1. Lower down the belly plate. The transmission filter is

located under the transmission pump.
2. Turn filter counterclockwise to remove.
3. Clean mounting surface. Apply thin film of oil to gasket

of new filter. 1
4. Install new filter. Turn the filter by hand until the seal
makes contact with the base. Use a filter wrench to
turn the filter 30° further.
5. Start engine. Check for leaks around the filter base.

Tighten filter only enough to stop leaks.
–UN–08MAR02
6. Stop engine.
7. Check oil level at sight glass on hydraulic tank. Add oil,

T152535
if necessary. See for recommended hydraulic fluids.
1710D Pressure filter

1—Pressure filter
EL62757,0000117 –19–10APR02–3/3

081403
PN=252
Drive Motor Removal And Installation

–UN–29AUG01
Securely block the wheels to prevent machine
movement. Failure to observe proper safety
precautions can lead to risk of personal injury.
T138834
NOTE: Following service instructions are general only.
For detailed instructions for each Forwarder Hydrostatic Drive Motor, Hoses
model, see group 0020 page 13 and enclosed
Rexroth mauals.
To remove the Hydrostatic Drive Motor: 03

0320
5
1. Tag and disconnect the hoses from the hydrostatic
drive motor.
2. Attach a suitable lifting device to the Hydrostatic Drive

Motor.
OUTJ003,0000304 –19–18JAN01–1/3
3. To remove the hydrostatic motor from the transfer

case, remove the four socket head capscrews and
slide the motor back 75 mm (3") to clear the spline.
When the bolts are removed, ensure that the motor is
adequately supported at all times to prevent damage to
the spline and seals.
–UN–29AUG01
To install the hydrostatic Drive Motor:
T138835
Hydrostatic Drive Motor Removal

081403
PN=253
1. Replace O-ring before assembly.
Attach the hydrostatic motor to the transfer case with

the four socket head capscrews. Tighten screws to
specified torque.
–UN–29AUG01
2. Connect the hoses to the hydrostatic motor.
NOTE: After re-installing or replacing motor, see

Hydrostatic Drive Motor Start-up procedure in
T138835
Section 03, Group 0320 page 47.
Hydrostatic drive motor Installation

3—Case Drain Hose
03
0320
6
–UN–29AUG01
T138837
Hydrostatic Drive Motor Hoses
OUTJ003,0000304 –19–18JAN01–3/3
Servicing Drive Motor
Drive Shaft Seals Replacement
1—Retaining Ring
2—Shim
–UN–29AUG01
3—Drive Shaft Seal
T138838
Hydrostatic Drive Motor, Drive Shaft Seal, Shim, Retaining Ring
Continued on next page JK11466,00000CE –19–09APR03–1/9

081403
PN=254
1. Protect the spline by wrapping it with tape.
Remove the retaining ring and shim.
–UN–29AUG01
T138839
Drive Shaft, Retaining Ring, Pliers
03
0320
7
JK11466,00000CE –19–09APR03–2/9
2. Insert two sheet metal screws into the rubber showing

at the two holes in the metal backing of the seal. Use
the screws as handles to lift out the seal.
–UN–20JUL01
T138750
Drive Shaft Seal, Screws, Pliers
JK11466,00000CE –19–09APR03–3/9
3. Use Seal Driver to press in new seal.
NOTE: Mark the seal depth on the bushing before

pressing in the seal.
4. Install the retaining ring and shim.

–UN–20JUL01
T138804

081403
PN=255
Constant Pressure Control Valve or Valve Seals

Replacement
1. Remove mounting screws to remove valve.
NOTE: Use care when removing valve. Valve is under

spring load.
Note the length of the adjustment screw.
NOTE: Do not remove adjustment screw.
2. Replace the o-ring.
3. Lubricate the alignment pin with grease. Install pin on

valve.
03
0320
8 4. Install valve on Hydrostatic Drive Motor.
–UN–20JUL01
T138843
Constant pressure control valve, O-ring
–UN–29AUG01
T138844
Constant Pressure Control Valve

–UN–29AUG01
T138845

081403
PN=256
Port Plate Seal Replacement
NOTE: In order to disassemble the motor, the rotary

group must be swiveled to line up with the output
shaft (zero position).
–UN–20JUL01
1. Measure and record the setting of the Displacement
Limiter Adjustment Screws.
1—Minimum Displacement Limiter Screw
T138846
2—Maximum Displacement Limiter Screw
Hydrostatic Drive Motor Section View, Displacement Limiter

Screws
03
0320
9
JK11466,00000CE –19–09APR03–6/9
2. Remove the Minimum Displacement Limiter Screw and

plug the port.
Remove the Maximum Displacement Limiter

Adjustment Screw.
–UN–20JUL01
3. Install a long screw in the maximum displacement
limiter port and swivel the rotary group to the zero
position.
T138847
Hydrostatic Drive Motor Section View, Displacement Limiter Screws
Removal
–UN–20JUL01
T138850
Hydrostatic Drive Motor Section View, Long Screw, Swivel Rotary

Group

081403
PN=257
4. Mark the position of the port plate to ease re-assembly.
Remove the mounting screws.
Remove the port plate.
–UN–29AUG01
5. Replace the o-ring. Apply a coating of grease to new
o-ring to hold it in place.
NOTE: Keep the rotary group vertical. The piston rings
T138851
should project beyond the cylinder bores.
6. Inspect the sliding surfaces of the control lens and port Hydrostatic drive Motor, Alignment Mark
plate.
7. Install port plate. Use a coating of grease to hold the

03
0320 control lens in position. Install mounting screws.
10
–UN–29AUG01
T138852
Hydrostatic Drive Motor Housing, Port Plate Removed, Seal
–UN–29AUG01
T138853

081403
PN=258
8. Install Minimum Displacement Limiter. Confirm that it is

installed to the correct depth.
Remove long screw from Maximum Displacement

Limiter port. Install Maximum Displacement Limiter.
Confirm that it is installed to the correct depth.
NOTE: The start-up procedure should always be followed

when the hydrostatic pump or motor has been
removed or replaced.
See the Hydrostatic Pump and Motor Start-up

Procedure in Group 0320.
03
0320
11
–UN–29AUG01
T138854
Hydrostatic Drive Motor Section View, Displacement Limiter
Installation
JK11466,00000CE –19–09APR03–9/9

081403
PN=259
Drive Pump Removal and Installation
03
0320
12
–UN–20JUL01
T138747
Coupling, Hydrostatic Drive Pump, Work Pump
IMPORTANT: Cleanliness procedures must be It is recommended that the machine be completely

observed when working on any washed down before removal begins.
prevent contamination of the Tag all hoses before removal to ease re-assembly.
hydraulic and hydrostatic systems.
Cap hoses and plug ports.
Failure to follow these procedures
may lead to equipment damage. The hydrostatic pump must be taken to a hydraulic
repair shop for repair where all the tools and expertise
The hydrostatic drive pump and the working pump are are available.
removed from the machine as an assembly. See
Section 02, Group Drive Coupling Removal and
Installation, for details.
OUTJ003,00002E6 –19–17JAN01–1/1

081403
PN=260
Servicing Drive Pump
03
0320
13
–UN–13AUG01
T138784
An example of drive pump assembly
JK11466,00000CF –19–09APR03–1/78
Drive Shaft Seal Replacement
1—Retaining Ring
–UN–13AUG01
T138748
Hydrostatic Drive Pump - Drive Shaft Seal
Continued on next page JK11466,00000CF –19–09APR03–2/78

081403
PN=261
1. Protect the drive shaft spline by wrapping it with tape.
2. Use pliers to remove the retaining ring.
–UN–20JUL01
T138749
Retaining Ring Removal
03
0320
14
JK11466,00000CF –19–09APR03–3/78
3. Insert two sheet metal screws into the rubber showing

–UN–20JUL01
T138750
Drive Shaft Seal Removal

081403
PN=262
4. Use seal driver to press in the new seal.
–UN–20JUL01
T138751
Drive Shaft Seal Installation
03
0320
15
JK11466,00000CF –19–09APR03–5/78
5. Use pliers to install the retaining ring.
6. Remove the tape from the drive shaft spline.
–UN–20JUL01
T138749
Retaining Ring Installation

081403
PN=263
03
0320
16
–UN–13AUG01
T138753
Charge Pump
1—Hydrostatic Drive Pump 4—Key 7—Pinion Gear 10—Housing

2—Retaining Ring 5—O-ring 8—Driven Gear 11—Screw
3—Pinion Gear Shaft 6—Valve Plate 9—O-ring
Charge Pump
JK11466,00000CF –19–09APR03–7/78
1. Mark the position of the cover plate to ease

re-assembly.
2. Remove the mounting screws.
3. Pry off the cover.

–UN–20JUL01
4. Remove and discard the seals.

T138754
Charge Pump Hosing Alignment Mark

081403
PN=264
NOTE: If serious wear is detected on any of the pump

components, the complete charge pump assembly
must be replaced.
5. Inspect the o-ring groove and the wear surface of the

valve plate.
–UN–20JUL01
Remove the pinion gear and inspect the teeth and
bearing surfaces for wear.
T138755
6. Replace the seals. Grease the o-rings prior to
installation and make sure they are seated properly in
their grooves.
03
0320
17
JK11466,00000CF –19–09APR03–9/78
7. When re-assembling the pinion gear and driven gear

make sure the chamfers are installed facing down into
the housing as shown.
Tighten the charge pump mounting bolts to the

specified torque.
–UN–13AUG01
T138756
Pinion Gear and Driven Gear Installation

081403
PN=265
Control Piston Cover Seals Replacement
1—Hydrostatic Drive Pump

2—O-ring
3—O-ring
4—Control Piston Cover
–UN–20JUL01
5—Adjustment Screw Lock Nut
6—Screw
T138757
Control Piston Covers
03
0320
18
JK11466,00000CF –19–09APR03–11/78
1. Mark the position of the cover plate to ease

re-assembly.
–UN–20JUL01
T138758
Control Piston Cover Alignment Mark

081403
PN=266
3. Rotate the cover. Remove the cover by tapping it

gently with a rubber mallet.
–UN–20JUL01
T138759
Control Piston Cover Removal, Rubber Mallet
03
0320
19
JK11466,00000CF –19–09APR03–13/78
4. Replace the o-ring.
–UN–20JUL01
T138760
Control Piston Cover O-ring Replacement

081403
PN=267
5. Mark cover position to ease re-assembly.
6. Measure the length of screw.
7. Use Allen key to hold adjustment screw. Use wrench to

loosen and remove nut.
–UN–13AUG01
T138761
Control Piston Cover Alignment Mark, Adjustment Screw
03
0320
20
–UN–13AUG01
T138785
JK11466,00000CF –19–09APR03–15/78
–UN–20JUL01
T138762
JK11466,00000CF –19–09APR03–16/78
9. Rotate cover to remove.

–UN–20JUL01
T138763

081403
PN=268
10. Replace the two o-rings. Inspect the o-ring seats and
sealing surfaces.
11. Install cover. Install locknut using measurement taken

in Step 6.
–UN–20JUL01
IMPORTANT: Check control piston centering
adjustment after re-installing the
covers. See this Section 03, Group
0361, for the procedures.
T138764
1—O-rings
Control Piston Cover - O-rings and Sealing Surfaces
2—O-ring Seats
3—Sealing Surfaces
03
0320
21
JK11466,00000CF –19–09APR03–18/78
Charge Pressure Relief Valve or Valve Seal

Replacement
1. Remove the Charge Pressure Relief Valve.
–UN–20JUL01
T138219
Hydrostatic Drive Pump, Charge Pressure Relief Valve

081403
PN=269
2. Replace the o-ring. Inspect the o-ring seats and

sealing surfaces.
3. Re-install the Charge Pressure Relief Valve
IMPORTANT: Do not change the position of the
–UN–20JUL01
adjustment screw. Check the valve
setting after re-installing the valve. See
Section 03, for procedures to adjust the
valve.
T138766
Charge Pressure Relief Valve
03
0320
22

081403
PN=270
High Pressure Relief Valves or Valve Seal

Replacement
IMPORTANT: If the lock nut is to be removed to

disassemble the valve, measure and
record the length of the adjustment
–UN–20JUL01
screw.
1. Remove the High Pressure Relief Valve.
T138767
sealing surfaces.
Hydrostatic Drive Pump, High Pressure Relief Valve
3. Re-install the High Pressure Relief Valve.

03
adjustment screw. Check the valve 0320
setting after re-installing the valve. See 23
Section 03 for procedures to adjust the
valve.
1—Lock Nut
High Pressure Relief Valve –UN–20JUL01

T138768

081403
PN=271
Replacing the Pressure Cut-off Valve
IMPORTANT: If the lock nut is to be removed to

disassemble the valve, measure and
record the length of the adjustment
screw.
–UN–20JUL01
1. Remove the Pressure Cut-off Valve.
T138769
sealing surfaces.
3. Re-install the High Pressure Relief Valve. Hydrostatic Drive Pump, Pressure Cut-off Valve

adjustment screw. Check the valve
03
0320 setting after re-installing the valve. See
24 Section 03, for procedures to adjust the
valve.
1—Lock Nut
–UN–20JUL01
T138770
Pressure Cut-off Valve


081403
PN=272
03
0320
25
–UN–20JUL01
T138773
Hydrostatic Drive Pump dissassembly
1—Housing 4—Rotary Group 6—Port Plate 8—Charge Pump

2—Control Piston Cover 5—Hydraulic Pilot Control 7—Valve Plate 9—Indexing Screw
3—Control Piston Assembly Device
Drive Pump Disassembly
JK11466,00000CF –19–09APR03–23/78
1. Remove the control device.
–UN–20JUL01
T138221
Hydrostatic Drive Pump, Control Device

081403
PN=273
2. Remove the charge pump assembly.
NOTE: Mark the position of the charge pump assembly to

ease re-assembly.
–UN–20JUL01
T138831
Hydrostatic Drive Pump, Charge Pump
03
0320
26
JK11466,00000CF –19–09APR03–25/78
3. Mark the position of the indexing screw (A).
Measure and record the length of the screw.
Rotate the screw to the disassembly position (B).
–UN–13AUG01
T138775
Hydrostatic Drive Pump, Indexing Screw

081403
PN=274
4. Remove the mounting screws on the port plate.
NOTE: Mark the position of the port plate to ease

re-assembly.
–UN–13AUG01
T138777
Hydrostatic Drive Pump, Port Plate Mounting Screws
03
0320
27
JK11466,00000CF –19–09APR03–27/78
5. Lift off port plate and control plate.
NOTE: Note the position of the control plate and indexing

screw.
Replace seal.
–UN–13AUG01
T138752
Hydrostatic Drive Pump, Port Plate Removal, Seal

081403
PN=275
6. Use a pry bar to push down the cylinder assembly (A).
Remove the indexing screw (B).
–UN–13AUG01
T138778
Hydrostatic Drive Pump, Pry Bar, Cylinder Assembly, Indexing
Screw
03
0320
28
JK11466,00000CF –19–09APR03–29/78
7. Remove the cylinder assembly.
–UN–13AUG01
T138779
Hydrostatic Drive Pump, Cylinder Assembly Removal

081403
PN=276
8. Use pliers to remove the retaining ring.
–UN–20JUL01
T138749
Retaining Ring Removal
03
0320
29
JK11466,00000CF –19–09APR03–31/78
9. Remove the radial seal ring.
Insert two sheet metal screws into the rubber showing

–UN–20JUL01
T138750
Hydrostatic Drive Pump, Retaining Ring and Radial Seal Removal

081403
PN=277
10. Use a rubber mallet to remove the drive shaft.
–UN–13AUG01
T138781
Hydrostatic Drive Pump, Drive Shaft Removal
03
0320
30
JK11466,00000CF –19–09APR03–33/78
11. Remove swashplate, bearings and bearing cups.
–UN–13AUG01
T138782
Hydrostatic Drive Pump, Swashplate, bearings, Bearing Cups
Removal

081403
PN=278
12. Remove joint pins.
–UN–20JUL01
T138783
Hydrostatic Drive Pump, Joint Pins Removal
03
0320
31
JK11466,00000CF –19–09APR03–35/78
Drive Pump Cylinder Disassembly
1. Remove the piston retaining plate with the pistons.
–UN–13AUG01
T138791
Cylinder Disassembly, Piston and Retaining Plate Removal

081403
PN=279
2. Remove the retaining ball and cup spring assembly.
–UN–13AUG01
T138792
Cylinder Exploded View, Retaining Ball, Cup Springs
03
0320
32
JK11466,00000CF –19–09APR03–37/78
3. Remove the retaining ring.
–UN–13AUG01
T138793
Cylinder Section, Retaining Ring Removal

081403
PN=280
4. Remove spring and discs.
1—Disc
2—Spring
3—Disc
4—Safety Ring
–UN–13AUG01
T138794
Cylinder Section, Spring and Discs
03
0320
33
JK11466,00000CF –19–09APR03–39/78
–UN–13AUG01
T138784
Hydrostatic Drive Pump, Control Piston
Control Piston Disassembly and Assembly
To disassembly the control piston

081403
PN=281
1. Measure and record the length of the screw on the

control piston cover. This measurement is needed to
set up the control piston zero-position during
re-assembly.
2. Remove the nut.
–UN–13AUG01
T138785
JK11466,00000CF –19–09APR03–41/78
3. Remove the cover.

03
0320 NOTE: Mark the position of the cover to ease
34 re-assembly.
–UN–13AUG01
T138786
JK11466,00000CF –19–09APR03–42/78
4. Remove the mounting screws on the other cover.
Rotate the cover 1/8 turn. Tap the cover off with a
rubber mallet.
NOTE: Mark the position of the cover to ease
–UN–13AUG01
re-assembly.
T138787
JK11466,00000CF –19–09APR03–43/78
5. Remove the control piston.

–UN–13AUG01
T138788

081403
PN=282
6. Disassemble the control piston.
Use an open cylindrical tool to pre-load the spring.
Remove the take-off ring.
–UN–13AUG01
1—Take-off Ring
T138789
JK11466,00000CF –19–09APR03–45/78
CAUTION: Use care when removing rings. Parts

03
are under spring load.
0320
35
7. Remove ring from shaft.
Remove retaining ring.
–UN–13AUG01
To assembly the control piston
T138790
JK11466,00000CF –19–09APR03–46/78
1. Use open cylindrical tool to pre-load spring. Install

rings. Install retaining ring.
–UN–13AUG01
T144380
JK11466,00000CF –19–09APR03–47/78
2. Install take-off ring.

–UN–13AUG01
T144381

081403
PN=283
3. Lubricate piston. Insert control piston into the housing.
Drive Pump Component Inspection
NOTE: Take care if reworking parts. Abrasives can

damage sealing surfaces.
–UN–13AUG01
Inspect the following components
• All sliding surfaces for scoring or wear.
T138788
• All seal seats for nicks and burrs.
• Bearings and bearing cups.
• Bearing surfaces of swashplate.
• Piston sliding surface of swashplate.
• The piston retaining plate.
• The drive shaft.
03
0320
36 Check the following components or issues
• Splines for damage and fretting.

• The running surfaces for wear
• For groove cut by shaft seal.
JK11466,00000CF –19–09APR03–49/78
Inspect the pistons.
Check the following components or issues
• There are no scratches or metal deposits on the sliding

surfaces.
–UN–13AUG01
• The shoes swivel smoothly.
• There is no lengthwise play between the piston and the
shoe.
NOTE: If any are damaged, the pistons must be replaced T138800
as a set.
Hydrostatic Drive Pump, Pistons
Inspect the following components or issues
• The cylinder bores and splines.

081403
PN=284
• The cylinder surface and control plate.
–UN–13AUG01
T138801
Hydrostatic Drive Pump, Cylinder Bores and Splines
03
0320
37
JK11466,00000CF –19–09APR03–51/78
• The positioning piston and link.
–UN–13AUG01
T138802
JK11466,00000CF –19–09APR03–52/78
–UN–13AUG01
T138803
Hydrostatic Drive Pump, Positioning Piston and Link

081403
PN=285
Rotary Group Assembly
1. Install bearing cup set in pump housing.
–UN–29AUG01
T138808
Hydrostatic Drive Pump Housing, Bearing Cups
03
0320
38
JK11466,00000CF –19–09APR03–54/78
2. Assemble bearings. Wire gliding stone and articulating

pin on the swashplate.
–UN–30APR01
T138809
Swashplate, Bearings Pre-assembly

081403
PN=286
3. Install the assembled swashplate in the housing.
NOTE: Be sure the swashplate is seated correctly.
After installing swashplate, remove any clamps used

during assembly.
–UN–29AUG01
T138848
Hydrostatic Drive Pump Housing, Swashplate Installation
03
0320
39
JK11466,00000CF –19–09APR03–56/78
4. Install joint pins.
–UN–29AUG01
T138810
Hydrostatic Drive Pump Housing, Articulating Pins Installation

081403
PN=287
5. Install rotary group assembly tool on pump housing.
–UN–29AUG01
T138811
Hydrostatic Drive Pump Housing, Rotary Group Assembly Tool
03
0320
40
JK11466,00000CF –19–09APR03–58/78
6. Install drive shaft in housing.
Install bearings and radial seal rings.
–UN–29AUG01
T138812
Hydrostatic Drive Pump Housing, Drive Shaft, Bearings, Seals

081403
PN=288
7. Install spring and discs as shown.
Install safety ring.
1—Disc
2—Spring
–UN–13AUG01
3—Disc
4—Safety Ring
T138794
Cylinder Section View, Spring, Discs, Safety Ring
03
0320
41
JK11466,00000CF –19–09APR03–60/78
8. Assemble rotary group.
–UN–29AUG01
T138814
Rotary Group

081403
PN=289
9. Lubricate pistons. Install pistons in cylinder.
–UN–29AUG01
T138815
Cylinder, Pistons Installation
03
0320
42
JK11466,00000CF –19–09APR03–62/78
10. Lubricate piston shoes and sliding surface of

swashplate. Install cylinder in housing.
Remove rotary group assembly tool.
–UN–29AUG01
T138816
Cylinder Installation, Rotary Group Assembly Tool, Pump Housing

081403
PN=290
Hydraulic Pilot Control Device or Device Seals

Replacement
1. Remove the mounting bolts. Remove the control

device.
–UN–20JUL01
T138221
Hydrostatic Drive Pump, Pilot Control Device
03
0320
43
JK11466,00000CF –19–09APR03–64/78
2. Replace the o-rings. There are three o-rings on the

front face and three on the underside.
3. Re-install the Control Device.
IMPORTANT: Check control piston centering
–UN–20JUL01
adjustment after re-installing the
Control Device. See this Section 03,
Group 0361, for the procedures.
T138772
Pilot Control Device, O-ring Seals

081403
PN=291
Mechanical Centering of Pump
NOTE: The control piston has strong centering springs to

ensure that once the pump is adjusted for the
neutral position it will always return to neutral.
When a control piston is exchanged or replaced, it
–UN–29AUG01
is generally necessary to mechanically center the
pump.
1. To ensure there is equal pressure on both sides of the
T138826
control module during the centering operation, it is
necessary to connect the X1 and X2 ports together by
means of hose or tubing no less than a 1/4 in. ID. The Hydrostatic Drive Pump, X1, X2 Connected; Gauges on MA and
MB
port sizes are 9/16" - 18 UNF.
2. Install 60 MPa (9000 psi) gauges at ports MA and MB

03
0320 on the Hydrostatic Drive Pump.
44
3. Engage the parking brake.
4. Run the engine at specified idle.
5. Press the drive pedal slowly to drive the machine

against the brakes. Operate valves with small pump
flow volume.
IMPORTANT: Do not drive against the parking brake

for more than 20 seconds at a time. Oil
bypassing the valves may overheat
causing equipment damage.
6. Loosen the jam nut on the Control Piston Adjustment

Screw.
Turn the adjusting screw until 1000 psi is read on MA

or MB then turn screw opposite direction until 1000 psi
is read on other pressure port. Turn the screw back,
splitting the distance between the previous two
positions. This should be the neutral position. Pressure
on MA and MB should be equal.
7. Tighten jam nut. Stop the engine. Remove the gauges.

Remove the hose connecting ports X1 and X2.

081403
PN=292
Hydraulic Centering of Control Module
NOTE: When control modules are exchanged or

replaced, it is generally necessary to center the
new module.
1. Install 60 MPa (9000 psi) gauges at ports X1 and X2 on

the Hydrostatic Drive Pump.
2. Install 60 MPa (9000 psi) gauges at ports MA and MB

on the Hydrostatic Drive Pump.
3. Engage the parking brake.
4. Press the drive pedal slowly to drive the machine

against the brakes. Operate valves with small pump
03
flow volume. 0320
45
IMPORTANT: Do not drive against the parking brake
for more than 20 seconds at a time. Oil
–UN–29AUG01
bypassing the valves may overheat
causing equipment damage.
5. Turn the adjusting screw so that gauges on ports X1
T138827
and X2 both show the same value.
IMPORTANT: The adjustment screw is an eccentric, Hydrostatic Drive Pump, X1, X2, MA, MB, Adjustment Screw
therefore, turning more than 90° in
either direction will have no further
centering effect, and could cause
damage to the eccentric pin.

081403
PN=293
NOTE: With Y1 and Y2 ports vented to atmosphere,

neutral position of the HD control is correctly
adjusted when any or all of the following
conditions exist:
• Approximately, when equal control pressures
–UN–29AUG01
are obtained at control pressure ports X1 and
X 2.
• The hydraulic motor does not turn when the
brake is released.
T138828
• Charge pressure is registered equally at ports
MA and MB , when flow output of the pump is
deadheaded against a locked motor.
1—Feedback Spring
2—Lever Arm
If difficulties are encountered in obtaining neutral position
of the control modules, check that the ends of the control
03
0320 spring are correctly located in the grooves near the end of
46 the feedback lever arms.
JK11466,00000CF –19–09APR03–68/78
Changing the Charge Pressure Filter
NOTE: The manufacturer recommends that the charge

filter be changed at least every 500 hours of
operation.
To change the charge filter:
1. Unscrew and remove the filter.
2. Clean the filter head gasket surface.
3. Lubricate the seal on the new canister with oil.

–UN–09APR02
4. Screw on the filter until the seal makes contact with the
housing. Use a filter wrench to tighten the canister 30°
further.
T153758

081403
PN=294
Assembly of Pump
1. Because the driveshaft rotates in the right hand

direction, the control plate and indexing pin must be
installed as shown.
–UN–29AUG01
T138817
JK11466,00000CF –19–09APR03–70/78
2. Position the nut on the indexing screw at the specified

basic setting. 03
0320
Pump Assembly—Specification 47
Indexing Screw—Basic Setting ...................................... 20 mm ±0.75 mm
–UN–29AUG01
T138849
JK11466,00000CF –19–09APR03–71/78
3. Insert the control plate.
Use a pry bar to push down the cylinder. Install the

indexing screw.
–UN–29AUG01
T138818

081403
PN=295
The control plate and indexing screw must be installed

as shown.
–UN–29AUG01
T138819
03
0320
48
–UN–29AUG01
T138820
JK11466,00000CF –19–09APR03–73/78
4. Install the port plate.
NOTE: Use care during assembly of spring loaded parts.
–UN–29AUG01
T138821
JK11466,00000CF –19–09APR03–74/78
5. Turn indexing screw to correct length measured during

disassembly.
–UN–29AUG01
T138822

081403
PN=296
6. Install control piston covers.
–UN–29AUG01
T138823
JK11466,00000CF –19–09APR03–76/78
7. Install charge pump assembly.

03
0320
49
–UN–20JUL01
T138831
JK11466,00000CF –19–09APR03–77/78
8. Install hydraulic pilot control device.
Adjust the control piston zero position. See this Section

03, Group 0361, for the procedure.
–UN–20JUL01
T138221
JK11466,00000CF –19–09APR03–78/78
Bleeding the Drive Hydraulics
If air enters the working or driving hydraulic system while

parts are changed, the air must be eliminated from the
components affected before the machine can be operated
again.
Continued on next page EL62757,00001EF –19–26NOV02–1/8

081403
PN=297
–UN–07APR03
03
0320
50
T189332
810D, 1110D and 1410D Drive hydraulic bleeding
B—Drive pump bleed connect,

Drive motor bleed connect

081403
PN=298
A—Drive pump bleed connect, Drive motor bleed

connect
–UN–08NOV02
03
0320
T161498
51
1010D Drive hydraulics bleeding: Drive pump
–UN–08NOV02
T161495
1010D Drive motor bleeding

081403
PN=299
Air must be eliminated from the driving hydraulics after the

system has been serviced or repaired, before the machine
is used again. During the operation oil will come out from
the hoses. Drain oil into a container.
1. If necessary, add first clean, filtered hydraulic oil to the

housings of the drive pump and drive motor through
the bleed connects until the housings are half full.
2. Next, fill up the hydraulic tank. Make sure that the

low-pressure hose of the drive pump is also filled with
oil (loosen the hose connector for the fill-up).
1—Drive pump bleed connect
–UN–28MAR02
B—Drive motor bleed connect
03
0320
52
T153142
1710D Drive hydraulics bleeding
A B
217 –UN–19MAR02
216
T152684
1710D drive hydraulics bleeding

081403
PN=300
3. Disconnect the wire connector at the stopping solenoid

(Y01) above the injection pump in order to prevent the
engine from starting during the bleeding process.
In models 1110D and 1710D do the following: Press

down the emergency stopper in the instrument panel to
–UN–08OCT02
ensure that the engine will not start during the air
bleeding process
T160264
Y01
810D, 1010D and 1410D Stopping solenoid Y01
03
0320
53
EL62757,00001EF –19–26NOV02–5/8
4. Make sure that the switch for driving direction is in the

center position. This ensures that the drive pump stays
at a zero angle. OR in models 810D and 1010D:
Disconnect the solenoids (Y102, Y103) from drive
direction valve.
–UN–07APR03
T189333
810D and 1010D Y102 and Y103 solenoids

081403
PN=301
5. Connect bleed hoses (thread size M16x2) to the

measuring points (204), (206) and (214) of the driving
hydraulics located at the drive pump
–UN–07APR03
T189333
03
0320 810D, 1110D, 1410D and 1710D Measuring points and
54 solenoids
EL62757,00001EF –19–26NOV02–7/8
in model 1010D Connect bleed hoses (thread size

M16x2) to the measuring points (205), (207) and (216)
of the driving hydraulics located at the drive pump
6. Operate the starter motor for appr. five seconds and

repeat the starting procedure after waiting one minute
(do this 3 ... 5 times), until no more air comes out of
the bleed hoses.
7. Disconnect the bleed hoses
8. Connect the stop solenoid and / or drive direction valve

solenoids.
–UN–11NOV02
T161492
EL62757,00001EF –19–26NOV02–8/8

081403
PN=302
Hydrostatic Pump and Motor Start-up

Procedure
NOTE: The following start-up procedure should always be

followed when the hydrostatic pump or motor has
been removed or replaced.
CAUTION: The machine must be parked with

the decking blade lowered to the ground, the
boom grapple and booms placed at rest, the
engine shut down and the wheels chocked
before any work on the hydraulic system is
initiated. Failure to take adequate safety
precautions can lead to serious personal injury.
The hydrostatic drive pump components are accessible 03

0320
when the cab is tilted to the service position.
55
Make certain all system components (hoses, fittings, etc.)

are clean prior to filling with fluid. Fill the tank with the
recommended hydraulic fluid. See the Section 00, Group
0040, for Recommended Fluid Specifications.
1. Release the brakes and jack up the wheels.
OUTJ003,00002F9 –19–18JAN01–1/6
2. Fill the hydrostatic pump and motor housings with

clean hydraulic fluid through the upper case drain port.
Fill the high pressure lines.
3. Fill the inlet line leading from the tank to the

hydrostatic pump. Check the line to make certain it is
–UN–20JUL01
free of restrictions and air leaks. Make certain the

fittings are properly tightened.
1—Hydrostatic Drive Pump Case Drain Port

T138829
2—Hydrostatic Drive Motor Case Drain Port
Continued on next page OUTJ003,00002F9 –19–18JAN01–2/6

081403
PN=303
4. Install a 5.0 mPa (1000 psi) pressure gauge to the

Charge Pressure Test Port MH1 on the Hydrostatic
Drive Pump to monitor the charge pressure during
start-up.
5. To ensure the engine will not fire when the starter
–UN–20JUL01
motor is cranked, disconnect the Fuel Shut-off
Solenoid Y55 on the engine.
T138830
03
0320
56

081403
PN=304
CAUTION: Do not crank the starter motor

unless the pump is in the neutral position (0
degrees swashplate angle). Take precautions to
prevent the machine from moving in case the
hydrostatic pump is actuated during start-up.
–UN–20JUL01
6. Crank the engine a few times, in short bursts, until
charge pressure reaches 50 psi or more, to prime the
pump and relieve trapped air. Excess air may be bled
from the drive system test port MH2.
T138250
7. Reconnect the wire connector (Y55) to the fuel shutoff
valve and start the engine. Run the engine at the
lowest possible RPM (750 RPM if possible) for 5
minutes. This will allow the system to be filled.
03
NOTE: Listen for abnormal noises during procedure. 0320
57
Stop the engine and inspect all hose connections for

leaks.
8. It is recommended that the directional control solenoids

Y102 and Y103 on the Direction Selection Valve be
disconnected until after initial start-up. This will ensure
that the pump remains in its neutral position.
9. Once the charge pressure has been established,

increase engine speed to specified value.
Hydrostatic Pump Start-up Procedure—Specification

Normal Engine—Speed ............................................................. 1850 RPM
10. Check the Charge Pressure on the gauge on test port

MH2. The charge pressure should be the specified
value. If the charge pressure is inadequate, shut
down and determine the cause for improper pressure.
Hydrostatic Pump Start-up Procedure—Specification

MH2—Pressure .................................... 3.0 mPa ± 0.2 mPa (435 psi ± 30
psi)
11. Operate the control to work the hydrostatic system

with no load at 20% of maximum speed. Deaerate the
system by bleeding air from the drive system test port
MH2.
Check the fluid level and add fluid, if necessary.

081403
PN=305
12. Continue to operate the system and gradually

increase to full speed, still with no load.
Check for creep in neutral. If necessary, center the

control module. See Section 03, Group 0361, for
procedures.
13. Reconnect the direction selection solenoids Y102 and

Y103. Lower the wheels. Start the engine, making
certain that the pump remains in neutral. Disengage
the parking brake. With the engine at normal speed
(1850 RPM), slowly move the machine forward and
backward approximately 30 cm (12 in.).
The charge pressure may decrease slightly during

forward or reverse operation. Continue to cycle slowly
03
0320 between forward and reverse for at least five minutes.
58
14. Check, and if necessary adjust the High Pressure
Relief Valves. See Section 03, Group 0361, for the
procedures.
15. Operate the system with no load for 15 minutes to

stabilize the temperature and remove any residual air
from the fluid.
OUTJ003,00002F9 –19–18JAN01–5/6
16. Replace the charge filter.
17. Shut down the engine, remove gauges and plug the
ports. Check the level in the tank and add hydraulic
fluid if needed.
–UN–29AUG01
18. Purge the system of air. See Section 03, Group 0360,
for procedures to bleed air from the hydrostatic
system.
T138833
NOTE: Air in the system may lead to erratic operation.
1—Charge Filter
OUTJ003,00002F9 –19–18JAN01–6/6

081403
PN=306
Group 0325
Checking and Adjusting Drive Hydraulics
1010D Checking and Adjusting
Charge Pressure
1. Connect a pressure transducer (0 ... 6 MPa) (0...870

psi) to measuring point (205).
2. Set the engine rpm’s to 1600.
The pressure should be 3,0 ± 0,2 MPa (435 ± 29 psi).
3. If necessary, adjust the pressure with adjusting screw

(208).
–UN–11NOV02
03
0325
1
T161491
1010D Measuring points 205 and 208
Continued on next page EL62757,00001F2 –19–26NOV02–1/7

081403
PN=307
Pilot Pressure
NOTE: Adjusting the drive pedal - look paragraph 8 for

instructions.
1. Connect he pressure transducer (0 ... 6 MPa) (0... 870

psi)to the measuring point (219) (at the fuel tank).
2. Select the driving direction ’neutral’.
3. Start the engine. When the drive pedal is in the upper
–UN–21NOV02
positon the pressure should be 0 + 0,1 MPa (0 + 14,5
psi).
4. Fully depress the drive pedal (the pilot valve drops
T161875
down). The pressure should be 3,0 ± 0,2 MPa (435 ±
03
0325 29 psi). If needed adjust the lenght of the cable coming
2 from the rear pedal to pilot valve with the help of a ball 1010D Measuring point 219
joint (3) at the valve side.
• Lenghtening will decrease the pressure.

• Shortening will increase the pressure. In some cases
you may need to:
– expand the pressure adjustment range by
loosening the screws (4) in the valve and moving
the valve upward (millimeter at a time)
–UN–11NOV02
– reduce the range by lowering the valve in its
fastening
NOTE: The stopping screw beneath the pedal has to be
felt when you press the drive pedal.
T161595
1010D, Checking pilot pressure

081403
PN=308
Drive Pressure
1. Connect pressure transducers (60 MPa) (8702 psi) to

measuring points (207) (forward) and (216) (reverse).
2. Disconnect the parking brake solenoid, Y41 from the

valve block so the parking brake will stay engaged.
–UN–08NOV02
3. Set the engine rpm’s to 1800.
4. Drive the machine both forward and backward against
T161495
the parking brake. Do not do this longer than 20
seconds at a time.
1010D Measuring point 216
5. The pressure should rise to 41,0 ± 0,5 MPa (5976 ± 72

psi) (both directions).
03
0325
6. If necessary, adjust the pressure with adjusting screw 3
(211).
NOTE: After the adjustmet, lock the adjustment screws to
–UN–08NOV02
16 Nm. Check the pressures after the locking.
7. Fit the parking brake solenoid Y41 back into the valve
and tighten the lockscrew hand tight.
T161496
8. Stop the engine.
1010D Parking brake solenoid Y41
–UN–20NOV02
T161514

081403
PN=309
Function of DA Cartridge Valve
1. Connect pressure transducer (6.0 MPa) (870 psi) to

measuring point (214).
2. Disconnect the parking brake solenoid, Y41 from the

valve block so the parking brake will stay engaged
3. Set the engine rpm’s to 1600 with the help of manual

throttle control.
4. The right setting for the DA Cartridge valve is 1,7 ±

0,05 MPa (246 ± 7,25 psi)
–UN–08NOV02
5. If necessary adjust the value with adjusting screw (1).
03
0325 6. Remove the pressure sensors and reconnect the
4 parking brake solenoid (Y41) ) and tighten the
T161488
lockscrew hand tight.
Motor Control Starting Point 1010D Measuring point 214 and adjusting screw (1)
–UN–08NOV02
T161496
1010D parking brake solenoid

081403
PN=310
–UN–21NOV02
T161875
03
0325
1010D Measuring point 219 5
1010D Measuring point 221 –UN–18NOV02

T161493
–UN–18NOV02
T161490
1010D
Continued Measuring
on next page point 226 EL62757,00001F2 –19–26NOV02–5/7

081403
PN=311
1. Connect a pressure transducer (6 MPa) (870 psi) to

measuring point (219) (at fuel tank) and pressure
transducer (60 MPa) (8700 psi) to (221) (between the
attachement block and the brake valve).
2. Disconnect the parking brake solenoid, Y41, to prevent

the machine to move.
3. Start the engine and let it idle. Select drive direction

neutral.
4. Start to press the drive pedal smoothly. When the

pressure at (219) raises to 1,4 ± 0,05 MPa (203 ± 7,25
psi), the pressure at (221) starts to rise.
5. If the pressure at (221) reaches the value 2,0...3,0

03
0325 MPa (290...435 psi) before the measuring point (219)
6 reaches 1,4 ± 0,05 MPa (203 ± 7,25 psi), turn the
adjusting screw (226) clockwise in small increments
and repeat the test.
6. If the pressure at (221) reaches the value 2,0...3,0

MPa (290...435 psi) after the measuring point (219)
has reached 1,4 ± 0,05 MPa (203 ± 7,25 psi), turn the
adjusting screw (226) counterclockwise in small
increments and repeat the test again.
7. Reconnect the parking brake solenoid plug (Y41) on

the wire harness and tighten the lockscrew hand tight.
Drive Pedal Adjustment
The drive pedal valve controls the displacement of the

hydrostatic drive pump. Pump displacement determines
the speed of the machine.
The drive pedal valve is operated by a control cable from

the drive pedals. The drive pedals are connected by a rod
under the cab floor. Either pedal can be used depending
on the direction the seat is facing.
See Section 03, hydrostatic drive system, for more

information.

081403
PN=312
03
0325
7
–UN–20JUL01
T138190
Drive Pedals and Drive Pedal Valve
1. The pedals are delivered ready-adjusted. If that the engine pilot voltage, coming from the
necessary adjust the high limit of the pedals’ move potentiometer, is 4 ± 0,2 V (charge voltage = 5,0
range by changing the length of the control lever ( V).
through the floor, from the bottom of the pedal) to
42° angle. Pedal’s nominal angle is then 17°.
a. Adjust the stop screw of the lever (situated in 3. Alternatively the potentiometer can be adjusted by
the adapter plate of the potentiometer) so that mesuring the total resistance between the pins
potentiometer’s control voltage of the engine is 1 X19/1 and X19/3.
± 0.2 V in pin X19/2, supply voltage 5.0 V in pin
X19/1 and minus pin X19/3. a. Keeping the pedal up, adjust the potentiometer’s
stop screw so that the recistance between the
b. Check that the roll of the potentiometer doesn’t pins X19/2 and X19/3 is 1/5 from the total
touch the counterpart during the adjustment. recistance which was measured earlier.
Finaly adjust the clearance of the
potentiometer’s counterpart from the roll to b. Pedal’s down-position is adjusted so that the
approximately 2 mm (0,08 in) during the pedal is recistance between pins X19/1 and X19/2 is
in the upper position. between 1/5 from the total recistance which was
measured earlier.
2. Limit the movement of the pedal (pedal down),
using a adjustment screw of the frame piece, so
EL62757,00001F2 –19–26NOV02–7/7

081403
PN=313
Charge pressure (810D supply pressure)
1. Disconnect the parking brake solenoid Y41 from the

valve block. After this, the parking brake will stay
engaged
2. Connect a pressure gauge (0 ... 6 MPa) (0... 870 psi)
–UN–22AUG01
to pressure measuring point (204). When the engine
RPM is 1600, the pressure should be 2.8 ... 3.2 MPa
(406 ...464 psi).
T138248
(207).
4. Fit the solenoid into the valve and tighten the
lockscrew hand tight. Parking brake solenoid Y41 in valve block
Y41—Park brake solenoid

(204)—Measure point
(207)—Adjust screw
03
0325
8
–UN–19FEB03
T153143
1110D, 1410D and 1710D Pump pressures
–UN–07APR03
T189331
810 D drive pump pressure
EL62757,000019D –19–21APR02–1/1

081403
PN=314
Pressure Cut-Off Valve Setting of The Drive

Pump

valve block . After this, the parking brake will stay
engaged.
–UN–22AUG01
2. Connect pressure gauges (60 MPa) (8702 psi) to
measuring points (214) (forward) and (206) (reverse).
T138248
3. Engage high gear.
Parking brake solenoid Y41 in valve block
4. Drive the machine both forward and backward even
though the brake is on. Do not do this longer than for
five seconds at a time.
03
5. The pressure should rise to 45,0 + 0,5 MPa (6526,70 0325
psi) except in 1710D 43.0+0.5 Mpa(6234 + 72 psi) 9
(both directions).

(210) (forward/reverse).
7. After making the adjustment, check the pressures once

again.
8. Fit the solenoid into the valve and tighten the
–UN–28MAR02
lockscrew hand tight.
(206)—Measure point, drive pressure backwards
(210)—Adjust screw
(214)—Measure point, drive pressure forward
T153142
Drive pump adjust screw 210
–UN–19FEB03
T153143
Drive pump pressure measuring points
EL62757,000019F –19–21APR02–1/1

081403
PN=315
Pressure Cut-Off Setting for the Drive Motor
Youl need a Hand gauge (500 bar) (7251 psi) to read the
value.
EL62757,00001F7 –19–26NOV02–1/2
1. Connect pressure transducer to measuring point (207).
2. Drive full speed using the 1st gear.
Concurrently start to press the brake pedal smoothly

and observe the pressure rising at the gauge.
3. When the machine speed has been slowed down with

03 the help of the brake pedal (to 40 ... 80 % of the
0325 maximum speed), the pressure will stay constant. This
10 constant pressure (29,0 ... 30,0 MPa)(4206 ... 4351
psi) is the set value for the pressure cut-off setting.
NOTE: If the brake pedal is pressed too much and the
–UN–08NOV02
speed of the machine is slowed down below 40 %
of the maximum speed, the pressure starts to rise
ever to set value of the pump’s cut-off value, 41
MPa (5946 psi).
T161484
4. Adjust the value from the adjusting screw (225).
Clockwise the pressure increases and to Measuring Point 207
counterclockwise the pressure decreases.
5. Repeat the test
–UN–11NOV02
T161596
Adjusting screw 225
EL62757,00001F7 –19–26NOV02–2/2

081403
PN=316
1710D Checking and adjusting drive motors

pressure cut-off settings
Drive motor cut-off Pressure 31 MPa (4496 psi)
03
0325
11

081403
PN=317
The tools needed: 3-mm hex key and 10-mm wrench

valve block. After this, the parking brake will stay
engaged.
2. Connect a pressure sensor to measuring point (206)
(...60 MPa) (0...8702 psi) and a pressure gauge to
measuring point (216) (...60 MPa) (0...8702 psi)
3. Disconnect the connector of the motor steering (pos.
C)
4. Connect a 24 V tension with a separate cable from the
power outlet next to the main switch to the motor
steering (pos.C).
5. Start the engine
6. Engage high gear and rear wheel drive. Let it idle.
7. Select the driving direction forward. A
03 B
0325 8. Set the adjustable speed range (snail) to 15 %
12 9. Press smoothly the drive pedal, the pressure will first 217
start to rise at measuring points (216) and (206).
10. The engine rpm and the pressures are increasing, but
–UN–19MAR02
at a certain point the pressure of (216) stops to
increase and finally it starts to decrease.
11. When the pressure at (206) reaches 31 MPa (4496
psi) the pressure at (216) should then be 14 ± 2 MPa 216
(2030 ± 290 psi).
T152684
C
a. If (206) reaches 31 MPa (4496 psi) and the value
at (216) is higher than 14± 2 MPa (2030 ± 290 psi) 1710D Hydraulic motor
, turn the adjusting screw (217) counterclockwise
in small increments and repeat the test.
b. If (206) reaches 31 MPa (4496 psi) and the value
at (216) is lower than 14± 2 MPa (2030 ± 290 psi),
turn the adjusting screw (217) clockwise in small
increments and repeat the test.
C—Adjusting screw
(216)—Measure point,
(217)—Adjusting screw, cut-of
–UN–19FEB03
T153143
1710D Pump pressures

081403
PN=318
12. Disconnect the cable between the power outlet and

the position C
13. Connect back the connector of the motor steering
(pos. C) .
14. After making the adjustment, fit the solenoid into the
valve and tighten the lockscrew hand tight
–UN–22AUG01
24V—Current
Y41—Solenoid
T138248
03
0325
13
–UN–20MAR02
T152801
24V Current
EL62757,00001A0 –19–21APR02–3/3

081403
PN=319
1410D and 1710D Checking the function of

hydrostatic flushing valve
The function of hydrostatic flushing valve is checked by

measuring the supply pressure (204).
1. Connect a pressure gauge to measuring points (204)

(0 ... 6 MPa) (0...870 psi) and (206) (0 ... 60 MPa)
(0...8702 psi) .
–UN–19FEB03
2. First, press the brake pedal all the way down
3. Press the accelerator pedal until the machine tries to
start moving.
4. The very moment the machine ’should’ start moving
T153143
(i.e. the pressure measuring point (206) rises) the
pressure at the measuring point (204) must drop by
03 appr. 0,1...0,6 MPa (14...87 psi).
(204)—Measure point, supply pressure
0325
(206)—Measure point, drive pressure backwards
14 NOTE: The hydrostatic flushing valve cannot be adjusted.
EL62757,000019E –19–21APR02–1/1

081403
PN=320
Group 0330
Work Hydraulics
Work Pump Theory of operation
03
0330
1
–UN–20JUL01
T138116
An Example of Work Pump
1— Pump Assembly 3—Load Sensing and Pressure 4—Load Sense Port 6—Pump Outlet
2—Case Drain Compensator Control 5—Pump Inlet
The working pump is a variable displacement, inline The pump is mounted on the hydrostatic drive pump
piston pump. The unit comprises two major assemblies auxiliary pad.
which are the pump assembly (1) and the
displacement control device (5).
Continued on next page OUTJ003,00002A7 –19–24OCT02–1/3

081403
PN=321
Work Hydraulics
03
0330
2
–UN–20JUL01
T138117
An example of Work Pump Section View
1—Housing 5—Valve Plate 9—Working Pistons and Shoes 12—Shaft Seal

2—Stroking Piston 6—Port Plate 10—Swash Plate S—Suction Port
3—Cylinder Barrel 7—Compensator Control 11—Drive Shaft P—Pressure Port
4—Spring 8—Control Piston
In operation, the drive shaft rotates the cylinder barrel. travel when the swashplate is angled at zero degrees
The cylinder barrel holds the nine working piston and (perpendicular to the axis of rotation). The piston has
shoe assemblies. The piston shoes are held in contact maximum travel when the swashplate is angled as far
with the face of the stationary swashplate. The working as possible (about 17 degrees). The speed of the dive
pistons are free to move in and out of the bores in the shaft remains constant. The further the piston moves,
cylinder barrel. the greater the displacement of the pump.
For the first half of a rotation, as a piston shoe rides The angle of the swashplate is determined by load
along the inclined swashplate the working piston conditions sensed in the compensator control
moves out of the cylinder bore drawing fluid from the assembly. If there is no load, a minimum flow is
suction port (S). During the second half of the rotation, delivered for cooling and lubrication only. This
the working piston moves back into the cylinder bore minimizes power usage and heating of the fluid.
forcing fluid out the pressure port (P).
The stroking piston (spring operated) and the control
The length of the working piston stroke depends on piston (hydraulically operated) position the swashplate
the angle of the swashplate. The piston has minimum in response to the compensator control.
Continued on next page OUTJ003,00002A7 –19–24OCT02–2/3

081403
PN=322
Work Hydraulics
The swashplate is normally held at its maximum angle same time, the pump operating pressure adjusts to the
by a spring (4) as well as system pressure on the actual load pressure plus a pressure differential
stroking piston (2). Inside the compensator control required for the control action. When the system is not
assembly, system pressure acts on a setting spring. demanding power, the load sense control will operate
When the system pressure overcomes the spring, fluid in stand-by mode.
is diverted to the control piston (8) reducing the angle
of the swashplate and reducing the output of the Typically, the differential pressure (LS delta pressure)
pump. When the system pressure falls below the is that between the pressure inlet and any service port
compensator setting, the spring in the compensator of the proportionally controlled boom control valve. The
control assembly returns to the normal position and the setting of the LS delta pressure is adjustable. The
spring on the Stroking Piston in the Pump Assembly factory setting is 2.5 MPa.(362 psi)
returns the swash plate to its maximum angle.
If the load pressure exceeds the system pressure
The second spool in the Compensator Assembly setting of 24.0 MPa(3480 psi), the displacement
determines the differential pressure required to control device de-strokes the pump until the correct
maintain constant output flow through an orifice of a pressure is re-established.
03
given size. 0330
3
Load sensing ensures that the pump always provides
only the amount of flow needed by the load. At the
OUTJ003,00002A7 –19–24OCT02–3/3

081403
PN=323
Work Hydraulics
Work Pump Start-up Procedure

–UN–20JUL01
Ensure that the tank and circuit are

clean and free of dirt before filling the
T138861
tank with hydraulic fluid. Always fill the
tank through the connector coupling
provided for this purpose. Hydraulic Tank, Filler Coupling
1—Filler Coupling
03
0330
4 1. Fill the tank with appropriate type of hydraulic fluid. To
ensure that the pump suction hose is also filled, keep
the pump suction hose connection loose during the
filling procedure.
See Section 00, Group 0040, for recommended

hydraulic fluid.
Loosen the pump suction hose fitting at the tank during

the filling procedure in order to bleed air and ensure
the pump suction hose is filled.
OUTJ003,0000321 –19–21JAN01–1/3
2. Before starting the engine, fill the pump with hydraulic

fluid through the case drain port. Also connect a bleed
hose to the measuring point on the auxiliary valve so
that trapped air will be purged as the pump is running.
1—Case Drain Port

–UN–20JUL01
T138862
Work Pump, Case Drain Port

081403
PN=324
Work Hydraulics
3. Connect a bleed hose to test port MP1 on the Auxiliary

valve so that trapped air will be purged once the pump
is running.
4. Ensure that the inlet and other hose connections are

tight.
–UN–22AUG01
5. To ensure that the engine will not fire when the starter
motor is cranked, disconnect the wire connector (Y55)
from the fuel shut-off valve..
T138863
6. Crank the engine few times, in short bursts, to prime
the pump and relieve trapped air. After that, remove Auxiliary Valve, MP1
bleed hose from the measuring point.
7. Reconnect the wire connector (Y55) onto the fuel

03
shut-off valve and start the engine, making sure that 0330
the pump is priming. Once fully primed, stop the 5
engine and check that all hose connections are leak
free.
Remove the bleed hose from the Auxiliary Valve.
8. Purge the system of air as detailed in Operator and

Service Manual, chapter 7.5.
Bleed the hydrostatic drive system of air. See Section

03, Group 0360, for procedures.
See instruction manuals
Rexroth A10VO Repair instruction
OUTJ003,0000321 –19–21JAN01–3/3

081403
PN=325
Work Hydraulics
Valves General
03
0330
6
–UN–15FEB03
T152780
1710D Auxiliary Valve
1—Pressure Reduction Valve 5—Test Port 119— Auxiliary 9—Solenoid Y33F — Front 13—Frame Brake Pressure
114— Parking Brake Functions Pressure Differential Lock Relief Valve
2—Pressure Reduction Valve 6—Solenoid Y41 — Parking 10—Solenoid Y33B — Rear 14—Solenoid Y65 — Frame
115— Auxiliary Functions Brake Differential Lock Brake Release
3—Test Port 111— System 7—Test Port 116— Load Sense 11—Solenoid Y39 — Rear
High Pressure Signal Pressure Drive Disengage
4—Solenoid Y208 — Constant 8—Pressure Switch W41A 12—Solenoid Y45 — Low Gear
Pressure (B5) — Parking Brake Select and Solenoid
Y46 — High Gear Select
The auxiliary valve solenoids control the following • Transfer Case High/Low Selection
functions: • Frame Brake
• Constant Control Pressure
• Parking Brake
• Front and Rear Differential Locks The Auxiliary Valve is located under the cab on the
• Rear Wheel Drive Engage fuel tank weldment.

081403
PN=326
Work Hydraulics
The boom control valve solenoids control the following

functions:
• Boom Slew
• Main Boom Up / Down
• Outer Boom Up / Down
• Extension Boom in / out
• Grapple Rotate
• Grapple Open / Close
• Steering
The boom control valve is located behind the cab at the

frame hinge.
–UN–08NOV02
03
0330
7
T161485
1010D Boom Control Valve
OUTJ003,00002A8 –19–09JAN01–2/5
The direction selection valve (only in 1010D)includes

solenoids which control the direction of the drive pump
output. The direction of flow determines the direction of
the machine.
The valve block also includes two work brake pressure
–UN–20JUL01
switches. The switches apply the work brakes when the
drive pedal pressure drops below 0.5 MPa (73 psi).
The direction valve is located on the fuel tank weldment.
See section 03, hydrostatic drive system, for more T138124

information. 1010D Direction Selection Valve

081403
PN=327
Work Hydraulics
–UN–11NOV02
03
0330
8
T161523
1010D Brake Pedal Valve
The brake pedals are used to apply the service brakes in

the axles. Either pedal can be used depending on the
direction the seat is facing.
The Brake pedal valves are located on the cab floor.
–UN–13OCT02
T152794
Brake pedal valve

081403
PN=328
Work Hydraulics
The brake valve includes:
The brake valve is located on the fuel tank weldment

under the auxiliary valve.
The thermostat valve directs hot oil from the drive pump
and motor case drains to the oil cooler in the radiator
assembly depending on the oil temperature. The valve
includes a by-pass in case flow through the cooler is
restricted.
The thermostat valve is located on the left side of the

radiator assembly.
–UN–01SEP02
301—Brake Charge pressure measuring point
307—Brake Charge pressure measuring point 03
Y41W—Brake valve switch 0330
9
T152793
Brake Valve
–UN–08OCT02
T159878
Brake valve disconnect switch Y41W
OUTJ003,00002A8 –19–09JAN01–5/5

081403
PN=329
Work Hydraulics
1010D Bleeding Work Hydraulic System
Before the machine is used again air must be eliminated

from all hydraulic components that have been serviced or
repaired. During the operation oil will come out from the
hoses. Drain oil into a container.
–UN–08NOV02
1. If necessary, add first clean, filtered oil to the housing
of the service pump through the bleed connect (A) until
the housing is half full
T161495
2. Next, fill up the hydraulic tank.
1010D Work pump bleed connection
3. Make sure that the suction hose of the service pump is
also filled with oil (loosen the hose connector for the
fill-up)
03
0330
10 4. Start the engine and let it idle.
5. Connect bleed hoses (thread M16x2) to the measuring

points (140), (111) and (116) in the working hydraulic
system.
6. Disconnect the bleed hoses as soon as no more air

comes out of them.
7. Connect a bleed hose to the measuring point (118).
–UN–08NOV02
8. Operate the rotator for appr. one minute in the other
direction.
9. Disconnect the bleed hose as soon as no more air
T161487
comes out of it.
10. Stop the engine and let air be removed from the oil 1010D Boom control valve bleed screw(1) and measuring point
tank (for appr. five minutes). (140)
11. Air is eliminated from the boom valve solenoids by

loosening the bleeding screws (1) at the end of the
solenoids and by operating the functions of the block
for appr. one minute. Close the screws.
12. Air is eliminated from the cylinders by slowly

–UN–08NOV02
operating the functions all the way to their extreme

positions at least twice. If necessary, check also the
directions of the various functions at the same time.
T161489
1010D Auxiliary valve meauring points

081403
PN=330
Work Hydraulics
13. Stop the engine and let air be removed from the oil in
the tank (for appr. five minutes).
14. Add oil until the level reaches the upper mark in the
measuring glass.
EL62757,00001F0 –19–26NOV02–2/2
03
0330
11

081403
PN=331
Work Hydraulics
810D,1110D and 1410D Bleeding Work

Hydraulic System

from all hydraulic system components that have been
serviced or repaired.
–UN–01OCT02
NOTE: If necessary, add first clean, filtered oil to the
housing of the working pump through the bleed
connect (B) until the housing is half full.
T159884
Auxiliary valve bleed connections
Make sure that the low-pressure hose of the working B—Work pump bleed connect
pump is also filled with oil (loosen the hose connector 111—Work pump pressure
03 for the fill-up). 117—Work pump LS pressure
114—Reduced pressure of the auxiliary functions
0330
12 2. Start the engine and allow it to idle.
3. Connect bleed hoses to the following measuring points

in the working hydraulic system:
a. The working pump pressure (111)
b. The reduced pressure of the auxiliary functions

(114)
c. Pilot pressure of the boom valve (123)

comes out of them.
5. Connect a bleed hose to the measuring point (117)

except 810D 116 of the LS pressure line going to the
working pump.

direction.
7. Disconnect the bleed hose as soon as no more air

comes out of it.
8. Stop the engine and let air be removed from the oil
tank (for appr. five minutes).
Continued on next page EL62757,000019B –19–21APR02–1/2

081403
PN=332
Work Hydraulics
Bleeding the solenoids of the boom valve
1. Loose the bleeding screws (A) on top of the solenoids

and operate the boom movements for appr. one
minute.
2. Close the screws.
Bleeding the cylinders
1. Slowly operate the functions all the way to their

extreme positions. Do this at least twice.
2. If necessary, you can also check the directions of
travel for the various functions at the same time.
• Stop the engine and let air be removed from the oil
–UN–13OCT02
in the tank (for appr. five minutes).
• Add oil until the level reaches the upper mark in the
03
measuring glass 0330
13
T159882
123 or 138—Measuring boom valve pilot pressure
A—Vent screws
1110D and 1410D Boom control valve
–UN–08APR03
T189328
EL62757,000019B –19–21APR02–2/2

081403
PN=333
Work Hydraulics
1710D Bleeding Work Hydraulic System

from all hydraulic system components that have been
serviced or repaired.
NOTE: If necessary, add first clean, filtered oil to the

housing of the working pump through the bleed
connect (1) until the housing is half full.

Make sure that the low-pressure hose of the working
pump is also filled with oil (loosen the hose connector
for the fill-up).
–UN–15APR02
2. Start the engine and allow it to idle.
03
0330 1—Work pump bleed connect
14
T152781
1710D Workpump
Continued on next page EL62757,000019B –19–21APR02–1/2

081403
PN=334
Work Hydraulics
3. Connect bleed hoses to the following measuring points

in the working hydraulic system:
• The pilot control pressure of the loader valve (125)
• The working pump pressure (111)
• The reduced pressure of the auxiliary functions (119)
–UN–11SEP02
comes out of them.
5. Connect a bleed hose to the measuring point (116) of
the LS pressure line going to the working pump.
T159293
direction.
7. Disconnect the bleed hose as soon as no more air 1710D Auxiliary valve measuring points
comes out of it.
8. Stop the engine and let air be removed from the oil
tank (for appr. five minutes).
03
A 0330
Bleeding the solenoids of the loader valve 125 15
1. Loose the bleeding screws (A) on top of the solenoids

and operate the boom movements for appr. one
minute.
2. Close the screws.
Bleeding the cylinders
1. Slowly operate the functions all the way to their

extreme positions. Do this at least twice.
–UN–19MAR02
2. If necessary, you can also check the directions of
travel for the various functions at the same time.
• Stop the engine and let air be removed from the oil
in the tank (for appr. five minutes). .
T152686
• Add oil until the level reaches the upper mark in the
measuring glass
1710D Boom valve
111—Work pump pressure

116—LS pressure line
119—Reduced pressure of the auxiliary functions
125—Pilot control pressure
A—Bleed screws
EL62757,000019B –19–21APR02–2/2

081403
PN=335
Work Hydraulics
03
0330
16

081403
PN=336
Group 0335
Work Hydraulics Service
Work Pump Removal and Installation
03
0335
1
–UN–04JUN03
T191670
1010D Hydraulic pump mounting
1—Hydraulic pump Rexroth 2—Direct control valve 3—Auxiliary valve

A10VO100DFLR
Continued on next page OUTJ003,000031F –19–21JAN01–1/4

081403
PN=337

Cap hydraulic ports, hoses, and
working on any hydraulic components.
fittings immediately after removal.
Block the wheels to prevent movement
Failure to follow these procedures
before disabling circuits
may lead to equipment damage.
03
0335
2

081403
PN=338
03
0335
3

081403
PN=339
03
0335
4
–UN–04JUN03
T191672
1110D Hydraulic pump mounting

081403
PN=340
1—Auxiliary valve 2—Direct control valve 3—Hydraulic oil tank 4—Hydraulic pump Rexroth
A10VO140
1. Drain the hydraulic tank. 4. Remove the screws securing the work pump to the
Hydrostatic Drive Pump and remove the work
2. Tag and remove the outlet, inlet, case drain and pump.
load sense hoses from the work pump. Cap the
hoses ends and plug the ports to prevent 5. Install the work pump in reverse order of removal.
contamination and to reduce spills. Tighten the pump mounting screws to the specified
torque.
3. Attach a suitable lifting device to the pump.
OUTJ003,000031F –19–21JAN01–4/4
03
0335
5

081403
PN=341
Work Pump Service
03
0335
6
–UN–31MAY01
T142393
Rexroth A10VO140 working pump service
1—Retaining Ring 9—Adjusting Shim 16—Port Plate 24—Pin

2—Drive Shaft Seal 10—Rear Tapered Roller 17—Capscrew 25—Retaining Ball
3—Housing Bearing 18—Rotary Group 26—Retaining Plate
4—O-ring 11—Disc 19—Control Plate 27—Pistons
5—Front Tapered Roller 12—O-ring 20—Retaining Ring 28—Control Piston Bearing
Bearing 13—Dowel Pin 21—Washer 29—Swashplate
6—Stroking Piston 14—Control Piston 22—Center Spring 30—Drive Shaft
7—Spring 15—Control Piston Guide 23—Cylinder Barrel 31—Swashplate Bearings
8—Stoking Piston Guide
Dissassembly of Work Pump
1.

081403
PN=342
Mark the position of the port plate to ease re-assembly.
2. Remove the capscrews retaining the port plate. Lift off

the port plate.
NOTE: The control valve and control plate are removed
–UN–31MAY01
with the port plate. Hold the control plate when
removing the port plate to prevent parts from
falling out.
T142398
1—Housing
2—Port Plate
3—Capscrew Port Plate Removal
03
0335
7
OUTJ003,0000320 –19–21JAN01–2/40
3. Remove the inner race of the rear bearing and the

adjustment shim from the drive shaft.
1—Drive Shaft
2—Adjustment Shim
3—Inner race of Rear Tapered Roller Bearing
–UN–31MAY01
T142399
Rear Bearing and Adjustment Shim
OUTJ003,0000320 –19–21JAN01–3/40
4. Remove the rotary group from the housing.
1—Rotary Group
–UN–31MAY01
T142400
Rotary Group

081403
PN=343
5. Remove the o-ring from the housing.
1—O-ring
–UN–31MAY01
T142401
Housing O-ring
03
0335
8
OUTJ003,0000320 –19–21JAN01–5/40
6. Remove the swashplate bearings from the housing.
1—Swashplate Bearings
–UN–31MAY01
T142402
Swashplate Bearings

081403
PN=344
7. Use a bearing puller to remove the outer race of the

front bearing from the housing.
1—Outer Race of Front Tapered Roller Bearing
–UN–31MAY01
T142403
Outer Race of Front Bearing
03
0335
9
OUTJ003,0000320 –19–21JAN01–7/40
8. Remove the drive shaft seal and retaining ring.
1—Retaining Ring
–UN–31MAY01
T142404
Drive Shaft Seal and Retaining Ring

081403
PN=345
9. Remove the control plate from the port plate.
1—Control Plate
2—Port Plate
–UN–11JUN01
T142991
Control Plate, Port Plate
03
0335
10
OUTJ003,0000320 –19–21JAN01–9/40
10. Use a bearing puller to remove the outer race of the

rear bearing from the port plate.
1—Outer Race of Rear Tapered Roller Bearing
–UN–31MAY01
T142406
Outer Race of Rear Bearing

081403
PN=346
11. Remove the o-rings from the port plate.
1—Port Plate O-rings
–UN–31MAY01
T142407
Port Plate O-rings
03
0335
11
OUTJ003,0000320 –19–21JAN01–11/40
12. Remove the control piston and guide from the port
plate.
NOTE: The control piston is located on the pilot valve

side of the port plate.
–UN–31MAY01
1—Control Piston
2—Control Piston Guide
T142409
Control Piston

081403
PN=347
13. Remove the stroking piston, guide and spring from

the port plate.
1—Stroking Piston
2—Spring
3—Stroking Piston Guide
–UN–31MAY01
T142409
Stroking Piston
03
0335
12
OUTJ003,0000320 –19–21JAN01–13/40
14. Remove the drive shaft and swashplate from the

rotary group.
1—Drive Shaft
2—Swashplate
3—Rotary Group
–UN–31MAY01
T142410
Drive Shaft, Swashplate, Rotary Group

081403
PN=348
15. Remove the pistons and retaining plate from the

cylinder barrel.
1—Pistons
2—Retaining Plate
3—Cylinder Barrel
–UN–31MAY01
T142411
Pistons, retaining ring, cylinder barrel
03
0335
13
OUTJ003,0000320 –19–21JAN01–15/40
16. Remove the retaining ball from the cylinder barrel.
1—Retaining Ball
2—Cylinder Barrel
–UN–31MAY01
T142412
Retaining Ball

081403
PN=349
17. Compress the center spring and remove the retaining

ring.
NOTE: The spring can be compressed using a bolt, nut

and washers.
–UN–31MAY01
Remove the center spring and washers from the
cylinder barrel.
1—Cylinder Barrel
T142413
2—Washer
3—Center Spring
4—Retaining Ring Center spring, washers, retaining ring
03
0335
14
OUTJ003,0000320 –19–21JAN01–17/40
18. Remove the pins from the cylinder barrel.
Assembly of Work Pump
1. Clean and lubricate components before assembly.
–UN–31MAY01
Replace all seals and o-rings with new parts. Lubricate
o-rings with grease before installing.
1—Pins
T142414
2—Cylinder Barrel
Pins, cylinder barrel

081403
PN=350
2. Install the pins in the cylinder barrel.
1—Pins
2—Cylinder Barrel
–UN–31MAY01
T142414
Pins, cylinder barrel
03
0335
15
OUTJ003,0000320 –19–21JAN01–19/40
3. Install the spring and washers in the cylinder barrel.
4. Compress the center spring and install the retaining

ring.
NOTE: The spring can be compressed using a bolt, nut
–UN–31MAY01
and washers.
1—Cylinder Barrel
2—Washer
T142413
3—Center Spring
4—Retaining Ring
Center spring, washers, retaining ring

081403
PN=351
5. Install the retaining ball in the cylinder barrel.
1—Retaining Ball
2—Cylinder Barrel
–UN–31MAY01
T142412
Retaining ball, cylinder barrel
03
0335
16
OUTJ003,0000320 –19–21JAN01–21/40
6. Install the pistons and retaining plate in the cylinder

barrel.
1—Pistons
2—Retaining Plate
3—Cylinder Barrel
–UN–31MAY01
T142411
Pistons and Retaining Plate

081403
PN=352
7. Install the drive shaft and swashplate on the rotary

group.
1—Drive Shaft
2—Swashplate
3—Rotary Group
–UN–31MAY01
T142410
Drive shaft, swashplate, rotary group
03
0335
17
OUTJ003,0000320 –19–21JAN01–23/40
8. Apply LOCTITE to control piston guide. Install the

control piston and guide on the port plate.
NOTE: The control piston is located on the pilot valve

side of the port plate.
–UN–31MAY01
1—Control Piston
2—Control Piston Guide
T142408
Control piston
LOCTITE is a trademark of Loctite Corp. Continued on next page OUTJ003,0000320 –19–21JAN01–24/40

081403
PN=353
9. Apply LOCTITE to stroking piston guide. Install the

stroking piston guide and spring on the port plate.
1—Stroking Piston
2—Spring
3—Stroking Piston Guide
–UN–31MAY01
T142409
Stroking piston
03
0335
18
LOCTITE is a trademark of Loctite Corp. OUTJ003,0000320 –19–21JAN01–25/40
10. Install new o-rings on the port plate.
1—Port Plate O-rings
–UN–31MAY01
T142407
Port plate o-rings

081403
PN=354
11. Press the outer race of the rear bearing into the port
plate.
1—Outer Race of Rear Tapered Roller Bearing
–UN–31MAY01
T142406
Outer race of rear bearing
03
0335
19
OUTJ003,0000320 –19–21JAN01–27/40
12. Install the control plate on the port plate.
NOTE: The control plate must be aligned as shown. For

clockwise rotation of the pump, the control plate is
positioned 4° to clockwise.
–UN–11JUN01
1—Control Plate
2—Port Plate
T142991
Control plate, port plate
–UN–11JUN01
T142419
Control Plate 4° to clockwise


081403
PN=355
13. Install the retaining ring and drive shaft seal in the
housing.
1—Retaining Ring
–UN–31MAY01
T142404
Drive shaft seal and retaining ring
03
0335
20
OUTJ003,0000320 –19–21JAN01–29/40
14. Press the outer race of the front bearing into the
housing.
1—Outer Race of Front Tapered Roller Bearing
–UN–31MAY01
T142403
Outer race of front bearing

081403
PN=356
15. Install the swashplate bearings in the housing.
1—Swashplate Bearings
–UN–31MAY01
T142402
Swashplate bearings
03
0335
21
OUTJ003,0000320 –19–21JAN01–31/40
16. Install a new o-ring on the housing.
1—O-ring
–UN–31MAY01
T142401
Housing o-ring

081403
PN=357
17. Install the rotary group in the housing.
NOTE: The swashplate must be installed with the

lubrication bore on the high pressure side.
1—Rotary Group
–UN–31MAY01
2—Swashplate Lubrication Bore
T142400
Rotary Group
03
0335
22
–UN–13AUG01
T142420
Swashplate lubrication bore
OUTJ003,0000320 –19–21JAN01–33/40
18. Install the adjustment shim and press the inner race
of the rear bearing on the drive shaft.
1—Drive Shaft
2—Adjustment Shim
3—Inner race of Rear Tapered Roller Bearing
–UN–31MAY01
T142399
Rear Bearing and adjustment shim


081403
PN=358
19. Install the port plate on the housing. Install the

capscrews retaining the port plate.
NOTE: The control valve and control plate are installed

with the port plate. Hold the control plate when
installing the port plate to prevent parts from
–UN–31MAY01
falling out.
Component inspection
T142398
Inspect all work pump components for wear. Replace any
worn or damaged parts as necessary.
Port Plate, Capscrews
The piston sliding surface of the swashplate can be
1—Housing
reground if lightly worn. Do not press out the control 2—Port Plate
piston and stroking piston bearings. 3—Capscrew
03
0335
23
OUTJ003,0000320 –19–21JAN01–35/40
The contacting surfaces of the control plate and cylinder

barrel can be reground if lightly worn. Use No. 1000 paper
to finish surfaces. Surfaces must be completely flat and
smooth.
1—Control Piston Bearing
–UN–31MAY01
T142415
Swashplate

081403
PN=359
–UN–31MAY01
T142416
Cylinder barrel, control plate
03
0335
24
OUTJ003,0000320 –19–21JAN01–37/40
Ensure that the control piston slides smoothly in the

guide.
–UN–31MAY01
T142417
Control piston
OUTJ003,0000320 –19–21JAN01–38/40
Ensure that the stroking piston slides smoothly in the

guide.
–UN–31MAY01
T142418

081403
PN=360
Drive shaft seal replacement
1.
Use pliers to remove retaining ring.
–UN–31MAY01
2. Remove seal.
NOTE: Grind screwdriver to make tool to remove seal.

Take care to avoid damaging seal seat.
T142395
3. Inspect seal seat on driveshaft.
4. Apply grease to new seal.
5. Use cylindrical installation tool to press in seal.

03
0335
NOTE: Do not press seal in too far. The seal will be 25
damaged if it is installed in contact with the
–UN–31MAY01
bearing.
6. Use pliers to install retaining ring.
T142396
1—Retaining Ring
3—Bearing
Drive Shaft Seal, Retaining Ring and Bearing section view
OUTJ003,0000320 –19–21JAN01–40/40

081403
PN=361
Auxiliary Valve Removal and Installation
Auxiliary Valve Removal
NOTE: The Auxiliary Valve and the Brake Valve are

removed together as an assembly.

parking brake. Stow the Boom. Shut down the engine.
Install the frame locking bar to prevent accidental

articulation. Block the wheels to prevent accidental
movement of the machine.
Open the vent tap on the hydraulic tank to release the

pressure to the hydraulic system.
03
0335
26 main switch OFF.
2. Tilt cab.
3. Tag and disconnect wiring harness connections at

Auxiliary Valve and the Brake Valve.
CAUTION: Do not disconnect any brake system

hose joints before all pressure has been
released from the accumulators. Hydraulic fluid
released under pressure can penetrate the skin
causing serious personal injury.
Brake system pressure can be checked at test

ports MB2 and MB3.


4. Tag and disconnect hoses at Auxiliary Valve and Brake

Valve. Cap the hoses and plug the ports.
5. Remove the screws securing the bracket. Lift the

valves and bracket assembly off machine.

081403
PN=362
6. Remove the auxiliary valve from the bracket for

servicing.
Auxiliary Valve Installation
1. Assemble the Auxiliary valve on the bracket.
Install the four M8 x 75 screws and tighten to the

specified torque.
2. Install the valves and bracket assembly on the frame.

Tighten the M12 x 25 screws to the specified torque.
03
0335
27

081403
PN=363
03
0335
28
–UN–22AUG01
T144918
Auxiliary Valve Port Designations
M1—Test Port MP1 — System PJ—Flow to Brake Valve A6—Flow to Rear Parking A4—Flow to Low Gear Select
High Pressure LS1—Load Sense Signal from Brakes B4—Flow to High Gear Select
M2—Test Port MP2 — Brake Valve PR—Flow to Hydrostatic Drive A5—Flow to Frame Brake
Auxiliary Functions LS2—Load Sense Signal from System B5—Flow from tee on Main
M3—Test Port MP3 — Load boom Control Valve T—Tank Return Boom Raise Line
Sense Signal LS3—Load Sense Signal to A1—Flow to Front Differential P1—Plugged (Flow to Frame
A6 (Top)—Pressure Switch Work Pump Pressure Lock Brake on Four-Wheel
W41A — Parking Compensator Valve A2—Flow to Rear Differential Short Frame Only)
Brakes M4—Test Port MB1 — Parking Lock T1—Plugged
P—Flow from Working Pump Brake Pressure A3—Flow to Rear Wheel Drive
Outlet A6—Flow to Front Parking Engage
Brakes
IMPORTANT: Cleanliness procedures must be Failure to follow these procedures

observed when working on any may lead to equipment damage.
prevent contamination of the 3. Connect hoses at the valve.

081403
PN=364
03
0335
29
–UN–22AUG01
T144921
Auxiliary Valve Electrical Connections
B5—Pressure Switch, Parking Y33F—Solenoid, Front Axle Y39—Solenoid, Rear Drive Y46—Solenoid, High Gear
Brake (W41A) Differential Lock Disengage Select
Y208—Solenoid, Constant Y33B—Solenoid, Rear Axle Y45—Solenoid, Low Gear Y65—Solenoid, Frame Brake
Pressure Differential Lock Select Release
Y41—Solenoid, Parking Brake
4. Connect the wiring harness connectors at the valve.

081403
PN=365
03
0335
30
–UN–22AUG01
T142356
Brake Valve Hydraulic Hoses

081403
PN=366
G3—To Port B3 on Brake G1—Pilot Pressure from Brake B2—Brake Pressure to Front B3—To Port G3 on Brake
Valve Pedal Valve Axle Valve
T—Tank Return thru Tee B1—Brake Pressure to Rear P—Pressure from Port PJ on S1—To Brake Accumulator
Fitting on Auxiliary Valve Axle Auxiliary Valve S2—To Brake Accumulator
X—To Load Sense Port LS1 on
Auxiliary Valve
5. Connect the hydraulic hoses at the brake valve.
OUTJ003,0000329 –19–21JAN01–6/7
6. Connect the electrical wiring connectors at the brake

valve. 03
0335
7. Bleed the brakes. See groups 1060 and 1160 for the 31
procedures.
–UN–06JUN01
B3—Brake Charge Pressure Switch
Y44—Work Pump Unloading Solenoid
T142357
OUTJ003,0000329 –19–21JAN01–7/7
Boom Control Valve Removal and Installation
To remove the boom control valve follow the next

procedure

081403
PN=367
03
0335
32
–UN–06JUN01
T142348
1—Screw 3—Washer 4—Spacer 5—Nut
2—Washer
2. Use a suitable overhead lifting device to position

CAUTION: Use appropriate support, slings
the valve and bracket on the hydraulic tank
and lifting device when lifting the valve.
weldment.
Failure to follow proper safety procedures
3. Install the four screws securing the bracket to the
can lead to risk of personal injury or
tank weldment. Tighten the screws to the specified
equipment damage
torque.
1. Position the valve on the bracket. Install the screws,
spacer, washers and nuts as shown. Tighten the
screws to the specified torque.

081403
PN=368
03
0335
33
–UN–06JUN01
T142349
Boom Control Valve Hose Connections
T—Grapple Rotate Motor Case A2—Outer boom Down B4—Extension Retract B6—Main Boom Lower
Drain Return B2—Outer boom up A5—GrappleRotate A7—Steer Right
P1—Pressure from Work A3—GrappleClose Counterclockwise B7—Steer Left
Pump B3—GrappleOpen B5—GrappleRotate Clockwise TP—Pilot Return to Tank
A1—Slew Clockwise A4—Extension Extend A6—Main Boom Raise T3—Return to Tank
B1—Slew Counterclockwise
4. Install the hoses on the valve. 5. Install the wiring harness connectors on the valve.

081403
PN=369
NOTE: The solenoid numbers are printed on the main switch OFF.
wires.
2. Remove the cover over the Boom Control Valve.
6. Install the valve cover. Install four screws and
washers securing the cover. Tighten the screws to 3. Tag and disconnect the wiring harness connectors.
the specified torque.
4. Tag and disconnect the hydraulic hoses. Cap the
To install the boom control valve follow the next hoses and plug the ports.
procedure
5. Use a sling to attach a suitable lifting device to the
1. Park the machine on a level surface. Engage the valve and bracket assembly.
parking brake.. Stow the Boom. Shut down the
engine. 6. Remove the four screws securing the boom bracket
to the hydraulic tank weldment. Lift the valve and
Install the frame locking bar to prevent accidental bracket assembly off the machine.
articulation. Block the wheels to prevent accidental
03
0335 movement of the machine. 7. Remove the screws, washers, spacers and nuts
34 securing the valve to the bracket. Remove the valve
Open the vent tap on the hydraulic tank to release from the bracket.
the pressure to the hydraulic system.
OUTJ003,0000327 –19–21JAN01–4/4

081403
PN=370
Boom Control Valve Disassembly and

Assembly
Tie Rods
NOTE: If problems arise within a spool section, it is

recommended that the entire section be replaced.


lead to equipment damage. 03
0335
1. Support the valve in a vertical position. 35
2. Loosen each tie rod nut a little at a time in turn.
3. Remove the nuts.
4. Leave the rods in place and lift off each spool section
one at a time to reach the problem section.
5. Inspect the seals and replace as necessary.
When re-assembling the valve, tighten all three tie rods in

stages:
1. Tighten each rod in turn to the first specified torque.
2. Next, tighten each rod in turn to the second specified

torque.
3. Last, tighten each rod in turn to the final specified

torque.

081403
PN=371
03
0335
36
–UN–20JUL01
T138866
Boom Control Valve, Inlet Section Exploded View
Inlet Section NOTE: Each spool section is designed for a specific

function. The spool sections are not
NOTE: Designations are used by the valve interchangeable.
manufacturer to indicate features included in
the valve. These designations are referred to Outlet Section
in any material from the manufacturer as well
as in the Parts Catalog. NOTE: Designations are used by the valve
Typical Spool Section the valve. These designations are referred to
NOTE: Designations are used by the valve as in the Parts Catalog.
the valve. These designations are referred to
as in the Parts Catalog.

081403
PN=372
03
0335
37
–UN–29AUG01
T138873

081403
PN=373
Hydraulic Fittings
Boom Control Valve, Hydraulic Fittings

Port Description
A1 Fitting Parker F40XS16-1/2
B1 Fitting Parker F40XS16-1/2
03
0335
38 B5 Fitting Parker F40XS16-1/2
T Fitting Parker F40XS20-3/4
P1 Fitting Parker 16-12F40XS
Elbow Parker 16CMXS
LS Fitting Parker F40XS10-1/4
Restrictor Monsun 0.07 mm Dia.
Fitting N/A N/A
Elbow Parker C6XS10
PL Test Fitting Hydrotecknic 2103-79-5100
PS Fitting Parker F40XS10-1/4
Elbow Parker C6XS10
Coupling Nut Parker TT4XS10-1/4
Test Fitting Hydrotecknic 2103-79-5100
TP Fitting Parker F40XS10-3/8
P2 Plug 1/2"
T3 Fitting Parker F40XS20-3/4
Elbow Parker V6XS20

081403
PN=374
Valve Sections and Solenoids
Valve Sections and Solenoids

Solenoid Valve Section Port Relief Function Restrictors
Y424 1 B Slew CCW 1.2 mm
Y425 1 A Slew CW 1.2 mm
Y422 2 B Jib Boom Raise 0.06 mm
Y423 2 A Jib Boom Lower 0.06 mm
Y416 3 B GrappleOpen 1.2 mm
Y417 3 A GrappleClose 1.2 mm
Y418 4 B Extension Boom Retract 0.08 mm
Y419 4 A Extension Boom Extend 0.08 mm
Y409 5 B GrappleRotate CCW 1.2 mm
Y408 5 A GrappleRotate CW 1.2 mm
03
Y421 6 B Main Boom Lower 1.2 mm
0335
Y420 6 A Main Boom Raise 0.08 mm 39
Y66L 7 B Steering Left 1.0 mm
Y66R 7 A Steering Right 1.0 mm
OUTJ003,0000328 –19–21JAN01–5/5

081403
PN=375
Thermostat Valve Removal and Installation


1. Disconnect the hose fitting on top of the thermostat

valve.
NOTE: Connect the suction hose of a wet-dry ’Shop Vac’

to the filler coupling on the hydraulic tank when
03
0335 disconnecting the hydraulic hose to the thermostat
40 valve. The Shop Vac will produce sufficient
vacuum to reduce the oil leakage to a minimum.
2. Remove the top of thermostat valve and replace the
–UN–20JUL01
thermostat.
3. Replace the top of thermostat valve.
T138887
4. Connect the hose fitting on top of the thermostat valve.
5. Start engine and check system for oil leaks.
6. Loosen the hose fitting on top of the thermostat valve

to bleed any air trapped in the cooler.
7. Check the oil level in hydraulic tank. Add fluid, as

necessary.
OUTJ003,0000349 –19–22JAN01–1/1

081403
PN=376
Hydraulic Pressure Filter Replacement
CAUTION: Before working on the hydraulics,

park the machine on a level surface, and
Grappleto the ground, shut off the engine and
block the wheels.
Failure to take adequate safety precautions can

lead to serious personal injury.

–UN–13AUG01
03
Clean the filter cover and immediate 0335
41
area before disassembly.
T144418
1—Hydraulic Pressure Filter
NOTE: The pressure filter can be cleaned when clogged
and, under normal circumstances, should not
require replacement. Clean or replace the
pressure filter only after hydraulic system
contamination or work pump damage.
1. Turn filter counterclockwise to remove.
2. Clean mounting surface. Apply thin film of oil to gasket

of new filter.
3. Install new filter. Turn the filter by hand until the seal
makes contact with the base. Use a filter wrench to
turn the filter 30° further.
4. Start engine. Check for leaks around the filter base.

Tighten filter only enough to stop leaks.
5. Stop engine.
6. Check oil level at sight glass on hydraulic tank. Add oil,

if necessary. See Section 00, Group 0004, Fuels and
Lubricants, for recommended hydraulic fluids.
OUTJ003,00006AD –19–16MAY01–1/1

081403
PN=377
Hydraulic Return Filter Replacement
NOTE: When filling the tank, retract the Boom cylinders

before checking the oil level in the tank.
Always fill the tank using the filler coupling to

ensure the oil is filtered before entering the
system.
Do not exceed the MAX level mark. The air space

allows the level to change during operations.
Do not mix different types of oil. See the Fluids

and Lubricants Specifications for recommended
hydraulic fluid.
03
0335 CAUTION: Before working on the hydraulics,
42
park the machine on a level surface, lower the
Grapple to the ground, shut off the engine and
block the wheels.
Failure to take adequate safety precautions can

lead to serious personal injury.

Clean the filter cover and immediate

area before disassembly. Cover the
housing opening immediately after
removing the filter to prevent
contamination of the hydraulic tank and
fluid.

NOTE: The bypass valve is part of the element. The

entire assembly is disposable.
The return filter is equipped with a by-pass set at 150 kPa

(22 psi). If the filter is clogged, a spring valve will allow oil
to flow directly into the tank.
Continued on next page EL62757,000011C –19–10APR02–1/6

081403
PN=378
The filter restriction pressure switch (W84) is set to close

at 130 kPa (18 psi) activating an indicator light (1010D)or
TMC alarm (in the cab. This warning will indicate a
clogged filter before the filter is by-passed.
A fluid level sensor (W81) is installed in the side of the

tank. This switch will close and activate indicator in the
TMC screen if the auricle fluid level drops below
minimum.
A fluid temperature sensor (W80A) is also installed in the

side of the tank. This switch will close and activate
indicator on the TMC screen if the temperature of the
auricle fluid rises above 80°C (176°F).
03
0335
43

081403
PN=379
2—Vent Screw
3—Breather
4—Hydraulic oil tank
5—O-ring
6—Canister
7—Filter element
8—Spring
9—O-ring
10—Cover
11—Screw
–UN–09APR03
03
0335
44
T189428
810D Hydraulic tank
–UN–09APR03
T189429
810D Changing return filter

081403
PN=380
1 —Vent screw
2—O-ring
3—O-ring
4—Canister
5—Filter
6—Clamp
7—O-ring
8—Cover
9—Screws
03
0335
45
–UN–08NOV02
T160627
1010D changing hydraulic return filter

081403
PN=381
CAUTION: Before working on the hydraulics,

park the machine on a level surface, lower the
decking blade, grapple to the ground, shut off
the engine.
IMPORTANT: When replacing the filter make sure that

no dirt enters the hydraulic system.
1. Open the vent screw (1 or 2) on top of the tank
2. Remove the screws of cover (10)
CAUTION: The filter cover is under spring

tension. Hold cover down while removing
screws
03
0335
46 Clamp guarantees that the filter functions properly.
NOTE: Filter assembly consists of a filter element (7) and

a canister (6). Filter is in lock position inside the
canister.
IMPORTANT: The filter and the canister must be lifted

together from the tank to prevent the
contamination to flow into the tank.
3. Put the filter element and the canister into an oil
–UN–11SEP02
collecting sump
4. Unlock the filter element by twisting it counterclockwise
T159297
5. Remove the filter element and clean the canister
1110D, 1410D and 1710D changing hydraulic return filter
6. Replace the filter element and put it inside the canister.
1—Vent screw
2—Lock position
Twist the filter element clockwise and check that it
3—O-ring
is locked inside the canister! You maybe need to 4—Spacer ring
press the filter while twisting it. 5—O-ring
6—Canister
7. Place the filter assembly in the tank together with the 7—Filter element
8—Spring
spring (8). Screw the cover (10) on.
9—O-ring
10—Cover
8. Start the engine and run for 5 minutes. Stop the engine 11—Screw
9. Check for any leakage at filter cover.
10. Close the vent screw.

081403
PN=382
11. Check oil level in tank. Add oil if necessary.
The filters are equipped with a pressure sensor. If the

pressure sensor sets off an alarm, renew the filter.
Otherwise, stick to maintenance periods.
NOTE: When the machine is initially started up in cold

conditions, the filter restriction indicator may light
up. The light should go out as the machine warms
up. If the light stays on after warm up, check the
filter.
03
0335
47
EL62757,000011C –19–10APR02–6/6

081403
PN=383
Hydraulic Tank Removal and installation
Hydraulic tank removal
1. Drain the hydraulic tank using the drain hose.
–UN–20JUL01
2. Tag and disconnect the work pump suction line, the
charge pump inlet line and the drain hose at the tank.
Cap the hoses and plug the ports.
T138882
3. Disconnect the wires to the temperature and level
sensors.
Hydraulic Tank
4. Disconnect the return lines at the return filter head.
1—Drain Hose
2—Work Pump Suction Line
5. If necessary for clearance, dismount the hydraulic 3—Drive Pump Inlet Line
03
0335 pressure filter bracket. Leave the hoses and wires 4—Hydraulic Oil Temperature Sensor
connected and move the filter assembly aside. 5—Hydraulic Oil Level Sensor
48
6—Return Filter Head
6. Remove the bolts securing the boomcontrol valve

bracket to the tank. Swing the valve off to the right side
of the machine to get clearance to remove the tank.
NOTE: The cover and valve remain assembled on the

bracket. The hoses and wiring harness remain
connected to the valve.
7. Remove the frame cover plates.
CAUTION: Proper safety precautions must be

taken when using any lifting devices.
Failure to follow these procedures may lead to

personal injury and equipment damage.
8. Attach a suitable lifting device to the tank.
Hydraulic Tank Removal and Installation—Specification

Hydraulic tank Weldment—
Weight............................................................................... 688 kg (1515 lb)
9. Remove the bolts securing the tank to the frame.
Lift the tank off the machine.

081403
PN=384
Hydraulic tank installation
1. Use a suitable lifting device to position the hydraulic

tank on the frame. Install the mounting screws and
tighten the screws to the specified torque.
2. Install the frame cover plates.
3. Install the boom control valve bracket assembly.
4. Connect the return lines to the valve bank.
5. Connect the work pump suction line, drive pump inlet

line and drain hose.
6. Install the hydraulic pressure filter bracket.

03
0335
IMPORTANT: Always fill the tank using the filler 49
coupling to ensure the oil is filtered
before entering the system.
Improper filling may result in

contamination of the hydraulic and
hydrostatic systems.
7. Fill the hydraulic tank. See Group 0040, for

recommended hydraulic fluids.
8. Bleed the air from the hydraulic system group 0310, for
procedures.
Bleed the air from the Hydrostatic Drive System. See

Section 03, Group 0360, for procedures.
9. Operate all hydraulic functions on the machine. Check

the level in the tank and add fluid, as necessary.
OUTJ003,0000347 –19–22JAN01–2/2

081403
PN=385
03
0335
50

081403
PN=386
Group 0340
Work Hydraulics Checking and Adjusting
Essential Tools



03
0340
1
Air Bleed Hose
To bleed air from test fittings on Hydrostatic Drive Pump.
OUTJ003,0000310 –19–18JAN01–2/2
Adjusting 1010D Pressures
Connect the pressure transducers (60 MPa) (8702 psi) to

the measuring point (111) and (118) (pump main pressure
and signal lines) in the working hydraulic system.
–UN–08NOV02
Adjusting the Maximum Pressure
1. Start the engine and and set the rpm’s to 1600.
T161489
2. The transducers are connected to measuring points
(111) and (118).
3. Engage the working rpm and boom.
4. Increase the pressure to maximum. For example by

using the ’extension-in’ movement
5. The pressure at measuring point (111) must be 24 ±

0,5 MPa (3480 ± 72,5 psi)
–UN–08NOV02
6. If necessary, adjust from adjusting screw (101).

Turning the screw clockwise will increase the pressure
T161483

081403
PN=387
Adjusting the Pressure Difference
1. The transducers are connected to measuring points

(111) and (118).
2. Engage the engine rpm and boom.
–UN–08NOV02
3. Lift the boom free of the load area
4. Slowly rotate the rotator at a steady speed, ensuring

that the pressure (111) stays constant for the
T161483
measuring process and does not exceed 15 MPa
(2175 psi).
5. Simultaneously, check the pressure at measuring

points (111) and (118). The pressure of (118) must be
03
0340 lower than the pressure of (111) by 2,4 ... 2,6 MPa
2 (348 ... 377 psi).

(102). Turning the screw clockwise will increase the
pressure difference.
EL62757,00001F9 –19–26NOV02–2/6
Checking the Boom Valve Pilot Control Pressure
1. Connect a (0 ... 60 MPa)(0...8702 psi)pressure

transducer to measuring point (140) on the boom
valve.
2. At measuring point (140), the pressure should be 3.5 ±

0,5 MPa (507 ± 72,5 psi).
What can be measured at the boom valve is the pilot

control pressure of the valve as well as the pressures
specific for each function.
The pilot control pressure cannot be adjusted.

–UN–08NOV02
T161485

081403
PN=388
Measuring the pressures for each function
1. The pressures of each movement can be measured

through measuring point (124).
2. First, connect a (0 ... 30 MPa) (0..4351 psi) pressure

transducer to quick coupler (124).
3. Engage the working rpm and boom.
a. Grapple close -function
• Operate the grapple close function.

• The pressure must rise up to 18,4 MPa (2668 psi)
–UN–08NOV02
as the movement is operated to extreme.
• If necessary, adjust from adjusting screw (133).
03
0340
b. Grapple open 3
T161486
• Operate the grapple open function.
• The pressure must rise up to 16,4 MPa (2378 psi)
• If necessary, adjust from adjusting screw (134).
c. Other functions
• Steering:
a. Operate steering function to right / left
b. The pressure must rise up to 20.4 MPa (2959
psi) as the movement is operated to extreme
c. If necessary, adjust from adjusting screw
(139).
Boom Slew:
a. Operate slewing function to right / left

b. The pressure must rise up to 20,9 MPa (3031
psi) as the movement is operated to extreme
c. If necessary, adjust from adjusting screw
(130).

081403
PN=389
Checking and Adjusting Auxiliary Function Pressure
• Differential locks.
• High/low gear.
1. Connect the pressure transducer (0...6 MPa) (0...870

psi) to the mesuring point (116).
–UN–08NOV02
2. Set the engine rpm’s to aprox. 1600.
3. Use ’extension in’ function to rise to pressure to the
T161480
maximum. When the engine is running the pressure at
the measuring point (116) should be 3,0 ± 0,1 MPa
(435 ± 14,5 psi).
4. If necessary adjust the pressure through adjusting

03
0340 screw (115).
4

081403
PN=390
Checking and Adjusting Frame Brake Pressure
The pressure used for the same frame brake is provided

by the lift cylinder, not directly from the pump.
1. Turn the seat backwards
2. Incresase the engine rpm’s
–UN–08NOV02
3. Grab for instance a stake with the grapple.
4. Use the main lift and keep it engaged.
T161481
5. Check the pressure at measuring point (141). The
pressure should be 21,0 -1 MPa (3045 -145 psi).
03
6. If necessary, adjust the pressure from adjusting screw 0340
(420). 5
Checking Pressures of Optional Equipment
All optional equipment (as installed at the factory) operate

with the maximum pressure. There are no separate
pressure adjustments.
• Pressure accumulators for boom damper.
CAUTION: Do not ever disconnect any brake

system hose joints before all pressure has been
–UN–11NOV02
eliminated from pressure accumulators.
T161521
EL62757,00001F9 –19–26NOV02–6/6

081403
PN=391
Adjustment of Pressure Difference
1. Connect pressure sensors (0 ... 30 MPa) (0...4351 psi)

to measuring points (111) and (117) in models 810D
and 1710D (116) (pump main pressure and signal
lines).
–UN–01OCT02
2. Engage the working rpm and boom
3. Lift the loader free of the load area.
T159884
4. Rotate the rotator freely and simultaneously check the
pressure at measuring points (111) and (117). The 810D, 1110D, 1410D and 1710D
pressure at (117) must be lower than that of (111) by
111—Measure point, work pump’s pressure
2.5...2.7 MPa (362...391 psi). 117—Measure point, work pump’s signal
pressure
03
0340 NOTE: When checking at measuring point (111) the
6 pressure should not rise over 15 MPa (2175 psi).

(102).
NOTE: Turning the screw clockwise will increase the

pressure difference
EL62757,00001A1 –19–21APR02–1/1
Adjusting the Maximum Pressure
1. The sensors are still connected to measuring points

(111) and (116 or 117).
2. The working rpm is engaged.
3. Increase the pressure to maximum. For example by

–UN–02OCT02
using the ’extension in’ movement.
• The pressure at measuring point (111) must be

24±0,5 MPa (3480±72 psi).
T160061
4. If necessary, adjust from adjusting screw (101).

Turning the screw clockwise will increase the pressure.
101—Max-pressure adjustment
102—Pressure difference adjustment
EL62757,00001A2 –19–21APR02–1/1

081403
PN=392
Adjusting the Boom Pressure
What can be measured at the loader valve is the pilot

control pressure of the valve as well as the pressures
specific for each function.
–UN–13OCT02
116—Measure point, pilot pressure
123—Measure point, pressures for each function
130—Adjusting screw, reduced pressure, boom slew
T159883
right
131—Adjusting screw, reduced pressure, boom slew
left 1110D and 1410D Auxiliary valve
136( in 810D 133)—Adjusting screw, reduced
pressure, grapple closed
137( in 810D 134)—Adjusting screw, reduced
pressure, grapple open
140—Adjusting screw, reduced pressure, steering left 03
141—Adjusting screw, reduced pressure, steering 0340
right 7
–UN–07APR03
T189327
–UN–07MAY03
T164905
1110D and 1410D Boom control valve

081403
PN=393
Measuring the pressures for each function
The pressures of each movement can be measured

through measuring point (116)
• First, connect a (0...30 MPa) (0...4351 psi) pressure
–UN–11SEP02
transducer to quick coupler (116).
• Engage the working rpm and boom
1. Grapple close
T159292
a. Operate the grapple close function.
The pressure must rise up to 18.3 MPa (2654 psi)
as the movement is operated to extreme. 1710D Auxiliary valve
b. If necessary, adjust from adjusting screw (135)
2. Grapple open
03
0340 a. Operate the grapple open function.
8 The pressure must rise up to 16.3 MPa (2364 psi)
b. If necessary, adjust from adjusting screw (136)
3. Other functions
Operate the function you want to check.
–UN–15FEB03
• Steering:
a. Operate steering function to right / left
b. The pressure must rise up to 20.4 MPa (2959 psi) as
the movement is operated to extreme
T152782
c. If necessary, adjust from adjusting screw (139) /
(140)
Boom Slew: 118—Measure point, pilot pressure

131—Adjusting screw, reduced pressure, boom
a. Grab the rear fram with the grapple slew
132—Adjusting screw, reduced pressure, boom
b. Operate slewing function to right / left
slew
c. The pressure must rise up to 20.4 MPa (2959 psi) 137—Adjusting screw, reduced pressure, grapple
MPa as the movement is operated to extreme closed
d. If necessary, adjust from adjusting screw (129) / 138—Adjusting screw, reduced pressure, grapple
(130) open
141—Adjusting screw, reduced pressure, steering
142—Adjusting screw, reduced pressure, steering

081403
PN=394
Checking the pilot pressure
1. Connect a (0...30 MPa) (0...4351 psi) pressure sensor

to measuring point (123).
2. Next, engage the loader and working RPMs (1500 ...
1700 rpm).
3. Increase the pressure up to the maximum level by
means of the ’extension in’ function, for instance
• At measuring point (123), the pressure should be 3.5
±0.5 MPa (507 ±72 psi).
The pressure relief valve cannot be adjusted.
123—Pressure measure point
–UN–13OCT02
A—Bleed screws
03
0340
9
T159882
Pilot pressure checking
EL62757,00001A3 –19–21APR02–3/3
Adjusting Auxiliary Functions
• Differential locks.
• High/low gear.
• Rear-wheel drive engage when the high gear is used.
–UN–13OCT02
The functions listed above operate with a reduced
pressure of 3.0 MPa (435 psi). The pressure is measured
at measuring point (114).
T159880
If necessary, the pressure is adjusted from adjusting
screw (113). This can be done while the engine is idling.
NOTE: Though the pressure is lower than the delta 113—Adjusting screw
114—Pressure measuring point
pressure of the pump, the adjustment should be (409)—Adjusting screw for frame brake.
checked by increasing the pressure up to the
maximum by engaging the ’extension in’
movement, for instance. The pressure at quick
coupler (114) must remain the same.
Stairs operate with a reduced pressure of 3.0 MPa (435

psi).
EL62757,00001A4 –19–21APR02–1/1

081403
PN=395
Adjusting Frame Brake
The pressure used for the same frame brake is provided

by the lift cylinder, not directly from the pump.
1. The boom and working rpm are engaged
–UN–15APR02
2. Grap for instance a stake with the grapple.
3. Use the main lift and keep it engaged.
4. Check the pressure at measuring point (411).
The pressure should be 21.0 MPa (3045 psi).
T152779
5. If necessary, adjust the pressure from adjusting screw
(409)
Frame brake
(411)—Pressure measure point

409—Adjusting screw
03
0340
10
–UN–20SEP02
T159616
EL62757,00001A5 –19–21APR02–1/1
Adjusting Proportional Decking Blade
The pressure for the proportional decking blade can be

measured from measuring point (116).
1. Operate cylinder function to in / out

2. The pressure must rise up to 20.3 MPa (2944 psi) MPa
3. If necessary, adjust from adjusting screw 516, located
on the workpump.
–UN–14OCT02
T160364
EL62757,0000061 –67–16OCT02–1/1

081403
PN=396
Hydraulic Function Cycle Times
The following are approximate hydraulic function operating

times. Operate one function at a time.
These figures are approximate and may vary slightly

according to the Grappleand boom used. Use these
figures as guidelines only.
The hydraulic oil should be at normal operating

temperature.
Set the engine speed to 1850 ± 50 RPM.
Set the Boom Speed Control potentiometer on the armrest

to 80% (3.80 on the Display Module).
03
0340
NOTE: All decals are marked at 80% during 11
manufacturer’s testing. The mark will be small but
should be visible.
Steer, Lock to Lock Time 5.0 Sec @ 2 km/h (1.25 mph)
Boom Slew Left 360° Time 10.3 sec
Boom Slew Right 360° Time 10.3 sec
Boom Main Boom Raise Time 5.0 sec
Boom Main Boom Lower Time 4.5 sec
Boom Jib Boom Raise Time 5.0 sec
Boom Jib Boom Lower Time 5.0 sec
Boom Extension Boom Extend Time 2.3 sec
Boom Extension Boom Retract Time 2.3 sec
GrappleRotate Left 360° Time 3.0 sec
GrappleRotate Right 360° Time 3.0 sec
OUTJ003,0000481 –19–13FEB01–1/1

081403
PN=397
Motor Start of Control Point Adjustment
1. Install a 6 MPa (1,000 psi) gauge at test port MH5 on

the Direction Valve.
–UN–13AUG01
T138236
Direction Valve, MH5
03
0340
12
OUTJ003,000078F –19–09SEP01–1/4
2. Install a 60 MPa (10,000 psi) gauge at test port MH4

on the Hydrostatic Motor.
–UN–10SEP01
T145356
Hydrostatic Motor, MH4
Continued on next page OUTJ003,000078F –19–09SEP01–2/4

081403
PN=398

auxiliary valve so that the parking brake will remain
engaged.
4. Start the engine.
–UN–22AUG01
5. Set the Drive Direction Selection Switch to Neutral.
6. Press the drive pedal smoothly. When the pressure at

MH5 reaches the specified value, the pressure at MH4
T138248
should start to rise.
Motor Start of Control Point Adjustment—Specification Auxiliary Valve, Solenoid Y41

Pilot Pressure at MH5—Pressure ............ 1.4 ± 0.1 MPa (203 ± 14.5 psi)
03
0340
13
OUTJ003,000078F –19–09SEP01–3/4
7. If the pressure at MH4 begins to rise before the

pressure at MH5 reaches the specified value, adjust
the Motor Start of Control Point by turning adjustment
screw CH5 clockwise in small increments. Repeat the
test.
–UN–30APR01
8. If the pressure at MH4 begins to rise after the pressure
at MH5 reaches the specified value, adjust the Motor
Start of Control Point by turning adjustment screw CH5
counterclockwise in small increments. Repeat the test.
T138253
9. Shut down the system. Remove the gauges.
Hydrostatic Motor, CH5
Reconnect solenoid Y41 on the auxiliary valve.
OUTJ003,000078F –19–09SEP01–4/4

081403
PN=399
Hose Inspection and Replacement
Check hydraulic hoses and fittings for leaks and

indications of wear. Tighten fittings or replace hoses, as
necessary.
All hydraulic lines (hoses) are sized to carry the required

flow rates at velocities low enough to eliminate excessive
pressure losses and heat generation.
Replacement hoses should not be a smaller diameter.

They must also be of a pressure rating equal to the one
being replaced.
Correct hose length and routing is essential to ensure

performance and hose life. When replacing hoses ensure
03
0340 that the type of hose and fittings and the length of hose
14 are exactly the same as those being replaced.
Kinked, stretched, twisted or pinched hoses will not

provide good performance or a long service life.
OUTJ003,0000574 –19–20MAR01–1/1

081403
PN=400
1010D Direction Selection Solenoids

Inspection and Replacement
The direction selection solenoids (Y102 and Y103) are

mounted on the Direction Valve located on the fuel tank
weldment.
–UN–09AUG01
To inspect for possible malfunction, check for a green
LED on each solenoid. The LED will light to indicate
current to the solenoid. Check visually for any evidence of
T138745
electrical failure (burning or melting).
Direction Selection Valve
If the problem affects only the forward or reverse
directions, interchange the solenoids. If the problem
switches to the other direction, replace the defective
solenoid. 03
0340
To replace the solenoids: 15
1. Disconnect the wire connectors
2. Remove the lock nut.
3. Slide the solenoids off the pilot spool.
4. Remove the pilot spool and clean, if required.
5. Replace the pilot spool, slide on the solenoids and

replace the lock nut. Reconnect the wire connectors.
OUTJ003,00002E5 –19–17JAN01–1/1

081403
PN=401
03
0340
16

081403
PN=402
Group 0350
Hydraulic Cylinders
Cylinder Service
Cylinder service equipment and tools

Torch
03
Used to heat piston to release Loctite during cylinder 0350
disassembly. 1
OUTJ003,0000343 –19–22JAN01–2/3
OUTJ003,0000343 –19–22JAN01–3/3
Cylinder Seals Replacement
1. Fasten cylinder in vise. Do not distort cylinder tube.
2. Loosen the rod guide.
–UN–29AUG01
3. Pull the piston rod assembly from the cylinder barrel.
T138771
Cylinder, Vise
Continued on next page JK11466,00000DB –19–10JUN03–1/4

081403
PN=403
Hydraulic Cylinders
4. Fasten the piston rod assembly in a vise.
Remove the piston seal and set screw.
CAUTION: When heating the piston, high

pressure may form from the Loctite. This
–UN–29AUG01
pressure may cause the piston to split or
separate.
Use caution to avoid risk of personal injury.
T138774
5. If necessary, apply heat to defeat the Loctite on the Cylinder Rod, Vise, Torch
piston threads. Heat the piston with a torch for 3 to 5
minutes until the material stays dark red. The o-ring
under the piston will be destroyed by the heating and
03 will have to be replaced.
0350
2
6. Remove the piston.
7. Remove the rod guide.
JK11466,00000DB –19–10JUN03–2/4
8. Replace the seal and o-ring on the piston.
1—Piston
2—O-ring
3—Piston Seal
–UN–29AUG01
T138780
Cylinder Piston
Continued on next page JK11466,00000DB –19–10JUN03–3/4

081403
PN=404
Hydraulic Cylinders
9. Disassemble the rod guide. Remove the guides, seal

and scraper ring.
10. Replace the seals on the rod guide. Assemble the

scraper ring, seal and guides inside the rod guide.
Replace the o-ring on the outside of the rod guide.
–UN–29AUG01
11. Lubricate the rod and slide the rod guide into place.
12. Apply LOCTITE 275 and thread the piston onto the
T138825
piston rod. Tighten the piston to the specified torque.
Install the set screw.
Cylinder Rod Guide
Cylinder Seals Replacement—Specification
Cylinder Piston—Torque ............................................. 700 N•m (516 lb-ft) 1—Rod Guide
2—Guide
3—Scraper Ring
13. Lubricate the piston and the cylinder barrel. Push the 03
4—Seal
0350
piston rod assembly into the cylinder barrel. 5—O-ring
3
14. Thread the rod guide into the cylinder barrel and
tighten.
15. Tack weld to lock the top nut.
LOCTITE is a trademark of Loctite Corp. JK11466,00000DB –19–10JUN03–4/4

081403
PN=405
Hydraulic Cylinders
Cylinder Internal Seal Leak Test
CAUTION: Testing cylinders for internal leakage

involves supporting hydraulic implements from
an overhead lifting device. Use appropriate
support, slings and lifting devices to prevent
personal injury or equipment damage when
lifting.
Implement functions can be slowed down if internal oil

leaks are occurring at a hydraulic cylinder or the valve.
With internal leakage, the implement will often creep

downward slowly, even when the control valve lever is not
being moved.
03
0350 1. Run the engine at normal speed.
4
2. Raise the implement normally using the machine

hydraulics.
3. Support the implement in the raised position using a

suitable lifting device.
4. Stop the engine.
5. Carefully and slowly release the support holding the

implement in the raised position. If the implement
settles slowly, oil may be bypassing the seals in the
cylinder or the control valve.
6. Replace the support holding the implement in a raised

position.
7. Carefully open the hose fitting on the "no load" side of

the cylinder. Drain the oil from the “no load” side of the
cylinder into a suitable container.
8. After the initial draining, carefully and slowly release

the support holding the implement in the raised
position.
If the piston seal in the cylinder is bypassing oil, then

oil will flow from the opened cylinder port.

081403
PN=406
Hydraulic Cylinders
If no oil flows from the open port, but the load

continues to settle, then the leakage is between the
valve spool and body of the control valve section.
NOTE: It is also possible for a port relief valve to pass oil

if contaminants have entered it. Before replacing a
valve section, replace the port relief valve.
OUTJ003,0000480 –19–13FEB01–2/2
Lifting Boom Cylinder Service

03
1. Extend manually the piston rod to remove any oil from 0350
the cylinder. 5
2. Fasten cylinder in vise. Do not distort the cylinder

barrel.
3. Loosen cylinder head.
4. Pull the piston rod assembly out of the cylinder barrel.

Fasten the piston rod assembly in a vise.
5. Remove the seal and guide rings from the outside of

the piston.
1—Hydraulic cylinder
2—Rod
3—Cylinder barrel
4—Piston
5—Hydraulic cylinder rod guide
–UN–10JUN03
6—Lubrication fitting
7—Bearing
8—Bushing
T191922
1110D Lifting boom cylinder
Continued on next page JK11466,00000DC –19–10JUN03–1/3

081403
PN=407
Hydraulic Cylinders
6. Bend up the tab retaining the piston to the piston rod.
7. If necessary to defeat the LOCTITE, heat the piston

with a torch for 3 to 5 minutes until the material stays
dark red. The O-ring under the piston will be destroyed
by the heating and will have to be replaced.
–UN–29AUG01
pressure may form from the LOCTITE. This
T139198
separate.
Cylinder Piston Locking Tab
Use caution to prevent personal injury.
CAUTION: Use care when handling heated

03
0350 piston, in order to prevent burns.
6
8. Unscrew the piston to remove it from the piston rod.
Slide the cylinder head off the piston rod.
9. Clean and inspect the piston. Remove old LOCTITE

from threads. Replace the O-ring inside the piston.
Install the guide rings and new seal on the outside of
the piston.
10. Clean and inspect the cylinder head. Remove and

replace the O-ring on the outside of the cylinder head.
Remove the seal and guide rings. Re-install the
scraper ring and guide rings with a new seal.
11. Clean and inspect the piston rod. Remove old

LOCTITE from threads.
12. Lubricate the rod and slide the cylinder head into
place.
13. Apply LOCTITE 270 to the piston rod threads. Install

the piston onto the piston rod. Tighten the piston to
the specified torque. Bend one locking tab into place.
Main Boom Cylinder Servicing—Specification

Piston—Torque ........................................................ 1360 N•m (1006 lb-ft)
LOCTITE is a trademark of Loctite Corp. Continued on next page JK11466,00000DC –19–10JUN03–2/3

081403
PN=408
Hydraulic Cylinders
14. Lubricate the piston rod assembly and the cylinder

barrel. Push the piston rod assembly into the cylinder
barrel.
15. Thread the cylinder head into the cylinder barrel and
tighten.
16. Replace the bushings at both ends of the cylinder.

Install the bushings with the slot facing down.
JK11466,00000DC –19–10JUN03–3/3
03
0350
7

081403
PN=409
Hydraulic Cylinders
Extension Cylinder Service
03
0350
8
–UN–22NOV02
T161791
1—Cylinder Tube 7—Scraper Ring 13—Ring 18—Support Ring

2—Support 8—Piston 14—Bushing 19—O-ring
3—Support Screw 9—Piston Seal 15—Bushing 20—Ring
4—Bushing 10—Plug 16—Seal Ring 21—O-ring
5—Piston Rod 11—Seal 17—Ring 22—Lock Nut
6—cylinder Cover 12—Set Screw
1.
Continued on next page JK11466,00000DC –19–10JUN03–1/6

081403
PN=410
Hydraulic Cylinders
Extend manually the piston rod to remove any oil 2. Fasten cylinder in vise. Do not distort the cylinder
from the cylinder. tube.
JK11466,00000DC –19–10JUN03–2/6
3. Loosen the cylinder cover.
4. Pull the piston rod assembly out of the cylinder tube
5. Fasten the piston rod assembly in a vise.
–UN–20JUL01
03
0350
T139208
9
JK11466,00000DC –19–10JUN03–3/6
6. Remove the piston seal and the set screw.

dark red. The O-ring under the piston will be destroyed
by the heating and will have to be replaced.
–UN–20JUL01
pressure may form from the LOCTITE. This
T139209
separate.
Cylinder Piston Locking Ring
Use caution to prevent personal injury.
CAUTION: Use care when handling heated

piston, in order to prevent burns.
8. Unscrew the piston to remove it from the piston rod.

Slide the cylinder cap off the piston rod.

081403
PN=411
Hydraulic Cylinders
9. Clean and inspect the piston and cylinder cap.
10. Replace the seals on the piston. Replace the O-ring

inside the piston.
11. Replace the O-ring on the outside of the cylinder
–UN–20JUL01
head.
12. Disassemble the cylinder cap. Remove the scraper

ring, seal and O-rings.
T139210
13. Replace the seal on the cylinder cap.
14. Assemble the O-ring, scraper ring and seal inside the
cylinder cap.
03
0350 15. Replace the O-ring on the outside of the cylinder cap.
10
place.
17. Apply Loctite 242 and thread the piston onto the
piston rod. Torque to 180 Nm. Install the set
screwLOCTITE 242 to the piston rod threads. Install
the piston onto the piston rod. Torque to the 180 Nm
(132.7 lb-ft). Install the set screw.
18. Lubricate the piston and cylinder tube. Push the

piston rod assembly into the cylinder tube.
19. Clean and inspect the piston rod. Remove old

LOCTITE from threads.
20. Remove the seals and guide rings.
21. Re-install the scraper ring and guide rings with new
seals
22. Thread the cylinder cap into the cylinder tube and
tighten.
23. Replace the bushings at the both ends of the cylinder.

Strike out the old bushing. Insert a new bushing.

081403
PN=412
Hydraulic Cylinders
24. Inspect the cylinder supports. Replace if necessary.
–UN–20JUL01
T139212
Extension Cylinder Supports
03
0350
11
JK11466,00000DC –19–10JUN03–6/6

081403
PN=413
Hydraulic Cylinders
Outer Boom Cylinder Servicing
1.
Extend manually the piston rod to remove any oil from

the cylinder.
2. Fasten the cylinder in a vise. Do not distort the cylinder

tube.
3. Loosen the cylinder cover.
4. Pull the piston rod assembly out of the cylinder tube.
5. Fasten the piston rod assembly in a vise. Remove the

piston seal and guide rings from the outside of the
03
0350 piston.
12
6. If necessary heat the piston with a torch for 3 to 5
minutes until the material stays dark red. The O-ring
under the piston will be destroyed by the heating and
–UN–10JUN03
will have to be replaced.
T191923
separate.
1—Hydraulic cylinder.
2—Piston Rod
7. Remove the piston and the cylinder cover. 3—Cylinder barrel
4—Piston
8. Clean and inspect the piston and piston rod cylinder 5—Cap
cover. 6—Lubrication fitting
7—Bearing
8—Bushing
9. Replace the seals on the piston.
10. Replace the O-ring inside the piston.
11. Disassemble the cylinder cover and remove the

scraper ring, seal and O-ring.
12. Replace the seals on the cylinder cover. Assemble

the O-ring, scraper ring and seal inside the cylinder
cover. Replace the O-ring on the outside of the
cylinder cover.
13. Lubricate the rod and slide the cylinder cover into
place. .
Continued on next page JK11466,00000DD –19–10JUN03–1/2

081403
PN=414
Hydraulic Cylinders
14. Apply Loctite 270 and thread the piston onto the
piston rod. Torque to 1890 Nm. Lubricate the piston
and cylinder tube. Push the piston rod assembly into
the cylinder tube.
15. Thread the cylinder cover into the cylinder tube and
tighten it.
16. Replace the bushings at the both ends of the cylinder.

Strike out the old bushing. Insert a new bushing
JK11466,00000DD –19–10JUN03–2/2
Grapple Cylinder Servicing - Supergrip SG 260/360

03
0350
13
–UN–06JUN01
T139309
Supergrip SG 260/360 Grapple Cylinder
1—Grease Fitting 5—Cylinder Head 9—Cylinder Head Seal 13—Bushings

2—Rod 6—Support Ring 10—Circlip 14—Cylinder Barrel
3—Bushings 7—O-ring 11—Piston Seal 15—Grease Fitting
4—Scraper 8—Guide Ring 12—Piston

081403
PN=415
Hydraulic Cylinders
NOTE: A seal kit is available consisting of items 4, 6, 7,

8, 9 and 11.

–UN–06JUN01
T139311
1. Fasten the cylinder in a vise. Do not distort the cylinder Cylinder, Vise
tube.
2. Manually extend the rod to drain any oil from the

03
0350 cylinder barrel.
14
3. Loosen the cylinder head. Use a wrench at least a
meter (3 ft) in length with machined flat edges. Slide
the cylinder head up the rod.
4. Remove the guide ring, seal and circlip from the

cylinder barrel and slide them up the rod.
OUTJ003,0000423 –19–06FEB01–2/10
5. Pull the piston rod assembly out of the barrel. Fasten

the rod assembly in a vice and place a support under
the rod.
–UN–06JUN01
T139312
Cylinder Rod, Vise

081403
PN=416
Hydraulic Cylinders
6. Remove and discard the seal from the piston.
1—Seal
2—Piston
–UN–06JUN01
T139314
Piston, Seal
03
0350
15
OUTJ003,0000423 –19–06FEB01–4/10

pressure forms from the Loctite. This could in
certain conditions cause the bottom of the
piston to split or separate.
–UN–06JUN01
Use care to avoid risk of personal injury.
7. If necessary to release the LOCTITE, heat the piston.
T139316
Stand beside to the piston rod when using the torch.
Heat the piston for 3 to 5 minutes until the material
stays dark red. Rod, Piston, Torch
8. Unscrew the piston, using a wrench at least 1 M (3 ft)

in length.
9. Slide the cylinder head, guide ring, seal and circlip off
the rod.
10. Clean and inspect the cylinder rod. Remove any

traces of old LOCTITE from the threads.
11. Clean and inspect the piston. Install new seal.
LOCTITE is a trademark of Loctite Corp. Continued on next page OUTJ003,0000423 –19–06FEB01–5/10

081403
PN=417
Hydraulic Cylinders
12. Clean and inspect the cylinder head. Remove and

discard the support rings, seal and scraper. Install
new support rings, seal and scraper.
1—Cylinder Head
2—Support Rings
–UN–06JUN01
3—Seal
4—Scraper
T139317
Cylinder Head, Seals
03
0350
16
OUTJ003,0000423 –19–06FEB01–6/10
position. Place the guide ring, seal and circlip on the
rod.
14. Install the piston on the rod. Apply LOCTITE 270 to

the threads. Torque the piston to the value specified.
–UN–06JUN01
The pistons on the SG 260 and the SG 360 are
torqued to different values.
Grapple Cylinder Servicing - Supergrip SG 260/360—Specification
T139318
Supergrip SG 260 Cylinder
Piston—Torque ............................................................ 700 N•m (525 lb-ft)
Rod, Cylinder Head, Seals
Piston—Torque ............................................................ 850 N•m (650 lb-ft)
15. Lubricate the piston and the cylinder barrel. Push the
cylinder rod assembly into the cylinder tube.
16. Install the circlip in the cylinder barrel. Position the

seal. Position the guide ring.
17. Thread the cylinder head into the cylinder barrel and
torque to top nut to the value specified.

Head—Torque ............................................................. 700 N•m (525 lb-ft)
Head—Torque ............................................................. 850 N•m (650 lb-ft)

081403
PN=418
Hydraulic Cylinders
18. Place the cylinder in a vise.
Drive out the old bushings using suitable mandrel. To

protect the sealing abilities of the bushings, be careful
not to damage the edges of the bore.
–UN–06JUN01
T139319
Cylinder Bushings Removal
03
0350
17
OUTJ003,0000423 –19–06FEB01–8/10
19. Insert new bushings using suitable mandrel.
–UN–06JUN01
T139320
Cylinder Bushings Installation

081403
PN=419
Hydraulic Cylinders
20. Remove grease fitting from cylinder.
Drill a 4 mm (3/16 in.) hole through the bushings. This

hole must be drilled in order to lubricate the bushing
from the grease fitting.
–UN–06JUN01
Cylinder Bushing Grease Fitting
Hole—Diameter ................................................................. 4 mm (3/16 in.)
Install the grease fitting.
T139321
21. Repeat this procedure at both ends of the cylinder.
03
0350
18
OUTJ003,0000423 –19–06FEB01–10/10
Grapple Cylinder Servicing - Loglift GF25/GF35
–UN–06JUN01
T139322
1—Piston Rod 5—Cylinder Head 9—O-ring 12—Piston Seal

2—Wiper Ring 6—O-Ring 10—Piston 13—Guide Ring
3—Seal 7—Support Ring 11—Piston Lock Tab 14—Cylinder Barrel
4—Guide Ring 8—O-ring

081403
PN=420
Hydraulic Cylinders
NOTE: A seal kit is available consisting of items 2, 3, 4,

6, 7, 8, 9, 12 and 13.

–UN–06JUN01
T139323
1. Fasten the cylinder in a vise. Do not distort the cylinder

tube.
2. Loosen the cylinder head. Pull the piston rod assembly

03
out of the cylinder barrel. 0350
19
3. Fasten the rod assembly in a vise.
4. Remove the seal and guide ring from the piston. Bend
up the lock tab on the piston.
OUTJ003,0000424 –19–06FEB01–2/7

pressure forms from the Loctite. This could in
certain conditions cause the bottom of the
piston to split or separate.
–UN–06JUN01
Use care to avoid risk of personal injury.
T139324
dark red. Heating will destroy the o-ring under the
piston requiring it to be replaced.
6. Remove the piston.
7. Slide the cylinder head off the rod.
8. Clean and inspect the rod. Remove all traces of old

LOCTITE from the threads.

081403
PN=421
Hydraulic Cylinders
9. Clean and inspect the piston. Replace the guide ring,

seal and o-ring on the piston.
–UN–06JUN01
T139325
OUTJ003,0000424 –19–06FEB01–4/7
10. Clean and inspect the cylinder head. Replace the
–UN–06JUN01
03 cylinder barrel seals and support ring. Replace the
0350 rod guide rings, seal and wiper.
20
T139326
position.
OUTJ003,0000424 –19–06FEB01–5/7
12. Apply LOCTITE 242 and thread the piston onto the
piston rod. Tighten the piston to the specified torque.
Bend one lock tab on the piston.
13. Lubricate the piston and the cylinder barrel. Push the
piston rod assembly into cylinder barrel.
–UN–06JUN01
14. Thread the top nut into the cylinder tube and tighten.
T139327

081403
PN=422
Hydraulic Cylinders
–UN–06JUN01
03
0350
21
T139328
1—Cylinder 2—Grease Fitting 3—Seal Ring 4—Bushing
15. Remove cylinder from grapple. Place piston end of 18. Install new seal rings.
the cylinder in a vise.
19. Repeat the procedure at the piston end of the
16. Remove the seal rings on both sides of the base cylinder. The piston end has a single bushing,
end of the cylinder. Strike out the two bushings which is also installed with the split facing down.
using a suitable mandrel. Be careful not to
damage the edges of the bore.
17. Insert new bushings, one from each side, with the
split in the bushings facing downwards.
OUTJ003,0000424 –19–06FEB01–7/7

081403
PN=423
Hydraulic Cylinders
03
0350
22

081403
PN=424
Group 0360
Hydraulic Schematics
Hydraulic Diagram Symbols
1—Working Line (Main)
2—Pilot Line (Control)
3—Enclosure Outline
4—Hydraulic Flow Direction
5—Pneumatic Flow Direction
6—Lines Crossing on Schematic
7—Hoses Joining
8—Flexible Lines
9—Lines to Reservoir - Above Fluid Level
10—Lines to Reservoir - Below Fluid Level
11—Mechanical Connection (Rod, Shaft, Lever, etc.)
03
0360
1
–UN–08MAY01
T142009
Hydraulic Schematic Symbols - Lines and Hoses
Continued on next page jk11466,00005A8 –19–20SEP02–1/5

081403
PN=425
1—Hydraulic Pump - Fixed Displacement

2—Hydraulic Pump - Variable Displacement
3—Hydraulic Pump - Bidirectional
4—Hydraulic Motor - Fixed Displacement
5—Hydraulic Motor - Variable Displacement
6—Hydraulic Motor - Bidirectional
03
0360
2
–UN–20JUL01
T138856
Hydraulic Schematic Symbols - Pumps and Motors

081403
PN=426
1—Single Acting
2—Double Acting - Single Rod End
3—Double Acting - Adjustable Cushion
4—Double Acting - Differential Piston
03
0360
3
–UN–20JUL01
T139189
Hydraulic Schematic Symbols - Cylinders

081403
PN=427
1—Spring
2—Manual
3—Push Button
4—Push - Pull Lever
5—Pedal
6—Mechanical
7—Detent
8—Pressure Compensated
9—Solenoid - Single Winding
10—Servo Motor
11—Pilot Pressure - Remote Supply
12—Pilot Pressure - Internal Supply
03
0360
4
–UN–08MAY01
T139203
Hydraulic Schematic Symbols - Methods of Operation

081403
PN=428
1—Check Valve
2—On - Off (Manual Shutoff)
3—Pressure Relief
4—Pressure Reducing
5—Flow Control with Fixed Restriction
6—Flow Control, Adjustable, Non-compensated
7—Flow Control Adjustable, Temperature and/or
Pressure Compensated
8—Velocity Fuse
9—Spool - Two Position, Two Way
10—Spool - Two Position, Three Way
11—Spool - Two position, Four Way
12—Spool - Three Position, Four Way
13—Spool - Two Position, In Transition
14—Spool - Infinite Position Valve
03
0360
5
–UN–08MAY01
T138886
Hydraulic Schematic Symbols - Methods of Operation
jk11466,00005A8 –19–20SEP02–5/5

081403
PN=429
Content
The hydraulic schematics are in following order by

machine models:
1. 810D
2. 1010D
3. 1110D
4. 1410D
5. 1710D
Every machine model includes the same pages, which are

listed below.
1. Boom Hydraulics
2. Transmission Hydraulics
03
0360 3. Brake Hydraulics
6 4. Extra Equipment Hydraulics
5. ’Options’ Hydraulics
6. Optional Clambunk Hydraulics
EL62757,0000001 –19–27MAY02–1/1

081403
PN=430
03
0360
7

081403
PN=431
810D Boom Hydraulics
Position Meaning Pressure Pressure Placement

(MPa) (psi)
100 Work pump Under the cab
101 Adjustment of work pump’s max. 24 3481 Work pump
pressure
102 Adjustment of work pump’s pressure 2,5 362,5 Work pump
difference
103 Return filter 0,15 22 Front frame
104 Hydraulic tank Front frame
105 Level guard Hydraulic tank
106 Temperature sensor Hydraulic tank
107 Bleeding Hydraulic tank
108 Bleed screw 0,02 3 Hydraulic tank
03
0360 109 Pressure valve W84 0,13 19 Hydraulic tank
8 110 Quick coupler , filling of hydraulic oil Main switch
111 Pressure measure point, work pump’s Attachement valve
pressure
112 Adjustment screw, reduced pressure of 3 435 Attachement valve
attachements
113 Pressure valve W41A, parking brake 2 290 Attachement valve
114 Pressure measure point, reduced Attachement valve
pressure of attachements
115 Attachement block Attachement valve
116 Pressure measure point, work pump’s Attachement valve
signal pressure
117 Differential front Attachement valve
119 Differential rear Attachement valve
120 Rear wheel drive, engagement with high Attachement valve
gear on
121 High/low gear Attachement valve
122 Orfice Boom valve
123 Pressure measure point, boom Boom valve
pressures for each movement
124 Pressure reduce valve 26 3771 Boom valve
125 Boom valve Under the cab
126 Pilot valve Boom valve
127 Lift cylinder Boom
128 Jib cylinder Boom
129 Telescope cylinder Boom

081403
PN=432
03
0360
9
–UN–09APR03
T189401

081403
PN=433
130 Pressure reduce, boom slew Boom valve

131 Boom slew float Under the cab
132 Cylinders for boom slew Boom
133 Reduced pressure for grapple, (closed) 19 2756 Boom valve
134 Reduced Pressure for grapple, (open) 17 2466 Boom valve
135 Grapple cylinder Boom
136 Rotator Boom
137 Frame steering Rear frame
138 Pressure measuring point, pilot pressure for Boom Behind the cabine
valve
139 Pilot valve, frame steering Above the Boom valve
03
0360
10

081403
PN=434
03
0360
11
–UN–09APR03
T189401

081403
PN=435
2/5 Transmission Hydraulics
Position Meaning Pressure (MPa) Pressure (psi) Placement

200 Pulse sensor, diesel engine Diesel engine
201 Transmission pump Under the cab
202 Oil cooler Front frame
203 Thermostat valve Under the cab
204 Measure point for charge pressure Transmission pump
205 Pressure sensor 1,5 217 Transmission pump
206 Measure point for drive pressure; drive pressure Transmission pump
backwards
207 Adjustment of hydrostatic charge pressure 3 435 Transmission pump
208 Drive pump pressure cut-off Transmission pump
209 Adjustment of pressure reduce valve: drive 48 6961,8 Transmission pump
03 pressure backwards
0360 210 Adjustment of hydrostatic drive pressure forward 45 6526,7 Transmission pump
12 and backwards
pressure forward
212 Pressure reduce valve, transmission pump Transmission pump
213 Charge pressure filter Transmission pump
214 Measure point for transmission pressure; drive Transmission pump
pressure forward
215 Direction identification valve in drive motor Drive motor
216 Measure point, motor’s control pressure/ motor Drive motor
pressure cut-off
217 Adjustment of drive motor’s pressure cut-off 36 5221 Drive motor
218 Drive motor’s pressure cut-off Drive motor
219 Pulse sensor, drive motor Drive motor
220 Drive motor Under the cab

081403
PN=436
03
0360
13
–UN–09APR03
T189402

081403
PN=437
3/5 Brake Hydraulics

300 Brake valve Under the cab
301 Measure point, pressure accumulator Under the cab
302 Pressure accumulator Under the cab
303 Pressure sensor, brake light 0,5 72,5 Brake valve
304 Measure point for brake pressure Brake valve
306 Orifice Brake valve
307 Measure point, pressure accumulator Brake valve
309 Pressure sensor, brakes’ charge pressure 10 1450 Brake valve
310 Front brake cylinders Front axle
03
311 Rear brake cylinders Rear axle
0360
14 312 Brake fluid container Cab, front
313 Front brake pedal Cabin
314 Rear brake pedal Cabin
315 Shuttle valve Brake valve

081403
PN=438
03
0360
15
–UN–09APR03
T189403

081403
PN=439
4/5 Extra Equipment Hydraulics

400 Hydraulic oil pump Under the cab
401 Hydraulic oil tank Front frame
402 Filling pump, hydraulic oil Under the cab
403 Quick coupler Main switch
404 Compressed air valve Hydraulic tank
405 Vacuum pump Under the cab
406 Bleeding valve filter Hydraulic tank
407 Vacuum valve 0.03 4,4 Under the cab
408 Bleeding valve 0.05 7,25 Under the cab
409 Adjustment screw, frame brake pressure 21 3046 Attachement valve
410 Solenoid Y65, frame brake Attachement valve
03
411 Measure point, frame brake pressure Middle joint
0360
16 412 Frame brake cylinder Middle joint
415 Steering valve Rear frame
416 Manual steering valve, frame steering Cabin
417 Steering valve, frame steering Pilot valve
418 Shuttle valve Front frame
419 Directional valve, stairs Front frame
420 Valve, stairs Front frame
421 Shuttle valve, clambunk Front frame
422 Quick couplers Front frame
423 Pilot valve for decking blade Under the cab
424 Floating valve for decking blade Under the cab
425 Manual reduction valve of decking blade At main switch
426 Decking blade cylinders Front frame
427 Valve, hand brake (extra equipment) Cabin

081403
PN=440
03
0360
17
–UN–09APR03
T189404

081403
PN=441
5/5 Options Hydraulics

502 Proportional valve for decking blade Under the cab
503 Proportional pilot valve for decking blade Under the cab
504 Adjustment for decking blade reduced pressure 21 3046 Proportional valve for
decking blade
506 Counter balance valve for decking blade Under the cab
508 Damper for lift On the boom slew cylinder
509 Lift cylinder Boom valve, rear
03 510 Damper for boom slew On the boom slew cylinder
0360
511 Cylinder, boom slew Boom foot
18
512 Cylinders, frame steering Middle joint
513 Control valve, ASF Front frame
514 Headboard move valve Headboard
515 Headboard move cylinder Under the cab
516 Pump, cabin lift Under the cab
517 Shuttle valve Hand pump
518 Pressure adjust valve Under cabin
519 Cabin lift cylinder, front Under the cab
520 Cabin lift cylinder, rear Under the cab

081403
PN=442
03
0360
19
–UN–09APR03
T189405
EL62757,00001E8 –19–22APR02–12/12

081403
PN=443
1010D Hydraulic Diagrams
1/5 Boom Hydraulics (F623175)
Position Item Pressure (MPa) Pressure (Psi) Location

101 Adjustment of work pump’s max. pressure 24 3481 Work pump
102 Adjustment of work pump’s pressure difference 2,5 362,5 Work pump
103 Return filter 0,15 21,75 Front frame
104 Temperature sensor, W 80A Front frame
105 Level guard,W 81 Front frame
107 Pressure balancing valve Front frame
108 Breather 0,02 3 Front frame
03 109 Pressure valve W84, clogging of the return filter 0,13 19 Front frame
0360
110 Quick coupler , filling of hydraulic oil Main switch
20
111 Measure point, work pump’s pressure Attachement valve
112 Measure point, reduced pressure of the parking Attachement valve
brake
114 Adjustment screw, reduced pressure of the parking 4 580 Attachement valve
brake
attachements
116 Measure point, reduced pressure of attachements Attachement valve
117 Attachement valve Attachement valve
118 Measure point, work pump’s signal pressure Attachement valve
119 Differential, front Attachement valve
120 Differential, rear Attachement valve
121 Rear wheel drive, engagement with high gear on Attachement valve
123 Orifice, 0.7 mm, for a signal line Boom valve
124 Measure point; Boom valve signal pressure Boom valve
125 Pressure reduction valve 26 3771 Boom valve
126 Boom valve Boom valve
127 Pilot valves (14 pcs) Boom valve
128 Pressure reduction valve, boom slew Under the cab
129 Boom slew cylinders Boom

081403
PN=444
03
0360
21
–UN–21NOV02
T162005

081403
PN=445

130 Reduced pressure for boom slew 21.5 3118 Boom valve
133 Reduced pressure for grapple, (closed) 19 2756 Boom valve
134 Reduced Pressure for grapple, (open) 17 2466 Boom valve
136 Rotator Boom
139 Reduced pressure for frame steering 21.5 3118 Boom valve
140 Boom valve, pilot pressure Under the cab
141 Frame brake pressure Under the boom
142 Frame brake cylinder Under the boom
03
0360 143 Check valve, drive circuit bleed line 0.2 29 On the hydraulic tank
22 144 Check valve, boom return 0.2 29 On the hydraulic tank

081403
PN=446
03
0360
23
–UN–21NOV02
T162005

081403
PN=447
2/5 Drive hydraulics (F623175)

201 Measure point, pump pilot pressure, forward Transmission pump
204 Pressure sensor, W 82A, charge pressure 1,5 217,5 Transmission pump
205 Charge pressure of hydrostatic system On the fuel pump
206 Measure point, pump pilot pressure, backwards Transmission pump
207 Measure point, drive pressure forward Transmission pump
208 Adjustment of hydrostatic system’s charge 3 MPa 435 Transmission pump
pressure
209 Transmission pump’s pressure cut-off Transmission pump
03 210 Adjustment of pressure reduction valve, drive 44 6381,7 Transmission pump
0360 pressure forward
24
211 Adjustment of drive pressure: forward and 41 5946,5 Transmission pump
backwards
212 Adjustment of pressure reduction valve, drive 44 6381,7 Transmission pump
pressure backwards
213 Pressure reduction valve, Transmission pump Transmission pump
214 Measure point, DA Cartridge Valve Transmission pump
216 Measure point, drive pressure backwards Transmission pump
217 Directional valve, drive forward and backwards Drive motor
218 Pressure sensor 0.4 58 Drive motor
219 Measure point, hydrostatics pilot pressure Drive direction valve
220 Drive pedal Cabine
221 Measure point, Drive motor pressure cut-off Drive motor
222 Direction recognition valve, Y103B Drive motor
223 —
224 Drive motor, pressure cut-off Drive motor
225 Adjustment of pressure cut-off, drive motor 29 4206 Drive motor
226 Adjustment of starting point of drive motor 1,4 203 Drive motor
adjustment
228 Check valve 0,05 7,25 Under the cab

081403
PN=448
03
0360
25
–UN–21NOV02
T162006

081403
PN=449
3/5 Brake hydraulics (F623175)
Position Item Pressure (MPa) Pressure (psi) Location

303 Measure point for brake pressure, rear brake Brake valve
cylinder
304 Measure point for brake pressure, front brake Brake valve
cylinder
305 Orfice Brake valve
308 Pressure sensor, W 37A, brakes’ charge pressure 10 1450 Brake valve
03 309 Front brake cylinder Front axle

0360 310 Rear brake cylinder Rear axle
26
311 Brake fluid container In the front of the cab
312 Front brake pedal Cabine
313 Rear brake pedal Cabine
314 Shuttle valve Under the cab

081403
PN=450
03
0360
27
–UN–21NOV02
T162007

081403
PN=451
4/5 Extra Equipment (F623175)
Position Item Pressure (MPa) Pressure (psi) Location

402 Directional valve, boom On the hydraulic tank
403 Boom swing damper Rear frame
404 Boom swing cylinder Rear frame
405 Boom lift damper Rear frame
406 Lift cylinder Rear frame
407 Frame steering cylinders Rear frame
408 Pilot valve, frame steering Cabine
409 Mechanical pilot valve, frame steering Pilot valve
03
411 Pilot valve, Headboard movement Under the cab
0360
28 412 Headboard movement cylinder Rear frame
413 Pilot valve, Decking blade Under the cab
414 Decking blade float valve Under the cab
415 Decking blade manual valve tap At main switch
417 Quick coupling Front frame
418 Directional valve Front frame
419 Valve block, auxiliary functions Under the cab
420 Adjustment of Frame brake pressure 21 3045 Attachement valve
421 Measure point, Frame brake pressure Frame brake
422 Frame brake Rear frame

081403
PN=452
03
0360
29
–UN–21NOV02
T162008

081403
PN=453
5/5 Options (F623175)
Position Item Pressure (MPa) Location

501 Measure point, Drive motor control pressure Drive motor
502 Drive pedal Cabine
503 Pilot pressure for pump and motor Drive direction valve
504 Speed limit valve Under the cab
505 Valve block, auxiliary functions Under the cab
506 Frame brake, valve (4-wheels) Rear frame
507 Frame brake cylinder, (4-wheels) Rear frame
508 Hand pump for cab lift Under the cab
509 Directional valve Manual pump
510 Cab lift cylinder Under the cab
03
0360
30

081403
PN=454
03
0360
31
–UN–21NOV02
T162009
EL62757,00001E8 –19–22APR02–12/12

081403
PN=455
1/5 Boom Hydraulics

0360
32
111 Pressure measure point, work pump’s pressure Attachement valve
attachements
114 Pressure measure point, reduced pressure of Attachement valve
attachements
116 Pressure measure point, , pressures for each Attachement valve
function of the boom
117 Pressure measure point, work pump’s signal Attachement valve
pressure
122 Pilot valve for boom valve boom valve
123 Pilot pressure for boom valve boom valve
124 Pressure measure point, Pilot pressure for boom 3.5 508 boom valve
valve
125 Pressure reduce valve 26 3771 boom valve
126 Orifice for a signal line boom valve
127 boom valve Under the cab
128 Pressure reduction for Boom slew Under the cab
130-131 Reduced pressure for boom slew 21.5 3118 boom valve
Continued on next page JK11466,0000001 –19–04APR03–1/12

081403
PN=456
03
0360
33
–UN–19MAY03
T164870

081403
PN=457

134 Rotator Boom
136 Reduced pressure for grapple, (closed) 19 2756 boom valve
137 Reduced Pressure for grapple, (open) 17 2466 boom valve
138 Telescope cylinder 21.5 3118 Boom
140-141 Reduced pressure for frame steering boom valve
142 Pilot valve, frame steering Under the cab
03
0360
34

081403
PN=458
03
0360
35
–UN–19MAY03
T164870

081403
PN=459

205 Pressure sensor 1,5 217 Transmission pump
backwards
36 and backwards
pressure forward
pressure forward
pressure cut-off

081403
PN=460
03
0360
37
–UN–19MAY03
T164871

081403
PN=461

03
0360
315 Shuttle valve Brake valve

081403
PN=462
03
0360
39
–UN–19MAY03
T164872

081403
PN=463

03
0360
419 Stairs’ steering valve Front frame
420 Stairs’ cylinder Front frame
422 Quick coupler Front frame
424 Valve, hand brake (extra equipment) Cabin

081403
PN=464
03
0360
41
–UN–19MAY03
T164873

081403
PN=465

502 Valve for load space expansion (VLS) Boom foot
503 Cylinders for load space expansion (VLS) Boom foot
504 Cylinders for Headboard expansion (2 pc.) (VLS) Headboard
505 Headboard lift valve Under the cab
506 Shuttle valve Hand pump
507 Pressure adjust valve Under cabin
508 Cabin, Lift cylinder, front Under the cab
509 Cabin, Lift cylinder, rear Under the cab
03
511 Damper for boom slew On the boom slew cylinder
0360
42 512 Cylinder for boom slew Boom foot
513 Plug boom valve, rear
514 Damper for lift On the boom slew cylinder
515 Lift cylinder Boom foot
clambunk
519 Load reduction valve for decking blade Under the cab
521 Headboard lift and move cylinder Headboard
522 Movement valve for decking blade Under the cab
525 On/Off -valve for decking blade Under the cab
526 Pilot valve for decking blade Under the cab

081403
PN=466
03
0360
43
–UN–19MAY03
T164874
JK11466,0000001 –19–04APR03–12/12

081403
PN=467
1/5 Boom Hydraulics

0360
44
attachements
attachements
pressure
123 Pressure measure point, pilot pressure for boom 3.5 508 boom valve
valve
124 Pressure reduce valve 26 3771 boom valve
125 Orifice for a signal line boom valve
129-130 Reduced pressure for boom slew 21.5 3118 boom valve
Continued on next page EL62757,0000062 –67–17OCT02–1/12

081403
PN=468
03
0360
45
–UN–09OCT02
T160341

081403
PN=469

133 Rotator Boom
135 Reduced pressure for grapple, (closed) 19 2756 boom valve
136 Reduced Pressure for grapple, (open) 17 2466 boom valve
137 Telescope cylinder 21.5 3118 Boom
139-140 Reduced pressure for frame steering boom valve
141 Pilot valve, frame steering Under the cab
03
0360
46

081403
PN=470
03
0360
47
–UN–09OCT02
T160341

081403
PN=471

205 Pressure sensor 1,0 MPa 145 Transmission pump
backwards
48 and backwards
pressure forward
pressure forward
pressure cut-off

081403
PN=472
03
0360
49
–UN–09OCT02
T160342

081403
PN=473

03
0360

081403
PN=474
03
0360
51
–UN–09OCT02
T160343

081403
PN=475

03
0360
424 Valve, hand brake (extra equipment)

081403
PN=476
03
0360
53
–UN–09OCT02
T160344

081403
PN=477

502 Valve for load space expansion Boom foot
503 Cylinders for load space expansion Boom foot
504 Cylinders for Headboard expansion (2 pc.) Headboard
506 Headboard lift cylinder Headboard
507 Hand pump for cab lift Front frame
508 Directional valve Hand pump
509 Pressure reduce valve Under the cab
03
0360
54 512 boom valve Under the cab
513 Plug boom valve, rear
clambunk
523 Headboard move cylinder Headboard
524 Headboard lift- and move valve Under the cab

081403
PN=478
03
0360
55
–UN–09OCT02
T160345
EL62757,0000062 –67–17OCT02–12/12

081403
PN=479
03
0360
56
–UN–07FEB02
T151078

081403
PN=480
1/6 Boom Hydraulics (F619741)

102 Adjustment of work pump’s pressure difference I2,5 1813 Work pump
105 Level guard Front frame
106 Temperature sensor Front frame
107 Bleeding Front frame
108 Bleed screw 0,02 3 Front frame
109 Pressure valve W84 0,13 19 Front frame
03
0360
112 Pressure measure point, , reduced pressure of Attachement valve 57
parking brake
114 Adjustment screw, reduced pressure of parking 6 870 Attachement valve
brake
attachements
pressure
attachements
124 Pilot valve for loader valve Loader valve
125 Pressure measure point, pilot pressure for loader 3.5 508 Loader valve
valve
126 Pressure reduce valve 26 3771 Loader valve
127 Orifice for a signal line Loader valve

081403
PN=481
03
0360
58
–UN–07FEB02
T151078

081403
PN=482

128 Loader valve Under the cab
131-132 Reduced pressure for boom slew 21.5 3118 Loader valve
135 Rotator Boom
137 Reduced pressure for grapple, (closed) 19 2756 Loader valve
138 Reduced Pressure for grapple, (open) 17 2466 Loader valve
141-142 Reduced pressure for frame steering 21.5 3118 Loader valve
03
143 Pilot valve, frame steering Under the cab 0360
59

081403
PN=483
03
0360
60
–UN–07FEB02
T151079

081403
PN=484
2/6 Transmission Hydraulics (F619741)

205 Pressure sensor 1,0 MPa Transmission pump
backwards
209 Adjustment of pressure reduce valve: drive 46 6672 Transmission pump
pressure backwards 03
210 Adjustment of hydrostatic drive pressure forward 43 6237 Transmission pump 0360
and backwards 61
211 Adjustment of pressure reduce valve: drive 46 6672 Transmission pump
pressure forward
pressure forward
pressure cut-off

081403
PN=485
03
0360
62
–UN–07FEB02
T151080
F619741 3/5

081403
PN=486
3/6 Brake Hydraulics (F619741)

03
0360
312 Brake fluid container Cab, front 63

081403
PN=487
03
0360
64
–UN–07FEB02
T151081
F619741 4/5

081403
PN=488
4/6 Extra Equipment Hydraulics (F619741)

407 Vacuum valve Under the cab
408 Bleeding valve Under the cab
410 Solenoid, frame brake Attachement valve
03
0360
412 Frame brake cylinder Middle joint 65
413 Loader valve Under the cab
420 Orifices Front frame

081403
PN=489
03
0360
66
–UN–07FEB02
T151082
F619741 5/5

081403
PN=490
5/6 Options Hydraulics (F619741)

502 Valve for load space expansion Boom foot
503 Cylinders for load space expansion Boom foot
504 Cylinders for Headboard expansion (2 pc.) Headboard
507 Hand pump for cab lift Front frame
508 Directional valve Hand pump
509 Pressure reduce valve Under the cab
03
0360
512 Loader valve Under the cab 67
513 Plug Loader valve, rear
clambunk
523 Headboard move cylinder Headboard
524 Headboard lift- and move valve Under the cab

081403
PN=491
03
0360
68
–UN–19FEB02
T151618

081403
PN=492
6/6 Optional Clambunk Hydraulics (F621882)

602 Adjustment of work pump’s max-pressure 24 3481 Work pump
603 Adjustment of work pump’s pressure difference 2.5 362,5 Work pump
604 Attachement block Under the cab
607 Adjustment screw, lift up 27 3916 Boom valve
608 Adjustment screw, lift down 5 725 Boom valve
610 Adjustment screw, steering right 21.5 3118 Boom valve
03
611 Adjustment screw, steering left 21.5 3118 Boom valve
0360
612 Plug Boom valve 69
613 Measure point, pilot pressure 3.5 508 Clambunk valve
614 Measure point, LS-Pressure Clambunk valve
615 Clambunk pilot valve Rear frame
616 Adjustment screw, right arm up 17.5 2538 Clambunk valve
617 Adjustment screw, right arm down 17.5 2538 Clambunk valve
618 Cylinder, right clambunk arm Rear frame
619 Adjustment screw, left arm up 17.5 2538 Clambunk valve
620 Adjustment screw, left arm down 17.5 2538 Clambunk valve
621 Cylinder, left clambunk arm Rear frame
622 Adjustment screw, cable tension 16 2321 Clambunk valve
623 Adjustment screw, releasing the cable tension 27 3916 Clambunk valve
624 Cable tensioning cylinders Rear frame
JK11466,00000A1 –19–06FEB03–14/14

081403
PN=493
03
0360
70

081403
PN=494
Group 0370
Diagnostic Information
Diagnose Work Hydraulics
Diagnose Work Hydraulics System
JK11466,000000A –19–06MAY03–1/1
1 Hydraulic System
– – –1/1
Hoses and Fittings Inspect all hoses. OK: Go on to next check.

03
LOOK: Hoses should not be twisted, kinked or show indications of wear. NOT OK: Straighten or
0370
replace hoses as
1
Inspect all fittings. required.
LOOK: Fittings should be tight. Check for accumulations of dust and dirt that may Tighten fittings or replace
indicate leaks. o-rings on fittings, as
required.
– – –1/1

081403
PN=495
Hydraulic Tank and Start engine. OK: Go on to next check.

Filters
LOOK: Hydraulic Return Filter Restriction Alarm should not be shown on TMC Screen NOT OK: Replace
hydraulic return filter.
NOTE: In cold conditions, the Hydraulic Return Filter Restriction Alarm may be shown
on TMC screen until the oil warms to normal operating temperature. The light must go
out after a few minutes.
Start engine. OK: Go on to next check.
LOOK: Hydraulic Pressure Filter Restriction Alarm should not be shown on TMC NOT OK: Replace
screen hydraulic pressure filter.
03 Start engine. OK: Go on to next check.

0370
2 LOOK: Low Hydraulic Oil Level Alarm should not be sown on TMC screen NOT OK: Add hydraulic
fluid to tank.
Start engine. OK: Go on to next check.
LOOK: Hydraulic Oil Temperature Alarm should not be shown. NOT OK: See secton 16
for procedures to
NOTE: Shut off engine before proceeding to next check. diagnose circuit
malfunction.
See Section 21, for

procedures to diagnose
Hydraulic System
Overheating.
– – –1/1
Work Pump OK: Go on to next check.
NOT OK: Tighten bolts or

fittings.
See Repair Manual,

Section 21, Group 2161,
for procedures to service
work pump.
T138625 –UN–20JUL01
Inspect hydraulic work pump.
LOOK: Pump should be in good condition. Check for indications of leaks at the fittings
and drive shaft seals. Mounting bolts should be tight. Test port caps should be in
place.
– – –1/1

081403
PN=496
2 Cab Tilt System
– – –1/1
Cab Tilt System OK: Go on to next check.
NOT OK: Service the

pump and cylinder as
required.
03
0370
3
T141587 –UN–13AUG01
Operate the Cab Tilt System to raise and lower the cab. (See group 1820 for
procedure))
LOOK/FEEL: Cab Tilt pump and cylinder should operate smoothly. The cylinder should
not settle under load.
– – –1/1
Cab Tilt Cylinder and Inspect Cab Tilt Cylinder. OK: Go on to next check.
Hoses
LOOK: Cylinder should be in good condition. Seals should not show indications of NOT OK: Repair or
leaks. replace cylinder as
required.
Inspect all hoses.
Straighten or replace
LOOK: Hoses should not be twisted, kinked or show indications of wear. hoses as required.
Inspect all fittings. Tighten or replace fittings

as required.
LOOK: Fittings should be tight. Check for accumulations of dust and dirt that may
indicate leaks. Tighten fittings or replace o-rings on fittings, as required.
– – –1/1

081403
PN=497
Cab Tilt Safety Support 1—Cab Tilt Safety Support OK: Check complete.
2—Rod
3—Lower Tube NOT OK: Repair or
4—Wing Screw replace safety support as
required.
Raise the cab.
Put the Safety Support in the “Locked” position by

dropping the rod into the lower tube. Secure the rod with
the wing screw.
LOOK: The safety support should be in good condition

with no bends, kinks or indications of wear. The full
length of the rod should drop smoothly into the lower
tube. The wing screw should be in place and should
securely hold the rod in position. The fasteners at the
top and bottom of the safety support should be in good
condition.
03
0370 T141588 –UN–13AUG01
4
– – –1/1

081403
PN=498
Diagnose Drive Hydraulics
Diagnose Drive system
This procedure is designed so the technician can make a

quick check of the operation of the machine while sitting
in the operator’s seat.
A location will be required that is level and has adequate

space to complete the driving checks and to work the
machine.
The engine and all other major components must be at

Complete the necessary visual checks (oil levels, oil

03
condition, external leaks, loose hardware, loose linkage, 0370
etc.) before doing the checkout. 5
No special tools or gauges are needed. Always start in

the left column and read completely, following this
sequence from left to right. Read each check completely
before performing.
At the end of each check, if no problem is found (OK),

you will be instructed to go to next check. If problem is
indicated (NOT OK), you will be given repair required.
Overheating, noise or vibration, Insufficient hydraulic fluid. Check hydraulic oil level on sight
low system pressure gauge on tank. Fill up tank, if
necessary.
Restrictions in lines. Check for hoses that are plugged or

pinched. Plugged hoses will remain
cool to the touch when the system
warms up to operating temperature.
Do not touch hot fittings. Repair as
necessary.
Leakage in lines or fittings. Inspect for leaks. Tighten fittings.

Repair or replace damaged hoses.
Continued on next page OUTJ003,00002D4 –19–17JAN01–1/8

081403
PN=499
Stuck thermostat valve or dirty oil Stuck valve by-passing cooler will
cooler. cause overheating. Repair if
necessary.
Clean oil cooler, if necessary.
Air in hydrostatic system. Check for foam in reservoir. Inspect

for leaks in charge pump inlet hose.
De-aerate system by letting reservoir

settle until the bubbles are gone.
Run the system slowly to move fluid
to the reservoir.
03
0370 By-pass valves in drive pump stuck (See Repair Manual for procedures
6 open. to service the by-pass valves.)
Flex plate and drive coupling Check work pump. If operation is

operating incorrectly. normal, flex plate and drive coupling
are in good working order.
See group 03, Hydraulic System

Adjustments, for proper pressures.
Incorrect charge and/or drive Low charge and low drive pressures
pressures can lead to poor system
performance. High drive pressures
can lead to overheating.
Brakes not releasing correctly Check the brakes and adjust if

necessary.
Low engine RPM Low engine speed will reduce

system performance. Adjust engine
speed.
Drive Will Not Operate in Either Cab steps are down. Raise cab steps.
Direction
Cab Steps Switch is malfunctioning. Diagnose the Cab Steps Switch.
Operator is not seated. Operator must be seated for Drive

Direction Select to function.
Seat Safety Switch is malfunctioning. Diagnose the Seat Safety Switch.

081403
PN=500
Incorrect pilot pressure in drive pedal Check Hydrostatic Drive System

circuit Pilot Pressure.
Faulty direction selection solenoids Inspect direction selection solenoids.

Replace if necessary.
Burst hose or loose fitting. Inspect hoses and fittings. Replace if

necessary.
Hydraulic hoses incorrectly installed. Check schematic to confirm correct

hose routing.
Brakes not released. Release brakes.

03
Fault in power train. Check transfer case, drivelines and 0370
axles for mechanical defect. 7
Diagnose Drive Pump
NOTE: The following troubleshooting tips refer to the

hydrostatic drive pump. See Diagnose Hydrostatic
Drive System, and Diagnose Hydrostatic Drive
Motor, for other procedures not shown here.
Confirm that there is a mechanical problem by

doing a test drive of the unit before doing any
repairs or adjustments.
’Neutral’ is difficult or impossible Control signal fault. Remove control lines to determine if
to find. pump returns to neutral without
control signal. If it does, remedy
control signal.
Faulty direction selection solenoids. Inspect solenoids. Replace as

necessary.
Faulty swashplate positioning A centering spring in the pump

control. control valve positions the
swashplate in the neutral position.
See Section 03, for procedures to
adjust centering of pump.
Contact authorized personnel to

repair or replace the control valve.

081403
PN=501
System overheating. Insufficient hydraulic fluid. Check the supply of oil to the pump.
Low oil level in the tank or a blocked
or kinked suction hose will not
provide sufficient oil to meet system
cooling demands.
Low charge pressure. See Section 03, for procedures to

check and adjust the charge
pressure.
Check the charge pump for leaks or

malfunctions.
Check the charge pressure filter for

03
0370 clogs.
8
High drive pressures. See Section 03, for procedures to
check and adjust the drive
pressures.
Low drive pressures. See Section 03 for procedures to

pressures.
Drive operates normally in one Fault in control line or pilot signal. Switch control lines. If drive operates
direction only. only in other direction, remedy pilot
signal. If drive problem remains
unchanged, service pump.
Faulty direction selection solenoids Inspect solenoids. Replace if

necessary.
Faulty swashplate positioning A centering spring in the pump


Faulty drive pressure relief valves. See Section 03 for procedures to

pressures. Switch drive pressure
relief valves to identify faulty valve
cartridge.

081403
PN=502
Faulty control module. Replace control module.
Drive will not operate in either Insufficient hydraulic fluid. Check the supply of oil to the pump.
direction. Low oil level in the tank or a blocked
or kinked suction hose will not
provide sufficient oil to supply the
drive loop. Check the tank breather.
Faulty direction selection solenoids. Inspect solenoids. Replace as

necessary.
Control signal not reaching pump. Check control hydraulic circuit to

Incorrect pilot pressure. confirm that signal is reaching pump
control.
03
0370
Faulty swashplate positioning A centering spring in the pump 9
By-pass valves are open. Towing procedures require drive

pressure relief valves to be put in
by-pass position. Close by-pass
valves. (See Repair Manual for
procedures.)

081403
PN=503
Low charge pressure. See Section 03 for procedures to

pressure.

malfunctions.

clogs.
Check suction line for blockage.
Remove and inspect the Charge

Pressure Relief Valve for damage.
03
0370 Replace if necessary.
10
Remove and inspect the Charge
Pump for damage. (See Repair
Manual for procedures to service the
Charge Pump.)
Drive pressure relief valves See Section 03 for procedures to

improperly set. check and adjust the drive
pressures.
Motor valve improperly set. Check charge pressure with pump in

stroke. See Section 03 for
procedures to check and adjust the
motor valves.
Wrong pump installed. Confirm that pump is designed for

right hand shaft rotation.
Drive operates in wrong Control lines switched. Re-connect control lines.

direction.
Drive system response is Insufficient hydraulic fluid. Check the supply of oil to the pump.
sluggish. Low oil level in the tank or a blocked
or kinked suction hose will reduce
output pressure.
Control signal not reaching pump. Check control hydraulic circuit to

Incorrect pilot pressure. confirm that signal is reaching pump
control.

081403
PN=504
Drive pressure relief valves See Section 03, for procedures to

improperly set. check and adjust the drive
pressures.
Low or uneven charge pressure. See Section 03 for procedures to

pressure.

malfunctions.

clogs.
03
Internal leaky in pump. Internal leakage will reduce drive 0370
pressures. Inspect o-rings, gaskets 11
and other fittings. Check for
excessive case drain flow.
Brakes not fully released. Release brakes.
Excessive noise or vibration. Insufficient hydraulic fluid. Check the supply of oil to the pump.
Low oil level in the tank or a blocked
or kinked suction hose will cause
cavitation in the pump.
Clogged charge pressure filter. High inlet vacuum will cause noise.
Replace filter.
Air in system. Bleed air from the system.(see

section 03 for procedures)
Diagnose Drive Motor

hydrostatic drive motor. See Diagnose Hydrostatic
Drive System, and Diagnose Hydrostatic Drive
Pump, for other procedures not shown here.

Improper Motor Output Speed Incorrect pump output. Check pump output.

081403
PN=505
Motor stuck at incorrect Confirm that rotary group is

displacement. swiveling properly. (See Repair
Manual for procedures to service
Hydrostatic Drive Motor.)
Drive Operates in One Direction Flushing valve spool stuck in one Clean or replace flushing valve.
Only position. Check operation of Solenoid 103B
on the motor.
Drive Will Not Operate in Either Incorrect loop flushing valve setting. Flushing valve setting should be 25
Direction psi lower than charge pressure relief
setting. See Section 03, for test
procedure.
03
0370 Drive Operates in Wrong Drive pressure lines connected to Reconnect drive pressure lines.
12 Direction wrong sides of motor.
Control signal lines at pump Reconnect control signal lines at

reversed. pump.
System Overheating Motor stalling causing oil to heat Contact service representative to
through relief valves. determine cause of motor stalling.
OUTJ003,00002D4 –19–17JAN01–8/8

081403
PN=506
Diagnose Hydraulic/ Hydrostatic Cooling

System
Temperature Alarm activated but Faulty sensor circuit Service sensor circuit. Replace
temperature indicated on sight sensor if necessary.
gauge is below 75°C (167°F)
Temperature Alarm activated and Dirty or clogged cooler. Clean exterior of oil cooler.
temperature indicated on sight
gauge is above 75°C (167°F)
thermostat valve malfunction. Service thermostat in thermostat

valve.
03
Hydrostatic Drive System See Section 03, for remedies 0370
overheating. regarding Hydrostatic Drive System 13
overheating.
OUTJ003,00002DC –19–17JAN01–1/1
Diagnose Cab Tilt Hydraulics
Cab tilts slowly or settles Faulty seals in cab tilt cylinder. Replace seals in cylinder.
between pump strokes
Faulty seals in cab tilt pump. Service cab tilt pump.
Leak in hoses or fittings. Inspect and repair hoses and fittings.
Faulty check valve or faulty relief Inspect valves and replace if

valve in manifold. necessary.
OUTJ003,00002DB –19–17JAN01–1/1

081403
PN=507
Diagnose Brake Hydraulics
Parking brake does not engage Parking brake solenoid Y41 Inspect solenoid Y41. Replace if
when parking brake switch is ON malfunction. Pressure not bled off necessary.
correctly.
Parking brake solenoid Y41 should
be de-energized when the switch is
ON in order to engage brakes.
The solenoid Y41 should be

energized when the switch is OFF in
order to release brakes.
Check parking brake pressure at

03
0370 MB1 on the auxiliary valve.
14
Brake cylinders worn, out of Inspect and repair brake cylinders.
adjustment or springs are broken. See Repair Manual for procedures to
service the brake cylinders.
Parking brake does not release Insufficient hydraulic pressure in Check parking brake pressure on the
when parking brake switch is parking brake circuit to release auxiliary valve. See Section 03, for
OFF spring applied brake. procedures to test and adjust
pressures.
Work brake does not engage Work brake solenoid Y41W Inspect solenoid Y41W at brake
when parking brake is malfunction. valve. Replace if necessary.
disengaged.
Check brake pressure at MB4 and
MB5 at brake valve. Pressures
should be between 6.5 MPa (955
psi) and 7.5 MPa (1102 psi). See
Section 02 for procedures to test
and adjust pressures.
Service brake does not apply Insufficient fluid level in brake master Check level in brake master cylinder
when pedal is pressed (but work cylinder. (ATF Tank). Refill if necessary.
brake works normally).
OUTJ003,00002DA –19–17JAN01–1/1

081403
PN=508
Troubleshooting

hydrostatic drive system. See Diagnose
Hydrostatic Drive Pump, and Diagnose
Hydrostatic Drive Motor, for other procedures not
shown here.

The following is a list of a few troubleshooting tips on this

machine. Do a test drive of the unit and determine that
there is a problem before you do any repairs or
adjustments.
03
0370
1. If the machine will not drive forward or backwards, 15
check that the displacement control valve gives signal
and is working properly.
2. If the machine will not drive forward or backwards,

check that the pressure relief valves are OK.
3. If the hydraulic oil gets hot when driving, check that the
loop flushing valve is working OK.
4. If the machine doesn’t reach its maximum speed,

check that the displacement control valve of hydraulic
motor (Y48) is working OK.
5. If the drive hydraulics feels forceless, check that the

pressure cut-off valve works OK (check the pressures
when driving forward and backwards).
6. If the machine will not drive forward or backwards,

make sure that the brakes are releasing properly.
After any service or repair is done, hydrostatic drive

transmission system must be purged.
AK12300,0000009 –19–23OCT02–1/1

081403
PN=509
Work Hydraulic Checkout Record Sheet
NOTE: See the following sections for detailed Operational

Checkouts of specific systems:
• Section 00, Group 0010- Machine Operational

Checkout
• Deere engine workshop manual for Engine
Operational Checkout
• Section 02, Group 0210- Hydrostatic System
• Section 18, Group 1810- Air Conditioner and
Heating Operational Checkout
OWNER DATE
HOURS
03
0370 PIN
16 TECHNICIAN

OK NOT OK COMMENTS
1. Hydraulic System Checks
❒ ❒
Work Pump ❒ ❒
2. Cab Tilt System
Cab Tilt System ❒ ❒
Cab Tilt Cylinder, Hoses and Fittings ❒ ❒
Cab Tilt Safety Support ❒ ❒
JK11466,00000D5 –19–20MAY03–1/1

081403
PN=510
Hydrostatic System Checkout Record Sheet
Drive Hydraulics OK NOT OK COMMENTS

1. Hydrostatic System Checks
Hydrostatic Charge Pressure Warning Light ❒ ❒
Drive Pump ❒ ❒
Drive Motor ❒ ❒
thermostat valve ❒ ❒
Oil Cooler ❒ ❒
Drive Direction Selection (only in 1010D) ❒ ❒
03
0370
17
JK11466,00000D9 –19–06JUN03–1/1

081403
PN=511
03
0370
18

081403
PN=512
Group 0380
Appendix Manuals
Rexroth Drive Motors
• A6VM107 in 810C
• AA6VM160HDXD in 1010D
• A6VM140 in 1110D and 1410D
• AA6VM200 in 1710D
JK11466,0000099 –19–30JAN03–1/1
Rexroth Drive Pumps

03
• AA4VG71 in 810D 0380
• A4VG90 in 1010D 1
• AA4VG125 in1110D
• AA4VG140 in 1410D
• AA4VG180 in 1710D
JK11466,0000098 –19–30JAN03–1/1
Rexroth Hydraulic Work Pumps
One manual conserning all listed pump models
• A10VO100 DFLR in 1010D

• A11VO140 in 1110D, 1410D and 1710D
JK11466,000009A –19–30JAN03–1/1
VOAC / Parker Boom Control Valves
• K90 LS in 1010D
• K170 in 1110D, 1410D and 1710D
JK11466,000009B –19–30JAN03–1/1

081403
PN=513
Appendix Manuals
03
0380
2

081403
PN=514
Section 04
Engine
Contents
Page
Group 0410—Engine mounting and dismounting

Engine Removal . . . . . . . . . . . . . . . . . . . . . .04-0410-1
Engine Installation . . . . . . . . . . . . . . . . . . . . .04-0410-3
Group 0420—Engine
See Deere Engine manuals for detailed
information. . . . . . . . . . . . . . . . . . . . . . . . .04-0420-1
04

081403
PN=1
Contents
04

081403
PN=2
Group 0410
Engine mounting and dismounting
Engine Removal
1. Clean engine compartment well

2. Disconnect battery cables.
3. Remove hood and cover plates.
4. Drain coolant from engine. Draining plug is located at
the bottom of radiator.
5. Remove air filter. Protect inlet port of turbocharger.
6. Remove exhaust muffler. Protect exhaust port of
turbocharger.
7. Disconnect all water hoses. Mark if necessary.
8. Mark if necessary and disconnect wires from
• Oil pressure switch
• Engine rpm sensor

• Start motor
• Alternator
• Coolant temperature sensor
• Stop solenoid
• Engine rpm regulator unit
• Water valve
04
9. Remove A/C compressor from engine. 0410
1
10. Don’t open hoses, leave compressor at engine
compartment.
11. Remove protection shields, which are around fan
blade and alternator and remove fan blade.
12. Disconnect fuel lines. Suction hose from low pressure
pump and return hose from injection pump.
13. Protect all connections against dirt.
14. Remove drive clutch mounting bolts.
15. Pull hydraulic pumps backwards a little and support
them to that place.
16. Install lift straps provided with engine and torque to
the following specifications..
Continued on next page JK11466,00000B2 –19–25FEB03–1/2

081403
PN=517
CAUTION: The only recommended method for

lifting the 6081 engine is with JDG23 Engine
Lifting Sling and safety approved lifting straps
that come with engine. Use extreme caution
when lifting and NEVER permit any part of the
body to be positioned under an engine being
lifted or suspended. Lift engine with
longitudinal loading on lift sling and lifting
–UN–23JUN99
brackets only. Angular loading greatly reduces
lifting capacity of sling and brackets.
RG10053
17. Attach JDG23 Engine Lifting Sling (A) to engine lifting
straps (B) and to overhead hoist or floor Boom
A—Engine Lifting Sling
NOTE: If engine lifting straps are misplaced, they should
B—Engine Lifting Straps
be procured through service parts or
SERVICEGARD Use of an engine lifting sling
(as shown) is the ONLY APPROVED method for
lifting engine.
04
0410
2
IMPORTANT: Lifting straps are designed to lift the
engine and small accessories such as
mounted to the engine auxiliary gear
drive, or belt-driven components, such
as air conditioning compressors and
alternators. If larger components, such
as hydraulic pumps are attached to
other locations on the engine, the lift
straps provided with the engine are not
intended for this purpose. Technician is
responsible for providing adequate
lifting devices under these situations.
18. Lift up a little and make sure that chains are well
connected. NOTE ! Engine wet weight is 620 kg.
Check that load chains can carry that weight.
19. Remove engine mounting bolts, 2 pcs front and 2 pcs
rear.
20. Lift engine up about 10 mm and pull engine forward
so much that drive clutch looses. Beware radiator
while lifting engine up.
21. Carefully lift engine to desired location.
SERVICEGARD is a trademark of Deere & Company JK11466,00000B2 –19–25FEB03–2/2

081403
PN=518
Engine Installation
1. Check the condition of engine mounting rubber pads.

2. .Lower engine down to engine compartment carefully.
Beware radiator .
3. While lowering and positioning engine to its place
install drive clutch.
4. Lower engine properly in its place.
5. Install engine mounting bolts.
6. See tightening torque from group 0030
7. Install hydraulic pumps. See sections 03 and 21 for
procedure
8. Install A/C compressor.
9. Install protection shields and fan blade.
10. Connect all wires to.
• Oil pressure switch
• Engine rpm sensor

• Start motor
• Alternator
• Coolant temperature sensor 04
• Stop solenoid 0410
3
• Engine rpm regulator unit
• Water valve
11. Install all water hoses.

12. Fill up the coolant
13. Fill up the engine oil
14. Connect fuel lines and bleed fuel system
15. Install exhaust muffler
16. Install air filter
17. Connect battery cables
18. Start engine and check for leaks
19. Look after engine temperature, coolant level and oil
pressure. If everything seems to be properly in
condition drive a short test drive.
20. Install hood and cover plates.
21. Check coolant and oil level after the engine has
cooled down.
NOTE: See additional repair instructions from Deere

engine manuals listed in next group
JK11466,00000B3 –19–25FEB03–1/1

081403
PN=519
04
0410
4

081403
PN=520
Group 0420
Engine
See Deere Engine manuals for detailed
information
JK11466,0000001 –19–15NOV02–1/1
04
0420
1

081403
PN=521
Engine
04
0420
2

081403
PN=522
Section 05
Engine Auxiliary system
Contents
Page
Group 0510—Auxiliary Systems

Auxiliary System Manuals . . . . . . . . . . . . . . .05-0510-1
05

081403
PN=1
Contents
05

081403
PN=2
Group 0510
Auxiliary Systems
Auxiliary System Manuals
See engine manual cover for find auxiliary system

manuals
jk114660001 –19–16DEC02–1/1
05
0510
1

081403
PN=525
Auxiliary Systems
05
0510
2

081403
PN=526
Section 16
Electrical-System
Contents
Page Page
Group 1610—Main Electrical System Pump Control Valves (PCVs) . . . . . . . . . . . .16-1640-7

System Description . . . . . . . . . . . . . . . . . . . .16-1610-1 Electronic Injector (EI) Wiring Harness
Main Switch. . . . . . . . . . . . . . . . . . . . . . . . . .16-1610-1 Connector . . . . . . . . . . . . . . . . . . . . . . . . .16-1640-7
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1610-4 Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1640-8
Using Booster Battery . . . . . . . . . . . . . . . . . .16-1610-8 Engine Control Unit (ECU) . . . . . . . . . . . . . .16-1640-9
1010D Fuses and Relays . . . . . . . . . . . . . .16-1610-11
Fuses On The Left-Hand Side in the Engine Group 1650—LCS- Loader Control System
Compartment . . . . . . . . . . . . . . . . . . . . . .16-1610-12 Theory of Operation . . . . . . . . . . . . . . . . . . .16-1650-1
Instrument Box Fuses and Relays. . . . . . . .16-1610-14 LCS Service Display . . . . . . . . . . . . . . . . . .16-1650-2
Wiring Visual Inspection . . . . . . . . . . . . . . .16-1610-15 Connecting the Service Display to the
ECU (Engine Control Unit) . . . . . . . . . . . . .16-1610-16 System . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1650-3
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . .16-1610-16 Using the Service Display . . . . . . . . . . . . . . .16-1650-3
Electrical Circuit Malfunction . . . . . . . . . . . .16-1610-16 Display Diagram . . . . . . . . . . . . . . . . . . . . . .16-1650-6
Inspect Electrical System . . . . . . . . . . . . . .16-1610-19 Main Window . . . . . . . . . . . . . . . . . . . . . . . .16-1650-8
Seven Step Electrical Test Procedure . . . . .16-1610-20 Alarm Windows . . . . . . . . . . . . . . . . . . . . . . .16-1650-8
Boom Settings. . . . . . . . . . . . . . . . . . . . . . . .16-1650-9
Group 1620—Electrical Schematics Adjusting the Boom During Operation . . . . .16-1650-13
Electrical Schematic Information . . . . . . . . . .16-1620-1 Balance Window . . . . . . . . . . . . . . . . . . . . .16-1650-14
Electrical Schematic Symbols . . . . . . . . . . . .16-1620-4 Measurement Window. . . . . . . . . . . . . . . . .16-1650-16
810D Wiring Diagrams . . . . . . . . . . . . . . . . .16-1620-8 Transmission Measurement Window . . . . . .16-1650-18
1010D Wiring Diagrams . . . . . . . . . . . . . . .16-1620-42 Auxiliary Equipment Measurement
1110D Wiring Diagrams . . . . . . . . . . . . . . .16-1620-68 Window . . . . . . . . . . . . . . . . . . . . . . . . . .16-1650-19
1410D Wiring Diagrams . . . . . . . . . . . . . . .16-1620-98 Module Outputs and Inputs . . . . . . . . . . . . .16-1650-20
1710D Wiring Diagrams . . . . . . . . . . . . . . 16-1620-129 System Settings . . . . . . . . . . . . . . . . . . . . .16-1650-30 16
Joystick Settings . . . . . . . . . . . . . . . . . . . . .16-1650-31
Group 1630—Electrical Sensors Service Window . . . . . . . . . . . . . . . . . . . . .16-1650-36
810D Location of ECU and engine
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1630-1 Group 1660—Alternator
1010D, 1110D and 1410D Location of Alternator Removal . . . . . . . . . . . . . . . . . . . .16-1660-1
ECU and engine sensors . . . . . . . . . . . . . .16-1630-2 Alternator Installation. . . . . . . . . . . . . . . . . . .16-1660-1
1710D Engine Sensors . . . . . . . . . . . . . . . . .16-1630-3
1010D Hydraulic Tank Sensors . . . . . . . . . . .16-1630-4 Group 1680—Starter Motor
810D, 1110D, 1410D and 1710D Hydraulic Starter Motor Removal . . . . . . . . . . . . . . . . .16-1680-1
Tank Sensors . . . . . . . . . . . . . . . . . . . . . .16-1630-5 Starter Motor Installation . . . . . . . . . . . . . . . .16-1680-1
810D, 1110D and 1410D The RPM
Sensor of the Drive Hydrostatics Motor . . .16-1630-6
1710D The RPM Sensor of the Drive
Hydrostatics Motor . . . . . . . . . . . . . . . . . . .16-1630-7
Group 1640—Control Systems

TMC Control System. . . . . . . . . . . . . . . . . . .16-1640-1
Electronic Control System Terminology . . . . .16-1640-2
Monitoring Engine Parameters . . . . . . . . . . .16-1640-3
Measuring Temperature . . . . . . . . . . . . . . . .16-1640-3
Measuring Engine Speed . . . . . . . . . . . . . . .16-1640-5
Water In Fuel (WIF) Sensor . . . . . . . . . . . . .16-1640-6

081403
PN=1
Contents
16

081403
PN=2
Group 1610
Main Electrical System
System Description
Forwarder utilises a 24 Volt negative ground electrical

system. Power is supplied by two 12-Volt batteries
connected in series, which are mounted in the left side of
the rear frame. The batteries are charged by a 140 A
alternator. The fire extinguisher system and engine/cab
heater is connected directly to the batteries. All other
equipment are supplied via the main switch. 12-Volt power
for the accessories (Radio, communication system etc.) is
supplied from a 24 / 12 Volt converter mounted in the cab.
The main fuse panels are installed in the cab.
IMPORTANT: Do not ever disconnect the electronic

system when the power is on.
CAUTION: The manufacturer shall assume no

responsibility for any alterations made to the
electrical system of the machine if the changes
are not in compliance with service bulletins.
There is a risk that the function of the safety
systems of the machine is jeopardized.
JK11466,000000E –19–29OCT02–1/1
Main Switch
The main switch (1) is behind a cover on the left-hand

side of the machine. 16
1610
There is a socket serving as a power outlet (24 V) next to 1
the main switch.
The main switch (1) is behind a cover on the left-hand

side of the machine.

081403
PN=529
In 1010D the main current coming from the battery is

divided between two 50 A fuses.
There is a socket serving as a power outlet (24 V) next to

the main switch. If the machine is equipped with an
automatic fire extinguishing system (opt. eq.) the system
will be switched on to the automatic mode when the main
–UN–10NOV02
switch is turned off.
T161519
1010D Main Switch
JK11466,00000D6 –19–20MAY03–2/4
1—Main Switch
2—Triggering handle for fire extinguisher
3—Quick coupler for hydraulic oil filling
4—Tap for decking blade’s floating system
5—Switch, hydraulic oil filling pump
6—Switch, vacuum pump
7—24V Current
–UN–01OCT02
16
1610
T159876
2
810D, 1110D & 1410D Main Switch

081403
PN=530
24V—Current
1—Main Switch
–UN–05MAR02
T152211
1710D Main switch
JK11466,00000D6 –19–20MAY03–4/4
16
1610
3

081403
PN=531
Batteries
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-valveated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
–UN–23AUG88
medical attention immediately.
If acid is swallowed:
TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 2 L (2 quarts).
3. Get medical attention immediately.
16
1610
Continued on next page EL62757,00001AF –19–21APR02–1/4
4

081403
PN=532
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
Theory of operation
The battery is made up of
• Positive plates
• Negative plates
• Separators
• Plate straps,
• Chemical solution (electrolyte)
The electrolyte is a solution of sulfuric acid and water.

Sulfuric acid is not lost during overcharging; therefore, if
the liquid solution is low, only water should be added.
In a fully charged battery, the positive plate is lead

peroxide (PBQ2), the negative plate is “spongy” lead (Pb),
and the electrolyte solution is about 1.270 times heavier
than water. The amount that the solution is heavier than
water is called specific gravity.
All batteries will self discharge at a rate of 0.001 specific

gravity point per 24 hour period at a constant 85°F. The 16
discharge rate increases as temperature increases and 1610
5
decreases as temperature decreases. If the machine is
not used for a period of time, the batteries must be
maintained or stored in a cool place.
Wipe batteries with a damp cloth. If terminals are

corroded, use a stiff brush and wash with an ammonia
solution. After washing, flush battery and compartment
with clear water.
Batteries should be maintained at an open circuit voltage

of 12.50 volts or greater. To determine open circuit
voltage do the following:
1. Turn master disconnect switch ON.

081403
PN=533
2. For machines that have not been run during the past
10 hours, go to Step 4.
3. For machines that have been run in the past 10 hours,

remove surface charge. Turn key switch to Position I
(RUN), turn on 3 or 4 work lights and leave them on
for 3 to 5 minutes. Turn ignition switch OFF and then
wait 2 minutes.
4. Measure voltage at alternator by placing the negative

lead of a multimeter to the case of the alternator and
the positive lead to the sense terminal of the alternator.
STABILIZED OPEN CIRCUIT

VOLTAGE PERCENT CHARGED
12.5 volts or more 100%
12.4 75%
12.2 50%
12.0 25%
11.7 or less 0%
Visual Check
1. Check for damage such as cracked or broken case

and electrolyte leakage.
If damage is seen, replace battery.
2. Check terminals for corrosion.
If corroded, clean using a wire brush or battery post

16 cleaner such as JT05838 Battery Post/Clamp Cleaner.
1610
6 3. Check posts for looseness.
If posts are loose, replace battery.
Load Test
Check battery capacity with a load tester such as

JT05832 Battery Load Tester. Follow tester
manufacturer’s instructions for proper load test
procedures.
If one battery fails load test, replace both batteries.

081403
PN=534
Essential Tools
JT05838 Battery Post/Clamp Cleaner
JT05460 Coolant/Battery Tester
JT05832 Battery Load Tester
Diagnose Battery Malfunction
Battery Using Too Much Water Shorted battery cell Check battery state of charge. (See
Procedure for Testing Batteries.)
Cracked battery case Check battery hold down clamps.

Replace battery.
Regulator Do Alternator Output Check. (See

Charging Circuit Operational
Checks.)
Cracked Battery Case Battery hold down clamp too tight, Install new battery. Install hold down
too loose or missing clamps correctly.
Low Battery Output Dirty or wet battery top, causing Clean battery top. Recharge battery.
discharge
Corroded or loose battery cable Clean and tighten cable end clamps.
ends Recharge battery.
Broken or loose battery posts Wiggle posts by hand. If posts are

loose or will turn, replace battery.
Loose fan/alternator belt or worn Inspect belt or pulley. Adjust or

16
pulleys replace as necessary. 1610
7
EL62757,00001AF –19–21APR02–4/4

081403
PN=535
Using Booster Battery
–UN–16JUL01
T142776
16
1610
8

081403
PN=536
CAUTION: The manufacturer shall assume no

responsibility for any alterations made to the
electrical system of the machine if the changes
are not in compliance with service bulletins.
There is a risk that the function of the safety
systems of the machine is jeopardized.
CAUTION: If you need an outside power source

to start the machine, be careful not to
short-circuit the battery while handling the
cables.
IMPORTANT: The machine is allowed to start with an

outside power source lower than 140 A
only, f.ex. another similar type machine
or auxiliary batteries. Connect the
auxiliary cables before starting the
assisting machine.
IMPORTANT: An over 140 A power source, f.ex.

booster, can only be used when quick
charging the batteries. In this case,
disconnect both cables between the
machine and batteries. The machine
can be started after the auxiliary power
source is disconnected.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Make sure the batteries are charged in a well
16
ventilated area. 1610
9
Always remove grounded (—) battery clamp
first and replace it last.
IMPORTANT: The machine electrical system is a

24-volt negative (—) ground. Use only
24-volt booster batteries.
IMPORTANT: Do not ever disengage the electronic

system when the power is on.
The batteries are located under the cab on the left-hand

side of the machine.

081403
PN=537
1. Connect the auxiliary positive cable, coming from a

24-volt power source, to the positive cable of the
machine to be started,
JK11466,00000D7 –19–20MAY03–3/4
2. Connect the auxiliary negative cable to the power

source and the other end to the negative cable or
frame of the machine to be started. Bear in mind this
order of connection when using auxiliary batteries
because a full battery is more sensitive to sparks.
3. Start engine.
4. Immediately after starting engine, disconnect end of

the negative cable from the ground stud. Then
–UN–16JUL01
disconnect the other end of the negative cable from the
negative terminal of the booster battery.
T142776
5. Disconnect one end of positive cable from positive
terminal of the booster battery and disconnect the
other end from the positive terminal of the starter.
Before boost starting, machine must be properly shut

down and secured to prevent unexpected machine
movement when engine starts.
Do not mix up the battery terminals. An incorrect

connection may seriously damage the alternator. Do not
disconnect the battery cables while the engine is running.
16
1610
10
JK11466,00000D7 –19–20MAY03–4/4

081403
PN=538
1010D Fuses and Relays
–UN–10NOV02
T161517
Fuses In Instrument box
Instrument Box Under the Cab
F1 LCS-module (10 A) The fuses can be found in a fuse box under the cab.
F2 Alarm lights (7,5 A)
F3 Parking brake, rear wheel drive, frame (7,5 A) Fuse box (1) fuses 1 ... 4:
brake release
F4 Horn (7,5 A) F41 Grid heater signal (10 A)
light
F5 ECU (10 A)
F42 Radio, Preheater (10 A)
F6 ECU (10 A) (opt. eq.) and
F7 Igniton switch (30 A) Timer (opt. eq.),
F8 Socket (10 A) F43 Preheater (opt. eq.) (25 A)

16
F10 Work light, boom (10 A) F44 Preheater (opt. eq.) (15 A) 1610
F11 Windscreen wipers and washers (10 A) K3 Engine Start 11
F16 A/C unit (20 A) K24 Engine Glow

F12 ... Work lights (10 A)
F20 Relays in Instrument box / Circuit board
F31 Main fuse (50 A)
K2 Wipers
K4 Blinker
Fuses for Optional Equipments
K6 A/C unit
F21 Tail light (20A)
K12 Wipers
F22 Emergency flasher (10A)
K14 Start prevent
F23 Direction indicator (5A)
K20 Radio
F24 Headboard, odometer, prepardness for (5A)
clambunk K22 A/C unit
F25 Low beam (10A) K23 Compressor
F26 High beam (5A)

F27 High beam (5A)
JK11466,00000C6 –19–07APR03–1/1

081403
PN=539
Fuses On The Left-Hand Side in the Engine

Compartment
The main current coming from the battery is divided

between two 60 A fuses.
If the machine is equipped with an automatic fire

extinguishing system (opt. eq.) the system will be
switched on to the automatic mode when the mains switch
is turned off.
EL62757,00001B2 –19–21APR02–1/3
Relay K3, Starting motor
Relay K15 Engine preheater & AC unit
16
1610
12
–UN–16OCT02
T160565
810D, 1110D and 1410D Circuit board
Continued on next page EL62757,00001B2 –19–21APR02–2/3

081403
PN=540
1710D Fuses and relays

F41 Preheater (opt. eq.) (20 A)
F42 Preheater (opt. eq.) (15 A)
and Timer (opt. eq.),
Radio and
Radio-telephone
F43 Air conditioner (opt. (25 A)
eq.)
F44 Reserve
F45 Socket 24 V (20 A)
Hydraulic pump
(fill-up) (opt. eq.)
F46 , Socket 24 V Fuel (15 A)
pump (fill-up) (opt.
eq.)
F47 Fire extinguishing (10 A)
system (opt.eq.
F48 Fire extinguishing (10 A)
system (opt.eq.
–UN–20MAR02
T152822
1710D Circuit Board
16
1610
EL62757,00001B2 –19–21APR02–3/3
13

081403
PN=541
Instrument Box Fuses and Relays
Instrument box fuses and relays

F1-F13 Work Lights 10 A
F14 Head light switch 10 A
F15 Ignition 20 A
F16 Parking lights 10 A
F17 Brake switch 7.5 A
F18 Air conditioner, Seat 7.5 A
compressor (opt. eq.)
F19 Horn 7.5 A
F20 Indicator lights 7A
F21 TMC 10 A
F22 Windscreen wipers 10 A
F23 Cigarette lighter 7.5 A
F24 Stairs 7.5 A
F25 Vacuum pump 5A
F26 ECU 10 A
F27 Rear window wipers 10 A
F28 Fuel valve, stopping 10 A
solenoid, motor ECU
F29 Air conditioner, valve (opt. 7.5 A
eq.)
F30 Hydraulics vacuum pump 20 A
, (opt. eq.)
F31 Low beam 7.5 A
F32 Voltage transformer 5A
F33 High beam 7.5 A
F34 Parking brakes 5A
16 F35 Parking brakes 5A

1610 F36 Working pump’s drop 7.5 A
14
K1 Electricity controlled by ignition switch
K2 Intermittent rear window wiper
K4 Blinker relay
K6 Seat compressor
K9 Hourmeter
K12 Intermittent windshield wiper
K14 Engine starting prevent
K20 Radio
K22 Air conditioner, (opt. eq.)
K40 Decking blade floating
–UN–17JUN02
T152823
810D, 1110D, 1410D Fuses

081403
PN=542
Other relays
Relay K4, Blinker relay in the instrument box
Relay K10, Air conditioner - slow speed
Relay K11, Air conditioner - fast speed
Relay K15, Engine preheater & AC unit
Relay K24, Grid heater, Front frame
Relay K38 and K39 Fuel pump - Front frame
K40 Decking blade floating
JK11466,00000D8 –19–20MAY03–2/2
Wiring Visual Inspection
If possible, inspect the wiring harness to locate the

problem area:
• Look for missing or worn braid covering, which may

indicate a wire problem.
• Look for bare or pinched wires that may short to ground
or short across to other wires.
• Look for loose or damaged connectors and terminals.
• Look for broken wires.
16
1610
When the problem has been located, follow these 15
procedures:
• If there is a minor damage to the wire (stripped wire

insulation), use heat shrink tubing or electrical tape to
protect the damaged area.
• If the damage is extensive, it may be necessary to
splice a segment of new wire into the original wire.
• If the terminals and connectors need to be replaced,
ensure that the correct terminal or connector is used.
NOTE: Any tie wraps or cable clamps removed during

repair procedures must be replaced as originally
installed.
OUTJ003,0000448 –19–06FEB01–1/1

081403
PN=543
ECU (Engine Control Unit)
ECU, engine control unit, is placed at the left side of the

machine, under the cab near the main switch.
EL62757,00001AE –19–21APR02–1/1
Using a Digital Multimeter
Using a Digital Multimeter Digital Multimeter It is

recommended that a digital multimeter (JT07306 or
equivalent with an analog display) be used to make the
required measurements in the diagnostic procedures. A
–UN–19JUN00
knowledge of the operation of the particular meter used is
assumed. Instructions for measuring voltages take the
following form: • Measure voltage from Point A (+) to Point
(B) (-) In this example, the positive test lead from the
RG11126
volt-ohm input of the meter should be connected to Point
A and the negative test lead from the common input of the
Digital multimeter
meter should be connected to Point B. Unless otherwise
stated, all voltage measurements are direct current (D.C.).
In making a resistance measurement, be careful to use
the correct resistance range on the meter. Disconnect
appropriate connectors or turn off key switch, as directed
by diagnostic procedures later in this group.
16
1610
TX,901505,QQ374 –19–10AUG95–1/1
16
Electrical Circuit Malfunction
Circuit Malfunctions
There are four major circuit malfunctions:
1. High-Resistance Circuit
2. Open Circuit
3. Grounded Circuit
4. Shorted Circuit
Continued on next page JK11466,000004E –19–13DEC02–1/5

081403
PN=544
RG9891 –UN–06JAN99
High Resistance Circuit
A—Unwanted resistance
1. High Resistance Circuit
A circuit having unwanted resistance (A) that causes a

voltage drop and reduces current flow.
JK11466,000004E –19–13DEC02–2/5
RG9892 –UN–06JAN99
A—A break or separation in

circuit
2. Open Circuit
A circuit having a break or a separation (A) that

16
prevent current from flowing in the circuit. 1610
17
JK11466,000004E –19–13DEC02–3/5
RG9893 –UN–06JAN99
Grounded Circuit
A—A voltage wire in contact

with machine frame
3. Grounded Circuit
A voltage wire contact with machine frame(A)

Continued on next page JK11466,000004E –19–13DEC02–4/5

081403
PN=545
–UN–06JAN99
RG9894
Shorted Circuit
4. Shorted Circuit • Voltage wire shorted to a ground wire (wires of

battery voltage or regulated voltage, shorted to a
A wire-to-wire contact of two adjacent wires that ground wire connecting a component to the battery
provides unwanted continuity between the two wires. negative terminal).
The following are types of short circuits: • Ground wire shorted to another ground wire (wires
of zero voltage)
• Voltage wire shorted to another voltage wire (wires
of equal or unequal voltage) NOTE: This type of short does not create an
• Voltage wire shorted to a sensor signal wire (wires observable malfunction. Therefore, no further
of unequal voltage). explanation for trouble shooting is necessary.
JK11466,000004E –19–13DEC02–5/5
16
1610
18

081403
PN=546
Inspect Visually Electrical System
Make the following visual electrical inspection prior to like burned insulation. Put your hand on the
starting the machine after receiving customer alternator. Heat in these parts when the unit has
complaint: not been operated for some time is a sure clue to
charging circuit problems.
1. Look for bare wires that could ground a component
or short across to another component. 7. If your visual inspection does not indicate the
possible malfunction, but your inspection does
2. Look for missing or worn conduit. This could indicate that the machine can be run, turn the
indicate a wire problem. ignition switch to position I (Run). Try out the
accessory circuits, indicator lights, gauge lights.
3. Look for loose or broken connectors and wires. How does each of these components work? Look
for sparks or smoke which might indicate shorts.
4. Inspect batteries for:
8. Start machine. Check all gauges for good operation
• Corroded terminals and check to see if system is charging or
• Loose terminals or battery posts discharging.
• Dirty condition
• Damp condition 9. In general, look for anything unusual.
• Cracked case
Many electrical failures cannot be detected even if the
5. Check alternator belt tension. machine is started. Therefore, a systematic and
complete inspection of the electrical system is
6. After machine has been shut down for five minutes necessary.
inspect for overheated parts. They will often smell
16
1610
TX,901505,QQ369 –19–07FEB96–1/1
19

081403
PN=547
Seven Step Electrical Test Procedure
–19–05MAR92
T7719AA
A—Battery Ground D—Fuse Or Circuit Breaker G—Battery Side Of I—Ground Side Of Component
B—Battery E—Component Side Of Fuse Component Terminal Terminal
C—Battery Side Of Fuse Or Or Circuit Breaker H—Light (Component) J—Component Ground
16 Circuit Breaker F—Switch
1610
20 Step 1—Switch ON
Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to Step 2.
Low voltage, repair high resistance. Open circuit from battery.
Step 2—Switch OFF
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 4.
Low voltage, repair high resistance.
No voltage. Go to Step 3.
Continued on next page TX,9015,QQ1697 –19–10AUG95–1/2

081403
PN=548
Step 3—Switch OFF

Check component side of circuit breaker for continuity to ground Continuity to ground. Repair grounded circuit at or before switch.
No continuity to ground, replace circuit breaker.
Step 4—Switch ON
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 6.
Low voltage, repair high resistance.
No voltage. Go to Step 5.
Step 5a
Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.
wire at (G) for battery voltage No voltage, repair grounded or open circuit at or after switch.
Step 6—Switch ON
Check lead to component at (G) for battery voltage Battery voltage normal. Go to Step 7.
Low voltage, repair high resistance in circuit between fuse and
component.
No voltage, repair high resistance or open circuit between fuse and
component.
Step 7—Switch ON
Check ground wire of component at (I) for voltage No voltage, good continuity to ground. Repair component.
Voltage, poor continuity to ground. Repair high resistance or open
ground circuit.
a
A multimeter will not apply a load to the circuit at step 5. The multimeter result is tested as a voltage condition in the result column.
16
1610
TX,9015,QQ1697 –19–10AUG95–2/2
21

081403
PN=549
16
1610
22

081403
PN=550
Group 1620
Electrical Schematics
Electrical Schematic Information
Schematics General connectors, ground locations. Each component will be

identified by the same identification letter/number used
The Electrical Schematics in Section 16, Group 1650, in the Electrical System Schematic.
System Diagrams, show the complete machine
electrical system. Each wire is identified by number or 1. Seek column
color (eg. 39A or RD, etc.). All connectors are 2. Double lines, conductor on circuit card
identified by letter/number designation (eg. X22, etc.) 3. Relay K7
and the number of the connector pin used in that 4. Reference, seek column 608 E
circuit (eg. 6, etc.). All components are identified by 5. Earth terminal, connector X3 terminal 3
letter/number designation (eg. K3, S1, B16, etc.), and 6. Fuse 25, 10A
are represented by a schematic symbol. Component 7. Connector hose X16 terminal 9
letter/number designation will indicate that component 8. Number of wire 65+
throughout the manual. Component descriptions (eg. 9. S9 in the box, not mounted on all machines
K3 Start Relay, S1 Ignition Switch, B16 Horn, etc.)are 10. Single line, wire
found on the legends provided with each schematic. 11. Magnet valve Y65
More information on each component can be found in 12. Machine frame
the Electrical Component Locators in Section 16 13. Operation symbol
Electrical Component Locators
The Electrical Component Locators are pictorial views

showing the location of all electrical components,
16
1620
Continued on next page OUTJ003,0000743 –19–02AUG01–1/4
1

081403
PN=551
16
1620
2
–UN–26NOV02
T162086
Example of wiring diagram
Continued on next page OUTJ003,0000743 –19–02AUG01–2/4

081403
PN=552
Codes for electric wire colours:

BE = blue BL = black BR = brown GN =green
GR =grey OR = orange RD = red YL = yellow
OUTJ003,0000743 –19–02AUG01–3/4
Ignition switch
In the illustration there is seen which connectors are used

in different positions of the ignition switch.
A—Connectors
B—Ignition switch positions
–UN–15OCT02
T159290
16
1620
OUTJ003,0000743 –19–02AUG01–4/4
3

081403
PN=553
Electrical Schematic Symbols
16
1620
4
–19–11OCT93
T7719BA
Continued on next page TX,901505,RP983 –19–26OCT93–1/3

081403
PN=554
16
1620
5
–19–11OCT93
T7719BB
Continued on next page TX,901505,RP983 –19–26OCT93–2/3

081403
PN=555
16
1620
6
–19–17MAR92
T7719BC
TX,901505,RP983 –19–26OCT93–3/3

081403
PN=556
16
1620
7

081403
PN=557
810D Wiring Diagrams
F626571 1/15
Position Description Scheme Location

F15 Fuse 20A, ignition switch 107 E PC-board
F28 Fuse 10A, fuel valve, Engine ECU 118 G PC-board
F36 Fuse 7,5A, working pump’s drop 113 L PC-board
F41 Fuse 20A, preheater 102 M Fuse box
F42 Fuse 15A, preheater, 24/12V voltage transformer 103 M Fuse box
F43 Fuse 25A, air conditioner 103 M Fuse box
F44 Fuse 7,5A, engine gridheater, signal light 104 M Fuse box
F45 Socket 24V, hydraulic oil fill-up pump, 20A 105 M Fuse box
F46 Fuse 20A, socket 24V, auxiliary fuel pump 106 M Fuse box
F47 Fuse 10A, DAFO 107 M Fuse box
F51 Main fuse, 60A 100 M Fuse box
F52 Main fuse, 60A 101 M Fuse box
G1 Alternator 106 T Engine
G2 Batteries 102 U Under the cabin
K1 Relay, ignition switch 115 F PC-board
K3 Relay, starting motor 108 S Fuse box
K14 Relay, starting prevent 111 J PC-board
K24 Relay, engine preheater 111 R Under the cabine
M1 Starting motor 104 T Engine
R2 Heater resistor, grid heater 111 V Engine
S1 Main switch 101 R Front frame
S2 Ignition switch 108 H Control panel
16 S56 Emergency STOP -button 112 D Control panel
1620 X21 16-pin connector 104 J Cabin floor
8
X22 24-pin connector 103 H Cabin floor
X23 7-pin connectorr 100 G Cabin floor
X49 7-pin connector 109 X Fuse box
X59 3-pin connector 112 U Front frame
XB1 9-pin connector 100 D PC-board
XB3 9-pin connector 107 F PC-board
XB6 9-pin connector 112 C PC-board
XB7 9-pin connector 113 M PC-board

081403
PN=558
Y1 Fuel valve 118 T Fuel tank

Y44 Magn. valve, working pump’s drop 113 U Front frame
16
1620
9

081403
PN=559
16
1620
10
–UN–09APR03
T189406

081403
PN=560
F626571 2/15

A2 Radio 214 R Ceiling
A3 Radio-telephone, extra equip. 218 D Ceiling
B1 Pressure switch, engine oil pressure 203 T Engine
B3 Pressure switch, brakes charge pressure 205 T Brake valve
B4 Pressure switch, hydraulic supply pressure 202 T Hydrostatic pump
B5 Pressure switch, parking brake 201 T Auxiliary valve
B11,B12 Loud speaker 214 V/215 V Ceiling
B29 Voltage transformer 214 K Instrument box
B40, B41 Loud speaker 216 V Ceiling
F8 Fuse 10A, radio 216 C PC-board
F20 Fuse 7,7A, indicator lights 201 C PC-board
F32 Fuse 5A, voltage transformer 214 F PC-board
H1 Warning light, charge 209 K Gauge panel
H2 Warning light, engine gridheater 203 K Gauge panel
H3 Indicator light, parking brake 201 K Gauge panel
H5 Indicator light, grid heater 203 J Gauge panel
H6 Indicator light, blinker 207 K Gauge panel
H10 Indicator light, working lights 208 K Gauge panel
H12 Indicator light, main beam 205 K Gauge panel
H18 Warning light, hydraulic supply pressure 202 K Gauge panel
H19 Warning light, brakes charge pressure 204 K Gauge panel
K9 Relay, hourmeter 212 H PC-board
K20 Relay, radio 216 I PC-board
P1 Hourmeter 212 P Instrument box
R3 Resistor, charge warning light 210 J Gauge panel
X6,X7 8-pin connectors 206 K, 200K Indicator lights 16
1620
X13 9-pin connector 208 G Cabin 11
X17 2-pin connector 218 F Cabin, rear
X21 16-pin connector 210 R Cabin floor
X46 9-pin connector 215 N Cabin
X50 8-pin connector 214 P Radio
X51 3-pin connector 214 S Radio
XB2 - XB10 9-pin connector 212 - 216 PC-board

081403
PN=561
16
1620
12
–UN–09APR03
T189407

081403
PN=562
F626571 3/15

AC Control unit, air conditioner 307 M Air conditioner
ASG Valve motor 308 U Air conditioner
B7 Potentiometer, temperature 310 E Air conditioner
B17 Thermostat, air conditioner 313 P Air conditioner
B33 Pressure switch, air conditioner 314 S Engine comp
B35 Thermostat, outside temperature 310 U Air conditioner
B36 Thermostat, cabin 308 U Air conditioner
B7C 3-pin connector 301 M Ceiling
E1 Preheater, engine 302 T Front frame
E30 Heater, seat 316 P Seat
F18 Fuse, air conditioner, seat compressor 315 D PC-board
F29 Fuse, air conditioner 308 E PC-board
H20 Back light 309 B AC unit
K10 Relay, slow speed 315 H AC unit
K11 Relay, high speed 315 K AC unit
K15 Relay, air conditioner & preheater 306 T Fuse box
K22 Relay, air conditioner 307 H PC-board
M2 Heater, fan 314 S Cabin
M6, M7 Fan, ceiling 317 T, 318 T Ceiling
P7 Time switch, preheater 300 J Ceiling
P7B 3-pin connector 301 G Ceiling
R5 - R6 Series resistors of the fan 310 H Inside fan cell
S25 Switch, defroster 312 D Heater
S28 Switch, defroster 312 A AC unit
S30 Kytkin, ilmastointi päällä / pois päältä 315 A AC unit
Switch, Air Conditioning ON/OFF 16
X13 9-pin connector 301 E Instrument box 1620
13
X16 9-pin connector 316 K Instrument box
X22 24-pin connector 307 S Cabin floor
X48 3-pin connector 316 N Seat
X58 3-pin connector 302 V Front frame
XB4 9-pin connector 315 F Front frame
XB5 9-pin connector 308 G Front frame
XB7 9-pin connector 306 I Front frame
XB9 9-pin connector 306 C Front frame
Y194 Magn.coupler, compressor 315 U Compressor

081403
PN=563
16
1620
14
–UN–09APR03
T189408

081403
PN=564
F626571 4/15

B15 Pressure switch, brake lights 414 K Brake valve
E8 Headlight 416 U Front frame
E10 Position light 406 U Front left
E11 Position light 407 U Front right
E12 Tail light 410 U Rear left
E14 Tail light 412 U Rear right
E24 Blinker 405 U Front left
E26 Blinker 407 U Front right
E52 Cigarette lighter 401 O Control panel
F14 Fuse, headlights 411 B PC-board
F16 Fuse, parking lights 410 B PC-board
F23 Fuse, cigarette lighter 400 B PC-board
F31 Fuse, low beam 416 K PC-board
F33 Fuse, main beam 417 K PC-board
F34 Fuse, parking lights left 411 K PC-board
F35 Fuse, parking lights right 413 K PC-board
K4 Blinker relay 402 M Instrument box
S14 Switch, hazard lights 402 E Control panel
S15 Switch, blinker 407 E Control panel
S18 Switch, headlights/parking lights 413 E Control panel
S19 Switch, low-/high beam 416 E Control panel
X1 Socket, 7-pin connector 410 R Cabin
X3 Socket,7-pin connector 405 R Cabin
X22 24-pin connector 405 O Cabin floor 16
1620
X27 7-pin connector 415 R Ceiling 15
XB9 9-pin connector 410 K PC-board

081403
PN=565
16
1620
16
–UN–09APR03
T189409

081403
PN=566
F626571 5/15

B16 Horn 500 S Front frame
F19 Fuse, horn 511 F PC-board
F22 Fuse, windscreen wiper 503 B PC-board
F27 Fuse, rear screen wiper 513 B PC-board
K2 Relay, wiper,rear window 513 J PC-board
K12 Relay, windshield 509 J PC-board
M41 Motor, washer, rear 502 T Engine comp
M42 Motor, washer, front 503 T Engine comp.
M5B Motor, rearscreen wiper 511 U Cabin
M5F Motor, windscreen wiper 506 U Cabin
M5L Motor, side screen wiper 519 U Cabin
M5R Motor, side screen wiper 516 U Cabin
S13 Push button, horn 500 I Control panel
S91 Switch, washer, rear 502 J Control panel
S92 Switch, washer, front 504 J Control panel
S101 Switch, rear screen wiper 508 J Control panel
S102 Switch, windscreen wiper 506 J Control panel
S103 Switch, side screen wiper 517 J Control panel
V11 Diode 506 Q Wiring
V13 Diode 510 Q Cabin
X12 9-pin connector 506 N Cabin, rear
X22 24-pin connector 502 Q Instrument box
X46 9-pin connector 501 D Instrument box 16
1620
XB4 9-pin connector 500 D PC-board 17
XB5 9-pin connector 508 N PC-board

081403
PN=567
16
1620
18
–UN–09APR03
T189410

081403
PN=568
F626571 6/15

E37 Indoor light 618 R Ceiling
E38 Service lightn 615 R Under the cab
E40 Work light, forward 600 T Cabin roof
E42 Work light, left 603 T Cabin roof
E44 Work light, right 609 T Cabin roof
E46 Work light, backward 612 T Cabin roof
E58 Work light, Boom 606 T Boom
F1 Fuse, work light 603 D PC-board
S26 Switch, indoor light 617 K Ceiling
S27 Switch, service light 615 K Control panel
S64 Switch, work light forwards 606 N Ceiling 16
1620
S67 Switch, work light left 603 N Ceiling
S68 Switch, work light right 609 N Ceiling
S69 Switch, work light backwards 612 N Ceiling
X11 9-pin connector 605 H Ceiling
X14 9-pin connector 602 J Instrument box
X37 2-pin connector 615 O Cabin
X46 9-pin connector 615 M Cabin

081403
PN=569
16
1620
20
–UN–09APR03
T189411

081403
PN=570
F626571 7/15

A4 Hub-module, CAN-bus 704 M Instrument box
A5 Display, TMC 710 C Seat
B23 Gas-/drivepedal, front 708 V Cabin, front
B24 Gas-/drivepedal, rear 709 V Cabin, rear
F17 Fuse, switches 709 F PC-board
F21 Fuse, TMC 703 C PC-board
H8 Alarm light, TMC 704 U Ceiling
J1 Splice 707 Q Wiring
S58 Switch, parking brake 714 D Control panel
S59 Switch, all-wheel drive 706 F Control panel
S60 Switch, steering on/off 717 E Control panel
X12 9-pin connector 704 R Instrument box
X18 3-pin connector 707 U Instrument box
X80 6-pin connector 711 V Instrument box
XB2 9-pin connector 704 E PC-board
XH1 8-pin connector 709 J Hub-module
XH3 8-pin connector 710 P Hub-module
Y41 Magn. valve, parking brake 716 S Front frame 16
1620
21

081403
PN=571
16
1620
22
–UN–09APR03
T189412

081403
PN=572
F626571 8/15

A6 Chair module, TMC 814 L Seat
A9 Control panel, left 801 Z Control panel, L
A10 Control panel, right 808 Control panel, R
B8 Buzzer, alarm 812 D Seat
B20 Steering lever, left 805 D Control panel, L
B21 Steering lever, right 815 D Control panel, R
B22 Machine steering, minilever 801 D Control panel, L
F60 Fuse, 12 V, Scales sensor 810 E Seat
S31-S35 Multifunction switches A,B,C,D Control panel, R
S36 Load narrowing 805 T Control panel, L
S37 Load spreading 806 T Control panel, L
S40 Switch, driving direction 817 D Control panel, R
S41 Switch, boom function On / Off 812 Y Control panel, R
S42 Button, high/low gear 813 F Control panel, R
S43 Button, front differential lock 814 F Control panel, L
S44 Button, rear differential lock 815 F Control panel, L
S45 Button, wiper 808 F Control panel, R
S46 Button, headboard up 806 X Control panel, L
S47 Button, headboard down 807 X Control panel, L
S48 Button, blade down 804 X Control panel, R
S49 Button, blade up 805 X Control panel, R
S50 Limit switch, seat direction 817 U Seat
S51 Limit switch, driver 819 U Seat
S57 Push button, working rpm’s 804 T Control panel, L
S76 Push button, frame brake release 803 T Control panel, L
S78 Push button, seat lock 813 Z Control panel, R 16
1620
S79 Push button, jib boom light 813 Y Control panel, R 23
S85 ALS-button, stake down 816 S Control panel, R
S86 ALS-button, stake down 817 s Control panel, R
S87 ALS-button, stake up 816 V Control panel, R
S88 ALS-button, stake up 817 V Control panel, R
X35 9-pin connector 816 S Seat
X42 9-pin connector 814 H Control panel, R
X43 9-pin connector 803 H Control panel, L
X44-X45 3-pin connector 800 H Control panel, L
X74 2-pin connector 810 B Instrument box
X82 2-pin connector 810 F Seat

081403
PN=573
16
1620
24
–UN–09APR03
T189413

081403
PN=574
S89 ALS-button, load space reset 816 Q Control panel, R

S111 ALS-button, load space tilt 811 Q Control panel, R
S112 ALS-button, load space tilt 812 Q Control panel, R
S113 PC-button SHIFT 813 Q Control panel, R
S114 PC-button TAB 814 Q Control panel, R
X16 6-pin connector 810 C Instrument box
X25 9-pin connector 810 P Control panel, R
X26 9-pin connector 802 R Control panel, L
X90,X91 2-pin connector 818 R Seat
XC1,XC2, 23-pin connector 807 H... Chair module
XC3
XC4 8-pin connector 800 M Chair module
16
1620
25

081403
PN=575
16
1620
26
–UN–09APR03
T189413

081403
PN=576
F626571 9/15

A7 Transmission module, TMC 900 N Front frame
B9 Fuel sensor 913 U Fuel tank
B14 Sensor rpm, driving speed/distance 914 V Hydraulic motor
B18 Pressure switch, return filter 905 U Hydraulic tank
J10 Splice 901 I Wiring
J11 Splice 910 H Wiring
J13 Splice 905 J Wiring
J14 Splice 914 R Wiring
J17 Splice 917 S Wiring
R1 Resistor 902 Z Wiring
S81 Limit switch, low gear 904 E Gear box
S82 Limit switch, high gear 906 E Gear box
X24 4-pin connector 908 R Front frame
X81 4-pin connector 904 H Front frame
XO1 3-pin connector 902 R Front frame
XT1 23-pin connector 900 L Transmission module
XT3 23-pin connector 913 P Transmission module
Y33B Magn. valve, rear differential lock 915 E Auxiliary valve
Y33F Magn. valve, front differential lock 913 E Auxiliary valve
Y39 Magn. valve, rear wheel drive 910 E Auxiliary valve
Y41W Magn. valve, work brake 907 E Brake valve 16
1620
Y45 Magn. valve, low gear 901 E Auxiliary valve 27
Y46 Magn. valve, high gear 902 E Auxiliary valve
Y48 Magn. valve, hydraulic motor 918 U Hydraulic motor
Y65 Magn. valve, frame brake 911 E Auxiliary valve
Y102 Magn. valve, driving forward 915 U Hydraulic pump
Y103 Magn. valve, driving reverse 916 U Hydraulic pump
Y103B Magn. valve, constant pressure valve, hydrostatic motor 911 U Hydraulic motor
Y208 Magn. valve, working pump’s pressure 918 E Auxiliary valve

081403
PN=577
16
1620
28
–UN–09APR03
T189414

081403
PN=578
F626571 10/15

B19 Temp. sensor, hydraulics 1003 D Hydraulic tank
B25 Level sensor, hydraulic oil 1002 U Hydraulic tank
B43 Back -up alarm 1006 U Rear frame
B52 Stairs 1003 T Front frame
F24 Fuse, stairs 1015 C PC-board
S29 Switch, stairs 1015 J Instrum. panel
X15 3-pin connector (opt. eq.). 1017 F Instrum. panel
X36 2-pin connector, back-up buzzer. 1006 R Front frame
X47 4-pin connector, decking blade. 1008 G Front frame
X67 3-pin connector, limit switch, stairs. 1003 R Front frame
X68 4-pin connector 1014 T Front frame
X152 3-pin connector 1018 H Instrum. panel
XT1 23-pin connector 1007 D Transmission module
XT2 23-pin connector 1006 K Transmission module
Y120D Magn. valve, stairs down 1016 T Front frame
Y120U Magn. valve, stairs up 1015 T Front frame
Y195D Magn. valve, blade down 1006 D Front frame
Y195U Magn. valve, blade up 1007 D Front frame
16
1620
29

081403
PN=579
16
1620
30
–UN–09APR03
T189415

081403
PN=580
F626571 11/15

A8 TMC-Boom module 1103 O Under the cabin
B53 Limit switch, damping of the steering 1103 X Middle joint
X79 3-pin connector 1100 J TMC-Boom module
X97 4-pin connector 1118 J Front frame
X99 3-pin connector 1102 J TMC-Boom module
XE1 23-pin connector 1100 M TMC-Boom module
XE4 8-pin connector 1100 Q TMC-Boom module
Y66L Magn. valve, steering L 1105 V Boom valve
Y66R Magn. valve, steering R 1106 V Boom valve
Y196 Magn. valve, ASF —function 1101 A Boom valve
Y197 Magn. valve, ASF —function 1103 A Boom valve
Y198 Magn. valve, boom flotation 1105 G Boom valve
Y211 Clambunk magn. valve 1114 U Front frame
Y231 Magn. valve, hydraulic headboard move, headboard down 1115 F Front frame
Y232 Magn. valve, hydraulic headboard move, headboard up 116 F Front frame
Y408 Magn. valve, rotator clockwise 1110 G Boom valve
Y409 Magn. valve, rotator counterclockwise 1108 G Boom valve
Y416 Magn. valve, grapple open 1111 G Boom valve
Y417 Magn. valve, grapple close 1113 G Boom valve
Y418 Magn. valve, extension out 1114 V Boom valve 16
1620
Y419 Magn. valve, extension in 1116 V Boom valve 31
Y420 Magn. valve, main boom up 1105 G Boom valve
Y421 Magn. valve, main boom down 1107 G Boom valve
Y422 Magn. valve, jib boom out 1111 V Boom valve
Y423 Magn. valve, jib boom in 1112 V Boom valve
Y424 Magn. valve, Boom counterclockwise 1108 V Boom valve
Y425 Magn. valve, Boom clockwise 1109 V Boom valve

081403
PN=581
16
1620
32
–UN–09APR03
T189416

081403
PN=582
F626571 12/15

A1 Engine ECU 1204 L Front frame
050 Grounding Point 1207 M Engine, ECU, wiring harness
B01 Oil Pressure Sensor 1214 F Engine
B02 Manifold Air Temperature Sensor 1211 G Engine
B03 Coolant Temperature Sensor 1212 G Engine
B04 Fuel Temperature Sensor 1210 G Engine
B08 Crank Sensor 1210 T Engine
F26 Fuse 10A, Engine ECU 1206 E PC board
R10 Resistor 1205 U Wiring
XB4 4-pin connector 1200 G PC-board
X10 3-pin connector 1206 S Near ECU
X21 16-pin connector 1207 C Under cabin
X02 9-pin connector 1202 F Wirings
X04 3-pin connector 1201 P Wirings
X06 30-pin connector 1208 I Engine ECU
X64 6-pin connector 1204 D Front frame
Y01 Magnitic Valve, Fuel Injectors 1216 F Engine
16
1620
33

081403
PN=583
16
1620
34
–UN–09APR03
T189417

081403
PN=584
F626571 13/15

E48, E49 Work light, forwards 1305 S, 1306 S Cabin roof
E50, E51 Work light, backwards 1302 S, 1303 S Cabin, middle
E54 Work light, backwards 1304 S Rear frame
E55, E56 Work light, Boom 1300 S, 1301 S Boom
F7 Fuse, work light, Boom 1301 C PC-board
F25 Fuse, vacuum pump 1312 F PC-board
F30 Fuse, compressor, seat 1309 B PC-board
K6 Relay, compressor, seat 1310 H PC-board
K38 Relay, fuel pump 1315 N Front frame
M10 Compressor, seat 1310 S Seat
M11 Fill-up pump, hydraulic oil 1314 R Under the cabin
M12 Vacuum pump, hydr. tank 1312 R Under the cabin
M16 Fuel pump 1316 R Front frame
S54 Switch, fill-up pump, hydraulic oil 1314 O Beside main switch
S55 Switch, hydraulic vacuum pump 1312 O Beside main switch
S61 Switch, fuel pump 1315 G Beside main switch
S65 Switch, work light forwards 1305 J Ceiling
S70 Switch, work light Boom 1300 J Ceiling
S71 Switch, corner lights 1303 J Control panel
X11 9-pin connector 1302 F Cabin
X12 9-pin connector 1301 G Cabin
X21 16-pin connector 1307 P Cabin floor
X22 24-pin connector 1301 N Cabin floor 16
1620
X28, X29, 2-pin connector 1319 G, 1315 H, 1300 Front frame 35
X30, X31 V, 1312 V
X40 2-pin connector 1310 P Front frame
X52 2-pin connector 1305 Q Front frame
X60 2-pin connector 1310 N Instrument box
X93 2-pin connector 1310 O. Instrument box
XB5 9 -pin connector 1312 D PC-board
Y77 Magn. valve, vacuum pump 1301 S Hydraulic tank

081403
PN=585
16
1620
36
–UN–09APR03
T189418

081403
PN=586
F626571 14/15

A13 Sensor, water separator 1410 H Water separator (optional)
A30 Control, Dafo-fire extinguisher 1403 C Ceiling
B30.1 Temp. sensor, Dafo. 1404 T Engine comp
B30.6 Temp. sensor, Dafo 1407 T Under the cabin
B31 Horn, Dafo 1408 K Engine comp.
E60 Work lights 1414 Q Jib boom
F40 Fuse, dozer blade flotation 1416 D Instrument box
H30 Alarm light, Dafo 1408 D Ceiling
K40 Relay, dozer blade flotation 1416 K Instrument box
M17 Seat lock, servomotor 1411 T Seat
R30 Resistor, Dafo fire extinguisher 1416 T Temp.sensor, Dafo
S74 Switch, dozer blade flotation 1414 E Instrument box
S99 Switch, testing the water separator 1410 M Control panel
X15 3-pin connector 1410 E Instrument box
X16 6-pin connector 1410 F Instrument box
X22 24-pin connector 1413 I Instrument box
X32 9-pin connector 1402 I Fire extinguisher
X38 2-pin connector 1416 J Seat
X60 2-pin connector 1419 O Instrument box
X63 2-pin connector 1407 C Ceiling
X87 3-pin connector 1401 M Fuse box
X92 2-pin connector 1414 M Jib boom
X95 2-pin connector 1411 K Seat
Y195 Magnetic valve, decking blade float 1416 T Front frame 16
1620
YS9 Trigger, Dafo-extinguisher 1409 O Front frame, rear 37

081403
PN=587
16
1620
38
–UN–09APR03
T189419

081403
PN=588
F626571 15/15

GND1 Grounding Instrument box
GND2 Grounding Under the cabin, left
GND3 Grounding Ceiling
GND4 Grounding Under the cabin, right
GND5 Grounding Seat
GND6 Grounding Engine
GND7 Grounding Front frame
GND10 Grounding Under cabin floor
16
1620
39

081403
PN=589
16
1620
40
–UN–09APR03
T189420
JK11466,0000004 –19–10APR03–33/33

081403
PN=590
16
1620
41

081403
PN=591
F626254 1/15
Pos. Description Diagram Location

F7 Fuse, Ignition 106 C PC-board
F8 Fuse, socket 24V 105 E PC-board
F31 Main fuse, 50A 100 L Instrument box
F32 Main fuse, 50A 101 L Instrument box
F41 Fuse 10A, glow indicator light 104 M Under the cabin
F42 Fuse 10A, preheater, radio 102 M Under the cabin
F43 Fuse 25A, preheater 103 M Under the cabin
F44 Fuse 15A, preheater 103 M Under the cabin
G1 Generator 108 T Engine
G2 Battery 102 T Under the cabin
K3 Relay, starting 105 L Under the cabin
K14 Relay,start prevent 114 L PC-board
K24 Relay, glow 110 M Under the cabin
R2 Glow plug 110 T Engine
M1 Starting motor 104 S Engine
S1 Main switch 100 P Front frame
S2 Ignition 108 G Dashboard
S56 Emergency stopper 113 C Dashboard
V2 Diode 110 C Ignition
X1 9-pin connection 100 B PC-board
X2 9-pin connection 114 C PC-board
X3 9-pin connection 106 E PC-board
16 X22 24-pin connection 104 J Instrument box
1620 X23 16-pin connection 102 J Instrument box
42
X59 3-pin connection 109 N Glow relay
X61 Socket, 24 V 103 T Main switch
X71 2-pin connection 103 K Instrument box
Y44 Magn. valve, working pump’s drop 112 T Front frame

081403
PN=592
16
1620
43
–UN–21NOV02
T161992

081403
PN=593
F626254 2/15

B2 Temperature sensor, Engine 213 U Engine
B3 Pressure switch, charge pressure, brakes 203 T Brake valve
B4 Pressure switch, drive hydraulic supply pressure 201 T Hydraulic pump
B10 Pressure switch, pressure filter (opt.) 208 T Front frame
B18 Pressure switch, return filter 206 T Hydraulic oil tank
F2 Fuse 7.5A, warning lights 211 C PC-board
H1 Warning light, charge 205 J Dashboard
H5 Warning light, glow plug 202 J Dashboard
H6 Warning light, hydraulic temperature 207 J Dashboard
H7 Warning light, hydraulic oil level 210 J Dashboard
H13 Warning light, hydr. return filter 206 J Dashboard
H15 Warning light, pressure filter 209 J Dashboard
H18 Warning light, drive hydraulic supply pressure 200 J Dashboard
H19 Warning light, brake charge 203 J Dashboard
P2 Tachometer/hourmeter 217 I Dashboard
P4 Fuel gauge 215 I Dashboard
P5 Temperature gauge, Engine 214 I Dashboard
R3 Resistance 205 K Instrument box
V3 Diode 205 L Instrument box
V1A Diode 200 O Dashboard
V1C Diode 204 O Dashboard
V1D Diode 206 O Dashboard
16 X6 8-pin connection 206 I Dashboard
1620
44 X7 8-pin connection 201 1 Dashboard
X8 10-pin connection 217 1 Dashboard
X9 5-pin connection 214 I Dashboard
X16 9-pin connection 210 D Instrument box
X22 24-pin connection 201 R Instrument box
X38 9-pin connection 202 L Instrument box
XJ2 2-pin connection 206 D Instrument box

081403
PN=594
16
1620
45
–UN–21NOV02
T161993

081403
PN=595
F626254 3/15

A1 ECU, Engine control unit 306 K Engine
B01 Sensor, oil pressure 314 E Engine
B02 Sensor, manifold air 311 F Engine
B03 Sensor, coolant temperature 313 F Engine
B04 Sensor, fuel temperature 310 G Engine
B08 Crank sensor 310T Engine
B24 Potentiometer, drive pedal 318 V Rear drive pedal
B26 Potentiometer, manual throttle 316 V Dashboard
F5 Fuse 10A, ECU 301 D PC-board
F6 Fuse 10A, ECU 305 C PC-board
H11 Warning light, yellow, ECU 313 U Dashboard
H12 Warning light, red, ECU 311 U Dashboard
R1 Resistor, CAN-Bus 307 U Engine
S57 Switch, manual throttle 314 T Dashboard
S84 Switch, ECU codes 312 U Dashboard
X1 9-pin connection 305 D PC-board
X10 3-pin connection 307 S Engine
X18 4-pin connection 316 S Manual throttle, potentiometer,
X19 4-pin connection 318 S Drive pedal, potentiometer
X20 6-pin connection 318 H Engine
X21 9-pin connection 318 M Instrument box
X23 16-pin connection 306 D Instrument box
16 X64 8-pin connection 301 U Engine
1620
46 X02 9-pin connection 301 K Engine
X06 30-pin connection 305 I Engine
Y01 Magnetic valve, injection pump 315 D Engine

081403
PN=596
16
1620
47
–UN–21NOV02
T161994

081403
PN=597
F626254 4/15

A2 Radio 412 Q Ceiling
A3 Radiophone (opt.) 415 D Cabin
B11 Loudspeaker 416 U Ceiling
B12 Loudspeaker 414 U Ceiling
B17 Thermostat, air conditioning 409 K Air conditioner
B29 Voltage transformer 411 E Instrument box
B33 Pressure switch, compressor 409 R Engine room
E1 Preheater, engine (extra equip.) 402 S Engine room
E30 Seat heater 405 R Seat
F16 Fuse 20A, air conditioner 405 D PC-board
K6 Relay, air conditioner 403 F PC-board
K20 Relay, radio 413 H PC-board
K22 Relay, air conditioner 408 F Instrument box
M2 Puhallin, air conditioner 407 S Air conditioner
P7 Time switch, preheater (opt.) 400 G Dashboard
S25 Switch, puhallin 405 J Air conditioner
X3 9-pin connection 404 H PC-board
X4 9-pin connection 413 H PC-board
X12 9-pin connection 411 M Instrument box
X15 4-pin connection 406 E Instrument box
X17 2-pin connection 415 F Instrument box
16 X48 2-pin connection 405 O Seat
1620
48 X50 8-pin connection 413 P Radio
X51 8-pin connection 413 R Radio
X58 6-pin connection 402 O Front frame
XP7 12-pin connection 401 F Time switch
Y194 Magn.coupler, compressor 409 T Engine room

081403
PN=598
16
1620
49
–UN–21NOV02
T161995

081403
PN=599

E37 Indoor light 501 T Cabin
E40 Work light, left 508 U Cabin roof
E41 Work light, left 509 U Cabin roof
E42 Work light, right 510 U Cabin roof
E43 Work light, right 511 U Cabin roof
E44 Work light, backwards 513 U Cabin roof
E45 Work light, backwards 514 U Cabin roof
E46 Tail light 501 U Cabin roof
E48 Work light, forward 504 U Cabin roof
E49 Work light, forward 506 U Cabin roof
E55 Work light, boom (opt.) 517 U Boom
E56 Work light, boom (opt.) 518 U Boom
F10 Fuse 10A, Work light, boom 517 D PC-board
F12 Fuse 10A , work light 501 D PC-board
F13 Fuse 10A, Tail light, Indoor light 504 D PC-board
F14 Fuse 10A, work light 506 D PC-board
S26 Switch, Indoor light 500 K Dashboard
S64 Switch, Tail light 502 L Dashboard
S65 Switch, work light, forward 504 L Ceiling
16 S66 Switch, work light, left 506 L Ceiling
1620
50 S67 Switch, work light, right 509 L Ceiling
S68 Switch, work light, backwards 512 L Ceiling
S70 Switch, Work light, boom 517 L Boom
X5 9-pin connection 501 F PC-board
X12 9-pin connection 501 O Instrument box
X23 16-pin connection 516 Q Instrument box
X41 9-pin connection 501 Q Ceiling
X73 2-pin connection 517 Q Front frame

081403
PN=600
16
1620
51
–UN–21NOV02
T161996

081403
PN=601

B16 Horn 601 T Front frame
E52 Cigarette lighter 618 R Dashboard
F4 Fuse 7.5A, horn 601 E PC-board
F9 Fuse 10A, compressor 616 E Instrument box
F11 Fuse 10A, wipers, washert 603 E PC-board
K2 Relay, wipers 612 M Instrument box
K12 Relay, wipers 606 M Instrument box
K23 Relay, compressor 614 M Instrument box
M4.1 Motor, washer 608 T Engine room
M4.2 Motor, washer 603 T Engine room
M5B Motor, rearscreen wiper 610 R Cabin
M5F Motor, windscreen wiper 606 T Cabin
M10 Compressor motor (extra equip.) 616 R Seat
S13 Push button, horn 601 K Dashboard
S91 Switch, washer, rear 608 I Dashboard
S92 Switch, washer, front 603 J Dashboard
S101 Switch, rear screen wiper 611 H Dashboard
S102 Switch, windscreen wiper 606 H Dashboard
X46 9-pin connection 611 B Seat
X22 24-pin connection 601 N Instrument box
16 X40 9-pin connection 616 U Instrument box
1620
52 X72 3-pin connection 614 H Instrument box

081403
PN=602
16
1620
53
–UN–21NOV02
T161997

081403
PN=603

A4 LCS HUB-Module, CAN-bus 702 M Instrument box
B5 Pressure switch, parking brake 717 T Front frame
F1 Fuse 10A, LCS-Module 702 C PC-board
F3 Fuse 7,5A, parking brake,rear wheel drive, frame brake 705 C PC-board
release
H8 Central alarm light 710 T Ceiling
J3 Splice 705 S Front frame
S58 Switch, parking brake 715 E Dashboard
S59 Switch, rear wheel drive 709 D Dashboard
S76 Switch, frame brake release 712 D Dashboard
XH1 8-pin connection 707 K HUB-Module
XH3 8-pin connection 702 P HUB-Module
Y41 Magn. valve, parking brake 716 T Front frame
Y102 Magn. valve, drive forward 705 T Front frame
Y103 Magn. valve, drive backwards 706 T Front frame
Y208 Magn. valve, work pump pressure 707 T Front frame
16
1620
54

081403
PN=604
16
1620
55
–UN–21NOV02
T161998

081403
PN=605

A5 LCS, Seat Module, CAN-bus 800 N Seat
B8 Buzzer, alarm 805 T Seat
B20 Steering lever, left 804 E Control panel, left
B21 Steering lever, rightt 818 E Control panel, right
B22 Machine steering, minilever 801 E Control panel, left
B23 Potentiometer, boom 807 U Control panel, left
H2 Signal light, safety switch 815 T Seat
H4 Signal light, limit switch 816 T Portaat
J4,5,7,8 Splices 808 H Seat Module
S40 Switch, drive direction 805 B Control panel, right
S42 Push button, high/low gear 808 B Control panel, right
S43 Push button, front differential lock 812 B Control panel, right
S44 Push button, rear differential lock 814 B Control panel, right
S45 Push button, wipers 807 B Control panel, right
S48 Push button, blade down 809 B Control panel, right
S49 Push button, blade up 811 B Control panel, right
S50 Limit switch, seat direction 813 V Seat
S51 Safety switch 814 V Seat
X16 9-pin connection 808 V Instrument box
X23 16-pin connection 809 V Instrument box
X42 9-pin connection 816 H Control lever, right
X43 9-pin connection 802 H Control lever, left
X44 4-pin connection 800 H Steering lever
X46 9-pin connection 802 R Seat
16 X90 2-pin connection 813 T Seat
1620
56 X91 2-pin connection 814 T Seat
XC1 23-pin connection 807 K Seat Module
XC4 8-pin connection 800 Q Seat Module
Y103B Magn.valve, hydr. motor pressure cut-off 810 U Hydrostatic motor

081403
PN=606
16
1620
57
–UN–21NOV02
T161999

081403
PN=607

A8 LCS, Boom ModuleCAN-bus 901 M Boom valve
B19 Temperature sensor, hydraulics 903 E Hydraulic oil tank
B25 Level sensor, hydraulic oil 902 E Hydraulic oil tank
B42 Pressure switch, work brake 901 T Front frame
B43 Back -up alarm (extra equip.) 906 T Rear frame
B52 Limit switch, stairs 904 E Stairs
X47 4-pin connection 911 I Front frame
X66 2-pin connection 904 S Rear frame
X67 3-pin connection 904 H Front frame
XE1 23-pin connection 907 Q Boom Module
XE2 23-pin connection 909 L Boom Module
XE3 23-pin connection 901 L Boom Module
XE4 8-pin connection 901 Q Boom Module
XY45 2-pin connection 907 R Front frame
XY65 2-pin connection 908 G Front frame
Y33B Magn. valve, rear differential lock 913 T Front frame
Y33F Magn. valve, front differential lock 912 T Front frame
Y39 Magn. valve, rear wheel drive 911 T Front frame
Y41W Magn. valve, work brake 910 D Front frame
Y45 Magn. valve, low gear 907 T Front frame
Y45B Magn. valve, speed limit 915 T Front frame
Y46 Magn. valve, high gear 909 T Front frame
Y65 Magn. valve, frame brake 908 D Front frame
Y195D Magn. valve, blade down 911 D Engine room
16 Y195U Magn. valve, blade up 913 D Engine room
1620
58

081403
PN=608
16
1620
59
–UN–21NOV02
T162000

081403
PN=609
10

A8 LCS Boom Module, CAN-bus 1000 M Boom valve
XE1 23-pin connection 1005 M Boom Module
XE2 23-pin connection 1011 M Boom Module
Y66L Magn. valve, steering left 1003 V Boom Module
Y66R Magn. valve, steering right 1004 V Boom Module
Y408 Magn. valve, rotator clockwise 1010 F Boom Module
Y409 Magn. valve, rotator counterclockwise 1008 F Boom Module
Y416 Magn. valve, grapple open 1011 F Boom Module
Y417 Magn. valve,grapple close 1012 F Boom valve
Y418 Magn. valve, extension in 1013 V Boom Module
Y419 Magn. valve, extension out 1011 V Boom Module
Y420 Magn. valve, main boom up 1005 F Boom Module
Y421 Magn. valve, main boom down 1007 F Boom Module
Y422 Magn. valve, jib boom out 1008 V Boom Module
Y423 Magn. valve, jib boom in 1010 V Boom Module
Y424 Magn. valve, boom slew left 1005 V Boom Module
Y425 Magn. valve, boom slew right 1007 V Boom Module
16
1620
60

081403
PN=610
16
1620
61
–UN–21NOV02
T162001

081403
PN=611
11

B15 Pressure switch, brake lights(opt.) 1114 H Brake valve
E8 Headlight (opt.) 1105 V Front frame
E9 Headlight (opt.) 1106 V Front frame
E10 Position light (opt.) 1103 V Front cabin, left
E11 Position light (opt.) 1108 V Front cabin, right
E12 Rear light, brake lights, blinkers (opt.) 1111 V Rear cabin, left
E14 Rear light, brake lights, blinkers (opt.) 1113 V Rear cabin, right
E24 Blinker (opt.) 1103 V Front cabin, left
E26 Blinker (opt.) 1107 V Front cabin, right
F21 Fuse 20A, headlight 1111 C Instrument box
F22 Fuse 10A, emergency flasher 1108 C Instrument box
F23 Fuse 5A, blinkers 1101 C Instrument box
F25 Fuse 10A, low beam 1112 K Instrument box
F26 Fuse 5A, position lightt 1111 K Instrument box
F27 Fuse 5A, position lightt 1114 K Instrument box
K4 Blinker relay 1102 N Instrument box
S14 Switch, hazard lights 1101 F Dashboard
S15 Switch, blinker 1106 G Dashboard
S18 Switch, headlight 1110 F Dashboard
X22 24-pin connection 1115 F Instrument box
X31 Socket, 7-pin connector 1107 S Cabin, front
X32 Socket, 7-pin connector 1102 S Cabin, front
X34 Socket, 7-pin connector 1111 O Cabin, rear
X39 Socket, 7-pin connector 1110 R Rear lights
16
1620
62

081403
PN=612
16
1620
63
–UN–21NOV02
T162002

081403
PN=613
12

B45 Sensor, odometer (opt.) 1209 R Gearbox
A12 Odometer (opt.) 1209 D Dashboard
A13 Water separtor alarm(opt.) 1214 J Dashboard
F24 Fuse 5A, headboard move, odometerpreparedness for 1204 C Instrument box
clambunk (opt.)
M17 Motor, seat swing locking 1201 U Seat
S60 Coupling , steering (extra equip.)) 1216 J Instrument box
S63 Switch, headboard move preparedness for clambunk 1203 H Dashboard
S78 Push button, seat swing locking 1201 F Control panel, right
S99 Push button, reset for water separatror alarm (opt.) 1214 N Dashboard
X22 24-pin connection 1203 N Instrument box
X33 4-pin connection 1203 O Front frame
X88 3-pin connection 1209 J Instrument box
X95 2-pin connection 1201 L Seat
Y100D Magn.valve, headboard down (opt.) 1203 R Front frame
Y100U Magn.valve, headboard up (opt.) 1204 R Front frame
16
1620
64

081403
PN=614
16
1620
65
–UN–21NOV02
T162003

081403
PN=615
13
The Positions of the Grounding Points Dot / broken line _ . .

_ . . _ illustrates the frame (galvanic connection through the
frame)
GND 1 Instrument box
GND 2 At main switch
GND 4 Cabin floor
GND 5 Battery
GND 6 Cabin floor
GND 7 Seat
GND 8 Front frame
GND 9 Engine
GND 10 Cabin ceiling
16
1620
66

081403
PN=616
16
1620
67
–UN–21NOV02
T162004
EL62757,0000001 –19–31OCT02–26/26

081403
PN=617
F625809 1/15

F51 Main fuse, 60A 107 N Fuse box
K14 Relay, starting prevent 111 M PC-board
16 S56 Emergency STOP -button 112 D Control panel
1620 X21 16-pin connector 104 J Cabin floor
68
X22 24-pin connector 103 J Cabin floor
X59 3-pin connector 114 N Front frame
XB6 9-pin connector 118 I PC-board

081403
PN=618
16
1620
69
–UN–16JAN03
T164053

081403
PN=619
16
1620
70
–UN–16JAN03
T164054

081403
PN=620
F625809 2/15

A3 Radio-telephone 218 D Ceiling
H5 Indicator light, grid heater 203 J Gauge panel
X6,X7 8-pin connectors 206 I, 200K Indicator lights 16
1620
X13 9-pin connector 214 N Cabin 71
X17 2-pin connector 218 F Cabin, rear
XB2 - XB10 9-pin connector PC-board
X172 2-pin connector 218 P

081403
PN=621
16
1620
72
–UN–16JAN03
T164055

081403
PN=622
F625809 3/15

AC Control unit, air conditioner 307 M Air conditioner
ASG Valve motor 308 U Air conditioner
K21 Relay, compressor 315 K PC-board
X48 3-pin connector 316 N Seat
XB4 9-pin connector 315 F Front frame 16
1620
XB5 9-pin connector 308 G Front frame 73

081403
PN=623
16
1620
74
–UN–16JAN03
T164056

081403
PN=624
F625809 4/15

1620
X27 7-pin connector 415 R Ceiling 75

081403
PN=625
16
1620
76
–UN–16JAN03
T164057

081403
PN=626
F625809 5/15

X46 9-pin connector 501 D Instrument box 16
1620

081403
PN=627
16
1620
78
–UN–16JAN03
T164058

081403
PN=628
F625809 6/15

1620
X11 9-pin connector 602 K Ceiling

081403
PN=629
16
1620
80
–UN–16JAN03
T164059

081403
PN=630
F625809 7/15

1620
81

081403
PN=631
16
1620
82
–UN–16JAN03
T164060

081403
PN=632
F625809 8/15

S78 Push button, seat 813 Z Control panel, R
X16 6-pin connector 810 C Instrument box 16
1620
X25 9-pin connector 810 P Control panel, R 83
X90,X91 2-pin connector 818 R Seat
XC1,XC2, 23-pin connector 807 H... Chair module
XC3

081403
PN=633
16
1620
84
–UN–16JAN03
T164061

081403
PN=634
F625809 9/15

1620
Y45 Magn. valve, low gear 901 E Auxiliary valve 85

081403
PN=635
16
1620
86
–UN–16JAN03
T164062

081403
PN=636
F625809 10/15

16
1620
87

081403
PN=637
16
1620
88
–UN–16JAN03
T164063

081403
PN=638
F625809 11/15

X33 4-pin connector 1102 I Front frame
XE3 23-pin connector. 1102 M TMC-Boom module
Y100D Magn. valve, headboard 1102 G Front frame
Y100L Magn. valve, headboard lock valve 1104 E Front frame
Y100U Magn. valve, headboard 1101 G Front frame
Y231 Magn. valve, clambunk or load space narrowing 1115 F
Y232 Magn. valve, clambunk or load space spreading 116 F
Y418 Magn. valve, extension out 1114 V Boom valve 16
1620

081403
PN=639
16
1620
90
–UN–16JAN03
T164064

081403
PN=640
F625809 12/15

X02 9-pin connector 1202 F Wirings
X04 3-pin connector 1201 P Wirings
16
1620
91

081403
PN=641
16
1620
92
–UN–16JAN03
T164065

081403
PN=642
F625809 13/15

1620
X28, X29, 2-pin connector 1319 G, 1315 H, 1300 Front frame 93
X30, X31 V, 1312 V

081403
PN=643
16
1620
94
–UN–16JAN03
T164066

081403
PN=644
F625809 14/15

A13 Sensor, water separator 1410 H Water separator (optional)
S78 Seat lock, switch 1410 F Control panel, R
S99 Switch, testing the water separator 1410 M Control panel
X92 2-pin connector 1414 M Jib boom
X95 2-pin connector 1411 K Seat 16
1620
Y195 Magnetic valve, decking blade float 1416 T Front frame 95
YS9 Trigger, Dafo-extinguisher 1409 O Front frame, rear

081403
PN=645
16
1620
96
–UN–16JAN03
T164067

081403
PN=646
F625809 15/15

GND5 Grounding Seat
JK11466,0000002 –19–04APR03–30/30
16
1620
97

081403
PN=647
16
1620
98
–UN–09OCT02
T160346
Continued on next page EL62757,00001EF –19–24APR02–1/32

081403
PN=648
F619759A 1/15

S56 Emergency STOP -button 112 D Control panel
X22 24-pin connector 103 J Cabin floor 16
1620
X23 7-pin connectorr 100 G Cabin floor 99
X59 3-pin connector 114 N Front frame

081403
PN=649
16
1620
,100
–UN–09OCT02
T160347

081403
PN=650
F619759A 2/15

X6,X7 8-pin connectors 206 I, 200K Indicator lights
X13 9-pin connector 214 N Cabin 16
1620
X17 2-pin connector 218 F Cabin, rear ,101
XB6 9-pin connector 211 J PC-board

081403
PN=651

X172 2-pin connector 218 P
16
1620
,102

081403
PN=652
16
1620
,103
–UN–09OCT02
T160348

081403
PN=653
F619759A 3/15

A1 Control unit, air conditioner 311 M Air conditioner
B6 Potentiometer, fan 309 E Air conditioner
S83 Switch, fans 318 I Ceiling
X21 16-pin connector 307 U Cabin floor
16 X46 318 C
1620
,104 X48 3-pin connector 316 N Seat
XK 9-pin connector 307 T Air conditioner
Y23 Directional valve, air conditioner . 311 U Engine comp

081403
PN=654
16
1620
,105
–UN–09OCT02
T160349

081403
PN=655
F619759A 4/15

16 X22 24-pin connector 405 O Cabin floor
1620
,106 X27 7-pin connector 415 R Ceiling

081403
PN=656
16
1620
,107
–UN–09OCT02
T160350

081403
PN=657
F619759A 5/15

16 XB4 9-pin connector 500 D PC-board
1620
,108 XB5 9-pin connector 508 N PC-board

081403
PN=658
16
1620
,109
–UN–09OCT02
T160351

081403
PN=659
F619759A 6/15

16 S64 Switch, work light forwards 606 N Ceiling
1620
,110 S66 Switch, work light forwards 600 N Ceiling

081403
PN=660
16
1620
,111
–UN–09OCT02
T160352

081403
PN=661
F619759A 7/15

16 Y41 Magn. valve, parking brake 716 S Front frame
1620
,112

081403
PN=662
16
1620
,113
–UN–09OCT02
T160353

081403
PN=663
F619759A 8/15

16 X16 6-pin connector 810 C Instrument box
1620
,114 X25 9-pin connector 810 P Control panel, R
X90 2-pin connector 818 R Seat

081403
PN=664
X91 2-pin connector 819 R Seat

XC1,XC2, 23-pin connector 807 H, 813 I, 814 I Chair module
XC3
16
1620
,115

081403
PN=665
16
1620
,116
–UN–09OCT02
T160354

081403
PN=666
F619759A 9/15

1620
Y45 Magn. valve, low gear 901 E Auxiliary valve ,117

081403
PN=667
16
1620
,118
–UN–09OCT02
T160355

081403
PN=668
F619759A 10/15

16
1620
,119

081403
PN=669
16
1620
,120
–UN–09OCT02
T160356

081403
PN=670
F619759A 11/15

Y100D Magn. valve, headboard 1102 G Front frame
Y100L Magn. valve, headboard lock valve 1104 E Front frame
Y100U Magn. valve, headboard 1101 G Front frame
Y418 Magn. valve, extension out 1114 V Boom valve
1620
Y420 Magn. valve, main boom up 1105 G Boom valve ,121

081403
PN=671
16
1620
,122
–UN–09OCT02
T160357

081403
PN=672
F619759A 12/15

X02 9-pin connector 1202 F
16
1620
,123

081403
PN=673
16
1620
,124
–UN–09OCT02
T160358

081403
PN=674
F619759A 13/15

1620
X28, X29, 2-pin connector 1319 G, 1315 H, 1300 Front frame ,125
X30, X31 V, 1312 V

081403
PN=675
16
1620
,126
–UN–09OCT02
T160359

081403
PN=676
F619759A 14/15

Y195 Magnetic valve, decking blade float 1416 T Front frame
16
1620
,127

081403
PN=677
16
1620
,128
–UN–09OCT02
T160360

081403
PN=678
F619759A 15/15

GND5 Grounding Seat
EL62757,00001EF –19–24APR02–32/32
16
1620
,129

081403
PN=679
16
1620
,130
–UN–26AUG02
T158807

081403
PN=680
F624309B 1/15

F15 Fuse, ignition switch 107 E PC-board
F28 Fuse, fuel valve, Engine ECU 118 G PC-board
F36 Fuse, working pump’s drop 113 L PC-board
F41 Fuse, preheater 102 M Fuse box
F42 Fuse, preheater, 24/12V voltage transformer 103 M Fuse box
F43 Fuse, air conditioner 103 M Fuse box
F44 Fuse, spare 104 M Fuse box
F45 Socket 24V, hydraulic oil fill-up pump 105 M Fuse box
F46 Fuse, socket 24V, auxiliary fuel pump 106 M Fuse box
F47 Fuse, DAFO 107 M Fuse box
F48 Fuse, DAFO 108 M Fuse box
F51 Main fuse 107 N Fuse box
F52 Main fuse 108 N Fuse box
S56 Emergency STOP -button 112 D Control panel
X49 9-pin connector 114 V Fuse box 16
1620
X65 Socket 24V 110 S Front frame, right ,131
X66 Socket 24V 110 S PC-board
XB9 9-pin connector 114 V PC-board

081403
PN=681
16
1620
,132
–UN–26AUG02
T158808

081403
PN=682
F624309B 2/15

B5 Pressure switch, parking brake 201 T Brake valve
F8 Fuse, radio 216 C PC-board
F20 Fuse, indicator lights 201 C PC-board
F32 Fuse, voltage transformer 214 F PC-board
H2 Warning light, engine oil pressure 203 K Gauge panel
J2,5, 8,9,12 Splice Wiring
X6 8-pin connector 206 I Indicator lights
X7 8-pin connector 200 K Indicator lights
X17 2-pin connector 218 F Cabin, rear 16
1620
X21 16-pin connector 210 R Cabin floor ,133

081403
PN=683
16
1620
,134
–UN–26AUG02
T158809

081403
PN=684
F624309B 3/15

A1 Control unit, air conditioner 311 M Air conditioner
B6 Potentiometer, fan 309 E Air conditioner
E1 Preheater, engine 302 T Engine comp
J1, 2, 3, 6 Splice 3- - - Wiring
M6 Fan, ceiling 317 T Ceiling
M7 Fan 318 T Ceiling
S83 Switch, fans 318 I Ceiling
X21 16-pin connector 307 U Cabin floor
X22 24-pin connector 307 S Cabin floor 16
1620
X48 3-pin connector 316 N Seat ,135
XK 9-pin connector 307 T Air conditioner
Y23 Directional valve, air conditioner . 311 U Engine comp

081403
PN=685
16
1620
,136
–UN–26AUG02
T158810

081403
PN=686
F624309B 4/15

1620
X27 3-pin connector 415 R Ceiling ,137

081403
PN=687
16
1620
,138
–UN–26AUG02
T158811

081403
PN=688
F624309B 5/15

K2 Relay, wiper, intermittent, rear window 513 J PC-board
K12 Relay, intermittent, windshield 509 J PC-board
M41 Motor, washer, rear . 502 T Engine comp
1620
XB5 9-pin connector 508 N PC-board ,139

081403
PN=689
16
1620
,140
–UN–26AUG02
T158812

081403
PN=690
F624309B 6/15

1620
S66 Switch, work light forwards 600 N Ceiling ,141

081403
PN=691
16
1620
,142
–UN–26AUG02
T158814

081403
PN=692
F624309B 7/15

J1 Splice 707 Q Instrument box
J4 Splice 708 Q Instrument box
1620
,143

081403
PN=693
16
1620
,144
–UN–26AUG02
T158815

081403
PN=694
F624309B 8/15

B22B Potentiometer, steering of the machine 802 D Control panel, L
J3 Splice 818 P Wiring
S36 Load area narrowing. 805 T Control panel, R
With Clambunk: Tightening of the cable
S37 Load area spreading. 806 T Control panel, R
With clambunk: Quick opening
S43 Button, front differential lock 814 F Control panel, R
S44 Button, rear differential lock 815 F Control panel, R
S45 Button, wiper, intermittent 808 F Control panel, R
S46 Button, clambunk closed 806 X Control panel, L
S47 Button, clambunk open 807 X Control panel, L
S48 Button, blade down 804 X Control panel, L
S49 Button, blade up 805 X Control panel, L
16
S51 Limit switch, driver 819 U Seat 1620
S57 Push button, working rpm’s 804 T Control panel, L ,145

X25 9-pin connector 810 P Control panel, R
X42 3-pin connector 814 H Cabin
XC1 23-pin connector 807 H Chair module

081403
PN=695
XC2 23-pin connector 813 I Chair module

XC3 23-pin connector 814 I Chair module
16
1620
,146

081403
PN=696
16
1620
,147
–UN–26AUG02
T158816

081403
PN=697
F624309B 9/15

RO1 Resistor 902 Z Wiring
Y33B Magn. valve, rear differential lock 913 E Front frame
Y33F Magn. valve, front differential lock 915 E Front frame
Y39 Magn. valve, rear wheel drive 910 E Front frame
Y41W Magn. valve, work brake 907 E Front frame
16 Y45 Magn. valve, low gear 901 E Front frame
1620
,148 Y46 Magn. valve, high gear 902 E Front frame
Y48 Magn. valve, hydraulic motor 918 U Front frame
Y65 Magn. valve, frame brake 911 E Front frame
Y102 Magn. valve, driving forward 915 U Front frame
Y103 Magn. valve, driving reverse 916 U Front frame
Y103B Magn. valve, constant pressure valve, hydrostatic motor 911 U Front frame
Y208 Magn. valve, working pump’s pressure 918 E Front frame

081403
PN=698
16
1620
,149
–UN–26AUG02
T158817

081403
PN=699
F624309B 10/15

X22 24-pin connector (opt. eq.) 1015 R Cabin floor
X24 4-pin connector (opt. eq.). 1008 R Front frame
16
1620
,150

081403
PN=700
16
1620
,151
–UN–26AUG02
T158818

081403
PN=701
F624309B 11/15

X61 12-pin connector 1114 R
X96 4-pin connector 1116 J
Y100D Magn. valve, headboard 1102 G Front frame forward
Y100U Magn. valve, headboard 1101 G Front frame backwards
Y100W Magn. valve, headboard 1104 G Front framelock valve
Y211 Clambunk magn. valve 1114 U
Y418 Magn. valve, extension out 1114 V Boom valve
Y419 Magn. valve, extension in 1116 V Boom valve
16 Y422 Magn. valve, jib boom out 1111 V Boom valve
1620
,152 Y423 Magn. valve, jib boom in 1112 V Boom valve

081403
PN=702
16
1620
,153
–UN–26AUG02
T158820

081403
PN=703
F624309B 12/15

XO9 Grounding Point 1207 M Engine, ECU
B01 Oil Pressure Sensor 1205 E Engine
B02 Fuel Temperature Sensor 1206 E Engine
B03 Coolant Temperature Sensor 1207 E Engine
B05 Water in Fuel Sensor 1207 S Engine
B06 MAT Sensor 1209 S Engine
B07 Fuel Pump Cam Sensor 1209 E Engine
B08 Crank Sensor 1210 E Engine
B09 Rail Pressure Sensor 1213 C Engine
C1 Magnetic Valve, Fuel Injector 1209 U Engine
W01 8-pin connector 1208 P Engine
XB4 4-pin connector 1200 G Circuit Board
XB5 9-pin connector 1200 D Circuit Board
X04 3-pin connector 1201 O Front frame
X06 15-pin connector 1203 J Engine, ECU
X07 15-pin connector 1205 Engine, ECU
X10 3-pin connector 1204 S Front frame
X21 16-pin connector 1201 D Cabin
16 X64 6-pin connector 1204 D Front frame
1620
,154 Y01 Pump Control Valve connector, front 1211 E Engine
Y02 Pump Control Valve connector, back 1212 E Engine

081403
PN=704
16
1620
,155
–UN–26AUG02
T158821

081403
PN=705
F624309B 13/15

X22 24-pin connector 1301 N Cabin floor
16 X28 2-pin connector 1319 G Front frame
1620
,156 X30 2-pin connector 1300 V Front frame

081403
PN=706
16
1620
,157
–UN–26AUG02
T158822

081403
PN=707
F624309B 14/15

K18 Relay, seat lock 1410 H Seat
X39 9-pin connector 1417 Q Seat (BEGE 2000)
X40 3-pin connector 1412 J Cabin, rear
X41 2-pin connector 1412 M Seat
16
1620
,158

081403
PN=708
16
1620
,159
–UN–26AUG02
T158823

081403
PN=709
F624309B 15/15

GND1 Earthing point Instrument box
GND2 Earthing point Under the cabin, left
GND3 Earthing point Ceiling
GND4 Earthing point Under the cabin, right
GND5 Earthing point Seat
GND8 Earthing point Front frame
GND9 Earthing point Front frame
GND10 Earthing point Under cabin floor
GND11 Earthing point Under cabin floor
EL62757,00001EF –19–24APR02–32/32
16
1620
,160

081403
PN=710
Group 1630
Electrical Sensors
810D Location of ECU and engine sensors
–UN–12SEP02
T154865
A—Oil pressure sensor D—Crank position sensor F—Engine coolant temperature G—Manifold air temperature
B—Pump control solenoid E—Fuel temperature sensor (ECT) sensor (MAT) sensor
C—Engine Cntrol Unit
16
ECU, Engine Control Unit is placed on the left side of 1630
the machine. 1
JK11466,000000B –19–08MAY03–1/1

081403
PN=711
Electrical Sensors
1010D, 1110D and 1410D Location of ECU and engine sensors
–UN–01OCT02
T159875
1010D - 1410D Engine sensors
A—Oil pressure sensor (B01) D—Crank position sensor F—Engine coolant temperature H—Temperature sensor for a
B—Pump control solenoid (B08) sensor (B03) temperature gauge
(Y01) E—Fuel temperature sensor G—Manifold air temperature
16
C—Engine Control Unit (ECU) (B04) (MAT) sensor (B02)
1630
2
EL62757,00001AE –19–21APR02–1/1

081403
PN=712
Electrical Sensors
1710D Engine Sensors
–UN–27MAY03
T152799
16
1630
3
1710D Engine Sensors
A—Electronic Injector (EI). F—Engine coolant sensor K—CAN-connection from TMC O—Earthing
Wiring Harness Connector G—Event sensor to ECU P—Terminal resistance of
B—Fuel temperature H—Oil pressure L—Power supply (to ECU) CAN-bus
C— Manifold air temperature I—Water in fuel M—CAN-Diagnostic Q—ECU
D—Fuel rail pressure J—Crank position N—ECU’s cables R—Oil pressure switch
E—Pump control valves
EL62757,00001B4 –19–21APR02–1/1

081403
PN=713
Electrical Sensors
1010D Hydraulic Tank Sensors
Hydraulic Oil Level Sensor
The sensor (3) triggers the alarm if the hydraulic oil level
drops below the acceptable limit.
Hydraulic Oil Temperature Sensor
The sensor (4) triggers the alarm if the hydraulic oil

temperature exceeds the acceptable limit.
Hydraulic Oil Return Filter Sensor
The sensor (5) triggers the alarm if the hydraulic oil filter
has clogged.
–UN–10NOV02
T161520
Hydraulic tank sensors
EL62757,000022E –19–29NOV02–1/1
16
1630
4

081403
PN=714
Electrical Sensors
810D, 1110D, 1410D and 1710D Hydraulic

Tank Sensors
Hydraulic Oil Level Sensor
The sensor (5) trickers the alarm if the hydraulic oil levels
drops below the acceptable limit.
Hydraulic Oil Temperature Sensor
The sensor (6) sets off the alarm if the hydraulic oil
temperature exceeds the acceptable limit.
Hydraulic Oil Return Filter Sensor
The sensor (7) triggers the alarm if the hydraulic oil filter
has clogged.
5—Level Sensor
6—Temperature Sensor
–UN–15FEB03
7—Return Filter Sensor
T152795
Hydraulic oil level sensor
16
1630
EL62757,00001B6 –19–21APR02–1/1
5

081403
PN=715
Electrical Sensors
810D, 1110D and 1410D The RPM Sensor of

the Drive Hydrostatics Motor
The sensor (A4) is located on the left-hand side of the

drive hydrostatics motor. The sensor has an impact on the
function of the speedometer and odometer as well as on
the coupling of the work brake.
A—RPM Sensor
–UN–01OCT02
T159873
810D, 1110D and 1410D RPM Sensor
EL62757,00001B5 –19–21APR02–1/1
16
1630
6

081403
PN=716
Electrical Sensors
1710D The RPM Sensor of the Drive

Hydrostatics Motor
The sensor (4) is located on the left-hand side of the drive

hydrostatics motor. The sensor has an impact on the
function of the speedometer and odometer as well as on
the coupling of the work brake.
A—RPM Sensor
A B
217
–UN–19MAR02
216
T152684
C
RPM Sensor
16
1630
EL62757,00001B5 –19–21APR02–1/1
7

081403
PN=717
Electrical Sensors
16
1630
8

081403
PN=718
Group 1640
Control Systems
TMC Control System
The TMC control system is used for controlling the DM

Ch
boom and the hydrostatic power transmission of the
forwarder, as well as the auxiliary functions related to the Hub Cr
boom and the hydrostatic power transmission.
Tr
When operating the machine in an ordinary manner, the
TMC display is in the run-time mode and it shows you
data that is necessary for usage.
For the instructions for the adjustment of parameters

related to the operation of the system see the TMC
instruction manual (attached).
–UN–12SEP02
• For detailed information see for example TMC
Operator’s Manual F058230 ECU
• See TMC Workshop Manual F058238
T159329
ECU—Engine Control Unit
Tr—Transmission module Placing of TMC modules and Engine Control Unit
Hub—Hub module
DM—Display module
Ch—Chair module
Cr—Boom module
16
1640
AK12300,0000004 –19–23OCT02–1/1
1

081403
PN=719
Control Systems
Electronic Control System Terminology
Actuator A device controlled by the ECU to perform a certain function.
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volts or 0 to 12 volts.
Boost Pressurized air in the intake manifold.
CAN Controller Area Network. The network on vehicles that allows communication between controllers.
DTC Diagnostic Trouble Code. This is a code that is stored in the ECU’s memory when it detects a problem in the
electronic control system. There are two types of codes: Active and Stored.
Digital A signal which consists of only two-volt levels — usually 0 volts and +5 volts.
ECT Engine Coolant Temperature (sensor). Measure the temperature of the engine coolant.
ECU Engine Control Unit. Computer that controls the fuel, air, and ignition systems on the engine.
EI Electronic Injector. The EI is an electronic injector that is controller by the ECU. The ECU controls the start of
injection and the amount of fuel injected by energizing and de-energizing the two-way valve on the injectors. See
ELECTRONIC INJECTOR (EI) OPERATION in Group 130 for details.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system fault codes according to
the J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect
Parameter Number (SPN).
J1939 The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on
heavy-duty vehicles, both on- and off-highway.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING
TEMPERATURE later in this group for details.
PCV Pump Control Valve. Opens the valve directing fuel from the fuel injection pump to the HPCR.
PROM Programmable, Read-Only Memory. A computer chip that contains the calibration information for the engine control
system.
16
1640 PWM Pulse Width Modulation. A digital electronic signal (not analog) which consists of a pulse generated at a fixed
2 frequency. When an actuator is controlled by a PWM signal, the on-time of the signal is increased or decreased
(modulated) to increase or decrease the output of the actuator.
RAM Random Access Memory. The RAM is the portion of the computer memory within the ECU that changes as the
engine is running and is stored while engine is off.
Sensor Device used by the ECU to monitor various engine parameters.
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to
the J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code
is the Failure Mode Identifier (FMI).
TPS Throttle Position Sensor. The TPS measures the position of the throttle, which is controlled by the machine
operator. (See MEASURING THROTTLE POSITION, later in this group for details.)
TWV Two-Way Valve. The TWV is energized to raise the outer valve allowing fuel to be injected into the cylinder.
WIF Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel.
RG41221,0000017 –19–28SEP00–1/1

081403
PN=720
Control Systems
Monitoring Engine Parameters
In order for the electronic control system to deliver fuel

according to a given set of operating conditions and, on
some applications to provide engine protection, the
following engine parameters are monitored by the ECU:
• Engine Coolant Temperature (ECT)

• Fuel Temperature
• Manifold Air Temperature (MAT)
• Fuel Rail Pressure
• Oil Pressure
• Crank Position
• Event Position
• Water in Fuel (WIF)
RG41221,0000018 –19–28SEP00–1/1
Measuring Temperature
The Engine Coolant Temperature (ECT) sensor and the

Manifold Air Temperature (MAT) sensor are temperature
sensitive variable resistors. The sensors’ resistance goes
down as the temperature that it is exposed to goes up
(negative temperature coefficient). The Engine Control
Unit (ECU) sends 5 volts to the sensor, monitors the
voltage drop across the sensor, and compares the voltage
drop to preprogrammed values in the ECU’s memory in
order to determine temperature. In addition to temperature
16
sensors, some applications use temperature switches. 1640
Temperature switches close when a specific temperature 3
is reached.
Continued on next page RG41221,0000019 –19–28SEP00–1/4

081403
PN=721
Control Systems
ECT (Engine Coolant Temperature) Sensor
The ECT sensor is located in the thermostat housing. The

ECU monitors engine coolant temperature for:
• Engine protection purposes.
–UN–23JAN01
• Starting fuel quantity determination — The ECU will
adjust the amount of fuel delivered during start-up
based on the initial ECT readings.
• Idle speed determination — In order to speed engine
RG11382A
warm-up, the ECU will increase idle speed after start-up
if a low coolant temperature is measured.
ECT Sensor in Thermostat Housing
RG41221,0000019 –19–28SEP00–2/4
Fuel Temperature Sensor
The fuel temperature sensor is located on the base of the

final fuel filter. The ECU uses this sensor to calculate fuel
density and adjust fuel delivery accordingly.
–UN–23JAN01
RG11385A
16
1640
4 Fuel Temperature Sensor
Continued on next page RG41221,0000019 –19–28SEP00–3/4

081403
PN=722
Control Systems
MAT (Manifold Air Temperature) Sensor
The MAT sensor is located on the bottom of the intake

manifold. This sensor is not included on all applications.
The ECU monitors manifold air temperature for engine
protection purposes.
–UN–23JAN01
RG11383A
MAT Sensor
RG41221,0000019 –19–28SEP00–4/4
Measuring Engine Speed
Both the crank position sensor and the event sensor

operate by detecting notches on their corresponding
gears. When a notch on the timing wheel is directly under
the sensor, a voltage is induced. The ECU monitors this
voltage to determine the location of the timing wheel.
16
1640
RG41221,0000021 –19–09OCT00–1/3
5
Crank Position Sensor
The crank position sensor is located on the front side of

the crank gear. It is an inductive type pickup sensor that
detects teeth on the timing wheel. The ECU uses the
crank position input to determine engine speed and
–UN–23JAN01
precise piston position in relation to the firing order. The

crank timing wheel is composed of 72 evenly spaced
teeth with 2 ground off. The ground teeth help the ECU
determine when cylinder #1 is at Top-Dead-Center (TDC).
RG11388A
Crank Position Sensor
Continued on next page RG41221,0000021 –19–09OCT00–2/3

081403
PN=723
Control Systems
Event Sensor
The event sensor is located on the side of the high

pressure fuel pump. It is an inductive type pickup sensor
that detects notches on the auxiliary gear of the high
pressure fuel pump camshaft. The auxiliary gear is
–UN–23JAN01
composed of 6 evenly spaced notches with one additional
notch offset to tell the ECU that cylinder #1 is approaching
Top-Dead-Center.
RG11389A
Event Sensor
RG41221,0000021 –19–09OCT00–3/3
Water In Fuel (WIF) Sensor
The WIF sensor is located inside the water separating

bowl of the final fuel filter. When water is detected in the
fuel, a signal is sent to the ECU. The ECU monitors this
for engine protection purposes.
–UN–23JAN01
RG11387A
16
1640
6 Water in Fuel Sensor (WIF) Harness
RG41221,0000022 –19–09OCT00–1/1

081403
PN=724
Control Systems
Pump Control Valves (PCVs)
The Pump Control Valves are located on the high

pressure fuel pump. The ECU sends an electronic signal
to the PCVs to regulate the delivery of fuel to the High
Pressure Common Rail (HPCR). When the PCV is
–UN–30JAN01
energized, fuel is allowed discharge from the fuel outlet on
the high pressure fuel pump to the HPCR. PCV #1 is
located closest to the front of the engine.
RG11664
Pump Control Valves (PCVs)
RG41221,00000F0 –19–29JAN01–1/1
Electronic Injector (EI) Wiring Harness

Connector
The EI wiring harness connector is located on the cylinder

head carrier. This connector provides voltage and a
ground for each of the EIs.
–UN–30JAN01
RG11665
16
1640
Electronic Injector (EI) Wiring Harness Connector 7
RG41221,00000F1 –19–29JAN01–1/1

081403
PN=725
Control Systems
Alarms
The TMC control system is equipped with a

condition-monitoring system that greatly facilitates the use
and maintenance of the system. The alarms are recorded
in the alarm log.
The alarms are registered in ECU but they can bee

glanced only in TMC.
There are two kind of alarms: active and previous active

(see the TMC manual1 attached).
1
See alarms -section in TMC manual.
EL62757,000017B –19–21APR02–1/1
16
1640
8

081403
PN=726
Control Systems
Engine Control Unit (ECU)
A1 A2 A3
B1 B2 B3
C1 C2 C3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3 30 Terminal
K1 K2 K3 Half of 60-Way
ECU Connector
60-Way
ECU Connector
16
1640
9
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
–19–17NOV00
Y1 Y2 Y3
30 Terminal
RG11390
Half of 60-Way
ECU Connector
John Deere Level 9 ECU
Continued on next page RG41221,0000023 –19–09OCT00–1/2

081403
PN=727
Control Systems
The Engine Control Unit (ECU) is the “brains” of the in controlling injection fuel quantity and injection timing.
Electronic Control System. The ECU is a The CPU communicates its desired fuel quantity and
self-contained unit containing electronic circuitry and timing to the fuel injection pump and EIs and it controls
computer software, which together perform the the self diagnostic system.
following functions:
Memory
• Convert the electrical signals from the various
sensors into digital signals The ECU contains 3 different types of memory:
• Make decisions of optimum fuel quantity and fuel
injection timing based on information from various — Random Access Memory - RAM
sensors
• Limit maximum fuel for operation on multiple power The RAM is like the working desk top of the ECU.
curves Data from the various sensors and the results of
• Provide all-speed governing various calculations are temporarily stored in RAM.
• Provide self diagnosis on the control system Information in RAM is lost when battery voltage to the
• Store trouble codes in memory ECU is removed.
The ECU connects to the wiring harness through 2 — Read Only Memory - ROM
30-way ECU connectors. Each connectors is marked
by terminal numbers. The ROM contains programmed information.
Information in ROM can only be read, not changed.
The ECU is composed of the following subsystems: ROM information is retained when battery voltage is
removed.
Analog/Digital Converters
— Electrical Erasable Programmable Read Only
This portion of the ECU converts the analog voltage Memory - EEPROM
signals from the various sensors into digital signals
that the central processing unit can “understand”. The EEPROM contains information programmed in at
the factory including engine specific data, and
Central Processing Unit (CPU) application data. Information in the EEPROM is
retained when battery voltage is removed.
The central processing unit performs the mathematical
16 computations and logical functions that are necessary
1640
10
RG41221,0000023 –19–09OCT00–2/2

081403
PN=728
Group 1650
LCS- Loader Control System
Theory of Operation
16
1650
1
–UN–04JUN03
T191691
1010D LCS system
1—Control panels —Chair module —Driving speed —Electrical diesel rpm control
—Loader speed control —Crane module —Hydraulical, Hydrostatic
transmission control
The LCS consists of a chair module, a HUB and a

boom module connected by a CAN-bus
Continued on next page JK11466,000000E –19–21MAY03–1/2

081403
PN=729
The chair module receives and transmits all the The Boom Control System does not include a
operators commands from the buttons and graphical display. monitoring of the machine interface
joysticks.The boom module controls and monitors the is done by traditional cauges, switshes, indicator lights,
boom control valve and the other functions of the main etc
boom hydraulic system.The boom speeds can be
adsjusted by a boom speed control potentiometer as The work rpm‘s are adjusted with a switch to make the
described later adjustment easy.Therae are also pedals controlling
both the hydrostatic system and diesel engine rpm‘s.
The Boom Speed Control potentiometer affects all Transmission control is hydraulically operated and no
boom functions except the grapple and the rotator electronics are involved.
speeds
JK11466,000000E –19–21MAY03–2/2
LCS Service Display
The LCS service display is used to maintain the

BoomControl System. While the service display is plugged
into the HUB module, the functions and parameters of the
Boom Control System can be adjusted.
CAUTION: When changing the system settings

using the display module note that incorrect
settings may cause damage to the machine and
16 endanger its operator and surroundings. Boom
1650 Control System settings may be changed by
2
authorized service personnel only.
OUTJ003,00006D5 –19–25JUN01–1/1

081403
PN=730
Connecting the Service Display to the

System
NOTE: To plug the Service Display into the LCS System,

use the cable provided with the display.
1. Turn the system OFF.
2. Plug one end of the cable into the ’CAN & PWR’
connector on the back of the display. Plug the other
end of the cable into one of the free connectors (XH1,
XH2, XH3 or XH4) on the HUB module in the
instrument box.
3. Turn the system ON.
4. Wait a moment until the Main Window opens up on the

screen. The service display is now ready to be used.
–UN–27JUN01
T143394
Service Display and HUB Module
OUTJ003,00006D7 –19–25JUN01–1/1
Using the Service Display
Navigating the screen using the Joystick

16
Use the right joystick to move the cursor around the 1650
screen. 3
Use the joystick buttons to select functions.
When the cursor is over a numerical value in a white box,

use the upper joystick button to increase the value. Use
the lower joystick button to decrease the value.
Display Symbols
The display windows contain two types of symbols:

functional and descriptive.
By clicking on a functional symbol you can move on to

another window or change the machine settings.
The descriptive symbols indicate that a certain function or

alarm is on, or show the value of a measurable function.
Continued on next page OUTJ003,00006D9 –19–25JUN01–1/12

081403
PN=731
T143396 –UN–27JUN01
Circular, colored buttons are function buttons that move

you on to the following window. A function button is
selected when a border of a paler color is shown around
it.
OUTJ003,00006D9 –19–25JUN01–2/12
T143397 –UN–27JUN01
The square grey boxes contain information for the user.
OUTJ003,00006D9 –19–25JUN01–3/12
T143398 –UN–29AUG01
Items on the display that can be selected are shown

inside a white box. To change a numerical value
contained in a box, use the joystick to move the pointer to
the value to be changed. To increase the value, press
upper button on the joystick; to decrease the value, press
the lower button.
OUTJ003,00006D9 –19–25JUN01–4/12
T143399 –UN–29AUG01
When selected, this white box will turn black. It will turn
white again once you have acknowledged the setting by
pressing OK or move to another selectable item.
16
1650
OUTJ003,00006D9 –19–25JUN01–5/12
4
T143400 –UN–27JUN01
Numerical values shown inside a grey box are machine

measurement values. They are for reference only and
cannot be changed.
OUTJ003,00006D9 –19–25JUN01–6/12
T143403 –UN–27JUN01
To acknowledge all settings of adjustable values and to

save them, click on the OK button.
OUTJ003,00006D9 –19–25JUN01–7/12
T143401 –UN–27JUN01
To access the System Help function, click on the question

mark button. The contents of the Help texts are display
specific.
Continued on next page OUTJ003,00006D9 –19–25JUN01–8/12

081403
PN=732
T143402 –UN–27JUN01
Navigating the screen using the Display Buttons
To return to the previous display, click on the Left Arrow

button.
OUTJ003,00006D9 –19–25JUN01–9/12
T143404 –UN–27JUN01
To navigate in the Settings Window and to select the

value to be adjusted, use the Arrow buttons.
OUTJ003,00006D9 –19–25JUN01–10/12
T143405 –UN–27JUN01
To navigate in the Alarm Log, use these Arrows.
OUTJ003,00006D9 –19–25JUN01–11/12
T143406 –UN–27JUN01
When you press OK, the Arrow buttons turn into "Plus"
and "Minus" buttons.
To decrease a value, press the "Minus" button.
To increase a value, press the "Plus" button.
How to use the Generalized Symbols
1. To navigate in the Settings windows, use the Arrow

buttons to move the pointer to a value.
16
1650
2. Press OK, after which the Arrow buttons turn into 5
"Minus" and "Plus" buttons.
3. To increase the value, use the "Plus" button; to

decrease it, use the "Minus" button.
4. To acknowledge the new value, press the OK button.

After pressing OK, the + and - buttons again become
Arrow buttons.
OUTJ003,00006D9 –19–25JUN01–12/12

081403
PN=733
Display Diagram
Please refer to the following diagram for all the LCS

service display windows and navigation options between
them.
Continued on next page OUTJ003,00006DA –19–25JUN01–1/2
16
1650
6

081403
PN=734
16
1650
7
–UN–27JUN01
T143407
Display Diagram
OUTJ003,00006DA –19–25JUN01–2/2

081403
PN=735
Main Window
The Main Window always appears first when the system

is switched on.
To browse any other windows, use the menu bar featured

on the bottom of the Main Window.
To use the menu bar, use the right joystick to move the
–UN–27JUN01
cursor to the desired symbol and press the button on the
joystick. The window corresponding to the selected
symbol will open.
T143408
Alternatively, you can use the buttons featured on the
lower part of the display module.
The menu bar symbols correspond to the following

windows (left to right):
• Boom Settings Window

• Measurements Window
• System Settings Window
• Joystick Settings Window
• Service Window
16
1650
OUTJ003,00006DB –19–26JUN01–1/1
8
Alarm Windows
The LCS Service Display features a machine condition

monitoring system that makes the use and servicing of the
machine easy. When a fault is detected, the system
opens up an alarm window on the display module.
n an alarm situation, the following type of alarm window

appears on the display:
–UN–27JUN01
• The window shows the alarm number and its cause in

plain text.
• While an alarm is on, you can access a Help Window to
T143409
see instructions related to the alarm in question.

• To exit the Alarm Window, press the Arrow key.
OUTJ003,00006DC –19–26JUN01–1/1

081403
PN=736
Boom Settings
To access the Boom Settings Window, select the Boom

Settings button on the Main Window.
–UN–27JUN01
T143410
OUTJ003,00006DD –19–26JUN01–1/5
Adjustable Functions
Functions that can be adjusted are shown on the left side

of the screen:
• Boom Slew
• Main Boom Up / Down
• Jib Boom Up / Down
• Extension Boom Extend/Retract
•
–UN–27JUN01
Grapple Rotate
• Grapple Open/close
16
• Decking Blade Up / Down 1650
• Steering 9
T143411
To browse the list of adjustable functions, use the up and
down arrows at the left side of the screen.
To set the parameters of the various functions, click on

the radio button beside the function symbol.
The direction of the functions movement (Up / Down,

clockwise/counterclockwise) is shown at the top of the
screen above the value boxes.
Continued on next page OUTJ003,00006DD –19–26JUN01–2/5

081403
PN=737
Adjustable Values
In the Boom Settings Window, you can set the following

parameters for each function:
• Minimum Current
• Maximum Current
• Acceleration Ramp
• Deceleration Ramp
•
–UN–27JUN01
Coil Resistance
• PMW frequency
NOTE: The PMW frequency is the same for all functions.
T143411
To change the settings:
1. Select the function to be set.
2. To select the value to be set, use the joystick to move

the cursor to the value.
Alternatively, use the Arrow buttons to move the cursor

to a value and select it by pressing OK.
3. To edit a value, use the buttons on the joystick or the +

and - buttons on the display.
16
1650
10

081403
PN=738
The following values can be set:
Minimum Current Setting
Determines the minimum current sent to the control valve

when the joystick is moved from neutral position past the
dead zone. The minimum current is so adjusted that the
movement stops just before the joystick is moved into the
dead zone.
–UN–27JUN01
Maximum Current Setting
Determines the maximum current sent to the control valve
T143412
when the joystick is pushed to its maximum position. The
maximum current setting determines the maximum speed
of the movement.
1—Minimum Current Setting
Acceleration Ramp 2—Maximum Current Setting
3—Acceleration Ramp
4—Deceleration Ramp
Determines the period required to increase the current
from minimum to maximum.
With a 0% or other very small setting, the boom

movement quickly responds to the movement of the
joystick. When the ramp setting is increased, the
movement starts more smoothly. Possible settings are
between 0% and 100%. If a delay is experienced with a
great ramp value while using the joystick normally, the
minimum current setting is too low.
NOTE: An Acceleration Ramp setting that is too low may

result in jerky movements.
16
Deceleration ramp 1650
11
Determines the period required to decrease the current

from maximum to minimum.
With a 0% or other very low setting, the movement stops

immediately when the boom joystick is rapidly moved to
its neutral position. With a greater ramp setting, the
movement stops more smoothly. Possible settings are
between 0% and 100%. If the movement continues at
crawling speed and then stops with a jerk, the minimum
current setting is too high.
Coil Resistance ([OHgr ])

081403
PN=739
Determines the proportional valve coil resistance The

usual setting is 25.
PWM Frequency (Hz)
The PWM frequency setting is not function specific but the

same for all functions. The usual setting is 140.
NOTE: The setting are enabled immediately, but you

must save them by pressing the OK button.
OUTJ003,00006DD –19–26JUN01–5/5
16
1650
12

081403
PN=740
Adjusting the Boom During Operation
In order to experiment with the effects of different settings

on the boom functions, the boom settings can be adjusted
during operation.
1. Select boom movement to be adjusted.
2. Select the value to be set by clicking on its symbol
–UN–27JUN01
(minimum current, maximum current, acceleration ramp
or deceleration ramp). The window for adjusting the
boom settings during the operation will open.
T143411
3. Turn on the boom.
NOTE: Only the movement being adjusted will operate.
If the left joystick is used to control the selected

movement, the right joystick symbol is shown on the
display. If the right joystick is used to control the selected
movement, the left joystick symbol is shown on the
display.
When the boom function is engaged, the corresponding

movement can be operated with the other control lever.
–UN–27JUN01
The settings can be adjusted by means of the joystick
buttons. Only the desired movement will be operated at
the time. When the settings are adjusted and the boom
function is deactivated, the cursor will appear on the
T143413
window. The settings will be confirmed with the
OK-button.
At the top center of the window, there is a stop watch 16

measuring the movements. The time of the movement in 1650
13
operation is indicated in tenths of seconds.
NOTE: The decking blade cannot be adjusted during

operation.
OUTJ003,00006DE –19–26JUN01–1/1

081403
PN=741
Balance Window
To access the Balance Window, click on the Balance

button in the top right hand corner of the Boom Settings
window.
–UN–27JUN01
T143416
–UN–27JUN01
T143414
16
1650
Continued on next page OUTJ003,00006DF –19–26JUN01–1/2
14

081403
PN=742
–UN–27JUN01
T143415
The balance setting is used to ensure that the impacts window. The percentage value beside the bar indicates
of a quick adjustment are the same on all movements. the proportion in which the quick adjustment value
The percentage value does not have the same impact influences the movement in question.
on all movements; instead, the balance values of
various movements must be changed to balance the To adjust the boom speed, use the left armrest
boom movements with all quick adjustment values. If potentiometer.
any movement slows down more than the others with
low quick adjustment values, the balance value of that The top right hand box indicates the boom quick
movement must be decreased. adjustment percentage value. This value influences the
part of each boom movement indicated by the
The darkened part of the bar shows the current values darkened section of the bar.
starting from which the joystick movement has an 16
1650
impact on the boom. The bottom right hand box shows in tenths of seconds
15
the running time of the activated movements.
The boom movements whose balance values can be
modified are shown on the left hand side in this
OUTJ003,00006DF –19–26JUN01–2/2

081403
PN=743
Measurement Window
To access the Measurement Window, click on the

Measurement button on the Main Window.
–UN–27JUN01
T143418
–UN–27JUN01
T143419
16
1650
Continued on next page OUTJ003,00006E0 –19–26JUN01–1/2
16

081403
PN=744
Boom Function Measurement Window
To access the Boom Function Measurement Window,

click on the Boom button (top left) on the Measurement
window.
The columns show (from left to right):
1. Boom Function Symbol
–UN–27JUN01
2. Current sent by the control unit to the function
operating valve.
3. The CAN message corresponding to the function. (A
value between -32767 and +32767)
T143421
4. Module output data. A value other than zero indicates
that the software is attempting to activate a solenoid.
5. Feedback current sent from the solenoid to the
module.
OUTJ003,00006E0 –19–26JUN01–2/2
16
1650
17

081403
PN=745
Transmission Measurement Window
To access the Transmission Measurement Window, click

on the Transmission button (top center) on the
Measurement window.
The icons across the top of the window show the following
information (left to right):
• The status of the parking brake switch
–UN–27JUN01
on 1, off 0
• The status of the work brake
on 1, off 0
T143422
• Seat direction
backwards 1, forward 0
• Cab Steps
up 1, down 0
• Seat Safety Switch
on 1, off 0
• The status of the high / low gear control sensors shows
the selected gear.
When the transmission control is enabled, the status is
1 (on) if a gear is selected and the control sensor of this
gear is active.
When the transmission control is not enabled, the status
is 1 (on) if a gear is selected.
Other symbols show the following information:
• The upper pictograph of the machine indicates status of

the forward drive direction solenoid Y102. Forward is
relative to the direction the seat is facing. On 1, Off 0.
16 • The lower pictograph of the machine indicates status of
1650 the reverse drive direction solenoid Y103. Reverse is
18
relative to the direction the seat is facing. On 1, Off 0.
• The pictograph of the solenoid Y103B indicates the
status of the Constant Pressure Control Valve Solenoid
on the Drive Motor. On 1, Off 0.
• Hydraulic Oil Temperature is indicated in °C.
OUTJ003,00006E1 –19–26JUN01–1/1

081403
PN=746
Auxiliary Equipment Measurement Window
To access the Auxiliary Equipment Measurement Window,

click on the Aux button (top right) on the Measurement
window.
The upper row of boxes show the following information

(left to right):
• Steering Symbol
–UN–27JUN01
• Current sent from Steering Lever
• CAN bus message (A value between -32767 and
+32767)
T143423
• Module input data for Steering Direction
1 = left, 0= neutral, 2 = right)
• Feedback current from the solenoid
The second row of boxes show the following information

(left to right):
• Decking Blade Symbol

• Two boxes showing the status of the Decking Blade
Raise and Lower buttons on the armrest. On 1, Off 0.
• Module output data for the Decking Blade status
• Feedback current from the solenoid to the module.
The bottom row of boxes show the following information

(left to right):
• Boom Speed Potentiometer Symbol

• Potentiometer Percentage
• Potentiometer current
16
1650
19
OUTJ003,00006E2 –19–26JUN01–1/1

081403
PN=747
Module Outputs and Inputs
To access the Module Output Status window, click on the

23 pin connectors of the Boom, Seat and Hub modules in
the Measurement window.
The name of the connector and the pin number refer to

the corresponding items in the wiring diagram. XE1/ 2 in
the boom module, for example, refers to connector 1, pin
–UN–27JUN01
2.
The windows show the module output status (0 = off, 1, =

on) or measurement data.
T143419
Measurement Window
OUTJ003,00006E3 –19–26JUN01–1/11
Boom Module Outputs and Inputs

23 pin connectors of the Boom module in the
Measurement window.
–UN–27JUN01
16
1650
20
T143425
–UN–27JUN01
T143424

081403
PN=748
Pin Function of Signal

1 Boom Slew Counterclockwise Solenoid Y424 (+)
2 Boom Slew Clockwise Solenoid Y425 (+)
3 Boom Slew Clockwise Solenoid Y425 (-)
4 Boom Slew Counterclockwise Solenoid Y424 (-)
5 Boom Main Boom Raise Solenoid Y420 (-)
6 Boom Main Boom Lower Solenoid Y421 (-)
7 Boom Main Boom Lower Solenoid Y421 (+)
8 Boom Main Boom Raise Solenoid Y420 (+)
9 Boom Jib Boom Raise Solenoid Y422 (+)
10 Boom Jib Boom Raise Solenoid Y422 (-)
11 Low Gear Select Solenoid Y45 (+)
12 Low Gear Select Solenoid Y45 (-)
13 High Gear Select Solenoid Y46 (+)
14 Boom Extension Extend Solenoid Y419 (-)
15 Boom Extension Extend Solenoid Y419 (+)
16 Boom Jib Boom Lower Solenoid Y423 (+)
17 Boom Jib Boom Lower Solenoid Y423 (-)
18 Boom Grapple Rotate Counterclockwise Solenoid Y409 (+)
19 Boom Grapple Rotate Clockwise Solenoid Y408 (+)
20 Boom Grapple Rotate Clockwise Solenoid Y408 (-)
21 Boom Grapple Rotate Counterclockwise Solenoid Y409 (-)
22 Boom Extension Retract Solenoid Y418 (-)
23 Boom Extension Retract Solenoid Y418 (+)
16
1650
21

081403
PN=749

1 Boom Grapple Close Solenoid Y417 (+)
2 Boom Grapple Open Solenoid Y416 (+)
3 Boom Grapple Open Solenoid Y417 (-)
4 Boom Grapple Close Solenoid Y416 (-)
5 Steer Left Solenoid Y66L (-)
6 Steer Right Solenoid Y66R (-)
7 Steer Right Solenoid Y66R (+)
8 Steer Left Solenoid Y66L (+)
9 Decking Blade Lower Solenoid Y195D (+)
10 Decking Blade Lower Solenoid Y195D (-)
11 Work Brake Solenoid Y41W (+)
12 Work Brake Solenoid Y41W (-)
13 Frame Brake Release Solenoid Y65 (+)
14 Back-up Alarm Buzzer B43 (-)
15 Back-up Alarm Buzzer B43 (+)
16 Decking Blade Raise Solenoid Y195U (+)
17 Decking Blade Raise Solenoid Y195U (-)
18 Front Differential Lock Solenoid Y33F (+)
19 Rear Differential Lock Solenoid Y33B (+)
20 Rear Differential Lock Solenoid Y33B (-)
21 Front Differential Lock Solenoid Y33F (-)
22 Rear Wheel Drive Disengage Solenoid Y39 (-)
23 Rear Wheel Drive Disengage Solenoid Y39 (+)
16
1650
22

081403
PN=750

1 Not used
2 Not used
3 Hydraulic Oil Temperature Sensor B19 Signal
4 Steer Sensor S53 Signal (Not used)
5 Not used
6 Not used
7 Not used
8 Not used
9 Steer Sensor S53 (+) (Not used)
10 Hydraulic Oil Temperature Sensor B19
11 Steer Sensor S53 (-) (Not used)
12 High Gear Select Solenoid Y46 (-)
13 Frame Brake Release Solenoid Y65 (-)
14 Hydraulic Oil Level Sensor B25 (-)
15 Not used
16 Drive Pedal Pressure Switch B42 (+)
17 Hydraulic Oil Level Sensor B25 (+)
18 Drive Pedal Pressure Switch B42 Signal
19 Hydraulic Oil Level Sensor B25 Signal
20 High Gear Sensor
21 Low Gear Sensor
22 Steps Up Sensor
23 Not used
16
1650
23

081403
PN=751
Chair Module Outputs and Inputs

23 pin connectors of the Chair module in the
Measurement window.
–UN–27JUN01
T143426
–UN–27JUN01
T143428
16
1650
24

081403
PN=752

1 High Gear Selected LED Indicator Light (at S42)
2 Front Differential Lock Engaged LED Indicator Light (at S43)
3 Not Used
4 Hydraulic Oil Level Warning Indicator Light H16 (-)
5 Not Used
6 Not Used
7 Rear Differential lock Engaged LED Indicator Light (at S44)
8 Hydraulic Oil Level Warning Indicator Light H16 (+)
9 Hydraulic Oil Temperature Warning Indicator Light H14 (+)
10 Hydraulic Oil Temperature Warning Indicator Light H14 (-)
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Seat Safety Switch Indicator Light
16 Central Warning Buzzer (+)
17 Central Warning Buzzer (-)
18 Windscreen Wiper Relays (front and rear)
19 Drive Direction Solenoid 103B at Drive Motor (+)
20 Drive Direction Solenoid 103B at Drive Motor (-)
21 Not Used
22 Not Used
23 Cab Steps Up Indicator Light
16
1650
25

081403
PN=753

1 High/Low Gear Select Push Button S42
2 Front Differential Lock Push Button S43
3 Seat Direction Limit Switch S50
4 Drive Direction Forward Selected Switch S40
5 Drive Direction Reverse Selected Switch S40
6 Seat Safety Switch
7 Rear Differential Lock Push Button S44
8 Decking Blade Down Push Button S48
9 Decking Blade Up Push Button S49
10 Windscreen Wiper Button
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Not Used
16 Not Used
17 Not Used
18 Not Used
19 Not Used
20 Not Used
21 Not Used
22 Common Ground for Right Armrest LED Indicator Lights
23 Common Ground for Right Armrest Switches
16
1650
26

081403
PN=754

1 Boom Jib Up / Down (+)
2 Common (+) for Left Joystick Lever B20
3 Boom Slew Lever (+)
4 Common (+) for Steering Lever B22
5 Boom Grapple Open/Close Lever (+)
6 Common (+) for Right Joystick Lever B21
7 Not Used
8 Common (+) for Boom Speed Potentiometer B23
9 Not Used
10 Boom Extension Boom Extend/Retract (+)
11 Steering Lever (+) B22
12 Boom Main Boom Up / Down Lever (+)
13 Boom Grapple Rotate Lever (+)
14 Not Used
15 Not Used
16 Seat Direction Limit Switch S50 (+)
17 Common (-) for Left Joystick Lever B20
18 Not Used
19 Common (-) for Steering Lever B22
20 Not Used
21 Common (-) for Right Joystick Lever B21
22 Boom Speed Potentiometer (+) B23
23 Common (-) for Boom Speed Potentiometer B23
16
1650
27

081403
PN=755
Hub Module Outputs and Inputs

23 pin connector of the Hub module in the Measurement
window.
–UN–27JUN01
T143427
–UN–27JUN01
T143429
16
1650
28

081403
PN=756

1 Power IN
2 Power IN
3 Drive Direction Forward Solenoid Y102
4 Drive Direction Reverse Solenoid
5 Work Pump Stroke Solenoid Y208
6 Central Warning Light H8
7 Parking Brake Engage
8 Not Used
9 To Ground Point 1 in Instrument Box
10 Grounds from Drive Direction Solenoids and Work Pump Stroke Solenoid
11 Rear Wheel drive Disengage Switch S59
12 Frame Brake Release Switch S58
13 Parking Brake Switch S58
14 Not Used
15 Not Used
16 Not Used
17 Not Used
18 Not Used
19 Not Used
20 Central Warning Light and Buzzer Input
21 Not Used
22 Not Used
23 Not Used
In addition, the module internal temperature and the CAN

top and bottom line voltage can be read in the
Measurement Window.
16
1650
29
OUTJ003,00006E3 –19–26JUN01–11/11

081403
PN=757
System Settings
To access the System Settings Window, click on the

System Settings button on the Main window.
In the System Settings window, the System Language can

be changed and the Display Contrast adjusted.
The default language installed in the system is English.
–UN–27JUN01
Any other languages (when available) must be installed
separately.
Other languages that may be available include:
T143430
• Finnish
• Swedish
• German
• French
The display contrast can be set between the values 0 and

16.
–UN–27JUN01
T143431
16
1650
OUTJ003,00006E4 –19–27JUN01–1/1
30

081403
PN=758
Joystick Settings
To access the Joystick Settings Window, click on the

Joystick Settings button on the Main window.
Joystick Dead Zone Setting
The Joystick Dead Zone Setting determines the distance

the joystick must be moved from the centered position
–UN–27JUN01
before it operates any function.
With a 5% setting, any movement at all of the joystick

from its neutral position sends the set minimum current to
T143432
the directional valve.
When this setting is increased, the dead zone of the

joystick is enlarged. The joystick must be moved more
before the directional valve receives the minimum current.
The typical setting is 10%.
–UN–27JUN01
T143433
16
1650
OUTJ003,00006E5 –19–27JUN01–1/6
31
Joystick Progression
To access the Joystick Progression Window, click on the

Joystick Progression button in the upper right corner of
the Joystick Settings window.
In this window, you can adjust the joystick progression in

the dimensions X, Y and Z.
–UN–27JUN01
This window is also used to modify the steering lever

progression settings.
T143434

081403
PN=759
Joystick Parameters
To access the Joystick Parameters Window, click on the

Joystick Parameters button (pictograph of wrench) on the
right side of the Joystick Settings window.
The maximum position and neutral position parameters of

the joysticks and the steering lever are expressed in Volts.
–UN–26FEB02
X1 refers to the Boom Speed Potentiometer parameters.
Parameters can be changed directly in the table in this

window. Alternatively, click on the joystick buttons on
T143435
either side of the table to open separate Calibration
windows.
To change Parameter Settings in the table on the Joystick

Parameters window:
1. Select the joystick movement to be modified in the

table.
2. To acknowledge the selection, press OK
3. To change the setting, use the + and - buttons.
16
1650
32

081403
PN=760
An easier way of adjusting the joystick maximum position

and neutral position parameters is to use the Calibration
windows that can be accessed by clicking on the function
buttons on the Joystick Parameters window.
To access the Left Joystick Calibration Window, click on

the Joystick Calibration button on the left side of the
Joystick Parameters window.
–UN–27JUN01
Set the joystick in its neutral position and press Start.
Smoothly roll the joystick around a few times so that it
passes through the maximum positions of the X and Y
dimensions. To find the extreme positions of the Z
T143463
dimension, use the buttons on the joystick. Finally, press
the Stop button.
The little triangles indicate the extreme values reached by

the joystick.
–UN–27JUN01
T143436
16
1650
33

081403
PN=761
NOTE: While adjusting the joysticks, the Start and Stop

buttons are used in connection with the display
module keys. Release the control lever and wait
two seconds before pressing the Stop button.
To access the Right Joystick Calibration Window, click on

the Joystick Calibration button on the right side of the
Joystick Parameters window.
–UN–27JUN01
To perform calibration, follow the same procedure used
for the left joystick.
T143464
–UN–27JUN01
T143466
16
1650
34

081403
PN=762
To access the Steering Lever Calibration Window, click on

the Steering Lever Calibration button on the right side of
the Joystick Parameters window.
Press Start. Push the articulated steering joystick to its

two maximum positions. Release the joystick and wait two
seconds before pressing Stop.
The little triangles indicate the extreme values reached by
–UN–27JUN01
the joystick.
T143465
–UN–27JUN01
T143437
16
1650
OUTJ003,00006E5 –19–27JUN01–6/6
35

081403
PN=763
Service Window
To access the Service Window, click on the Service

button on the Main window.
–UN–27JUN01
T143438
–UN–27JUN01
T143439
16
1650
36

081403
PN=764
Testing Window
To access the Testing Window, click on the TST button

on the Service window.
The following outputs can be tested (top to bottom):
• Work Pump Stroke (Y208)

• Drive Direction Forward (Y102)
•
–UN–27JUN01
Drive Direction Reverse (Y103)
• Constant Pressure Control Valve (Y103B)
To test the output, checkmark the corresponding ON/OFF
T143440
box.
NOTE: The two drive direction outputs cannot be tested

simultaneously.
NOTE: The outputs can only be tested while the parking

brake is engaged.
OUTJ003,00006E7 –19–27JUN01–2/12
Module Program Versions
To access the Module Program Versions Window, click on

the VER button on the Service window. 16
1650
The Module Program Versions Window displays the 37
module program versions and the month and year of their
first use. The Version Window date is for reference only,
and the systems reads it directly from the modules.
–UN–27JUN01
Version Window data includes:
• Abbreviation for the module (Cr = Boom Module, Ch =

T143441
Chair module, Hb = Hub Module)

• Program version (96A, etc.)
• The month and year of the first use of the program
version

081403
PN=765
Alarm Settings
To access the Alarm Settings Window, click on the ALR

button on the Service window.
The Alarm Settings Window shows which alarms are

enabled.
To browse through the alarms, use the up and down
–UN–27JUN01
arrows at the right side of the window.
A check mark in the box to the left of an alarm indicates

that it is enabled. For some of the alarms, limits can be
T143442
set, which are shown in the box to the right of the alarm.
The alarms include:
1. Seat module connection failure

2. Boom module connection failure
3. Hydraulic oil level low
4. Hydraulic oil temperature
5. Hub module external auxiliary alarms
6. Boom module connector XE1 output failure
7. Boom module XE2 connector output failure
8. Seat module XC connector output failure
9. Hub module XH connector output failure
10. CAN bus failure
11. Low battery voltage
12. Joystick out of range
13. Steering lever out of range
16
1650
38

081403
PN=766
General Machine Settings
To access the General Machine Settings Window, click on

the MCH button on the Service window.
A check mark in the box indicates that a setting is

enabled.
General machine settings include (top to bottom):
–UN–27JUN01
• Parameter file management
• Cab Steps Position Switch (installed / not installed)
• Seat Safety Switch (installed / not installed)
T143443
• Rear facing brake pedal (installed / not installed)
NOTE: The rear facing brake pedal makes the use of a

high gear possible while the seat is facing the
rear.
Parameter File Management
In the Service Window, all machine parameters can be

saved in Parameter Files. In addition, you can browse,
activate and delete various parameter files in this Window.
16
1650
39

081403
PN=767
To browse the parameter files saved in the display

module, select the name of a machine parameter file. The
name is shown at the top of the General Machine Settings
window. To browse the files, use the + and - buttons or
the buttons on the joystick. Press OK, and the Edit
Parameter File window will open.
The name of a selected parameter file can be edited in

the Edit Parameter File window.
–UN–27JUN01
To use the Edit window:
1. Use the Arrow keys to move the black horizontal bar
T143443
onto a character.
2. Click on the PUSH button; the character is selected

and printed in the file name field at the top of the
window.
3. Select the following character etc., until you have

finished entering a file name.
The parameter file name may contain a maximum of

eight characters, such as 12345678. The file name can
also be shorter than this.
–UN–27JUN01
To delete characters, use the < button.
To toggle between lower and upper case characters,
T143444
press the C-lock button. To browse the characters and
display more of them, press the Extra button.
16 4. Once you have finished entering the file name,

1650 acknowledge it by clicking on the NEXT button.
40
5. In case the file name you acknowledged is found in the

display module, the Parameter File Management
window opens. In case the file name is not found in the
display module, a window for creating a new parameter
file is opened.

081403
PN=768
NOTE: The manufacturer recommends using descriptive

file names (such as a machine number) to avoid
the parameter files getting mixed up.
To use the Parameter File Management window:
• To delete the selected parameter file from the display

module, use the Delete button.
• To enable the parameters in the selected parameter file,
–UN–27JUN01
use the Send button. The display module then transmits
the selected parameters to the other modules in the
system.
• To return to the Edit Window without making any
T143445
changes, press Cancel.
OUTJ003,00006E7 –19–27JUN01–7/12
In case the file name is not found in the display module, a

window for creating a new parameter file is opened. While
creating a new parameter file, the existing parameters of
the system are used.
• To create a new parameter file using the system

parameters, press Create. The parameter file is named
according to the name entered in the Edit Window.
• To return to the Machine Settings window without
–UN–27JUN01
making any changes, press Cancel.
16
1650
41
T143446

081403
PN=769
Automatic Program Updates
To access the Automatic Program Updates Window, click

on the UPD button on the Service window.
This window displays the system modules and their

program versions. In case one of the modules contains an
outdated program version, the system suggests an
automatic program update by check marking the box of
–UN–27JUN01
the module in question.
To update a module program version:
T143447
1. Select the modules to be updated by clicking on the
selection box to the right of the module number.
To deselect a box, click again.
2. Press START to initiate the update. The program

update starts.
OUTJ003,00006E7 –19–27JUN01–9/12
The progress bar of each module indicates the progress

of the program update. The update is performed for each
module in succession. As the update progresses, the
16 window shows the following messages for each module to
1650 be updated:
42
• Writing flash
• Verifying
• Verification OK
When all modules to be updated read ’Verification OK’, –UN–27JUN01
the program update is complete.

T143448
NOTE: Do not turn off the system during a program

update. After the update is complete, switch off
the system.

081403
PN=770
Alarm Log
To access the Alarm Log Window, click on the ’!’ button

on the Service window.
The Alarm Log Window shows the alarms registered in

the alarm log.
In case several different alarms have been registered in
–UN–27JUN01
the log, you can browse these by using the Up and Down
Arrow buttons.
To get more information on an alarm, press the help
T143449
button.
OUTJ003,00006E7 –19–27JUN01–11/12
System Management
To access the System Management Window, click on the

SMW button on the Service window.
The System Files list shows the files contained in the file
system.
To format the file system, press FORMAT.
–UN–27JUN01
NOTE: As the file system is formatted, all data contained
16
in it is removed (such as alternative language 1650
options and module program update files). Take 43
T143450
care when using the FORMAT button.
OUTJ003,00006E7 –19–27JUN01–12/12

081403
PN=771
16
1650
44

081403
PN=772
Group 1660
Alternator
Alternator Removal
1. Battery disconnect switch OFF. Disconnect battery

ground cable.
2. Tag and disconnect wires from alternator.
3. Remove drive belt.
OUTJ003,0000558 –19–16MAR01–1/3
4. Remove capscrew from alternator link.
–UN–24AUG01
T145051
OUTJ003,0000558 –19–16MAR01–2/3
5. Remove the alternator mounting capscrews and nuts.
6. Remove the alternator.

16
1660
1
–UN–24AUG01
T145052
OUTJ003,0000558 –19–16MAR01–3/3
Alternator Installation
1. Position the alternator on the bracket and secure it with

the mounting capscrews.
NOTE: Do not tighten the fasteners at this time.

–UN–24AUG01
T145053

081403
PN=773
Alternator
2. Connect the alternator link to the alternator. Finger

tighten.
NOTE: Make sure the alternator link is properly

positioned for correct belt alignment.
–UN–24AUG01
T145054
OUTJ003,0000559 –19–16MAR01–2/3
3. Tighten the alternator support bracket capscrew to

specified torque.
Alternator Installation—Specification
Alternator Mounting Capscrew—
Torque ............................................................................. 43 N•m (32 lb-ft)
–UN–24AUG01
4. Tighten the alternator link capscrew to specified torque.
Alternator Installation—Specification
Alternator Link Capscrew—
T145055
Torque ............................................................................. 24 N•m (18 lb-ft)
5. Install the drive belt.

1—Alternator Mounting Capscrew
2—Alternator Link Capscrew
6. Connect the wires to the alternator.
7. Connect the battery ground cable. main switch ON.

16
1660
OUTJ003,0000559 –19–16MAR01–3/3
2

081403
PN=774
Group 1680
Starter Motor
Starter Motor Removal
NOTE: For more information on the engine, see the

Cummins Operation and Maintenance Manual - B
Series Engines, Bulletin No. 3810205-13, Printed
7/97.
1. Main switch OFF. Disconnect the ground cable from

the batteries.
OUTJ003,0000566 –19–19MAR01–1/3
2. Tag and disconnect the wires from the starter solenoid.
–UN–24AUG01
T145049
OUTJ003,0000566 –19–19MAR01–2/3
3. Remove the screws retaining the starter motor.

Remove the starter motor.
16
1680
1
–UN–24AUG01
T145050
OUTJ003,0000566 –19–19MAR01–3/3
Starter Motor Installation
1. Install the starter motor. Install the mounting screws.

Tighten the screws to the specified torque.
Starter Motor Installation—Specification

–UN–24AUG01
Starter Motor Mounting Screws—

Torque ............................................................................. 43 N•m (32 lb-ft)
T145050

081403
PN=775
Starter Motor
2. Install the wires on the starter solenoid.
3. Connect the battery ground cable. main switch ON.
–UN–24AUG01
T145049
OUTJ003,0000567 –19–19MAR01–2/2
16
1680
2

081403
PN=776
Section 17
Frames
Contents
Page
Group 1710—Frame installation

Overall description. . . . . . . . . . . . . . . . . . . . .17-1710-1
Essential Tools . . . . . . . . . . . . . . . . . . . . . . .17-1710-2
Other Material . . . . . . . . . . . . . . . . . . . . . . . .17-1710-6
Frames, Covers and Panels . . . . . . . . . . . . .17-1710-7
Group 1720—Frame Hinge

Frame Joint . . . . . . . . . . . . . . . . . . . . . . . . . .17-1720-1
Frame Joint Removal . . . . . . . . . . . . . . . . . .17-1720-6
Frame Joint Bearings Installation . . . . . . . .17-1720-13
Hinge Pin Installation . . . . . . . . . . . . . . . . .17-1720-15
Frame Brake Theory Of Operation . . . . . . .17-1720-22
Frame Brake Removal . . . . . . . . . . . . . . . .17-1720-24
Frame Brake Unit Servicing. . . . . . . . . . . . .17-1720-26
Friction Pad Changing. . . . . . . . . . . . . . . . .17-1720-31
Adjustment
Frame Brake . . . . . . . . . . . . . . . . . . . . . .17-1720-32
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1720-33
Group 1740—Operational Checks

Checkout Procedure . . . . . . . . . . . . . . . . . .17-1740-1
Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1
17

081403
PN=1
Contents
17

081403
PN=2
Group 1710
Frame installation
Overall description
The frame joint is installed in the rear frame. It allows the

frames to move in two axes relative to one another. The
machine can articulate for steering and the frames can tilt
to keep the wheels in contact with uneven ground. The
steering cylinders are mounted between the front frame
and the frame joint. A drive shaft passes through the
frame joint to transmit power to the rear axle.
The frame brake locks the rear frame to the frame joint to
prevent the rear frame from tilting during boom operations.
The brake is automatically applied when the boom is
enabled by turning the operator’s seat to face the rear.
The brake can be manually released by a switch on the
dashboard. Steering is unaffected by the use of the frame
brake.
The logbed is comprised of stakes and a headboard

mounted on the side rails of the rear frame. The stakes
can be removed or repositioned. A movable headboard is
an option on this machine.
OUTJ003,000046F –19–08FEB01–1/2
Access to the engine compartment is by tilting the hood or

lowering the belly pan. Both covers are slowed in moving
by pneumatic cylinders. The belly pan is also equipped
with a safety hook that will prevent the steps from
dropping more than a few inches.
–UN–21JUN01
17
T139430
1710
1
–UN–20JUL01
T139432
OUTJ003,000046F –19–08FEB01–2/2

081403
PN=779
Frame installation
Essential Tools

SERVICEGARD is a trademark of Deere & Company OUTJ003,00003DA –19–02FEB01–1/15
Axle Support . . . . . . . . . . . . . . . . . . . . . . . . TA0899
Used to support front bogie during Frame Joint Removal

procedure.
–UN–19JUN01
T139888
TA0899 - Axle Support
OUTJ003,00003DA –19–02FEB01–2/15
Frame Support . . . . . . . . . . . . . . . . . . . . . . . TA0902

17
Used to support hinge end of the front frame during
1710
2 Frame Joint Removal procedure. –UN–19JUN01
T139887
TA0902 - Frame Support
Continued on next page OUTJ003,00003DA –19–02FEB01–3/15

081403
PN=780
Frame installation
Frame Support . . . . . . . . . . . . . . . . . . . . . . . TA0898
Used to support front end of the front frame during Frame

Joint Removal procedure.
–UN–19JUN01
T139886
OUTJ003,00003DA –19–02FEB01–4/15
Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . TA0918
Used to lift frame joint during Frame Joint Removal

procedure.
–UN–21JUL01
T139894
OUTJ003,00003DA –19–02FEB01–5/15
Nut Driver . . . . . . . . . . . . . . . . . . . . . . . . . . TA0908
Used to remove nut from frame joint during Frame Joint

Removal procedure.
–UN–21JUL01
17
T139895
1710
3
OUTJ003,00003DA –19–02FEB01–6/15
Bearing Driver . . . . . . . . . . . . . . . . . . . . . . . TA0910
Used to install larger rear bearing cup in rear frame bore

during Frame Joint Bearings Installation procedure.
–UN–21JUL01
T139896

081403
PN=781
Frame installation
Used to install smaller front bearing cup in rear frame

bore during Frame Joint Bearings Installation procedure.
–UN–21JUL01
T139897
OUTJ003,00003DA –19–02FEB01–8/15
Used to install upper hinge pin bearing cones during

Hinge Pin Installation procedure.
–UN–21JUL01
T139898
OUTJ003,00003DA –19–02FEB01–9/15
Bearing/Pin Driver . . . . . . . . . . . . . . . . . . . . . TA0913
Used to install lower hinge pin spherical bearing during

–UN–21JUL01
17
1710 T139899
4
OUTJ003,00003DA –19–02FEB01–10/15
Pin Driver . . . . . . . . . . . . . . . . . . . . . . . . . . TA0914
Used to install upper hinge pin during Hinge Pin

Installation procedure.
–UN–21JUL01
T139900

081403
PN=782
Frame installation
Nut Driver . . . . . . . . . . . . . . . . . . . . . . . . . . TA0917
Used to install upper hinge pin nut during Hinge Pin

–UN–18JUN01
T139901
OUTJ003,00003DA –19–02FEB01–12/15
O-ring Seal Expander. . . . . . . . . . . . . . . . . . 479265-1
Used to install o-ring seals on frame brake pistons during

Frame Brake Unit Servicing procedure.
–UN–29AUG01
T139902
OUTJ003,00003DA –19–02FEB01–13/15
Seal Pusher . . . . . . . . . . . . . . . . . . . . . . . . 479265-2
Used to install seals on frame brake pistons during Frame

Brake Unit Servicing procedure.
–UN–29AUG01
17
T139903
1710
5
OUTJ003,00003DA –19–02FEB01–14/15
Piston Installation Tool . . . . . . . . . . . . . . . . . 479266-1
Used to install frame brake pistons during Frame Brake

Unit Servicing procedure.
–UN–29AUG01
T140115
OUTJ003,00003DA –19–02FEB01–15/15

081403
PN=783
Frame installation
Other Material
Number Name Use
N/A (U.S.) Never-Seez Anti-siezing compound applied to

frame joint nut during Frame Joint
Bearings Installation procedure.
N/A (U.S.) EP2 Grease 4.3 L (1.14 gal) used to grease

frame joint during Frame Joint
Bearings Installation procedure.
N/A (U.S.) Loctite 242 Used to secure screws retaining

lower bearing retainer plate during
N/A (U.S.) Loctite 242 Used to secure bolts retaining lower

hinge pin locking bar during Hinge
Pin Installation procedure.
N/A (U.S.) Loctite 242 Used to secure bolts retaining upper

hinge pin locking bar during Hinge
Pin Installation procedure.

cylinder pins during Hinge Pins
N/A (U.S.) Molykote G-rapid lubricant Applied to contacting surfaces of

frame brake housing and actuating
gear during Frame Brake Unit
Servicing procedure.
N/A (U.S.) Loctite 222 Used to secure frame brake return

spring bolts during Frame Brake unit
N/A (U.S.) Loctite 222 Used to secure bolts retaining the

17
1710 frame brake unit during the Frame
6 Brake Installation procedure.
N/A (U.S.) Loctite 222 Used to secure nuts retaining the top
plate to the frame brake unit during
the Frame Brake Installation
procedure.
OUTJ003,00003DC –19–02FEB01–1/1

081403
PN=784
Frame installation
Frames, Covers and Panels
–UN–10JUN03
T191921
1110D front frame
Continued on next page OUTJ003,00003D2 –19–01FEB01–1/6
17
1710
7

081403
PN=785
Frame installation
17
1710
8 –UN–13AUG03
T191928
1110D rear frame and components

081403
PN=786
Frame installation
The Cab Steps Switch will prevent the machine from cab steps are up, an indicator light on the operator’s
being driven unless the steps are raised. When the seat armrest will be lit.
OUTJ003,00003D2 –19–01FEB01–3/6

by pneumatic cylinders. The belly pan is also equipped
with a safety hook that will prevent the steps from
dropping more than a few inches.
–UN–21JUN01
Frame is made of normalised fine grain steel. This
material allows very high strength and it is easy to weld,
machine and form. In cases of failure contact to your
dealer or manufacturer for proper repair instructions.
T139430
The front frame supports the engine, hydrostatic drive
system, transfer case, drive shafts, front bogie, fuel and Engine Enclosure, Hood
hydraulic tanks, hydraulic system components, operator’s
cab and hood. Covers and hatches on the underside allow
access to the front axle, drive shafts and transfer case.
Rear frame Belly plate is supported by gas springs. Frame

is equipped with separate counter weight, which is
mounted by bolts. Batteries are located at the rear end of
–UN–20JUL01
frame. In cases of failure contact to your dealer or
manufacturer for proper repair instructions.
The rear frame supports the rear axle, boom, frame joint,
T139432
frame brake, grapple rest and backup alarm. There are
access covers for the frame joint, frame brake, drive Engine Access Panel, Belly Pan
shafts and rear axle.
17
1710
9

081403
PN=787
Frame installation
Access to the cab is by steps installed on the front left

corner of the front frame.
–UN–20JUL01
T139429
Cab Step
OUTJ003,00003D2 –19–01FEB01–5/6

by pneumatic cylinders.
NOTE: The belly pan is equipped with a safety hook. To

open the belly pan, remove the screws. The belly
–UN–18JUN01
pan will drop to the safety hook. Move the safety
hook to lower the pan to the limit of the pneumatic
cylinder.
T139058
Hood
17
1710
10
–UN–20JUL01
T139059
Belly Pan
OUTJ003,00003D2 –19–01FEB01–6/6

081403
PN=788
Group 1720
Frame Hinge
Frame Joint
17
1720
1
–UN–10JUN03
T191924
810D frame joint components

081403
PN=789
Frame Hinge
–UN–18JUN01
T139092
1010D Frame Joint components Installed
1—Upper Hinge Pin Locking 5—Steer Cylinder Pin 10—Spherical Bearing 14—Front Bearing
Bar with hydraulic hose 6—Upper Pin Bearing 11—Lower Bushing Retaining 15—Rear Bearing
bracket 7—Nut Plate 16—Rear Bearing Seal
2—Bolt (short) 8—Bolt (long) 12—Lower Hinge Pin 17—Frame Joint Drive Shaft
3—Upper Hinge Pin 9—Lower Hinge Pin Locking 13—Front Bearing Seal
4—Fastening Plate with Bar
retaining screws
17
1720
2

081403
PN=790
Frame Hinge
17
1720
3
–UN–04JUN03
T191685
1110D Frame joint components

081403
PN=791
Frame Hinge
The frame joint articulates for steering and rolls to provided to temporarily lock the frames for stability
allow the front and rear frames to tilt independently as when loading.
the machine maneuvers across uneven ground. The
main component of the middle joint is a large The joint articulates on two vertically aligned pins for
machined casting. A drive shaft runs through the joint steering. The top pin uses two opposed tapered roller
transmitting power to the rear axle. bearings preventing the frames from moving vertically
out of line. The bottom pin uses a self-centering
The frame joint is mounted in two sets of tapered roller bushing. Steering power is provided by two hydraulic
bearings allowing it to roll freely. A frame brake is cylinders mounted in the front frame.
17
1720
4

081403
PN=792
Frame Hinge
–UN–18JUN01
T139093
1010D Frame Joint, Hinge Pins, Bearings Exploded
1—Bolt (short) 8—Ring 15—Spherical Bearing 23—Nut

2—Hydraulic Hose Bracket 9—Set Screw 16—Screw 24—Seal Ring
3—Upper Hinge Pin Locking 10—Nut 17—Frame Joint 25—Spring Pin
Bar 11—Bolt (long) 18—Plug 26—Plate
4—Upper Hinge Pin 12—Lower Hinge Pin Locking 19—Front Bearing Seal 27—Washer
5—Grease Fitting Bar 20—Front Bearing 28—Screw
6—Upper Pin Bearing Seal 13—Lower Hinge Pin 21—Rear Bearing 29—Grease Fitting
7—Upper Pin Bearing 14—Bearing Retaining Plate 22—Rear Bearing Seal
The tapered roller bearings supporting the frame joint Several lifting, supporting and installation tools have
assembly are not exposed to high speed rotation, and been designed for the removal and replacement of the
given correct lubrication, should not require middle joint. See section 45, for tool fabrication
replacement. Removal of the frame joint may be drawings.
required for repair of the steering cylinder or hinge pin 17
mountings. Damage to the main taper roller bearings 1720
or seals will require the complete removal and 5
disassembly of the frame joint.
OUTJ003,00003D3 –19–01FEB01–5/5

081403
PN=793
Frame Hinge
Frame Joint Removal
NOTE: It is recommended that the removal and repair of

the middle joint only be performed in a
maintenance area with proper lifting equipment. It
may be easier to remove the wheel and tire
–UN–18JUN01
assemblies before starting work on the joint area.
CAUTION: Use appropriate support, slings and

lifting devices to prevent personal injury or
T139094
equipment damage when lifting the frame.
Axle Support TA0899
1. Lift the front of the machine. Remove the front wheel
and tire assemblies. Position two axle supports
TA0899 under the front bogie. See section 45, for Tool
Drawings.
OUTJ003,00003D4 –19–01FEB01–1/12
2. Position the frame supports TA0902 under the hinge

end of the front frame, and TA0898 under the front end
of the front frame. See section 45, for Tool Drawings.
3. Position a sling for the rear frame at three lifting points.

Place two at the rear and one at the boom tower.
–UN–18JUN01
Support the rear frame level.
4. Remove the rear wheel and tire assemblies. Remove

the rear bogie. See Section 02, for the procedures.
T139095
Frame Supports TA0902, TA0898, Sling
17
1720
6

081403
PN=794
Frame Hinge
5. Remove the steering cylinder pins and move the

cylinder ends away from the hinge bosses.
–UN–18JUN01
T139096
Frame Hinge, Cylinder Pins
17
1720
7

081403
PN=795
Frame Hinge
6. Relieve the pressure in the frame brake, using one of

two alternative procedures.
To relieve pressure in the frame brake circuit with the

engine running, use the following procedure:
–UN–18JUN01
a. Turn the operators seat to face the rear.
b. Position the Boom boom in the bunk with the main

boom cylinder fully retracted.
T142804
c. Activate the frame brake release switch.
Frame Brake Switch
d. Ignition switch off. Remove ignition key.
1—Frame Brake Switch
main switch off.

engine not running, use the following procedure:
Attach a hose to the test port MA1 on the frame brake

and bleed the fluid into a suitable container.
7. Relieve pressure in the accumulators by activating the

parking brake switch ON/OFF 2 or 3 times.
CAUTION: Before disconnecting any hydraulic

components ensure that the engine is stopped
Remove handle from the main switch

17 Failure to follow these procedures may

1720 lead to equipment damage.
8
8. Tag and disconnect the hydraulic hose to the frame

brake.

081403
PN=796
Frame Hinge
CAUTION: High pressure in the brake system is

maintained through the use of pressure
accumulators. Always check that the system
pressure has been reduced before
disconnecting any brake system components.
Brake system pressure can be checked at test
ports MB4 and MB5.
9. Tag and disconnect the hydraulic hoses to the rear

axle brakes.
10. Disconnect the wires to the back-up alarm.
NOTE: Note the positions of any clamps removed or ties

cut. They must be replaced as originally installed.
11. Remove the cover from the boom control valve. Tag
and disconnect the boom operation hoses at the
valve. Cap the hoses and plug the ports.
12. Remove the upper pivot pin. Remove the setscrew

retaining the nut to the pin. Remove the nut. Remove
the bolts retaining the wedge. Drive out the pin.
13. Remove the lower pivot pin. Remove the bolts

retaining the wedge. Drive out the pin.

14. Carefully move the rear frame back at least one

meter (3 feet) away from the front frame to allow
sufficient room to remove the 81 cm (32 in) long
middle joint assembly.
17
1720
9

081403
PN=797
Frame Hinge
15. Disconnect the rear drive shaft from the frame joint
drive shaft and move it off to one side.
–UN–18JUN01
T139103
OUTJ003,00003D4 –19–01FEB01–6/12
16. Remove the frame joint drive shaft. See Section 02,
Group 0230, for the procedures.
NOTE: Before removing the frame joint drive shaft, rotate

it by hand to check if the bearings are running
freely and evenly with no scraping or uneven
–UN–18JUN01
resistance. If there is no damage to the shaft
bearings, they can be reused.
T139104
OUTJ003,00003D4 –19–01FEB01–7/12
17. Attach a lifting bracket TA0918 into the top hinge pin
bosses in the middle joint.
NOTE: This bracket can also be used to prevent the

frame joint from rotating when removing the end
nut.
–UN–18JUN01
17
1720 T139105
10

081403
PN=798
Frame Hinge
18. Remove the retainer plate from the end nut on the
rear of the frame joint assembly. Remove the nut
using a special nut driver tool , TA0908 and a 25 mm
(1" in.) drive socket wrench.
CAUTION: The frame joint assembly weighs
–UN–18JUN01
approximately 180 kg (400 lb). Use the specified
lifting bracket and appropriate support, slings
and lifting devices to prevent personal injury or
equipment damage when removing the frame
T139106
joint.
19. Carefully remove the frame joint assembly out from

the front of the rear frame using the lifting bracket
TA0918.
OUTJ003,00003D4 –19–01FEB01–9/12
20. Remove and discard the rear bearing seal from the
bearing bore in the rear frame.
NOTE: Removal of the frame joint can damage the rear

(smaller) bearing. It is recommended that the
bearing be removed and replaced with a new
–UN–18JUN01
bearing whenever the frame joint assembly is
removed from the frame.
T139107
17
1720
11

081403
PN=799
Frame Hinge
21. Thoroughly clean and inspect the front (larger) taper

roller bearing and seal for wear or damage. Spin the
bearing by hand and check for free rotation to see if it
is suitable to reuse.
NOTE: The front frame joint bearing seal cannot be
–UN–18JUN01
replaced without removal and destruction of the
front bearing. Although it is normal practice to
replace seals when servicing components, this
seal may be reused if it is not worn or damaged in
T139108
any way. If however the bearing must be
replaced, the seal should be replaced at the same
time.
If both the bearing and seal are suitable for reuse,

clean the bearing rollers thoroughly with solvent to
remove all dirt and old grease, carefully dry the
bearing, and repack the rollers with grease.
OUTJ003,00003D4 –19–01FEB01–11/12
22. Inspect the frame joint machining and the bore in the
rear frame for wear and damage. Clean thoroughly,
removing all dirt and old grease.
–UN–18JUN01
17
1720 T139109
12
OUTJ003,00003D4 –19–01FEB01–12/12

081403
PN=800
Frame Hinge
Frame Joint Bearings Installation
NOTE: See Section 02, Group 0230, Drive Shafts, for

procedures to replacing the frame joint drive shaft
bearings.
–UN–18JUN01
1. Install both bearing cups into the drive shaft bore in the
frame joint at room temperature. Use special bearing
driver tool TA0910 for the larger rear bearing cup and
TA0911 for the smaller front bearing cup.
T139110
2. Install the front (larger) frame joint bearing seal on the
frame joint ensuring that the lip of the seal evenly
contacts the machined surface. Apply a thin coating of 1—Bearing Cup
2—Bearing Driver
thin lubricating oil to the outer diameter of the seal to
ease its installation.
NOTE: The seal cannot be installed with the bearing cone

in place.
CAUTION: Use extreme caution when handling

the heated bearing to avoid severe burns.
3. Heat the front bearing cone to 150°C (300°F). Install

the heated bearing onto the frame joint ensuring that
the bearing is fully seated before the bearing cools.
When the bearing has cooled, check to see that it

rotates freely and pack it with EP2 grease.
CAUTION: The frame joint assembly weighs

approximately 180 kg (400 lb). Use the specified
lifting bracket and appropriate support, slings
and lifting devices to prevent personal injury or
equipment damage when installing the frame
joint.
17
4. Install the frame joint into the rear frame bore so that 1720
the front bearing cup seats to its cone. Take care not 13
to damage the seal.

081403
PN=801
Frame Hinge
CAUTION: Use extreme caution when handling

the heated bearing to avoid severe burns.
5. Heat the rear (smaller) bearing cone to 150°C (300°F)

and install the heated bearing onto the frame joint
using the round main shaft end nut and the Nut Driver
–UN–18JUN01
Tool TA0908 to fully seat the bearing before it cools.
NOTE: Apply just enough torque to seat the bearing. Do

not tighten to the final torque until the bearing has
T139112
cooled.
When the bearing has cooled, check that it rotates 1—Rear Bearing
freely and pack it with EP2 grease. 2—Frame Joint End Nut
3—Nut Driver Tool TA0908
6. Install the rear (smaller) bearing seal.
17
1720
14

081403
PN=802
Frame Hinge
7. Coat the inner bearing surface and the threads of the

round end nut with NEVER-SEEZanti-seize compound
and install the end nut. Tighten the nut to specified
torque.
Frame Joint Bearings Installation—Specification
–UN–18JUN01
Frame Joint Nut—Torque .......................................... 1000 N•m (725 lb-ft)
Rotate the frame joint assembly 360° to ensure that it

rotates freely with no evidence of binding or uneven
T139106
resistance.
8. Install a grease fitting into the end of the frame joint

assembly and thoroughly grease the joint with EP2
grease. Ensure that clean grease is visible at both
bearing seals. The grease fitting must be removed to
install the retainer plate.
NOTE: Approximately 4.3 L (1.14 gal) of grease will be
–UN–18JUN01
required to fully grease the frame joint assembly.
9. Install the end nut retainer plate, retainer bolts and

washers.
T139114
10. Install the frame joint drive shaft. See Section 02,
Group 0230, Drive Shafts, for the procedures.
11. Re-install the grease fitting into the end of the frame
joint assembly.
17
1720
15
NEVER-SEEZ is a trademark of Emhart Chemical Group OUTJ003,00003D5 –19–01FEB01–3/3
Hinge Pin Installation
1. Use bearing driver tool TA0912 to install the two upper

pin bearing cups into the upper front frame hinge boss.
2. Install the two upper pin bearing cones and the spacer
ring.
NOTE: Use tie wraps to temporarily hold the bottom cone

and spacer ring in place.

081403
PN=803
Frame Hinge
3. Install the lower pin bearing retainer plate onto the

lower front frame hinge boss. Apply LOCTITE 242
and tighten the six screws to specified torque.
Hinge Pin Installation—Specification

Lower Bearing Retainer Plate
Screws—Torque .............................................................. 35 N•m (25 lb-ft)
–UN–18JUN01
1—Lower Hinge Bearing Retainer Plate
2—Capscrews
T139118
LOCTITE is a trademark of Loctite Corp. OUTJ003,00003D6 –19–01FEB01–2/11
4. Press the lower pin spherical bearing into the lower

hinge boss using bearing driver tool TA0913 until it
contacts the retainer plate.

–UN–18JUN01
5. Lift the rear frame into place using a sling secured at

three positions (two at the rear and one at the Boom
T139119
mounting tower), keeping the frame level as it is mated
with the front frame.
1—Lower Hinge Pin Spherical Bearing
NOTE: When the front and rear frame bosses are aligned
in the correct position, remove the tie wrap
holding the bearing and spacer ring in the upper
17
1720 hinge boss.
16

081403
PN=804
Frame Hinge
6. Install the lower hinge pin from the top, using the long
driver tool TA0913 inserted through the top hinge pin
bores. Make sure that the locking bar slots in the pin
are aligned with the slots in the frame before the pin is
driven into place.
–UN–18JUN01
T139120
OUTJ003,00003D6 –19–01FEB01–4/11
7. Install the bottom hinge pin locking bar using the two
shorter bolts. Apply LOCTITE 242 to the threads of
the bolts.
–UN–18JUN01
T139121
8. Install the top hinge pin using Pin Driver Tool TA0914.
Make sure that the locking bar slots in the pin are
aligned with the slots in the frame before the pin is
driven in fully. Also, make sure that the spacer ring
stays in place under the bottom bearing cone.
–UN–18JUN01
9. Install the upper hinge pin locking bar and the
hydraulic hose retainer bracket using the two longer
bolts. Use Loctite 242 on the threads bolts.
17
T139122
1720
10. Install the upper hinge pin nut. Tighten the nut to
17
specified torque using a special nut driver socket
TA0917 and a 1/2 in. drive socket wrench.
Hinge Pin Installation—Specification

Upper Hinge Pin Nut—Torque .................................... 150 N•m (110 lb-ft)

081403
PN=805
Frame Hinge
11. Using one of the diagonal holes in the top hinge pin
locking nut as a guide, drill a hole, 4.7 mm (0.19 in
3/16" drill) diameter and 3.0 mm (0.12 in) deep, into
the end of the top hinge pin.
–UN–18JUN01
T139123
OUTJ003,00003D6 –19–01FEB01–7/11
12. Install the set screw.
–UN–18JUN01
T139124
OUTJ003,00003D6 –19–01FEB01–8/11
13. Install the steer cylinders on the frame joint. Apply

NEVER-SEEZ anti-siezing compound to the pin.
Insert the pin. Install the fastening plate and retaining
screws.
–UN–18JUN01
17
1720 T139125
18
NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page OUTJ003,00003D6 –19–01FEB01–9/11

081403
PN=806
Frame Hinge
14. Install grease fittings on the upper hinge pin and the
lower front frame hinge boss.
Thoroughly grease the top and bottom hinge pins and

the steering cylinder pins.
–UN–18JUN01
15. Reconnect the hydraulic hoses to the rear axle
service brake, parking brake and differential lock.
16. Reconnect the hose to the frame brake.
T139126
17. Reconnect the boom operation hoses at the Boom
Control Valve.
18. Reconnect the wires to the back-up alarm. Any

clamps removed or ties cut must be replaced as
originally installed.
19. Install the rear bogie. See Section 02, Group 0200,
for the procedures.
Install the wheels and tires.
17
1720
19

081403
PN=807
Frame Hinge
CAUTION: Always install the frame lock bar

before working near the machine articulation.
Failure to observe proper safety precautions
can lead to risk of severe personal injury or
death.
–UN–23AUG88
X9811

fluids.

knowledgeable medical source.
20. Bleed the Frame Brake using the following procedure:
a. Turn the operators seat to the rear.
b. Run the engine at normal idle.
c. Apply a load to the boom by raising the main

boom until the main lift cylinder is fully extended.
(The frame brake will be engaged at this point).
d. Loosen the hydraulic supply line at the fitting to the

frame brake until all the air is removed from the
circuit. Tighten the fitting.
17
1720
20 21. Bleed the air from the brakes. See Section 10, Group
1060, and Section 11, Group 1160, for the
procedures.
22. Before the machine is returned to service, drive the

forwarder over uneven ground, steering fully in both
directions to ensure that both the steering and frame
joint rotation function correctly.
OUTJ003,00003D6 –19–01FEB01–11/11

081403
PN=808
Frame Hinge
17
1720
21

081403
PN=809
Frame Hinge
Frame Brake Theory Of Operation
17
1720
22
–UN–22AUG01
T138166
Continued on next page JK11466,0000013 –19–01NOV02–1/2

081403
PN=810
Frame Hinge
1—Bushing 6—Frame Brake Housing 9—Spring 13—Auxiliary Valve

2—Gear Rack 7—Frame Brake Pressure Test 10—Washer 14—Frame Brake Solenoid Y65
3—Articulating Gear Port MA1 11—Spring Retainer Screw 15—Tee in Main Boom Raise
4—Piston 8—Retainer Cover 12—Frame Brake Hose Line
5—Piston Seal
The frame brake is provided to temporarily lock the The frame brake is hydraulically applied and spring
frames when the boom lift up -function is actuated. released. The actuating mechanism is mounted on the
This allows the full weight of both frames to act as rear frame. Two single-acting hydraulic pistons move
counterweight to stabilize the machine when using the the actuating gear forward to engage a gear rack
boom. Two single-acting hydraulic cylinders press mounted on the frame joint. The brake prevents the
friction pads to the brake disc as the frame brake is frame joint from rolling in the rear frame bearings.
on. This brake disc is mounted to the rear frame and Steering is unaffected by the use of the frame brake.
brake cylinders and friction pads are mounted to the
front frame. When the machine stops, TMC-system The hydraulic supply is from the main boom lift circuit.
engages the service brake and de-energizes the When pressure is applied to the boom cylinder,
solenoid valve (pos. 1 in figure 1). In that case the hydraulic fluid is supplied through a check valve and
valve allows the hydraulic pressure to the frame brake 1.0 mm Dia. flow restrictor to the Y65 solenoid on the
cylinders (pos. 5) when using the boom lift up – auxiliary valve.
function (pos. 4). The frame brake releases when TMC
energizes the valve (pos. 1) and lets the pressure go When de-energized, the Y65 solenoid allows fluid to
to the drain line, when starting to drive again. The flow to the frame brake. When energized by the Frame
check valve (pos. 2) in the pressure line prevents Brake Release switch on the dashboard, the solenoid
pressure drop in the frame brake. Relief valve (pos. 3) valve directs the flow to the tank and the return springs
limits the maximum pressure for frame brake (setting release the frame brake.
pressure 25 MPa). Note! Change friction pads, when
there are ~2 mm of running surface left. Fluid flows from the auxiliary valve to the frame brake
Troubleshooting: Failure: Cause for the failure: 1. through an adjustable pressure relief valve, located on
Frame brake looses grip Relief valve (pos. 3) leaks the Auxiliary Valve. The pressure relief valve is
Incorrect setting pressure of relief valve Solenoid valve provided to protect the frame brake from pressure
(pos. 1) leaks Leakage in brake cylinders (pos. 5) spikes. The relief valve is adjustable but pre-set at the
Check valve (pos. 2) leaks 2. Frame brake stays on factory to 21.5 MPa (3100 psi).
Solenoid valve stacked open No current for Y65
Stacked drain line When the drive pedal is pressed, raising the drive
pedal pilot pressure above 150 kPa (22 psi), solenoid
The frame joint articulates for steering and rolls to Y65 on the Auxiliary Valve is energized. The solenoid
allow the front and rear frames to tilt independently as valve directs the flow to the tank and the return springs
the machine maneuvers across uneven ground. A release the frame brake. The work brakes are also
frame brake is provided to temporarily lock the frames released when the drive pedal is pressed. 17
for stability when operating the boom. 1720
Maximum pressure at the test port MA1 on the frame 23
The brake is automatically applied when the boom is brake is 21.5 MPa (3120 PSI).
operated. The frame brake is automatically disengaged
when the forwarder is moving. The frame brake can Frame brake cylinders and friction pads are mounted
also be manually released by a switch on the to the front frame and brake disc is mounted to middle
dashboard. joint.
JK11466,0000013 –19–01NOV02–2/2

081403
PN=811
Frame Hinge
Frame Brake Removal

Securely block the wheels to prevent machine
movement. Relieve the pressure in the frame
brake hydraulic system.


1. Articulate the forwarder to its maximum angle, either

left or right to access the frame brake.
2. Relieve the pressure in the frame brake, using one of

two alternative procedures.
OUTJ003,00003D7 –19–01FEB01–1/3

engine running, use the following procedure:
17
1720
24 a. Turn the operators seat to face the rear.
b. Position the boom boom in the bunk with the main

–UN–18JUN01
boom cylinder fully retracted.
c. Activate the frame brake release switch.

T142804
d. Ignition switch OFF. Remove ignition key.
main switch off.
1—Frame Brake Switch

081403
PN=812
Frame Hinge

engine not running, use the following procedure:
Attach a hose to the test port MA1 on the frame brake

and bleed the fluid into a suitable container.
–UN–18JUN01
3. Disconnect the hydraulic supply hose from the rear of
the frame brake unit in the rear frame hinge area. Plug
the port and cap the hose.
T139098
4. Remove the six mounting capscrews from the top of
the frame brake unit. Remove the two bolts with nuts
retaining the top plate. Remove the frame brake unit
from the machine.
Frame Brake Removal—Specification

Frame Brake Unit—Weight .................................................... 40 kg (88 lb)
OUTJ003,00003D7 –19–01FEB01–3/3
17
1720
25

081403
PN=813
Frame Hinge
Frame Brake Unit Servicing
17
1720
26 –UN–20JUL01
T139130
Frame Brake Unit


081403
PN=814
Frame Hinge
1—Frame Brake Housing 5—Spring Retainer Screw 8—Retainer Cover 10—Frame Brake Supply Hose
2—Articulating Gear 6—Washer 9—Frame Brake Pressure Test 11—Gear Rack
3—Piston 7—Spring Port MA1 12—Bushing
4—Piston Seal
IMPORTANT: Cleanliness procedures must be Failure to follow these procedures

observed when working on any may lead to equipment damage.
prevent contamination of the 1. Thoroughly clean the outside of the frame brake
hydraulic and hydrostatic systems. unit to prevent internal contamination.
OUTJ003,00003D8 –19–01FEB01–2/10
2. Remove the four return spring bolts and remove the

actuating gear from the frame brake housing.
–UN–20JUL01
T139131
OUTJ003,00003D8 –19–01FEB01–3/10
CAUTION: Use caution when using compressed

air to remove the pistons. The pistons must be
retained by a block of wood because they can
exit the housing with great force, causing
serious injury or equipment damage.
–UN–18JUN01
3. Position the frame brake unit so that the pistons face
down onto a block of wood and apply compressed air
to the frame brake hydraulic hose port to push the 17
pistons from the brake unit.
T139132
1720
27
4. Inspect the frame brake gear for damaged teeth and
replace the gear if necessary.

081403
PN=815
Frame Hinge
5. Thoroughly clean and inspect the frame brake piston

bores for scoring, nicks and damage. The bore
diameters should be within specified tolerances. If the
piston bores are worn oversized, the brake unit block
must be replaced.
–UN–18JUN01
Frame Brake Unit Servicing—Specification
Frame Brake Piston Bores—
Minimum Diameter ............................................... 50.000 mm (1.9685 in.)
Frame Brake Piston Bores—
Maximum Diameter .............................................. 50.039 mm (1.9705 in.)
T139133
OUTJ003,00003D8 –19–01FEB01–5/10
6. Inspect the return springs, bolts and washers for wear

or damage and replace any parts as necessary.
NOTE: If the return springs become weak or damaged,

they may not release the frame brake properly
and they should be replaced.
–UN–20JUL01
Always replace a complete set of four springs to
ensure that they release evenly.
T139134
The frame brake uses 150 mm (5.875 in) bolts with 44
mm (1.73 in) free length springs compressed to 42 mm
(1.65 in). Measure the springs. If any of the springs are
shorter than their free length, they should be replaced.

Return Spring—Free Length ............................................ 44 mm (1.73 in)
Return Spring—Compressed
Length ............................................................................... 42 mm (1.65 in)
7. Thoroughly clean and inspect the two pistons,

discarding the old o-rings and seal rings.
17
1720
28

081403
PN=816
Frame Hinge
CAUTION: Use caution when handling the

heated seal to avoid burns.
8. Use the seal expander tool 479265-1 to install two new

piston o-rings into the seal grooves on each piston.
–UN–18JUN01
Pre-heat the seals in an oil bath to 150°C (302°F).
Insert the piston onto the installation tool. Stretch the
new seal over the tool to the edge of the seal groove.
Repeat the procedure to install the o-ring on the other
T139135
end of the piston.
1—Seal Expander Tool 479265-1

2—O-ring Seal
OUTJ003,00003D8 –19–01FEB01–7/10
9. Use the seal pusher tool 479265-2 to install the seal

onto the o-ring already in place. Repeat the procedure
to install the seal on the other end of the piston.
1—Seal Pusher Tool 479265-2

2—Seal
–UN–18JUN01
T139136
OUTJ003,00003D8 –19–01FEB01–8/10
10. Insert the pistons into the frame brake unit using
Piston Installation Tool 479266-1 so that the flattest
17
end of the pistons face inward.
1720
29
11. Clean the threads of the return spring bolts and holes
in the back of the actuating gear with solvent. Allow
–UN–18JUN01
the threads to dry thoroughly.
12. Before installing the actuating gear, apply a coating of

Molykote G-rapid lubricant to the contact surfaces
T139137
between the actuating gear and the frame brake

housing.
1—Frame Brake Unit

2—Piston
3—Piston Installation Tool 479266-1

081403
PN=817
Frame Hinge
13. Install the return springs and washers onto the return
spring bolts.
Apply LOCTITE 222 to the threads of the bolts and

install them through the frame brake housing into the
actuating gear. Tighten bolts to compress each spring
–UN–18JUN01
to the specified compressed length.

Return Spring—Compressed
T139138
Length ............................................................................... 42 mm (1.65 in)
–UN–18JUN01
T139139
17
1720
30

081403
PN=818
Frame Hinge
Friction Pad Changing
1. Drive machine to flat area and turn machine in max

steering angle
2. Loosen seven cap screws. Note ! Because the

tightening torque of the cap screws is 900Nm very high
forces may be needed to open screws.
3. Remove pads.
4. Press brake pistons in.
5. Check the condition of the brake plate.
6. Any big cracks or bends are not allowed. Change plate

if necessary.
7. Clean and grease bushings, which are between pads.

Use waterproof grease.
8. Install new pads.
9. Clean cap screws and tighten them to 900Nm. Threads

must be unoiled.
10. Check that the brake works properly.
JK11466,0000084 –19–07JAN03–1/1
17
1720
31

081403
PN=819
Frame Hinge
Frame Brake Pressure
SERVICE EQUIPMENT AND TOOLS

Gauge 30 MPa (4500 psi)
CAUTION: Adjustments to the frame brake are
–UN–20JUL01
made with the engine running. Accidental
articulation of the machine can lead to risk of
severe personal injury. Apply the frame
T138183
articulation locks to the steering cylinders
before working on the frame brake or joint area
of the machine. Frame Brake MA1
1. Connect a 30 MPa (4500 psi) gauge to test port MA1

on the frame brake.
2. Run the engine at specified idle.
Frame Brake Pressure Adjustment —Specification
–UN–22AUG01
Engine—Speed ........................................................................... 1800 rpm
3. Turn the operators seat to the rear to enable the boom.
T144922
4. Raise the main boom until the lift cylinder is fully
extended. This will hold the lift circuit under load and
engage the frame brake. Frame Brake Pressure Reducing Valve
5. Check the frame brake pressure at test port MA1. The 1—Frame Brake Pressure Reducing Valve
pressure should be at the specified value. Check that
both gear racks of the frame brake are fully engaged.
Frame Brake Pressure Adjustment —Specification

MA1—Pressure ......................................................... 21.5 MPa (3120 psi)
6. If necessary, adjust the pressure by turning the

adjustment screw on the Frame Brake Pressure
Reducing Valve.
17
1720 NOTE: If the pressure cannot be adjusted to the correct
32 value and there are obvious signs of oil leakage,
the frame brake will have to be serviced.
OUTJ003,0000115 –19–17DEC00–1/1

081403
PN=820
Frame Hinge
Steering
–UN–20JUL01
T138146
Steering Cylinders with Boom Control Valve
Two Steer cylinders are mounted inside the front frame A switch on the left armrest of the operator’s seat
under the cab. The cylinders bend the vehicle at the activates solenoids on the far right spool of the Boom
frame hinge to turn the machine left and right. control valve operating the steer cylinders.
Continued on next page OUTJ003,00002B3 –19–10JAN01–1/2
17
1720
33

081403
PN=821
Frame Hinge
–UN–20JUL01
T138147
Steering Cylinders and Frame Hinge
1—Grease Line 3—Fastening Plate 5—Pivot Pin 6—Steer Cylinder

2—Screw 4—Grease Fitting
OUTJ003,00002B3 –19–10JAN01–2/2
17
1720
34

081403
PN=822
Group 1740
Operational Checks
Checkout Procedure
This procedure is designed so the mechanic can make a

quick check of the system using a minimum amount of
diagnostic equipment.
The engine or other major components must be at

Locate system check in the left column and read

completely, following this sequence from left to right. Read
each check completely before performing.
OUTJ003,000058D –19–12APR01–1/2


–UN–23AUG88
fluids.
X9811
17
knowledgeable medical source. 1740
1
OUTJ003,000058D –19–12APR01–2/2
1 Frames
– – –1/1

081403
PN=823
Operational Checks
Condition and NOTE: The machine should be kept clean, especially in the winter. OK: Go on to next check.
Cleanliness
Inspect the machine for cleanliness. NOT OK: Remove snow,
LOOK: There should be no snow, dirt and slash on the machine. freezes.
NOTE: When using a power washer, do not aim the stream at the joint between the
pedestal and the boom base.
– – –1/1
Frame Joint Inspect the frame joint. OK: Go on to next check.
LOOK: Frame joint should be in good condition and NOT OK: Lubricate frame
properly lubricated. joint and pins. Tighten
fasteners.
LOOK: Pins should be in good condition and properly
lubricated. fasteners should be tight. (See group 1730 for
T141594 –UN–21JUL01
LOOK: Bearing seals should be in good condition and frame joint.)
properly lubricated.
1—Hinge Pins OK: Go on to next check.

2—Steer Cylinder Pins
NOT OK: Lubricate pins
Start engine. and bearings.
Use the Steering Lever to articulate the machine left and (See group 1730 for
right. procedures to replace
pins and bearings.)
T141595 –UN–21JUL01
LOOK/FEEL: Frame joint hinge pins and bearings should
Frame Joint Hinge Pins operate smoothly.
1—Frame Joint Bearings OK: Go on to next check.
17 Start engine. NOT OK: Lubricate

1740 bearings.
2 Drive machine slowly over uneven surface.
(See group 1730 for
LOOK: Rear frame should roll relative to front frame, procedures to service the
keeping all wheels in firm contact with the ground. frame joint.)
T141596 –UN–21JUL01
Bearings should operate smoothly.
Frame Joint Bearings Damage to the main
NOTE: Shut off engine before proceeding to next check. tapered roller bearings
will require the complete
removal and disassembly
of the frame joint.
– – –1/1

081403
PN=824
Operational Checks
Panels and Covers Open hood. OK: Go on to next check.
LOOK: Hood should be in good conditions with no dents NOT OK: Repair or
or damage. Latches and hinges should operate replace latches. Repair or
smoothly. The pneumatic cylinder should be in place and replace pneumatic
operate smoothly to slow movement of hood. cylinder. Repair or
replace seal on air intake
Close hood. cap.
T141597 –UN–21JUL01
LOOK: The pneumatic cylinder should operate smoothly Replace hood, grill or
to slow movement of hood. Hood should fit properly. Air screen, if necessary.
cleaner rubber bellows should fit properly, making a
proper seal with the hood. Latches should hold hood
securely.
Remove front grill.
LOOK: The grill should be clean and in good condition.

The screen behind the grill should be clean and
undamaged. Fasteners should hold grill securely.

block wheels to prevent machine movement NOT OK: Repair or
before working under machine. Failure to replace safety hook.
observe proper safety precautions can result Repair or replace
in personal injury. pneumatic cylinder.
Replace belly pan if
Open the front frame belly pan. damaged.
T141598 –UN–21JUL01
LOOK: Belly pan should be undamaged. Safety hook
should be in place and stop belly pan from dropping
more than a few inches. The pneumatic cylinder should
operate smoothly to slow movement of belly pan.
Close belly pan.
LOOK: Fasteners should be tight and hold belly pan

securely.

block wheels to prevent machine movement NOT OK: Tighten
before working under machine. Failure to fasteners. Replace
observe proper safety precautions can result covers, if missing or 17
in personal injury. damaged. 1740
3
Inspect front frame drive shaft access covers.
T141599 –UN–21JUL01
Inspect panels on front frame at hinge and on either side OK: Go on to next check.
of cab.
NOT OK: Tighten
LOOK: Panels should be in place and undamaged. fasteners. Replace
Fasteners should be tight. panels, if missing or
damaged.
T141600 –UN–21JUL01
– – –1/2

081403
PN=825
Operational Checks
1—Frame Joint Access Cover OK: Go on to next check.

2—Rear driveshaft Access Cover
3—Rear Frame Belly Pan NOT OK: Tighten
fasteners. Replace
CAUTION: Apply parking brake and securely damaged.
block wheels to prevent machine movement
before working under machine. Failure to
observe proper safety precautions can result
T141601 –UN–21JUL01
in personal injury.
Inspect covers on boom pedestal and on the underside

of the rear frame.

Inspect covers on the cab. OK: Go on to next check.
LOOK: Covers should be in place and undamaged. NOT OK: Tighten

Fasteners should be tight. fasteners. Replace
damaged.
T141602 –UN–21JUL01
–19– –2/2
17
1740
4

081403
PN=826
Section 18
Cabin
Contents
Page
Group 1810—Cabin Environment

About This Group . . . . . . . . . . . . . . . . . . . . .18-1810-1
Overall Description . . . . . . . . . . . . . . . . . . . .18-1810-2
1010D Safety and alarms . . . . . . . . . . . . . . .18-1810-3
1010D Cabin Component Locator . . . . . . . .18-1810-10
1010D Operator’s seat . . . . . . . . . . . . . . . .18-1810-14
1010D Controls . . . . . . . . . . . . . . . . . . . . . .18-1810-15
Emergency Stop Button . . . . . . . . . . . . . . .18-1810-18
Warning Lamps and Buzzer . . . . . . . . . . . .18-1810-18
Preparedness for telephone . . . . . . . . . . . .18-1810-19
Cabin Component locator . . . . . . . . . . . . . .18-1810-20
Operator’s seat . . . . . . . . . . . . . . . . . . . . .18-1810-21
1110D and 1410D Armrest Controls . . . . . .18-1810-22
1710D Armrest Controls . . . . . . . . . . . . . . .18-1810-23
Dashboard . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-25
Group 1820— Cabin Service

Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1820-1
Cabin Service . . . . . . . . . . . . . . . . . . . . . . . .18-1820-1
1010D Lifting and Lowering the Cab . . . . . . .18-1820-3
How to Lifting and Lowering the the Cab. . . .18-1820-7
1010D Cab Tilt Cylinder Replacement. . . . . .18-1820-9
1010D Cab Mount Replacement . . . . . . . . .18-1820-13
1010D Cab Removal and installation . . . . .18-1820-14
18

081403
PN=1
Contents
18

081403
PN=2
Group 1810
Cabin Environment
About This Group
This Group includes following information
• Safety features
• Operator‘s seat
• Important controls
Issues are divided into two groups: 1010D and other

models. Issues are handled in a general level. See
operator‘s manuals for further information about individual
forwarder model.
JK11466,0000003 –19–04APR03–1/1
18
1810
1

081403
PN=829
Cabin Environment
Overall Description
The cab is mounted on the frame by four vibration

dampening rubber mounts. The left hand mounts can be
released to allow the cab to be tilted in order to service
drive and hydraulic components in the frame. The cab is
tilted by a hand pump operating a hydraulic cylinder under
the cab. A support is provided to hold the cab in the
raised position.
The connections between to the cabin and the frame are

limited to the following
• Four rubber mounts, cab tilt cylinder and support

• Brake pedal valves hydraulic hoses
• Drive Pedal to Drive Pedal Valve cable
• Drive Pedal to Engine Throttle cable
• Manual Throttle to Engine Throttle cable
• Four AC/heater hoses through a bulkhead fitting at the
lower front right corner of the cab
• Electrical harnesses under the cab
Bear in mind that should a warning light go on or the

central warning light blink, this always indicates that there
is something that does not function properly within the
system. This being the case, discontinue loading and turn
off the engine. See the Instructions for use of Timberjack
TMC (Total Machine Control), Appendix.
The operation of the alarm system is detailed in the

Instructions for use TMC.
TMC is a registered trade mark of Timberjack. JK1146600001 –19–31DEC01–1/1
18
1810
2

081403
PN=830
Cabin Environment
1010D Safety and alarms
Emergency button
The emergency stopper (13) is in the dashboard. If the

knob is pushed down the engine will stop, all functions of
the machine will terminate, and the parking brake will be
engaged. The emergency stopper can be released by
turning the knob.
NOTE: Learn how to use the stopper in case of

emergency!
–UN–03JUL02
T156563
1010D Emergency button
Continued on next page EL62757,000020E –19–27NOV02–1/7
18
1810
3

081403
PN=831
Cabin Environment
Warning lights on the dashboard
Warning indicator lights on the dashboard will be lit when

certain conditions arise. Some of these warnings also
activate the central warning light and buzzer.
CAUTION: If a warning light is lit, shut down the

machine. Do not operate the machine until the
problem has been remedied.
Continued operation of the machine may lead to

equipment damage and, in some cases, risk of
injury.
Qualified personnel can refer to the Operations and Test
–UN–25JUN02
Manual for procedures to troubleshoot and repair the
machine.
1. Hydraulic Oil Temperature. Alarms*, if the temperature
T156565
exceeds 75 °C (167 °F).
2. Hydraulic Oil Level. Alarms*, if level drops below
1010D Warning lights
minimum (min. = 72 l /19 gal))
3. No use
4. Warning light will be lit when the pressure exceeds
0,13 MPa (18,8 psi). Replace the filter.
5. Fuel level
6. Glow.
7. Battery charge
8. Hydrostatic Drive Pressure. Alarms*, when the
pressure drops below 1,5 MPa (217 psi).
9. Brake Charge Pressure. Alarms*, when the pressure
drops below 10 MPa (1450 psi)
10. Coolant temperature. Alarms*, if the temperature
exceeds 100 °C (212°F) .
*Besides the warning light also warns with the central

warning light and buzzer.
18
1810
4

081403
PN=832
Cabin Environment
Alarm lights and fault codes from the engine
Engine alarms are shown as red or yellow fault codes on

the dashboard
• Yellow light (stage 2) warns

• Red light (stage 1) asks to stop the machine
–UN–21OCT02
– When the red light blinks, it also activates the central
warning light and the buzzer.
NOTE: During operating the machine, the switch must be
T156564
in drive position (the swich is pointing to the left)
Reading the blinking fault codes: 1010D Led lights
R—Red light code

❒ Turn off the engine, turn the switch to the right and wait
Y—Yellow light code
about 30 seconds.
❒ Turn ignition key to position I
❒ The blinking always starts with a light serie 3 2 (read 3
and 2).
The code means: Starting the active alarms.
❒ Next blinking code means the likely cause, like 6 3
(stage 2, Engine coolant temperature high).
❒ After the alarm has been read:
• turn the engine off
• turn the switch to the left and wait about 30 seconds
• start the engine
The previously active fault codes are saved in ECU’s data

storage.
These history files are shown after the blinking code 3 3.
NOTE: The light can also blink without having any alarms
in the system. The light code in this case is 3 2 -
8 8 - 3 3 - 8 8 (8 8 means ’No code’)
Fault Codes and how they are used
Terms:
• SPN (Suspect Parameter Numbers).

– stands for the parameter that has a problem (like.
110 = coolant)
• FMI (Failure Mode Indicator) 18
– stands for what is wrong (like. 0 = the temperature 1810
5
is too high)
• Together they make the fault code:

081403
PN=833
Cabin Environment
SPN 110 FMI 0, Coolant temperature above normal-

engine overheat.
• That fault code is expressed with a light code on the
dashboard:
– 6 9 (1st stage alarm, red code)
18
1810
6

081403
PN=834
Cabin Environment
List from fault codes
Light SPN FMI Stage 2, Stage 1, Reason for alarm

code Yellow Red light
light
11 91 3 x RPM Throttle Input High
12 91 4 x RPM Throttle Input Low
15 29 3 x Gas pedal Throttle Input High
16 29 4 x Gas pedal Throttle Input Low
18 110 3 x Coolant temperature voltage high
19 110 4 x Coolant temperature voltage low
21 620 3 x Sensor supply voltage high
22 620 4 x Sensor supply voltage low
23 100 3 x Engine oil pressure voltage high
24 100 4 x Engine oil pressure voltage low
25 105 3 x Manifold air temperature voltage high
26 105 4 x Manifold air temperature voltage high
28 629 13 X ECU failure
32 - - Beginning of active codes
33 - - Beginning of previously active codes
37 174 3 x Fuel temperature voltage high
38 174 4 x Fuel temperature voltage low
39 637 2 x Crank position input noise
39 637 10 x Crank position input pattern error
63 110 16 x Engine coolant temperature high
65 100 1 X Engine oil pressure low
66 105 16 x Manifold air temperature high
68 1569 31 x Engine protection derate
69 110 0 X Engine overheat
71 1076 0 x Closure too long possibly due to slow valve response. Service/repair supply pump.
72 1076 1 x Closure too short possibly due to overly slow valve response or excessive battery
voltage.• Possible ECU or supply pump problem.
73 1076 5 X Check actuator wires for open circuit.• Look for bad connections. Engine will not
run.
74 1076 6 X Check actuator wires for short to ground or to each other. Engine will not run.
75 1076 7 x ECU has failed to detect closure possibly due to a slow responding valve.
76 1076 10 X Possibly due to increased resistance in the circuit. Check for weak shorts to
ground or power.
77 1076 3 X Check actuator wires for short to battery
18
79 2000 6 X Internal ECU failure (Pump solenoid current supply failure)
1810
81 174 16 x Fuel temperature moderately high 7

081403
PN=835
Cabin Environment
84 158 17 x ECU power down error

88 - - No code
Central Alarm light on the ceiling
The central alarm light is located on the cab ceiling. The

central alarm buzzer is located on the seat back.
The light will flash and the buzzer will sound when certain
dashboard warning lights are activated.
Central Alarm Codes
The Central Alarm Light on the cab ceiling will flash in

case of certain control module malfunctions. The light will
flash in specific four blink patterns of long and short
flashes corresponding to specific malfunctions.
This serie is always followed by four short blinks • • •

•
Alarm Light codes: The reason for the alarm:

number - = long
• = short
••••
1 —••• CHAIR Module missing
2 •—•• Boom Module missing
3 ——•• Hydraulic Oil Level Alarm
4 ••—• Hydraulic Oil Temperature Alarm
5*) —•—• Hub -combination alarm:
- engine 1st* stage alarms
- brake charge pressure
- hydraostatic charge pressure
6 •——• Boom module, XE1 short circuited or cut
7 ———• Boom module, XE2 short circuited or cut
8 •••— Chair module, XC short circuited or cut
9 —••— Hub module, XH short circuited or cut
10 ••—• No CAN connection: H/L missing
11 ——•— Low battery voltage
12 ••—— Control lever out of range
13 —•—— Steering joystick out of range
18
*) Alarm nr. 5 - check if the alarm comes from the engine.
1810
8 In that case the red led light is active on the dashboard.

081403
PN=836
Cabin Environment
Cab Steps Safety Switch
An indicator light on the left armrest will be lit when the

steps are down. When the stairs are lift up, the light will
go out.
–UN–12JUL01
If you try to drive the machine with the stairs down, the
light will be lit and the driving is prevented ( when the
parking brake is disengaged, the light starts to blink in the
panel.)
T142897
NOTE: If the cab steps drop while the machine is being
operated in Low Gear, the drive direction valve Cab Steps Safety Switch Indicator Light
will shift into neutral and the machine will come to 1—Cab Steps Safety Switch Indicator Light
a stop.
If the cab steps drop while the machine is being

operated in High Gear, the machine will continue
until it is brought to a stop by the operator.
After the machine has come to a stop, it will

remain in neutral unless the cab steps are raised.
To drive the machine with the cab steps down:
1. Press the Rear Wheel Drive Engage Switch on the

dashboard to overide the cab steps switch circuit.
2. Select the drive direction using the switch on the

armrest. Drive the machine.
3. The Rear Wheel Drive Engage switch will have to be

pressed again each time the machine stops and the
Work Brakes are engaged.
EL62757,000020E –19–27NOV02–7/7
18
1810
9

081403
PN=837
Cabin Environment
1010D Cabin Component Locator
–UN–25JUN02
T156559
1010D Cab Component Locator
1—Brake Pedal 6—Ignition Switch 13—Heater/AC Controls 20—Fire Extinguisher

2—Drive Pedal 7—Dashboard Switches 14—Dome Light 21—Left Armrest Control
3—Instrument Box (Includes 8—Indicator Lights 15—Central Warning Light Panel
Fuses, Relays and HUB 9—Gauges 16—Speaker 22—Right Armrest Control
Module 10—Emergency Stop Button 17—AM/FM Radio Panel
4—Dashboard/Instrument 11—Engine Throttle 18—Exterior Light Switches
Panel Adjustment 19—Operator’s Seat (Includes
5—24 V Socket 12—Heater/Air Conditioner SEAT Module on seat
Unit back)
18
1810
10

081403
PN=838
Cabin Environment
Radio
An AM / FMRadio with two speakers is installed in the cab

ceiling.
See the Radio / CD players manufacturer’s manual for
–UN–13JUN01
more information.
The radio is available when the Ignition Switch is OFF.
T142764
NOTE: If the engine is not running, any electrical system
used will drain the batteries.
Radio / CD player
NOTE: A circuit provides power to maintain the radio
memory regardless of the position of the
Disconnect Switch. However, the stations will
have to be reset if the machine batteries are
removed or disconnected.
18
1810
11

081403
PN=839
Cabin Environment
–UN–26NOV02
T160621
18 1010D instrument box

1810
12 1—Panel 3—PC-board 5—Hub-module 7—Converter
2—Main fuses 4—Fuses 6—Relays
Instrument Box
The Instrument Box is situated under the dashboard,

behind a panel.

081403
PN=840
Cabin Environment
Cab Air Filters
The cab air system has three filters:
• The cab air exhaust filter is located on the left side of

the cab next to the door.
–UN–08NOV02
• The cab air intake filter is located on the AC/Heater Unit
near the cab floor.
• The outside air intake filter is located behind the
AC/Heater Unit service panel on the right side of the
T161479
cab (behind the tool box).
The filters require periodic maintenance. See Section 6 for Cab Air Exhaust Filter
more information.
–UN–13JUN01
T142770
Cab Air Intake Filter
–UN–08NOV02
T161478
Outside Air Intake Filter
AK12300,0000032 –19–10OCT01–4/4
18
1810
13

081403
PN=841
Cabin Environment
1010D Operator’s seat
–UN–25JUN02
T156566
1010D Kab-seat
A—Armrest C—Lock / release switch E—Direction limit switch G—Armrest adjust levers
B—Control panel D—Seat safety switch F—Electric control unit
18
Seat Lock / Release Switch Seat Safety Switch Indicator Light
1810
14 The switch located on the rı́ght side of the right control An indicator light on the left armrest will be lit when the
panel, locks or releases the swing of the seat. This operator is out of the seat.The light is blinking, when
switch is operated when the Ignition switch is in I (ON) the system prevents loading or driving the machine.
-position. See chapter 5 [acute ]Seat safety switch’.
Continued on next page EL62757,000020C –19–27NOV02–1/3

081403
PN=842
Cabin Environment
The Indicator Light of the Stairs down, the light will be lit and the driving is prevented.
See chapter 5 ’ Stairs’ indivator light’.
The light on the left armrest will lit when the stairs are
down. If you try to drive the machine with the stairs
EL62757,000020C –19–27NOV02–2/3
Seat Direction Limit Switch
–UN–13JUN01
A switch on the seat pedestal activates certain circuits
depending on the direction the seat is facing.
T142751
NOTE: The boom can be operated only when the seat is
facing the rear.
1010D Seat Direction Limit
The boom is automatically enabled when the seat faces Switch
the rear. It can be disabled when the seat is in this
1—Seat Direction Limit Switch
position by pressing the high gear select button on the
armrest. The indicator light on the switch will start to flash.
EL62757,000020C –19–27NOV02–3/3
1010D Controls
Armrest controls
1—Steering Lever
2—Left Joystick (Boom Control Lever)
3—Boom Speed Potentiometer
4—Cab Steps Switch Indicator Light
5—Seat Safety Switch Indicator Light
–UN–24NOV02
18
1810
15
T156567
1010D Left Armrest
Continued on next page OUTJ003,00005DB –19–10MAY01–1/3

081403
PN=843
Cabin Environment
1—Drive Direction Select Switch

2—Right Joystick (Boom Control Lever)
3—High Gear Select Button
4—Decking Blade Lower Button
5—Front Differential Lock Button
6—Seat Swing Electrical Lock / Release Button (with
power ON)
7—Rear Differential Lock Button
8—Decking Blade Raise Button
9—Wiper Button
–UN–24NOV02
T156568
1010D Right Armrest
Continued on next page OUTJ003,00005DB –19–10MAY01–2/3
18
1810
16

081403
PN=844
Cabin Environment
Dashboard
1. Ignition Switch
• P = Empty
• STOP = Engine stop
• ON (I) = Power on
• II = Glow
• START = Start
2. Cigarrette lighter
3. Emergency Stop Button
4. Dome Light
5. Rear Wheel Drive Engage
6. Frame Brake Release
7. Rear Windscreen Washer
8. Rear Windscreen Wiper
9. Engine Warning Lights
10. Warning Lights
11. Fuel Gauge
12. Tachometer
13. Emergency stopper
14. Electrical Adjustment of Working rpm
15. ON/OFF-Switch for Working rpm
16. Headboard movement (option)
17. Engine Coolant temperature Gauge. Normal operating
temperature is 60...100 °C (140...212 °F)
18. Warning Lights
19. Turn indicator
20. Parking Brake
21. Gauge lights
22. Track Light
23. Front Windscreen Wiper
24. Front Windscreen Washer
25. Horn
18
1810
17
–UN–21OCT02
T156561
1010D Dashboard
OUTJ003,00005DB –19–10MAY01–3/3

081403
PN=845
Cabin Environment
Emergency Stop Button
The emergency stopper (1) is in the right side panel. If the

knob is pushed down the engine will stop, all functions of
the machine will terminate, and the parking brake will be
engaged. The emergency stopper can be released by
–UN–05MAR02
turning the knob clockwise.
1—Emergency stopper
T152202
Emergency stop button
EL62757,000017D –19–21APR02–1/1
Warning Lamps and Buzzer
1. Buzzer and TMC warning lamp (yellow), give warning

that something is wrong. The TMC display indicates
what is wrong.
2. Fire alarm lamp (red) The fire alarm flashes and the
–UN–12SEP02
alarm sounds if fire is registered by the detectors. You
should then trigger the fire extinguisher1 system. See .
3. Control unit for fire extinguisher system.
T152199
Alarm lights and Buzzer
1
in certain markets / optional equipment
EL62757,0000175 –19–19APR02–1/1
18
1810
18

081403
PN=846
Cabin Environment
Preparedness for telephone
A mobile phone or a radiotelephone can be mounted into

the cabin. Preparedness for the phone consists of 12 V
power transmission which can be connected to connection
X17 in the instrument box.
The end of aerial lead (50 W) is situated close to

connection X17 in the instrument box.
The other end of aerial lead (50 W) is on the roof
EL62757,0000176 –19–19APR02–1/1
18
1810
19

081403
PN=847
Cabin Environment
Cabin Component locator
Warning lights are located on the front dashboard.

1—Front dashboard
2—Signal lights
3—TMC-display
4—Left control panel
5—Right control panel
6—Drive pedal
7—Brake pedal
8—Light switches
9—Engine preheater
10—Warning lamps
11—Light switches
12—Control unit for fire extinguisher system
13—CD player
14—Radio
15—Heater/AC controls
–UN–30JAN03
T164091
18 General view of Cab Component Locator

1810
20
JK11466,00000A8 –19–06FEB03–1/1

081403
PN=848
Cabin Environment
Operator’s seat
–UN–12SEP02
T159289
18
1810
21
1110D-1710D Operator‘s seat
1. Armrest • The function is ON when the power is ON.

• The armrest is adjustable in all directions
3. Chair module
2. Control Panel • Most of the controls and swithes are installed to
• There is a push button on the right side of the the Chair2-module.
right control panel. Button is used to release or
stop the swing of the seat. 4. Seat safety switch
Continued on next page EL62757,000004D –54–15SEP02–1/2

081403
PN=849
Cabin Environment
• Function of the seat safety switch is explained in • The height could be set in 5 positions
group 5-2. • Pull rear handle for adjustment of the rear part
of the seat
5. Weight setting with a mechanical knob (depending • Pull from handle for adjustment of the front part
on model) of the seat
• Turn knob for appropiate weight.
11. Backrest angle
6. Mechanical swing (depending on model) • Could be adjusted forward of backwards
7. Ventilation • Pull handle for required position
8. Weight setting (depending on model)
• Push for harder suspension 12. ACS - Air Comfort System (depending on the
• Pull for softer suspension model)
a. Thight support
9. Heater b. Side support, seat
• Adjustable c. Side support, back
• Temperature between +27° to 42° C. d. Trippel lumbar support
More support, press “+”
10. Heightriser Less support, press “-”
EL62757,000004D –54–15SEP02–2/2
1110D and 1410D Armrest Controls
1—Steering
2—Boom control lever, left
3—Front differential lock,1
4—Rear differential lock
5—Working rpm
6—Frame brake release
7— Headboard up
8— Headboard down
9—Load space spreading
10—Load space narrowing –UN–17OCT02
18
1810
22
T160562
Left arm control panel
1
see section 5-2, Using differential locks

081403
PN=850
Cabin Environment
1—Driving direction switch

2—Boom control lever, right
3—High/Low gear
4—Boom functions on/off
5—For optional equipment use
6—Windscreen wiper
7—Blade up1
8—Blade down
9—Seat lock (used when the power in ON)
A, B, C , D, E = Multifunction buttons for TMC use
–UN–15OCT02
T152196
Right arm control panel
1
Operation of the decking blade, see section 11, Decking blade
EL62757,0000171 –19–19APR02–2/2
1710D Armrest Controls
1—Steering
2—Boom control lever, left
3—Front differential lock,1
4—Rear differential lock
5—Working rpm
6—Frame brake release
7— Headboard up/Clambunk closed,2
8— Headboard down / Clambunk open
–UN–12SEP02
18
1810
23
T152195
Left armrest control panel
1
see section 5-2, Using differential locks
2
see Section 11-5, Clambunk

081403
PN=851
Cabin Environment
1—Driving direction switch

2— Boom control lever, right
3—High/Low gear
4—Boom functions on/off
5—Seat
6—Windscreen wiper
7—Blade up1
8—Blade down
A, B, C , D, E = Multifunction buttons for TMC use
–UN–15OCT02
T152196
1
Operation of the decking blade, see section 11, Decking blade
EL62757,0000171 –19–19APR02–2/2
18
1810
24

081403
PN=852
Cabin Environment
Dashboard
1—Hazard lights
2—Horn
3—In reserve
4— Stairs
5—In reserve
6—Rear wheel drive; engagement (when high gear is
on)
7—Windscreen washer *
8—Windscreen wiper *
9—Left side window wiper *
10—Right side window wiper*
11—Rear window washer
12—Rear window wipe *
13—Emergency stop
14—Cigarette lighter (24 V)
15—Ignition switch
16—In reserve
17—Decking blade float1
18—Head lamp; high beam/low beam
19—Switch, headlights
20—Turn indicator lights
21—Ministick steering on/off; opt. eq
22—In reserve
23—Parking brake
18
1810
25
–UN–17OCT02
T152191
Front dashboard
1
See: Equipment, Decking blade
EL62757,000016D –19–19APR02–1/1

081403
PN=853
Cabin Environment
18
1810
26

081403
PN=854
Group 1820
Cabin Service
Other Material
Number Name Use

cab mount dampeners during Cab
Mount Replacement procedure.
N/A (U.S.) Loctite 270 Used to secure set screw locking

cab mount dampener during Cab
Mount Replacement procedure.
OUTJ003,00003E3 –19–02FEB01–1/1
Cabin Service
Seat Belt Replacement
The complete seat belt assembly should be replaced after

three years of usage, regardless of appearance.
Between replacement intervals, carefully examine the

buckle, webbing and attaching hardware. Be sure that the
retractor, if equipped, locks to prevent belt extension after
latching buckle. Be sure the attaching hardware is in place
and tighten, if necessary. Replace the seat belt if it does
not operate properly, or if it is damaged, worn or
deteriorated.
Replace entire seat belt assembly if any components

show signs of damage. Replace only with replacement
parts approved for your machine.
18
1820
1

081403
PN=855
Cabin Service
18
1820
2
–UN–04JUN03
T191694
1110D Windows

081403
PN=856
Cabin Service
Windows installation
The cab windows are an impact resistant plastic

material retained by frames and sealing tape. All of the
frames are fastened by the same type of screw.
JK11466,000004A –19–13DEC02–3/4
To Install the Windows:
1. Apply the sealing tape around both sides of the

window and to the cab window frame.
2. Position the window on the cab frame.
–UN–29AUG01
3. Put the retaining frame in place and install the screws.
T144735
Typical Window Installation
JK11466,000004A –19–13DEC02–4/4
1010D Lifting and Lowering the Cab
NOTE: Make sure that nobody is too close to the cab

when it is raised and lowered.
NOTE: Do not raise the cab unless the machine is parked

on level ground. The machine must not be moved,
but the engine can be run while the cab is up (this 18
is necessary for some checks and adjustments). 1820
3
1. Lift the engine hood.
Continued on next page EL62757,000021D –19–28NOV02–1/8

081403
PN=857
Cabin Service
2. Turn fastening pins (two) on the left hand side of the

cab to unlock position
–UN–13JUN01
T142837
EL62757,000021D –19–28NOV02–2/8
3. Turn the control valve up position with the handle, and

pump with the handle until the cab is raised to its
upmost posion
–UN–13JUN01
T142838
Handpump valve lift-position
18
1820
4

081403
PN=858
Cabin Service
CAUTION: The mechanical lock must always be

in place before working under the raised cab.
Always fully tilt the cab and ensure the
mechanical support is in the "LOCK" position
by dropping the rod into the lower tube. Secure
the rod in place using the wing screw.
Failure to observe this safety precaution can

lead to risk of personal injury or severe
machine damage.
4. Secure the safety support
–UN–13JUN01
T142839
EL62757,000021D –19–28NOV02–4/8
CAUTION: Before lowering the cab, clear the

travel path of any obstructions. Make sure all
personnel are standing clear of the cab.
Failure to observe this safety precaution can

lead to risk of personal injury or machine
–UN–13JUN01
damage.
1. Pump the handle to move the cab to the fully raised

position.
T142837
EL62757,000021D –19–28NOV02–5/8
Release the mechanical lock by releasing the wing screw 18

and sliding the rod up into the upper tube. Fold the 1820
5
support away.
–UN–13JUN01
T142840

081403
PN=859
Cabin Service
2. Turn the control valve on the pump to the DOWN

position.
3. Pump the handle to lower the cab.
NOTE: If pausing while lowering the cab, turn the control
–UN–13JUN01
valve to the UP position during the pause. This
will ensure that the cab will not come down even
if the cylinder check valve is open.
T142841
4. After lowering the cab, return the pump handle to the
stored potion.
Leave the control valve on the pump in the DOWN

position.
EL62757,000021D –19–28NOV02–7/8
5. Turn the fastening pins on the two left hand cab

mounts to the LOCKED position.
–UN–13JUN01
T142842
EL62757,000021D –19–28NOV02–8/8
18
1820
6

081403
PN=860
Cabin Service
How to Lifting and Lowering the the Cab
IMPORTANT: See to it that nobody comes too close

to the machine when you lift or lower
the cab.
To lift the cab do following
1. Remove the cab attaching bolts (1).

There is one bolt for each cab corner
2. Turn the up/down valve (2) clockwise until it stops in
the extreme position.
3. Pump up the cab by means of the lever (3) until it does
not rise anymore.
–UN–05MAR02
4. Secure the cab with the lock bar (4) before you start
working under the cab
IMPORTANT: Do not lift the cab if the machine is not
T152216
standing on level ground. Do not drive
the machine if the cab is in the upper
position. You can run the engine while Lifting the cab
the cab is up (if you are adjusting the
1—Attaching bolts
pressures, for instance). 2—Up/down valve
3—Pumping lever
To Lower the cab do following
18
1820
7

081403
PN=861
Cabin Service
–UN–05MAR02
T152217
Lowering the cab
4—Lock bar
1. Lower the lock bars (4) of the cab

2. Turn the up/down valve (2) counterclockwise
3. Pump the cab down by means of the lever
4. Fit the cab attaching bolts again.
Specification
Cab attaching bolts—Torque ................................ 100 Nm (73.7 lbt-ft)
EL62757,0000187 –19–21APR02–2/2
18
1820
8

081403
PN=862
Cabin Service
1010D Cab Tilt Cylinder Replacement
Cab Tilt Cylinder Removal
CAUTION: Use proper safety precautions when

tilting the cab in order to prevent situations
–UN–20JUL01
with risk of personal injury.
1. Tilt the cab. Secure the cab support.
T139149
Support the cab to prevent it from falling all the way
over. 1010D Cab tilting
2. Take the load off the cab lift cylinder by using the
pump to lower the cab onto the support.
OUTJ003,00003E1 –19–02FEB01–1/9

–UN–20JUL01
3. Tag and disconnect the hoses to the cylinder. Cap the
T139150
hoses and plug the ports.
Cap the hoses and plug the ports
OUTJ003,00003E1 –19–02FEB01–2/9
4. Disconnect the cylinder mounts by removing the cotter 18

pins, washers and swivel pins. 1820
9
Remove cylinder.
–UN–20JUL01
T139151
Continued on next page OUTJ003,00003E1 –19–02FEB01–3/9

081403
PN=863
Cabin Service
Cab Tilt Cylinder Installation

–UN–18JUN01

T139152
NOTE: Bleed air from cab tilt hydraulics before installing
the cylinder. 1010D Cab Tilt Pump, Cylinder, Hoses
1—RAISE Port
1. Retract the cylinder fully. Support the cylinder higher 2—LOWER Port
than the hand pump.
2. Loosely connect the hose to the RAISE port on the

cylinder. Leave the hose to the LOWER port
disconnected.
OUTJ003,00003E1 –19–02FEB01–4/9
3. Turn the pump control valve to the UP position.
–UN–18JUN01
T139153
1010D Cab Tilt Pump Control Valve, UP
18
1820
10

081403
PN=864
Cabin Service
4. Connect an external hydraulic power pump to the fill

port on the hand pump.
5. Supply oil slowly at low pressure until oil appears at

the RAISE port of the cylinder, indicating the air is bled
from the raise side of the system.
–UN–19JUN01
Tighten the hose connected to the RAISE port of the
cylinder.
T139154
6. Fully extend the cylinder, adding oil to the pump
reservoir, as needed.
1010D Cab Tilt Pump, Fill Port
OUTJ003,00003E1 –19–02FEB01–6/9
7. Loosely connect the hose to the LOWER port of the

cylinder.
8. Turn the pump control valve to the DOWN position.
9. Operate the pump handle until oil appears at the hose
–UN–19JUN01
fitting on the LOWER port, indicating that all air is bled
from the hose.
Tighten the hose fitting.
T139155
10. With the control valve in the DOWN position, operate
the hand pump until the cylinder starts to retract. 1010D Cab Tilt Cylinder, Lower Port; Cab Tilt Pump, DOWN
Then turn the pump control valve to UP and operate
the hand pump until the cylinder stops retracting.
Return the pump control valve to DOWN. Maintain

pressure in the external hydraulic power pump and
add four pumps with the hand pump lever.
11. Release the pressure from the external pump.

Disconnect the external pump from the hand pump.
18
1820
12. Use the hand pump to fully retract the cylinder, 11
topping up the reservoir as needed.

081403
PN=865
Cabin Service
13. Install the plug in the fill port of the hand pump.
14. Test the relief valve.
Operate the pump until the cylinder is fully retracted,

then continue to pump until the relief valve releases
–UN–19JUN01
the extra pressure.
Check all hoses and fittings for leaks.
T139156
1—Filler Port Plug
1010D Cab Tilt Pump, Filler Port Plug
OUTJ003,00003E1 –19–02FEB01–8/9
15. Install the cylinder. Install the pivot pins, washers and
cotter pins.
16. Unlock the support. Raise and lower the cab a few
times to remove any air from the hydraulic system.
–UN–20JUL01
17. Lower the cab and turn the cab mounts to the
LOCKED position
T139151
1010D Cab Tilt Cylinder, Attaching Hardware
OUTJ003,00003E1 –19–02FEB01–9/9
18
1820
12

081403
PN=866
Cabin Service
1010D Cab Mount Replacement
–UN–19JUN01
T139158
An Example of Cab Mounts Exploded View
1—Lock Screw 4—Frame Lug 7—Screw and Washer 10—Fastening Pin

2—Pin 5—Dampener 8—Lock Screw and Nut 11—Cover Plate
3—Set Screw 6—Cover Plate 9—Cab Frame 12—Screw and Washer
OUTJ003,00003DF –19–02FEB01–1/5

using any lifting equipment.
Failure to use proper procedures can lead to

risk of personal injury or equipment damage.
–UN–20JUL01
1. Attach a suitable lifting device to the cab. Remove all

18
four pins. Raise the cab just enough to clear the frame
1820
lugs. It is not required to disconnect hoses, wires or 13
the cab tilt cylinder.
T139159
IMPORTANT: Do not lift the cab so far that the hoses An example of Cab Mount Exploded View, Set Screw, Dampener
and wires are damaged.
2. Remove the set screws and remove the old dampener.
Continued on next page OUTJ003,00003DF –19–02FEB01–2/5

081403
PN=867
Cabin Service
3. Remove all grease and oil from the bore of the frame
lug using a clean wiper.
–UN–19JUN01
T139160
OUTJ003,00003DF –19–02FEB01–3/5
4. Install new dampeners in the frame lugs.Apply a

coating of NEVER-SEEZ to the inside bore of the
steel sleeve in the dampener.
5. Lower the cab into position.
–UN–20JUL01
6. Insert the pin. Install the locking screw.
T139159
NEVER-SEEZ is a trademark of Emhart Chemical Group OUTJ003,00003DF –19–02FEB01–4/5
7. The inside sleeve of the dampener is off-center. Level

the cab allowing the dampener to rotate inside the
frame lug.
8. Lock the dampener in place by installing the set screw.

Use LOCTITE 270 on the set screw. Do not tighten
–UN–20JUL01
the set screw to the point where it distorts the outer
steel sleeve.
T139161
LOCTITE is a trademark of Loctite Corp. OUTJ003,00003DF –19–02FEB01–5/5
18 1010D Cab Removal and installation

1820
14
parking brake. Lower the decking blade to the ground
and stow the boom. Block the wheels. Install the frame
locking bar to prevent accidental articulation of the
machine.
2. Tilt the cab.

081403
PN=868
Cabin Service
CAUTION: Ensure that the cab is properly

supported before working underneath it.
Failure to follow proper safety procedures can

lead to risk of personal injury or equipment
damage
–UN–24AUG01
3. Install the Cab Support Bar (Tool Number TA0949).
T145085
Cab Support Bar TA0949
OUTJ003,00003E0 –19–02FEB01–2/16
4. Disconnect the cab lift cylinder and the safety support

where they fasten to the cab. Use the pump to retract
the cylinder. Fold the support out of the way.
5. Disconnect the wiring harnesses to the cab.
–UN–21JUL01
NOTE: Note the location of any clamps or ties removed.
1—Cab Lift Cylinder

2—Safety Support
T140405
18
1820
15

081403
PN=869
Cabin Service


6. Disconnect the hose from the Brake Master Cylinder

(ATF tank) at the brake pedal valve. The Brake Master
Cylinder (ATF tank) is located on the exhaust support.
Cap the hose and plug the port.
7. Disconnect the hose from the Brake Valve at the brake

pedal valve. Cap the hose and plug the port.
–UN–18JUN01
T140407
OUTJ003,00003E0 –19–02FEB01–4/16
8. Remove the nuts to disconnect the throttle cables at

the fuel pump on the engine.
NOTE: Note the location of any clamps removed. They

must be replaced as originally installed.
–UN–20JUL01
Use tie wraps to secure the cables to the cab.
T138961
OUTJ003,00003E0 –19–02FEB01–5/16
18 9. Disconnect the drive pedal cable at the drive pedal

1820 valve.
16
Use tie wraps to secure the cable to the cab.

–UN–20JUL01
T138137

081403
PN=870
Cabin Service
CAUTION: Do not disconnect the Air

Conditioner System hoses from the AC
compressor. Accidental release of refrigerant
can cause personal injury. The Air Conditioning
System is to be handled by qualified
technicians only.
–UN–18JUN01
10. Dismount the AC Compressor from the engine.
T140410
Use tie wraps to secure the compressor and hoses to

the cab.
CAUTION: Allow the system to cool before

handling the cab heater hoses. Accidental
release of hot engine coolant cab cause serious
burns.
CAUTION: Disconnect only the heater hoses.

Do not disconnect the Air Conditioning System
refrigerant hoses. Accidental release of
refrigerant can cause personal injury.
11. Close the Heater Water Shutoff valve in the Air

Conditioning Unit by turning the Heater Control all the
way to the left.
Disconnect the cab heater hoses at the bulkhead

fitting on the lower front right corner of the cab.

lifting device when lifting the cab.

damage
12. Attach a suitable overhead lifting device to a sling

positioned through the cab roof.
18
Remove the cab support bar. 1820
17
Lower the cab to the normal operating position.

081403
PN=871
Cabin Service
13. Remove the screws retaining the cab mount pins on

the right side of the cab. Remove the cab mount pins.
NOTE: Use the overhead lifting device the relieve the

loading on the pins.
–UN–18JUN01
14. Lift the cab from the machine.
NOTE: Replace the cab mount rubber dampers, when the

cab is removed. See Cab Mount Replacement, in
T140413
this group, for the procedures.

lifting device when lifting the cab.

damage
1. Use a suitable overhead lifting device to position the

cab on the machine.
OUTJ003,00003E0 –19–02FEB01–8/16
2. Install the cab mount pins on the right side of the cab.
Install the locking screws (M8 x 16) and tighten to the
specified torque..
–UN–18JUN01
T140413
18
1820
18

081403
PN=872
Cabin Service
CAUTION: Ensure that the cab is properly

supported before working underneath it.

damage
–UN–24AUG01
3. Use the overhead lifting device to tilt the cab to the
service position. Install the Cab Support Bar (Tool
Number TA0949).
T145085
Cab Support Bar TA0949
OUTJ003,00003E0 –19–02FEB01–10/16
4. Use the cab tilt pump to extend the cab tilt cylinder.
Install the pin, washers and cotter pins retaining the
cylinder rod to the cab.
5. Install the cab safety support. Install the pin and cotter
pin retaining the top of the support to the cab.
–UN–20JUL01
Lock the safety support in position by dropping the rod
inside the support tube and tightening the wing screw.
T139151
18
1820
19

081403
PN=873
Cabin Service
6. Connect the cab heater hoses at the bulkhead fitting

on the lower front right corner of the cab.
–UN–18JUN01
T140411
OUTJ003,00003E0 –19–02FEB01–12/16
CAUTION: Do not disconnect the Air

Conditioner System hoses from the AC
compressor. Accidental release of refrigerant
can cause personal injury. The Air Conditioning
System is to be handled by qualified
technicians only.
–UN–18JUN01
7. Install the AC Compressor on the engine.
NOTE: Any hose clamps removed must be replaced as T140410

18
1820
20

081403
PN=874
Cabin Service
8. Connect the drive pedal cable at the drive pedal valve.
–UN–20JUL01
T138137
OUTJ003,00003E0 –19–02FEB01–14/16
9. Install the nuts to connect the throttle cables at the fuel

pump on the engine.

–UN–20JUL01
T138961
18
1820
21

081403
PN=875
Cabin Service


10. Connect the hose from the Brake Valve to the brake
pedal valve.
11. Connect the wiring harnesses to the cab.
NOTE: Any clamps or ties removed must be replaced as

12. Remove the cab support bar and lower the cab to the
–UN–18JUN01
operating position.
13. Check the throttle cable adjustment. Idle the engine

and check the operation of the manual throttle and
T140407
the drive pedals.
14. Check the Drive Pedal Valve cable adjustment. See

TM1952, 1158 Operation and Test Manual, for
procedures to adjust the Hydrostatic Pilot Pressure.
15. Check the level in the Brake Master Cylinder (ATF

tank).
If necessary, bleed the brake pedal system. See

Section 10, Group 1060, for the procedures.
16. Check the operation of the cab heater and air

conditioner.
18
1820
22
OUTJ003,00003E0 –19–02FEB01–16/16

081403
PN=876
Section 19
Heating and Air Conditioning System
Contents
Page
Group 1910—General
Theory of operation . . . . . . . . . . . . . . . . . . . .19-1910-1
AC/Heater Controls . . . . . . . . . . . . . . . . . . . .19-1910-5
Proper Refrigerant Handling . . . . . . . . . . . . .19-1910-7
Risks and Counter-Measures . . . . . . . . . . . .19-1910-8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1910-9
Group 1920—Air Conditioning / Heater

Components
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .19-1920-1
AC Compressor. . . . . . . . . . . . . . . . . . . . . . .19-1920-3
AC Condenser . . . . . . . . . . . . . . . . . . . . . . .19-1920-3
AC Filter-dryer-receiver . . . . . . . . . . . . . . . .19-1920-4
AC Expansion Valve . . . . . . . . . . . . . . . . . . .19-1920-4
AC Evaporator . . . . . . . . . . . . . . . . . . . . . . .19-1920-5
Group 1930—Diagnosing Air Conditioning / Heater

System
AC Operational Checks. . . . . . . . . . . . . . . . .19-1930-1
Air Conditioning System . . . . . . . . . . . . . . . .19-1930-1
Cab Heater System. . . . . . . . . . . . . . . . . . . .19-1930-6
AC Checkout Record Sheet . . . . . . . . . . . . .19-1930-7
Diagnose Heater/Air Conditioner . . . . . . . . . .19-1930-8
Refrigerant Hoses and Tubing
Inspection . . . . . . . . . . . . . . . . . . . . . . . .19-1930-10
Refrigerant Level Check . . . . . . . . . . . . . . .19-1930-10
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .19-1930-12
19

081403
PN=1
Contents
19

081403
PN=2
Group 1910
General
Theory of operation
The specifications of this air conditioning system are the

following:
1. Control panel
2. Air conditioning unit
3. Condenser
4. Water valve
5. Dryer incl. sight glass
6. Compressor
7. Fresh air filter
8. Recirculation filter
9. Coarse filter
The heater system consists mainly of the heater element

inside the cab and water valve which is infinitely regulated
by control (A).
The cooling system is built up of the cooler element

(evaporator) inside the cab, compressor and condenser
adjacent to the engine fan. The cooler is switched on / off
with the switch (C).
The thermostat of the evaporator controls the

electromagnetic clutch of the compressor, making sure
that water accumulated in the evaporator will not freeze.
The fan inside the cab is used both for the heater and the
cooler. Fan speed is regulated with the control (B).
The fresh air damper regulates the amount of fresh air

entering the cab. Setting is made with control (D).
The input air is filtered through a coarse and a fine filter.

Recirculated air passes through a separate filter.

19
1910
1

081403
PN=879
General
–UN–06JUN01
T139468
Air Conditioning System

19
1910 1—AC Compressor 3—AC Receiver/dryer 5—AC Evaporator 7—Heater Coil (See next page)
2 2—AC Condenser 4—AC Expansion Valve 6—Blower

081403
PN=880
General
The Heater and Air Conditioner Unit located in the cab, When the heater is operated, hot engine coolant
houses the heater coil, Air Conditioner cooling passes through the heater coil. Air flowing over the coil
evaporator coil, and a three speed blower motor. is heated and blown into the cab.
When the blower motor is on, fresh air is drawn Engine coolant is circulated from the engine to the
through the cab air filter. The air flow passes through heater coil and back to the engine using the pressure
the heater coil and cooler evaporator coil and out the differential in the water jacket. When the heater is not
vents in the top of the heater A/C unit. Normally only in use, the shut-off valve at the back of the engine
one of the coils will be operating at a given time. should be turned off.
JK11466,0000044 –19–12DEC02–3/5
When the air conditioner is operated, cool refrigerant

passes through the evaporator coil. Air flowing over the
coil is cooled and blown into the cab.
Refrigerant is circulated from the compressor to the

condenser on the back of the cab, then to the evaporator
coil in the A/C unit in the cab.
–UN–06JUN01
T139467
19
1910
3

081403
PN=881
General
The refrigerant moves around the air conditioner circuit

cooling the evaporator coil and carrying the heat to the
condenser.
The refrigerant picks up heat when it goes through a

change of state from a liquid to a gas at the evaporator. It
will later give up this heat when it changes from a gas to
a liquid at the condenser.
In operation:
1. The compressor takes used refrigerant from the

evaporator as a cool, low pressure gas and sends it to
the condenser as a hot, high pressure gas. The
temperature rises as the heat is concentrated in the
compressed gas.
–UN–06JUN01
2. In the condenser the hot, high pressure gas is cooled
by air passing over the coil. It remains at high pressure
but condenses to a liquid as it cools.
3. The liquid refrigerant is stored at the receiver/dryer
T139473
under high pressure. The receiver/dryer filters out
impurities and removes any water vapor.
4. The high pressure liquid refrigerant is sent to the AC System Diagram
expansion valve mounted on the inlet pipe of the
1—Compressor
evaporator. The valve sends it to the evaporator as a 2—Condenser
low pressure, atomized liquid. 3—Receiver Dryer
5. The sudden change of pressure causes the refrigerant 4—Expansion Valve
to change state from a liquid to a gas taking heat from 5—Evaporator
the air passing over the coil. The cooled air is blown
into the cab. The used refrigerant is cycled to the
compressor.
JK11466,0000044 –19–12DEC02–5/5
19
1910
4

081403
PN=882
General
AC/Heater Controls
The AC/Heater Controls are located on the control panel

on the AC/Heater Unit.
1—Blower Speed Switch
–UN–28JUN02
2—Temperature control valve
3—Cooling system control (turned off when the
switch is counterclockwise in its extreme position)
4—Inside air recirculation / outside air brought in;
T156801
selector switch (For the outside air, turn the
switch clockwise to its extreme position)
AC controls
OUTJ003,00005D9 –19–10MAY01–1/6
Control Settings
–UN–04JUL02
A) In the summer, when the weather is warm and the humidity is
normal:
1. Open the outside air circulation (4).
T157104
2. Disengage heating and select the temperature you
wish through the cooling system (3).
3. Direct the air flow to the vents you wish.
OUTJ003,00005D9 –19–10MAY01–2/6
B) In the summer, when the weather is hot and the humidity is

high:
–UN–04JUL02
1. Open the inside air recirculation (4).
2. Disengage heating and select the temperature you
wish through the cooling system (3).
T157105
3. Turn the fan switch to the maximum speed.
Continued on next page OUTJ003,00005D9 –19–10MAY01–3/6

19
1910
5

081403
PN=883
General
IMPORTANT: The inside air recirculation of the

cooling system must not be obstructed.
Make sure that the protective mesh is
–UN–04JUL02
not clogged.
C) In the autumn or early winter, when the weather is damp, there

is rain or wet snow or the windshield is fogging:
T157106
1. Turn the fan switch to the maximum speed, switch on
the cooling system and adjust the heating as
necessary.
2. Open the inside air recirculation (4).
3. Direct the air to the window vents.
4. When the air inside the cab has dried up, close the
inside air recirculation or adjust it to a lower level,
switch off the cooling system and select the
temperature you wish.
OUTJ003,00005D9 –19–10MAY01–4/6
D) In the winter, when the weather is moderately cold:
–UN–04JUL02
2. Select the temperature you wish (2).
T157107
Continued on next page OUTJ003,00005D9 –19–10MAY01–5/6
19
1910
6

081403
PN=884
General
E) In the winter, when the weather is extremely cold and the

humidity low:
–UN–04JUL02
2. Select the temperature you wish (2).
F) In the winter, when the weather is cold and dry; when the
T157108
cooling system has been little used or not used at all:
Operate the cooling system for a few minutes every week.

This is enough to ensure that the drive shaft seal of the
compressor, other packings, joints, and rubber hoses are
lubricated.
IMPORTANT: Operate the cooling system in the

winter after the machine has reached
the normal operating temperature. Do
not operate the cooling system all the
time if the outside temperature is below
0oC.
Maintenance of the Air Conditioner - see chapter 11.
OUTJ003,00005D9 –19–10MAY01–6/6
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits components or refrigerant oils

discharge of any refrigerant into the atmosphere, and intended for use with R12
requires that refrigerant be recovered using the refrigerant.
approved recovery equipment.
Recovery, recycling and charging stations for R12 and
IMPORTANT: To meet government standards R134a refrigerants MUST NOT be interchanged.
relating to the use of refrigerants, Certain seals are not compatible with refrigerant oil
R134a is used in the air conditioning used in R134a systems. Therefore, eliminate mixing
system. Refrigerant R134a is not R134a equipment, refrigerant, and refrigerant oils with
detrimental to the ozone in the R12 systems to prevent compressor damage. Never
atmosphere because it does not use R134a in a system that previously contained R12
contain chlorine. However, it is without following the specifications outlined in
illegal to discharge any refrigerant Technical Manual DSTY 21689.
into the atmosphere. It must be
recovered using the appropriate Using the correct refrigerant oil is also important. R12
recovery stations. systems use a mineral oil and R134a systems require
a polykylenglycol (PAG) oil (a synthetic oil). The two
IMPORTANT: Use correct refrigerant recovery, oils are not compatible and MUST NOT be
recycling and charging stations. DO interchanged. 19
1910
NOT use refrigerant, hoses, fittings,
7
OUTJ003,000049A –19–13FEB01–1/1

081403
PN=885
General
Risks and Counter-Measures
CAUTION: The air conditioning system contains

refrigerant that is under pressure.
Do not disconnect the hoses of the system.
Refrigerant released into the air may be

harmful. Charging the air conditioning system
with a refrigerant of the wrong type will result in
serious damage to the system.
CAUTION: Risk of personal injury!
• Liquid that has been released from the

system has a very low temperature, and it
quickly becomes gasified.
• Warming up the filter-dryer-receiver will result
in the build-up of the gas pressure and may
cause a risk of explosion.
• The gas is colorless and heavier than air, and
it spreads on the ground.
• The gas begins to choke without any
premonitory symptoms.
• Splashing refrigerant causes frostbite and
serious damage to eyes. When working on
the air conditioning system, always wear
good, tight-fitting safety glasses because
refrigerant under pressure may start leaking
abruptly. In addition, cover your hands as
well as all other bare spots of skin.
• When refrigerant burns, it disintegrates into
noxious gases.
CAUTION: Danger of Fire and Explosion!
Do not warm up the filter-dryer-receiver beyond

50 degrees centigrade (122°F), because the high
pressure of the liquid may cause an explosion.
What to Do If Fire Breaks Out ?
Cool down the filter-dryer-receiver with a jet of water.
Leak and Clean-Up
19
1910
8
Continued on next page EL62757,00001DA –19–22APR02–1/2

081403
PN=886
General
When arranging the refrigerant evacuation equipment,

make sure that no dangerous discharges of refrigerant
pass into the work area with people.
EL62757,00001DA –19–22APR02–2/2
First Aid
Accident First aid
Gas is inhaled Go out to breathe fresh air
Skin contact Frostbitten parts of body are
rinsed with lukewarm water
Splashes into eyes Continuous rinsing with a
two-percent saline solution for 20
minutes
In gestion of refrigerant Seek medical advice
EL62757,00001DB –19–22APR02–1/1
19
1910
9

081403
PN=887
General
19
1910
10

081403
PN=888
Group 1920
Air Conditioning / Heater Components
Introduction
IMPORTANT: The air conditioner must be serviced

and repaired by authorized personnel.
Specifications:
Type and Amount of Refrigerant and the Maximum

Pressure Allowed
CAUTION: The air conditioning system has

been charged with R-134a refrigerant. Do not
use any other type of refrigerant!
The specifications of this air conditioning system are the

following:
Refrigerant
Refrigerant Charging volume High pressure
R134a 1,5 kg 8-15 bar
5,5 lbs 116-217 psi
If the air conditioning system has been modified to use

another type of refrigerant, write the new specifications
here:
Refrigerant
Refrigerant Charging volume High pressure
R____ ____ kg ______bar
____ lbs _____ bar
Date of modification: _______________________
Continued on next page EL62757,00001D8 –19–22APR02–1/2
19
1920
1

081403
PN=889
–UN–04JUN03
T191690
19
1920 1110D Air conditioning components
2
1—Control panel 4—Pressure switch 7—Compressor 9—Radiator
2—Evaporator 5—Spool valve 8—O-ring 10—O-ring
3—Receiver-Dryer 6—Radiator
EL62757,00001D8 –19–22APR02–2/2

081403
PN=890
AC Compressor
A six cylinder, swash plate type compressor is used in the

air conditioning system. The compressor is the pump of
the system, circulating and increasing the refrigerant
pressure. An electromagnetic clutch is fitted on the
–UN–06MAR02
compressor and is used to disengage the compressor
when cooling is not required.
Service valves are attached to the suction and pressure
T152366
ports on the compressor.
The compressor is located on the right side of the engine. Compressor
JK11466,0000004 –19–31DEC02–1/1
AC Condenser
Upon entering the condenser, the gas is hot and under a

high pressure. The gas is cooled down by cool air flowing
through the condenser coils and, consequently, the gas is
liquefied under a high pressure. Next, the liquefied
–UN–06MAR02
refrigerant flows into the filter-dryer-receiver.
The condenser is mounted in front of the radiator.
T152367
JK11466,0000004 –19–31DEC02–1/1
19
1920
3

081403
PN=891
AC Filter-dryer-receiver
1. Sightglass
2. Moisture indicator (by color)
3. Service valve
4. Filter insert
5. Pressure switch
The purpose of the filter-dryer-receiver is to receive the

refrigerant coming from the condenser, and to filter out
humidity and impurities in a built-in drier. On top of the
filter-dryer-receiver there is a sightglass (1) which makes it
possible to check whether there is enough of the
refrigerant in the tank. Through the sightglass of the
–UN–06MAR02
moisture indicator (2) you can see weather the
filter-dryer-receiver is serviceable.
The receiver/dryer is mounted on a bracket on the back of
T152368
the radiator.
JK11466,0000004 –19–31DEC02–1/1
AC Expansion Valve
The expansion valve controls the amount of refrigerant

allowed to enter the evaporator coil. The expansion valve
is mounted on the inlet pipe of the evaporator. Upon
entering the expansion valve, the refrigerant is under a
–UN–06MAR02
high pressure and it is injected through a nozzle into the
evaporator where the pressure drops sharply.
The valve admits fresh refrigerant to the evaporator as

warm refrigerant is discharged from the evaporator. T152369
Warm refrigerant leaving the evaporator heats the sensing Expansion valve
bulb. Gas in the sensing bulb expands, exerting pressure
1—From the condenser
on the diaphragm. The operating pin pushes the ball away 2—Into the evaporator
from the seat, allowing fresh refrigerant to enter the 3—Into the pipe located next after evaporator
evaporator.
19
1920
4
JK11466,0000004 –19–31DEC02–1/1

081403
PN=892
AC Evaporator
The evaporator cools down and dries the air before the air
is forced into the cab. A fan draws in warm air through the
evaporator, forcing the air through the lamellas and ducts
of the evaporator. The refrigerant receives the thermal
–UN–06MAR02
energy contained in the air that cools down while passing
through the evaporator. After this, the cooled-down air is
forced into the cab.
T152370
The evaporator coil is located below the blower in the
Heater/Air Conditioner Unit in the cab. It consists of a
series of thin cooling fins. Evaporator
NOTE: During the operation of the air conditioner the

evaporator also dehumidifies the air. Moisture in
the air is condensed at the evaporator where it
drips down to a drain pan and drains out of the
cab through a drain hose.
JK11466,0000004 –19–31DEC02–1/1
19
1920
5

081403
PN=893
19
1920
6

081403
PN=894
Group 1930
Diagnosing Air Conditioning / Heater System
AC Operational Checks
This procedure is designed so the mechanic can make T.M. Group or CTM number required for repair will be
a quick check of the system using a minimum amount given. If verification is needed, you will be given next
of diagnostic equipment. If you need additional best source of information:
information, read Theory of Operation (Group
9031-05). Group: 10 (System Operational Checks)
The engine or other major components must be at Group: 15 (Diagnostic Information)

Group: 20 (Adjustments)
Locate system check in the left column and read
completely, following this sequence from left to right. Group: 25 (Tests)
Read each check completely before performing.
CTM (Component Technical Manual)
At the end of each check, if no problem is found, that
check is complete. When a problem is indicated, NOTE: Diagnose AC/Heater System electrical
additional checks or repair information will be given. components.
OUTJ003,0000497 –19–13FEB01–1/1
1 Air Conditioning System
– – –1/1
Hoses and Fittings Engine OFF. OK: Check complete.
Inspect all hoses and fittings. NOT OK: Reposition

hoses as required.
LOOK: Hoses should be not be twisted, kinked or show indications of wear. Hoses and Tighten or replace
fittings should be clean. Hoses and fittings should not show signs of leakage, such as clamps. Tighten fittings or
oil or dust accumulation at fittings. replace O-rings in fittings.
Replace hoses required.
Inspect hose clamps.
LOOK: Clamps must be in place and tight. Clamps must have rubber inserts or
cushions in place to prevent clamps from crushing or wearing into hoses.
– – –1/1
19
1930
1

081403
PN=895
AC Compressor Check Engine OFF. OK: Check complete.
Inspect the compressor. NOT OK: Repair or

replace components as
LOOK: The compressor pulley should be in good condition. required.
Compressor mounting cap screws should be tight.
Inspect the compressor clutch.
LOOK: Electrical connections to compressor clutch should be clean and tight. Wiring to
compressor should be in good condition.
There should be a slight clearance between the plate pulley and the plate. The clutch
plate and sprocket should be clean.
– – –1/1
AC Compressor Belt Inspect compressor belt. OK: Check complete.

Check
LOOK/FEEL: The belt should be free of oil and grease. The belt should be in good NOT OK: Replace belt if
condition, NOT frayed, worn or glazed. oily, greasy, cracked or
otherwise damaged.
Inspect the pulley.
Repair or replace
LOOK: The belt should be aligned with pulleys. The compressor belt pulley should be tensioner if belt is loose.
in good condition, NOT worn or grooved.
Check the belt tensioner.
LOOK: The belt should be tight.
NOTE: With moderate thumb pressure the belt should deflect approximately 15 mm
(1/2") between the pulleys.
– – –1/1
19
1930
2

081403
PN=896
AC Condenser Check Engine OFF. OK: Check complete.
Inspect condenser cores. NOT OK: Clean, repair or

replace condenser core.
LOOK: The condenser core should be free of dirt or debris. Replace engine fan, if
required.
The condenser should not show signs of leakage, dust accumulation or oily areas.
The condenser fins should be straight, not bent or damaged.
Inspect engine fan.
LOOK: The fan blades in good condition, not worn, bent, broken or missing.
NOTE: The condenser element must be cleaned regularly by blowing lightly with
compressed air. Blow through the condenser in the direction opposite to the normal
flow of air.
IMPORTANT: To avoid equipment damage, do not use high air pressures to

clean the condenser.
– – –1/1
AC Receiver Dryer Check OK: A blue color is

normal.
NOT OK: If the indicator

is a pink or grey color,
the receiver dryer must
be replaced.
T139488 –UN–06JUN01
1—Moisture Indicator
Check the moisture indicator on the receiver dryer.
LOOK: The moisture indicator should be a blue color.
NOTE: The dryer must be replaced every two years or whenever the hoses are
replaced.
– – –1/1
19
1930
3

081403
PN=897
AC Evaporator Check Engine OFF. OK: Check complete.
Inspect core. NOT OK: Repair, replace

or clean evaporator. Clear
LOOK: The evaporator core should be free of dirt and debris. drainage holes.
The Evaporator core fins should be straight.
NOTE: The drainage outlets in the pan under the evaporator should be clear of
obstruction.
– – –1/1
Outside Air Intake Filter OK: Check complete.

Check
NOT OK: Clean or
replace filter, as required.
T159298 –UN–11SEP02
19
Remove or open the covers to check the condition of the filter.
1930
4
LOOK: The filter should be clean and in good condition.
NOTE: In dusty conditions it may be necessary to check the filter daily, or at least as
often as the engine air filter.
– – –1/1

081403
PN=898
Inside Air Intake Filter OK: Check complete.

Check
NOT OK: Clean or
T139490 –UN–06JUN01
NOTE: In dusty conditions it may be necessary to check the filter daily, or at least as
often as the engine air filter.
– – –1/1
Exhaust Air Filter Check OK: Check complete.
NOT OK: Clean or

T139491 –UN–06JUN01
NOTE: The exhaust filter can be checked about half as often as the intake filters.
– – –1/1
Cab Door and Window Open and close door and windows. OK: Check complete.
Seals Check
LOOK: Doors and windows should contact seals evenly. NOT OK: Adjust door and
windows to close against
Inspect seals. seals properly. Replace
seals as necessary.
LOOK: Seals should be in position and in good condition.
19
1930
5
– – –1/1

081403
PN=899
Cab Air Recirculation Remove panel on right side of cab. OK: Go on to next check.
Baffle
Observe baffle while operating Cab Air Recirculate switch. NOT OK: Repair baffle as
required.
LOOK: Baffle should move to block outside air duct.
– – –1/1
2 Cab Heater System
– – –1/1
Heater Hoses and Engine OFF. OK: Check complete.

Fittings
Inspect all hoses and fittings. NOT OK: Reposition
hoses as required.
LOOK: Hoses should be not be twisted, kinked or show indications of wear. Hoses and Tighten or replace
fittings should be clean. Hoses and fittings should not show signs of leakage, such as clamps. Tighten fittings or
oil or dust accumulation at fittings. replace O-rings in fittings.
Replace hoses required.
Inspect hose clamps.
LOOK: Clamps must be in place and tight. Clamps must have rubber inserts or
cushions in place to prevent clamps from crushing or wearing into hoses.
– – –1/1
Heater Water Shutoff Open cab Instrument Box panel to access Shutoff valve. OK: Check complete.
Valve
Check Shutoff Valve operation. NOT OK: Repair or
replace Shutoff Valve as
LOOK/FEEL: Valve should operate smoothly. Water flow to heater core should be cut required.
off completely.
– – –1/1
19
1930
6

081403
PN=900
AC Checkout Record Sheet
OWNER DATE
HOURS
PIN
TECHNICIAN

OK NOT OK COMMENTS
1. Air Conditioning System Checks
Compressor ❒ ❒
Compressor Belt ❒ ❒
Condenser ❒ ❒
Receiver/Dryer ❒ ❒
Evaporator ❒ ❒
Outside Air Intake Filter ❒ ❒
Inside Air Intake Filter ❒ ❒
Exhaust Air Filter ❒ ❒
Cab Door and Window Seals ❒ ❒
Cab Air Recirculation Baffle ❒ ❒
Cab Heater System
Heater Hoses and Fittings ❒ ❒
Heater Water Shutoff Valve ❒ ❒
OUTJ003,0000596 –19–16APR01–1/1
19
1930
7

081403
PN=901
Diagnose Heater/Air Conditioner
NOTE: Diagnostic charts are arranged from most

probable and simplest to verify, to least likely
more difficult to verify. Remember the following
steps when diagnosing a problem:
• Step 1. Operational Check Out Procedure

• Step 2. Diagnostic Charts
• Step 3. Adjustments and/or Tests
No heat Thermostatic switch off Increase switch setting.
No coolant flow to heater coil Open flow control valve. Locate

obstruction in valves, hoses or
heater coil.
Low heat Restricted air filter in cab Clean or replace filter.
Dirt in heater core Clean heater core.
Blower not running Check Air Conditioner fuse F16 on

PC board in instrument box.
Blower not running at higher speed Increase blower speed to second or

third level or replace switch.
Too much incoming cold air Turn Cab Air Recirculate Switch to
recirculating inside air.
Low engine coolant temperature Check engine temperature gauge.

Wait for temperature to increase
when cold. Change engine cooling
system thermostat.
Window fogs up Lack of outside air Clean or replace intake air filter.
Turn Cab Air Recirculate Switch to
intake outside air
Air humidity too high for reduction by Activate air conditioning unit when
heat only heat is on.
19
1930
8

081403
PN=902
No Cooling Compressor not engaged Check that drive belt is in place and
properly tensioned. Check that
compressor clutch is engaged Check
Air Conditioner fuse F16 on the
PC-board in the instrument box.
Low refrigerant With compressor running, look for air

bubbles in sight glass on the
receiver/dryer. If bubbles are seen,
contact an authorized service
person.
Insufficient cooling Restricted air filter in cab Clean or replace filter.
Heater unit on Switch heater off.
A/C temperature switch set too high Turn switch down.
Blower not running at high speed Increase blower speed to second or

third level.
Restricted air flow through A/C Clean cores of dust or debris with
evaporator or condenser low pressure (30 psi) compressed air
or water.
Compressor drive belt slipping Check condition and tension of belt.

Replace or retention.
Low refrigerant charge Look for air bubbles in sight glass

after compressor has run for five
minutes. (Sight glass is on
receiver/dryer located on back of
radiator)
Too much moisture in refrigerant If moisture level indicator on

receiver/dryer shows pink, have air
conditioner serviced within 100 hours
by an authorized service person. If
indicator is blue, the unit is dry.
OUTJ003,0000498 –19–13FEB01–2/2
19
1930
9

081403
PN=903
Refrigerant Hoses and Tubing Inspection
When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
special care should be given to inspecting hoses and viscosity oil before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51B
To assist in making leak-proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all
OUTJ003,000057F –19–22MAR01–1/1
Refrigerant Level Check
1. Run the engine at 1500 RPM.
Refrigerant Level Check—Specification

Engine—Speed ......................................................................... 1500 RPM
–UN–06JUN01
2. Switch on the air conditioner. Set the fan speed and
thermostat to maximum.
T139550
3. Inspect the sight glass on the receiver dryer. The
Receiver/dryer is located on a bracket on the back of
the radiator.
1—Sight Glass
Continued on next page OUTJ003,000049D –19–13FEB01–1/5
19
1930
10

081403
PN=904
a. Insufficient refrigerant level:
–UN–15JUN01
• Continuous flow of bubbles or flow that appears
foamy.
• Little temperature difference between low
T139551
pressure and high pressure sides.
• Pressure on high pressure side is unusually low.
Stop the compressor immediately and contact

authorized personnel to check the system and add
refrigerant.
IMPORTANT: Operating the system with insufficient

refrigerant will result in damage to the
compressor.
OUTJ003,000049D –19–13FEB01–2/5
b. Insufficient refrigerant level:
–UN–15JUN01
• A few bubbles are seen at intervals of a few
seconds.
• High pressure side is warm. Low pressure side is
T139552
cool.
Check for leaks. Repair if necessary.
Contact authorized personnel to check the system

and add refrigerant.
IMPORTANT: Operating the system with insufficient

refrigerant will result in damage to the
compressor.
OUTJ003,000049D –19–13FEB01–3/5
c. Correct refrigerant level:

–UN–15JUN01
• The refrigerant is clear and only a few bubbles

pass by when the engine speed is changed.
• Pressure is normal.
• High pressure side is hot. Low pressure side is
T139553
19
cold. 1930
11
Continued on next page OUTJ003,000049D –19–13FEB01–4/5

081403
PN=905
d. Excessive refrigerant level.
–UN–15JUN01
• No bubbles at all.
• Pressure on both sides is unusually high.
• High pressure side is very hot.
T139554
Contact authorized personnel to check the system
and bleed off some refrigerant.
4. Inspect all hoses and connections for leaks.
NOTE: The refrigerant R134a may appear slightly cloudy

during operation even if the system has been
correctly charged. If in doubt, contact qualified
personnel.
OUTJ003,000049D –19–13FEB01–5/5
Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the
components in the system to form bubbles at the
source of the leak.
OUTJ003,0000580 –19–22MAR01–1/1
19
1930
12

081403
PN=906
Section 37
Booms 37
Contents
Page
Group 3710—Forwarder Booms

Theory of Operation . . . . . . . . . . . . . . . . . . 37 -3710-1
Boom Slew System . . . . . . . . . . . . . . . . . . . 37 -3710-4
Group 3720—Boom Parts Removal and Installation

Other Material . . . . . . . . . . . . . . . . . . . . . . . 37 -3720-1
Essential Tools . . . . . . . . . . . . . . . . . . . . . . 37 -3720-2
Assembly Instructions . . . . . . . . . . . . . . . . . 37 -3720-3
Main Boom Cylinder . . . . . . . . . . . . . . . . . . 37 -3720-3
Slewing Cylinders Installation . . . . . . . . . . . 37 -3720-7
Boom Slew Cylinders Service . . . . . . . . . . . 37 -3720-9
1010D Outer Cylinder . . . . . . . . . . . . . . . . 37 -3720-12
CF572 Extension Cylinder. . . . . . . . . . . . . 37 -3720-16
Group 3730—Booms Removal and installation

Outer Boom Removal . . . . . . . . . . . . . . . . . 37 -3730-1
Outer Boom Installation. . . . . . . . . . . . . . . . 37 -3730-2
Main Boom Removal . . . . . . . . . . . . . . . . . . 37 -3730-5
Main Boom Installation . . . . . . . . . . . . . . . . 37 -3730-7
Tower Removal . . . . . . . . . . . . . . . . . . . . . . 37 -3730-9
Tower Installation . . . . . . . . . . . . . . . . . . . 37 -3730-10
Tower Service . . . . . . . . . . . . . . . . . . . . . . 37 -3730-12

Boom Operational Checkout Record
Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 -3740-1
Diagnose Boom. . . . . . . . . . . . . . . . . . . . . . 37 -3740-3
Group 3750—Boom overall maintenance

See Operator‘s Manual F063390 for Detailed
Service instructions . . . . . . . . . . . . . . . . . 37 -3750-1
tm2123 (14AUG03) 37 -1 Forwarders Technical Manual

081403
PN=1
Contents
37
tm2123 (14AUG03) 37 -2 Forwarders Technical Manual

081403
PN=2
Group 3710
Forwarder Booms
Theory of Operation
37
3710
1
–UN–15NOV02
T152542
Forwarders Boom
1—Base 5—Extension boom 8—Outer boom cylinder 11—Rotator

2—Tower 6—Slewing cylinder 9—Extension boom cylinder 12—Grapple
3—Main boom 7—Main boom cylinder 10—Link 13—Grapple cylinder
4—Outer boom
The forwarder is equipped with a hydraulic boom boom The boom is controlled using joysticks on the armrests
with grapple which is used to load cut timber into the of the seat. The left joystick controls jib boom Up /
log bunk. Down, slew rotation and extension boom extend
retract. The right joystick controls main boom Up /
The boom has five cylinders which may require Down, grapple rotation. The Seat Direction Switch on
periodic maintenance or repair. The slew rotation the seat pedestal enables the boom controls only
cylinders at the base of the tower rotate the entire when the seat is facing the rear.
boom up to 190° from center in either direction (380°
total slewing angle). The main boom cylinder, mounted When the boom’s main boom is raised, the frame
on the tower, raises and lowers the boom and jib brake is automatically engaged. The frame brake
sections together. The jib cylinder, mounted on the provides stability by locking the front and rear frame
main boom, raises and lowers the jib section of the together, preventing them from tilting independently.
boom. The extension cylinder, mounted inside the jib The frame brake can be disengaged by a switch on
extends and retracts the extension boom. The grapple the dashboard.
cylinder, mounted on the grapple, opens and closes
the grapple.
tm2123 (14AUG03) 37 -3710-1 Forwarders Technical Manual

081403
PN=909
Forwarder Booms
The boom’s serial number will be found on a plate on

the tower above the slew mechanism.
37
3710
2

081403
PN=910
Forwarder Booms
37
3710
3
–UN–21JUN01
T139453
–UN–21JUN01
T139454
1—Extension Boom Cylinder 2—First Extension Boom 3—Second Extension Boom
In addition to the booms and cylinders previously mounted on top of the jib boom. The second extension
described, the CF585 and CF510 booms have a boom is extended by a slider and chain arrangement
second extension boom. The extension cylinder is inside the first extension boom.
EL62757,00001C4 –19–22APR02–3/3

081403
PN=911
Forwarder Booms
Boom Slew System

37
3710
4
–UN–21JUN01
T139455
The boom is rotated by an arrangement of two barrel at each end. A valve mounted on the pedestal
double-ended hydraulic cylinders built into the directs hydraulic flow to the both sides of the tower,
pedestal. The rotation cylinders at the base of the moving the racks in opposite directions, rotating the
tower rotate the entire boom up to 190° from center in tower. The valve relief cartridges are set at 23 MPa
either direction (380° total slewing angle). (3120 psi).
A gear at the bottom of the tower engages two rack The cylinders are serviced on the machine.
bars. Each rack bar has a hydraulic piston in a cylinder

081403
PN=912
Forwarder Booms
37
3710
5
–UN–21JUN01
T139456
Boom Slew Relief Valve
1—Valve Housing 3—Holder 4—Rubber Pad 5—Tie Wrap

2—Relief Cartridge

081403
PN=913
Forwarder Booms
37
3710
6
–UN–21JUN01
T139457
Boom Tower and Pedestal
1—Boom Tower 5—Circlip 9—Seal 13—Pedestal

2—Plug 6—Seal 10—Bearing 14—Capscrew
3—Roller Bearing 7—Support Plate 11—Scraper 15—Washer
4—Support Ring 8—Screws 12—Grease Fitting
JK11466,0000053 –19–16DEC02–3/3

081403
PN=914
Group 3720
Boom Parts Removal and Installation
Other Material
Number Name Use 37

3720
1
N/A (U.S.) Loctite 270 Used to secure piston on rod during
Main Boom Cylinder Servicing
procedure.

Jib Boom Cylinder Servicing
procedure.

Extension Cylinder Servicing
procedure.
N/A (U.S.) Loctite 270 Used to secure set screw on cylinder

head during Extension Cylinder

cylinder supports during Extension
Cylinder Servicing procedure.

Extension Cylinder Servicing
procedure.
N/A (U.S.) Loctite 270 Used to secure set screw on cylinder

head during Extension Cylinder

pistons during Slew Cylinders
Number Name Use

cylinder pins.
N/A (U.S.) Sikaflex - 221 Sealing compound applied to tower

seal flange during tower seal
replacement procedure.
N/A (U.S.) Loctite 243 Used to secure seal support plate

locking screws during tower seal
replacement procedure.
JK11466,0000004 –19–02DEC02–1/1

081403
PN=915
Essential Tools
37 NOTE: Order tools according to information given in the
3720
2
SERVICEGARD is a trademark of Deere & Company JK11466,0000059 –19–16DEC02–1/2
Lock Nut Wrench
Used to loosen and tighten lock nuts on Boom cylinder

pins.
–UN–29AUG01
T139164
JK11466,0000059 –19–16DEC02–2/2

081403
PN=916
Assembly Instructions
IMPORTANT: When removing joint pins or other 37

3720
load-bearing structures bear in mind the 3
following:
❒ The lifting capacity of the boom or

pulley must be adequate.
❒ The hoisting equipment must be
reliable and in good working order.
❒ The booms must be properly
supported in every direction




EL62757,00001C7 –19–22APR02–1/1
Main Boom Cylinder
Before working on the boom.
• Park the vehicle and block the wheels

• After working on any hydraulic component, air may
have to be removed from the system.
• Air bubbles in the system may cause sudden,
unintended movements of the Boom.
• Also, air bubbles heat up quickly causing burns to
packing material
• See group 0310, for the procedures to bleed the
hydraulic system.
Continued on next page OUTJ003,00003EA –19–02FEB01–1/6

081403
PN=917
NOTE: The lock nuts on the end of the boom pins can be
tightened using a tool similar to those shown.
37
3720
4
NOTE: the cylinder weighs approximately 165 kg.
Main boom cylinder removal
–UN–29AUG01
T139164
separate.
1. Raise the boom. Turn the loader 90° in order to clear

the headboard. Support the main boom in a horizontal
position.
2. Release the pressure to the hydraulic system.


3. Tag and disconnect the hydraulic hoses at the cylinder.

Cap the hoses and plug the ports.


4. Use a lifting strap to attach a suitable lifting device to

the main boom cylinder.

081403
PN=918
5. Remove the lock nut from the cylinder pin. Remove the
screw retaining the pin. Drive out the pin. Note the
location of any spacer rings used between the cylinder 37
3720
end and the mounting flanges. 5
1—Retaining Screw
–UN–29AUG01
2—Pin
3—Spacer Ring
4—Cylinder
5—Lock Nut
T139165
–UN–29AUG01
T139166
Typical Cylinder Pin
OUTJ003,00003EA –19–02FEB01–3/6
6. Use a suitable overhead lifting device to swing the

cylinder down and support it in a horizontal position .
Main Boom Cylinder Removal—Specification

Main Boom Cylinder—Weight ............................................. 60 Kg (132 lb)
–UN–29AUG01
7. Remove the lower pin joint using the same procedure
used to remove the upper pin.
8. Lower the cylinder to the ground.
T139167

081403
PN=919
Main boom cylinder installation
37 1. Position the cylinder using an overhead lifting device.

3720
6
Fit the piston end of the cylinder into the bracket at the
tower base. Position any spacer rings used between
the cylinder end and the mounting flanges. Insert the
–UN–29AUG01
pin. Apply LOCTITE 243 and install the pin retaining
screw. Install the lock nut on the pin.
Main Boom Cylinder Installation—Specification
T139167
Main Boom Cylinder—Weight ............................................. 60 Kg (132 lb)
LOCTITE is a trademark of Loctite Corp. OUTJ003,00003EA –19–02FEB01–5/6
2. Raise the cylinder to a vertical position. Fit the base

end of the cylinder into the bracket in the main boom.
Position any spacer rings used between the cylinder
end and the mounting flanges. Insert the pin. Apply
LOCTITE 243 and install the pin retaining screw.
Install the lock nut on the pin.
–UN–29AUG01
1—Retaining Screw
2—Pin
3—Spacer Ring
T139165
4—Cylinder
5—Lock Nut
–UN–29AUG01
T139166

LOCTITE is a trademark of Loctite Corp. OUTJ003,00003EA –19–02FEB01–6/6

081403
PN=920
Slewing Cylinders Installation
1. Remove the piston, guide ring and scraper ring from 37

3720
the end of the rack bar by removing four screws and 7
washers.
Continued on next page JK11466,0000028 –19–08NOV02–1/2

081403
PN=921
37
3720
8
–UN–22NOV02
T161778
1.— Boom Pedestal Base 5.— Clamp 9.— Cap screw 13. —Drain Plug
2. —Service Step 6.— Hydraulic Line 10.— Bushing 14. —Fill Plug
3.— Cap screw 7.— Tie Strap 11. —O-ring 15.— Max. Fill Level
4. —Washer 8. — Cylinder Tube 12. —Piston on Rack Bar 16. —Min. Fill Level
2. Replace piston seals. 8. Fill the pedestal with oil.
3. Seal Ring Install scraper ring, guide ring and piston 9. Connect the hydraulic lines on the cylinders.
on the end of the rack bar by inserting four screws
and washers. 10. Replace the tie straps
4. Use loctite 243 and torque the screws to 85 Nm. 11. Install the service steps and shield using screws
and clamps.
5. Replace cylinder tube O-ring.
12. Carefully operate the boom slewing function to
6. Lubricate piston and cylinder tube. Install the remove any air from the hydraulic system and to
cylinder tube on the pedestal base. confirm correct connections.
7. Torque the screws to 110 Nm.
JK11466,0000028 –19–08NOV02–2/2

081403
PN=922
Boom Slew Cylinders Service
1. Park the machine and block the wheels. 37

3720
9
2. Release pressure to hydraulic system.
JK11466,0000057 –19–16DEC02–1/6
3. Tie down Boom in centered position To drain oil from

pedestal, remove plug and drain oil into suitable
container.
1—Drain Plug
–UN–29AUG01
T139219
JK11466,0000057 –19–16DEC02–2/6
4. Remove screws and clamps to remove shield and

service steps.
5. Disconnect the hydraulic lines from the cylinder barrels

and remove the tie straps and holders.
6. Remove each cylinder barrel by removing six screws

and bushings.
Discard and replace the O-ring on the cylinder barrel.
NOTE: The rack bar remains in the pedestal during

servicing of the piston.
–UN–20JUL01
T139220

081403
PN=923
7. To remove the piston, remove the four screws.

Remove the guide ring and scraper ring.
37
3720
10
8. Clean and inspect the piston for wear. Replace if
necessary. Replace piston seals.
–UN–20JUL01
9. Install scraper ring, guide ring and piston on the end of
the rack bar by inserting four screws and washers. Use
LOCTITE 243 and tighten screws to the specified
torque.
T139221
10. Lubricate piston and cylinder barrel.
11. Install cylinder barrel on pedestal base. Tighten 1—Rack Bar

2—Scraper Ring
screws to the specified torque.
3—Guide Ring
4—Seal
12. Repeat the servicing procedure at each cylinder. 5—Piston
6—Bushing (4)
7—Cap Screw (4)
LOCTITE is a trademark of Loctite Corp. JK11466,0000057 –19–16DEC02–4/6
13. Fill each cylinder with hydraulic oil. Connect hydraulic

lines. Replace tie straps with holders and rubber
pads.
14. Install service steps and shield using screws and

clamps.
–UN–20JUL01
T139222

081403
PN=924
15. Fill pedestal with oil. See section 00 Fluids and

Lubricants, for recommended boom slew housing oil.
37
3720
16. Operate carefully the boom rotation function to 11
remove any air from the hydraulic system and to
confirm correct connections.
–UN–29AUG01
Bleed the hydraulic system, if necessary. See
Operator‘s manual F 063723 page 5-2-1, for the
procedures.
T139223
1—Fill Port
JK11466,0000057 –19–16DEC02–6/6

081403
PN=925
1010D Outer Cylinder

37 Removal
3720
12
1. Fold the loader into the rest position.
–UN–29AUG01
2. Release the pressure to the hydraulics system.

T139168

3. Tag and disconnect the hoses at the cylinder. Cap the

hoses and plug the ports.


4. Support the cylinder in a sling from an overhead lifting

device.
Jib Boom Cylinder Removal—Specification

Jib Boom Cylinder—Weight ................................................ 65 Kg (143 lb)
Continued on next page OUTJ003,00003ED –19–02FEB01–1/6

081403
PN=926
5. Disassemble the linkage. Remove the lock nut and the

retaining screw and drive out the pin. Note the location
of any spacer rings used on between the cylinder end 37
3720
and the linkage lever. 13
NOTE: Removing the pin will allow the arms and the
–UN–29AUG01
lever to fall out of the linkage assembly. Be
prepared to support the parts as they come loose.
1—Retaining Screw
T139169
2—Pin
3—Linkage Arm
4—Ring
5—Cylinder
6—Lock Nut
7—Linkage Lever
OUTJ003,00003ED –19–02FEB01–2/6
6. Remove the lock nut from the cylinder pin. Remove the
screw retaining the pin. Drive out the pin. Note the
location of any spacer rings used between the cylinder
end and the mounting flanges.
7. Lower the cylinder to the ground.
–UN–29AUG01
1—Retaining Screw
2—Pin
3—Spacer Ring
T139166
4—Cylinder
5—Lock Nut
Continued on next page OUTJ003,00003ED –19–02FEB01–3/6

081403
PN=927
Installation
37
3720 CAUTION: Use proper safety precautions when
14 using any lifting equipment.
–UN–29AUG01
1. Hoist the cylinder into position using an overhead lifting

device.
T139168
Jib Boom Cylinder Installation—Specification
Jib Boom Cylinder—Weight ................................................ 65 Kg (143 lb)
OUTJ003,00003ED –19–02FEB01–4/6
2. Fit the base end of the cylinder into the bracket on the
boom. Position any spacer rings used between the
cylinder end and the mounting flanges. Insert the pin.
Apply LOCTITE 243 and install the pin retaining
screw. Install the lock nut onto the pin.
–UN–29AUG01
1—Retaining Screw
2—Pin
3—Spacer Ring
4—Cylinder
T139166
5—Lock Nut
LOCTITE is a trademark of Loctite Corp. Continued on next page OUTJ003,00003ED –19–02FEB01–5/6

081403
PN=928
3. Assembly the linkage. Position any spacer rings used

between the cylinder end and the linkage lever. To
insert the pin, lift the arms, lever and cylinder rod into 37
3720
place one at a time as the pin reaches them. Apply 15
LOCTITE 243 and install the pin retaining screw.
Install the pivot nut onto the pin.
–UN–29AUG01
T139169
Failure to follow these procedures may 1—Retaining Screw

2—Pin
3—Linkage Arm
4—Ring
4. Connect the hydraulic hoses to the cylinder. 5—Cylinder
6—Lock Nut
5. Carefully operate the jib boom raise and lower 7—Linkage Lever
functions to remove any air from the hydraulic system
and to confirm correct connections.
If necessary bleed the hydraulic system. See section

LOCTITE is a trademark of Loctite Corp. OUTJ003,00003ED –19–02FEB01–6/6

081403
PN=929
CF572 Extension Cylinder

37
3720
16
–UN–29AUG01
T139170
CF572 Extension Boom Hose Routing
1—Hose Cover 4—Extension Cylinder 5—Grapple Operation Hoses at 6—Wear Pads

2—Jib Boom Hydraulic Hoses jib 7—Extension Boom
3—Extension Cylinder Pin at
jib
Continued on next page OUTJ003,00003EF –19–02FEB01–1/10

081403
PN=930
37
3720
17
–UN–29AUG01
T139171
NOTE: The jib is shown separately for clarity. The jib 1. Extend the loader completely. Support the main
is not removed for this procedure. boom and jib in a horizontal position using a
suitable support. Support the extension boom in a
sling from an overhead lifting device.
CAUTION: Use proper safety precautions
when using any lifting equipment.
2. Remove the grapple. See Section 38, Group 3800,
for procedures.

081403
PN=931
3. Remove the hose cover. Remove the jib end cover.
37 4. Release the pressure to the hydraulic system.

3720
18
–UN–29AUG01
T139172
5. Tag and disconnect the hydraulic hoses to the

extension cylinder. Disconnect the grapple operation
hoses where they meet the lines on the jib.
6. Disconnect the base end of the cylinder from the jib by

removing the circlips and driving out the pin.
OUTJ003,00003EF –19–02FEB01–3/10
7. Loosen the wear pads at the end of the jib. Remove

the extension boom together with the extension
cylinder from the jib boom using the overhead lifting
device.
8. Disconnect the piston end of the cylinder from the

extension by removing the circlips and striking out the
pin.
9. Remove the cylinder from the extension boom.
CF572 Extension Cylinder Removal—Specification

CF572 Extension Cylinder—
Weight.................................................................................... 46 Kg (90 lb)
–UN–20JUL01
T139173

081403
PN=932
Install
1. Inspect the wear pads on the jib boom. Replace, if 37

3720
necessary. 19
–UN–29AUG01
T139174
OUTJ003,00003EF –19–02FEB01–5/10
2. Inspect the wear pads on the extension boom. Replace

if necessary.
–UN–29AUG01
T139175
OUTJ003,00003EF –19–02FEB01–6/10
3. Inspect the bushings for the cylinder mounting pin.

–UN–29AUG01
T139176

081403
PN=933
37
3720
20
–UN–29AUG01
T139171
5. Support the extension boom in a horizontal position
CAUTION: Use proper safety precautions
using a sling from an overhead lifting device.
when using any lifting equipment.

4. Park the vehicle. Block the wheels. Support the

main boom and jib boom in a horizontal position
using a suitable support.

081403
PN=934
6. Manually extend the cylinder. Fit the cylinder into the

extension boom. Connect the piston end of the cylinder
to the extension by inserting the pin and installing the 37
3720
circlips. 21
7. Lubricate the extension. Slide the extension into the jib

using the overhead lifting device.
Adjust the wear pads by simultaneously tightening both

sides until there is no clearance, then back them off
one quarter turn.
–UN–20JUL01
T139173

081403
PN=935
8. Connect the base end of the cylinder to the jib by

inserting the pin and installing the circlips.
37
3720
22
9. Install the jib end cover.
10. Attach the grapple. See Section 38, Group 3800, for
–UN–29AUG01
the procedures.

T139172

11. Connect the grapple operation hoses to the lines on

the jib. See Section 38, Group 3800, for the
procedures.
12. Connect the hydraulic hoses to the cylinder. Install

the hose cover.
13. Carefully operate the extension and grapple functions

to remove any air from the hydraulic system and to
If necessary bleed the hydraulic system. See section

OUTJ003,00003EF –19–02FEB01–10/10

081403
PN=936
Group 3730
Booms Removal and installation
Outer Boom Removal
1. Park the machine on a level surface. Engage the 37

3730
parking brake. 1
2. Open the vent tap on the hydraulic tank to release the

pressure in the hydraulic system.
3. Install the frame articulation lock to prevent accidental

articulation of the frame. Block the wheels to prevent
accidental movement of the machine.
4. Remove the forwarder head.
5. Remove the extension boom. See Section 37, Group

6. Remove the jib boom cylinder. See Section 37, Group

3720, for the procedure.
NOTE: The linkage connecting the jib boom to the main

boom at the jib boom cylinder is disassembled
when the jib boom cylinder is removed.
OUTJ003,00003F5 –19–02FEB01–1/3
7. Disconnect the hydraulic hoses at the main boom.

–UN–06JUN01

T141804


8. Use a lifting strap to attach a suitable lifting device to

the jib boom.
Jib Boom Removal—Specification

Jib Boom—Weight ............................................................. 240 kg (529 lb.)
Continued on next page OUTJ003,00003F5 –19–02FEB01–2/3

081403
PN=937
9. Remove the locknut from the jib boom pin.
37 Remove the screw securing the pin. Remove the pin

3730
2
and any spacers, if installed.
NOTE: Note the locations of any spacers used.
–UN–06JUN01
10. Lift the boom off the machine.
1—Lock Nut
T141806
2—Spacers
3—Pin
4—Locking Screw
OUTJ003,00003F5 –19–02FEB01–3/3
Outer Boom Installation

parking brake.


pressure in the hydraulic system
4. ApplyLOCTITE 243 to the locking screw. Install the

locking screw.
Jib Boom Installation—Specification

Jib Boom Pin Lock Nut—Torque .............................. 1300 N•m (959 lb-ft)
Install lock nut on pin and tighten to specified torque.

LOCTITE is a trademark of Loctite Corp. Continued on next page OUTJ003,0000576 –19–21MAR01–1/4

081403
PN=938

using any lifting equipment. 37
3730
Failure to use proper procedures can lead to 3
–UN–06JUN01
5. Use an overhead lifting device to position the jib boom
on the main boom.
T141805
Jib Boom—Weight ............................................................. 240 kg (529 lb.)
OUTJ003,0000576 –19–21MAR01–2/4
6. Position spacers, if used. Install pin.
7. Apply LOCTITE 243 to the locking screw. Install the

locking screw.
Install lock nut on pin and tighten to specified torque.
–UN–06JUN01
T141806
1—Lock Nut
2—Spacers
3—Pin
4—Locking Screw
LOCTITE is a trademark of Loctite Corp. Continued on next page OUTJ003,0000576 –19–21MAR01–3/4

081403
PN=939

37 hydraulic component in order to
3730
4
–UN–06JUN01
8. Connect the hydraulic hoses at the main boom.
T141804
9. Install the extension boom. See Section 37, Group
3720, for the procedures
10. Install the jib boom cylinder. See Section 37, Group
11. Install the forwarder head.
12. Bleed the hydraulic system. Check the Boom

functions, to confirm the hose connections.
OUTJ003,0000576 –19–21MAR01–4/4

081403
PN=940
Main Boom Removal

3730
parking brake. Lower the decking blade to the ground. 5


4. Remove the forwarder head.


7. Remove the jib boom. See Section 37, Group 3730, for
the procedure.
8. Remove the main boom cylinder. See Section 37,

Group 3100, for the procedure.

081403
PN=941

37 hydraulic component in order to
3730
6

9. Disconnect the hydraulic hoses at the main boom.
–UN–06JUN01
T141807
OUTJ003,00003F6 –19–02FEB01–2/4
10. Use a sling to attach an overhead lifting device to the

main boom.
Main Boom Removal—Specification

Main Boom—Weight.......................................................... 300 kg (662 lb.)
CAUTION: Use proper safety precautions when –UN–06JUN01

T141808

081403
PN=942
11. Remove the locknut from the main boom pin.
Remove the screw securing the pin. Remove the pin 37

3730
and any spacers, if installed. 7
NOTE: Note the locations of any spacers used.
–UN–06JUN01
12. Lift the main boom off the machine.
1—Lock Nut
T141809
2—Spacers
3—Pin
4—Locking Screw
OUTJ003,00003F6 –19–02FEB01–4/4
Main Boom Installation

parking brake.

Install the frame articulation lock to prevent accidental



2. Use an overhead lifting device to position the main

boom on the tower.
Main Boom Installation—Specification

Main Boom—Weight.......................................................... 300 kg (662 lb.)

081403
PN=943
3. Position spacers, if used. Install pin.
37 4. Apply LOCTITE 243 to the locking screw. Install the

3730
8
locking screw
Install the lock nut on the pin and tighten to the
–UN–06JUN01
specified torque.
Main Boom Installation—Specification

Main Boom Pin Lock Nut—
T141809
Torque ................................................................... 1,890 N•m (1,394 lb-ft)

observed when working on any 1—Lock Nut
hydraulic component in order to 2—Spacers
prevent contamination of the hydraulic 3—Pin
and hydrostatic systems. 4—Locking Screw

5. Connect the hydraulic hoses at the tower.
6. Install the main boom cylinder. See Section 31, Group

7. Install the jib boom. See Section 31, Group 3100, for
the procedure.

3100, for the procedures

10. Install the grapple. See Section 38, Group 3800, for
the procedures.
11. Bleed the hydraulic system. Check the Boom

functions, to confirm the hose connections.
LOCTITE is a trademark of Loctite Corp. OUTJ003,0000577 –19–21MAR01–2/2

081403
PN=944
Tower Removal

3730
parking brake. Lower the decking blade to the ground. 9

Install the frame articulation lock to prevent accidental

2. Remove the grapple See Section 40, Group 4020, for

the procedures.

3730 , for the procedures.

5. Remove the jib boom. See Section 31, Group 3730, for
the procedure.
6. Remove the main boom cylinder. See Section 37,

Group 3720, for the procedure.
7. Remove the main boom. See Section 37, Group 3730,

for the procedures.
8. Remove the fair lead securing the hydraulic hoses to

the tower.
9. Use a sling to attach a suitable overhead lifting device

to the tower.
OUTJ003,00003F7 –19–02FEB01–1/3
10. Remove the plug and drain the oil from the pedestal
housing into a suitable container.
11. Lift the tower off the machine.
1—Pedestal Drain Plug

–UN–06JUN01
T141812

081403
PN=945
12. Inspect the bushings and sleeves. replace, if

necessary.
37
3730
10 1—Bushing
2—Sleeve
–UN–06JUN01
T141813
OUTJ003,00003F7 –19–02FEB01–3/3
Tower Installation
1. Use a suitable overhead lifting device to position tower

on pedestal.
NOTE: Take care when aligning tower spline with rotate

cylinder rack bars.

081403
PN=946
2. Refill the pedestal housing with oil.
NOTE: The upper sight glass is installed in the pedestal 37

3730
fill port. 11
3. Install the fair lead securing the hydraulic hoses to the
–UN–06JUN01
tower.
4. Install the main boom. See Section 37, Group 3100, for
the procedures.
T141816
5. Install the main boom cylinder. See Section 37, Group
6. Install the jib boom. See Section 37, Group 3100, for
the procedure.


9. Install the grapple. See Section 40, Group 4020, for

the procedures.
OUTJ003,0000578 –19–21MAR01–2/2

081403
PN=947
Tower Service
37 To replace the bearing and seal on the tower:
3730
12
1. Remove the circlip securing the bearing. Remove the
support ring. Remove the bearing.
Inspect the bearing and replace, if required.
2. Install the bearing. Install the support ring. Install the

circlip.
3. Remove the screws securing the seal support plate.

Remove the seal.
4. Apply a coating of sealing compound Sikaflex - 221 to

the seal flange.
5. Install new seal.
6. Install seal support plate. Apply LOCTITE 243 to

screws. Install screws and torque to specified torque.
Tower Bearings and Seals Replacement—Specification

Tower Seal Support Plate
Screws—Torque .............................................................. 49 N•m (36 lb-ft)
1—Boom Tower
2—Plug
3—Roller Bearing
4—Support Ring
5—Circlip
6—Seal
7—Support Plate
8—Screws
–UN–06JUN01
T141814
LOCTITE is a trademark of Loctite Corp. Continued on next page OUTJ003,000057A –19–21MAR01–1/2

081403
PN=948
To replace the bearing and seals on the pedestal:
1. Remove seal. 37
3730
13
2. Remove bearing. Inspect bearing for indications of
wear and replace, if necessary.
3. Remove scraper.
4. Install new scraper as shown.
NOTE: The scraper must be installed with the lip facing

up.
5. Install bearing as shown.
NOTE: The bearing must be installed with the slot offset

30° from the grease fittings on the pedestal
–UN–06JUN01
housing.
6. Install new seal as shown.
T141815
NOTE: The seal must be installed with the lip facing up.
1—Seal
2—Bearing
3—Scraper
4—Grease Fitting
5—Pedestal
OUTJ003,000057A –19–21MAR01–2/2

081403
PN=949
37
3730
14

081403
PN=950
Group 3740
Boom Operational Checkout Record Sheet
NOTE: See the following sections for detailed Operational 37

3740
Checkouts of specific systems: 1
• Deere engine Workshop Manual Fxxxxx

• Deere engine Workshop manual Fxxxxxx-
Engine Operational Checkout
• Section 21 - Group 21xx- Hydraulic System
• Section 03, Group 03xx- Hydrostatic System
• Section 80, Group 80xx- Air Conditioner and
Heating Operational Checkout
OWNER DATE
HOURS
PIN
TECHNICIAN

Continued on next page OUTJ003,0000597 –19–17APR01–1/2

081403
PN=951
OK NOT OK COMMENTS
1. Frames
37
3740
2 Frame Joint ❒ ❒
Panels and Covers ❒ ❒
Cleanliness ❒ ❒
Cleanliness ❒ ❒
2. Boom
Cleanliness
Cylinders Rod Seals ❒ ❒
Boom and Cylinder Pins ❒ ❒
Extension Boom Wear Pads ❒ ❒
Extension Boom Cylinders ❒ ❒
Boom Fasteners ❒ ❒
Slew Housing Oil Level ❒ ❒
Boom Cylinder Internal Seals ❒ ❒
Boom Slew ❒ ❒
Main Boom Raise / Lower ❒ ❒
Jib Boom Raise / Lower ❒ ❒
Extension Boom Extend / Retract ❒ ❒
Frame Brake ❒ ❒
3. forwarder Head
GrappleLink ❒ ❒
GrappleFrame and delimbing knives ❒ ❒
Cylinder Rod Seals ❒ ❒
Rotator Motor ❒ ❒
GrappleRotate ❒ ❒
OUTJ003,0000597 –19–17APR01–2/2

081403
PN=952
Diagnose Boom
Symptom Problem Solution 37

3740
3
Boom does not lift rated Defective valve spool port reliefs at Service valve. (See the group 0335,
maximum load boom control valve. for procedures.)
Defective main relief valve at boom Service valve. (See the group 0335,
Control Valve. for procedures.)
Defective cylinder seals. Service cylinder. Replace seals as

necessary. (See the group 0350, for
procedures to service boom
cylinders.)
Cylinder piston sticking in barrel or Service cylinder. Replace piston as

loose on rod. necessary. (See group 0350, for
procedures to service boom
cylinders.)
Improper work pump output . Test and adjust work pump

maximum pressure. See the Section
03 for procedures.
Defective or worn work pump. Test pump flow. See the Section 03,
for test procedure.
If necessary, service work pump.

(See group 0335, for procedures to
service pump.)
Boom does not keep load up Control spool or port relief in Boom Service valve.
Control Valve by-passing oil.
Dirt causing control spool in Boom Service valve.

Control Valve to stick.

necessary.

loose on rod. necessary.
Continued on next page OUTJ003,000047C –19–12FEB01–1/5

081403
PN=953
37 Improper main pressure Defective main relief valve at Boom Service valve.
3740
4
Control Valve.

maximum pressure. See Section 03
for procedures.
High free circulation pressure in Improper work pump output. Test and adjust work pump
hoses Excessive oil flow. maximum pressure. See the Section
03 for procedures.
Original hoses replaced with hoses Replace hose with correct size.
that are too narrow.
Blocked hoses or filter. Clear hoses. Check hydraulic return

filter restriction warning light.
Extension boom extends on its Defective control spool in Boom Service valve.
own control valve.

necessary.

All or any Boom functions too Insufficient oil. Check level in hydraulic tank. Add
slow oil, if necessary.
Defective valve spool port reliefs at Service valve.

Boom control valve.
Defective main relief valve at Boom Service valve.

Control Valve.

maximum pressure. See Section 03
for procedures.
Defective or worn work pump. Test pump flow. See Section 03 for
test procedure.
Engine does not maintain correct Adjust engine speed control throttle.
RPM

081403
PN=954
Grappledoes not hold Defective control spool in Boom Service valve. 37

3740
control valve. 5

necessary.

Boom slews on its own Defective control spool in Boom Service valve.
control valve.
Excessive heating Insufficient oil. Check level in hydraulic tank. Add

oil, if necessary.
Improper work pump output. Test and adjust work pump

Excessive oil flow. maximum pressure. See the Section
03 for procedures.
Defective or worn work pump. Test pump flow. See Section 03for
test procedure.


Boom control valve.

Control Valve.

081403
PN=955
37 Slows down when lifting Insufficient oil. Check level in hydraulic tank. Add
3740
6
oil, if necessary.

Boom control valve.

Control Valve.
Engine does not maintain correct Adjust engine speed control throttle.
RPM
test procedure.
Pulsating oil flow Leak in hose or fitting. Check hoses and fittings. Repair as
necessary.
Insufficient oil. Check level in hydraulic tank. Add

oil, if necessary.
test procedure.

Erratic slewing Defective valve spool or port reliefs Service valve.

at Boom control valve.
Slewing support bearing worn. Replace bearing.
Air in cylinders. Carefully operate cylinders too

extreme positions several times to
eliminate air from hydraulics.
Oil drains out of cylinders Defective cylinder seals. Service cylinder. Replace seals as
necessary.

081403
PN=956
Water in slew housing Defective slewing seals. Drain water through oil drain plug. 37
3740
Replace oil. 7
Replace seals.
Defective spool in Boom control Spool contaminated with dirt. Disassemble and clean spool.
valve
Spool bent. Replace spool.
Ice in valve. Service valve to remove water.
Oil overheating causing spool to Remedy hydraulic overheating. See

stick. Section 03, for troubleshooting
procedures.
Cylinder does not respond Cylinder piston sticking in barrel or Service cylinder. Replace piston as
immediately to control lever. loose on rod. necessary.
Cylinder lags.
OUTJ003,000047C –19–12FEB01–5/5

081403
PN=957
37
3740
8

081403
PN=958
Group 3750
Boom overall maintenance
See Operator‘s Manual F063390 for Detailed
Service instructions
37
3750
See Operators manual F 063723 pages from 4-12-1 to 1
4-12-5 for boom maintenance instructions
JK11466,0000026 –19–08NOV02–1/1

081403
PN=959
Boom overall maintenance
37
3750
2

081403
PN=960
Section 38
Decking Blade
Contents
Page 38

Decking Blade . . . . . . . . . . . . . . . . . . . . . . . .38-3810-1
Group 3820—Service
Other Material . . . . . . . . . . . . . . . . . . . . . . . .38-3820-1
Decking Blade Cylinder Removal . . . . . . . . .38-3820-1
Decking Blade . . . . . . . . . . . . . . . . . . . . . . . .38-3820-2
Decking Blade Hoses . . . . . . . . . . . . . . . . . .38-3820-5
Diagnose Decking Blade . . . . . . . . . . . . . . . .38-3820-5
Decking Blade . . . . . . . . . . . . . . . . . . . . . . . .38-3820-5

081403
PN=1
Contents
38

081403
PN=2
Group 3810
Theory of Operation
Decking Blade
38
3810
1
–UN–21JUN01
T139465
1—Cylinder 3—Retaining Screw 5—Tie Wrap 6—Hose Clamp
2—Pin 4—Hydraulic Hose
A decking blade is installed on the front of the rocks and earth, pushing other machines or dislodging
machine. The hydraulically operated blade is used to stumps.
help stack cut timber. It is not to be used for moving
OUTJ003,0000474 –19–08FEB01–1/1

081403
PN=963
Theory of Operation
38
3810
2

081403
PN=964
Group 3820
Service
Other Material
Number Name Use

decking blade cylinder pins during
Decking Blade Installation procedure.
38
3820
1
OUTJ003,000040D –19–05FEB01–1/1
Decking Blade Cylinder Removal

–UN–27JUN01

T139229
1. Park the machine and block the wheels. Rest the
decking blade on the ground.
2. Remove tie wrap and clamp holding hydraulic hose to

cylinder.
3. Tag and disconnect hydraulic hoses at cylinder. Place

suitable container to catch any lost hydraulic fluid.
4. Disconnect cylinder at base end. Remove retaining

screw and drive out pin. Rest the cylinder on the
decking blade arm.
5. Disconnect cylinder at piston end. Remove retaining

screw and drive out pin.
6. Remove cylinder.
Decking Blade Cylinder Removal—Specification

Decking Blade Cylinder—Weight ........................................... 38 kg (85 lb)
OUTJ003,000040A –19–05FEB01–1/1

081403
PN=965
Service
Decking Blade
Removal
1. To access the decking blade mounts, remove the

forward tires from the front bogies and allow the bogie
–UN–27JUN01
housings to tilt down.
38
3820
2
T139225
OUTJ003,000040B –19–05FEB01–1/7

lifting devices when supporting the decking
blade.
Support the frame on blocks before working

under the forwarder.
–UN–27JUN01
Failure to follow proper safety precautions can
damage.
T139226
2. Remove the decking blade weldment by separating the
arms at the bolted joint. Support the decking blade
before removing the bolts.
Decking Blade Removal—Specification

Decking Blade Weldment—
Weight................................................................................. 275 kg (606 lb)
OUTJ003,000040B –19–05FEB01–2/7
3. Disassemble the mounts.
4. Remove the bolts retaining the pivot pins. Access the

bolts through the belly pan on the underside of the
front frame. Remove the pivot pin.
–UN–27JUN01
5. Inspect the spherical bearings and replace if

necessary. Remove the circlip to remove the bearing.
T139227
Continued on next page OUTJ003,000040B –19–05FEB01–3/7

081403
PN=966
Service
Installation
1. Assemble the mounts.
2. Insert the pivot pins. Install the retaining bolts. Tighten

the bolts to specified torque.
–UN–27JUN01
Decking Blade Installation—Specification
38
Decking Blade Pivot Pin Bolts—
3820
Torque ........................................................................... 118 N•m (87 lb-ft)
3
T139227
OUTJ003,000040B –19–05FEB01–4/7
3. Install the decking blade weldment.

Decking Blade Weldment—
Weight................................................................................. 275 kg (606 lb)
Install the bolts with lock washers. Tighten the bolts to
–UN–27JUN01
specified torque.

Decking Blade Armature
T139226
Mounting Bolts—Torque .............................................. 471 N•m (420 lb-ft)
Continued on next page OUTJ003,000040B –19–05FEB01–5/7

081403
PN=967
Service
4. Rest cylinder on decking blade arm.
Decking Blade Cylinder Installation—Specification

Decking Blade Cylinder—Weight ........................................... 38 kg (85 lb)
5. Place piston end of cylinder into bracket on decking

blade arm. Apply NEVER-SEEZ anti-siezing
–UN–27JUN01
compound to pin. Insert pin and install retaining screw.
38
3820
4 6. Lift base end of cylinder into bracket on vehicle frame.
Apply NEVER-SEEZ anti-siezing compound to pin.
T139229
Insert pin and install retaining screw.
7. Connect hydraulic hoses. Install tie wrap and clamp

holding hydraulic hose to cylinder.
8. Install the front wheels and tires, if removed. Tighten

the wheel nuts to specified torque.

Wheel Nuts—Torque ................................................... 550 N•m (400 lb-ft)
NEVER-SEEZ is a trademark of Emhart Chemical Group OUTJ003,000040B –19–05FEB01–6/7
9. Grease the armature.
NOTE: There are six points to be greased on the decking

blade. The belly pan must be opened to reach two
of them.
–UN–27JUN01
10. Carefully operate the decking blade raise and lower
functions to remove any air from the system and to
Bleed the hydraulic system, if necessary. See Section T139230
21, Group 2160, for the procedures.
1—Belly Pan
OUTJ003,000040B –19–05FEB01–7/7

081403
PN=968
Service
Decking Blade Hoses
NOTE: Flow from the Work Pump is routed to the

Pressure Filter, then to a tee on the Auxiliary
Valve, then to the Decking Blade Valve.
38
3820
5
OUTJ003,000040F –19–05FEB01–1/1
Diagnose Decking Blade
JK11466,00000AC –19–06FEB03–1/1
1 Decking Blade
– – –1/1
Decking Blade and Arms Inspect the decking blade. OK: Go on to next check.
LOOK: Decking blade should be in good condition and NOT OK: Tighten
not be bent, dented or damaged. fasteners. Replace
decking blade or arms, if
Inspect the arms. necessary.
LOOK: Arms should be in good condition. Arms should

T141630 –UN–18JUN01
be properly aligned so that the decking blade is level.
Fasteners should be tight. Cylinder guards should be in
place and secure.
– – –1/1
Arm and Cylinder Pins Inspect arm and cylinder pins. OK: Go on to next check.
LOOK: Arm and cylinder pins should be in good NOT OK: Tighten
condition. Pins should be properly lubricated. Fasteners fasteners. Grease pins.
should be tight. Replace pins, as
required.
T141631 –UN–18JUN01
– – –1/1

081403
PN=969
Service
Hoses and Fittings Inspect hoses and fittings for tightness. NOT OK: Tighten fittings
or replace o-rings on
LOOK: Fittings should be tight and free of leaks. Check for accumulations of dust and fittings, as required.
dirt that may indicate leaks. Replace hoses as
required.
LOOK: Hoses should not be twisted on kinked or show indications of wear.
– – –1/1
38 Cylinders Rod Seals Check cylinder rod seals. NOT OK: Service
3820 cylinder. See Section 21,
6 LOOK: Seals should not show any indication of leaks. Group 2165, for
NOTE: See Section 03 for procedures to test cylinder decking blade cylinders.
internal seals.
T141632 –UN–18JUN01
– – –1/1
Decking Blade Up / OK: Check complete.

Down
NOT OK: See Section 16
to diagnose electrical
control circuits.
Remedy possible
mechanical or hydraulic
T141633 –UN–13AUG01 T141634 –UN–13AUG01
problems. Check
hydraulic hose
Press the Raise Decking Blade button on the armrest. connections. See Section
03,for more information.
LOOK: The decking blade should be raised.
Press the Lower Decking Blade button on the armrest.
LOOK: The decking blade should be lowered.
NOTE: Each control should operate the appropriate function.
The functions should operate promptly and smoothly.
NOTE: Whenever the decking blade is raised or lowered the work pump should
operate at maximum output.
– – –1/1

081403
PN=970
Section 40
Grapple
Contents
Page

Supergrip SG 260 / 360 . . . . . . . . . . . . . . . .40-4010-1
Loglift GF25/35 Grapple . . . . . . . . . . . . . . . .40-4010-3
Group 4020—Removal and Installation 40

Other Material . . . . . . . . . . . . . . . . . . . . . . . .40-4020-1
Supergrip SG 260/360 Grapple . . . . . . . . . . .40-4020-1
Supergrip SG 260/360 Grapple Removal . . .40-4020-2
Supergrip SG 260/360 Grapple Rotator
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-6
Supergrip SG 260/360 Grapple
Installation . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-7
Loglift GF25/GF35 Grapple . . . . . . . . . . . . . .40-4020-8
Loglift GF25/GF35 Grapple Removal . . . . . .40-4020-8
Loglift GF25/GF35 Grapple Rotator
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-9
Loglift GF25/GF35 Grapple Cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . .40-4020-10
Loglift GF25/GF35 Grapple Cylinder
Installation . . . . . . . . . . . . . . . . . . . . . . . .40-4020-11
Installation . . . . . . . . . . . . . . . . . . . . . . . .40-4020-12
Loglift GF25/GF35 Grapple Installation . . . .40-4020-13
Group 4030—Grapple Service

Supergrip SG 260/360 Grapple Bushings
Replacement . . . . . . . . . . . . . . . . . . . . . . .40-4030-1
Loglift GF25/GF35 Grapple Connecting Rod
Bearings Replacement. . . . . . . . . . . . . . . .40-4030-2
Loglift GF25/GF35 Grapple Frame Bearings
Replacement . . . . . . . . . . . . . . . . . . . . . . .40-4030-3
Group 4040—Grapple Rotator

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .40-4040-1
Grapple Rotator Servicing . . . . . . . . . . . . . . .40-4040-2
Cleaning the Rotator Magnetic Plug . . . . . . .40-4040-7
Group 4050—Diagnostics
Diagnose Grapple . . . . . . . . . . . . . . . . . . . . .40-4050-1
Grapple . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-4050-1

081403
PN=1
Contents
40

081403
PN=2
Group 4010
Theory of Operation
Supergrip SG 260 / 360
40
4010
1
–UN–21JUN01
T139461
1—Frame 4—Inner Grapple Arm 7—Connecting Rod Pin Joint 10—Hydraulic Cylinder Piston
2—Outer Grapple Arm 5—Inner Grapple arm Pin Joint 8—Hydraulic Cylinder Rod Pin Joint
3—Outer Grapple Arm Pin 6—Connecting Rod 9—Hydraulic Cylinder Pin
Joint Joint
The Supergrip SG 260/360 is a short wood grapple Do not use the grapple to lift
mounted on the end of the boom. The grapple consists personnel.
of a frame and two grapple arms which are opened
and closed by a hydraulic cylinder. The Supergrip SG grapple consists of a frame, inner
and outer grapple arms, two connecting rods and the
The grapple is intended to handle timber; cut-to-length, grapple open/close cylinder.
whole tree and waste wood. It is not intended to be
used to lift rocks or spare parts, etc. It is not intended The inner and outer grapple arms are mounted
to be used as a hoist when servicing other vehicles opposite one another on separate pivot points on the
(mounting or removing tracks, etc.). frame. In operation, the hydraulic cylinder pulls the
tops of the arms together, spreading the tips or it
IMPORTANT: When testing the grapple the pushes the tops apart, bringing the tips together. The
operator should be aware that the cylinder operates as a mechanical stop for the
load may slip at any time. maximum opening of the grapple. The grapple arms fit
Unauthorized personnel should be together when closed, operating as a mechanical stop
kept back 15 meters (50 feet) from for the minimum opening of the grapple.
the grapple’s working area.

081403
PN=973
Theory of Operation
Two rods connecting the inner and outer grapple arms All bushings in the grapple are made from a
help transfer the force between the arms. self-lubricating plastic compound material. The
bushings are designed with a lip seal for protection
The cylinder is equipped with hydraulic dampening for against dust and dirt.
"Soft Stop" to eliminate shock loads.
OUTJ003,0000473 –19–08FEB01–2/2
40
4010
2

081403
PN=974
Theory of Operation
Loglift GF25/35 Grapple
40
4010
3
–UN–21JUN01
T139463
Loglift GF25/GF35 Grapple
1—Cylinder 4—Pin 6—Grapple Arm - RH 8—Bushing

2—Frame 5—Screw 7—Connecting Rod 9—Grapple Arm - LH
3—Nut
The Supergrip SG 260/360 is a short wood grapple The Supergrip SG grapple consists of a frame, inner
mounted on the end of the boom. The grapple consists and outer grapple arms, two connecting rods and the
of a frame and two grapple arms which are opened grapple open/close cylinder.
and closed by a hydraulic cylinder.
The inner and outer grapple arms are mounted
The grapple is intended to handle timber; cut-to-length, opposite one another on separate pivot points on the
whole tree and waste wood. It is not intended to be frame. In operation, the hydraulic cylinder pulls the
used to lift rocks or spare parts, etc. It is not intended tops of the arms together, spreading the tips or it
to be used as a hoist when servicing other vehicles pushes the tops apart, bringing the tips together. The
(mounting or removing tracks, etc.). cylinder operates as a mechanical stop for the
maximum opening of the grapple. The grapple arms fit
IMPORTANT: When testing the grapple the together when closed, operating as a mechanical stop
operator should be aware that the for the minimum opening of the grapple.
load may slip at any time.
Unauthorized personnel should be Two rods connecting the inner and outer grapple arms
kept back 15 meters (50 feet) from help transfer the force between the arms.
the grapple’s working area.
The cylinder is equipped with hydraulic dampening for
Do not use the grapple to lift "Soft Stop" to eliminate shock loads.
personnel.
Continued on next page JK11466,00000D2 –19–09APR03–1/2

081403
PN=975
Theory of Operation
All bushings in the grapple are made from a bushings are designed with a lip seal for protection
self-lubricating plastic compound material. The against dust and dirt.
JK11466,00000D2 –19–09APR03–2/2
40
4010
4

081403
PN=976
Group 4020
Removal and Installation
Other Material
Number Name Use

connecting rod pins during
Connecting Rod Bearings
Replacement procedure.

grapple arm pins during Frame
Bearings Replacement procedure.
N/A (U.S.) NEVER-SEEZ Anti-siezing compound applied to 40

4020
cylinder pins during Frame Bearings 1
Replacement procedure.
OUTJ003,0000421 –19–05FEB01–1/1
–UN–06JUN01
T139232
1—Outer Grapple Arm 4—Connecting Rods 7—Hydraulic Cylinder Piston 9—Inner Grapple arm Pin Joint
2—Outer Grapple Arm Pin 5—Hydraulic Cylinder Rod Pin Joint 10—Inner Grapple Arm
Joint 6—Frame 8—Connecting Rod Pin Joint
3—Hydraulic Cylinder Pin
Joint
OUTJ003,000041F –19–05FEB01–1/1

081403
PN=977
Supergrip SG 260/360 Grapple Removal
CAUTION: The grapple has sharp steel edges.

Use protective gloves when working on the
grapple.
–UN–06JUN01
1. Park the vehicle and block the wheels. Prepare a
suitable base to rest the grapple by nailing blocks to a
pallet as shown.
T139233
2. Close the grapple completely. extend the boom and
bring the grapple to rest on a suitable base. Support
40 the boom in this position. 1—Pallet
4020 2—Nailed Block
2
OUTJ003,0000410 –19–05FEB01–1/2


3. Release the pressure to the hydraulics. Disconnect the

hydraulic hoses at the rotator. Place a container under
the grapple to catch any hydraulic fluid that may be
lost when the hoses are disconnected. Cap the hoses
and plug the ports.
4. Disconnect the rotator at the boom by removing the top

pin of the pivot link.
–UN–06JUN01
NOTE: If necessary, tie a lifting strap to the grapple to

support it in a vertical position.
T139234
OUTJ003,0000410 –19–05FEB01–2/2

081403
PN=978

Removal
1. Disconnect the hoses at the cylinder. Cap the hoses

and plug the ports.
–UN–06JUN01
2. To remove the rotator, remove the six screws and nuts
around the rotator base.
T139235
1—Grapple Cylinder
2—Grapple Frame
3—Rotator
4—’Grapple Close’ Hydraulic Fitting
5—’Grapple Open’ Hydraulic Fitting 40
4020
3
OUTJ003,0000411 –19–05FEB01–1/1

Removal
NOTE: The cylinder may be serviced while the grapple is

on the boom. Lower the boom and firmly support
the grapple. Optionally, remove the grapple from
–UN–06JUN01
the boom and place the grapple on suitable base.
1. If the grapple has been removed from the boom, tie a

lifting strap around the frame to support the grapple in
T139236
a vertical position.

1—Lifting Strap

2. Disconnect the hydraulic hoses at the cylinder.

081403
PN=979
3. Disassemble the pin joint at the cylinder rod, then the

cylinder base. Remove the nut and cap screw.
Remove the washers. Strike out the pin using a brass
mandrel. Be careful not to damage the bushing and the
taper on the pin.
–UN–06JUN01
T139237
40
4020
4
–UN–06JUN01
T139238
OUTJ003,0000412 –19–05FEB01–2/3
4. Repeat the procedure to remove the pin and the other

end.
NOTE: When you pull the mandrel back out, the

connecting rods will drop out of the assembly.
Support the cylinder and the rods to prevent them
–UN–06JUN01
from falling out in an uncontrolled manner.
5. Remove the cylinder.

T139239
–UN–06JUN01
T139240
OUTJ003,0000412 –19–05FEB01–3/3

081403
PN=980

Installation
NOTE: To install the cylinder: The cylinder may be

serviced while the grapple is on the boom. Lower
the boom and firmly support the grapple.
Optionally, remove the grapple from the boom and
place the grapple on suitable base.
1. Make sure holes are clean and free of burrs. Clean

and file away burrs if required.
Grease the bushings and pins.

40
4020
5
OUTJ003,0000414 –19–05FEB01–1/4
2. Assemble the pin joint at the piston rod end of the

cylinder. Insert the pin using a suitable mandrel. Be
careful not to damage the bushing or the taper on the
pin.
–UN–06JUN01
T139243
OUTJ003,0000414 –19–05FEB01–2/4
3. Install the washers, cap screw and nut. Apply a light

coating of oil to the fasteners before installing.
–UN–06JUN01
T139244

081403
PN=981
4. Assemble the pin joint at the cylinder base. Insert the

pin using a suitable mandrel. Lift the connecting rods
and cylinder into place one at a time as the pin
reaches them. Be careful not to damage the bushing or
the taper on the pin.
–UN–06JUN01
5. Apply a light coating of oil to the cap screws and nut.
Pre-assemble one washer and cap screw on the nut.
The nut has a groove on the side that should be
pre-assembled.
T139245
6. Insert the assembly into the pin. Install the washer and
cap screw on the other side.
40
4020
6
–UN–06JUN01
T139246
OUTJ003,0000414 –19–05FEB01–4/4

Installation
NOTE: To install the Rotator: Place the grapple on a

suitable base.
–UN–06JUN01
1. Place rotator on grapple frame. Install screws at rotator

base. Tighten screws to the specified torque.
Supergrip SG 260/360 Grapple Rotator Installation—Specification

T139247
Rotator Mounting Screws—

Torque ......................................................................... 200 N•m (270 lb-ft)

081403
PN=982
2. Connect hoses from grapple cylinder to ports on rotator

base.
2—Grapple Frame
3—Rotator
–UN–06JUN01
5—’Grapple Open’ Hydraulic Fitting
T139235
OUTJ003,0000415 –19–05FEB01–2/2
40
4020
Supergrip SG 260/360 Grapple Installation 7
–UN–06JUN01
T139248
1—Boom 4—’Grapple Rotate Clockwise’ 6—Grapple 9—Top Pin

2—Hose Cover Hose 7—’Grapple Closed’ Hose 10—Pivot Link
3—’Grapple Rotate 5—Rotator 8—’Grapple Open’ Hose
Counterclockwise’ Hose
1. Place the grapple on a suitable base. Position the 4. Carefully operate the grapple functions to remove
boom over the grapple. air from the hydraulic system and to check correct
connections.
2. Attach the grapple to the boom by inserting the top
pin of the pivot link. Install the washer and nut. Bleed the hydraulic system, if necessary. See
3. Connect the hydraulic hoses as shown.
OUTJ003,0000416 –19–05FEB01–1/1

081403
PN=983
Loglift GF25/GF35 Grapple
40
4020
8
–UN–06JUN01
T139249
1—Cylinder 4—Pin 6—Grapple Arm - RH 8—Bushing
2—Frame 5—Screw 7—Connecting Rod 9—Grapple Arm - LH
3—Nut
OUTJ003,0000420 –19–05FEB01–1/1
Loglift GF25/GF35 Grapple Removal
1. Park the vehicle and block the wheels. Prepare a

suitable base to rest the grapple by nailing blocks to a
pallet as illustrated.
–UN–06JUN01
2. Close the grapple completely. extend the boom and

bring the grapple to rest on a suitable base. Support
the boom in this position.
T139250
1—Pallet
2—Nailed Block

081403
PN=984


3. Release the pressure to the hydraulics. Disconnect the

hydraulic hoses to the rotator. Place a container under
the grapple to catch any hydraulic fluid that may be
lost when the hoses are disconnected. Cap the hoses
and plug the ports. 40
4020
9
4. Disconnect the rotator at the boom by removing the top
pin of the pivot link.
–UN–06JUN01
5. If necessary, tie a lifting strap to the frame to support
the grapple in a vertical position.
T139251
OUTJ003,0000417 –19–05FEB01–2/2
Loglift GF25/GF35 Grapple Rotator Removal
1. Disconnect the hoses at the cylinder. Cap the hoses

and plug the ports.
2. Remove the rotator by removing the six screws and

–UN–06JUN01
nuts around the rotator base.
2—Grapple Frame
T139235
3—Rotator
5—’Grapple Open’ Hydraulic Fitting
OUTJ003,0000418 –19–05FEB01–1/1

081403
PN=985
Loglift GF25/GF35 Grapple Cylinder Removal
1. Tie a lifting strap around the grapple frame to support

the grapple in a vertical position.
1—Lifting Strap
–UN–06JUN01
T139253
OUTJ003,0000419 –19–05FEB01–1/2
40
4020
10
–UN–06JUN01
T139254
2. Remove the pin at the piston end of the cylinder. out the pin. Be prepared to support the weight of
Remove the screw, washer and locknut and strike the cylinder with the lifting strap. Be prepared to
out the pin. Manually extend the piston rod and rest catch the connecting rod as it drops out of the
the cylinder end on the grapple frame. assembly.
3. Remove the pin at the base end of the cylinder. 4. Remove the cylinder.
Remove the screw, washer and locknut and strike
OUTJ003,0000419 –19–05FEB01–2/2

081403
PN=986
Loglift GF25/GF35 Grapple Cylinder Installation
40
4020
11
–UN–06JUN01
T139254
1. Fit the base end of the cylinder into the bracket on 3. Fit the piston end of the cylinder into the bracket on
the grapple arm. Manually extend the piston rod the grapple arm.
and rest the cylinder end on the grapple frame. Lift
the connecting rod into position. 4. Apply NEVER-SEEZ to the pin. Insert the pin and
install the screw, washer and locknut.
2. Apply NEVER-SEEZ to the pin. Insert the pin. Be
careful not to damage the bushing or the taper on 5. Lubricate the cylinder bearings from the grease
the pin. Install the screw, washer and locknut. fittings on the cylinder ends.
NEVER-SEEZ is a trademark of Emhart Chemical Group OUTJ003,000041C –19–05FEB01–1/1

081403
PN=987

Installation
1. Place the rotator on the grapple.
2. Install the six screws and nuts around the rotator base.
3. Connect the hoses to the cylinder as shown.
40
4020
12
–UN–06JUN01
T139257
OUTJ003,000041D –19–05FEB01–1/1

081403
PN=988
Loglift GF25/GF35 Grapple Installation
40
4020
13
–UN–06JUN01
T139248
1—Boom 4—’Grapple Rotate Clockwise’ 6—Grapple 9—Top Pin
2—Hose Cover Hose 7—’Grapple Closed’ Hose 10—Pivot Link
3—’Grapple Rotate 5—Rotator 8—’Grapple Open’ Hose
Counterclockwise’ Hose
1. Place the grapple on a suitable base. Position the 4. Carefully operate the grapple functions to remove
boom over the grapple. air from the hydraulic system and to test correct
connections.
2. Attach the grapple to the boom by inserting the top
pin of the pivot link. Install the washer and nut. Bleed the hydraulic system, if necessary. See
3. Connect the hydraulic hoses as shown.
OUTJ003,000041E –19–05FEB01–1/1

081403
PN=989
40
4020
14

081403
PN=990
Group 4030
Grapple Service
Supergrip SG 260/360 Grapple Bushings
Replacement
NOTE: To replace the bushings: Remove the grapple

from the boom. Place the grapple on a suitable
base. Remove the cylinder. Tie a lifting strap to
–UN–06JUN01
the frame.
1. Use a suitable device to lift the grapple and manually

open the arms. Place the grapple on the floor with the
T139241
arms spread.
2. Remove the arms and connecting rods by

40
disassembling the pin joints. To disassemble a pin 4030
joint, remove the nut and cap screw. Remove the 1
washers. Drive out the pin using a brass mandrel. Be
careful not to damage the bushing and the taper on the
pin.
OUTJ003,0000413 –19–05FEB01–1/2
3. Tap out the old bushings using a suitable mandrel. To

protect the sealing abilities of the bushings, be careful
not to damage the edges of the bore.
4. Insert the new bushings using a suitable mandrel. Be

careful not to damage the edges of the bushing.
–UN–06JUN01
5. Assemble the arms and connecting rods.
6. Lift the grapple and manually close the arms. Place the T139242
grapple on a suitable base. Install the cylinder.
OUTJ003,0000413 –19–05FEB01–2/2

081403
PN=991
Grapple Service
Loglift GF25/GF35 Grapple Connecting Rod Bearings Replacement
40
4030
2
–UN–06JUN01
T139255
1—Connecting Rod 3—Grease Fitting 4—Seal Ring 5—Bearing
2—Retaining Ring
1. Remove the connecting rod by removing the screw, 5. Repeat the procedure for the other end of the rod.
washer and locknut and striking out the pin. Place
the rod in a vise with the grease fittings facing 6. Re-install the connecting rod. Apply NEVER-SEEZ
upwards. anti-siezing compound to the pin. Insert the pin and
fasten the screw and locknut. Install the cotter pin
2. Pry out the retaining rings on both sides of the rod on the locknut. One end of the rod is installed with
and remove the seal rings. Strike out the bearing the cylinder.
using a suitable mandrel. Be careful not to damage
the edges of the bore. 7. Lubricate the connecting rod bearings from the
grease fittings on the pins.
3. Insert new bearing with the split in the bearing
facing downwards.
4. Install new seal rings and press in the retaining

rings.
NEVER-SEEZ is a trademark of Emhart Chemical Group OUTJ003,000041A –19–05FEB01–1/1

081403
PN=992
Grapple Service
Loglift GF25/GF35 Grapple Frame Bearings Replacement
40
4030
3
–UN–06JUN01
T139256
1—Frame 2—Seal Ring 3—Bearing 4—Retaining Ring
1. Tie a lifting strap around the grapple frame. 6. Repeat the procedure at each bearing.
2. Remove the grapple arms from the frame by 7. Re-attach the grapple arms to the frame. Apply
removing cotter pin, locknut and screw and striking NEVER-SEEZ to the pin. Insert the pin and fasten
out the pin. the screw and locknut. Install the cotter pin on the
locknut.
3. Place the grapple frame upside down on a work
bench. 8. Lubricate the grapple arm bearings through the
grease fittings on the pins.
4. At each bearing, pry out the retaining ring on each
side of the bearing and remove the seal rings.
Strike out the bushing using a suitable mandrel.
5. Insert the new bushing with the split facing the top
plate of the grapple frame. Install new seal rings
and press in the retaining rings.
NEVER-SEEZ is a trademark of Emhart Chemical Group OUTJ003,000041B –19–05FEB01–1/1

081403
PN=993
Grapple Service
40
4030
4

081403
PN=994
Group 4040
Grapple Rotator
Essential Tools

SERVICEGARD is a trademark of Deere & Company OUTJ003,000042A –19–06FEB01–1/6

40
4040
Lifting Eye, 1/2” . . . . . . . . . . . . . . .Indexator 5010 142 1
Used to lift rotator during Rotator Servicing procedure.
Lifting Eye, 3/4” . . . . . . . . . . . . . . .Indexator 5010 143
–UN–06JUN01
Used to lift rotator during Rotator Servicing procedure.
T139329
OUTJ003,000042A –19–06FEB01–2/6
Seal Installer . . . . . . . . . . . . . . . . . Indexator 5010 125
Used to install Teflon Seals on rotator shaft during Rotator

–UN–06JUN01
T139331
OUTJ003,000042A –19–06FEB01–3/6
Vane Compressor . . . . . . . . . . . . . .Indexator 5010 146
Used to install vanes on rotator shaft during Rotator

–UN–06JUN01
T139333
Continued on next page OUTJ003,000042A –19–06FEB01–4/6

081403
PN=995
Grapple Rotator
Wedge Punch. . . . . . . . . . . . . . . . . Indexator 5010 132
Used to remove wedge from rotator base during Rotator

–UN–06JUN01
T139335
OUTJ003,000042A –19–06FEB01–5/6
40
4040
2 Plug Removal/Installation Tool . . . . . . Indexator 5010 134
Used to remove/install plug on rotator base during Rotator

–UN–06JUN01
T139337
OUTJ003,000042A –19–06FEB01–6/6
Grapple Rotator Servicing
–UN–06JUN01
T139329
Lifting Eye 5010 142 or 5010 143

081403
PN=996
Grapple Rotator
NOTE: See Section 38, Group 3800, for procedures to

remove and install the grapple Rotator.
NOTE: Special Lifting Eye tools 5010 142 or 5010 143

are available.
1. Remove the stator upper plate by removing the cap

screws.
2. Inspect and replace the o-ring under the stator upper

plate.
3. Inspect and replace the Teflon seal kit on the rotator

shaft. A special Seal Installer tool (5010 125) is 40
4040
available. 3
1—Stator Upper Plate
2—O-ring
3—Teflon Seal
4—Rotator Shaft
5—Rotator Body
6—Cap Screw
–UN–06JUN01
T139330
–UN–06JUN01
T139331
Seal Installer Tool 5010 125

081403
PN=997
Grapple Rotator
4. Lift the stator ring off the rotator shaft.
5. Inspect and replace the o-ring under the stator ring.
6. Inspect and replace the vanes. A special Vane

Compressor tool (5010 146) is available to install the
vanes. Push the vanes into the grooves in the rotator
shaft as the tool is rotated.
7. Replace the stator ring on the rotator shaft.
1—Stator Ring
2—O-ring
40 3—Spring
4040 4—Vane
4 5—Rotator Body
–UN–06JUN01
T139332
Vane Compressor Tool 5010 146 –UN–06JUN01
T139333

081403
PN=998
Grapple Rotator
8. Loosen cap screws on rotator base.
9. Remove locking screw from rotator base. Remove cup

springs. Remove wedge. A special Wedge Punch tool
(5010 132) is available for the removal of the wedge.
10. Remove stator lower plate and rotator shaft.
11. Remove and inspect scraper ring.
12. Remove rotator shaft/stator ring assembly from the

rotator base.
13. Remove support ring and seal from rotator shaft. 40

4040
Discard seal. 5
14. Remove, inspect and clean axial ball bearing and

washers.
1—Rotator Shaft
2—Washer
3—Axial Ball Bearing
4—Shim
5—Seal
6—Support Ring
7—Stator Lower Plate
8—Scraper Ring
9—Cap Screw
10—Washer
11—Rotator Base
12—Wedge
13—Cup Spring
14—Locking Screw
–UN–06JUN01
T139334
–UN–06JUN01
T139335
Wedge Punch tool 5010 132

081403
PN=999
Grapple Rotator
15. Install the axial ball bearing, washers and shim on the
rotator shaft. Install the new seal and the support on
the rotator shaft.
16. Lubricate the rotator shaft and place the rotator

shaft/stator ring assembly in the stator lower plate.
17. Install the scraper ring on the rotator shaft.
18. Place the stator upper plate on the assembly. Install

the cap screws assembling the stator sections.
40 Rotator Servicing—Specification
4040 Stator Screws—Torque ................................................. 120 N•m (90 lb-ft)
6
19. Place the rotator shaft/stator ring/stator lower plate
assembly on the rotator base. Check that the
shimming allows the base to rotate freely.
20. Insert the wedge to lock the base to the rotator shaft.
Insert the cup springs and install the plug. A special
Plug Remover/Installer tool (5010 134) is available.
Tighten the cap screws on the rotator base to the
specified torque.
Rotator Servicing—Specification
Rotator Base Screws—Torque ....................................... 50 N•m (35 lb-ft)
1—Stator Upper Plate
2—Stator Upper Plate O-ring
3—Rotator Shaft/Stator Ring Assembly
–UN–06JUN01
4—Stator Ring O-ring
5—Washer
6—Axial Ball Bearing
7—Shim
8—Seal
T139336
9—Support Ring
10—Stator Lower Plate
11—Scraper Ring
12—Rotator Base
13—Wedge
14—Cup Spring
15—Plug
16—Cap Screws
17—Cap Screws
–UN–06JUN01
T139337
Plug Remover/Installer 5010 134
OUTJ003,0000429 –19–06FEB01–5/5

081403
PN=1000
Grapple Rotator
Cleaning the Rotator Magnetic Plug
NOTE: The rotator is equipped with a magnetic plug to

collect metallic impurities from the oil. This plug
should be inspected and cleaned regularly.
To clean the magnetic plug:
1. Lower the grapple to the ground.
–UN–06JUN01
2. Remove and clean plug.
3. Install plug and tighten to the specified torque.

40
T139338
Cleaning the Rotator Magnetic Plug—Specification 4040
Magnetic Plug—Torque ................................................... 20 N•m (15 lb-ft) 7
4. After cleaning the magnetic plug operate the grapple 1—Magnetic Plug
through ten complete rotations in one direction to flush
the oil from the rotator.
OUTJ003,0000428 –19–06FEB01–1/1

081403
PN=1001
Grapple Rotator
40
4040
8

081403
PN=1002
Group 4050
Diagnostics
Diagnose Grapple
JK11466,00000AC –19–06FEB03–1/1
1 Grapple
– – –1/1
40
4050
Grapple Link 1—Grapple Link Pins OK: Go on to next check. 1
Inspect the grapple link. NOT OK: Tighten nut.

Grease pins.
LOOK: Grapple link and pins should be in good
condition. Link pins should be properly lubricated.
Locknut should be tight.
T141621 –UN–18JUN01
1—Damped Pivot Link OK: Go on to next check.
NOTE: The damped pivot link includes a brake NOT OK: Adjust the
arrangement which can be adjusted to provide pressure on the link brake
resistance to the swinging motion of the grapple. pads by tightening the
nut. If link cannot be
Start the engine. Turn the operator’s seat to face the adjusted tight enough,
rear to enable the boom controls. replace the brake pads.
T141622 –UN–18JUN01
Slew the boom. Observe the grapple.
Damped Pivot Link
LOOK: Grapple should not swing excessively.
– – –1/1
Grapple Frame and Arms Inspect the grapple frame and arms. OK: Go on to next check.
LOOK: Grapple frame and arms should be in good NOT OK: Repair or
condition and not have dents or indications of wear. replace grapple frame
and arms, as required.
T141623 –UN–18JUN01
– – –1/1

081403
PN=1003
Diagnostics
Grapple Arm and Inspect grapple arm and cylinder pins. OK: Go on to next check
Cylinder Pins
LOOK: Grapple arm and cylinder pins should be in good NOT OK: Tighten
condition. Pins should be properly lubricated. Fasteners fasteners. Grease pins.
should be tight. Replace pins, as
required.
T141624 –UN–18JUN01
Grapple Arm and Cylinder
Pins
– – –1/1
40
4050
2 Hoses and Fittings Inspect hoses and fittings for tightness. OK: Go on to next check.
LOOK: Fittings should be tight and free of leaks. Check for accumulations of dust and NOT OK: Tighten fittings
dirt that may indicate leaks. or replace o-rings on
fittings, as required.
LOOK: Hoses should not be twisted on kinked or show indications of wear. Replace hoses as
required.
– – –1/1
Cylinder Rod Seals Check cylinder rod seals. OK: Go on to next check.
LOOK: Seals should not show any indication of leaks. NOT OK: Service
cylinder.
NOTE: See Section 03 for procedures to test cylinder
internal seals.
T141632 –UN–18JUN01
– – –1/1
Grapple Rotate Motor Inspect grapple rotate motor. OK: Go on to next check.
LOOK: Motor should be in good condition. Check for NOT OK: Tighten bolts.
accumulations of dust and dirt that may indicate leaks.
Mounting bolts should be tight.
T141626 –UN–18JUN01
– – –1/1

081403
PN=1004
Diagnostics
Grapple Rotate OK: Go on to next check.
NOT OK: Diagnose

electrical control circuits.
Remedy possible
problems. Check
hydraulic hose
connections.
T142800 –UN–12JUL01 T142801 –UN–12JUL01
40
Start engine. Turn seat to face rear of machine in order to enable the boom functions. 4050
3
Move the right joystick to the right (away from the operator).
LOOK: The grapple should rotate clockwise.
Move the right joystick to the right (towards the operator).
LOOK: The grapple should rotate counterclockwise.

– – –1/1

081403
PN=1005
Diagnostics
Grapple Open/Close OK: Go on to next check.
NOT OK: Diagnose

electrical control circuits.
Remedy possible
problems. Check
hydraulic hose
connections.
T142802 –UN–12JUL01
40
4050
4
T142803 –UN–12JUL01
Start engine. Turn seat to face rear of machine in order to enable the boom functions.
Press the upper button on the left joystick.
LOOK: The grapple should open.
Press the lower button on the left joystick.
LOOK: The grapple should close.
– – –1/1

081403
PN=1006
Section 45
Tool Drawings
Contents
Page
Group 4510—Dealer Fabricated Tools

TA0898 Frame Support. . . . . . . . . . . . . . . . .45-4510-1
TA0899 Axle Support . . . . . . . . . . . . . . . . . .45-4510-2
TA0902 Frame Support. . . . . . . . . . . . . . . . .45-4510-3
TA0904 Wrench Adapter, boom Bolts . . . . . .45-4510-4
TA0908 Nut Driver . . . . . . . . . . . . . . . . . . . .45-4510-5
TA0909#1 Driver, Drive Shaft Bearing
Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-6
TA0909#2 Driver, Drive Shaft Bearing
Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-7 45
TA0909#3 Driver, Drive Shaft Seals . . . . . . .45-4510-8
TA0910 Bearing Driver . . . . . . . . . . . . . . . . .45-4510-9
TA0911 Bearing Driver . . . . . . . . . . . . . . . .45-4510-10
TA0912 Bearing Driver . . . . . . . . . . . . . . . .45-4510-11
TA0913 Bearing/Pin Driver . . . . . . . . . . . . .45-4510-12
TA0914 Pin Driver. . . . . . . . . . . . . . . . . . . .45-4510-13
TA0917 Nut Driver . . . . . . . . . . . . . . . . . . .45-4510-14
TA0918 Lifting Bracket . . . . . . . . . . . . . . . .45-4510-15
TA0949 Cab Support Bar . . . . . . . . . . . . . .45-4510-18
479265-1 O-ring Seal Expander . . . . . . . . .45-4510-19
479265-2 Seal Pusher. . . . . . . . . . . . . . . . .45-4510-20
479266-1 Piston Installation Tool . . . . . . . .45-4510-21
F603762/F603764 Axle Mounting Bolt
Installation Tool . . . . . . . . . . . . . . . . . . . .45-4510-22

081403
PN=1
Contents
45

081403
PN=2
Group 4510
Dealer Fabricated Tools
TA0898 Frame Support
45
4510
1
–UN–06JUN01
T139339
Used to support front end of the front frame during The Frame Support is placed under front end of front
Frame Joint Removal procedure. frame during bogie removal and installation.
OUTJ003,000042F –19–06FEB01–1/1

081403
PN=1009
TA0899 Axle Support
45
4510
2
–UN–06JUN01
T139340
Used to support front bogie during Frame Joint Support placed under each bogie housing during bogie
Removal procedure. removal and installation.
OUTJ003,000042D –19–06FEB01–1/1

081403
PN=1010
TA0902 Frame Support
45
4510
3
–UN–06JUN01
T139341
Used to support hinge end of the front frame during Support placed under back end of front frame during
Frame Joint Removal procedure. bogie removal and installation.
OUTJ003,000042E –19–06FEB01–1/1

081403
PN=1011
TA0904 Wrench Adapter, boom Bolts
45
4510
4
–UN–06JUN01
T139343
A—19 mm Square driver x 3.0” B—19 mm Hex driver x 2.0”
Used to torque boom bolts. • 2.50” Suitable Alloy Impact Steel
Materials required:
OUTJ003,000043F –19–06FEB01–1/1

081403
PN=1012
TA0908 Nut Driver
45
4510
5
–UN–06JUN01
T139344
A—1” Square Thru D—16 mm Diameter Hole, 4 E—Snap Socket #IM732 F—10 ± 1.5 mm Recess
B—160 mm I.D. Recess Places 1” Drive - 1” Shallow
C—74 mm I.D. Recess Single Square Modified
Used to remove and install nut on frame joint during • .750” N.S. Plate G40-21-44W
Frame Joint Removal procedure.
Materials required:
OUTJ003,0000431 –19–06FEB01–1/1

081403
PN=1013
TA0909#1 Driver, Drive Shaft Bearing Cups
45
4510
6
–UN–06JUN01
T139345
A—Knurled B—Round Nose
Used to install Bearing Cups on frame during Frame • CR Round Stock

Materials required:
OUTJ003,0000440 –19–06FEB01–1/1

081403
PN=1014
TA0909#2 Driver, Drive Shaft Bearing Cone
45
4510
7
–UN–06JUN01
T139346
Used to install Bearing Cone on drive shaft during • CR Round Stock

Frame Hinge Drive Shaft Installation.
Materials required:
OUTJ003,0000441 –19–06FEB01–1/1

081403
PN=1015
TA0909#3 Driver, Drive Shaft Seals
45
4510
8
–UN–06JUN01
T139347
Used to install Drive Shaft Seals during Frame Hinge • CR Round Stock
Drive Shaft Installation.
Materials required:
OUTJ003,0000442 –19–06FEB01–1/1

081403
PN=1016
TA0910 Bearing Driver
45
4510
9
–UN–06JUN01
T139352
A—Knurled
Used to install larger rear bearing cup in rear frame • 1-1/4 “ Diameter CR Round x 250 lg
bore during Frame Joint Bearings Installation • 50 mm G40 21 x 44W Plate Steel x 270 mm
procedure. Diameter
Materials required: NOTE: All tolerances ± 1.5 unless otherwise specified.
• 3/8 x 1-1/2” HSTL Flat x 104 mm
OUTJ003,0000432 –19–06FEB01–1/1

081403
PN=1017
45
4510
10
–UN–06JUN01
T139353
A—Knurled
Used to install smaller front bearing cup in rear frame • 1-1/4 “ Diameter CR Round x 250
bore during Frame Joint Bearings Installation • 50 mm G40 21 x 44W Plate Steel x 230 mm
procedure. Diameter
Materials required: NOTE: All tolerances ± 1.5 unless otherwise specified.
• 3/8 x 1-1/2” HSTL Flat x 86 mm
OUTJ003,0000433 –19–06FEB01–1/1

081403
PN=1018
45
4510
11
–UN–06JUN01
T139354
A—Knurled
Used to install upper hinge pin bearing cones during • Stamp Tool Number on handle.
Hinge Pin Installation procedure. • All tolerances ±1.5 mm unless otherwise specified.
• Machine finish on driver cup to be 125
Materials required:
• 1.25” Diameter (31.75 mm) CR Round

• 30 mm or 1.25” G40.21-44W STLRX 95 mm
diameter
or substitute with CR Steel Round
OUTJ003,0000435 –19–06FEB01–1/1

081403
PN=1019
TA0913 Bearing/Pin Driver
–UN–06JUN01
45
4510
12
T139355
A—Knurled
Used to install lower hinge pin spherical bearing during • 30 mm or 1.25” G40.21-44W Steel Plate x 110 mm
Hinge Pin Installation procedure. Diameter Rough
or substitute with CR Round
Used to install lower hinge pin during Hinge Pin
Installation procedure. • Stamp Tool Number on handle.
• All tolerances ±1.5 mm unless otherwise specified.
Materials required: • Machine finish on driver cup to be 125
OUTJ003,0000436 –19–06FEB01–1/1

081403
PN=1020
TA0914 Pin Driver
45
4510
13
–UN–06JUN01
T139356
A—Knurled
Used to install upper hinge pin during Hinge Pin • Stamp Tool Number on handle.
Installation procedure. • All tolerances ±1.5 mm unless otherwise specified.
• Machine finish on driver cup to be 125
Materials required:

• 30 mm or 1.25” G40.21-44W STLRX 95 mm
diameter
or substitute with CR Steel Round
OUTJ003,0000438 –19–06FEB01–1/1

081403
PN=1021
TA0917 Nut Driver
45
4510
14
–UN–06JUN01
T139357
A—Typical 4 Places B—Preheat C—Cut Socket to 25 mm D—.50” Square Drive

Socket is Snap-on IM500 -
1-9/16” x 1/2” Drive Shallow
Used to install upper hinge pin nut during Hinge Pin • CR Round C 1020
Installation procedure. Carburize and case harden to RC45
Materials required:
OUTJ003,0000439 –19–06FEB01–1/1

081403
PN=1022
TA0918 Lifting Bracket
45
4510
15
–UN–06JUN01
T139358
TA0918-1 Lifting Bracket Assembly
Used to lift frame joint during Frame Joint Removal • .25” x 2.5” MS. Flat x 62 mm lg
procedure. • 2.5” Square x .188” Wall Tube x 338 mm
• 2.5” Square x .188” Wall Tube x 450 mm
Materials required: • .75” Square Key Stock x 118 mm
• .75” Diameter CR C1020 Round x 338 mm

081403
PN=1023
45
4510
16
–UN–06JUN01
T139359
TA0918-2 Lifting Bracket, Base
Base used in TA0918 Lifting Bracket Assembly. • 4.75” CR Round G1020 x 164 mm
Materials required:

081403
PN=1024
45
4510
17
–UN–06JUN01
T139342
TA0918-3 Lifting Bracket, Nut
A—M6 x 6 Thread B—14 mm Diameter Hole

4 Places @ 90°
Nut used in TA0918 Lifting Bracket Assembly. • 3.50” CR Round

• 3.0” O.D. Thin Wall M.S. Tubing
Materials required:
OUTJ003,0000430 –19–06FEB01–3/3

081403
PN=1025
TA0949 Cab Support Bar
–UN–20AUG01
45
4510
18
T139360
TA0949 Cab Support Bar
Used to support cab in raised position during servicing • 1.0 O.D. x .50 I.D. Tube
procedures. • 1/4 x 3 MS. Flat
• .13 or .60 rubber glued to inside face
Materials required:
OUTJ003,0000451 –19–07FEB01–1/1

081403
PN=1026
479265-1 O-ring Seal Expander
45
4510
19
–UN–06JUN01
T139361
Used to expand the diameter of the o-ring seals
installed on the frame brake pistons during Frame
Brake Unit Servicing procedure.
OUTJ003,000043A –19–06FEB01–1/1

081403
PN=1027
479265-2 Seal Pusher
45
4510
20
–UN–06JUN01
T139363
Used to push the seals over the bushings and into the
grooves in the pistons during Frame Brake Unit
OUTJ003,000043B –19–06FEB01–1/1

081403
PN=1028
479266-1 Piston Installation Tool
45
4510
21
–UN–06JUN01
T139364
Used to guide the complete piston assembly into the
frame brake housing during Frame Brake Unit
OUTJ003,000043E –19–06FEB01–1/1

081403
PN=1029
F603762/F603764 Axle Mounting Bolt Installation Tool
45
4510
22
–UN–06JUN01
T139365
F603762 Axle Mounting Bolt Installation Tool - Handle
1—AV 19 2—3/4” Square
Used to torque long horizontal axle mounting bolts

during Bogie Removal and Installation procedures.

081403
PN=1030
45
4510
23
–UN–06JUN01
T139366
F603764 Axle Mounting Bolt Installation Tool
Used to torque long horizontal axle mounting bolts

during Bogie Removal and Installation procedures.
OUTJ003,0000443 –19–06FEB01–2/2

081403
PN=1031
45
4510
24

081403
PN=1032
Section 80
Optional Equipments
Contents
Page
Group 8010— Engine Preheater; EbenSprächer

Operation and maintenence . . . . . . . . . . . . .80-8010-1
Group 8020—1410 and 1710D Decking Blade

Lowering the Decking Blade . . . . . . . . . . . . .80-8020-1
Decking Blade’s Float . . . . . . . . . . . . . . . . . .80-8020-2
Group 8030—Fire Extinguisher

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-8030-1
Fire Alarm and Actions . . . . . . . . . . . . . . . . .80-8030-2
After a fire . . . . . . . . . . . . . . . . . . . . . . . . . . .80-8030-5
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . .80-8030-6
80

081403
PN=1
Contents
80

081403
PN=2
Group 8010
Engine Preheater; EbenSprächer
Operation and maintenence
–UN–28MAR02
80
8010
1
T153144
Sektionsritning
WE—Water inlet 2—Flame sensor 8—Heat exchanger 14—Fuel branch piece

WA—Water outlet 3—Combustion chamber 9—Overheating switch 15—Cable tree
V—Combustion air 4—Control unit 10—Water pump 16—Fuse bracket
B—Fuel 5—Heater plug 11—Exhaust silencer 17—Relay for switching on the
A—Fumes 6—Temperature sensor 12—Combustion air silencer vechicle’s fan
1—Combustion motor 7—Flame tube 13—Fuel feeder pump 18—Timer
NOTE: See Ebensprächer manual enclosed for • The control lamp on the timer will light on starting
detailed information • The combustion air fan and the water pump start
to run, and the ignition plug glows (preliminary
The preheater heats the engine, cabin and hydraulic glow).
system according to preselected times. • After a preliminary glow period (about 40
seconds), and regardless of operation, the fuel
The preheater is controlled by a timer. See information dispenser pump starts to supply fuel at rapid
later on. impulse frequency to give full load in the
combustion chamber and the fuel ignites
NOTE: Before starting the heater or before
pre-programming the heating sequence, set The ignition plug is switched off when the control
the cabin heating control to its maximum open unit receives a signal from the flame sensor that the
position and the fan speed to position 1. fuel is burning.
1. Switching on 2. Heating
Continued on next page EL62757,00001FF –19–24APR02–1/8

081403
PN=1035
• Depending on the heating need the heating b. A renewed start will be made if the burner
power will be automatically adjusted: 5000 W / should go out during operation. The malfunction
2200 W switch-off will then be actuated if it does not start
• The settings of the control unit dictate the within 90 seconds or if it starts and then goes
temperatures at which the power level changes. out again within 3 minutes
• Should there be only a limited need for heat, c. If overheated (e.g., due to lack of water, poorly
enabling the coolant to reach a temperature of 85 vented cooling system), the overheating sensor
°C (185 °F), the heating system will switch over switches off and consequently the fuel supply
to an inactive state. This is when the fan will will be cut off, thus actuating the malfunction
continue operating for another 130 seconds to switch-off. After rectifying the cause of
cool down the heater overheating, press in the button on the
• The timer warning lamp will still be on and the overheating circuit breaker and also reset the
water pump will go on operating. malfunction switch-off as above, so that the
• As soon as the coolant temperature drops to a heater can be started.
level of 75°C (167 °F), the heating system will be d. The malfunction switch-off will be activated if
automatically engaged again. voltage of the electrical system should fall below
about 20 V or rise above about 28 V.
IMPORTANT: Do not start the diesel engine while e. The heater will not start at all if the ignition plug
the preheater is running. Similarly, is defective or if the electric circuit to the
wait until the trailer operation (appr. dispenser pump is broken.
two minutes) is over before you start f. Functioning of the blower motor is checked on
the engine. Otherwise, the preheater starting and the malfunction switch-off will be
may be damaged. activated if it is not running.
80 5. Correction of malfunction
8010
2
3. Switching off
The supply of fuel is cut off when the timer switches Check the following items if the heater does not start
the heater off. The indicating lamp goes out. when being switched on:
The combustion air fan and the water pump
continue to run for about 130 seconds and are then ❒ Also check the fuse for the cab fan. No heated air
switched off automatically. will enter the cab if this fuse has blown, although
4. Safety devices the heater starts and heats the engine.
The flame is monitored by the flame sensor, and ❒ Switch the heater OFF and ON, but not more than
the maximum permitted temperature by the twice. Authorized personnel or workshop should be
overheating switch. Both of these affect the control contacted if the heater still does not start.
unit, which switches off the burner in the event of
malfunctioning. Maintenance of the engine preheater
a. The starting sequence will be repeated if the
heater does not ignite within 90 seconds after Remember to keep the preheater and its surroundings
the fuel supply is turned on. If the heater still clean, especially near the exhaust system of the
does not start within the additional 90 seconds, preheater.
the malfunction switch-off will take place. The
malfunction switch-off can be cancelled by briefly ❒ Check hoses, joints and other components for
switching the heater off and then on again overall shape and tightness.

081403
PN=1036
❒ Start the heater about once a month even during

CAUTION: Risk of fire. the summer and allow it to run for a few minutes to
prevent binding of the fan and water pump.
❒ Always switch off the battery main switch to protect
the control unit before any electric welding on the
machine, also see Section 8, welding.
80
8010
3

081403
PN=1037
Timer for engine and cabin preheater
The preheater is started with the timer, i.e., either directly

or at preset time.
All signals in the display will flash when electric power

supply is connected. The heater cannot be switched on in
this mode, i.e., the heater timer must first be properly set.
1. Setting the timer

• Press and hold down (1) until the time flashes (basic
setting for the first time: press (1) briefly)
• Set the current time using (4) and (5).
When the time display stops flashing, the time has
–UN–03OCT02
been stored.
The weekday begins to flash.
• Set the current weekday using (4) and (5)
T153141
When the display stops flashing, the setting has been
stored. Acceptable setting can also be skipped by
pressing (1). When the ignition switch of the machine
is turned on, the current time is displayed in the timer. 1—Time indication/setting
2—Preselection
3—Heating on
When the ignition switch is turned off the display 4—Adjust backward
80 disappears after 15 seconds. When there is no display 5—Adjust forward
8010
4
the current time appears by pressing (1) . 6—Stored memory indication
7—Day of week
8—Symbol for remote control (opt. eq.)
NOTE: Before starting the heater or before 9—Current time / program time
pre-programming the heating sequence, set the 10—Temperature indication (opt. eq.)
cabin heating control to its maximum open 11—Operating display
position and the fan speed to position
NOTE: If a fault occurs when you switch the heater on (or

if the heater is on), the operating display shows
"F" and a fault code (two numbers) in 15 seconds.
See Malfunction codes later on this section.
2. Direct starting of heater without preselection

(ignition of the base machine is off)
• Press (3), start of heating.
Heating symbol (3) and the heating duration is

displayed. The heating duration is factory-preset to 120
min.

081403
PN=1038
3. Changing the heating duration

a. Temporarily:
Start heating; press (3).
To reduce heating duration: press (4).
To increase heating duration (to max. 120 min):
press (5).
b. Permanently
Do not switch heating on.
Press the (4) key and hold it down (approx. 3 s) until

the display appears and flashes.
Release the key.
–UN–03OCT02
Then set the heating duration (10...120 min) using
the(4) or (5) key. The new heating duration is set when
the display disappears.
T153141
4. Switching off the heater
Press (3), automatic cooling phase, about 130
seconds.
5. Heating without preselection (ignition of the base
machine is on)
Press (3) . 80
8010
Heating stays in operation until ignition is switched off. 5
After ignition is switched off, a residual heating period
of 15 min remains.
This can be changed (1...120 min) by pressing the (4)
or (5) key. Switching off the heater: press (3).
6. Heating operation preselection
There are three preset times in the memory. Only one
can be activated at a time (the memory number is
displayed).
A) Set the program time and day
Press the key (2)(1...3 times) until the desired memory
display begins to flash.
Briefly press and then release (4) or (5) . The program
time flashes.
Then set the program time for heating using (4) or (5).
When the display stops flashing, the time has been
stored. The program day begins to flash, set the
weekday using (4) or (5).
The preselected time and weekday are stored as soon
as the display changes over to the current time.

081403
PN=1039
Flashing ’heating on’ key (3) indicates an activated

preselection. The current time disappears and only the
activated memory number is displayed.
When there is no memory number displayed no
memory is activated. This is done by pressing (2)
several times. Neutral setting is after the memory
number 3.
B) Checking activated memory
Press (2) . The activated preselected time and
preselected day are displayed for approx. 5 s.
7. Advice in event of malfunctioning:
❒ In the event of malfunctioning, switch off and then
on again (but not more than twice)
❒ check the main fuse
❒ ensure that the flow of air is unrestricted
❒ contact an authorized service agent.
NOTE: If you try to switch on the heater without result

five times in a row or if the heater overheats three
times in a row, the operation will be disabled.
(Fault code F50 or F15).
Malfunction codes of the engine preheater
80 Example: display shows: F33 (current fault) and

8010
6
heating-on symbol flashes

081403
PN=1040
F00 No malfunction
F01 Warning about overvoltage
F02 Warning about undervoltage
F09 TRS 003 unplugging
F10 Overvoltage shutoff
F11 Undervoltage shutoff
F12 Overheating
F13 Possible overheating detected
F14 Too big difference between overheating- and water temperature
*F15 Operation disable because perm.number of possible overheatings exceeded
F20 Glow plug break
F21 Glow plug output overload
F33 Malfunction in combustion engine
F37 Waterpump not working
F42 Water pump short-circuit
F43 Other component short-circuit
F47 Fuel pump short-circuit
F48 Fuel pump break
*F50 Operation disable due to excessive start attempts
F51 Flame signal already at start
F52 Safety time exceeded- no start
80
F53 Flame cutout from POWER control stage 8010
F54 Flame cutout, HIGH-setting 7
F55 Flame cutout, Medium-setting
F56 Flame cutout, LOW-setting
F59 Too quick rise in water temperature.
F60 Temperature sensor break
F61 Temperature sensor short-circuit
F64 Flame sensor break
F65 Flame sensor short-circuit
F71 Overheating sensor break
F72 Overheating sensor short-circuit
F90 Control unit defective (internal fault / reset)
F93 Control unit defective (RAM-error)
F94 Control unit defective (EPROM-error)
F97 Internal control unit fault
*) Steps to cancel the disabled operation (fault code

F15 or F50)
1. A How to empty the fault memory:

081403
PN=1041
• Switch power on.

• Press(3) . Fault code appears.
• Press (1) to the bottom and in 2 seconds
simultaneously press (2).
• Switch power off
• Press (1) and (2) simultaneously and switch the
power on. Display shows: - - : - -
• Display flashes, heating-on symbol doesn’t.
• After about 3 seconds the heater will go on (the
disabled operation is canceled).
• Display, when the heater has started to operate:
AF : 00
2. In case of having the error F50, do the following:
• Disconnect the wire coming to the fuel pump of the

preheater.
• Try to start the preheater normally.
This gives the alarm F48 to the display.
• After that, it is possible to deactivate the fault code
as described above.
80
8010
8
EL62757,00001FF –19–24APR02–8/8

081403
PN=1042
Group 8020
1410 and 1710D Decking Blade
Lowering the Decking Blade
If the machine dies and the decking blade has stayed in

upper position, the engine hood can not be opened before
the decking blade has been lowered down.
–UN–12SEP02
Operator can lower the decking blade with the help of
cylinders that are used through a tap (3) at the main
switch.
T159330
NOTE: After lowering, close the tap by twisting it.
1410 D and 1710 D decking blade

lowering
EL62757,0000206 –19–24APR02–1/1
80
8020
1

081403
PN=1043
1410 and 1710D Decking Blade
Decking Blade’s Float
Decking blade’s float position switch (17) is situated on

the front dashboard.
IMPORTANT: Diesel engine must be on, before you

can use the float position.
The switch has 3 positions, 0, 1, 2
• Float position is ON, when you press the switch to

position 2.
After that the switch will stay in position 1.
• Position 0 will stop the float position.
NOTE: Stopping the engine also stops floating.
NOTE: If you start the engine and the switch is in position

1, you can’t use the float position.
Stop the engine, choose position 0 and start

again.
17—Decking blade float position switch

80
8020
2
–UN–17OCT02
T152191
EL62757,0000207 –19–24APR02–1/1

081403
PN=1044
Group 8030
Fire Extinguisher
General
Fire extinguisher system1.
This installation includes a container with extinguishing

medium, connected to a system of pipes/hoses with
nozzles in the protected areas.
Heat detectors are actuated in the event of fire and make

an electric circuit to the fire alarm.
The alarm is given by:
• pulsating light and sound signals

• red light on the cab roof
• horn underneath the cover on the hydraulic reservoir.
80
8030
1
in certain markets / optional equipment 1
EL62757,0000200 –19–24APR02–1/1

081403
PN=1045
Fire Extinguisher
Fire Alarm and Actions
Fire alarm during operating the machine
NOTE: Only the fire alarm will be activated when the

main switch is ON
–UN–12SEP02
ACTIONS:
Operator!
T152199
1. Trigger the alarm
2. Take a hand-held extinguisher with you and check that
the fire does not spread.
The fire fighting installation can be triggered in three

ways:
1. Manually from the cab by pressing the triggering
–UN–05MAR02
button (3) on the control unit.
1—Warning light - machine malfunction (yellow)
T152200A
2—Fire alarm light (red)
3—Control unit trigger button
80
8030 Alarm lights
2

081403
PN=1046
Fire Extinguisher
2. Breaking the main power supply by turning the main

switch (1) OFF
3. Triggering device, pull the triggering handle.
Fire alarm when the machine is not operated
The fire extinguisher system will be automatically triggered

in the event of fire when the machine is unmanned and
the main switch is OFF.
1—Main Switch
4—Triggering handle
–UN–05MAR02
T152211
80
8030
3
–UN–15SEP02
T152355

081403
PN=1047
Fire Extinguisher
80
8030
4
Fire Extinguisher System in the machine 6. Junction box –UN–15SEP02

T159363
a. Central Unit
1. Fire extinguisher b. Fuse box
2. Signal Horn c. Signal horn
3. Support d. Not in use
4. Fuse box e. Thermal sensor
5. Connector housing f. Tripping
EL62757,0000202 –19–24APR02–3/3

081403
PN=1048
Fire Extinguisher
After a fire
The alarm ceases when the fire is put out and detectors
have cooled down. Open the ventilation covers so that
smoke and fumes can be vented.
IMPORTANT: Before opening any covers or engine

hood, wait at least 30 minutes to let the
machine cool down.
IMPORTANT: Be prepared with a hand extinguisher

while airing the machine.
CAUTION: Avoid breathing in fumes from the

fire.
Clean the machine with water as soon as possible after a

fire.
Restoring the machine after a fire: Contact service

personnel to establish the reason for the fire and to
restore the fire extinguisher system.
80
8030
5
EL62757,0000201 –19–24APR02–1/1

081403
PN=1049
Fire Extinguisher
Control unit
1. Green light emitting diode, indicating that the system is

operative.
Goes out if the power supply is broken.
2. Yellow light emitting diode, supervising the detector
–UN–06MAR02
circuit.
Lights up if the circuit is broken or if the end resistor is
removed.
3. Yellow light emitting diode, supervising the circuit to
T152354
the gas generator in the mechanical / electrical
triggering unit.
Lights up if the circuit is broken or when the gas Control unit of the fire extinguisher system
generator is triggered
1—Green
4. Yellow light emitting diode. 2—Yellow
Lights up when the system is in the manual mode = 3—Yellow
Battery master switch is ON. 4—Yellow
5. Triggering button for the system. 5—Triggering button for the system
6—Toggle switch for alarm and error testing
Issues a pulsating light when the fire alarm is given
and a steady light when the system is triggered
electrically.
6. Toggle switch for alarm and error testing.
a. Upper position, testing the alarm.
The alarm 5 of the installation shall be activated,
80 push-button (5) flashes and diode (1) and (3) will
8030
6
show a steady light.
b. Middle position: Simulating break of the
detector circuit and the detonator loop.
Diodes 1, 2 and 3 should light. Diode 4 should also
light if the battery master switch is ON. The steady
light for the electrically triggered system will also be
reset when the toggle switch is moved to the middle
position.
c. Lower position, operating mode:
Diode 1 should light, and also 4 if the battery
master switch is ON.
Check every day:
❒ That diode 1 lights up, and also 4 if the battery master

switch is ON, when switch 6 is in the operation mode.

081403
PN=1050
Fire Extinguisher
IMPORTANT: Before leaving the machine, remember

to turn the main switch to 0 to set the
automatic monitoring and triggering of
the fire extinguishers.
Check every week:
❒ That diodes 1, 2 and 3 light up when switch 6 is set to

its middle position.
❒ That diode 4 also lights up if the battery master switch
is ON
❒ That the light and sound alarms are activated and that
push-button 5 flashes, diodes 1 and 3 light up when
switch 6 is moved to its upper position.
❒ Ensure that the hand-held extinguishers are in place
and that the indicators show that they are full.
Annual inspection
The system is to be inspected once a year by authorized

service personnel. This inspection is a condition of the
insurance companies.
IMPORTANT: Disconnect the connector of the control

unit before carrying out any of the 80
8030
following tasks; 7
• pressure-jet washing
• steam-jet washing
• electric welding
• battery charging
EL62757,0000203 –19–24APR02–2/2

081403
PN=1051
Fire Extinguisher
80
8030
8

081403
PN=1052
Index
Page Page
A Bleeding Air
Brake System . . . . . . . . . . . . . . . . . . . .02-0250-17
AC/Heater Controls Hydrostatic System . . . . . . . . . . . . . . . .03-0320-49
Control Settings . . . . . . . . . . . . . . . . . . .19-1910-5 Working Hydraulic System . . . . . . . . . .03-0330-10
Air Conditioner Bogie
First aid. . . . . . . . . . . . . . . . . . . . . . . . . .19-1910-9 Changing Bogie Housings Oil . . . . . . . .02-0240-23
Introduction . . . . . . . . . . . . . . . . . . . . . . .19-1920-1 Bogie Removal and Installation
Risks and counter-measures. . . . . . . . . .19-1910-8 F603762/F603764 Axle Mounting Bolt Installation
Air conditioning Tool . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-22
Hoses and tubing inspection . . . . . . . . .19-1930-10 TA0898 Frame Support. . . . . . . . . . . . . .45-4510-1
Leak testing . . . . . . . . . . . . . . . . . . . . .19-1930-12 TA0899 Axle Support . . . . . . . . . . . . . . .45-4510-2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1640-8 TA0902 Frame Support. . . . . . . . . . . . . .45-4510-3
Alternator Bogies
Installation. . . . . . . . . . . . . . . . . . . . . . . .16-1660-1 Front bogie Axle Installation . . . . . . . . . .02-0240-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . .16-1660-1 Front Bogie Installation . . . . . . . . . . . . . .02-0240-4
Anti-slip and bogie tracks fitting . . . . . . . . .01-0110-6 Boom
Auxiliary Function Pressure Assembly instructions . . . . . . . . . . . . . . 37 -3720-3
Check and Adjust . . . . . . . . . . . . . . . . . .03-0340-4 Boom Cylinders Removal and Installation . . . . . .37
Auxiliary Valve -3720-3
Installation. . . . . . . . . . . . . . . . . . . . . . .03-0335-27 Description . . . . . . . . . . . . . . . . . . . . . . 37 -3710-1
Removal . . . . . . . . . . . . . . . . . . . . . . . .03-0335-26 Diagnostic Information. . . . . . . . . . . . . . 37 -3740-3
Removal and Installation . . . . . . . . . . . .03-0335-26 Extension Boom Removal . . . . . . . . . . 37 -3720-16
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-17 Extension Cylinder Installation . . . . . . 37 -3720-16
Axle Oil Extension Cylinder Servicing. . . . . . . . . .03-0350-8
Checking Bogie Housings Oil Level . . .02-0240-22 Jib Cylinder Removal . . . . . . . . . . . . . 37 -3720-12
Checking Rear Differential Oil Level . . .02-0240-18 boom
Axles Main Boom Cylinder Removal. . . . . . . . 37 -3720-3
Change Bogie Axle Differential Oil . . . .02-0240-19 Boom
Change Bogie Housings Oil . . . . . . . . .02-0240-23 Main Boom Cylinder Servicing . . . . . . . .03-0350-5 Indx
Outer Cylinder Installation . . . . . . . . . . 37 -3720-14 1
Change Single Axle Differential Oil . . . .02-0240-21
Change Single Axle Wheel Ends Oil . . .02-0240-24 Boom CF7
Check Bogie Housings Oil Level . . . . . .02-0240-22 Specifications . . . . . . . . . . . . . . . . . . . .00-0020-21
Check Single Axle Wheel Ends Oil Boom CF885
Level . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-24 Specifications . . . . . . . . . . . . . . . . . . . .00-0020-31
Front Bogie Installation . . . . . . . . . . . . . .02-0240-4 Boom Control Valve
Rear Axle Installation . . . . . . . . . . . . . .02-0240-13 Operation . . . . . . . . . . . . . . . . . . . . . . .03-0310-13
Axles and Bogies Specifications . . . . . . . . . . . . . . . . . . . .03-0310-13
Operation . . . . . . . . . . . . . . . . . . . . . . . .02-0240-3 Boom Cylinders
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-10 Main Boom Cylinder Servicing . . . . . . . .03-0350-5
Booster batteries . . . . . . . . . . . . . . . . . . . .16-1610-8
Brake fluid
Quality . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-9
Brake Hydraulics
B Diagnostic Information. . . . . . . . . . . . . .03-0370-14
Brake pedal circuit
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1610-4 Filling . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-14
Battery Brakes
Booster . . . . . . . . . . . . . . . . . . . . . . . . . .16-1610-8 Charging pressure . . . . . . . . . . . . . . . .02-0250-16
Malfunctions . . . . . . . . . . . . . . . . . . . . . .16-1610-7 Checking. . . . . . . . . . . . . . . . . . . . . . . .02-0250-14
Operation . . . . . . . . . . . . . . . . . . . . . . . .16-1610-4 Checking Drive Brake
Bleeding Pedal Brake. . . . . . . . . . . . . . . . . . . .02-0250-17
Working hydraulic system . . . . . . . . . . 03-0330-12, Mechanical Adjustment . . . . . . . . . . . . .02-0250-10
03-0330-14 Mechanical adjustment . . . . . . . . . . . . .02-0250-15
tm2123 (14AUG03) Index-1 Forwarders Technical Manual

081403
PN=1
Index
Page Page
Operation . . . . . . . . . . . . . . . . . . . . . . . .02-0250-2 Loglift GF25/GF35 Grapple Cylinder

Work Brake . . . . . . . . . . . . . . . . . . . . . .02-0250-16 Removal . . . . . . . . . . . . . . . . . . . . . .40-4020-10
Main Boom Cylinder Removal. . . . . . . . 37 -3720-3
Main Boom Cylinder Servicing . . . . . . . .03-0350-5
C Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-5
Cab Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Cab Mount Replacement . . . . . . . . . . .18-1820-13
Cab Removal . . . . . . . . . . . . . . . . . . . .18-1820-14
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1820-3
Lowering . . . . . . . . . . . . . . . . . . . . . . . . .18-1820-3 D
Operation . . . . . . . . . . . . . . . . . . . . . . . .18-1810-2
Window Installation . . . . . . . . . . . . . . . . .18-1820-3 DA Cartrige Valve function
Cab lift pump oil Check and adjust . . . . . . . . . . . . . . . . . .03-0325-4
Quality . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-10 Dashboard
Cab Tilt Cylinder Front . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-25
Installation. . . . . . . . . . . . . . . . . . . . . . .18-1820-10 Dealer Fabricated Tools
Replacement. . . . . . . . . . . . . . . . . . . . . .18-1820-9 F603762/F603764 Axle Mounting Bolt Installation
Cab Tilt Hydraulics Tool . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-22
Diagnostic Information. . . . . . . . . . . . . .03-0370-13 TA0898 Frame Support. . . . . . . . . . . . . .45-4510-1
Cabin Service . . . . . . . . . . . . . . . . . . . . . . .18-1820-1 TA0899 Axle Support . . . . . . . . . . . . . . .45-4510-2
Cabine TA0902 Frame Support. . . . . . . . . . . . . .45-4510-3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1820-7 TA0904 Wrench Adapter, Loader
Capacities Bolts . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-4
Fluids and lubricants . . . . . . . . . . . . . . . .00-0040-2 TA0908 Nut Driver . . . . . . . . . . . . . . . . .45-4510-5
Charge Pressure TA0909#1 Driver, Drive Shaft Bearing
Check and adjust . . . . . . . . . . . . . . . . . .03-0325-1 Cups . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-6
Indx Control panels TA0909#2 Driver, Drive Shaft Bearing
2 Left . . . . . . . . . . . . . . . . . . 18-1810-22, 18-1810-23 Cone . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-7
Right . . . . . . . . . . . . . . . . . 18-1810-22, 18-1810-23 TA0909#3 Driver, Drive Shaft Seals . . . .45-4510-8
Control System TA0910 Bearing Driver . . . . . . . . . . . . . .45-4510-9
TMC . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1640-1 TA0911 Bearing Driver . . . . . . . . . . . . .45-4510-10
Coolant TA0912 Bearing Driver . . . . . . . . . . . . .45-4510-11
Quality . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-8 TA0913 Bearing/Pin Driver . . . . . . . . . .45-4510-12
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1710-7 TA0914 Pin Driver . . . . . . . . . . . . . . . .45-4510-13
Crane Valve Pilot Control Pressure TA0917 Nut Driver . . . . . . . . . . . . . . . .45-4510-14
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . .03-0340-2 TA0918 Lifting Bracket . . . . . . . . . . . . .45-4510-15
Crane valve pressures for each function TA0949 Cab Support Bar . . . . . . . . . . .45-4510-18
Measuring . . . . . . . . . . . . . . . . . . . . . . . .03-0340-3 479265-1 O-ring Seal Expander . . . . . .45-4510-19
Crank Position Sensor . . . . . . . . . . . . . . . .16-1640-5 479266-1 Piston Installation Tool . . . . .45-4510-21
Cylinders 79265-2 Seal Pusher . . . . . . . . . . . . . .45-4510-20
Decking Blade Cylinder Installation . . . . .38-3820-2 Decking Blade
Decking Blade Cylinder Removal . . . . . .38-3820-1 Decking Blade Cylinder Installation . . . . .38-3820-2
Extension Boom Removal . . . . . . . . . . 37 -3720-16 Decking Blade Cylinder Removal . . . . . .38-3820-1
Grapple Cylinder Servicing - Loglift Decking Blade Installation . . . . . . . . . . . .38-3820-2
GF25/GF35 . . . . . . . . . . . . . . . . . . . .03-0350-18 Decking Blade Removal . . . . . . . . . . . . .38-3820-2
Grapple Cylinder Servicing - Supergrip SG Float . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-8020-2
260/360 . . . . . . . . . . . . . . . . . . . . . . .03-0350-13 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3820-5
Grapple Rotator Servicing . . . . . . . . . . . .40-4040-2 Lowering . . . . . . . . . . . . . . . . . . . . . . . . .80-8020-1
Jib Cylinder Removal . . . . . . . . . . . . . 37 -3720-12 Operation . . . . . . . . . . . . . . . . . . . . . . . .38-3810-1
Loglift GF25/GF35 Grapple Cylinder Direction Selection Solenoids
Installation . . . . . . . . . . . . . . . . . . . . .40-4020-11 Inspection and Replacement . . . . . . . . .03-0340-15

081403
PN=2
Index
Page Page
Drive Coupling Empty fault memory . . . . . . . . . . . . . . . .80-8010-7

Operation . . . . . . . . . . . . . . . . . . . . . . . .02-0210-2 Maintenance . . . . . . . . . . . . . . . . . . . . . .80-8010-2
Drive Lines Malfunction codes . . . . . . . . . . . . . . . . . .80-8010-6
Diagnostic Information. . . . . . . . . . . . . .02-0230-11 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . .80-8010-4
Drive motor Engine Speed
Hydrostatic flushing valve . . . . . . . . . . .03-0325-14 Measuring . . . . . . . . . . . . . . . . . . . . . . . .16-1640-5
Pressure cut-off. . . . . . . . . . . . . . . . . . .03-0325-11 Event Sensor . . . . . . . . . . . . . .16-1640-5, 16-1640-6
Drive Pressure Extension Boom
Check and adjust . . . . . . . . . . . . . . . . . .03-0325-3 Removal . . . . . . . . . . . . . . . . . . . . . . . 37 -3720-16
Drive Pump Extension Cylinder
Charge pressure . . . . . . . . . . . . . . . . . . .03-0325-8 Installation. . . . . . . . . . . . . . . . . . . . . . 37 -3720-16
Drive pump
Cut off valve setting . . . . . . . . . . . . . . . .03-0325-9
Drive Shafts
Operation . . . . . . . . . . . . . . . . . . . . . . . .02-0230-3 F
Universals . . . . . . . . . . . . . . . . . . . . . . .02-0230-12
Filter
Hydraulic Pressure Filter
E Replacement . . . . . . . . . . . . . . . . . . .03-0335-41
Filters
ECU . . . . . . . . . . . . . . . . . . . . 16-1610-16, 16-1630-2 Hydraulic Pressure Filter . . . . . . . . . . . .03-0310-16
Engine Control Unit. . . . . . . . . . . . . . . . .16-1640-9 Fire Extinguisher System . . . . . . . . . . . . . .80-8030-1
EI After a fire. . . . . . . . . . . . . . . . . . . . . . . .80-8030-5
Wiring Harness Connector . . . . . . . . . . .16-1640-7 Control unit . . . . . . . . . . . . . . . . . . . . . . .80-8030-6
Electrical Fire Alarm . . . . . . . . . . . . . . . . . . . . . . . .80-8030-2
Alternator Installation . . . . . . . . . . . . . . .16-1660-1 Fluids and lubricants
Alternator Removal . . . . . . . . . . . . . . . . .16-1660-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . .00-0040-2
Electrical Schematic Information . . . . . . .16-1620-1 Frame Brake . . . . . . . . . . . . . . . . . . . . . .17-1720-22 Indx
Operation . . . . . . . . . . . . . . . . . . . . . . .17-1720-22 3
Grounded circuit . . . . . . . . . . . . . . . . . .16-1610-17
High resistance circuit . . . . . . . . . . . . . .16-1610-17 Specifications . . . . . . . . . . . . . . . . . . . .17-1720-22
Inspection . . . . . . . . . . . . . . . . . . . . . . .16-1610-19 Frame Brake Pressure
Open circuit . . . . . . . . . . . . . . . . . . . . .16-1610-17 Check and Adjust . . . . . . . . . . . . . . . . . .03-0340-5
Schematic symbols . . . . . . . . . . . . . . . . .16-1620-4 Frame Brake Unit Servicing
Shorted circuit. . . . . . . . . . . . . . . . . . . .16-1610-18 479265-1 O-ring Seal Expander . . . . . .45-4510-19
Test equipment . . . . . . . . . . . . . . . . . . .16-1610-16 479266-1 Piston Installation Tool . . . . .45-4510-21
Test procedure . . . . . . . . . . . . . . . . . . .16-1610-20 79265-2 Seal Pusher . . . . . . . . . . . . . .45-4510-20
Electrical Motors and Actuators Frame Hinge
Starter Motor Installation . . . . . . . . . . . . .16-1680-1 Frame Brake Removal . . . . . . . . . . . . .17-1720-24
Starter Motor Removal . . . . . . . . . . . . . .16-1680-1 Frame Brake Unit Servicing . . . . . . . . .17-1720-26
Electronic Control System Frame Joint. . . . . . . . . . . . . . . . . . . . . . .17-1720-1
Terminology . . . . . . . . . . . . . . . . . . . . . .16-1640-2 Frame Joint Bearings Installation . . . . .17-1720-13
Electronic Injector Frame Joint Removal . . . . . . . . . . . . . . .17-1720-6
Wiring Harness Connector . . . . . . . . . . .16-1640-7 Hinge Pin Installation . . . . . . . . . . . . . .17-1720-15
Emergency Stopper Frame Joint . . . . . . . . . . . . . . . . . . . . . . . .17-1720-1
Using . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-18 Frame Joint Bearings Installation . . . . .17-1720-13
Engine Control Unit . . . . . . . . . . . . . . . . . .16-1640-9 Hinge Pin Installation . . . . . . . . . . . . . .17-1720-15
Engine Coolant Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . .17-1720-6
Measuring Temperature . . . .16-1640-3, 16-1640-4 Frame Joint Installation
Engine oil TA0910 Bearing Driver . . . . . . . . . . . . . .45-4510-9
Quality . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-7 TA0911 Bearing Driver . . . . . . . . . . . . .45-4510-10
Engine Parameters. . . . . . . . . . . . . . . . . . .16-1640-3 Frame Joint Installtion
Engine Preheater . . . . . . . . . . . . . . . . . . . .80-8010-1 TA0908 Nut Driver . . . . . . . . . . . . . . . . .45-4510-5

081403
PN=3
Index
Page Page
Frame Joint Removal Supergrip SG 260/360 Grapple Bushings

TA0898 Frame Support. . . . . . . . . . . . . .45-4510-1 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4030-1
TA0899 Axle Support . . . . . . . . . . . . . . .45-4510-2 Supergrip SG 260/360 Grapple Cylinder
TA0902 Frame Support. . . . . . . . . . . . . .45-4510-3 Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-5
TA0908 Nut Driver . . . . . . . . . . . . . . . . .45-4510-5 Supergrip SG 260/360 Grapple Cylinder
TA0918 Lifting Bracket . . . . . . . . . . . . .45-4510-15 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1710-7 Supergrip SG 260/360 Grapple
Frame Brake Removal . . . . . . . . . . . . .17-1720-24 Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-7
Frame Brake Unit Servicing . . . . . . . . .17-1720-26 Supergrip SG 260/360 Grapple
Frame Joint. . . . . . . . . . . . . . . . . . . . . . .17-1720-1 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-2
Frame Joint Bearings Installation . . . . .17-1720-13 Supergrip SG 260/360 Grapple Rotator
Frame Joint Removal . . . . . . . . . . . . . . .17-1720-6 Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-6
Hinge Pin Installation . . . . . . . . . . . . . .17-1720-15 Supergrip SG 260/360 Grapple Rotator
Operation . . . . . . . . . . . . . . . . . . . . . . . .17-1710-1 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Fuel Grapple Rotator Servicing
Quality . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-4 Cleaning the Magnetic Plug . . . . . . . . . .40-4040-7
Fuel Temperature Sensor Grapples
Measuring Temperature . . . .16-1640-3, 16-1640-4 Loglift GF25/35 Grapple . . . . . . . . . . . . .40-4010-3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1610-12 Operation . . . . . . . . . . . . . . . . . . . . . . . .40-4010-1
Engine compartment . . . . . . . . . . . . . . .16-1610-11 Supergrip SG 260/360 . . . . . . . . . . . . . .40-4010-1
F603762/F603764 Axle Mounting Bolt Installation Grease
Tool Quality . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-10
Bogie Removal and Installation . . . . . . .45-4510-22
H
G
Heating and Air Conditioning
Indx Gear oil Diagnostic Information. . . . . . . . . . . . . . .19-1930-8
4 Quality . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-9 Heating and Air conditioning
Grapple Operational Checks. . . . . . . . . . . . . . . . .19-1930-1
Grapple Cylinder Servicing - Loglift Heating and Air Conditioning
GF25/GF35 . . . . . . . . . . . . . . . . . . . .03-0350-18 Refrigerant Level Check . . . . . . . . . . . .19-1930-10
Grapple Cylinder Servicing - Supergrip SG High/low gear, changing the oil. . . . . . . . .02-0220-17
260/360 . . . . . . . . . . . . . . . . . . . . . . .03-0350-13 Hinge Drive Shaft Installation
Grapple Rotator Servicing . . . . . . . . . . . .40-4040-2 TA0909#1 Driver, Drive Shaft Bearing
Loglift GF25/GF35 Grapple . . . . . . . . . . .40-4020-8 Cups . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-6
Loglift GF25/GF35 Grapple Connecting Rod TA0909#2 Driver, Drive Shaft Bearing
Bearings Replacement . . . . . . . . . . . .40-4030-2 Cone . . . . . . . . . . . . . . . . . . . . . . . . . .45-4510-7
Loglift GF25/GF35 Grapple Cylinder TA0909#3 Driver, Drive Shaft Seals . . . .45-4510-8
Installation . . . . . . . . . . . . . . . . . . . . .40-4020-11 Hinge Pin Installation
Loglift GF25/GF35 Grapple Cylinder TA0912 Bearing Driver . . . . . . . . . . . . .45-4510-11
Removal . . . . . . . . . . . . . . . . . . . . . .40-4020-10 TA0913 Bearing/Pin Driver . . . . . . . . . .45-4510-12
Loglift GF25/GF35 Grapple Frame Bearings TA0914 Pin Driver . . . . . . . . . . . . . . . .45-4510-13
Replacement . . . . . . . . . . . . . . . . . . . .40-4030-3 TA0917 Nut Driver . . . . . . . . . . . . . . . .45-4510-14
Loglift GF25/GF35 Grapple Hub gears
Installation . . . . . . . . . . . . . . . . . . . . .40-4020-13 Check oil level . . . . . . . . . . . . . . . . . . .02-0240-24
Loglift GF25/GF35 Grapple Removal . . .40-4020-8 Hydraulic Cylinders
Loglift GF25/GF35 Grapple Rotator Seals Replacement . . . . . . . . . . . . . . . . .03-0350-1
Installation . . . . . . . . . . . . . . . . . . . . .40-4020-12 Hydraulic Hoses
Loglift GF25/GF35 Grapple Rotator Inspection and Replacement . . . . . . . . .03-0340-14
Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-9 Hydraulic oil
Supergrip SG 260/360 Grapple . . . . . . . .40-4020-1 Quality . . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-9

081403
PN=4
Index
Page Page
Hydraulic return filter Grapple Cylinder Servicing - Supergrip SG

Replacing . . . . . . . . . . . . . . . . . . . . . . .03-0335-42 260/360 . . . . . . . . . . . . . . . . . . . . . . .03-0350-13
Hydraulic System Grapple Rotator Servicing . . . . . . . . . . . .40-4040-2
Auxiliary Valve Installation. . . . . . . . . . .03-0335-27 Hydraulic Pressure Filter . . . . . . . . . . . .03-0310-16
Auxiliary Valve Removal . . . . . . . . . . . .03-0335-26 Hydraulic/Hydrostatic Cooling . . . . . . . .03-0310-10
Auxiliary Valve Removal and Loglift GF25/GF35 Grapple Cylinder
Installation . . . . . . . . . . . . . . . . . . . . .03-0335-26 Installation . . . . . . . . . . . . . . . . . . . . .40-4020-11
Cylinder Internal Seal Leak Test . . . . . . .03-0350-4 Loglift GF25/GF35 Grapple Cylinder
Cylinder Seals Replacement . . . . . . . . . .03-0350-1 Removal . . . . . . . . . . . . . . . . . . . . . .40-4020-10
Hose Inspection and Replacement . . . .03-0340-14 Loglift GF25/GF35 Grapple Rotator
Hydraulic Function Cycle Times . . . . . .03-0340-11 Installation . . . . . . . . . . . . . . . . . . . . .40-4020-12
Hydraulic Tank Installation . . . . . . . . . .03-0335-48 Loglift GF25/GF35 Grapple Rotator
Hydraulic Tank Removal . . . . . . . . . . . .03-0335-48 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-9
Loader Control Valve Disassembly and Main Boom Cylinder Servicing . . . . . . . .03-0350-5
Assembly. . . . . . . . . . . . . . . . . . . . . .03-0335-35 Schematic Symbols. . . . . . . . . . . . . . . . .03-0360-1
Loader Control Valve Removal and Specifications . . . . . . . . . . . . . . . . . . . .00-0020-12
Installation . . . . . . . . . . . . . . . . . . . . .03-0335-31 Steering . . . . . . . . . . . . . . . . . . . . . . . .17-1720-33
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-12 Supergrip SG 260/360 Grapple Cylinder
Thermal Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-5
Installation . . . . . . . . . . . . . . . . . . . . .03-0335-40 Supergrip SG 260/360 Grapple Cylinder
Work Pump Assembly. . . . . . . . . . . . . . .03-0335-6 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Work Pump Component Inspection . . . .03-0335-23 Supergrip SG 260/360 Grapple Rotator
Work Pump Disassembly . . . . . . . . . . . .03-0335-6 Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-6
Work Pump Drive Shaft Seal Supergrip SG 260/360 Grapple Rotator
Replacement . . . . . . . . . . . . . . . . . . .03-0335-25 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Work Pump Removal and Installation . . .03-0335-1 System . . . . . . . . . . . . . . . . . . . . . . . . . .03-0310-5
Work Pump Start-up Procedure . . . . . . .03-0330-4 Thermal Valve. . . . . . . . . . . . . . . . . . . .03-0310-15
Hydraulic System Adjustments Valve Functions . . . . . . . . . . . . . . . . . . .03-0330-6
Frame Brake Pressure . . . . . . . . . . . . .17-1720-32 Valve Locations. . . . . . . . . . . . . . . . . . . .03-0330-6 Indx
5
Hydraulic system, working hydraulic Work Pump . . . . . . . . . . . . . . . . . . . . . . .03-0330-1
Bleeding . . . . . . . . . . . . . . 03-0330-12, 03-0330-14 Hydrostatic Drive Motor
Hydraulic Tank Constant Pressure Control Valve
Installation. . . . . . . . . . . . . . . . . . . . . . .03-0335-48 Replacement . . . . . . . . . . . . . . . . . . . .03-0320-8
Removal . . . . . . . . . . . . . . . . . . . . . . . .03-0335-48 Constant Pressure Control Valve Seals
Hydraulic tank Replacement . . . . . . . . . . . . . . . . . . . .03-0320-8
Replace return filter. . . . . . . . . . . . . . . .03-0335-42 Diagnostic Information. . . . . . . . . . . . . .03-0370-11
Hydraulic Tank and Filters Drive Shaft Seals Replacement. . . . . . . .03-0320-6
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-16 Port Plate Seal Replacement . . . . . . . . .03-0320-9
Hydraulic/Hydrostatic Cooling Removal and Installation . . . . . . . . . . . . .03-0320-5
Operation . . . . . . . . . . . . . . . . . . . . . . .03-0310-10 Servicing . . . . . . . . . . . . . . . . . . . . . . . . .03-0320-1
Specifications . . . . . . . . . . 00-0020-13, 03-0310-10 Specifications . . . . . . . . . . . . . . . . . . . .00-0020-13
Hydraulic/Hydrostatic Cooling System Start-up Procedure . . . . . . . . . . . . . . . .03-0320-55
Diagnostic Information. . . . . . . . . . . . . .03-0370-13 Hydrostatic Drive Pump
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .03-0310-13 Changing the Charge Pressure
Boom Control Valve . . . . . . . . . . . . . . . .03-0310-5 Filter . . . . . . . . . . . . . . . . . . . . . . . . .03-0320-46
Decking Blade Cylinder Installation . . . . .38-3820-2 Charge Pressure Relief Valve
Decking Blade Cylinder Removal . . . . . .38-3820-1 Replacement . . . . . . . . . . . . . . . . . . .03-0320-21
Decking Blade Hoses . . . . . . . . . . . . . . .38-3820-5 Charge Pressure Relief Valve Seal
Extension Cylinder Servicing. . . . . . . . . .03-0350-8 Replacement . . . . . . . . . . . . . . . . . . .03-0320-21
Frame Brake Removal . . . . . . . . . . . . .17-1720-24 Charge Pump Replacement . . . . . . . . .03-0320-16
Frame Brake Unit Servicing . . . . . . . . .17-1720-26 Charge Pump Seals Replacement . . . .03-0320-16
Grapple Cylinder Servicing - Loglift Component Inspection . . . . . . . . . . . . .03-0320-36
GF25/GF35 . . . . . . . . . . . . . . . . . . . .03-0350-18 Control Piston Assembly . . . . . . . . . . . .03-0320-33

081403
PN=5
Index
Page Page
Control Piston Cover Seals Grapple Cylinder Servicing - Supergrip SG

Replacement . . . . . . . . . . . . . . . . . . .03-0320-18 260/360 . . . . . . . . . . . . . . . . . . . . . . .03-0350-13
Control Piston Disassembly . . . . . . . . .03-0320-33 Grapple Rotator Servicing . . . . . . . . . . . .40-4040-2
Cylinder Disassembly . . . . . . . . . . . . . .03-0320-31 Jib Boom Installation. . . . . . . . . . . . . . . 37 -3730-2
Diagnostic Information. . . . . . . . . . . . . . .03-0370-7 Jib Boom Removal . . . . . . . . . . . . . . . . 37 -3730-1
Disassembly . . . . . . . . . . . . . . . . . . . . .03-0320-25 Loader Slew System . . . . . . . . . . . . . . . 37 -3710-4
Drive Shaft Seal Replacement . . . . . . .03-0320-13 Loglift GF25/GF35 Grapple . . . . . . . . . . .40-4020-8
High Pressure Relief Valve Seal Loglift GF25/GF35 Grapple Connecting Rod
Replacement . . . . . . . . . . . . . . . . . . .03-0320-23 Bearings Replacement . . . . . . . . . . . .40-4030-2
High Pressure Relief Valves Loglift GF25/GF35 Grapple Cylinder
Replacement . . . . . . . . . . . . . . . . . . .03-0320-23 Installation . . . . . . . . . . . . . . . . . . . . .40-4020-11
Hydraulic Centering of Control Loglift GF25/GF35 Grapple Cylinder
Module . . . . . . . . . . . . . . . . . . . . . . .03-0320-45 Removal . . . . . . . . . . . . . . . . . . . . . .40-4020-10
Hydraulic Pilot Control Device Loglift GF25/GF35 Grapple Frame Bearings
Replacement . . . . . . . . . . . . . . . . . . .03-0320-43 Replacement . . . . . . . . . . . . . . . . . . . .40-4030-3
Hydraulic Pilot Control Device Seals Loglift GF25/GF35 Grapple
Replacement . . . . . . . . . . . . . . . . . . .03-0320-43 Installation . . . . . . . . . . . . . . . . . . . . .40-4020-13
Mechanical Centering of Pump . . . . . . .03-0320-44 Loglift GF25/GF35 Grapple Removal . . .40-4020-8
Pressure Cut-off Valve Replacement . .03-0320-24 Loglift GF25/GF35 Grapple Rotator
Pressure Cut-off Valve Seal Installation . . . . . . . . . . . . . . . . . . . . .40-4020-12
Replacement . . . . . . . . . . . . . . . . . . .03-0320-24 Loglift GF25/GF35 Grapple Rotator
Pump Assembly . . . . . . . . . . . . . . . . . .03-0320-47 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-9
Removal and Installation . . . . . . . . . . . .03-0320-12 Main Boom Installation . . . . . . . . . . . . . 37 -3730-7
Rotary Group Assembly . . . . . . . . . . . .03-0320-38 Main Boom Removal. . . . . . . . . . . . . . . 37 -3730-5
Servicing . . . . . . . . . . . . . . . . . . . . . . . . .03-0320-1 Supergrip SG 260/360 Grapple . . . . . . . .40-4020-1
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-12 Supergrip SG 260/360 Grapple Bushings
Start-up Procedure . . . . . . . . . . . . . . . .03-0320-55 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4030-1
Hydrostatic Drive System Supergrip SG 260/360 Grapple Cylinder
Indx Diagnostic Information. . . . . . . . . . . . . . .03-0370-5 Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-5
6 Direction Selection Solenoids Inspection and Supergrip SG 260/360 Grapple Cylinder
Replacement . . . . . . . . . . . . . . . . . . .03-0340-15 Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-12 Supergrip SG 260/360 Grapple
Hydrostatic System Adjustment Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-7
Motor Start of Control Point . . . . . . . . .03-0340-12 Supergrip SG 260/360 Grapple
Hydrostatic System Pressures Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-2
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-12 Supergrip SG 260/360 Grapple Rotator
Installation . . . . . . . . . . . . . . . . . . . . . .40-4020-6
I Removal . . . . . . . . . . . . . . . . . . . . . . .40-4020-3
Tower Bearing Replacement . . . . . . . . 37 -3730-12
Instrument box fuses . . . . . . 16-1610-11, 16-1610-12 Tower Installation . . . . . . . . . . . . . . . . 37 -3730-10
Tower Removal. . . . . . . . . . . . . . . . . . . 37 -3730-9
Loader Control Valve
J Disassembly and Assembly . . . . . . . . .03-0335-35
Jib Cylinder Hydraulic Fittings . . . . . . . . . . . . . . . . .03-0335-38
Removal . . . . . . . . . . . . . . . . . . . . . . . 37 -3720-12 Inlet Section . . . . . . . . . . . . . . . . . . . . .03-0335-36
Outlet Section . . . . . . . . . . . . . . . . . . . .03-0335-36
Removal and Installation . . . . . . . . . . . .03-0335-31
L Tie Rods . . . . . . . . . . . . . . . . . . . . . . . .03-0335-35
Typical Spool Section . . . . . . . . . . . . . .03-0335-36
Loader Valve Sections and Solenoids. . . . . . . .03-0335-39
Grapple Cylinder Servicing - Loglift Loglift GF25 Grapple
GF25/GF35 . . . . . . . . . . . . . . . . . . . .03-0350-18 Specifications . . . . . . . . . . . . . . . . . . . .00-0020-34

081403
PN=6
Index
Page Page
Loglift GF35 Grapple Parking Brake Pressure

Specifications . . . . . . . . . . . . . . . . . . . .00-0020-35 Check and Adjust . . . . . . . . . . . . . . . . . .02-0250-8
Lubricant Pedal Brake (Drive Brake) Pressure
Storage . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-10 Check . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-9
Lubricants and Fluids Periodic Maintenance
General. . . . . . . . . . . . . . . . . . . . . . . . . .00-0040-1 Prepare Machine for Maintenance . . . . .02-0210-3
Pilot Pressure
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0325-2
M Power Train
Axle and Bogie . . . . . . . . . . . . . . . . . . . .02-0240-4
Main Boom Brakes . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-2
Installation. . . . . . . . . . . . . . . . . . . . . . . 37 -3730-7 Component Locator. . . . . . . . . . . . . . . . .02-0210-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . 37 -3730-5 Drive Coupling . . . . . . . . . . . . . . . . . . . .02-0210-2
Main Boom Cylinder Drive Shafts . . . . . . . . . . . . . . . . . . . . . .02-0230-3
Installation. . . . . . . . . . . . . . . . . . . . . . . 37 -3720-6 Operation . . . . . . . . . . . . . . . . . . . . . . . .02-0210-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . 37 -3720-3 Specifications . . . . . . . . . . . . . . . . . . . .00-0020-10
Maintenance Transfer Case . . . . . . . . . . . . . . . . . . . . .02-0220-2
Change Bogie Axle Differential Oil . . . .02-0240-19 Power Unit
Change Single Axle Differential Oil . . . .02-0240-21 Specifications . . . . . . . . . . . . . . . . . . . . .00-0020-9
Check Bogie Housings Oil Level . . . . . .02-0240-22 Powered Wheels and Fastenings
Check Single Axle Wheel Ends Oil Wheel Inspection . . . . . . . . . . . . . . . . . .01-0110-3
Level . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-24 Pressure Cut-Off Setting
Manifold Air Temperature Sensor Check and adjust . . . . . . . . . . . . . . . . .03-0325-10
Measuring Temperature . . . .16-1640-3, 16-1640-5 Pressure Difference
Maximum Pressure Adjusting . . . . . . . . . . . . . . . . . . . . . . . . .03-0340-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . .03-0340-1 Pressure filter
Measuring Engine Speed . . . . . . . . . . . . . .16-1640-5 Renew filter of drive hydraulic system . . .03-0320-3
Measuring Temperature . . . . . . . . . . . . . . .16-1640-3 Pressures
Miscellaneous Systems Convertion Table for Pressures. . . . . . .03-0310-12 Indx
7
Decking Blade. . . . . . . . . . . . . . . . . . . . .38-3810-1 Pump Control Valves . . . . . . . . . . . . . . . . .16-1640-7
Grapples . . . . . . . . . . . . . . . . . . . . . . . . .40-4010-1
Motor control starting point
Check and adjust . . . . . . . . . . . . . . . . . .03-0325-4
R
Refrigerant
O Handling . . . . . . . . . . . . . . . . . . . . . . . . .19-1910-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1820-9
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0030-8
Return filter
Operating the Machine
Replace hydraulic return filter . . . . . . . .03-0335-42
AC/Heater Controls . . . . . . . . . . . . . . . . .19-1910-5
Rotator and Grapple
Cab Steps Switch . . . . . . . . . . . . . . . . . .18-1810-9
Specifications . . . . . . . . . 00-0020-21, 00-0020-28,
Operator’s station . . . . . . . . . . . . . . . . . . .18-1810-20
00-0020-31
Operator’s Station
Cab Air Filters. . . . . . . . . . . . . . . . . . . .18-1810-13
Cab Component Locator . . . . . . . . . . . .18-1810-10
Left Armrest Controls . . . . . . . . . . . . . .18-1810-15 S
Optional Equipment Pressures
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0340-5 Safety
Safety Features. . . . . . . . . . . . . . . . . . . .00-0010-7
Safety, maintain safety cabin . . . . . . . . . . .00-0010-9
P Seat
Seat Direciton Limit Switch . . . . . . . . . .18-1810-15
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1710-7 Seat Belt Replacement. . . . . . . . . . . . . . . .18-1820-1

081403
PN=7
Index
Page Page
Sensors Frame Joint Removal . . . . . . . . . . . . . . .45-4510-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . .16-1630-3 TA0899 Axle Support
Hydraulic Oil Level . . . . . . . . . . . . . . . . .16-1630-5 Bogie Removal and Installation . . . . . . . .45-4510-2
Hydraulic Oil Return Filter . . . . . . . . . . . .16-1630-5 Frame Joint Removal . . . . . . . . . . . . . . .45-4510-2
Hydraulic Oil Temperature . . . . . . . . . . .16-1630-5 TA0902 Frame Support
RPM of Drive Motor . . . . . . .16-1630-6, 16-1630-7 Bogie Removal and Installation . . . . . . . .45-4510-3
Serial number Frame Joint Removal . . . . . . . . . . . . . . .45-4510-3
Service Brake Pressure TA0908 Nut Driver
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-9 Frame Joint Installation . . . . . . . . . . . . . .45-4510-5
Service equipment and tools Frame Joint Removal . . . . . . . . . . . . . . .45-4510-5
Powered wheels and fastenings . . . . . . .01-0110-1 TA0909#1 Driver, Drive Shaft Bearing Cups
Single axle wheel ends Hinge Drive Shaft Installation . . . . . . . . .45-4510-6
Change Single Axle Wheel Ends Oil . . .02-0240-24 TA0909#2 Driver, Drive Shaft Bearing Cone
Specifications . . . . . . . . . . . . . . . . . . . . . . .00-0020-3 Hinge Drive Shaft Installation . . . . . . . . .45-4510-7
Auxiliary Valve . . . . . . . . . . . . . . . . . . .00-0020-17 TA0909#3 Driver, Drive Shaft Seals
Axles/Bogies . . . . . . . . . . . . . . . . . . . . .00-0020-10 Hinge Drive Shaft Installation . . . . . . . . .45-4510-8
Boom . . . . . . . . . . . . . . . . . . . . . . . . . .00-0020-21 TA0910 Bearing Driver
Brakes . . . . . . . . . . . . . . . . . . . . . . . . .00-0020-11 Frame Joint Installation . . . . . . . . . . . . . .45-4510-9
Hydraulic System . . . . . . . . . . . . . . . . .00-0020-12 TA0911 Bearing Driver
Hydraulic Tank and Filters . . . . . . . . . .00-0020-16 Frame Joint Installation . . . . . . . . . . . . .45-4510-10
Hydraulic/Hydrostatic Cooling . . . . . . . .00-0020-13 TA0912 Bearing Driver
Hydrostatic Drive Motor. . . . . . . . . . . . .00-0020-13 Hinge Pin Installation . . . . . . . . . . . . . .45-4510-11
Hydrostatic Drive Pump . . . . . . . . . . . .00-0020-12 TA0913 Bearing/Pin Driver
Hydrostatic Drive System . . . . . . . . . . .00-0020-12 Hinge Pin Installation . . . . . . . . . . . . . .45-4510-12
Hydrostatic System Pressure . . . . . . . .00-0020-12 TA0914 Pin Driver
Loader Control Valve . . . . . . . . . . . . . .03-0310-13 Hinge Pin Installation . . . . . . . . . . . . . .45-4510-13
Loglift GF25 Grapple. . . . . . . . . . . . . . .00-0020-34 TA0917 Nut Driver
Loglift GF35 Grapple. . . . . . . . . . . . . . .00-0020-35 Hinge Pin Installation . . . . . . . . . . . . . .45-4510-14
Indx Power Train . . . . . . . . . . . . . . . . . . . . .00-0020-10 TA0918 Lifting Bracket
8 Steering & Decking Blade Cylinders . . .00-0020-16 Frame Joint Removal . . . . . . . . . . . . . .45-4510-15
Supergrip SG 260 Grapple . . . . . . . . . .00-0020-32 Telephone
Supergrip SG 360 Grapple . . . . . . . . . .00-0020-33 Prepardness . . . . . . . . . . . . . . . . . . . . .18-1810-19
Transfer Case . . . . . . . . . . . . . . . . . . . .00-0020-10 Temperature
Work Pump . . . . . . . . . . . . . . . . . . . . . .00-0020-15 Measuring . . . . . . . . . . . . . . . . . . . . . . . .16-1640-3
Starter Motor Terminology
Installation. . . . . . . . . . . . . . . . . . . . . . . .16-1680-1 Electronic Control System . . . . . . . . . . . .16-1640-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . .16-1680-1 Tests
Steering Cylinder Internal Seal Leak Test . . . . . . .03-0350-4
Operation . . . . . . . . . . . . . . . . . . . . . . .17-1720-33 Electrical . . . . . . . . . . . . . . . . . . . . . . . .16-1610-20
Steering & Decking Blade Cylinders Hydraulic Function Cycle Times . . . . . .03-0340-11
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-16 Thermal Valve
Storing lubricants . . . . . . . . . . . . . . . . . . .00-0040-10 Operation . . . . . . . . . . . . . . . . . . . . . . .03-0310-15
Stowing a disabled boom . . . . . . . . . . . . . .00-0050-6 Removal and Installation . . . . . . . . . . . .03-0335-40
Supergrip SG 260 Grapple Specifications . . . . . . . . . . . . . . . . . . . .03-0310-15
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-32 Tightening torgues . . . . . . . . . . . . . . . . . . .00-0030-1
Supergrip SG 360 Grapple Tires
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-33 Pressures . . . . . . . . . . . . . . . . . . . . . . .00-0020-18
Removal and Installation . . . . . . . . . . . . .01-0110-4
Tire Pressure . . . . . . . . . . . . . . . . . . . . .01-0110-5
T TMC
Control System . . . . . . . . . . . . . . . . . . . .16-1640-1
TA0898 Frame Support Torque values
Bogie Removal and Installation . . . . . . . .45-4510-1 Flare Fittings . . . . . . . . . . . . . . . . . . . . .00-0030-17

081403
PN=8
Index
Page Page
Flat face O-ring seal fitting . . . . . . . . . .00-0030-10 Work Pump Component Inspection . . . .03-0335-23
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0030-5 Working Hydraulic System
Inch SAE four bolt flange fitting. . . . . . .00-0030-11 Auxiliary functions . . . . . . . . . . . . . . . . . .03-0340-9
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0030-7 Boom pressures . . . . . . . . . . . . . . . . . . .03-0340-7
Metric Flanged Head. . . . . . . . . . . . . . .00-0030-13 Frame Brake . . . . . . . . . . . . . . . . . . . . .03-0340-10
Metric four bolt flange fitting . . . . . . . . .00-0030-12 Max. pressure . . . . . . . . . . . . . . . . . . . . .03-0340-6
O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0030-8 Pressure Difference . . . . . . . . . . . . . . . .03-0340-6
O-ring Fittings . . . . . . . . . . . . . . . . . . . .00-0030-14 Worklamp (Xenon)
SAE Code 61 and 62 Flanges . . . . . . .00-0030-15 Safety instructions. . . . . . . . . . . . . . . . .00-0010-16
Tapered Pipe Treads (NPTF and 479265-1 O-ring Seal Expander
NPT) . . . . . . . . . . . . . . . . . . . . . . . . .00-0030-16 Frame Brake Unit Servicing . . . . . . . . .45-4510-19
Tower 479266-1 Piston Installation Tool
Bearing Replacement . . . . . . . . . . . . . 37 -3730-12 Frame Brake Unit Servicing . . . . . . . . .45-4510-21
Installation. . . . . . . . . . . . . . . . . . . . . . 37 -3730-10 79265-2 Seal Pusher
Removal . . . . . . . . . . . . . . . . . . . . . . . . 37 -3730-9 Frame Brake Unit Servicing . . . . . . . . .45-4510-20
Towing the machine . . . . . . . . . . . . . . . . . .00-0050-2
Transfer Case
Checking the Transfer Case Oil . . . . . .02-0220-15
Operation . . . . . . . . . . . . . . . . . . . . . . . .02-0220-2
Specifications . . . . . . . . . . . . . . . . . . . .00-0020-10
Transfer Case Installation . . . . . . . . . . .02-0220-11
Transfer Case Removal . . . . . . . . . . . . .02-0220-4
Transmission
Control . . . . . . . . . . . . . . . . . . . . . . . . .03-0310-11
Hydrostatic System . . . . . . . . . . . . . . . . .03-0310-2
System . . . . . . . . . . . . . . . . . . . . . . . . . .02-0220-3
Transmission, control . . . . . . . . . . . . . . . . .02-0220-3
Transporting the Machine . . . . . . . . . . . . . .00-0050-1
Troubleshooting Techniques. . . . . . . . . . .00-0060-30 Indx
9
Warning signals
Lights and buzzer . . . . . . . . . . . . . . . . .18-1810-18
Water in Fuel Sensor . . . . . . . . . . . . . . . . .16-1640-6
Wheels
Installation. . . . . . . . . . . . . . . . . . . . . . . .01-0110-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-2
Tire Pressure . . . . . . . . . . . . . . . . . . . . .01-0110-5
Wheel Inspection . . . . . . . . . . . . . . . . . .01-0110-3
Wiring Harness
Visual Inspection. . . . . . . . . . . . . . . . . .16-1610-15
Work Pump
Assembly . . . . . . . . . . . . . . . . . . . . . . . .03-0335-6
Disassembly . . . . . . . . . . . . . . . . . . . . . .03-0335-6
Drive Shaft Seal Replacement . . . . . . .03-0335-25
Load Sensing . . . . . . . . . . . . . . . . . . . . .03-0330-1
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-0330-1
Removal and Installlation . . . . . . . . . . . .03-0335-1
Specifications . . . . . . . . . . . 00-0020-15, 03-0330-1
Start-up Procedure . . . . . . . . . . . . . . . . .03-0330-4

081403
PN=9
Index
Indx
10

081403
PN=10
APPENDIX MANUALS
FOR
FORWARDERS TECHNICAL MANUAL TM2123
APPENDIX MANUALS
FOR
FORWARDERS TECHNICAL MANUAL TM2123
PART I
AXLES AND TRANSFER CASES
Manual Page
LOK 53 5-42
LOK 100 43-89
LOK 101 90-127
LOK 102 127-171
LOK 103 172-213
LOK 104 214-256
LOK 114 256-300
LOK 115 301-335
LOK 116 336-385
LOK 117 386-430
LOK 118 431-471
LOK 121 472-513
LOK 124 514-540
LOK 128 541-588
LOK 129 589-647
LOK 130 648-690
LOK 131 690-731
PART II
HYDRAULIC AND HYDROSTATIC PUMPS & MOTORS
A10VO Working pump repair manual 733-756

AA4VG Hydrostatic pump 757-806
AA6VM Hydrostatic motor 807-847
2
PART III
VALVES
L90LS Control valve 849-880
K170LS Control valve 881-904
PART IV
OTHERS
Ebersprächer engine heater 905-933
3
4
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 53
Type: Front Axle in
Timberjack 1710
Description: Rigid Axle with Planetary Hubs
Valid for Serial #: LOK 53 / 0 / 1
Date: February 20, 1997
Contents Page
Maintenance Schedule ............................................................................................... II-IV
Table of Lubricants ......................................................................................................... V
Repair Instruction....................................................................................................... 1-25
1. General Instructions......................................................................................................................1
2. Tightening Torques for Bolts and Nuts (Differential Section) .......................................................2
3. Differential.....................................................................................................................................3
3.1. Exchange of the Complete Differential .........................................................................4
3.2. Replacement of Crown Wheel and Pinion ....................................................................5
3.3. Exchange of The Compensating Gears......................................................................11
3.4. Exchange of the Pinion Bearings ................................................................................12
3.5. Exchange of the Crown Wheel Bearings ....................................................................12
3.6. Exchange of the Shaft Seals.......................................................................................12
4. Differential Lock ..........................................................................................................................13
4.1. Checking the Function of the Differential Lock ...........................................................13
4.2. Exchanging Parts of the Differential Lock ...................................................................13
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock ......................14
5. Multiple Disk Brake and Brake Cylinder .....................................................................................16
5.1. Air Gap Inspection of the Multi Disk Brake .................................................................16
5.2. Air Gap Adjustment of the Brake ................................................................................16
5.3. Emergency Release of the Parking Brake ..................................................................17
5.4. Exchange of the Brake Cylinder .................................................................................18
5.5. Exchange of the Disk Brake .......................................................................................20
6. Tightening Torques for Bolts and Nuts (Planetary Hub) .............................................................22
7. Exchange of the Complete Planetary Hub..................................................................................22
8. Planetary Gearing .......................................................................................................................23
8.1. Opening the Planetary Hub.........................................................................................23
8.2. Exchange of the Sun Gear Shaft ................................................................................23
8.3. Replacement of the Planet Gears, Planet Bearings and Planetary Pins ....................23
8.4. Exchange of the Ring Gear.........................................................................................24
8.5. Reassembly of the Planetary Hub...............................................................................24
9. Spindle and Wheel Bearings ......................................................................................................25
9.1. Exchange of Wheel Bearings and Spindle Ring .........................................................25
9.2. Replacement of the Slide Ring Seal ...........................................................................26
9.3. Replacement of the Axle Spindle................................................................................26
Drawings: Installation drawing SAP 7601.101, assembly drawings 00.75000.260 ; R 72000-113 ;

QMA Nr. :09.004.0
Maintenance Schedule
Type: Rigid Axle LOK 53
Figure: Installation Drawing fig. SAP 7601.101
Date: February 20, 1997 page II
Caution: The axle when delivered by NAF does not contain any lubrication oil!
Differential, brakes and planetary hubs share the same oil supply, however, the hubs are
connected with the main oil reservoir only through a small channel. It will take a long time
until the oil in the hub and in the differential will be on the same level. Therefore separate
filling-in and level control for differential and both hubs is necessary.
Operating hours Explanation (see Fig. SAP 7601.101)

Before starting operation Differential and brakes:
Make sure that three oil drain plugs (54) with copper
seal rings are properly tightened with 90 Nm torque.
Remove oil filler plug (143) and add approx. 32 L oil
according to the table of permitted lubricants until the
level has reached the control mark of the dip stick
(145). (Alternatively open the plug on the vertical face
opposite of the brake cylinder and fill in oil until the
lower edge of the threaded hole is reached.) Close oil
filler plug with copper seal ring and tighten with 90
Nm torque.
Planetary hubs:
Turn wheel hub such that - looking at the hub - the
plugs (15) are in a position 11 oćlock and 3 oćlock,
the control plug exactly level with the centre line of the
axle. Remove both plugs and through the upper hole
add approx. 5 L oil according to the table of permitted
lubricants until the lower edge of the plug is reached.
Close both plugs (15) with copper seal rings and
tighten with 55 Nm torque.
After the first working day Due to stresses of the vehicle motion the wheel nuts
will seat themselves properly. Timely tightening of
these will prevent damage to the wheel rims
(tightening torque of the wheel nuts: 550 Nm).
Date: February 20, 1997 page III
After 50-100 operating hours Bolts and nuts may settle due to loads and vibrations
of the vehicle. Retightening all visible bolts can pre-
vent leaks and major damage. The center nut (hex nut
WS50) of the input cardan flange with adhesive
locking must not be retightened.
Oil change in differential and brakes:
Change oil while it is warm. First clean oil drain plugs
(54, 145; 2x ), dip stick (146), oil filler plug (143) and
surrounding areas of any dirt. Then remove filler plug,
open main oil drain plug at the differential and then
the auxiliary drain plugs at the bottom of both axle
beams and drain oil completely into a suitable basin
(approx. 32 L). Clean magnetic inset of oil drain plugs
from any metal wear. Screw in oil drain plugs (54) with
new copper seal rings and tighten with 90 Nm torque.
Add oil according to the following table of lubricants
until the level has reached the control mark of the dip
stick. Close oil filler plug with copper seal ring and
Oil change in planetary hubs:
Change oil at both planetary hubs. Turn wheel hub
such that - looking at the hub - the plugs (15) are in a
position 2 oćlock and 6 oćlock. Clean plugs and
surrounding areas of any dirt. Remove both plugs
(upper plug first to let air come into the hub) and drain
the oil completely. Then turn the wheel hub such that
the plugs are in a position 11 oćlock and 3 oćlock,
axle. Through the upper hole add approx. 5 L oil
lower edge of the plug is reached. Close both plugs
(15) with copper seal rings and tighten with 55 Nm
torque.
After every 500 operating hours Check oil level and add oil if required.
or at least monthly
Date: February 20, 1997 page IV
After every 2000 operating hours Change oil in differential and in both planetary hubs
or at least annually when it is warm, see explanation above for oil change
at 50-100 operating hours.
Multi disk operating brake:
Under normal circumstances the operating brake will
not wear. However the air gap should still be
inspected every 2000 hours.
Initial setup of a new brake:
Air gap of disks = 2,2 - 2,7 mm
Cylinder stroke = 4,75 - 5,75 mm
If required inspect disks and adjust air gap or cylinder
stroke or replace disks (see repair instruction).
Table of Lubricants
Date: February 20, 1997 page V
Permitted is any name brand EP-gear-oil, suited for brakes with bronce sintered disks
("LS"-oil), which meets the following specifications:
Required specification: API GL-5 or MIL-L-2105D
Required viscosity grade: SAE 90, SAE 85W-90, SAE 80W-90, SAE 75W-90
e.g.
Manufacturer Name Quantity
ARAL Degol 3216
DEA Deagear LS SAE 85W-90 approx. 32 ltr. for Differential with

Dearon BHS SAE 90 brakes and 5 ltr. for each hub;
the actual quantity has to be
Fuchs Renogear LS90 checked by the control mark of
Renogear HLS 90 the dipstick
Shell Gear oil 90 LS

Repair Instruction, Differential Section
Figure: Assembly Drawing fig. 00.75000.260.0
Date: February 20, 1997 page 1
1. General Instructions
1.1. When working on differential or multi disk brake the axle must be removed from the
vehicle. When working on the planetary drive the axle can remain attached to the
vehicle, only the wheels must be removed. When attaching the wheels again tighten
wheel nuts with 550 Nm (M22x1.5 flat collar nut with spring washer).
1.2. For proper repairs it is required that the workplace be kept clean, because even
slight deposit of dirt will seriously reduce the life time of the bearings. A few special
tools will be needed which will be mentioned in the appropriate sections. Basic
mechanical knowledge is also required.
1.3. All disassembled bolts and nuts which were secured with an adhesive coating on the
thread are to be replaced with new adhesive coated nuts and bolts. Remove the old
hardened glue from the chamfer at the beginning of the thread. During assembly of a
new coated bolt this space is needed for peeled surplus coating. During assembly of all
adhesive coated bolts or nuts it is important the final position or torque is achieved
within 3-5 minutes. If after 5 minutes there is any movement then the adhesive will not
reach its proper holding potential.
If no adhesive coated bolts or nuts are available then the old ones can be used if they
are secured with Loctite 243 (or other fluid bolt locking of medium strength) provided
the instructions printed on the label are properly followed.
1.4. It is suggested that any removed O-rings or gaskets be replaced with new ones,
even if there does not appear to be any damage.
2. Tightening Torques for Bolts and Nuts (Differential Section)

Drawing no. Name NAF Part no. Tightening Torque
1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
3 grooved nut 7329.071 see Chapter 3.2.3.
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 hex bolt M16x1,5x50 10.9 VP 7322.077 310 Nm
17 screw plug M30x1,5 8.8 1040.103 95 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
25 grooved nut M185x1,5 7329.012 see Chapter 3.2.3.
30 hex nut M14x1.5 10 1060.003 135 Nm + Loctite 639
32 cylinder M30x1.5 5263.061 90 Nm + Loctite 542
50 hex nut M40x1.5 7329.057 800 Nm + Loctite 639
52 Allen bolt M10x20 8.8 1020.212 49 Nm
54 plug M20x1,5 with magnet 9556.021 53 Nm
103 allen bolt M20x2x90 10.9 1020.620 560 Nm
104 hex bolt M20x2x90 10.9 1010.668 560 Nm
113 allen bolt M10x30 10.9 VP 1020.260 67 Nm
143 screw plug R ¾" 8.8 1040.151 90 Nm
145 screw plug R ¾" with magnet 73230.025 90 Nm
147 dip stick adapter R ¾" 7322.064 90 Nm
148 breather R½" tapered 9556.030 75 Nm
149 reducing plug R ¾" x R½" (tap.) 1750.705 100 Nm
152 allen bolt M10x80 10.9 1020.257 67 Nm

3. Differential
Fig. 1
3.1. Exchange of the Complete Differential

If the differential is damaged excessively it is more advantageous to replace the complete
differential instead of repairing it.
3.1.1. Disassembly of the Complete Differential
After the axle has been removed from the vehicle (remove drive shaft and hydraulic
connections of the brake cylinders and drain oil from the axle) release the parking brake as
described in Chapter 5.3. Open the hex / allen bolts (103, 104) on both sides of the
differential and remove the axle beams (101, 102) with the planetary hubs. The complete
brake (actuating cylinder, disks and dowel pins Æ20) will remain in the axle beam. Pull the
drive shafts (140) out of the differential gear.
3.1.2. Reassembly of the Complete Differential
Before starting reassembly check the adjustment of the differential lock as per 4.2 Make
sure that the coupling sleeve (pos. 21 in external section) properly sits on the spline end of
the sun gear and in the plane bearing of the axle spindle. Then shift the short spline end of
the drive shaft (140) into the coupling sleeve in the axle beam. Install a new O-ring (5) onto
the step of the differential flange (6, 36). Note that both split spring pins (107) properly sit in
their bores in the differential. Attach the complete axle beam to the differential and fasten
with hex bolts and allen bolts (103, 104).
Before reinstallation of the axle to the vehicle loosen (ie. screw in) the emergency release
bolt as per 5.3.
3.2. Replacement of Crown Wheel and Pinion

Crown wheel and pinion (13) can only be replaced as a set since the gearing has been
lapped together. The gears that match are marked with the same serial number.
3.2.1. Disassembly of Crown Wheel and Pinion (13)
After the axle has been removed from the vehicle (remove drive shaft and drain oil from the
axle), first of all open the hex nut (50, wrench size 50) in the input cardan flange (51), later it
would be more complicated to counterhold the high loosening torque which may exceed
1000 Nm. The nut is locked with Loctite, preheating it to 120°-160°C with a blow lamp is
recommended. Then disassemble the complete differential as described in Chapter 3.1.1.
Loosen 2 Allen bolts (4) and remove flange (6) at the crown wheel side of the differential,
then dislodge the differential cage (11) with the crown wheel attached to it. The opposite
flange (36) can remain on the differential housing.
Pull the input flange (51) from the pinion shaft and dislodge the pinion (13) to the inside of
the differential housing by hitting onto the end of the shaft. Loosen hex bolts (9) and pull the
crown wheel from the differential cage.
If there has been a heavy damage in the differential, then at least there will be a hidden
damage to the bearings (8, 24) of the differential cage and especially to the bearings (43,
48) of the pinion. It is suggested that they be replaced at this time, due to the costs involved
in replacing them in subsequent repairs.
Extract the outer rings of both taper roller bearings (43, 48) from the differential housing,
also take out the adjusting washer (45). To disassemble the bearings of the differential
cage pull the inner rings of the taper roller bearings from the differential cage. Before
loosening the grooved nuts (3, 25) in the flanges record the original position of these nuts
which is useful for reassembly. Mark the groove where they are fixed by the locking plates
with a color spot, and with a simple depth gauge measure their distance from the flange
face. Then on both flanges (6, 36) open hex bolt (1) which fixes the locking plate (2) and
screw out the grooved nuts (3, 25). With a soft arbor hit the outer rings of the bearings out
of the flanges, and pull the inner rings from the differential cage.
3.2.2. Reassembly of the Pinion
3.2.2.1. Adjusting the Contact Pattern
In order to adjust a good contact pattern of the hypoid gearing, the proper thickness of the
adjusting washer (45) is to be determined as follows, see Fig.2:
- Measure the actual width L1 of the taper roller bearing (43). To avoid mistakes, the jaw
length of the caliper gauge must be at least 120 mm. The dimension L1 may vary
between 33.34 and 33.54 mm.
- Measure the actual thickness Lr of the pinion head. Lr may vary between 53.87 and
54.47 mm.
- Record the mounting
distance Le which can
be read from the face of
the pinion. Le will be
approximately
83.83 mm.
Fig.2: Determining the dimension se to adjust contact pattern

- Determine the necessary thickness se for the adjusting washer (45) as follows:
se = 174.3 - Le - Lr - L1 [mm]
Choose a washer thickness which is closest to the calculated value. The washers are
available with a thickness of 2.50, 2.75 and 3.00 mm. Insert the selected adjusting washer
(45) and press in the outer ring of bearing (43) from the inside and the outer ring of bearing
(48) from the outside of the differential housing. Push the bearing inner ring (43) onto the
pinion shaft (if necessary evenly warm up the bearing to 80°-110°C). Then ist is necessary
to adjust the bearings of the bevel pinion.
3.2.2.2. Adjustment of the Pinion Bearings
The spacer sleeve (47) has a length of 25.9 mm, the adjusting washers (44) vary in
thickness from 0.96 to 1.44 mm with a step of 0.04 mm. Select the spacer sleeve and two
to three adjusting washers with a total width of (se+25.60) mm for now and - washers first -
slide them onto the shaft of the pinion. (se is the thickness of the washer (45) for
adjustment of the contact pattern, see Chapter 3.2.2.1.) Insert this unit into the differential
housing and hold in place from the inside. Install the inner ring of bearing (48) and the
cardan flange (51) onto the pinion shaft, for the time being without O-ring and shaft seals.
Apply and tighten hex nut (50) with 800 Nm torque. During tightening the nut, with a
hammer tap against the housing of where the bearings are located in order to properly align
the taper rollers. Also tap against the face of the pinion shaft with a brass mandril while
turning the pinion back and forth. Inspect the bearing preload; if required through the use of
thinner adjusting washers (44) the proper bearing preload is to be adjusted.
The pinion bearings cannot have any axial play, ie. the pinion should let itself be turned with
0.5 to 6 Nm frictional torque. This value is valid only for new bearings and with removed
crown wheel and without shaft seals. For used bearings the setting value is 0 to 5 Nm.
Record the finally adjusted frictional torque of the bearings.
3.2.2.3. Quick Adjustment of the Pinion Bearings with Special Tools
The adjustment of the pinion bearings according to the method described above can
require several trials and therefore will take some time. Recommended is a more accurate
method which requires following special tools, see Fig.3:
- spacer sleeve A NAF-# 05.73110.058.0
- spacer sleeve B NAF-# 05.73110.059.0
- squeeze ring NAF-# 05.73070.052.0 (for single use only)
Put a new squeeze ring into the axial groove of spacer sleeve A, then insert spacer
sleeve B into the groove. Sleeve B in advance, shift this unit onto the shaft of the bevel
pinion. Install the inner ring of bearing (48) onto the pinion shaft, for the time being without
O-ring and shaft seals. Apply and tighten hex nut (50) until the frictional torque of the pinion
has reached 1.0-2.0 Nm. If you tighten the nut too much and the given limit of frictional
torque is exceeded, you have to repeat the procedure with a new squeeze ring. During
tightening the nut, with a hammer tap against the housing of where the bearings are located
in order to properly align the taper rollers. Also carefully tap against the face of the pinion
shaft with a brass mandril while turning the pinion back and forth.
Again disassemble the spacer sleeves A and B together with the sqeeze ring and
determine the total width Lq of this unit with an accuracy of 0.01 mm. Due to tolerances
during manufacturing Lq can vary between 27.82 and 29.26 mm. For final assembly select
the original spacer sleeve (47) and adjusting washers (44) with a total thickness of
min. (Lq - 0.01 mm) and max. (Lq + 0.03 mm)
Assemble with this selected spacer sleeve and washers and, still without O-ring and shaft
seals, tighten the hex nut (50) with 800 Nm torque. Now check the bearing adjustment: the
pinion bearings must not
have any axial play, and the
pinion should let itself be
turned with 0.5 to 6 Nm
frictional torque. This value is
valid only for new bearings
and with removed crown
wheel and without shaft
seals. For used bearings the
setting value is 0 to 5 Nm.
The bearing adjustment
should be ok, if required the
proper bearing preload is to
be adjusted through the use
of an adjusting washer (44)
one step thicker (in case of
too much pretension) or
thinner (in case of axial play
or too little pretension).
Fig.3: Determining Lq for adjustment of the pinion bearings
3.2.2.4. Finish Assembly
of Pinion
When it is sure that the bearings are well adjusted, loosen nut (50) and again remove the
cardan flange (51). Install a new O-ring (49) into the groove of the shaft. Then press two
seals (first 87a then 87b) into the housing (42) and fill 50% of the volume between both
seals with grease. It should be noted that the seals are installed in the correct illustrated
orientation. Clean the threads of shaft and nut from dirt or grease, then shift the cardan
flange (51) onto the spline of the shaft. Cover the threads of pinion shaft and nut (50) on
their whole length and circumference with Loctite 639. The applying and tightening of the
nut must not take any longer than 3-5 minutes to avoid any hardening of the adhesive. The
nut cannot be applied using an impact wrench since this will promote early hardening and
the adhesive will be spun off the threads. Tighten the nut with 800 Nm torque.
Measure and record the frictional torque of the bearings, now including the friction of the
shaft seals but still without crown wheel. This value will be needed for the assembly of the
bearings of the crown wheel.
3.2.3. Reassembly of the Crown Wheel

Check that both dowel pins (12) are in their bore in the differential cage, then set the crown
wheel onto the differential cage and fasten with 16 new coated bolts (9) and hardened
washers (10). Then press the inner rings of the taper roller bearings (8, 24) onto their seat.
Press the outer rings of both taper roller bearings (8, 24) into their seats in the flanges (6,
36), then screw in the grooved nuts (3, 25) to their previously recorded position. From this
position turn out groove nut (3) 1 thread (ie. one turn).
Install a new O-ring (7) to the step of the flange (6) and make sure that the shifting sleeve
(56) of the differential lock is properly held by the shifting fork (27). Insert the differential
cage (with crown wheel) into the differential housing, during this the shifting sleeve must not
fall down from the shifting fork. Mount the flange (6) with two Allen bolts (4). Use four
additional bolts M20x2x40 per side to fix the flanges (6, 36) solidly. Now turn in the groove
nut (3) to get a backlash of 0.15 to - 0.25 mm between the teeth of bevel pinion and crown
wheel. If measured at the hole circle of the drive shaft flange (Æ »127 mm) this is 0.3 to 0.5
mm.
If the proper backlash is attained install locking plate (2) and bolt (1) to lock groove nut (3)
into place, then adjust the preload of the crown wheel bearings (8) and (24). For this adjust
groove nut (25) by putting an arbor into one of the grooves and hitting with a hammer, until
the desired bearing friction torque of 1.0 to 3.0 Nm is reached. This can be measured with a
torque gauge at the drive shaft flange by adding a value of 0.2 Nm to 0.7 Nm to the torque
determined in Chapter 3.2.2.2. or 3.2.2.3. (bearing friction torque).
3.2.4. Checking the Contact Pattern
A bad contact pattern will result in less strength of the hypoid gearing and in bad noise
behaviour. If the proper adjusting washer (45) has been selected according to the
description in Chapter 3.2.2.1., the contact pattern of the hyoid gearing should be ok and
this is only a final check.
Loosen the Allen bolts (4) and remove flange (6) completely, along with the differential
cage. Coat four flanks on the ring gear with a thin layer of oil based marking paint and
assemble differential cage and flange. Turn the pinion to and fro such that the contact
pattern is marked on the paint. Remove flange and diff.-cage and inspect the contact
pattern which should look like that of Figure 6.
If the contact pattern resembles that of Figure 4 or 5 then by adjusting the pinion position as
shown in these Figures a pattern shown in Figure 6 can be achieved. The pinion can be
moved by changing the thickness of adjusting washer (45), ie. the complete procedure of
adjusting the bearings and the tooth backlash has to be repeated.
Note: When adjusting always note proper preload of crown wheel bearings (8) and (24) and
when turning groove nuts (3) and (25) ensure proper backlash. Always remove old paint
from ring gear when rechecking.
Fig.4: bad contact pattern Fig.5: bad contact pattern
Fig.6: good contact pattern

If bearing preloads, tooth backlash and contact pattern have been properly adjusted then
both groove nuts (3) and (25) are to be secured with locking plates (2) and new adhesive
coated hex bolts (1). Remove the additional hex bolts M20x2x40 which fixed the differential
flanges.
Note: The axial play of the shifting claws of the differential lock is to be adjusted according
to Chapter 4.2 if any of the following components were exchanged:
differential housing (42) differential cage (11)
crown wheel bearings (8, 24) crown wheel and pinion (13)
differential flanges (6, 36) shifting fork (27)
cupling sleeve (21) shifting sleeve (56)
3.3. Exchange of The Compensating Gears

Both halves of the differential cage (11) can only be exchanged as a set. Both halves are
marked in their orientation to one another with mating numbers and must be be assembled
in this orientation only.
Disassembly
Disassemble the differential from the axle according to Chapter 3.1.1. Then loosen 2 Allen
bolts (4) and remove the flange (6). Take the complete differential cage with crown wheel
out of the differential housing. Remove the inner ring of bearing (24), loosen allen bolts (22)
and take the differential cage apart.
Inspect for damage and wear and replace if required the compensating gears (18),
differential gears (15), crossbolt (16), thrust washers (14), and thrust plates (19).
Assembly
The thickness of the thrust washers (14) is to be chosen such that the backlash between
the closest point between the differential gears and compensating gears is zero. The
maximum backlash allowed is 0.3 mm. When turning one compensating gear (15) while
holding the other still there should not be any noticeable resistance and there cannot be
any unevenness in the turning.
Assemble the differential cage halves in their marked orientation to one another and tighten
with new adhesive coated allen bolts (22). Insert inner ring of bearing (24) onto the
differential cage. Install the differential cage in the differential housing (42), set a new O-
ring (7) onto the step of the flange and mount the flange (6) with Allen bolts (4). Finish
assembly of the complete axle as described in Chapter 3.1.2.
3.4. Exchange of the Pinion Bearings

Exchanging the taper roller bearings (43, 48) is also recommended, when there is an
exchange of crown wheel and pinion, see the detailed description in Chapter 3.2.
3.5. Exchange of the Crown Wheel Bearings

3.6. Exchange of the Shaft Seals

Drain the oil from the differential and remove the drive shaft from the input cardan flange
(51). The hex nut (50) in the cardan flange is locked with Loctite, the loosening torque may
exceed 1000 Nm. Therefore preheating the nut to 120°-160°C with a blow lamp is recom-
mended. Loosen the nut (WS 50) and pull the cardan flange from the spline end of the
pinion shaft. Now, both radial shaft seals (87) can be pulled out. It is also recommended to
exchange the O-ring (49), extract it from the groove in the shaft. Check the sealing surface
of the cardan flange (51) for any marks of wear and replace it if necessary.
With a steel brush remove rests of old hardened glue from the threads of shaft and nut and
clean from any dirt and grease. Install new shaft seals, note that the lips of the seals are
installed in the proper orientation as shown. Fill 50% of the volume between seals (87) with
grease, install new O-ring (49), and shift the cardan flange (51) onto the spline of the shaft.
Now cover the threads of shaft and nut with Loctite 639. The applying and tightening of the
nut must not take any longer than 3-5 minutes to avoid any hardening of the adhesive. The
nut cannot be applied using an impact wrench since this will promote early hardening and
the adhesive will be spun off the threads. Tighten the nut with 800 Nm torque.
4. Differential Lock
4.1. Checking the Function of the Differential Lock
Prior to opening the axle it must be determined whether the lock itself is damaged or the
external engaging components. To inspect the function of the differential lock, jack up the
vehicle such that the wheels of the axle are no longer touching the ground. Block the input
cardan flange of the differential or the corresponding drive shaft. Turn one wheel.
When the differential lock is open (ie. no line pressure) the opposite wheel will turn in the
opposite direction. If the differential lock is engaged (ie. line pressure acting) neither the
right or left wheel will turn; although, small turning action is permitted due to backlash.
4.2. Exchanging Parts of the Differential Lock

For any repair works at the differential lock it is recommended to disassemble the complete
differential from the axle as described in Chapter 3.1.1. Loosen 2 Allen bolts (52) and
remove the differential flange (36) together with the shifting sleeve (56), the differential cage
can remain in the differential housing. Loosen the hex nut (30) at the shifting rod, counter
the loosening torque at the opposite end of the shifting rod. The nut is locked with Loctite,
therefore preheating it with a blow lamp to 120°-160°C is recommended.
4.2.1. Exchanging Piston and U-Ring Seal
Extract the aluminum piston (33) from the cylinder (32). The old U-ring seal (40) can be
removed out of its groove in the piston with a sharp tool. Inspect piston and cylinder for any
marks of wear and replace if necessary. Snap a new seal ring (40) into the groove, the seal
lips facing the short end of the piston. Insert the piston into the cylinder (32) and turn it such
that the shifting lever lateron can be assembled into the groove of the piston.
4.2.2. Exchanging the Cylinder
Unscrew the cylinder (32, wrench size 46) from the differential flange (36). Before screwing
in a new cylinder cover its thread with Loctite 542 (alternatively OKS-paste or any other fluid
thread sealing). Screw in the cylinder with a new copper seal ring (34) and tighten with
90 Nm. After mounting the cylinder there must not be any hydraulic pressure for 6-8 hours
until the fluid sealing becomes fully effective.
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock
The axial play of the shifting claws is to be adjusted if any of the following components were
exchanged:
Fig.7: Dimensions "X" and "Y" for determining the adjustment of the differential lock
Depress the shifting fork (27), without assembling shifting sleeve (56), compression spring
(28), and adjusting washers (29), against the flange (36) and with a depth gauge measure
dimension "X" (theoretical dimension 44 mm), see Fig. 7.
Depress the shifting fork (27), this time with assembled shifting sleeve (56), towards the
differential centre until the teeth of the shifting sleeve and coupling sleeve (21) have
completely meshed, and then measure dimension "Y" (theoretical dimension 41.5 mm).
The thickness "s" of the washer package (29) is determined as follows:
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
The thickness "s" of the washer package can vary between 1.5 - 4.0 mm. The washers are
available with a thickness of 1.5, 2.0 and 2.5 mm.
For final assembly of the differential lock clean the threads of shifting rod (26) and hex nut
(30) from rests of hardened glue and any dirt or grease. Insert the compression spring (28)
into the flange (36), Then insert the shifting rod (26) together with shifting fork (27) and
shifting sleeve (56). Cover the thrads of nut and shifting rod with Loctite 639 on their whole
length and circumference, put the shifting lever (31) onto the shifting rod and properly into
the groove of the piston and tighten the nut. Counter the tightening torque at the flattened
opposite end of the shifting rod.
Snap a new O-ring (7) onto the step of the flange (36) and install the complete flange to the
differential housing. Fasten with 2 Allen bolts (52) and finish assembly of the complete axle
as described in Chapter 3.1.2.
Repair Instruction, Multiple Disk Brake
Figures: Assembly Drawings fig. 00.75000.260, QMA Nr.: 09.004.0
Date: February 20,1997 page 16
5. Multiple Disk Brake and Brake Cylinder

Because it is a completely enclosed system the brake in general is maintenance free. The
maintenance procedures are reduced to regular inspections of air gap and cylinder stroke
as per 5.1. and an inspection for leakage and loose bolts of the spring loaded brake
cylinder.
In the event that the brake cannot be loosened, even though the brake relief valve is used,
or due to the loss of brake supply pressure it is possible to mechanically loosen the brake
through the use of an emergency mechanism which compresses the spring set. This
makes it possible to tow a broken down vehicle.
The lubrication oil level as well as the oil levels of both activation systems of the brake are
to be inspected and if required corrected with the prescribed fluids after every
maintenance cycle or every repair service. Also upon completion of all work the brake is
to set-up as per point 5.2. and 5.3., inspected and tested.
5.1. Air Gap Inspection of the Multi Disk Brake

The vehicle must be properly secured to prevent it from rolling. Pressure connections (I)
must be inspected for pressure.
After removal of the screw plug (143) on the top of the axle beam, measure dimension "X"
between both ball ramp disks with a feeler gauge in both the braked and unbraked
condition (see assembly drawing of the differential section). The difference of both
measurements should be between 2.2 and 3 mm. If this value is exceeded then the air
gap is to be readjusted as per 5.2.
The air gap can also be inspected by measuring the cylinder stroke: Remove screw cap
(154) with a wrench WS 24 and take out the screw intended for emergency release (155).
The movement of the pressure piston (164) when loosening and engaging the brake is to
be measured with an appropriate tool (ie. dial gauge or depth gauge). If the cylinder stroke
exceeds a value of 6 to 7 mm, then a readjustment as per 5.2. must be performed.
5.2. Air Gap Adjustment of the Brake

The vehicle must be properly secured to prevent it from rolling. Brake connections (I) must
be inspected for no pressure. Ensure a container is within reach to collect any hydraulic oil
which may leak from the cylinder housing. Remove brake connection (I) and screw cap
Then loosen four allen screws (152) and disassemble spring loaded cylinder (151) from
the brake cylinder (150). Both allen screws (170) mustn`t be unscrewed. Loosen counter
nut (159) for doing this hold the pressure piston (164) in position with a wrench WS 16.
After this, unscrew completely the adjustment allen screw (158) and clean thread of
adjustment allen screw (158) and counter nut (159) of oil and glue reside. Turn the
counter nut (159) on the adjustment allen screw (158) untill the screw head. Coat with
Loctite 242 the complete length of threaded part of adjustment allen screw (15). Then
clockwise turn the adjustment allen screw (158) with an allen key WS 8 until a torque of 8
to 15 Nm is obtained. By doing this the brake disks are under sufficient pressure, not
allowing the output shaft to turn. The required air gap of 2.4 mm is obtained by turning the
adjustment allen screw (158) back 3.5 turns. By doing this hold the pressure piston (164)
in position with a wrench WS 16.
After this adjustment the counter nut (159) must be tightened with 49 Nm. For doing this,
hold the pressure piston (164) in position with a wrench WS 16. If the brake cylinder
underpart (150) or the pressure piston (164) is wetted with Loctite must these rests
completly removed.
Brake cylinder underpart (150) bleed through breather screw III and check the stroke
through gauge. The movement of the pressure piston (164) when loosening and engaging
the brake is to be measured with the appropriate tool (ie. dial gauge or depth gauge). If
the cylinder stroke exceeds a value of 5,25 mm, then a readjustment is necessary.
After this adjustment is completed, note that the o-ring (176) is properly seated in the
groove of the cylinder underpart (150). Then assemble the spring loaded cylinder (151) on
the brake cylinder (150) and tighten the four allen screws (152). Insert screw for
emergency release (155) with protecting cap (167). Check the o-ring (168) and mount the
screw cap (154) by hand tighten.
Upon completion the operating brake as well as the parking brake are to be actuated
several times while the vehicle is parked in order for the various components to seat and
align themselves properly. Afterwards, both compression chambers finally are to be bled
over breather valves III, in order to remove any air in the system.
5.3. Emergency Release of the Parking Brake

First the vehicle must be properly secured to prevent it from rolling. Emergency release of
the parking brake also is necessary before disassembling the brake cylinder from the axle
beam or before disassembling the complete axle beam from the differential housing.
Both pressure connections I and II must be inspected for no pressure. Ensure a container
is within reach to collect any hydraulic oil which may leak from the cylinder housing,
Remove screw cap (154) with a wrench WS 24 and take out the screw for emergency
release (155). With the use of a wrench WS 19 turn in the hexagon screw for emergency
release (155) clockwise, until a tight bottoming out is felt. Now the spring set is fully
compressed and the brake is released. In this condition the vehicle can be towed to the
nearest repair centre ie. other repairs can be initiated provided the proper safety
procedures are followed.
Caution: In this condition stopping the vehicle with the parking brake is no longer
possible! Because of this proper safety procedures must be taken when towing or
parking the vehicle.
To reinstall to driving conditions loosen the hexagon screw for emergency release (155) in
a counterclockwise manner. The spring loaded mechanism for the parking brake is now in
its normal condition and the housing is to be closed again with the screw cap (154).
5.4. Exchange of the Brake Cylinder

In general the brake is made up of two components which have been bolted together,
namely the upper part (151) which is the spring loaded mechanism for the parking brake
and the lower part (150) with the compression wedge (181). To exchange the brake
cylinder or any part of it the axle can remain in the vehicle. In this case accurately block
the vehicle with wheel chocks, as the parking brake will not be acting with removed brake
cylinders!
5.4.1. Exchange of the Spring Loaded Cylinder
Caution: Under no circumstances should the housing of the spring loaded cylinder
be opened with force, since the sudden release of the springs can endanger the
person attempting the repairs.
Disassembly:
Pressure connections (I) must be inspected for no pressure. Ensure a container is within
reach to collect any hydraulic oil which may leak from the cylinder housing, then remove
screw cap (154) with a wrench WS 24
Caution: both allen screw (170) mustn`t be unscrewed.
the brake cylinder (150).
Assembly:
After this, note that the o-ring (176) is properly seated in the groove of the cylinder
underpart (150). Then assemble the spring loaded cylinder (151) on the brake cylinder
(150) and tighten the four allen screws (152). Insert screw for emergency release (155)
with protecting cap (167). Check the o-ring (168) and mount the screw cap (154) by hand
tighten. Bleed the spring loaded cylinder (151) through breather screw III.
Upon completion the parking brake are to be actuated several times while the vehicle is
parked in order for the various components to seat and align themselves properly.
Afterwards, both compression chambers finally are to be bled over breather valves III, in
order to remove any air in the system.
5.4.2. Exchange of the Cylinder for the Operating Brake

Disassembly:
Caution: both allen screw (170) mustn`t be unscrewed.
Drain the lubricating oil from the differential and remove the hydraulic connections from
the brake cylinder. Loosen 4 allen bolts (152) but both allen screws (170) mustn`t be
unscrewed and remove the spring loaded cylinder (151). After loosening the three allen
screws (113) the complete lower part of the brake cylinder (150) including the
compression wedge (181) can be removed from the axle beam (101, 102).
Assembly:
The centering ring (165), which is of a mineral oil resistant foam, ensures that the
compression wedge (181) is in-line with the length axis of the brake. It must be noted that
prior to insertion the flanks of the compression wedge (181) are parallel to the
compression rollers (182) of the ball ramp actuator (118). Place a new o-ring (178) in the
groove of the cylinder housing (162) and insert the complete lower part of the brake
cylinder (150) into the hole of the axle beam (101, 102) and tighten with new coated allen
bolts (113).
Continue assembly of the spring loaded upper part of the brake cylinder as per 5.4.1.
Refill lubricating oil into the differential, see the description in the maintenance schedule.
5.4.3. Exchange of Seal Rings in the Brake Cylinder
5.4.3.1. Seal Rings in the Spring Loaded Cylinder
Caution: The assembled piston unit (157) must not be disassembled under any
circumstances, since the sudden release of the spring compression (approx.
8000 N) can endanger the person doing the work. Repairs of this unit are actually not
intended since special tools and jigs are required. When there is any damage it is to be
completely replaced and sent in for examination.
Disassembly:
First disassemble spring loaded cylinder (151) from the brake cylinder (150) as per 5.3.1.
Then mount 2 auxiliary screws (M 10x95) with nut instead crosswise and tighten by hand
in the disassembled spring loaded cylinder (151). After loosening both allen screws (170),
loosen the 2 auxiliary screws simultaneously and take off the cylinder (upper part) (160).
Now the piston (157) can be removed and the seal ring (174) guide rings (12);(17) can
renewed.
Assembly:
Install new seal (174) guide rings (12), (17) into the grooves and insert the assembled
piston unit (157) into the cylinder housing (156). Special attention must be given to the
sealing edge of the seal ring (174) that they are not damaged during insertion. Also
special attention must be given to the arrangement of the contact surface from the piston
unit (157) and take on the cylinder (upper part) (160). Then mount 2 auxiliary screws with
nut crosswise and tighten by hand simultaneously till both parts are in contact. Tighten
both allen screws (170) and disassemble the 2 auxiliary screws.
Continue assembly as per 5.4.1.
5.4.3.2. Seal Rings in the Lower Part of the Brake Cylinder (Operating Brake)
First remove the spring loaded upper part of the brake cylinder (151) as per 5.4.1., then
disassemble the lower part as per 5.4.2
After removal of the the complete lower part of the brake cylinder (150) all individual
pieces of the cylinder such as pressure piston (164), compression wedge (181), with guide
ring (165) can be disassembled.
Install new piston seal rings (180, 177) and new guide rings (166, 179) in the grooves and
assemble all parts of the cylinder lower part (162).
Continue assembly as per 5.4.2 and 5.4.1.
5.5. Exchange of the Disk Brake

The inner disks (120) with the brake linings have a thickness of 4.9-0.15 mm.
If the thickness is less than 4.5 mm then the entire disk set is to be exchanged.
Disassembly:
First completely remove the brake cylinder as per 5.4.1 and 5.4.2, then loosen the hex
bolts (103, 104) and remove the complete axle beam (101, 102) together with the multi
disk brake in it. Brake and dowel pins (122) remain the time being in the axle beam. After
the toothed rings (121) have been extracted from the dowel pins the disks (119, 120) and
the ball ramp activation mechanism (118) can be removed from the axle beam (101, 102).
The main components of the ball ramp activation mechanism (118) can only be
exchanged as a complete set. Only the tension springs (148) can be detached and
exchanged.
Assembly
Note that the four dowel pins (122) properly sit in their bores in the axle beam. The three
outside disks (119) and three inside disks (120) are to be assembled in the illustrated
orientation. First a new outer disk (119) is to be placed followed by an inner disks (120)
and an outer (119) and so on. An inner disk (120) is directly on each side of the ball ramp
activation disks.
Both outer outside disks (119) per brake side are to
be mounted crosswise onto the dowel pins (122).
The inner most outer disk per brake side does not
get inserted into the dowel pin (122) but rather into
the clutches of the ball ramp disks (118).
After all six outer disks and six inner disks and ball
ramp activation mechanism have been assembled,
insert a toothed ring (121) on each of the four
dowel pins (122) as an assembly aid. The six inner
disks (120) are to be orientated with a splined
mandrel, eg. with drive shaft (140). It must be noted
Fig.8: Multiple Disk Brake that the bores in the inner disks make an inline
channel to allow cooling oil to flow.
Install a new O-ring (5) to the step of the differential flange and mount the complete axle
beam with hex bolts (103, 105). When doing this the splines of the drive shaft (140) are
inserted into the splined profile of the shifting sleeve and compensating gear.
Attach the brake cylinder as per 5.4.2 and 5.4.1 and adjust the air gap of the brake as per
5.2.
After the hydraulic oil is properly filled in the brake system, the operation of the operating
brake and park brake must be tested either on a test stand or during driving tests. After a
certain break-in period of the brake linings, which is determined by the load put on the
brake, the disks will have been broken-in and a readjustment to the brake can be
necessary.
Repair Instruction, Planetary Hub
Figures: Assembly Drawings fig. R 72000.113.0
6. Tightening Torques for Bolts and Nuts (Planetary Hub)

2 hex bolt M16x90 10.9 VP 1510.536 310 Nm
15 plug M20x1.5 with magnet 9556.021 56 Nm
16 plug M30x1.5 VP 7323.016 220 Nm
17 flat collar nut M22x1.5 1060.402 550 Nm
28 hex bolt M16x40 10.9 VP 7322.069 310 Nm
32 hex bolt M12x30 10.9 1010.301 125 Nm
39 grooved nut M85x2 7329.073 2000 Nm+ Loctite 639
7. Exchange of the Complete Planetary Hub

When working on the planetary hub the axle does not have to be removed from the
vehicle. Only the side of the axle, which will be worked on, needs to be jacked up and the
wheel with the rim must be detached after removing the flat collar nuts (17).
Disassembly
Drain the lubricating oil from the differential and from the hub as described in the
maintenance schedule. Loosen all 16 hex bolts (28) and remove the complete planetary
hub unit. In case of a broken drive shaft (140) also the axle beam (101, 102) has to be
removed from the differential (see 3.1.1.) and carefully cleaned of any particles of metal
wear of even metal chips.
Inspect the coupling sleeve (21) and the plane bearing (25) in the axle spindle (27) for
wear and replace them for a new ones if necessary.
Assembly
Before starting reassembly note that the coupling sleeve (21) properly sits on the spline
end of the sun gear (40) and in the plane bearing (25) of the axle spindle (27). Then shift
the long spline end of the drive shaft (140) into coupling sleeve and compensating gear in
the differential. Install a new O-ring (26) onto the step of the spindle (27). Note that both
dowel pins (59) properly sit in their bores in the axle beam (101, 102). Attach the complete
planeetary hub unit to the axle beam and fasten with hex bolts (28). Inspect and adjust the
axial play of the sun gear according to chapter 8.5., then refill lubricating oil as explained
in the maintenance schedule.
8. Planetary Gearing
8.1. Opening the Planetary Hub
Drain the lubricating oil from the hub and as well from the differential as desribed in the
maintenance schedule. Then open the 4 hex bolts (32) at the back of the hub and remove
the complete planet carrier. All gears are accessible now.
8.2. Exchange of the Sun Gear Shaft

Pull the sun gear shaft (40) out of the axle spindle (27). For reassembly simply shift the
sun gear shaft into the bore of the spindle and note that its spline end properly meshes
with the internal spline of the coupling sleeve (21).
8.3. Replacement of the Planet Gears, Planet Bearings and Planetary Pins
Disassembly
Loosen hexagon head bolts (2) and lift out the inner half of the planet carrier (4). If
necessary use a suitable pulling device. Remove the thrust washers (11) and pull out the
planet gears (10). Now the needle bearings (8) together with 2 supporting washers (9)
and an other thrust washer (11) can be pulled from the planetary pin (7). To extract the
planetary pin out of its bore in the planet carrier (13) screw a bolt puller into the thread
M12 of the planetary pin and pull out the pin. Older versions of the planetary hub unit may
not have a thread in the planetary pin, in this case fix the bolt puller to the face of the pin
by welding.
Assembly
Press new planetary pins (7) into the bores in the planet carrier (13). Depending on
scattering in the coefficient of friction and in the dimensions, a pressing force of up to
50 kN might be possible. Therefore it is recommended to use a hydraulic press.
Before starting reassembly note that all four shear bushings (5) are properly pressed into
the bores of the planet carrier (13). Set a thrust washer (11) onto the planetary pin (7),
with its bended lip in the recess of the casting. Then install a supporting washer (9), a
needle bearing (8), a second supporting washer and a second thrust washer onto the
planetary pin. Assemble the inner half of the planet carrier (4) to its external part (13),
being careful that the bended lips of the thrust washers (11) engage properly with the
appropriate recesses of the casted planet carrier. Fasten both carrier halves with new hex
bolts (2) and hardended washers (3). Finish the assembly as per 8.5.
8.4. Exchange of the Ring Gear

Detach the planet carrier as per 8.1. and pull out the sun gear shaft. The grooved nut (39)
is locked with Loctite, preheating it to 120°-160°C is necessary; it also has been tightened
with high torque, therefore prepare a torque amplifier. Open the grooved nut (39) at the
spindle. Then pull the ring gear carrier (38) from the spindle (27) and keep all parts of the
washer package (62) for reassembly. Dislodge the snap ring (37) and draw off the ring
gear (1). Slide a new ring gear (1) onto the ring gear carrier and let the snap ring (37) snap
into its groove. The ring gear should be movable by approx. 0.4 mm radial and 1.0 mm
axial on the ring gear carrier (38).
If spindle (27), spindle ring (30), wheel bearings (31, 36), hub (34) and ring gear carrier
(38) have not been exchanged, an adjustment of the wheel bearings is not necessary.
Remove rests of hardended glue from the threads of spindle (27) and nut (39) with a steel
brush, and clean of any dirt and grease. To avoid scoring when tightening the nut, cover
the machined face of the ring gear carrier (38) with Klüber-paste "Wolfracote SSP", do not
cover the nut with this paste! Install the ring gear carrier onto the spline of the spindle,
then put the complete original washer package (62) onto the spindle. Cover the treads of
spindle and nut on their whole length and circumference with Loctite 639 and tighten the
nut with 2000 Nm torque (use torque wrench with torque amplifier).
Finish the assembly as per 8.5.
8.5. Reassembly of the Planetary Hub

Remove the centre plug (16) in the planet carrier together with the adjusting washers (19).
Now the complete planet carrier can be reassembled. To engage the planetary gears with
the sun gear and the ring gear, twist the planet carrier slightly back and forth when
attaching it. Fasten the planet carrier with 4 hexagon head bolts (32).
To adjust the axial play between the sun gear shaft
(40) and the plug (16), push the sun gear shaft
towards the centre of the differential with a mandril (»
Æ 20) and slight hits of a hammer. With a depth
gauge measure the distance "A" from the sink at the
centre bore of the planet carrier to the face of the
sun gear, see Fig.9. Determine the thickness "s" of
the washer package (19) as follows:
"smin" = 22 - "A" "smax" = 23 - "A"
The washers are available with a thickness of 1.0
and 2.5 mm. Install a new coated plug (16) with the
washers (19) and tighten with 220 Nm torque.
Fig.9: Adjustment of the sun gear
Fill in lubricating oil as described in the maintenance schedule.

9. Spindle and Wheel Bearings

9.1. Exchange of Wheel Bearings and Spindle Ring
Disassembly
Detach the planet carrier as per 8.1. and pull out the sun gear shaft (40). The grooved nut
(39) is locked with Loctite, preheating it to 120°-160°C is necessary; it also has been
tightened with high torque, therefore prepare a torque amplifier. Open the grooved nut
(39) at the spindle. Then pull the ring gear carrier (38) and the washer (62) from the
spindle (27). Draw off the wheel hub (34) together with the outer rings of the wheel
bearings. With a bearing puller pull the outer rings of the taper roller bearings (31, 36) out
of the wheel hub, then pull the spindle ring (30) together with the inner raceway of the
taper roller bearing (31) from the spindle. Remove the slide ring seals ("Cat" seal, #29)
from the grooves in the spindle ring and in the wheel hub.
Assembly
Before starting assembly measure and record dimension "X1" of the spindle (theoretical
dimension 22±0.2, see Fig.9). Remove rests of hardended glue from the threads of spindle
(27) and nut (39) with a steel brush. Insert a new O-ring (49) into the groove of the spindle
(27), then install the spindle ring (30) onto the spindle. To install a new slide ring seal (29)
it is favourable to use a special tool which is supplied by the manufacturer of theses seal
rings (e.g. Caterpillar, Goetze, Busak&Shamban); otherwise insert the seal rings into the
grooves of spindle ring and wheel hub by hand. The seal rings are very brittle, be careful
not to brake them. Press the inner ring of taper roller bearing (31) onto the spindle (27),
then press the outer rings of the bearings (31, 36) into the wheel hub. Set the wheel hub
onto the spindle and press the inner ring of taper roller bearing (36) onto the spindle.
Set the ring gear carrier (38) onto the spine of the spindle and cover ths machined face of
the ring gear carrier with anti-scoring-paste "Klüber Wolfracote SSP". Screw the grooved
nut (39) onto the spindle (for the time beeing do not use Loctite), and tighten the nut until
the frictional torque of the wheel bearings and the seal ring reaches a value of 20-22 Nm.
During tightening of the nut continuously hit the wheel hub with a hammer at the location
where the bearings are situated. Additionally turn the wheel hub to make sure that the
taper rollers are properly aligned. Now measure and record the dimension "X2" (theoretical
dimension 20±0.75, see Fig.10). Determine the necesssary thickness "d" of the washer
(62) as follows:
"dmax" = (X1 - X2) mm "dmin" = (X1 - X2) - 0.15 mm
The washers (62) are available with a thickness of 1.375 - 2.5 mm, step 0.125 mm. Again
unscrew the grooved nut and clean the threads of spindle (27) and nut (39) of any dirt and
grease. Again cover the face of the ring gear carrier (38) with anti-scoring-paste, do not
cover the nut with this paste! Install the selected adjusting washer (62) onto the spindle.
Cover the treads of spindle and nut on their whole length and circumference with Loctite
639 and tighten the nut with 2000 Nm torque (use torque wrench with torque amplifier).
Fig.10: Adjustment of the wheel bearings
9.2. Replacement of the Slide Ring Seal

The replacement of the slide ring seals (29, "Cat" seal) already is described in detail in
Chapter 9.1. However, it is not necessary to pull all bearing rings from their seats as
described there.
9.3. Replacement of the Axle Spindle

To replace the axle spindle follow the instructions in Chapter 9.1. After the wheel bearings
are disassembled, the axle spindle (27) can be exchanged by loosening the hex bolts (28).
When reassembling also insert a new O-ring (26).
1 Ring Gear 11 Thrust Washer 23 Coupling Sleeve 32 Hex. Bolt 49 O-ring

2 Hex. Bolt 13 Planetary Cage outer 24 Snap Ring 33 Wheel Stud 59 Dowel Pin
3 Washer 14 Gasket 25 Sleeve 34 Wheel Hub 62 Adjusting Washer/s
4 Planetary Cage Inner. 15 Screw Plug 26 O-ring 35 O-ring 101 Axle Beam
5 Shear Sleeve 16 Screw Plug 27 Axle Stub 36 Tapered Roller Brg. 102 Axle Beam
7 Planetary Shaft 17 Flat Collar Nut 28 Hex. Bolt 37 Snap Ring 140 Axle Shaft
8 Needle Bearing Ring 18 Limes Type Ring 29 Axial Face Seal 38 Ring Gear Carrier
9 Supporting Washer 19 Washer Set 30 Axle Stub Ring 39 Groove Nut
10 Planetary Gear 31 Tapered Roller Brg. 40 Sun Gear Shaft
Repair Instruction, Modification sheet
Figures:
Description Date
Original Version ............................................................................................Feb. 19, 1997
Revisions reserved
Neunkirchen on July 17, 1997
Partnumber for Diff. (Drawing no. 00.75000.260.0)
87a. Oil seal Drive shaft flange
1. Screw for locking plate
87b. Oil seal Drive shaft flange
2. Locking plate for groove nut
101. Right Axle beam
3. Groove nut Crown gear side
102. Left Axle beam
4. Allen screw for Diff.-flange
103. Axle beam screw
5. O-ring Axle beam, Diff.
6. Diff.-flange Crown gear side
106. Split spring pin Axle beam
7. O-ring Diff.-flange
113. Allen screw for Operating brake cylinder
8. Diff.-cage bearing Crown gear side
118. Driven disk
9. Crown wheel screw
119. Dive disk
10. HV washer crown wheel
120. Operating disk
11. Diff.-cage
12. Dowel pin for crown wheel
13. Crown wheel / pinion
14. Butting ring for compensating gear
15. Compensating gear
16. Cross bolt
17. -
18. Differential gear
19. Thrust washer for Differential gear
20. Circlip for Clutch-coupling sleeve
21. Clutch-coupling sleeve Diff.-lock
22. Allen screw Diff.-cage
23. -
24. Diff.-cage bearing (at lock)
25. Groove nut Diff.-Sperrenseite
26. Shifting rod Diff.-lock
27. Shift fork Diff.-lock
28. Compression spring Diff.-lock
29. Adjusting washers Diff.-lock
30. Nut for gear shift
31. Gear shift Diff.-lock
32. Shift cylinder Diff.-lock
33. Piston Diff.-lock
34. Seal ring shift cylinder
35. Piston seal Diff.-lock ex factory No. 1
36. Diff. flange (lock)
37. -
38. -
39. Oil control plug Diff.
40. Groove ring Diff.-lock
41. -
42. Diff.-housing
43. Pinion head bearing
44. Pinion bearing adjusting washer
45. Print pattern adjusting washer
46. Spacer sleeve Pinion bearing
48. Outer Pinion bearing
49. O-ring Drive shaft flange
50. Drive shaft flange nut
51. Drive shaft flange
52. Allen screw Diff .-flange
53. -
54. Oil drain plug Diff.
55. Seal ring to this
56. Shifting sleeve Diff .-lock
57. -
58. -
59. -
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 100
Type: LOK 100 Bogie Axle
Description: Portal Bogie Axle with Balanced-Bogie Unit

Used as a front axle in Timberjack 1410D Forwarder
Valid from Serial #: LOK 100 / 0 / 1
Date: February 10,2003
Contents Page
Maintenance Schedule ................................................................................................... II
Repair Instruction ....................................................................................................... 1-30
1. General Instructions................................................................................................................... 1
2. Tightening Torque’s for Bolts and Nuts ..................................................................................... 2
3. Differential.................................................................................................................................. 5
3.1. Exchange of the Complete Differential ..................................................................... 5
3.2. Replacement of Crown Wheel and Pinion ................................................................ 6
3.3. Exchange of The Compensating Gears.................................................................. 12
3.4. Exchange of the Pinion Bearings ............................................................................ 13
3.5. Exchange of the Crown Wheel Bearings ................................................................ 13
3.6. Exchange of the Shaft Seals................................................................................... 13
4. Differential Lock ....................................................................................................................... 13
4.1. Checking the Function of the Differential Lock ....................................................... 13
4.2. Exchanging Parts of the Differential Lock ............................................................... 14
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock................... 14
5. Multiple Disk Brake and Brake Cylinder .................................................................................. 17
5.1. Air Gap Inspection of the Multi Disk Brake ............................................................. 17
5.2. Air Gap Adjustment of the Brake ............................................................................ 17
5.3. Emergency Release of the Parking Brake .............................................................. 18
5.4. Exchange of the Brake Cylinder.............................................................................. 18
5.5. Exchange of the Disk Brake.................................................................................... 20
6. Balanced Bogie (BB) Planetary Gear and Slewing Ring ......................................................... 22
6.1. Disassembly of the Bogie Housing ......................................................................... 22
6.2. Reassembly of the Bogie Housing .......................................................................... 22
6.3. Exchange of Sun Gear Shaft (140) and Seal Rings (142) ...................................... 23
6.4. "Balanced Bogie" (BB) Planetary Gear ................................................................... 24
6.5. Exchange of the Slewing Ring ................................................................................ 25
7. Gear Drive Inside The Bogie Housing ..................................................................................... 26
7.1. Exchange of the Needle Bearings........................................................................... 26
7.2. Exchange of The Gears .......................................................................................... 26
8. Portal Drive and Wheel Bearings............................................................................................. 27
8.1. Disassembly of The Portal Gear and Pinion Shaft.................................................. 27
8.2. Exchange of The Face Seal.................................................................................... 27
8.3. Exchange of The Wheel Bearings .......................................................................... 27
8.4. Reassembly of The Portal Drive and Adjustment of the Wheel Bearings............... 28
8.5. Exchange of The Sperical Roller Bearing (29)........................................................ 29
Drawings: Installation drawing / Lubrication Plan PTA 5500.106,
Assembly drawings R 1020-112; R 00.92500.044.0, R 1040-040,
Assembly Device / Special Tools Sk 2.94-213; Sk 4.94-1029; Sk 4.96-1019, Sk 2.96-136
Type: Bogie Axle LOK 100
Figure: Installation Drawing / Lubrication Plan Fig. PTA 5500.106
Date: February 10,2003 page II
Differential and brakes share the same oil supply, but there is a separate oil supply for
both bogie housings. Therefore separate filling-in and level control for differential and both
bogie housings is necessary.
Operating hours Explanation (see Fig. PTA 5500.106)
Make sure that the oil drain plug (42) with copper seal ring
is properly tightened with 90 Nm torque. Remove oil filler
plug (40) in the brake housing and add approx. 13 L oil
according to the table of permitted lubricants until the level
has reached the control mark of the dip stick (41).
(Alternatively open the plug on the vertical face opposite of
the brake cylinder and fill in oil until the lower edge of the
threaded hole is reached.) Close oil filler plug with copper
seal ring and tighten with 90 Nm torque.
Bogie housings:
The tandem housing must be in a horizontal position.
Make sure that the oil drain plugs (62, 63) with copper seal
rings are properly tightened with 90 Nm torque. Remove
one of the fill plugs (60) and the control plug (61, in the
centre cover) . Add approx. 52 L oil as per lubrication chart
until the oil starts overflowing from the control plug (61).
Tighten the fill plug (60) with 90 Nm, the control plug (61)
with 55 Nm.
Bogie pendulum bearing (slewing ring):
At all 10 grease nipples (90, 10 per side with white plastic
cap) grease with grease gun until the gap has sealed itself
with grease all the way around the circumference. Leave
excessed grease built up. Again cover grease nipples with
white plastic caps.
After the first working day Due to stresses of the vehicle motion the wheel nuts will
seat themselves properly. Timely tightening of these will
prevent damage to the wheel rims (tightening torque of the
wheel nuts: 550 Nm).
Date: February 10,2003 page III
After the first 250 operating Bolts and nuts may settle due to loads and vibrations of the
hours vehicle. Retightening all visible bolts can prevent leaks and
major damage. The use of a torque wrench is strongly
recommended, for tightening torques see the table in the
repair instruction. The center nut (hex nut WS50) of the
input cardan flange with adhesive locking must not be
retightened.
Change oil while it is warm. First clean oil drain plug (42),
dip stick (41), oil filler plug (42) and surrounding areas of
any dirt. Then remove filler plug, open oil drain plug at the
differential and drain oil completely into a suitable basin
(approx. 13 L). Clean the magnetic inset of the oil drain
plug from any metal wear. Screw in the oil drain plug (42)
with new copper seal ring and tighten with 90 Nm torque.
Add oil according to the following table of lubricants until
the level has reached the control mark of the dip stick.
Oil change in both bogie housings:
The bogie housing must be in a horizontal position. Prior to
draining the oil the axle should be at least 30 minutes at
rest allowing all the dirt particles to settle in the appropriate
reservoirs. Also before opening a plug clean its surrounding
area to avoid dirt coming into the housing. First remove one
of the fill plugs (60) and the control plug (61), then open the
main oil drain plugs (62), two per tandem housing, and
drain into a clean container since it is possible that this
portion of oil is used again. Then remove the unusable oil
plugs (63, with magnetic inset), also two per tandem
housing, and let the oil drain into a separate basin. Close
the drain plugs (62, 63) with new copper seal rings and
tighten with 90 Nm torque, the plug with magnetic inset at
the lower position. Add oil as per lubrication chart into the
fill plug (60) until the oil starts overflowing from the control
plug (61) (first the collected old oil, complete with new clean
oil). Tighten the fill plug (60) with 90 Nm, the control plug
(61) with 55 Nm.
Date: February 10,2003 page IV
After every 250 operating Clean the area around the grease nipples (90, 10 at each
hours side) and remove the white plastic caps. Grease with
grease gun at all 10 grease nipples per side until the gap
has sealed itself with grease all the way around the
circumference. Leave excessed grease built up. Again
cover the grease nipples with white plastic caps.
After every 500 operating Check oil levels in differential (dipstick 41) and in both
hours or at least monthly bogie housings (control plug 61) and add oil if required.
After every 2000 operating Differential and brakes
hours or at least annually Change oil in differential when it is warm, see explanation
above for oil change at 250 operating hours, however, the
complete amount of oil has to be exchanged.
Under normal circumstances the operating brake will not
wear. However the air gap should still be inspected every
2000 hours. Initial setup of a new brake:
Air gap of disks = 2.0-2.5 mm
Cylinder stroke = 5.0-6.0 mm
After every 5000 operating Bogie housings:
hours Change oil in both bogie housings as described above for
oil change at 250 operating hours.
Table of Lubricants
Figure: Installation Drawing, Lubrication Plan Fig. PTA 5500.106
Date: February 10,2003 page V
Required viscosity grade: SAE 90 (SAE 85W-90, SAE 80W-90, SAE 75W-90)
e.g.
ARAL Degol 3216

approx. 13 ltr. for differential with
BP Energear LS 90 brakes and 52 ltr. for each bogie
housing of LOK 100; the actual
DEA Deagear LS SAE 85W-90 quantity has to be checked by
Dearon BHS SAE 90 the control mark of the dipstick
or by control plugs.
Esso Gear oil LSA 85W-90
Fuchs Renogear LS90

Renogear HLS 90
Mobil Mobilube SHC-LS

Repair Instruction, General Introductions
Figure: 
1.1. Liability and Guarantees for safety related components:
We strongly recommend changing complete components in the case of safety related
components such as ( control cylinders, steering cylinders, brake cylinders, spring
housing cylinders, etc. ).
Once a safety related component has been disassembled or opened, all guarantees
and liabilities will be void and therefore NAF will not assume product liability for the
drive unit. This also applies, even if the complete drive unit is still under guarantee.
1.2. When working on differential, multi disk brake or bogie gear drive the axle must be
removed from the vehicle. After reassembly, when attaching the wheels again tighten
the wheel nuts with 550 Nm (M22x1.5 flat collar nut with spring washer).
slight deposit of dirt will seriously reduce the life time of the bearings. An assembly
crane and a few special tools will be needed which will be mentioned in the appropriate
sections. Basic mechanical knowledge is also required.
1.4. All disassembled bolts and nuts which were secured with an adhesive coating on
the thread are to be replaced with new adhesive coated nuts and bolts. Remove the
old hardened glue from the chamfer at the beginning of the thread. During assembly of
a new coated bolt this space is needed for peeled surplus coating. During assembly of
all adhesive coated bolts or nuts it is important the final position or torque is achieved
within 3-5 minutes. If there is any movement after 5 minutes then the adhesive will not
1.5. For high strength adhesive bolt locking in the following manual Loctite 639 is
recommended. If this should not be available, Loctite 275 can be used as a substitute.
1.6. It is suggested that any removed shaft seals, O-rings or gaskets be replaced with
new ones, even if there does not appear to be any damage.
1.7. The following repair instructions are based on the bogie axle LOK100 which has a
special planetary gear at the input to the bogie housing. This "Balanced Bogie" (BB)
unit has the effect of a better load distribution between front and back wheel of the
bogie.
1.8. This manual can also be applied on versions earlier than LOK100. The prototype
versions of these bogie axles differ only in details, which do not affect the validity of
this manual..
Repair Instruction, Tightening Torque’s
Type: Bogie Axle 100
Figures: R 1020-112, R 00.92500.044.0, R 1040-040
2. 2. Tightening Torques for Bolts and Nuts

2.1. Differential Section, Fig. no. R 1020-112
Position no. Name NAF Part no. Tightening Torque
1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
3 Grooved nut 7329.072 see Chapter 3.2.3.
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 Hex bolt M16x40 10.9 VP 7322.069 310 Nm
22 Allen M12x80 8.8 VP 1020.374 79 Nm
30 Hex nut M14x1.5 10 1060.003 135 Nm + Loctite 639
32 Cylinder M30x1.5 5263.092 90 Nm + Loctite 542
39 Plug R ¾" 1040.103 90 Nm
50 Hex nut M40x1.5 7329.057 800 Nm + Loctite 639
54 Plug R ¾" magnet 7323.025 90 Nm
103 Hex bolt M18x2x70 10.9 1010.662 465 Nm

Figures: R 1020-112, R 00.92500.044.0, R 1040-040
2.2. Axle Beam with Multiple Disk Brake

Fig. no. 00.92500.044.0 (LOK 100 with BB)
103 Hex bolt M18x2x70 10.9 1010.662 465 Nm
108 Breather M10x1 tapered 1250.002 22 Nm
113 Allen bolt M10x30 10.9 VP 1020.260 49 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
123 Grease nipple M8x1 tapered 1250.104 15 Nm
124 Hex bolt M18x2x70 10.9 VP 1010.666 465 Nm
126 Allen bolt M18x2x70 10.9 VP 1020.616 465 Nm
143 Plug R ¾" 1040.151 90 Nm
147 Reducer fitting R ¾" 7322.074 90 Nm
148 Breather R½" tapered 9556.030 75 Nm
149 Reducing plug R ¾" x R½" (tap.) 1750.705 100 Nm

Figures: R 1020-112, R 00.92500.044.0, R 1040-040
2.3. Bogie Housing,

Fig. no. R 1040-040 (LOK 100 with BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
39 Flat collar nut M22x1.5 1060.402 550 Nm
46 Hex bolt M16x60 10.9 VP 1010.544 310 Nm
52 Grooved nut M85x2 7329.036 see Chapter 8.4.
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
62 Plug M30x1.5 with magnet 7323.013 105 Nm
160 Hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x50 10.9 1020.518 280 Nm

Figure: 00.75000.260.0
3. Differential
After the axle has been removed from the vehicle (remove cardan shaft and hydraulic
connections of brake cylinders and differential lock and drain oil from the axle) release the
parking brake as described in Chapter 5.3. Open the hex bolts (103) on both sides of the
differential housing. Remove the combined boogie housing and axle beam from the
differential. The complete brake (actuating cylinder, disks and dowel pins ∅16) and the
protruding shaft (140) will remain in the axle beam.
Before starting reassembly check the adjustment of the differential lock as per 4.2. Install
new O-rings (5) onto the steps of the differential flanges (6, 36). Note that all 3 ie. 4 dowel
pins (3x107, 4x106) properly sit in their bores in the differential. Attach the complete axle
beam and bogie housing to the differential. When shifting the spline end of the shaft (140)
into the differential gear (15) assist by rotating the cardan flange to and fro. Fasten the
axle beam to the differential with hex bolts (103) and washers (105).
bolt as per 5.3.
Attention: The core hole for one of the bolts (104) is a through-hole, therefore this bolt
must be sealed with Loctite 542 (alternatively locking paste OKS or other fluid sealing),
see the following Figure 1.
Figure: 00.75000.260.0
Fig. 1: Side view of differential housing. The marked threaded hole is a through-hole.
The bolt in this position must be sealed with locking paste OKS or other fluid sealing
(eg. Loctite 542)
bolt as per 5.3.

After the axle has been removed from the vehicle (remove drive shaft and drain oil from
the axle), first of all open the hex nut (50, wrench size 50) in the input cardan flange (51),
later it would be more complicated to counterhold the high loosening torque which may
exceed 1000 Nm. The nut is locked with Loctite, preheating it to 120°-160°C with a blow
lamp is recommended. Then disassemble the complete differential as described in
Chapter 3.1.1.
Figure: 00.75000.260.0
the differential housing by hitting onto the end of the shaft. Loosen hex bolts (9) and pull
the crown wheel from the differential cage.
48) of the pinion. It is suggested that they be replaced at this time, due to the costs
involved in replacing them in subsequent repairs.
Figure: 00.75000.260.0

Push the bearing inner ring (43) onto the pinion shaft (if necessary evenly warm up the
bearing to 80°-110°C). In order to adjust a good contact pattern of the hypoid gearing, the
proper thickness of the adjusting washer (45) is to be determined as follows, see Fig.2:
- Measure the actual distance L1
from the outer ring of the taper
roller bearing (43) to the face of the
pinion. To avoid mistakes, the jaw
length of the caliper gauge must be
at least 120 mm. The dimension L1
may vary near 93.57 mm.
- Record the mounting distance Le
which can be read from the face of
the pinion. Le will be approximately
82.73 mm.
- Determine the necessary thickness
se for the adjusting washer (45) as
follows:
se = 178.8 - Le - L1 [mm]
Choose a washer thickness which is
closest to the calculated value. The
washers are available with a thickness
Fig.2: Determining the dimension se to adjust the between 2.00 and 3.00 mm, step 0.25.
contact pattern of the hypoid gearing Insert the selected adjusting washer
(45) and press in the outer ring of
bearing (43) from the inside and the outer ring of bearing (48) from the outside of the
differential housing. Then ist is necessary to adjust the bearings of the bevel pinion.
The spacer sleeve (47) is available with a width of 11.3 mm and 11.78 mm, the adjusting
washers (44) vary in thickness from 0.96 to 1.44 mm with a step of 0.04 mm. Select a
combination of two spacer sleeves and between them an adjusting washer with a total
width of (se+21.88) mm for now and slide them onto the shaft of the pinion. (se is the
thickness of the washer (45) for adjustment of the contact pattern, see Chapter 3.2.2.1)
Insert this unit into the differential housing and hold in place from the inside. Install the
inner ring of bearing (48) and the cardan flange (51) onto the pinion shaft, for the time
being without O-ring and shaft seals. Apply and tighten hex nut (50) with 800 Nm torque.
During tightening the nut, with a hammer tap against the housing of where the bearings
are located in order to properly align the taper rollers. Also tap against the outer face of
Figure: 00.75000.260.0
the pinion shaft with a brass mandril while turning the pinion back and forth. Inspect the
bearing preload; if required through the use of different spacer sleeves (47) and/or
adjusting washers (44) the proper bearing preload is to be adjusted.
The pinion bearings cannot have any axial play, ie. the pinion should let itself be turned
with 0.5 to 6 Nm frictional torque. This value is valid only for new bearings and with
removed crown wheel and without shaft seals. For used bearings the setting value is 0 to
5 Nm.
3.2.2.3. Finish Assembly of Pinion
seals (88 and 87) into the housing (42) use WZ 213 and fill 50% of the volume between
both seals with grease. It should be noted that the seals are installed in the correct
illustrated orientation. Clean the threads of shaft and nut from dirt or grease, then shift the
cardan flange (51) onto the spline of the shaft. Cover the threads of pinion shaft and nut
(50) on their whole length and circumference with Loctite 639. The applying and tightening
of the nut must not take any longer than 3-5 minutes to avoid any hardening of the
adhesive. The nut cannot be applied using an impact wrench since this will promote early
hardening and the adhesive will be spun off the threads. Tighten the nut with 800 Nm
torque.
Figure: 00.75000.260.0

Check that both dowel pins (12) are in their bore in the differential cage, then set the
crown wheel onto the differential cage and fasten with 16 new coated bolts (9) and
hardened washers (10). Then press the inner rings of the taper roller bearings (8, 24) onto
their seat. Press the outer rings of both taper roller bearings (8, 25) into their seats in the
flanges (6, 36), then screw in the grooved nuts (3, 25) to their previously recorded
position. From this position turn out groove nut (3) 1 thread (ie. one turn).
cage (with crown wheel) into the differential housing, during this the shifting sleeve must
not fall down from the shifting fork. Mount the flange (6) with two Allen bolts (4). Use four
additional bolts M18x2x40 per side to fix the flanges (6, 36) solidly. Now turn in the
groove nut (3) to get a backlash of 0.15 to - 0.25 mm between the teeth of bevel pinion
and crown wheel. If measured at the hole circle of the drive shaft flange (∅ ≈127 mm)
also this dimension is 0.15 to 0.25 mm.
into place, then adjust the preload of the crown wheel bearings (8) and (24). For this
adjust groove nut (25) by putting an arbor into one of the grooves and hitting with a
hammer, until the desired bearing friction torque of 1.0 to 3.0 Nm is reached. This can be
measured with a torque gauge at the drive shaft flange by adding a value of 0.5 Nm to 1.5
Nm to the torque determined in Chapter 3.2.2.2 (bearing friction torque).
description in Chapter 3.2.2.1, the contact pattern of the hyoid gearing should be ok and
If the contact pattern resembles that of Figure 4 or 5 then by adjusting the pinion position
as shown in these Figures a pattern shown in Figure 6 can be achieved. The pinion can
be moved by changing the thickness of adjusting washer (45), ie. the complete procedure
of adjusting the bearings and the tooth backlash has to be repeated.
Note: When adjusting always note proper preload of crown wheel bearings (8) and (24)
and when turning groove nuts (3) and (25) ensure proper backlash. Always remove old
paint from ring gear when rechecking.
Figure: 00.75000.260.0
coated hex bolts (1). Remove the additional hex bolts M18x2x40 which fixed the
differential flanges.
Figure: 00.75000.260.0
to Chapter 4.2. if any of the following components have been exchanged:
Finish assembly of the complete axle as described in Chapter 3.1.2.

marked in their orientation to one another with mating numbers and must be assembled in
this orientation only.
Disassembly
out of the differential housing. Remove the inner ring of bearing (24), loosen allen bolts
(22) and take the differential cage apart.
Assembly
Assemble the differential cage halves in their marked orientation to one another and
tighten with new adhesive coated Allen bolts (22). Insert inner ring of bearing (24) onto the
Figure: 00.75000.260.0



pinion shaft. Now, both radial shaft seals (87 and 88) can be pulled out. It is also
recommended to exchange the O-ring (49), extract it from the groove in the shaft. Check
the sealing surface of the cardan flange (51) for any marks of wear and replace it if
necessary.
With a steel brush remove rests of old hardened glue from the threads of shaft and nut
and clean from any dirt and grease. Install new shaft seals, note that the lips of the seals
are installed in the proper orientation as shown. Fill 50% of the volume between seals (88
and 87) with grease, install new O-ring (49), and shift the cardan flange (51) onto the
spline of the shaft. Now cover the threads of shaft and nut with Loctite 639. The applying
and tightening of the nut must not take any longer than 3-5 minutes to avoid any
hardening of the adhesive. The nut cannot be applied using an impact wrench since this
will promote early hardening and the adhesive will be spun off the threads. Tighten the nut
with 800 Nm torque.
Figure: 00.75000.260.0

For any repair works at the differential lock it is recommended to disassemble the
complete differential from the axle as described in Chapter 3.1.1. Loosen 2 Allen bolts
(52) and remove the differential flange (36) together with the shifting sleeve (56), the
differential cage can remain in the differential housing. Loosen the hex nut (30) at the
shifting rod, counter the loosening torque at the opposite end of the shifting rod. The nut is
locked with Loctite, therefore preheating it to 120°-160°C with a blow lamp is
recommended.
removed out of its groove in the piston with a sharp tool. From serial no.: 4 is a piston (33)
with a additional piston sealing (35) installed. Inspect piston and cylinder for any marks of
wear and replace if necessary. Snap a new seal ring into the groove, the seal lips facing
the short end of the piston. The additional piston sealing (35) must install with special
assembly tool WZ 509 (Sk.2.96-136), because the piston sealing (35) is two-parted and
this piston sealing (35) must calibrate with special tool WZ 509 (Sk.2.96-136). Insert the
piston into the cylinder (32) and turn it such that the shifting lever lateron can be
assembled into the groove of the piston.
Unscrew the cylinder (32) from the differential flange (36) use WZ 012. Before screwing in
a new cylinder cover its thread with Loctite 542 (alternatively OKS-paste or any other fluid
The axial play of the shifting claws is to be adjusted if any of the following components
have been exchanged:
Figure: 00.75000.260.0
Depress the shifting fork (27), without assembling shifting sleeve (56), compression
spring (28), and adjusting washers (29), against the flange (36) and with a depth gauge
measure dimension "X" (theoretical dimension 44 mm), see Fig. 7.
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0
(30) from rests of hardened glue and any dirt or grease. Insert the compression spring
(28) into the flange (36), Then insert the shifting rod (26) together with shifting fork (27)
and shifting sleeve (56). Cover the threads of nut and shifting rod with Loctite 639 on their
whole length and circumference, put the shifting lever (31) onto the shifting rod and
properly into the groove of the piston and tighten the nut. Counter the tightening torque at
the flattened opposite end of the shifting rod.
Put on new O-ring (7) onto the step of the flange (36) and install the complete flange to
the differential housing. Fasten with 2 Allen bolts (52) and finish assembly of the complete
axle as described in Chapter 3.1.2.
Figures: Assembly Drawings fig. 00.92500.044.0, QMA Nr.: 09.004.0

cylinder.
maintenance cycle or every repair service. Also upon completion of all work the brake is to
set-up as per point 5.2. and 5.3., inspected and tested.

condition (see assembly drawing of the axle beam section). The difference of both
measurements should be between 2.0 and 2.5 mm. If this value is exceeded then the air
gap is to be readjusted as per 5.2
The air gap can also be inspected by measuring the cylinder stroke: Ensure a container is
within reach to collect any lubrication oil which may leak from the cylinder housing, then
remove screw cap (150). The movement of the adjusting bolt (158) when loosening and
engaging the brake is to be measured with an appropriate tool (ie. dial gauge or depth
gauge). If the cylinder stroke exceeds a value of 6 to 7 mm, then a readjustment as per
5.2 must be performed.

First compress the spring with pressure through connection I, while at the same time bleed
through breather screw III to make sure there is no air in the hydraulic system. The basic
adjustment is executed with the brake in this condition.
For this clockwise turn the adjustment bolt (158) with an allen key WS 6 until a torque of 8
allowing the output shaft to turn. The required air gap of 2 to 2.5 mm is obtained by turning
the adjusting bolt (158) back 3 to 3.5 turns.
After this adjustment is completed, note that the O-ring (151) is properly seated in the
groove of the screw cap (150), then mount and hand-tighten screw cap (150). Upon
completion the operating brake as well as the parking brake are to be actuated several
times while the vehicle is parked in order for the various components to seat and align
themselves properly. Afterwards, both compression chambers finally are to be bled over
breather valves III, in order to remove any air in the system.

is within reach to collect any lubrication oil which may leak from the cylinder housing, then
remove screw cap (150). With the use of a wrench SW13 turn out the emergency release
bolt (152) counterclockwise, until a tight bottoming out is felt. Now the spring set is fully
To reinstall to driving conditions loosen the emergency release bolt (152) in a clockwise
manner, until a distance of 5mm between the housing cover and the top of the emergency
release bolt is reached. This position can be felt since the turning torque of this bolt will
suddenly drop significantly at this position. The emergency release bolt is now in its
normal condition and the housing is to be closed again with the screw cap (150).
Note: The thread of the emergency release bolt (152) is of the self locking type, meaning
that turning due to vibration need not be a concern. However, constant use of the
emergency release bolt can significantly reduce the securing torque such that an
additional safety on the thread of the bolt needs to be incorporated in the form of a
common locking adhesive. For this prior to completely loosening (turn in clockwise
direction) the release bolt (152) apply the adhesive on the upper most threads.

and the lower part (111) with the activation spike (109). To exchange the brake cylinder or
any part of it the axle can remain in the vehicle. In this case accurately block the vehicle
with wheel chocks, as the parking brake will not be acting with removed brake cylinders!
Disassembly:
the brake cylinder, then it is recommended to release the parking brake with the
emergency release bolt, see Chapter 5.3. Loosen 3 allen bolts (115) and remove the
spring loaded cylinder (117).
Assembly:
Prior to the reinstallation of the upper part (117) screw out the self locking adjusting bolt
(158) with an Allen key WS 6 until its rounded end is flush with the face of piston (157).
Also note that the emergency release bolt (152) is in a released position, ie. turned out as
per 5.3. Clean the guiding surfaces of lower and upper part of the brake cylinder from any
dirt and put a new O-ring into the groove in the lower part (111), then install the upper part
and fasten with 3 Allen bolts (115) with lock washers (114).
Subsequently the emergency release bolt has to be screwed in to its driving position (see
Chapter 5.3.) and the air gap of the brake must be adjusted as per 5.2. Refill lubricating oil
into the differential, see the description in the maintenance schedule.
Disassembly:
First the spring loaded cylinder (117) is to be removed as per 5.4.1. After loosening the
three Allen bolts (113) the complete lower part of the brake cylinder (111) including the
activating wedge (109) can be removed from the axle beam (101, 102).
Assembly:
actuating wedge (109) is in-line with the length axis of the brake. It must be noted that
prior to insertion the flanks of the actuating wedge (109) are parallel to the compression
rollers (163) of the ball ramp actuator (118). Place a new O-ring (110) in the groove of the
cylinder housing (165) and insert the complete lower part of the brake cylinder (111) into
the hole of the axle beam (101, 102) and tighten with new coated Allen bolts (113).

First engage emergency release of the spring loaded cylinder (117) as per 5.3. Then again
screw on the cover (150) and press onto it, such pressing in the piston (156) with the disk
springs. Extract the round wire snap ring (153) and take out the ball (154). The
assembled piston (156) can now be pulled out of the cylinder housing (169) and both U-
ring seals (164) and (170) as well as O-ring (155) can be extracted from their grooves.
Install new seals (155), (164) and (170) into the grooves and insert the assembled piston
unit (156) into the cylinder housing (169). Special attention must be given to the sealing
edge of the U-rings that they are not damaged during insertion. Place the ball (154) into its
bore and snap in the round wire snap ring (153) into the groove of the cylinder housing
(169).
Disengage emergency release as per 5.3.
disassemble the lower part as per 5.4.2. After removal of the snap ring (168) all individual
pieces of the cylinder such as compression spring (162), piston (161) with guide band
(167) and piston (170) with U-ring seals (159, 166) can be disassembled.
Install new U-ring seals (159, 166) and a new guide band (167) in the grooves and
assemble all parts of the cylinder housing (165). Finally compress spring (162) and install
snap ring (168). Continue assembly as per 5.4.2. and 5.4.1.

The inner disks (120) with the brake linings have a thickness of 4.9-0.15 mm. If the
thickness is less than 4.5 mm then the entire disk set is to be exchanged.
Disassembly:
First completely remove the brake cylinder as per 5.4.1. and 5.4.2., then loosen the hex
exchanged as a complete set., Only the tension springs (148) can be detached and
exchanged.
Assembly
activation disks.
Both outer outside disks (119) per brake side are to be mounted crosswise onto the dowel
pins (122). The inner most outer disk per brake side does not get inserted into the dowel
pin (122) but rather into the clutches of the
ball ramp disks (118).
After all six outer disks and six inner disks
and ball ramp activation mechanism have
been assembled, insert a toothed ring (121)
on each or the four dowel pins (122) as an
assembly aid. The six inner disks (120) are
to be orientated with a splined mandrel eg.
with drive shaft (140). It must be noted that
the bores in the inner disks make an inline
Install a new O-ring (5) to the step of the
differential flange and mount the complete
axle beam with hex bolts (103, 105). When
Fig.8: Multiple Disk Brake doing this the splines of the drive shaft (140)
are inserted into the splined profile of the
shifting sleeve and compensating gear.
Attach the brake cylinder as per 5.4.2. and 5.4.1. and adjust the air gap of the brake as
per 5.2.
necessary.
Repair Instruction,
BB Gear and Slewing Ring
Figures: Assembly Drawings Fig. 00.92500.078.0
6. Balanced Bogie (BB) Planetary Gear and Slewing Ring

6.1. Disassembly of the Bogie Housing
First loosen all 8 hex bolts (10) at the bearing stud (8, centre cover), insert M10x40 long
extraction bolts and remove the bearing stud along with the mounted gear (6). Then
loosen 16 Allen bolts (125) at the rear of the bogie housing and four Allen bolts (126) at
the top outside and remove the entire bogie housing (31) to the side. During this the
balance planetary drive will remain in the axle beam (101) and can now be taken out as a
complete subassembly [LOK 100: ].
[LOK 99: There is not any BB planetary gear, the shaft (140) coming out of the differential
is directly mounted to the bearing stud (8). Before starting the disassembly with released
parking brake turn back and forth either the cardan flange at the differential or one of the
output shafts (34), to be sure that the backlash of the splines in the brake disks is aligned.
Then activate the parking brake to hold the brake disks in this position. Pull out the
bearing stud (8) along with the mounted shaft (140). Then dismount the bogie housing as
described above.]
6.2. Reassembly of the Bogie Housing

Set the seal ring (1) onto the step of the bogie housing (31), the seal lip pointing in the
direction of the bogie housing. Put grease onto the sealing surface of the slewing ring
where the lip of the seal ring (1) will be sliding.
Install the complete BB planetary unit into the axle beam. To find the tooth gaps of the sun
gear (140) and internal toothing of the slewing ring (172) you can slightly turn each one of
the planet gears (136). Now mount the complete assembled bogie with new adhesive
coated Allen bolts (125) and (126) and tighten in a crosswise manner with 465 Nm. For
the 4 upper Allen bolts (126), which are screwed in from the outside of the bogie housing,
hardened washers (127) are to be used.
When assembling the bogie housing it should be noted that the lip of seal (1) does not
become damaged. During the assembly the tandem housing (31) initially centres itself
over the two dowel pins (128) at the slewing ring (172). During continued insertion of the
bogie housing it is to be rotated back and forth, such that the teeth of the internal ring gear
(2) can mesh with the planetary gears (136) of the balance planetary drive. [LOK 99:
There is not any mesh with a planetary gear.]
Prior to the reassembly of bearing stud (8) the necessary thickness "s" of the shim
package (9) is to be determined, see the following figure 9. [Not valid for LOK 99, there
are no shims.]
Repair Instruction,
- Move the complete planetary

drive in the direction of the
differential until it butts up solidly
and measure dimension "A".
(theoretical dimension of "A" is 155
± 0.7 mm)
- Calculate the thickness "s" of the
washer package (9):
smin = 154.5 - "A" = ..... mm
smax = 156.5 - "A" = ..... mm
The theoretical thickness "s" of the
shims can vary from 0 to 5.0 mm. If
you should calculate a negative
value of "s" do not mount any shim.
- This setup will give an axial play
from 0.5 to 2.5 mm between the
compression stud (12) in the gear
(6) and the intermediate plate
(134).
Fig. 9: Adjusting the axial play in the BB gear
Install a new O-ring (11) in the groove of the bearing stud, insert the selected package of
shims (9) and mount the bearing stud (8) along with the mounted gear (6). By slightly
turning gear (6) the teeth of the planet gears (136) can mesh with the teeth of gear (6).
[LOK 99: Install a new O-ring (11) in the groove of the bearing stud and mount the bearing
stud along with the mounted shaft (140). The brake disks (120) are still fixed in their
original position by the activated parking brake. By slightly turning the shaft (140) the teeth
of the spline have to find the gaps of the internal spline in brake disks, shifting sleeve (56)
and differential gear (15).]
Tighten the bearing stud (8) with adhesive coated hex bolts (10). Finally apply grease to
the slewing ring (172) at all grease nipples (123, 10x per slewing ring) until grease seeps
out over the entire circumference and cover all grease nipples with white plastic caps
(179).
6.3. Exchange of Sun Gear Shaft (140) and Seal Rings (142)
[LOK 99: The drive shaft (140) in the bogie axle without BB gear can be disassembled just
by removing the bearing stud (8), also see detailed description for exchanging the bogie
input gear (6) in Chapter 6.4.4.]
Repair Instruction,
6.3.1. Disassembly of Shaft (140) and Seal Rings (142)

Disassemble the bogie housing (31) as per 6.1. and take out the assembled planetary
cage (129), (130). Release the parking brake by hydraulic pressure or by the emergency
release bolt (see Chapter 5.3.), and turn back and forth either the cardan flange at the
differential or one of the output shafts (34), to be sure that the backlash of the splines in
the brake disks is aligned. Then activate the parking brake to hold the brake disks in this
position. Remove the sun gear shaft (140) sideways. Extract the outer seal ring (142) in
the axle beam, then remove the auxiliary washer (176) and the circlip ring (174). Then the
second seal ring (142) can be pulled out.
6.3.2. Assembly of Shaft (140) and Seal Rings (142)
Install one new seal ring (142) with the lip pointing towards the axle centre. Then snap the
circlip ring (174) into its groove in the axle beam and pull the seal ring close to the circlip
ring. Insert the auxiliary washer (176) and then the second seal ring (142) with its lip
pointing towards the outside. Insert a new compression stud (141) into the sun gear shaft
(140) and fit the sun gear shaft splines into the splines of the inner disks (120), shifting
sleeve and compensating gear. The brake disks (120) are still fixed in their original
position by the activated parking brake. The shaft will be centered by the auxiliary washer
between the two seal rings (142), nevertheless be careful not to hurt the seal lips with the
edges of the spline shaft. Continue assembly as per 6.2.
6.4. "Balanced Bogie" (BB) Planetary Gear

6.4.1. Exchange of the complete BB Gear
For a complete exchange of the BB gear the bogie housing has to be removed from the
axle beam, see descriptions in Chapters 6.1. and 6.2.
6.4.2. Exchange of Planetary Gears and Planetary Studs
After disassembling the complete planetary cage place it face down, i.e. hex bolts (131)
upside. Loosen the hex bolts and remove the planetary cage (129) upwards. The
planetary studs (135) will remain in the lower half (130) of the planetary cage.
Remove the thrust washers (137) and pull off the upper row of planetary gears (136) and
the needle bearings (138). The lower row of planetary gears and needle bearings can be
removed after thrust plates (134) are extracted. Now the planetary studs (135) can be
pressed out of the planetary cage (130).
Assembly:
Press fit new planetary studs (135) into the planetary cage (130). Install new thrust
washers (137) with their bended nose in the recess of the planetary cage. Shift needle
bearings (138) and planetary gears (136) over the planetary studs, then install thrust plate
(134) and continue assembling the second row of needle bearings and planetary gears.
Put a thrust washer (137) on each of the gears, press all four shear bushings (133) into
their bores and mount the upper half of the planetary cage. Take care that the bended
Repair Instruction,
noses of the thrust washers (137) properly fit into the recesses of the planetary cage.
Tighten both halves of the planetary cage with hardened washers (132) and new adhesive
coated hex bolts (131). Finish the assembly as per 6.2.
6.4.3. Exchange of the Ring Gear
After dismounting the bogie housing from the axle beam as per 6.1. open the six Allen
bolts (3). To disassemble the ring gear screw two forcing bolts M12x50 into the ring gear.
With a hammer hit the dowel pins (4) completely into their bore in the bogie housing, then
press a new ring gear onto the pins and fasten with new coated Allen bolts (3). Finish the
assembly as per 6.2.
6.4.4. Exchange of the Bogie Input Gear
For this work, the axle does not need to be removed from the vehicle. First loosen all 8
hex bolts (10) at the bearing stud (8, centre cover), insert M10x40 long extraction bolts
and remove the bearing stud along with the mounted gear (6). [LOK 99: For disassembly
of the bearing stud see description in 6.1. Push off the gear (6) along with the spherical
roller bearing (7) from the bearing stud, extract the circlip ring (13) and extract both
washer (14, 15) with the bearing (7). Remove compression stud (12) with the use of an M8
x 40 long forcing bolt.
Press in a new compression stud (12) and a new spherical roller bearing (7) in a new gear
(6) and both washer with (14, 15) also snap in the circlip ring (13). Then insert the bearing
stud (8) into the bearing (7). Continue assembly as well as setup of axial play between
compression stud (12) and intermediate plate (134) as per 6.2.
6.5. Exchange of the Slewing Ring

Dismount the bogie housing as per 6.1. To disassemble the slewing ring (172) loosen the
hex bolts (124).
Insert a new seal ring (175) into the new slewing ring (172) and fill the hollow space of the
seal ring with grease. Set a new O-ring (173) onto the step of the slewing ring.
The hardening gap of the slewing ring (area not hardened between begin and end of
hardened raceway) is marked on the inner ring with a red line. The slewing ring must be
mounted in such a manner that this area (red mark) is at the top; then this part of the
raceway will not be heavily stressed. With the new slewing ring (172) in the proper
orientation, mount it to the axle beam (101) and secure with new adhesive coated hex
bolts (124). Tighten the bolts "crosswise" with 465 Nm.
Reassemble the complete BB planetary unit and the bogie housing as per 6.2.
Repair Instruction, Bogie Gear Drive
Figures: Assembly Drawings Fig. R 1040-041
7. Gear Drive Inside the Bogie Housing

7.1. Exchange of the Studs
After loosening of the hex bolts (22), the tin cover (21) and the gasket (20) can be
removed. Turn in a puller into the M12 thread on the face of the stud (18) and pull it out.
Apply a new O-ring (19) into the groove of the stud and place a new gasket (20) between
the cover (21). Insert it into the hole of the bogie housing (31), gear (23, 27) and spacer
ring (16) and secure with new adhhesive coated hex bolts (22).
7.2. Exchange of the Gears and Needle bearings

First remove the complete bogie housing (31) as per 6.1. Then remove the inner or three
studs (18) of a wheel side per 7.1. The gears (23, 27) can now be removed through the
large central opening of the bogie housing. Note, that gears (23) and (27) aren’t identical.
The spacer rings (16) can be pulled out through their respective hole (∅ ≈71mm).
Both needle bearing rings (24) and O-ring (19) can now be exchanged. Note, there is a
circlip ring (17) for positionfixing, between needle bearing rings integrated. When
disassembled, insert the circlip ring (17) again. Insert the new needle bearing rings (24)
into the gears (23) and (27). The new gears (23,27) are inserted through the large opening
(dia. approx. 200) into the tandem housing beginning with outer most gear and assembled
as per 7.1.
When inserting a new spacer ring (16) it must be noted that the hardened face and the
chamfer of the inner diameter of every spacer ring is orientated facing outward.
Finish assembly as per 6.2.
Repair Instruction, Portal Drive
8. Portal Drive and Wheel Bearings

When working on the portal drive it is not required to completely remove the axle from the
vehicle. It is sufficient when the side of the vehicle, which is being worked on, is jacked up
and the wheels with rims are removed. Drain oil from the bogie housing, the majority of the
oil can be used again, see description for oil change at 250 op. hrs.
8.1. Disassembly of the Portal Gear, Drive Pinion and Pinion Shaft
Loosen the hex bolts (46) and the Allen bolts (57, 2 per wheel), and remove the complete
housing (33). For the time being the drive pinion (153) together with the cylinder roller
bearing (41) has to remain in the housing (33). Extract the inner raceway of the roller
bearing (42) from the drive pinion (153).
Loosen the grooved nut (52) while countering against the flange of the output shaft (34)
use WZ 082. The nut is locked with Loctite, therefore the loosening torque can be as high
as 1500 Nm! It will be necessary to preheat the nut to about 150°C. Remove the gear (49)
from the output shaft (34) and disassemble the drive pinion (153). Both of them now easily
can be exchanged, as well as the roller bearings (41, 42) of the pinion shaft.
Open the hex bolts (26) and remove the cover (25) at the rear of the bogie housing (use 2
forcing bolts M8x30). Open circlip (156) and push the pinion shaft (43) out of the bogie
housing by inserting a rod ∅35 mm into the centre bore of the gear (30).
8.2. Exchange of the Face Seal

Disassemble the portal gear (49) as per 8.1. and take the output shaft (34) out of the
housing (33). Now both halves of the face seal (37) can be exchanged, use WZ 049.
Finish the assembly as per 8.4. If nothing else than the face seal will be exchanged during
this repair work, a new adjustment of the wheel bearings is not necessary, provided the
same set of adjusting washers (51) is used.
8.3. Exchange of the Wheel Bearings

Disassemble the portal gear (49) as per 8.1. and pull the output shaft (34) out of the
housing (33). Pull the inner ring of taper roller bearing (36) from the gear and pull the inner
ring of taper roller bearing (35) from the output shaft. Extract the outer raceways of both
wheel bearings from the housing (33).
Install the outer raceways of both wheel bearings (35, 36) into the housing (33), then press
the inner ring of taper roller bearing (35) firmly against the stub axle ring (56) on the output
shaft. Press the inner ring of taper roller bearing (36) onto the bearing seat on the portal
gear. Adjust the wheel bearings and finish the assembly as per 8.4.
8.4. Reassembly of the Portal Drive and Adjustment of the Wheel Bearings
Insert the drive pinion (153) onto its roller bearing (43) in the housing (33), Set the portal
gear (49) onto the spline end of the output shaft (34), its teeth meshing with those of the
pinion (43). For an adjustment of the wheel bearings the thickness of the adjusting washer
(51) has to be determined as follows, see the bogie assembly drawing or Fig.10:
Fig. 10: Dimensions X1 and X2 for adjustment of the wheel bearings

• Measure the dimension "X1" of the output shaft (34), theoretical value 38±0.3 mm
• Set the portal gear (49) onto the spline end of the output shaft (34). For this step use
a special mounting ring Sk4.94-1029 with reduced tolerance instead of the centering
ring (50). To avoid scoring, cover the outside face "∆" of the mounting ring with
special paste "Klüber Wolfracote SSP". Insert this ring into the gear and without
using Loctite tighten the grooved nut (52) until the wheel bearings reach a frictional
torque of 20-22 Nm (including the face seal). During tightening the nut with a
hammer continuously hit the housing and the gear where the bearings are situated
and turn the output shaft to be sure that the taper rollers are properly aligned. Then
measure dimension "X2", theoretical value 20±1.4 mm.
• Select a washer (50) with thickness "d"
dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
The washers are available with a thickness of 1.375-2.500 mm, step 0.125 mm.
• Again unscrew the grooved nut and with a steel brush clean the threads of nut and
shaft from any rests of hardened glue and from grease or dirt. Install the selected
washer (51). Cover the outside face "∆" of the centering ring (50) with antiscoring
paste "Klüber Wolfracote SSP" and put it into the centering bore of the gear (49).
Now cover the threads of shaft and nut with Loctite 639 on their whole length and
circumference, and tighten the nut with 2000 Nm torque. The resulting frictional
torque of the wheel bearings (incl. the face seal) should be between 20 and 35 Nm.
If the special mounting ring for determination of "X2" is not available select a washer (51)
with the theoretical thickness of 2.00 mm. Install this washer and the centering ring (50,
outside face covered with antiscoring paste), and without using Loctite tighten the grooved
nut (52) with 2000 Nm torque use WZ 082. The frictional torque of the wheel bearings
(incl. the face seal) must be between 20 and 35 Nm. In the case of axial play or less
pretension reduce the thickness of the adjusting washer, in the case of too high pretension
of the bearings increase the thickness of the adjusting washer and repeat this procedure.
For every step again cover the centering ring with antiscoring paste, but take care that no
paste reaches the threads! If you found the suitable washer, for the final assembly lock
the grooved nut with Loctite 639.
Check that all 8 dowel pins (47) sit closely in their boring in the bogie housing and install a
new gasket (48). Apply grease excessively to the rollers of bearing (42) in the bogie
housing to make sure that all rollers are in contact with their outer raceway. Then mount
the housing (33) together with the pinion shaft (43) to the bogie housing (31). Screw in
new adhesive coated hex bolts (46) and 2 Allen bolts (57) and tighten crosswise in two
stages, at first with a torque of 100 Nm, and finally with a torque of 310 Nm (280 Nm for
Allen bolts without coating).
Finally install the original cover (25) with a new gasket (32) at the rear of the bogie housing
and tighten with lock washers (27) and hex bolts (26).
8.5. Exchange of the Sperical Roller Bearing (29)

Remove the complete housing (33) with portal gear (49) and pinion shaft (43) as per 8.1.
forcing bolts M8x30). Extract the circlip (156) and push the pinion shaft (43) out of the
bogie housing by inserting a rod ∅35 mm into the center bore of the gear (30).
Extract the circlip ring (28) and press the gear (30) out of the bearing (29) to the inside of
the bogie housing. Extract the circlip (157) and pull the bearing (29) out of the cover (158).
For reassembly of the new spherical roller bearing press the bearing into its seat in the
cover (158) and fix it with circlip (157). Then press the gear (30) into the center of the
bearing (29) and snap the circlip ring (28) into its groove on the gear (30).
For the following step it is recommended to install an auxiliary bolt (part of assembly
device / special tool Sk 4.96-1019, see appendix)
To fixing the gear (30) with the cover (158) again turning aside and mount the assembly
group during this turn this assembly group till the pivot of the special tool Sk 4.96-1019.
engage in a threadhole. Then fasten the cover (158) with new allen screws. Remove the
assembly special tool Sk 4.96-1019.
Set the pinion shaft into toothing of gear (30) and snap the circlip ring (155) into its groove
on the gear (30) and finish assembly as per 8.4.
NAF Tool table for LOK 100 axles
Description: WZ number:
Insert punch WZ 213

To insert the seal rings 1160.208 for drive shaft flange
(short distance)
(with ring for longe distance)
Groove socket wrench WZ 012
for diff.lock shifting cylinder 5263.092
Mandrel and calibre socket WZ 509
For seal rings 1180.811
in diff. lock shifting
for groove nut 7329.036 on shaft in portal hub
Installer tool WZ 049
for slide ring 1180.301
Partnumber for Differential Section (Drawing no. R1020-112)
1. Screw for locking plate 103. Axle beam screw

2. Locking plate for groove nut 104. Axle beam screw
3. Groove nut Crown gear side 105. –
4. Allen screw for Diff.-flange 106. Dowel pin Axle beam (Look side)
5. O-ring Axle beam, Diff. 107. Dowel pin Axle beam (Crown gear side)
6. Diff.-flange Crown gear side 108. Drive shaft
11. Diff.-cage
16. Cross bolt
17. Bushing
23. Seeger supporting plate
25. Groove nut Diff.-lock side
35. Piston seal Diff.-lock
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -
59. -
87. Oil seal Drive shaft flange
102. Left Axle beam
Partnumber for Axle Housing Section (Drawing no. 00.92500.044.0)
101 Right Axle beam 131 Screw planetary cage

102 Left Axle beam 132 HV washer to 131
103 Axle beam screw 133 Shear pin planetary cage
104 Axle beam screw 134 Intermediate shims BB-Gear
105 HE-S ring 135 BB planetary stud
106 Dowel pin Axle beam (Lock side) 136 BB planetary gear
107 Dowel pin Axle beam (Crown gear side) 137 butting shim for planetary
108 Breather for bogie housing 138 planetary bearing
109 Brake chocke 139 Butting shim planetary bearing
110 O-ring for brake cylinder 140 Drive shaft
111 Operating brake cylinder complete 141 Bearing pin in the drive shaft
112 - 142 Oil seal in this Axle beam
113 Allen screw for Operating brake cylinder 143 Oil fill plug
114 Spring washer for 115 144 Seal ring for 143
115 Allen screw for parking brake cylinder 145 Dip stick Axle beam
116 O-ring among parking brake cylinder 146 Seal ring for 147
117 Parking brake cylinder complete 147 Reducer fitting for dip stick
118 Engagement disk 148 Breather
119 On the outside-brake disk 149 Reducer fitting for breather
120 Inside-brake disk 150 -
121 Tooth ring 171 Spring between engagement disk
122 Locking bolt for brake disk 172 Turning-ring coupling
123 Grease nipple ( radial at this turning-ring 173 O-ring turning-ring coupling
coupling ) 174 Seegerring in this Axle beam
124 Hex bolt turning-ring coupling 175 Oil seal in this turning-ring coupling
125 Allen screw turning-ring coupling below 176 Holding ring for sun gear shaft
126 Allen screw turning-ring coupling above 177 Wearing plate
127 HV washer for 126 178 Allen screw for 177
128 Dowel pin for turning-ring coupling 179 White plug
129 Planetary cage, inner half
130 Planetary cage, outer half
Partnumber for Bogie Housing Section
(Drawing no R1040-40)
1 Oil seal turning-ring coupling on the outside 123 Grease nipple ( radial at this slewing-ring)
2 BB gear rim 125 Allen screw slewing-ring below
3 Allen screw BB gear rim 126 Allen screw slewing-ring above
4 Dowel pin BB gear rim 127 HV washer for 126
5 Washer for 22 128 Dowel pin for turning-ring coupling
6 BB-sun gear 150 Cover
7 Pendulum roller bearing for BB-sun gear 177 Wearing plate
8 Tandem housing – middle bearing bolt 178 Allen screw for 177
9 Plane washer for middle bearing bolt 8 179 White plug
10 Screw Tandem middle bearing bolt
11 O-ring tandem middle bearing bolt
12 Bearing pin BB-sun gear
13 Circlip in cylinder roller bearing 7 only in new
14 Seeger supporting washer in BB-sun gear
15 Washer in BB-sun gear
16 Centering sleeve for intermediate gear bolt 18
17 Cocking bolt for Centering sleeve 16
18 Interim gear bolt
19 O-ring intermediate gear bolt
20 Plane gasket for sheet-metal cover 21
21 Sheet-metal cover
22 Screws for sheet-metal cover
23 Bogie housing intermediate gear wheel
24 Needle bearing for intermediate gear wheel 23
25 Portal pinion cover
26 Screws for cover 25
27 Locking clip for 26
28 Seegerring portal pendulum roller bearing
29 Portal pendulum roller bearing
30 Bogie housing driven wheel
31 Tandem axle beam
32 Gasket Portal pinion cover
33 Wheel bearing housing
34 Output shaft with flange
35 Outer wheel bearing
36 Inner wheel bearing
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
41 Outer cylinder roller bearing Portal pinion
42 Inner cylinder roller bearing Portal pinion
43 Pinion shaft
44 Hex bolt for wheel bearing housing
45 HV washer for 44 and 46
47 Dowel pin for wheel bearing housing
48 Plane gasket wheel bearing housing
49 Portalgear
50 Centering sleeve for Portalgear
51 Wheel bearing adjusting washer
52 Groove nut for wheel bearing
53 Oil drain plug bogie housing with magnet
54 Oil drain plug bogie housing without magnet
55 Seal ring to 53, 54
56 Stub axle ring
57 Allen screw wheel bearing housing
58 VSK ring to 57
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 101
Type: Front Axle in
Timberjack 1410 BHD “6-Wheel“
Description: Rigid Axle with Planetary Hubs
Date: March 23,2001
Contents Page
Maintenance Schedule ............................................................................................... II-IV
1. General Instructions......................................................................................................................1
2. Tightening Torques for Bolts and Nuts (Differential Section) .......................................................2
3. Differential.....................................................................................................................................3
3.1. Exchange of the Complete Differential .........................................................................3
3.2. Replacement of Crown Wheel and Pinion ....................................................................3
3.3. Exchange of The Compensating Gears......................................................................10
3.4. Exchange of the Pinion Bearings ................................................................................11
3.5. Exchange of the Crown Wheel Bearings ....................................................................11
3.6. Exchange of the Shaft Seals.......................................................................................11
4. Differential Lock ..........................................................................................................................12
4.1. Checking the Function of the Differential Lock ...........................................................12
4.2. Exchanging Parts of the Differential Lock ...................................................................12
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock ......................13
5. Multiple Disk Brake and Brake Cylinder .....................................................................................15
5.1. Air Gap Inspection of the Multi Disk Brake .................................................................15
5.2. Air Gap Adjustment of the Brake ................................................................................15
5.3. Emergency Release of the Parking Brake ..................................................................16
5.4. Exchange of the Brake Cylinder .................................................................................17
5.5. Exchange of the Disk Brake .......................................................................................19
6. Tightening Torques for Bolts and Nuts (Planetary Hub) .............................................................21
7. Exchange of the Complete Planetary Hub..................................................................................21
8. Planetary Gearing .......................................................................................................................22
8.1. Opening the Planetary Hub.........................................................................................22
8.2. Exchange of the Sun Gear Shaft ................................................................................22
8.3. Replacement of the Planet Gears, Planet Bearings and Planetary Pins ....................22
8.4. Exchange of the Ring Gear.........................................................................................23
8.5. Reassembly of the Planetary Hub...............................................................................23
9. Spindle and Wheel Bearings ......................................................................................................24
9.1. Exchange of Wheel Bearings and Spindle Ring .........................................................24
9.2. Replacement of the Slide Ring Seal ...........................................................................25
9.3. Replacement of the Axle Spindle................................................................................25
Drawings: Installation drawing SAP 7501.132, assembly drawings 00.75000.288.0; R 72000.113.0;

QMA Nr. :09.004.0 Assembly Device / Special Tool Sk 2.94-213
Date: March 23,2001 page II

Make sure that oil drain plug (54) with copper seal ring
is properly tightened with 90 Nm torque. Remove oil
filler plug (143) and add approx. 27 L oil according to
the table of permitted lubricants until the level has
reached the control mark of the dip stick (145).
(Alternatively open the plug on the vertical face
Nm torque.
Planetary hubs:
Date: March 23,2001 page III
WS 50) of the input cardan flange with adhesive
Change oil while it is warm. First clean oil drain plug
(54), dip stick (145), oil filler plug (143) and
from any metal wear. Screw in oil drain plug (54) with
new copper seal ring and tighten with 90 Nm torque.
torque.
or at least monthly
Date: March 23,2001 page IV
Table of Lubricants
Date: March 23,2001 page V
e.g.
ARAL Degol 3216


Date: March 23,2001 page 1

1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 allen bolt M10x16 8.8 1020.203 49 Nm
9 hex bolt M16x45 10.9 VP 1010.563 310 Nm
22 Allen M12x85 8.8 VP 1020.374 125 Nm
25 grooved nut M158x1,5 7329.012 see Chapter 3.2.3.
54 plug R ¾" with magnet 73230.025 90 Nm
103 hex bolt M18x2x70 10.9 1010.662 465 Nm
104 hex bolt M18x2x80 10.9 1010.639 465 Nm
143 plug R ¾" 7322.064 90 Nm
152 Allen bolt M10x80 10.9 1020.257 67 Nm

3. Differential
connections of the brake cylinders and drain oil from the axle) release the parking brake
as described in Chapter 5.3. Open the hex / allen bolts (103, 104) on both sides of the
differential and remove the axle beams (101, 102) with the planetary hubs. The complete
brake (actuating cylinder, disks and dowel pins Æ20) will remain in the axle beam. Pull the
drive shafts (140) out of the differential gear.
the sun gear and in the plane bearing of the axle spindle. Then shift the short spline end
of the drive shaft (140) into the coupling sleeve in the axle beam. Install a new O-ring (5)
onto the step of the differential flange (6, 36). Note that all 3 ie. 4 dowel pins (3x107,
4x106) properly sit in their bores in the differential. Attach the complete axle beam to the
differential and fasten with hex bolts (103, 104).
The bolt in this position must be sealed with fluid sealing (eg. Loctite 542)
bolt as per 5.3.

Chapter 3.1.1.
length of the caliper gauge must be at least 120 mm. The dimension L1 may vary
between 33.34 and 33.54 mm.
- Measure the actual thickness Lr of the pinion head. Lr will be approximately 49.34 mm.
be read from the face
of the pinion. Le will be
approximately 88.66
mm.

se = 174.3 - Le - Lr - L1 [mm]
available with a thickness of 2.50, 2.75 and 3.00 mm. Insert the selected adjusting washer
(45) and press in the outer ring of bearing (43) from the inside and the outer ring of
bearing (48) from the outside of the differential housing. Push the bearing inner ring (43)
onto the pinion shaft (if necessary evenly warm up the bearing to 80°-110°C). Then ist is
necessary to adjust the bearings of the bevel pinion.
hammer tap against the housing of where the bearings are located in order to properly
align the taper rollers. Also tap against the face of the pinion shaft with a brass mandril
while turning the pinion back and forth. Inspect the bearing preload; if required through the
use of thinner adjusting washers (44) the proper bearing preload is to be adjusted.
5 Nm.
O-ring and shaft seals. Apply and tighten hex nut (50) until the frictional torque of the
pinion has reached 1.0-2.0 Nm. If you tighten the nut too much and the given limit of
frictional torque is exceeded, you have to repeat the procedure with a new squeeze ring.
are located in order to properly align the taper rollers. Also carefully tap against the face
of the pinion shaft with a brass mandril while turning the pinion back and forth.
frictional torque. This value
is valid only for new
bearings and with removed
crown wheel and without
shaft seals. For used
bearings the setting value is
0 to 5 Nm.

seals (first 88 then 89) into the housing (42) and fill 50% of the volume between both seals
with grease. It should be noted that the seals are installed in the correct illustrated
orientation. Clean the threads of shaft and nut from dirt or grease, then shift the cardan
flange (51) onto the spline of the shaft. Cover the threads of pinion shaft and nut (50) on
their whole length and circumference with Loctite 639. The applying and tightening of the
nut must not take any longer than 3-5 minutes to avoid any hardening of the adhesive.
The nut cannot be applied using an impact wrench since this will promote early hardening
and the adhesive will be spun off the threads. Tighten the nut with 800 Nm torque.
and crown wheel. If measured at the hole circle of the drive shaft flange (Æ »127 mm) this
is 0.3 to 0.5 mm.
Nm to the torque determined in Chapter 3.2.2.2. or 3.2.2.3. (bearing friction torque).


marked in their orientation to one another with mating numbers and must be be assem-
bled in this orientation only.
Disassembly
Assembly
tighten with new adhesive coated allen bolts (22). Insert inner ring of bearing (24) onto the



pinion shaft. Now, both radial shaft seals (88/89) can be pulled out. It is also
necessary.
and clean from any dirt and grease. Install new shaft seals with tool (WZ 213), note that
the lips of the seals are installed in the proper orientation as shown. Fill 50% of the volume
between seals (88/89) with grease, install new O-ring (49), and shift the cardan flange (51)
onto the spline of the shaft. Now cover the threads of shaft and nut with Loctite 639. The
applying and tightening of the nut must not take any longer than 3-5 minutes to avoid any
with 800 Nm torque.

complete differential from the axle as described in Chapter 3.1.1. Loosen 2 Allen bolts (4)
and remove the differential flange (36) together with the shifting sleeve (56), the
locked with Loctite, therefore preheating it with a blow lamp to 120°-160°C is
recommended.
assembly tool no. (WZ 509) Sk.2.96-136, because the piston sealing (35) is two-piece and
this piston sealing (35) must calibrate with special tool no. (WZ 509) Sk.2.96-136. Insert
the piston into the cylinder (32) and turn it such that the shifting lever lateron can be
Unscrew the cylinder (32, wrench size 46) from the differential flange (36). Before
screwing in a new cylinder cover its thread with Loctite 542 (alternatively OKS-paste or
any other fluid thread sealing). Screw in the cylinder with a new copper seal ring (34) and
tighten with 90 Nm. After mounting the cylinder there must not be any hydraulic pressure
for 6-8 hours until the fluid sealing becomes fully effective.
were exchanged:
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
and shifting sleeve (56). Cover the thrads of nut and shifting rod with Loctite 639 on their
Snap a new O-ring (7) onto the step of the flange (36) and install the complete flange to
Figures: Assembly Drawings fig. QMA Nr.: 09.004.0

cylinder.


completly removed.


cylinders!
Disassembly:
the brake cylinder (150). Both allen screw (170) mustn`t be unscrewed.
Assembly:

Disassembly:
Assembly:
bolts (113).
Disassembly:
renewed.
Assembly:

Disassembly:
exchanged.
Assembly
Note that the four dowel pins (122) properly sit in
their bores in the axle beam. The three outside
disks (119) and three inside disks (120) are to be
assembled in the illustrated orientation. First a
new outer disk (119) is to be placed followed by
an inner disks (120) and an outer (119) and so
on. An inner disk (120) is directly on each side of
the ball ramp activation disks.
Both outer outside disks (119) per brake side are
to be mounted crosswise onto the dowel pins
(122). The inner most outer disk per brake side
does not get inserted into the dowel pin (122) but
Fig.8: Multiple Disk Brake rather into the clutches of the ball ramp disks
(118).
After all six outer disks and six inner disks and ball ramp activation mechanism have been
assembled, insert a toothed ring (121) on each of the four dowel pins (122) as an
assembly aid. The six inner disks (120) are to be orientated with a splined mandrel, eg.
with drive shaft (140). It must be noted that the bores in the inner disks make an inline
5.2.
necessary.
Figures: Assembly Drawings fig. R.72000.113.0

2 hex bolt M16x90 10.9 VP 1510.536 310 Nm
16 plug M30x1.5 VP 7323.016 220 Nm
28 hex bolt M16x40 10.9 VP 7322.069 310 Nm
32 hex bolt M12x30 10.9 1010.301 125 Nm
39 grooved nut M85x2 7329.073 2000 Nm+ Loctite 639

Disassembly
Assembly

Disassembly
by welding.
Assembly

with high torque, therefore prepare a torque amplifier. Open the grooved nut (39) with
WZ081 at the spindle. Then pull the ring gear carrier (38) from the spindle (27) and keep
all parts of the washer package (62) for reassembly. Dislodge the snap ring (37) and draw
off the ring gear (1). Slide a new ring gear (1) onto the ring gear carrier and let the snap
ring (37) snap into its groove. The ring gear should be movable by approx. 0.4 mm radial
and 1.0 mm axial on the ring gear carrier (38).
nut with 2000 Nm torque (use tool WZ 081 and torque wrench with torque amplifier).

To adjust the axial play between the sun gear shaft (40) and the plug (16), push the sun
gear shaft towards the centre of the differential with a mandril (»Æ 20) and slight hits of a
hammer. With a depth gauge measure the distance "A" from the sink at the centre bore of
the planet carrier to the face of the sun gear, see Fig.9. Determine the thickness "s" of the
washer package (19) as follows:
"smin" = 22 - "A" "smax" = 23 - "A"
The washers are available with a thickness of 1.0 and
2.5 mm. Install a new coated plug (16) with the
Fill in lubricating oil as described in the maintenance

schedule.


Disassembly
(39) at the spindle. Then pull the ring gear carrier (38) and the washer (62) from the
spindle (27). Draw off the wheel hub (34) together with the outer rings of the wheel
bearings. With a bearing puller pull the outer rings of the taper roller bearings (31, 36) out
of the wheel hub, then pull the spindle ring (30) together with the inner raceway of the
taper roller bearing (31) from the spindle. Remove the slide ring seals ("Cat" seal, #29)
Assembly
it is favourable to use a special tool WZ 234 which is supplied by NAF; otherwise insert
the seal rings into the grooves of spindle ring and wheel hub by hand. The seal rings are
very brittle, be careful not to brake them. Press the inner ring of taper roller bearing (31)
onto the spindle (27), then press the outer rings of the bearings (31, 36) into the wheel
hub. Set the wheel hub onto the spindle and press the inner ring of taper roller bearing
(36) onto the spindle.
(62) as follows:
639 and tighten the nut with 2000 Nm torque (use torque wrench with torque amplifier).
Fig.10: Adjustment of the wheel bearings

The replacement of the slide ring seals (29, "Cat" seal with use the tool WZ 234) already
is described in detail in Chapter 9.1. However, it is not necessary to pull all bearing rings
from their seats as described there.

To replace the axle spindle follow the instructions in Chapter 9.1. After the wheel bearings
are disassembled, the axle spindle (27) can be exchanged by loosening the hex bolts (28).
When reassembling also insert a new O-ring (26).
Repair Instruction, Modification Sheet
Figures: --
Date: March 23,2001
Description Date
Original Version ............................................................................................March 23,2001
Revisions reserved
Neunkirchen on March 23,2001

Insert punch WZ 213
To insert the seal rings 1160.208 for
drive shaft flange
(short distance)
for seal rings 1180.811
for groove nut 7329.073 in wheel hub
Partnumber for Diff. (Drawing no. 00.75000.288.0) 88. Oil seal Drive shaft flange
102. Left Axle beam
118. Driven disk
119. Dive disk
120. Operating disk
11. Diff.-cage
16. Cross bolt
17. -
23. -
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -
59. -
2 Hex. Bolt 13 Planetary Cage outer 24 Snap Ring 33 Wheel Stud 59 Dowel Pin
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 102
Type: Bogie Axle

Used in FMG Timberjack 1410B havy duty / 1470
Date: March 22,2001
Contents Page
Maintenance Schedule ....................................................................................................II
1. General Instructions ...................................................................................................................1
2. Tightening Torque’s for Bolts and Nuts......................................................................................2
3. Differential ..................................................................................................................................5
3.1. Exchange of the Complete Differential ......................................................................5
3.2. Replacement of Crown Wheel and Pinion.................................................................6
3.3. Exchange of The Compensating Gears ..................................................................12
3.4. Exchange of the Pinion Bearings.............................................................................13
3.5. Exchange of the Crown Wheel Bearings.................................................................13
3.6. Exchange of the Shaft Seals ...................................................................................13
4. Differential Lock .......................................................................................................................13
4.1. Checking the Function of the Differential Lock ........................................................13
4.2. Exchanging Parts of the Differential Lock................................................................14
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock ...................14
5. Multiple Disk Brake and Brake Cylinder ...................................................................................17
5.1. Air Gap Inspection of the Multi Disk Brake ..............................................................17
5.2. Air Gap Adjustment of the Brake .............................................................................17
5.3. Emergency Release of the Parking Brake...............................................................18
5.4. Exchange of the Brake Cylinder ..............................................................................18
5.5. Exchange of the Disk Brake ....................................................................................20
6. Balanced Bogie (BB) Planetary Gear and Slewing Ring ..........................................................22
6.1. Disassembly of the Bogie Housing ..........................................................................22
6.2. Reassembly of the Bogie Housing...........................................................................22
6.3. Exchange of Sun Gear Shaft (140) and Seal Rings (142).......................................23
6.4. "Balanced Bogie" (BB) Planetary Gear....................................................................24
6.5. Exchange of the Slewing Ring.................................................................................25
7. Gear Drive Inside The Bogie Housing......................................................................................26
7.1. Exchange of the Needle Bearings ...........................................................................26
7.2. Exchange of The Gears...........................................................................................26
8. Portal Drive and Wheel Bearings .............................................................................................27
8.1. Disassembly of The Portal Gear and Pinion Shaft ..................................................27
8.2. Exchange of The Face Seal ....................................................................................27
8.3. Exchange of The Wheel Bearings ...........................................................................27
8.4. Reassembly of The Portal Drive and Adjustment of the Wheel Bearings ...............28
8.5. Exchange of The Sperical Roller Bearing (29) ........................................................29
Assembly drawings 00.75000.260.0, 00.92500.044.0, 00.92500.045.0,
Assembly Device / Special Tools Sk 2.94-213; Sk 2.96-136; Sk 4.94-1029
Date: March 22,2001 page II
Bogie housings:
with 55 Nm.
white plastic caps.
Date: March 22,2001 page III
retightened.
(61) with 55 Nm.
Date: March 22,2001 page IV
Table of Lubricants
Date: March 22,2001 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: ¾
bogie.
this manual.
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

2.1. Differential Section, Fig. no. 00.75000.260.0
1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x20 8.8 1020.212 49 Nm
9 Hex bolt M16x1,5x40 10.9 VP 7322.066 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
39 Plug R ¾" 1040.103 90 Nm
50 Hex nut M40x1.5 7329.057 800 Nm
54 Plug M20x1,5 with magnet 9556.021 53 Nm
103 Hex bolt M20x2x90 10.9 1010.668 560 Nm
104 Allen bolt M20x2x90 10.9 1010.620 500 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0
2.2. Axle Beam with Multiple Disk Brake and BB-Gear

Fig. no. 00.92500.044.0 (LOK 102 with BB)
103 Hex bolt M20x2x90 10.9 1010.668 560 Nm
104 Allen bolt M20x2x90 10.9 1010.620 500 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 Hex bolt M20x2x90 10.9 VP 1010.669 500 Nm
131 Hex bolt M20x2x130 10.9 VP 1510.507 560 Nm
143 Plug R ¾" 1040.151 90 Nm
149 Reducing plug R ¾" x R½" 1750.705 100 Nm

(tap.)
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 102 with BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
46 Hex bolt M16x60 10.9 VP 1010.544 310 Nm
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
160 Hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x70 10.9 1020.512 280 Nm

Figure: 00.75000.260.0
3. Differential
parking brake as described in Chapter 5.3. Open the hex bolts (103, 104) on both sides of
the differential housing. Remove the combined boogie housing and axle beam from the
differential. The complete brake (actuating cylinder, disks and dowel pins Æ16) and the
axle beam to the differential with hex bolts (103, 104) and washers (105).
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
Push the bearing inner ring (43) onto the
pinion shaft (if necessary evenly warm up
the bearing to 80°-110°C). In order to
adjust a good contact pattern of the hypoid
gearing, the proper thickness of the
adjusting washer (45) is to be determined
as follows, see Fig.2:
- Measure the actual distance L1 from the
outer ring of the taper roller bearing (43)
to the face of the pinion. To avoid
mistakes, the jaw length of the caliper
gauge must be at least 120 mm. The
dimension L1 may vary between 86.77
and 87.57 mm.
- Record the mounting distance Le which
can be read from the face of the pinion.
Le will be approximately 89.23 mm.
- Determine the necessary thickness se
Fig.2: Determining the dimension se to
for the adjusting washer (45) as follows:
adjust the contact pattern of the hypoid
se = 178.8 - Le - L1 [mm]
Figure: 00.75000.260.0
available with a thickness between 2.00 and 3.00 mm, step 0.25. Insert the selected
adjusting washer (45) and press in the outer ring of bearing (43) from the inside and the
outer ring of bearing (48) from the outside of the differential housing. Then ist is
5 Nm.
Figure: 00.75000.260.0
Again disassemble the spacer sleeves

A and B together with the sqeeze ring
and determine the total width Lq of this
unit with an accuracy of 0.01 mm. Due
to tolerances during manufacturing Lq
can vary between 23.56 and
25.00 mm. For final assembly select
two spacer sleeves (47) and an
adjusting washer (44) with a total
thickness of
min. (Lq - 0.01 mm) and
max. (Lq + 0.03 mm)
Assemble with this selected spacer
sleeves and washer and, still without
O-ring and shaft seals, tighten the hex
nut (50) with 800 Nm torque. Now
check the bearing adjustment: the
pinion bearings must not have any
axial play, and the pinion should let
itself be turned with 0.5 to 6 Nm
frictional torque. This value is valid
Fig.3: Determining dimension Lq for only for new bearings and with
adjustment of the pinion bearings removed crown wheel and without
shaft seals. For used bearings the setting value is 0 to 5 Nm.
The bearing adjustment should be ok, if required the proper bearing preload is to be
adjusted through the use of an adjusting washer (44) one step thicker (in case of too much
pretension) or thinner (in case of axial play or too little pretension).
seals (88 and 87) into the housing (42) and fill 50% of the volume between both seals with
grease. It should be noted that the seals are installed in the correct illustrated orientation.
Clean the threads of shaft and nut from dirt or grease, then shift the cardan flange (51)
onto the spline of the shaft. Cover the threads of pinion shaft and nut (50) on their whole
length and circumference with Loctite 639. The applying and tightening of the nut must
not take any longer than 3-5 minutes to avoid any hardening of the adhesive. The nut
cannot be applied using an impact wrench since this will promote early hardening and the
adhesive will be spun off the threads. Tighten the nut with 800 Nm torque.
Figure: 00.75000.260.0
and crown wheel. If measured at the hole circle of the drive shaft flange (Æ »127 mm)
Nm to the torque determined in Chapter 3.2.2.2 or 3.2.2.3 (bearing friction torque).
Figure: 00.75000.260.0
Figure: 00.75000.260.0

Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
assembly tool no. Sk.2.96-136, because the piston sealing (35) is two-piece and this
piston sealing (35) must calibrate with special tool no. Sk.2.96-136. Insert the piston into
the cylinder (32) and turn it such that the shifting lever lateron can be assembled into the
groove of the piston.
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
per 5.2.
necessary.
Repair Instruction,

First loosen all 8 hex bolts (10) at the bearing stud (8, centre cover with Timberjack-Logo),
insert M10x40 long extraction bolts and remove the bearing stud along with the mounted
gear (6). Then loosen 16 Allen bolts (125) at the rear of the bogie housing and four Allen
bolts (126) at the top outside and remove the entire bogie housing (31) to the side. During
this the balance planetary drive will remain in the axle beam (101) and can now be taken
out as a complete subassembly [LOK 102: ].

(2) can mesh with the planetary gears (136) of the balance planetary drive.
package (9) is to be determined, see the following figure 9.
Repair Instruction,
- Move the complete planetary drive in the direction of the differential until it butts up
solidly and measure dimension "A". (theoretical dimension of "A" is 171.5 ± 2.5 mm)
- Calculate the thickness "s" of the washer package (9):
smin = 172.5 - "A" = ..... mm
smax = 173.5 - "A" = ..... mm
The theoretical thickness "s" of the shims can vary from 0 to 5.0 mm. If you should
calculate a negative value of "s" do not mount any shim.
- This setup will give an axial play from 0.5 to 2.5 mm between the compression stud
(12) in the gear (6) and the intermediate plate (134).
Install a new O-ring (11) in the groove

of the bearing stud, insert the selected
package of shims (9) and mount the
bearing stud (8) along with the
mounted gear (6). By slightly turning
gear (6) the teeth of the planet gears
(136) can mesh with the teeth of gear
(6).
Tighten the bearing stud (8) with
adhesive coated hex bolts (10).
Finally apply grease to the slewing
ring (172) at all grease nipples (123,
10x per slewing ring) until grease
seeps out over the entire
circumference and cover all grease
nipples with white plastic caps (179).

Repair Instruction,

Assembly:
Repair Instruction,

hex bolts (10) at the bearing stud (8, centre cover with Timberjack-Logo), insert M10x40
long extraction bolts and remove the bearing stud along with the mounted gear (6). Push
off the gear (6) along with the spherical roller bearing (7) from the bearing stud, extract the
circlip ring (13) and extract both washer (14, 15) with the bearing (7). Remove
compression stud (12) with the use of an M8 x 40 long extraction bolt.

hex bolts (124).


The spacer rings (16) can be pulled out through their respective hole (Æ »71mm).
as per 7.1.

Loosen the grooved nut (52) while countering against the flange of the output shaft (34).
The nut is locked with Loctite, therefore the loosening torque can be as high as 1500 Nm!
It will be necessary to preheat the nut to about 150°C. Remove the gear (49) from the
output shaft (34) and disassemble the drive pinion (153). Both of them now easily can be
exchanged, as well as the roller bearings (41, 42) of the pinion shaft.
housing by inserting a rod Æ35 mm into the centre bore of the gear (30).

housing (33). Now both halves of the face seal (37) can be exchanged. Finish the
assembly as per 8.4. If nothing else than the face seal will be exchanged during this repair
work, a new adjustment of the wheel bearings is not necessary, provided the same set of
adjusting washers (51) is used.


· Measure the dimension "X1" of the output shaft (34), theoretical value 38±0.3 mm
· Set the portal gear (49) onto the spline end of the output shaft (34). For this step use
ring (50). To avoid scoring, cover the outside face "D" of the mounting ring with
· Select a washer (50) with thickness "d"
dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
· Again unscrew the grooved nut and with a steel brush clean the threads of nut and
washer (51). Cover the outside face "D" of the centering ring (50) with antiscoring
nut (52) with 2000 Nm torque. The frictional torque of the wheel bearings (incl. the face
seal) must be between 20 and 35 Nm. In the case of axial play or less pretension reduce
the thickness of the adjusting washer, in the case of too high pretension of the bearings
increase the thickness of the adjusting washer and repeat this procedure. For every step
again cover the centering ring with antiscoring paste, but take care that no paste reaches
the threads! If you found the suitable washer, for the final assembly lock the grooved nut
with Loctite 639.
8.5. Exchange of Gear (30) the Sperical Roller Bearing (29)

forcing bolts M8x40).
Extract the snap ring (28) and from the inside pull off gear (30) from the bearing (29) to the
bogie housing. Ectract bearing (29) from bogie housing (31).
For reassembly first install new spherical roller bearing (29) into bogie housing (31). Then
insert new gear (30) through the opening of the portal drive and insert into center diameter
of the bearing (29). When doing this brace against the inner ring with a proper tool and
press-in the gear with help of an M16 x 80 long hex bolt into bearing (29). Install snap ring
(28) into its groove on the gear (30). Mount new gasket (32) and tighten cover (25) with
hex bolts (26).

Insert punch WZ 213
drive shaft flange
(short distance)
Partnumber for Tandemaxle LOK 102 (Drawing no. R1020-112)

11. Diff.-cage
16. Cross bolt
17. Bushing
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -
59. -
102. Left Axle beam
Partnumber for Tandemaxle LOK 102 (Drawing no. 00.92500.044.0)
101 Right Axle beam

102 Left Axle beam
103 Axle beam screw
104 Axle beam screw
105 HE-S ring
106 Dowel pin Axle beam (Lock side)
107 Dowel pin Axle beam (Crown gear side)
108 Breather for bogie housing
109 Brake chocke
110 O-ring for brake cylinder
111 Operating brake cylinder complete
112 -
113 Allen screw for Operating brake cylinder
114 Spring washer for 115
115 Allen screw for parking brake cylinder
116 O-ring among parking brake cylinder
117 Parking brake cylinder complete
118 Engagement disk
119 On the outside-brake disk
120 Inside-brake disk
121 Tooth ring
122 Locking bolt for brake disk
123 Grease nipple ( radial at this turning-ring
coupling )
124 Hex bolt turning-ring coupling
125 Allen screw turning-ring coupling below
126 Allen screw turning-ring coupling above
127 HV washer for 126
128 Dowel pin for turning-ring coupling
129 * Planetary cage, inner half
130 * Planetary cage, outer half
131 * Screw planetary cage
132 * HV washer to 131
133 * Shear pin planetary cage
134 * Intermediate shims BB-Gear
135 * BB planetary stud
136 * BB planetary gear
137 * butting shim for planetary
138 * planetary bearing
139 * Butting shim planetary bearing
140 Drive shaft
141 * Bearing pin in the drive shaft
142 Oil seal in this Axle beam
143 Oil fill plug
144 Seal ring for 143
145 Dip stick Axle beam
147 Reducer fitting for dip stick
148 Breather
149 Reducer fitting for breather
150 -
171 Spring between engagement disk
172 Turning-ring coupling
173 O-ring turning-ring coupling
174 Seegerring in this Axle beam
175 Oil seal in this turning-ring coupling
176 Holding ring for sun gear shaft
177 Wearing plate
178 Allen screw for 177
179 White plug
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 103
Type: Bogie Axle in Timberjack 1710
Date: 25 February 2000
Contents Page
Maintenance Schedule ....................................................................................................II
1. General Instructions ...................................................................................................................1
2. Tightening Torques for Bolts and Nuts.......................................................................................2
3. Differential ..................................................................................................................................5
3.1. Exchange of the Complete Differential ......................................................................5
3.2. Replacement of Crown Wheel and Pinion.................................................................6
3.3. Exchange of The Compensating Gears ..................................................................12
3.4. Exchange of the Pinion Bearings.............................................................................13
3.5. Exchange of the Crown Wheel Bearings.................................................................13
3.6. Exchange of the Shaft Seals ...................................................................................13
4. Differential Lock .......................................................................................................................13
4.1. Checking the Function of the Differential Lock ........................................................13
4.2. Exchanging Parts of the Differential Lock................................................................14
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock ...................14
5. Multiple Disk Brake and Brake Cylinder ...................................................................................17
5.1. Air Gap Inspection of the Multi Disk Brake ..............................................................17
5.2. Air Gap Adjustment of the Brake .............................................................................17
5.3. Emergency Release of the Parking Brake...............................................................18
5.4. Exchange of the Brake Cylinder ..............................................................................18
5.5. Exchange of the Disk Brake ....................................................................................20
6. Balanced Bogie (BB) Planetary Gear and Slewing Ring ..........................................................22
6.1. Disassembly of the Bogie Housing ..........................................................................22
6.2. Reassembly of the Bogie Housing...........................................................................22
6.3. Exchange of Sun Gear Shaft (140) and Seal Rings (142).......................................23
6.4. "Balanced Bogie" (BB) Planetary Gear....................................................................24
6.5. Exchange of the Slewing Ring.................................................................................25
7. Gear Drive Inside The Bogie Housing......................................................................................26
7.1. Exchange of the Needle Bearings ...........................................................................26
7.2. Exchange of The Gears...........................................................................................26
8. Portal Drive and Wheel Bearings .............................................................................................27
8.1. Disassembly of The Portal Gear and Pinion Shaft ..................................................27
8.2. Exchange of The Face Seal ....................................................................................27
8.3. Exchange of The Wheel Bearings ...........................................................................27
8.4. Reassembly of The Portal Drive and Adjustment of the Wheel Bearings ...............28
8.5. Exchange of The Sperical Roller Bearing (29) ........................................................29
Assembly drawings 00.75000.260.0, 00.92500.044.0, 00.92500.066.0,
Assembly Device / Special Tools Sk 4.96-1019
Date: 25 February 2000 page II
Bogie housings:
centre cover). Add approx. 65 L oil as per lubrication chart
with 55 Nm.
white plastic caps.
Date: 25 February 2000 page III
retightened.
(61) with 55 Nm.
Date: 25 February 2000 page IV
Table of Lubricants
Figure: Installation Drawing, Lubrication Plan Fig. 7101-903
Date: 25 February 2000 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: ¾
Date: 25 February 2000 page 1
bogie.
1.8. This manual can also be applied on versions earlier than LOK52/3. The prototype
this manual.
Repair Instruction, Tightening Torques
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

1 hex bolt M8x16 10.9 VP 101.129 36 Nm
3 grooved nut 03.73290.072.0 see Chapter 3.2.3.
4 Allen bolt M10x20 8.8 102.212 49 Nm
9 hex bolt M16x1,5x40 10.9 VP 03.73220.066.0 310 Nm
22 Allen M12x85 8.8 VP 102.335 79 Nm
25 grooved nut 03.73290.012.0 see Chapter 3.2.3.
32 cylinder M30x1.5 03.52630.061.0 90 Nm + Loctite 542
39 plug R ¾" 104.103 90 Nm
50 hex nut M40x1.5 03.73290.057. 800 Nm
54 plug M20x1,5 with magnet 03.95560.021.0 53 Nm
103 hex bolt M20x2x90 10.9 101.668 560 Nm
104 allen bolt M20x2x90 10.9 101.620 500 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

Fig. no. 00.92500.044.0 (LOK 103 with BB)
103 hex bolt M20x2x90 10.9 101.668 560 Nm
104 allen bolt M20x2x90 10.9 101.620 500 Nm
108 breather M10x1 tapered 125.002 22 Nm
115 Allen bolt M10x45 8.8 102.208 49 Nm
123 grease nipple M8x1 tapered 125.104 15 Nm
124 hex bolt M20x2x90 10.9 VP 101.669 500 Nm
131 hex bolt M20x2x130 10.9 VP 151.507 560 Nm
143 plug R ¾" 104.151 90 Nm
147 reducer fitting R ¾" 03.73220.074.0 90 Nm
148 breather R½" tapered 03.95560.030.0 75 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 103 with BB)
10 hex bolt M10x25 10.9 VP 101.234 72 Nm
22 hex bolt M10x20 10.9 VP 101.233 72 Nm
26 hex bolt M10x25 10.9 VP 101.234 72 Nm
46 hex bolt M16x60 10.9 VP 101.544 310 Nm
52 grooved nut M85x2 03.73290.036.0 see Chapter 8.4.
54 plug M30x1.5 104.103 105 Nm
57 Allen bolt M16x70 10.9 102.517 280 Nm
62 plug M30x1.5 with magnet 03.73230.013.0 105 Nm
160 hex bolt M16x45 10.9 101.567 310 Nm
178 Allen bolt M16x70 10.9 102.512 280 Nm

Figure: 00.75000.260.0
3. Differential
differential. The complete brake (actuating cylinder, disks and dowel pins Æ16) and the
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
dimension L1 may vary between 86.77
and 87.57 mm.
Fig.2: Determining the dimension se to
adjust the contact pattern of the hypoid
se = 178.8 - Le - L1 [mm]
Figure: 00.75000.260.0
5 Nm.
Figure: 00.75000.260.0

two spacer sleeves (47) and an
thickness of
max. (Lq + 0.03 mm)
Figure: 00.75000.260.0
and crown wheel. If measured at the hole circle of the drive shaft flange (Æ »127 mm)
Figure: 00.75000.260.0

Figure: 00.75000.260.0
Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
assembly tool no. WZ 509, because the piston sealing (35) is two-piece and this piston
sealing (35) must calibrate with special tool no. WZ 509. Insert the piston into the cylinder
(32) and turn it such that the shifting lever lateron can be assembled into the groove of the
piston.
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
pin (122) but rather into the clutches of the ball
ramp disks (118).
After all six outer disks and six inner disks and
ball ramp activation mechanism have been
assembled, insert a toothed ring (121) on each
or the four dowel pins (122) as an assembly
aid. The six inner disks (120) are to be
orientated with a splined mandrel eg. with drive
shaft (140). It must be noted that the bores in
the inner disks make an inline channel to allow
cooling oil to flow.
differential flange and mount the complete axle
beam with hex bolts (103, 105). When doing
Fig.8: Multiple Disk Brake this the splines of the drive shaft (140) are
inserted into the splined profile of the shifting
sleeve and compensating gear.
Attach the brake cylinder as per 5.4.2. and
5.4.1. and adjust the air gap of the brake as per 5.2.
necessary.
Repair Instruction,
Figures: Assembly Drawings Fig. 00.92500.044.0,
00.92500.066.0


Repair Instruction,
00.92500.066.0
smin = 172.5 - "A" = ..... mm
smax = 173.5 - "A" = ..... mm
(6) and the intermediate plate (134).
- X Attention: Disassemble the lock

snap ring (13) from the new cylinder
roller bearing before inserting.

(179).
Repair Instruction,
00.92500.066.0

Assembly:
Repair Instruction,
00.92500.066.0

hex bolts (10) at the bearing stud (8, centre cover with Timberjack-Logo). To remove the
bearing bolt, insert two extraction bolts M8x90 long and keep strictly this procedur.
Otherwise the cylinder roller drop into the bogie housing. Pull out the gear (6) along with
the complete cylinder roller bearings (7) from the bogie housing. Extract the cylinder roller
bearings (7) with an extractor from the gear (6). Remove compression stud (12) with the
use of an M8 x 40 long extraction bolt.
Press a new compression stud (12) and both new cylinder roller bearing (7) in the (new)
gear (6) Attention: Disassemble the lock snap ring (13) before inserting. Then insert the
bearing stud (8) into the bearing (7). Continue assembly as well as setup of axial play
between compression stud (12) and intermediate plate (134) as per 6.2.

hex bolts (124).


The spacer rings (16) can be pulled out through their respective hole (Æ »71mm).
as per 7.1.

housing by inserting a rod Æ35 mm into the centre bore of the gear (30).



· Measure the dimension "X1" of the output shaft (34), theoretical value 38±0.3 mm
· Set the portal gear (49) onto the spline end of the output shaft (34). For this step use
ring (50). To avoid scoring, cover the outside face "D" of the mounting ring with
· Select a washer (50) with thickness "d"
dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
· Again unscrew the grooved nut and with a steel brush clean the threads of nut and
washer (51). Cover the outside face "D" of the centering ring (50) with antiscoring
with Loctite 639.

bogie housing by inserting a rod Æ35 mm into the center bore of the gear (30).

11. Diff.-cage
16. Cross bolt
17. -
23. -
37. -
38. -
41. -
42. Diff.-housing
53. -
57. -
58. -
59. -
1 Oil seal turning-ring coupling on the outside 123 Grease nipple ( radial at this turning-ring
2 BB gear rim coupling )
3 Allen screw BB gear rim 125 Allen screw turning-ring coupling below
4 Dowel pin BB gear rim 126 Allen screw turning-ring coupling above
5 Washer for 22 127 HV washer for 126
6 BB-sun gear 128 Dowel pin for turning-ring coupling
7 Cylinder roller bearings for BB-sun gear 150 Cover
8 Tandem housing – middle bearing bolt 151 Circlip ring
9 Plane gasket for middle bearing bolt 8 152 Guide ring
10 Screw Tandem middle bearing bolt 153 Drive pinion
11 O-ring tandem middle bearing bolt 154 Circlip ring
12 Bearing pin BB sun 155 Centering sleeve
13 Circlip in cylinder roller bearing 7 only in new 156 Circlip ring
14 Allen screw 157 Circlip ring
15 Axial oil seal ring to 7 158 Cover
16 Centering sleeve for intermediate gear bolt 18 159 Allen screw for 158
17 Cocking bolt for Centering sleeve 16 160 Hex bolt
18 Interim gear bolt 161 Washer
19 O-ring intermediate gear bolt 162 Wearing plate
20 Plane gasket for sheet-metal cover 21 177 Wearing plate
21 Sheet-metal cover 178 Allen screw for 177
22 Screws for sheet-metal cover 179 White plug
31 Tandem axle beam
32 O-ring Portal pinion cover
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
44
45 HV washer for 46
49 Portalgear
52 Grooved nut for wheel bearing
53
54
56 Stub axle ring
58 VSK ring to 57
59 oil fill plug for bogie housing
60 Cover
101 Right Axle beam

102 Left Axle beam
103 Axle beam screw
104 Axle beam screw
105 HE-S ring
109 Brake chocke
112 -
118 Engagement disk
121 Tooth ring
coupling )
140 Drive shaft
143 Oil fill plug
148 Breather
150 -
177 Wearing plate
179 White plug
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 104
Type: Bogie Axle in Timberjack 1710

Date: 28 March 2000
Contents Page
2. Tightening Torques for Bolts and Nuts ...................................................................................... 2
3. Differential.................................................................................................................................. 5
3.1. Exchange of the Complete Differential...................................................................... 5
5.1. Air Gap Inspection of the Multi Disk Brake.............................................................. 17
6. Balanced Bogie (BB) Planetary Gear and Slewing Ring.......................................................... 22
Drawings: Installation drawing / Lubrication Plan PTA 5600.104, Assembly drawings 00.75000.260.0,
00.92500.044.0, 00.92500.066.0, Assembly Device / Special Tools Sk 4.96-1019
Date: 28 March 2000 page II
Bogie housings:
with 55 Nm.
white plastic caps.
Date: 28 March 2000 page III
retightened.
(61) with 55 Nm.
Date: 28 March 2000 page IV
Table of Lubricants
Date: 28 March 2000 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: 28 March 2000 page 1
bogie.
.
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
3 grooved nut M 128x1.5 7329.082 see Chapter 3.2.3.
4 Allen bolt M10x20 8.8 1020.212 49 Nm
9 hex bolt M16x1,5x40 10.9 VP 7322.066 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
25 grooved nut M158x1.5 7329.012 see Chapter 3.2.3.
39 plug R ¾
" 1040.103 90 Nm
103 hex bolt M20x2x90 10.9 1010.668 560 Nm
104 allen bolt M20x2x90 10.9 1010.620 500 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

Fig. no. 00.92500.044.0 (LOK 104 with BB)
103 hex bolt M20x2x90 10.9 1010.668 560 Nm
104 allen bolt M20x2x90 10.9 1010.620 500 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 hex bolt M20x2x90 10.9 VP 1010.669 500 Nm
131 hex bolt M20x2x130 10.9 VP 1510.507 560 Nm
143 plug G ¾
" 1040.151 90 Nm
147 reducer fitting R ¾

" 7322.074 90 Nm
148 breather G½
" tapered 9556.030 75 Nm
149 reducer fitting G ¾

" x G½
" (tap.) 1750.705 100 Nm
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 104 with BB)
10 hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 hex bolt M10x25 10.9 VP 1010.234 72 Nm
46 hex bolt M16x60 10.9 VP 1010.544 310 Nm
52 grooved nut M85x2 7329.036 see Chapter 8.4.
54 plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
160 hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x70 10.9 1020.512 280 Nm

Figure: 00.75000.260.0
3. Differential
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
dimension L1 may vary near 101.1 mm.
Fig.2: Determining the dimension se to adjust
the contact pattern of the hypoid gearing
se = 202 - Le - L1 [mm] (as experience shows use a thickness near 2.5 or 2.6)
Figure: 00.75000.260.0
outer ring of bearing (48) from the outside of the differential housing. Then ist is necessary
The first spacer sleeve (46) has a fix measurement of 20.9 mm. The second spacer
sleeve (47) is available with a width of 11.3 mm; 11.78 mm and 12.26 mm, the adjusting
width of (near 34 mm ) for now and slide them onto the shaft of the pinion. Insert this unit
into the differential housing and hold in place from the inside. Install the inner ring of
bearing (48) and the cardan flange (51) onto the pinion shaft, for the time being without O-
ring and shaft seals. Apply and tighten hex nut (50) with 800 Nm torque. During tightening
the nut, with a hammer tap against the housing of where the bearings are located in order
to properly align the taper rollers. Also tap against the outer face of the pinion shaft with a
brass mandril while turning the pinion back and forth. Inspect the bearing preload; if
required through the use of different spacer sleeves (47) and/or adjusting washers (44)
the proper bearing preload is to be adjusted.
5 Nm.
are located in order to properly align the taper rollers. Also carefully tap against the face of
the pinion shaft with a brass mandril while turning the pinion back and forth.
Figure: 00.75000.260.0

two spacer sleeves (46 / 47) and an
thickness of
max. (Lq + 0.03 mm)
length and circumference with Loctite 639. The applying and tightening of the nut must not
take any longer than 3-5 minutes to avoid any hardening of the adhesive. The nut cannot
be applied using an impact wrench since this will promote early hardening and the
Figure: 00.75000.260.0
and crown wheel. If measured at the hole circle of the drive shaft flange (∅ ≈127 mm) also
this dimension is 0.15 to 0.25 mm.
Figure: 00.75000.260.0
Figure: 00.75000.260.0

Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
piston.
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
ramp disks (118).
necessary.
Repair Instruction,
00.92500.066.0


Repair Instruction,
00.92500.066.0
smin = 172.5 - "A" = ..... mm
smax = 173.5 - "A" = ..... mm


(179).
Repair Instruction,
00.92500.066.0

Assembly:
Repair Instruction,
00.92500.066.0


hex bolts (124).


as per 7.1.




dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
with Loctite 639.


11. Diff.-cage
16. Cross bolt
17. -
23. -
37. -
38. -
41. -
42. Diff.-housing
53. -
57. -
58. -
59. -
Partnumber for bogie housing ( drw.no 00.92500.066) 59 oil fill plug for bogie housing
60 Cover
1 Oil seal turning-ring coupling on the outside 62 Oil drain plug bogie housing without magnet
2 2 BB gear rim 123 Grease nipple ( radial at this turning-ring
3 Allen screw BB gear rim coupling )
4 Dowel pin BB gear rim 125 Allen screw turning-ring coupling below
5 Washer for 22 126 Allen screw turning-ring coupling above
6 BB-sun gear 127 HV washer for 126
7 Cylinder roller bearings for BB-sun gear 128 Dowel pin for turning-ring coupling
8 Tandem housing – middle bearing bolt 150 Cover
9 Plane gasket for middle bearing bolt 8 151 Circlip ring
10 Screw Tandem middle bearing bolt 152 Guide ring
11 O-ring tandem middle bearing bolt 153 Drive pinion
12 Bearing pin BB sun 154 Circlip ring
13 Circlip in cylinder roller bearing 7 only in new 155 Centering sleeve
14 Allen screw 156 Circlip ring
15 Axial oil seal ring to 7 157 Circlip ring
16 Centering sleeve for intermediate gear bolt 18 158 Cover
17 Cocking bolt for Centering sleeve 16 159 Allen screw for 158
18 Interim gear bolt 160 Hex bolt
19 O-ring intermediate gear bolt 161 Washer
20 Plane gasket for sheet-metal cover 21 162 Wearing plate
21 Sheet-metal cover 177 Wearing plate
22 Screws for sheet-metal cover 178 Allen screw for 177
23 Bogie housing intermediate gear wheel 179 White plug
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
44
45 HV washer for 46
49 Portalgear
53
54
56 Stub axle ring
58 VSK ring to 57
Partnumber for Axle beam LOK 104 (Drawing no. 00.92500.044.0)
101 Right Axle beam 131 * Screw planetary cage

102 Left Axle beam 132 * HV washer to 131
103 Axle beam screw 133 * Shear pin planetary cage
104 Axle beam screw 134 * Intermediate shims BB-Gear
105 HE-S ring 135 * BB planetary stud
106 Dowel pin Axle beam (Lock side) 136 * BB planetary gear
107 Dowel pin Axle beam (Crown gear side) 137 * butting shim for planetary
108 Breather for bogie housing 138 * planetary bearing
109 Brake chocke 139 * Butting shim planetary bearing
111 Operating brake cylinder complete 141 * Bearing pin in the drive shaft
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 114
Type: Bogie Axle

Used in Timberjack Forwarder 1410D heavy duty
Date: July 30,2002
Contents Page
3. Differential.................................................................................................................................. 5
Assembly drawings R 00.75000.391.0, 00.92500.044.0, 00.92500.045.0,
Assembly Device / Special Tools Sk 2.94-213; Sk 2.96-136; Sk 4.94-1029
Date: July 30,2002 page II
Bogie housings:
with 55 Nm.
At all 10 grease nipples (90, with 10 per side and with white
plastic cap) grease with grease gun until the gap has
sealed itself with grease all the way around the
cover grease nipples with white plastic caps.
Date: July 30,2002 page III
repair instruction. The center nut (hex nut wrench size 50)
of the input cardan flange with adhesive locking must not
be retightened.
(61) with 55 Nm.
Date: July 30,2002 page IV
Table of Lubricants
Date: July 30,2002 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: July 30,2002 page 1
bogie.
this manual.
Figures: 00.75000.391.0, 00.92500.044.0, 00.92500.045.0

2.1. Differential Section, Fig. no. R 00.75000.391.0
1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x20 8.8 1020.212 49 Nm
9 Hex bolt M16x1,5x40 10.9 VP 7322.066 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
25 Grooved nut M158x1,5 7329.012 see Chapter 3.2.3.
50 Hex nut M40x1.5 7329.057 800 Nm
54 Plug M30x1,5 1040.103 90 Nm
103 Hex bolt M18x2x80 10.9 1010.639 400 Nm

Figures: 00.75000.391.0, 00.92500.044.0, 00.92500.045.0

Fig. no. 00.92500.044.0 (LOK 114 with BB)
103 Hex bolt M18x2x80 10.9 1010.639 400 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 Hex bolt M18x2x100 10.9 VP 1010.631 400 Nm
131 Hex bolt M16x120 10.9 VP 1510.550 290 Nm
143 Plug R ¾ " 1040.151 90 Nm
147 Reducer fitting R ¾ " 7322.064 90 Nm
148 Breather R½ " tapered 9556.030 75 Nm
149 Reducing plug R ¾ " x R½ " (tap.)1750.705 100 Nm

Figures: 00.75000.391.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 114 with BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.201 72 Nm
46 Hex bolt M16x65 10.9 VP 1010.535 310 Nm
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x50 10.9 1020.509 280 Nm
178 Allen bolt M16x50 10.9 1020.518 280 Nm

Figure: 00.75000.3910.0
3. Differential
new O-rings (5) onto the steps of the differential flanges (6, 36). Note that all dowel pins
(2x106) properly sit in their bores in the differential. Attach the complete axle beam and
bogie housing to the differential. When shifting the spline end of the shaft (140) into the
differential gear (15) assist by rotating the cardan flange to and fro. Fasten the axle beam
to the differential with hex bolts (103) and washers (105).
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.3910.0
screw out the groove nut (25). With a soft arbor hit the outer rings of the bearings out of
the flanges, and pull the inner rings from the differential cage.
(46,038mm) from the outer ring of the
taper roller bearing + Lr (64,9mm) to the
face of the pinion. To avoid mistakes,
the jaw length of the caliper gauge must
be at least 120 mm. The dimension L1 +
Lr may vary near 110.938mm.
Fig.2: Determining the dimension se to adjust - Record the mounting distance L which
e
the contact pattern of the hypoid gearing can be read from the face of the pinion.
se = 198.5 - Le - Lr - L1 [mm]
Figure: 00.75000.3910.0
available with a thickness between 2.5; 2.75 and 3.0 mm, step 0.25. Insert the selected
outer ring of bearing (48) from the outside of the differential housing. Then is necessary to
adjust the bearings of the bevel pinion.
to three adjusting washers with a total width of (se + 40.35) mm for now and slide them
onto the shaft of the pinion. (se is the thickness of the washer (45) for adjustment of the
contact pattern, see Chapter 3.2.2.1.) Insert this unit into the differential housing and hold
in place from the inside. Install the inner ring of bearing (48) and the cardan flange (51)
onto the pinion shaft, for the time being without O-ring and shaft seals. Apply and tighten
hex nut (50) with 800 Nm torque. During tightening the nut, with a hammer tap against the
housing of where the bearings are located in order to properly align the taper rollers. Also
tap against the outer face of the pinion shaft with a brass mandril while turning the pinion
back and forth. Inspect the bearing preload; if required through the use of a thinner
adjusting washer (44) the proper bearing preload is to be adjusted.
1.5 Nm.
pinion has reached 1.0 - 2.0 Nm. If you tighten the nut too much and the given limit of
Figure: 00.75000.3910.0
Again disassemble the spacer sleeves A

and B together with the sqeeze ring and
determine the total width Lq of this unit
with an accuracy of 0.01 mm. Due to
tolerances during manufacturing Lq can
vary between 42.75 and 43.35 mm. For
final assembly select the original spacer
sleeve (47) and an adjusting washer (44)
with a total thickness of
max. (Lq + 0.03 mm)
sleeve and washer and, still without O-
ring and shaft seals, tighten the hex nut
(50) with 800 Nm torque. Now check the
bearing adjustment: the pinion bearings
must not have any axial play, and the
pinion should let itself be turned with 0.5
Fig.3: Determining dimension Lq for to 2 Nm frictional torque. This value is
adjustment of the pinion bearings valid only for new bearings and with
removed crown wheel and without shaft
seals. For used bearings the setting
value is 0 to 5 Nm.
seals (87) into the Cover (57) and fill 50% of the volume between both seals with grease.
It should be noted that the seals are installed in the correct illustrated orientation. Install a
new O-ring (58) and set on the cover and fix it with hex. screws (52). Clean the threads of
shaft and nut from dirt or grease, then shift the cardan flange (51) onto the spline of the
shaft. Cover the threads of pinion shaft and nut (50) on their whole length and
circumference with Loctite 639. The applying and tightening of the nut must not take any
longer than 3-5 minutes to avoid any hardening of the adhesive. The nut cannot be
applied using an impact wrench since this will promote early hardening and the adhesive
will be spun off the threads. Tighten the nut with 800 Nm torque.
Figure: 00.75000.3910.0
flanges (6, 36) and set in the original adjusting washer (3) under the inner ring (8), then
screw in the groove nut (25) to their previously recorded position.
additional bolts M18x2x40 per side to fix the flanges (6, 36) solidly. Now the backlash
must get a value of 0.15 to - 0.25 mm between the teeth of bevel pinion and crown wheel.
If measured at the hole circle of the drive shaft flange (∅ ≈127 mm) also this dimension is
0.15 to 0.25 mm.
If the proper backlash is attained, adjust the preload of the crown wheel bearings (8) and
(24). For this adjust groove nut (25) by putting an arbor into one of the grooves and hitting
with a hammer, until the desired bearing friction torque of 1.0 to 3.0 Nm is reached. This
can be measured with a torque gauge at the drive shaft flange by adding a value of 0.5
Nm to 1.5 Nm to the torque determined in Chapter 3.2.2.2 or 3.2.2.3 (bearing friction
torque).
be moved by change the thickness of adjusting washer (45), i.e. the complete procedure
Figure: 00.75000.3910.0
and when turning groove nut (25) ensure proper backlash. The diff. cage can be moved by
change the thickness of adjusting washer (3). Always remove old paint from ring gear
when rechecking.
groove nut (25) has to be secured with locking plate (2) and new adhesive coated hex bolt
(1). Remove the additional hex bolts M18x2x40 which fixed the differential flanges.
Figure: 00.75000.3910.0
Figure: 00.75000.3910.0

Disassembly
Assembly



mended. Loosen the nut (wrench size 50) and pull the cardan flange from the spline end
of the pinion shaft. Now, both radial shaft seals (87) can be pulled out. It is also
Figure: 00.75000.3910.0
necessary.
and clean from any dirt and grease. Install new shaft seals with WZ 213, note that the lips
of the seals are installed in the proper orientation as shown. Fill 50% of the volume
between seals (87) with grease, install new O-ring (49), and shift the cardan flange (51)
with 800 Nm torque.

recommended.
removed out of its groove in the piston with a sharp tool. Inspect piston and cylinder for
any marks of wear and replace if necessary. Snap a new seal ring into the groove, the
seal lips facing the short end of the piston. The additional piston sealing (35) must install
with special assembly tool no. WZ 509, because the piston sealing (35) is two-piece and
this piston sealing (35) must calibrate with special tool no. WZ 509. Insert the piston into
Figure: 00.75000.3910.0

Figure: 00.75000.3910.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.3910.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
axle beam with hex bolts (103). When doing
per 5.2.
necessary.
Repair Instruction,


Repair Instruction,
smin = 155.5 - "A" = ..... mm
smax = 156.5 - "A" = ..... mm

(6).

Repair Instruction,

Assembly:
Repair Instruction,


hex bolts (124).


as per 7.1.




dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
with Loctite 639.

hex bolts (26).

Insert punch WZ 213
drive shaft flange
(short distance)
Partnumber for Tandemaxle LOK 114 (Drawing no. R 00.75000.391.0)

3. Adjusting washer Crown gear side
7. O-ring Diff.-housing / Diff.-flange
11. Diff.-cage
16. Cross bolt
17. -
23. Seeger supporting plate Diff.-cage
37. -
38. -
39. -
41. -
42. Diff.-housing
46. Cover
52. Hex. screw drive shaft cover
53. Locking washer to hex screw
55. Seal ring to oil drain plug
57. Drive shaft cover
58. O-ring Drive shaft cover
59. –
106. Dowel pin Axle beam
101 Right Axle beam

102 Left Axle beam
103 Axle beam screw
104 Axle beam screw
105 HE-S ring
109 Brake chocke
112 -
118 Engagement disk
121 Tooth ring
coupling )
140 Drive shaft
143 Oil fill plug
148 Breather
150 -
177 Wearing plate
179 White plug
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 115
Type: LOK 115
Description: Rigid axle with planetary hubs

Used as front axle in Timberjack 1010D also 1110D forwarder
Date: September 13, 2002
Contents Page
Maintenance Schedule ...............................................................................................II-IV
1. General Instructions ..................................................................................................................... 1
2. Tightening Torques for Bolts and Nuts (Differential Section) ....................................................... 2
3. Differential .................................................................................................................................... 3
3.1. Exchange of the Complete Differential......................................................................... 3
3.2. Replacement of Crown Wheel and Pinion.................................................................... 4
3.3. Exchange of The Compensating Gears ..................................................................... 10
3.4. Exchange of the Pinion Bearings ............................................................................... 11
3.5. Exchange of the Crown Wheel Bearings.................................................................... 11
3.6. Exchange of the Shaft Seals ...................................................................................... 11
4. Differential Lock ......................................................................................................................... 11
4.1. Checking the Function of the Differential Lock........................................................... 11
4.2. Exchanging Parts of the Differential Lock .................................................................. 12
4.3. Adjustment of the Axial Play and Reassembly of the Differential Lock ...................... 12
5. Multiple Disk Brake and Brake Cylinder ..................................................................................... 14
5.1. Air Gap Inspection of the Multi Disk Brake................................................................. 14
5.2. Air Gap Adjustment of the Brake................................................................................ 14
5.3. Emergency Release of the Parking Brake ................................................................. 15
5.4. Exchange of the Brake Cylinder ................................................................................. 15
5.5. Exchange of the Disk Brake ....................................................................................... 18
6. Tightening Torques for Bolts and Nuts (Planetary Hub) ............................................................ 20
7. Exchange of the Complete Planetary Hub ................................................................................. 20
8. Planetary Gearing....................................................................................................................... 21
8.1. Opening the Planetary Hub ........................................................................................ 21
8.2. Exchange of the Sun Gear Shaft................................................................................ 21
8.3. Replacement of the Planet Gears, Planet Bearings and Planetary Pins.................... 21
8.4. Exchange of the Ring Gear ........................................................................................ 22
8.5. Reassembly of the Planetary Hub .............................................................................. 22
9. Spindle and Wheel Bearings...................................................................................................... 23
9.1. Exchange of Wheel Bearings and Spindle Ring......................................................... 23
9.2. Replacement of the Slide Ring Seal........................................................................... 24
9.3. Replacement of the Axle Spindle ............................................................................... 24
Drawings: Installation drawing SAP 7501.147; assembly drawings E.75000.245.0 R1030-066;
QMA Nr. : 09.004.0
Date: September 13, 2002 page II

Make sure that three oil drain plugs (54) with copper
Remove oil filler plug (143) and add approx. 28 L oil
level has reached the control mark of the dip stick
(145). (Alternatively open the plug on the vertical face
Nm torque.
Planetary hubs:
Date: September 13, 2002 page III
WS50) of the input cardan flange with adhesive
Change oil while it is warm. First clean oil drain plugs
(54, 3x ), dip stick (145), oil filler plug (143) and
from any metal wear. Screw in oil drain plugs (54) with
new copper seal rings and tighten with 90 Nm torque.
torque.
or at least monthly
Date: September 13, 2002 page IV
Table of Lubricants
Date: September 13, 2002 page V
e.g.
ARAL Degol 3216

Figure: Assembly Drawing fig. E.75000.245.0
Date: September 13, 2002 page 1

1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 hex bolt M16x45 10.9 VP 1110.563 310 Nm
22 Allen M12x80 10.9 VP 1020.374 125 Nm
50 hex nut M40x1.5 7329.057 800 Nm
52 Allen bolt M10x20 8.8 1020.212 49 Nm
103 hex bolt M18x2x70 10.9 1010.662 465 Nm
104 hex bolt M18x2x80 10.9 1010.639 465 Nm
143 plug R ¾" 1040.151 90 Nm
152 Allen bolt M10x80 10.9 1020.257 67 Nm

3. Differential
connections of the brake cylinders and drain oil from the axle) release the parking brake
as described in Chapter 5.3. Open the hex bolts (103, 104) on both sides of the differential
and remove the axle beams (101, 102) with the planetary hubs. The complete brake
(actuating cylinder, disks and dowel pins ∅16) will remain in the axle beam. Pull the drive
shafts (140) out of the differential gear.
4x106) properly sit in their bores in the differential. Attach the complete axle beam to the
differential and fasten with hex bolts (103, 104).
Fig. 1: Side view of differential housing. The marked threaded hole is a through-
hole. The bolt in this position must be sealed with fluid sealing (eg. Loctite 542)
bolt as per 5.3.

Chapter 3.1.1.
length of the caliper gauge must be at least 120 mm. The dimension L1 may vary near
33.338 mm.
- Measure the actual thickness Lr of the pinion head. Lr may vary near and 54.47 mm.
be read from the face
of the pinion. Le will be
approximately
83.83 mm.

se = 174.3 - Le - Lr - L1 [mm]
available with a thickness of 2.50, 2.75 and 3.00 mm. Insert the selected adjusting
washer (45) and press in the outer ring of bearing (43) from the inside and the outer ring
of bearing (48) from the outside of the differential housing. Push the bearing inner ring
(43) onto the pinion shaft (if necessary evenly warm up the bearing to 80°-110°C). Then
ist is necessary to adjust the bearings of the bevel pinion.
hammer tap against the housing of where the bearings are located in order to properly
align the taper rollers. Also tap against the face of the pinion shaft with a brass mandril
while turning the pinion back and forth. Inspect the bearing preload; if required through the
use of thinner adjusting washers (44) the proper bearing preload is to be adjusted.
5 Nm.
frictional torque. This value
is valid only for new
bearings and with removed
crown wheel and without
shaft seals. For used
bearings the setting value is
0 to 5 Nm.
3.2.2.4. Finish
Assembly of Pinion
seals (87) into the housing (42) and fill 50% of the volume between both seals with
hardened washers (10). Set the supporting washer (23) onto its shoulder on the
differential cage, then press the inner rings of the taper roller bearings (8, 24) onto their
seat. Press the outer rings of both taper roller bearings (8, 25) into their seats in the
and crown wheel. If measured at the hole circle of the drive shaft flange (∅ ≈127 mm) this
is 0.3 to 0.5 mm.
Nm to the torque determined in Chapter 3.2.2.2. or 3.2.2.3. (bearing friction torque).


marked in their orientation to one another with mating numbers and must be be assem-
bled in this orientation only.
Disassembly
out of the differential housing. Remove the inner ring of bearing (24) and the supporting
washer (23), loosen allen bolts (22) and take the differential cage apart.
Inspect for damage and wear and replace if required the compensating gears (18) with
plane bearings (17), differential gears (15), crossbolt (16), thrust washers (14), and thrust
plates (19).
Assembly
tighten with new adhesive coated allen bolts (22). Install supporting washer (23) and insert
inner ring of bearing (24) onto the differential cage. Install the differential cage in the
differential housing (42), set a new O-ring (7) onto the step of the flange and mount the
flange (6) with Allen bolts (4). Finish assembly of the complete axle as described in
Chapter 3.1.2.



pinion shaft. Now, both radial shaft seals (87) can be pulled out. It is also recommended to
exchange the O-ring (49), extract it from the groove in the shaft. Check the sealing surface
of the cardan flange (51) for any marks of wear and replace it if necessary.
and clean from any dirt and grease. Install new shaft seals with tool WZ 213, note that the
lips of the seals are installed in the proper orientation as shown. Fill 50% of the volume
with 800 Nm torque.

locked with Loctite, therefore preheating it with a blow lamp to 120°-160°C is
recommended.
wear and replace if necessary. Snap a new seal ring into the groove, the seal lips in the
direction of the short end of the piston. The additional piston sealing (35) must install with
special assembly tool no. WZ 509, because the piston sealing (35) is two-parts and this
piston sealing (35) must calibrate with special tool no. WZ 509. Insert the piston into the
cylinder (32) and turn it such that the shifting lever lateron can be assembled into the
were exchanged:
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
and shifting sleeve (56). Cover the thrads of nut and shifting rod with Loctite 639 on their
Figures: Assembly Drawings fig. R1020-113, QMA Nr.: 09.004.0

cylinder.


completly removed.


cylinders!
Disassembly:
the brake cylinder (150). Both allen screw (170) mustn`t be unscrewed.
Assembly:

Disassembly:
Assembly:
bolts (113).
Disassembly:
renewed.
Assembly:


Disassembly:
exchanged.
Assembly
activation disks.
pin (122) but rather into the clutches of the ball ramp disks (118).
Fig.8: Multiple Disk Brake

assembled, insert a toothed ring (121) on each of the four dowel pins (122) as an
assembly aid. The six inner disks (120) are to be orientated with a splined mandrel, eg.
with drive shaft (140). It must be noted that the bores in the inner disks make an inline
5.2.
necessary.
Figures: Assembly Drawings fig. R1030-066

2 hex bolt M16x85 10.9 151.555 310 Nm
15 plug M20x1.5 with magnet 03.95560.021.0 56 Nm
16 plug M30x1.5 VP 03.73230.016.0 220 Nm
28 hex bolt M16x40 10.9 VP 101.534 310 Nm
32 hex bolt M12x30 10.9 101.301 125 Nm
39 grooved nut M85x2 03.73290.036.0 2000 Nm+ Loctite 639

Disassembly
Assembly

Disassembly
by welding.
Assembly

with high torque, therefore prepare a torque amplifier. Open the grooved nut (39) at the
spindle. Then pull the ring gear carrier (38) from the spindle (27) and keep all parts of the
washer package (62) for reassembly. Dislodge the snap ring (37) and draw off the ring
gear (1). Slide a new ring gear (1) onto the ring gear carrier and let the snap ring (37) snap
into its groove. The ring gear should be movable by approx. 0.4 mm radial and 1.0 mm
axial on the ring gear carrier (38).
nut with 2000 Nm torque (use torque wrench with torque amplifier).

To adjust the axial play between the sun gear shaft (40) and the plug (16), push the sun
gear shaft towards the centre of the differential with a mandril (≈∅ 20) and slight hits of a
hammer. With a depth gauge measure the distance "A" from the sink at the centre bore of
the planet carrier to the face of the sun gear, see Fig.9. Determine the thickness "s" of the
washer package (19) as follows:
"smin" = 22 - "A" "smax" = 23 - "A"
The washers are available with a thickness of 1.0
and 2.5 mm. Install a new coated plug (16) with the
Fill in lubricating oil as described in the maintenance

schedule.


Must during a repair the face seal be opened is the installation of a new face seal set
requiredly even if the wear range still isn't reached.
Disassembly
(39) at the spindle with tool WZ 082. Then pull the ring gear carrier (38) and the washer
(62) from the spindle (27). Draw off the wheel hub (34) together with the outer rings of the
wheel bearings. With a bearing puller pull the outer rings of the taper roller bearings (31,
36) out of the wheel hub, then pull the spindle ring (30) together with the inner raceway of
the taper roller bearing (31) from the spindle. Remove the slide ring seals ("Cat" seal, #29)
Assembly
it is favourable to use a special tool WZ 049 which is supplied by the manufacturer of
theses seal rings (e.g. Caterpillar, Goetze, Busak&Shamban); otherwise insert the seal
rings into the grooves of spindle ring and wheel hub by hand. The seal rings are very
brittle, be careful not to brake them. Press the inner ring of taper roller bearing (31) onto
the spindle (27), then press the outer rings of the bearings (31, 36) into the wheel hub. Set
the wheel hub onto the spindle and press the inner ring of taper roller bearing (36) onto
the spindle.
(62) as follows:
639 and tighten the nut with 2000 Nm torque (use WZ 082 and torque wrench with torque
amplifier).

The replacement of the slide ring seals (29,
"Cat" seal) already is described in detail in
Chapter Must during a repair the face seal be
opened is the installation of a new face seal
set requiredly even if the wear range still isn't
reached.
9.1. However, it is not necessary to pull all
bearing rings from their seats as described
there.

To replace the axle spindle follow the
instructions in Chapter Must during a repair
the face seal be opened is the installation of a
Fig.10: Adjustment of the wheel bearings new face seal set requiredly even if the wear
range still isn't reached.
9.1. After the wheel bearings are disassembled, the axle spindle (27) can be exchanged
by loosening the hex bolts (28). When reassembling also insert a new O-ring (26).
Repair Instruction, Modification Sheet
Figures: --
Date: September 13, 2002
Description Date
Original Version............................................................................................ Sep. 13, 2002
R 72000.109.0
2 Hex. Bolt 13 Planetary Cage outer 24 Snap Ring 33 Wheel bolt 59 Dowel Pin
NAF Tool table for LOK 115 axle

for groove nut 7329.036 in wheel hub
for slide ring 1180.301 in wheel hub
Insert punch WZ 213
drive shaft flange
(short distance)
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 116

Used as a front axle in Timberjack 1270D / 1410D Forwarder
Date: February 12,2003
Contents Page
3. Differential.................................................................................................................................. 5
Assembly drawings R 1020-112; R 00.92500.044.0, R 00.92500.116.0,
Date: February 12,2003 page II
Bogie housings:
with 55 Nm.
Slewing ring:
The slewing ring has lifetime lubrication in the raceway
grease volume and need no service. The only service work
is replacement of solied grease in buffer volume.
First oben lubricating outlet plugs (92, 2 per side covered
with white plastic caps)
At in both grease nipples (90, 2 per side covered with white
plastic caps) grease with grease gun until grease sqeeze
out from the lubricating outlet (92, 2 per side with white
plastic cap). Then close outlet plugs and grease again with
grease gun until grease sqeeze out from the gap has
Date: February 12,2003 page III
Date: February 12,2003 page IV
retightened.
(61) with 55 Nm.
Date: February 12,2003 page V
After every 250 operating Slewing ring:

hours The slewing ring has lifetime lubrication in the raceway
grease volume and need no service. The only service work
is replacement of solied grease in buffer volume.
First clean the area around the grease nipples and oulet
plugs (90/92) Then oben lubricating outlet plugs (92, 2 per
side covered with white plastic caps)
plastic caps) grease with grease gun until grease sqeeze
out from the lubricating outlet (92, 2 per side with white
plastic cap). Then close outlet plugs and grease again with
grease gun until grease sqeeze out from the gap has
Table of Lubricants
Date: February 12,2003 page VI
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
bogie.
this manual..
Figures: R 1020-112, R 00.92500.044.0, R 00.92500.116.0

1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 Hex bolt M16x40 10.9 VP 7322.069 310 Nm
22 Allen M12x80 8.8 VP 1020.374 79 Nm
39 Plug R ¾" 1040.103 90 Nm
50 Hex nut M40x1.5 7329.057 800 Nm + Loctite 639
54 Plug R ¾" magnet 7323.025 90 Nm
103 Hex bolt M18x2x70 10.9 1010.662 465 Nm

Figures: R 1020-112, R 00.92500.044.0, R 00.92500.116.0

Fig. no. 00.92500.044.0 (LOK 116 with BB)
103 Hex bolt M18x2x70 10.9 1010.662 465 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 Hex bolt M18x2x110 10.9 VP 1010.684 465 Nm
143 Plug R ¾" 1040.151 90 Nm

Figures: R 1020-112, R 00.92500.044.0, R 00.92500.116.0
2.3. Bogie Housing,

Fig. no. R 00.92500.116.0 (LOK 116 with BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x16 10.9 VP 1010.298 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.201 72 Nm
46 Hex bolt M16x60 10.9 VP 1010.544 310 Nm
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
160 Hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x50 10.9 1020.518 280 Nm

Figure: 00.75000.260.0
3. Differential
bolt as per 5.3.
Figure: 00.75000.260.0
(eg. Loctite 542)
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
Figure: 00.75000.260.0

82.73 mm.
follows:
se = 178.8 - Le - L1 [mm]
Figure: 00.75000.260.0
5 Nm.
torque.
Figure: 00.75000.260.0

Figure: 00.75000.260.0
Figure: 00.75000.260.0

Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
assembly tool WZ 509 (Sk.2.96-136), because the piston sealing (35) is two-parted and
this piston sealing (35) must calibrate with special tool WZ 509 (Sk.2.96-136). Insert the
piston into the cylinder (32) and turn it such that the shifting lever lateron can be
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0
Put on new O-ring (7) onto the step of the flange (36) and install the complete flange to

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
per 5.2.
necessary.
Repair Instruction,

[LOK 99: There is not any BB planetary gear, the shaft (140) coming out of the differential
is directly mounted to the bearing stud (8). Before starting the disassembly with released
parking brake turn back and forth either the cardan flange at the differential or one of the
output shafts (34), to be sure that the backlash of the splines in the brake disks is aligned.
Then activate the parking brake to hold the brake disks in this position. Pull out the
bearing stud (8) along with the mounted shaft (140). Then dismount the bogie housing as
described above.]

are no shims.]
Repair Instruction,

± 0.7 mm)
washer package (9):
smin = 154.5 - "A" = ..... mm
smax = 156.5 - "A" = ..... mm
(134).
[LOK 99: Install a new O-ring (11) in the groove of the bearing stud and mount the bearing
stud along with the mounted shaft (140). The brake disks (120) are still fixed in their
original position by the activated parking brake. By slightly turning the shaft (140) the teeth
of the spline have to find the gaps of the internal spline in brake disks, shifting sleeve (56)
and differential gear (15).]
(179).
[LOK 99: The drive shaft (140) in the bogie axle without BB gear can be disassembled just
by removing the bearing stud (8), also see detailed description for exchanging the bogie
input gear (6) in Chapter 6.4.4.]
Repair Instruction,


Assembly:
Repair Instruction,
and remove the bearing stud along with the mounted gear (6). [LOK 99: For disassembly

hex bolts (124).

After loosening of the hex bolts (22), the tin cover (21) can be removed. Turn in a puller
into the M12 thread on the face of the stud (18) and pull it out.
Apply a new O-ring (19) into the groove of the stud. Clean planar faces and apply new
liquid gasket (for ex. Loctite 518) between the cover (21). Insert it into the hole of the
bogie housing (31), gear (23) and spacer ring (16) and secure with new adhhesive coated
hex bolts (22).

studs (18) of a wheel side per 7.1. The gears (23) can now be removed through the large
central opening of the bogie housing. The spacer rings (16) can be pulled out through their
respective hole (∅ ≈71mm).
Needle bearing rings (24) and O-ring (19) can now be exchanged. Note, there are butting
covers (17) as buffer discs, between gears and bolts integrated. When disassembled,
insert the butting covers (17) again. Insert the new needle bearing rings (24) into the gears
(23) and set on the butting covers (17). The new gears (23) are inserted through the large
opening (dia. approx. 200) into the tandem housing beginning with outer most gear and
assembled as per 7.1.




dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
• In the case of axial play or less pretension reduce the thickness of the adjusting
washer, in the case of too high pretension of the bearings increase the thickness of
the adjusting washer and repeat this procedure. For every step again cover the
centering ring with antiscoring paste, but take care that no paste reaches the
threads! If you found the suitable washer, for the final assembly lock the grooved nut
with Loctite 639.
• Again unscrew the grooved nut (52) and with a steel brush clean the threads of nut
and shaft from any rests of hardened glue and from grease, dirt, oil, and corrosion
inhibitors
• Again rup in face "∆" of centering sleeve (50) with special antiscoring paste "Klüber
Wolfracote SSP". (do not apply any to nut (52) and place the selected washer (51).
• Now coat the whole circumference and length of threads of shaft (34) and nut (52)
with Loctite 639, and tighten the nut with 2000 +100 Nm torque use WZ 082. The
resulting frictional torque of the wheel bearings (incl. the face seal) should be
between 20 and 35 Nm.
• Insert splines of pinion shaft (43) into the profile of gear (30) and apply grease
excessively to the rollers of bearing (41/42) on the bearing outer ring.
• Check that all 8 dowel pins (47) sit closely in their boring in the bogie housing. Clean
planar faces and apply new liquid flange sealant on to the clean flange surface side
of partal housing.
• Apply grease excessively to the rollers of bearing (42) in the bogie housing to make
sure that all rollers are in contact with their outer raceway.
• Then mount the housing (33) together with the pinion shaft (43) to the bogie housing
(31). Screw in new adhesive coated hex bolts (46) and 2 Allen bolts (57) and tighten
crosswise in two stages, at first with a torque of 100 Nm, and finally with a torque of
310 Nm (280 Nm for Allen bolts without coating).
• Finally install the original cover (25) with a new gasket (32) at the rear of the bogie
housing and tighten with lock washers (27) and hex bolts (26).

Insert punch WZ 213

(short distance)
Partnumber for Differential Section (Drawing no. R1020-112)

11. Diff.-cage
16. Cross bolt
17. Bushing
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -
59. -
102. Left Axle beam
Partnumber for Axle Housing Section (Drawing no. 00.92500.044.0)
101 Right Axle beam 131 Screw planetary cage

102 Left Axle beam 132 HV washer to 131
103 Axle beam screw 133 Shear pin planetary cage
104 Axle beam screw 134 Intermediate shims BB-Gear
105 HE-S ring 135 BB planetary stud
106 Dowel pin Axle beam (Lock side) 136 BB planetary gear
107 Dowel pin Axle beam (Crown gear side) 137 butting shim for planetary
108 Breather for bogie housing 138 Planetary bearing
109 Brake chocke 139 Butting shim planetary bearing
111 Operating brake cylinder complete 141 Bearing pin in the drive shaft
129 Planetary cage, inner half
130 Planetary cage, outer half
Partnumber for Bogie Housing Section
(Drawing no R 00.92500.116.0)
2 BB gear rim 125 Allen screw slewing-ring below
3 Allen screw BB gear rim 126 Allen screw slewing-ring above
4 Dowel pin BB gear rim 127 HV washer for 126
6 BB-sun gear 150 Cover
7 Pendulum roller bearing for BB-sun gear 177 Wearing plate
8 Tandem housing – middle bearing bolt 178 Allen screw for 177
12 Bearing pin BB-sun gear
14 Seeger supporting washer in BB-sun gear
15 Washer in BB-sun gear
17 Butting cover for gear wheel 23
20 *
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
48 Guide bushing for pinion shaft
49 Portalgear
52 Groove nut for wheel bearing
56 Stub axle ring
58 VSK ring to 57
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 117
Type: LOK 117 Portal Bogie Axle

Used in Timberjack Forwarder 1110D
Date: August 02, 2002
Contents Page
2. 2. Tightening Torques for Bolts and Nuts .................................................................................. 2
3. Differential.................................................................................................................................. 5
7. Gear Drive Inside the Bogie Housing ...................................................................................... 27
7.1. Exchange of the Studs ............................................................................................ 27
7.2. Exchange of the Gears and Needle bearings ......................................................... 27
8.1. Disassembly of the Portal Gear, Drive Pinion and Pinion Shaft.............................. 28
8.2. Exchange of the Slide ring ...................................................................................... 28
8.3. Exchange of the Wheel Bearings............................................................................ 28
8.4. Reassembly of the Portal Drive and Adjustment of the Wheel Bearings ................ 29
8.5. Exchange of Gear (30) the Sperical Roller Bearing (29)......................................... 31
Drawings: Installation drawing / Lubrication Plan PTA 5500.113, Assembly drawings R 1020-112,
00.92500.044.0, 00.92500.021.0,
Date: August 02, 2002 page II
according to the table of permitted lubricants lubricants until
the mark of dipstik (41) is reached. Close oil filler- and oil
control- plug with copper seal ring and tighten with 90
Nm torque.
Bogie housings:
with 55 Nm.
white plastic caps.
Date: August 02, 2002 page III
retightened.
oil control plug (41), oil filler plug (40) and surrounding
areas of any dirt. Then remove filler plug, open oil drain
plug at the differential and drain oil completely into a
suitable basin (approx. 12 L). Clean the magnetic inset of
the oil drain plug from any metal wear. Screw in the oil
drain plug (42) with new copper seal ring and tighten with
90 Nm torque. Add approx. 12 L oil according to the table of
permitted lubricants until the mark of dipstik (41) is reached.
Close oil filler- and oil control- plug with copper seal ring
and tighten with 90 Nm torque.
(61) with 55 Nm.
Date: August 02, 2002 page IV
After every 250 operating Clean the area around the lubricator nipples (90, 10 at each
After every 500 operating Check oil levels in differential (oil dip stick 41) and in both
Table of Lubricants
Date: August 02, 2000 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: August 02, 2002 page 1
1.7. The following repair instructions are based on the bogie axle LOK 117 which has a
bogie.
.
Figures: R1020-112, 00.92500.044.0, 00.92500.021.0

1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 hex bolt M16x40 10.9 VP 1010.534 310 Nm
22 Allen M12x80 10.9 VP 1020.374 125 Nm
39 plug R ¾ 1040.151 70 Nm
103 hex bolt M18x2x70 10.9 1010.662 400 Nm
104 hex bolt M18x2x80 10.9 1010.639 400 Nm

Figures: R1020-112, 00.92500.044.0, 00.92500.021.0

Fig. no. 00.92500.044.0 (LOK 117 with BB)
103 hex bolt M18x2x70 10.9 1010.662 400 Nm
104 hex bolt M18x2x80 10.9 1010.639 400 Nm
115 Allen bolt M10x45 8.8 1020.208 45 Nm
131 hex bolt M12x100 10.9 VP 1010.323 115 Nm
143 plug R ½" 1040.125 55 Nm

Figures: R1020-112, 00.92500.044.0, 00.92500.021.0
2.3. Bogie Housing,

Fig. no. 00.92500.021.0 (LOK 117 with BB)
10 hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 hex bolt M10x25 10.9 VP 1010.201 72 Nm
46 hex bolt M12x50 10.9 VP 1010.326 115 Nm
52 hex. nut M40x1.5 7316.048 see Chapter 8.4.
54 plug M30x1.5 1040.103 105 Nm
125 allen bolt M18x2x70 10.9 VP 1020.216 400 Nm

Figure: R 1020-112
3. Differential
bolt as per 5.3.

Chapter 3.1.1.
Figure: R 1020-112
Fig.2: Determining the dimension se to adjust Le will be approximately 82.73 mm.
se = 178.8 - Le - L1 [mm] (as experience shows use a thickness near 2.00 to 3.00)
Figure: R 1020-112
thickness of the washer (45) for adjustment of the contact pattern, see Chapter 3.2.2.1.)
5 Nm.
Figure: R 1020-112

spacer sleeve (47) and an adjusting
washer set (44) with a total thickness
of
max. (Lq + 0.03 mm)
sleeve and washer and, still without O-
ring and shaft seals, tighten the hex
Figure: R 1020-112
Figure: R 1020-112
Figure: R 1020-112

Disassembly
Assembly
Figure: R 1020-112



necessary.
between seals (88 and 87) with grease, install new O-ring (49), and shift the cardan flange
(51) onto the spline of the shaft. Now cover the threads of shaft and nut with Loctite 639.
The applying and tightening of the nut must not take any longer than 3-5 minutes to avoid
any hardening of the adhesive. The nut cannot be applied using an impact wrench since
this will promote early hardening and the adhesive will be spun off the threads. Tighten the
nut with 800 Nm torque.
Figure: R 1020-112

and remove the differential flange (6) and remove differential cage (11) along with
mounted crown gear. Loosen the hex nut (30) at the shifting rod (26), counter the
loosening torque at the opposite end of the shifting rod. The nut is locked with Loctite,
therefore preheating it to 120°-160°C with a blow lamp is recommended.
Unscrew the cylinder (32, wrench size 46) from the differential housing (42). Before
assembly the new cylinder clean the threads from any oil or old adhesive and cover its
with Loctite 542 (alternatively OKS-paste or any other fluid thread sealing). Screw in the
cylinder with a new copper seal ring (34) and tighten with 90 Nm. After mounting the
cylinder there must not be any hydraulic pressure for 6-8 hours until the fluid sealing
becomes fully effective.
differential flanges (6) shifting fork (27)
Figure: R 1020-112
spring (28), and adjusting washers (29), against the diff.-housing (42) and with a depth
gauge measure dimension "X" (theoretical dimension 29 mm), see Fig. 7.
completely meshed, and then measure dimension "Y" (theoretical dimension 27 mm).
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: R 1020-112
Install diff. cage (11) with crown gear. Snap a new O-ring (7) onto the step of the flange (6)
and install the complete flange to the differential housing. Fasten with 2 Allen bolts (4) and
finish assembly of the complete axle as described in Chapter 3.1.2.

cylinder.


completly removed.


cylinders!
Disassembly:
Assembly:
bolts (113).
Disassembly:
Assembly:
Disassembly:
renewed.
Assembly:
assemble all parts of the cylinder lower part (162). Continue assembly as per 5.4.2 and
5.4.1.

Disassembly:
exchanged.
Assembly
activation disks.
ramp disks (118).
necessary.
Repair Instruction,
00.92500.021.0

this the balance planetary drive will remain in the axle beam (101/102) and can now be
taken out as a complete subassembly [LOK 75].

Repair Instruction,
00.92500.021.0
smin = 131.5 - "A" = ..... mm
smax = 132.5 - "A" = ..... mm

(179).
Repair Instruction,
00.92500.021.0

Assembly:
Repair Instruction,
00.92500.021.0


hex bolts (124).

the cover (21). Insert it into the hole of the bogie housing (31), gear (23) and spacer ring
(16). The stud is to be turned and orientated such that split taper sleeve (17) interlocks
with the groove of stud (18) and secure with new adhhesive coated hex bolts (22).

First remove the complete bogie housing (31) as per 6.1. Then remove the inner or both
central opening (∅ ≈200mm) of the bogie housing. The spacer rings (16) can be pulled
out through their respective hole (∅ ≈71mm).
Needle bearing ring (24) and O-ring (19) can now be exchanged. Insert the new needle
bearing rings (24) into the gears (23). The new gears (23) are inserted through the large
chamfer of the inner diameter of every spacer ring is orientated facing outward of 71 mm
diameter hole.

Loosen the hex bolts (46, 45), and remove the complete housing (33). Pull out pinion shaft
(43) including cylinder roller bearing inner rings (41) and (42) from the bogie housing (31).
Extract the bearing outer ring of the roller bearing (41) from the housing (33) and bearing
outer ring of the roller bearing (42) from the bogie housing (31).
Loosen the nut (52) while countering against the flange of the output shaft (34). The nut is
locked with Loctite, therefore the loosening torque can be as high as 1500 Nm! It will be
necessary to preheat the nut to about 150° celsius. Remove the gear (49) including
centering sleeve (50) from the output shaft (34) and extract the centering sleeve (50) and
bearing inner ring (36) from the gear (49).
8.2. Exchange of the Slide ring

housing (33). Now both halves of the slide ring (37) can be exchanged with useing the
installer tool (WZ 049). Finish the assembly as per 8.4. If nothing else than the slide ring
will be exchanged during this repair work, a new adjustment of the wheel bearings is not
necessary, provided the same set of adjusting washers (51) is used.

Set the portal gear (49) onto the spline end of the output shaft (34), its teeth meshing with
those of the pinion (43). For an adjustment of the wheel bearings the thickness of the
adjusting washer (51) has to be determined as follows, see the bogie assembly drawing or
Fig.10:

• Press on new bearing inner ring (36) onto new gear (40), press in centering sleeve
(50) and together slide onto output shaft (34).
• Rup in face "∆" of centering sleeve (50) with special paste "Klüber Wolfracote SSP".
• Apply nut (52) onto output shaft (34) and tighten untill a bearing turning torque of 20
to 22 Nm (including seal (37)) is reached. For this the rollers of the wheel bearing are
to be seated and orientated by tapping against housing (33) and gear (49), ie. By
turning the output shaft (34) 1 to 2 turns.
• Measure dimension "X2", theoretical value 24 ± 2.0 mm.
• Select a washer package (51) with thickness "d"

max. thickness dmax = X1 - X2 = ........mm
min. thickness dmin = X1 - X2 - 0.15mm = ........mm
The washers are available with a thickness of 1.25 - 3.5 mm, step 0.125 mm.
• Again unscrew the nut (52) and with a steel brush clean the threads of nut and shaft
from any rests of hardened glue and from grease or dirt.
• The threads of the nut and outputahft must be free of any dirt, oil, and corrosion
inhibitors. Now coat the whole circumference and length of threads of shaft (34) and
nut (52) with Loctite 639, and tighten the nut with 800 +100 Nm torque. The resulting
frictional torque of the wheel bearings (incl. the face seal) should be between 20 and
35 Nm.
Insert splines of pinion shaft (43) into the profile of gear (30) and apply grease excessively
to the rollers of bearing (41/42) on the bearing outer ring. Check that all 7 dowel pins (47)
sit closely in their boring in the bogie housing and install a new gasket (48).
Then mount the housing (33) to the bogie housing (31). Screw in new adhesive coated
hex bolts (45/46) and tighten crosswise in two stages, at first with a torque of 60 Nm, and
finally with a torque of 115 Nm.
and tighten hex bolts (26) + lock washers (27).

hex bolts (26).

Insert punch WZ 213
drive shaft flange
(short distance)
Partnumber for Diff. (Drawing no. R 1020-112) 101. Right Axle beam
102. Left Axle beam
105. –
106. Dowel pin Axle beam (Look side)
107. Dowel pin Axle beam (Crown gear side)
108. Drive shaft
11. Diff.-cage
16. Cross bolt
17. Bushing
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -

Partnumber for bogie housing ( drw.no 00.92500.021) 123 Grease nipple ( radial at this turning-ring
coupling )
1 Oil seal turning-ring coupling on the outside 125 Allen screw turning-ring coupling below
2 2 BB gear rim 126 Allen screw turning-ring coupling above
3 Allen screw BB gear rim 127 HV washer for 126
4 Dowel pin BB gear rim 128 Dowel pin for turning-ring coupling
5 Washer for 22 172 Slewing ring
6 BB-sun gear 179 White plug
7 Cylinder roller bearings for BB-sun gear
8 Tandem housing – middle bearing bolt
9 Plane gasket for middle bearing bolt 8
12 Bearing pin BB sun
14 Oil plug
15 Oil seal ring to 14
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
49 Portalgear
52 Hex. nut for wheel bearing
56 Stub axle ring

115 Allen screw for parking brake cylinder 145 -
116 O-ring among parking brake cylinder 146 -
117 Parking brake cylinder complete 147 -
119 On the outside-brake disk 149 -
122 Locking bolt for brake disk 172 Slewing ring
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 118
Type: LOK 118

Rear axle Timberjack Forwarder 1410D
Date: September 25,2002
Contents Page
3. Differential.................................................................................................................................. 5
Assembly drawings R 00.75000.391.0, 00.92500.044.0, 00.92500.045.0,
Assembly Device / Special Tools Sk 2.94-213; Sk 4.94-1029
Date: September 25,2002 page II
Bogie housings:
with 55 Nm.
At all 10 grease nipples (90, with 10 per side and with white
plastic cap) grease with grease gun until the gap has
Date: September 25,2002 page III
repair instruction. The center nut (hex nut wrench size 50)
of the input cardan flange with adhesive locking must not
be retightened.
(61) with 55 Nm.
Date: September 25,2002 page IV
Table of Lubricants
Date: September 25,2002 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: September 25,2002 page 1
reach its proper holding potential. If no adhesive coated bolts or nuts are available then
the old ones can be used if they are secured with Loctite 243 (or other fluid bolt locking
of medium strength) provided the instructions printed on the label are properly
followed.
bogie.
this manual.
Figures: 00.75000.391.0, 00.92500.044.0, 00.92500.045.0

2.1. Differential Section, Fig. no. R 00.75000.391.0
1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x20 8.8 1020.212 49 Nm
9 Hex bolt M16x1,5x40 10.9 VP 7322.066 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
25 Grooved nut M158x1,5 7329.012 see Chapter 3.2.3.
50 Hex nut M40x1.5 7329.057 800 Nm
54 Plug M30x1,5 1040.103 90 Nm
103 Hex bolt M18x2x80 10.9 1010.639 400 Nm

Figures: 00.75000.391.0, 00.92500.044.0, 00.92500.045.0

Fig. no. 00.92500.044.0 (LOK 118 with BB)
103 Hex bolt M18x2x80 10.9 1010.639 400 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 Hex bolt M18x2x100 10.9 VP 1010.631 400 Nm
131 Hex bolt M16x120 10.9 VP 1510.550 290 Nm
143 Plug R ¾ " 1040.151 90 Nm
147 Reducer fitting R ¾ " 7322.064 90 Nm
148 Breather R½ " tapered 9556.030 75 Nm
149 Reducing plug R ¾ " x R½ " (tap.)1750.705 100 Nm

Figures: 00.75000.391.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 118 with BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.201 72 Nm
46 Hex bolt M16x65 10.9 VP 1010.535 310 Nm
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x50 10.9 1020.509 280 Nm
178 Allen bolt M16x50 10.9 1020.518 280 Nm

Figure: 00.75000.3910.0
3. Differential
new O-rings (5) onto the steps of the differential flanges (6, 36). Note that all dowel pins
(2x106) properly sit in their bores in the differential. Attach the complete axle beam and
bogie housing to the differential. When shifting the spline end of the shaft (140) into the
differential gear (15) assist by rotating the cardan flange to and fro. Fasten the axle beam
to the differential with hex bolts (103) and washers (105).
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.3910.0
screw out the groove nut (25). With a soft arbor hit the outer rings of the bearings out of
the flanges, and pull the inner rings from the differential cage.
(46,038mm) from the outer ring of the
taper roller bearing + Lr (64,9mm) to the
face of the pinion. To avoid mistakes,
the jaw length of the caliper gauge must
be at least 120 mm. The dimension L1 +
Lr may vary near 110.938mm.
Fig.2: Determining the dimension se to adjust - Record the mounting distance L which
e
the contact pattern of the hypoid gearing can be read from the face of the pinion.
se = 198.5 - Le - Lr - L1 [mm]
Figure: 00.75000.3910.0
available with a thickness between 2.5; 2.75 and 3.0 mm, step 0.25. Insert the selected
outer ring of bearing (48) from the outside of the differential housing. Then is necessary to
adjust the bearings of the bevel pinion.
to three adjusting washers with a total width of (se + 40.35) mm for now and slide them
onto the shaft of the pinion. (se is the thickness of the washer (45) for adjustment of the
contact pattern, see Chapter 3.2.2.1.) Insert this unit into the differential housing and hold
in place from the inside. Install the inner ring of bearing (48) and the cardan flange (51)
onto the pinion shaft, for the time being without O-ring and shaft seals. Apply and tighten
hex nut (50) with 800 Nm torque. During tightening the nut, with a hammer tap against the
housing of where the bearings are located in order to properly align the taper rollers. Also
tap against the outer face of the pinion shaft with a brass mandril while turning the pinion
back and forth. Inspect the bearing preload; if required through the use of a thinner
adjusting washer (44) the proper bearing preload is to be adjusted.
1.5 Nm.
seals (87) into the Cover (57) and fill 50% of the volume between both seals with grease.
It should be noted that the seals are installed in the correct illustrated orientation. Install a
new O-ring (58) and set on the cover and fix it with hex. screws (52). Clean the threads of
shaft and nut from dirt or grease, then shift the cardan flange (51) onto the spline of the
shaft. Cover the threads of pinion shaft and nut (50) on their whole length and
circumference with Loctite 639. The applying and tightening of the nut must not take any
longer than 3-5 minutes to avoid any hardening of the adhesive. The nut cannot be
applied using an impact wrench since this will promote early hardening and the adhesive
will be spun off the threads. Tighten the nut with 800 Nm torque.
Figure: 00.75000.3910.0

flanges (6, 36) and set in the original adjusting washer (3) under the inner ring (8), then
screw in the groove nut (25) to their previously recorded position.
additional bolts M18x2x40 per side to fix the flanges (6, 36) solidly. Now the backlash
must get a value of 0.15 to - 0.25 mm between the teeth of bevel pinion and crown wheel.
If measured at the hole circle of the drive shaft flange (∅ ≈127 mm) also this dimension is
0.15 to 0.25 mm.
If the proper backlash is attained, adjust the preload of the crown wheel bearings (8) and
(24). For this adjust groove nut (25) by putting an arbor into one of the grooves and hitting
with a hammer, until the desired bearing friction torque of 1.0 to 3.0 Nm is reached. This
can be measured with a torque gauge at the drive shaft flange by adding a value of 0.5
Nm to 1.5 Nm to the torque determined in Chapter 3.2.2.2 or 3.2.2.3 (bearing friction
torque).
be moved by change the thickness of adjusting washer (45), i.e. the complete procedure
Figure: 00.75000.3910.0
and when turning groove nut (25) ensure proper backlash. The diff. cage can be moved by
change the thickness of adjusting washer (3). Always remove old paint from ring gear
when rechecking.

groove nut (25) has to be secured with locking plate (2) and new adhesive coated hex bolt
(1). Remove the additional hex bolts M18x2x40 which fixed the differential flanges.
Figure: 00.75000.3910.0

Disassembly
Assembly



mended. Loosen the nut (wrench size 50) and pull the cardan flange from the spline end
of the pinion shaft. Now, both radial shaft seals (87) can be pulled out. It is also
Figure: 00.75000.3910.0
necessary.
and clean from any dirt and grease. Install new shaft seals with WZ 213, note that the lips
of the seals are installed in the proper orientation as shown. Fill 50% of the volume
with 800 Nm torque.

recommended.
removed out of its groove in the piston with a sharp tool. Inspect piston and cylinder for
any marks of wear and replace if necessary. Snap a new seal ring into the groove, the
seal lips facing the short end of the piston. The additional piston sealing (35) must install
with special assembly tool no. WZ 509, because the piston sealing (35) is two-piece and
this piston sealing (35) must calibrate with special tool no. WZ 509. Insert the piston into
Figure: 00.75000.3910.0

Figure: 00.75000.3910.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.3910.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
axle beam with hex bolts (103). When doing
per 5.2.
necessary.
Repair Instruction,


Repair Instruction,
smin = 155.5 - "A" = ..... mm
smax = 156.5 - "A" = ..... mm

(6).

Repair Instruction,

Assembly:
Repair Instruction,


hex bolts (124).


as per 7.1.




dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
with Loctite 639.

hex bolts (26).
Insert punch WZ 213

(short distance)
Installer ring WZ 049

3. Adjusting washer Crown gear side
7. O-ring Diff.-housing / Diff.-flange
11. Diff.-cage
16. Cross bolt
17. -
23. Seeger supporting plate Diff.-cage
37. -
38. -
39. -
41. -
42. Diff.-housing
46. Cover
52. Hex. screw drive shaft cover
53. Locking washer to hex screw
55. Seal ring to oil drain plug
57. Drive shaft cover
58. O-ring Drive shaft cover
59. –
106. Dowel pin Axle beam

SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 121
Type: LOK 121

Rear axle Timberjack Harvester 1470D
Date: 27 September 2002
Contents Page
2. Tightening Torques for Bolts and Nuts ...................................................................................... 2
3. Differential.................................................................................................................................. 5
00.92500.044.0, 00.92500.066.0, Assembly Device / Special Tools Sk 4.96-1019
Date: 27 September 2002 page II
Bogie housings:
centre cover). Add approx. 67.5 L oil as per lubrication
chart until the oil starts overflowing from the control plug
(61). Tighten the fill plug (60) with 90 Nm, the control plug
(61) with 55 Nm.
white plastic caps.
Date: 27 September 2002 page III
retightened.
drain into a container. Close the drain plugs (62) with new
copper seal rings and tighten with 90 Nm torque, the plug
with magnetic inset at the lower position. Add oil as per
lubrication chart into the fill plug (60) until the oil starts
overflowing from the control plug (61). Tighten the fill plug
(60) with 90 Nm, the control plug (61) with 55 Nm.
Date: 27 September 2002 page IV
Table of Lubricants
Date: 27 September 2002 page V
e.g.
ARAL Degol 3216

BP Energear LS 90 brakes and 67.5 ltr. for each
bogie housing of LOK 121; the
DEA Deagear LS SAE 85W-90 actual quantity has to be
Dearon BHS SAE 90 checked by the control mark of
the dipstick or by control plugs.
Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: 27 September 2002 page 1
bogie.
.
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x20 8.8 1020.212 49 Nm
9 hex bolt M16x1,5x40 10.9 VP 7322.066 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
39 plug R ¾
" 1040.103 90 Nm
103 hex bolt M20x2x90 10.9 1010.668 560 Nm
104 allen bolt M20x2x90 10.9 1010.620 500 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

Fig. no. 00.92500.044.0 (LOK 121 with BB)
103 hex bolt M20x2x90 10.9 1010.668 560 Nm
104 allen bolt M20x2x90 10.9 1010.620 500 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 hex bolt M20x2x90 10.9 VP 1010.669 500 Nm
131 hex bolt M20x2x130 10.9 VP 1510.507 560 Nm
143 plug G ¾
" 1040.151 90 Nm
147 reducer fitting R ¾

" 7322.074 90 Nm
148 breather G½
" tapered 9556.030 75 Nm
149 reducer fitting G ¾

" x G½
" (tap.) 1750.705 100 Nm
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 121 with BB)
10 hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 hex bolt M10x25 10.9 VP 1010.234 72 Nm
46 hex bolt M16x60 10.9 VP 1010.544 310 Nm
52 grooved nut M85x2 7329.036 see Chapter 8.4.
54 plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
160 hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x70 10.9 1020.512 280 Nm

Figure: 00.75000.260.0
3. Differential
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
se = 202 - Le - L1 [mm] (as experience shows use a thickness near 2.5 or 2.6)
Figure: 00.75000.260.0
The first spacer sleeve (46) has a fix measurement of 20.9 mm. The second spacer
sleeve (47) is available with a width of 11.3 mm; 11.78 mm and 12.26 mm, the adjusting
width of (near 34 mm ) for now and slide them onto the shaft of the pinion. Insert this unit
required through the use of different spacer sleeves (47) and/or adjusting washers (44)
the proper bearing preload is to be adjusted.
5 Nm.
Figure: 00.75000.260.0

additional bolts M18x2x40 per side to fix the flanges (6, 36) solidly. Now turn in the groove
nut (3) to get a backlash of 0.15 to - 0.25 mm between the teeth of bevel pinion and crown
wheel. If measured at the hole circle of the drive shaft flange (∅ ≈127 mm) also this
dimension is 0.15 to 0.25 mm.
Figure: 00.75000.260.0
Figure: 00.75000.260.0

Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
piston.
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
pin (122) but rather into the clutches of the ball ramp disks (118).
this the splines of the drive shaft (140) are
Fig.8: Multiple Disk Brake Attach the brake cylinder as per 5.4.2. and
5.4.1. and adjust the air gap of the brake as per
5.2.
necessary.
Repair Instruction,
00.92500.066.0


Repair Instruction,
00.92500.066.0
smin = 172.5 - "A" = ..... mm
smax = 173.5 - "A" = ..... mm


(179).
Repair Instruction,
00.92500.066.0

Assembly:
Repair Instruction,
00.92500.066.0


hex bolts (124).


as per 7.1.

and use WZ 082. The nut is locked with Loctite, therefore the loosening torque can be as
high as 1500 Nm! It will be necessary to preheat the nut to about 150°C. Remove the gear
(49) from the output shaft (34) and disassemble the drive pinion (153). Both of them now
easily can be exchanged, as well as the roller bearings (41, 42) of the pinion shaft.

housing (33). Now both halves of the face seal (37) can be exchanged (use Installer ring
WZ 234). Finish the assembly as per 8.4. If nothing else than the face seal will be
exchanged during this repair work, a new adjustment of the wheel bearings is not


using Loctite tighten the grooved nut (52) with WZ 082 until the wheel bearings reach
a frictional torque of 20-22 Nm (including the face seal). During tightening the nut
with a hammer continuously hit the housing and the gear where the bearings are
situated and turn the output shaft to be sure that the taper rollers are properly
aligned. Then measure dimension "X2", theoretical value 20±1.4 mm.

dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
circumference, and tighten the nut with 2000 Nm torque use WZ 082. The resulting
35 Nm.

Insert punch WZ 199

(short distance)

11. Diff.-cage
16. Cross bolt
17. -
23. -
37. -
38. -
41. -
42. Diff.-housing
53. -
57. -
58. -
59. -
Partnumber for bogie housing ( drw.no 00.92500.066)
1 Oil seal turning-ring coupling on the outside 58 VSK ring to 57

2 2 BB gear rim 59 oil fill plug for bogie housing
3 Allen screw BB gear rim 60 Cover
4 Dowel pin BB gear rim 62 Oil drain plug bogie housing without magnet
5 Washer for 22 123 Grease nipple ( radial at this turning-ring
6 BB-sun gear coupling )
7 Cylinder roller bearings for BB-sun gear 125 Allen screw turning-ring coupling below
8 Tandem housing – middle bearing bolt 126 Allen screw turning-ring coupling above
9 Plane gasket for middle bearing bolt 8 127 HV washer for 126
10 Screw Tandem middle bearing bolt 128 Dowel pin for turning-ring coupling
11 O-ring tandem middle bearing bolt 150 Cover
12 Bearing pin BB sun 151 Circlip ring
13 Circlip in cylinder roller bearing 7 only in new 152 Guide ring
14 Allen screw 153 Drive pinion
15 Axial oil seal ring to 7 154 Circlip ring
16 Centering sleeve for intermediate gear bolt 18 155 Centering sleeve
17 Cocking bolt for Centering sleeve 16 156 Circlip ring
18 Interim gear bolt 157 Circlip ring
19 O-ring intermediate gear bolt 158 Cover
20 Plane gasket for sheet-metal cover 21 159 Allen screw for 158
21 Sheet-metal cover 160 Hex bolt
22 Screws for sheet-metal cover 161 Washer
23 Bogie housing intermediate gear wheel 162 Wearing plate
24 Needle bearing for intermediate gear wheel 23 177 Wearing plate
25 Portal pinion cover 178 Allen screw for 177
26 Screws for cover 25 179 White plug
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
44
45 HV washer for 46
49 Portalgear
53
54
56 Stub axle ring

SERVICE AND REPAIR MANUAL
Type : LOK 124/0 Transfer Case in TJ 1010D Forwarder
Name : VG 35-594
Valid as of Serial No. : 01
Date : 15.07.2002
TABLE OF CONTENTS
1 GENERAL AND MAINTENACE 2
1.1 Introduction 2
1.2 Spare Parts Ordering 2
1.4 Work Conditions and Tools 3
1.5 Maintenance 3
1.5.1 Lubrication Table 3
1.5.2 Maintenance Intervals 4
2 REPAIR MANUAL 8
2.1 Exchange of Seals 8

2.1.1 Exchange of Output Flange Seals to front Axle 8
2.1.2 Exchange of Output Flange Seals to rear Axle 8
2.2 All Wheel Drive Release Shifter 9

2.2.1 Exchange of Tapered Roller Bearing (No.7 & 27) 10
2.2.2 Exchange of Tapered Roller Bearing (No.1) 12
2.2.3 Exchange of Gaskets 12
2.2.4 Exchange of Output Shaft 13
2.2.5 Exchange of Shifting Sleeve 13
2.2.6 Exchange of Compression Springs 13
2.3 Transmission 14
2.3.1 Exchange of Input Pinion (3) and Bearing (1) 14
2.3.2 Exchange of Gear Block (23) and Bearings 15
2.3.3 Exchange of Gear (29) and Bearings (27, 30) 16
2.3.4 Exchange of Shaft (36), Gear (33) and Bearings (32, 35) 17
2.3.5 Exchange of Shifting Sleeve (31) 18
2.4 Shifting Cylinder 19

2.4.1 Exchange of Gaskets (49, 50, 51) 19
2.4.2 Exchange of Cylinder (52) 24
2.4.3 Exchange of Shifting Rod (43) and Shifting Fork (42) 25
1
Name : VG 35-594
Date : 15.07.2002
1 GENERAL AND MAINTENACE

1.1 Introduction
Series production of the LOK 124 Transfer Case began in April 2002 This model contains
two speed gears which are engaged hydraulically. The main power input is via connection
fitting a Hydromotor AA6VM 160. The output for the front axle is via a Mechanics 7c-
Flange and is permanent. The output for the rear axle is also via a Mechanics 7c-Flange,
but can be turned off (all wheel drive shift).
The rear axle drive can be turned off during motion and under power.
The turning on of the rear axle drive is also possible while in motion and under power, but
not if the wheels are spinning.
The all wheel drive shift is hydraulic.
1.2 Spare Parts Ordering
Spare parts for this NAF Transfer Case are best ordered directly from an official
TIMBERJACK Distributor, since usually most required parts can be delivered directly
from storage. Even if the parts are not in stock it is still recommended to order the parts
from the distributor and not the factory. Distributors can usually describe the required parts
in greater detail and supply the required part number more precisely to avoid
misunderstandings and wrong part deliveries. For any spare parts order provide the full and
exact type with factory number and year built. The location of the name plate is on the
housing half in the vicinity of the oil fill plug. (See Figure 1).
Only use original NAF spare parts. Use of parts from other manufacturers voids any
guarantees and can limit functionality and product life.
Figure 1
2
Name : VG 35-594
Date : 15.07.2002
1.3 Parts Liability and Guarantees for safety related components

components such as ( control cylinders, steering cylinders, brake cylinders, spring housing
cylinders, etc. ).
Once a safety related component has been disassembled or opened, all guarantees and
liabilities will be void and therefore NAF will not assume product liability for the drive
unit. This also applies, even if the complete drive unit is still under guarantee.
1.4 Work Conditions and Tools
For a proper repair a clean and well lit workplace is required. Enough room should also be
available in order to lay out and sort various parts and assemblies.
Also a proper and complete array of quality tools which constitute a basic set is required. In
addition to this, various special tools and measuring instruments are required, most of the
time a proper set of tools are essential especially if one is performing the repair often. Grief
and anger are easily avoided this way. The special tools are described in more detail in the
appropriate sections, i.e. marked (ex. with WZ. no.).
Also a basic understanding and for certain repairs even a special training is reguired.
1.5 Maintenance
1.5.1 Lubrication Table
Lubrication Table for LOK 124 / 0
Lubrication Point No. Fill Volume Lubricant

Transfer- Case 60/61/62 4,5 Litre SAE 80 (API GL 4 res. MIL-L-2105 )
Description of Lubrication Points:
No.: 60 ⇒ Oil Fill Plug
No.: 61 ⇒ Oil Dip Stick
No.: 62 ⇒ Oil Drain Plug with magnet
(also see Figure 2)
Examples of Name Brand EP-Transmission Oils SAE 90 per specifications API-GL 4 i.e. MIL-L-2105B
Texaco / DEA (Geartex EP-A SAE 80W)

Mobil (Mobilube GX 80-A)
Shell (HSG 80W-90)
BP (Gear Oil EP SAE 80 W)
ELF (Tranself EP SAE 80 W)
Please follow the instructions of the Lubrication Plan in regards to Fill Volume
3
Name : VG 35-594
Date : 15.07.2002
1.5.2 Maintenance Intervals

NAF Transfer cases are designed and manufactured based upon many years of experience
and understanding of the requirements of working machines. Trouble-free functioning and
continuous readiness can only be guaranteed if the Transfer case is properly cared for,
carefully handled, and is regularly maintained. Part of this includes the adherence of the
maintenance intervals, the use of the proper lubricants as per the lubrication chart and the
inspection of various important maintenance points.
Maintenance Intervals for LOK 124/0
Position Transfer Case various visible nuts and bolts
No. (60/61/62)
Op. Hours
0/ (start-up) 1
-250 (till) 2 4
500 (every) 3
2000 (every) 2
1 = First Time Fill (see Section 1.5.2.1)
2 = Oil Change (see Section 1.5.2.2)
3 = Oil Level Inspection (see Section 1.5.2.3)
4 = Inspection if required corrected (see Section 1.5.2.4)
Figure 2 Figure 3
4
Name : VG 35-594
Date : 15.07.2002
1.5.2.1 First Time Fill

Note: The Transfer case when delivered from NAF does not contain any oil.
Description: The transmission housing and shifting housing have separate oil reservoirs.
• Transfer Case
Remove oil fill plug (No.60) and add oil as per the lubrication chart until the upper mark of
the of the dip stick (No.61) is reached. Check level again after 5 minutes and if required
add more oil. Tightening torque of oil fill plug (No.60) is 53 Nm. (Figure 2)
1.5.2.2.Oil Change
• Transfer Case
Change oil while it is warm. For this clean drain plug (No.62), dip stick (No.61), screw plug
(No.60), and surrounding area thoroughly. Remove fill plug (No.60) and then drain plug
(No.62) and drain oil completely. Prior to installing drain plug (No.62) again check and if
required clean the magnet from any debris or chips. Tighten drain plug (No.62) and add oil
according to the Lubrication Chart until the top mark on the dip stick (No 61) is reached.
Tightening torque of the fill plug (No.60) and drain plug (No.62) is 53 Nm. (see Figures 2/3)
1.5.2.3 Oil Level Inspection
• Transfer Case
Proper oil level is at the top mark of dip stick (No.61), if required add oil. (see Figure 2)
1.5.2.4 Inspection
• various visible nuts and bolts
Due to stresses and vibrations exerted on the axle, it is possible for various bolts and nuts
to become loose. Timely tightening of these will prevent any leaks or other damage.
The glued nut for the drive shaft flange (pinion nut) must not be tightened.
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Name : VG 35-594
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Figure 4
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Name : VG 35-594
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1. Grooved ball bearing 43. - 85. Oil seal

2. Screw Plug 44. - 86. Oil seal
3. Driving pinion 45. Hex nut 87. Plug
4. Grooved ball bearing 46. Washer package 88. Screw Plug
5. Washer package 47. - 89. Seal ring
6. Snap ring 48. - 90. Screw stud
7. Shift fork 49. - 91. Breather
8. Hex bolt 50. - 92. Elbow
9. Washer 51. - 93. Plug
10. Spacer sleeve 52. Shift cylinder 94. Seal ring
11. Gasket 53. Allen screw 95. Seal ring
12. Dowel pin 54. Hex bolt 96. Locking washer
13. Hex bolt 55. Hex bolt 97. Locking washer
14. Locking washer 56. Hex bolt 98. Locking washer
15. Housing 57. Gasket 99. Dip stick
16. Housing 58. Housing 100. Shifting rod
17. Screw Plug 59. O-ring 101. Allen screw
18. Nilos ring 60. Quad ring 102. -
19. Shear pin 61. Support washer 103. -
20. Cylinder roller bearing 62. Quad ring 104. -
21. Nilos-ring 63. Support washer 105. -
22. Washer 64. Split spring pin 106. -
23. Gear block 65. Piston 107. -
24. Washer 66. Tapered-roller bearing 108. -
25. Cylinder roller bearing 67. Washer package 109. -
26. Washer package 68. Scraper ring 110. Seal ring
27. Grooved ball bearing 69. Shifting sleeve 111. Snap ring
28. Washer 70. Compression spring 112. -
29. Spur gear 71. Washer 113. -
30. Needle cage 72. Nut 114. Adjusting washer
31. Shifting sleeve 73. Snap ring 115. Spacer sleeve
32. Needle cage 74. Snap ring 116. Bushing
33. Spur gear 75. - 117. Hex bolt
34. Centric ring 76. Tapered-roller bearing 118. Fish plate
35. Cylinder roller bearing 77. Tapered-roller bearing 119. Pressure switch cpl.
36. Shaft 78. Washer
37. O-ring 79. -
38. Cardan flange 80. -
39. Hex. nut 81. Cardan flange
40. Oil seal 82. O-ring
41. Oil seal 83. Hex. nut
42. Shift lever 84. Output shaft
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2 Repair Manual
2.1 Exchange of Seals
Note: For this work the transmission does not need to be removed from the vehicle, if the
transfer case is easily accessible. (see Figure 4)
2.1.1 Exchange of Output Flange Seals to front Axle
• Loosen nut (No.39). For easier disassembly heat up to 100° C.
(The loosening torque can be as high as 800 Nm)
• Pull off cardan flange (No 38) and remove seals (No.40) and (No.41) with puller.
• Exchange O-ring (No.37) and install in pinion groove.
• Press into housing (No.16) new seals (No.40) and (No.41) and fill the volume between
bearing (No.35) and the lips of (No.40) and (No.41) with 50% long endurance grease.
• Press on cardan flange (No.38)
• Clean M40x1.5 thread of nut (No.39) and shaft (No.36) of dirt, oil and corrosion inhibitors.
• Coat both threads the entire length and circumference with Loctite 639.
• Thread nut (No.39) onto output pinion (No.36) and tighten with 800 Nm. The final
tightening torque must be reached within 2 to 5 minutes, in order for the Loctite to be fully
effective.
2.1.2 Exchange of Output Flange Seals to rear Axle
• Loosen nut (No.83) For easier disassembly heat up to 100° C.
(The loosening torque can be as high as 800 Nm).
• Pull off cardan flange (No.81) and remove seals (No.85) and (No.86) with puller.
• Exchange O-ring (No.82) and install in pinion groove.
the lips of (No.85) and (No.86) with 50% long endurance grease.
• Press on cardan flange (No.81).
• Clean M40x1.5 thread of nut (No.83) and shaft (No.84) of dirt, oil and corrosion
inhibitors.
• Thread nut (No.83) onto output shaft (No.84) and tighten with 800 Nm. The final
tightening torque must be reached within 2 to 5 minutes, in order for the Loctite to be
fully effective.
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Name : VG 35-594
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2.2 All Wheel Drive Release Shifter

Note: For this work the transmission does not to be removed from the vehicle, if the
transfer case is easily accessible.
Remove cardan shaft.
Drain oil completely (see Section 1.5.2.2).
Figure 5
Figure 6
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Name : VG 35-594
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2.2.1 Exchange of Tapered Roller Bearing (No.7 & 27)

(see Figure 4 / Figure 5 or Figure 6)
• Loosen hex nuts (No.12 & 26) and remove complete all wheel drive-release shifter.
Shifting sleeve (No.69 / Fig.4) and bearing inner ring (No.66 / Fig.4) remain in the
transmission.
• Loosen nut (No.19) For easier disassembly heat up to 100° C and counter by holding
against the profile of output shaft (No.6). (Loosen torque can be as high as 800 Nm)
• Pull of cardan flange (No. 18)
• Press out, output shaft (No.6) of housing (No.23) through the inside.
• Remove wiper ring (No.29).
• Press out bearing outer rings (No. 1 & 7) from housing (No.23).
• Pull off bearing inner ring (No.1) from output shaft (No.6).
• Press on new bearing inner ring (No.1) onto output shaft (No.6).
• Insert bearing outer rings (No. 1 & 7) into housing (No.23)
• Replace wiper ring (No.29).
• Replace O-ring (No.28) and install into pinion groove.
• Insert output shaft (No.6), from the inside, into housing (No.23) and install washer (No.8),
adjusting washers (No.9 / Fig.6) with spacer sleeve (No.10).
• Insert cardan flange (No,18) onto shaft splines.
• Thread nut (No.19) onto output shaft (No.6) with no Loctite and tighten with 400 -800 Nm
and noting previous alignment markings.
• Inspect the axial play of the output shaft against the face with a dial gauge (required value
0,05 - 0,15 mm / no bearing preload) and if required adjust by either adding or taking away
adjusting washers (No.9 / Fig.6).
• Clean threads of nut (No.19) and output shaft (No.6) of dirt, oil and corrosion in inhibitors.
• Coat both threads of the output shaft (No.6)and nut (No.19) the entire length and
circumference with Loctite 639.
• Thread nut (No.19) onto output shaft (No.6) and tighten with 800 Nm. The final position
must be reached within 2 to 5 minutes, in order for the Loctite to be fully effective.
• Verify claw separation distance (see Section 2.2.11).
• Replace gasket (No.57) and o-ring (No 59).
• Mount complete all wheel drive release shifter (complete housing) onto transfer case.
Tightening torque for hex bolts (No.55 & 56) is 115 Nm.
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Name : VG 35-594
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2.2.1.1 Verification Claw separation „s“

(see Figure 4)
• Completely dismantle the all wheel drive release shifter.
• Remove shifting sleeve (No.69) and bearing inner ring (No.66) from shaft (No.36).
• Slide piston (No.65) to one side against housing (No.58) i.e. adjusting washers (No.67).
• Press shifting sleeve (No.69) along with bearing inner ring (No.66) against bearing outer
ring (No.66). The claws of the shifting sleeve (No.69) and output shaft (No.84) must be
engaged during this action.
• Measure the claw separation against the face of the output shaft claws with a feeler gauge.
„s“ = 0,2 to 0,7

„s“ < 0,2 mm add washers (No.67) accordingly
„s“ > 0.7 mm remove washers (No.67) accordingly
• Being careful to insert compression springs (No.70) into the counter sunk holes of the
shifting sleeve, slide shifting sleeve (No.69) and bearing inner ring (No.66) onto shaft
profile (No.36).
• Replace gasket (No.57) and o-ring (No.59).
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Name : VG 35-594
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2.2.2 Exchange of Tapered Roller Bearing (No.1)

(see Figure 4, Figure 5, Figure 6)
• Loosen hex bolts (No. 12 & 26) and remove complete all wheel drive release shifter.
(Figure 5 & 6)
• Remove shifting sleeve along with bearing inner ring (No.1) from shaft and then pull off
bearing inner ring from shifting sleeve.
• Pull out piston (No.4) from housing (No.23).
• Remove bearing outer ring (No.1) from piston (No.4). When doing this be careful not to
damage the sealing surface of the piston.
• Install new bearing inner ring and outer ring (No.1) into the shifting sleeve and piston
(No.4) respectively.
• Verify claw separation distance (see Section 2.2.1.1)
• Replace gasket (No.22) and o-ring.
• Mount complete all wheel drive release shifter-assembly(complete housing) onto transfer
case.
2.2.3 Exchange of Gaskets
(see Figure 5, Figure 6)
• Loosen hex bolts (No.12 & 26) and remove complete all wheel drive release shifter.
(Figure 5 & 6)
• Pull out piston (No.4) from housing (No.23).
• Press out of the housing grooves both quad rings (No.3 & 21) including both supporting
rings (No.2 & 20).
• Install new quad rings (No.3 & 21) and supporting rings (No.2 & 20).
• Insert piston (No.4) into housing (No.23).
Care must be taken that neither the quad rings (No. 3 & 21) and the supporting rings (No
2 & 20) are damaged during insertion. The slotted supporting ring (No.20) is especially
vulnerable.
• The claw separation distance „s“ does not need to be adjusted again if the original washer
package (No.5) is installed again, and that no other parts were exchanged other than
gaskets.
• Replace gasket (No.22) and o-ring.
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Name : VG 35-594
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2.2.4 Exchange of Output Shaft

(see Section 2.2.1)
2.2.5 Exchange of Shifting Sleeve

(see Section 2.2.1)
2.2.6 Exchange of Compression Springs

(see Figure 4)
• Remove 16 compression springs (No.75).
• Remove shifting sleeve (No.69) from shaft (No.36).
• Remove 10 compression springs (No.70)
The compression springs (No.75) and (No.70) are identical and have the same part
number.
• Install new compression springs (No.75 & 70) into the housing.
• Being careful to insert compression springs (No.70) into the counter sunk holes of the
shifting sleeve, slide shifting sleeve (No.69) onto shaft (No.36).
• Replace gasket (No.57) and o-ring (No.59).
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Name : VG 35-594
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2.3 Transmission
Note: For repairs on the transmission, it must be removed from the vehicle.
• Cardan shaft must be removed.
• Oil must be drained completely (see Section 1.5.2.2).
• Remove transmission (ie. transfer case) from the frame and store with the input side facing
down, or affix to an assembly jig.
2.3.1 Exchange of Input Pinion (3) and Bearing (1)
(see Figure 4)
• Loosen hex bolts (No.13 & 14).
• Remove housing half (No.15) from housing half (No.16). It may be required by tapping
with a Ø16 brass mandrel through the threaded hole of screw plug (No.2), i.e. against the
face of shaft (No.36), to assist in splitting of the two housing halves.
• Remove bearing (No.1) from output pinion (No.3).
• Turn input pinion to assembly orientation.
(position is milled into bearing (No.1)
• Remove gear block (No.23) complete with both bearing inner rings (No.20 & 25) through
the top.
• Remove snap ring (No.6), take out fitting washer (No.5), and remove input pinion (No.3)
upwards from housing (No.16). If required assist with a soft hammer by tapping against the
face of input pinion (No.3).
• Remove bearing (No.4) from input pinion (No.3).
• Press into housing (No.16) new bearing (No.1) and slide new bearing onto input pinion
(No.3).
• Install snap ring (No.6) into housing half (No.16) and mount preassembled input pinion
(No.3) complete with bearing into housing (No.16).
• Also install gear block (No.23) into housing (No.16).
• Place new gasket (No.11) between and mount housing (No. 15) again.
Tighten hex bolts (No.13 & 14) with 67 Nm.
• Remove snap ring (No.6) from housing (No.16).
• Shift input pinion (No.3) complete with assembly sleeve (Ø i = 71mm; Ø a = 80mm, l =
100mm) against housing (No.15), such that bearing (No.1) is against housing (No.15).
• Insert snap ring (No.6) into housing half (No.16), and measure distance „a1“ with a feeler
gauge between bearing (No.4) and snap ring (No.6). The washer package (No.5) thickness
is to be 0,1 to 0,25 mm small than measured distance „a1“.
• Remove snap ring (No.6) from housing (No.16) and install selected washer package (No.5)
followed by again installing snap ring (No.6) into housing (No.16).
• Insert 16 compression springs (No.75) and mount complete all wheel drive release shifter
with hex bolts (No.55 & 56). Tightening torque is 115 Nm.
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Name : VG 35-594
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2.3.2 Exchange of Gear Block (23) and Bearings

(see Figure 4)
• Disassemble gear block (23). See section 2.3.1.
• Remove bearing outer rings (No.20 & 25) from housings (No.15 & 16) and fitting washer
(No.26) from housing (No.15).
• Pull off bearing inner rings (No.20 & 25) along with supporting washers (No.22 & 24) and
Nilos ring (No.21) from gear block (No.23).
• Install new bearing inner rings (No.20 & 25) along with new supporting washers (No.22 &
24) and new Nilos ring (No.21) onto gear block (No.23).
• Insert bearing outer rings (No.20 & 25) into housing (No.15) and (No.16) without fitting
washers (No.26).
• Install preassembled gear block (No.23) into housing (No.16).
• Install new gasket (No.11) between halves.
• Mount housing (No.15) and for now tighten with four hex bolts (No.13).
• Insert setup bolt M12x80 into the face of gear block (No.23) and with the aid of a lever
move the gear block back and forth and measure the axial play „x2“ with a dial gauge. The
selection of the washer package (No.26) is to be 0,2 to 0,4 mm smaller in thickness than
the measured axial play „x2“.
• Remove housing (No.15) again.
• Remove bearing outer ring (No.20) from housing (No.15) with the aid of a bearing puller,
and insert the selected washer package (No.26) into the housing hole and install bearing
outer ring (No.20) again.
• Install now gasket (No.11) between halves.
• Mount housing (No.15) and tighten hex bolts (No.13 & 14) with 67 Nm.
• Inspect axial play „x2“ again. It must be between 0,1 and 0,25 mm.
• Mount input shaft (No.3) again as per Section 2.3.1.
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Name : VG 35-594
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2.3.3 Exchange of Gear (29) and Bearings (27, 30)

(see Figure 4)
Note: Bearing (No.27), Washer (No,28), Gear (No.29), and both needle bearings (No 30) can
be removed without the disassembly of shaft (No.30).
face of shaft (No.36), to assist in splitting of the two housing halves. For now shafts (No.3,
23, 36) remain in housing (No.16).
• Pull off bearing (No.27), remove snap ring (No.74) and fitting washers from housing
(No.15).
• Remove gear (No.29) and needle bearing (No.30).
• Inspect shaft (No.36). If the shaft in the area of the needle bearing shows sign of wear then
the shaft is to be exchanged as per section 2.3.4.
• Install new needle bearing (No.30), gear (No.29) and washer (No.28) onto shaft (No.36)
and slide new bearing (No.27) against the axial shoulder of shaft (No.36).
• Shift shaft (No.36) complete with bearing (No 27) with assembly sleeve (Ø i = 51 mm;
Ø a = 60mm; l = 65mm ) against housing (No.16), such that bearing (No.35) is against
housing (No.16).
• Install snap ring (No.74) and measure distance „X3“ between bearing (No.27) and snap ring
(No.74). The selected washer package (No.73) thickness is to be 0,2 to 0,4 mm smaller
than the measured distance „X3“.
• Remove snap ring (No.74) again and install selected washer package (No.73) and then
reinsert snap ring (No.74).
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Name : VG 35-594
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2.3.4 Exchange of Shaft (36), Gear (33) and Bearings (32, 35)
(see Figure 4)
• Loosen nut (No.39). If required for easier disassembly heat to 100°C and counter against
cardan flange (No.38). (The loosening torque can be as high as 800 Nm).
(The loosening torque can be as high as 800 Nm)
• Lift off cardan flange (No.38) and remove seals (No.40) and (No.41) with a puller.
• Pull off bearing (No.27), remove snap ring (No.74) and fitting washers from housing
(No.15).
• Remove gear (No.29) and needle bearing (No.30).
• Loosen nut (No.45), while countering against SW13 of shifting rod.
• Remove shifting fork (No.42) and shifting rod (No.43).
• Pull off sliding sleeve (No.31) from shaft (No.36) and remove compression springs
(No.70).
• Remove shaft (No.36) from the inner side of housing (No.16). If required assist by tapping
against the face of shaft (No.36) with a soft hammer.
• Remove bearing (No.35) from shaft (No.36).
• Remove washer (No.34), gear (No.33) and both needle bearings (No.32) from shaft
(No.36).
• Install new needle bearing (No.32), gear (No.33) and washer (No.34) onto shaft (No.36)
and slide new bearing (No.35) against the axial shoulder of shaft (No.36).
• Install preassembled shaft (No.36) into housing (No.16).
• Exchange o-ring (No.37) in pinion groove.
bearing (No.35) and the lips of (No.40) and (No.41) with 50% long endurance grease.
• Press on cardan flange (No.38).
• Clean M40x1,5 thread of nut (No.39) and shaft (No.36) of dirt, oil and corrosion inhibitors.
• Thread nut (No.39) onto input pinion (No.36) and tighten with 800Nm. The final
tightening torque must be reached within 2 to 5 minutes, in order for the Loctite to be fully
effective.
• Install sliding sleeve (No 31) onto shaft (No.36) and shifting fork (No.42) without, for
now, fitting washers (No.44) onto shifting rod (No.43).
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Name : VG 35-594
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• Clean threads of nut (No.45) and shifting rod (No.43) of dirt, oil and corrosion inhibitors.
• Thread nut (No.45) onto shifting rod (No.43) while countering against SW 13 and
tightening to 135 Nm. The final tightening torque must be reached within 2 to 5 minutes, in
order for the Loctite to be fully effective.
2.3.5 Exchange of Shifting Sleeve (31)
see Section 2.3.4 and 2.4.2
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Name : VG 35-594
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2.4 Shifting Cylinder

Note: Many components of the shifting cylinder can be exchanged without having to remove
the transfer case from the vehicle, if the cylinder is easily accessible. However, for the
exchange of various parts the transfer case does need to be opened up and therefore it must be
removed from the vehicle. (see Figure 15)
2.4.1 Exchange of Gaskets (49, 50, 51)
• Remove hydraulic hose connections, loosen allan screw (No.53), and disassemble fish
plate (No.118). Then loosen hex. Bolt (No.117) and take off complete pressure switch
(No.116).
• Loosen hex bolts (No.54) and pull cylinder (No.52) from shifting rod (No.43).
• Remove snap ring (No.103) and disassemble ring (No.104) along with shaft seal (No.51)
from the cylinder (No.52). Insert new seal (No.51, (rubber seal lip ahead) and ring
(No.104) into the cylinder (No.52) and secure again with snap ring (No.103).
• Extract snap ring (No.105) and remove the piston (No.109) together with supporting
washer (No.107) from the shifting rod (No.43). Also extract snap ring (No.108) and
remove the centering (No.47) from the shifting rod. Extract shaft seal (No.49) from the
groove in the centering ring and replace with a new seal.
• With a sharp tool lift the piston seal (No.50, having two parts) out of its groove in the
piston. Use an assembly tool to install a new piston seal (No.50) in the groove of the piston
(No.109), first install the rubber ring then the composite ring. Ensure that the orientation of
the seal lips is in the correct direction.
• Guide centering ring (No.47) again onto shifting rod (No.43) and seat into housing
(No.16).
• Install snap ring (No.108), supporting washer (No.107), new o-ring (No.106) into the
groove, then insert piston (No.109) and secure with snap ring (No.105).
Caution: During disassembly and assembly of both snap rings, extra care must be taken
not to damage the sealing surfaces of the shifting rod. Best cover the sealing surfaces
with adhesive film while mounting the snap rings. Also do not overstretch the snap rings
with the circlip pliers, they must sit in their grooves under proper tension.
• If other parts are replaced a new adjustment must be done again. (see chapter 2.4.1.1)
• Mount new gasket (No.46 + original washer adjusting set) with new o-ring (No.48) and
install cylinder (No.52) again and tighten with hex bolts (No.54) with 46 Nm. Mount the
complete pressure switch (No.116).and tighten hex bolt (No.117) then assemble fishplate
(No.118) and tighten allan screw (No.53). Connect the hydraulic connections.
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Name : VG 35-594
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2.4.1.1 Adjustment of Shift Cylinder

Purpose:
Adjustment of the axial position for the shift cylinder by means of different washer package.
In order to prevent that the required overlapping of the gear tooth shifting in the first speed fell
not becomes.
Procedure:
• Insert first speed. The shifting rod is pulled by hand to the cylinder housing outside up till
the stop of the piston at this.
Measure the axial distance between the shifting rod front side to the front end shift
cylinder. (Fig. 11).
• Measure „L 1 “ = .........mm.
Fig. 11
• Loose fixing screws and remove cylinder housing with gasket from the shifting rod.
• Measure length of the cylinder housing with 1 piece gasket. (Fig. 12).
• Measure „L 2 “ = ..........mm.
Fig.12
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Name : VG 35-594
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• Pull shifting rod outside by hand till the shifting sleeve is stopped on the spur gear. (1. Gear)
Gap „s“ = 0 mm.
Measure overlying length of shifting rod till the cylinder- contact surface of the
transmissions housing (Fig. 13).
• Measure „L 3 “ = ..........mm.
Fig.13
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Name : VG 35-594
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• Selection of the washer package (No.46) part No. 2108.034.0

Measure „x“ calculate.
„x1“ = „L 3 “ - 3.5 = ........ – 3.5 =

.........mm
„x2“ = „L 2 “ + „L 1 “ = ...... + .....=

........mm
„x“ = „x1“ - „x2“ = .....-......= ........mm
Consisting:
„x“ necessary package (with part No.)
0 - 1,4 No. 1 1 pc. Gasket 9850.037
1,5 - 2,6 No. 2 2 pc. Gasket 9850.037

1 pc. Washer 7315.147
2,7 - 4,0 No. 3 2 pc. Gasket 9850.037

1 pc. Washer 7315.143
2 pc. Washer 7315.147
Should there a „x“ value below -1 (negative value) or above 4,0 arise, is to open the
transmission and to seek for not permitted value after the reason for this one.
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2.4.1.2 Installation of the washer package
Package No. 1 1 pc. Gasket 9850.037 will installed between transmissions

housing and cylinder housing enclosed
Package No. 2 2 pcs. Gasket 9850.037 will installed between transmissions

housing and cylinder housing enclosed.
1 pc. Washer 7315.147 will installed between transmissions
housing and centering enclosed.
Package No. 3 2 pcs. Gasket 9850.037 and 1 pcs Washer 7315.143 will
installed between transmissions housing and cylinder housing
enclosed in stratification „Gasket – Washer – Gasket“.
2 pcs. Washer 7315.147 will installed between transmissions
housing and centering enclosed
The installation position for the gasket and washers is in fig.14 represented.
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Name : VG 35-594
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Figure 14
With this adjustment is reached, that in shift position „1st. Gear“ the axial distance between
shifting sleeve and spur gear („1st. Gear“) has approx. 3.5 – 4.5 mm behaves. The desired
shift overlap is guaranteed with this.
2.4.2 Exchange of Cylinder (52)

see Section 2.4.1
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Name : VG 35-594
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2.4.3 Exchange of Shifting Rod (43) and Shifting Fork (42)

(see Figure 15)
Note: To exchange the shifting rod (No.43) or shifting fork (No.42) the transfer case must be
removed from the vehicle.
• Remove cardan shaft.
• Drain oil completely (see Section 1.5.2.2).
• Remove transmission (i.e. transfer case) from the frame and store with the input side facing
down, or affix to an assembly jig.
• Loosen hex bolts (No.55 & 56) and remove complete all-wheel-drive-shift.
• Remove housing half (No.15) from housing half (No.16) It may be required by tapping
• Remove sliding sleeve (No,69) along with bearing inner ring (No.66) from shaft (No.36)
and also remove ten compression springs (No.70).
• Pull off bearing (No.27).
• Remove washer (No.28) and gear (No.29) from shaft (No.36).
• Remove cover (No.53) and loosen nut (No.45) while countering at the width over flats of
shifting rod SW13 (No.43).
• Loosen hex bolts (No.54) and pull cylinder (No.52) from shifting rod (No.43).
• Remove shifting fork (No.42) along with shifting sleeve (No.31).
• Pull out shifting rod (No.43) towards the cylinder side.
• Continue disassembly of snap ring (No.94), piston (No.90), seeger support washer (No.95)
and other snap ring (No.94).
• Replace o-ring (No.93)
• Assemble snap ring (No.94), seeger support washer (No.95), piston (No.90) and second
snap ring (No.94) onto new shifting rod (No.43).
• Install shifting rod (No.43) again from the cylinder side.
• Install sliding sleeve (No,31) onto shaft (No.36) and shifting fork (No.42), onto shifting rod
(No.43).
• Clean threads of nut (No.45) and shifting rod (No.43) of dirt, oil and corrosion inhibitors.
• Thread nut (No.45) onto shifting rod (No.43) while countering against SW 13 and
tightening to 135 Nm. The final tightening torque must be reached within 2 to 5 minutes, in
order for the Loctite to be fully effective.
• Install again sliding sleeve (No.69) along with bearing inner ring (No.66) onto shaft (No
36), and again insert the ten compressions springs (No.70) into the appropriate seats.
• Mount l6 housing (No.15) and tighten hex bolts (No.13 & 14) with 67 Nm.
25
Name : VG 35-594
Date : 15.07.2002
• Insert 16 compression springs (No.75) and mount complete all wheel drive release shifter-
assembly with hex bolts (No.55 & 56). Tightening torque is 115 Nm.
Figure 15
43. Shifting rod 103. Snap ring

45. Nut 104. Ring
46. Washer package + gasket 105. Snap ring
47. Centering 106. O-ring
48. O-ring 107. Supporting washer
49. Shaft seal 108. Snap ring
50. Piston seal 109. Piston
51. Seal 116. Pressure switch complete
52. Cylinder 117. Hex. Bolt
53. Allen screw 118. Fish plate
54. Hex. bolt
Revisions reserved
Neunkirchen on 15.07.2002
26
Name : VG 35-594
Date : 15.07.2002
NAF Special tool table for LOK 124 transfer cases

for groove nut 73290.062 on shaft
Insert punch WZ 079
To insert oil seals 1160.214 and 1160.215 on both output flanges
27
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 128
Description: Portal Bogie Axle with without Balanced-Bogie Unit

Used as a rear axle in Timberjack 1010D forwarder
Date: October 08,2002
Contents Page
3. Differential.................................................................................................................................. 5
Assembly drawings 00.75000.260.0,R 00.92500.078.0, R 1040-041,
Date: October 08,2002 page II
Bogie housings:
with 55 Nm.
white plastic caps.
Date: October 08,2002 page III
retightened.
(61) with 55 Nm.
Date: October 08,2002 page IV
Table of Lubricants
Date: October 08,2002 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: October 08,2002 page 1
bogie.
this manual..
Figures: 00.75000.260.0, R 00.92500.078.0, R 1040-041

1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 Hex bolt M16x40 10.9 VP 7322.069 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
39 Plug R ¾" 1040.103 90 Nm
50 Hex nut M40x1.5 7329.057 800 Nm
54 Plug R ¾" magnet 7323.025 90 Nm
103 Hex bolt M18x2x80 10.9 1010.639 400 Nm

Figures: 00.75000.260.0, R 00.92500.078.0, R 1040-041

Fig. no. 00.92500.078.0 (LOK 128 without BB)
103 Hex bolt M18x2x80 10.9 1010.639 465 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 Hex bolt M18x2x70 10.9 VP 1010.666 465 Nm
143 Plug R ¾" 1040.151 90 Nm

Figures: 00.75000.260.0, R 00.92500.078.0, R 1040-041
2.3. Bogie Housing,

Fig. no. R 1040-041 (LOK 128 without BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
46 Hex bolt M16x60 10.9 VP 1010.544 310 Nm
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
160 Hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x50 10.9 1020.518 280 Nm

Figure: 00.75000.260.0
3. Differential
bolt as per 5.3.
Figure: 00.75000.260.0
(eg. Loctite 542)
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
Figure: 00.75000.260.0

82.73 mm.
follows:
se = 178.8 - Le - L1 [mm]
Figure: 00.75000.260.0
5 Nm.
torque.
Figure: 00.75000.260.0

Figure: 00.75000.260.0
Figure: 00.75000.260.0

Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
assembly tool no. Sk.2.96-136, because the piston sealing (35) is two-piece and this
piston sealing (35) must calibrate with special tool no. Sk.2.96-136. Insert the piston into
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
per 5.2.
necessary.
Repair Instruction,

[LOK 128: There is not any BB planetary gear, the shaft (140) coming out of the
differential is directly mounted to the bearing stud (8). Before starting the disassembly with
released parking brake turn back and forth either the cardan flange at the differential or
one of the output shafts (34), to be sure that the backlash of the splines in the brake disks
is aligned. Then activate the parking brake to hold the brake disks in this position. Pull out
the bearing stud (8) along with the mounted shaft (140). Then dismount the bogie housing
as described above.]

are no shims.]
Repair Instruction,

± 0.7 mm)
washer package (9):
smin = 154.5 - "A" = ..... mm
smax = 156.5 - "A" = ..... mm
(134).
[LOK128: Install a new O-ring (11) in the groove of the bearing stud and mount the
bearing stud along with the mounted shaft (140). The brake disks (120) are still fixed in
their original position by the activated parking brake. By slightly turning the shaft (140) the
teeth of the spline have to find the gaps of the internal spline in brake disks, shifting sleeve
(56) and differential gear (15).]
(179).
[LOK 128: The drive shaft (140) in the bogie axle without BB gear can be disassembled
just by removing the bearing stud (8), also see detailed description for exchanging the
bogie input gear (6) in Chapter 6.4.4.]
Repair Instruction,


Assembly:
Repair Instruction,
and remove the bearing stud along with the mounted gear (6). [LOK128: For disassembly

hex bolts (124).


as per 7.1.




dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm

Insert punch WZ 213

(short distance)

11. Diff.-cage
16. Cross bolt
17. Bushing
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -
59. -
102. Left Axle beam
R 00.92500.078.0
7 Cylinderroller bearing 130 *

101 Right Axle beam 131 *
102 Left Axle beam 132 *
103 Axle beam screw 133 *
104 Axle beam screw 134 *
105 HE-S ring 135 *
106 Dowel pin Axle beam (Lock side) 136 *
107 Dowel pin Axle beam (Crown gear side) 137 *
108 Breather for bogie housing 138 *
109 Brake chocke 139 *
111 Operating brake cylinder complete 141 Oil seal in this Axle beam
118 Actuator disk 148 Breather
120 Coated-brake disk 150 -
121 Tooth ring 171 Spring between actuator disk
125 Allen screw turning-ring coupling below 176 Washer between oil seals in axle beam
129 *
Partnumber for bogie housing ( drw.no R1040-41)
2 * 125 Allen screw slewing-ring below
3 * 126 Allen screw slewing-ring above
4 * 127 HV washer for 126
6 * 140
7 Cylinder roller bearings for Drive shaft 140 Drive shaft
8 Tandem housing – middle bearing bolt 172 Slewing ring
12 *
14 Oil plug
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
49 Portalgear
56 Stub axle ring
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 129

Used as front axle in Timberjack 810D Forwarder
Date: 15 January 2003
Contents Page
3. Differential.................................................................................................................................. 5
3.3. Exchange of the Compensating Gears ................................................................... 10
9. Tightening Torques for Bolts and Nuts (Transfer Case).......................................................... 32
10. Transfer Case .......................................................................................................................... 33
10.1. Exchange of Seals (85), (86) .................................................................................. 33
10.2. All Wheel Drive Release Shifter .............................................................................. 33
10.3. Exchange of Transmission Shafts, Gears and Bearings ........................................ 37
10.4. Gear Shifting ........................................................................................................... 41
Drawings: Installation drawing / Lubrication Plan PTA 4400.106, Assembly drawings: Diff. 7500.253;
Transfer case 00.98000.191.0; Axle housings 00.92500.044.0, 00.92500.112.0,
Date: 15 January 2003 page II
according to the table of permitted lubricants until the oil
starts overflowing from the control plug (41). Therefore
open these plug on the vertical face opposite of the
cardanflange side it is the brake cylinder side. Close oil
filler- and oil control- plug with copper seal ring and tighten
with 90 Nm torque.
Transfer case:
Make sure that oil drain plug (82) with copper seal ring is
properly tightened with 60 Nm torque. Remove oil filler
plug (80) and add approx. 3.5 L oil according to the table
of permitted lubricants until the level has reached the
upper mark of the oil dip stick (81).
Bogie housings:
Make sure that the oil drain plugs (62, 63) with copper
Remove one of the fill plugs (60) and the control plug (61,
in the centre cover). Add approx. 52 L oil as per lubrication
chart until the oil starts overflowing from the control plug
(61). Tighten the fill plug (60) with 90 Nm, the control plug
(61) with 55 Nm.
Slewing ring:
grease volume and need no service. The only service
work is replacement of solied grease in buffer volume.
First oben lubricating outlet plugs (92, 2 per side covered
with white plastic caps)
At in both grease nipples (90, 2 per side covered with
white plastic caps) grease with grease gun until grease
sqeeze out from the lubricating outlet (92, 2 per side with
white plastic cap). Then close outlet plugs and grease
Date: 15 January 2003 page III
again with grease gun until grease sqeeze out from the
gap has sealed itself with grease all the way around the
Date: 15 January 2003 page IV
After the first 250 operating Bolts and nuts may settle due to loads and vibrations of
hours the vehicle. Retightening all visible bolts can prevent leaks
and major damage. The use of a torque wrench is strongly
retightened.
oil control plug (41), oil filler plug (40) and surrounding
areas of any dirt. Then remove filler plug, open oil drain
plug at the differential and drain oil completely into a
suitable basin (approx. 12 L). Clean the magnetic inset of
the oil drain plug from any metal wear. Screw in the oil
drain plug (42) with new copper seal ring and tighten with
90 Nm torque. Add approx. 12 L oil according to the table
of permitted lubricants until the oil starts overflowing from
the control plug (41). Therefore open these plug on the
vertical face opposite of the cardanflange side it is the
brake cylinder side. Close oil filler- and oil control- plug
with copper seal ring and tighten with 90 Nm torque.
The bogie housing must be in a horizontal position. Prior
to draining the oil the axle should be at least 30 minutes at
rest allowing all the dirt particles to settle in the
appropriate reservoirs. Also before opening a plug clean
its surrounding area to avoid dirt coming into the housing.
First remove one of the fill plugs (60) and the control plug
(61), then open the main oil drain plugs (62), two per
tandem housing, and drain into a clean container since it
is possible that this portion of oil is used again. Then
remove the unusable oil plugs (63, with magnetic inset),
also two per tandem housing, and let the oil drain into a
separate basin. Close the drain plugs (62, 63) with new
copper seal rings and tighten with 90 Nm torque, the plug
with magnetic inset at the lower position. Add oil as per
lubrication chart into the fill plug (60) until the oil starts
overflowing from the control plug (61) (first the collected
old oil, complete with new clean oil). Tighten the fill plug
(60) with 90 Nm, the control plug (61) with 55 Nm.
Date: 15 January 2003 page V
After the first 250 operating Oil change in transfer case:

hours Change oil while it is warm. First clean oil drain plug (82),
any dirt. Then remove filler plug, open main oil drain plug
at the transfer case and drain oil completely. Tighten drain
plug (82) with 60 Nm and add approx. 3.5 L oil according
to the table of permitted lubricants until the level has
reached the upper mark of the oil dip stick (81).
Slewing ring:
After every 250 operating The slewing ring has lifetime lubrication in the raceway
hours grease volume and need no service. The only service
work is replacement of solied grease in buffer volume.
First clean the area around the grease nipples and oulet
plugs (90/92) Then oben lubricating outlet plugs (92, 2 per
side covered with white plastic caps)
At in both grease nipples (90, 2 per side covered with
white plastic caps) grease with grease gun until grease
sqeeze out from the lubricating outlet (92, 2 per side with
white plastic cap). Then close outlet plugs and grease
again with grease gun until grease sqeeze out from the
gap has sealed itself with grease all the way around the
After every 500 operating Check oil levels in differential (control plug 41); transfer
hours or at least monthly case (dip stick 81) and in both bogie housings (control
plug 61) and add oil if required.
Date: 15 January 2003 page VI

hours or at least annually Change oil in differential and transfer case when it is
warm, see explanation above for oil change at 250
operating hours, however, the complete amount of oil has
to be exchanged.
Table of Lubricants
Date: 15 January 2003 page VII
e.g.
ARAL Degol 3216

approx. 3.5 ltr. for transfer case
BP Energear LS 90 approx. 12 ltr. for differential with
brakes and 52 ltr. for each bogie
DEA Deagear LS SAE 85W-90 housing of LOK 129; the actual
Dearon BHS SAE 90 quantity has to be checked by
the control mark of the dip stick
Esso Gear oil LSA 85W-90 or by control plugs.
Fuchs Renogear LS90
Renogear HLS 90

Figure: 
Date: 15 January 2003 page 1
bogie.
.
Figures: 7500.253, 00.92500.044.0, 00.92500.112.0

2.1. Differential Section, Fig. no. 7500.253
1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 hex bolt M14x40 10.9 VP 1010.424 185 Nm
22 Allen M10x80 10.9 VP 1020.335 67 Nm
39 plug R ½" 1040.125 55 Nm
103 hex bolt M18x2x70 10.9 1010.662 400 Nm
104 hex bolt M18x2x60 10.9 1010.653 400 Nm

Figures: 7500.253, 00.92500.044.0, 00.92500.112.0

Fig. no. 00.92500.044.0 (LOK 129 with BB)
103 hex bolt M18x2x70 10.9 1010.662 400 Nm
104 hex bolt M18x2x60 10.9 1010.653 400 Nm
115 Allen bolt M10x45 8.8 1020.208 45 Nm
131 hex bolt M12x100 10.9 VP 1010.323 115 Nm
143 plug R ½" 1040.125 55 Nm

Figures: 7500.253, 00.92500.044.0, 00.92500.112.0
2.3. Bogie Housing,

Fig. no. 00.92500.112.0 (LOK 129 with BB)
10 hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 hex bolt M10x25 10.9 VP 1010.201 72 Nm
46 hex bolt M12x50 10.9 VP 1010.326 115 Nm
54 plug M30x1.5 1040.103 105 Nm

Figure: 7500.253
3. Differential
4x106) properly sit in their bores in the differential. Install a new O-ring (85) onto the step
and mount the complete transfer case onto differential. Attach the complete axle beam
and bogie housing to the differential. When shifting the spline end of the shaft into the
differential gear (15) assist by short rotating the cardan flange in both direction. Fasten the
bolt as per 5.3.

Drain oil from the axle and transfer case. After the axle has been removed from the
vehicle (dismount transfer case from the axle), first of all open the hex nut (50, wrench
size 55) on the input pinion (13), later it would be more complicated to counterhold the
high loosening torque which may exceed 1000 Nm. The nut is locked with Loctite,
preheating it to 120°-160°C with a blow lamp is recommended. Then disassemble the
complete differential as described in Chapter 3.1.1.
Figure: 7500.253
Dislodge the pinion (13) to the inside of the differential housing by hitting onto the end of
the shaft. Loosen hex bolts (9) and pull the crown wheel from the differential cage.
Figure: 7500.253
se = 147 - Le - L1 [mm] (as experience shows use a thickness near 2.4 to 3.65)
Install the adjusting washers (44) vary in thickness from 0.96 to 1.44 mm with a step of
0.04 mm and the spacer sleeve (47) has a fix measurement of 24.9 mm.,. Select a
combination of spacer sleeve and an adjusting washer set with a total width of (between
26.90 and 28.10 mm ) for now and slide them onto the shaft of the pinion. Insert this unit
bearing (48) onto the pinion shaft. Apply and tighten hex nut (50) with 800 Nm torque.
bearing preload; if required through the use of different adjusting washers set (44) the
proper bearing preload is to be adjusted.
5 Nm.
When it is sure that the bearings are well adjusted, loosen nut (50) again. Then press two
seals (87) into the housing (42) and fill 50% of the volume between both seals with
grease. It should be noted that the seals are installed in the correct illustrated orientation,
since otherwise the seal between the differential and transfer case is not guaranteed.
Clean the threads of shaft and nut from dirt or grease. Cover the threads of pinion shaft
and nut (50) on their whole length and circumference with Loctite 639. The applying and
tightening of the nut must not take any longer than 3-5 minutes to avoid any hardening of
the adhesive. The nut cannot be applied using an impact wrench since this will promote
early hardening and the adhesive will be spun off the threads. Tighten the nut with 800
Nm torque.
Figure: 7500.253

Figure: 7500.253
Figure: 7500.253
3.3. Exchange of the Compensating Gears

Disassembly
Assembly
Figure: 7500.253



Drain the oil from the differential and transfer case. Loosen hex nut (68) and remove
complete transfer case from the differential housing (42). Now, the radial shaft seals (87)
can be pressed out and replaced with new ones. Install new shaft seals with tool WZ 200.
When installing new seals note that the lips of the seals are installed in the proper
orientation as shown, in order to ensure a proper seal between the differential and transfer
case. Fill 50% of the volume between seals (87) with grease, install new O-ring (85), and
mount the transfer case onto the differential housing.

Figure: 7500.253
Figure: 7500.253
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm

cylinder.
to set-up as per point 5.2 and 5.3, inspected and tested.


completly removed.


cylinders!
Disassembly:
Assembly:
bolts (113).
Disassembly:
Assembly:
Disassembly:
First disassemble spring loaded cylinder (151) from the brake cylinder (150) as per 5.3.1
renewed.
Assembly:
5.4.1.

Disassembly:
exchanged.
Assembly
activation disks.
ramp disks (118).
per 5.2.
necessary.
Repair Instruction,
00.92500.112.0

balance planetary drive will remain in the axle beam (101/102) and can now be taken out
as a complete subassembly [LOK 129].

Repair Instruction,
00.92500.112.0
smin = 131.5 - "A" = ..... mm
smax = 132.5 - "A" = ..... mm

(179).
Repair Instruction,
00.92500.112.0

Assembly:
Repair Instruction,
00.92500.112.0


hex bolts (124).

Inlay a new O-ring (19) into the groove of the stud. Insert it into the hole of the bogie
housing (31), gear (23) and spacer ring (16). The stud is to be turned and orientated such
that split taper sleeve (17) interlocks with the groove of stud (18) and secure with new
adhhesive coated hex bolts (22). Apply new liquid flange sealant on to the clean surface
side of partal housing before the cover (21) installed.

diameter hole.



Fig.10:


• The threads of the nut and output sahft must be free of any dirt, oil, and corrosion
35 Nm.
sit closely in their boring in the bogie housing and apply new liquid flange sealant on to the
clean flange surface side of partal housing.
Fig. 11: Rope spur for liquid sealant of the portal housing

hex bolts (26).
Repair Instruction, Transfer Case
Figures: Assembly Drawings fig. 00.98000.191.0
Date: January 15, 2003 page 30
9. Tightening Torques for Bolts and Nuts (Transfer Case)

2 screw plug 104.125 60Nm
8 hex bolt M8x16 10.9 VP 101.128 34 Nm
13 hex bolt 101.210 67 Nm
17 screw plug 03.95560.019.0 60 Nm
45 hex nut M14 x 1,5 10 106.003 135 Nm + Loctite
53 cover 03.73020.003.0 140 Nm
54 hex bolt 151.242 46 Nm
55 hex bolt M12 x 80 10.9 151.338 115 Nm
56 hex bolt M12 x 40 10.9 151.320 115 Nm
72 grooved nut M52 x 1,5 03.73290.062.0 800 Nm
83 nut 03.73290.057.0 see 11.2.1
88 screw plug M 14 x 1,5 104.105 33 Nm
93 screw plug 104.114 35 Nm
101 allen screw M8 x 16 8.8 VP 102.113 23 Nm
The above tightening torques are approximate values when assembling the connections
with a calibrated torque wrench, the really acting tightening torque scattering within +/-
10%.
10. Transfer Case

When serving the transfer case the axle can remain attached to the vehicle if the transfer
case can be removed from the axle. The required axial removal dimension is
approximately 85 mm.
Prior to the removal of the transfer case the oil is to be drained from the differential.
First remove the hydro-motor, then loosen hex nut (39) and remove the complete transfer
case from the differential housing.
When attaching the transfer case to the differential first fill the room between the two seals
(113) with 50 % grease and place a new o-ring (40) in between and then mount the
complete transfer case onto the differential housing again. It must also be noted that the
sealing lips of seals (113) are not damaged.
10.1. Exchange of Seals (85), (86)

For this service work the transfer case can remain in the vehicle if their is room for
servicing.
First drain the oil completely, then engage the allwheel drive, loosen nut (83) and pull off
drive shaft flange (81). Now the seals (85) and (86) and o-ring (82) can be removed.
Caution: Because of the adhesive lock the loosening torque of nut (83) can be more than
800 Nm. If required the nut can be heated to 100°C.
Insert new seals (85) and (86) into housing (58), and fill 50 % of the space between the
two seals with long last grease. Then place o-ring (82) into the groove of the shaft and
insert drive shaft flange (81) onto the profile of the shaft.
Tighten nut (83) onto the shaft until the required axial play of 0,05 mm to a maximum of
0,15 mm for bearings (76) and (77) is obtained.
Prior to assembly the threads of the nut and shaft are to be cleaed and coated with Loctite
639 (alternatively 275).
10.2. All Wheel Drive Release Shifter

For service work to the all wheel drive release shifter the transfer case can remain in the
vehicle if there is enough room for servicing. Before opening the gear box it has to be
cleaned to make sure that no dirt will get into it.
First remove the drive shaft from the flange (81) of the disconnectable output and drain
the oil by opening the oil drain plug (17).
10.2.1. Exchange of Bearings (76) and (77)

Disassembly:
First of all the hex nut (83) in the cardan flange must be loosened. It is locked with Loctite,
the loosening torque might exceed 800 Nm! For this reason preheating the nut with a blow
lamp to about 120°-max.160°C is recommended. Counter against the loosening torque at
the opposite cardan flange. Unscrew the nut and draw the cardan flange (81) from the
shaft. Loosen hex bolts (55) and (56) and remove complete assembled housing (58) from
the transfer case. The shifting sleeve (69) and the bearing inner ring (66) for now remain
in the transfer case. Remove both seal rings (85, 86) from the housing (58) and extract O-
ring (82) from the groove in the shaft (84).
Now the shaft (84) can be pressed out through the inside of housing (58) and the seal ring
(68) can be disassembled. Extract both bearing outer rings (76) and (77) from the hous-
ing (58) and pull bearing inner ring (76) from the shaft (84).
Assembly and adjustment of bearings:
Insert new bearing inner ring (76) onto shaft (84) and new bearing outer rings (76) and
(77) and seal ring (68) into housing (58). Then set spacer ring (78) onto the step of the
shaft, install a set of adjusting washers (114) with a preliminary total thickness of 1.5 mm
and the spacer sleeve (115) on the shaft, and put the shaft into the housing (58). Shift
inner ring of bearing (77) and then cardan flange (81) onto the shaft and without using
Loctite tighten nut (83) with 800 Nm torque. Now check the adjustment of the bearings:
- The adjustment is correct if the axial play of the shaft is between 0 and 0.1 mm, there
must not be any pretension.
- If the axial play of the shaft is more than 0.1 mm select a thinner set of washers (114).
- If there is pretension on the bearings, select a thicker set of washers (114).
The actually needed total thickness of adjusting washers (114) can vary from 0.5 to
1.8 mm, the washers are available from 0.5 to 1.0 mm with a step of 0.1 mm.
If the bearing adjustment is o.k., once more unscrew the hex nut (83) and remove the
flange. Place O-ring (82) into the groove of the shaft and press oil seals (85, 86) into the
housing (83), fill the space between the sealing lips half way with long life grease. Then
insert drive shaft flange (81) onto the profile of the shaft. Clean the threads of nut and
shaft from dirt, grease or oil. Cover both threads with Loctite 639 (alternatively 275) on
their whole length and circumference and tighten the nut again with 800 Nm torque. Do
not use an impact screwer to avoid the glue to be thrown off.
Adjust the disengagement clutch as described in the following chapter.
10.2.2. Adjustment of the disengagement clutch

Prior to the attachment of the preassembled housing (58) to the transfer case the mesh
gap between the face of shaft (84) and the shifting sleeve (69) is to be inspected to
ensure it has remained between 0.2 mm to 0.7 mm.
Remove shifting sleeve (69) along with bearing inner ring (66) from shaft (36) and press
them against bearing outer ring (66, in preassembled housing 58) such that the face of
piston (65) is against housing (58), ie. against the adjusting washers (67). The teeth of
shaft (84) and shifting sleeve (69) must be meshed for this. Now, with the use of a feeler
gauge the mesh gap of the face can be measured.
- If the gap is less than 0.2 mm the thickness of the washer package (67) is to be adjusted
accordingly by adding washers.
- If the gap is more than 0.7 mm the thickness of the washer package (67) is to be
adjusted by removing washers.
Install new gasket (57) and o-ring (59). and insert shifting sleeve (69) onto the splines of
shaft (36), ensuring that the compression springs (70, equal to 75) are properly located
inside the holes of the shifting sleeve (69) and of the housing (15). Now mount pre-
assembled housing (58) and tighten with hex bolts (55) and (56).
10.2.3. Exchange of Bearing (66)

Disassembly:
Loosen hex bolts (55) and (56) and remove complete assembled housing (58) from
transfer case. Remove piston (65) from housing (58). The piston should be held rather
firmly by friction of the seal rings, it can be necessary to press it out of the housing (58) by
installing a hydraulic hand lever press to the thread M14x1.5 for the all-wheel drive
disengegement. Extract bearing outer ring (66) from the piston. When doing this ensure
that both internal and external sealing surfaces of the piston do not become damaged.
Then remove shifting sleeve (69) from shaft (36) and extract bearing inner ring (66) from
the shifting sleeve.
Assembly:
Insert new bearing inner and outer ring (66) into shifting sleeve (69) and piston (65)
respectively. Continue assembly i.e. adjustment of the mesh gap of the release shifter as
per 10.2.2.
10.2.4. Exchange of Seals (60, 61 and 62, 63)
Disassembly:
Loosen hex bolts (55) and (56) and remove complete assembled housing (58) from
transfer case and remove piston (65) from housing (58). Now extract both seals (60) and
(62) and both supporting rings (61) and (63) from the housing grooves.
Assembly:
Frst install new seals into the bottom of the housing grooves, then install the supporting
rings. When inserting the piston (65) into housing (58) one must be very careful that
neither the seals (60) and (62) or supporting rings (61) and (63) become jammed or are
sheared off. Especially vulnerable is the split supporting ring (63).
If besides the seals and rings no other component were exchanged then the mesh gap
does not need to be readjusted. However, it should be ensured that the previously used
washer package (67) is again installed.
10.2.5. Exchange of Output Shaft (84) and Shifting Sleeve (69)
For this work proceed according to 11.2.1and 11.2.3 The mesh gap between the face of
the coupling sleeve (69) and the shaft (84) is to be readjusted as per 11.2.2.
10.2.6. Exchange of Compression Springs (70, 75)

Disassembly:
Loosen hex bolts (55) and (56) and remove complete assembled housing (58) including
piston (65). Then extract shifting sleeve (69) from shaft (36) profile and remove the 10
compression springs (70) and 16 compression springs (75). The springs (70) and (75) are
identical and have the same order number.
Assembly:
Install all springs into shifting sleeve (69) and housing (15) and insert the shifting sleeve
onto the shaft profile (36). Now install new gasket (57) and O-ring (59) and mount the
complete preassembled housing (58), tighten with hex bolts (55) and (56) together with
spring washers (97).
10.3. Exchange of Transmission Shafts, Gears and Bearings

10.3.1. Opening the Transfer Case
Place the input side of the transfer case face down, and from underneath support the
housing with suitable blocks. Then loosen hex bolts (55) and (56) and remove complete
assembled housing of the all wheel drive release shifter (58) in the up direction. Pull out
the coupling sleeve (69) with inner ring of bearing (66). Remove all springs (70, 75) and
keep them for reassembly.
Loosen the lock of groove nut (72), i.e. bend its collar out of the grooves in the shaft. The
nut additionally is locked with Loctite, therefore preheat the nut to about 120°-160°C and
loosen it. Counter the loosening torque at the internal spline of the input shaft (3) with the
low or high speed gear engaged (shift cylinder not in neutral position). Open plug (2) and
through this hole screw a bolt M12x80 (or longer) into the center thread of the input shaft
(3). Now loosen all hex bolts (13), face input side of transfer case up and remove housing
(16) from housing (15) also in the up direction. Assist by tapping with a rubber or brass
hammer onto the bolt M12 in the input pinion (3) and against the face of output shaft (36).
10.3.2. Exchange of Input Pinion (3) and Bearings (1, 4)

Disassembly:
Orientate the input pinion such that it will bypass gear block (23) and can be pressed out
bearing (1) towards the top. It may be required to assist with light taps of a 16 mm
diameter brass mandrel through the G ¾” thread of screw plug (2). Bearing (1) can only be
removed together with shafts (23) and (36). See chapter 11.3.5.
Remove bearing (4) from pinion (3). Remove snap ring (6) and adjusting washers (5) from
housing (16).
Assembly:
First insert bearing (4) onto input pinion (3)and insert both pieces into the hole of installed
bearing (1). Place a new gasket (11) between and from above place housing (16) onto
housing (15) and tighten both housing halves with hex bolts (13).
Push input pinion (3) towards housing (15) with the aid of assembly sleeve (Din = 61 mm,
Dout = 70 mm, L = 100 mm), such that bearing (1) is against housing (15), and then
measure dimension „a1“ between bearing (4) and the snap ring. The washer package (5)
thickness must be 0,2 mm to 0,4 mm smaller than the measured dimension „a1“.
Install washer package (5) and snap in snap ring (6) again.
Turn in screw plug (2), install compression springs (70) and (75), insert shifting sleeve (69)
onto shaft (36) and mount complete assembled housing of the all wheel drive release
shifter (58) again onto the transfer case and tighten with hex bolts (55) and (56). Prior to
this insert new gasket (57) and o-ring (59).
10.3.3. Exchange of Shaft (36), Gears (29, 33) and Bearings (27, 30, 32)
Disassembly:
First remove input pinion (3) from housing (15) as per 11.3.2. Then extract snap ring (74)
and supporting washer (73). Afterwards loosen the lock of grove nut (72) and loosen nut
(72), while countering against the 40 x 36 DIN 5482 splines of shaft (36).
Caution: The loosening torque can exeed 1500 Nm! For easier disassembly heat the
grove nut to approximately 150 degrees celsius.
Loosen hex bolt (8) and now press out and remove complete assembled shaft (36)
including shifting fork (7) together with gear block (23). Press out bearing (27) towards the
bottom out of housing (15).
The components mounted on shaft (36) such as: washer (28), gear (29), bearing (30),
inner ring (35), shifting sleeve (31), coupling sleeve (19), gear (33), bearing (32),
intermedite rings (34) and washer (111) can now be removed one after the other and
replaced with new components.
Caution: The two needle bearings (30) and (32) must contain needle rollers of same
diameter tolerances such that the bearing load is equally distributed.
Therefore the two needle bearings of a gear can only be exechanged as a set.
Assembly:
Insert new bearing (27) with mounted snap ring (71) into and against the shoulder of
housing (15), install support washer (73) and mount snap ring (74). Then from the top
install preassempled shaft (36) including shifting fork (7) together with gear block (23). By
doing this shaft (36) must be inserted into the hole of bearing (27), shifting fork (7) is
inserted onto the shifting rod (100), and gear block (23) is inserted into bearing outer ring
(20). One must be especially careful when doing this not to damage Nilosring (18).
Now tighten shifting fork (7) to shifting lever (42) with a new adhesive thread couted hex
bolt (8). Apply groove nut (72) onto shaft (36), while countering against the splines of shaft
(36), and lock (ie. caulk) the nut in two places.
Prior to assembly clean the threads of the nut and shaft and coat with Loctite 639
(alternatively 275). Install input pinion (3) again into the hole of bearing (1).
10.3.4. Exchange of Gear Block (23) and Bearings (20, 25)
Disassembly:
Gear block (23) can only be exchanged together with shaft (36).
First remove input pinion (3) from housing (15) as per 11.3.2, and then the gear block from
housing (15) as per 11.3.3 and pull off bearing inner rings (20) and (25) from gear block
(23). Extract bearing outer ring (20) from housing (15) and bearing outer ring (25) from
housing (16).
Assembly:
Adjusting the Axial Backlash of the Intermediate Shaft (23) as per 11.3.5. From the top
install gear block (23) together with preassembled shaft (36) and shifting fork (7). By doing
this shaft (36) must be inserted into the hole of bearing (27), shifting fork (7) is inserted
onto the shifting rod (100), and gear block (23) is inserted into bearing outer ring (20). One
must be especially careful when doing this not to damage Nilosring (18). Continue
assembly as per 11.3.2 and 11.3.3
10.3.5. Adjusting the Axial Backlash of the Intermediate Shaft (23)
If the intermediate shaft (23) or its bearings have been exchanged the axial play of the
roller bearings (20, 25) has to be adjusted. For this adjustment, input and output shafts (3,
36) should not be mounted for the time being.
Install supporting washers (22) and (24), Nilos seal rings (21) and (18), and bearing inner
rings (20) and (25) onto the shaft (23) and insert outer raceways of the roller bearings (20,
25) into the housings (15, 16), for the time being without adjusting washers (26). Handle
this shaft carefully and do not spoil the Nilos rings by bending. Install preassembled shaft
(23) into housing (16), place new gasket (11) between housings, mount housing (15) on
top of housing (16), and tighten both halves with 4 hex bolts (13).
Turn in a M12x80 hex bolt into the thread on the face of the shaft and measure the axial
play of the roller bearings by moving shaft (23) back and forth. The washer package (26)
is to be selected 0.2 to 0.4 mm smaller than the axial play was measured without the
adjusting washers.
Again open the gear box and take out the intermediate shaft (23). Extract bearing outer
ring (20) from housing (15), insert the selected washer package (26) into the seat of the
housing, and again insert bearing outer ring (25) into the housing.
10.3.6. Closing the Transfer Case

Place a new gasket (11) between and from above place housing (15) onto housing (16).
Support by carefully hitting the housing with a rubber hammer. Tighten both housing
halves with hex bolts (13).
Cover the clean threads of the output shaft and of the grooved nut (72) with Loctite 639 on
their whole length and circumference, then screw on the nut and tighten with 800 Nm
torque. Counter the torque at the internal spline of the input shaft or at the internal spline
of the output shaft (which still has to be supported by a solid block). Additionally lock the
nut by bending its collar into both grooves of the shaft.
Install all springs (70, 75) into shifting sleeve (69) and housing (15) and insert the shifting
sleeve onto the spline of the output shaft (36). Install new gasket (57) and O-ring (59) and
mount the complete preassembled housing (58), tighten with hex bolts (55) and (56)
together with locking washers (97).
Push input pinion (3) towards housing (15) with the aid of an assembly sleeve (Din = 61
mm, Dout = 70 mm, L = 100 mm), such that bearing (1) is against housing (15), and then
measure the gap between the outer ring of the ball bearing (4) and the circlip ring (6). The
total thickness of the washer package (5) must be 0.2 - 0.4 mm smaller than the
dimension measured. If the input shaft and its bearings have not been exchanged the
original washers should be ok.
Remove the circlip ring (6), install the washer package (5) and again snap in the circlip
ring (6). Install plug (2) and both oil drain plugs (17, 93) with new copper seal rings.
10.4. Gear Shifting

All components of the shifting cylinder, with the exception of shifting rod (43), can be
exchanged without the removal of the transfer case from the vehicle provided it is easily
accessible.
10.4.1. Exchange of the Shifting Cylinder (52) and of the Seals (49), (50), and
(51) in the Cylinder
Remove hydraulic connections, loosen allan screw (53), and disassemble fishplate (116)
then loosen hex bolt (117) and take off the complete pressure switch (118).
Loosen hex bolts (54), and pull the cylinder (52) from the shifting rod (43).
Remove snap ring (103) and disassemble ring (104) along with shaft seal (51) from the
cylinder (52). Insert new seal (51, rubber seal lip ahead) and ring (104) into the cylinder
(52) and secure again with snap ring (103).
Extract snap ring (105) and remove the piston (109) together with supporting washer (107)
from the shifting rod (43). Also extract snap ring (108) and remove the centering ring (47)
from the shifting rod. Extract shaft seal (49) from the groove in the centering ring and
replace with a new seal.
With a sharp tool lift the piston seal (50, having two parts) out of its groove in the piston.
Use an assembly tool to install a new piston seal (50) in the groove of the piston (109),
first install the rubber ring then the composite ring.
Insert centering ring (47) again onto shifting rod (43), install snap ring (108), insert
supporting washer (107), install new o-ring (106) into the groove, insert piston (109) and
secure with snap ring (105).
Caution: During disassembly and assembly of both snap rings, extra care must be
taken not to damage the sealing surfaces of the shifting rod. Best cover the sealing
surfaces with adhesive film while mounting the snap rings. Also do not overstretch the
snap rings with the circlip pliers, they must sit in their grooves under proper tension.
Mount new gasket (46) and new o-ring (48) and install cylinder (52) again and tighten with
hex bolts (54). Mount the complete pressure switch (116).and tighten hex bolt (117) then
assemble fishplate (118) and tighten allan screw (53). Connect the hydraulic connections.
10.4.2. Exchange of the Shifting Rod (43)

10.4.2.1. Disassembly of the Shifting Rod
Remove transfer case from the vehicle and open the transfer case as described in chapter
11.3.1.
Pull spacer ring (28), gear (29) and needle bearings (30) from the shaft (36). Loosen two
hex bolts (54) and remove the shifting cylinder (52). Open nut (45) on the shifting rod
(43). On the flattened outer end of the shifting rod (43) with a wrench (WS 13) you can
counterhold the loosening torque of the nut (45). The nut is locked with Loctite, preheating
it up to 120°-160°C is recommended. Then pull out the shifting sleeve (31) together with
shifting fork (7) and lever (42). Pull the shifting rod (43) out of the housing (16).
10.4.2.2. Assembly of the Shifting Rod
Insert a new shifting rod (43) through the hole in the housing (16). Shift shifting fork (7)
and shifting lever (42) together with shifting sleeve (31) over the spline on the output shaft
and onto the end of the shifting rod. Cover the threads of the shifting rod and of hex nut
(45) on their whole length and circumference with Loctite 639 install support washer (44)
and tighten the nut with 135 Nm torque. During this counter the shifting rod at its flattened
opposite end (wrench size 13). Mount centering ring (47) and piston (109) onto the shifting
rod as per 10.4.1.,mount new gasket (46) and new o-ring (48) and install cylinder (52)
again and tighten with hex bolts (54). Mount the complete pressure switch (116).and
tighten hex bolt (117) then assemble fishplate (118) and tighten allan screw (53). Connect
the hydraulic connections.
Shift two needle bearings (30, both belonging to the same tolerance class of diameter)
onto the output shaft, then insert gear (29) and spacer ring (28). The close the transfer
case as described in chapter 11.3.6.
10.4.3. Exchange of Shifting Fork (7), Shifting Lever (42) and Shifting Sleeve (31)
Disassemble according to the description in chapter 11.4.2.1, however, the shifting rod
can remain in the housing (16).
To exchange shifting fork or lever, open hex bolt (8) which connects both parts. The bolt is
locked with Loctite, preheating it up to 120°-160°C is recommended. For reassembly with
exchanged new parts, note that the threads of shifting lever (42) and bolt (8) are clean
from dirt, oil or rests of hardened glue. Then cover both threads on the whole
circumference with Loctite 639 and fasten with 34 Nm torque.
Finish assembly as described in chapter 11.4.2.2.
10.4.4. Exchange of the Shifting Rod (100)

Te exchange this intermediate shifting rod (100) the gear box has to be opened according
to chapter 11.3.1 Then open the Allen bolt (101), take the pair of washers out of the
groove in the rod and pull or hit out the shifting rod. Insert the new rod into the bore in the
housing (15) and lock with two washers (9) and a new Allen bolt (101) which has a
selfadhesive coating. Finish assembly as per 11.3.6.
Fig. 10: Section drawing for shifting cylinder

43. Shifting rod 103. Snap ring
44. Supporting washer 104. Ring
45. Nut 105. Snap ring
46. Gasket 106. O-ring
47. Centering 107. Supporting washer
48. O-ring 108. Snap ring
49. Shaft seal 109. Piston
50. Piston seal 116. Pressure switch complete
51. Seal 117. Hex. Bolt
52. Cylinder 118. Fish plate
53. Allen screw
54. Hex. bolt
Insert punch WZ 200

To insert the seal rings 1160.121 in diff. housing near
pinion between diff.housing and transfer case
(short distance)
Installer tool / Socket wrench WZ 550
for pinion 7502.152 in diff
Installer tool / Arm brackets WZ 209
for nut 73290.063 in in diff.
Partnumber for Diff. (Drawing no. 7500.253) 68. Nut for transfer case screwing
71. Bolt for transfer case screwing
85. O-Ring for transfer case sealing
87. Oil seals between Diff. and Transfer case
102. Left Axle beam
106. Dowel pin for Axle beam
107. Dowel pin for Axle beam
10. Washer crown wheel
118. Driven disk
11. Diff.-cage
119. Dive disk
120. Operating disk
121. Spring
122. Dowel pin for drive disk
16. Cross bolt
17. -
23. Circlip as support washer for bearing
37. -
38. -
41. -
42. Diff.-housing
46. -
49. -
51. -
53. -
57. -
58. -
59. -
Partnumber for Transfer case (Drawing no. 00.98000.191.0)
1. Grooved ball bearing 41. Locking washer 81. Drive shaft flange
2. Screw Plug 42. Shifting lever 82. O-ring
3. Driving pinion 43. Shifting rod 83. Nut
4. Grooved ball bearing 44. Support washer 84. Output shaft
5. Washer package 45. Hex nut 85. Oil seal
6. Seeger, ring 46. Gasket 86. Oil seal
7. Shifting fork 47. Centering 87. Screw Plug
8. Washer 48. O-ring 88. -
9. Hex bolt 49. Shaft seal 89. -
10. Distance bushing 50. Piston seal 90. -
11. Gasket 51. Seal 91. Breather
12. Dowel pin 52. Shift cylinder 92. Elbow
13. Hex bolt 53. Allen screw 93. Reducing nipple
14. Locking clip 54. Hex bolt 94. -
15. Housing 55. Hex bolt 95. Seal ring
16. Housing 56. Hex bolt 96. Locking washer
17. Screw Plug 57. Gasket 97. Locking washer
18. - 58. Housing 98. Dowel pin
19. - 59. O-ring 99. -
20. Cylinder roller bearing 60. Quad ring 100. Shifting rod
21. Nilosring 61. Support washer 101. Allen screw
22. Supporting plate 62. Quad ring 102. -
23. Spur gear block 63. Support washer 103. Snap ring
24. Supporting plate 64. Split spring pin 104. Ring
25. Cylinder roller bearing 65. Piston 105. Snap ring
26. Washer package 66. Tapered-roller bearing 106. O-ring
27. Grooved ball bearing 67. Washer package 107. Support washer
28. Washer 68. Scraper ring 108. -
29. Spur gear 69. Shifting sleeve 109. Pistion
30. Needle cage 70. Compression spring 110. Seal ring
31. Shifting sleeve 71. Circlip 111. Washer
32. Centering sleeve 72. Nut 112. -
33. Spur gear 73. Supporting plate 113. -
34. Centering sleeve 74. Seeger-ring 114. Adjusting washer
35. - 75. - 115. Spacer sleeve
36. Shaft 76. Tapered-roller bearing 116. Pressure switch compl.
37. Circlip 77. Tapered-roller bearing 117. Hex bolt
38. Bolt 78. Washer 118. Fish plate
39. Nut 79. -
40. O-ring 80. -
coupling )
14 Oil plug
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
48 Bushing
49 Portalgear
56 Stub axle ring
Partnumber for axle beam (Drawing no. 00.92500.044.0)
101 Right Axle beam

102 Left Axle beam
103 Axle beam screw
104 Axle beam screw
105 HE-S ring
109 Brake chocke
112 -
118 Engagement disk
121 Tooth ring
coupling )
140 Drive shaft
143 Oil fill plug
145 -
146 -
147 -
148 Breather
149 -
150 -
172 Slewing ring
177 Wearing plate
179 White plug
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 130

Used as rear axle in Timberjack 810D Forwarder
Date: 19 December 2002
Contents Page
3. Differential.................................................................................................................................. 5
00.92500.044.0, 00.92500.112.0,
Date: 19 December 2002 page II
Before starting Differential and brakes:
operation Make sure that the oil drain plug (42) with copper seal ring is
properly tightened with 90 Nm torque. Remove oil filler plug (40)
in the brake housing and add approx. 12 L oil according to the
table of permitted lubricants until the oil starts overflowing from
the control plug (41). Therefore open these plug on the vertical
face opposite of the cardanflange side it is the brake cylinder
side. Close oil filler- and oil control- plug with copper seal ring
and tighten with 90 Nm torque.
Bogie housings:
The tandem housing must be in a horizontal position. Make
sure that the oil drain plugs (62, 63) with copper seal rings are
properly tightened with 90 Nm torque. Remove one of the fill
plugs (60) and the control plug (61, in the centre cover). Add
approx. 52 L oil as per lubrication chart until the oil starts
overflowing from the control plug (61). Tighten the fill plug (60)
with 90 Nm, the control plug (61) with 55 Nm.
Slewing ring:
The slewing ring has lifetime lubrication in the raceway grease
volume and need no service. The only service work is
replacement of solied grease in buffer volume.
First oben lubricating outlet plugs (92, 2 per side covered with
white plastic caps)
plastic caps) grease with grease gun until grease sqeeze out
from the lubricating outlet (92, 2 per side with white plastic cap).
Then close outlet plugs and grease again with grease gun until
grease sqeeze out from the gap has sealed itself with grease all
the way around the circumference. Leave excessed grease
built up. Again cover grease nipples with white plastic caps.
After the first working Due to stresses of the vehicle motion the wheel nuts will seat
day themselves properly. Timely tightening of these will prevent
damage to the wheel rims (tightening torque of the wheel nuts:
550 Nm).
Date: 19 December 2002 page III
After the first 250 Bolts and nuts may settle due to loads and vibrations of the
operating hours vehicle. Retightening all visible bolts can prevent leaks and
recommended, for tightening torques see the table in the repair
instruction. The center nut (hex nut WS50) of the input cardan
flange with adhesive locking must not be retightened.
Change oil while it is warm. First clean oil drain plug (42), oil
control plug (41), oil filler plug (40) and surrounding areas of
(approx. 12 L). Clean the magnetic inset of the oil drain plug
from any metal wear. Screw in the oil drain plug (42) with new
copper seal ring and tighten with 90 Nm torque. Add approx. 11
L oil according to the table of permitted lubricants until the oil
starts overflowing from the control plug (41). Therefore open
these plug on the vertical face opposite of the cardanflange
side it is the brake cylinder side. Close oil filler- and oil control-
plug with copper seal ring and tighten with 90 Nm torque.
draining the oil the axle should be at least 30 minutes at rest
allowing all the dirt particles to settle in the appropriate
area to avoid dirt coming into the housing. First remove one of
the fill plugs (60) and the control plug (61), then open the main
oil drain plugs (62), two per tandem housing, and drain into a
clean container since it is possible that this portion of oil is used
again. Then remove the unusable oil plugs (63, with magnetic
inset), also two per tandem housing, and let the oil drain into a
separate basin. Close the drain plugs (62, 63) with new copper
seal rings and tighten with 90 Nm torque, the plug with
magnetic inset at the lower position. Add oil as per lubrication
chart into the fill plug (60) until the oil starts overflowing from
the control plug (61) (first the collected old oil, complete with
new clean oil). Tighten the fill plug (60) with 90 Nm, the control
plug (61) with 55 Nm.
Date: 19 December 2002 page IV
After every 250 Slewing ring:

operating hours The slewing ring has lifetime lubrication in the raceway grease
volume and need no service. The only service work is
replacement of solied grease in buffer volume.
First clean the area around the grease nipples and oulet plugs
(90/92) Then oben lubricating outlet plugs (92, 2 per side
covered with white plastic caps)
plastic caps) grease with grease gun until grease sqeeze out
from the lubricating outlet (92, 2 per side with white plastic cap).
Then close outlet plugs and grease again with grease gun until
grease sqeeze out from the gap has sealed itself with grease all
the way around the circumference. Leave excessed grease
built up. Again cover grease nipples with white plastic caps.
After every 500 Check oil levels in differential (control plug 41) and in both
operating hours or at bogie housings (control plug 61) and add oil if required.
least monthly
After every 2000 Differential and brakes
operating hours or at Change oil in differential when it is warm, see explanation
least annually above for oil change at 250 operating hours, however, the
Under normal circumstances the operating brake will not wear.
However the air gap should still be inspected every 2000 hours.
If required inspect disks and adjust air gap or cylinder stroke or
replace disks (see repair instruction).
After every 5000 Bogie housings:
operating hours Change oil in both bogie housings as described above for oil
change at 250 operating hours.
Table of Lubricants
Date: 19 December 2002 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: 19 December 2002 page 1
bogie.
.
Figures: 00.75000.226.0, 00.92500.044.0, 00.92500.112.0

1 hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x16 8.8 1020.203 49 Nm
9 hex bolt M14x40 10.9 VP 1010.424 185 Nm
22 Allen M10x80 10.9 VP 1020.335 67 Nm
39 plug R ½" 1040.125 55 Nm
103 hex bolt M18x2x70 10.9 1010.662 400 Nm
104 hex bolt M18x2x60 10.9 1010.653 400 Nm

Figures: 00.75000.226.0, 00.92500.044.0, 00.92500.112.0

Fig. no. 00.92500.044.0 (LOK 130 with BB)
103 hex bolt M18x2x70 10.9 1010.662 400 Nm
104 hex bolt M18x2x60 10.9 1010.653 400 Nm
115 Allen bolt M10x45 8.8 1020.208 45 Nm
131 hex bolt M12x100 10.9 VP 1010.323 115 Nm
143 plug R ½" 1040.125 55 Nm

Figures: 00.75000.226.0, 00.92500.044.0, 00.92500.112.0
2.3. Bogie Housing,

Fig. no. 00.92500.021.0 (LOK 130 with BB)
10 hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 hex bolt M10x25 10.9 VP 1010.201 72 Nm
46 hex bolt M12x50 10.9 VP 1010.326 115 Nm
54 plug M30x1.5 1040.103 105 Nm

Figure: 00.75000.226.0
3. Differential
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.226.0
se = 147 - Le - L1 [mm] (as experience shows use a thickness near 2.4 to 3.65)
Figure: 00.75000.226.0
Install the adjusting washers (44) vary in thickness from 0.96 to 1.44 mm with a step of
0.04 mm and the spacer sleeve (47) has a fix measurement of 24.9 mm.,. Select a
combination of spacer sleeve and an adjusting washer set with a total width of (between
26.90 and 28.10 mm ) for now and slide them onto the shaft of the pinion. Insert this unit
required through the use of different adjusting washers set (44) the proper bearing preload
is to be adjusted.
5 Nm.
Figure: 00.75000.226.0

Figure: 00.75000.226.0
Figure: 00.75000.226.0
3.3. Exchange of the Compensating Gears

Disassembly
Assembly



Figure: 00.75000.226.0
necessary.
between seals (88 and 87) with grease, install new O-ring (49), and shift the cardan flange
(51) onto the spline of the shaft. Now cover the threads of shaft and nut with Loctite 639.
The applying and tightening of the nut must not take any longer than 3-5 minutes to avoid
any hardening of the adhesive. The nut cannot be applied using an impact wrench since
this will promote early hardening and the adhesive will be spun off the threads. Tighten the
nut with 800 Nm torque.

Figure: 00.75000.226.0

Figure: 00.75000.226.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm

cylinder.
to set-up as per point 5.2 and 5.3, inspected and tested.


completly removed.


cylinders!
Disassembly:
Assembly:
bolts (113).
Disassembly:
Assembly:
Disassembly:
First disassemble spring loaded cylinder (151) from the brake cylinder (150) as per 5.3.1
renewed.
Assembly:
5.4.1.

Disassembly:
exchanged.
Assembly
activation disks.
ramp disks (118).
per 5.2.
necessary.
Repair Instruction,
00.92500.112.0

this the balance planetary drive will remain in the axle beam (101/102) and can now be
taken out as a complete subassembly [LOK 130].

Repair Instruction,
00.92500.112.0
smin = 131.5 - "A" = ..... mm
smax = 132.5 - "A" = ..... mm

(179).
Repair Instruction,
00.92500.112.0

Assembly:
Repair Instruction,
00.92500.112.0


hex bolts (124).

Inlay a new O-ring (19) into the groove of the stud. Insert it into the hole of the bogie
housing (31), gear (23) and spacer ring (16). The stud is to be turned and orientated such
that split taper sleeve (17) interlocks with the groove of stud (18) and secure with new
adhhesive coated hex bolts (22). Apply new liquid flange sealant on to the clean surface
side of partal housing before the cover (21) installed.

diameter hole.



Fig.10:


• The threads of the nut and output sahft must be free of any dirt, oil, and corrosion
35 Nm.
sit closely in their boring in the bogie housing and apply new liquid flange sealant on to the
clean flange surface side of partal housing.

hex bolts (26).
Insert punch WZ 201

(short distance)
Partnumber for Diff. (Drawing no. 00.75000.226.0) 89. Oil seal Drive shaft flange
102. Left Axle beam
118. Driven disk
119. Dive disk
120. Operating disk
11. Diff.-cage
16. Cross bolt
17. -
23. -
36. -
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. –

coupling )
14 Oil plug
31 Tandem axle beam
37 Face seal
38 Wheel bolt
39 Flat nut
40 Lock washer
43 Pinion shaft
48 Bushing
49 Portalgear
56 Stub axle ring

115 Allen screw for parking brake cylinder 145 -
116 O-ring among parking brake cylinder 146 -
117 Parking brake cylinder complete 147 -
119 On the outside-brake disk 149 -
122 Locking bolt for brake disk 172 Slewing ring
SERVICE MANUAL AND
REPAIR INSTRUCTION
LOK 131

Used as a rear axle in Timberjack 1110D forwarder
Date: December 10,2002
Contents Page
3. Differential.................................................................................................................................. 5
Assembly drawings 00.75000.260.0, 00.92500.044.0, 00.92500.045.0, QMA Nr.: 09.004.0
Assembly Device / Special Tools Sk 4.96-1019, Sk 2.96-136
Date: December 10,2002 page II
Bogie housings:
with 55 Nm.
Slewing ring:
grease volume. The only service work is replacement of
solid grease in buffer volume.
At all 2 grease nipples (90, 2 per side with white plastic cap)
grease with grease gun until the gap has sealed itself with
grease all the way around the circumference. Leave
white plastic caps.
Date: December 10,2002 page III
retightened.
(61) with 55 Nm.
Date: December 10,2002 page IV
grease gun at all 2 grease nipples per side until the gap has
Table of Lubricants
Date: December 10,2002 page V
e.g.
ARAL Degol 3216

Fuchs Renogear LS90

Renogear HLS 90

Figure: 
Date: December 10,2002 page 1
bogie.
this manual.
Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

1 Hex bolt M8x16 10.9 VP 1010.129 36 Nm
4 Allen bolt M10x20 8.8 1020.212 49 Nm
9 Hex bolt M16x1,5x40 10.9 VP 7322.066 310 Nm
22 Allen M12x85 8.8 VP 1020.335 79 Nm
39 Plug R ¾" 1040.103 90 Nm
50 Hex nut M40x1.5 7329.057 800 Nm
54 Plug M20x1,5 with magnet 9556.021 53 Nm
103 Hex bolt M20x2x90 10.9 1010.668 560 Nm
104 Allen bolt M20x2x90 10.9 1010.620 500 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0

Fig. no. 00.92500.044.0 (LOK 131 with BB)
103 Hex bolt M20x2x90 10.9 1010.668 560 Nm
104 Allen bolt M20x2x90 10.9 1010.620 500 Nm
115 Allen bolt M10x45 8.8 1020.208 49 Nm
124 Hex bolt M20x2x90 10.9 VP 1010.669 500 Nm
131 Hex bolt M20x2x130 10.9 VP 1510.507 560 Nm
143 Plug R ¾" 1040.151 90 Nm

Figures: 00.75000.260.0, 00.92500.044.0, 00.92500.045.0
2.3. Bogie Housing,

Fig. no. 00.92500.045.0 (LOK 131 with BB)
10 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
22 Hex bolt M10x20 10.9 VP 1010.233 72 Nm
26 Hex bolt M10x25 10.9 VP 1010.234 72 Nm
46 Hex bolt M16x60 10.9 VP 1010.544 310 Nm
54 Plug M30x1.5 1040.103 105 Nm
57 Allen bolt M16x70 10.9 1020.517 280 Nm
160 Hex bolt M16x45 10.9 1010.567 310 Nm
178 Allen bolt M16x70 10.9 1020.512 280 Nm

Figure: 00.75000.260.0
3. Differential
bolt as per 5.3.

Chapter 3.1.1.
Figure: 00.75000.260.0
3.2.2.1. Adjusting the Contact
Pattern
Push the bearing inner ring (43) onto
the pinion shaft (if necessary evenly
warm up the bearing to 80°-110°C). In
order to adjust a good contact pattern
of the hypoid gearing, the proper
thickness of the adjusting washer (45)
is to be determined as follows, see
Fig.2:
- Measure the actual distance L1 from
the outer ring of the taper roller
bearing (43) to the face of the pinion.
To avoid mistakes, the jaw length of
the caliper gauge must be at least
120 mm. The dimension L1 may vary
near 93.57 mm.
Fig.2: Determining the dimension se to adjust which can be read from the face of
the contact pattern of the hypoid gearing the pinion. Le will be approximately
82.73 mm.
Figure: 00.75000.260.0
se = 178.8 - Le - L1 [mm]
5 Nm.
Figure: 00.75000.260.0
Figure: 00.75000.260.0
Figure: 00.75000.260.0

Disassembly
Assembly
Figure: 00.75000.260.0



necessary.
with 800 Nm torque.
Figure: 00.75000.260.0

recommended.
piston.
Figure: 00.75000.260.0
"s" min. = "X" - "Y" + 0.2 mm = ..... mm
"s" max. = "X" - "Y" + 0.7 mm = ..... mm
Figure: 00.75000.260.0

cylinder.




Disassembly:
Assembly:
Disassembly:
Assembly:

(169).

Disassembly:
exchanged.
Assembly
activation disks.
Fig.8: Multiple Disk Brake doing this the splines of the drive shaft
(140) are inserted into the splined profile of
the shifting sleeve and compensating gear.
per 5.2.
necessary.
Repair Instruction,


Repair Instruction,
smin = 172.5 - "A" = ..... mm
smax = 173.5 - "A" = ..... mm
(134).

(6).
Fig. 9: Adjusting the axial play in the BB gear 10x per slewing ring) until grease
seeps out over the entire circumference and cover all grease nipples with white plastic
caps (179).
Repair Instruction,

Assembly:
Repair Instruction,


hex bolts (124).


as per 7.1.




dmax = X1 - X2 - 16mm
dmin = X1 - X2 - 16.15mm
with Loctite 639.


11. Diff.-cage
16. Cross bolt
17. Bushing
37. -
38. -
41. -
42. Diff.-housing
46. -
53. -
57. -
58. -
59. -
102. Left Axle beam
101 Right Axle beam

102 Left Axle beam
103 Axle beam screw
104 Axle beam screw
105 HE-S ring
109 Brake chocke
112 -
118 Engagement disk
121 Tooth ring
coupling )
140 Drive shaft
143 Oil fill plug
148 Breather
150 -
177 Wearing plate
179 White plug
Insert punch WZ 213

(short distance)
PART II
HYDRAULIC AND HYDROSTATIC PUMPS & MOTORS
A10VO Working pump repair manual
AA4VG Hydrostatic pump
AA6VM Hydrostatic motor

PART III
VALVES
L90LS Control valve
K170LS Control valve

Directional control
valve L90LS
Proportional, load-sensing and
pressure compensated
Catalogue HY17-8504/UK
Catalogue HY17-8504/US
February, 2001
Catalogue HY17-8504/UK/US Directional Control Valves
Technical Information L90LS
Catalogue layout
In addition to general information and basic technical data, this resents. Alternatively, one or more pressure, flow or voltage op-
catalogue contains descriptions of the many optional functions tions are given.
you can specify for the L90LS, so that we may customize it to On page 7 is a general circuit diagram, which shows the
control your machine optimally. basic function areas of the L90LS, as well as the item numbers
Each function area of the valve is given as a subheading, that represent them. The same item numbers are of course
followed by a brief description. When different options are used in all sub-circuit diagrams elsewhere in the catalogue.
available for a function area, the subheading is followed by an Please note that, unless stated otherwise, all sections and
item number in square brackets, e.g. Pr essur
Pressur
essuree rrelief
elief valve views of the valves have been drawn as seen from the inlet
[16]. This is followed by a series of coded options, e.g. PA1
[16] A1, section.
PS
PS, YY, together with a brief description of what each code rep-
Computer-aided valve specification

We have developed a computer program to specify the L90LS and hydraulic circuit diagram for your valve, as well as a
on the basis of the criteria for each individual machine func- unique ID number that is stamped into the valve data plate.
tion. The program facilitates optimal configuration of the valve Your valve specifications are then stored on our database to
for maximum performance in different applications. It also gen- facilitate rapid identification in the event of service enquiries or
erates documentation in the form of a detailed specification re-ordering.
Early consultation with Parker saves time and money

Our experienced engineers have in-depth knowledge of control characteristics and economic criterie. By consulting
different types of hydraulic system and the ways in which they Parker early in the project planning stage, you are assured of a
work. They are at your disposal to offer expert advice on the comprehensive hydraulic system that gives your machine the
best system for the desired combination of machine functions, best possible operating and control characteristics.
Conversion factors
1 kg = 2.2046 lb
1N = 0.22481 lbf
1 bar = 14.504 psi
1l = 0.21997 UK gallon
1l = 0.26417 US gallon
Parker reserves the right to modify products without prior no-
tice. 1 cm3 = 0.061024 in3
Typical curves and diagrams are used in this catalog. 1m = 3.2808 feet
Even though the catalog is revised and updated continuously, 1 mm = 0.03937 in
there is always the possibility of errors. For more detailed infor- 9/5 °C + 32 = °F
mation about the products, please contact Parker.
2 Parker Hannifin AB
Mobile Controls Division
Borås, Sweden
List of contents Page

General .......................................................................................................................... 4
Technical data ............................................................................................................... 6
Inlet section
Inlet sections [15] .......................................................................................................... 8
Pressure relief valve [16] ........................................................................................ 9
Pressure setting [17] ............................................................................................... 9
Load signal system [20] ....................................................................................... 10
Pump-unloading function [22] .............................................................................. 11
Tank connection T1 [25] ....................................................................................... 11
Pump connection P1 [26] ..................................................................................... 11
End section
End section, basic variant [30] ............................................................................. 12
LS connection [31] ................................................................................................ 12
Pump connection P2 [32] ..................................................................................... 12
Counterpressure valve / tank connection T2 [33] ................................................ 13
Tank connection T3 [34] ....................................................................................... 13
Internal-pilot pressure supply [37] ....................................................................... 14
Pilot filter [39] ........................................................................................................ 14
Separate tank connection for pilot circuit [40] ..................................................... 14
Activation of lever disengagement [42] ............................................................... 14
Spool sections
Cross-sectional drawings ..................................................................................... 15
Basic variants of spool section [47] ..................................................................... 16
Spool actuators [50]
Directly operated, with open spool-end ......................................................... 17
ON/OFF remote-controlled, with open spool-end .......................................... 18
Remote-controlled, proportional spool actuators with open spool-end ....... 18
Lever brackets [51] ......................................................................................... 18
Directly operated with enclosed spool-ends ................................................. 19
Proportionally remote-controlled, with enclosed spool-ends ........................ 19
Proportionally remote-controlled, with enclosed spool-ends ........................ 20
Onn/off remote controlled, with enclosed spool-ends ................................... 20
Connector ........................................................................................................ 20
Lever bracket [51] ........................................................................................... 21
Lever disengagement [52] ............................................................................. 21
Pilot restrictor [55 A, B] ................................................................................... 21
Choice of spool
Spool function [60] .......................................................................................... 22
Flow requirements [61 A, B] ........................................................................... 22
Area ratios [62] ................................................................................................ 23
Load characteristics [63] ................................................................................ 23
Force feedback [64 A, B] ............................................................................... 23
Pressure compensator / load-hold check valve [66] ..................................... 24
Damping of pressure compensator [67] ........................................................ 24
Spool designations [69] .................................................................................. 24
Flow settings [72] ............................................................................................ 25
Feed-reducing valve [75] ..................................................................................... 25
Port relief and/or anti-cavitation valves [76 A, B] ................................................ 26
System functions
System signal lines [80] ........................................................................................ 27
Individual LS connection [81] ............................................................................... 27
Two-speed function [82] ....................................................................................... 28
Internal connection of service port [85] ............................................................... 28
Function manifolds [90-99] ................................................................................... 28
Dimensional drawing, spool actuators with enclosed spool end .............................. 29
Dimensional drawing, spool actuators with open spool end .................................... 30
Direct levers ................................................................................................................ 31
[00] refer to position numbers in the customer specification.
Borås, Sweden
General
The L90LS is a stackable, multi-section, draulic or electro-hydraulic remote con- range of common, section- or port-spe-
load-sensing, pressure-compensated di- trol. Some of our remote-controlled spool cific optional functions can be integrated
rectional valve for mobile machines such actuators can be fitted with a supple- into the L90LS. Examples include:
as cranes, skylifts, forklift trucks, plat- mentary direct lever to give a dual-con-
form trucks, excavators and harvesters. trol and/or emergency facility. The wide • a bypass function in the inlet section
It is designed for working pressures of range of actuating options gives the ma- for systems fed by fixed pumps
up to 320 bar and a maximum pump flow chine designer great freedom in terms of • a pump-unloading function that
of 150 l/min. The valve can be given ex- control criteria and component location. blocks the pump inlet when activated,
cellent simultaneous-operating charac- thus enabling an emergency-stop
teristics, which enable several machine Customization and economy function to be incorporated into the
functions to be operated responsively at The L90LS can be tailored optimally to system
the same time, regardless of the sizes of control either simple or complex ma- • section-specific pressure compensa-
individual loads. chine-functions and combinations tion
To facilitate precise customization for thereof. Its facilities for integrating total,
different applications, the L90LS is of • section-specific load-hold check
wholly customized solutions for a wide functions
wholly modular construction. Each valve range of applications give low system
is therefore built to order, so that it incor- costs and minimal energy consumption. • port-specific relief and anti-cavitation
porates exactly the valve functions and functions
values needed to control the given ma- Safety and serviceability • port-specific feed reduction
chine in an optimal way. The design of the L90LS makes it easy • port-specific force-feedback functions
for machine manufacturers to comply that enable force-sensing and also
Compact, integral system with national and international safety provide a hydraulic ramp function
construction regulations, such as those contained in
• a load-signal copying function to
The total modularity of the L90LS gives the EC Machinery Directive. Special
eliminate micro-sinking
unique opportunities to integrate a wide safety functions for machines such as
range of normally external functions into cranes and skylifts can be integrated • a built-in pilot-pressure function in the
the valve. Such functions can be com- into the valve in a logical and simple end section
mon or specific to individual spool-sec- way. With all system functions contained • a counterpressure function that gives
tions, so that widely differing criteria for in a robust, compact, pre-tested unit with exceptionally good make-up charac-
individual machine functions can be met minimal external pipework, overall safety teristics and the possibility of unload-
in just one valve. This enables compact, and reliability is greatly improved at the ing lowering movements
tailored, logical, pre-tested, service- same time as servicing and the training • section-specific two-speed functions
friendly system solutions to be created of personnel is made much easier. that enable switching between per-
for many different types of machine. formance and precision work in ma-
In situations where flow demands Spool sections and flow rates chines such as cranes and skylifts
vary so greatly that two separate direc- The L90LS can be supplied in combina-
tional valves would normally be required, • automatic stopping functions for se-
tions of 1-12 spool sections or in combi-
the L90LS can, with the aid of a special lected machine movements in the
nation with special function manifolds fit-
adapter plate, be flanged to a larger event of overload or the reaching of
ted between spool sections. The maxi-
valve such as the K170LS or K220LS to other pre-determined limits
mum recommended flow rate per spool
give a compact, unitized system solution section is 125 l/min, or 90 l/m when • a lever-disengagement function that
and optimum economy. equipped with a pressure compensator. immobilizes direct levers when remote
control is engaged
Wide range of spool actuators Examples of optional functions • priority for machine functions such as
The spools in the L90LS can be actuated Depending on the application and oper- brakes and steering.
directly by means of levers or remotely ating criteria of the machine, a wide
by pneumatic, electro-pneumatic, hy-
Borås, Sweden
B A B A
T1
P2B
T2B
T3B
P1
PL LS PX LSPB
L90LS with levers for direct spool actuation and equipped with
bypass for systems fed by pumps with fixed displacement.
B A B A PS
TPB
T1B
P2
P1 T3
PL PX LSPB
LS
L90LS with electro-hydraulic remote-controlled spool actuators pilot-oil supply, counterpressure function, section-specific pres-
and equipped with direct-acting pressure relief valve for sys- sure compensators, port-specific feed reducing valves, port-
tems fed by LS pumps, pump-unloading function, integrated relief and anti-cavitation valves, etc.
Borås, Sweden
Technical data
Connection for hydraulic
remote control, PC.
Service port connection, B-port.
Tank connection Pilot pressure supply
T1 [25] for external use, PS.
Separate tank connec-

tion for pilot circuit, TP
[40]
Pump connection
P2 [32]
Tank connection
T2 [33]
Tank connection
T3 [34]
Pump connection
LS connection from parallel
P1 [21]
valve LSP [31]
LS
PX Service port connection, A-port.
PL
Pressures Synthetic, fire-resistant and environmentally friendly oils can

Pump inlet max. 320 bar* (4600 psi) also be used. If in doubt about the suitability of an oil, please
Service ports max. 350 bar* (5000 psi) contact your nearest Parker representative for information.
Tank connection max. 20 bar (290 psi) Viscosity, function range 15-5000 mm2/s (cSt)
(at start-up)
Flow rates, recommended Viscosity, working range 15-380 mm2/s (cSt)
Pump connection max. 150 l/min (40 US gpm)
Service port, with pressure Technical information in this catalogue applies to an oil vis-
compensator max. 90** l/min (24 US gpm) cosity of 30 mm2/s (cSt) and temperature of 50 °C (122 °F).
Service port, without pressure
compensator max. 125** l/min (33 US gpm) Connections
Return from service port max. 150 l/min (40 US gpm) Connection Location G-version UN-version
* Stated pressures are absolute shock pressures P1 inlet section G 3/4 1 1/16-12 UN-2B
at 10 bar tank pressure. P2 end section G 1/2 7/8-14 UNF-2B
** Depending on spool variant. T1 inlet section G 3/4 1 1/16-12 UN-2B
T2,T3 end section G 3/4 1 1/16-12 UN-2B
Feed reducing valves TP end section G 3/8 3/4-16 UNF-2B
Setting range 50 - 330 bar (725-4800 psi) A, B spool section G 1/2 7/8-14 UNF-2B
LS, PL inlet section G 1/4 9/16-18 UNF-2B
Internal pilot pressure PX inlet section G 1/4 9/16-18 UNF-2B
Fixed setting 22 or 35 bar (320 or 508 psi) PS end section G 1/4 9/16-18 UNF-2B
PS2 end section G 1/8 7/16-20 UNF-2B
Temperature PC spool section G 1/4 9/16-18 UNF-2B
Oil temperature, function range -20 to 90 °C (-4 to 194 °F) ACP, ACE, ACEF spool section G 1/8 1/8-27 NPTF
Oil temperature, working range +20 to 90 °C (68 to 194 °F) LSA/B spool section G 1/8 7/16-20 UNF-2B
LSP end section G 1/4 9/16-18 UNF-2B
Filtration
Filtration must be arranged so that Target Contamination Class Weights
18/14 according to ISO 4406 is not exceeded. Inlet section 5.5 kg 12.1 lb
For the pilot circuit, Target Contamination Class 16/13 End section 4.2 kg 9.3 lb
according to ISO 4406 is recommended. Spool section with spool actuator:
C, B3 4.1 kg 9.0 lb
Hydraulic fluids ACE 5.2 kg 11.5 lb
Best performance is obtained if mineral-base oil of high quality CH, CHB3, CHX, PC 4.5 kg 9.9 lb
and cleanness is used in the hydraulic system. PCH 4.7 kg 10.4 lb
Hydraulic fluids of type HLP (DIN 51524), oil type A for au- EC, EB, 5.2 kg 11.5 lb
tomatic gearboxes and engine oil type API CD can be used. ECH, ECHL, EBHL 5.4 kg 11.9 lb
Borås, Sweden
Hydraulic circuit diagram showing basic functions of L90LS
50 66 76 75 50
PS
B A B A TPB 40
25 T1B
22 32
P2
39
20 37
33
15, 16
T3 34
26 P1
PL PX LSPB
LS
67 60 47 60 31
The item numbers in the hydraulic circuit diagram and ta- is equipped according to the description below. For other
ble below refer to the valve function areas for which differ- equipment alternatives, see under respective valve-function
ent options are available. The valve in the example above area [Item number] in catalogue.
Item Item
No. Code Description No. Code Description
15 CFC Inlet with bypass for systems with fixed pump. 47 TTT Section 1 equipped with pressure compensator,
separate feed reducers for A- and B-ports, and
16 PS Pilot-operated main pressure relief valve.
prepared for port relief valves in both service
20 KB Prepared for load-signal copying. ports.
22 BEN Electrically activated pump-unloading function 000 Section 2 without pressure compensator, feed re-
that blocks the pump and unloads the load ducer or port relief valve.
signal.
50 EC Section 1 equipped with proportional electro-
25 T1B Tank connection in inlet plugged. hydraulic remote control.
26 P1 Pump connection in inlet open. CH Section 2 equipped for direct operation with
spring centring.
31 LSPB Load-signal connection for parallel-connected
valve plugged. 60 D Sections 1 and 2 equipped with spool for double-
acting function, with service ports blocked in
32 P2 Pump connection
neutral position.
33 MF Counterpressure valve with fixed setting.
66 K Pressure compensator with built-in check valve
34 T3 Tank connection open. function.
37 R Pressure reducing valve with separate safety 67 0.8 Restriction of load signal to pressure compensator.
valve for internal pilot pressure supply.
75 Pressure setting for feed reducers in A- and B-
39 S Internal coarse filter for pilot circuit. ports.
40 TPB Prepared for separate tank connection from pilot 76A N2 Anti-cavitation valve in A-port.
circuit.
76B Pressure setting for combined port-relief and anti-
cavitation valve in B-port.
Borås, Sweden
Inlet section
Pump connection P1 [26] Tank connection T1 [25]
Pressure relief valve [16]
Inlet section for fixed or vari-

able pump [15]
Gauge port:
Copied load
signal LS
Pump pressure PX
Load signal PL
Pump unloading function [22]
The inlet section comes in four basic variants; one for fixed pumps, The variant for fixed pumps can be converted easily in the field
two for systems with variable pumps and another - a simple to work with variable pumps, and vice versa. (CFC ↔ LS1).
plate - for use when none of the inlet section’s integrated func- Functions for maximum pressure relief, copying of the load
tions is required. Inlet sections are equipped with pump and signal and pump unloading (which blocks the hydraulic energy
tank connections, a connection for the load signal to LS pumps supply to the valve) can be integrated into the inlet section.
and gauge ports for measuring the pump and load-signal pres-
sures. In all basic variants, the pump connection P1 [26] and
tank connection T1 [25] are open, while the other connections
are plugged.
Inlet sections [15]

CFC Inlet section for systems with fixed pump. The section
is equipped with an adjustable, pilot-operated pres-
sure relief valve [16], which protects the pump and in- P1 P1
let side of the valve. A built-in bypass diverts excess
oil directly to tank. The bypass pressure level is con-
PL PX PL PX
trolled by the load signal, and is approx. 10 bar above
the actual load-signal pressure.
CFC LS1
LS1 Inlet section for systems with LS pump. Equipped with
an adjustable, pilot-operated pressure relief valve
[16], which protects the pump and inlet side of the
valve. T1
LS2 Inlet section for systems with LS pump. Equipped with

a non-adjustable, direct-acting pressure relief valve
[16], which protects the pump and inlet side of the P1
valve. The LS2 variant is normally equipped with a
copy function for the load signal, KS [20].
IP Inlet plate without functions. Contains only connec-
tions for pump, load signal and a gauge port for meas-
uring tank pressure.
∆p (bar)
PL
TX
P1
PL PX
IP
LS
LS2
CFC – Inlet section for systems with fixed pump.
LS1 – Inlet section for systems with LS pump.
q (l/min) LS2 – Inlet section for systems with LS pump.
CFC – Idling (no load) pressure drop over bypass. P1 –T1. IP – Inlet plate without functions.
Borås, Sweden

The inlet section is normally equipped with a pressure relief
valve to protect the pump and valve from pressure peaks in the
system when there are rapid changes in the load pressure.
PA1 Direct-acting pressure relief valve, PLC183, with very
fast opening sequence and good pressure characteri-
stic. The interchangeable PLC cartridge is factory set.
The cartridge has a make-up function, which means
that oil is able to flow from the tank gallery to the pump
gallery in the event of negative pressure in the pump
circuit. The valve is intended for the LS2 inlet section
[15]. For setting values, please see Pressure setting
[17].
PS Pilot-operated pressure relief valve with fast opening
sequence and very low pressure override, which ef-
fectively prevents overloading of the hydraulic pump
and the machine. The valve is adjustable and is deliv-
ered factory-set according to the value specified. The
valve is intended for the CFC and LS1 inlet sections
[15].
Y Plug which can replace the pressure relief valve in the
LS2 inlet section [15]. The Y-plug blocks the connec- PA1 - Direct-acting pressure relief valve.
tion between the pump and tank completely.
Pressure setting [17]

Pressure setting for PA1 [16]
The PA1 direct-acting pressure relief valve is delivered
with a fixed setting. The following standard settings
are available:
Pressure setting in bar: 63, 80, 100, 125, 140, 160,
175, 190, 210, 230, 240, 250, 260, 280, 300 and 330.
Pressure setting for PS [16]
The PS pilot-operated pressure relief valve is adjust-
able from 50 to 320 bar. The valve can, however, be
delivered with a fixed setting according to the value
specified.
PS - Pilot-operated pressure relief valve.
∆p (bar) Pressure relief characteristic
q (l/min)
PS - Pilot-operated pressure relief valve.
Borås, Sweden
Load signal system [20]

The load-signal system consists of a series of shuttle valves,
one for each spool section in the directional valve. The shuttle
valves compare the load signals from all actuated spool sec-
tions and transmit the signal with the highest value to the PL Load signal to bypass
connection in the inlet section. If the valve has a load-signal or pump regulator
copying function, the signal is transmitted to a copy spool,
which makes a copy of the signal and transmits it to the LS
port.
If the load-signal chain is extended to a parallel-connected
valve via the LSP port [31], then the highest load signal from
the parallel-connected valve is included in the comparisons
made by the load-signal chain in the first valve.
In the case of the CFC variant of the L90LS, i.e. the variant Load signal from
fed by a fixed pump, the highest load signal is transmitted to spool section
the bypass valve, which regulates the pressure in the pressure
gallery to approx. 10 bar above the value of the signal.
KB - Inlet section without copy spool.
KB Inlet section without copy spool.
The load signal goes directly to the bypass in CFC
systems, or to the PL connection in LS systems.
KS Inlet section with copy spool. Copied load signal to
The load signal acts on a copy spool, which sends a pump regulator
copied load signal to the LS connection.
The copying system permits a certain consumption
in the load-signal line to the pumpregulator, without
Pump
the load signal being influenced. This enables simpler
system construction, with the possibility of installing
logic systems in the LS circuit. Thanks to drainage in
the pump LS regulator, the system gives better winter
operating characteristics with faster response, since
the oil in the LS circuit is always warm. Moreover, it Load signal from
prevents the tendency for the load to sink slightly at spool section
the beginning of the lifting phase.
Inlet sections of type LS2 [15] are normally
equipped with copy spools. KS - Inlet section with copy spool.
Borås, Sweden
Pump-unloading function [22]

If required, the valve can be equipped with a pump-unloading
function in the inlet section. This enables machine manufactur- Tank
ers to equip their machines with an emergency-stop function to
comply with the EC Machinery Directive. The function can be
controlled either electrically or hydraulically.
(The inlet section is not normally machined to accommo-
date the pump-unloading function.)
BB The inlet section is machined to accommodate a
pump-unloading function, and plugged. This permits From To pressure gallery
the building in of a pump-unloading function at a later pump Load signal
date if required.
BEN Electrically controlled pump-unloading function. When
the current to the electromagnet is broken, the pump
is blocked and the load signal drained to tank. In both
LS and CFC systems, this means that the pressure BB - Machined to accommodate pump-unloading function,
gallery is shut off from the pump inlet and the pump is and plugged.
unloaded.
BX Hydraulically controlled pump-unloading function.
When an external hydraulic signal with the same pres-
sure as the pump is connected to the BX port, the
pump is blocked and the load signal drained to tank.
In both LS and CFC systems, this means that the
pressure gallery is shut off from the pump inlet and
the pump is unloaded.
Connection: G1/2 or 9/16-18 UNF-2B.
Tank connection T1 [25]

T1 Tank connection T1 is open. Normal variant.
T1B Tank connection T1 is blocked.
T1X Used together with CFC [15] and MF or MP counter-
pressure functions [33] only. Tank connection T1 in the
BEN - Electrically controlled pump-unloading function.
inlet section is separated from the tank galleries in the
spool sections. Pump oil that is not used flows via the
bypass directly to tank via T1, while returning oil from
the actuators flows to tank via the counterpressure
valve in the end section and tank connection T3.
Pump connection P1 [26]

P1 Pump connection P1 is open. Normal variant.
P1B Pump connection P1 is plugged.
External connection of signal

pressure from pump line
BX – Connection of signal pressure. BX - Hydraulically controlled pump-unloading function.
Borås, Sweden
End section
Counterpressure valve/ Separate tank connection

tank connection T2 [33] for pilot circuit [40]
Pilot pressure
connection, PS
Pilot filter [39]
Internal pilot pres-

sure supply [37]
LS-connection [31]
The end section can be equipped with a number of optional In the basic version of the end section, all connections are
functions to customize it optimally for the given application. It plugged.
can, for instance, be equipped with a pressure-reducing valve As an alternative to the standard end-section, an adapter
to supply internal pilot-pressure for hydraulic or electro-hydrau- plate can be fitted to serve as a common end-section for the
lic spool actuators, and a fixed counterpressure valve in the T2 L90LS and a K170LS or K220LS valve. In such cases, note that
port. it is the inlet of the series-K valve that should be connected to
the pump.
End section [30]

US Standard end-section
AP Adapter plate for flanging L90LS to K170LS with exter-
nal feedback of load signal from L90LS inlet to
adapter plate (valve not supplied with this feedback). T
P P2B
AP3 Same as AP, except that LS signal is fed back to the
adapter plate internally via signal duct 3. This version
is preferable when the signal ducts do not need to be
used. See ‘System functions’, page 27.
ASAP3 Same as AP3, but for flanging L90LS to K220LS.
LS connection [31]
LSP Port for connection of LS signal from other valve open.
This connection is used to receive the load signal from
a parallel-connected valve.
LS LS
LSPB Port for LS signal from other valve plugged.
T T2B T T2B
Pump connection P2 [32] T3B T3B

P2 Alternative pump connection in rear face. The connec-
tion can, for example, be used to feed valves located
to the rear, or for double feeding of the valve in appli- LSPB LSP
cations where many machine functions with very high
flow demands are operated simultaneously. Under cer-
tain provisions, the connection can also be used in LSP US
situations when feeding from the rear face is the most
suitable option in terms of available space. When LSP – Port for connection of LS signal from other valve is open.
feeding via P2, the pump-unloading function [22] can- US – Standard end-section.
not be used.
P2B Alternative pump connection plugged.
Borås, Sweden
Counterpressure valve / tank connection T2 [33] T

T2 Alternative tank connection T2 open.
T2B Alternative tank connection T2 plugged. T
MF Counterpressure valve factory set to give 5 bar P P2B
counterpressure. Tank connection T1 must be plugged
(T1B) [25] and tank connection T3 [34] must be open.
If the system has a fixed pump, CFC [15], the sepa-
rate tank line T1X [25] from the bypass can be used to
reduce the idling (no load) losses in the system.
LS
Tank connection T3 [34] T
LS
T3 Tank connection T3 is open. T T2
T3
T3B Tank connection T3 is plugged.
T3B
LSPB LSPB
T2 – Without counter- MF – Factory-set
pressure valve. counterpressure valve.
Common copy spool for Section 1, Section 2, Adapter plate, Section 2, Section 1,
series-K and L90LS valve series-K series-K AP [15] L90LS L90LS
Connection of tank in case

Inlet, series-K of external pilot-pressure External feedback of load signal Simple inlet plate,
valve connection, TP [40] (not supplied ex-factory) IP [15], L90LS
Series-K valve flanged to a L90LS valve with the aid of AP plate. Load signal fed back externally.
Common copy spool for se- Section 1, Section 2, Adapter plate, AP3 [15] with internal Internal feedback
ries-K and L90LS valve series-K series-K feedback of load signal from L90LS of load signal
inlet
Connection of tank in case

Inlet, series-K of external pilot-pressure Section 2, Section 1, Simple inlet plate,
valve connection, TP [40] L90LS L90LS IP [15], L90LS
Series-K valve flanged to a L90LS valve with the aid of AP3 plate. Load signal fed back internally.
Borås, Sweden
Internal-pilot pressure supply [37] Separate tank connection for pilot circuit [40]
R Internal pilot-pressure supply is a valve function, built This connection is machined into the end section only when the
into the end section, which works as both a pressure valve is furnished with internal pilot-pressure supply [37].
regulator and a pressure relief valve in the pilot circuit.
TP Separate tank connection for the pilot circuit is open.
For safety reasons, the R-cartridge has also been
The connection to the main tank gallery of the direc-
equipped with a separate safety-valve function that
tional valve is blocked. The function is intended for
prevents the maximum permissible reduced pressure
systems in which there is a risk of dynamic pressure
from being exceeded. A check valve prevents pilot oil
fluctuations in the tank line, which cause fluctuations
from leaking back to the pump, and therefore enables
in the pilot circuit when there is a common tank line.
the pressure in the pilot circuit to be maintained in the
event of a temporary fall in pump pressure, e.g. during TPB The end section is machined to provide a separate
a rapid lowering movement. tank connection for the pilot circuit, and plugged. The
Pilot pressure for external use, e.g. for delivery to tank return of the pilot circuit is connected to the tank
PCL4 remote control valves, can be tapped from the gallery of the directional valve.
PS connection on the B-side of the end section. Pres-
sure setting: 35 bar.
Activation of lever disengagement [42]
R22 Same as R, but with 22 bar pressure setting.
RB The end section is machined to accommodate the le-
R43 Same as R, but with 43 bar pressure setting. ver disengagement function, and plugged.
REN Electrically controlled lever-disengagement for remote-
Pilot filter [39] controlled spool actuators equipped with supplemen-
tary direct lever. When there is no current to the REN
S Coarse filter with bypass function in the internal pilot
solenoid, pilot pressure to remote hydraulic or electro-
pressure supply. The filter protects the pilot circuit
hydraulic controls is blocked. The effect is that direct
from dirt, especially during start-up of the system.
levers cannot be used when remote control is en-
YS Adapter for connection of external filter for pilot oil. gaged and vice versa.
Enables the pilot circuit to be supplied with cleaner oil
REA Same as REN, except that pilot pressure to the remote
compared with the rest of the system.
controls is blocked when the REA solenoid is ener-
gized.
YS
PS PS REN PS
TPB TPB TP
T T T
PS PS PS
T T T
P P2B P P2B P P2B
S
S R
R
LS
LS LS
T T2
T T2 T T2
T3B PS T3B
T3B
PS2 LSPB
LSPB LSPB
REN
R - internal pilot-pressure supply. R - internal pilot-pressure supply. R - internal pilot-pressure supply.

S - coarse filter with bypass function. YS - adapter for connection of external S - coarse filter with bypass function.
TPB - end section machined to accom- pilot-pressure filter. TP - end section machined to accommo-
modate separate tank connection for pi- TPB - end section machined to accom- date separate tank connection for pilot
lot circuit, and plugged. modate separate tank connection for pi- circuit, and connection open.
lot circuit, and plugged. REN - lever disengagement function
through electrically controlled blocking
of pilot pressure.
Borås, Sweden
Spool sections
The L90LS is stackable and can be supplied in combinations of spool and spool-actuator. This enables optimum customization
1-12 spool sections. Each section can be equipped individually to the application and particular machine function in question.
with a variety of optional functions, as well as different types of
Spool actuator, enclosed variant, type ECH

Pressure setting, feed Port relief and/or anti-
reducing valve [75] cavitation function [76]
Flow setting [72]
Pilot restriction [55]
Spool function [60]

Spool designation [69]
Damping of pressure
compensator [67] Pressure compensator [66]
Spool actuator, enclosed variant, type PC

Flow requirement [61]
Spool actuator [50]
Spool actuator [50]
System signal line [80] Load-hold check valve [66]
Spool actuator, open variant, type C

Basic variant [47]
Lever bracket [51]
Borås, Sweden
Basic variants of spool section [47] B A B A

Spool sections are available in different variants depending on
the choice of optional functions:
000 Not machined for pressure compensator, load-hold
check valve, feed reducer, port-relief or anti-cavitation T T
valves. P P
V00 Section fitted with load-hold check valve, but not ma-
chined for port relief valves.
T00 Section fitted with pressure compensator, but not ma-
TA0 Section fitted with pressure compensator and feed re-
duction in A-port, but not machined for port relief
valves.
LS LS
TC0 Section fitted with pressure compensator and com- T T
mon feed reduction in A- and B-ports, but not ma-
TT0 Section fitted with pressure compensator and indi-
vidual feed reduction in A- and B-ports, but not ma-
chined for port relief valves. Variant 000 (00T) Variant V00 (V0T)
**T All of the section variants above are available in ver-
sions that are machined for, and can be fitted with, B A
port relief and/or anti-cavitation valves in service ports B A
A and B. In such cases, the letter T is given in the
third position in the product designation, e.g. 00T,
V0T, T0T, TAT, TCT and TTT. For further information,
see Port relief and/or anti-cavitation valves [76]. T
T
V** and T** have the same machining and can be converted P P
easily from one variant to another at any time. However, the
machining for *0*, *A*, *C* and *T* sections is different.
For further information, see also “Pressure compensator /
load-hold check valve [66]” and “Feed reducing valve [75]”.
LS LS
T T
Variant T00 (T0T) Variant TA0 (TAT)
B A B A
T T
P P
B A B A
T T
LS LS
T T
Variant **T prepared for port-relief and/or anti-cavitation valves
in service-ports A and B.
Above left: section with Y-plug in A-port and combined port-
relief and anti-cavitation valve in B-port.
Above right: section with combined port-relief and anti-cavita- Variant TC0 (TCT) Variant TT0 (TTT)
tion valves in both A and B ports.
Borås, Sweden
Spool actuators
Spool actuators of both the open and enclosed type can be
used on the L90LS. Open spool-actuators, in which the spool-
end is exposed, are simpler and cheaper. They are intended
for use in systems where low capital cost is a priority. They can
be operated directly by means of linear levers or mechanical
coordinate levers (joysticks), or can be connected to remote
controls by means of wires.
With enclosed spool-actuators, the spool-ends are totally
enclosed in oil-filled caps. Enclosed spool actuators are in-
tended primarily for hydraulic and electro-hydraulic remote
control, but can also be the preferred choice for direct control
in aggressive environments.
Many different versions of spool actuator are available. De-
tails can be found on pages 17-20.
C
Directly operated, with open spool-end
C
C Spring-centred spool actuator
Steplessly operable with
spring-return to neutral. LM
Spring force in neutral: 60 N
Spring force when fully actuated: 130 N
B3 Three-position spool actuator B3

Equipped with 3-position mechanical
detent that gives 3 fixed positions:
neutral and fully actuated in either
direction. Spool remains in selected
position and must be moved B3
deliberately from one position LU
to another.
Force needed on spool to
overcome detent: approx. 160 N
FD
FD Friction-detented spool actuator
Lever remains at selected stepless
position. A force index indicates
when the lever is in neutral.
FD
Borås, Sweden
Spool actuators [50] contd.

ON/OFF remote-controlled, with open spool-end ACE
ACE Electro-pneumatic spool actuator, ON/OFF
Spring-centred. Can be fitted with
supplementary local lever
(optional) for direct, stepless
actuation of spool.
Control pressure: min. 4 bar
max. 10 bar
Spring force in neutral: 95 N
Spring force when spool
fully actuated: 160 N
Solenoid: 12 V DC 0.85 A
24 V DC 0.42 A
Voltage tolerance: ±20%
Connections: G 1/8 or NPTF 1/8-27
ACEF Electro-pneumatic spool actuator, ON/OFF

Identical to the ACE, except that it
has a common pressure gallery for LM
primary air. The primary air can be
connected to either the first or the
ACEF 727101D
last of the adjacent spool-sections
equipped with ACEF actuators.
Connection thread: G 1/8 or NPTF 1/8-27
Remote-controlled, proportional spool actuators with

open spool-end
ACP Pneumatic proportional spool-actuator LU
Can be fitted with supplementary
local lever (optional) for direct,
stepless actuation of spool.
The ACP is best controlled by
means of our VP04 remote-control
valve (see separate brochure).
Breakaway pressure*: 2 bar
Final pressure*: 5.5 bar
max. 10 bar ACP
Connection thread: G 1/8 or NPTF 1/8-27
727101D
Lever brackets [51]

LM For spool actuators with open spool-end
LU Spool-sealing cover without lever bracket for
spool actuators with open spool-end
*
The breakaway pressure is the pressure needed for the direc-
tional valve to open the connection “pump to service port”. The
final pressure is the lowest pressure needed to effect full actua-
tion of a spool in the directional valve. This data must be taken
into consideration when choosing control units, since the open-
ing pressure of the control unit must be lower than the breaka-
way pressure of the spool actuator in order to avoid jerky start-
ing and stopping. However, the control unit’s final pressure
must be higher than the final pressure of the directional valve in
order to ensure that the spools can be fully actuated.
Borås, Sweden

Directly operated with enclosed spool-ends Proportionally remote-controlled, with enclosed
CH Spring-centred spool actuator
spool-ends
Has enclosed spool-ends for use in PC Hydraulic spool-actuator
aggressive environments, and/or to
enable the lever-disengagement PCH Hydraulic spool-actuator with facility for supple-
function [52] to be incorporated. mentary local lever for direct control
Steplessly operable with spring-return The PC and PCH are proportional, hydraulically con-
to neutral. trolled spool actuators with spring-centring to neutral.
Spring force in neutral: 70 N They are intended to be controlled by the PCL4 re-
Spring force with spool fully actuated: 140 N mote-control valve. When determining a suitable con-
CHX Spring-centred spool actuator trol pressure for the PCL4, bear in mind that its
Same as CH, but with stronger springs breakaway pressure should be approx. 1 bar lower
to compensate for friction in external than that of the directional valve in order to ensure
linkage arms etc. gentle starting and stopping. The pilot pressure for the
Spring force in neutral: 85 N PCL4 can be tapped from the internal pilot-pressure
Spring force with spool fully actuated: 250 N supply in the end section of the directional valve, via
the PS connection.
CHB3 Three-position spool actuator
Equipped with 3-position mechanical Control pressure, breakaway*: 5.5 bar
detent that gives 3 fixed positions: Control pressure, final*: 15.0 bar
neutral and fully actuated in either Permissible pressure in pilot cap: max. 35 bar
direction. Spool remains in selected Connections: G ¼ or 9/16-18 UNF
position and must be moved deliberately
from one position to another.
Force needed on spool to * See page 18.
overcome detent: approx. 160 N
See also separate catalogue for PCL4.
CH, CHX CHB3 CH, CHX

CH, CHX
Stroke length
limitation
P-B, A-T Qset B
CHB3
Stroke length
limitation PC
P-A, B-T Qset A
PCH
PC
Stroke length
limitation PC, PCH
P-A, B-T Qset A Control signal
P-A, B-T
Stroke length
limitation
P-B, A-T
PCH
Stroke length
Control signal
limitation
P-B, A-T
P-B, A-T Qset B
Stroke length
limitation
P-A, B-T Qset A
Borås, Sweden

Proportionally remote-controlled, with enclosed Onn/off remote controlled, with enclosed
spool-ends spool-ends
EC Electro-hydraulic spool actuator EB Electro-hydraulic spool actuator
ECH Electro-hydraulic spool actuator with facility for EBHL Electro-hydraulic spool actuator with facility for
supplementary local lever for direct control supplementary local lever for direct control
The EC and ECH are proportional, electro-hydrauli- The EB and EBHL are electro-hydraulically controlled
cally controlled spool actuators with spring centering on-off spool actuators with spring centering to neutral.
to neutral. They are intended to be controlled remotely They are intended to be controlled remotely by means
by the IQAN or EHC35 control systems. Pilot-pressure of on-off signals. Pilot-pressure oil for the QDC25 con-
oil for the PVC25 converter-valves is led to the spool verter-valves is led to the spool actuators through in-
actuators through internal ducts in the directional ternal ducts in the directional valve. This means that
valve. This means that only the electric cables from only the electric cables from the control system to the
the control system to the converter valve need to be solenoid valve need to be connected externally. The
connected externally. The converter valve is equipped converter valve is equipped with manual override.
with manual override. The EBHL can be operated steplessly by hand le-
The ECH can be operated directly and steplessly ver.
by a supplementary local lever (optional). Spring force in neutral 85 N
Spring force in neutral 60 N Spring force with spool fully actuated 250 N
Spring force with spool fully actuated 350 N Control current for QDC25, 12 V 1300 mA
Control current for PVC25, 12 V Control current for QDC25, 24V 650 mA
Breakaway* min. 550 mA
Fully actuated max. 980 mA
Control current for PVC25, 24V Connector
Breakaway* min. 260 mA AMP Junior-Timer type C, 963040-3
Fully actuated max. 510 mA Bosch 1 928 402 404
Measuring connections: G1/4 or 9/16-18 UNF
ECHL Same as ECH, but with weaker centering spring. *
Suitable for use, e. g. when spool actuator is The breakaway current refers to the current needed for the di-
mainly intended to be operated directly. rectional valve to open the connection “pump to service port”.
Spring force in neutral 85 N The final current is the lowest current needed to effect full ac-
Spring force with spool fully actuated 250 N tuation of a spool in the directional valve. This data must be
Control current for PVC25, 12 V taken into consideration when choosing control units, since the
Breakaway* min. 550 mA opening current of the control unit must be lower than the
Fully actuated max. 820 mA breakaway current of the spool actuator in order to avoid jerky
Control current for PVC25, 24V starting and stopping. However, the control unit’s final current
Breakaway* min. 260 mA must be higher than the final current of the directional valve in
Fully actuated max. 440 mA order to ensure that the spools can be fully actuated.
Other data as for ECH above.
Manual Actuation Actuation

override P-A, B-T P-B, A-T
EC, EB
EC, EB
ECH, ECHL,
EBHL
Stroke length
limitation
P-A, B-T Qset A
EC,
ECH, ECHL,
EB,
EBHL
Stroke length ECH,
limitation ECHL
P-B, A-T Qset B
EBHL
Stroke length
limitation
P-A, B-T Qset A
Borås, Sweden
Lever bracket [51] 0

In addition to the normal lever-attachment angle, L1, the lever 1 20°
bracket is available in 8 other angles, designated L0 to L8 (see L * = P–A B–T
figure opposite). In the L4 variant, for instance, the lever is 20°
2
mounted parallel with the spool. A B
20°
L1 Standard lever-bracket for directly operated spool ac- 3

tuators with enclosed spool-ends, e.g. CH, and for re-
20°
mote-controlled spool actuators that have facility for
supplementary local lever for direct control, e.g. ECH. 4
20°
5
20°
6
20°
7 20°
8
Lever brackets L can be given different attachment angles.

Lever disengagement [52]
All spool actuators with enclosed spool-ends (both directly op-
erated ones and the remote-controlled ones that have a sup-
plementary local lever for direct control) can be furnished with
a function that disengages the local levers when pilot pressure
is connected to remote levers. The function requires the end
section to be equipped with the REN or REA [42] electrically
controlled pilot-pressure-blocking function. (In the case of the
PCH spool actuator, pilot pressure for the PCL4 remote-control
valve should be taken from the PS2 connection on the A-side of
the end section, which gives pilot oil only when the local lever
is disengaged.) Pilot pressure
LR Local lever for direct control disengaged when pilot- Schematic illustration of lever disengagement.
pressure signal is received from REN or REA function.
B
Pilot restrictor [55 A, B]
To give gentle control characteristics, remote-controlled spool
actuators with enclosed spool-ends are fitted with pilot
restrictors, which can be chosen individually for each service
port. The restrictor gives a kind of ramp function.
/ Without pilot restrictor
0.8 0.8 mm pilot restrictor
A
Pilot restrictor
Borås, Sweden
Choice of spool Spool symbols

The spool is the most important link between the operator’s ac- B A
tuation of a control lever and the behaviour of the correspond-
ing machine function. The designs of our spools are therefore
customized to meet the operating criteria of each individual
D
machine function as accurately as possible. Spools are de-
signed with the aid of a computerized specification system,
which takes all factors into account.
EA
Spool function [60]
There are many spool variants: D, EA, EB, M, CA, Dm, Da and
Db, which are customized for different flows, load conditions EB
and actuator area ratios. The spools are also available with dif-
ferent degrees of force feedback from the A- and/or B-side.
D Double-acting spool for, e.g. double-acting cylinder.
Blocked in the neutral position. M
EA Single-acting spool for, e.g. single-acting cylinder.
Blocked in the neutral position. Service port B
blocked. CA
EB Single-acting spool for, e.g. single-acting cylinder.
Blocked in the neutral position. Service port A
blocked.
Dm
M Double-acting spool for, e.g. hydraulic motor. Float
position function in neutral position.
CA Regenerative spool for rapid feeding of cylinder via
the A-port. The large side of the cylinder is connected Da
to the A-port.
Dm Double-acting spool with drainage A to T and B to T,
which prevents pressure build-up in the neutral posi- Db
tion. The spool is used as a double-acting spool in
combination with, e.g. an overcentre valve. P T
Da Double-acting spool with drainage A to T, which
prevents pressure build-up in the A-port in the neutral
position. The spool is used as a double-acting spool in
combination with, e.g. an overcentre valve.
Db Double-acting spool with drainage B to T, which
prevents pressure build-up in the B-port in the neutral
q (l/min) Flow rate in motor connection
position. The spool is used as a double spool in com-
bination with, e.g. an over-centre valve.
Flow requirements [61 A, B]

There is a wide range of computer-optimized spool designs for
the L90LS with nominal flows of up to 90 l/min per spool-sec-
tion when the sections are equipped with individual pressure-
compensators.
Without individual pressure-compensators, flows up to 125
l/min per spool section are obtainable, depending on the ad-
justed differential between the load-signal pressure and the
pump pressure.
On the basis of the desired flows to the A and B ports en-
tered in the ordering documentation, our computerized valve-
specification system selects a spool to give at least the speci-
fied flow, at the same time taking all other parameters into ac-
count.
The maximum flow is then set by limiting the spool stroke by
means of adjustment screws on the spool actuators or, in the
case of electro-hydraulic remote control, by tuning the electron-
ics.
Spool stroke (mm)
See “Flow settings [72]” for details on factory-set maximum
flows.
Typical curves showing flow as a function of spool stroke.
Borås, Sweden
Area ratios [62]

The area ratio for a spool section is calculated by dividing the F
cylinder area that is connected to the B-port by the area con-
nected to the A-port. When the large side of the cylinder is con-
nected to the A-port, the area ratio is less than 1. The area ratio
for a motor is 1.
A B
PT
LAB - Lift load can change between the A- and B-port.
F
Load characteristics [63]
The characteristics of the lift load can be specified according
to five typical cases. This information is entered so that the
spool can be be customized optimally for the intended appli-
cation.
LAB Lift load can alternate between A-port and B-port.
LA Lift load normally on A-port only. A B
LB Lift load normally on B-port only.

LN No or low lift-load on A- and B-ports. PT
S Slewing function. LA - Lift load normally on A-port only.
Force feedback [64 A, B] A B

The L90LS can be furnished with a force-feedback function to
give operators of the LS system the same positive sense of
force-control obtained with constant-flow (CFO) systems. This
makes it easier for the operator to avoid damaging the ma- PT
chine in applications such as digging, since he is able to LB - Lift load normally on B-port only.
sense increasing resistance or outright obstacles to the move-
ment of a machine function.
Force feedback also gives a kind of ramp function that re- Flow rate (%) Force feedback
sults in more gentle transition between rapid changes in the
speed of a machine movement. This in turn has a stabilizing
effect on the hydraulic system and results in smoother opera-
tion of the machine. Both characteristics are important, espe-
cially for functions like slewing movements. In addition to in-
creasing the efficiency of the machine, they also minimize
wear.
Light
The A and B ports individually can be given any one of
load
three different levels of force feedback. The higher the level,
the greater the reduction in speed for a given lever stroke as Heavy
resistance rises. This means that the operator must move the load
lever further if he wishes to maintain the same speed of move-
ment with rising resistance.
/ No force feedback
FN Normal level of force feedback
FH High level of force feedback Lever stroke (%)
FL Low level of force feedback
The force feedback function is not available for directly oper-
ated valves.
Borås, Sweden
Pressure compensator / load-hold check valve [66]

When there are demands for very good simultaneous-operating q (l/min) Flow rate curves
characteristics or intensive, multi-section operability and re-
sponsiveness, individual spool-sections in the L90LS can be
equipped with integral pressure-compensators. Sections so
equipped are not then influenced by other simultaneously-op-
erated machine functions, regardless of the variations in loads,
provided there is sufficient pump capacity.
Responding to the instantaneous value of the load signal,
the pressure compensator regulates continuously the flow
through the spool to maintain a constant pressure-differential
between the pump and service-port sides of the spool. This re-
sults in a constant flow to the consumer for a given lever stroke,
regardless of the load pressure or any activity in other spool
sections.
The standard variant of the pressure compensator is desig-
nated K. Three other variants, designated KL, KH and KX,
which give 85, 120 and 150 % of the standard flow respec- Load pressure (bar)
tively, are also available. They are intended to enable further
customization of the spool section to suit the flow requirements Load-independent flow with pressure compensator.
of the actuator.
All Parker pressure compensators are fast and responsive,
and come with an integrated load-hold check-valve function. If
necessary, spool sections with pressure compensators can
also be equipped with feed-reducing valves in the service
ports to regulate the delivery pressure to the consumer to the
desired level.
(V** and T** spool-sections [47] have the same machining
and can be converted easily to accommodate feed-reducing
and port-relief valves.)
/ Section not machined for pressure compensator or
load-hold check valve.
K Standard pressure compensator.
KL Compensator that gives 85% of specified spool’s
nominal flow.
KH Compensator that gives 120% of specified spool’s
nominal flow.
KX Compensator that gives 150% of specified spool’s
nominal flow.
N Section equipped with load-hold check valve.
X Section machined for pressure compensator or load-
hold check valve, and plugged.
Damping of pressure compensator [67]

The LS restrictor affects the response of the pressure compen-
sator, and is normally chosen at 0.8 mm.
/ No LS restrictor for compensator.
0.6 Alternative LS restrictor for compensator.
0.8 Recommended LS restrictor for compensator.
1.0 Alternative LS restrictor for compensator.
Spool designations [69]

To facilitate optimal customization to meet the criteria of each
individual machine function, the choice of spools is made with
the aid of our computerized specification program. The infor-
mation entered at items 60-66 forms part of the basis for the
choice of spool.
Borås, Sweden
Flow settings [72]

The strokes of spools controlled by enclosed spool-actuators
can be arrested to limit the maximum flow to service ports A
and B. Setting B-port
Qset The valve is supplied with factory-set maximum flows

to the spool section. The settings agree with the speci-
fied flow-requirements to the A and B ports [61 A, B].
QsetA The valve is supplied with factory-set maximum flow to
the spool section. The setting agrees with the speci-
fied flow-requirement to the A port [61 A].
QsetB The valve is supplied with factory-set maximum flow to
the spool section. The setting agrees with the speci-
fied flow-requirement to the B port [61 B].
When setting the flow rates for spool sections not equipped
Setting A-port
with pressure compensators in systems fed by LS pumps, the
settings are made with a ∆p of 15 bar between the pump pres-
sure at the PX port and the load signal at the PL port at full flow
take-off. (For flow setting with PC spool-actuators, please see
page 19.)
Limiting the maximum flow over the spool by means of me-
chanical stroke-length limitation of the spool stroke.
Feed-reducing valve [75]

The L90LS with sections designated *A*, *C* or *T* at item [47] qm (l/min) Reduction characteristics
is equipped with feed-reducing valves.
Sections designated *A* have feed reduction in the A-port;
those designated *C* have common feed reduction for the A-
and B-ports; those designated *T* have individually adjustable
feed reduction for the A-port and B-port.
Feed reduction is used for system functions that require a
lower maximum pressure compared with the normal working
pressure of the system. The feed-reducing valve, which is step-
lessly adjustable from 50 to 320 bar, reduces the delivery pres-
sure in the service port to the pre-set level.
Through the use of feed-reducing valves, the delivery pres-
sure can be limited without consuming any more than a pilot
flow (<2 l/min).
For feed reduction to be installed, the section must be
equipped with a pressure compensator. Since the feed-reduc-
ing valve is a 2-way valve, pressure shocks that arise after the
feed-reducing valve must be limited with the aid of a port relief
valve. The pressure setting on the port relief valve should be as
Pred (bar)
close as possible to the setting on the feed-reducing valve,
although at least 10 bar higher.
Pred = reduced pressure
qm = flow rate in service port
Setting of feed reduction in the A-port [75A]
Setting values for the A-port are from 50 to 300 bar.
Setting of feed reduction in the B-port [75B]

Setting values for the B-port are from 50 to 300 bar.
Borås, Sweden
Port relief and/or anti-cavitation valves [76 A, B]

In spool sections designated **T [47], the PLC053 can be used
as a combined port-relief and anti-cavitation valve in the serv-
ice ports to protect the valve and consumer from high system
pressure and pressure surges.
The PLC053 is a direct-acting pressure relief valve with a
very fast opening sequence and good pressure characteristic.
The interchangeable PLC cartridge is factory set. The make-up
function enables oil to flow from the tank gallery to the service-
port side in the event of negative pressure in the service ports,
in order to prevent cavitation.
/ Section not machined for port relief valves.
X2 Section machined for port relief valve. Service port
open to tank. Circuit diagram for PLC053 pressure relief valve.
Y2 Section machined for port relief valve. Connection A/B
to tank blocked with plug.
∆p (bar) Pressure relief characteristic
N2 A/B side of section equipped with anti-cavitation valve.
50-350 Standard pressure settings (in bar) for port relief
valves in A- or B-ports:
50, 63, 80, 100, 125, 140, 160, 175, 190, 210, 230,
250, 260, 280, 300, 320 and 350.
q (l/min)
∆p (bar) Make-up characteristics
q (l/min)
Borås, Sweden
System functions B A
The L90LS can be equipped with integrated functions to create
complete system solutions. The load signal from any service
port or spool section can be connected with signal ducts and
utilized to stop or limit the pressure to individual machine func-
Two speed
tions. T
In cranes, this auxiliary controlling concept is implemented P
with the aid of the M11 function manifold [90]. Another example
of how the load-signal ducts can be exploited is in the control
of thrust pressure to rock drills, according to the instantaneous
rotational torque (rotation-pressure controlled thrust).
System signal lines [80]

SF Valve section equipped with 3 signal lines that can be LS LS
connected internally to individual load signals [81], as T
well as signal line for activation of two-speed function Lever disengage line
[82] and signal line for disengagement of direct levers 3
[52]. (Lever disengagement not applicable to C, B3 or 2 Signal lines
1
ACE spool actuators [50]).
LSB LSA
Individual LS connection [81] SF – System signal line
/ No LS connection to signal lines. No possibility of
external connection either.
A1B Load signal from port A connected to duct 1.
A1B2 Load signal from port A connected to duct 1.
Load signal from port B connected to duct 2.
LSB LSA LSB LSA
A2B Load signal from port A connected to duct 2.
A1B3 A2B
A2B2 Load signal from both ports A and B connected to
duct 2.
AB No connection between load signal and signal ducts.
AB2 Load signal from port B connected to duct 2.
AB3 Load signal from port B connected to duct 3.
The load signal from more than one section can be connected LSB LSA LSB LSA
to the same duct. A check valve in each section prevents back-
A2B2 AB
ward transmission of the load signal from the ducts into indi-
vidual sections.
In addition to connection with the signal ducts, the load sig-
nal is also available for external connection at the base of the
valve.
LSB LSA LSB LSA
AB2 A1B
LSB LSA LSB LSA LSB LSA
A1B2 A2B3 AB3
Borås, Sweden
Two-speed function [82]

Any number of spool sections in the L90LS can be furnished q (%) Flow
with a two-speed function to enable switching between per-
formance and precision work with machines such as cranes
and skylifts.
The two-speed function is activated with the aid of the M11
function manifold [90]. Activation reduces the flow to the con-
sumer as indicated below:
QR2 Flow to consumer reduced to 20% of normal flow.
QR3 Flow to consumer reduced to 30% of normal flow. Normal
QR4 Flow to consumer reduced to 40% of normal flow.

QR5 Flow to consumer reduced to 50% of normal flow. QR4
QR2
N.B.
When a spool section is equipped with a two-speed function,
the pressure compensator in the section does not have a
load-hold check valve function. For this reason, overcentre Lever stroke (%)
valves are required for the controlled actuator.
Diagram shows curves for:
Normal flow.
Flow with QR4 activated.
Internal connection of service port [85] Flow with QR2 activated.
Thanks to the internal service-port connections, system solu-
tions employing function manifolds that require the service port
to be used by the manifold can be integrated without the need
A B
for external piping.
M Gives internal service-port connection downstream of
the spool section.
A013 Gives internal service-port connection both down-
stream and upstream of the spool section.
M
Function manifolds [90-99]
The L90LS can be equipped with function manifolds that en-
able complete system solutions to be integrated into the valve.
Standard function manifolds are available for overload pro-
tection, two-speed function, float position, priority for steering
and brakes, etc. In addition to the standard units, we custom-
build function manifolds to meet special system criteria. Please
contact Parker for further information. Sectional manifold with internal connection of service ports to
downstream function manifold.
Borås, Sweden
Dimensional drawing
Spool actuators with enclosed spool end (inch)
157,5 (6.20)
129,5 (5.10)
(1.06)
27
11,5 (0.45)
45 (1.77)
90 (3.54)
max.160 (6.30) 179 (7.05)

54 (2.13) 125 (4.92)
45 (1.77) 45 (1.77)
(0.12) 40,5 (1.59) (1.50) (1.26) (0.94)
3 36 (1.42) 38 32 24
43 (1.69)
53 (2.09)
61,4 (2.42)
94 (3.70)
CH
CHX
40 (1.57)
L
ECH
ECHL
EBHL
PC
12 40 (1.57)
35 (1.38)
(0.47)
(0.12) 3
(1.75) 44,5 45 (1.77)
max. 115 (4.53) max. 160 (6.30)
No. of L L L with inlet plate IP [15]
sections mm inch mm inch
1 169 6.65 144 5.67
2 209 8.23 184 7.24
3 249 9.80 224 8.82
41 (1.61)
4 289 11.38 264 10.39

5 329 12.95 304 11.97
(0.93) 23,5
6 369 14.53 344 13.54

7 409 16.10 384 15.12
8 449 17.68 424 16.69
67,5 (2.66) 9 489 19.25 464 18.27
87 (3.43) 10 529 20.83 504 19.84
11 569 22.40 544 21.42
12 609 23.98 584 22.99
Connection threads, see page 6.
Borås, Sweden
Dimensional drawing
Spool actuators with open spool end (inch)
165,2 (6.50)
129,5 (5.10)
57 (2.24)
(1.06)
27
(0.45)
11,5
45 (1.77)
90 (3.54)
152,5 (6.00)
52,5 (2.07) 68 (2.68) (1.50) (1.26) (0.94)
(0.35) 9 38 32 24
(0.14) 3,5
61,4 (2.42)
C
B3
40 (1.57)
ACE
L
C
B3
35 (1.38)
40 (1.57)
(0.47)
12
(1.38)
35 1,5 (0.06)
(0.31)
43 (1.69) 8 63 (2.48) No. of L L L with inlet plate IP [15]
sections mm inch mm inch
1 169 6.65 144 5.67
2 209 8.23 184 7.24
3 249 9.80 224 8.82
4 289 11.38 264 10.39
5 329 12.95 304 11.97
6 369 14.53 344 13.54
7 409 16.10 384 15.12
41 (1.61)
8 449 17.68 424 16.69

9 489 19.25 464 18.27
(0.93) 23,5
10 529 20.83 504 19.84

11 569 22.40 544 21.42
67,5 (2.66) 12 609 23.98 584 22.99
87 (3.43)
Connection threads, see page 6.
Borås, Sweden
Direct levers
Levers for open spool-actuators (inch)
)
(1.06
Levers M7 and M71 are made of steel with an anti-rust surface ∅ 2 7
treatment, and fitted with a knob of black plastic. The knob on
the M71 lever has a top window for the insertion of a symbol. (0.98)
The lever kits are delivered complete with pin sets for mounting ∅25
to the valve.
207 (8.15)
172 (6.77)
22 (0.87)
22 (0.87)
46 (1.81) 53 (2.09)
Lever M7 Lever M71
Direct lever for enclosed spool-actuators

Lever for directly operated spool-actuators with enclosed
spool-end, and for remote controlled spool-actuators that have
a facility for a supplementary local lever for direct control.
The ML1 lever is made of steel and has an anti-rust surface
treatment. The lever knob is of black plastic and has a top win-
.50)
dow for the insertion of a symbol. The lever kit consists of a

knob, the lever shaft and a lock nut.
165 (6
(0.83)
21
22
(0.87)
Ordering number Designation Lever ML1
9122 1780-08 M7
9122 1780-11 M71
8234 9390-01 ML1
Borås, Sweden
For further information, please contact:
Parker Hannifin AB Catalogue HY17-8504/UK

Mobile Controls Division Catalogue HY17-8504/US
SE-501 78 Borås Ed. 0105
Sweden
Tel +4633 16 91 00
Fax +4633 12 11 43
www.parker.com
Directional Control
MobileHydraulics Valve K170LS
Proportional valve for systems
with variable pumps
Catalogue 9129 8557-02 GB

Catalogue 9129 8557-06 US
March, 2000
Catalogue 9129 8557-02/06 Directional Control Valves
Technical Information K170LS
Catalog layout
This catalog has been designed to give a brief overview of of coded options, e.g. PA1
A1, Y1
Y1, together with a brief descrip-
K170LS valves, and to make it easy for you to study and tion of what each code represents. Alternatively, one or more
choose from the different options available, so that we may pressure, flow or voltage options are given.
customize your valve in accordance with your wishes. In addi- On page 7 is a general circuit diagram showing the basic
tion to general information and basic technical data, the cata- function areas in a K170LS valve and the item numbers that
log therefore contains descriptions of the options available for represent them. Naturally, the same item numbers are used for
various so-called “function areas” of the valve. the respective function areas in all sub-circuit diagrams that
Each function area is given as a subheading, followed by a appear elsewhere in the catalog. Please note that, unless stat-
brief description. When options are available for a function ed otherwise, all sections and views of the valves have been
area, the subheading is followed by an “Item number” in brack- drawn as seen from the inlet section.
ets, e.g. Pr essur
Pressur
essuree rrelief
elief valve [16]
[16]. This is followed by a series
How to order your valve

The K170LS directional control valve can be easily specified The computer also generates a unique identification number
using Parker computer programme. This means the customer for each valve type and customer. The number is then stamped
can optimize his valve specification to give the best perform- into the I.D. plate of each valve. The specification of your valve
ance for his application and specific hydraulic system. is then recorded by Parker, so that exact identification of the
Once the demands placed on each individual function have product can be made at any time in the future to facilitate re-
been specified the computer will select the valve design repeat ordering or servicing.
quired to give optimum performance. The computer also pro-
duces complete documentation for your valve, in the form of a
detailed specification and hydraulic circuit diagram.
Early consultation with Parker saves time and money

Our experienced engineers have in-depth knowledge of the characteristics and economic demands. By consulting Parker
different types of hydraulic system and the ways in which they early in the project planning stage, you are assured of a com-
work. They are at your disposal to offer qualified advice on the prehensive hydraulic system that gives your machine the best
best system for the desired combination of functions, control possible operating and control characteristics.
Conversion factors
1 kg = 2.2046 lb
1N = 0.22481 lbf
1 bar = 14.504 psi
1l = 0.21997 UK gallon
Parker reserves the right to modify products without prior no- 1l = 0.26417 US gallon
tice. Typical curves and diagrams are used in this catalog. 1 cm3 = 0.061024 in3
Even though the catalog is revised and updated continuously, 1m = 3.2808 feet
there is always the possibility of errors. For more detailed infor- 1 mm = 0.03937 in
mation about the products, please contact Parker. 9/5 °C + 32 = °F
Mobile Hydraulics Borås, Sweden
Table of contents Page

Valve description, general ..................................................................... 4
Technical data ........................................................................................ 6
General hydraulic circuit diagram ........................................................ 7
Inlet section
Internal pilot pressure supply [12] ...................................................... 8
Pilot pressure [13] ............................................................................... 8
Pilot filter [14] ...................................................................................... 8
Load signal system ............................................................................. 9
Inlet section basic type [15] ............................................................... 9
Pressure relief valve [16] .................................................................... 9
Pressure setting [17] ......................................................................... 10
Tank connection, T2 [24] .................................................................. 10
Counterpressure valve [24] .............................................................. 10
Tank, T1 and pump, P1 connection [25, 26] .................................... 10
End section
End section basic type [30] .............................................................. 11
LS connection [31] ............................................................................ 11
Pump connection, P2 [32] ................................................................ 11
Tank connection, T3 [34] .................................................................. 11
Separate tank connection for pilot circuit, TP [40] ........................... 11
Spool section
Cross-sectional drawings ................................................................. 12
Material design [48] .......................................................................... 12
PC and PCH ................................................................................. 13
EC, ECH, EB and EBH ................................................................. 14
Pilot restrictor [55 A, B] ................................................................ 15
Cable connector [56] ................................................................... 15
Spool selection [60-74]
Spool function [60] ....................................................................... 16
Flow requirements [61 A, B] ........................................................ 16
Area relationships [62] ................................................................. 17
Load characteristics [63] ............................................................. 17
Force feedback [64 A, B] ............................................................ 17
Pressure compensator / load-hold check valve [66] ................... 18
Damping of pressure compensator [67] ..................................... 19
Spool designation [69] ................................................................. 19
Flow settings [72] ......................................................................... 19
Feed reduction valve [75 A, B] ......................................................... 19
Port relief and/or anti-cavitation valves [76 A, B] ............................. 20
Function block [90-99] ...................................................................... 21
Dimensional drawing ........................................................................... 22
[00] refers to item numbers in the customer specification.
General
The K170LS is a stackable, proportional, Control characteristics Valve characteristics

load-sensing (LS), pressure-compensat- The control characteristics for both lifting • Copied load signal - The system
ed directional control valve, which can and lowering movements are outstand- permits consumption in the load sig-
also be adapted to give force-sensing ing, thanks to the unique function adap- nal line to the pump, without the sig-
control characteristics. It is designed for tation of spools, pressure compensators, nal level being affected.
many different applications, both mobile feed reducing valves etc. Each function
and industrial, and is widely used in ma- • Pressure compensation -
is completely independent of other
chines such as front-end loaders, back- Pressure-compensated spools for
simultaneously operated functions. lifting and lowering movements.
hoe loaders, excavators, cranes, forestry
equipment, metal presses and forging Separate compensator for each spool
Construction section for excellent pressure
hammers.
With its function-adapted spool sec- The K170LS is a stackable valve, and compensation.
tions, wide range of additional functions can be delivered in combinations of 1 to
• Feed reducers - Individually
and standard accessories, the K170LS 9 spool sections. It is designed for sys-
adjustable between 30 and 300 bar
enables the user to optimize the ma- tem pressures of up to 320 bar (nodular
for each service port. Reduction can
chine and its hydraulic system in the fol- iron), and can be fitted with motor-port
also be controlled remotely.
lowing ways: relief valves that open at a maximum
pressure of 350 bar. Suitable flow range • Force control - Force-sensing control
Compact system construction can be up to 280 l/min (2x280 l/min with characteristics (made available
mid inlet). The recommended flow per through the pressure-feedback op-
While the K170LS can contain many inte-
grated functions, it requires a minimum section is 170 l/min with a pressure com- tion) give not only effective force
of external piping. With the aid of a spe- pensator, and 220 l/min without. control, but also more gentle transition
As an optional, the K170LS can be across at speed changes and greater
cial adapter plate, it can be mounted di-
rectly to the similar, smaller-flow L90LS given a built-in pilot pressure supply in stability in the hydraulic system.
directional valve, giving great compact- the inlet section, as well as pressure • Counterpressure valve - Built-in
ness and outstanding operating econo- compensation and feed reduction in the counterpressure valve in two versions
my. spool sections. The feed reducer is ad- (fixed setting or pilot control) for best
justable from 30 to 300 bar. Force application-adaptation.
Freedom in machine design feed-back (optional) enables a force-
sensing function to be incorporated in to • Flexible, modular construction makes
The K170LS is designed for proportional it easy to re-build or expand the valve
hydraulic or electro-hydraulic remote the valve. Moreover, fixed or pilot-operat-
ed counterpressure valves can be inte- to meet changing needs.
control. This gives great freedom in the
location of components, and in the run- grated into inlet section to give back- • Our port-relief valves have outstand-
ning of pipework, hoses and cables. pressure supported load lowering and ing pressure characteristics, even as
exceptionally god anti-cavitation charac- secondary pressure limiters, and re-
Economy teristics. spond very quickly to sudden
changes in load.
The K170LS can be modified or expand- System adaptation
ed to suit customer specifications. Func- • The valve can be flanged to specially
The K170LS is a load sensing, adapted Parker function blocks that
tion and application adaptation enables pressure-compensated directional valve
energy consumption to be kept to a mini- enable even more functions to be in-
with unique possibilities for adaptation in tegrated into a compact, single unit
mum. respect of both functions and applica- with minimal piping.
tions to systems with variable LS pumps.
LSPB
B A B A B A
PS
P1
PL
PX
LS
T1
T2B
K170LS with built-in hydraulic, electro-hydraulic, or combined

manual and electro-hydraulic spool actuator. In this example,
the valve is not equipped with a copying function for the load
signal (LS).
B A B A TP B A B A
PS
P1B
P1
PL
PX
LS
TX
T1
T2B
The K170LS valve connected to a L90LS valve. The L90LS

valve is used for functions which requires less flow. This gives
price advantages as well as operational advantages. The valve
in this example fitted with an internal pilot pressure supply and
individual pressure compensator, feed reduction and pressure
relief valves.
Technical data
Pump connection LSP, LS connection
P1 [26] from parallel valve [31]
Load pressure
not copied, PL
Service port B
Tank
Gauge port, connection
Pump pressure T3 [34]
PX
Copied load
signal, LS Pump
connection
Pilot pressure P2 [32]
supply for
external use, PS
Separate tank
connection for
Tank connection pilot circuit, TP
T1 [25] [40]
Connection for Service port A

Tank connection
T2 [24] Pilot operation of hydraulic remote
counter pressure control, PC
valve MP [24] (A and B side)
Pressure Filtration
Valves of grey-iron type Filtration must be arranged so that Target Contamination Class
Pump inlet max 2601) bar (38001) psi) 18/14 according to ISO 4406 is not exceeded.
Service ports max 2801) bar (40001) psi) For the pilot system, Target Contamination Class 16/13
Valves of nodular-iron type according to ISO 4406 is recommended.
Pump inlet max 3301) bar (48001) psi)
Service ports max 3501) bar (50001) psi)
Hydraulic fluids
The best performance is obtained if mineral-base oil of high
Pump regulator ∆p min 182) bar (2602) psi) quality and cleanness is used in the hydraulic system.
Compensator K3 ∆p min 302) bar (4352) psi) Hydraulic fluids of type HLP (DIN 51524), oil for automatic
Return line pressure, static max 15 bar (220 psi) gearboxes Type A and engine oil type API CD can be used.
1) Pressures given are maximum absolute relief Synthetic, fire-resistant and environmentally friendly oils can
pressures at 10 bar (145 psi) tank pressure also be used. If in doubt about the suitability of an oil, please
2) Pressure drop pump to valve max 3 bar (44 psi) contact your nearest Parker representative for information.
Internal pilot pressure Viscosity, function range 15-5000 mm2/s (cSt)
Standard setting 35 bar (500 psi) (at start-up)
Optional setting 45 bar (650 psi) Viscosity, working range 15-380 mm2/s (cSt)
Feed reducer Technical information in this catalogue applies to a viscosi-
Adjustment range 30 to 300 bar ty of 30 mm2/s (cSt) and temperature of 50 °C (122 °F).
(435 to 4350 psi) Weight
Counterpressure valve Inlet section 5.5 kg 18.7 lb approx.
Fixed setting 5 bar (70 psi) Spool section type PC 9.1 kg 20.1 lb approx.
Pilot operated, signal pressure max 30 bar (435 psi) Spool section type EC 10.8 kg 23.8 lb approx.
Pressure ratio, End section 4.1 kg 9.0 lb approx.
pilot signal : counterpressure 1.2 : 1 Connections
Recommended flow rates Threads type G are designed for a flat gasket according to ISO
228/1 (BSP pipe threads)
Pump connection max 2803)l/min (75 USgpm) Type UN are designed for sealing by means of an O-ring according
Service port with compensator max 1704)l/min (45 USgpm) to standard SAE J 1926/1
Service port without compensator max 2204)l/min (60 USgpm) P1 inlet section G1 or 1 5/16 - 12 UN-2B
Return from service port max 280 l/min (75 USgpm) P2 end section G1 or 1 5/16 - 12 UN-2B
3) 2 x 280 l/min (2 x 75 USgpm) with mid inlet section T1, T2 inlet section G1 or 1 5/16 - 12 UN-2B
4) Depending on spool version A, B spool section G3/4 or 1 1/16 - 12 UN-2B
LS, PL inlet section G1/4 or 9/16 - 18 UNF-2B
Temperature PX, PS inlet section G1/4 or 9/16 - 18 UNF-2B
Oil temperature, function range -20 to 80 °C (-4 to 176 °F) MP inlet section G1/4 or 9/16 - 18 UNF-2B
Oil temperature, working range +20 to 80 °C (68 to 176 °F) LSP end section G3/8 or 9/16 - 18 UNF-2B
T3 end section G1/4 or 9/16 - 18 UNF-2B
PC spool section G1/4 or 9/16 - 18 UNF-2B
TP end section G1/4 or 9/16 - 18 UNF-2B
Hydraulic circuit diagram showing basic functions for K170LS
55
50
55 76 50 76
40 31
40
34
26
14
32
15
12, 13 75
16, 17
24 66 67 60 75 66 67 60
25
Shaded zones are functions or function groups to be found further on in the text.
The item numbers in the hydraulic circuit diagram and ta- above is equipped according to the description below. For
ble below refer to the functions or function groups for which other equipment alternatives, see under respective function
different options are available. The valve in the example [item number] in the catalogue.
Item Code Description Item Code Description

12 R Pressure reducing valve with separate safety 50 EC Section 1 equipped with proportional electro-
valve for internal pilot pressure supply. hydraulic remote control
13 35 Reduced pressure set to 35 bar PC Section 2 equipped with proportional hydraulic re-
mote control
14 S Internal coarse filter for pilot circuit.
55 0,8 Restrictor in pilot supply line
15 LS Load-sensing system
60 EA Section 1 equipped with spool for single acting
16 PA1 Direct operated main pressure relief valve, with
function. Connect to A-port. B-port plugged
fixed setting.
D Section 2 equipped with spool for double acting
17 280 Pressure setting for main pressure relief valve
function.
24 MF Fixed counterpressure valve
66 K1 Pressure compensator with built-in check valve
25 T1 Tank connection open function
26 P1 Pump connection open 67 0,8 Restriction of load signal to compensator.
31 LSPB Load-signal connection for parallel-connected 75 MR With separate feed reducer on motor ports A
valve plugged. and B
32 P2 Pump connection open 76 Y2 Section 1 port A. Service line cavity blocked M-T
34 T3B Tank connection plugged X2 Section 1 port B. Service line cavity open M-T
40 TP Separate tank connection for pilot return Section 2 ports A and B. Combined port relief and
anti-cavitation valve
Inlet section [12-29]

Pump connection Tank connection
P1 [26] T1 [25]
Counter pressure
valve. Tank connec-
Pressure relief tion
valve PA1 [16] T2 [24]
Internal
pilot pressure
supply [12]
Load signal
copy spool
Pilot strainer
[14]
Load pressure
(not copied) Pilot pressure
connection PL supply connection
for external use
Gauge port PS
pump pressure Load pressure (copied)
PX connection LS
The inlet section is equipped with pump (P1) and tank connec- tank connection T1 [25] are open, while the other connections
tions (T1, T2), a connection for the load signal to LS pumps are plugged.
(LS), a connection for pilot pressure supply for external use Functions such as maximum pressure relief, copying of the
(PS), a gauge point for pump (PX) and load signal pressures load signal, pressure reduction for internal pilot-supply, as well
(PL). In the basic variant, the pump connection P1 [26] and as a pilot filter and counterpressure valves can also be integrat-
ed into the section.
∆p (bar) Internal pilot pressure reducer characteristics

Internal pilot pressure supply [12]
R Pressure reducer for pilot supply.
Internal pilot pressure supply is a valve function, built
into the inlet section, which works as both a pressure 50
reducer and a pressure relief valve in the pilot circuit.
For safety reasons, the R-cartridge has also been 40
equipped with a separate safety valve function that
prevents the maximum permissible reduced pressure 30
from being exceeded. A check valve prevents pilot oil
from leaking back to the pump, and therefore enables 20
the pressure in the pilot supply circuit to be main-
tained in the event of a temporary fall in pump pres- 10
sure, e.g. during a rapid lowering movement, to se-
cure pilot supply during pump pressure drop, we reco- 0
0 4 8 12
mend to connect an accumulator to the PS port.
Pilot pressure for external use, e.g. for delivery to q (l/min)
PCL4 hydraulic remote control valves, can be tapped
from the PS connection on the inlet section.
RX Without pressure reducer for pilot supply.
Pilot pressure [13]

The pilot supply pressure can be set at either 35 or 45 bar.
Pilot filter [14]

S Built in strainer for the pilot supply.
Coarse strainer with bypass function in the internal pi-
lot pressure supply. The strainer protects the pilot cir-
cuit from dirt, especially during start-up of the system.
YS Adapter for connection of external filter for pilot pres-
sure oil. Enables the pilot circuit to be supplied with
cleaner oil compared with the rest of the system. See
also filtration, page 6.
Internal pilot-pressure Internal pilot-pressure
supply R and pilot strainer S supply R and adapter YS.
(Filter is not supplied with
valve)
Load signal system

The load signal system consists of a number of shuttle valves,
which compare the load signals from different spool sections
and send the highest signal to the connection PL, or to a copy-
ing spool in the inlet section.
The system permits a certain consumption in the load signal
line to the pump, without the load signal level being affected.
This enables simpler system design, with the possibility of in-
stalling logic systems in the LS circuit. Thanks to drainage in
the pump LS regulator, the system gives better winter operating
characteristics with faster response, since the oil in the LS cir-
cuit is always warm. In addition to this, the system prevents
disruptive micro-sinking of the load in the beginning of the lift-
ing phase.
Inlet section type [15]

The inlet section is available in two variants, one for CP sys-
tems and one for systems with LS pumps.
LS Inlet section for systems with LS pump.
The system is equipped with a directly controlled pres-
sure relief valve, PA1[16], which protects the pump
and inlet side of the valve. The LS is always equipped
with a load-signal copy function.
CP Inlet section for constant pressure systems.
Same as LS but without load-signal copy function, LS.
A025 Inlet section for un-loading constant pressure systems Inlet section type A025 for un-loading constant pressure
(CPU). systems (CPU).

The inlet section is normally equipped with a pressure relief
valve to protect the pump and valve from pressure peaks in the
system.
PA1 Direct acting port relief valve, PLC183, with very fast
opening sequence and good pressure characteristics.
The replaceable PLC cartridge is factory set. The car-
tridge has a make-up function, which means that oil is
able to flow from the tank gallery to the pump gallery
in the event of underpressure in the pump circuit. For
setting values, please see Pressure settings [17].
Y1 Without relief valve.
Plug which can replace the pressure relief valve. The Pressure relief valve PA1
Y1-plug blocks the connection between the pump and
tank completely.
Without relief valve Y1
Pressure setting [17] ∆p (bar) Pressure relief characteristics

Pressure setting for PA1 [16]
The PA1 direct acting pressure relief valve is delivered
with a fixed setting. The standard settings (in bar) 300
available are as follows:
Setting pressure in bar: 50, 63, 80, 100, 125, 140, 160,
175, 190, 210, 230, 240, 250, 260, 280, 300 and 330.
200
The settings 280, 300 and 330 bar are only applicable
to valves of nodular-iron.
PA1 needs to be set 20 bar above pump pressure. 100
See also technical data, page 6.
Tank connection T2 [24] 0

0 50 100 150 200
T2B Alternative tank connection T2 plugged. Common
variant. q (l/min)
T2 Alternative tank connection T2 open. ∆p (bar) Anti-cavitation characteristics
Counterpressure valve 14
The counterpressure valve, which raises the pressure in the
12
valve’s tank gallery, is placed in the inlet section. It is available
in two versions: MF with fixed setting and MP with pilot-con-
10
trolled setting.
By raising the counterpressure, the anti-cavitation charac- 8
teristics of the K170LS are improved still further. This might, for
example, be desirable in situations where make-up flow is di- 6
rected into the large side of the cylinder during the lowering of
loads. Good make-up characteristics eliminate the risk of cavi- 4
tation and reduce the risk of damage to the cylinder seals.
They are also important for functions in which a lowering move- 2
ment changes to a lifting movement without a time delay.
The pilot-operated version gives counterpressure only when 0
it receives a signal. It can be employed in such a way that the 0 50 100 150 200
signal to the counterpressure valve is connected only to the q (l/min)
spool-actuator signal(s) controlling the lowering movement(s)
that need extra counterpressure. In this way, unnecessary loss-
es can be avoided.
MF Counterpressure valve factory set to give 5 bar coun-

terpressure at a flow of 20 l/min.
MP Pilot operated counterpressure valve for external con-
trol of counterpressure between 0 and 36 bar. Tank
connection T1 [25] must be open and tank connection
T3 must be plugged (T3B [34]).
The MP pilot operated variant only gives a counter-
pressure upon receipt of signal. This can be exploited
so that the signal to the counterpressure valve is con- T1
nected only to the spool actuating signal(s) controlling
the lowering movement(s) that need an extra counter-
pressure, thus avoiding unnecessary losses. Max per-
mitted signal pressure is 30 bar. The relationship be- Counterpressure valve MF
tween pressure and signal is 1.2:1.

T1 Tank connection T1 is open. Common variant.
T1B Tank connection T1 is blocked.

P1 Pump connection P1 is open. Common variant.
P1B Pump connection P1 is plugged. T1
MP
Pilot operated counterpressure valve MP
End section [30 - 44]
Tank connection
T3 [34]
LS connection [31]
Separate tank
connection for
pilot circuit
TP, [40]
Pump connection
P2 [32]
The end section is available in two variants, one with all con- against an L90LS valve. The adapter plate contains only the pi-
nections machined and one without machined connections for lot tank connection and through channels which connect the
pump (P2), and tank (T3). pump, tank, pilot pump, pilot tank and LS channels of the
In the basic variant, the LS connection LSP [31], pump con- K170LS and L90LS valves, respectively. Thus, the pump and
nection P2 [32] and tank connection T3 [34] are plugged. tank need only be connected to the K170LS valve.
In addition to the two standard models, there is a special The valves are turned so that the adapter plate serves as a
adapter plate (AP) which is used when the valve flanges common end plate for the K170LS and L90LS.
End section [30]

US Standard end section.
AP Adapter plate for flanging K170LS to L90LS.
See catlogue L90LS.
LS-connection [31]
LSP Port open for connection of LS-signal from other valve.
This connection is used to receive the load signal from LSP
a parallel connected valve.
TP
LSPB Port for LS signal from other valve plugged. LS signal PS
is internally drained.
Pump connection P2 [32] T3

P1
P2 Alternative pump connection in rear face.
The connection can, for example, be used to feed P2
valves located to the rear, or for double feeding of the
valve in applications where many functions with very
high flow demands are operated simultaneously. The
connection can also be used in situations where feed-
ing from the rear face is the most suitable option in
terms of space available. PL
P2B Alternative pump connection plugged. Common vari- PX
ant. LS

T3 Tank connection T3 is open.
T1
T3B Tank connection T3 is plugged. Common variant.
Separate tank connection for the pilot circuit [40]

T2B
TP Separate tank connection for the pilot circuit is open.
The connection to the main tank gallery of the direc- Only with LSP [31]
tional valve is blocked in the inlet section. The function
is recomended for systems in which there is a risk of In the case of parallel connected valves, the PL connection
dynamic pressure fluctuations in the tank line, which load-sensing signal in the last valve passes to the LSP connec-
cause fluctuations in the pilot circuit when there is a tion in the first valve. The rear valve can be fed with pump oil,
common tank line. by connecting P2 and P1.
NB! TP connection can not be plugged.
/ Not prepared for separate pilot return.
Spool section [45-89]

Spool section with actuator type PC
Feed reduction P-B [75B]
Port relief valve, Port B [76B] Feed reduction P-A [75A]
Port relief valve, Port A [76A]
Spool actuator [50]
Spool actuator [50]
Spool [69]
Damping of
pressure Pressure
compensator compensator
[67] [66]
The K170LS directional valve is stackable and can be deliv-

ered in combinations of 1 to 9 spool sections. Each section can
be equipped individually with a large number of optional func-
tions, spools and spool actuators for optimum adaptation to the
application and controlled function.
Material design [48]

G Spool section in grey-iron design, (Max 260 bar in
pump port and max 280 bar in service port).
S Spool section in nodular-iron design, (Max 330 bar in
pump port and max 350 bar in service port).

PC, PCH - Hydraulic spool actuator
PC Hydraulic spool actuation.
PCH Hydraulic spool actuation with manual operation.
The PC and PCH are proportional, hydraulically con-
trolled spool actuators with spring centring to the neu-
tral position. They are intended to be hydraulicly re-
mote controlled by PCL4.
When choosing a control pressure for the PCL4, its
starting pressure should be approx. 1 bar lower than
that of the directional valve, in order to ensure gentle
starting and stopping. The pilot pressure for the con-
trol pressure valve can connected to the PS port for
the internal pilot pressure supply in the inlet section of
the directional valve.
PC Control pressure, start 5.6 bar
Control pressure, final 20.5 bar
PCH Control pressure, start 5 bar
Control pressure, final 21 bar
Permissible pressure in
pilot cap max. 50 bar
Connections: G1/4 or 9/16-18 UNF
PC, PCH Hydraulic spool actuators
PC
PCH
PCH
Air bleeder
Alt. connection
P-A, B-T
Air bleeder
PCH, PC
Stroke length
limitation P-B,
Connection for
A-T Qset B [72]
pilot pressure
P-B, A-T
PC Air bleeder
Stroke length limitation
P-A, B-T Qset A [72]
Alt. connection
Connection for
P-A, B-T
pilot pressure
P-A, B-T
Stroke length
limitation P-B,
A-T Qset B [72]

Electro-hydraulic proportional spool actuator Electro-hydraulic on-off spool actuator
EC Electro-hydraulic spool actuator. EB Electro-hydraulic spool actuator.
ECH Electro-hydraulic spool actuator with manual operation EBH Electro-hydraulic spool actuator with manual operation
facility. facility.
The EC and ECH are proportional, electro-hydraulical- The EB and EBH are electro-hydraulically controlled
ly controlled spool actuators with spring centring to on-off spool actuators with spring centering to the neu-
the neutral position. They are intended to be controlled tral position. They are intended to be controlled re-
remotely by the IQAN or EHC35 control systems. motely by means of on-off signals. Pilot pressure oil for
Please see separate data sheet for further information the converter valves is led to the spool actuators
about Parker remote control systems. Pilot pressure oil through internal ducts in the valve. This means that
for the converter valves is led to the spool actuators only the electric cables from the control system to the
through internal ducts in the valve. This means that valve solenoids need to be connected externally. The
only the electric cables from the control system to the Parker QDC102 is used as the converter valve. Please
valve solenoids need to be connected externally. The contact Parker for further information.
Parker PVC102 is used as the converter valve. Please
The EBH can be operated steplessly by means of a
contact Parker for further information.
hand lever.
The ECH can also be operated steplessly by means of
Control current for QDC102, 12 V 1300 mA
a hand lever.
Control current for QDC102, 24 V 650 mA
Control current for:
Gauge port: G1/4 or 9/16-18 UNF
PVC102, 12 V - Starting min. 420 mA
PVC102, 12 V - Fully actuated max. 900 mA
PVC102, 24 V - Starting min. 230 mA
PVC102, 24 V - Fully actuated max. 500 mA
Gauge port: G1/4 or 9/16-18 UNF
EC, ECH, EB, EBH Electro-hydraulic spool actuator
EC, EB
ECH, EBH
ECH
EBH
Control P-A, B-T

Control P-B, A-T
QDC102/PVC102
Gauge port
ECH, EBH
EC, EB
EC
EB
Pilot restrictor [55 A,B]

To give gentle remote control, the EC, ECH, EB, EBH, PC and
PCH spool actuators are fitted with pilot restrictors, which can
be chosen individually for each service port. The restrictor
gives a kind of ramp function.
For the EC, ECH, EB and EBH, the following options are
available: B
/ Without pilot restrictor
0.8 0.8 mm pilot restrictor (Normal)
A
For PC, PCH the following options are available:
/ Without pilot restrictor (Normal)

Pilot restrictor for EC, ECH, EB and EBH spool actuators
Straight cable connector
Ø6 - 10
Cable connector [56]

50
32
/ Without connector
0 Connector straight
Elbow connector
90 Connector 90 degree elbow
The PVC102 and QDC102 converter valves can be delivered

with cable connectors if specified by the customer. If electric
cables with fitted connectiors are required, these too are avail-
able from Parker, but must be ordered separately.
Spool selection [60-74]

Spool options
The spool is the most important link between the operator’s ac-
tivation of a lever unit and the movement of the controlled func- D
tion. For this reason, Parker makes a wide range of standard
spools to meet many different function-specific demands.
Spool selection is effected with the aid of a computerized spec- Dm
ification program, using a series of different parameters to de-
termine the optimum spool for the job.
Da
Spool function [60]
There are many spool variants which are adapted for different
flows, load conditions and actuator area ratios. The spools are Db
also available with different degrees of force feedback from the
service ports A and/or B.
M
D Double-acting spool for, e.g. double-acting cylinders.
Blocked in the neutral position.
Dm Double-acting spool with drainage of service ports A MA
and B to tank, which prevents pressure build up in the
neutral position. The spool is used as a double spool
in combination with a double over-centre valve. MB
Da Double-acting spool with drainage of service port A to
tank, which prevents pressure build up in service port
A in the neutral position.
EA
Db Double-acting spool with drainage of service port B to
tank, which prevents pressure build up in service port
B in the neutral position. EA3
EA Single-action spool for, e.g. single-acting cylinder.
Blocked in neutral position. Service port B blocked.
EA3 Single-acting spool for, e.g. single-acting cylinders.
Blocked in neutral position. Service port B blocked EB
during lifting function. Lowering function at both serv-
ice ports A and B.
EB Single-acting spool for, e.g. single-acting cylinders.
Blocked in neutral position. Service port A blocked.
M Double-acting spool for, e.g. hydraulic motors. Float-
ing function in neutral position.
MA Double-acting spool for, e.g. hydraulic motors. Float-
ing function in neutral position, service port A to Tank. CB
MB Double-acting spool for, e.g. hydraulic motors. Float-
ing function in neutral position, service port B to Tank.
CB Regenerative spool for rapid feeding of cylinder via
service port B. The large side of the cylinder is con-
nected to service port B.
Flow requirement [61 A,B] q (l/min) Flow rate in service connection

The K170LS directional valve has a range of optimized spool
240
designs for nominal flows up to 170 l/min when the section is
220
equipped with an individual pressure compensator, K1 [66].
See “Pressure compensator and/or load-hold check valve [66]” 200
for flow with other compensators. 170
Without an individual pressure compensator, flows up to 160
220 l/min are obtainable, depending on the pre-set regulating
difference in the LS pump. 120
110
The desired flow to the service ports A and B is entered in
the ordering documentation. Parker’s computerized specifica- 80
tion system then selects spools to give at least the flow re- 60
quired, also taking other parameters into account. 40
The maximum flow is then set by limiting the spool stroke by 30
15
means of adjustment screws on the spool actuator or, in the 0
case of electro-hydraulic remote control, by setting the maxi- 0 1 2 3 4 5 6 7 8
mum current. Spool stroke (mm)
See “Flow settings” [72] for details on factory setting of
maximum flow. Typical curves showing flow as a function of spool stroke
Area relationship [62]

The area relationship for a section is calculated by dividing the
cylinder area that is connected to the service port B by the
area that is connected to the service port A. When the larger
side of the cylinder is connected to the service port A, the rela-
tionship is less than 1. The area relationship for a motor is 1.
LAB - Load can change between the A- and B-port.
Load characteristics [63]

The character of the load can be selected according to five
typical cases. This information is entered so that the spool can
be given the best possible adaptation to the intended applica-
tion.
LAB Lift load can change between service ports A and B.

LA Lift load normally on service port A only.
LB Lift load normally on service port B only.
LN No or low lift load on service ports A and B.
LA - Load normally on A- port only.
S Slewing function.
LB - Load normally on B- port only.
Force feedback [64 A,B]

The K170LS is available with a force-feedback option, which Flow rate in % Optional force feedback
enables the positive sense of force control from CFO systems
to be transmitted to LS systems, thus enabling force-control
characteristics to be incorporated in individual valve sections. 100
With force control, the operator is better able to sense the in-
crease in machine load when a hard obstacle is met, e.g. in
digging operations. 75
Force feed-back also gives a kind of ramp function, which re-
sults in more gentle transitions during speed changes. This in
turn has a stabilizing effect on the hydraulic system, and the 50
machine operating characteristics become smoother. Both Light Havy
these characteristics are important, especially for slewing func- load load
tions and similar movements. With force feedback, machine 25
wear is reduced and efficiency increases.
The section can be equipped with force feedback for the
service ports A and B individually. The degree of force feed- 0
back can be chosen from three levels. The higher the level of 0 25 50 75 100
force feedback, the greater the reduction in the function’s
Lever stroke in %
speed upon increasing resistance for the same lever stroke. It
follows from this that the lever must be moved further in order
Force feedback
for the speed to remain the same when the load is increasing.
/ No force feedback
FN Normal level of force feedback
FH High level of force feedback
FL Low level of force feedback
Pressure compensator and/or load-hold check valve [66]

Pressure compensators
The primary purpose of pressure compensation is to maintain a q (l/min) Flow rate curves
constant flow rate to a function, regardless of pressure varia-
tions in the system. The facility is of special value in lifting func-
tions.
200
Excellent simultaneous operation characteristics
In cases where several machine functions are operated simul- 160
taneously, the spool sections in the K170LS can be equipped
with individual, integrated pressure compensators. Subject to 120
available pump capacity, sections so equipped will deliver the
pre-determined constant flow regardless of other simultaneous- 80
ly operated functions, and regardless of variations in load or
feed pressure. Parker integrated pressure compensators have 40
a very quick response time and incorporate built-in load-hold
check valves. 0
0 100 200 300
Increased or reduced function speed where required
To meet demands for exact speed in certain functions, Parker Load pressure (bar)
integrated pressure compensators comes in a number of fixed
Load independent flow with pressure compensator
variants that give flow rates from nominal to +55% through the
selfsame spool (see K1 to KN1 below). To accommodate
changing operating conditions, a variant that can be adjusted
on site to give ±20% of nominal flow is also available (see KS
below).
K1 Fixed pressure compensator with load-hold check

valve. The spool gives nominal flow.
valve. The spool gives 20% more than nominal flow.
valve. The spool gives 55% more than nominal flow.
N.B. Pump must deliver a pressure of at least ∆p=30
bar. (30 bar above load signal reported to pump regu-
lator.)
KN1 Fixed pressure compensator with extra fast load-hold
check valve. The spool gives 15% more than nominal
flow.
KS Adjustable pressure compensator with load-hold
check valve. The spool gives ±20% of nominal flow.
N1 Load-hold check valve.
X1 Prepared for compensator and load-hold check valve.
Pressure compensator for constant flow in service port (KN1).
Damping of pressure compensator [67]

The load-signal restrictor affects the response of the pressure
compensator.
0.6 Alternative LS restrictor for comp. ∅0.6 mm

0.8 Recommended LS restrictor for comp. ∅0.8 mm
1.0 Alternative LS restrictor for comp. ∅1.0 mm
Spool designation [69]

The task of spool selection can be submitted to Parker’s com-
puterized specification program, which adapts the spool to
match the specific demands of each function, thus optimizing
the spool.
The information given at positions 61, 62, 63, 64 and 66
therefore makes up part of the basis for the choice of spool.
Flow settings [72]

With PC and PCH spool actuators, flow limitation over the spool
to motor ports A and B can be effected by means of mechani-
cal limitation of the spool stroke length.
Qset When the spool section is equipped with a PC or PCH
spool actuator, it can be delivered with a factory-set
maximum flow rate. Setting is carried out according to
the stated flow requirements to the A-and B-ports Restrictor for damping of pressure compensator.
[61 A, B].
Qset A When the spool section is equipped with a PC or PCH
the stated flow requirements to the A-ports [61 A].
Qset B When the spool section is equipped with a PC or PCH
the stated flow requirements to the B-ports [61B].
When setting the flow rates for sections without pressure com-
pensators in systems with LS pumps, the flow setting is made
with a ∆p of 18 bar between the pump pressure in PX and the
load signal in PL, at full flow take-up.
For details on setting the flow for PC spool actuators, see
page 13.
Feed reduction valves [75] Pred (bar) Reducer characteristics

Any section in the K170LS valve can be equipped with individ-
ual feed reducing valves for the service ports A and B. These
are used for those functions in the system which require a low-
er maximum pressure than the normal operating pressure of
300
the system. The reducing valve is infinitely adjustable between
30 and 300 bar. It serves to reduce the pump pressure so that
the feed pressure in the section in which it is fitted does not ex-
ceed the pre-set value.
200
The use of feed reducing valves enables the pressure to be
limited without using any more than a pilot flow (<2 l/min).
In the case of feed reduction, the section must be fitted
with a pressure compensator. Since the feed reducing valve is
100
a two-way valve, pressure shocks that arise after the feed re-
ducing valve must be limited with the aid of a port relief valve.
The pressure setting on the port relief valve [76 A,B] can be
set as low as 10 bar above reducer setting. 0
0 50 100 150 200
Setting of feed reduction in the A-port [75A] qm (l/min)
Setting values for the A-port are from 30 to 300 bar.
Pred = Reduced pressure
Setting of feed reduction in the B-port [75B] qm = Flow at service port
Setting values for the B-port are from 30 to 300 bar.
Port relief and/or anti-cavitation valves [76 A,B]

A specially designed cartridge valve is used as a port relief ∆p (bar) Pressure relief characteristics
and anti-cavitation valve, PA, in the service ports. Its function is
to protect the valve and consumer from pressure peaks and ex-
cessive pressure in the system. The very rapid opening se-
quence and good pressure characteristics make the cartridge
valve an excellent port relief valve. The anti-cavitation valve
300
causes oil to flow from the tank gallery to the service port side
in the event of underpressure in the service ports.
200
Separate anti-cavitation valve in service ports
As an alternative to the port relief valve, the service ports can
be fitted with anti-cavitation valves, N2 cartridges. These ena-
ble oil to flow from the tank gallery to the service port side in 100
the event of underpressure.
The connection between tank and service port can also be
blocked using an Y2-plug.
0
0 50 100 150 200
Anti cavitation characteristics q (l/min)
The curve shows the pressure drop between tank connection
and service port when the PA or N2 cartridge is used as an ∆p (bar) Anti-cavitation characteristics with PA or N2
anti-cavitation valve.
X2 Service port A or B open to tank. 14
Y2 Service port A and/or B to tank blocked with plug. 12

N2 Service port A and/or B side of section equipped with
anti-cavitation valve.
10
50-350 Standard pressure settings for port relief valves (PA) in 8

bar:
50, 63, 80, 100, 125, 140, 160, 175, 190, 210, 230, 6
240, 250, 260, 280, 300*, 330* and 350*.
* Applies only to valves of nodular-iron design. 4
See also technical data, page 6.
2
The pressure setting on the port relief valve can be set as low
as 10 bar above reducer setting. [75 A,B]. 0
0 50 100 150 200
q (l/min)
Port B is equipped with a Port B is open to tank (X2)

combined port relief valve and port A has no tank
and anti-cavitation valve. connection (Y2).
(PA) Port A is equipped with
an anti-cavitation valve (N2).
Function block [90-99]

The K170LS can be equipped with function blocks (manifolds)
that enables complete system solutions to be integrated into
the valve.
Please contact Parker for more details on integrated sys-
tem solutions. In addition to standard blocks, Parker’s custom-
builds function blocks to meet special system demands.
Below is an example of a specially designed function block
for a specific customer.
This block, like most of our function blocks, is built up using

standard cartridge valves. Only the block itself is unique.
Dimensional drawing (inch)
(3.90) 99 PCA a)
61,5 PCB b) (2.42)
111 (LSP, T3)

64,5 (2.54)
37 (1.46)
(4.37)
16,5 (0.65)
89 (3.50)
128 (5.04)
190 (7.48) 0,5 (0.02)

135,5 (5.33) 43,5
60,2 (P1, T1) (2.37)
52,7 (YS) (2.07)
(1.71)
62,7 (T2, MP)
(2.47)
No. of L L
Sections mm inch
((1.97))
L
(50)
1 200 7.87
PCB b)
2 250 9.84
3 300 11.81
(0.47) 12 PCA a)
4 350 13.78
5 400 15.75
86 (3.39)
6 450 17.72 (0.73)

44,5 (LSP)
7 500 19.69 max 18,5

(1.75)
8 550 21.65
9 600 23.62
max 18,5
(0.73)
(1.85)
47 36 (1.42)
(5.94) 151 (2x) 94 (3.70)
265,5 (10.45)
348 (13.70)
134 (5.28)
55 (2.17)
30
(1.18)
39,5 (YS)
48 (1.89)
(1.56)
(4.07) 103,5 (T2, MP)
140,5 (5.53)
163 (6.42)
177,5 (6.99)
(0.47)
12
a) Pilot-pressure connection PCA activates service port A

b) Pilot-pressure connection PCB activates service port B
For further information please contact:
Parker Hannifin AB Catalogue 9129 8557-02 (GB)

Mobiles Controls Division Catalogue 9129 8557-06 (US)
SE-501 78 Borås Ed. 0010
Sweden
MobileHydraulics Tel +4633 16 91 00
Fax +4633 12 11 43
www.parker.com
PART IV
OTHERS
Ebersprächer engine heater

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Technical manual

For complete service information also see:

This manual is written for an experienced technician.

Live with safety: Read the safety messages in the

: This is the safety-alert symbol. When you see this

This technical manual is concise guide for specific

Fundamental service information is available from other

This Manual covers the following range of Forwarders

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tm2123 (14AUG03) Forwarders Technical Manual

tm2123 (14AUG03) Forwarders Technical Manual

SECTION 02—Power Train Group 1820— Cabin Service

SECTION 05—Engine Auxiliary system SECTION 45—Tool Drawings 17

SECTION 16—Electrical-System SECTION 80—Optional Equipments

All information, illustrations and specifications in this manual are based on

tm2123 (14AUG03) i Forwarders Technical Manual

tm2123 (14AUG03) ii Forwarders Technical Manual

tm2123 (14AUG03) iii Forwarders Technical Manual

tm2123 (14AUG03) iv Forwarders Technical Manual

Group 0010—Safety features Service Recommendations for O-Ring

Group 0020—General Specifications Group 0050—Transporting and Towing

tm2123 (14AUG03) 00-1 Forwarders Technical Manual

Operational Checkout Record Sheet . . . . . .00-0060-27

tm2123 (14AUG03) 00-2 Forwarders Technical Manual

Comply with instructions in this manual and also your

Should there be any information or instructions in this

This machine should not be operated or maintained by

As the maintainer ensure that you become familiar with all

tm2123 (14AUG03) 00-0010-1 Forwarders Technical Manual

A—Punched serial number on

Continued on next page EL62757,00001E5 –19–22APR02–1/5

tm2123 (14AUG03) 00-0010-2 Forwarders Technical Manual

Continued on next page EL62757,00001E5 –19–22APR02–2/5

tm2123 (14AUG03) 00-0010-3 Forwarders Technical Manual

A—Punched serial number on

Continued on next page EL62757,00001E5 –19–22APR02–3/5

tm2123 (14AUG03) 00-0010-4 Forwarders Technical Manual

A—Serial number B—Behind the front frame, on

Continued on next page EL62757,00001E5 –19–22APR02–4/5

tm2123 (14AUG03) 00-0010-5 Forwarders Technical Manual

A—Serial number B—Behind the front frame, on

tm2123 (14AUG03) 00-0010-6 Forwarders Technical Manual

Please remember, the Operator is the key to

Recognize Safety Information

This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the

Follow recommended precautions and safe operating

tm2123 (14AUG03) 00-0010-7 Forwarders Technical Manual

A signal word—DANGER, WARNING, or CAUTION—is

DANGER or WARNING safety signs are located near

Replace Safety Signs

Carefully study all of the safety messages that are in this

More specific measures are illustrated with pictographs

Keep safety signs in good condition. Repair or replace

tm2123 (14AUG03) 00-0010-8 Forwarders Technical Manual

Cabin is safety tested according to international ROPS,