SM D150B EN

Copyright © New Holland
D150B
Print No. 87693704 A - EU

English - Printed in Italy
D150B
D150B
CRAWLER
Repair Manual
87693704 A - EU
D150B CRAWLER
Repair Manual
87693704 A - EU
Table of Contents
Description Section Number
General Tab 1
Section Index - General
Standard Torque Specifications 1001
Fluids and Lubricants 1002
Metric Conversion Chart 1003
Engine Tab 2
Section Index- Engine
Engine and Radiator Removal and Installation 2000
After Cooler 2003
For Engine Repair, see the Engine Repair Manual 87519804
Fuel System Tab 3

Section Index- Fuel System
For Fuel System Repair, see the Engine Repair Manual 87519804
Electrical Tab 4
Section Index - Electrical
Removal and Installation of Electrical Components 4001
Electrical Specifications and Troubleshooting 4002
Batteries 4003
Instrument Cluster 4005
Tracks Tab 5
Section Index - Tracks
Inspection of Track Components 5502
Sealed and Lubricated Track (SALT) 5504
Track Frame and Suspension 5506
Idler, Track Adjuster, and Recoil Housing 5508
Sprocket 5509
Track Roller 5511
Copyright © 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87693704 A - EU Issued October, 2007
D150B CRAWLER
Repair Manual
87693704 A - EU
Table of Contents (Continued)
Power Train Tab 6

Section Index - Power Train
Hydrostatic Pumps and Motors System Overview 6000
Removal and Installation of Hydrostatic Pumps and Motors 6001
Hydrostatic Drive Specifications, Pressure Checks, Troubleshooting 6002
Transmission Controller 6003
Final Drives 6007
Brakes Tab 7
Section Index - Brakes
Removal and Installation of Brake Components 7001
Brake System Troubleshooting 7002
Hydraulics Tab 8
Section Index - Hydraulics
How to Read Hydraulic Schematics 8000
Removal and Installation of Hydraulic Components 8001
Hydraulic System Specifications, Troubleshooting and Pressure Checks 8002
Cleaning the Hydraulic System 8003
Equipment Pump 8004
Equipment Control Valve 8005
Cylinders 8006
Accumulator 8010
Mounted Equipment Tab 9

Section Index - Mounted Equipment
Pedals and Levers 9001
Air Conditioning Troubleshooting and System Checks 9003
Air Conditioning System Service 9004
Removal and Installation of Heater and Air Conditioning System Components 9005
Air Conditioning Compressor and Clutch 9006
Dozer Blade 9007
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) 9008
Air and Mechanical Suspension Seats and Seat Belts 9009
Ripper 9010

D150B CRAWLER
Repair Manual
87693704 A - EU
Table of Contents (Continued)
Schematic Set
Hydraulic and Electrical Schematics In Rear Pocket

SECTION INDEX
GENERAL
Section Title Section Number

General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
87693704 A - EU Issued 10-07 Printed in E.C.

1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
Pound- Newton
used.
Size Inches metres
1/4 inch 144 to 180 16 to 20
Grade 5 Bolts, Nuts, and Studs
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Pound- Newton Pound- Newton

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/8 inch 220 to 264 298 to 358
Pound- Newton 3/4 inch 380 to 456 515 to 618
Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
3/4 inch 270 to 324 366 to 439
1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983

1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or 10.9
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is Pound- Newton
used. Size Inches metres
M4 36 to 48 4 to 5
Grade 8.8 Bolts, Nuts, and Studs M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
8.8
M8 324 to 384 37 to 43
Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres
M5 60 to 72 7 to 8 M10 54 to 64 73 to 87
M6 96 to 108 11 to 12 M12 93 to 112 125 to 150
M8 228 to 276 26 to 31 M14 149 to 179 200 to 245
M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

M20 450 to 540 610 to 730
Pound- Newton M24 780 to 940 1050 to 1275

Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
Grade 12.9 Bolts, Nuts, and Studs
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9
fasteners.

1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

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

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

1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
O-ring Boss End
O-ring Face Seal End Fitting or Lock Nut
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
6.4 mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm
Thread Pound- Newton

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

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

1002
Section
1002
FLUIDS AND LUBRICANTS

1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change .....................................................................................16.4 Liters (17.3 U.S. Quarts)
Capacity without Filter Change ................................................................................15.6 Liters (16.5 U.S. Quarts)
Type of Oil ..................................................................................... See Engine Oil Recommendations on page 4
Engine Cooling System
Capacity without Heater ......................................................................................... 32.47 Liters (8.6 U.S. Gallons)
Type of Coolant ..........................................Ethylene glycol and water mixed for the lowest ambient temperature
(at least 50/50 mix)
Fuel Tank
Capacity ..................................................................................................................... 246 Liters (65 U.S. Gallons)
Type of Fuel ......................................................................................... See Diesel Fuel Specifications on page 5
Transmission and Hydraulic System
Hydraulic Reservoir Refill Capacity ........................................................................... 98.4 Liters (26 U.S. Gallons)
Type of Oil ...................................................................................................... New Holland AMBRA Master-Tran
Final Drives
Capacity ......................................................................................................................14.2 Liters (15 U.S. Quarts)
Type of Lubricant ..............................................................................................New Holland AMBRA Hypoide 90
Track Rollers
Capacity ................................................................................................................. 275 mL (9.3 U.S. fluid ounces)
Front Idlers
Carrier Rollers
Capacity ............................................................................................................... 334 mL (11.3 U.S. fluid ounces)
SALT and ALT track pins
CAB/ROPS Tilt System
Reservoir Refill Capacity ..........................................................................................0.36 Liters (0.38 U.S. Quarts)
Type of Oil ...................................................................................................... New Holland AMBRA Master-Tran
ENVIRONMENT
Before you service this machine and dispose of oil, fluids and lubricants, always remember the environment. Do
not put oil or fluids into the ground or into containers that can leak. Check with your local environmental, recycling
center or your Case dealer for correct disposal information.
NOTE: See operators manual and equipment lubrication chart for service intervals.

1002-4
ENGINE OIL RECOMMENDATIONS

New Holland AMBRA Engine oil is recommended
See the chart below for
for use in your New Holland engine. New Holland
recommended viscosity at
AMBRA Engine Oil will lubricate your engine
ambient air temperature
correctly under all operating conditions.
ranges.
If New Holland AMBRA Multi-Viscosity Oil is not
NOTE: Do not put performance
available, use only oil meeting API engine oil service
additives or other oil additive
category CH-4 (preferred) or CG-4.
products in the engine crankcase.
The oil change intervals given in this
RH99K130
manual are according to tests with
New Holland AMBRA lubricants.
BC06B150

1002-5
DIESEL FUEL
Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
If you keep fuel in storage for a period of time, you
power and high fuel consumption.
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following Note.
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel requirements in as cool as possible. Remove water from the storage
your area. If the temperature of the fuel is below the cloud container at regular intervals.
point (wax appearance point), wax crystals in the fuel will
cause the engine to lose power or not start.
The diesel fuel used in this machine must meet the
specifications in the chart below or Specification
D975-81 of the American Society for Testing and
Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ..............................................................................................................................................34
Flash point, minimum .......................................................................................................................... 60° C (140° F)
Cloud point (wax appearance point), maximum .........................................................-20° C (-5° F) See Note above
Pour point, maximum ................................................................................................-26° C (-15° F) See Note above
Viscosity, at 88° C (100° F)
Centistokes ..................................................................................................................................................2.0 to 4.3
Saybolt Seconds Universal ............................................................................................................................32 to 40

1002-6
NOTES

Section
1003
1003
METRIC CONVERSION CHART

1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilopascal 0.145 038 lb/sq. inch

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

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

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

litre/min. 0.219 969 gallon/min. (Imperial)

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

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

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

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

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

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

SECTION INDEX
ENGINE

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000
After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003
For Engine Repair, see the Engine Repair Manual 87519804

Section
2000
ENGINE AND RADIATOR REMOVAL AND

INSTALLATION
2000

2000-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2000-3
SPECIFICATIONS
Torques
Engine mount bolts ...................................................................................205 to 230 Nm (151 to 170 pound-feet)
Engine support mounting bolts......................................................................118 to 133 Nm (87 to 98 pound-feet)
Radiator mount bolts .........................................................................................68 to 82 Nm (50 to 60 pound-feet)
Radiator and after cooler hose clamps .......................................................... 11 to 12 Nm (97 to 106 pound-inch)
Air filter to turbo hose clamps......................................................................... 3.4 to 4.5 Nm (30 to 40 pound-inch)
Fan mounting bolts.........................................................................................26 to 33 Nm (19.5 to 24 pound-feet)
Drive shaft to flywheel mount bolts ...........................................................335 to 375 Nm (245 to 275 pound-feet)
Brush guard mounting bolts ......................................................................570 to 730 Nm (420 to 540 pound-feet)

2000-4
RADIATOR
Removal STEP 7
STEP 1
Park the machine on a level surface. Lower the blade
to the floor and stop the engine.
STEP 2
Put the master disconnect switch in the OFF position.
STEP 3
Open engine side panels. Disconnect the coolant
reservoir hose and remove the engine side panels.
STEP 4 BD07F083-01
Make sure the engine is cool and slowly remove the Tag the wires and disconnect them from the air filter
radiator cap. Attach a hose to the drain cock and restriction switch.
drain the radiator into a suitable container.
STEP 8
STEP 5
BD07F148-01 BD07F132-01
Remove the two bolts securing the grille. Lower the Remove the after cooler tube.
grille.
STEP 9
STEP 6
BD07F147-01 BD07F131-01
Remove the horn. Remove the air filter hose, disconnect the crankcase
ventilation hose.

2000-5
STEP 10 STEP 14
BD07F129-01
Remove the after cooler tube. BD07F144-01
Tag and disconnect the lift cylinder cross over hoses,

STEP 11 tag and remove the “T” fittings from the side of the
radiator wrap.
STEP 15
BD07G158-01
Remove the two plugs, remove the hood front

mounting bolts.
BD07H108-01
STEP 12 Remove the upper radiator hose.
STEP 16
BD07F128-01
Remove the two plugs, remove the hood rear

mounting bolts. BD07H107-01
Disconnect the lower radiator hose.

STEP 13
Attach lifting equipment to the hood, remove the
hood from the machine.

2000-6
STEP 17 STEP 19
1
2
BD07F135-01
BD07F141-01
Remove the front belly plate. Place a container

beneath the machine to catch hydraulic oil that will
drain when the oil cooler line is disconnected from
the oil cooler. Disconnect the lines and install plugs
BS07H289-01 and caps.
1. SPACER
2. FAN MOUNTING BOLTS (4)
STEP 20
Remove the fan and spacer from the engine.
STEP 18
Connect a vacuum pump to the hydraulic reservoir,
turn on the vacuum pump.
BD07F146-01
In the grill area, remove the two mounting bolts

securing the top of the radiator to the machine.

2000-7
STEP 21 Installation
STEP 24
If radiator mounts were removed for replacement,
apply a light coat of water from bottom of shank to 3
mm (1/8 inch) up from bottom. Insert mount in
welded bracket by rotating and pushing mount until
partially positioned. Install bolt making sure that bolt
head does not overhang the outside diameter of the
mount metal insert; if it does, use a smaller bolt.
Push the mount into the bracket with enough force to
ensure there is no gap between bottom surface of
mount head and surface of bracket.
BD05H157-01
STEP 25
Connect suitable lifting equipment to the radiator.
Remove the lower mounting bolts and washers from Attach lifting equipment to the radiator. Place the
the radiator. radiator into position on the mounts.
STEP 22 STEP 26
Raise one side of the radiator slightly and install two
Remove the radiator from the machine.
washers on top of the mount. Do the same on the
other mount. Put two washers on a bolt and install
STEP 23 the bolt from bottom. Install washers and bolt on
Remove radiator mounts only if replacement is other side of radiator.
necessary.
STEP 27
Center the radiator on the engine fan drive pulley
within ± 2.5 MM (0.09 inch). Tighten bolts to a torque
of 68 to 82 Nm (50 to 60 pound-feet).
STEP 28
1
2
3
4
BS07K832-01
1. BLOCK (2) 3. BOLT

2. WASHER 4. BOLT
In the grill area, apply Loctite 242 to the threads of
the bolts, install and tighten bolt 3 to 135.5 to 149 Nm
(110 to 110 pound-feet), install and tighten bolts 4 to
76 to 87 Nm (56 to 64 pound-feet).

2000-8
STEP 29 STEP 31
BD07F147-01
Install the horn. BD07F135-01
STEP 30
BD07F141-01
BD07F148-01 Connect the lines. Install the front belly plate.
Close the grille, install and tighten the two bolts
securing the grille. STEP 32
Stop and disconnect the vacuum pump from the
reservoir.

2000-9
STEP 33 STEP 36
1 2
BD07H107-01
Install the lower hose. Position clamps and tighten to

a torque of 11 to 12 Nm (97 to 106 pound-inch).
STEP 37
BD07H108-01
BS07H289-01
1. SPACER Install the upper hose. Position clamps and tighten to
2. FAN MOUNTING BOLTS (4) a torque of 11 to 12 Nm (97 to 106 pound-inch).
Install the spacer on the engine pulley.
STEP 38
STEP 34
Clean the mating surfaces of the fan and spacer,
apply anti-seize to the surfaces.
STEP 35
Install the fan and torque mounting bolts to 26 to 33
Nm (19.5 to 24 pound-feet).
BD07F144-01
Connect the “T” fittings to the side of the radiator

wrap according to tags installed during removal.
Connect the lift cylinder cross over hoses according
to tags installed during removal. Remove and discard
tags.
2000-10
STEP 39 STEP 43
Attach lifting equipment to the hood, place the hood
in position on the machine.
STEP 40
BD07F083-01
Connect the wires to the air filter restriction switch,

remove and discard tag.
BD07G158-01 STEP 44
Install the hood front mounting bolts and hand
tighten.
STEP 41
BD07F132-01
Install the after cooler tube. Position clamps and

tighten to a torque of 11 to 12 Nm (97 to 106
pound-inch).
BD07F128-01
Install the hood rear mounting bolts and tighten, STEP 45

install the two rubber plugs.
STEP 42
Tighten the front hood mounting bolts, install the two
rubber plugs.
BD07F129-01

pound-inch).

2000-11
STEP 46 STEP 47
Install the engine side panels, connect the coolant
reservoir hose to the radiator.
STEP 48
Fill the radiator with a mixture of 50% ethylene glycol
and 50% water. Install the radiator cap. Fill the
coolant reservoir up to the FULL mark on the
reservoir.
STEP 49
Put the master disconnect switch in the ON position.
BD07F131-01 STEP 50
Install the air filter hose. Position clamps and tighten Start the engine and run the engine at low idle.
to a torque of 3.4 to 4.5 Nm (30 to 40 pound-inch). Check for leaks. When the coolant is at operating
Connect the crankcase ventilation hose and tighten temperature, stop the engine. When engine has
the clamp. cooled, check the coolant level at the reservoir.

2000-12
ENGINE
Removal STEP 5
NOTE: If machine is equipped with a brush guard do Step
1 otherwise go to Step 2.
STEP 1
Connect suitable lifting equipment to brush guard.
Remove two lower bolts and lock nuts, remove the
two upper bolts and washers securing the brush
guard. Remove brush guard.
STEP 2
Open engine side panels. Disconnect the coolant
reservoir hose and remove the engine side panels.
BD07F132-01
STEP 3 Remove the after cooler tube.

Make sure the engine is cool and slowly remove the
radiator cap. Attach a hose to the drain cock and STEP 6
drain the radiator into a suitable container.
STEP 4
BD07F131-01
Remove the air filter hose, disconnect the crankcase

ventilation hose.
BD07F083-01
Tag the wires and disconnect them from the air filter STEP 7
restriction switch.
BD07F129-01
Remove the after cooler tube.

2000-13
STEP 8 STEP 12
BD07G158-01 BD07H107-01
Remove the two plugs, remove the hood front Disconnect the lower radiator hose.
mounting bolts.
STEP 13
STEP 9
2
1
BD07F128-01
Remove the two plugs, remove the hood rear

mounting bolts.
STEP 10
Attach lifting equipment to the hood, remove the
hood from the machine.
STEP 11
BS07H289-01
1. SPACER
Remove the fan and spacer from the engine.
BD07H108-01
Remove the upper radiator hose.

2000-14
STEP 14 STEP 18
Tilt the ROPS cab or canopy, see section 9008.
STEP 15
BD05H172-01
If equipped, discharge the air conditioning system,

BD07F127-01 see section 9004. Disconnect the electrical
If machine is equipped with a heater, loosen the connector for the clutch and the compressor hoses.
clamp and disconnect heater hose. Plug the hoses and cap the fittings.
STEP 16 STEP 19
BD07F130-01
Disconnect the wires from the alternator. BD07F138-01
Disconnect the electrical connector from the engine

STEP 17 controller.
STEP 20
BD05H103-01
Disconnect the battery cable and the wiring harness

BD07F097-01
wires from the starter.
Connect a vacuum pump to the fuel tank, turn on the
pump. Disconnect the fuel lines. Plug the lines and
cap the fittings, turn off the vacuum pump.

2000-15
Disconnect grounding cable from the bell housing.
STEP 26
STEP 22 Connect suitable lifting equipment to lifting eyes on
Attach lifting equipment to the engine. the engine. Raise the engine and move into position
on machine. Move engine rearward, slip the drive
STEP 23 shaft onto the hydrostat pumps. Carefully lower the
Remove the engine mounting bolts. engine into machine.
STEP 24 STEP 27
Raise the engine slightly. Move engine forward, slip Install and hand tighten the rear motor mounting
the drive shaft off of the hydrostat pumps. bolts and nuts. Center the flywheel housing in the
frame. Do not bind bolts.
STEP 25
STEP 28
Remove the engine from the machine.
Install and hand tighten the front engine mount bolts
and nuts. Center engine on radiator within ± 1.5 MM
(0.05 inch).
IMPORTANT: Torque front mounts first.
STEP 29
Torque the front engine mount bolts to 205 to 230
Nm (151 to 170 pound-feet).
STEP 30
Torque the rear engine mount bolts to 205 to 230 Nm
(151 to 170 pound-feet). Disconnect lifting equipment
from engine lifting eyes.
STEP 31
Install the grounding cable to the bell housing.
STEP 32
BD07F127-01
Connect the heater hose and tighten the clamp.
STEP 33
Lower the ROPS cab or canopy, see section 9008.

2000-16
STEP 34 STEP 37
1 2
BD05H172-01
If equipped, remove the plugs from the hoses and

caps from the fittings. Connect the electrical
connector for the clutch and the compressor hoses.
STEP 38
BS07H289-01 BD07F138-01
1. SPACER
Connect the electrical connector to the engine
controller.
Install the spacer on the engine pulley.
STEP 39
STEP 35
Clean the mating surfaces of the fan and spacer,
apply anti-seize to the surfaces.
STEP 36
Install the fan and torque mounting bolts to 26 to 33
Nm (19.5 to 24 pound-feet).
BD07F097-01
Connect a vacuum pump to the fuel tank, turn on the

pump. Remove the plugs from the lines and caps the
fittings, connect the fuel lines. Turn the vacuum
pump off and remove.

2000-17
STEP 40 STEP 43
BD05H103-01 BD07G158-01
Connect the battery cable to the starter solenoid and Install the hood front mounting bolts and hand
torque to 22.5 to 29.4 Nm (16.5 to 21.6 pound-feet). tighten.
Push the rubber boot onto the terminal. Connect the
ignition switch wire to the bottom of the starter STEP 44
solenoid and torque to 2.6 to 4.6 Nm
(23 to 41 pound-in).
STEP 41
BD07F128-01
Install the hood rear mounting bolts and tighten,

install the two rubber plugs.
BD07F130-01
Connect the wires to the alternator. STEP 45

Tighten the front hood mounting bolts, install the two
STEP 42 rubber plugs.
Attach lifting equipment to the hood, place the hood
in position on the machine.

2000-18
STEP 46 STEP 49
BD07F083-01 BD07F131-01
Connect the air filter restriction switch, remove and Install the air filter hose. Position clamps and tighten
discard tag. to a torque of 3.4 to 4.5 Nm (30 to 40 pound-inch).
Connect the crankcase ventilation hose and tighten
STEP 47 the clamp.
STEP 50
Install the engine side panels, connect the coolant
reservoir hose to the radiator.
STEP 51
Fill the radiator with a mixture of 50% ethylene glycol
and 50% water. Install the radiator cap. Fill the
coolant reservoir up to the FULL mark on the
reservoir.
STEP 52
BD07F132-01
If equipped with a brush guard, connect suitable
lifting equipment to brush guard and move into
position. Install the two lower bolts, lock nuts, and
washers. Install the two upper bolts and washers.
pound-inch).
Torque the upper bolts to 570 to 730 Nm
(420 to 540 pound-feet).
STEP 48
STEP 53
Check and ensure that the engine has been filled
with the correct engine oil, see section 1002.
STEP 54
Start engine and run at low idle. Check for leaks.
Check that gauges show the correct indications.
STEP 55
If equipped, see section 9004 and charge the air
conditioning system.
BD07F129-01

pound-inch).

Section
2003
2003
AFTER COOLER

2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2003-3
TROUBLESHOOTING AFTER COOLER

STEP 1
Park machine on level ground, lower the blade. Put
transmission in neutral, apply the parking brake. Turn
off engine.
STEP 2
Open the engine side panels, inspect cooler
components for damaged or missing parts.
STEP 3
BD05H098
Inspect the after cooler outlet flex hose for leaks or

holes and insure that the clamps are tight, tighten to
STEP 5
BD05H102
Inspect the turbocharger flex hose for leaks or holes

and insure that the clamps are tight, tighten to a
torque of 11 to 12 Nm (97 to 106 pound-inch).
STEP 4
BD05H097
Inspect the intake manifold flex hose for leaks or

STEP 6
Visually inspect top of after cooler for damage or
leaks
NOTE: If the leak source has not been located, remove
and test the after cooler.
BD05H101
Inspect the after cooler inlet flex hose for leaks or


2003-4
AFTERCOOLER REMOVAL
Removal STEP 4
STEP 1
BD05H098
Loosen clamps and remove air cooler outlet hose.

BD05H102
Loosen clamps on the turbocharger outlet hose. STEP 5

Have an assistant hold the after cooler in place while
STEP 2 removing the mounting bolts.
STEP 6
BD05H101
Loosen clamps and remove air cooler inlet hose.
STEP 3 BD05H099
Remove the two bolts on the left side of the after

cooler.
BD05H097
Loosen clamps and remove Intake hose.

2003-5
STEP 7 Installation
STEP 1
Have an assistant hold the after cooler in place while
installing the mounting bolts.
STEP 2
BD05H100
Remove two bolts from the right side of the after

cooler.
STEP 8
Lower the after cooler and remove it from the
machine. BD05H099
Install two left side mounting bolts
Leak Test STEP 3
BD05H100
Install two right side mounting bolts.

BS03B028
STEP 4
Check the core for leaks by closing off the outlet tube
and attaching regulated air pressure 550kPa (80psi) Torque mounting bolts to 28 to 34 Nm (20.5 to 25
to the inlet tube. Submerge the cooler in water and pound feet).
watch for air leakage.
NOTE: If leakage is detected replace the after cooler.

2003-6
STEP 5 STEP 7
BD05H102 BD05H097
Install air cooler inlet hose. Tighten clamps at Install air cooler outlet hose and tighten clamps at
turbocharger outlet, tighten to a torque of 11 to 12 engine intake, tighten to a torque of 11 to 12 Nm (97
Nm (97 to 106 pound-inch). to 106 pound-inch).
STEP 6 STEP 8
BD05H101 BD05H098
Tighten clamps at air cooler inlet, tighten to a torque Tighten clamps at air cooler outlet, tighten to a torque
of 11 to 12 Nm (97 to 106 pound-inch). of 11 to 12 Nm (97 to 106 pound-inch).

SECTION INDEX
FUEL SYSTEM

For Fuel System Repair, See the Engine Repair Manual 87519804

SECTION INDEX
ELECTRICAL SYSTEM

Removal and Installation of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001
Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005

4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER

AND ALTERNATOR

4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DRIVE BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4001-3
STARTER
Removal Installation
1. Park the machine on a level surface. 1. Position the starter in the flywheel housing.
2. Lower the attachments to the floor. 2. Apply Loctite 242 to the threads of the mounting
bolts. Install the bolts, washers, and torque the
3. Apply the parking brake and stop the engine,
bolts to 77 to 87 Nm (56 to 64 pound-feet).
remove the key from the ignition switch.
3. Connect the battery cable to the starter solenoid
4. Fasten a Do Not Operate tag to the instrument
and torque to 22.5 to 29.4 Nm (16.5 to 21.6
panel.
pound-feet). Push the rubber boot onto the
5. Open the left rear ROPS door. terminal. Connect the ignition switch wire to the
bottom of the starter solenoid and torque to 2.6
6. Put the battery disconnect switch in the off
to 4.6 Nm (23 to 41 pound-inches).
position.
4. Install the right-hand side lower panel.
7. Open the right-hand side engine panel.
5. Close the right-hand side engine panel.
8. Remove the right-hand side lower panel.
6. Put the battery disconnect switch in the on
9. Fasten identification tags to the wires for the
position.
starter. Disconnect the wire from the bottom of
the starter solenoid. Pull the rubber boot away 7. Close the left rear ROPS door.
from the terminal and disconnect the battery
8. Remove the Do Not Operate tag from the
cable.
instrument panel.
BD05H103-01
10. Support the starter. Loosen and remove the

mounting bolts. Remove the starter.

4001-4
ALTERNATOR
Removal
1. Park the machine on a level surface. 13. Remove the mount bolt from the bottom of the
alternator
2. Lower the attachments to the floor.
14. Loosen the bolt at the top of the alternator.
remove the key from the ignition switch. 15. Support the alternator and remove the bolt and
washer.
4. Fasten a Do Not Operate tag to the instrument
panel. 16. Remove the alternator from the mounting
bracket
5. Open the left rear ROPS door.
6. Put the battery disconnect switch in the off Installation
position.
1. Hold the alternator and alignment with the
7. Open the right-hand engine side panel. mounting bracket and install the bolt and washer
8. Remove the right-hand side lower panel. at the top of the alternator.
9. Install a 12.7mm (1/2 inch) drive breaker bar in 2. Install the bolt at the bottom of the alternator.
the bracket for the automatic belt tensioner. 3. Connect the wiring harness connector (3) to the
alternator.
4. Connect the wiring harness to the alternator,
while pressing in on connector move the locking
lever to the locked position.
5. Connect the heavy red wire to the B+ terminal.
Install the washer and nut on the B+ terminal and
torque to 7.5 to 8.0 Nm (66 to 71 pound-inches).
Push the rubber boot (1) over the wire and B+
terminal.
6. Use the breaker bar to hold the tension pulley out
of the way while installing the drive belt on the
alternator pulley. Make sure that the drive belt is
BD05H105-01
seated in the grooves in each of the pulleys.
10. Lift up on the breaker bar to release the belt
tension, and remove the drive belt from the 7. Install the right-hand side lower panel.
alternator pulley.
8. Close the right-hand engine side panel.
9. Put the battery disconnect switch in the on
position.
1
10. Close the left rear ROPS door.
instrument panel.
BD05H104-01
11. Remove the nut (1) and lock washer. Disconnect

the wire from the terminal.
12. Lift the lever and disconnect the wiring harness
wire from the alternator.
4001-5
DRIVE BELT REPLACEMENT

1. Park the machine on a level surface. 10. Lift up on the breaker bar to release the belt
tension while removing the old drive belt.
2. Lower the attachments to the floor.
11. Use the breaker bar to hold the tension pulley out
of the way while installing the new drive belt on
remove the key from the ignition switch.
the pulleys. Make sure that the drive belt is
4. Fasten a Do Not Operate tag to the instrument seated in the grooves in each of the pulleys.
panel.
12. Install the right-hand side lower panel.
5. Open the left rear ROPS door.
13. Close the right-hand engine side panel.
6. Put the battery disconnect switch in the off
position.
instrument panel.
7. Open right-hand side engine panel.
8. Remove the right-hand side lower panel.
9. Put a 12.7 (1/2 inch) drive breaker bar in the
bracket for the automatic belt tensioner.
BD05H105-01

4001-6
NOTES

4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING

4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GROUNDING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL SYSTEM WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MAIN ELECTRICAL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Accessory Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Ignition Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Start Sensing Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fleet Relay (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuse Block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuse Block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Right Parking Brake Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Tilt Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Left Parking Brake Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Brake Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Decelerator Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Decelerator Pedal Low Idle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Drivetrain Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Left Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Right Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Left Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Right Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Left Motor Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Right Motor Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reverse Ratio Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FNR Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Blade Control Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Hydraulic Safety Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Blade Lift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Blade Lower Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Tilt Left Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Tilt Right Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Equipment Valve Twist Left Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Equipment Valve Twist Right Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Equipment Valve Ripper Joystick (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Equipment Valve Ripper Lift Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Equipment Valve Ripper Lower Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Instrument Cluster Connector A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Instrument Cluster Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Enter Escape Instrument Cluster Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4002-3
Up Down Menu Instrument Cluster Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydrostat Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Transmission Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Front Floodlight/Monitor Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Rear Floodlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Floodlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Floodlights (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Rear Floodlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cab Interior Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cab Interior Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Converter 24 volts to 12 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Accessory Power Jack 12 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Optional ROPS Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Optional Air Suspension Seat - Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Blower Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
HVAC Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Temperature Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Low Pressure AC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
High Pressure AC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Condenser Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Front Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Front and Rear Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Rear Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Front and Rear Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Front and Rear Windshield Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Left Hand Door Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Left and Right Hand Door Windshield Wiper Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Right Hand Door Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Left and Right Hand Door Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Left and Right Hand Door Windshield Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fleet Tracker Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Grounding points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
USING BOOSTER BATTERIES TO START THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4002-4
NOTES

4002-5
SPECIFICATIONS
Electrical System ................................................................................................................. 24 Volt Negative Ground
Battery (Two Batteries Connected in Parallel)
Group Size .......................................................................................................................................... 31-700CCA
Reserve Capacity ............................................................................................................................... 170 Minutes
Cold Cranking Capacity
at 0° F (-17° C) ............................................................................................................................. 700 Amperes
at -20° F (-29° C) ......................................................................................................................... 520 Amperes
Load for Capacity (load) Test ............................................................................................................... 350 Amperes
Alternator ..................................................................................................................................... 24 Volt 65 Amperes
Starter................................................................................................................................ 24 Volt Solenoid Actuated
NOTE: During inspection of connectors look for moisture, burnt, corroded or bent pins. For troubleshooting procedures on
the drivetrain control module and hydrostat controlling components see Section 6003.
BS07J144-01
FUSE AND RELAY PANELS

4002-6
GROUNDING POINTS
BD07F079-01 BD07J045-01
GND P2 – PUMPS AND VALVE GROUND GND C13 – RIGHT HAND CONSOLE NEXT TO
POWER CONVERTER
BD07F133-01
BD07J046-01
GND E3 – ENGINE GROUND AT LEFT REAR ENGINE MOUNT
GND L14 – LIGHTS GROUND, LEFT CENTER TOP OF CAB
BD07J044-01
BD07J047-01
GND C19 – LEFT HAND CONSOLE NEXT TO
DRIVE TRAIN CONTROLLER GND M4 – INSTRUMENT CLUSTER GROUND
BEHIND CONSOLE

4002-7
ELECTRICAL SYSTEM WIRE IDENTIFICATION
Wire and Connector Identification Codes

Wire Identification
M3/A7 A7 is pin ID in the connector
100 - Cluster 500 - 12 Volt
Connector Identification 200 - Drivetrain 800 - A/C
C - Micro M - Main 300 - Engine 900 - Menu Sw
D - Dash P - Pumps and Motors 400 - Joysticks
M3 connector ID E - Engine V - Valve
L - Lighting SA - Splice
Wire
From To
Identification
ACC M18 M19
ACC M19 RESISTOR
BATT+ M17 SA-9
BATT+ SA-9 M3/AA1
BATT+ SA-9 M3/AA2
BATT+ SA-9 M3/AA3
BATT+ SA-9 M3/AA4
BATT+ SA-9 M3/AA5
BATT+ SA-9 M3/AA6
IGN+ M2/B3 SA-10
IGN+ SA-10 M2/D2
IGN+ SA-10 M3/AA8
IGN+ SA-10 M3/AA9
IGN+ SA-10 M3/AA1
IGN 1 C1/13 SA-7
IGN 1 C1/41 SA-7
IGN 1 C1/42 SA-7
IGN 1 SA-7 C4/7
IGN 1 M10/7 SA-2
IGN 1 SA-2 M7/A
IGN 1 SA-2 M8/A
IGN 1 SA-2 M3/A1
IGN 1 SA-2 M9/1
IGN 1 SA-2 M9/5
IGN 2 M3/A9 M10/16
IGN 2 C4/16 SA-2
IGN 2 SA-2 C1/27
IGN 2 SA-2 C1/1
IGN 2 SA-2 C9/A
IGN 3 M1/15 SA-4
IGN 3 SA-4 M3/A8
IGN 3 SA-4 M11/27
IGN 3 E1/27 E2/40
START D2B/17 D14

4002-8

Wire Identification
Wire
From To
Identification
START D14 D1/13
START M1/13 M2/B10
V1acc M2/A2 M10/42
V1acc C4/42 SA-10
V1acc SA-10 C5/9
V1acc SA-10 C7/A
V1acc SA-10 C16/1
V1acc SA-10 C14/2
V1acc SA-10 C17/1
V1acc P1/9 SA-2
V1acc SA-2 P5/2
V1acc SA-2 P6/2
V1acc SA-2 P10/A
V1acc V1/A V25/A
V2acc M2/A3 SA-3
V2acc SA-3 M13/A
V2acc SA-3 M22/A
W E4 E1/16
W M11/16 M16/5
0-D D15 SA-1
0-D SA-1 D1/34
0-D M1/34 M4
0-D M4 SA-1
0-D SA-1 M16/6
0-D 2A/6 SA-1
0-D SA-1 D1/39
0-D M1/39 M4
0-D SA-1 M16/8
0-D 2A/12 SA-1
0-D SA-1 D1/40
0-D M1/40 M4
0-D SA-1 M9/2
0-D 2B/15 SA-1
0-D SA-1 M22/B
0-D 2B/22 SA-1
0-D SA-1 M7/C

4002-9

Wire Identification
Wire
From To
Identification
0-D SA-1 M8/C
0-D SA-1 M13/B
0-D SA-1 M15
0-D SA-1 M14/B
0-D SA-1 M20
0-E E2/5 SA-1
0-E SA-1 SA-3
0-E SA-3 E7/8
0-E SA-4 E10/B
0-E E2/6 SA-1
0-E SA-3 E3
0-E E3 SA-4
0-E SA-4 E5/B
0-E E2/10 SA-1
0-E SA-4 E5/A
0-E E2/11 SA-1
0-E E11/3 SA-1
0-L SA-6 L1/10
0-L C8/10 C19
0-L C19 C9/B
0-L C13 C22
0-L SA-6 L1/11
0-L C8/11 C19
0-L C19 C12/B
0-L C13 C17
0-L L3/2 L14
0-L L14 SA-6
0-L SA-6 L1/12
0-L C8/12 C19
0-L C19 C3/A
0-L C13 C16
0-L L2/2 SA07
0-L DA07 L14
0-L L14 SA-1
0-L SA-1 L4/2
0-L C19 C1/2

4002-10

Wire Identification
Wire
From To
Identification
0-L C13 C15
0-L L11/B SA-7
0-L SA-1 L5/2
0-L C19 C1/28
0-L C13 C20
0-L L8 SA-7
0-L SA-1 L6/2
0-L C19 C13
0-L C13 C14
0-L SA-1 L7/2
0-L C13 C14
0-L SA-1 L15/5
0-L SA-1 L10/C
0-P+V P9/B P2
0-P+V P2 P1/X
0-P+V V1/X SA-1
0-P+V SA-1 V21/2
0-P+V P8/2 SA-1
0-P+V SA-1 P2
0-P+V SA-1 V24/2
0-P+V P3/1 SA-1
0-P+V SA-1 V23/B
0-P+V P3/4 SA-1
0-P+V SA-1 V9
0-P+V P4/1 SA-1
0-P+V P4/4 SA-1
0-P+V P7/2 SA-1
15 D14 D1/12
15 M1/12 SA-8
15 SA-8 M2/B8
15 SA-8 M14/A
30 D14 D1/4
30 M1/4 M3/A2
50 D14 D1/11
50 M1/11 M2/B2
103 D2A/24 D1/35

4002-11

Wire Identification
Wire
From To
Identification
103 M1/35 M11/11
103 E1/11 E7/A
104 D2B/11 D1/27
104 M1/27 M10/46
104 C4/46 C5/2
104 P1/2 P10/H
104 V1/H V12
111 D2B/6 D12/1
114 D2B/2 D12/3
118 D2B/8 D11/1
120 D2A/2 D1/25
120 M1/25 M10/30
120 C4/30 C5/5
120 P1/5 P10/M
120 V1/M V23/A
121 D2A/5 D1/33
121 M1/33 M10/29
121 C4/29 C5/3
121 P1/3 P10/K
121 V1/K V11
125 D2B/7 D11/3
133 D2B/5 D1/6
133 M1/6 M10/31
133 C4/31 C5/6
133 P1/6 P9/A
134 D2B/3 D1/36
134 M1/36 M10/34
134 C4/34 C5/4
134 P1/4 P10/O
134 V1/O V10
135 D2A/13 D15
204 C1/4 C5/12
204 P1/12 P4/2
205 C1/5 C5/1
205 P1/1 P10/B
205 V1/B V9

4002-12

Wire Identification
Wire
From To
Identification
206 C1/6 C4/48
206 M10/48 M2/B4
210 C7/B C1/10
211 C7/C C1/11
215 V24/1 V1/U
215 P10/U P1/16
215 C5/16 SA-4
215 SA-4 C1/15
215 SA-4 C1/29
216 C1/16 C5/13
216 P1/13 P4/3
217 C1/17 C5/10
217 P1/10 P6/3
218 C1/18 C5/11
218 P1/11 P6/1
219 M5/C M10/36
219 C4/36 C1/19
223 M23/A M10/41
223 C4/41 C1/23
224 C3A/H C1/24
230 C1/30 C5/14
230 P1/14 P3/3
231 C1/13 C5/15
231 P1/15 P3/2
237 C1/37 C4/13
237 M10/13 M7/B
238 C6/C C1/38
243 C1/43 C5/8
243 P1/8 P5/3
244 C1/44 C5/7
244 P1/7 P5/1
248 C1/48 C5/17
248 P1/17 P10/V
248 V1/V V25/B
250 C3A/G C1/50
251 C3A/F C1/51

4002-13

Wire Identification
Wire
From To
Identification
252 C3A/J C1/52
256 C2/56 C4/11
256 M10/11 M6/B
260 C2/60 C4/19
260 M10/19 M8/B
262 C2/62 C4/12
262 M10/12 M5/B
264 C2/64 C6/B
265 C2/65 C4/20
265 M10/20 M6/C
268 C2/68 C5/31
268 P1/31 P7/1
269 C2/69 C5/32
269 P1/32 P8/1
271 C12/A C2/71
272 C2/72 C5/18
272 P1/18 P10/D
272 V1/D V21/1
279 M6/A M10/18
279 C4/18 SA-8
279 SA-8 C2/79
279 SA-8 C6/A
280 C2/80 C4/43
280 M10/43 SA-11
280 SA-11 M23/B
280 SA-11 M5/A
302 M3/A5 M11/1
302 E1/1 SA-2
302 SA-2 E11/2
302 SA-2 E2/2
302 SA-2 E2/3
302 SA-2 E2/8
302 SA-2 E2/9
312 M12 M11/23
312 E1/23 E2/12
317 M3/D1 M11/21

4002-14

Wire Identification
Wire
From To
Identification
317 E1/21 E2/17
329 M2/D10 M11/24
329 E1/24 E2/29
332 M2/B9 M11/25
332 E1/25 E2/32
334 D2A/4 D1/16
334 M1/16 SA-6
334 SA-6 M10/45
334 C4/45 SA-6
334 SA-6 C1/39
334 SA-6 C3/D
334 SA-6 M9/3
334 SA-6 M11/18
334 E1/18 E2/34
335 D2A/3 D1/26
335 M1/26 SA-5
335 SA-5 M11/20
335 SA-5 M10/44
335 SA-5 M9/4
335 E1/20 E2/35
335 C4/44 SA-5
335 SA-5 C1/40
335 SA-5 C3A/E
337 M3/B2 M11/26
337 E1/26 E2/37
342 E11/1 E2/42
375 M12 M11/28
375 E1/28 E2/75
389 C3A/E C4/39
389 M10/39 M11/29
389 E1/29 E2/89
415 C10/7 C17/5
416 C10/12 C17/6
417 C10/11 C17/7
418 C17/8 C16/6
419 C17/9 C16/5

4002-15

Wire Identification
Wire
From To
Identification
421 C18/1 C5/22
421 P1/22 P10/W
421 V1/W V16/1
422 C18/2 C5/23
422 P1/23 P10/J
422 V1/J V15/1
423 C18/3 C5/24
423 P1/24 P10/L
423 V1/L SA-2
423 SA-2 V15/2
423 SA-2 V16/2
424 C18/4 C5/19
424 P1/19 P10/P
424 V1/P V13/1
425 C18/5 C5/20
425 P1/20 P10/Q
425 V1/Q V14/1
426 C18/6 C5/21
426 P1/21 P10/S
426 V1/S SA-5
426 SA-5 V13/2
426 SA-5 V14/2
427 C18/7 C5/25
427 P1/25 P10/G
427 V1/G V17/1
428 C18/8 C5/26
428 P1/26 P10/E
428 V1/E V18/1
429 C18/9 C5/27
429 P1/27 P10/R
429 V1/R SA-3
429 SA-3 V17/2
429 SA-3 V18/2
451 C21/1 C5/28
451 P1/28 P10/T
451 V1/T V19/1

4002-16

Wire Identification
Wire
From To
Identification
452 C21/2 C5/29
452 P1/29 P10/N
452 V1/N V20/1
453 C21/3 C5/30
453 P1/30 P10/F
453 V1/F SA-4
453 SA-4 V19/2
453 SA-4 V20/2
501 M3/A6 M10/28
501 C4/28 SA-9
501 SA-9 C8/6
501 L1/6 L8
501 SA-9 C14/1
501 SA-9 C3A/B
504 C15 SA-12
504 SA-12 C8/8
504 L1/8 L15/17
504 SA-12 C14/4
505 C14/5 C8/9
505 L1/9 L15/12
800 L9 L13/10
800 L9 L1/5
800 C8/5 C4/23
800 M10/23 M2/A9
811 L10/B L13/1
813 L12 L13/3
814 L12 L13/4
815 L12 L13/5
816 L12 L13/6
817 L11/3 SA-5
817 SA-5 L9
817 SA-5 L13/7
818A L13/8 L1/4
818A C8/4 C23/A
818B E12/A E1/12
818B M11/12 M10/15

4002-17

Wire Identification
Wire
From To
Identification
818B C4/15 C23/B
818C E12/B E6
819 L10/A SA-8
819 L13/9 SA-8
819 L11/A SA-8
819 SA-8 L1/7
819 C8/7 C4/26
819 M10/26 M2/A1
899 L9 L12
912 D5/2 D1/5
912 M1/5 M2/A6
921 D2B/12 D6/1
921 D6/1 D1/14
921 M1/14 M10/21
921 C4/21 C8/3
921 L1/3 SA-2
921 SA-2 L2/1
921 SA-2 L3/1
922 D6/2 D1/3
922 M1/3 M2/A4
931 D7/1 D4
932 D7/2 D4
933 D4 D9/6
933 D9/6 D8/2
933 D8/2 D7/3
933 D7/3 D1/21
933 M1/21 SA-7
933 SA-7 M15
933 SA-7 M2/A5
934 D7/4 D1/22
934 M1/22 M10/47
934 C4/47 C20
935 D7/5 D1/23
935 M1/23 M10/38
935 C4/38 C20
943 D8/3 D1/32

4002-18

Wire Identification
Wire
From To
Identification
943 M1/32 M11/14
943 E1/14 E5A/1
951 D9/1 D1/17
951 M1/17 M15
952 D9/2 D1/7
952 M1/7 M15
953 D10/2 D9/3
953 D9/3 D7/6
953 D7/6 D1/31
953 M1/31 SA-12
953 SA-12 M10/3
953 SA-12 M2/A7
953 C4/37 SA-11
953 SA-11 C22
953 SA-11 C20
954 D9/4 D1/38
954 M1/38 M10/14
954 C4/14 C22
955 D9/5 D1/28
955 M1/28 M10/8
955 C4/8 C22
963 D10/3 D1/18
963 M1/18 M11/13
963 E1/13 E5B/1
992 M3/A4 M1/37
992 D1/37 D11/2
992 D11/2 D12/2
992 D11/2 D2B/14
992 D12/2 D13/2
992 D13/2 D2B/2
993 D13/3 D1/8
993 M1/8 M11/7
993 E1/7 E10/A
4111 D2B/10 D1/10
4111 M1/10 M10/10
4111 C4/10 C17/11

4002-19

Wire Identification
Wire
From To
Identification
1M M16A/7 M2/A1
1N-A M2/B7 M3/A1
1N-B M2/D8 M16A/1
911A D5/1 D1/2
911A M1/2 M10/24
911A C4/24 C8/1
911A L1/1 SA-3
911A SA-3 L5/1
911A SA-3 L6/1
911A D5/1 D2B/9
911B D5/1 D1/1
911B M1/1 M10/22
911B C4/22 C8/2
911B L1/2 SA-4
911B SA-4 L4/1
911B SA-4 L7/1

4002-20
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Example 1
Front, right side of the engine. 2
Check Points Reading Possible Cause of Bad Reading
3
Check the 10 ampere fuse at
4 5
location 3 and 4C in the fuse block.
Good Bad fuse.
(See fuse and relay location on
page 4.)
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 24 Volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the alternator.
6
1. This title is the component name.

2. Location of component on the machine.
3. This column shows the location of the check point.
4. This column shows the indication of the check.
5. This column shows the possible cause of a bad test indication.
6. The numbers in the parentheses show the number of the title of the related component.
7. This statement assumes that all other problems are solved at this point in the test.
NOTE: During inspection of connectors look for moisture, burnt, corroded or bent pins. For troubleshooting procedures on
the drivetrain control module and hydrostat controlling components see Section 6003.

4002-21
MAIN ELECTRICAL SYSTEM TROUBLESHOOTING

NOTE: For the System Schematic, component and symbol identification refer to the Schematic Poster located at the rear of this
manual.
IMPORTANT: The battery must be at full charge and all connections clean and tight before testing. Use a multimeter for the
following tests.
1 – Battery
Left ROPS access panel.
Refer to Section 4003 and check the battery.
2 – Master Disconnect Switch

Left ROPS access panel.
NOTE: Put the master disconnect switch in the OFF position.

Battery positive terminal to battery
Bad battery cable between battery negative terminal and master
negative terminal cable connection 24 Volts
disconnect switch.
on master disconnect switch.
Battery positive terminal to ground. 0 volt Bad master disconnect switch.
NOTE: Put the master disconnect switch in the ON position.

Bad master disconnect switch or bad cable between master
Battery positive terminal to ground. 24 Volts
disconnect switch and ground.
3 – Alternator
Right front side of engine.

Bad wire 1A between the alternator and the battery terminal of
B+ terminal for wire 1A to ground. 24 Volts the starter (6). Bad cable between the battery terminal of the
starter and the positive post of the battery (1).
NOTE: Put the ignition switch in the RUN position.
D+ terminal to ground. 24 Volts Bad wire from instrument cluster to the alternator.

4002-22
4 – Ignition Switch
Dash panel.
NOTE: Disconnect the connector from the ignition switch. Turn the ignition switch to the RUN position.
Between the BATT and the RUN
Continuity Bad ignition switch.
terminals of the ignition switch.
Between the BATT and the ACC
NOTE: Hold the key switch in the START position.

Between the BATT and all other
5 – Starter Solenoid
Right rear side of the engine compartment.
Terminal e to ground. Continuity Bad ground circuit.
NOTE: Put the directional control in the neutral position and the parking brake control levers in the applied
position. Have another person hold the ignition switch in the START position.
Bad wire 21D between the starter solenoid and the starter relay
Terminal for wire W (21D) to ground. 24 Volts
(12).
Terminal B to ground. 24 Volts Bad starter solenoid.
6 – Starter
Lower right side of the engine.

Terminal for battery positive wire to Bad cable between the battery terminal of the starter and the
24 Volts
ground. positive post of the battery (1).
NOTE: Put the directional control in the neutral position and the parking brake control levers in the applied
position. Have another person hold the ignition switch in the START position.
Bad wire 21D between the starter and the starter relay. Bad
Terminal for wire W (21D) to ground. 24 Volts
starter relay (12).

4002-23
7 – Accessory Relay
Left ROPS side panel.
Terminal for wire 0 to ground. Continuity Bad ground circuit.

Bad wire BL (15) between the accessory relay and the ignition
Terminal for wire BL (15) to ground. 24 Volts
switch, bad ignition switch (4).
Terminal for wire BL (ACC) to
24 Volts Bad accessory relay.
ground.
8 – Grid Heater Relay

Engine compartment.

Bad wire (375) between the grid heater relay and the engine
Terminal for wire V (375) to ground. Continuity
controller, bad engine controller.
NOTE: Put the ignition switch to RUN position, temperature must be below 0° C (32° F).
Bad wire (312) between the grid heater relay and the engine
Terminal for wire O (312) to ground. 24 Volts
Bad wire between the grid heater relay and the grid heater
Terminal B to ground. 24 Volts
fuse, bad fuse (13A on schematic).
Terminal G to ground. 24 Volts Bad grid heater relay.
9 – Grid Heater
Located in the left side of the engine in intake manifold, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Disconnect wire from grid heater to grid heater relay.
Negative terminal to ground Continuity Bad ground circuit.
Positive terminal of grid heater to Resistance If an open or short circuit is obtained, replace the grid heater.
ground

4002-24
10 – Ignition Relay
Terminal 86 to ground. Continuity Bad ground circuit.
Bad fuse F13, bad wire 21A between the relay and fuse panel
Terminal for wire R (21A) to ground. 24 Volts
B.
NOTE: Place the ignition switch in the ON position.
Terminal for wire BR (50) to ground. 24 Volts Bad wire BR (50) to ignition switch, bad ignition switch (4).
Terminal 87 to ground. 24 Volts Bad ignition relay.
11 – Safety Relay
NOTE: Put the ignition switch in the RUN position and the parking brake control levers in the APPLIED position.
Bad wire to drivetrain control module, bad drivetrain control
Terminal for wire P (206) to ground. 24 Volts
module (24), bad proximity switches (18, 19, and 17).
NOTE: If power is not present check fuse F19 and F20.
12 – Starter Relay
NOTE: Put the ignition switch in the RUN position and the parking brake control levers in the APPLIED position.
Terminal for wire P (21C) to ground. 24 Volts Bad wire 21C to safety relay, bad safety relay (11).
NOTE: Put the ignition switch in the START position.
Terminal for wire O (337) to ground. 24 Volts Bad wire 337 to engine controller, bad engine controller.
NOTE: If power is not present check fuse F15 and F18.

4002-25
13 – Start Sensing Relay

NOTE: Put the master disconnect switch in the ON position and the ignition switch in the START position. Put the
directional control in the neutral position and the parking brake control levers in the applied position.
Terminal for wire W (START) to Check fuse F12. Bad wire between start sensing relay and
24 Volts
ground. ignition switch Bad ignition switch (4).
Check fuse F15 and F18. Bad wire between relay and engine
Terminal for wire W (332) to ground. 24 Volts
Terminal for wire Y (329). 24 Volts Bad start sensing relay.
14 – Fleet Relay (Option)


Check fuse F12. Bad wire between fleet relay and ignition switch
Bad ignition switch (4).
15 – Fuse Block A
Left side ROPS access panel.
Check and replace fuses as required.
16 – Fuse Block B
Left side ROPS access panel.
Check and replace fuses as required.

4002-26
17 – Right Parking Brake Proximity Switch

Right side ROPS panel.
NOTE: Apply right parking brake lever, disconnect proximity switch.

Between the cavities of switch Continuity Switch out of adjustment, bad proximity switch
NOTE: Using a feeler gauge, adjust clearance of proximity switch to 1 to 3 MM. (0.040 to 0.118 in). Recheck
switch.


Terminal for wire BR (IGN) to Bad wire BR (IGN) between the brake proximity switch and fuse
24 Volts
ground. F19, bad fuse F19.
Terminal for wire V (260) to ground. 24 Volts Bad brake proximity switch.
18 – Tilt Proximity Switch

Left side ROPS panel.
NOTE: Lower ROPS, disconnect proximity switch.

switch.

Terminal for wire R (1002) to ground. Continuity Bad ground circuit.

Terminal for wire GY (1003) to Bad wire GY (1003) between the tilt proximity switch and fuse
24 Volts
ground. F19, bad fuse F19.
Terminal for wire BL (1001) to
24 Volts Bad tilt proximity switch.
ground.

4002-27
19 – Left Parking Brake Proximity Switch

Left side ROPS panel.
NOTE: Apply left parking brake lever, disconnect proximity switch.

switch.


Terminal for wire BL (1001) to Bad wire BL (1001) between the brake proximity switch and tilt
24 Volts
ground. proximity switch, bad tilt proximity switch (18).
Terminal for wire W (237) to ground. 24 Volts Bad brake proximity switch.
20 – Brake Pedal Potentiometer

Center foot pedal.
NOTE: The purpose of this check is only for the power and grounding circuit. For additional adjustments of the
brake potentiometer see Section 9001.
NOTE: Disconnect the connector at the brake pedal potentiometer, put the master disconnect in the ON position
and the ignition switch in the RUN position.
Bad wire P (256) to drivetrain controller, bad drivetrain
Terminal for wire P (256) to ground. Continuity
controller, bad ground circuit.
Bad wire W (279) to drivetrain controller, bad drivetrain
controller, bad power circuit, check fuse F20.
21 – Decelerator Pedal Potentiometer

Right foot pedal.
decelerator potentiometer see Section 9001.
NOTE: Disconnect the connector at the decelerator potentiometer, put the master disconnect in the ON position
and the ignition switch in the RUN position.
Bad wire GY (262) to drivetrain controller, bad drivetrain
Terminal for wire GY (262) to ground. Continuity
Bad wire Y (280) to drivetrain controller, bad drivetrain
Terminal for wire Y (280) to ground. 5 Volts

4002-28
22 – Decelerator Pedal Low Idle Switch

Right foot pedal.
throttle potentiometer see Section 9001.
NOTE: Disconnect the connector at the pedal low idle switch, put the master disconnect in the ON position and
the ignition switch in the RUN position.
Bad wire 0 (223) to drivetrain controller, bad drivetrain
Terminal for wire 0 (223) to ground. Continuity
Bad wire Y (280) to drivetrain controller, bad drivetrain
Terminal for wire Y (280) to ground. 5 Volts
23 – Throttle Potentiometer
Left console.
throttle potentiometer see Section 9001.
NOTE: Disconnect the connector at the throttle potentiometer, put the master disconnect in the ON position and
the ignition switch in the RUN position.
Bad wire GY (238) to drivetrain controller, bad drivetrain
Terminal for wire GY (238) to ground. Continuity
Bad wire W (279) to drivetrain controller, bad drivetrain
24 – Drivetrain Control Module

Left console access panel.
NOTE: Disconnect the connector at the drivetrain controller, put the master disconnect switch in the ON position.
Terminal for wire 0, pin 2 and 28, to
Continuity Bad ground circuit.
ground.

Terminal for wire BR (IGN2), pin 1
24 Volts Bad wire BR (IGN2) to fuse F20, bad fuse.
and 27, to ground.
NOTE: If all tests are good, replace drivetrain controller.
25 – Left Motor Speed Sensor

Left motor.
NOTE: Speed sensor can only be tested by the drivetrain controller, see section 6003 fault 4311.

4002-29
26 – Right Motor Speed Sensor

Right motor.
NOTE: Speed sensor can only be tested by the drivetrain controller, see section 6003 fault 4312.
27 – Left Pump Solenoid

Left pump.
NOTE: Disconnect the connector at the left pump solenoid, on connector to the main harness.
Less than 10
Ohm at Bad ground circuit.
ground.
25° C (77° F)
NOTE: On connector to the solenoid.
5.75 ±0.75
Between terminals 1 and 2 Ohm at Bad forward solenoid
25° C (77° F)
5.75 ±0.75
Between terminals 3 and 4 Ohm at Bad reverse solenoid
25° C (77° F)
28 – Right Pump Solenoid

Right pump.
NOTE: Disconnect the connector at the right pump solenoid, on connector to the main harness.
Less than 10
Ohm at Bad ground circuit.
ground.
25° C (77° F)

5.75 ±0.75
Between terminals 1 and 2 Ohm at Bad forward solenoid
25° C (77° F)
5.75 ±0.75
Between terminals 3 and 4 Ohm at Bad reverse solenoid
25° C (77° F)

4002-30
29 – Left Motor Solenoid

Left motor.
NOTE: Disconnect the connector at the left motor solenoid, on connector to the main harness.
Less than 10
Terminal for wire 0, pin 2, to ground. Ohm at Bad ground circuit.
25° C (77° F)

5.75 ±0.75
Between terminals 1 and 2 Ohm at Bad solenoid
25° C (77° F)
30 – Right Motor Solenoid

Right motor.
NOTE: Disconnect the connector at the right motor solenoid, on connector to the main harness.
Less than 10
Terminal for wire 0, pin 2, to ground. Ohm at Bad ground circuit.
25° C (77° F)

5.75 ±0.75
Between terminals 1 and 2 Ohm at Bad solenoid
25° C (77° F)
31 – Reverse Ratio Switch

Left console.
NOTE: Disconnect the connector at the reverse ratio switch. Put the master disconnect switch and ignition switch
in the ON position.
Terminal for wire BL (V1ACC) to
24 Volts Check fuse F2.
ground.
NOTE: Place reverse ration switch in the second position.

Between cavity A and B of switch
Continuity Bad reverse ratio switch.
connector.
NOTE: Place reverse ration switch in the third position.

Between cavity A and C of switch
connector.
NOTE: Place reverse ration switch in the fourth position.

Between cavity A, B, and C of switch
connector.

4002-31
32 – FNR Directional Control

Left console.
NOTE: The purpose of this check is only for the START circuit of the machine. For additional tests of the
directional control see Section 6003.
NOTE: Disconnect the connector at the directional control. Put the directional control in the NEUTRAL position.
Between connectors 5 and 6 on
Continuity Bad directional control.
directional control.
NOTE: DO NOT reconnect the directional control. Put the master disconnect switch in the ON position and the
ignition switch in the RUN position. Put the parking brake control levers in the applied position.
Cavity 1 and 5 of connector to Check fuse F19. Check wire BR (IGN) from directional control
24 Volts
ground. to fuse F19.
33 – Brake Pressure Switch

Left ROPS side panel behind ROPS tilt cylinder.
NOTE: Put the master disconnect switch and ignition switch in the ON position. Disconnect the harness
connector for the brake pressure switch.
Terminal for wire BL (V1ACC) to
24 Volts Check fuse F2.
ground.
Between the connector pins of the
Open Bad pressure switch.
pressure switch connector.
WARNING: Start the engine, DO NOT place the directional control in the F or R position, move hand throttle to ½
throttle position.
Continuity Bad pressure switch.
NOTE: Hydrostatic charge pressure must be checked to make sure it is at proper pressure, see section 6002. The
pressure switch is normally open and closes at 11.4 to 12.8 Bar (165 to 185 psi).

4002-32
34 – Brake Solenoid
Left ROPS side panel behind ROPS tilt cylinder.
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector for the brake
solenoid.
Check brake solenoid coil resistance 9 to 10 Ohm

between the connector cavities of the at 25° C Bad brake solenoid.
solenoid connector. (77° F)
Main harness terminal for wire 0 to

Continuity Bad ground circuit.
ground.
NOTE: Have another person place the ignition switch in the run position. Release the parking brake levers. DO
NOT press the brake pedal.
Main harness terminal for wire GY Bad wire between the brake solenoid and the drivetrain
24 Volts
(215) to ground. controller. Bad drivetrain controller (24).
NOTE: If the readings are good, replace the brake solenoid. Also see Section 6002 and check the hydrostat
charge pressure.
35 – Equipment Valve Blade Control Joystick

Right side console.
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector C17 for the blade
control joystick.
Terminal for wire 0, pin 2, to ground Continuity Bad ground circuit.
Terminal for wire BL (V1ACC), pin 1,

24 Volts Bad fuse F2, bad wire from joystick to fuse F2.
to ground
NOTE: If joystick still does not function, replace joystick.
36 – Equipment Valve Diagnostic Port

Right ROPS side panel.
NOTE: Disconnect the harness connector C17 for the blade control joystick.
From pin 5 at joystick connector to
Ohm Bad wire or bad connector.
pin 12 of diagnostic port

4002-33
37 – Equipment Valve Hydraulic Safety Solenoid Valve

Right ROPS side panel, end plate equipment valve.
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector for the hydraulic
valve solenoid.
Terminal for wire 0 to ground Continuity Bad ground circuit.
NOTE: Have another person place the ignition switch in the run position. Release the parking brake levers. DO
NOT start the engine.
Bad drivetrain controller (24), bad wire from solenoid to
Terminal for wire LB (272) to ground 24 Volts
drivetrain controller.
Check hydraulic control solenoid coil
40 Ohm at 20°
resistance between the connector Bad hydraulic control solenoid.
C (68° F)
cavities of the solenoid connector.
38 – Equipment Valve Blade Lift Solenoid

NOTE: Disconnect the harness connector for the blade lift solenoid.
Check solenoid coil resistance
12 Ohm at 20°
between the connector cavities of the Bad solenoid.
C (68° F)
solenoid connector.
39 – Equipment Valve Blade Lower Solenoid

NOTE: Disconnect the harness connector for the blade lower solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
40 – Equipment Valve Tilt Left Solenoid

NOTE: Disconnect the harness connector for the blade tilt left solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.

4002-34
41 – Equipment Valve Tilt Right Solenoid

NOTE: Disconnect the harness connector for the blade tilt right solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
42 – Equipment Valve Twist Left Solenoid

NOTE: Disconnect the harness connector for the blade twist left solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
43 – Equipment Valve Twist Right Solenoid

NOTE: Disconnect the harness connector for the blade twist right solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
44 – Equipment Valve Ripper Joystick (Option)

Right side console.
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector C16 for the blade
ripper joystick.
Terminal for wire 0, pin 2, to ground Continuity Bad ground circuit.
Terminal for wire BL (V1ACC), pin 1,

24 Volts Bad fuse F2, bad wire from joystick to fuse F2.
to ground
NOTE: If joystick still does not function, replace joystick.

4002-35
45 – Equipment Valve Ripper Lift Solenoid (Option)

NOTE: Disconnect the harness connector for the ripper lift solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
46 – Equipment Valve Ripper Lower Solenoid (Option)

NOTE: Disconnect the harness connector for the ripper lower solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
47 – Instrument Cluster Connector A

Located on back of instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-A from the instrument cluster.
Check fuse F18, bad ignition switch (4), bad wire from AIC-A to
Connector terminal 1 to ground 24 Volts
fuse F18.
Connector terminal 6 and 12 to Continuity Bad ground circuit.

ground
48 – Instrument Cluster Connector B

Located on back of instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-B from the instrument cluster.
Check fuse F18, bad ignition switch (4), bad wire from AIC-A to
Connector terminal 21 to ground 24 Volts
fuse F18.
Connector terminal 15 and 22 to Continuity Bad ground circuit.

ground

4002-36
49 – Enter Escape Instrument Cluster Switch

Dash panel.
Terminal for wire R (992) to ground. 24 Volts Check fuse F14, bad wire from switch to fuse.
NOTE: Push and hold switch in enter or escape position.
From pin 2 to pin 1. Continuity Bad switch.
50 – Up Down Menu Instrument Cluster Switch

Dash panel.
Terminal for wire R (992) to ground. 24 Volts Check fuse F14, bad wire from switch to fuse.
NOTE: Push and hold switch in up or down position.
51 – Air Filter Restriction Switch

Air cleaner outlet to the engine.
NOTE: Disconnect the wires from the air filter restriction switch.
Between terminals of air filter
Open Bad air filter restriction switch.
restriction switch.
Terminal of wire 0 to ground. Continuity Bad ground connection.

Bad wire G (103) between air filter restriction switch and
Wire G (103) to ground. 24 Volts
instrument cluster connector A 24. Bad connector.

4002-37
52 – Hydrostat Filter Restriction Switch

Hydrostat filter housing behind right rear ROPS access panel.
Check between the hydrostat filter
restriction switch housing and the Continuity Bad ground connection.
filter housing.
NOTE: Disconnect wire GY (134) from the hydrostat filter restriction switch terminal.
Hydrostat filter restriction switch
Open Bad hydrostat filter restriction switch.
terminal to ground.
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the RUN position.
Terminal for wire GY (134) to Bad wire GY (134) between hydrostat filter restriction switch and
24 Volts
ground. instrument cluster connector B 3. Bad connectors.
53 – Transmission Temperature Sender

Right rear ROPS filter access panel, lower hydraulic reservoir.
Check between the housing of the
transmission temperature sender Continuity Bad ground connection.
and housing hydraulic reservoir.
NOTE: Disconnect wire P (121) from the transmission temperature connector. Put the master disconnect switch
in the ON position and the ignition switch in the RUN position.
Bad wire P (121) between the transmission temperature sender
Wire P (121) to ground. 5 Volts and the instrument cluster connector A 5. Bad connectors.
Check the oil temperature gauge.
Check oil temperature gauge reading Low

with wire P (121) disconnected from temperature Bad oil temperature gauge.
sender terminal. area
Connect wire P (121) to ground and High

check reading of oil temperature temperature Bad oil temperature gauge.
gauge. area
NOTE: If all readings are good, replace the transmission temperature sender.

4002-38
54 – Hydraulic Filter Restriction Switch

Hydraulic filter housing behind right rear ROPS access panel.
Check between the hydraulic filter
restriction switch housing and the Continuity Bad ground connection.
filter housing.
NOTE: Disconnect wire W (104) from the hydraulic filter restriction switch terminal.
Hydraulic filter restriction switch
Open Bad hydraulic filter restriction switch.
terminal to ground.
Bad wire W (104) between hydraulic filter restriction switch and
Wire W (104) to ground. 24 Volts
the instrument cluster connector B 11. Bad connectors.
55 – Warning Buzzer
Front console.
NOTE: Put the ignition switch in the RUN position. If the buzzer does not sound, do the following checks.
Terminal for wire P (135) at warning
24 Volts Bad instrument cluster (47).
buzzer to ground.
NOTE: Turn the ignition switch OFF. Disconnect wires from warning buzzer terminals.
Between terminals of warning
30 Ohm Bad warning buzzer
buzzer.
NOTE: If all readings are good, replace the warning buzzer.

4002-39
56 – Fuel Level Sender

Top of the fuel tank.
NOTE: Disconnect the wiring harness connector from the fuel level sender connector. Put the master disconnect
switch in the ON position.

Bad wire Y (120) between fuel level sender and instrument
Wire Y (120) to ground. 5 Volts cluster connector A 2. Bad connectors. Check fuel level gauge in
instrument cluster.
Check reading of fuel level gauge
with fuel level sender connector Empty Bad fuel level gauge.
disconnected.
Connect wire Y (120) to ground.
Full Bad fuel level gauge.
Check reading of fuel level gauge.
Between terminal Y (120) of fuel 25 to 275

Bad fuel level sender.
level sender connector to ground. Ohm
NOTE: Connect connector to fuel level sender.
7.0 to 9.0
volts (fuel
Cavity for wire Y (120) at fuel level tank empty) -
Bad fuel level sender.
sender to ground. 1.5 to 3.5
volts (fuel
tank full)
57 – Transmission Charge Pressure Switch

Right rear of hydrostat pumps.
NOTE: Disconnect wire LB (133) from the charge pressure switch terminal.
Transmission charge pressure switch
Continuity Bad charge pressure switch.
terminal to ground.
Bad wire LB (133) between transmission charge pressure switch
Wire LB (133) to ground. 5 Volts
and instrument cluster connector B 5. Bad connectors.
NOTE: Start and run the engine at approximately 1500 rpm (r/min).
Terminal of charge pressure switch
Open Bad charge pressure switch.
to ground.

4002-40
58 – Front Floodlight/Monitor Light Switch

Dash panel.
NOTE: Put the master disconnect switch in the ON position, put the ignition switch in the RUN position.
Bad wire BL (912) between front floodlight/monitor light switch
and fuse F6, bad fuse. Bad accessory relay (7).
NOTE: Turn the front floodlight/monitor switch ON.

Terminal for wire Y (911A) at light
24 Volts Bad light switch.
switch to ground.
Terminal for wire Y (911A) at light
24 Volts Bad wire Y (911) between light switch and light bulbs.
bulbs to ground.
59 – Rear Floodlight Switch

Dash panel.
Bad wire BL (922) between front floodlight/monitor light switch
and fuse F4, bad fuse. Bad accessory relay (7).
NOTE: Turn the front floodlight/monitor switch ON.

Terminal for wire GY (921) at light
24 Volts Bad light switch.
switch to ground.
Terminal for wire GY (921) at light
24 Volts Bad wire GY (921) between light switch and light bulbs.
bulbs to ground.
60 – Front Floodlights
Front of ROPS or CSF.
NOTE: Disconnect connector at front floodlights.
Between terminals of light. Continuity Bad bulb
Terminal for wire 0 to ground. Continuity Bad ground circuit
61 – Front Floodlights (Option)

Front of ROPS or CSF.

4002-41
62 – Rear Floodlights
Rear of ROPS or CSF.
63 – Backup Alarm
Right rear ROPS access panel for hydraulic filter.

NOTE: DO NOT start the vehicle, place the ignition switch in the run position, release the parking brake levers
and place the directional control in reverse.
Bad wire O (205) between backup alarm and drivetrain
Terminal for wire O (205) to ground. 24 Volts
controller. Bad drivetrain controller (24).
NOTE: If all readings are good replace the backup alarm.
64 – Horn Button
Dash panel.
Terminal for wire R (992) to ground. 24 Volts Bad wire R (992) to fuse F14, bad fuse. Bad wire 1B to battery.
NOTE: Have another person hold down the horn button.
Terminal for wire O (993) to ground. 24 Volts Bad horn button.
65 – Horn
Front RH side of the radiator.
NOTE: Disconnect the wire 0 from the horn. Have another person hold down the horn button.
Horn terminal for wire 0 to ground. 24 Volts Bad horn.
Horn terminal for wire O (993) to Bad wire O (993) between the horn and horn button, bad horn
24 Volts
ground. button (64).

4002-42
66 – Electronic Diesel Control

Located on left side of engine, open engine compartment to gain access.
Correct
Reading
NOTE: Put the ignition switch in the OFF position. Put the master disconnect switch in the OFF position.
Disconnect connector EDC7.
Terminal for wire 0 pin 5, 6, 10, and Continuity Bad ground circuit.
11 to ground
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire R (302) pin 2, 3, 8, 24 volts Bad fuse F15, bad wire R (302).
and 9 to ground
NOTE: Use diagnostic service tool for additional tests on EDC7.
67 – Water In Fuel Sensor

Located in the left side of the engine compartment on water separator housing, open engine compartment to gain access.
Correct
Reading
Terminal for wire 0 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire R (302) to ground 24 volts Bad fuse F15, bad wire R (302).
Terminal for wire GY (342) to ground 24 volts Bad water separator sensor.
NOTE: Remove sensor from filter and place probes in water, water in fuel fault should display on instrument
cluster, if not replace sensor.
68 – 12 Volt Radio Ready (Option)

Located in the cab.
Correct
Reading
Terminal in radio connector for wire Continuity Bad ground circuit.

0 to ground
NOTE: Put master disconnect switch and ignition switch in ON position.
Terminal in radio connector for wire Check fuse F2, also check circuit 12V. Also check the remote
12 volts
LB (505) to ground radio power converter (73).
Terminal in radio connector for wire Check fuse F2, also check circuit 12V. Also check the remote
12 volts
R (504) to ground radio power converter (73).

4002-43
69 – Right Speaker (Option)

Located in the cab.
Correct
Reading
NOTE: Disconnect connector from right speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (68) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the right speaker and the radio or a bad
Voltage
RSPK to ground radio (68).
Pin 2 in wiring harness connector Continuity Bad circuit between the right speaker and the radio (68).
RSPK to ground
NOTE: If the readings are good, replace the right speaker.
70 – Left Speaker (Option)

Located in the cab.
Correct
Reading
NOTE: Disconnect connector from left speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (68) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the left speaker and the radio or a bad
Voltage
LSPK to ground radio (68).
Pin 2 in wiring harness connector Continuity Bad circuit between the left speaker and the radio (68).
LSPK to ground
NOTE: If the readings are good, replace the left speaker.
71 – Cab Interior Lamps Switch

Left and right headliners in cab.

Terminal R (501) in connector to
24 Volts Bad wire R (501) to fuse F16, bad fuse.
ground.
NOTE: Turn the interior light switch on.
Positive connector at light to ground. 24 Volts Bad wire between light and switch. Bad switch.

4002-44
72 – Cab Interior Lamps

Left and right headliners in cab.
Between bulb contacts. Continuity Bad bulb.
NOTE: Turn the interior light switch on.
Terminal R (501) to ground. 24 Volts Bad wire R (501) to lamp switch, bad interior lamp switch (71).
73 – Power Converter 24 volts to 12 volts

Located in the cab under right console cover.
Correct
Reading
Terminal for wires 0 to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position.
Terminal for wire R (501) to ground 24 volts Bad fuse F16, also check circuit R (501)
Terminal for wire R (504) to ground 12 volts Bad power converter
NOTE: Put ignition switch in ON position.
Terminal for wire BL (V1ACC). to Bad fuse F2, bad accessory relay (7), also check circuit BL
24 volts
ground (V1ACC).
Terminal for wire LB (505) to ground 12 volts Bad power converter
74 – Accessory Power Jack 12 Volt

Left side console.
Terminal for wire R (504) to ground. Check fuse F2, also check circuit 12V. Also check the remote
12 Volts
power converter (73).

4002-45
75 – Optional ROPS Heater

Operator’s compartment.

Terminal for wire BL (V2ACC) to Bad wire BL (V2ACC) between ROPS heater and fuse F3, bad
24 Volts
ground. fuse.
NOTE: If readings are good, replace the ROPS heater.
76 – Optional Air Suspension Seat - Air Compressor

Operator’s compartment.

Terminal for wire BL (V2ACC) to Bad wire BL (V2ACC) between ROPS heater and fuse F3, bad
24 Volts
ground. fuse.
NOTE: If readings are good, replace the seat air compressor.
77 – Blower Motor
Rear of cab under consoles.
NOTE: No information at time of print.
78 – Thermostat
79 – Water Valve

4002-46
80 – Blower Resistor
81 – Blower Switch
Top of cab.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the RUN position.
Terminal for wire Y (899) to ground. 24 Volts Bad wire Y (899) to mode switch, bad mode switch (82).
NOTE: Turn the blower switch to the LOW position.
Terminal L to ground. 24 Volts Bad blower switch.
NOTE: Turn the blower switch to the MEDIUM 1 position.
Terminal M 1 to ground. 24 Volts Bad blower switch.
NOTE: Turn the blower switch to the MEDIUM 2 position.
Terminal M 2 to ground. 24 Volts Bad blower switch.
NOTE: Turn the blower switch to the HIGH position.
Terminal H to ground. 24 Volts Bad blower switch.
82 – HVAC Mode Switch

Top of cab.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the RUN position. Turn the
blower switch to the HIGH position.
Bad wire BL (800) to fuse F8, bad fuse, bad accessory relay
(7).
NOTE: Turn the AC switch on.
Terminal for wire V (817) to ground. 24 Volts Bad HVAC mode switch.

4002-47
83 – Temperature Control Switch

Top of cab.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the RUN position.
(7).
NOTE: Turn the temperature control switch while measuring voltage.
Will this work?

Terminal for wire BL (811) to ground. Bad temperature control switch.
Varying Volts
84 – Low Pressure AC Switch

Located under right side rear console in cab.
NOTE: Switch opens at 14 to 42 kPa (2 to 6 psi) falling, switch closes at 117 to 159 kPa (17 to 23 psi) and rising.
Make sure AC system is at operating pressure.
Between terminal of switch Continuity Bad switch.
85 – High Pressure AC Switch

Located on the compressor output hose left side of engine.
NOTE: Switch opens at 2689 to 2827 kPa (390 to 410 psi) rising, switch closes at 1654 to 1792 kPa (240 to 260
psi) and falling. Make sure AC system is at operating pressure.
Between terminal of switch Continuity Bad switch.
86 – Compressor Clutch
Air compressor on the left side of the engine.
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the RUN position and the
AC switch in the ON position. Put the blower switch in the HIGH position and turn the thermostat switch to
maximum cool.
+ terminal on compressor clutch to Bad wire between clutch and high/low pressure switches, bad
24 Volts
ground. switches.
NOTE: If the test is good and the clutch does not work, replace the clutch coil.

4002-48
87 – Condenser Blower Motor

Top rear of cab.

(7).
NOTE: Put the AC switch in the ON position. Put the blower switch in the HIGH position and turn the thermostat
switch to maximum cool.
Terminal for wire V (817) to ground 24 volts Bad wire V (817) to mode switch, bad mode switch (82).
NOTE: If the tests are good and the condenser blower motor(s) do not work, replace the motor(s).
88 – Front Windshield Wiper

Front windshield.

Bad wire BL (933) to fuse F5, bad fuse. Bad accessory relay
Terminal for wire BL (933) 24 Volts
(7).
NOTE: Turn the wiper switch ON.

Terminal for wire V (932) at wiper Bad wire from wiper switch to wiper motor, bad wiper switch
24 Volts
motors to ground. (89).
NOTE: If the tests are good and the wiper does not work, repair or replace the wiper motors.
89 – Front and Rear Windshield Wiper Switch

Front dash panel.
Terminal for wire BL (933) and wire Bad wire BL (933) or wire BL (953) to fuses F5 and F7, bad
24 Volts
BL (953) at wiper switch to ground. fuse. Bad accessory relay (7).

Terminal for pin 2 and pin 5, to
24 Volts Bad wiper switch.
ground.

4002-49
90 – Rear Windshield Wiper

Rear windshield.

(7).

24 Volts
91 – Front and Rear Windshield Washer Switch

Front dash panel.
(7).
NOTE: Have another person push and hold the washer switch in the ON position.
Terminal for wire B (943) at washer
24 Volts Bad washer switch.
switch to ground.
92 – Front and Rear Windshield Washer

Left engine compartment door.
Terminal for wire O to ground. Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have another person push and hold the washer switch in the
ON position.
Terminal for wire B (943) at washer
24 Volts Bad wire B (943), bad washer switch (91).
motor to ground.
NOTE: If the tests are good and the washer pump does not work, repair or replace the washer pump.

4002-50
93 – Left Hand Door Windshield Wiper

Left hand door.

(7).

24 Volts
94 – Left and Right Hand Door Windshield Wiper Switch Assembly

Front dash panel.
Terminal for wire BL (933) and wire Bad wire BL (933) or wire BL (953) to fuses F5 and F7, bad
24 Volts
BL (953) at wiper switch to ground. fuse. Bad accessory relay (7).

Terminal for pin 2 and pin 5, to
24 Volts Bad wiper switch.
ground.
95 – Right Hand Door Windshield Wiper

Right hand door.

(7).

24 Volts

4002-51
96 – Left and Right Hand Door Windshield Washer Switch

Front dash panel.
(7).
NOTE: Have another person push and hold the washer switch in the ON position.
Terminal for wire O (963) at washer
24 Volts Bad washer switch.
switch to ground.
97 – Left and Right Hand Door Windshield Washer

Left engine compartment door.
Terminal for wire O to ground. Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have another person push and hold the washer switch in the
ON position.
Terminal for wire O (963) at washer
24 Volts Bad wire O (963), bad washer switch (96).
motor to ground.
NOTE: If the tests are good and the washer pump does not work, repair or replace the washer pump.
98 – Diagnostic Port
Left console access panel for drive train controller.
Terminal for pin A to ground Continuity Bad ground circuit
Bad wire R (501) between diagnostic port and fuse F15, bad
Terminal for wire R (501) to ground 24 volts
fuse.
99 – Fleet Tracker Port

Left console access panel for drive train controller.
Terminal pin 6 and 8 to ground Continuity Bad ground circuit
Bad wire between fleet tracker port and fuse F1 and F10, bad
Terminal pin 1 and 7 to ground 24 volts
fuse.

4002-52
100 - 105 Grounding points

See page 6 for locations on machine.
NOTE: Check grounding points for rust and corrosion, clean as needed.
USING BOOSTER BATTERIES TO START THE ENGINE

5. Connect the negative (−) jumper cable to a good
WARNING: Batteries produce explosive frame ground away from the battery.
gases. Keep sparks, flame, and cigarettes
6. Put the master disconnect switch in the ON
away. Ventilate when charging or using in an
position.
enclosed space. Always shield eyes when
working near batteries. 7. Start the engine and have the other person
SA031 disconnect the negative (−) jumper cable first
Two persons are required for this procedure. Make and the positive (+) jumper cable last.
sure the person making the connection is wearing
face protection.
1. Sit in the operators seat and have the other
person make the connections. Make sure the
booster battery is 24 Volts.
2. If you are using another machine for power,
make sure the two machines do not touch.
3. Put the master disconnect switch in the OFF
position.
4. Connect the positive (+) jumper cable to the
positive (+) battery terminal.

4002-53
CONNECTORS
CONNECTOR C1 - MICRO CONTROLLER CONNECTOR C2 - MICRO CONTROLLER
C2
CAV CIRCUIT CAV CIRCUIT

56 256 69 269
60 260 71 271
62 262 72 272
64 264 79 279
C1
65 265 80 280
68 268
1 IGN2 28 0
2 0 29 215
4 204 30 230 CONNECTOR C3 - DIAGNOSTIC
5 205 31 231
6 206 37 237
10 210 38 238
11 211 39 334
13 IGN1 40 335
15 215 41 IGN1
16 216 42 IGN1
17 217 43 243
18 218 44 244
19 219 48 248
23 223 50 250 DE_HD10-9-1939P
24 224 51 251 CAV CIRCUIT CAV CIRCUIT

27 IGN2 52 252 A 0 F 251
B 501 G 250
C 335 H 224
D 334 J 252
E 389

4002-54
CONNECTOR C4 - FROM MICRO CONTROLLER CONNECTOR C5 - FROM MICRO CONTROLLER
TO DASH HARNESS TO PUMPS AND MOTORS
C5

1 205 18 272
C4 2 104 19 424
CAV CIRCUIT CAV CIRCUIT 3 121 20 425
7 IGN1 28 501 4 134 21 426
8 955 29 121 5 120 22 421
10 4111 30 120 6 133 23 422
11 256 31 133 7 244 24 423
12 262 34 134 8 243 25 427
13 237 36 219 9 V1acc 26 428
14 954 37 953 10 217 27 429
15 818B 38 935 11 218 28 451
16 IGN2 39 389 12 204 29 452
18 279 41 223 13 216 30 453
19 260 42 V1acc 14 230 31 268
20 265 43 280 15 231 32 269
21 921 44 335 16 215 33 Not Used
22 911B 45 334 17 248
23 800 46 104
24 911A 47 934
26 819 48 206

4002-55
CONNECTOR C6 - THROTTLE POSITION CONNECTOR C8 - FROM MICRO CONTROLLER
SENSOR TO LIGHT HARNESS
C6 DEU_DT04-12P

A 279 1 911A 7 819
B 264 2 911B 8 504
C 238 3 921 9 505
4 818A 10 0
CONNECTOR C7 - REVERSE RATIO SWITCH 5 800 11 0

6 501 12 0
CONNECTOR C9 - INDICATOR LIGHT
DEU_DT06-3S
CAV CIRCUIT
A V1acc C9
B 210 CAV CIRCUIT
C 211 A IGN2
B 0

4002-56
CONNECTOR C10 - FROM MICRO CONTROLLER CONNECTOR C14 - DC CONVERTER
TO DIAGNOSTIC PORT
DEU_DT06-6S
DEU_DT06-12S CAV CIRCUIT CAV CIRCUIT
1 Not Used 7 415 2 V1acc 5 505
2 Not Used 8 Not Used 3 0 6 0
3 Not Used 9 Not Used

CONNECTOR C15 - CIGAR LIGHTER
5 Not Used 11 417
6 Not Used 12 416
CONNECTOR C12 - INDICATOR LIGHT
C15
CAV CIRCUIT
A 504
C12 B 0
CAV CIRCUIT
A 271
B 0

4002-57
CONNECTOR C16 - RIPPER POWER AND CONNECTOR C18 - BLADE CONTROLLER
DIAGNOSTICS
DEU_DT04-12P
DEU_DT06-8S
1 V1acc 5 419 2 422 8 428
2 0 6 418 3 423 9 429
3 Not Used 7 Not Used 4 424 10 Not Used
4 Not Used 8 Not Used 5 425 11 Not Used
6 426 12 Not Used
CONNECTOR C17 - BLADE POWER AND

DIAGNOSTICS
CONNECTOR C20 - REAR WIPER
(HARNESS VIEW)
C20
DEU_DT06-12S CAV CIRCUIT
CAV CIRCUIT CAV CIRCUIT 1 0
1 V1acc 7 417 2 934
2 0 8 418 3 953
3 Not Used 9 419 4 935

5 415 11 4111
6 416 12 Not Used

4002-58
CONNECTOR C21 - RIPPER CONTROL CONNECTOR C22 - RIGHT DOOR WIPER
(HARNESS VIEW)
C22
CAV CIRCUIT
DEU_DT04-12P
1 0
2 954
1 451 7 Not Used
3 953
2 452 8 Not Used
4 955
3 453 9 Not Used

4002-59
CONNECTOR D1 - FROM MAIN HARNESS TO
DASH
1 911B 21 933
2 911A 22 934
3 922 23 935
4 30 24 Not Used
5 912 25 120
6 133 26 335
7 952 27 104
8 993 28 955
10 4111 30 Not Used
11 50 31 953
12 15 32 943
13 START 33 121
14 921 34 0
15 IGN3 35 103
16 334 36 134
17 951 37 992
18 963 38 954
19 Not Used 39 0
20 D+ 40 0
D1

4002-60
CONNECTOR D2A - INSTRUMENT CLUSTER A CONNECTOR D2B - INSTRUMENT CLUSTER B
87410948
87419488
1 Not Used 14 992
1 IGN3 14 Not Used
2 114 15 0
2 120 15 Not Used
3 134 16 Not Used
3 335 16 Not Used
4 Not Used 17 START
4 334 17 Not Used
5 133 18 IGN3
5 121 18 Not Used
6 111 19 Not Used
6 0 19 Not Used
7 125 20 992
8 118 21 IGN3
9 911A 22 0
11 104 24 4111
11 Not Used 24 103
12 921 25 Not Used
12 0 25 Not Used
13 D+ 26 Not Used
13 135 26 Not Used

4002-61
CONNECTOR D4 - FRONT WIPER CONNECTOR D6 - REAR HEADLAMPS SWITCH
(HARNESS VIEW)
D4
245781C1
CAV CIRCUIT
CAV CIRCUIT
1 0
1 921
2 931
1 921
3 933
2 922
4 932
3 Not Used
4 Not Used
CONNECTOR D5 - FRONT HEADLAMPS SWITCH 5 Not Used
6 Not Used
CONNECTOR D7 - FRONT/REAR WIPER SWITCH
245781C1
CAV CIRCUIT
1 911B
1 911A
1 911A
D7
2 912
CAV CIRCUIT
3 Not Used
1 931
4 Not Used
2 932
5 Not Used
3 933
6 Not Used
3 933
4 934
5 935
6 953
6 953

4002-62
CONNECTOR D8 - FRONT/REAR WASHER CONNECTOR D10 - DOOR WASHER SWITCH
SWITCH
245781C1
245781C1
CAV CIRCUIT
CAV CIRCUIT 1 Not Used
1 Not Used 2 953
2 933 3 963
2 933 4 Not Used
3 943 5 Not Used
5 Not Used
6 Not Used
CONNECTOR D11 - UP/DOWN SWITCH
CONNECTOR D9 - DOOR WIPER SWITCH
245781C1
CAV CIRCUIT
1 118
D9 2 992
CAV CIRCUIT 2 992
1 951 2 992
2 952 3 125
3 953 4 Not Used
3 953 5 Not Used
4 954 6 Not Used
5 955
6 933
6 933

4002-63
CONNECTOR D12 - ENTER/ESC SWITCH CONNECTOR D14 - IGNITION SWITCH
225253C1
245781C1
CAV CIRCUIT
CAV CIRCUIT
1 30
1 111
2 START
2 992
2 START
2 992
3 50
3 114
4 15
4 Not Used
5 Not Used
5 Not Used
6 Not Used
6 Not Used
CONNECTOR D13 - HORN SWITCH
245781C1
CAV CIRCUIT
1 Not Used
2 992
2 992
3 993
4 Not Used
5 Not Used
6 Not Used

4002-64
CONNECTOR E1 - FROM ENGINE TO FRONT CONNECTOR E2 - ENGINE CONTROLLER
CONSOLE
E1

1 302 16 W
2 D+ 17 Not Used
3 Not Used 18 334
5 Not Used 20 335
6 Not Used 21 317
7 993 22 Not Used
8 Not Used 23 312
9 Not Used 24 329
10 21D 25 332
11 103 26 337
12 818B 27 IGN3 BOSCH-89-POLE
13 963 28 375 CAV CIRCUIT CAV CIRCUIT

14 943 29 389 2 302 29 329
15 Not Used 3 302 32 332
5 0 34 334
6 0 35 335
8 302 37 337
9 302 40 IGN3
10 0 42 342
11 0 75 375
12 312 89 389
17 317

4002-65
CONNECTOR E5/A - WINDSHIELD WASHER 2 CONNECTOR E11 - WATER IN FUEL SENSOR
E5A, E5B E11

A 943 1 342
B 0 2 0
3 302
CONNECTOR E5/B - WINDSHIELD WASHER 1

CONNECTOR E12 - A/C HIGH PRESSURE
SWITCH
E5A, E5B
CAV CIRCUIT
PAC_12065863
A 963
B 0 CAV CIRCUIT
A 818b
B 818C

4002-66
CONNECTOR L1 - FROM LIGHT HARNESS TO CONNECTOR L2 - LEFT REAR LIGHT
MICRO CONTROLLER
L2
DEU_DT06-12S
CAV CIRCUIT
1 921
1 911A 7 819
2 0
2 911B 8 504
3 921 9 505
4 818A 10 0 (CANOPY ONLY) CONNECTOR L2 -
REAR LEFT WORK LIGHT
5 800 11 0
6 501 12 0
(CANOPY ONLY) CONNECTOR L1 -

CANOPY WORK LIGHTS
225316C1
CAV CIRCUIT
1 921
2 0
L1

1 911A 7 Not Used
2 911B 8 Not Used
3 921 9 Not Used

4002-67
CONNECTOR L3 - RIGHT REAR LIGHT CONNECTOR L4 - LEFT FRONT LIGHT
L2 L2

1 921 1 911B
2 0 2 0
(CANOPY ONLY) CONNECTOR L3 - (CANOPY ONLY) CONNECTOR L4 -

REAR RIGHT WORK LIGHT FRONT LEFT LOWER WORK LIGHT
225316C1
CAV CIRCUIT
1 921
225316C1
2 0
CAV CIRCUITT
1 911B
2 0

4002-68
CONNECTOR L5 - CENTER FRONT LIGHT CONNECTOR L6 - CENTER FRONT LIGHT
L2 L2

1 911A 1 911A
2 0 2 0
(CANOPY ONLY) CONNECTOR L5 - (CANOPY ONLY) CONNECTOR L6 -

FRONT LEFT UPPER WORK LIGHT FRONT RIGHT UPPER WORK LIGHT
225316C1 225316C1

1 911A 1 911A
2 0 2 0

4002-69
CONNECTOR L7 - RIGHT FRONT LIGHT CONNECTOR L9 - CONTROL PANEL
L9
CAV CIRCUIT
L2 1 817
CAV CIRCUIT 2 Not Used
1 911B 3 Not Used
2 0 4 800
5 899
(CANOPY ONLY) CONNECTOR L7 -

FRONT RIGHT LOWER WORK LIGHT CONNECTOR L10 - PDT
225316C1
L10
CAV CIRCUIT
CAV CIRCUIT
1 911B
A 819
2 0
B 811
C 0

4002-70
CONNECTOR L11 - CONDENSER CONNECTOR L13 - HEATER A/C UNIT
225350C1 ?
CAV CIRCUIT CAV CIRCUIT CAV CIRCUIT
1 819 1 811 7 817
2 0 2 0 8 818A
3 817 3 813 9 819
4 Not Used 4 814 10 800
5 Not Used 5 815 11 Not Used
6 Not Used 6 816 12 Not Used
CONNECTOR L12 - HEATER A/C UNIT CONNECTOR L15 - RADIO
L12
CAV CIRCUIT
1 815
2 813
3 814
L15
4 816
5 899
1 L+ 8 L-
6 816
3 R+ 10 R-
5 0 12 505
7 504 14 Not Used

4002-71
CONNECTOR M1 - FROM DASH TO MAIN
HARNESS
1 911B 21 933
2 911A 22 934
3 922 23 935
4 30 24 Not Used
5 912 25 120
6 133 26 335
7 952 27 104
8 993 28 955
10 4111 30 Not Used
11 50 31 953
12 15 32 943
13 START 33 121
14 921 34 0
15 IGN3 35 103
16 334 36 134
17 951 37 992
18 963 38 954
19 Not Used 39 0
20 D+ 40 0
M1

4002-72
CONNECTOR M2 - FUSE PANEL
M2
CAV CIRCUIT
CAV CIRCUIT
C4 Not Used
A1 1M
C5 Not Used
A2 V1acc
C6 Not Used
A3 V2acc
C7 Not Used
A4 922
C8 Not Used
A5 933
C9 Not Used
A6 912
C10 Not Used
A7 953
D1 BUSS +
A8 Not Used
D2 IGN+
A9 800
D3 BUSS +
A10 819
D4 21C
B1 21A
D5 BUSS +
B2 50
B3 IGN+ D6 Not Used
B4 206 D7 BUSS +
B5 Not Used D8 1N
B6 Not Used D9 BUSS +
B7 1N D10 329
B8 15
B9 332
B10 START
C1 Not Used
C2 Not Used
C3 Not Used

4002-73
CONNECTOR M3 - FUSE AND RELAY PANEL
87312843
CAV CIRCUIT
CAV CIRCUIT B3 Not Used
AA1 BATT+ B4 Not Used
AA7 Not Used B10 Not Used
AA8 IGN+ C1 -
Not Used
10
AA9 IGN+
D1 317
AA10 IGN+
D2 21D
A1 1N
D3 Not Used
A2 30
D4 Not Used
A3 21A
D5 Not Used
A4 992
D6 Not Used
A5 302
D7 Not Used
A6 501
D8 Not Used
A7 Not Used
D9 Not Used
A8 IGN3
D10 Not Used
A9 IGN2
A10 IGN1
B1 21C
B2 337

4002-74
CONNECTOR M5 - DECELERATOR PEDAL CONNECTOR M7 - PROXIMITY SWITCH LEFT
M5 DEU_DT06-3S

A 280 A IGN1
B 262 B 237
C 219 C 0
CONNECTOR M5A - LOW IDLE SWITCH CONNECTOR M8 - PROXIMITY SWITCH RIGHT
CAV CIRCUIT
A 223
B 280
CONNECTOR M6 - BRAKE PEDAL
DEU_DT06-3S
CAV CIRCUIT
A IGN1
B 260
C 0
DEU_DT06-3S
CAV CIRCUIT
A 279
B 256
C 265

4002-75
CONNECTOR M9 - JOYSTICK CONNECTOR M10 - FROM DASH HARNESS TO
MICRO CONTROLLER
M10
DEU_DT06-6S CAV CIRCUIT CAV CIRCUIT

CAV CIRCUIT 7 IGN1 28 501
1 IGN1 8 955 29 121
2 0 10 4111 30 120
3 334 11 256 31 133
4 335 12 262 34 134
5 IGN1 13 237 36 219
6 Not Used 14 954 37 953
15 818B 38 935
16 IGN2 39 389
18 279 41 223
19 260 42 V1acc
20 265 43 280
21 921 44 335
22 911B 45 334
23 800 46 104
24 911A 47 934
26 819 48 206

4002-76
CONNECTOR M11 - FROM FRONT CONSOLE TO CONNECTOR M13 - ROPS HEATER
ENGINE
PAC_12015792
CAV CIRCUIT
A V2acc
M11
B 0
1 302 16 W
CONNECTOR M14 - ACC POWER RELAY
2 D+ 17 Not Used
3 Not Used 18 334
5 Not Used 20 335
6 Not Used 21 317
7 993 22 Not Used
8 Not Used 23 312
9 Not Used 24 329
10 21D 25 332
M14
11 103 26 337
CAV CIRCUIT
12 818B 27 IGN3
A 15
13 963 28 375
B 0
14 943 29 389
15 Not Used
CONNECTOR M15 - LEFT DOOR WIPER

(HARNESS VIEW)
CONNECTOR M12 - GRID HEATER RELAY v
M15
CAV CIRCUIT
1 0
PAC_2973781 2 951
CAV CIRCUIT 3 933
B 375 4 952
A 312

4002-77
CONNECTOR M16A - FLEET MANAGEMENT CONNECTOR M23 - LOW IDLE SWITCH
M16A

1 1N 5 W
PAC_12065863
2 Not Used 6 0
3 Not Used 7 1M CAV CIRCUIT
4 Not Used 8 0 A 223

B 280
CONNECTOR M22 - POWER SEAT
PAC_12015792
CAV CIRCUIT
A V2acc
B 0

4002-78
CONNECTOR P1 - FROM PUMPS AND MOTORS CONNECTOR P3 - LEFT HAND PUMP
TO MICRO CONTROLLER
DEU_DT06-4S
P1
CAV CIRCUIT
CAV CIRCUIT
1 0
1 205 18 272
2 230
2 104 19 424
3 231
3 121 20 425
4 0
4 134 21 426
5 120 22 421
6 133 23 422 CONNECTOR P4 - RIGHT HAND PUMP
7 244 24 423
8 243 25 427
9 V1acc 26 428
10 217 27 429
11 218 28 451
12 204 29 452
13 216 30 453
14 230 31 268
15 231 32 269
16 215 33 Not Used
17 248
DEU_DT06-4S
CAV CIRCUIT
1 0
2 216
3 204
4 0

4002-79
CONNECTOR P5 - LEFT HAND MOTOR SPEED CONNECTOR P7 - LEFT HAND MOTOR
SENSOR SOLENOID
DEU_DT06-4S DEU_DT06-2S

1 244 1 268
2 V1acc 2 0
3 243
4 Not Used
CONNECTOR P8 - RIGHT HAND MOTOR
SOLENOID
CONNECTOR P6 - RIGHT HAND MOTOR SPEED
SENSOR
DEU_DT06-2S
CAV CIRCUIT
DEU_DT06-4S 1 269
CAV CIRCUIT 2 0
1 218
2 V1acc
3 217
4 Not Used

4002-80
CONNECTOR P9 - CHARGE PRESSURE
SONSOR
256342A1
CAV CIRCUIT
A 133
B 0
CONNECTOR P10 - FROM PUMPS TO

HYDRAULIC VALVE
P10

A V1acc N 452
B 205 O 134
C Not Used P 424
D 272 Q 425
E 428 R 429
F 453 S 426
G 427 T 451
H 104 U 215
J 422 V 248
K 121 W 421
L 423 X 0
M 120

4002-81
CONNECTOR V1 - TO HYDRAULIC VALVE CONNECTOR V13 - BLADE TILT LEFT
V1 DEU_DT06-2S
CAV CIRCUIT CAV CIRCUIT CAV CIRCUIT

A V1acc N 452 1 424
B 205 O 134 2 426
C Not Used P 424
D 272 Q 425
CONNECTOR V14 - BLADE TILT RIGHT
E 428 R 429
F 453 S 426
G 427 T 451
H 104 U 215
J 422 V 248
K 121 W 421
L 423 X 0
M 120
DEU_DT06-2S
CAV CIRCUIT
1 425
2 426

4002-82
CONNECTOR V15 - BLADE LOWER CONNECTOR V17 - BLADE ANGLE RIGHT

1 422 1 427
2 423 2 429
CONNECTOR V16 - BLADE RAISE CONNECTOR V18 - BLADE ANGLE LEFT

1 421 1 428
2 423 2 429

4002-83
CONNECTOR V19 - RIPPER LOWER CONNECTOR V21 - POWER TO VALVE

1 451 1 272
2 453 2 0
CONNECTOR V20 - RIPPER RAISE CONNECTOR V23 - FUEL LEVEL SENDER
V23
CAV CIRCUIT
1 120
DEU_DT06-2S 2 0
CAV CIRCUIT
1 452
2 453

4002-84
CONNECTOR V24 - BRAKE RELEASE SOLENOID
DEU_DT06-2S
CAV CIRCUIT
1 215
2 0
CONNECTOR V25 - BRAKE RELEASE SWITCH
V25
CAV CIRCUIT
1 V1acc
2 248

4002-85
NOTES

4002-86

4002-85
INDEX
Symbols Brake Release Switch .......................................83
12 Volt Radio .........................................................42 Center Front Light .............................................68
Charge Pressure Sensor ...................................80
A Cigar Lighter ......................................................56
Accessory Power Jack 12 Volt ..............................44 Condenser ........................................................70
Accessory Relay ....................................................23 Control Panel ....................................................69
Air Conditioner DC Converter ....................................................56
Compressor Clutch ...........................................47 Decelerator Pedal .............................................74
Condenser Blower Motor ..................................48 Diagnostic .........................................................53
High Pressure Switch ........................................47 Door Washer Switch .........................................62
Low Pressure Switch .........................................47 Door Wiper Switch ............................................62
Air Filter Restriction Switch ....................................36 Engine Controller ..............................................64
Air Suspension Seat-Air Compressor ....................45 Enter/ESC Switch ..............................................63
Alarm Fleet Management ............................................77
Backup ..............................................................41 From Dash Harness to Micro Controller ............75
Oil Pressure/Coolant Temperature ...................38 From Dash to Main Harness .............................71
Alternator ...............................................................21 From Engine to Front Console ..........................64
From Front Console to Engine ..........................76
B From Light Harness to Micro Controller ............66
Backup From Main Harness to Dash .............................59
Alarm .................................................................41 From Micro Controller to Dash Harness ............54
Battery ...................................................................21 From Micro Controller to Diagnostic Port ..........56
Blower From Micro Controller to Light Harness ............55
Switch ................................................................46 From Micro Controller to Pumps and Motors ....54
Blower Motors ........................................................45 From Pump to Hydraulic Valve .........................80
Blower Resistor .....................................................46 From Pumps and Motors to Micro Controller ....78
Boosting Batteries to Start the Engine ...................52 Front Headlamps Switch ...................................61
Brake Front Left Lower Work Light (Canopy Only) ......67
Pedal Potentiometer ..........................................27 Front Left Upper Work Light (Canopy Only) ......68
Pressure Switch ................................................31 Front Right Lower Work Light (Canopy Only) ...69
Solenoid ............................................................32 Front Right Upper Work Light (Canopy Only) ...68
Buzzer Front Wiper .......................................................61
High Temperature .............................................38 Front/Rear Washer Switch ................................62
Low Oil Pressure ...............................................38 Front/Rear Wiper Switch ...................................61
Fuel Level Sender .............................................83
C Fuse and Relay Panel M3 .................................73
Cab Fuse Panel M2 ..................................................72
Interior Lamps ...................................................44 Grid Heater Relay .............................................76
Interior Lamps Switch ........................................43 Heater A/C Unit .................................................70
Cluster, Instrument Connector A ...........................35 Horn Switch .......................................................63
Cluster, Instrument Connector B ...........................35 Ignition Switch ...................................................63
Connector Ignition switch ....................................................63
A/C High Pressure Switch .................................65 Indicator Light .............................................55, 56
ACC Power Relay .............................................76 Instrument Cluster A .........................................60
Blade Angle Left ................................................82 Instrument Cluster B .........................................60
Blade Angle Right .............................................82 Joystick .............................................................75
Blade Controller ................................................57 Left Door Wiper .................................................76
Blade Lower ......................................................81 Left Front Light ..................................................67
Blade Power and Diagnostics ...........................57 Left Hand Motor Speed Sensor .........................79
Blade Raise .......................................................81 Left Hand Pump ................................................78
Blade Tilt Left ....................................................81 Left Hand Solenoid ...........................................79
Blade Tilt Right ..................................................81 Left Rear Light ..................................................66
Brake Pedal .......................................................74 Low Idle Switch .................................................74
Brake Release Sonenoid ..................................83 Connector M23 77
Micro Controller .................................................53
4002-86
PDT ...................................................................69 Connector D5 ........................................................61
Power Seat ........................................................77 Connector D6 ........................................................61
Power to Valve ..................................................83 Connector D7 ........................................................61
Proximity Switch Left .........................................74 Connector D8 ........................................................62
Proximity Switch Right ......................................74 Connector D9 ........................................................62
Radio .................................................................70 Connector E1 ........................................................64
Rear Headlamps Switch ....................................61 Connector E11 ...................................................... 65
Rear Left Work Light (Canopy Only) .................66 Connector E12 ...................................................... 65
Rear Right Work Light (Canopy Only) ...............67 Connector E2 ........................................................64
Rear Wiper ........................................................57 Connector E5A ...................................................... 65
Reverse Ratio Switch ........................................55 Connector E5B ...................................................... 65
Right Door Wiper ...............................................58 Connector L1 ......................................................... 66
Right Front Light ................................................69 Connector L1 (Canopy Only) .................................66
Right Hand Motor Speed Sensor ......................79 Connector L10 ....................................................... 69
Right Hand Pump ..............................................78 Connector L11 ....................................................... 70
Right Hand Solenoid .........................................79 Connector L12 ....................................................... 70
Right Rear Light ................................................67 Connector L13 ....................................................... 70
Ripper Control ...................................................58 Connector L15 ....................................................... 70
Ripper Lower .....................................................82 Connector L2 ......................................................... 66
Ripper Power and Diagnostics ..........................57 Connector L2 (Canopy Only) .................................66
Ripper Raise .....................................................82 Connector L3 ......................................................... 67
ROPS Heater ....................................................76 Connector L3 (Canopy Only) .................................67
Throttle Position Sensor ....................................55 Connector L4 ......................................................... 67
To Hydraulic Valve ............................................80 Connector L4 (Canopy Only) .................................67
Up/Down Switch ................................................62 Connector L5 ......................................................... 68
Water in Fuel Sensor ........................................65 Connector L5 (Canopy Only) .................................68
Windshield Washer 1 ........................................65 Connector L6 ......................................................... 68
Windshield Washer 2 ........................................65 Connector L6 (Canopy Only) .................................68
Work Lights (Canopy Only) ...............................66 Connector L7 ......................................................... 69
Connector C1 ........................................................53 Connector L7 (Canopy Only) .................................69
Connector C10 ......................................................56 Connector L9 ......................................................... 69
Connector C12 ......................................................56 Connector M1 ........................................................71
Connector C14 ......................................................56 Connector M10 ...................................................... 75
Connector C2 ........................................................53 Connector M15 ...................................................... 76
Connector C20 ......................................................57 Connector M16A ................................................... 77
Connector C21 ......................................................58 Connector M2 ........................................................72
Connector C3 ........................................................53 Connector M3 ........................................................73
Connector C5 ........................................................54 Connector M5A .....................................................74
Connector D1 ........................................................59 Connector P1 ........................................................78
Connector D10 ......................................................62 Connector P10 ...................................................... 80
Connector D11 ......................................................62 Connector P3 ........................................................78
Connector D2A ......................................................60 Connector P7 ........................................................79
Connector D2B ......................................................60 Connector P8 ........................................................79
Connector D4 ........................................................61 Connector P9 ........................................................80

4002-87
Connector V1 .........................................................80 Fuse Block A .........................................................25
Connector V13 .......................................................81 Fuse Block B .........................................................25
Connector V14 .......................................................81
Connector V15 .......................................................81 G
Connector V16 .......................................................81 Grid Heater ............................................................23
Connector V17 .......................................................82 Grid Heater Relay ..................................................23
Connector V18 .......................................................82 Grounding points ...............................................6, 52
Connector V19 .......................................................82
Connector V20 .......................................................82 H
Connector V21 .......................................................83 Heater
Connector V23 .......................................................83 Grid ...................................................................23
Connector V24 .......................................................83 ROPS ................................................................45
Connector V25 .......................................................83 Horn .......................................................................41
Horn Button ...........................................................41
D HVAC Mode Switch ...............................................46
Decelerator Pedal Low Idle Switch ........................28 Hydraulic Filter Restriction Switch .........................38
Decelerator Pedal Potentiometer ..........................27 Hydrostat Filter Restriction Switch ........................37
Diagnostic Port ......................................................51 Hydrostatic Charge Pressure Switch .....................39
Door
Windshield Wiper, Left and Right Hand ............50 I
Windshield Wiper, Left Hand .............................50 Ignition Relay .........................................................24
Windshield Wiper, Right Hand ..........................50 Ignition Switch .......................................................22
Drivetrain Control Module ......................................28 Instrument Cluster Connector A ............................35
Instrument Cluster Connector B ............................35
E
Electrical System Wire Identification .......................7 J
Electronic Diesel Control .......................................42 Jump Starting the Vehicle .....................................52
Enter Escape Instrument Cluster Switch ...............36
Equipment Valve L
Blade Control Joystick .......................................32 Left
Blade Lift Solenoid ............................................33 Motor Solenoid ..................................................30
Blade Lower Solenoid .......................................33 Motor Speed Sensor .........................................28
Diagnostic Port ..................................................32 Parking Brake Proximity Switche ......................27
Ripper Joystick (Option) ....................................34 Pump Solenoid ..................................................29
Ripper Lift Solenoid (Option) .............................35 Left and Right Hand Door
Ripper Lower Solenoid (Option) ........................35 Windshield Washer ...........................................51
Safety Solenoid .................................................33 Windshield Washer Switch ................................51
Tilt Left Solenoid ...............................................33 Left Speaker ..........................................................43
Tilt Right Solenoid .............................................34 Lights
Twist Left Solenoid ............................................34 Cab Interior .......................................................44
Twist Right Solenoid .........................................34 Front Floodlights ...............................................40
Rear Floodlights ..........................................40, 41
F
Fleet Relay (Option) ..............................................25 M
Fleet Tracker Port ..................................................51 Main
FNR Directional Control .........................................31 Electrical System Troubleshooting ....................21
Front Master Disconnect Switch .....................................21
And Rear Windshield Washer ...........................49 Monitor Light Switch ..............................................40
And Rear Windshield Washer Switch ...............49
Floodlight/Monitor Light Switch .........................40 P
Floodlights .........................................................40 Potentiometer
Windshield Wiper ..............................................48 Brake .................................................................27
Front and Rear Deceleratior Pedal .............................................27
Windshield Wiper Switch ...................................48 Throttle ..............................................................28
Fuel Power Converter (24 volts to 12 volts) ..................44
Level Sender .....................................................39
Fuse and relay panels .............................................5
4002-88
R HVAC Mode ...................................................... 46
Radio Hydraulic Filter Restriction ................................ 38
12 Volt ...............................................................42 Hydrostat Filter Restriction ................................ 37
Rear Ignition ..............................................................22
And Front Windshield Washer ..........................49 Left and Right Hand Door Windshield Washer .51
And Front Windshield Washer Switch ...............49 Left and Right Hand Door Windshield Wiper ....50
Floodlight Switch ...............................................40 Left Parking Brake Lever ..................................27
Floodlights .........................................................41 Master Disconnect ............................................21
Windshield Wiper ..............................................49 Monitor Lights ................................................... 40
Rear and Front Rear Floodlights ................................................ 40
Windshield Wiper Switch ...................................48 Reverse Ratio ................................................... 30
Relay Right Parking Brake Lever ................................ 26
Accessory ..........................................................23 Temperature Control ......................................... 47
Fleet (Option) ....................................................25 Transmission Charge Pressure ........................39
Grid Heater ........................................................23 Up Down Menu Instrument Cluster Switch .......36
Ignition ...............................................................24
Safety ................................................................24 T
Start Sensing Power .........................................25 Temperature
Starter ...............................................................24 Transmission Sender ........................................37
Reverse Ratio Switch ............................................30 Temperature Control
Right Switch ...............................................................47
Motor Solenoid ..................................................30 Thermostat ............................................................45
Motor Speed Sensor .........................................29 Throttle Potentiometer ...........................................28
Parking Brake Proximity Switche ......................26 Tilt Proximity Switch ..............................................26
Pump Solenoid ..................................................29 Transmission Charge Pressure Switch .................39
Right Speaker ........................................................43 Transmission Temperature Sender .......................37
ROPS Heater .........................................................45
U
S Understanding the Troubleshooting Tables .......... 20
Safety Relay ..........................................................24 Up Down Menu Instrument Cluster Switch ............ 36
Sensor
Water In Fuel .....................................................42 W
Shifter Warning Buzzer .....................................................38
Directional control .............................................31 Water In Fuel Sensor ............................................42
Solenoid Water Valve ...........................................................45
Brake .................................................................32 Windshield Washer
Hydraulics Safety ..............................................33 Front And Rear .................................................49
ON OFF Hydraulics ...........................................33 Left and Right Hand Door .................................51
Starter ...............................................................22 Windshield Washer Switch
Speaker Front And Rear .................................................49
Left ....................................................................43 Left and Right Hand Door .................................51
Right ..................................................................43 Windshield Wiper
Specifications ..........................................................5 Front ..................................................................48
Start Sensing Relay ...............................................25 Left Hand Door ..................................................50
Starter ....................................................................22 Rear ..................................................................49
Starter Relay ..........................................................24 Right Hand Door ...............................................50
Starter Solenoid .....................................................22 Wire Identification ....................................................7
Switch
Air Filter Restriction ...........................................36
Blower ...............................................................46
Brake Pressure .................................................31
Cab Interior Lights .............................................43
Enter Escape Instrument Cluster Switch ...........36
Front And Rear Windshield Washer ..................49
Front and Rear Windshield Wiper .....................48
Front Floodlights ...............................................40
Horn Button .......................................................41

Section
4003
4003
BATTERIES

4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4003-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or
INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or
milk. Follow with milk of magnesia, beaten
have been recently charged.
egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
WARNING: Some batteries have a Keep out of reach of children.

ventilation tube. If there is battery acid in the D-47-53A
ventilation tube, this battery acid can be

released when the battery is turned upside
down. If you turn the battery upside down,
make sure that the end of the ventilation tube
is away from you and away from any other
people in the area. Battery acid can cause
severe burns.
48-57B
SPECIAL TOOLS
B795328
The CAS10147 tester is used to do the Capacity

(Load) Test. This tool is first used on Page 6.

4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the If damage causes an electrolyte leak, replace the
level of the electrolyte every 1000 hours of operation battery.
or six months, whichever occurs first. For all other
Inspect the battery at regular intervals for dirt,
batteries, check the level of the electrolyte every 250
corrosion, and damage. Electrolyte and dirt on the
hours of operation.
top of the battery can cause the battery to discharge
NOTE: A maintenance free battery will have the words by making a passage for the current to flow.
Maintenance Free on the decal on the top of the battery. If
If the battery must be cleaned, remove the battery
the center part of the decal has been removed for access to
from the battery carrier and clean the battery, cable
the battery caps, it is possible that the words Maintenance
terminals, and the battery carrier. When available,
Free have been removed from the decal.
use Case Battery Saver and Cleaner according to
Check the level of the electrolyte more often during the instructions on the container. Case Battery Saver
hot weather. The use of a large amount of water by and Cleaner also helps prevent corrosion. If Case
the battery can be caused by high battery Battery Saver and Cleaner is not available, use
temperature or a voltage regulator setting that is too baking soda and water as a cleaner. DO NOT permit
high. Keep the electrolyte level above the top of the any type of cleaner to enter the cells of the battery.
plates in the battery at all times to prevent damage to
Install the battery in the machine and make sure the
the battery.
fasteners are tight. Apply Case Battery Saver and
NOTE: On maintenance free batteries it is necessary to Cleaner or Urethane Seal Coat to the cable terminals
remove the center part of the decal for access to the battery to prevent corrosion. See the Parts Counter Catalog.
caps. Do not discard the center part of the decal. Install the DO NOT apply grease.
center part of the decal after the battery caps have been
installed.
If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is 5 mm
(¼ inch) below the level of the ring. Do not add more
water than is needed. Too much water can cause
bad performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.

4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the battery. 1 2
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check B790863
A hydrometer is used to check the specific gravity 1. TEMPERATURE IN F 2. TEMPERATURE IN C

(weight) of the electrolyte. The specific gravity is an SPECIFIC GRAVITY CHART
indication of the level of charge for each cell. 4. Make a record of the corrected specific gravity
Hydrometers are made to show the correct specific reading for each cell.
gravity when the temperature of the electrolyte is 5. If the difference between the high reading and
26.7°C (80°F). the low reading is 0.050 or more, charge the
When you check the specific gravity, you must know battery and check the specific gravity again. If
the temperature of the electrolyte. If your hydrometer after charging, the difference is still 0.050 or
does not have a thermometer, get a thermometer to more, install a new battery.
check the temperature of the electrolyte. The 6. The corrected specific gravity reading shows the
thermometer must indicate a high temperature of at level of charge for the cell. The level of charge
least 52°C (120°F). must be at least 75% in each of the cells. ln
1. Remove enough electrolyte from a cell so that maintenance free batteries the level of charge is
the float is free in the tube. at least 75% if the corrected specific gravity
reading is 1.240 or higher. In all other batteries
NOTE: If the specific gravity cannot be checked without the level of charge is at least 75% if the corrected
first adding water to the cell, the battery must be charged specific gravity reading is 1.230 or higher.
for 15 minutes at 15 to 25 amperes to mix the water with
the electrolyte. Then check the specific gravity. 7. If the difference between the high reading and
the low reading is less than 0.050, and the level
2. Read the float. of charge is at least 75% in all of the cells, do the
3. Read the thermometer. If the reading is above Capacity (Load) Test.
26.7°C (80°F) add specific gravity points to the 8. If the difference between the high reading and
reading for specific gravity. If the reading is the low reading is less than 0.050, but the level
below 26.5°C (80°F) subtract specific gravity of charge is less than 75% in any of the cells,
points from the reading for specific gravity. See charge the battery and check the specific gravity
the following illustration and add or subtract again. If after charging:
specific gravity points as needed.
A. The level of charge is less than 75% in any of
the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.

4003-6
Capacity (Load) Test NOTE: Never apply a load for longer than 15 seconds.
After each 15 seconds, turn the load control knob to OFF for
This test can be done using a variable load tester at least one minute.
such as the Sun Electric VAT -33. Other test
equipment can be used. Connect the test equipment 4. Apply a 15 ampere load to the battery for 15
according to the instructions of the manufacturer of seconds. Wait at least three minutes before
the equipment. applying the load again.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section. 6. Find the correct load for this test in Specifications
2. Prepare the tester (Sun Electric VAT-33 shown) in Section 4001.
for the test. NOTE: The correct load is half of the cold cranking
A. Select the voltmeter range that will measure 1 amperes at -17°C (0°F).
to 18 volts. 7. Turn the load control knob until the ammeter
B. Make sure the load control knob is in the OFF indicates the specified load. Keep the load for 15
position. seconds and read the voltmeter. Turn the load
control knob to OFF.
C. Select the ammeter range that will measure 0
to 1000 amperes. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
D. Move the volt lead switch to the NT. position. Temperature of . . . . . . . . . . . . . . . Minimum Voltage
3. Connect the tester to the battery as shown. electrolyte
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
2
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
B. If the test result is less than the voltage
shown, discard the battery.
B790499
1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF

ARROW AWAY FROM
BATTERY)

4003-7
CHARGING A BATTERY
The charging rate must be decreased if:
WARNING: Never try to charge the battery if
the electrolyte in the battery is frozen. 1. Too much gas causes the electrolyte to flow from
47-83
the cells.
Before you charge the battery, check the level of the 2. The temperature of the electrolyte rises above
electrolyte. 52°C (125°F).
It is difficult to give an exact charging rate because of The battery is fully charged when, over a three hour
the following variable conditions: (1) temperature of period at a low charging rate, no cell is giving too
the electrolyte, (2) level of charge, and (3) condition much gas, and the specific gravity does not change.
of the battery. Use the charging guide for the correct
charging rate and time.
See Specifications in Section 4001 for the reserve
capacity of the battery in this machine.
Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under Charge
Specifications
10 Hours at 5 Amperes
80 Minutes or Less 5 Hours at 10 Amperes
Above 80 to 125 Minutes 7.5 Hours at 10 Amperes
Above 125 to 170 Minutes 10 Hours at 10 Amperes
*lnitial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part
of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been
removed from the decal.
Continued on next page

4003-8
Charging Guide For Batteries Other Than Maintenance Free

Batteries
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under Charge
Specifications
80 Minutes or Less 5 Hours at 10 Amperes
Above 80 to 125 Minutes 7.5 Hours at 10 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
*lnitial rate for standard taper charger.
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
specific gravity is 1.250 or more an d the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will permit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.

Section
4005
INSTRUMENT CLUSTER
4005

4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Using The Arrow Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reset The Trip Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjusting Steering Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting Shuttle Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting Maximum Transmission Speed Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Speed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Erasing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DRIVE TRAIN FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ELECTRO-HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EST Fault Retrieval for Electro-Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4005-3
INSTRUMENT CLUSTER
4 5 6
2 3 7 8
1 9
10
19 11
18 12
17 16 15 14 13
BD07G118-02
1. TRANSMISSION FILTER CLOG WARNING LAMP 11. HYDRAULIC FILTER CLOG WARNING LAMP
2. CHARGE PRESSURE LOW WARNING LAMP 12. FUEL GAUGE
3. TRANSMISSION TEMPERATURE GAUGE 13. GRID HEATER INDI CATOR LAMP
4. FAULT WARNING LAMP 14. FUEL LEVEL LOW WARNING LAMP
5. DIGITAL DISPLAY 15. AIR FILTER RESTRICTION WARNING LAMP
6. STOP MACHINE OPERATIONS WARNING 16. ENGINE COOLANT TEMPERATURE WARNING LAMP
7. BATTERY CHARGE GAUGE 17. TRANSMISSION TEMPERATURE WARNING LAMP
8. LOW ENGINE OIL PRESSURE WARNING LAMP 18. ENGINE COOLANT TEMPERATURE GAUGE
9. PARKING BRAKE ENGAGED LAMP 19. FRONT WORK LAMP INDICATION LAMP
10. ALTERNATOR INDICATORL
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:

4005-4
Self-Test Power Circuit Test

1. Turn the ignition (key) switch to the ON position. A. Check fuses F14 and F18. If fuses are bad,
replace the fuses and repeat Self-Test. If the
2. The instrument cluster will automatically check fuse is good, go to next step.
each monitored system.
B. Check wires 13 and 40 for continuity.
3. All LED’s (Light Emitting Diodes) will illuminate Repair/replace the wires as required. If
for 2 - 3 seconds. continuity is found go to next step.
4. Four gauges will energize for 2 - 3 seconds. C. Check ignition relay for proper operation, see
Section 4002. If the ignition relay checks
5. The warning alarm will sound for 2 - 3 seconds.
good, go to next step.
6. If there is an open circuit between a sensor and D. Check the ignition switch for proper operation,
the instrument cluster, the LED will flash and the see Section 4002. If the ignition switch checks
warning alarm will sound for 5 seconds. good, go to next step.
7. If there were no faults detected during the check, E. Check circuit 1B to battery
all monitored systems will return to normal
operation.
8. If only some of the LEDs illuminate, replace the
instrument cluster.
9. If the LEDs illuminate, but the warning alarm
does not sound, see section 4002 and test the
alarm circuit.
10. If the warning alarm sounds but the LEDs do not
illuminate, if no power is present at buzzer,
replace the instrument cluster, if power is present
at the buzzer, replace the buzzer.
11. If the warning alarm does not sound and the
LEDs do not illuminate on the instrument cluster,
do the following steps to test the power circuit:

4005-5
LCD Multi-function Display 1. In the example, the machine hours are

displayed. Machine hours will always be
displayed briefly, on start up. After, the machine
is started, the display will show engine rpm’s.
After, beginning travel, the machine will display
travel speed, if default settings were not changed
by the operator.
2. This example, shows that the Transmission
Control Lever is in Neutral. The display will show
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is
positioned.
BD07G118-01 3. This example shows the transmission at 60%.
The LCD Multi-Function Display is located at the 60% is the default speed. When the ignition
center of the modular dashboard. On start up the switch has been shut off it will default the
cluster will flash the instructional lamps and the LCD transmission to this setting.
Multi-Display will display New Holland LOGO, with 4. This zone will display fault codes when an error
the next service interval and current hour reading. has accord in the engine controller, drivetrain
controller, or blade controller.
5. This zone will display additional and optional
information.
2 3
4 5
BD06G113-01
LCD MULTI-FUNCTION DISPLAY
Information will be displayed in different zones on the
LCD, as directed by the operator or machine. In
most situations the operator or technician will be
given specific information to follow if conditions are
not correct.

4005-6
Multi-function Display Screens Using The Arrow Keys

At any time, during operation or with the key switch
on, the operator may scroll through two information
screens and two trip screens by using the arrow
1 3 keys. These four screens are in a circular loop and
may be reached by pressing the up or down key. The
following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen.
2 4
BD06G112-01
Located on the dash panel are the operating
switches for the instrument cluster. Use the switches
to move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
1. Up arrow key: Use this key to scroll up to
selections.
BD06G112-01
2. Down arrow key: Use this key to scroll down to From the driving screen push the down arrow.
selections.
3. Escape key: Use this key to exit and return to
the driving screen. Use this key anytime you
would like to start over and begin again, plus use
to check active, acknowledge errors.
4. Enter key: Use this key to confirm, yes, this is
the desired function.
NOTE: Arrows on the screen will indicate if selections are
up or down from the current selection.
NOTE: Display units can be changed by the operator.
BD06N046-01
Info 1 is the first information screen using the down

arrow from the driving screen. It displays engine
RPM’s, speed, fuel level, and the voltage level.

4005-7
BD06F170-01
By continuing to scroll down, the fifth screen will
display the Trip 2 screen. Trip 1 and Trip 2 screens
BD06F027-01
Info 2 will be displayed next. The Info 2 screen will can be reset independently. The previous screen can
display coolant temperature, turbocharger air be accessed by using the up arrow key.
temperature, engine oil temperature in either
Fahrenheit or Celsius, as well as oil pressure PSI.
BD06F169-01
Press the down button again and the Trip 1 screen
will display. The LCD provides two trip computers.
These will display since last reset the total time in
hours, the total fuel, and the average fuel
consumption per hour.

4005-8
Reset The Trip Information
BD06F172-01
The trip screen will indicate a reset message. At this
BD06F170-01
screen, press confirm to clear the numbers and reset
Highlight the trip screen you wish to set. the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.
BD06G112-01
Press the confirm button.
BD06G112-01
Press the confirm button to reset the trip selection to

zero.

4005-9
Adjusting Steering Sensitivity

The direction control lever has three sensitivity
settings.
● Smooth
● Normal
● Fast
To change the sensitivity:
BD06G112-01
3. Select the SETTINGS menu by pressing the
enter button. The display will show SETTINGS at
the top followed by:
● Max Spd
● Shuttle
● Steer
4. Push the down arrow and go to steer.
BD06G112-01 NOTE: Normal is the setting from the factory.
1. Press and hold the enter button for 2 to 3
5. Press the enter button.
seconds until the screen shows SELECT at the
top. 6. Use the up or down arrow button until the desired
choice is blinking.
7. Push the enter button to confirm the selection
and store the choice.
NOTE: The setting menu may be hidden entirely with the
EST.
Adjusting Shuttle Parameter

To adjust the shuttle parameter follow the same
steps as for steering sensitivity.
The shuttle choices are the same:
● Smooth
BD06G112-01 ● Normal
2. Press the down arrow until SETTINGS is on
displayed. ● Fast
After selecting desired value press the enter button
to confirm the selection and store the choice.
Adjusting Maximum Transmission

Speed Parameter
To adjust the maximum transmission speed follow
the same steps as for steering sensitivity.
The transmission speed choices will be 70, 80, 90 or
100 per cent.
After selecting the desired value press the enter
button to confirm and store the choice.

4005-10
Transmission Speed Controls NOTE: When the crawler engine is shut off the
transmission speed will default to 60%.
BD02M166-01
BD06G113-01
1. Transmission speed up button The transmission speed gauge will allow the operator
2. Transmission speed down button to know which speed is selected. When the crawler
The CASE K Series crawlers have infinitely variable engine is shut off the transmission speed will default
speeds in forward and revers from 0 to 9.7 km/h (0 to to 60% as shown.
6.0 mph). The maximum speed is selectable in a The digital display will reflect the position of the
range of 10 increments. To move from on speed to direction control lever as “F” forward, “N” neutral, or
another press the UP (1 for DOWN (2) button. The “R” reverse.
operator may increment up one touch at a time or
NOTE: The crawler will not move unless the engine rpm is
hold the button to move through the transmission
above 1000.
speeds.
NOTE: A flashing F or R indicates the directional control
NOTE: The speed can only be increased to the maximum
lever must be returned to neutral before movement is
transmission speed setting which can be adjusted. See
allowed.
Adjusting Maximum Transmission Speed
Parameter on page 9. From the factory 90% is the highest
speed.

4005-11
RETRIEVING FAULT CODES
General Fault Code Identification Fault Code Grouping

1. Press and hold the escape key and up arrow key 1. 1000 to 1999 vehicle errors.
for more than 2 seconds to access the fault
2. 2000 to 2999 not used.
codes.
3. 3000 to 3999 engine errors.
NOTE: If a fault is active and a warning lamp is
illuminated the escape key (3) will only need to be pressed 4. 4000 to 4999 transmission errors.
once to display the fault.
5. 5000 to 5999 eltro-hydraulic system errors.
6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
1 3
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.
NOTE: Fault codes will show the number of occurrences,
this can be used to see if a yellow or white fault is recurring
on a regular basis and needs repaired.
2 4
Erasing Faults
1. Hold the enter button for 3 seconds.
BD06G112-01
1. UP KEY 2. Press the down arrow until “RESET” is
2. DOWN KEY highlighted.
3. ESCAPE KEY
4. ENTER KEY 3. Press the enter button.
2. Yellow Faults, buzzer will beep once every 2 4. The next screen display shows “CLEAR
seconds: ERRORS” and “RESTORE FATORY
SETTINGS”.
A. Operator can acknowledge it by pressing the
enter key. 5. Highlight “CLEAR ERRORS” and press enter.
B. The message will disappear. 6. “CONFIRM” will be displayed.
C. Buzzer will not beep anymore. 7. Press enter to erase active errors.
D. Yellow lamp will stay ON.
E. Fault will remain in yellow list until it is closed.
3. Red Faults, buzzer will be continuous,
alternating sounds:
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.

4005-12
ENGINE FAULT CODES
DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR
Coolant temperature sensor signal not See OTS (Oil Temperature Sensor) plausibility
3006
plausible check (Fault 3033)
Sensor defective or short circuit to external
Coolant temperature sensor signal above
3007 source.
range max.
Check wiring or replace sensor.
Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
No CAN plausibility check performed, restart
3009 Coolant temperature sensor null (via CAN) system, if problem reoccurs.
3015 Fuel temperature signal above range max. source.
Sensor defective or short circuit to ground.
3016 Fuel temperature signal below range min.
Boost pressure sensor signal above range
3019 source.
max.
3021 Boost pressure sensor null (via CAN) system, if problem reoccurs.
Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal not plausible of range.
3023 Atmospheric pressure sensor signal not

plausible
Ambient pressure sensor inside ECU is defect.
3024 Atmospheric pressure sensor signal above
Replace ECU (not necessary if never running in
range max.
high altitude and if turbocharger is without VGT)
Atmospheric pressure sensor signal below
3025
range min.
Inaccurate oil pressure sensor or defect (e.g. too
low oil level, leakage...) in the oil system.
3028 Oil pressure sensor pressure too low
Check oil pressure sensor for accuracy and
check oil system.
3029 Oil pressure sensor short-circuit to battery source.
3030 Oil pressure sensor short-circuit to ground
Inaccurate oil pressure sensor or defect (e.g.
short to ground).
3031 Oil pressure sensor ADC conversion error
check oil system.
4005-13

CODE DEFINITION
STEPS FOR REPAIR
Inaccurate oil pressure sensor or defect (e.g.

blocked piping) in the oil system.
3032 Oil pressure sensor pressure too high
check oil system.
Inaccurate oil or coolant temperature sensors or
insufficient oil or coolant recirculation (low
coolant level etc.).
3033 Oil temperature sensor signal not plausible
Check oil and coolant temperature sensor for
accuracy and check oil and coolant system for
proper functioning.
Oil temperature sensor signal above range
3034 source.
max.
Oil temperature sensor signal below range Sensor defective or short circuit to ground.
3035
min. Check wiring or replace sensor.
Oil temperature sensor signal CAN
3036 system, if problem reoccurs.
transmission disturbed
3037 Boost pressure sensor signal low
3051 Alternator voltage governor defect.

Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3060 Cylinder 1 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
3061 Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
to battery Check the wiring or replace injector
3062 Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to low side
Check the wiring and replace injector
replace ECU
Cylinder 5 injector cable short-circuit low side Short circuit in wiring with external source.
3065

4005-14

CODE DEFINITION
STEPS FOR REPAIR

replace ECU.
replace ECU
3069
replace ECU.
replace ECU
3073
3074 Check the wiring and the injection signals,

Cylinder 6 signal low
replace ECU.
3075 Defective coil of injector.

Cylinder 6 short-circuit high side to low side
replace ECU
3077 Cylinder 2 injector cable short-circuit low side Short circuit in wiring with external source.
replace ECU.
replace ECU
3081

4005-15

CODE DEFINITION
STEPS FOR REPAIR

replace ECU.
Signal interrupted do to wiring problem, defective
or incorrectly installed crankshaft speed sensor.
3088 Crankshaft sensor lost synchronization Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
Check wiring, sensor installation and proper
3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
or incorrectly installed camshaft phase sensor.
3090 Camshaft sensor lost phase Check wiring, sensor installation and proper
functioning of camshaft phase sensor (evaluate
raw signals)
3091 Camshaft sensor phase synchronization
functioning of camshaft phase sensor (evaluate
failure
raw signals).
or incorrectly installed camshaft or crankshaft
Offset between camshaft and crankshaft sensor.
3093
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor
Defective rail pressure sensor, defect in other
injection relevant component.
3104 Rail pressure relief valve open Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components
PRV does not open once the pressure limit is
reached: Mechanical defect or wrong application
Rail pressure relief valve pressure shock
3105 parameter.
requested
Check application value of maximum rail
pressure, check functioning of the PRV
PRV does not open even after pressure shock:
Rail pressure relief valve did not open after Stuck PRV or wrong application parameter.
3106
pressure shock Check application value of maximum rail
pressure, check functioning of the PRV

4005-16

CODE DEFINITION
STEPS FOR REPAIR
Short circuit of wiring to external source or inside

Metering unit output short-circuit to battery on
3107 relay.
low side
Check wiring or replace relay
Rail pressure sensor offset monitoring signal
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
3111 Rail pressure sensor offset monitoring signal rail pressure sensor, replace sensor
below range min.
Short circuit of wiring to external source or
defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
max.
Check wiring and proper functioning of rail
pressure sensor
Short circuit of main relay to external source or
Grid heater battery switch relay short-circuit to defective main relay.
3113
battery Check the wiring connecting the battery to the
EDC or replace main relay
Short circuit to ground of main relay or defective
Grid heater battery switch relay short-circuit to main relay.
3114
ground Check the wiring connecting the battery to the
EDC or replace main relay
3118 ECM 12V sensor supply voltage high Ambient pressure sensor inside ECU is defective.
Replace ECU (not necessary if never running in
3119 ECM 12V sensor supply voltage low high altitude and if turbocharger without VGT)
Short circuit to ground of grid heater.
3131 Grid heater always switched on
Check grid heater switch and replace it
3137 Broken or disconnected wiring or defective relay.

Metering unit open load
Check of wiring or replace relay
Defective wiring, ECU, power stage or metering
unit.
3138 Metering unit signal not plausible
Check wiring, ECU, power stage and metering
unit
High pressure system: Rail pressure sensor
inaccurate, high pressure pump defective.
Set point of fuel volume flow through metering
3141 Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
3147 Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
range check oil system.
3154 Grid heater relay short-circuit to battery relay.
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
Broken or disconnected wiring or defective relay.
3156 Grid heater relay no load

4005-17

CODE DEFINITION
STEPS FOR REPAIR
High pressure side: Leakage in high pressure

section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
3171 Fuel rail/system pressure - too low pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
clogged, leakage in low pressure side).
Metering unit stuck in open position,
zero-delivery throttle clogged, metering unit
without power due to electrical error.
3172 Fuel rail/system pressure - too high
Low pressure side: Pressure before gear pump
too high (e.g. by pressure relieve valve), pressure
after zero-delivery throttle too high.
3173 Fuel rail/system pressure - too low See fault 3171
3174 Fuel rail/system pressure - too high See fault 3172
Leakage in the high pressure section, injection
nozzle stuck in open position, worn high pressure
3175 Fuel system leak detected – large leak
pump, worn injector, leaking pressure relieve
valve, injector reflux too high.
High pressure system: Leakage in the high
pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
3176
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.
Defective CAN controller of Body Computer,
3178 Time-out of CAN message BC2EDC1 undervoltage of BC, missing BC, CAN cable
connecting the BC is disconnected or broken.
Short circuit in wiring. Check presence and
correct connection of the BC to the network,
3179 Time-out of CAN message BC2EDC2 Check correct functioning of the BC CAN
controller and its voltage supply. Check wiring.
Defective CAN controller of Vehicle Control
Module, undervoltage of VCM, missing VCM,
CAN cable connecting the VCM is disconnected
or broken. Short circuit in wiring. Check presence
3180 Time-out of CAN message VCM2EDC
and correct connection of the VCM to the
network, Check correct functioning of the VCM
CAN controller and its voltage supply. Check
wiring.

4005-18

CODE DEFINITION
STEPS FOR REPAIR
3188 Cylinder 1 open load

3196 Cylinder 3 open load Broken wire or disconnection of wiring or inside
injector.
3200 Cylinder 4 open load Check the wiring or replace injector.
Short circuit of high-side to battery or ground.
3210 Bank 1 general short-circuit on injection cable
Check the wiring or replace injector.
Short circuit of low-side to ground in injector
Bank 1 injection cable short-circuit low side to
3211 cable.
ground
cause the defect, internal ECU problem.
3213 Bank 1 unclassified error
replace ECU
Short circuit of high-side to battery or ground.
3218 Bank 2 general short-circuit on injection cable
Short circuit of low-side to ground in injector
Bank 2 injection cable short-circuit low side to
3219 cable.
ground
3221 cause the defect, internal ECU problem.
Bank 2 unclassified error
replace ECU
Clock error or interruption of the power supply
3227 voltage.
Injection processor error - stop engine
Check the power supply or replace ECU if
problem reoccurs.
Defective ECU, reset ECU.
3228 Injection processor error - stop engine
If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too
long.
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
due to software bug.
Replace ECU if problem reoccurs (Send in ECU
for investigation)
3232 Injection processor error - stop engine Defective ECU.
3233 Injection processor error - stop engine Replace ECU if problem reoccurs

4005-19

CODE DEFINITION
STEPS FOR REPAIR
Electric disturbances, internal defect of the ECU

3238 Communication error of CJ940 processor leading to a SPI bus communication error.
Replace ECU if failure remains present
3242 Recovery which is locked Electronic disturbances, various hardware
defects (ECU internal) or configuration problems.
3243 Recovery which is suppressed
Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
the value with the according table). If error occurs
3244 Recovery which is visible
repeatedly, reprogram EDC. If error remains,
replace EDC.
Defective monitoring module or CPU (e.g.
impaired functioning of the CPU clock) of the
EDC. Disturbed SPI-Bus.
Communication supervision watchdog control If error exists only temporary (i.e. injection
3245
flag reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
be replaced
Watch dog switch off path defect.
3246 Redundant shutoff paths during initial If failure remains after ECU initialization: replace
ECU
3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem.
If failure remains after ECU initialization: replace
3248 Redundant shutoff paths during initial ECU
3253 Error status ADC monitoring
3254 Error status ADC monitoring Buffer overrun
3255 Error status ADC monitoring No additional information available at time of print
3256 Error status ADC monitoring

3258 Short-circuit to battery at high side power
relay.
stage
Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
3259
stage Check of wiring or replace relay
Broken or disconnected wiring or defective relay.
3260 Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
Electronic disturbances, requested torque
increase via tester, wrong application of injection
3265 Energizing time exceeds limit of over run
relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU

4005-20

CODE DEFINITION
STEPS FOR REPAIR
Electronic disturbances, internal ECU problem.

3266 Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Insufficient voltage supply of a CJ940
component: Low battery voltage, defective wiring,
internal defect of the EDC.
3279 Supply voltage CJ940 lower limit
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
in the EDC.
3281 Sensor supply voltage 1 low
replace EDC
or in the EDC.
replace EDC
in the EDC.
replace EDC
or in the EDC.
replace EDC

4005-21

CODE DEFINITION
STEPS FOR REPAIR

in the EDC.
replace EDC
3998 Use the “EASY” program in the EST tool to view
An error has occurred that is not in the AIC
the fault. Use the fault description to analyze the
3999 program
error, contact TSG for further assistance.

4005-22
DRIVE TRAIN FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
Left forward pump solenoid circuit open or over

4121
current
Right forward pump solenoid circuit open or over

4131
current
1. Connectors not mated fully, pins not pushed
4141 Left reverse pump solenoid circuit open or over into connector fully, bent pin or broken wire at
current rear of connector.
Right reverse pump solenoid circuit open or over
2. Wiring or solenoid circuits open.
4151 3. Wiring or solenoid circuits shorted.
current
4. Failed Drivetrain Control Module.
4212 Left motor solenoid circuit open or over current
4222 Right motor solenoid circuit open or over current
4311 Left speed sensor out of range into connector fully, bent pin or broken wire at
rear of connector.
2. Water in connector
3. Bad fuse in drivetrain controller fuse block
4. Wiring or sensor circuits open
4312 Right speed sensor out of range 5. Wiring or sensor circuits shorted
6. Failed Drivetrain Control Module
Check power at pin A, if sensor is assembled correctly
4321 Foot pedal pot out of range
output at pin B should be between 0.7 to 4.25 V.
Check power at switch, check switch for proper

4322 Idle validation switch not working
functioning.
Decel lockout pedal completely depressed for a Check if decel pedal is stuck at low idle, reset by
4323
long time putting the joystick into neutral and park levers up.

4324 Hand throttle out of range

4331 Brake pedal potentiometer out of range
Check for power at the solenoid when the safety lever

are down and joystick is in F or R position. Check if
4332 Brake release pressure switch open
there is 200 psi at port P at the solenoid valve. Check
the resistance of the solenoid.
into connector fully, bent pin or broken wire at
rear of connector.
4341 No engine speed
3. Wiring or sensor circuits shorted
rear of connector.
4421 Backup alarm circuit open or over current 2. Water in connectors
3. Wiring or relay circuits open
4. Wiring or relay circuits shorted

4005-23

rear of connector.
4431 Brake release valve circuit open or over current 2. Water in connectors
4. Wiring or sensor circuits shorted
4521 Bump up switch stuck on at power up into connector fully, bent pin or broken wire at
rear of connector.
2. Button is mechanically stuck
4522 Bump down switch stuck on at power up 3. Wiring or switch circuits shorted
4531 Directional control steering axis faulted into connector fully, bent pin or broken wire at
rear of connector.
2. Faulty directional control
4532 Directional control forward/reverse axis faulted
3. Wiring or directional control circuits open
4. Wiring or directional control circuits shorted
4533 Directional control forward/reverse axis faulted
4622 No CAN communication with engine controller Check CAN lines between the EDC and the DTC.
4721 No pilot pressure rear of connector.
2. Check for charge pressure at hydrostatic
pumps, see section 6002

4005-24
ELECTRO-HYDRAULIC SYSTEM
5101 Blade joystick EEPROM read error Turn machine off and restart, if fault reoccurs replace
5102 Blade joystick EEPROM write error joystick
Blade joystick PWM output fault for lift/lowering

5103
function
5104 Blade joystick sensor fault for lift/lowering function 1. Connectors not mated fully, pins not pushed
5105 Blade joystick PWM output fault for tilting function
rear of connector.
5106 Blade joystick sensor fault for tilting function 2. Water in connectors
Blade joystick PWM output fault for angle control
5107 4. Wiring or sensor circuits shorted
function
5. Failed Control Module
5108 Blade joystick sensor fault for angle control function
Turn machine off and restart, if fault reoccurs replace

5109 Blade joystick EEPROM write error
joystick
5110 Blade joystick memory fault No information at time of print.
5111 Ripper joystick EEPROM read error Turn machine off and restart, if fault reoccurs replace
5112 Ripper joystick EEPROM write error joystick.

Ripper joystick PWM output fault for lift/lowering into connector fully, bent pin or broken wire at
5113
function
rear of connector.
2. Water in connectors
5114 Ripper joystick sensor fault for lift/lowering function 4. Wiring or sensor circuits shorted
Turn machine off and restart, if fault reoccurs replace
5115 Blade joystick memory fault
joystick.

4005-25
EST Fault Retrieval for 7. After five seconds the main menu appears on the
monitor as shown below.
Electro-Hydraulic System
1. Connect the EST to the diagnostic connector.
2. Start the EST software and select the dozer type
you are currently working on.
3. Select the blade/ripper joystick option.
4. Change to the configuration page by pressing
button (1).
BS07B025
8. Enter the error menu by pressing 3.

9. On the error menu selection 1, STATUS, the
1
current error status can be retrieved from the
2 joysticks.
10. On the error menu selection 2, CLEAR, the
errors can be cleared form the joysticks.
11. Press 1 to get a complete error list, if a ripper
joystick is connected, the blade joystick will now
download the saved error from the ripper joystick
BS07B023
which will take a couple of seconds.
5. After entering the configuration page the joystick
is shown in the item selection box. Select the 12. If no ripper is on the machine the display will
joystick and press the “Configure Selected Item” read, RIPPER NOT FOUND, press 0 to continue.
(2).
13. If a ripper is installed on the machine the EST will
6. An emulation of the Rexroth BB3 will appear on automatically move to the joystick.
the monitor.
14. An ERROR STATUS screen will be displayed.
15. There are two entry types ACTIVE ERRORS and
PASSIVE ERRORS.
16. ACTIVE ERRORS are fault which are not
resolved in the system.
17. PASSIVE ERRORS are faults which are
resolved in the system and are stored for
analyses.
18. Errors will include the error code, CODE, number
of occurrences, OCC, and timestamp when the
error was last detected, TIME.
BS07B024
NOTE: Fault code cross reference from EST faults to
instrument cluster electro-hydrualic system faults.
EST AIC EST AIC

1-4 5103 29 - 31 5109
5-7 5104 32 and 33 5101
8 - 11 5105 34 and 35 5111
12 - 14 5106 36 and 37 5102
15 - 18 5107 38 and 39 5112
19 - 21 5108 40 5110
22 - 25 5113 41 5115
26 - 28 5114

4005-26
INSTRUMENT CLUSTER FAULT CODES
9129 CAN timed out during operation If error is permanent or repeats often, check CAN
wiring harness and connections on the CAN bus
9130 CAN timed out during operation circuits.

SECTION INDEX
TRACK

Inspection of Track System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5502
Sealed and Lubricated Track (SALT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5504
Track Frame and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5506
Idler, Track Adjuster, and Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5508
Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5509
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5511

5502
Section
5502
INSPECTION OF TRACK SYSTEM COMPONENTS

5502-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Impact and Low Impact Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PIN AND BUSHING WEAR FOR NEW HOLLAND LUBRICATED TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
New Holland Advanced Track Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRACK LINK WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRACK SHOE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRACK AND CARRIER ROLLER WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IDLER WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WEAR CHART FOR INTERNAL PIN AND BUSHING WEAR
(PITCH EXTENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WEAR CHART FOR FLOATING BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WEAR CHART FOR VERTICAL BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WEAR CHART FOR TRACK LINK WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WEAR CHART FOR TRACK SHOE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WEAR CHART FOR TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WEAR CHART FOR CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WEAR CHART FOR IDLER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5502-3
SPECIAL TOOL
B4007091
CAS-1950A MEASURING TOOLS KIT

5502-4
INTRODUCTION
The purpose of this section is to help you measure The remainder of the track system components are
the wear of track system components, and to the same for the New Holland Sealed and Lubricated
understand the cause of the wear. Track and New Holland Advanced Track Life.
Also, by measuring wear and using the charts in this
section you will be able to determine the remaining High Impact and Low Impact
life of many of the components. Conditions
Three types of track systems are used on this To determine if the machine is being used in a low or
machine: high impact working condition, see the following
1. New Holland Sealed and Lubricated Track definitions.
(SALT) which is assembled with oil. Seals are A low impact condition is when the bar(s) on the track
installed at each end of the bushings to keep the shoe completely engage the ground and the ground
lubricant in the bushing. is free of bumps.
A high impact condition is when the bar(s) on the
track shoe do not completely engage the ground and
there is constant contact with rocks or large
irregularities.
4
2
3
B900616
1. PLUG 3. BUSHING
2. PIN 4. LUBRICANT
2. New Holland Advanced Track Life (ATL) is a

sealed and lubricated track and incorporates a
large diameter bushing that is free to rotate on
the standard track bushing. This allows wear to
be distributed over the entire circumference of
the bushing and because it is free to rotate, it
does not create the scrubbing wear between the
sprocket and the bushing as the conventional
track does.
4 2
3 1 5
BS96A027
1. BUSHING 4. RUBBER PLUG

2. LUBRICANT 5. ROTATING BUSHING
3. PIN

5502-5
PIN AND BUSHING WEAR FOR NEW HOLLAND LUBRICATED TRACK

Because the lubricant in the bushing decreases wear Internal wear of the bushing will occur when the
on the ID of the bushings and the OD of the pin to a lubricant has been lost. Dry bushings will feel warm.
minimum amount, the track pitch does not increase
One of two methods can be used to measure the
to cause faster wear on the OD of the bushings.
wear of the bushings. Both are shown.
As the bushings move around the sprocket, wear
Use the small caliper and measure the wear on the
occurs on the OD of the bushings. The wear occurs
front and rear of a bushing as shown. Make several
on the front and rear of the bushings. The faster the
measurements across the worn area to find the most
speed of the machine and excessive use of reverse,
wear. Make sure that the bushing is clean and that
the faster the wear of the bushings.
the caliper is 90 degrees to the bushing. Record the
Rapid wear of the bushings is caused by operating measurements on the Track Component Appraisal
the machine when the tracks are too tight. The tight Form. Measure two more bushings at 0.9 to 1.2 M (3
track chain increases the pressure between the to 4 feet) intervals and record the measurements on
bushings and sprocket teeth which causes more the Track Component Appraisal Form. See chart on
friction and rapid wear on the bushing OD. Tight Page 13 to find the percent wear.
tracks are caused by wrong adjustment and mud or
other debris filling the sprocket teeth.
To help prevent wear caused by tight tracks, adjust
the deflection of the track according to instructions in
Section 5504. Remember, if the sprocket teeth are 1 1
filled with mud or other debris, adjust the track
deflection without cleaning the sprocket teeth.
Vertical wear of the bushings is caused by changing
directions. Each time the machine changes direction 2
the bushings slide across the bottom of the teeth
before touching the forward or reverse drive side of B900594
the sprocket teeth. Another cause of vertical wear is 1. FORWARD OR REVERSE WEAR 2. VERTICAL WEAR
track chains that are too tight because the track
Use the depth gauge to measure the vertical wear of
chain is not adjusted correctly or because of packing.
a bushing as shown. Make several measurements
across the worn area to find the most wear. Make
sure that the bushing and track shoe are clean and
that the depth gauge is perpendicular to the track
shoe. Measure two more bushings at 0.9 to 1.2 M (3
to 4 feet) intervals and record the measurements.
See the chart on Page 13 to find the percent of wear.

5502-6
New Holland Advanced Track Life Use the small caliper and measure the wear on the
bushing. Make several measurements across the
bushing area to find the most wear. Make sure that
the bushing is clean and that the caliper is 90
degrees to the bushing. Measure two more bushings
at 0.9 to 1.2 M (3 to 4 feet) intervals and record the
measurements. See chart on Page 14 to find the
percent wear.
BS98G005
This system uses lubricated track with a large

diameter bushing that is free to rotate on the
standard bushing. This allows wear to be distributed
over the entire circumference of the outer bushing.
Because the bushing is free to rotate, it does not
create the scrubbing action between the sprocket
and bushing as the conventional crawler track chain
does. The service life has up to doubled with this
design and is recommended for HIGH ABRASIVE
AND LOW IMPACT applications where bushing and
sprocket wear may be severe.

5502-7
TRACK LINK WEAR

The only wear that can be measured is wear of the Shown below is wear on the side of the rail. This
rail (top) on the track links. This wear is caused by wear occurs because of contact with the flanges on
the rolling and sliding contact with the track and the rollers and the idler. This wear will occur faster
carrier rollers and the idler. Other causes of wear are during side hill operation, turning, and with increased
speed, a tight track chain, track shoe width, the work track pitch which makes the track flexible.
environment and increased track pitch.
To measure the height of the track links (wear of rail),
assemble the rulers in the CAS-1950A kit. Make sure
that the rail and the bottom of the track shoe are
clean. Make the measurement in the areas shown in
the illustration at the bottom of this column. Make
sure that the vertical ruler is at 90 degrees to the
track shoe. Record the smallest measurement.
Measure two more track links at 0.9 to 1.2 M (3 to 4
feet) intervals and record the measurements. See B900598
the chart on Page 16 to find the percent of wear. Shown below is wear on the top of the boss for the
pin. This wear is caused by the flanges on the track
links and the decreased diameter of the track rollers.
This is the result of bad maintenance and track
system management.
B900596
Shown below is uneven wear on the rail. Wear over

the pins will occur faster because of the narrow width
of the rail and contact with the rollers. This wear can B900599
also be caused by working on an uneven surface Shown below is wear on the inside of the track link.
(rocks) which can cause the track rail to hit the This wear is caused by contact with the tips of the
roller(s). sprocket teeth. This wear occurs because the
sprocket is not aligned with the track and rear track
The wear in the center of the rail is caused by contact
roller, increased track pitch which makes the track
with the idler and carrier and track rollers.
flexible, side hill operation and wide track shoes.
B900597
B900600

5502-8
Shown below is a cracked track link. The most
probable cause of cracks is using track shoes that
are too wide and are carrying the weight of the
machine near the ends of the track shoes.
B900601
TRACK SHOE WEAR

The only wear that can be measured is the wear of Shown below is a cracked grouser and a broken
the grouser on the track shoe. This wear is normal. corner on the track shoe. This is caused by using
track shoes that are too wide for use on rough
To measure the height of the grouser, use the track
terrain.
adjuster to tighten the track chain. Use the depth
gauge in the CAS-1950A kit to measure the height of
the grouser 1/3 of the way from the end of the track
shoe as shown. Record the measurement. See the
chart on Page 17 to find the percent of wear.
B900613
Shown below are worn bolt holes in a track shoe.

This is caused by loose bolts. Make sure that the
bolts are tightened to the specified torque.
BS97N008
Shown below are worn or broken corners on the

ends of the grouser. This is caused by working on
rough terrain.
B900614
B900612

5502-9
TRACK AND CARRIER ROLLER WEAR

The only wear that can be measured is wear on the If the outer track rollers have excessive wear
treads of the roller. This wear is normal and occurs compared to the inner rollers, rotate rollers as shown.
as the track links move under or over the rollers. The
Seven rollers.
front and rear track roller wear faster than the track
rollers between them. Measure the middle track
rollers first and more often. The reason for this is that
when the middle rollers are 40% worn, it is
recommended that the track rollers be rotated to
increase the life of all the track rollers.
If equipped with track guides (rock guards) loosen
and remove the cap screws that hold the track
guides and remove the track guides. It is important to
measure both treads for an accurate indication of
wear. When installing the track guides, apply Loctite
242 to the threads on the cap screws.
Use the large caliper from the CAS-1950A kit and
measure both treads as shown. Make sure that the BS07K601
treads are clean. Measure at the center of the treads Eight rollers.
because this is the area of the most wear. Record the
measurements. See the chart on Pages 18 or 19 to
find the percent of wear.
B900602
BS07K602
Shown below is normal tread wear.
B900604

5502-10
Shown below is wear on the side of the flanges. This Shown below are flat areas on the treads of a carrier
wear is caused by side hill operation, extended track roller. This wear is caused by the track links sliding
pitch which makes the track flexible, the front and on the tread because the roller does not rotate. The
rear track rollers not aligned with the idler and same wear can occur on the track rollers. Keep the
sprocket, and the carrier roller not aligned with the area around the rollers clean to prevent this wear.
track.
B900607
B900605
Shown below is wear on the OD of the flanges. This

wear is caused by wear on the rail on the track links
and wear on the tread of the roller which causes the
flanges to touch the bosses for the pins in the track
links. This is the result of bad maintenance and track
system management.
B900606

5502-11
IDLER WEAR
The only wear measured on the idler is the tread Shown below is wear on the side of the flange. This
wear. This wear is normal and is caused by the track wear is caused by side hill operation, extended track
links moving around the idler. pitch which makes the track flexible and the carrier
roller not aligned with the track. Check the idler
Use the depth gauge to measure tread wear as
alignment according to instructions in Section 5508.
shown. Make sure that the treads are clean. Measure
at the center of the treads because this is the area of
the most wear. Record the measurements. See the
chart on Page 20 to find the percent of wear.
B900609
Wear on the OD of the flange is caused by packing

between the track links and packing behind the idler
roller. This wear is of little importance except when
B900608 measuring tread wear.
B900610

5502-12
WEAR CHART FOR INTERNAL PIN AND BUSHING WEAR

(PITCH EXTENSION)
For sealed track with 190 mm (7.48 in) pitch.
Measured across 5 pins
Length Measurement
Percent Worn
mm Inches
761.23 29.97 0
762.25 30.01 10
763.27 30.05 20
764.28 30.09 30
765.30 30.13 40
766.31 30.17 50
767.58 30.22 60
768.85 30.27 70
770.38 30.33 80
772.16 30.40 90
773.93 30.47 100**
** Turn pins and bushings before this point. It is
recommended the pins and bushings be replaced if
the wear exceeds this point.
BS97N004
NOTE: Do not turn pins on ATL track, this should only be done on sealed track pins.

5502-13
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR

For New Holland sealed and lubricated track with 190 mm (7.48 in) pitch.
Caliper Measurement Percent Worn

mm Inches High Impact* Low Impact*
65.00 2.56 0 0
64.26 2.53 12 10
63.50 2.50 27 20
62.99 2.48 37 30
62.23 2.45 50 40
61.72 2.43 60 50
60.96 2.40 74 60
59.94 2.36 88 70
59.18 2.33 100** 80
57.40 2.26 108 90
55.62 2.19 120 100**
* A Low Impact condition is when the grousers on the track shoe
completely engage the ground and the ground is free of bumps.
* A High Impact condition is when the grousers on the track
shoe do not completely engage the ground and there is
constant contact with rocks or large irregularities.
BS97N001

5502-14
WEAR CHART FOR FLOATING BUSHING

For advanced track life with 190 mm (7.48 in) pitch chain.
Caliper Measurement Percent Worn Percent Worn

mm Inches Low Impact High Impact
MM (INCH) PERCENT WORN PERCENT WORN
85.60 3.37 0 0
85.09 3.35 4 7
84.58 3.33 9 14
84.07 3.31 13 20
83.56 3.29 17 27
83.05 3.27 22 34
82.55 3.25 27 41
82.04 3.23 33 49
81.52 3.21 38 56
81.02 3.19 43 64
80.51 3.17 48 70
80.01 3.15 52 76
79.50 3.13 57 80
78.99 3.11 62 84
78.48 3.09 67 88
77.97 3.07 72 93
77.47 3.05 78 96
76.96 3.03 84 100
76.45 3.01 92 103
75.94 2.99 96 106
75.43 2.97 100 110
BS98G005

5502-15
WEAR CHART FOR VERTICAL BUSHING WEAR

For New Holland sealed and lubricated track with 190 mm (7.48 in) pitch.
Depth Gauge
Percent Worn
Measurement
mm Inches High Impact* Low Impact*
80.60 3.17 0 0
79.75 3.14 12 10
78.99 3.11 27 20
78.48 3.09 37 30
77.72 3.06 50 40
77.21 3.04 60 50
76.45 3.01 74 60
75.43 2.97 88 70
74.67 2.94 100** 80
72.89 2.87 108 90
71.12 2.80 120 100**
BS97N002

5502-16
WEAR CHART FOR TRACK LINK WEAR

For track with 190 mm (7.48 in) pitch.
Depth Gauge
Measurement Percent Worn
mm Inches
119.0 4.685 0
118.5 4.665 7
118.0 4.645 14
117.5 4.625 21
117.0 4.605 27
116.5 4.585 33
116.0 4.565 39
115.4 4.545 45
114.9 4.525 50
114.4 4.505 55
113.9 4.485 60
113.4 4.465 65
112.9 4.445 70
112.4 4.425 75
111.9 4.405 79
111.4 4.385 83
110.9 4.365 87
110.4 4.345 91
109.9 4.325 94
109.3 4.305 97
108.8 4.285 100
BS97N003

5502-17
WEAR CHART FOR TRACK SHOE WEAR
Depth Gauge
mm Inch
55.5 2.18 0
54.2 2.13 4
53.1 2.09 8
51.9 2.04 12
50.7 1.99 16
49.5 1.94 20
48.3 1.90 24
47.1 1.85 28
45.9 1.80 32
44.7 1.75 36
43.5 1.71 40
42.3 1.66 44
41.0 1.61 48
39.8 1.56 52
38.6 1.51 56
37.4 1.47 60
35.0 1.37 68
32.6 1.28 76
30.2 1.18 84
27.8 1.09 92
25.40 1.00 100
BS97N008

5502-18
WEAR CHART FOR TRACK ROLLER
Caliper Measurement
Percent Worn
mm Inches
203.00 8.00 0
202.20 7.96 6
201.40 7.92 12
200.60 7.89 18
199.80 7.86 24
199.40 7.85 28
198.60 7.81 34
197.80 7.78 40
197.00 7.75 44
196.20 7.72 49
195.40 7.69 54
194.60 7.66 58
193.80 7.62 62
193.00 7.59 67
192.20 7.56 71
191.40 7.53 76
190.60 7.50 80
190.20 7.48 83
189.40 7.45 87
189.00 7.44 90
187.80 7.39 93
187.00 7.36 97
186.20 7.33 100
BS97N005

5502-19
WEAR CHART FOR CARRIER ROLLER
Caliper Measurement
Percent Worn
mm Inches
171.50 6.75 0
170.70 6.72 8
170.30 6.70 12
169.90 6.68 16
169.50 6.67 20
168.70 6.64 28
168.30 6.62 33
167.90 6.61 37
167.50 6.59 41
167.10 6.57 45
166.30 6.54 52
165.90 6.53 55
165.50 6.51 58
165.10 6.49 61
164.30 6.46 66
163.50 6.43 72
163.10 6.42 75
162.70 6.40 78
162.30 6.38 81
161.50 6.35 86
160.70 6.32 92
158.60 6.24 94
157310 6.18 96
156.30 6.15 98
155.50 6.12 100
BS97N006

5502-20
WEAR CHART FOR IDLER WHEEL
Depth Gauge
mm Inch
19.00 0.75 0
19.40 0.76 8
19.90 0.78 16
20.40 0.80 23
20.90 0.82 30
21.40 0.84 37
21.90 0.86 44
22.40 0.88 50
22.90 0.90 56
23.40 0.92 62
23.90 0.94 68
24.40 0.96 74
24.90 0.98 80
25.40 1.00 85
25.90 1.02 90
26.40 1.04 95
26.90 1.06 100
BS97N007

Section
5504
5504
NEW HOLLAND SEALED AND LUBRICATED TRACK
(SALT)

5504-2
TABLE OF CONTENTS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
When to Turn the Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing to Turn the Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing the Track Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Usage Guide for Pins, Bushings, Spacers, Links, and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRACK CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5504-3
SPECIFICATION
Torque
Master link bolts.............................................................................................652 to 720 Nm (481 to 531 pound feet)
Standard link shoe bolts ................................................................................652 to 720 Nm (481 to 531 pound feet)
Track Adjustment
Track deflection ........................................................................................................38 to 50 mm (1-1/2 to 2 inches)
Lubricant
Lubricant .............................................................. 35 ± 2.5 CC of New Holland AMBRA Hypoide 90 gear lubricant
Special Tools
B614342M-01
The nozzle shown MUST be used when lubricating

New Holland Sealed and Lubricated Track. The use
of any other nozzle will damage the seal in the rubber
plug. The part number of the nozzle is CAS10762-1.
B866034U-01
The lubricator uses a vacuum function to make sure

that the seals are seated, and a pressure system to
fill the reservoir in the track pins. The part number of
the lubricator is CAS10762 B616311M-01
The tools shown are used to install the plug in each

track pin. The part number is CAS1851.

5504-4
B614336M-01
The brush must be used to clean the bore of all pins B614340M-01
that are to be used for a wet turn. The part number of The wood drill shown is used to remove the plug from
the brush is CAS1853. the track pins. The drill is 12.5 mm (1/2 inch) in
diameter. Buy the wood drill at a local store.

5504-5
Track Adjustment 4. If the deflection is not correct, remove the cap at

the front of the track adjuster.
Tracks that are too tight will cause increased track
and sprocket wear, increased fuel consumption and
decreased power. Use the following procedure to 5. To tighten the track:
adjust the track. A. Add grease to the track adjuster to decrease
1. Do not clean the track. Adjust the track tension the deflection of the track.
for the ground conditions in which you will be
working. If you are working in mud, adjust with
mud on the tracks.
2. Drive the machine forward the length of the
machine and stop the machine with a pin over
the front carrier roller. Do not use the brakes to
stop the machine.
BD02H015-01
B. When the deflection is correct, install the cap.

6. To loosen the track:
A. Loosen the valve in the track adjuster two
turns only, with a socket to allow grease to
flow from the track adjuster.
BD02H010-01
3. Put a straightedge over the track and measure

the track deflection. The measurement must be
38 to 51 mm (1-1/2 to 2 inches).
BD02H016-01
B. When the deflection is correct, tighten the

valve to 61 to 74 Nm (45 to 55 pound-feet).
Install the cap.
BD02H013-01

5504-6
6
5
14
3
4 10
13
11 12
7
BC00C0031
1. MASTER LINK, PIN HALF 6. MASTER LINK, BUSHING HALF 11. SPACER
2. SPACER 7. SEAL 12. BOLT
3. SEAL 8. PIN 13. TRACK SHOE
4. BUSHING 9. PLUG 14. MASTER LINK BOLT
5. LINK 10. NUT
MASTER LINK WITH TWO BOLTS IN EACH HALF

5504-7
TRACK
Removal STEP 4
STEP 1
B614434M-01
Put blocks under the track at the rear of the machine

BD02H011-01
to hold the bottom part of the track and prevent injury
1. MASTER LINK when the master link is separated.
Park the machine on a level surface and stop the
machine so that the master link is centered on the STEP 5
rear of the sprocket.
STEP 2
B614434M-01
Loosen all bolts that hold the track shoe and remove
three bolts.
BD02H016-01 STEP 6
Loosen the valve in the track adjuster two turns only,
so that the track can be loosened.
STEP 3
Use the weight of your body on the track between the
idler and carrier roller, or use a jack or hoist in the
same area to loosen the track.
B614444M-01
Hold the track shoe and remove the last bolt and
remove the track shoe.

5504-8
STEP 7 Installation
STEP 14
FRONT OF MACHINE
866L95
Put the track under the track rollers so that the track
shoes are in the position shown.
STEP 15
B94040108-01
Make sure that the track chain mounting surface and
Use a pry bar to completely separate the halves of the track shoe mounting surface are free of dirt and
the master link. rust. Use 36 grit sandpaper to clean the mounting
surfaces.
STEP 8
Fasten acceptable lifting equipment to the bottom STEP 16
part of the track. Carefully lower the machine onto the track, making
sure that the teeth on the sprocket engage the track
STEP 9 links.
Remove the blocks and lower the track to the floor.
STEP 17
STEP 10 Use the lifting equipment to carry the track over the
Fasten acceptable lifting equipment to the top of the idler and the carrier roller and onto the sprocket.
track and carry the track to the front of the machine
and lower the track to the floor. STEP 18
Use the lifting equipment to raise the bottom part of
STEP 11 the track and use the blocks to hold the track in place
Use acceptable lifting equipment to raise the as during removal
machine until the track rollers are free of the track.
STEP 19
STEP 12
Use acceptable supports to hold the machine in
place.
STEP 13
Remove the track from under the machine.
B9400108M-01
Use a pry bar to put the top link in position on the

bottom link.

5504-9
STEP 20 STEP 22
3 2
1 4
BS07K438
B94040106M-01 Apply Loctite 242 to the bolts. Start and snug bolts 2
Put the track shoe in position on the master link. and 3 to the track shoe, thread the remaining master
Install the top bolts to hold the track shoe in place. link bolts to the track shoe.
STEP 21 STEP 23
Tighten the bolts as shown until the mating surfaces
of the master links contact each other. Gradually
tighten the master link bolts to 652 to 720 Nm (481 to
531 pound-feet). Do not over tighten the bolts.
STEP 24
Tap each bolt and the track shoe with a brass or lead
hammer to assure the joint is seated. Check the
torque on the bolts.
STEP 25
Adjust the track according to the instructions in this
B94040110M-01 section.
Start the bottom bolts into the master link. Tighten
the top bolts to pull the halves of the master link
together.

5504-10
When to Turn the Bushings

Because there is less internal wear of the bushings
and external wear of the pins with New Holland
Sealed and Lubricated Track, measuring the
increase of track pitch IS NOT the correct way to
learn if the bushings need to be turned.
The correct way to learn if the bushings need to be
turned is to measure the outside diameter of several
bushings.
It is recommended that the bushings be turned
before wear is more than 100%.
The outside diameter of a new bushing is 62.0 mm B614306M-01
(2.44 inches). The minimum (time to turn) outside 3. Clean the track chain using high pressure water
diameter is 55.88mm (2.20 inches) for low impact or steam. If a wet turn is to be made, the track
applications and 57.15 mm (2.75 inches) for high chain must be clean.
impact applications.
4. With the track shoe surface down, make a mark
on a top of each bushing. This will help you to
Preparing to Turn the Bushings turn the bushings the correct amount when the
track chain is assembled.
General Information
5. With the track shoe surface up, make mark at
1. A wet turn can be made when pins, bushings and one end of each pin at the top. This will help you
seal are in condition to be used again to make a install the pins correctly when the track is
sealed and lubricated joint. assembled.
2. A dry turn can be made when pins, bushings and
seals are in condition to be used again but not
good enough to make a sealed joint. Lubricant is
not added after assembly.
3. Check to see how many joints do not show
leakage. A joint that shows leakage can be
assembled only as a dry turn if new parts are not
used.
Preparing the Track Chain

1. Loosen and remove the bolts, nuts and track
shoes.
2. If a wet turn is to be made, use a 12.5 mm (1/2
inch) wood drill and a low RPM electric drill and
remove the plugs from the pins. The plugs can
also be removed as shown after the track has
been disassembled.

5504-11
Usage Guide for Pins, Bushings, Spacers, Links, and Seals

The following information will help you to make a
judgment as to whether track assembly will make a
wet turn or a dry turn.
A wet turn is made when pins, bushings and seals
are in condition to be used again to make a sealed
and lubricated joint.
A dry turn is made when pins, bushings and seals
are in condition to be used again, but not good
enough to make a sealed joint. Lubricant is not
added after assembly.
Pins
865386M
3. The pin shown has a tapered end. This pin can

be used again after a new chamfer is made on
the end of the pin. The pin must have a chamfer
to prevent damage to the bore in the link.
B860749J
1. The pin shown has a large area of metal

removed from the surface of the pin. A pin like
this MUST NOT be used again.
B860750J
4. The pin shown has a wear ridge. This pin can

only be used for a dry turn. When installing a pin
like this, turn the pin end for end. The supply hole
must be toward the link rail when the pin is
installed.
B865379M
2. The pin shown has grooves in the circumference

of the pin. A pin like this can be used for a wet or
dry turn.

5504-12
Bushings
B865384M
5. The pin shown has a closed supply hole. The pin

B865388M
can be used for a wet or dry turn. If used for a
wet turn, the supply hole and reservoir must be 1. CRACK
clean. Use a wire brush and an electric drill to 1. The bushing shown has a crack in the OD. A
clean the reservoir. bushing with a crack in the OD can only be used
for a dry turn. A crack in the ID that does not go
all the way can be used for a wet or dry turn.
B865383M
B604126M
2. The bushing shown has a seal wear pattern that

is not centered on the end of the bushing. This
busing CANNOT be used for a wet turn. The
bushing can be used for a dry turn.
B865382M
The pins show rust, pitting and discoloration. Each

pin can be used for a wet or dry turn. Pins with rust
must have the rust removed.

5504-13
5. The bushing shown has a groove that is not even
all the way around the bushing. If this bushing
came from a wet joint, the bushing can be used
for a wet turn. If this bushing came from a dry
joint, the bushing can only be used for a dry turn.
2
1
1
B865389M
1. PITTING
3. The bushing shown has pitting in the area 1
between the seal and the spacer. If the pitting is
B865390M
not deep, the bushing can be used for a wet turn.
1. WIDE GROOVE 2. NARROW GROOVE
6. A bushing that has deep pitting or scratches in
the area between the spacer and seal can only
be used for a dry turn.
7. A bushing that has pitting in the bore, if the
pitting is not deep, the bushing can be used for a
wet turn. If the pitting is deep, the bushing can
only be used for a dry turn.
1
B865388M
1. CRACK
4. The bushing shown has a fine crack in the area
between the seal and the spacer. This bushing
can be used for a wet or dry turn. A bushing with
two or more fine cracks or one large and rough
crack can only be used for a dry turn.
B865375M
8. The bushing shown has rust in the bore. This

bushing can only be used for a dry turn. Use a
wire brush and electric drill and remove the rust.

5504-14
Spacers Links
1. Spacers that are cracked or have large areas of
metal missing near the end(s) and on the OD or
ID cannot be used again.
B865378M
1. The link shows wear in the area of the spacer.

This wear is acceptable. If the link is to be used
B865376M for a wet turn, use a wire brush and an electric
1.LUBRICATION NOTCH drill and remove the rust and dirt from the bore
2. A spacer must have a lubrication notch on each for the seal.
end to be acceptable for use in a wet turn. A
spacer with one lubrication notch can be used for Seals
a dry turn. A spacer without lubrication notches
must be discarded. 1. A seal removed from a wet joint can be used
again for a wet turn.
2. A seal removed from a dry joint can only be used
1 for a dry turn.
B865387M
1. PITTING 2. GROOVES
3. The spacer shown has pitting and grooves.
B e c a u s e t he s p ac e r has both lubrication
notches, the spacer can be used for a wet turn.
The spacer is acceptable for a dry turn.

5504-15
TRACK CHAIN
Disassembly 5. Actuate the other ram and press the pin out of
the other link.
NOTE: The following procedures are for reference only.
1. Install the carrier and driver needed to
disassemble the track chain.
B604120M-01
6. Retract the ram and remove the link from the

driver and the pin from the bushing.
B604112M-01 7. Move the track chain forward one bushing.
2. Put the track chain on the table so that the track
shoe surface is up and pin half of the master link 8. Actuate one of the rams to press the pin and
will be the first link disassembled. bushing out of a link.
IMPORTANT: Before pressing a bushing and pin out of

the link, make sure that the drivers are aligned with the pin
and bushing to prevent damage to the bores in the link.
3. Put the bushing in the first notch in the carrier
and actuate one of the rams to press that pin out
of a link.
B604112M-01

driver.
B604116M-01

driver.

5504-16
10. Actuate the other ram to press the pin and C. Put the guide (CAS1851-1 or CAS1851-2) on
bushing out of the other link. the end of the pin and lubricate the bore of the
guide.
B604124M-01
11. Retract the ram and remove the link from the B616316M-01
driver and the pin from the bushing. D. Use the driver CAS1851 and drive the plug
into the pin. The plug must be approximately
12. Repeat steps 7 through 11 until the track chain is
10 mm (0.39 inch) below the end of the pin.
disassembled.
5. Make sure that there is a good chamfer on both
13. Remove the spacers from the pins and seals.
ends of all the pins so that metal will not be
14. Remove the seals and rubber rings from the removed from the bores in the links when the
links. links are pressed onto the pins.
15. Clean all parts in cleaning solvent. 6. The first link assembly to be assembled is the
bushing half of the master link.
16. Use a wire brush and clean the seal bore in each
link. 7. Install a bushing in the far notch. If the bushings
are being turned, put the bushing in the carrier so
17. Use a wire brush and clean the reservoir in each
that the mark made before disassembly is on
pin.
top.
See Usage Guide for Pins and Bushings.
8. Install a link half on one of the drivers and
actuate the ram to hold the link half against the
Assembly carrier.
IMPORTANT: If a wet turn is being made, the parts of the 9. Install the other link half on the other driver and
track must be clean. actuate the other ram until the link half touches
1. Remove the drivers used for disassembly and the bushing. Check to make sure that the parts
install the drivers used to assemble the track are even with each other.
chain. The same carrier is used.
2. Use a straightedge and measure the offset of the
drivers. The offset of the drivers must be 36.8
mm (1.449 inches). Add or remove shims
between the long driver and base as required.
3. Adjust the relief valve for the track press to 40
539 kn (119.250 psi).
4. If a wet turn is being made, install a new plug in
each pin.
A. Make sure that the bore in the pin is clean and
free of any lubricant.
B604140M-01
B. Lubricate the bore in the pin with Loctite
10. Actuate the ram to press the bushings into both
Safety Solvent or water and soap.
link halves.

5504-17
11. Measure the bushing projection at both ends of
the bushing. If the measurement is not 3.95 mm
(0.156 inch) add or remove shims between the
long driver and base as required.
B604206M-01
15. Apply sealant from the kit to the outer half of the
bore for the pin in two links. The bore for the seal
must be free of any foreign material.
B604142M-01
16. Make sure that the bores for the rubber ring and
12. Use the gauge and pin to check the spacing of
seal are free of oil and install a rubber ring and
the link halves.
seal in both links.
17. Put the links on the drivers and a bushing in the
carrier so that the mark is on top.
B604202M-01
13. Check to make sure the link halves are level.

14. Install a pin in the bushing so that the mark is on
B604208M-01
top. The remainder of the pins must be installed
18. Hold the master link level and actuate the rams
so that the plugs are all on the same side. Apply
until the drivers touch the links.
Molykote Type G to both ends of two spacers
according to the instructions on the container.
Then install spacers on both ends of the pin.
B604212M-01
19. Press the links onto the pin and bushing.

5504-18
C. Push the nozzle all the way into the plug.
D. Push down and hold the vacuum button until
the gauge reads 68 to 91 kPa (20 to 27
inches) vacuum.
E. Release the vacuum button. The reading must
not decrease for a minimum or 5 seconds.
F. If the joint will not hold the vacuum for 5
seconds, push down and hold the vacuum
button for a long time to see if the joint will
hold vacuum as specified.
G. Before disassembling the links, use a pry bar
B604215M-01
and move the link in both directions to seat the
20. Use the gauge and pin to check the spacing seal(s). Do the vacuum check again. If the
between the links. joint still does not hold the vacuum, the links
must be removed and the cause found.
21. Measure the bushing projection at each end of
the bushing. The bushing projection must be H. Push down and hold the oil button until gauge
3.95 mm (0.156 inch). reads 551 to 586 kPa (80 to 85 psi) then
release the oil button.
22. If the bushing projection is not as specified, add
or remove shims as required for the long driver. I. After the oil button is released, the reading of
the pressure gauge must be 140 to 205 kPa
23. Repeat steps 14 through 17 and step 19 and (20 to 30 psi).
install the second set of links.
28. Make sure the mounting surfaces on the track
24. Check the end play of the outside links at the pin shoes and track chain are clean and smooth.
joint.
29. Install the track shoes and new nuts and bolts.
A. Use a dial indicator against one of the outside
links or the end of the pin. 30. Tighten the bolts to 652 to 720 Nm (481 to 531
pound feet).
B. Set the dial indicator to 0 (zero).
31. Tighten master link bolts to 652 to 720 Nm (481
C. Use a screwdriver between the inside the to 531 pound feet).
outside link to move the outside link and read
the dial indicator.
D. Check the end play several times to make
sure that the reading is correct.
E. The end play must not be more than 0.13 mm
(0.005 inch). Zero end play is the best, but not
required.
25. If the end play is not as specified, add shims as
required for the short driver.
26. Repeat steps 14 through 17 and step 19 until the
track chain is assembled.
27. As soon as possible, begin to fill the pins with
gear lubricant.
A. Make sure that the nozzle CAS10762-1 is
installed on the tube on the control handle.
B. Prepare the lubrication equipment according
to the instructions of the manufacturer.

Section
5506
TRACK FRAME AND SUSPENSION
5506

5506-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EQUALIZER BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing the Center Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Self-Aligning Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5506-3
SPECIAL TORQUES
Pivot shaft mounting bolts ...........................................................................815 to 1045 Nm (600 to 770 pound-feet)
Equalizer beam bracket to the track frame bolts ...........................................515 to 618 Nm (380 to 456 pound feet)
Pivot shaft retainer plate bolts .......................................................................146 to 180 Nm (107 to 133 pound feet)
Equalizer beam pivot pin retaining bolts........................................................515 to 618 Nm (380 to 456 pound feet)
SPECIAL TOOLS

5506-4
BS06J412
BS06J411
TRACK FRAME ALIGNMENT PLATE 380500002
TRACK ALIGNMENT PLATE AND PIN ASSEMBLY 380500001

5506-5
TRACK FRAME
2
7
3 23
5 6
23
4
8 4
10 4
22
12 11 9
24
14
4 15
16
19 20 21
13 17
24
18
BC05H098
1. EQUALIZER BEAM 9. TRACK FRAME 17. SHIMS

2. EQUALIZER BEAM PIN 10. FRAME 18. RETAINER PLATE
3. EQUALIZER BEAM PIN CAP SCREW 11. PIVOT SHAFT 19. RETAINER PLATE CAP SCREW
4. WASHER 12. CLAMP 20. COVER GASKET
5. MOUNTING BRACKET 13. CLAMP CAP SCREW 21. COVER
6. MOUNTING BRACKET PIN 14. SEAL CLAMP 22. SPACER
7. MOUNTING BRACKET PIN CAP SCREW 15. RETAINER 23. BUSHING
8. BEAM BRACKET CAP SCREW 16. SEAL 24. LUBRICATION PLUG

5506-6
NOTE: If pivot shaft is being replaced do steps 9 through
STEP 1 14, if pivot shaft is not being replaced go to step 15.
Remove the track, see section 5504.
STEP 9
STEP 2 Support the pivot shaft in the frame brackets.
Attach lifting equipment to the track frame (9).
NOTE: The track frame subassembly weighs STEP 10
approximately 950 Kg (2100 pounds).
STEP 3
Remove the cover (21) and gasket (20). 10
STEP 4 22
Loosen and remove cap screws (19).
STEP 5 12
Remove the retainer (18) and shims (17).
STEP 6
BC05K073
Loosen the seal clamp (14) for seal (16).
Place spacers (22) on the front bolts between the
block (12) and the frame (10), hand tighten the bolts
STEP 7
Loosen and remove the cap screws (8) and washers STEP 11
that mount the mounting bracket (5) to the track
frame (9).
STEP 8
Carefully move the track frame from the pivot shaft.
BD05H121
Install the alignment tools, 380500001, to the

sprocket mounting surface on the final drive.

5506-7
STEP 12 STEP 15
BD05H121 BD05H112
Orient a hole in the pivot shaft (11) to the top as Bolt the track frame alignment gauge, 380500002, to
shown. the 3 holes at the rear of the rack frame (9).
STEP 13 STEP 16
BD05H122 BD05H106
Measure the distance on each side of the machine Attach suitable lifting equipment to track frame (9), lift
and center the pivot shaft (11) on the frame (10). and make sure that the track frame will set level
during installation.
NOTE: Center pivot shaft within 1 mm (0.040 inch).
NOTE: The track frame subassembly weighs
STEP 14 approximately 950 Kg (2100 pounds).
STEP 17
1 2
BC05K073
Torque the front pivot shaft mounting bolts (1) first

then the rear mount bolts (2) to 815 to 1045 Nm BD05H123
(600 to 770 pound-feet). Use caution when installing the track frame (9), do
not damage the pivot seal (16).
NOTE: Apply a thin film of grease on the pivot shaft (11)
to help the pivot shaft seal (16) slide over the shaft (11).

5506-8
STEP 18 STEP 22
Install the cap screws (19) and torque to 146 to 180
Nm (107 to 133 pound feet).
STEP 23
BD05H109
Carefully slide the track frame (9) assembly over the

pivot shaft (11).
NOTE: When sliding track frame over the pivot shaft be
careful not to damage the seal (16). BC05H100
Place the cover (21) against the retainer plate (18)

STEP 19 and measure the gap between the cover (21) and the
track frame (9) pivot housing.
STEP 24
Add 0.8 mm (0.030 inch) to this measurement, this
will be the amount of shims that will be required.
NOTE: A minimum of one gasket is required for a proper
seal.
STEP 25
Install required shims, gasket (20), cover (21), and
cap screws onto track frame (9), tighten cap screws.
BD05H108
Slide the track frame over the pivot shaft so the STEP 26
alignment gauge is flush with the sprocket final drive
mounting surface.
STEP 20
24
9
B A
21 24
BC05K074
Remove the lubrication plugs (24). Fill the pivot

housing with grease, pump grease in the hole in the
BD05H107 track frame (9) until grease comes out of the hole in
Measure the distance from the track frame retaining the cover (21).
plate surface (A) to the pivot shaft end (B). NOTE: Exercise caution while greasing to prevent the
seals (16) from being damaged.
STEP 21
Install shims (17) and retainer plate (18).
5506-9
STEP 27 STEP 32
BD05H110
Position alignment tools, 380500001, on the lower

portion of the sprocket mounting surface of the final
drives. Place a straight edge on the tools that is long
enough to reach the front of the track frame (9).
NOTE: The straight edge should be positioned directly in
line with the track rollers shafts.
STEP 28
A
BC05H101
HORIZONTAL MEASUREMENT
NOTE: The views are from the top looking down.
Track frame (9) alignment can be checked after the
BD05H111
unit is assembled. Measure track rollers parallel and
Measure distance from the straight edge to the end diagonal alignment as shown.
of the roller shaft that is located below the equalizer
beam (A). NOTE: Alignment should be within 3 mm (0.12 inch).
STEP 29 STEP 33
Measure distance from the straight edge to the end If parallel alignment is out of tolerance, check
of the roller shaft that is located in front of the alignment of the rear track roller to the sprocket by
equalizer beam (B). projecting a straight edge on each side of the
sprocket to the track roller.
STEP 30
Move the front of the rack frame in or out until the
rollers are parallel within 1.5 mm (0.060 inch).
STEP 31
Torque the cap screws on the equalizer beam
mounting bracket (5) to 515 to 618 Nm
(380 to 456 pound feet) to the track frame (9).

5506-10
STEP 34
To center the roller add or remove shims between
the end of the pivot shaft and retainer.
STEP 35
After rear roller to sprocket alignment is established
re-measure parallel and diagonal alignment.
STEP 36
If frames need adjusted loosen the cap screws (8) on
the bracket (5) and repeat steps 27 through 31.
BC05H102
DIAGONAL MEASUREMENT

5506-11
EQUALIZER BEAM
Removal STEP 42
STEP 37
Remove the track from one side of the machine, see
section 5504.
STEP 38
BD05H115
Remove the hose and elbow from the pivot pin.
STEP 43
BD05H120
Remove the covers from the track frames.
STEP 39
Raise the front of the machine just enough to remove
the weight of the machine from the center pivot for
the equalizer beam.
STEP 40
Block the machine. BD05H114
Remove the cap screws, washers and bushings from

STEP 41 the center pivot pin.
STEP 44
Install the cap screws in the threaded holes in the
center pivot pin retainer plate.
STEP 45
Tighten the cap screws to start the pivot pin out of
the frame.
STEP 46
Remove the pivot pin.
BD05H119
Remove the grease fitting and nut from the hose.

5506-12
STEP 54
Install new seals in the equalizer beam.
STEP 55
Apply clean grease to the pivot pin and the bore of
the self-aligning bearing for the side of the equalizer
that will be mounted into the removed mounting
bracket.
STEP 56
BD05H118 Install the pin, bushing, washer and cap screw into
On the side of the machine that the track was not the mounting bracket and equalizer bar, tighten the
removed, loosen and remove the cap screw, washer cap screw.
and bushing from the pivot pin.
NOTE: Track is shown removed for clarity only. STEP 57
Attach lifting equipment to the equalizer and carefully
STEP 48 place the equalizer in position on the track frames.
Remove the pivot pin from the bracket.
STEP 58
STEP 49 Apply clean grease to the pivot pin and the bore of
the self-aligning bearing for the mounting bracket.
STEP 59
Install the pin, bushing, washer and cap screw into
the mounting bracket and equalizer bar, tighten the
cap screw.
STEP 60
BD05H117
From the side of the machine that the track was
removed, remove the cap screws that mount the
equalizer mounting bracket to the track frame.
STEP 50
Raise the machine enough to allow for clearance to
remove the equalizer beam.
BD05H113
STEP 51
Lower the frame into alignment with the equalizer
Block the machine.
beam.
STEP 52
Attach lifting equipment to the mounting bracket.
STEP 53
Carefully remove the equalizer beam from the
machine.
IMPORTANT: Support the opposite side of the equalizer,
it will fall from the track frame.

5506-13
STEP 61 Replacing the Self-Aligning
Bushing
STEP 71
Remove the snap rings and seals from each side of
the self-aligning bearing.
STEP 72
Remove the snap ring from each side of th e
self-aligning bearing.
STEP 73
BD05H114
Press the self-aligning bearing out of the equalizer.
Install the pivot pin, bushings, washers and cap
screws. Torque the cap screws to 515 to 618 Nm
(380 to 456 pound feet). STEP 74
Clean the bore for the self-aligning bearing.
STEP 62
Connect the grease hose to the center pivot pin. STEP 75
Install a snap ring in one of the grooves in the bore
STEP 63 for the self-aligning bearing.
Check the alignment of the track frames, see track
frame installation this section. STEP 76
Align the fracture (6) within ± 5° on outer bearing
STEP 64 face as shown in illustration on page 13.
Install the guards on the track frames.
STEP 77
STEP 65 Press the bearing into the bore until the self-aligning
bearing touches the snap ring.
Install the track, see section 5504.
STEP 78
STEP 66
Install the other snap ring.
Grease all pivot pins.
STEP 79
Replacing the Center Bushing
Install the seal on each side of the self-aligning
bushing.
STEP 67
Press the bushing and seals out of the equalizer NOTE: The seal must be assembled with rubber side
beam. towards the bearing, metal side to the outside of the beam
assembly.
STEP 68
STEP 80
Clean the bore for the bushing.
Install the outer snap rings.
STEP 69
Press the bushing into the bore of the equalizer
beam until it is 8 mm (0.30 inch) below the side of the
equalizer beam.
STEP 70
Press new seals into the bore so that the lip of the
seal is toward the outside.
NOTE: The seal must be assembled with the metal side
towards the bushing.

5506-14
1
3
2 6
8 7 7
8 8
BC05H099
1. EQUALIZER BEAM 4. BEARING 7. BUSHING

2. SEAL 5. SNAP RING 8. SEAL
3. SNAP RING 6. ORIENTATION OF FRACTURE
EQUALIZER BEAM SEALS AND BUSHINGS

5506-15
NOTES

5506-16

Section
5508
IDLER, TRACK ADJUSTER, AND RECOIL HOUSING
5508

5508-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IDLER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RECOIL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Destroying the Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5508-3
SPECIFICATIONS
Idler Lubricant ...................................................................................................... New Holland AMBRA Hypoide 90
Capacity ..................................................................................................................... 225 mL (8.6 U.S. fluid ounces)
SPECIAL TORQUES
Idler Bracket Springs Preload Bolts.........................................................................................48 Nm (35 pound-feet)
Bolts Securing Track Adjuster to Idler ...........................................................183 to 223 Nm (135 to 165 pound-feet)
Recoil Housing Mounting Bolts......................................................................183 to 223 Nm (135 to 165 pound-feet)
Track Adjuster Valve .............................................................................................61 to 74 Nm (45 to 55 pound-feet)
SPECIAL TOOLS
2
1
3
4
B407315M-01
CAS-1450
8 5
7
6
BC07M404
SEAL INASTALLER, TRACK ROLLER, FABRICATE AT LOCAL
SHOP B407317M-01
CAS-1682
1. 28 MM 5. 70 MM
These tools are used to do the leakage test on the
2. Ø 110.5 MM 6. Ø 102.5 MM
idler.
3. Ø 52.5 MM 7. Ø 83 MM
4. 50 MM 8. 20 MM
The top portion of the tool is made of Teflon, the

bottom portion is made of mild steel.

5508-4
IDLER LEAKAGE TEST

1. Connect the shutoff valve to the pressure 3. Turn the knob counterclockwise to close the
regulator valve. Connect a fitting for the air pressure regulator valve.
supply hose to the shutoff valve.
4. Connect the line from the pressure gauge to the
quick disconnect fitting in the idler wheel.
1 5. Make sure that the shutoff valve is open.

6. Open the pressure regulator valve until the
pressure gauge indicates 172 kPa (25 psi).
7. Use the bracket and turn the shaft three to ten
revolutions.
8. Close the pressure regulator valve until the
pressure gauge indicates 110 kPa (15 psi).
9. Close the shutoff valve. The idler must hold this
2 pressure for 10 seconds. Loss of air pressure
B407320M-01
during this time indicates a bad part or wrong
assembly.
1. SHUT OFF VALVE 2. PRESSURE REGULATOR VALVE
2. Install the adapter fitting in the oil hole in the idler
wheel shaft. Use a seal washer with the adapter.
BD07K184-01

5508-5
IDLER
Removal 8. Remove two nuts (12) and washers (13) from

each bottom wear bar (14) inside the track frame
1. Refer to Section 5504 and remove the track from (27). Remove wear bar, shim(s) (15) and bolts
the idler. (16).
2. Raise the front of the machine to provide
9. Remove two bolts (17) and washers (18) from
clearance between the track links and the idler
each thrust plate (19). Remove thrust plates and
(21).
shim(s) (20). Tag shims for location.
3. Remove four bolts (1) and washers (2). Remove
yoke cover (3). 10. Install bolts (17) in the idler brackets (22).
4. Remove four bolts (4) and washers (5). Remove 11. Connect a lifting sling to the bolts (17) installed in
track adjuster cover (6). Step 10.
5. Remove four bolts (7) and washers (8) securing 12. Connect acceptable lifting equipment to the
the idler (21) to the track adjuster (26). lifting sling.
6. Remove four bolts (9) and washers (10). 13. Slide the idler (21) off the track frame (27).
7. Slide the idler (21) forward on the track frame 14. Retain the wear plates (23), springs (24) and
(27) and remove shims (11). Tag shims for spring seats (25) from the idler bracket (22) for
location. use during installation.
3 9 10
21
6 2 20
1
5 18
11
4 17
26 16
8 19
7
22
25
13
24
12
15
23
14
27
BC05H103
1. BOLT 10. WASHER 19. THRUST PLATE

2. WASHER 11. SHIM(S) 20. SHIM(S)
3. YOKE COVER 12. NUT 21. IDLER
4. BOLT 13. WASHER 22. IDLER BRACKET
5. WASHER 14. WEAR BAR 23. WEAR PLATE
6. TRACK ADJUSTER COVER 15. SHIM(S) 24. SPRING
7. BOLT 16. BOLT 25. SPRING SEAT
8. WASHER 17. BOLT 26. TRACK ADJUSTER
9. BOLT 18. WASHER 27. TRACK FRAME

5508-6
Disassembly STEP 4
STEP 1
Remove all dirt and grease from the idler.
STEP 2
BD07K129-01
Remove the plug from the idler wheel. Drain the oil
from the idler.
STEP 5
BD07K127-01
Fasten acceptable lifting equipment to the idler so

that the idler will be in a horizontal position. Make
sure the drain plug is on the bottom.
STEP 3
BD07K130-01
Place the roller on a work bench.
STEP 6
BD07K128-01
Loosen the drain plug.
BD07K131-01
Loosen the wedge bolt.

5508-7
STEP 7 STEP 10
BD07K132-01 BD07K135-01
Turn the wedge bolt out 3 to 4 turns. Remove the wedge bolt from the wedge.
STEP 8 STEP 11
BD07K133-01 BD07K136-01
Hit the wedge bolt to loosen the wedge. Remove the wedge from the bracket and shaft.
STEP 9 STEP 12
BD07K134-01 BD07K137-01
Loosen the wedge bolt several more turns and push Attach lifting equipment to the bracket.
the wedge to the bottom of the roller.

5508-8
STEP 13 STEP 16
B509838RM BD07K141-01
Remove the bracket from the shaft. Remove the O-ring from the bracket.
STEP 14 STEP 17
BD07K139-01 BD07K142-01
Loosen the seal ring from the O-ring. Remove the seal ring from the O-ring.
STEP 15 STEP 18
BD07K140-01 BD07K143-01
Remove the seal ring from the bracket. Remove the seal ring from the idler wheel.

5508-9
STEP 19 STEP 23
BD07K144-01 BD07K147-01
Remove the O-ring from the idler wheel. Put the idler wheel in a press, press on the shaft to
remove the bushing housing.
STEP 20
STEP 24
BD07K145-01
Remove the O-ring from the shaft. BD07K148-01
Make sure there is enough clearance for the bushing

STEP 21 housing to come out of the idler.
IMPORTANT: The bushing housing and shaft will drop
from the roller, be sure to secure them during removal.
STEP 25
Turn the idler over and repeat steps 23 through 24
and remove the other bushing housing.
BD07K146-01
Loosen and remove the bolts for the bushing

housing.
STEP 22
Turn the idler over and repeat steps 6 through 21 and
remove the other bracket.

5508-10
STEP 26 STEP 29
BD07G176-01 BD07G179-01
Remove the O-ring from the bushing housing. Remove the bushing from the housing.
STEP 27 STEP 30
Repeat steps 26 through 29 and remove the other
bushing from the bushing housing.
Inspection
1. Discard the O-rings. New O-rings must be used
during assembly.
2. Discard the rubber rings and metal rings. New
parts must be used during assembly.
3. Inspect the bushings and the bushing surfaces of
the shaft for scoring, pitting and other damage.
Use new parts as required.Inspect the bushing
BD07G177-01 surfaces on the shaft for scoring, pitting and
Put the bushing housing on blocks on a press, place other damage.
a bushing driver on the bushing.
4. Inspect the bores for the rubber rings in the
brackets and in the idler for damage that will
STEP 28 result in leakage. Use new parts as required.
BD07G178-01
Press the bushing out of the housing.

5508-11
Assembly STEP 34
STEP 31
BD07G183-01
Install a new O-ring on the bushing housing, lubricate

BD07G180-01
the O-ring with clean oil.
Place a new bushing on the bushing housing, align
the hole in the bushing with the pin on the housing. STEP 35
Repeat steps 31 through 34 and assemble the other
STEP 32 bushing housing.
STEP 36
BD07G181-01
Place a driver on the bushing.

BD07K149-01
STEP 33 Clean the inside of the idler, remove any rust from
the mating surfaces.
STEP 37
BD07G182-01
Press the bushing into the bushing housing.

NOTE: Pin should be 0.5 to 1.0 mm (0.020 to 0.040
BD07K150-01
inches) below the bushing surface.
Place the bushing housing on the idler.

5508-12
STEP 38 STEP 41
BD07K151-01 BD07K154-01
Install two long bolts to align the bushing housing Torque the bushing retaining bolts to 40.2 to 47 Nm
with the idler. (30 to 35 pound feet).
STEP 39 STEP 42
Flip the idler over on the press.
STEP 43
BD07K152-01
Place a block on the bushing housing, press the

bushing housing into the idler until flush.
BD07K155-01
STEP 40 Clean the inside of the idler, remove any rust from
the mating surfaces.
STEP 44
BD07K153-01
Remove the two aligning bolts, apply Loctite 242 to

the threads of the bolts, install the retaining bolts for
the bushing housing. B509838RM
Lubricate the bushing surfaces on the shaft with

clean oil, insert the shaft into the idler.

5508-13
STEP 45 STEP 48
BD07K157-01 BD07K160-01
Place the bushing housing on the idler. Remove the two aligning bolts, apply Loctite 242 to
the threads of the bolts, install the retaining bolts for
STEP 46 the bushing housing.
STEP 49
B509901M
Install two long bolts to align the bushing housing

with the idler. BD07K161-01
Torque the bushing retaining bolts to 40.2 to 47 Nm

STEP 47 (30 to 35 pound feet).
STEP 50
BD07K159-01
Place a tube and block on the bushing housing.

BD07K162-01
Mount and zero a dial indicator.

5508-14
STEP 51 STEP 54
BD07K163-01 BD07K166-01
Pull up on the shaft and check end play of the shaft, Clean the O-ring surface area in the bushing
the end play must be between 0.2 to 0.88 MM (0.008 housing.
to 0.035 inch).
STEP 55
STEP 52
BD07K167-01
BD07K164-01 Place the metal ring into the special tool. Push down
Clean the rubber ring and steel seal. on the tool until the rubber ring is seated in the
bushing housing.
STEP 53 NOTE: Use soap and water on the rubber ring to ease
installation.
STEP 56
BD07K165-01
Push the steel seal onto the rubber ring until it is

seated.
BD07K168-01
Make sure the face seal is level in the bushing

housing.

5508-15
STEP 57 STEP 60
BD07K169-01 BD07K172-01
Install a new O-ring on the shaft. Place the metal ring into the special tool. Push down
on the tool until the rubber ring is seated in the
STEP 58 bracket.
NOTE: Use soap and water on the rubber ring to ease
installation.
STEP 61
BD07K170-01
Lubricate the O-ring with clean oil.
STEP 59
BD07K173-01
Make sure the face seal is level in the bracket.
STEP 62
BD07K171-01
Clean the O-ring surface area in the bracket.
BD07K174-01
Measure the bottom side of the wedge.

5508-16
STEP 63 STEP 67
BD07K175-01 BD07K178-01
Measure the top side of the wedge, mark the end Use acceptable lifting equipment and place the
with the smallest measurement. bracket onto the shaft, place a block on the bracket.
STEP 64 STEP 68
BD07K176-01 BD07K179-01
Put the marked end of the wedge towards the top of Press down on the bracket until the notch is centered
the bracket. in the wedge hole.
STEP 65 STEP 69
BD07K177-01 BD07K180-01
Turn the shaft so the notch in the shaft can be seen. Press the wedge into the bracket hole.
STEP 66
Lubricate the face seal surfaces with clean 10W
motor oil.

5508-17
STEP 70 STEP 72
BD07K181-01 BD07K183-01
Start the wedge retaining bolt into the wedge. Fill the idler with 225 mL (8.6 U.S. fluid ounces) of
New Holland AMBRA Hypoide 90.
STEP 71
STEP 73
Rotate the shaft in the idler several times.
STEP 74
Do the leakage test according to the instructions in
this section. Make sure the idler has been assembled
correctly and there are no defects in the metal parts
that will result in leakage.
STEP 75
BD07K182-01
Torque the wedge retaining bolt to 127.5 to 143.5

Install a new O-ring on the plug, install and tighten

the plug.

5508-18
Installation STEP 77
NOTE: Refer to Section 5501 for wear specifications
STEP 76
2
BS07M175
BS07M177
1 After establishing the minimum value, add shims to
the thinner of the two flanges so the the overall
thickness (2) of both flanges is within 1.0 mm
(0.04 inch). The minimum thickness with shims and
wear bar is 38.9 mm (1.53 inches).
STEP 78
BS07M176
Measure the frame thickness with out shims at points

indicated above. The minimum thickness (1) without
shims is 27.8 mm (1.094 inches).
BD07M025-01
There are 4 rubber coated idler support springs on

each idler. The purpose of the spring is to prevent the
idler from bouncing as wear occurs between the
wear bars, idler support hook, and track frame.
STEP 79
The spring should not be compressed more than
7.6 mm (0.30 inch) or damage may occur to the
spring. Use appropriate bolt length and washer
combination to compress springs 3.8 to 6.3 mm
(0.15 to 0.25 inch).

5508-19
STEP 80 STEP 84
BD07M026-01 BD05H131-01
As wear occurs in the filed, washers may be Install the original shim(s) (20), thrust plates (19),
removed from under the bolt head to eliminate washers (18), and bolts (17). Tighten the bolts (17).
bouncing, or longer bolts may be used if required.
STEP 85
STEP 81 E F
F
BC05H105
E. IDLER MUST BE CENTERED IN TRACK FRAME

F. 0.8 MM (1/32 INCH) MAXIMUM CLEARANCE
BD05H127-01
Measure from the center of the idler (21) to the inside
Install three washers (10) and bolts (9) in the idler edge of the track frame (27). The idler must be
bracket (22). Tighten the bolts to a torque of 48 Nm centered in the track frame. If the idler is not centered
(35 pound-feet) to preload the springs (24). in the track frame, remove or add shims (20)
between the thrust plates (19) and idler brackets (22)
STEP 82 as necessary so that the idler is centered in the track
Put 242 Loctite on the threads in the holes in the idler frame.
brackets (22) for the bolts (7) that fasten the idler (21)
to the track adjuster (26).
STEP 83
Place the original shims (11) on the idler brackets
(22). Install the washers (8) and bolts (7) to secure
the track adjuster (26) to the idler (21). Tighten the
bolts (7) to a torque of 183 to 223 Nm

5508-20
STEP 86 STEP 88
After the idler (21) has been centered, check the Position the track adjuster cover (6) and secure using
clearance between the thrust plates (19) and track four washers (5) and bolts (4).
frame (27). The clearance must be as little as
possible and not more than 0.8 mm (1/32 inch). STEP 89
Remove shims (20) as required. Position the yoke cover (3) and secure using four
washers (2) and bolts (1).
STEP 87
When the idler (21) is in the correct position,
assemble the track according to the instructions in
Section 5504.

5508-21
3 9 10
21
6 2 20
1
5 18
11
4 17
26 16
8 19
7
22
25
13
24
12
15
23
14
27
BC05H103
1. BOLT 8. WASHER 15. SHIM(S) 22. IDLER BRACKET

2. WASHER 9. BOLT 16. BOLT 23. WEAR PLATE
3. YOKE COVER 10. WASHERS (3) 17. BOLT 24. SPRING
4. BOLT 11. SHIM(S) 18. WASHER 25. SPRING SEAT
5. WASHER 12. NUT 19. THRUST PLATE 26. TRACK ADJUSTER
6. TRACK ADJUSTER COVER 13. WASHER 20. SHIM(S) 27. TRACK FRAME
7. BOLT 14. WEAR BAR 21. IDLER

5508-22
TRACK ADJUSTER
2 3
5
7
4
9 6
10
11
BS02H052
1. YOKE 5. SEAL 9. WEAR RING

2. CHECK VALVE 6. BUSHING 10. PACKING RING
3. GREASE FITTING 7. BACKUP RING 11. SPACER
4. SNAP RING 8. PISTON
Removal 5. Move the idler all the way forward on the track
frame.
1. Loosen the valve in the track adjuster (2) to
release the pressure in the track adjuster. 6. Remove the front covers in place over the track
adjuster.
2. Fasten acceptable lifting equipment to the top of
the track and lift the track to push the piston (8) 7. Remove the bolts and washers that fasten the
into the track adjuster as far as possible. track adjuster to the idler.
3. Disconnect the lifting equipment from the track. 8. Separate the idler and track adjuster.
4. Separate the ends of the tracks according to the 9. Remove the track adjuster from the track frame.
instructions in Section 5504. It is not necessary 10. Remove the tube spacer (11) from inside the
to remove the track. recoil housing.

5508-23
Disassembly STEP 4
STEP 1
Tighten the valve (2) in the track adjuster.
STEP 2
BD07M003-01
Remove the excess grease from the end of the

piston.
STEP 5
BD07M001-01
Use a grease gun to inject grease into the track

adjuster to push the piston out of the cylinder.
STEP 3
BD07M004-01
Remove the packing ring (10) and the wear ring (9)
from the piston.
STEP 6
BD07M002-01
The piston takes a lot of pressure to remove and will

come out with force.
BD07M005-01
Remove the snap ring (4) from the piston.

5508-24
STEP 7 STEP 10
BD07M006-01 BD07M009-01
Remove the seal (5) from the piston. Loosen the valve (2).
STEP 8 STEP 11
BD07M007-01 BD07M010-01
Remove the bushing (6) from the piston. Remove the valve (2).
STEP 9 STEP 12
Remove the grease from the bore of the cylinder.
BD07M008-01
Remove the backup ring (7) from the piston.

5508-25
Inspection Assembly
1. Discard the seal.
STEP 13
2. Clean all parts in cleaning solvent.
3. Check the bushing and wear ring for damage.
4. Check the piston for scratches and rust.
BD07M013-01
Put the backup ring (7) on the piston.
STEP 14
BD07M011-01
5. Check the cylinder bore for scratches and rust.
BD07M014-01
Put the bushing (6) on the piston.

BD07M012-01
6. Clean the valve and check for damage. STEP 15

7. Check the tube spacer for damage.
BD07M015-01
Install the seal (5) on the piston so that the lips are
toward the snap ring.

5508-26
STEP 16 STEP 19
BD07M016-01 BD07M019-01
Install the snap ring (4) in the groove on the end of Install the wear ring (9).
the piston.
STEP 20
STEP 17
BD07M020-01
BD07M016-01 Use an expectable driver and drive the the wear ring
Lubricate the backup ring, bushing and seal with into the cylinder until seated.
clean oil. Install the piston into the cylinder. Be
careful not to damage the seal. STEP 21
Put 601 Loctite (green) on the OD of the packing ring
STEP 18 (10).
STEP 22
Push the piston into the cylinder, catch any grease or

solvents that will come out of the valve hole. BD07M021-01
Put the packing ring (10) on the piston. Be sure the

metal part of the packing ring is toward the cylinder.

5508-27
1. Be sure that the piston is pushed all the way into
the track adjuster.
2. Install the tube spacer in the recoil housing.
3. Place the track adjuster in place on the track
frame.
4. Put 242 Loctite (blue) on the threads of the holes
in the idler brackets for the bolts that hold the
track adjuster in place.
5. Align the track adjuster with the idler.
6. Install the bolts and washers that fasten the track
BD07M022-01 adjuster to the idler. Tighten the bolts to 183 to
Use an expectable driver and drive the the packing 223 Nm (135 to 165 pound-feet).
ring into the cylinder until seated.
7. Push the idler to the rear to engage the track
adjuster with the recoil housing.
STEP 24
8. Install the front covers.
9. Connect the track according to the instructions in
Section 5504.
BD07M023-01
Install the valve (2) into the track adjuster yoke.
STEP 25
BD07M024-01
Tighten the valve to 61 to 74 Nm


5508-28
RECOIL HOUSING
1. Install the tube spacer inside the recoil housing.
WARNING: The recoil spring in the recoil
housing is highly compressed. Using the 2. Put the recoil housing on the track frame.
wrong method to release this 3. Install the bolts and washers that hold the recoil
compression will result in personal injury. housing in place. Tighten the bolts to 183 to 223
Release (destroy) the compression of the Nm (135 to 165 pound-feet).
recoil spring according to instructions in
this section. 4. Install the valve in the track adjuster. Tighten the
48-70 valve to 61 to 74 Nm (45 to 55 pound-feet).
1. Loosen the valve in the track adjuster to release 5. Remove the hydraulic ram.
the pressure in the track adjuster.
6. Install the covers on the track frame.
2. Use acceptable lifting equipment to lift the top of
the track and push the piston into the track 7. Adjust the tension of the track according to the
adjuster as far as possible. instructions in Section 5504.
3. Disconnect the lifting equipment from the track.

4. Remove the covers from the track frame.
5. Use a hydraulic ram and push the idler all the
way forward.
6. Loosen and remove the bolts and washers that
fasten the recoil housing to the track frame.
7. Remove the recoil housing from the track frame.
8. Remove the tube spacer from inside the recoil
housing.
Destroying the Recoil Spring

NOTE: If the recoil housing is not to be used again, the
recoil spring must be cut to release the tension of the recoil
spring.
1. Use an acetylene cutting torch through the hole
in the bottom of the recoil housing and cut
through as much of the recoil spring as can be
seen. This will remove the tension of the recoil
spring and the recoil housing can be safely
discarded.

Section
5509
SPROCKETS
5509

5509-2
TABLE OF CONTENTS
SPROCKET SEGMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5509-3
REMOVAL FOR ALT TRACK

NOTE: See Section 5001 for checking wear on the 6. Put an acceptable support under the rear of the
sprocket. machine to hold the machine in place.
1. Refer to Section 5504 and separate the track. It 7. Loosen and remove the nuts from the bolts
is not necessary to completely remove the track. holding the sprocket.
2. Remove the track from the sprocket. IMPORTANT: Sprocket weight is in excess of 45 kg (100
lb). Get help when removing the sprocket to prevent hurting
3. Remove the bolts that hold the outer cover at the
yourself.
rear of the track frame.
8. Remove the sprocket.
4. Remove the outer cover.
5. Raise the rear of the machine until the sprocket
is free of the track links.
1
7
2
5
7 4 3
6
BC05H061
1. FINAL DRIVE 3. SPROCKET 5. WASHER (14) 7. ALIGNMENT MEASUREMENT

2. BOLT (14) 4. NUT (14) 6. TRACK ROLLER

5509-4
INSTALLATION FOR ALT TRACK

1. Install the sprocket bolts in the final drive hub, 5. Check to see that the sprocket is centered on the
mount the sprocket. rear track roller within 3 mm (1/8 inch), see item
7 in illustration on page 3.
2. Use Loctite No. 242 and install the washers and
nuts on the bolts. NOTE: If the sprocket is not centered as specified, see
NOTE: Do not get loctite on the surface between nut and section 5506 and align track frame to the sprocket.
washer. This will change the co-efficiency of the friction and 6. Use Loctite No. 242 and install the outer cover at
will effect the bolt torque and clamp load. the rear of the track frame.
3. Torque the nuts to 576 Nm (425 pound-feet) in 7. Install the bolts and washers that hold the outer
the sequence shown. cover in place. Tighten the bolts.
4. Repeat the torque sequence. 8. Refer to Section 5504 and connect the track.
13 1
10 11
6 9
4 3
8 7
2 5
12
BS07D370

5509-5
REMOVAL FOR SALT TRACK

NOTE: See Section 5001 for checking wear on the 3. Remove the sprocket segment.
sprocket.
4. Install and torque the sprocket segment before
1. Move the machine until a sprocket segment is proceeding, see page 6.
not engaged into the track.
5. Repeat steps 1 through 4 for the remaining
2. Loosen and remove the nuts from the bolts sprocket segments.
holding the sprocket segment.
1
6
2
6 4
3
5
BC05H063
1. FINAL DRIVE 3. SPROCKET SEGMENT 5. TRACK ROLLER

2. BOLT (50) 4. NUT (50) 6. ALIGNMENT MEASUREMENT

5509-6
INSTALLATION FOR SALT TRACK

1. Install the sprocket segment. 3. Torque the nuts to 698 Nm (515 pound-feet) in
the sequence shown.
2. Use Loctite No. 242 and install the nuts on the
bolts. 4. Check to see that the sprocket is centered on the
rear track roller within 3 mm (1/8 inch), see item
NOTE: Do not get loctite on the surface between nut and
6 in illustration on page 5.
segment. This will change the co-efficiency of the friction
and will effect the bolt torque and clamp load. NOTE: If the sprocket is not centered as specified, see
section 5506 and align track frame to the sprocket.
5
3
1
BS07D371

5511
Section
5511
TRACK AND SUPPORT ROLLER

5511-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Filling The Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5511-3
SPECIFICATIONS
Track Roller Lubricant
Type ..................................................................................................................New Holland AMBRA Hypoide 90
Carrier Roller Lubricant
Type ..................................................................................................................New Holland AMBRA Hypoide 90
Capacity ............................................................................................................... 334 mL (11.3 U.S. fluid ounces)
Special Torques
Bolts for mounting bracket ....................Apply Loctite 242 then torque to 434 to 447 Nm (320 to 330 pound-feet)
Valve in track adjuster ............................................................................................. 61 to 74 (45 to 55 pound-feet)
SPECIAL TOOLS
2 2
1 1
3 3
4 4
8 5 8 5
7 7
6 6
BC07M404 BC07M404
SEAL INASTALLER, TRACK ROLLER, FABRICATE AT LOCAL SEAL INASTALLER, SUPPORT ROLLER, FABRICATE AT
SHOP LOCAL SHOP
1. 28 MM 5. 70 MM 1. 28 MM 5. 70 MM
2. Ø 110.5 MM 6. Ø 102.5 MM 2. Ø 120 MM 6. Ø 112 MM
3. Ø 52.5 MM 7. Ø 83 MM 3. Ø 62 MM 7. Ø 92.5 MM
4. 50 MM 8. 20 MM 4. 50 MM 8. 20 MM
The top portion of the tool is made of Teflon, the

bottom portion is made of mild steel.

5511-4
TRACK ROLLER
Removal 3. Use acceptable lifting equipment to lift the top of

the track and push the piston into the track
1. If equipped with track guards, remove the track adjuster as far as possible.
guards as required to remove a track roller.
4. Disconnect the lifting equipment from the track.
A. To remove one of the middle track rollers,
remove both center rock guards. 5. Raise the machine to get as much clearance as
possible between the track chain and the track
B. To remove a front or rear track roller, remove rollers (1).
both middle track guards, and the front or rear
track guard as required. 6. Put blocks under the machine to hold the
machine in place.
C. Loosen and remove the nuts and bolts that
hold the spacers between the track guards. 7. Loosen and remove the self-locking bolts (3) that
fasten the inside of the track roller (1) to the track
D. Loosen and remove the cap screws that frame (2).
fasten the front and rear track guards to the
middle track guards. NOTE: The weight of a track roller is approximately 49.8
kg (110 pounds). Be careful when removing the track roller
E. As required, loosen and remove the cap to prevent personal injury.
screws that fasten the center rock guards to
the track frame.
F. Remove the track guards.
G. Remove the spacers that fell onto the track
chain.
2. Loosen the valve in the track adjuster two turns.
BD02H016-01

5511-5
B900332
1. TRACK ROLLER 2. TRACK FRAME 3. SELF-LOCKING BOLT

5511-6
Disassembly STEP 6
STEP 1
Clean the track roller with cleaning solvent.
STEP 2
Remove the plug from the end of the shaft.
STEP 3
Drain the oil from the track roller.
STEP 4
BD07G169-01
Remove the seal from the end cap.
STEP 7
BD07G167-01
Place roller in a press, press end cap down and

remove snap ring.
STEP 5 BD07G170-01
Remove the O-ring from the shaft and the seal from
the roller.
STEP 8
Repeat the steps 4 through 7 for the other end cap.
BD07G168-01
Remove the end cap from the shaft.

5511-7
STEP 9 STEP 12
BD07G171-01 BD07G174-01
Remove the bushing housing mounting bolts. Press the bushing housing out of the roller.
STEP 10 STEP 13
Repeat the steps 9 through 12 for the other bushing
housing.
STEP 14
BD07G172-01
Place the roller on blocks.
STEP 11
BD07G175-01
Remove the shaft from the bushing housing.
STEP 15
BD07G173-01
Allow space for the bushing housing to be pressed

out.
BD07G176-01
Remove the O-ring from the bushing housing.

5511-8
STEP 16 STEP 18
BD07G177-01 BD07G179-01
Place a bushing driver on the bushing. Remove the bushing from the housing.
STEP 17 STEP 19
Repeat Steps 15 through 18 for the other bushing.
Inspection
during assembly.
2. Discard the rubber rings and metal rings. New
3. Inspect the bushings and the bushing surfaces of
the shaft for scoring, pitting and other damage.
Use new parts as required.
BD07G178-01
Press the bushing out of the housing.

5511-9
4 5
6
3 7
2
8
1
9
10
11
12
BS07H184
1. SHAFT 5. BUSHING 9. PLUG

2. END CAP 6. BUSHING HOUSING 10. SNAP RING
3. BOLT 7. O-RING 11. FACE SEAL
4. O-RING 8. O-RING 12. GUIDE PIN

5511-10
Assembly STEP 23
STEP 20
BD07G183-01
Install a new O-ring on the bushing housing.

BD07G180-01
Place a new bushing on the bushing housing, align STEP 24

the hole in the bushing with the pin on the housing. Repeat Steps 20 through 23 for the other bushing
and housing.
STEP 21
STEP 25
BD07G181-01
Place a driver on the bushing.

BD07G184-01
Clean the inside of the roller, remove any rust from

STEP 22 the mating surfaces.
STEP 26
BD07G182-01
Press the bushing into the bushing housing.

NOTE: Pin should be 0.5 to 1.0 mm (0.020 to 0.040 BD07G185-01
inches) below the bushing surface. Place the roller on a press, place the bushing
housing in the roller.

5511-11
STEP 27 STEP 30
BD07G186-01
Install two long bolts to align the bushing housing BD07G189-01
with the roller. Apply Loctite 242 to the threads of the bolts. Install
and torque the bushing retaining bolts to 40.2 to 47
STEP 28 Nm (30 to 35 pound feet).
STEP 31
BD07G187-01
Place a block on the bushing housing.

BD07G190-01
STEP 29 Invert the roller on the press, place the shaft in the
roller.
STEP 32
BD07G188-01
Press the bushing housing into the roller until it is

seated in the roller.
BD07G191-01
Place the bushing housing in the roller.

5511-12
STEP 33 STEP 36
BD07G192-01 BD07G195-01
Install two long bolts to align the bushing housing Apply Loctite 242 to the threads of the bolts. Install
with the roller. and torque the bushing retaining bolts to 40.2 to 47
STEP 34
STEP 37
BD07G193-01
Place a tube and block on the bushing housing. BD07G196-01
Push the shaft in, mount and zero a dial indicator.

STEP 35
STEP 38
BD07G194-01
Press the bushing housing into the roller until it is BD07G197-01
seated in the roller. Check end play of the shaft, the end play must be
between 0.3 to 1.0 MM (0.011 to 0.039 inch).

5511-13
STEP 39 STEP 42
BD07G198-01 BD07G201-01
Clean the bore for the rubber ring on the bushing Push the rubber ring onto the steel seal until it is
housing. seated.
STEP 40 STEP 43
BD07G198-01 BD07G202-01
Clean the rubber ring and steel seal. Place the metal ring into the special tool.
STEP 41 STEP 44
BD07G200-01 BD07G203-01
Place the rubber ring on the steel seal. Start the rubber ring into the bushing housing.

5511-14
STEP 45 STEP 48
BD07G204-01 BD07G207-01
Push down on the tool until the rubber ring is seated Lubricate the O-ring and seal face with clean engine
in the bushing housing. oil.
STEP 46 STEP 49
BD07G205-01 BD07G208-01
Remove the tool. Clean the bore for the rubber ring in the end cap.
STEP 47 STEP 50
BD07G206-01 BD07G209-01
Install a new O-ring onto the shaft. Place the metal ring into the special tool.

5511-15
STEP 51 STEP 54
BD07G210-01 BD07G213-01
Start the rubber ring into the end cap. Start the end cap onto the shaft, make sure the flat
surfaces are aligned.
STEP 52
STEP 55
BD07G211-01
Push down on the tool until the rubber ring is seated BD07G214-01
in the end cap. Press the end cap down just enough to clear the
snap ring groove.
STEP 53
STEP 56
BD07G212-01
Remove tool, lubricate the face of the steel ring with BD07G215-01
clean engine oil. Start the snap ring over the end of the shaft.

5511-16
STEP 57 Filling The Track Roller
1. Turn the shaft so that the fill opening is on top
and the mounting surface on the end cap is at
the bottom.
2. Fill the track roller with New Holland AMBRA
Hypoide 90 gear lubricant.
BD07G216-01
Work the snap ring into the groove on the shaft.
STEP 58
BD07G217-01
Check that the snap ring is seated and does not

extend beyond the flat surfaces of the shaft.
STEP 59
Repeat Steps 39 through 58 for the other rubber ring
and metal ring.

5511-17
Leakage Test STEP 65
STEP 60
Connect the shutoff valve to the pressure regulator
valve. Connect a fitting for the air supply hose to the
shutoff valve. Connect this assembly to an air hose.
STEP 61
Install the adapter and quick disconnect fitting. Use a
seal washer with the adapter.
STEP 62
Turn the knob counterclockwise to close the
pressure regulator valve. BD07H141-01
Open the pressure regulator valve until the pressure

STEP 63 gauge indicates 172 kPa (25 psi).
Connect the line from the pressure gauge to the track
roller. STEP 66
Close the shutoff valve. The track roller must hold
STEP 64 this pressure for 10 seconds. Loss of air pressure
Make sure that the shutoff valve is open. during this time indicates a bad part or wrong
assembly.

5511-18
Installation
3
B900332
1. TRACK ROLLER 3. SELF-LOCKING BOLT

2. TRACK FRAME TIGHTEN TO 434 TO 447 NM (320 TO 330 POUND-FEET) WITH LOCTITE

5511-19
1. Apply 242 Loctite to the threads in the holes in 10. If the machine is equipped with track guards:
the track frame (2) for the self-locking bolts (3)
A. Apply 242 Loctite to the threads in the holes
that hold the track roller (1) in place.
on the inside of the track frame for the bolts
2. Hold the track roller (1) in alignment with the that hold the track guards in place.
track frame (2) and install two self-locking bolts
B. As required, hold the track guard in alignment
(3) to hold the track roller (1) in place.
with the track frame and install the hardened
3. Install the other self-locking bolts (3) that hold the washers and bolts that hold the track guards
track roller (1) in place. in place.
4. Tighten the self-locking bolts (3) to 434 to 447 C. Tighten the bolts.
D. Apply 242 Loctite to the threads in the holes
5. Install the valve in the track adjuster. on the outside of the track frame for the cap
screws that hold the track guards in place.
6. Tighten the valve to 61 to 74 Nm (45 to 55
pound-feet).
7. Raise the machine and remove the blocks.
8. Lower the machine.
9. Adjust the tension of the track according to the
instructions in Section 5504.

5511-20
CARRIER ROLLER
Removal Disassembly
1. Loosen the valve in the track adjuster two turns.
STEP 1
Clean the carrier roller with cleaning solvent.
STEP 2
BD02H016-01
2. Use acceptable lifting equipment to lift the top of

the track and push the piston into the track
adjuster as far as possible. BD07H003-01
3. Support the track with blocks to keep it clear of Loosen plug from end of shaft.
the support roller, lower the lifting equipment.
4. Loosen the mounting bolts (2) in the track
STEP 3
support roller mounting bracket.
1
BD07H004-01
Remove the plug and drain the oil from the carrier
BS07H214
roller.
1. SEAL HOUSING PINS
2. MOUNTING BOLTS STEP 4
5. Remove the roller (1) from the machine.
BD07H005-01
Remove the end cap bolts.

5511-21
STEP 5 STEP 8
BD07H006-01 BD07H004-01
Remove the end cap from the roller. Remove the bearing retainer bolts and plate.
STEP 6 STEP 9
BD07H007-01 BD07H010-01
Remove and discard the O-ring from the end cap. Using a suitable puller, remove the outer bearing and
carrier roller from the shaft.
STEP 7
STEP 10
BD07H008-01
Loosen the bearing retainer bolts. BD07H011-01
Remove the bearing cups from the roller.

5511-22
STEP 11 STEP 14
BD07H012-01 BD07H015-01
Remove the retaining ring for the seal housing from Press the bearing from the inner shoulder on the
the shaft. shaft.
STEP 12 STEP 15
BD07H013-01 BD07H016-01
Remove the seal and seal retainer from the shaft. The bearing will have to be pressed off of the outer
shoulder also.
STEP 13
STEP 16
BD07H014-01
Remove the roller seal from the shaft. BD07H017-01
Remove and discard the O-ring.

5511-23
Inspection 2. Discard the rubber rings and metal rings. New

during assembly. 3. Replace the bearings as a set.
2 3 4 5 6 7 8 9 10
11
12
16
13
15 14
BS07H183
1. PLUG 5. BEARING RETAINER PLATE 9. SEAL HOUSING 13. O-RING

2. BOLT 6. ROLLER 10. HOUSING PIN 14. SEAL FACE
3. END CAP 7. BEARING 11. SHAFT 15. O-RING
4. BOLT 8. O-RING 12. RETAINING RING 16. O-RING

5511-24
Assembly STEP 20
STEP 17
BD07H021-01
Press the bearing cup into the roller until it is seated.

BD07H018-01
Install a new O-ring on the shaft. STEP 21

Repeat steps 19 and 20 for the other bearing cup.
STEP 18
STEP 22
BD07H019-01
Heat the bearing to 135° C (275° F). Install the BD07H022-01
bearing on the shaft. Clean the inside of the roller.
WARNING: Always wear heat protective STEP 23

gloves to prevent burning your hand when
handling heated parts.
SM121A
STEP 19
BD07H023-01
Secure the shaft in a soft jawed vise, place the roller

on the shaft.
NOTE: Make sure that the bolt holes for the end cap are
BD07H020-01 facing up.
Place the bearing cup in the roller, place a suitable
driver on the cup.

5511-25
STEP 24 STEP 27
BD07H024-01 BD07H065-01
Heat the bearing to 135° C (275° F). Install the Check end play of the shaft, the end play must be
bearing on the shaft. between 0.2 to 1.16 MM (0.0078 to 0.045 inch).
WARNING: Always wear heat protective STEP 28

gloves to prevent burning your hand when
handling heated parts.
SM121A
STEP 25
BD07H027-01
Install a new O-ring on the roller end cap.
STEP 29
BD07H025-01
Install the bearing retainer plate and bolts.
STEP 26
BD07H028-01
Lubricate the O-ring with clean engine oil, align the

bolt holes and put the end cap and retaining bolts on
the roller.
BD07H026-01
Apply Loctite 242 to the threads of the bolts. Install

and torque the bolts to 53.7 to 63.4 Nm
(39.5 to 46.5 pound feet).

5511-26
STEP 30 STEP 33
BD07H029-01
Apply Loctite 242 to the threads of the bolts. Install BD07H033-01
and torque the bolts to 38.2 to 45.1 Nm Clean the seal retainer.
(28 to 33 pound feet).
STEP 34
STEP 31 Place the metal ring into the special tool.
STEP 35
BD07H030-01
Clean the rubber ring and steel seal.

BD07H034-01
STEP 32 Press the seal retainer onto the seal.
STEP 36
BD07H031-01
Push the rubber ring onto the steel seal until it is BD07H035-01
seated. Make sure that the seal seats evenly into the seal
retainer.

5511-27
STEP 37 STEP 39
Place the metal ring into the special tool.
STEP 40
BD07H030-01
Clean the rubber ring and steel seal.
STEP 38 BD07H036-01
Place the seal and special tool onto the roller.
STEP 41
BD07H031-01
Push the rubber ring onto the steel seal until it is

seated. BD07H037-01
Press the seal into the roller until it is seated evenly.
STEP 42
BD07H038-01
Lubricate the O-ring and the metal surfaces of the

seals, place the seal retainer onto the shaft.

5511-28
STEP 43
BD07H039-01
Place two pieces of pipe onto the nipples of the seal

retainer. Press the retainer down just enough to
install the retaining ring, install the retaining ring.
STEP 44
BD07H040-01
Fill the roller with 334 mL (11.3 U.S. fluid ounces) of

New Holland AMBRA Hypoide 90 gear lubricant.
STEP 45
BD07H041-01
Install a new O-ring on the plug, put the plug into the
end cap. Torque plug to 149 to 190 Nm

5511-29
Installation 3. Align the carrier roller with the track chain.
1. Place the carrier roller into the carrier roller 4. Torque the mounting bolts (2) to 205 to 260 Nm
support bracket. (155 to 190 pound feet). Alternate tightening
sequence until torque stabilizes on both bolts.
2. Align the seal housing pins (1) to holes in the
carrier roller support bracket. 5. Raise the track and remove the blocks.
6. Lower the track.
7. Adjust the tension of the track according to the
1 1
BS07H214
1. SEAL HOUSING PINS

2. MOUNTING BOLTS

5511-30

SECTION INDEX
POWER TRAIN

Hydrostatic Pumps and Motors System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6000
Removal and Installation of Hydrostatic Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001
Hydrostatic Drive Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
Transmission Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007

Section
6000
HYDROSTATIC PUMPS AND MOTORS

SYSTEM OVERVIEW
6000

6000-2
TABLE OF CONTENTS
HYDROSTATIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HOW IT WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6000-3
HYDROSTATIC SYSTEM OVERVIEW

All closed loop hydrostatic power trains are basically as their name implies a closed loop. In a standard hydraulic
system, the oil flows from the reservoir, to the pump, to the control valve (to do the work), and then back through
the cooler, filter and then to the reservoir.
In a hydrostatic closed loop system, the pump and the drive motor are directly connected to each other. The
hydrostatic pump sends oil directly to the motor and this same oil returns back to the pump. The pump is usually a
piston type unit that has the ability to vary the rate and the direction of the oil flow. This is accomplished by
changing the position of the pump's swash plate in relation to the rotating group (made up of pistons and cylinder
block). The angle of the swash plate causes the pistons to stroke into and out of the cylinder block bores as it is
rotated. Changing this angle varies the piston stroke and, therefore, the amount of oil being pumped to the motor.
Tilting the swash plate in the opposite direction will reverse the flow to the motor and hence the direction of motor
rotation.
High pressure oil is also used to minimize wear in the rotating group, as well as drive the motors. To prevent the
slippers on the pistons from wearing out too rapidly as they rotate, there is a small hole drilled through the piston
and slipper to allow oil to constantly form a cushion between the slipper and swash plate. The same pressure the
piston sees while pumping will be passed through the drilled hole to provide a column of oil for the piston to ride
upon. A smaller area of the slipper is pressurized than the area of the piston. This difference in area will keep the
slipper held against the swash plate. The head of the slipper seals this pressurized oil to the swash plate.
With the high pressures required to drive the machines, some of the closed loop oil will leak into the case drain of
the components. This lost oil must be re-supplied to keep the system working. A fixed displacement charge pump
is used to make up for this loss. The charge pump supplies cooled and filtered oil from the reservoir, under a
relatively low pressure (425 psi) to the closed loop, keeping the system charged and supply fluid to operate the
control system.
In order for the low pressure charge oil to get into the closed loop, a check valve is placed between the charge oil
supply and each side of the closed loop. As the unit drives, one side of the closed loop will increase in pressure.
This increase in pressure would increase the leakage from the loop and, the oil returning from the motor to the
pump would not be adequate.
The pressure on the return side of the loop would be low enough to allow oil to flow from the charge pump circuit,
through the check valve to keep the pump fully supplied with oil. The check valve on the drive side of the circuit
would be held closed by the high pressure on that side of the loop. When the direction of travel is reversed, charge
flow would then enter the loop on the opposite side.
If the machine were to become disabled, the drive wheels would lock because they are directly coupled to the
hydrostatic drive system through the final drives. A pair of bypass (tow) valves in each pump will allow the machine
to be moved for service. Once the brakes are released The bypass valve separates the forward and reverse side of
the closed loop. When the valves are opened approximately two turns, the loop oil can bypass the pump and the
unit can be moved. Use caution when the bypass valves are opened to prevent the machine from moving out of
control. With the bypass valves open, do not move the machine more than 1 mph or more than 100 feet.

6000-4
HOW IT WORKS
The 1150K crawler utilizes a dual path closed loop hydrostatic drive system to operate both tracks independently.
The engine provides power for two hydrostatic pumps, one for each track, to supply oil to the drive motor for each
track. The drive motors are directly coupled to the left or right final drive assembly. The tracks are then controlled
via a joystick from the left side of the operator’s platform. The two tracks being powered individually allow for power
turns and counter rotation.
The hydrostatic pump is a piston pump design that allows for the variable displacement of oil. The amount of oil
flow from the pump to the drive motor controls the speed of the vehicle in the forward and reverse directions. As
the amount of oil being pumped increases so does the vehicle speed. As one might expect as the amount of oil
being pumped decreases the vehicle speed decreases and the amount of torque or pulling power the vehicle has
increases. The swash plate is controlled by the operator electronically and changes the angle of the rotating piston
group. As the angle of the swash plate gets larger the amount of oil pumped and the pressure of that oil increases.
As the swash plate goes to a neutral position the flow of oil stops and the vehicle comes to rest. The direction of the
swash plate is what controls the directional flow of oil. Therefore the pump always turns the same direction but the
swash plate angles determine which way the flow available to do work travels.
The piston motors then receives oil from the pump, which causes a piston group to rotate. The motors are used to
power the final drives. The variable motor also has a swash plate which can rotate to increase or decrease speed.
With variable pumps and motors the operator can select an appropriate speed for operation. Oil leaving the motors
goes directly back to the pump and the cycle starts again.
Not all of the original oil returns to the hydrostatic pump. Some of the oil is lost to the reservoir through internal
leakage of the pumps and motors. This oil is then picked up by the hydraulic pump, cooled, filtered, and put back
into the closed loop via the charge pump. The oil that leaks from the pump and motors is not enough to keep the
closed loop oil cool, therefore a shuttle valve is incorporated into the motor to direct some additional oil back to the
reservoir.
If the system continued to operate without a charge pump it would only operate for a few cycles before pump
cavitation and failure would occur. For that reason a charge pump supplies cool and filtered oil to replenish oil lost
from the internal leakage of the pump and motors as well as the oil that is drained off from the shuttle valve for
cooling. The charge pump also provides oil to release the parking brake.

6000-5
BS06K191
1. CHARGE FILTER 2. BENT AXIS MOTOR 3. TANDEM PUMP

6000-6
BS06M468
BENT AXIS DRIVE MOTOR

6000-7
1 3 4
2
4 5
BS06M469
HYDROSTATIC DRIVE PUMP WITH CHARGE PUMP
1. MECHANICAL LINKAGE (NOT USED ON CRAWLER) 3. PRESSURE OVERRIDE 5. CHARGE RELIEF

2. CHARGE PUMP 4. CIRCUIT RELIEFS 6. ELECTRONIC CONTROLS

6000-8
FUNCTIONALITY
The variable displacement hydrostatic pump and the charge pump are driven by the diesel engine.
The charge pump, pumps oil through the charge filter. If the charge filter cartridge is excessively dirty, the charge
filter restriction indicator will alert you of this problem. If back pressure is too high in front of a dirty charge filter
cartridge, the charge circuit bypass valve opens and directs part of the charge oil back to the inlet side of the
charge pump after going through the charge circuit strainer.
The charge pressure is limited to 425 PSI by two charge pressure relief valves and can be checked at the test port
located on the test panel. Charge pressure oil is directed to the appropriate low pressure side of the variable
displacement pump (dependent upon travel direction) by way of the check/replenishing valves. The
check/replenishing valves are integrated into the high pressure circuit relief valves. Charge oil compensates for
leakage in our closed loop system.
The charge pump generates a variable flow dependent upon the speed of the engine. The faster the engine speed,
the higher the charge pump flow. The charge flow is directed to the directional control valve. The directional control
valve (which is controlled by electro proportional valves which receive a signal from the controller) uses the charge
flow to create control pressure and sends it out to the required side of the servo cylinder. The servo cylinder then
creates the angular movement of the swash plate.
The directional control valve is defaulted to its neutral position. While in neutral oil from both sides of the servo
cylinder has a path to tank. When forward movement is requested by the operator the joystick sends a signal to the
controller stating which direction the operator would like to travel and at what speed. Based upon this input from
the operator the controller opens the forward electro proportional valve and sends charge pressure to the
corresponding side of the servo cylinder. A sensor measuring track speed communicates with the controller and
allows for closed loop control. The EP valve then shifts as necessary to maintain the desired speed.
When the machine is traveling, high pressure oil is pumped to the hydraulic motors by the travel pumps. In the
event the oil pressure exceeds 6000 PSI the travel circuits are protected by circuit relief valves which are set at
6000 PSI and protect the forward and reverse directions.
The pump and motor swash plate angles have ten preset positions. These positions are controlled by the
micro-controller and EP valves and toggled between by the operator with bump_up and bump_down buttons
located on the travel joystick. By toggling between these preset positions the speed of the vehicle is changed. The
motor EP valves control the swash plate by allowing a certain amount of drive side high pressure oil to energize the
appropriate side of the adjusting cylinder. The adjusting cylinder will either retract or extend based upon how the
EP valve is set. The swash plate angle is increased or decreased by retracting and extending the adjusting
cylinder. As the angle increases CRAWLER speed decreases and torque increases. As the angle decreases speed
increases and torque decreases.
A shuttle spool is also integrated into the motor housing. The spool reacts to drive side high pressure oil and allows
return side low pressure hot oil to exit the motor and return to the hydraulic reservoir.
Direction and speed are both controlled by a joystick located in the left hand console. As the joystick is moved
forward the machine begins forward movement. Once in the forward detent track speed is controlled by bump_up
and bump_down buttons located on the joystick. These buttons change the speed by a predetermined amount and
display the selected speed on the dash. There are 10 preset operating positions that the operator can bump up and
down between. The speed defaults to 3 MPH every time the engine is started. Holding the bump_up and
bump_down buttons for a continuous time will continue to shift up or down through the preset operating speeds.
This same process also holds true for the reverse direction.
For greater working efficiency the speed of reverse is variable based upon maximum speed in the forward
direction. The maximum reverse speed can be 80% to 130% of the maximum forward speed. The forward to
reverse ratio is controlled by the forward speed set by the bump_up and bump_down buttons as well as the setting
selected on the reverse speed knob.
Steering is also commanded by the joystick located in the left hand console. When the operator commands turning
(must be in forward or reverse to turn) the inside track decreases in speed and the outside track remains at the
same speed (Pivot Turn). Counter rotation is possible when a pivot turn is not adequate (NOTE: Control lever must
be in the forward or reverse direction). When the operator moves the joystick past the pivot turn position, counter
rotation will take place. The inside track shall begin to move in the reverse direction of the outside track. As the
joystick is stroked against its stop the tracks will be driven at commanded speed for the forward or reverse direction
with both tracks being driven in opposite directions.

6001
Section
6001
REMOVAL AND INSTALLATION OF

HYDROSTATIC PUMPS AND MOTORS

6001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HYDROSTATIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PUMP AND MOTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6001-3
SPECIFICATIONS
Manufacture.................................................................................................................................................... Rexroth
NOTE: For additional torques see illustrations at the rear of this section.
Torques
Pump mount bolts to frame ...............................................................................68 to 81 Nm (50 to 60 pound feet)
Rear bracket to pumps ...................................................................................68 to 77 Nm (50 to 56.5 pound feet)
Hydrostat motor mount bolts to brake housing .........................................250 to 280 Nm (183 to 210 pound feet)
Split flange clamps on pumps for hoses to motors .........................................90 to 100 Nm (66 to 74 pound feet)
Split flange clamps on motors for hoses to pumps ...............................135 to 150 Nm (99.5 to 110.5 pound feet)
Inlet hose clamps ....................................................................................... 6.5 to 7.6 Nm (58 to 68 pound inches)
Drive shaft to flywheel mount bolts ...........................................................285 to 305 Nm (210 to 225 pound feet)
Center Housing Rear Cover
30mm hex bolts .........................................................................................430 to 485 Nm (315 to 355 pound feet)
18mm hex bolts .............................................................................................. 77 to 100 Nm (57 to 74 pound feet)
NOTE: For final drive removal and repair see section 6007.

6001-4
1
2 3
14
13 5
10
6
12
7
11
8
9
BD07F096-01
1. HYDRAULIC PUMP 8. CHARGE PRESSURE SWITCH CONNECTOR

2. SUCTION HOSE REAR CHARGE PUMP 9. PILOT PRESSURE TO CONTROL VALVE
3. BRAKE PRESSURE HOSE 10. TO HYDROSTAT FILTER
4. RIGHT MOTOR LOWER HIGH PRESSURE11. LEFT MOTOR UPPER HIGH PRESSURE
5. LEFT MOTOR LOWER HIGH PRESSURE 12. SOLENOID CONNECTORS
6. FROM EQUIPMENT VALVE 13. FILTER RETURN HOSE
7. SUCTION HOSE FRONT CHARGE PUMP 14. DIAGNOSTIC HOSES

6001-5
HYDROSTATIC PUMP
Removal STEP 7
Disconnect the hydrostat filter output hose (13) and
NOTE: After removal of hoses, cap and plug hoses and
move over to the pumps, remove the hose with the
fittings to prevent foreign material from entering the
pumps.
hydraulic system.
STEP 8
STEP 1
Disconnect the equipment valve return hose (6).
Park the machine on a level surface, lower the blade
and any attachment to the floor, apply the parking
brake levers and turn off the master disconnect. STEP 9
Disconnect the solenoids (12).
STEP 2
Tilt the ROPS cab or canopy, see section 9008. STEP 10
Disconnect pressure switch (8).
STEP 3
STEP 11
1 Disconnect the three diagnostic hoses (14).
2
STEP 12
Disconnect the brake pressure hose (3).
4
3
STEP 13
Disconnect left and right motor high pressure hoses.
STEP 14
Remove two bolts and clamps from front mounting
bracket.
BD07F086-01
1. RESERVOIR VENT 3. TRANSMISSION FILTER STEP 15

2 HYDRAULIC FILTER 4. BACK UP ALARM Attach suitable lifting equipment to the pumps,
Remove the vent from the hydraulic reservoir and ensure proper balance of the pumps to keep from
connect a vacuum pump to the reservoir. Turn on the tilting during removal.
vacuum pump.
IMPORTANT: DO NOT disconnect two hoses at the STEP 16
same time going to the hydraulic reservoir. Plug or cap any Remove the two front mounting bolts.
hose prior to disconnecting another.
STEP 17
NOTE: Tag all hoses and wires before disconnecting for
proper identification for assembly. See page 4 for locations. Remove the two rear mount bolts
STEP 4 STEP 18
Disconnect the hydraulic pump (1) inlet hose and Raise the pumps slowly, move the pumps to the rear
pressure hose. and slip the input shaft off of the pump splines.
Carefully remove the pumps from the machine.
STEP 5 IMPORTANT: When removing and installing hoses and
Disconnect the rear (2) and front charge pump inlet fittings from the old pump to the new pump, replace all
hoses (7). O-rings and install the hoses and fittings at the same angles
as when removed.
STEP 6
Disconnect the hydrostat filter hose (10).

6001-6
NOTE: Remove caps and plugs for hoses and fittings just
prior to the connection of that hose.
IMPORTANT: DO NOT remove plugs or caps from two
hoses at the same time going to the hydraulic reservoir.
STEP 19
BD06E007
Install the front wiper seal, do not drive the seal in

flush but leave it raised as shown. Coat the shaft
splines with Loctite 767 anti-seize.
STEP 22
Connect hydrostat filter hose to the buttom of the
BD06E004-01 pumps.
Apply Loctite 243 to the bolt threads. Install and
tighten the drive shaft mounting bolts to 285 to 305 STEP 23
STEP 20
BD06E008-01
Carefully lower the pumps into the machine. Slide the

pumps forward onto the shaft until the shaft engages
BD06E005-01 the seal, as shown. Align the mounting bolt holes and
install the mounting bolts.
STEP 24
Remove the lifting equipment from the pumps.
STEP 25
Torque the rear mount bolts to 68 to 81 Nm
STEP 26
Torque the two front mounting bolts to 68 to 81 Nm
BD06E006-01
Install the front and rear mounting bushings.

6001-7
STEP 27 STEP 37
If removed, connect the inlet hoses to the reservoir. Connect the hydrostat filter output hose (13).
Torque the clamp on the inlet hoses to a torque of
6.5 to 7.6 Nm (58 to 65 lb-in). STEP 38
Connect the hydrostat filter inlet hose (10).
STEP 28
STEP 39
Connect the front charge pump inlet hose (7). Torque
the clamp on the inlet hose to a torque of 6.5 to 7.6
Nm (58 to 65 lb-in).
STEP 40
Connect the rear charge pump inlet hose (2). Torque
the clamp on the inlet hose to a torque of 6.5 to 7.6
Nm (58 to 65 lb-in).
STEP 41
Turn off the vacuum pump. Disconnect the vacuum
BD06E009-01
pump from the reservoir, install the vent in the
Install the flywheel covers.
hydraulic reservoir.
STEP 29 STEP 42
Install the two bolts and clamps to the front mounting
Lower the ROPS cab or canopy, see section 9008.
bracket.
STEP 43
STEP 30
Check the oil level in the reservoir and fill as needed,
Connect the left and right motor high pressure hoses.
see section 1002.
Snug the split flange clamps down evenly and then
torque to 90 to 100 Nm (66 to 74 pound feet).
STEP 44
STEP 31 Start and run the engine at low idle for 3 minutes, run
the machine at full throttle for 5 minutes while moving
Connect the brake solenoid pressure hose (3).
the machine in forward, reverse, left and right
steering positions.
STEP 32
Connect the remaining three hoses to the diagnostic STEP 45
center (14).
Shut the engine off and tilt the ROPS cab or canopy,
see section 9008, and check for leaks.
STEP 33
Connect the pressure switch wiring (8). STEP 46
Check the oil level in the reservoir and fill as needed,
STEP 34 see section 1002.
Connect the solenoids (12).
STEP 35
Connect the equipment valve return hose (6).
STEP 36
Connect hydraulic pump (1) inlet hose and outlet
hose. Torque the clamp on the inlet hose to a torque
of 6.5 to 7.6 Nm (58 to 65 lb-in).

6001-8
HYDROSTATIC MOTORS
Removal STEP 5
NOTE: After removal of hoses, cap and plug hoses and
fittings. 2 3
STEP 1
1
brake levers and turn off the master disconnect.
STEP 2
Tilt the ROPS cab or canopy, see section 9008. 4
STEP 3 BD06E011-01
1. CASE DRAIN 3. SOLENOID

2. SPEED SENSOR 4. BRAKE RELEASE
Disconnect the rear case drain hose, solenoid and
speed sensor wiring harness.
NOTE: Brake release hose (4) does not need to be
disconnected but should be disconnected and moved out of
the area of the motor to prevent damage during removal.
STEP 6
Disconnect high pressure hoses from the motor.
BD06E010-01 STEP 7
Remove the rear cover plate from the center box, Disconnect the front case drain hose.
use suitable lifting equipment to lower the plate.
STEP 8
STEP 4
Remove all but one mount bolt to the brake housing.
Support the motor with blocks of wood and remove
1 the last mounting bolt.
2
STEP 9
Carefully work the motor out of the brake housing
4
3 and remove it from the machine.
IMPORTANT: When removing and installing fittings from
the old motor to the new motor, replace all O-rings and
install the fittings.
BD07F086-01
1. RESERVOIR VENT 3. TRANSMISSION FILTER

2 HYDRAULIC FILTER 4. BACK UP ALARM
Remove the vent from the hydraulic reservoir and
connect a vacuum pump to the reservoir. Turn on the
vacuum pump.

6001-9
Turn off the vacuum pump. Disconnect the vacuum
STEP 10 pump from the reservoir, install the vent in the
Lubricate the splines on the motor shaft with Loctite hydraulic reservoir.
767 anti-seize.
STEP 17
STEP 11 Lower the ROPS cab or canopy, see section 9008.
Carefully work the motor into the machine and into
the brake housing. STEP 18
Check the oil level in the reservoir and fill as
STEP 12 necessary, see section 1002.
Apply Loctite 243 to the bolt threads. Start all four
mounting bolts to the final drive and snug them up STEP 19
evenly. Torque the mounting bolts to 250 to 280 Nm Start and run the engine at low idle for 3 minutes, run
(183 to 210 pound feet). the machine at full throttle for 5 minutes while moving
the machine in forward, reverse, left and right
STEP 13 steering positions.
Connect the front case drain hose.

STEP 20
Shut the engine off and check for leaks.
STEP 14
Connect high pressure hoses to the motor. Snug the
STEP 21
split flange clamps down evenly and then torque to
135 to 160 Nm (99.5 to 110.5 pound feet).
STEP 15
2 3
BD06E010-01
4 Install the rear cover and torque the 30mm hex bolts
to 430 to 485 Nm (315 to 355 pound feet), the 18mm
hex bolts to 77 to 100 Nm (57 to 74 pound feet).
BD06E011-01
1. CASE DRAIN 3. SOLENOID

2. SPEED SENSOR 4. BRAKE RELEASE
Connect the rear case drain hose, solenoid and
speed sensor wiring harness.
NOTE: Connect the brake release hose (4).

6001-10
PUMP AND MOTOR MOUNTING
1
4
5
6
11
9
10
8 7
BC07F266
RIGHT SIDE VIEW
1. HOSE TO FILTER 7. MOUNTING NUTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)

2. CASE DRAIN TO RESERVIOR 8. CASE DRAIN CROSS OVER
3. REAR CHARGE PUMP SUCTION 9. HIGH PRESSURE TO LEFT MOTOR
4. CASE DRAIN CROSS OVER 10. HIGH PRESSURE TO RIGHT MOTOR
5. FRONT CHARGE PUMP SUCTION 11. CONNECTOR LONG TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
6. BOLT USE LOCTITE 243 TORQUE TO 285 - 305 NM (210 - 225 FT LBS)

6001-11
1
2
12
11
10
5
8
7 6
9
BC07F264
LEFT SIDE VIEW
1. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS) 7. CONNECTOR TORQUE TO 90 - 100 NM (66.4 - 74.8 FT-LBS)
2. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS) 8. MOUNTING NUTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)
3. STEM 45° TORQUE TO 163 - 224 NM (120 TO 165 FT-LBS) 9. HOSE CASE DRAIN
4. BOLT APPLY LOCTITE 243 TORQUE TO 250 - 280 NM 10. FRONT CHARGE PUMP SUCTION HOSE
(183 - 210 FT-LBS) 11. ‘T’ FITTING
5. CONNECTOR LONG TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
12. HOSE FLANGE
6. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 70 FT LBS)

6001-12
1
2 3 4
5
BC07F265
BOTTOM VIEW
1. BOLT TORQUE TO 135 - 160 NM (99.5 - 110.5 FT-LBS) 4. HOSE PUMP CASE DRAIN
2. CONNECTOR 1.0 ORFS-ORB 1.0 5. MOUNTING BOLTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)
3. CONNECTOR 3/4 ORFS-ORB 5/8 6. BOLT TORQUE TO 68 - 77 NM (50 - 56.5 FT-LBS)

6002
Section
6002
HYDROSTATIC DRIVE SPECIFICATIONS

PRESSURE CHECKS AND TROUBLESHOOTING

6002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKS TO DO BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING CHARGE PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checking the Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECKING PRESSURE OF RIGHT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHECKING PRESSURE OF LEFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PUMP PRESSURE RELIEF LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6002-3
SPECIFICATIONS
Charge Pump Pressure .....................................................................................................................30 bar (435 psi)
Left Pump Pressure Override Valve ............................................................................................................... Blocked
Left Forward Pump Port MA ...........................................................................................................420 bar (6092 psi)
Left Reverse Pump Port MB...........................................................................................................420 bar (6092 psi)
Right Pump Pressure Override Valve............................................................................................................. Blocked
Right Forward Pump Port MB.........................................................................................................420 bar (6092 psi)
Right Reverse Pump Port MA ........................................................................................................420 bar (6092 psi)
NOTE: The hydraulic and hydrostatic oil must be at an operating temperature of 49° to 63° C (120° to 145° F) when checking
pressure specifications. The pressure override valves are adjusted until fully seated and considered blocked for any pressure
relief.
SPECIAL SERVICE TOOLS
B877558M
CAS-1804 PRESSURE TEST FITTING KIT
CHECKS TO DO BEFORE TROUBLESHOOTING

1. Check the oil level, type, and grade in the 3. Check controls for correct operation.
hydraulic reservoir. See Section 1002 for correct
4. Check engine r/min (rpm).
hydraulic oil specifications.
2. Check hydrostatic oil filter condition and change
as necessary.

6002-4
CHECKING CHARGE PUMP PRESSURE

Equipment Required 7. When the charge pressure stops increasing,
record the pressure reading.
CAS-1804 Pressure test and fitting kit.
8. Move the hand throttle to the IDLE position.
Charge Pump Pressure Test 9. Use the UP range button to place the machine in
Make sure the oil is at operating temperature. its highest range. The instrument cluster will
reflect the hydrostat range.
1. It will be necessary to operate the machine
against an immovable object or into a spoil pile. 10. Make sure both parking brakes are in the OFF
The surface must be one that will allow the track position.
to dig in, in both FORWARD and REVERSE. 11. Place the directional control in the F position.
2. Connect a pressure gauge with a capacity of at 12. Raise and maintain engine r/min (rpm) at 2000.
least 69 bar (1000 psi) to the quick disconnect When the pressure stops increasing, record the
fitting marked Charge Pump (3). pressure readings.
3. Connect two 414 to 690 bar (6000 to 10,000 psi) 13. Move the Hand throttle to the IDLE position.
gauges on the quick disconnect fitting marked
Right Reverse Pump Port MA (2), Right Forward 14. Place the directional control in the R position.
Pump Port MB (1). The hose for the pressure 15. Raise and maintain engine r/min (rpm) at 2000.
gauge must have at least a 690 bar (10,000 psi) When the pressure stops increasing, record the
rating. pressure readings.
16. Move the Hand throttle to the IDLE position,
4 5 place the directional control in neutral and apply
the parking brakes, stop the engine.
NOTE: Reconnect the two 414 to 690 bar (6000 to 10,000
psi) gauges on the quick disconnect fitting marked Left
Reverse Pump Port MB (5), Left Forward Pump Port MA
3 (4), repeat procedures 2 through 16.
1 2
17. Compare the pressure readings recorded to the
specifications on page 3.
NOTE: If charge pressure readings dropped more than
BD06K126 1.8 bar (25 psi) between N and F or R during procedures
4. Direct the gauge into the ROPS or cab to view 11 or 14 it will be required to determine if the leakage is in
them from the operators seat. the brake release system or the hydrostat system.
WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
5. Start the engine, select engine r/min (rpm) on the

instrument cluster display.
6. Raise and maintain engine r/min (rpm) at 2000.

6002-5
Understanding Results of the Test 21. Turn off the vacuum pump, repeat procedures 2
through 8 and check the pressure.
NOTE: Charge pressure is used to shift the servo control
pistons, hydraulic blade control systems, and release the NOTE: If pressure increased replace the filter head, if
brakes. Low charge pressure may be the result of a failure pressure did not increase, reconnect the filter bypass line
in either of these systems. and go to the next procedure.
18. If pressure is not within specification on page 3 22. Adjust the pressure settings of the charge pump
during procedure 7 go to procedure 19, if the relief valves by doing the following procedure:
pressure dropped during procedure 11 or 14 go A. Tilt the ROPS cab/canopy, see section 9008.
to procedure 22.
NOTE: For locations of relief valves, see pump pressure
Adjusting Charge Pressure Settings relief locations page 9.
IMPORTANT: Adjust both front and rear charge pumps at B. Remove the adjusting screw cover.
the same time with the same amount of turns of the C. Loosen the adjusting screw jam nut.
adjusting screws.
D. Turn the adjusting screw clockwise to
increase pressure and counterclockwise to
decrease pressure.
NOTE: One turn will result in a pressure change of
1 approximately 3.8 Bar (55 psi).
E. Lower the ROPS cab/canopy, see section
9008.
F. Turn off the vacuum pump, repeat procedures
2 3 through 8 to check the pressure setting.
23. Adjust the charge pressure relief valves again if
necessary.
BD06E002
1. RESERVOIR VENT 2. BYPASS LINE

19. Remove the vent from the hydraulic reservoir
and connect a vacuum pump to the reservoir.
Turn on the pump.
20. Disconnect the filter bypass return line, plug the
line and cap the fitting.

6002-6
Checking the Brake Circuit 3. If the pressure increases replace the brake
solenoid, see section 7001, if the pressure still
NOTE: Check oil levels in both final drives to determine if remains low during procedure 11 or 14 replace
hydraulic system oil is present. the brake piston O-rings, see section 7001.
1. The brake system can be isolated by plugging A. Tilt the ROPS cab/canopy, see section 9008.
the feed line to the brake solenoid.
B. Turn on the vacuum pump.
C. Connect the reservoir return line from the
1 brake solenoid.
D. Lower the ROPS cab/canopy, see section
9008.
E. Turn off the vacuum pump and disconnect it
2 from the reservoir. Install the vent in the
hydraulic reservoir.
4. If the pressure did not increase during
procedures 1 through 3 there is an internal
problem in the hydrostatic pump system. Do the
BD06K044
following procedures to isolate the problem.
1. FEED LINE 2. RESERVOIR RETURN LINE
A. While moving the machine forward at low
A. Tilt the ROPS cab/canopy, see section 9008.
speed, note the pressure reading, make a
B. Remove the vent from the hydraulic reservoir slow right turn, note the pressure reading,
and connect a vacuum pump to the reservoir. make a slow left turn, note the pressure
Turn on the pump. reading.
C. Disconnect the feed line from the brake B. While moving the machine in reverse at low
solenoid, plug the line and cap the fitting. speed, note the pressure reading, make a
slow right turn, note the pressure reading,
D. Lower the ROPS cab/canopy, see section
make a slow left turn, note the pressure
9008.
reading.
E. Turn off the vacuum pump and repeat
5. If the pressure did not recover during straight
procedures 3 through 16.
forward motion check both right and left forward
2. If the pressure increases do the following to pumps. If pressure did not recover during right
further isolate the problem. turn check the left forward pump, during left turn
check the right forward pump.
A. Tilt the ROPS cab/canopy, see section 9008.
6. If the pressure did not recover during straight
B. Turn on the vacuum pump.
reverse motion check both right and left reverse
C. Connect the feed line to the brake solenoid. pumps. If pressure did not recover during right
turn check the left reverse pump, during left turn
D. Disconnect the reservoir return line from the
check the right reverse pump.
brake solenoid, plug the line and cap the
fitting. NOTE: See procedures in this section for checking
forward and reverse pumps.
E. Lower the ROPS cab/canopy, see section
9008.
F. Turn off the vacuum pump and repeat
procedures 3 through 16.

6002-7
CHECKING PRESSURE OF RIGHT PUMP

Equipment Required 10. Move the Hand throttle to the IDLE position.
CAS-1804 Pressure test and fitting kit. 11. Place the directional control in the R position.
Right Pump Pressure Test When the pressure stops increasing, record the
pressure readings.
Make sure the hydraulic and hydrostatic oil is at
operating temperature. 13. Move the Hand throttle to the IDLE position,
place the directional control in neutral and apply
1. It will be necessary to operate the machine the parking brakes, stop the engine.
against an immovable object or into a spoil pile.
The surface must be one that will allow the track 14. Compare the pressure readings recorded to the
to dig in, in both FORWARD and REVERSE. specifications on page 3.
15. If pressures are not within specification on page
WARNING: Always know the location of all 3, tilt the ROPS cab/canopy, see section 9008.
16. Adjust the pressure reliefs of the right pump by
doing the following procedure:
injury or death can result if you do not follow A. Check the torque of the pressure relief valves
these instructions. in the pump body, 150 Nm (110 lb-ft).
SA015 B. Remove the plastic cap from the pressure
2. Connect two 690 bar (10,000 psi) gauges on the relief valve, loosen the jam nut and turn the
quick disconnect fitting marked Right Reverse adjusting screw in to increase the pressure
Pump Port MA (1) and Right Forward Pump Port and out to decrease the pressure. Pressure
MB (2). The hose for the pressure gauge must setting of 420 bar (6092 psi).
have at least a 690 bar (10,000 psi) rating.
relief locations page 9.
17. Lower the ROPS cab/canopy, see section 9008.
18. Repeat Steps 3 through 14 to check the pressure
setting.
19. If pressure is still not within specification on page
3, tilt the ROPS cab/canopy, see section 9008.
2 1
20. Adjust the pressure over ride valve by doing the
following procedure:
A. Remove the plastic cap from the POR valve,
loosen the jam nut and turn the adjusting
BD06K126 screw in until it just seats, tighten the jam nut.
3. Direct the gauges into the ROPS or cab to view
them from the operators seat. IMPORTANT: DO NOT over tighten the adjusting screw
in the POR valve, this WILL damage internal components
4. Start the engine. of the POR valve.
5. Make sure the Hand Throttle is in the idle
position.
22. Repeat procedures 3 through 14 to check the
6. Use the UP range button to place the machine in pressure setting.
its highest range. The instrument cluster will
reflect the hydrostat range. NOTE: If the pressure reading is not within specifications
see section 6001 removal and installation of power train
7. Make sure both parking brakes are in the OFF
components, replace the pumps.
position.
8. Place the directional control in the F position.
When the pressure stops increasing, record the
pressure reading.

6002-8
CHECKING PRESSURE OF LEFT PUMP

Equipment Required 10. Move the Hand throttle to the IDLE position.
CAS-1804 Pressure test and fitting kit. 11. Place the directional control in the R position.
Left Pump Pressure Test When the pressure stops increasing, record the
pressure readings.
Make sure the hydraulic and hydrostatic oil is at
operating temperature. 13. Move the Hand throttle to the IDLE position,
place the directional control in neutral and apply
1. It will be necessary to operate the machine the parking brakes, stop the engine.
against an immovable object or into a spoil pile.
The surface must be one that will allow the track 14. Compare the pressure readings recorded to the
to dig in, in both FORWARD and REVERSE. specifications on page 3.
15. If pressures are not within specification on page
WARNING: Always know the location of all 3, tilt the ROPS cab/canopy, see section 9008.
16. Adjust the pressure reliefs of the left pump by
doing the following procedure:
injury or death can result if you do not follow A. Check the torque of the pressure relief valves
these instructions. in the pump body, 150 Nm (110 lb-ft).
SA015 B. Remove the plastic cap from the pressure
2. Connect a 690 bar (10,000 psi) gauges on the relief valve, loosen the jam nut and turn the
quick disconnect fitting marked Left Reverse adjusting screw in to increase the pressure
Pump Port MB (2) and Left Forward Pump Port and out to decrease the pressure. Pressure
MA (1). The hose for the pressure gauge must setting of 420 bar (6092 psi).
have at least a 690 bar (10,000 psi) rating.
relief locations page 9.
1 2 17. Lower the ROPS cab/canopy, see section 9008.
18. Repeat Steps 3 through 14 to check the pressure
setting.
19. If pressure is still not within specification on page
3, tilt the ROPS cab/canopy, see section 9008.
20. Adjust the pressure over ride valve by doing the
following procedure:
A. Remove the plastic cap from the POR valve,
loosen the jam nut and turn the adjusting
BD06K126 screw in until it just seats, tighten the jam nut.
3. Direct the gauges into the ROPS or cab to view
them from the operators seat. IMPORTANT: DO NOT over tighten the adjusting screw
in the POR valve, this WILL damage internal components
4. Start the engine. of the POR valve.
5. Make sure the Hand Throttle is in the idle
position.
22. Repeat procedures 3 through 14 to check the
6. Use the UP range button to place the machine in pressure setting.
its highest range. The instrument cluster will
reflect the hydrostat range. NOTE: If the pressure reading is not within specifications
see section 6001 removal and installation of power train
7. Make sure both parking brakes are in the OFF
components, replace the pumps.
position.
8. Place the directional control in the F position.
When the pressure stops increasing, record the
pressure reading.

6002-9
PUMP PRESSURE RELIEF LOCATIONS
1
BC07F266
RIGHT SIDE VIEW
1. MAIN PRESSURE RELIEF LEFT REVERSE 2. FRONT CHARGE PUMP PRESSURE RELIEF
NOTE: Main pressure relief for the left side forward is located on the opposite side of the pump directly across from the forward
pressure relief valve.

6002-10
BC07F264
LEFT SIDE VIEW
1. REAR CHARGE PUMP PRESSURE RELIEF 2. MAIN PRESSURE RELIEF RIGHT FORWARD
NOTE: Main pressure relief for the right side reverse is located on the opposite side of the pump directly across from the
reverse pressure relief valve.

6002-11
1 2
BC07F265
BOTTOM VIEW
1. RIGHT OVERRIDE PRESSURE RELIEF VALVE 2. LEFT OVERRIDE PRESSURE RELIEF VALVE

6002-12
NOTES

Section
6003
6003
DRIVETRAIN CONTROLLER

6003-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE DRIVETRAIN CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE, HAND, AND FOOT THROTTLE POTENTIOMETER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RETREIVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Erasing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Steering Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Shuttle Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Maximum Transmission Speed Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL AND INSTALLATION OF THE PUMP SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FAULT 4121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FAULT 4131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FAULT 4141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FAULT 4151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FAULT 4212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FAULT 4222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FAULT 4311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FAULT 4312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FAULT 4321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FAULT 4322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FAULT 4323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FAULT 4324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FAULT 4331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FAULT 4332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FAULT 4341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FAULT 4421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
FAULT 4431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
FAULT 4521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FAULT 4522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FAULT 4531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FAULT 4532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FAULT 4533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
FAULT 4622 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
FAULT 4721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6003-3
REMOVAL AND INSTALLATION OF THE DRIVETRAIN CONTROL MODULE

STEP 1 STEP 5
Park the machine on a level surface, lower blade and
any attachments.
STEP 2
Apply parking brakes, turn ignition switch and master
disconnect off.
STEP 3
BD07F150-01
Unsnap connector lock tab.
STEP 6
Continue to push locking tab until the connector
disconnects from the controller.
STEP 7
BD06K007-01
Remove left arm rest.
STEP 4
BD07F152-01
Check connector for corrosion, check seal for

damage.
BD07F154-01 STEP 8
Remove four mounting screws, remove the cover for
the controller.
BD07F151-01
Repeat the procedure for the other connector.

6003-4
STEP 9 STEP 11
BD07F153-01 BD07F154-01
Install the mounting bolts, start the connectors into Install the cover and mounting screws.
the controller with the locking bar slid completely out
of the connector. STEP 12
IMPORTANT: DO NOT force the connector into the
controller, be sure to align the pins.
STEP 10
BD06K007-01
Install the left arm rest.
BD07F150-01
Slide the locking bar into the connector to draw the

connector into place on the controller.
NOTE: Make sure the locking bar snap’s into the locked
position.

6003-5
BRAKE, HAND, AND FOOT THROTTLE POTENTIOMETER CALIBRATION

1. Put the master disconnect switch in the on 9. After moving brake pedal and no error message
position and the ignition switch in the run appears on the instrument cluster press both
position. buttons for one second and release, the
instrument cluster will read (CAL HTR).
2. Push and hold both the bump up and bump down
buttons on the directional control. 10. Slowly move the hand throttle from low idle to
high idle three times.
3. Turn the ignition switch to the on position and
hold the buttons for 5 seconds or until the NOTE: During this operation if the instrument cluster
instrument cluster reads (HP 125-135), release reads (ERR RANGE), minimum/maximum values are out of
the buttons. range or potentiometer was not moved in the last five
seconds since the start of calibration mode.
4. Use the bump up/down buttons to select the
machine horse power range, (HP 125-135 or 11. After moving hand throttle and no error message
HP 150 - 160). appears on the instrument cluster press both
buttons for one second and release, the
NOTE: By selecting a different machine will cause the
instrument cluster will read (CAL FTR).
calibration to be incorrect and machine functions to be
impaired. 12. Slowly move the foot throttle (Decel Pedal) from
high idle to low idle three times.
5. When the machine being calibrated is displayed
press both buttons for one second and release, NOTE: During this operation if the instrument cluster
the instrument cluster will read (LT or LGP/WT). reads (ERR RANGE), minimum/maximum values are out of
range or potentiometer was not moved in the last five
seconds since the start of calibration mode. During this
machine track gauge, (LT or LGP/WT).
operation if the instrument cluster reads (ERR SWITCH),
NOTE: By selecting a different machine will cause the the low idle switch is not functioning or is out of
calibration to be incorrect and machine functions to be adjustment.
impaired.
13. After moving foot throttle (Decel Pedal) and no
7. When the machine being calibrated is displayed error message appears on the instrument cluster
press both buttons for one second and release, press both buttons for one second and release,
the instrument cluster will read (CAL BRK). the instrument cluster will read (CAL OK). Stop
and restart the machine, values are stored in
8. Slowly move the brake pedal from release to
internal memory.
applied position three times.
14.If at any time during calibration the instrument
NOTE: During this operation if the instrument cluster
cluster reads (CAL FAIL), stop the engine and
reads (ERR RANGE), minimum/maximum values are out of
restart the procedure.

6003-6
RETREIVING FAULT CODES

NOTE: If you have and active fault the fault menu can be Erasing Faults
accessed by pressing service/enter (4) on the dash rocker
switch. If there are no active faults, you must press the up 1. Hold the enter button until the display shows
arrow (1) and the escape button (3) to access the fault SERVICE.
menu, if no faults are recorded the monitor will display 2. Press the down arrow until RESET is highlighted.
(NONE).
3. Press enter, the display shows CLEAR ERRORS
AND RESTORE FATORY SETTINGS.
1 3 4. Highlight CLEAR ERRORS and press enter to
erase active errors.
NOTE: This will clear only the faults from the drive train
controller, the engine controller will hold faults in memory
an can be recovered by the EST.
2 4
BD06G112-01
1. Press and release the service/enter button (4).

Use up or down arrows (1 or 2) to display fault
codes menu, (FAULTS). Press the service/enter
button (4) to select the faults menu then the
down arrow (2) to retrieve the faults.
2. The first fault code display will be the fault code
number. (1 #####F).
3. Press the down arrow (2), the second part of the
fault code display will be the hours when the fault
was recorded. (1 #####.#).
4. Press the down arrow (2), the third part of the
fault code display will be the number of times the
fault has occurred. (1 ##X).
5. Press the down arrow (2), if there is a second
fault recorded the display will read (2 #####F),
repeat steps two through four to retrieve all fault
codes.
6. Continue to toggle the down arrow (2) until all
fault codes are recorded for repair or repairs are
completed.
7. Press the down arrow (2) until the clear fault
code menu is displayed, (CLEAR FC). Select the
clear fault code menu by pressing the
service/enter button (4), the item will flash and
display (CLEAR?). Pressing the service/enter (4)
button again will confirm this selection and faults
codes will be removed.
NOTE: If a reset is not desired at this time, press the
down arrow (2) again and (NO CLEAR) will be displayed.

6003-7
ADJUSTING PARAMETERS
Adjusting Steering Sensitivity

The direction control lever has three sensitivity
settings.
1 3
● Smooth
● Normal
● Fast
To change the sensitivity:
2 4
1 3 BD06G112-01
3. Select the SETTINGS menu by pressing the
enter button. The display will show SETTINGS at
the top followed by:
● Max Spd
● Shuttle
2 4 ● Steer
4. Push the down arrow and go to steer.
BD06G112-01
NOTE: Normal is the setting from the factory.
1. Press and hold the enter button for 2 to 3
seconds until the screen shows SERVICE at the 5. Press the enter button.
top. 6. Use the up or down arrow button until the desired
choice is blinking.
7. Push the enter button to confirm the selection
1 3 and store the choice.
NOTE: The setting menu may be hidden entirely with the
EST.
Adjusting Shuttle Parameter

To adjust the shuttle parameter follow the same
2 4 steps as for steering sensitivity.
The shuttle choices are the same:
BD06G112-01
2. Press the down arrow until SETTINGS is on ● Smooth
displayed. ● Normal
● Fast
After selecting desired value press the enter button
to confirm the selection and store the choice.

6003-8
Adjusting Maximum Transmission NOTE: When the crawler engine is shut off the
transmission speed will default to 60%.
Speed Parameter
To adjust the maximum transmission speed follow
the same steps as for steering sensitivity.
The transmission speed choices will be 70, 80, 90 or
100 per cent.
After selecting the desired value press the enter
button to confirm and store the choice.
Transmission Speed Controls
1
BD06G113-01
The transmission speed gauge will allow the operator
to know which speed is selected. When the crawler
2 engine is shut off the transmission speed will default
to 60% as shown.
The digital display will reflect the position of the
direction control lever as “F” forward, “N” neutral, or
“R” reverse.
BD02M166-01
NOTE: The crawler will not move unless the engine rpm is
1. Transmission speed up button above 1000.
2. Transmission speed down button NOTE: A flashing F or R indicates the directional control
The CASE K Series crawlers have infinitely variable lever must be returned to neutral before movement is
speeds in forward and revers from 0 to 9.7 km/h (0 to allowed.
6.0 mph). The maximum speed is selectable in a
range of 10 increments. To move from one speed to
another press the UP (1 for DOWN (2) button. The
operator may increment up one touch at a time or
hold the button to move through the transmission
speeds.
NOTE: The speed can only be increased to the maximum
transmission speed setting. The factory setting is 90%.

6003-9
REMOVAL AND INSTALLATION OF THE PUMP SOLENOIDS

STEP 1 STEP 5
Park the machine on a level surface, lower blade and
any attachments.
STEP 2
Apply parking brakes, turn ignition switch and master
disconnect off.
STEP 3
Tilt ROPS cab or canopy.
STEP 4
BD07F095-01
Remove the retaining nut for the solenoids, remove

the solenoids.
NOTE: Remove and replace both front or rear pump
solenoids as a unit.
STEP 6
Slide the solenoids onto the control valve shaft,
install the retaining nut and tighten.
NOTE: Make sure the wires are routed in such a manner
that they will not rub against the pump housings.
BD07F095-01
Disconnect the electrical connector for the solenoids

STEP 7
being replaced.
Connect the electrical connector.
NOTE: Make sure the connector seal is in place and
serviceable.
STEP 8
Lower ROPS cab or canopy.

6003-10
FAULT 4121
Left Forward Pump Solenoid Circuit STEP 2
Open or Over Current
Condition:
1
Crawler will not move forward.
Possible Failure Modes:

1. Connectors not mated fully, pins not pushed into
connector fully, bent pin or broken wire at rear of
connector. 2
BD07F095-01
3. Wiring or solenoid circuits shorted.
1. CONNECTOR P4 2. CONNECTOR P3
4. Failed Drivetrain Control Module.
Clean and inspect the Left Forward Pump Solenoid
NOTE: Go to the electrical schematic for a complete view Connection.
of the controller circuit.
A. Turn ignition switch and master disconnect off.
STEP 1 B. Tilt ROPS cab or canopy.

Find out if the fault code is still active. C. Disconnect the Left Forward Pump Solenoid,
Connector P3.
A. Turn ignition switch to RUN position to power
drivetrain controller. D. Inspect pins 1 through 4. Clean connections.
B. Clear all fault codes from the controller. E. Clean female pins by installing and removing.
NOTE: Prior to clearing fault codes write down all fault F. Measure the resistance of the coil at the Left
codes, number of occurrences, and engine hours at last Forward Pump Solenoid, Connector P3 pins 1
occurrence. and 2. The resistance should be 23.75 Ohms
± 0.75 Ohms.
C. To check for fault code: Move directional
control to neutral, ignition switch to run NOT OK – Replace the solenoid. Return to Step 1 to
(engine does not need to be running), move confirm elimination of fault.
both parking levers to down position, move
OK – Go to Step 3.
hand throttle to high idle position, and push
directional control to forward position.
STEP 3
NOT OK – Fault code 4121 is recorded again. Go to
Check the Left Forward Pump Solenoid Ground
Step 2.
Connection.
OK – Fault is not recorded again. Ok for return to
A. Measure the resistance between Connector
service.
P3, pin 1 and battery ground, must be less
than 10 Ohms.
NOT OK – Determine break in ground connection
and repair. Return to Step 1 to confirm elimination of
fault.

6003-11
STEP 4 STEP 5
1
1 2
2 3
BD07F088-01 BD07C149-01
1. CONNECTOR C5 1. CONNECTOR C1
2. CONNECTOR P1 2. CONNECTOR C2
3. LEFT ROPS STRUT
Check for open circuit in the Left Forward Pump
Check for open circuit in the Left Forward Pump Solenoid control wire between connectors C5 and
Solenoid circuit between P3 and P1. C1.
A. Disconnect Connector P1. A. Disconnect the Main Drivetrain Controller,
Connector C1.
B. Inspect pin 15 on Connector P1. Clean
Connections. B. Inspect pin 31 on Connector C1. Clean
connections.
C. Clean female pins by installing and removing.
D. Check for open circuit between pin 2 of the
Left Forward Pump Solenoid, Connector P3, D. Check for open circuit between pin 15 of
and pin 15 of Connector P1. Connector C5,and pin 31 of the Main
Drivetrain Controller, Connector C1.
NOT OK – Determine the break between connector
P1 and P3 and repair. Return to Step 1 to confirm NOT OK – Determine break between connector C1
elimination of fault. and C5 and repair. Return to Step 1 to confirm
elimination of fault.
STEP 6
Replace the Drivetrain Control Module.
NOTE: Prior to changing Drivetrain Control Module
contact Technical Services for further assistance.
A. Remove and replace Drivetrain Control
Module.
B. Write symptom on failed Drivetrain Control
Module.
C. Install program with Electronic Service Tool
(EST) and recalibrate system.

6003-12
FAULT 4131
Right Forward Pump Solenoid Circuit STEP 2
Condition:
1
Crawler will not move forward.

connector. 2
BD07F095-01
3. Wiring or solenoid circuits shorted.
Clean and inspect the Right Forward Pump Solenoid
NOTE: Go to the Electrical Schematic for a complete view Connection.
Find out if the fault code is still active. C. Disconnect the Right Forward Pump Solenoid,
A. Turn ignition switch to RUN position to power Connector P4.
NOTE: Prior to clearing fault codes write down all fault F. Measure the resistance of the coil at the Right
codes, number of occurrences, and engine hours at last Forward Pump Solenoid, Connector P4 pins
occurrence. 1 and 2. The resistance should be 23.75
C. To check for fault code: Move directional Ohms ± 0.75 Ohms.
hand throttle to high idle position, and push OK – Go to Step 3.
STEP 3
Step 2. Check the Right Forward Pump Solenoid Ground
Connection.
service. A. Measure the resistance between Connector
P4, pin 1 and battery ground, must be less
than 10 Ohms.
fault.

6003-13
STEP 4 STEP 5
1
1 2
2 3
BD07F088-01 BD07C149-01
3. LEFT ROPS STRUT
Check for open circuit in the Right Forward Pump
Check for open circuit in the Right Forward Pump Solenoid control wire between connectors C5 and
Solenoid circuit between P4 and P1. C1.
Connector C1.
Connections. B. Inspect pin 4 on Connector C1. Clean
connections.
Right Forward Pump Solenoid, Connector D. Check for open circuit between pin 13 of
P4, and pin 13 of Connector P1. Connector C5,and pin 4 of the Main
NOT OK – Determine break between connector P1
and P4 and repair. Return to Step 1 to confirm NOT OK – Determine break between connector C1
STEP 6
Module.
Module.

6003-14
FAULT 4141
Left Reverse Pump Solenoid Circuit STEP 2
Condition:
1
Crawler will not move in reverse.

connector. 2
2. Wiring or solenoid circuits open
BD07F095-01
3. Wiring or solenoid circuits shorted
Inspect the Left Reverse Pump Solenoid connection
NOTE: Go to the Electrical Schematic for a complete view and Resistance.
Find out if the fault code is still active. C. Disconnect the Left Reverse Pump Solenoid,
A. Turn ignition switch to RUN position to power Connector P3.
Drivetrain Controller. D. Inspect pins 1 through 4. Clean connections.
NOTE: Prior to clearing fault codes write down all fault F. Measure the resistance of the coil at the Left
codes, number of occurrences, and engine hours at last Reverse Pump Solenoid, Connector P3 pins
occurrence. 3 and 4. The resistance should be 23.75
both parking levels to down position, move
hand throttle to high idle position, and pull OK – Go to Step 3.
directional control to reverse position (backup
alarm should sound). STEP 3
NOT OK – Fault code 4141 is recorded again. Go to Check Left Reverse Pump Solenoid Ground
Step 2. Connection.
OK – Fault is not recorded again. Ok for return to A. Measure the resistance between Connector
service. P3, pin 4 and battery ground, must be less
than 10 Ohms.
fault.

6003-15
STEP 4 STEP 5
1
1 2
2 3
BD07F088-01 BD07C149-01
3. LEFT ROPS STRUT
Check for open circuit in the Left Reverse Pump
Check for open circuit in the Left Reverse Pump Solenoid control wire between connectors C5 and
Solenoid Circuit between connectors P3 and P1. C1.
Connector C1.
connections. B. Inspect pin 30 on Connector C1. Clean
connections.
Left Reverse Pump Solenoid, Connector P3, D. Check for open circuit between pin 14 of
and pin 14 of the Drivetrain Controller, Connector C5, and pin 30 of the Main
Connector P1. Drivetrain Controller, Connector C1.
NOT OK – Determine break between connector P1 NOT OK – Determine break between connector C1
and P3 and repair. Return to Step 1 to confirm and C5 and repair. Return to Step 1 to confirm
elimination of fault. elimination of fault.
OK – Go to Step 5. OK – Go to Step 6.
STEP 6
Module.
Module.

6003-16
FAULT 4151
Right Reverse Pump Solenoid Circuit STEP 2
Condition:
1
Crawler will not move in reverse.

connector. 2
BD07F095-01
3. Wiring or solenoid circuits shorted
Inspect the Right Reverse Pump Solenoid
NOTE: Go to the Electrical Schematic for a complete view Connection and Resistance.
Find out if the fault code is still active. C. Disconnect the Right Reverse Pump
A. Turn ignition switch to RUN position to power Solenoid, Connector P4.
NOTE: Prior to clearing the fault codes write down all F. Measure the resistance of the coil at the Right
fault codes, number of occurrences, and engine hours at Reverse Pump Solenoid, Connector P4 pins
last occurrence. 3 and 4. The resistance should be 23.75
hand throttle to high idle position, and pull OK – Go to Step 3.
directional control to reverse position (backup
alarm should sound). STEP 3
NOT OK – Fault code 4151 is recorded again. Go to Check Right Reverse Pump Solenoid Ground
Step 2. Connection.
OK – Fault is not recorded again. Ok for return to A. Measure the resistance between Connector
service. P4, pin 4 and battery ground, must be less
than 10 Ohms.
fault.

6003-17
STEP 4 STEP 5
1
1 2
2 3
BD07F088-01 BD07C149-01
3. LEFT ROPS STRUT
Check for open circuit in the Right Reverse Pump
Check for open circuit in the Right Reverse Pump Solenoid control wire between connectors C5 and
Solenoid Circuit between connectors P4 and P1. C1.
Connector C1.
connections. B. Inspect pin 16 on Connector C1. Clean
connections.
Right Reverse Pump Solenoid, Connector D. Check for open circuit between pin 13 of
P4, and pin 13 of Connector P1. Connector C5, and pin 16 of the Main
NOT OK – Determine break between connectors P1
and P4 and repair. Return to Step 1 to confirm NOT OK – Determine break between connectors C1
STEP 6
Module.
Module.

6003-18
FAULT 4212
Left Motor Solenoid Circuit Open or Over NOTE: Go to the Electrical Schematic for a complete view
Current of the controller circuit.
Condition: STEP 1
Find out if the fault code is still active.
Crawler will not operate at full speed.
Possible Failure Modes: drivetrain controller.
1. Connectors not mated fully, pins not pushed into B. Clear all fault codes from the controller.
connector fully, bent pin or broken wire at rear of NOTE: Prior to clearing fault codes write down all fault
connector. codes, number of occurrences, and engine hours at last
2. Wiring or solenoid circuits open occurrence.
3. Wiring or solenoid circuits shorted C. To check for fault code the machine needs to
be driven at a speed above the 50%
4. Failed Drivetrain Control Module transmission speed range.
Step 2.
service.

6003-19
STEP 2
2
1 4
BD07F107-01
1. LEFT MOTOR SPEED SENSOR 3. LEFT MOTOR SOLENOID CONNECTOR P7

2. LEFT MOTOR SPEED SENSOR CONNECTOR P5 4. LEFT MOTOR SOLENOID
Inspect the Left Motor Solenoid Connection and STEP 3

Resistance. Check Left Motor Solenoid Ground Connection.
A. Turn ignition switch and master disconnect off. A. Measure the resistance between Connector
B. Remove rear access cover to hydrostat P7, pin 2 and Battery ground, must be less
motors. than 10 Ohms.
C. Disconnect the Left Motor Solenoid, NOT OK – Determine break in ground connection
Connector P7. and repair. Return to Step 1 to confirm elimination of
fault.
D. Inspect pins 1 and 2. Clean connections.
E. Clean female pins by installing and removing.
F. Measure the resistance of the coil at the Left
Motor Solenoid, Connector P7 pins 1 and 2.
The resistance should be 22.70 Ohms ± 0.75
Ohms.
NOT OK – Replace the solenoid. Return to Step 1 to
confirm elimination of fault.

6003-20
STEP 4 STEP 5
1
1 2
2 3
BD07F088-01 BD07C149-01
3. LEFT ROPS STRUT
Check for open circuit in the Left Motor Solenoid
Check for open circuit in the Left Motor Solenoid control wire between connectors C5 and C2.
Circuit between connections P7 and P1.
A. Disconnect the Main Drivetrain Controller,
A. Disconnect Connector P1. Connector C2.
B. Inspect pin 31 on Connector P1. Clean B. Inspect pin 68 on Connector C2. Clean
connections. connections.
C. Clean female pin by installing and removing. C. Clean female pins by installing and removing.
D. Check for open circuit between pin 1 of the D. Check for open circuit between pin 31 of
Left Motor Solenoid, Connector P7, and pin Connector C5, and pin 68 of the Main
31 of Connector P1. Drivetrain Controller, Connector C2.
STEP 6
Module.
Module.
STEP 7
Install the rear cover and torque the 30mm hex bolts
to 430 to 485 Nm (315 to 355 lb-ft), the 18mm hex
bolts to 77 to 100 Nm (57 to 74 lb-ft).

6003-21
FAULT 4222
Right Motor Solenoid Circuit Open or NOTE: Go to the Electrical Schematic for a complete view
Over Current of the controller circuit.
Condition: STEP 1
Crawler will not operate at full speed.
Possible Failure Modes: drivetrain controller.
1. Connectors not mated fully, pins not pushed into B. Clear all fault codes from the controller.
connector fully, bent pin or broken wire at rear of NOTE: Prior to clearing fault codes write down all fault
connector. codes, number of occurrences, and engine hours at last
2. Wiring or solenoid circuits open occurrence.
3. Wiring or solenoid circuits shorted C. To check for fault code the machine needs to
4. Failed Drivetrain Control Module transmission speed range.
Step 2.
service.

6003-22
STEP 2
1 4
BD07F103-01
1. RIGHT MOTOR SPEED SENSOR CONNECTOR P6 3. RIGHT MOTOR SOLENOID CONNECTOR P8

2. RIGHT MOTOR SOLENOID 4. RIGHT MOTOR SPEED SENSOR
Inspect the Right Motor Solenoid Connection and STEP 3

Resistance. Check Right Motor Solenoid Ground Connection.
A. Turn ignition switch and master disconnect off. A. Measure the resistance between Connector
B. Remove rear access cover to hydrostat P8, pin 2 and Battery ground, must be less
motors. than 10 Ohms.
C. Disconnect the Right Motor Solenoid, NOT OK – Determine break in ground connection
Connector P8. and repair. Return to Step 1 to confirm elimination of
fault.
D. Inspect pins 1 and 2. Clean connections.
F. Measure the resistance of the coil at the Right
Motor Solenoid, Connector P8 pins 1 and 2.
The resistance should be 22.70 Ohms ± 0.75
Ohms.
NOT OK – Replace the solenoid. Return to Step 1 to

6003-23
STEP 4 STEP 5
1
1 2
2 3
BD07F088-01 BD07C149-01
3. LEFT ROPS STRUT
Check for open circuit in the Right Motor Solenoid
Check for open circuit in the Right Motor Solenoid control wire between connectors C5 and C2.
A. Disconnect Connector P1. Connector C2.
B. Inspect pin 32 on Connector P1. Clean B. Inspect pin 69 on Connector C2. Clean
connections. connections.
C. Clean female pin by installing and removing. C. Clean female pins by installing and removing.
D. Check for open circuit between pin 1 of the D. Check for open circuit between pin 32 of
Right Motor Solenoid, Connector P8, and pin Connector C5, and pin 69 of the Main
32 of Connector P1. Drivetrain Controller, Connector C2.
STEP 6
Module.
Module.
STEP 7

6003-24
FAULT 4311
Left Speed Sensor Out of Range NOTE: Go to the Electrical Schematic for a complete view
Condition:
STEP 1
Track speed input is at zero when motion is
commanded and engine speed is non-zero, for a
long period. A. Turn ignition switch to RUN position to power
Possible Failure Modes: B. Clear all fault codes from the controller.
1. Connectors not mated fully, pins not pushed into NOTE: Prior to clearing fault codes write down all fault
connector fully, bent pin or broken wire at rear of codes, number of occurrences, and engine hours at last
connector. occurrence.
2. Water in connectors C. To check for fault code the machine needs to
3. Bad fuse in drivetrain controller fuse block be driven at a speed above the 50%
transmission speed range.
5. Wiring or sensor circuits shorted Step 2.
6. Failed Drivetrain Control Module OK – Fault is not recorded again. Ok for return to
service.

6003-25
STEP 2
2
1 4
BD07F107-01
1. LEFT MOTOR SPEED SENSOR 3. LEFT MOTOR SOLENOID CONNECTOR P7

2. LEFT MOTOR SPEED SENSOR CONNECTOR P5 4. LEFT MOTOR SOLENOID
Inspect the Left Speed Sensor Connection. STEP 3

B. Remove rear access cover to hydrostat 1
motors.
C. Disconnect the Left Speed Sensor,
Connector P5. 2 3
D. Inspect pins 1, 2, and 3. Clean connections.
E. Check for water in connectors.
F. Clean female pins by installing and removing.
NOT OK – Replace sensor. Return to Step 1 to
BD07F088-01
1. CONNECTOR C5
OK – Go to Step 3. 2. CONNECTOR P1
3. LEFT ROPS STRUT
Check for open circuit in the Left Speed Sensor
A. Disconnect Connector P1.
B. Inspect pins 7 and 8 on Connector P1. Clean
connections.
C. Clean female pin by installing and removing.
6003-26
D. Check for open circuit between pin 1 of the NOT OK – Determine break between connector C1
Left Speed Sensor, Connector P5, and pin 7 and C5 and repair. If no break is found in Step 4 or 5,
of Connector P1. re place Sens or. Re turn to Step 1 to co nfirm
E. Check for open circuit between pin 3 of the
Left Speed Sensor, Connector P5, and pin 8 OK – Go to Step 5.
of Connector P1.
F. Check for open circuit between pin 2 of the STEP 5
Left Speed Sensor, Connector P5, and pin 9 Replace the Drivetrain Control Module.
of Connector P1. NOTE: Prior to changing Drivetrain Control Module
NOT OK – Determine break between connector P1 contact Technical Services for further assistance.
and P5 and repair. Return to Step 1 to confirm A. Remove and replace Drivetrain Control
elimination of fault. Module.
OK – Go to Step 4. B. Write symptom on failed Drivetrain Control
Module.
STEP 4 (EST) and recalibrate system.
STEP 6
1 2 Install the rear cover and torque the 30mm hex bolts
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Check for open circuit in the Left Speed Sensor
Circuit between connectors C5 and C1.
Connector C1.
B. Inspect pins 43 and 44 on Connector C1.
Clean connections.
D. Check for open circuit between pin 7 of
Connector C5, and pin 44 of the Main
E. Check for open circuit between pin 8 of

6003-27
FAULT 4312
Right Speed Sensor Out of Range NOTE: Go to the Electrical Schematic for a complete view
Condition:
STEP 1
Tra ck sp eed inp ut is at zer o when m otion is
commanded and engine speed is non-zero, for a
long period. A. Turn ignition switch to RUN position to power
Possible Failure Modes: B. Clear all fault codes from the controller.
1. Connectors not mated fully, pins not pushed into NOTE: Prior to clearing fault codes write down all fault
connector fully, bent pin or broken wire at rear of codes, number of occurrences, and engine hours at last
connector. occurrence.
2. Water in connector C. To check for fault code the machine needs to
3. Bad fuse in drivetrain controller fuse block be driven at a speed above the 50%
5. Wiring or sensor circuits shorted Step 2.
6. Failed Drivetrain Control Module OK – Fault is not recorded again. Ok for return to
service.

6003-28
STEP 2
1 4
BD07F103-01
1. RIGHT MOTOR SPEED SENSOR CONNECTOR P6 3. RIGHT MOTOR SOLENOID CONNECTOR P8

2. RIGHT MOTOR SOLENOID 4. RIGHT MOTOR SPEED SENSOR
Inspect the Right Speed Sensor Connection. STEP 3

B. Remove rear access cover to hydrostat 1
motors.
C. Disconnect the Right Speed Sensor,
Connector P6. 2 3
D. Inspect pins 1, 2, and 3. Clean connections.
E. Check for water in connectors.
F. Clean female pins by installing and removing.
NOT OK – Replace sensor. Return to Step 1 to
BD07F088-01
1. CONNECTOR C5
OK – Go to Step 3. 2. CONNECTOR P1
3. LEFT ROPS STRUT
Check for open circuit in the Right Speed Sensor
A. Disconnect Connector P1.
B. Inspect pins 10 and 11 on Connector P1.
Clean connections.
6003-29
D. Check for open circuit between pin 1 of the STEP 4
Right Speed Sensor, Connector P6, and pin
11 of Connector P1.
E. Check for open circuit between pin 3 of the 1 2
10 of Connector P1.
F. Check for open circuit between pin 2 of the
9 of Connector P1.
NOT OK – Determine break between connector P1
and P6 and repair. Return to Step 1 to confirm
BD07C149-01
OK – Go to Step 4. 1. CONNECTOR C1
2. CONNECTOR C2
Check for open circuit in the Right Speed Sensor
Circuit between connectors C5 and C1.
Connector C1.
Clean connections.
E. Check for open circuit between pin 11 of
NOT OK – Determine break between connector C1
and C5 and repair. If no break is found, replace
Sensor. Return to Step 1 to confirm elimination of
fault.
STEP 5
Module.
Module.
STEP 6

6003-30
FAULT 4321
Decelerator Potentiometer Circuit Out of STEP 2
Range
1 3
Condition: 2
Anti stall function is no longer active, engine will stall

under heavy load.

connector.
2. Water in connectors BD06M029-01
1 BRAKE POTENTIOMETER 3 DECELERATOR

3. Adjust sensor and re-calibrate
2 BRAKE PEDAL POTENTIOMETER
4. Wiring or sensor circuits shorted Inspect the Decelerator Potentiometer Connection.
5. Failed Drivetrain Control Module NOTE: The connector for the decelerator is on the front
NOTE: Go to the Electrical Schematic for a complete view side of the fire wall.
of the controller circuit. A. Turn ignition switch and master disconnect off.
STEP 1 B. Disconnect the Decelerator Potentiometer,

Connector M5.
C. Inspect pins A, B, and C. Clean connections.
drivetrain controller. D. Check for water in connectors.
NOTE: Prior to clearing fault codes write down all fault NOT OK – Replace and adjust Decelerator
codes, number of occurrences, and engine hours at last Potentiometer. Return to Step 1 to confirm
occurrence. elimination of fault.
C. To check for fault code: Move directional OK – Go to Step 3.
control to neutral, ignition switch to run
(engine does not need to be running), move
the decelerator pedal to low idle position.
Step 2.
service.

6003-31
STEP 3 STEP 4
1 2
1
2
BD07F091-01 BD07C149-01
2. CONNECTOR C2
2. CONNECTOR M10
NOTE: Connectors are located behind the fuse and relay Check for open circuit in the Decelerator
panels. Potentiometer Circuit between connections C4 and
C1.
Check for open circuit in the Decelerator
Potentiometer Circuit between connectors M5 and A. Disconnect the Main Drivetrain Controller,
M10. Connector C1 and Connector C2.
A. Disconnect Connector M10. B. Inspect pin 19 on Connector C1 and pins 62

and 80 on Connector C2. Clean connections.
B. Inspect pins 43, 12 and 36 on Connector
M10. Clean connections. C. Clean female pin by installing and removing.
C. Clean female pins by installing and removing. D. Check for open circuit between pin 43 of
D. Check for open circuit between pin A, B, and Drivetrain Controller, Connector C2.
C of the Decelerator Potentiometer Circuit,
Connector M5, and pins 43, 12 and 36 on E. Check for open circuit between pin 12 of
Connector M10. Connector C4, and pin 62 of the Main
NOT OK – Determine break between connector M5
and M10 and repair. Return to Step 1 to confirm F. Check for open circuit between pin 36 of
elimination of fault. Connector C4, and pin 19 of the Main
and M5 and repair. Return to Step 1 to confirm

6003-32
STEP 5 STEP 6
Adjust the decelerator potentiometer using the Replace the Drivetrain Control Module.
electronic service tool (EST).
NOTE: The Fully Up Decelerator Position and High contact Technical Services for further assistance.
Throttle Lever Position will be between 2.75 to 4.45 Volts
(nominal readings), and the Fully Depressed Position or
Module.
Low Throttle Lever Position will be between 0.5 to 2.25
Volts (nominal readings). B. Write symptom on failed Drivetrain Control
Module.
NOT OK – Voltage is found to be out of acceptable
limits, replace and adjust Decelerator Potentiometer. C. Install program with Electronic Service Tool
Return to Step 1 to confirm elimination of fault. (EST) and recalibrate system.

6003-33
FAULT 4322
Idle Validation Switch Not Working C. Release the decelerator pedal, a continuity
reading should be obtained.
Condition: NOTE: If continuity is not obtained replace the
Engine will not idle properly with decelerator pedal switch.
usage. D. Push the decelerator pedal to the low idle
position, reading of 0 Ohm should be
Possible Failure Modes: obtained.
1. Connectors not mated fully, pins not pushed into NOT OK – If 0 Ohm is not obtained press the switch
connector fully, bent pin or broken wire at closed by hand, if 0 Ohm is not obtained change the
connector. switch, if 0 Ohm is obtained adjust the decelerator
pedal stop bolt. Return to Step 1 to confirm
3. Wiring or switch circuits shorted
NOTE: Go to the Electrical Schematic for a complete view STEP 3
1
2
STEP 1
drivetrain controller. 3
B. Clear all fault codes from the controller.
NOTE: Prior to clearing fault codes write down all fault
codes, number of occurrences, and engine hours at last
occurrence.
BD06M029-01
1 BRAKE POTENTIOMETER 3. IDLE VALIDATION SWITCH
control to neutral, ignition switch to run, start 2 BRAKE PEDAL BEHIND PEDAL
and run the engine, move both parking levers
to down position, move the decelerator pedal Inspect the Idle Validation Switch Connection.
to low idle position. NOTE: The connector for the switch is on the front side of
NOT OK – Fault code 4322 is recorded again. Go to the fire wall.
Step 2. A. Turn ignition switch and master disconnect off.
OK – Fault is not recorded again. Ok for return to B. Disconnect the Idle Validation Switch,
service. Connector M5A.
C. Inspect pins A and B. Clean connections.
STEP 2
Inspect the Decelerator Pedal Adjustment. D. Check for water in connectors.
NOTE: The connector for the switch is on the front side of E. Clean female pins by installing and removing.
the fire wall. NOT OK – Replace and adjust decelerator pedal
A. Disconnect the Idle Validation Switch, stop bolt to activate Idle Validation Switch. Return to
Connector M5A. Step 1 to confirm elimination of fault.
B. Use a multi meter to check ohm readings OK – Go to Step 4.

between pins A and B.

6003-34
STEP 4 STEP 5
1 2
1
2
BD07F091-01 BD07C149-01
2. CONNECTOR C2
2. CONNECTOR M10
NOTE: Connectors are located behind the fuse and relay Check for open circuit in the Idle Validation Switch
panels. Circuit between connections C4 and C1and C2.
Check for open circuit in the Idle Validation Switch A. Disconnect the Main Drivetrain Controller,
Circuit between connectors M5A and M10. Connector C1 and Connector C2.
A. Disconnect Connector M10. B. Inspect pin 23 on Connector C1 and pin 80

on Connector C2. Clean connections.
B. Inspect pins 41 and 43 on Connector M10.
Clean connections. C. Clean female pin by installing and removing.
D. Check for open circuit between pin A and B of Drivetrain Controller, Connector C2.
the Idle Validation Switch Circuit, Connector
M5A, and pins 41 and 43 on Connector M10. E. Check for open circuit between pin 41 of
NOT OK – Determine break between connector M5A Drivetrain Controller, Connector C1.
elimination of fault. NOT OK – Determine break between connector C1or
C2 and C4 and repair. Return to Step 1 to confirm
OK – Go to Step 5. elimination of fault.
STEP 6
Module.
Module.

6003-35
FAULT 4323
Decelerator Lockout Pedal Completely STEP 2
Depressed for a Long Time
1 3
Condition: 2
Machine stops movement and must be reset by

selecting neutral on FNR selector.

1. Holding decelerator pedal against stop for 30
seconds or more.
connector fully, bent pin or broken wire at rear of BD06M029-01
connector. 1 BRAKE POTENTIOMETER 3 DECELERATOR

2 BRAKE PEDAL POTENTIOMETER
Inspect the Decelerator Potentiometer Connection.
NOTE: The connector for the decelerator is on the front
5. Wiring or sensor circuits shorted side of the fire wall.
6. Failed Drivetrain Control Module A. Turn ignition switch and master disconnect off.
NOTE: Go to the Electrical Schematic for a complete view B. Disconnect the Decelerator Potentiometer,
of the controller circuit. Connector M5.
STEP 1 C. Inspect pins A, B, and C. Clean connections.

Find out if the fault code is still active. D. Check for water in connectors.
A. Turn ignition switch to RUN position to power E. Clean female pins by installing and removing.
NOT OK – Replace and adjust Decelerator
B. Clear all fault codes from the controller. Potentiometer. Return to Step 1 to confirm
codes, number of occurrences, and engine hours at last OK – Go to Step 3.
occurrence.
both parking levers to down position.
Step 2.
service.

6003-36
STEP 3 STEP 4
1 2
1
2
BD07F091-01 BD07C149-01
2. CONNECTOR C2
2. CONNECTOR M10
NOTE: Connectors are located behind the fuse and relay Check for open circuit in the Decelerator
panels. Potentiometer Circuit between connections C4 and
C1.
Check for open circuit in the Decelerator
Potentiometer Circuit between connectors M5 and A. Disconnect the Main Drivetrain Controller,
M10. Connector C1 and Connector C2.
A. Disconnect Connector M10. B. Inspect pin 19 on Connector C1 and pins 62

and 80 on Connector C2. Clean connections.
B. Inspect pins 43, 12 and 36 on Connector
M10. Clean connections. C. Clean female pin by installing and removing.
D. Check for open circuit between pin A, B, and Drivetrain Controller, Connector C2.
C of the Decelerator Potentiometer Circuit,
Connector M5, and pins 43, 12 and 36 on E. Check for open circuit between pin 12 of
Connector M10. Connector C4, and pin 62 of the Main
and M10 and repair. Return to Step 1 to confirm F. Check for open circuit between pin 36 of
elimination of fault. Connector C4, and pin 19 of the Main

6003-37
STEP 5 STEP 6
Adjust the decelerator potentiometer using the Replace the Drivetrain Control Module.
NOTE: The Fully Up Decelerator Position and High contact Technical Services for further assistance.
Throttle Lever Position will be between 2.75 to 4.45 Volts
(nominal readings), and the Fully Depressed Position or
Module.
Low Throttle Lever Position will be between 0.5 to 2.25
Volts (nominal readings). B. Write symptom on failed Drivetrain Control
Module.
limits, replace and adjust Decelerator Potentiometer. C. Install program with Electronic Service Tool
Return to Step 1 to confirm elimination of fault. (EST) and recalibrate system.

6003-38
FAULT 4324
Hand Throttle Out of Range STEP 2
Inspect the Hand Throttle Connection.
Condition:
Engine speeds do not respond to hand throttle.
B. Disconnect the Hand Throttle Connector C6.
Possible Failure Modes: C. Inspect pins A, B, and C. Clean connections.
1. Connectors not mated fully, pins not pushed into D. Check for water in connectors.
connector. E. Clean female pins by installing and removing.
2. Water in connectors NOT OK – Replace and adjust Hand Throttle

Potentiometer. Return to Step 1 to confirm
3. Adjust sensor and re-calibrate elimination of fault.
4. Wiring or sensor circuits shorted OK – Go to Step 3.
NOTE: Go to the Electrical Schematic for a complete view
STEP 1
occurrence.
the hand throttle from to low idle position
several times.
Step 2.
service.

6003-39
STEP 3 STEP 4
Adjust the hand throttle potentiometer using the
1 2 NOTE: The High Idle Throttle Lever Position will be
between 2.75 to 4.45 Volts (nominal readings), and the Low
Idle Throttle Lever Position will be between 0.5 to 2.25
Volts (nominal readings).
limits, replace and adjust Hand Throttle
Potentiometer. Return to Step 1 to confirm
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2 STEP 5
Check for open circuit in the Hand Throttle Replace the Drivetrain Control Module.
Potentiometer Circuit between connections C6 and NOTE: Prior to changing Drivetrain Control Module
C1 and C2. contact Technical Services for further assistance.
A. Disconnect the Main Drivetrain Controller, A. Remove and replace Drivetrain Control
Connector C1 and Connector C2. Module.
B. Inspect pin 38 on Connector C1 and pins 64 B. Write symptom on failed Drivetrain Control
and 79 on Connector C2. Clean connections. Module.
C. Clean female pin by installing and removing. C. Install program with Electronic Service Tool
D. Check for open circuit between pin A of the (EST) and recalibrate system.
Hand Throttle Potentiometer, Connector C6,
and pin 79 of the Main Drivetrain Controller,
Connector C2.
E. Check for open circuit between pin B of the
Connector C2.
F. Check for open circuit between pin C of the
Connector C1.
or C2 and C6 and repair. Return to Step 1 to confirm

6003-40
FAULT 4331
Brake Pedal Potentiometer Out of Range STEP 2
Condition: 1 3
2
Crawler will not move, driving is not possible

connector.
BD06M029-01
4. Wiring or sensor circuits open 1 BRAKE POTENTIOMETER 3 DECELERATOR
5. Wiring or sensor circuits shorted 2 BRAKE PEDAL POTENTIOMETER
Inspect the Brake Pedal Potentiometer Connection.
NOTE: The connector for the brake potentiometer is on
the front side of the fire wall.
STEP 1 B. Disconnect the Brake Pedal Potentiometer,
Find out if the fault code is still active. Connector M6.
A. Turn ignition switch to RUN position to power C. Inspect pins A, B, and C. Clean connections.
D. Check for water in connectors.
codes, number of occurrences, and engine hours at last NOT OK – Replace and adjust Brake Pedal
occurrence. Potentiometer. Return to Step 1 to confirm
control to neutral, ignition switch to run OK – Go to Step 3.
hand throttle to high idle position and push
directional control to forward position, press
the brake pedal fully and release.
Step 2.
service.

6003-41
STEP 3 STEP 4
1 2
1
2
BD07F091-01 BD07C149-01
2. CONNECTOR C2
2. CONNECTOR M10
NOTE: Connectors are located behind the fuse and relay Check for open circuit in the Brake Pedal Sensor
panels. Circuit between connections C4 and C1.
Check for open circuit in the Decelerator A. Disconnect the Main Drivetrain Controller,
Potentiometer Circuit between connectors M5 and Connector C2.
M10. B. Inspect pins 56, 65, and 79 on Connector C2.
A. Disconnect Connector M10. Clean connections.
B. Inspect pins 18, 11, and 20 on Connector C. Clean female pin by installing and removing.
M10. Clean connections. D. Check for open circuit between pin 18 of
C. Clean female pins by installing and removing. Connector C4, and pin 79 of the Main
D. Check for open circuit between pin A, B, and
C of the Brake Potentiometer Circuit, E. Check for open circuit between pin 11 of
Connector M6, and pins 18, 11, and 20 on Connector C4, and pin 56 of the Main
Connector M10. Drivetrain Controller, Connector C2.
NOT OK – Determine break between connector M6 F. Check for open circuit between pin 20 of
and M10 and repair. Return to Step 1 to confirm Connector C4, and pin 65 of the Main
elimination of fault. Drivetrain Controller, Connector C2.
OK – Go to Step 4. NOT OK – Determine break between connector C2

and C4 and repair. Return to Step 1 to confirm
OK – Check Sensor mounting, and re-calibrate. Go
to Step 5.

6003-42
STEP 5 STEP 6
Adjust the Brake Pedal Potentiometer using the Replace the Drivetrain Control Module.
Electronic Service Tool (EST).
NOTE: The Fully Up Position will be between 2.75 to 4.5 contact Technical Services for further assistance.
Volts (nominal readings), and the Fully Depressed Position
will be between 0.5 to 2.25 Volts (nominal readings).
Module.
limits, replace and adjust Brake Pedal Potentiometer.
Module.
Return to Step 1 to confirm elimination of fault.

6003-43
FAULT 4332
Brake Release Pressure Switch Open STEP 2
Condition: 1

2 3
1. Blown fuse F2.
connector.
BD07F093-01
4. Wiring or switch circuits open 1 BRAKE VALVE 3 CONNECTOR V25
5. Wiring or switch circuits shorted 2 BRAKE PRESSURE SWITCH
Inspect the Brake Pressure Switch Connection.
of the controller circuit. B. Disconnect the Brake Pressure Switch,
Connector V25.
STEP 1 C. Inspect pins A and B. Clean connections.
A. Check fuse F2.
B. Turn ignition switch to RUN position to power
drivetrain controller. NOT OK – Replace the Brake Pressure Switch.
C. Clear all fault codes from the controller.
occurrence.
D. To check for fault code: Move directional
control to neutral, ignition switch to run, start
the engine, move both parking levers to down
position, attempt to move the machine.
Step 2.
service.

6003-44
STEP 3 STEP 4
1 2 contact Technical Services for further assistance.
Module.
Module.
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Check for open circuit in the Brake Pressure Switch
Circuit between connections V25 and C1.
Connector C1.
B. Inspect pin 48 on Connector C1. Clean
connections.
D. Check for open circuit between pin B of the
Brake Pressure Switch, Connector V25, and
pin 48 of the Main Drivetrain Controller,
Connector C1.
to Step 4.
NOTE: Pressure switch circuit listed below.

WIRE FROM CONNECTOR TO CONNECTOR
V1acc V25-A V1-A
248 V25-B V1-V
V1acc V1-A P10-A
248 V1-V P10-V
V1acc P10A P1-9
248 P10-V P1-17
V1acc P1-9 C5-9
248 P1-17 C5-17
V1acc C5-9 C4-42
248 C5-17 C1-48
V1acc C4-42 M10-42
V1acc M10-42 M2-A2

6003-45
FAULT 4341
No Engine Speed STEP 2
Condition:
Engine Speed input is zero but track speed is
non-zero for long length of time.
NOTE: If fault codes 4533 and 4622 are also present
there is a CAN communication error, see fault 4622.
Possible Failure Modes: 1

1. Speed sensor on engine bad.
BD07F081-01
connector. 1. SPEED PICKUP
3. Wiring or sensor circuits open Replace Engine Speed Pickup.
4. Wiring or sensor circuits shorted NOT OK – Return to Step 1 to confirm elimination of

fault.
of the controller circuit. STEP 3
STEP 1
Module.
NOTE: Prior to clearing fault codes write down all fault Module.
occurrence.
C. To check for fault code the machine needs to
Step 2.
service.

6003-46
FAULT 4421
Backup Alarm Relay Circuit Over Current STEP 3
or Open Circuit
Condition: 1 2
When in reverse, Backup Alarm will not sound.

connector.
BD07C149-01
3. Wiring or relay circuits open
1. CONNECTOR C1
4. Wiring or relay circuits shorted 2. CONNECTOR C2
5. Failed Drivetrain Control Module Check for open circuit between the Backup Alarm
Circuit and connectors C1.
of the controller circuit. A. Disconnect the Main Drivetrain Controller,
Connector C1.
STEP 1 B. Inspect pin 5 on Connector C1. Clean
Find out if the fault code is still active. connections.
A. Turn ignition switch to RUN position to power C. Clean female pins by installing and removing.
D. Check for open circuit between the Backup
B. Clear all fault codes from the controller. Alarm wire 205 and pin 5 of Connector C1.
NOTE: Prior to clearing fault codes write down all fault NOT OK – Determine break between the Backup
codes, number of occurrences, and engine hours at last Alarm and connector C1 and repair. Return to Step 1
occurrence. to confirm elimination of fault.
C. To check for fault code: Move directional OK – Go to Step 4.
NOTE: Backup Alarm circuit listed below.
both parking levers to down position, move WIRE FROM CONNECTOR TO CONNECTOR
hand throttle to high idle position, and push 205 V1-B P10-B
directional control to reverse position.
205 P10-B P1-1
NOT OK – Fault code 4421 is recorded again. Go to 205 P1-1 C5-1
Step 2. 205 C5-1 C1-5
service. STEP 4
STEP 2 NOTE: Prior to changing Drivetrain Control Module
Check ground circuit at backup alarm. contact Technical Services for further assistance.
NOT OK – Determine break in ground circuit and A. Remove and replace Drivetrain Control
repair. Module.
OK – Go to Step 3. B. Write symptom on failed Drivetrain Control
Module.

6003-47
FAULT 4431
Parking Brake Solenoid Circuit Over STEP 3
Current or Open Circuit
1
Condition:
Possible Failure Modes: 2 3

connector.
BD07F093-01
1 BRAKE VALVE 3 CONNECTOR V25
4. Wiring or sensor circuits shorted 2 BRAKE PRESSURE SWITCH
5. Failed Drivetrain Control Module Inspect the Brake Pressure Switch Connection.
NOTE: Go to the Electrical Schematic for a complete view A. Turn ignition switch and master disconnect off.
of the controller circuit. B. Disconnect the Brake Pressure Switch,
Connector V25.
STEP 1
C. Inspect pins A and B. Clean connections.
drivetrain controller. E. Clean female pins by installing and removing.
B. Clear all fault codes from the controller. NOT OK – Replace the Brake Pressure Switch.
codes, number of occurrences, and engine hours at last OK – Go to Step 4.
occurrence.
Step 2.
service.
STEP 2
Check ground circuit at brake solenoid.
NOT OK – Determine break in ground circuit and
repair.

6003-48
STEP 4 STEP 5
Module.
Module.
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Check for open circuit between the Parking Brake
Solenoid and connector C1.
Connector C1.
Clean connections.
Connector V24, and pins 15 and 29 of the
Main Drivetrain Controller, Connector C1.
NOT OK - Determine break between the Parking
Brake Solenoid and connector C1 and repair. Return
to Step 1 to confirm elimination of fault.
NOTE: Brake Solenoid circuit listed below.
215 V24-1 V1-U
215 V1-U P10-U
215 P10-U P1-16
215 P1-16 C5-16
215 C5-16 C1-15 & 29

6003-49
FAULT 4521
Bump Up Switch Stuck On at Power Up STEP 2
Condition:
The Instrument Cluster is indicating that the 1
Maximum Speed setting is increasing, when Bump
Up Switch is not being commanded.

connector.
2. Button is mechanically stuck
3. Wiring or switch circuits shorted BD02M166-01
4. Failed Drivetrain Control Module 1. BUMP UP SWITCH 2. BUMP DOWN SWITCH

Inspect the Bump Up Switch Connection.
B. Check for button mechanically stuck.
STEP 1
Find out if the fault code is still active. C. Clear buttons of any foreign debris.
A. Turn ignition switch to RUN position to power NOT OK – Return to Step 1 to confirm elimination of
drivetrain controller. fault.
B. Clear all fault codes from the controller. OK – Go to Step 3.
NOTE: Prior to clearing fault codes write down all fault STEP 3
Check for open circuit in the Bump Up Switch.
occurrence.
A. Disconnect the Bump Up Switch Connector.
control to neutral, ignition switch to run B. Check wiring and connector for Bump Up
(engine does not need to be running), move Switch.
NOT OK – Replace handle and button, and return to
Step 1 to confirm elimination of fault.
Step 2.
STEP 4
OK – Fault is not recorded again. Ok for return to Replace the Drivetrain Control Module.
service.
Module.
Module.

6003-50
FAULT 4522
Bump Down Switch Stuck On at Power STEP 2
Up
Condition:
1
The Instrument Cluster is indicating that the
Maximum Speed setting is decreasing, when Bump
Down Switch is not being commanded.
2
connector.
2. Button is mechanically stuck BD02M166-01
3. Wiring or switch circuits shorted 1. BUMP UP SWITCH 2. BUMP DOWN SWITCH
4. Failed Drivetrain Control Module Inspect the Bump Down Switch Connection.
of the controller circuit. B. Check for button mechanically stuck.
STEP 1 C. Clear buttons of any foreign debris.

Find out if the fault code is still active. NOT OK – Return to Step 1 to confirm elimination of
fault.
drivetrain controller. OK – Go to Step 3.
STEP 3
NOTE: Prior to clearing fault codes write down all fault Check for open circuit in the Bump Down Switch.
occurrence. A. Disconnect the Bump Down Switch
Connector.
control to neutral, ignition switch to run B. Check wiring and connector for Bump Down
(engine does not need to be running), move Switch.
both parking levers to down position, move NOT OK – Replace handle and button, and return to
hand throttle to high idle position, and push Step 1 to confirm elimination of fault.
Step 2. STEP 4
OK – Fault is not recorded again. Ok for return to Replace the Drivetrain Control Module.
service.
Module.
Module.

6003-51
FAULT 4531
Directional Control Steering Axis Faulted STEP 3
Condition:
Crawler will not move, driving is not possible. 1
1. Connectors not mated fully, pins not pushed into 2
connector.
BD07C154-01
4. Wiring or directional control circuits shorted 1. FNR 2. M9
5. Failed Drivetrain Control Module Inspect the directional control Connection (1).
B. Inspect pins 1, 2, 3, 4, 5, and 6. Clean
connections.
STEP 1
Find out if the fault code is still active. C. Clean female pins by installing and removing.
A. Turn ignition switch to RUN position to power NOT OK – Replace directional control. Return to
drivetrain controller. Step 1 to confirm elimination of fault.
B. Clear all fault codes from the controller. OK – Go to Step 4.

occurrence.
Step 2.
service.
STEP 2
A. Turn ignition switch off.
B. Disconnect the directional control, Connector
M9.
C. Turn the ignition switch on and check for
power at pins 1 and 5 at the directional control
Connector M9.
NOT OK – Replace fuse F19.

6003-52
STEP 4 STEP 5
Module.
Module.
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Check for open circuit in the directional control Circuit
between connections M9 and C1.
Connector C1.
B. Inspect pins 13, 41, and 42 on Connector C1.
Clean connections.
D. Check for open circuit between pins 1 and 5 of
the directional control, Connector M9, and
pins 13, 41, and 42 of the Main Drivetrain
Controller, Connector C1.
directional control. Return to Step 1 to confirm

6003-53
FAULT 4532
Directional Control Forward/Reverse STEP 3
Axis Faulted
Condition:
1
Crawler will not move, driving is not possible.

connector.
BD07C154-01
1. FNR 2. M9
4. Wiring or directional control circuits shorted
Inspect the directional control Connection (1).
B. Inspect pins 1, 2, 3, 4, 5, and 6. Clean
connections.
STEP 1 C. Clean female pins by installing and removing.

Find out if the fault code is still active. NOT OK – Replace directional control. Return to
drivetrain controller. OK – Go to Step 4.
occurrence.
Step 2.
service.
STEP 2
A. Turn ignition switch off.
M9.
C. Turn the ignition switch on and check for
power at pins 1 and 5 at the directional control
Connector M9.

6003-54
STEP 4 STEP 5
Module.
Module.
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Connector C1.
Clean connections.

6003-55
FAULT 4533
Directional Control Forward/Reverse STEP 2
Axis Faulted A. Turn ignition switch off.
Condition: M9.
Crawler will not move, driving is not possible. C. Turn the ignition switch on and check for
NOTE: If fault codes 4341 and 4622 are also present power at pins 1 and 5 at the directional control
there is a CAN communication error, see fault 4622. Connector M9.
1. Faulty FNR joystick
2. Connectors not mated fully, pins not pushed into STEP 3
connector.
3. Faulty directional control 1
5. Wiring or CAN circuits open
2
6. Wiring or CAN circuits shorted
BD07C154-01
STEP 1 1. FNR 2. M9
Find out if the fault code is still active. Inspect the directional control Connection (1).
A. Turn ignition switch to RUN position to power A. Turn ignition switch and master disconnect off.
B. Clear all fault codes from the controller. M9.
NOTE: Prior to clearing fault codes write down all fault C. Inspect pins 1, 2, 3, 4, 5, and 6. Clean
codes, number of occurrences, and engine hours at last connections.
occurrence.
(engine does not need to be running), move NOT OK – Replace directional control. Return to
both parking levers to down position, move Step 1 to confirm elimination of fault.
Step 2.
service.

6003-56
STEP 4 STEP 5
Module.
Module.
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Connector C1.
Clean connections.

6003-57
FAULT 4622
No CAN EEC1 communication with STEP 2
Instrument Cluster Inspect the CAN bus Connection.
A. Remove the instrument cluster and
Condition: disconnect the connectors.
Not receiving message from the Instrument Cluster B. Inspect pins on connector. Clean connections.
Possible Failure Modes: C. Clean female pin by installing and removing.
1. No power to ECU NOT OK – Replace Instrument cluster. Return to

connector fully, bent pin or broken wire at rear of OK – Go to Step 3.
connector.
STEP 3
3. Wiring or CAN bus circuits open
4. Wiring or CAN bus circuits shorted
5. Faulty CAN bus contact Technical Services for further assistance.
6. Failed Drivetrain Control Module A. Remove and replace Drivetrain Control
Module.
of the controller circuit. B. Write symptom on failed Drivetrain Control
Module.
STEP 1 C. Install program with Electronic Service Tool
Find out if the fault code is still active. (EST) and recalibrate system.
occurrence.
Step 2.
service.

6003-58
FAULT 4721
No Pilot Pressure STEP 2
Condition:
No hydraulic controls for equipment.

2
connector.
1
BD07F109-01
4. Wiring or solenoid circuits shorted 1 CONNECTOR V21
5. Failed Drivetrain Control Module 2 ACCUMULATOR
Inspect the hydraulic solenoid connection.
B. Disconnect the hydraulic solenoid, Connector
STEP 1 V21.
C. Inspect pins 1 and 2. Clean connections.
drivetrain controller. D. Check for water in connectors.
NOTE: Prior to clearing fault codes write down all fault NOT OK – Replace hydraulic solenoid. Return to
codes, number of occurrences, and engine hours at last Step 1 to confirm elimination of fault.
occurrence. OK – Go to Step 3.
control to neutral, ignition switch to run, start STEP 3
the engine, move right parking lever to down Check ground circuit at hydraulic solenoid.
position, move hydraulic control joystick in any
NOT OK – Determine break in ground circuit and
direction.
repair.
Step 2.
service.

6003-59
STEP 4 STEP 5
Module.
Module.
BD07C149-01
1. CONNECTOR C1
2. CONNECTOR C2
Check for open circuit in the Brake Pedal Sensor
Circuit between connections V21 and C2.
Connector C2.
B. Inspect pin 72 on Connector C2. Clean
connections.
Brake Pedal Potentiometer, Connector V21,
Connector C2.
and V21 and repair. Return to Step 1 to confirm
to Step 5.
NOTE: Hydraulic Solenoid circuit listed below.
272 V21-1 V1-D
272 V1-D P10-D
272 P10-D P1-18
272 P1-18 C5-18
272 C5-18 C2-72

6003-60
NOTES

Section
6007
FINAL DRIVES
6007

6007-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL HUB SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL AND DISASSEMBLY OF FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly of the Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly of the Ring Gear Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly of the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly of the Ring Gear and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly of the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly of the Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EXPANSION PLUG REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6007-3
SPECIFICATIONS
Final Drive Lubricant Capacity (Each) .........................................................................................15 Liter (4 U.S. Gal)
Lubricant................................................................................................................New Holland AMBRA Hypoide 90
SPECIAL TORQUES
Drive Hub Rolling Torque .....................................................................................8.5 ± 2.5 Nm (75 ± 20 pound-inch)
Input Shaft Bearing Retainer Plate Mounting Bolts ...............................................77 to 87 Nm (57 to 64 pound-foot)
Park Brake Housing Plate .....................................................................................77 to 87 Nm (57 to 64 pound-foot)
Brake Housing Cover M20 X 50 12 pnt ......................................................650 to 730 Nm (480 to 538.5 pound-foot)
Counter Shaft Bearing Retainer Plate Mounting Bolts ....................................125 to 150 Nm (93 to 112 pound-foot)
Spindle Housing ............................................................................................310 to 380 Nm (230 to 280 pound-foot)
Ring Gear Retaining Plate.............................................................................310 to 380 Nm (230 to 280 pound-foot)
Sun Gear Shaft Retaining Plate ......................................................................125 to 150 Nm (93 to 112 pound-foot)
Output Gear Bearing Retainer Plate Mounting Bolts.......................................125 to 150 Nm (93 to 112 pound-foot)
Planetary Carrier to Drive Hub ......................................................................310 to 380 Nm (230 to 280 pound-foot)
Final Drive to Frame ......................................................................................656 to 725 Nm (485 to 535 pound-foot)
SPECIAL TOOLS
BD06M251-01 BD06H027-01
The tool shown above is used to check the rolling Expansion plug installation tool 380002800
torque for the planetary housing. the bar is made
CAS-19545 driver kit
from 3/4 inch (19 mm) square mild steel and is 22
inches (559 mm) long. The nut is welded in the CAS-1955 driver kit
center of the bar. Size of nut is optional.
A cap screw is required to remove the outer bearing

cup for the input shaft from the gear housing. The
cap screw is an M16-2 x 320 mm (12.5 inches).
The bolt can be acquired through common parts, part
number 627-16320.

6007-4
INSPECTION
STEP 1 STEP 6
Clean all parts in cleaning solvent. Inspect the rollers used in the pinion gears for pitting,
scoring and other damage.
STEP 2
It is recommended that the face seal be discarded STEP 7
and a new face seal installed during assembly. Inspect the gears for wear and damage. If a gear is
worn or damaged, check the gear in mesh with the
STEP 3 worn or damaged gear.
It is recommended that the self-locking nuts that hold
the sprocket segments be discarded and new STEP 8
self-locking nuts be used during assembly. Inspect the splines for wear and damage.
STEP 4 STEP 9
Inspect the rollers in the bearings for pitting, scoring Inspect the planetary housing and gear housing for
and other damage. damage and cracks.
NOTE: If a bearing or bearing cup needs to be replaced,
both parts must be new.
STEP 5
Inspect the bearing cups for pitting, scoring and other
damage.

6007-5
WHEEL HUB SEAL REPLACEMENT
Removal STEP 15
STEP 10
Remove the dirt and grease from the carrier and
planetary housing.
STEP 11
Separate the track and move the track from the drive
sprocket, see section 5504.
STEP 12
Raise the machine high enough so that the sprocket
teeth are free of the track links. Use an acceptable
support to hold the machine in place. BD06M046-01
Drain the oil from the final drive and drive hub.
STEP 13
STEP 16
BD06M043-01
Remove the cap screws that mount the rock guard. BD06M045-01
Loosen and remove the cap screws that hold the

STEP 14 carrier.
STEP 17
BD06M044-01
Remove the rock guard.

BD06M047-01
Locally fabricate two lifting eyes to aid in removal of

the planetary carrier.

6007-6
STEP 18 STEP 23
BD06M048-01 BD06M169-01
Install three of the cap screws in the threaded holes Remove the plate in the bottom to the center section.
in the carrier. Install nuts, washers and lifting
brackets on the top two cap screws as shown. STEP 24
STEP 19
Put a drain pan below the planetary housing and
tighten the cap screws evenly to pull the carrier out of
the planetary housing.
STEP 20
BD06M170-01
NOTE: The following photo’s are from an older machine,

the procedures are the same. The motor and brake have
been removed to better show the work area. It is not
necessary to remove the brake and motor at this time.
Loosen and remove the cap screws that hold the
retainer for the output gear.
BD06M049-01
Install a lifting sling on the lifting eyes as shown. STEP 25

NOTE: The weight of the planetary carrier is
approximately 277 lb’s (125.5 kg).
STEP 21
Remove the carrier.
STEP 22
Remove the rear cover from the machine to gain
access to the hydrostatic motors.
BD06M171-01
Use prybars to remove the retainer and shims.

6007-7
STEP 26 STEP 30
BD06M172-01 BD06M175-01
Loosen and remove the cap screws and retainer that Loosen and remove the cap screws that hold the
holds the sun gear shaft. retainer for the ring gear.
STEP 27 STEP 31
BD06M173-01 BD06M176-01
Remove the sun gear shaft. Remove the retainer.
STEP 28 STEP 32
Remove two sprocket tooth segments.
STEP 29
BD06M177-01
Remove the shims. The shims can stay with the

retainer.
BD06M174-01
Rotate the planetary housing so that the sprocket

tooth segment that was removed is at the track rail.
Install lifting slings as shown.

6007-8
STEP 33 STEP 36
BD06M178-01 BD06M181-01
Remove the ring gear from the spindle. This can be If bearing needs to be replaced, remove the bearing
difficult to do. from the spindle.
STEP 34 STEP 37
BD06M179-01 BD06M182-01
Remove the planetary housing and ring gear from Remove the other half of the face seal from the
the machine. Lower the planetary housing to the floor spindle.
and remove the ring gear.
STEP 38
STEP 35
BD06M183-01
BD06M180-01 Remove the dirt and grease from the bore for the
Remove the half of the face seal that was installed in face seal.

6007-9
STEP 40
BD06M203-01
If the bearings are being replaced, drive the bearing

cups out of the planetary housing. BD06M204-01
Start a new inner bearing cup into the planetary

housing.
STEP 41
BD06M205-01
Use an acceptable driver and press the bearing cup

into the housing until the bearing cup stops moving.
STEP 42
Repeat steps 40 and 41 for the outer bearing cup.

6007-10
STEP 43
WARNING: Use insulated gloves or mittens
when working with hot parts.
47-41B
STEP 46
BD06M252-01
Heat the bearings for the spindle to 250° F (121° C).
STEP 44
BD06M186-01
Install the bearing on the spindle.
STEP 47
BD06M184-01
Make sure that the bore for the face seal is free of
gear lubricant. If the original face seal is to be
installed, make sure that the rubber ring is free of
gear lubricant.
BD06M217-01
STEP 45 Let the bearing cool. Lubricate the bearing on the
spindle and on the hub for the ring gear.
BD06M185-01
Install half of the face seal.

6007-11
STEP 48 STEP 51
BD06M218-01 BD06M221-01
Install the planetary housing WITHOUT the face Install the retainer and shims.
seal.
STEP 52
STEP 49
BD06M222-01
BD06M219-01 Tighten the cap screws to pull the ring gear onto the
Use acceptable lifting equipment to start the ring spindle.
gear onto the spindle. Hit the ring gear with soft
hammers to drive the ring gear onto the spindle until STEP 53
the cap screws can be used to pull the ring gear all
the way onto the spindle.
STEP 50
BD06M223-01
Install the remainder of the cap screws and tighten

the cap screws to 310 to 380 Nm (230 to 280
pound-foot).
BD06M220-01
Install the shims that were removed during

disassembly on the retainer for the ring gear.

6007-12
STEP 54 STEP 58
Loosen and remove the remaining nuts and
sprockets segments.
STEP 55
BD06M227-01
If the rolling torque is not as specified, loosen and

remove the cap screws that hold the retainer and
remove the retainer and shims.
BD06M224-01
Fasten the tool shown on page 3 to the planetary STEP 59

housing. The nut must be centered on the spindle.
STEP 56
BD06M228-01
Add or remove shims as required.
BD06M222-01 STEP 60
Use a lb-in torque wrench and check the rolling
torque of the planetary housing. Read the torque
wrench while the planetary housing is moving.
IMPORTANT: If the planetary housing is out of balance,
you must read the torque wrench for a complete revolution
to find the high and low reading for the rolling torque. Add
the high and low readings together and divide the answer
by two. The answer is the rolling torque.
STEP 57
The rolling torque must be 8.5 ± 2.5 Nm (75 ± 20
pound inch).
BD06M229-01
Install the shims, retainer and cap screws.

6007-13
STEP 61 STEP 64
BD06M226-01 BD06M230-01
Tighten the cap screws to 310 to 380 Nm (230 to 280 Fasten the lifting equipment to the planetary housing
pound-foot). and remove the ring gear from the spindle.
STEP 62 STEP 65
BD06M225-01 BD06M231-01
Check the rolling torque again. Remove the planetary housing and ring gear from
the spindle.
STEP 63
STEP 66
BD06M227-01
When the rolling torque is as specified, loosen and BD06M232-01
remove the cap screws, retainer and shims. Make sure that the bore for the face seal in the
planetary housing is free of lubricant.

6007-14
STEP 67 STEP 70
Use the lifting equipment to start the ring gear onto
the spindle. Be careful so that the face seal does not
come out of the housing. Drive the ring gear onto the
spindle with a soft hammer.
STEP 71
BD06M233-01
Install the face seal. Make sure that the face seal is
seated in the bore.
STEP 68
BD06M236-01
Apply Loctite 242 to the threads on the spindle.
STEP 72
BD06M234-01
Apply a small amount of clean oil to the sealing

surface of the face seal.
STEP 69
BD06M235-01
Install the shims, retainer and cap screws.
BD06M231-01
Start the planetary housing onto the spindle.

6007-15
STEP 73 STEP 76
BD06M226-01 BD06M239-01
Tighten the cap screws to 310 to 380 Nm (230 to 280 Install the retainer with the shoulder toward the sun
pound-foot). gear shaft and the cap screws.
STEP 74 STEP 77
BD06M237-01 BD06M240-01
Install the sun gear shaft. Prevent the sun gear shaft from turning and tighten
STEP 75 pound-foot).
STEP 78
BD06M238-01
Apply Loctite 242 to the treads in the sun gear shaft.

BD06M242-01
Install a new O-ring in the groove for the retainer for

the output gear. Make sure that the shims are on the
retainer.

6007-16
STEP 79 STEP 83
BD06M241-01 BD06M245-01
Apply Loctite 242 to the threads in the gear housing. Install the remainder of the cap screws and tighten
STEP 80 pound-foot).
Lubricate the O-ring and the bore of the retainer with
petroleum jelly. STEP 84
STEP 81
BD06M246-01
Apply a 1/8 inch (3 mm) bead of Loctite 515 to the

BD06M243-01
planetary housing as shown.
Install the retainer and two cap screws.
STEP 85
STEP 82
BD06M248-01
BD06M244-01
Engage the pinion gears with the sun gear shaft and
Tighten the cap screws evenly to pull the retainer into ring gear.
the gear housing.

6007-17
STEP 86 STEP 89
BD06M249-01 BD06M043-01
Push the carrier into the planetary housing. Install the rock guard and cap screws, tighten the cap
screws.
STEP 87
STEP 90
Install the track, see section 5504.
STEP 91
Raise the machine and remove support from under
the machine.
STEP 92
Adjust the track, see section 5504.
BD06M250-01
Apply Loctite 242 to the threads of the cap screws.

Install the cap screws.
STEP 88
Torque the cap screws to 310 to 380 Nm (230 to 280
pound-foot).

6007-18
REMOVAL AND DISASSEMBLY OF FINAL DRIVE
Disassembly of the Final Drive STEP 96
STEP 93
Mount the final drive in a stand, turn the final drive
until the carrier faces up.
STEP 94
BD06M078-01
Tighten cap screws to loosen the carrier from the

planetary carrier.
STEP 97
BD06M076-01
Remove the mounting cap screws from the planetary

carrier housing.
STEP 95
BD06M07-01
Attach a lifting device to the carrier.
STEP 98
BD06M077-01
Install puller cap screws.
BD06M080-01
Remove the four cap screws on the output bearing

retainer.

6007-19
STEP 99 STEP 102
BD06M081-01 BD06M084-01
Use a pry bar and remove the bearing retainer. Remove the retaining plate.
STEP 100 STEP 103
BD06M085-01
BD06M082-01
Remove the sun shaft from the final drive.
If the shims stay on the final drive housing, remove
them and place them on the bearing retainer.
STEP 104
STEP 101
BD06M086-01
Loosen the retainer cap screws.

BD06M083-01
Place the brake disc’s back into the housing, apply NOTE: Rotate housing on it’s input side.
pressure to the disc’s and loosen the sun shaft
retaining cap screws.

6007-20
STEP 105 STEP 108
BD06M087-01 BD06M090-01
Remove the retainer. Remove the half of the face seal that was installed in
STEP 106
STEP 109
BD06M088-01
Remove the shims and keep shims with the retainer. BD06M091-01
Place a block in the end of the spindle sun shaft hole.

STEP 107
STEP 110
BD06M089-01
Attach lifting equipment to the sprocket hub and BD06M092-01
remove it and ring gear from the final drive. Remove the bearing from the spindle.

6007-21
STEP 111 STEP 114
BD06M094-01 BD06M097-01
Use a pry bar and loosen the inner half face seal. Install puller cap screws into the spindle housing.
STEP 112 STEP 115
BD06M095-01 BD06M098-01
Remove the inner half face seal. Tighten the cap screws to loosen the spindle housing
from the final drive.
STEP 113
STEP 116
BD06M096-01
Loosen and remove the cap screws that mount the BD06M099-01
spindle. Attach lifting equipment to the spindle housing.

6007-22
STEP 117 STEP 120
BD06M100-01 BD06M103-01
Remove the spindle housing from the final drive. Use a pry bar to lift the retainer past the O-ring.
STEP 118 STEP 121
BD06M101-01 BD06M104-01
Pull the output gear up and out of the final drive Remove the retainer from the final drive.
housing at an angle to clear the idler gear.
STEP 122
STEP 119
BD06M105-01
BD06M102-01 Remove the shims for the retainer, place the shims
Remove the four cap screws from the retainer. with the retainer.

6007-23
STEP 123 STEP 126
BD06M106-01 BD06M109-01
Pull the small idler gear from the large idler gear. Remove the retainer plate.
STEP 124 STEP 127
BD06M107-01 BD06M110-01
Turn the final drive so the large idler gear is at the Install a bolt, M16-2 x 320 mm (12.5 inches), tighten
bottom, remove the large idler gear from the final the bolt to push the bearing out of the housing.
drive.
STEP 128
STEP 125
BD06M111-01
BD06M108-01 Remove the input shaft.
Remove the four Allen screws from the bearing
retainer plate.

6007-24
STEP 129 STEP 132
BD06M187-01 BD06M114-01
Use acceptable tools to remove the bearing cups Remove the outer bearing cup from the input shaft.
from the retainers for the idler shaft and output gear.
STEP 133
STEP 130
BD06M115-01
BD06M112-01 Remove the snap ring from the input shaft.

Remove the input shaft bearing cup.
STEP 134
STEP 131
BD06M116-01
BD06M113-01 Remove the brake spline hub from the input shaft.
Remove the idler gear bearing cup.

6007-25
STEP 135 Disassembly of the Ring Gear Hub
STEP 138
BD06M117-01
Remove the inner snap ring from the input shaft.

BD06M120-01
STEP 136 Install lifting eye’s into the holes in the ring gear.
Attach lifting equipment to the lifting eye’s and
remove the ring gear from the planetary carrier.
STEP 139
BD06M118-01
If the seal came out with the input shaft remove the
seal from the shaft.
STEP 137 BD06M203-01
Drive the bearing cups out of the planetary housing.
STEP 140
BD06M119-01
Remove the bearings from the input shaft, idler

gears, and output gear.
BD06M211-01
Loosen and remove the cap screws and retainers

that secure the hub.

6007-26
STEP 141 Disassembly of the Carrier
STEP 143
BD06M212-01
Remove the hub from the ring gear.

BD06M191-01
STEP 142 Put the carrier in a press for removal of the groove
pins that hold the pinion shafts. Two groove pins are
used for each pinion shaft.
NOTE: The weight of the planetary carrier is
approximately 277 lb’s (125.5 kg).
STEP 144
BD06M213-01
Use an acceptable tool to remove the bearing.
BD06M190-01
Use the short driver from the CAS-19545 driver kit

and press the outer groove pin into the carrier as far
as the driver will permit.
STEP 145
Remove the short driver and install the long driver
from the CAS-1955 driver kit. Press the groove pins
all the way out of the carrier.
STEP 146
Repeat steps 143 through 145 for the other pinion
shafts.

6007-27
STEP 147 STEP 149
BD06M192-01 BD06M194-01
Use a hammer and driver to push the pinion shaft Remove the two thrust washers.
against the expansion plug. When you drive the
expansion plug from the carrier, the pinion shaft will STEP 150
fall out of the carrier. Do not let the pinion shaft fall to
the floor.
STEP 148
BD06M195-01
Push the spacers and rollers out of the pinion gear.
BD06M139-01
Remove the pinion gear. Hold the spacer the bottom

of the pinion gear to prevent the rollers from falling
out of the pinion gear.

6007-28
Assembly of the Ring Gear and STEP 153

Hub

47-41B
STEP 151
BD06M214-01
Apply Loctite 242 to the threads in the ring gear.
STEP 154
BD06M213-01
Heat the bearing for the hub of the ring gear to 250°F
(121° C) and install the bearing on the hub.
STEP 152
BD06M215-01
Install the retainers and cap screws.
STEP 155
BD06M212-01
Let the bearing and hub cool. Install the hub in the
ring gear.
BD06M216-01
Tighten the cap screws to 125 to 150 Nm (93 to 110

pound-foot).

6007-29
STEP 156 Assembly of the Carrier
STEP 159
BD06M204-01
Start a new inner bearing cup into the planetary

housing. BD06M196-01
Apply petroleum jelly to one of the thrust washers for

STEP 157 a pinion gear.
STEP 160
BD06M205-01

into the housing until the bearing cup stops moving. BD06M197-01
Put the pinion gear on the thrust washer.

STEP 158
Repeat steps 156 and 157 for the outer bearing cup. STEP 161
BD06M198-01
Install a narrow spacer.

6007-30
STEP 162 STEP 165
BD06M199-01 BD06M202-01
Apply petroleum jelly to the bore of the pinion gear Install the narrow spacer.
and install 25 rollers.
STEP 166
STEP 163
BD06M207-01
BD06M200-01 Install the pinion gear assembly in the carrier.

Install the wide spacer.
STEP 167
STEP 164
BD06M208-01
BD06M201-01 Install the other thrust washer.

Install 25 rollers.

6007-31
STEP 168 STEP 170
BD06M209-01 BD06M206-01
Install the pinion shaft so that the holes for the Drive new groove pins into the carrier and pinion
groove pins are aligned. shaft. The groove pins are easier to install if the
groove pins are put in a freezer for 45 minutes before
STEP 169 installation.
STEP 171
Repeat steps 159 through 170 for the other pinion
gears.
STEP 172
See EXPANSION PLUG REPLACEMENT, page 51
this section for proper procedures to install the
expansion plugs.
BD06M210-01
Hold the pinion shaft in place and install a pin to hold

the pinion haft in place.

6007-32
Assembly of the Final Drive STEP 175
STEP 173
BD06M121-01
Install the bearing on the input shaft. Make sure that

BD06M252-01
the bearing is seated on the shaft.
Put all bearing to installed in an oven and heat the
bearings to 250° F (121° C). STEP 176
WARNING: Use insulate gloves or mittens

47-41B
STEP 174
BD06M117-01
Install the inner snap ring onto the input shaft.
STEP 177
BD06M122-01
Install the bearing on the input shaft. Make sure that

the bearing is seated on the shaft.
BD06M116-01
Install the brake disk flange.

6007-33
STEP 178
47-41B
STEP 179
BD06M115-01
Install the snap ring onto the input shaft.
BD06M123-01
Install the bearing on the idler gear. Make sure that

the bearing is seated on the idler gear.
STEP 180
BD06M124-01
Install the bearing on the idler shaft. Make sure that

the bearing is seated on the idler shaft.

6007-34
STEP 181 STEP 184
BD06M125-01 BD06M112-01
Install the bearings on the output gear. Make sure Use and acceptable driver and press the bearing
the bearings are seated on the output gear. cups into the gear housing.
STEP 185
STEP 182
BD06M113-01
Use and acceptable driver and press the bearing

BD06M189-01
cups into the gear housing.
into the retainer for the idler shaft and the retainer for
the output gear. STEP 186
STEP 183
BD06M126-01
Install the seal into the final drive housing for the
input shaft, the lips of the seal must face out away
BD06M188-01
from you.
into the spindle.

6007-35
STEP 187 STEP 190
BD06M127-01 BD06M128-01
Install the input shaft. Torque bearing retainer Allen screws to 77 to 87 Nm

(57 to 64 pound-foot).
STEP 188
STEP 191
BD06M134-01
Install the input shaft bearing cup. BD06M050-01
Check the input shaft rolling torque.

STEP 189 NOTE: Rolling torque above 1.1 Nm (10 inch-pound) a
shim must added.
STEP 192
BD06M190-01
Install the input shaft bearing retainer.
BD06M051-01
Remove the four Allen screws from the bearing

retainer plate.

6007-36
STEP 193 STEP 196
BD06M052-01 BD06M052-01
Remove the retainer plate. Install the shim and retainer plate.
STEP 194 STEP 197
BD06M053-01 BD06M128-01
Install a bolt, M16-2 x 320 mm (12.5 inches). Torque bearing retainer Allen screws to 77 to 87 Nm
STEP 195
STEP 198
BD06M054-01
Tighten the bolt just enough to move the bearing BD06M107-01

race up 2 to 3 MM (1/8 inch), remove the bolt. Install the idler gear.

6007-37
STEP 199 STEP 202
BD06M129-01 BD06M137-01
Install the idler shaft. Install and tighten the cap screws to 125 to 150 Nm
STEP 200
STEP 203
BD06M135-01
Install the shims that were removed during BD06M139-01

disassembly. The thickness of each shim set must be Use a dial indicator and check the free travel of the
the same. idler gear. The free travel must be 0.0 to 0.004 inch
(0.0 to 0.1 mm).
STEP 201
STEP 204
If the free travel for the idler gear is not as specified,
add or remove shims of the same thickness for each
shim set and check the free travel again.
BD06M136-01
Install the retainer without the O-ring.

6007-38
STEP 205 STEP 208
BD06M140-01 BD06M141-01
Loosen and remove the cap screws that hold the Install a new O-ring in the groove in the retainer.
retainer.
STEP 209
STEP 206
BD06M142-01
BD06M104-01 Lubricate the bore for the retainer and the O-ring with
Remove the retainer. clean oil.
STEP 207 STEP 210
BD06M105-01 BD06M143-01
Remove the shims. Keep the shims separate for the Put the shims in place on the gear housing.
final assembly.

6007-39
STEP 211 STEP 214
BD06M144-01 BD06M154-01
Install the retainer. Tighten the cap screws to 125 to 150 Nm (93 to 110
pound-foot).
STEP 212
STEP 215
BD06M145-01
Apply Loctite 242 to the threads of the cap screws BD06M147-01
and install the cap screws. Install the retainer for the output gear without the
O-ring and without shims.
STEP 213
STEP 216
BD06M146-01
Pull the retainer cow evenly into the gear housing. BD06M148-01
Install two cap screws and hand tighten leaving a

gap of 6 MM (¼ inch).

6007-40
STEP 217 STEP 221
BD06M149-01 BD06M152-01
Install the gear with the extended portion facing Lower the spindle onto the gear sousing.
down.
NOTE: The weight of the spindle is approximately
140 lb’s (63 kg).
STEP 218
STEP 222
BD06M150-01
Install the output gear.

BD06M153-01
Apply Loctite 242 to the threads of the cap screws.

STEP 219 Install and tighten the cap screws to 310 to 380 Nm
STEP 223
BD06M151-01
Apply a 3 mm (1/8 inch) bead of Loctite 515 around

the opening as shown.
BD06M155-01
STEP 220 Remove the cap screws that hold the retainer.
Apply Loctite 242 to the threads in the holes.

6007-41
STEP 224 STEP 227
BD06M147-01 BD06M158-01
Remove the retainer. Install the brake disc and apply pressure to prevent
the sun gear shaft from turning, tighten the cap
STEP 225 screws to 125 to 150 Nm (93 to 110 pound-foot).
STEP 228
BD06M156-01
Install the sun gear shaft.

BD06M159-01
STEP 226 Install the shims that were removed during

disassembly.
STEP 229
BD06M157-01
Install the retainer and cap screws that hold the sun
gear shaft.
BD06M160-01
Install the retainer without the O-ring.

6007-42
STEP 230 STEP 233
The free travel must be 0.001 to 0.006 inch (0.025 to
0.152 mm).
STEP 234
If the free travel is not as specified, add or remove
shims as required and check the free travel again.
STEP 235
BD06M162-01
Install and tighten the cap screws to 125 to 150 Nm

(93 to110 pound-foot).
STEP 231
BD06M165-01
When the free travel is correct, loosen and remove

the cap screws that hold the retainer.
STEP 236
BD06M164-01
Install a dial indicator through the hole in the spindle

to check the free travel of the output gear. If you do
not have an extension for the dial indicator install a
1.4 X 8 inch (3 X 200 mm) rod in the hole in the
spindle. Make sure that the extension or rod does not
go through one of the holes in the out put gear.
STEP 232 BD06M166-01
Remove the retainer and shims. Keep the retainer

and shims together for assemble later in the
procedure.
BD06M164-01
Raise and lower the sun gear shaft and output gear
to check the free travel of the output gear.
6007-43
STEP 237 STEP 240
BD06M157-01 BD06M161-01
Loosen and remove the cap screws and retainer for Make sure that the bore for the face seal is free of
the sun gear shaft. gear lubricant. If the original face seal is to be
installed, make sure that the rubber ring is free of
STEP 238 gear lubricant.
STEP 241
BD06M156-01
Remove the sun shaft from the final drive.

BD06M095-01
STEP 239 Install half of the face seal.
BD06M252-01
Heat the bearings for the spindle to 250° F (121° C).

6007-44
STEP 244
47-41B
STEP 242
BD06M056-01
Install the planetary housing WITHOUT the face

seal.
STEP 245
BD06M167-01
Install the bearing on the spindle.
STEP 243
BD06M058-01
Install the shims that were removed during

disassembly.
BD06M168-01 STEP 246

Let the bearing cool. Lubricate the bearing on the
spindle and on the hub for the ring gear.
BD06M059-01
Install the retainer.

6007-45
STEP 247 STEP 250
BD06M062-01 BD06M064-01
Tighten the cap screws to pull the ring gear onto the Use a torque wrench and check the rolling torque of
spindle. the planetary housing. Read the torque wrench while
the planetary housing is moving.
STEP 248 IMPORTANT: If the planetary housing is out of balance,
you must read the torque wrench for a complete revolution
to find the high and low reading for the rolling torque. Add
the high and low readings together and divide the answer
by two. The answer is the rolling torque.
STEP 251
The rolling torque must be 8.5 ± 2.5 Nm (75 ± 20
pound inch).
STEP 252
BD06M061-01

pound-foot).
STEP 249
BD06M062-01
If the rolling torque is not as specified, loosen and

remove the cap screws that hold the retainer and
remove the retainer and shims.
STEP 253
Add or remove shims as required.
BD06M063-01
Fasten the fabricated tool onto the planetary

housing. The nut must be centered on the spindle.

6007-46
STEP 254 STEP 257
BD06M060-01 BD06M062-01
Install the shims, retainer and cap screws. When the rolling torque is as specified, loosen and
remove the cap screws, retainer and shims.
STEP 255
STEP 258
BD06M061-01
Tighten the cap screws to 310 to 380 Nm (230 to 280 BD06M056-01
pound-foot). Fasten the lifting equipment to the planetary housing

and remove the planetary housing and ring gear from
STEP 256 the spindle.
STEP 259
Make sure that the bore for the face seal in the
planetary housing is free of lubricant.
BD06M064-01
Check the rolling torque again.

6007-47
STEP 260 STEP 265
BD06M057-01 BD06M060-01
Install the face seal. Make sure that the face seal is Install the shims, retainer and cap screws.
seated in the bore.
STEP 266
STEP 261
Apply a small amount of clean oil to the sealing
surface of the face seal.
STEP 262
BD06M061-01

pound-foot).
STEP 267
BD06M056-01
Start the planetary housing onto the spindle.
STEP 263
Be careful so that the face seal does not come out of
the housing. Drive the ring gear onto the spindle with
a soft hammer.
STEP 264
Apply Loctite 242 to the threads on the spindle.
BD06M065-01
Install the sun gear shaft.
STEP 268
Apply Loctite 242 to the treads in the sun gear shaft.

6007-48
STEP 269 STEP 272
BD06M066-01 BD06M069-01
Install the retainer with the shoulder toward the sun Install a new O-ring in the groove for the retainer for
gear shaft and the cap screws. the output gear.
STEP 270 STEP 273

Apply Loctite 242 to the threads in the gear housing.
STEP 274
Lubricate the O-ring and the bore of the retainer with
petroleum jelly.
STEP 275
BD06M067-01

pound-foot).
STEP 271
BD06M070-01
Install the retainer and two cap screws.
STEP 276
Tighten the cap screws evenly to pull the retainer into
the gear housing.
BD06M068-01
Install the shims on the retainer.

6007-49
STEP 277 STEP 280
BD06M071-01 BD06M073-01
Install the remainder of the cap screws and tighten Engage the pinion gears with the sun gear shaft and
the cap screws to 125 to 150 Nm (93 to 110 ring gear.
pound-foot).
STEP 281
STEP 278
BD06M074-01
BD06M072-01 Remove the lifting equipment from the planetary

Apply a 1/8 inch (3 mm) bead of Loctite 515 to the housing, loosen and remove the separating bolts.
planetary housing as shown.
STEP 282
STEP 279 Apply Loctite 242 to the threads of the cap screws.
Apply Loctite 242 tot he threads in the planetary Install the cap screws.
housing.

6007-50
STEP 283 STEP 285
Install the cap screws.
STEP 286
pound-feet).
STEP 287
See section 5509 and install the sprockets.
STEP 288
See section 7001 and install the brakes.
BD06M075-01
STEP 289
Torque the cap screws to 310 to 380 Nm (230 to 280
See section 6001 and install the hydrostatic motor.
pound-foot).
STEP 290
STEP 284
Fill the planetary housing and gear housing with
Move the housing into alignment with the frame.
85W - 140 EP gear lubricant.
STEP 291
Install the track, see to section 5504.

6007-51
EXPANSION PLUG REPLACEMENT

STEP 292 STEP 296
Prior to welding on the machine turn the master
disconnect off.
STEP 293
BD06H003-01
Apply a 2 to 3 mm bead of Loctite 504 around the

bottom corner of the plug counterbore.
BD06H006-01 STEP 297

Weld a nuts onto the expansion plugs to be removed.
IMPORTANT: To help prevent damage to electronic
equipment and arcing current going through the bearings,
connect the grounding clamp to the nut.
STEP 294
BD06H004-01
Insert the plug into the counterbore. Set the driver,

380002800, on top of the plug and center the tool to
the bore.
STEP 298
BD06H002-01
Install a bolt into the nut and tap with a hammer to

remove the expansion plug.
STEP 295
Make sure the housing bores and new plugs are
clean and free of oil/grease.
BD06H005-01
Strike the tool with enough force to bottom the tool on

the housing.

6007-52
NOTES

SECTION INDEX
BRAKES

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7001
Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002

7001
Section
7001
REMOVAL AND INASTALLATION OF

BRAKE COMPONENTS

7001-2
TABLE OF CONTENTS
BRAKE DISC’S AND SPRING WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7001-3
BRAKE DISC’S AND SPRING WASHERS
Disassembly STEP 6
STEP 1
brake levers and turn off the master disconnect.
STEP 2
Remove the rear cover on the machine.
STEP 3
1
BD06K045-01
2 Loosen all four of the brake spring housing mounting

bolts ½ of a turn.
NOTE: The final drive is shown removed for clarity only.
3 STEP 7
4
BD06E002-01

Remove the vent from the hydraulic reservoir and
connect a vacuum pump to the reservoir. Turn on the
vacuum pump.
STEP 4
BD06K046-01
Loosen the bolts evenly until the spring pressure is

released.
STEP 8
BD06K054-01
Disconnect brake line at brake housing, plug the line

and cap the fitting, turn off the vacuum pump.
STEP 5
Remove the hydrostatic motor, see section 6001. BD06K047-01
Remove the spring housing from the final drive.

7001-4
STEP 9 STEP 13
BD06K048-01 BD06K031-01
Remove the outer separator plate. Loosen all four of the mounting screws on the spring
housing evenly until spring pressure is released.
STEP 10
STEP 14
BD06K049-01
Remove the friction plate. BD06K029-01
Remove the four screws from the housing and

STEP 11 remove the housing cover and piston.
Repeat steps 9 and 10 until all of the separator and
friction plates are removed. STEP 15
STEP 12
BD06K036-01
Remove the piston from the cover, remove and

BD06K033-01
discard the O-rings.
Make alignment marks on the housing and cover.

7001-5
STEP 16 Inspection
1. Check piston for gouging or scaring.
2. Check piston housing for gouging or scaring.
3. Check brake separator plates for discoloration,
excessive wear, or scaring.
4. Check brake friction plates for excessive wear,
discoloration, scoring, flaking or material over
large areas and damaged internal teeth. Check
the groove depth of the friction plates, the groove
depth can not be less than 0.1 MM. (0.004 in) on
either side of the plate.
BD06K028-01
NOTE: If a friction plate or brake separator plate is
Remove the outer spring washer. damaged, install a new set of friction plates and brake
separator plates for that brake. DO NOT mix old and new
parts in a brake.
STEP 17
5. Inspect the friction plate gear for damaged and
missing teeth.
6. Check springs for cracks and missing spring
fingers.
BD06K027-01
Remove the inner spring washer.
STEP 18
Repeat steps 16 and 17 for the other spring washers.
STEP 19
BD06K034-01
Remove the spring guide from the housing.

7001-6
Assembly STEP 23
STEP 20
BD06K038-01
Install the third bevel washer with the bevel of the

BD06K034-01
fingers facing down.
Insert the spring guide with the bevel in the slot.
STEP 24
STEP 21
BD06K039-01
BD06K027-01
Install the fourth bevel washer with the bevel of the
Install the first bevel washer with the bevel of the fingers facing up.
fingers facing down.
STEP 25
STEP 22
BD06K037-01
BD06K028-01
Install new O-rings onto the piston.
Install the second bevel washer with the bevel of the
fingers facing up.

7001-7
STEP 26 STEP 29
BD06K041-01 BD06K043-01
Lubricate the bore of the cover with hydraulic oil. Install the piston and cover into the housing, align the
marks made during disassembly.
STEP 27 IMPORTANT: Make sure to start the cover straight into
the housing, the piston and or O-rings can be damaged if
not straight.
STEP 30
BD06K042-01
Insert the piston into the cover.

IMPORTANT: Make sure to start the cover straight onto
the piston, the piston and or O-rings can be damaged if not
straight. BD06K030-01
Install the four mounting screws.

STEP 28
STEP 31
BD06K040-01
Lubricate the bore of the housing with hydraulic oil. BD06K031-01
Tighten the screws evenly until the cover makes

contact with the housing.

7001-8
STEP 32 STEP 35
BD06K032-01 BD06K052-01
Torque screws to 77 to 87 Nm (57 to 64 pound feet). Make sure to align the separator plates slots onto the
dowel pins.
STEP 33
STEP 36
Continue to alternate between separator plates and
friction plates until all are installed.
NOTE: Six separator and six frictions plates are used in
each final drive.
STEP 37
BD06K050-01
Install a friction plate by aligning the teeth of the

friction plate with the teeth of the input shaft.
STEP 34
BD06K046-01
Install the spring housing onto the final drive, start

the mounting bolts evenly around the housing.
BD06K051-01
Install a separator plate into the final drive.

7001-9
STEP 38 STEP 42
BD06K045-01 BD06K054-01
Tighten the bolts evenly until the spring housing is Remove the plug from the line and the cap from the
snug against the final drive. fitting and install the brake release hose.
IMPORTANT: Make sure to pull the spring housing
straight onto the final drive, the spring housing can be STEP 43
damaged if not straight. Turn off the vacuum pump. Disconnect the vacuum
pump from the reservoir, install the vent into the
STEP 39 hydraulic reservoir.
STEP 44
Start and run the engine at low idle.
STEP 45
Place the park brake levers in the off position, place
the FNR selector in the F position.
STEP 46
Slowly increase engine rpm until the machine moves.
NOTE: The machine should start moving about 1250 to
1500 rpm.
BD06K053-01
Torque spring housing bolts to 650 to 730 Nm (479 to STEP 47

538 pound feet). Place the FNR selector in the N position and place
the parking brake levers in the applied position. Stop
STEP 40 the engine.
Install the hydrostatic motor, see section 6001.
STEP 48
STEP 41 Check to leaks at the brake housing, check the oil
level in the hydraulic reservoir, add oil as required.
Turn on the vacuum pump.
STEP 49
Install the rear cover onto the machine.

7001-10
SOLENOID VALVE
NOTE: Tilt the ROPS canopy/cab to gain access to the
solenoid, see section 9008. STEP 7
Mount the solenoid and tighten the mounting bolts.
STEP 1
Clean the area around the solenoid valve. STEP 8
Connect the hydraulic lines.
STEP 2
Disconnect the harness connector. STEP 9
Turn off and disconnect the vacuum pump from the
hydraulic reservoir and install breather.
STEP 3
Remove breather from the reservoir and connect a
vacuum pump to the hydraulic reservoir. Turn on the STEP 10
pump. Connect the harness connector.
STEP 4 STEP 11
Tag and disconnect hydraulic lines for proper Lower the ROPS cab/canopy, see section 9008.
location during assembly.
STEP 12
STEP 5 Start and run the engine at low idle.
Plug or cap all lines and fittings.
STEP 13
STEP 6 Place the park brake levers in the off position, place
the FNR selector in the F position.
STEP 14
Slowly increase engine rpm until the machine moves.
NOTE: The machine should start moving about 1250 to
1500 rpm.
STEP 15
Place the FNR selector in the N position and place
the parking brake levers in the applied position.
STEP 16
BD06K044-01
Stop the engine, raise the cab/canopy, see section
Remove the valve. 9008.
NOTE: If only replacing the cartridge valve, torque the

STEP 17
cartridge to 27 to 34 Nm (20 to 25 lb-ft) and coil retaining
Check to leaks at the brake solenoid, check the oil
nut to 5 to 6 Nm (50 to 55 lb-in).
level in the hydraulic reservoir, add oil as required.
STEP 18
Lower the ROPS cab/canopy, see section 9008.

7002
Section
7002
BRAKE SYSTEM TROUBLESHOOTING

7002-2
TABLE OF CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7002-3
TROUBLESHOOTING
NOTE: For complete electrical troubleshooting procedures see Section 4001.
WARNING: FOR THIS PROCEDURE BLOCK BOTH TRACKS FRONT AND REAR TO PREVENT ANY
ACCIDENTAL MOVEMENT.
Brake Solenoid
Brake solenoid is located under the ROPS behind the ROPS tilt cylinder.
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector for the brake
solenoid and pressure switch.
Check brake solenoid coil resistance 41.8 ohm at
between the connector pins of the 20° C Bad brake solenoid.
solenoid connector. (68° F)
Open Bad pressure switch.
WARNING: DO NOT start the engine, place the ignition switch in the run position, release the parking brake
levers, DO NOT press the brake pedal, place the directional control in the F position, move hand throttle to ½
throttle position.
Bad wire between the brake solenoid and the drivetrain
Terminal for wire 215 to ground. 24 volts
controller. Bad drivetrain controller.
NOTE: If the readings are good, replace the brake solenoid.

WARNING: Start the engine, DO NOT place the directional control in the F or R position, move hand throttle to
½ throttle position.
Continuity Bad pressure switch.
NOTE: Hydrostatic charge pressure must be checked to make sure it is at proper pressure, see section 6002.
The pressure switch is normally open and closes at 11.4 to 12.8 Bar (165 to 185 psi).
2 3
1
4
BD06K057-01
1. BRAKE VALVE BLOCK 3. BRAKE SOLENOID

2. PRESSURE SWITCH 4. TILT CYLINDER

7002-4
NOTES

SECTION INDEX
HYDRAULICS

How to Read Hydaulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8000
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Equipment Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Equipment Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8010

Section
8000
HOW TO READ HYDRAULIC SCHEMATICS
8000

8000-2
TABLE OF CONTENTS
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbol Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Using Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crossing or Joining Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Motor Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Directional Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Composite Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flow Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SIMPLE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COMMON SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Line and Line Fuctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mechanical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8000-3
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC
Introduction Using Schematic Symbols

A hydraulic schematic diagram is a line drawing Reservoirs
composed of hydraulic symbols that indicate the
types of the components the hydraulic circuit
contains and how they are interconnected. Accurate
diagrams of hydraulic circuits are essential to the
service technician who must repair them. The
VENTED RESERVOIR PRESSURIZED RESERVOIR
schematic diagram is a valuable aid in diagnosing
possible causes of a problem when troubleshooting BS07B620
machinery. A rectangle with the top removed represents a

vented reservoir. A rectangle with the top in place
The purpose of this section is to show how to read
represents a pressurized reservoir.
and effectively use schematic circuit diagrams.
Circuit Diagrams
1. Cutaway Circuit Diagrams show the internal
construction of the components, as well as the
flow paths. By using colors, shades or various PRESSURIZED RESERVOIR PRESSURIZED RESERVOIR
patterns in the lines and passages, they are able
BS07B621
to show many different conditions of flow and The are other schematic diagrams that show a
pressure. Cutaway diagrams take considerably slightly different version of a pressurized reservoir,
longer to produce because of their complexity. but the symbols are similar and easily recognized. An
2. Schematic Circuit Diagrams, the “shorthand” oval with a short line on top or a rectangle with
system of the industry, are usually preferred for curved sides represents a reservoir that is
troubleshooting. A schematic diagram is made pressurized.
up of simple geometric symbols for the
components and their controls and connections.
Symbol Systems
There are several systems of symbols used when RETURN LINE ABOVE
making schematic diagrams. They are as follows: THE OIL LEVEL
BS07B622
I.S.O. - International Standards Organization Lines connected to the reservoir usually are drawn
A.N.S.I. - American National Standards Institute from the top, regardless of where the actual
connection is.
A.S.A. - American Standards Association
J.I.C. - Joint Industry Conference
A combination of these symbols is shown in this
section. There are differences between the symbols,
but there is enough similarity so that if you
understand the symbols in this section, you will be SUCTION LINE OR RETURN LINE
able to interpret other symbols as well. BELOW THE OIL LEVEL
BS07B623
If the hydraulic line terminates below the fluid level, it
is drawn all the way to the bottom of the symbol
BS07B624
RESERVOIR WITH SUCTION LINE ATTACHED AT THE
BOTTOM

8000-4
A hydraulic line connected to the bottom of the Lines, Tubes, and Hoses
reservoir may be drawn from the bottom of the A hydraulic line, tube, hose, or any conductor that
symbol if the bottom connection is essential to the carries the fluid between components is shown as a
system operation. line.
BS07B626
A working line, such as an inlet pressure or return, is
shown as a solid line.
BS07B625
If the pump inlet must be charged or flooded with a BS07B627
positive head of oil above the inlet port, the reservoir OIL FLOWS ONE WAY ONLY
symbol will be above the pump symbol with a suction
line drawn out of the bottom of the reservoir symbol.
Every vehicle or system reservoir has at least two
hydraulic lines connected to it, and some may have
many more. Often the components that are BS07B628
connected to the reservoir are spread all over the OIL CAN FLOW EITHER WAY
schematic. Rather than having a number of Working lines with arrows show direction of flow.
confusing lines all over the schematic, it is customary
to draw individual reservoir symbols close to the
components. The reservoir is usually the only
component symbol pictured more than once. BS07B629
Pilot or control lines are broken into long dashes.
BS07B630
Drain lines for leakage oil are broken into short
dashes.
BS07B631
A flexible line is show as an arc between two dots
and is always represented by a solid line.
BS07B632
Quite often you will see an enclosure outline that
indicates that there are several symbols that make
up a component assembly such as a valve or a valve
stack. The enclosure outline appears like a box and
is broken with dashes on all sides.

8000-5
Crossing or Joining Lines
BS07B633 Variable Displacement Variable Displacement

LINES THAT ARE NOT CONNECTED Pressure Compensated
The shortest distance between two components that BS07B636
are connected is a straight line. There are lines that A variable displacement pump is designated by
cross other lines, but are not connected. There are a drawing an arrow through the pump symbol at 45
number of ways to show crossing lines. degrees. To indicate a variable displacement
pressure compensated pump, a small box with an
arrow in it will be added to the side of the pump
symbol
BS07B634
LINES THAT ARE CONNECTED
Lines that are connected are shown with a dot that
represents the connection or shown as a tee Lever Controlled Pedal or Treadle
connection. The dot connection is the most Controlled
commonly used when drawing schematic diagrams. BS07B637
If the pump is controlled by a lever or a pedal, it will
be shown on the side of the pump.
Pump Symbols
Outlet
Inlet
Pump with Drive Shaft Pump with Drive Shaft
and Directional Arrow
Fixed Displacement
Fixed Displacement
Reversible BS07B638
A drive shaft is shown as two short parallel lines
BS07B635 extending from the side of the pump. If a curved
There are many basic pump designs. A simple fixed arrow is shown on the drive shaft, it will indicate the
displacement pump is shown as a circle with a black direction of the rotation.
triangle that is pointing outwards. The black triangle
is like an arrow head and points in the direction that
the oil will flow. If the pump is reversible or designed
to pump in either direction, it will have two black
triangles in it and they will be opposite each other.

8000-6
Hydraulic Motor Symbols
Double Rod End Cylinder

BS07B643
Nonreversible Motor Reversible Motor A double rod end cylinder has a rod extending from
BS07B639 each end of the rectangle.
Hydraulic motor symbols are circles with black
triangles, but opposite a pump the triangles point
inward to show the motor is a receiver of oil. One
triangle is used for a non-reversible motor and two
triangles are used for a reversible motor.
Single Rod End Fixed Cushion Both Ends
Pump BS07B644
Motor
BS07B640
A simple schematic diagram is shown with a
hydraulic motor connected to a hydraulic pump. Single Rod End Adjustable Cushion Rod End Only
Cylinder Symbols
730LBE
SINGLE ROD END ADJUSTABLE CUSHION ROD END ONLY
Some cylinders have cushions built into them. The
Tee cushion slows down the movement of the piston as it
Rectangle nears the end of its stroke. Cylinder cushions are
shown as a smaller rectangle on the piston. If the
cushion has an adjustable orifice, a slanted arrow is
drawn at 45 degrees across the symbol.
BS07B641
A cylinder symbol is a simple rectangle representing
the barrel. The piston and rod are represented by a
tee that is inserted into the rectangle. The symbol
can be drawn in any position.
Port
Single Acting Cylinder Double Acting Cylinder

BS07B642
If the cylinder is single acting, there is only one port
shown on the symbol. The port is shown on the end
of the cylinder that receives pressurized fluid and the
opposite end of the cylinder is left open.
A double acting cylinder symbol has both ends
closed and has two ports on the symbol.

8000-7
Pressure Control Symbols Relief Valve

The basic symbol is a square (which is called an
envelope) with external port connections and an Pressure Line
arrow inside to show the oil passage and direction of
flow. Usually this type of valve operates by balancing
the oil pressure against a spring, so a spring is
shown on one side of the symbol and a pilot pressure
line on the other side.
Pump Relief
Normally Closed Valve
Arrow Offset Arrow Aligned BS07B648
From Ports With Ports
A relief valve is shown as a normally closed symbol
Inlet connected between the pressure line and the
Pilot
Line reservoir. The flow direction arrow points away from
Spring the pressure line port and toward the reservoir. This
shows very graphically how a relief valve operates.
When pressure in the system overcomes the valve
Outlet Visualize square spring, flow is from the pressure line through the
Normally Closed moving toward spring relief valve to the reservoir.
BS07B646
A normally closed valve, such as a relief or sequence Pressure Reducing Valve
valve, is shown with the arrow offset from the ports High Pressure Inlet
and toward the pilot pressure line side of the square.
The spring holds the valve closed until the pilot line
oil pressure is greater than the spring pressure.
Mentally visualize a build up of pressure in the pilot Pilot
Line Drain Line to
line and the square moving over, compressing the
spring. The oil now can flow through the valve. Reservoir
Reduced Outlet Pressure

Normally open
BS07B649
A pressure reducing valve is shown as a normally
Inlet Pilot open symbol in a pressure line. This valve works
Line opposite of a relief valve, since it senses outlet
Spring
pressure versus inlet pressure. As the outlet
pressure builds, it works against a predetermined
spring force. As the spring force is overcome, flow
Outlet Visualize square
Normally Open through the valve is modulated or shut off.
moving toward spring
BS07B647
A normally open valve is shown with the arrow
connecting the two ports. It closes when the pressure
overcomes spring force. Mentally visualize a build up
of pressure in the pilot line and the square moving
over, compressing the spring. The oil flow through
the valve is now blocked.

8000-8
Sequence Valve Directional Control Symbols
Supply Line Simplified Symbols
To Primary One Way Valve
Relief Cylinder
Valve Pump
No Flow
Sequence
Valve Free Flow
To Secondary
Cylinder BS07B676
A simple ball check valve is shown. When oil
BS07B650
pressure is exerted on the left side of the ball, the ball
The normally closed symbol is also used for a
is forced into the V and no oil can flow past it. When
sequence valve. The inlet port is connected to a
oil pressure is applied to the right side of the ball, the
primary cylinder and the outlet port o the secondary
ball moves away from the V and oil can flow past.
cylinder line. When the piston in the primary cylinder
reaches the end of its stroke, the pressure in the
supply line increases. The sequence valve is also By Pass Valve
connected to the supply line and also feels the
increase in pressure. As pressure increases, the
square and directional flow arrow moves over,
connecting the inlet and outlet ports, allowing fluid to Spring
flow to the secondary cylinder.
BS07B677
A by pass valve is shown as a one way valve with a
spring on the ball end of the symbol. This shows that
a pressurized flow will be necessary to overcome the
spring force and allow flow around the ball.

8000-9
Composite Symbols Three - Position Valves
One - Way Valves
Free
Flow
No BS07B680
Flow Visualize a build up OPEN CENTER THREE POSITION VALVE
of pressure on the
One way valve shown right side of valve
in the closed position
BS07B678
A more complex one way valve is shown. This
directional control symbol uses a multiple envelope
(square) system that has a separate square for each
position. Remember all of the port connections are
made to the envelope that shows the neutral BS07B681
condition of the valve. Within each envelope are CLOSED CENTER THREE POSITION VALVE
arrows showing the flow paths when the valve is Three position valves will have a centered (neutral)
shifted to that position. position. The centered position can be either open or
closed to flow. The open center is usually used with a
Two - Position Valves fixed displacement pump and the closed center is
Cylinder usually used with a variable displacement pump.
Control Valve
Pump Rod End
Relief
Valve
Cylinder
Piston End
BS07B679
A simple control valve has two envelopes
(representing the spool) if it is a two position valve.
The envelopes show the flow conditions when they
are in one position. The above schematic is showing
that oil is being supplied to the rod end of the
cylinder. If we visualize the directional control valve
moved to the other position, it would be shown as
below.
BS07B710
Pressurized oil is being supplied to the piston end of
the cylinder and oil from the rod end of the cylinder is
allowed to flow to the reservoir.

8000-10
Actuating Controls Flow Control Symbols
Restrictors
Lever
Pedal
Non Adjustable Adjustable
Restrictor Restrictor
BS07B682
BS07B686
The basic flow control symbol is a representation of a

restrictor. If the restrictor is adjustable, a slanted
arrow is drawn across the symbol. The restrictor
could be a special fitting with a small hole in it or a
small drilled passageway within a valve. If it is an
Two Position Controlled Two Position adjustable restriction, it could be thought of as a
by External Controlled water faucet that can be controlled by turning the
Pilot Pressure By Solenoids handle to regulate the flow. Restrictors can be
applied to meter out, meter in, and bleed off circuits.
BS07B683
Adjustable Restrictor Adjustable Restrictor

Three Position, Solenoid Controlled Pressure Pressure and
With Internal Pilot Assist Pressure Compensated Temperature
BS07B684
Compensated
Valve spools are controlled by levers, pedals, pilot BS07B687
oil, electric solenoids, etc. which are called actuating There are adjustable restrictors that are pressure
controls. These actuating controls are shown by compensated. That means that the size of the
symbols placed on the ends of the envelopes. openings in the restrictor will change with increases
and decreases in pressure. A perpendicular arrow
Solenoid Control With Internal indicates pressure compensation. If the restrictor has
Pilot Pressure both pressure and temperature compensation, the
symbol for a thermometer will also be shown.
BS07B685
THREE POSITION, SPRING CENTERED
To show that a valve is spring centered, a spring
symbol is placed at each end of the envelope. The
above schematic shows that an electrical solenoid
and pilot pressure assist are required to overcome
spring force to move the valve spool.

8000-11
Accessories An oval with details inside indicates an accumulator.

The details inside will tell you what type of
Filters, strainers, and heat exchangers are
accumulator it is: spring loaded, gas charged, or
represented as squares that are turned 45 degrees
other features.
and have the port connection at the corners.
Gas Charged
Filter or Strainer
BS07B691
BS07B688
A dotted line perpendicular to the flow line indicates a The divider line indicates there is a separator
filter or strainer. between the charge and the oil. A hollow triangle
indicates gas.
Cooler
Spring Loaded
BS07B689
A solid line perpendicular to the flow with black BS07B692
triangles pointing out indicates a cooler. A spring shows that the accumulator is spring
loaded.
Heater
BS07B690
The symbol for a heater is like the symbol for a
cooler, except the black triangles point in.
Temperature Control Unit

BS07B693
Two sets of triangles pointing in and out indicates a
temperature control.
As you can see, the black triangles point in the
direction that the heat is dissipated. or in the case of
the control unit, they show that the heat can be
regulated.

8000-12
SIMPLE SCHEMATIC
The illustration below has put some of the previous symbols together to form a simple hydraulic schematic. See if
you can find your way around the schematic without reading the text for each valve. The text explains the function
of each valve.
Detent
D Float
C
C
B
BS07B596

8000-13
Valve A Valve C
This valve is a three position valve. The spool is lever This valve is also similar to valve A, but is designed
operated and spring centered. It is an open center to control a single acting cylinder. When you
valve. Visually place the envelopes into the center visualize placing the upper envelope in the center
position and you will see that the valve will direct oil position you will see that oil can drain back to the
into one end or the other of cylinder A. when the reservoir from cylinder C.
spool in valve A is moved out of the centered At the same time, oil from the pump can flow through
position, the valves downstream will receive no oil. valve C to the next valve.
Valve B Valve D
Valve B is similar to valve A but it is a four position Valve D is a lever operated, spring centered valve
valve. The fourth position is a float position and is and is designed to control a hydraulic motor. If a
held into that position with a detent. With this valve hydraulic motor was turning a flywheel and the oil
the cylinder B can be extended, retracted, or placed supply and return were shut off abruptly, this would
in the float position. Visualize the envelope for the cause damage to the hydraulic lines, the motor, or
float position in the inlet passageway. whatever it was powering. Therefore when the valve
You will see that oil can continue to flow to the next supplying the motor is shut off, the motor should be
valve downstream and that the rod in cylinder B able to slow down gradually. The center (neutral)
could be pushed back and forth. The oil could move position of valve D will allow that to happen by letting
from one end of the cylinder. oil from the outlet of the motor return to the inlet side.
Use this information to read hydraulic schematics.
The more experience you have reading schematics,
the easier and more comfortable it will become to
use hydraulic schematics as a troubleshooting guide.

8000-14
COMMON SYMBOLS
Line and Line Fuctions Mechanical Devices
Mechanical Connections
Solid Line Two Parallel Lines
Main Line (Shafts, Levers, etc.)
Dashed Line
Pilot Line
Dotted Line
Exhaust or Drain
Variable Component
(Run arrow through
Enclosure symbol at 45°)
Outline
Lines
Crossing
Spring
Lines
Crossing
BS07B696
Lines
Joining
Liquid Direction
of Flow
Gaseous Direction
of Flow
Flexible Line
BS07B694

8000-15
Pumps and Motors Reservoirs

Hydraulic Pump
Fixed Displacement Reservoir Open
to Atmospere
Hydraulic Pump
Variable Displacement Pressurized Reservoir
Pressure
Compensated Variable
Displacement Pump Line to Reservoir
Below Fluid Level
Fixed Displacement
Hydraulic Pump
(Two Directional Flow) Line to Rexervoir
Above Fluid Level
BS07B699
Hydraulic Motor
Fixed Displacement
Hydraulic Motor
Variable Displacement
Hydraulic Oscillator
BS07B695

8000-16
Cylinders Valves
Single Acting
Check Valve
Pilot Operated
Double Acting
Check
Single Rod End
On-Off
Double Acting Manual Shut-off
Double Rod End
Single Rod End Pressure

Fixed Cushion Reducing Valves
Both Ends
Single Rod End
Rod End Only Non-Adjustable

Adjustable Cushion Restrictor
Differential
Cylinder
Adjustable
BS07B706
Restrictor
Adjustable
Restrictor
Pressure
Compensated
Adjustable
Restrictor
(Temperature and
Pressure
Compensated)
BS07B697

8000-17
Valve Actuators
Regulating or
Selector Valves
Solenoid
2-Position
2-Way Valve
Detent
2-Position
3-Way Valve
Spring
2-Position
4-Way Valve
Manual
3-Position
4-Way Valve
Push Button
2-Position 4-Way
Open Center
Cross Over Push-Pull
Lever
Valve Capable of
Infinite Positioning
(Indicated by
Horizontal Lines
Drawn Parallel to Pedal
the Envelope)
Pressure Relief
Valve
Mechanical
BS07B698
BS07B700

8000-18
Accessories
Pressure
Compensated
Filter
Cooler
Pilot Pressure
Remote Supply
Heater
Temperature
Controller
Liquid Supply
Accumulator
Hydro-Pneumatic
BS07B708
Reversing
Motor
Station or
Test Point
Pressure
Indicator
Temperature
Indicator
BS07B705

8000-19
Presssure
Switch
Quick Disconnects
(Disconnected)
Quick Disconnects
(Connected)
BS07B707

8000-20
NOTES

8001
Section
8001
REMOVAL AND INSTALLATION

OF HYDRAULIC COMPONENTS

8001-2
TABLE OF CONTENTS
DOZER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparing Pump For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8001-3
DOZER CONTROL VALVE
Removal STEP 5
NOTE: Tilt the ROPS cab or canopy before proceeding.
See Section 9008.
STEP 1
Remove the dirt and grease from the hoses
connections at the dozer control valve.
STEP 2
1
2
BD06E077-01
Remove the two mounting bolts and accumulator

3 mounting bracket.
4
STEP 6
BD06E00-01

Remove the breather from the reservoir and connect
a vacuum pump to the opening. Start the vacuum
pump.
STEP 3
Tag all lines for proper identificat ion during
BD06E078-01
assembly.
Tag all solenoid connectors, press in on the tab and
pull up on the connector.
STEP 4
Disconnect the hoses from the dozer control valve. NOTE: Grasp the connector and pull it straight up, DO
Install plugs or caps in/on all open hoses and fittings, NOT pull on the wires.
stop the vacuum pump. Remove the mount bolts for
the control valve, remove the control valve from the STEP 7
machine. Attach suitable lifting equipment to the dozer control
valve, remove the mounting bolts and valve from the
machine.

8001-4
Installation STEP 6
Mount the accumulator bracket to the dozer control
STEP 1 valve bracket.
Align the dozer control valve mounting holes with the NOTE: Lower the ROPS cab or canopy before proceeding.
associated holes in the mounting bracket. Install the See Section 9008.
bolts, washers, lock washers, and nuts to secure the
control valve. STEP 7
With the engine running at low idle, hold each control
STEP 2 lever in the angle left and right, tilt left and right, raise
Start the vacuum pump and remove the plugs from and lower power positions to open the main relief
the hoses and caps from valve fittings. valve for five seconds. Stop the engine and check for
leaks.
STEP 3
NOTE: If equipped with auxiliary hydraulics repeat setp 5
Connect the hoses to the dozer control valve. for the attachment.
STEP 4 STEP 8
Turn off and disconnect the vacuum pump. Install the Check the level of oil in the reservoir and add oil as
breather in the reservoir. required. See Section 1002.
STEP 5
Connect the electrical connectors to the seleniods.

8001-5
EQUIPMENT PUMP
Removal STEP 4
Install a plug in each hose and fitting. Tighten the
NOTE: Tilt the ROPS cab or canopy before proceeding.
clamp on the plug installed in the suction hose. Stop
See Section 9008.
the vacuum pump.
STEP 1 STEP 5
Remove the dirt and grease from the hose
Remove the pump and discard gaskets.
connections at the pump.
STEP 2 Installation
STEP 1
1 Install a new gasket and mount the hydraulic pump.
2
STEP 2
3 4
4
BD06E00-01 1
1. RESERVOIR VENT 3. TRANSMISSION FILTER 2 3
Remove the breather from the reservoir and connect
a vacuum pump to the opening. Start the vacuum
pump. BD06E076-01
NOTE: If dozer is equipped with a PTO drive pump, 1. PUMP SUCTION HOSE 3. PUMP
2. PUMP HIGH PRESSURE HOSE 4. FROM HYDROSTAT
disconnect the PTO before proceeding.
FILTER
STEP 3
Start the vacuum pump. Remove the plugs from the
hoses. Connect the hoses to the pump. Connect the
4 hose to the hydrostat filter
STEP 3
Stop the vacuum pump.
STEP 4
1
Disconnect the vacuum pump from the opening in
2 3 the reservoir. Install the breather.
NOTE: If dozer is equipped with a PTO drive pump,
connect the PTO before proceeding.
BD06E076-01 NOTE: Lower the ROPS cab or canopy before proceeding.
1. PUMP SUCTION HOSE 3. PUMP See Section 9008.
2. PUMP HIGH PRESSURE HOSE 4. FROM HYDROSTAT
FILTER STEP 5
Check the level of the oil in the reservoir and add oil
Disconnect the hoses from the pump. Disconnect the as required. See Section 1002.
hose from the hydrostat filter.

8001-6
STEP 6 Preparing Pump For Use
If a new or overhauled pump has been installed,
prepare the pump for use. STEP 1
Start and run the engine at half throttle for three
STEP 7 minutes.
Start and run the engine at half throttle for 30
seconds and check for leaks. Then stop the engine. STEP 2
With the engine running at half throttle, hold the
STEP 8 blade control lever in the tilt position for five seconds.
Check the level of the oil in the reservoir and add oil Then return the blade control lever to neutral for five
as required. See Section 1002. seconds.
STEP 3
Repeat Step 2 for three minutes.
STEP 1
With the engine running at full throttle, repeat Steps 2
and 3.
STEP 2
Stop the engine and check for leaks.
STEP 3
Replace the hydraulic oil filter.
STEP 4
Check the level of oil in the reservoir and add oil as
required. See Section 1002.

8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAIN RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOAD SENSE RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CIRCUIT RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLOWMETER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test No. 1 - Equipment Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Understanding Results of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 2 - Dozer/Ripper Circuits and Main Relief Valve Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load Sense Relief Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dozer Circuits Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ripper Circuits - (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Understanding Results of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FLOWMETER CHECK SHEET METRIC MEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FLOWMETER CHECK SHEET U. S. MEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8002-3
SPECIFICATIONS
Temperature of Hydraulic Oil When Testing ................................................................ 52° to 79° C (125° to 175° F)
Hydraulic Pump Output .......................................................................................138 L/min at 207 bar at 2300 r/min
(36.4 U.S. gpm at 3000 psi at 2300 rpm))
Main Relief Valve Pressure ............................................................................................................185 bar (2683 psi)
Load Sense Pressure .....................................................................................................................163 bar (2364 psi)
Delta P Pressure ........................................................................................................... 10 to 16 Bar (145 to 232 psi)
Circuit Relief Valves ........................................................................................... 198 bar (2872 psi) with Hand Pump
SERVICE TOOLS
B877558 B877168
CAS-1804 PRESSURE TEST KIT CAS-1808 FLOWMETER FITTING KIT
B877895 B785789
CAS-10090 HAND PUMP CAS-10280 FLOWMETER
NOTE: The needle valve on the accumulator block must be screwed in for the hydraulics to work correctly.

8002-4
HYDRAULIC CONTROL VALVE
6
7
5
8
4 9
7
3
8
8
2
8
1
11 10
12
BS06M038
1. LOAD SENSE RELIEF VALVE 5. A PORT CIRCUIT RELIEF 9. B PORT CIRCUIT RELIEF
2. DOZER TILT SECTION 6. END COVER 10. BLOCK COVER
3. DOZER LIFT SECTION 7. HYDRAULIC VALVE FTDRE4 11. MAIN RELIEF VALVE
4. DOZER ANGLE SECTION 8. HYDRAULIC VALVE FTDRE2 12. HOUSING TILT AND ANGLE

8002-5
MAIN RELIEF VALVE PRESSURE TEST
Equipment Required 9. Hold the hydraulic control lever for the Lift
Cylinders in the RAISE position.
345 bar (5000 psi) Pressure Gauge with Test Hose
10. Record the reading on the pressure gauge and
Female Diagnostic Coupler from pressure test fitting check that the pressure reading is within the
kit specification on page 3.
11. If the pressure is not correct, adjust the main
Pressure Test Procedure relief valve according to the following procedure.
See page 4 for the location of the load sense
relief valve.
1 A. Remove the cover from the main relief valve
and loosen the lock nut on the adjusting
screw.
B. Turn the adjusting screw into the main relief
valve to increase the pressure or out of the
main relief valve to decrease the pressure.
C. Repeat Steps 5 to 8 to check the pressure
setting. Adjust the main relief valve again as
necessary.
D. When the pressure setting is correct, prevent
BD07F085-01
the adjusting screw from turning while the lock
1. PRESSURE TEST PORT DIAGNOSTIC COUPLER
nut is tightened. Install the cover on the main
relief valve.
WARNING: Make sure that everyone is clear
12. Stop the engine and remove the pressure gauge.
of the dozer blade prior to proceeding.
13. If the main relief valve cannot be adjusted to the
1. Raise the right side panel for the equipment correct pressure setting:
control valve.
A. Remove the main relief valve and inspect for
2. Make sure the hydraulic system fluid is at damaged or worn parts or damaged O-rings.
operating temperature of 52° to 79° C (125° to Repair as necessary.
175° F).
B. Do a Hand Pump pressure test. Replace the
3. Connect the diagnostic coupler and pressure relief valve if pressure can not be adjusted.
gauge to the test port coupler (1).
14. Reinstall and/or replace the main pressure relief
4. Loosen the jam nut on the Load Sense relief valve.
valve.
15. Repeat steps 3 through 9 and recheck pressure
5. Turn the adjusting screw in and count and record setting.
the number of turns the adjusting screw turns
16. Loosen the jam nut on the Load Sense relief
until it bottoms out, tighten the jam nut.
valve.
IMPORTANT: DO NOT force the adjusting screw, this will
17. Turn the adjusting screw out the number of turns
damage the load sense relief valve.
it took to bottom it out, tighten the jam nut.
6. Make sure the Parking Brakes are applied and
IMPORTANT: Once the main relief pressure has been
the directional control is in the NEUTRAL
adjusted it will be required to readjust the load sense
position.
pressure, see Load Sense Relief Valve Pressure Test this
7. Start and run the engine at FULL THROTTLE. section.
8. Release the right parking brake lever only to
activate the hydraulic system.
NOTE: It is only required to release the right hand park
brake lever to activate the hydraulic system.

8002-6
LOAD SENSE RELIEF VALVE PRESSURE TEST
Equipment Required 8. Record the reading on the pressure gauge and

check that the pressure reading is within the
345 bar (5000 psi) Pressure Gauge with Test Hose specification on page 3.
Female Diagnostic Coupler from pressure test fitting NOTE: This pressure will be the load sense pressure plus
kit the Delta P of 8 Bar (120 psi).
9. If the pressure is not correct, adjust the load
Pressure Test Procedure sense relief valve according to the following
procedure. See page 4 for the location of the
load sense relief valve.
1 A. Loosen the lock nut on the adjusting screw.
B. Turn the adjusting screw into the load sense
relief valve to increase the pressure or out of
the load sense relief valve to decrease the
pressure.
C. Repeat Steps 5 to 8 to check the pressure
setting. Adjust the load sense relief valve
again as necessary.
D. When the pressure setting is correct, prevent
BD07F085-01
nut is tightened.
1. PRESSURE TEST PORT DIAGNOSTIC COUPLER
10. Stop the engine and remove the pressure gauge.
WARNING: Make sure that everyone is clear 11. If the load sense relief valve cannot be adjusted
of the dozer blade prior to proceeding. to the correct pressure setting:
A. Remove the load sense relief valve and
1. Raise the right side panel for the equipment
inspect for damaged or worn parts or
control valve.
damaged O-rings. Repair as necessary.
2. Make sure the hydraulic system fluid is at
B. Do a Hand Pump pressure test. Replace the
operating temperature of 52° to 79° C (125° to
relief valve if pressure can not be adjusted.
175° F).
12. Reinstall and/or replace the load sense pressure
3. Connect the diagnostic coupler and pressure
relief valve.
gauge to the test port coupler (1).
13. Repeat steps 3 through 9 and recheck pressure
4. Make sure the Parking Brakes are applied and
setting.
the directional control is in the NEUTRAL
position.
5. Start and run the engine at FULL THROTTLE.
6. Release the right parking brake lever only to
activate the hydraulic system.
NOTE: It is only required to release the right hand park
brake lever to activate the hydraulic system.
7. Hold the hydraulic control lever for the Lift
Cylinders in the RAISE position.

8002-7
CIRCUIT RELIEF VALVE PRESSURE TEST
Equipment Required 6. Compare the pressure reading recorded to the

specifications on page 3.
CAS-10090 Hand Pump with Test Hose
7. If the pressure is not correct, adjust the circuit
345 bar (5000 psi) Pressure Gauge relief valve according to the following procedure.
Adapter and Plug from pressure test fitting kit A. Remove the cover from the circuit relief valve
and loosen the lock nut on the adjusting
Pressure Test Procedure screw.
NOTE: The circuit relief valves are in the angle and if B. Turn the adjusting screw into the circuit relief
equipped Ripper/Auxiliary circuits. valve to increase the pressure or out of the
circuit relief valve to decrease the pressure.
1. Raise the right ROPS side panel for the
equipment control valve. C. Repeat Steps 5 and 6 to check the pressure
setting. Adjust the circuit relief valve again as
2. Remove the hydraulic line from the work port for necessary.
the circuit relief valve to be tested and install a
plug in the end of the hose fitting. D. When the pressure setting is correct, prevent
3. Connect the CAS-10090 hand pump and nut is tightened. Install the cover on the circuit
pressure gauge to the open work port in the relief valve.
equipment control valve where the line was
disconnected. 8. If the circuit relief valve cannot be adjusted to the
correct pressure setting:
4. Make sure that the hand pump is full of oil and
the temperature of the oil is approximately 21° C A. Remove the circuit relief valve and inspect for
(70° F). damaged or worn parts or damaged O-rings.
Repair as necessary.
5. Operate the hand pump and read the pressure
gauge. Record the highest pressure. Repeat this B. Do a Hand Pump pressure test. Replace the
step several times to be sure of the pressure relief valve if pressure can not be adjusted.
setting. 9. Reinstall and/or replace the circuit relief valve.
10. Repeat steps 5 and 6 and recheck pressure
setting.
11. Repeat steps 2 through 10 for the other work
ports if necessary.

8002-8
FLOWMETER TESTS
WARNING: Two persons are required to 7. Disconnect the hose from the fitting on the inlet
perform the flowmeter tests for safety to avoid port of the equipment control valve and install a
possible injury. cap onto the fitting.
One person must be seated in the operators 8. Install a tee in the end of the outlet hose from the
seat with the engine running. The second hydraulic pump and install a plug into the
person is to control the flowmeter and take the opposite end of the tee fitting.
readings.
M750
9. Connect a hose from the tee at the hydraulic
pump outlet hose to the inlet of the Flowmeter.
Equipment Required 10. Turn off the vacuum pump.
CAS-10280 Flowmeter 11. Lower and secure the ROPS cab/canopy. See
CAS-1808 Flowmeter Fitting Kit Section 9008.
CAS-101092 Vacuum Pump 12. Connect a hose to the outlet of the Flowmeter
and place the opposite end of the hose into the
General Information fill port below the level of the oil in the reservoir.
Secure the hose to the fill port to prevent it from
The Flowmeter measures the volume, pressure and falling out during the test.
temperature of the hydraulic oil as the hydraulic oil
13. Open the pressure Load Valve on the Flowmeter
flows through the Flowmeter.
all the way. Make sure the flow switch is in the
Test No. 1 will indicate whether or not there are FLOW position and move the range switch to the
problems in the line between the reservoir and the HI position.
equipment pump, also whether or not the equipment
14. Set the instrument cluster to read engine r/min
pump is working within acceptable standards of
(rpm).
efficiency.
15. Start and run the engine at full throttle. Push
Test No. 2 will indicate if there are problems in the
down the temperature switch on the Flowmeter
dozer and ripper hydraulic circuits.
and read the temperature gauge. The
A check sheet is at the end of this section. A copy of temperature of the oil must be at least 52° C
the check sheet can be made to use as a record for (125° F).
the test results.
16. If the temperature of the hydraulic oil is not as
specified, run the engine at full throttle and close
Test No. 1 - Equipment Pump Flow the pressure Load Valve on the Flowmeter until
Test the pressure gauge indicates 103 bar (1500 psi).
Continue to run the engine until the temperature
1. Park the machine on a level surface. of the oil is as specified.
2. Lower the dozer and the ripper to the ground. 17. Open the pressure Load Valve completely.
3. Put directional control in NEUTRAL and apply 18. Adjust the engine speed to 2300 r/min (rpm).
the parking brakes. Stop the engine. Make sure the pressure Load Valve on the
4. Place the ignition switch in the ON position, Flowmeter is fully open and read the flow gauge.
place the right parking brake lever in the Write the flow reading on line 1 on the check
operation position. Move the control levers in all sheet for minimum pressure.
direction s to rele ase any pressure in the 19. Slowly close the pressure Load Valve on the
hydraulic circuits, place the right parking brake Flowmeter until the pressure gauge indicates
lever in the applied position and turn the ignition 138 bar (2000 psi). Make sure to keep the engine
switch off. running at 2300 r/min (rpm). Read the flow
5. Tilt the ROPS cab/canopy to gain access to the gauge and write the reading on line 2 on the
equipment control valve. See Section 9008. check sheet.
6. Remove the vent from the hydraulic reservoir 20. Open the pressure Load Valve on the
and connect a vacuum pump to the fitting. Turn Flowmeter. Decrease the engine speed and stop
on the vacuum pump. the engine.

8002-9
Understanding Results of Test Test No. 2 - Dozer/Ripper Circuits

1. If the output at minimum pressure was less than and Main Relief Valve Flow Tests
138 L/min (36.4 U.S. gpm) the problem can be a 1. Tilt the ROPS cab/canopy to gain access to the
leak or a restriction between the equipment equipment control valve. See Section 9008.
pump and reservoir, or a badly worn or damaged
equipment pump. 2. Remove the flowmeter return line from the
reservoir and replace the filler cap.
2. If the output at minimum pressure was 138 L/min
(36.4 U.S. gpm) or more there are no problems 3. Turn the vacuum pump on.
between the equipment pump and reservoir. The 4. Remove the plug from the tee at the outlet hose
equipment pump can be worn or damaged and from the hydraulic pump and the cap from the
still have good flow at minimum pressure. fitting on the equipment control valve.
3. Some loss of output at 138 bar (2000 psi) is 5. Connect the tee fitting at the outlet hose from the
normal. The loss can also show the equipment hydraulic pump to the equipment control valve.
pump is worn or damaged. Use the efficiency of
the equipment pump to make a judgement as to 6. Turn the vacuum pump off.
whether or not the equipment pump must be 7. Lower and secure the ROPS cab/canopy. See
repaired or replaced. Section 9008.
4. The efficiency of the equipment pump is found by 8. Place the outlet hose of the Flowmeter back into
dividing the flow at 138 bar (2000 psi) by the flow the fill port of the reservoir below the level of the
at minimum pressure. oil. Secure the hose to the fill port to prevent it
from falling out during the test.
EXAMPLE
9. Open the pressure Load Valve on the Flowmeter
STEP 18 - 98 L/min (26 U.S. gpm) all the way. Make sure the flow switch is in the
Flow position and move the range switch to the
HI position.
STEP 19 - 87 L/min (23 U.S. gpm)
10. Start and run the engine at full throttle. Push
23 divided by 26 equals 0.88 = 88% efficient down the temperature switch on the Flowmeter
and read the temperature gauge. The
87 divided by 98 equals 0.88 = 88% efficient temperature of the oil must be at least 52° C
(125° F).
5. If the efficiency is below 75% it is recommended 11. If the temperature of the hydraulic oil is not as
that the equipment pump be repaired or specified, run the engine at full throttle, hold the
replaced. blade control lever in the RAISE position and
slowly close the pressure valve on the Flowmeter
until the pressure gauge indicates 103 bar (1500
psi). Continue to run the engine until the
temperature of the oil is as specified.
12. Lower the blade to the ground and open the
pressure Load Valve on the Flowmeter.

8002-10
Load Sense Relief Valve Test Dozer Circuits Flow Tests
WARNING: Make sure that everyone is clear WARNING: Make sure that everyone is clear
of the dozer blade prior to proceeding. of the dozer blade prior to proceeding.
13. Maintain the engine speed at full throttle and 21. Set the instrument cluster to read engine r/min
hold the blade control lever in the RAISE (rpm).
position.
22. Start the engine and adjust the engine speed to
14. This step will indicate the pressure at which the 2300 r/min (rpm).
load sense relief valve begins to open. As the
23. Hold the blade control lever in the LIFT position
pressure Load Valve on the Flowmeter is closed,
and adjust the pressure valve on the Flowmeter
the flow indication will decrease slowly until the
as required to keep the pressure at 138 bar
load sense relief valve begins to open at which
(2000 psi). Adjust the engine speed to keep the
time the flow indication will start decreasing
engine running at 2300 r/min (rpm). Read the
rapidly. STOP closing the pressure Load Valve
flow gauge and write the reading on the check
and read the pressure gauge.
sheet.
15. Write the reading of the pressure gauge on the
24. Hold the blade control lever in the LOWER
check sheet, Load Sense Relief Valve begins to
(Power Down) position and adjust the pressure
open.
valve on the Flowmeter as required to keep the
16. This step will indicate the pressure at which the pressure at 138 bar (2000 psi). Adjust the engine
load sense relief valve is completely open. speed to keep the engine running at 2300 r/min
Continue to close the pressure valve on the (rpm). Read the flow gauge and write the reading
Flowmeter until the indication of the flow gauge on the check sheet.
is zero. This is the pressure at which the load
25. Hold the blade control lever in the ANGLE
sense relief valve is completely open.
RIGHT position and adjust the pressure valve on
NOTE: This pressure will be the load sense pressure plus the Flowmeter as required to keep the pressure
the Delta P of 8 Bar (120 psi). at 138 bar (2000 psi). Adjust the engine speed to
keep the engine running at 2300 r/min (rpm).
17. Write the reading of the pressure gauge on the
Read the flow gauge and write the reading on the
check sheet, Load Sense Relief Valve
check sheet.
completely open with Delta P pressure.
26. Hold the blade control lever in the ANGLE LEFT
18. If the pressures in Steps 14 and 16 are as
position and adjust the pressure Load Valve on
specified on page 3, proceed to step 21.
the Flowmeter as required to keep the pressure
19. If the pressure setting of the load sense relief at 138 bar (2000 psi). Adjust the engine speed to
valve is not as specified on page 3, then attempt keep the engine running at 2300 r/min (rpm).
to adjust the load sense relief valve to correct the Read the flow gauge and write the reading on the
pressure setting. If adjustment does not correct check sheet.
the pressure setting, the load sense relief valve
27. Hold the blade control lever in the TILT RIGHT
must be removed and inspected for possible
repair or replacement. See Section 8005.
20. If the load sense relief valve was adjusted, at 138 bar (2000 psi). Adjust the engine speed to
repaired or replaced, do Steps 13 through 17 keep the engine running at 2300 r/min (rpm).
again. Read the flow gauge and write the reading on the
check sheet.
28. Hold the blade control lever in the TILT LEFT
at 138 bar (2000 psi). Adjust the engine speed to
keep the engine running at 2300 r/min (rpm).
check sheet.

8002-11
Ripper Circuits - (if equipped) Understanding Results of Test
WARNING: Make sure that everyone is clear 1. If the flow indication for each circuit was
of the ripper prior to proceeding. approximately the same as the flow indication at
the same pressure in Test No. 1 - Equipment
29. Hold the ripper control lever in the LIFT position Pump flow Test, the circuit is good.
and adjust the pressure Load Valve on the 2. If the flow indication for a circuit was more than
Flowmeter as required to keep the pressure at 3.79 L/min (1 gpm) less than the flow indication
138 bar (2000 psi). Adjust the engine speed to at the same pressure in Test No. 1 - Equipment
keep the engine running at 2300 r/min (rpm). Pump Flow Test, there is leakage in that circuit.
check sheet. 3. Leakage in the dozer/ripper circuits can be
caused by:
30. Hold the ripper control lever in the LOWER
position and adjust the pressure Load Valve on A. Damaged or worn packing in one or both
the Flowmeter as required to keep the pressure cylinders in that circuit.
at 138 bar (2000 psi). Adjust the engine speed to B. Damaged or missing O-rings on the plugs or
keep the engine running at 2300 r/min (rpm). circuit relief valve to the work ports in the
Read the flow gauge and write the reading on the control valve.
check sheet.
C. Damaged or worn spool or spool bore in the
31. Open the pressure Load Valve on the control valve section for that circuit.
Flowmeter. Decrease the engine speed and stop
the engine. D. A ripper circuit can have a circuit relief valve
not adjusted to the correct pressure setting or
32. Place the ignition switch in the ON position, worn and damaged.
place the right parking brake lever in the
operation position. Move the control levers in all 4. If the flow indication for all of the circuits was
direction s to release any pressure in the more than 3.79 L/min (1 gpm) less than the flow
hydraulic circuits, place the right parking brake indication at the same pressure in Test No. 1 -
lever in the applied position and turn the ignition Equipment Pump Flow Test, there is leakage at
switch off. a point common to the entire system.
33. Tilt the ROPS cab/canopy to gain access to the A. The main relief valve not adjusted to the
hydraulic spool valve. See Section 9008. correct pressure setting or the main relief
valve begins to open at 205 bar (2973 psi) or a
34. Remove the flowmeter return line from the lower pressure, adjust the main relief valve
reservoir and replace the filler cap. and do flow test over.
35. Turn the vacuum pump on. B. Damaged or worn main relief valve. Also
36. Remove the tee fitting from the hydraulic pump inspect for damaged or missing O-rings and
hose and the equipment control valve. seals.
37. Connect the hydraulic pump hose to the

equipment control valve.
38. Turn the vacuum pump off and remove the hose
from the vent fitting.
39. Install the vent in the reservoir.
40. Lower and secure the ROPS cab/canopy. See
Section 9008.
41. Check the oil level in the reservoir, add oil as
needed. See Section 1002.
42. Start and run the engine at 2300 r/min (rpm) and
hold the blade control in the raise position for 5
seconds. Lower the blade to the ground and stop
the engine.
43. Check for hydraulic leaks, repair as necessary.

8002-12
Checking for Cylinder Leakage 4. Disconnect the hydraulic line from the cylinder
rod end of the cylinder to be tested and install a
NOTE: The following procedure applies to all hydraulic plug or cap on the end of the hydraulic line.
cylinders except the angle cylinders. The angle cylinders are
designed with a by-pass that allows leakage past the 5. Install a hose in the open port to the cylinder rod
cylinder packing when the angle cylinder is extended. To end and put the other end of the hose in a
check cylinder packing in the angle cylinder, disassemble suitable container.
the angle cylinder according to instructions in Section 6. Start the engine. Move and hold the hydraulic
8006. control lever to extend the cylinder to be tested.
1. Start the engine and extend the cylinder rod on 7. If the cylinder packing is leaking, oil will flow
the cylinder to be checked to its maximum from the open port on the rod end of the cylinder.
stroke.
2. Stop the engine.
3. Place the ignition switch in the ON position,
place the right parking brake lever in the
operation position. Move the control levers in all
direction s to rele ase any pressure in the
hydraulic circuits, place the right parking brake
lever in the applied position and turn the ignition
switch off.

8002-13
FLOWMETER CHECK SHEET METRIC MEASURE

Owner _____________________________________Date______________________Hours______________
Model_________________________ Product Identification Number__________________________________
Oil Temperature: At start of test ________________________ ° C. At end of test_________________________° C.
Test No. 1 - Equipment Pump Efficiency
1. _______________ L/min at minimum pressure at 2300 r/min
2._________________ L/min at 138 bar at 2300 r/min
The efficiency of the equipment pump is line 2 divided by line 1.
Example: .88 .88 = 88% efficient

87 ÷ 98.00
Test No. 2 - Dozer/Ripper Circuits and Load Sense Relief Valve
Load Sense relief valve begins to open at__________________ bar.
Load Sense relief valve completely open at ________________ bar. See Specifications on page 3.
NOTE: This pressure will be the load sense pressure plus the Delta P of 8 bar.
Engine Speed 2300 r/min
Dozer Lift ____________________ L/min at 138 bar Tilt Right ____________________ L/min at 138 bar
Dozer Lower _________________ L/min at 138 bar Tilt Left _____________________ L/min at 138 bar
Angle Right __________________ L/min at 138 bar Ripper Lift ___________________ L/min at 138 bar
Angle Left ___________________ L/min at 138 bar Ripper Lower ________________ L/min at 138 bar

8002-14
FLOWMETER CHECK SHEET U. S. MEASURE

Owner _____________________________________ Date _____________________ Hours ______________
Model ________________________ Product Identification Number __________________________________
Oil Temperature: At start of test ________________________° F. At end of test ________________________ ° F.
Test No. 1 - Equipment Pump Efficiency
1._______________ gpm at minimum pressure at 2300 rpm
2.________________ gpm at 2000 psi at 2300 rpm
The efficiency of the equipment pump is line 2 divided by line 1.
Example: .88 .88 = 88% efficient

23 ÷ 26.00
Test No. 2 - Dozer/Ripper Circuits and Load Sense Relief Valve
Load Sense relief valve begins to open at __________________ psi.
Load Sense relief valve completely open at _________________ psi. See Specifications on page 3.
NOTE: This pressure will be the load sense pressure plus the Delta P of 120 psi.
Engine Speed 2300 rpm
Dozer Lift ___________________ gpm at 2000 psi Tilt Right ____________________ gpm at 2000 psi
Dozer Lower _________________ gpm at 2000 psi Tilt Left______________________ gpm at 2000 psi
Angle Right __________________ gpm at 2000 psi Ripper Lift ___________________ gpm at 2000 psi
Angle Left ___________________ gpm at 2000 psi Ripper Lower _________________ gpm at 2000 psi

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM

8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8003-3
SPECIAL TOOLS
806128
CAS10508, fitting kit.
806127
CAS101162A, filter unit, portable.
TR98H032
CAS10192, vacuum pump.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check
hydraulic system permits efficient operation with a the hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
testing in a laboratory. Examples of the D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
19. Decrease the engine speed to low idle.
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
22. Stop the engine.
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 1002 for
specifications.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 12. Be sure all control levers are in the NEUTRAL
position.
2. Completely retract the cylinders of all
attachments on the machine. Angle the blade to 13. Start and run the engine at low idle.
the right, the right cylinder will be fully retracted
IMPORTANT: Check the oil level in the hydraulic
and the left will be fully extended. Stop the
reservoir frequently while doing step 13. Have another
engine.
person hold a container under the hydraulic lines while you
do step 13.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 14. Slowly move each control lever in both directions
the attachments in place before proceeding until oil begins to flow from the open line. Hold
to the next step! the control lever in place until clean oil flows from
the open line.
39-4
NOTE: Any attachment or part of an attachment that is 15. Stop the engine.
raised must be supported with acceptable equipment to 16. Connect the system line to the CLOSED end of
prevent the attachment from falling. each cylinder.
3. Move each control lever in both directions to 17. Connect a suitable drain line to the OPEN end of
release pressure in the hydraulic circuits. each cylinder and place the other end in an
4. Loosen and remove the filler cap from the acceptable container for contaminated oil.
reservoir. 18. Start the engine and run the engine at low idle.
19. Slowly and completely extend all cylinders. As
the piston rod comes in/out of the cylinder, oil will
be pushed out of the OPEN end of the cylinders.
NOTE: Any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
20. Support any attachments that will be in the
RAISED position.
21. Stop the engine.
22. Disconnect the drain lines and connect the
5. Drain the hydraulic oil from the reservoir. system lines to the cylinders.
A. The reservoir holds approximately 20 U.S. 23. Check the oil level in the hydraulic reservoir. Add
gallons (75.7 litres) of hydraulic oil. oil as required. See Section 1002 for
specifications.
B. Have available acceptable equipment to drain
the hydraulic oil. 24. Install the filler cap on the reservoir.
C. Remove the drain cap from the remote drain. 25. Remove the hydraulic filter elements from the
machine.
6. Apply brakes at least 30 times to drain oil from
accumulators. 26. Install new hydraulic filter elements on the
machine.
7. Remove the hydraulic filter elements from the
machine. 27. Start and run the engine at 1500 rpm (r/min),
operate each hydraulic circuit to completely
8. Install new hydraulic filter elements on the extend and retract the cylinders.
machine.
28. Stop the engine and check for leaks. Check the
9. Install the drain cap in the remote drain. oil level in the hydraulic reservoir. Add oil as
10. Fill the hydraulic reservoir with 20 U.S. gallons required. See Section 1002 for specifications.
(75.7 litres) of Case TCH Fluid.
11. Disconnect the line from the OPEN end and
CLOSED end of each cylinder.
8003-8
NOTES

Section
8004
8004
HYDRAULIC PUMP

8004-2
TABLE OF CONTENTS
SPECIFICATIONS PUMP WITH PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP WITH PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EQUIPMENT PUMP WITHOUT PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8004-3
SPECIFICATIONS PUMP WITH PTO

Manufacturer .................................................................................................................................................... Parker
Equipment pump output .................................................................76.8 L/min at 20 680 kPa, 207 bar, at 2000 r/min
(20.3 U.S. gpm at 3000 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Air vent ............................................................................................................................. 9 Nm (80 pound-inches)
Pump housing bolts.........................................................................................................271 Nm (200 pound-feet)
PTO shaft retainer ...............................................................................................................68 Nm (50 pound-feet)
Set screw PTO shaft retainer ........................................................................................... 9 Nm (80 pound-inches)
Shaft cover screws ........................................................................................... 8 to 9 Nm (67 to 77 pound-inches)
Wear Tolerances .......................................................................................................... See Inspection in this section
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 3. Hold the blade control lever in the TILT position
or overhauled equipment pump: for five seconds. Then put the blade control lever
in the NEUTRAL position for five seconds.
1. Start and run the engine at half throttle for three
minutes. 4. Repeat Step 3 for three minutes.
2. With the engine running at half throttle, move the 5. Increase the engine speed to full throttle and
blade control lever into a TILT position. Hold the repeat Steps 3 and 4.
blade control lever in this position until the blade
6. Stop the engine and check for leaks.
stops moving.

8004-4
EQUIPMENT PUMP WITH PTO
Disassembly STEP 4
STEP 1
Clean the equipment pump in cleaning solvent.
STEP 2
BD02E040
Make alignment marks on the drive end cover, the

gear housing, and the thru-drive housing so that you
will be able to assemble the parts correctly later.
STEP 5
BD02E034
.Put the equipment pump in a vise with protective jaw

caps.
STEP 3
BD02E035
Remove the PTO shaft cover.
STEP 6
BD02E039
Remove the air vent.
BD02E037
Remove the bolts and washers.

8004-5
STEP 7 STEP 10
BD02E041 BD02E064
Loosen the two set screws, one on each side of Use a pry bar to remove the shaft seal from the
thru-drive housing. bearing retainer.
STEP 8
STEP 11
BD02E042
Using a suitable tool, remove the bearing retainer.

BD02E043
Use a soft hammer to loosen the thru-drive housing

STEP 9 from the gear housing.
STEP 12
BD02E062
Remove the O-ring from the bearing retainer.

BD02E044
Remove the thru-drive housing.

8004-6
STEP 13 STEP 16
BD02E075 BD02E050
Remove the wear plate from the gear housing. Remove the gear housing.
STEP 14 STEP 17
BD02E045 BD02E070
Remove the driven gear. Remove O-rings from both sides of gear housing.
STEP 15
STEP 18
BD02E046
Remove the drive gear.

BD02E052
Remove the wear plate from the drive end cover.

8004-7
STEP 19 STEP 22
BD02E053 BD02E087
Remove the retaining ring for the seal retainer from Remove the O-ring from the seal retainer.
the drive end cover.
STEP 20 STEP 23
BD02E084
BD02E054
Use a pry bar to remove the shaft seal from the seal
Use a pry bar to remove the shaft seal from the drive
retainer.
end cover.
STEP 21 STEP 24
BD02E086
Use a slide puller to remove seal retainer. BD02E081
Remove the shaft from the thru-drive housing.

NOTE: Use a brass drift small enough to clear internal
splines in shaft.

8004-8
Inspection 5. .Inspect the ends, bearing shaft area and teeth of

each gear for scoring. If the scoring is excessive
1. Discard shaft seals, wear plates and O-rings. use a new pump.
2. Clean the remaining parts in cleaning solvent.
1
3. Check all machined surfaces for damage. Use
fine emery cloth to remove any minor damage.
4. Inspect the bearings in the drive end cover and
the thru-drive cover. If any bearings are worn
excessively, use a new pump.
2
BD02E091
1 1. DRIVE GEAR 2. DRIVEN GEAR

6. Inspect the pockets in the gear housing for
grooves, pitting, and other damage. If there is
severe damage, use a new pump.
BD02E082
1. THRU-DRIVE HOUSING BEARINGS

1
1
BD02E092
1. GEAR POCKETS
7. Inspect thru shaft bearings for scoring, if scored,
replace the thru shaft assembly.
BD02E083
1. DRIVE HOUSING BEARINGS
BD02E093

8004-9
Assembly STEP 27
STEP 25
BD02E067
Using a suitable driver install a new seal in the seal

BD02E065
retainer. Install a new O-ring on the seal retainer.
Using a suitable driver install a new seal in the NOTE: The seal must be pressed flush with the
bearing retainer. Install a new O-ring on the bearing counter bore with lip of seal away from pump gears.
retainer.
STEP 28
STEP 26
BD02E069
BD02E066
1. TAPERED SIDE OF RETAINER
Using a suitable driver install a new seal in the drive
end cover. Use a light coat of grease to lubricate the O-ring and
seal. Install the seal retainer with the tapered side
NOTE: The seal must be pressed flush with face of down.
the recess with lip of seal towards pump gears.
STEP 29
BD02E068
Use a suitable driver to seat the seal retainer.

8004-10
STEP 30 STEP 33
BD02E085 BD02E092
Install the retaining ring. Install new O-rings on both sides of the gear housing.
STEP 31 STEP 34
BD02E072 BD02E074
1. OIL GROOVES 2. VENT HOLE Apply a thin layer of grease on both faces of the gear
housing. Install the gear housing.
Install a new wear plate with bronze side up. Make
sure the oil grooves are facing to the right while
looking at the pump from the vent side of the drive STEP 35
cover.
1
STEP 32
BD02E075
1. OIL GROOVES
Install a new wear plate with bronze side towards
BD02E073 gears. Make sure the oil grooves are facing to the
Use clean oil to lubricate pump gears and shafts. right while looking at the pump from the vent side of
Install drive and driven gears into drive cover. the drive cover.

8004-11
STEP 36 STEP 38
BD02E077 BD02E042
Install the thru-drive housing. Use a thin coat of grease to lubricate the O-ring and
seal. Install the bearing retainer, use a suitable tool
STEP 37 and torque the retainer 68 Nm (50 pound-feet).
STEP 39
BD02E078
Install the thru shaft.

BD02E079
Install and torque the bearing retainer set screws

9 Nm (80 pound-inches).

8004-12
STEP 40 STEP 42
BD02E038 BD02E080
Install and torque the housing bolts 271 Nm Install and torque the vent.
(200 pound-feet).
STEP 41
BD02E036
Install and torque thru shaft cover.

8004-13
EQUIPMENT PUMP WITHOUT PTO
Disassembly STEP 6
Put alignment marks across the gear (7 and 8) shafts
STEP 1 and the housing (9) to aid assembly. Remove gears
Remove all dirt, oil, and grease from the exterior of (7 and 8) and housing (9).
the equipment pump.
STEP 7
STEP 2 Remove and discard seals (10 and 11) and thrust
Put alignment marks on the closed end cover (3), plate (12).
housing (9) and shaft end cover (19) to aid assembly.
STEP 8
STEP 3 Put shaft end cover (19) in a soft jawed vise with the
Put the equipment pump in a soft jawed vise with the retaining ring (13) facing upward. Remove retaining
closed end cover (3) facing upward. ring.
STEP 4 STEP 9
Remove the four bolts (1) and washers (2). Remove Remove retainer (14) with O-ring (15) and oil seal
closed end cover (3). (16) installed. Remove and discard O-ring and oil
seal. If necessary, put retainer in soft jawed vise
taking care not to overtighten vise and damaging
STEP 5
retainer. Then, use suitable tool and pry oil seal from
Remove and discard seals (4 and 5) and thrust plate bore of retainer. Discard oil seal.
(6).
7
1
4
2
5 8
6
9
10
12
17 11
18
15
14
13
19
16
BS00H032
1. BOLT 6. THRUST PLATE 11. SEAL 16. OIL SEAL

2. WASHER 7. DRIVEN GEAR 12. THRUST PLATE 17. SEAL
3. CLOSED END COVER 8. DRIVE GEAR 13. RETAINING RING 18. PLUG
4. SEAL 9. HOUSING 14. RETAINER 19. SHAFT END COVER
5. SEAL 10. SEAL 15. O-RING

8004-14
Inspection STEP 15
Check the inside diameter of the bushings in the
STEP 12 closed end cover (3) and shaft end cover (19) for
Clean all parts in cleaning solvent. Be careful not to scoring. If bushings are scored replace the
remove the alignment marks made during associated cover.
disassembly.
STEP 16
STEP 13 Inspect gears (7 and 8) for cracked, broken, or
Check all machined surfaces for damage. Use fine chipped gear teeth. Check splines on drive gear (8)
emery cloth to remove minor damage. shaft for cracks, breaks, chipping, or twisted
condition. Replace if any defects are observed.
STEP 14
Hold a straight edge across the gear housing (9)
pocket and use a feeler gauge to measure the
amount of wear caused by the gear teeth in the gear
pocket. If the wear in any gear pocket is more than
0.18 mm (0.007 inch), use a new gear housing or
replace the pump.
7
1
4
2
5 8
6
9
10
12
17 11
18
15
14
13
19
16
BS00H032
1. BOLT 6. THRUST PLATE 11. SEAL 16. OIL SEAL

2. WASHER 7. DRIVEN GEAR 12. THRUST PLATE 17. SEAL
3. CLOSED END COVER 8. DRIVE GEAR 13. RETAINING RING 18. PLUG
4. SEAL 9. HOUSING 14. RETAINER 19. SHAFT END COVER
5. SEAL 10. SEAL 15. O-RING

8004-15
Assembly STEP 24
Put housing (9) with seals (10 and 11) and thrust
STEP 17 plate (12) installed on shaft end cover (19) making
Install the two plugs (18) in the shaft end cover (19). sure alignment marks made during disassembly are
aligned.
STEP 18
STEP 25
Put the shaft end cover (19) in a vise with the
retaining ring end upward. Use clean oil to lubricate the drive gear (8). Install
drive gear using care not to damage lips of seal (17).
STEP 19
STEP 26
Install a new seal (17) in the bore of the shaft end
cover (19). Press the seal flush with face of recess in Use clean oil to lubricate the driven gear (7). Install
cover with lip of seal towards inside of cover. the driven gear. Make sure the alignment marks
made during disassembly are aligned.
STEP 20
STEP 27
Install new oil seal (16) in retainer (14) flush with bore
of retainer with seal lip towards inside of retainer Put new thrust plate (6) on housing (9). Install new
(away from gear). seal (5) on thrust plate and new seal (4) in groove in
housing. If necessary, use petroleum jelly to hold
seal in position on housing.
STEP 21
Install new O-ring (15) in groove of retainer (14).
STEP 28
Install closed end cover (3) on housing (9).
STEP 22
Install assembled retainer (14) in shaft end cover
STEP 29
(19) and secure with retaining ring (13).
Install four washers (2) and bolts (1). Tighten bolts
evenly to a torque of 271 Nm (200 lb-ft).
STEP 23
Put new thrust plate (12) on side of housing (9) that
mates with shaft end cover (19). Install new seal (11)
on thrust plate. Install new seal (10) on housing. If
necessary, use petroleum jelly to hold seal in position
on housing.

8004-16
NOTES

Section
8005
EQUIPMENT CONTROL VALVE
8005

8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8005-3
SPECIFICATIONS
Manufacturer .................................................................................................................................................. Rexroth
Special Torques
End plate mounting nuts .....................................................................................................37 Nm (27 pound feet)
Electro-hydraulic valves ............................................................................................... 12 Nm (106 pound inches)
Plugs M18 X 1.5 ..................................................................................................................60 Nm (44 pound feet)
Pre-charge valve .................................................................................................................60 Nm (44 pound feet)
Allen head cover screws .................................................................................................. 6 Nm (53 pound inches)
Compensator spool plug ...................................................................................................100 Nm (74 pound feet)
Circuit relief valves ..............................................................................................................90 Nm (66 pound feet)
Check valve.........................................................................................................................60 Nm (44 pound feet)
Load sense relief valve .......................................................................................................20 Nm (15 pound feet)
Plug M22 X 1.5....................................................................................................................60 Nm (44 pound feet)
Main pressure relief valve .................................................................................................100 Nm (74 pound feet)
Plug M33 X 1.5...............................................................................................................120 Nm (88.5 pound feet)
Main Relief Valve Pressure ............................................................................................................185 bar (2683 psi)
Load Sense Pressure .....................................................................................................................163 bar (2364 psi)
Delta P Pressure ........................................................................................................... 10 to 16 Bar (145 to 232 psi)
Circuit Relief Valves ........................................................................................... 198 bar (2872 psi) with Hand Pump

8005-4
4 5
1
2
3
6
7
27
26
25 8
6
7 9
6 10
27 7
26
25
11
6
9
7
10
6
27 6
26
25 12
6
13
14
24
15
23 6
16
12
17
22
18
21 20 19
BS06J149

8005-5
1. NUT M8 8. HOUSING SECTION RIPPER 15. PLUG M33 X 1.5 22. LOAD SENSE RELIEF
2. WASHER 9. COMPENSATOR SPOOL 16. SLEEVE 23. CHECK VALVE
3. STUD M8 X 120 10. PLUG M22 X 1.5 17. SPRING 24. PRE-CHARGE VALVE
4. END PLATE 11. HOUSING SECTION ANGLE 18. UNLOADING SPOOL 25. CONE
5. HYDRAULIC VALVE FTDRE4 12. PLUG MHDB16 19. UNLOADING ORIFICE 26. SPRING
6. O-RINGS 13. LOAD SENSE REGULATOR 20. HOUSING TILT AND LIFT 27. PLUG M18 X 1.5
7. CIRCUIT RELIEF VALVE 14. MAIN RELIEF VALVE 21. PLUG M22 X 1.5

8005-6
28 29 30 31
6
8
31
32
33
30
29
11 6
34 31
44
29 30
6
35
36
30 40
6 37
41
42
43
38
39
9
10
20
BS06J150
6. O-RINGS 28. RIPPER SPOOL 34. LIFT SPOOL 40. SPRING RETAINER
8. HOUSING SECTION RIPPER 29. RETAINER 35. TILT SPOOL 41. ADJUSTING SCREW
9. COMPENSATOR SPOOL 30. SPRING 36. HYDRAULIC VALVE FTDRE4 42. COVER
10. PLUG M22 X 1.5 31. RETAINER 37. HYDRAULIC VALVE FTDRE2 43. SCREW
11. HOUSING SECTION ANGLE 32. ANGLE SPOOL 38. SCREW M5 X 80 44. RING
20. HOUSING TILT AND ANGLE 33. SPRING 39. BLOCK COVER

8005-7
37
46 47
43
45
6
41
8 11
41
42 6 30
29
28 32
43
6
30
40
BS06J148
6. O-RINGS 30. SPRING 42. COVER

8. HOUSING SECTION RIPPER 32. ANGLE SPOOL 43. SCREW
11. HOUSING SECTION ANGLE 37. HYDRAULIC VALVE FTDRE2 45. COVER
28. RIPPER SPOOL 40. SPRING RETAINER 46. LOCK NUT
29. RETAINER 41. ADJUSTING SCREW 47. NUT HEX

8005-8
DISSASEMBLY
STEP 1 STEP 11
Remove valve from machine, see section 8001. Remove load sense relief valve (22).
STEP 2 STEP 12
Remove bolts (43), covers (42 and 45), springs (30), Remove plug (21).
and spring retainers (29, 31, and 40).
STEP 13
STEP 3 Remove check valve (23).
Remove bolts (38), cover (39), springs (30 and 33),
and spring retainers (29 and 31). STEP 14
Remove pre-charge valve (24).
STEP 4
Use wooden dowel and push spools (28, 32, 34, and STEP 15
35) from housings (8, 11, and 20). Attach tags to the Remove plug (27), spring (26), and cone (25).
spools to which bore they were removed for proper
assembly.
STEP 16
IMPORTANT: Do not force spools from housing, if spool Remove hydraulic valves (5, 36, and 37).
binds work back and forth until spool comes out freely.
STEP 17
STEP 5 Remove nuts (1) and washers (2), remove end plate
Remove circuit relief valves (7). (4).
STEP 6 STEP 18
Remove plug (10) and compensator (9). If equipped remove ripper housing (8).
STEP 7 STEP 19
Remove main relief valve (14). Remove angle housing (11).
STEP 8 STEP 20
Remove load sense regulator (13).
2
STEP 9
Remove plug (15), sleeve (16), spring (17), plug (21).
STEP 10 1
Use wooden dowel and push the unloading spool 1
(18) from housing (20).
IMPORTANT: Do not force spool from housing, if spool
binds work back and forth until spool comes out freely.
BS03C025
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from
load sense relief valve (22).

8005-9
STEP 21 STEP 22
2
1
2
2
1
1
1
BS03C026 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
load sense regulator valve (13). plug (12).
STEP 23
1
1
2
BS03C029

Remove and discard O-rings and thrust rings from main pressure relief valve (14).

8005-10
STEP 24
3
4
2 1
1
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from circuit relief valves (7).
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 3. Check the spools and the spool bores for
damage and wear.
NOTE: If the O-rings for the adjusting screws are not
leaking do not remove the adjusting screws, if they must be 4. Check the parts of the pressure relief valve,
removed make a note of the number of turns required to anticavitation valves, and the anticavitation and
remove them. circuit relief valves. Use new parts as necessary.
2. Clean all parts in cleaning solvent. Inspect the other parts of the control valve. If any of
the parts are damaged, install new parts.

8005-11
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on the circuit relief valves (7). Torque relief valve (A) into valve to 200 Nm
(147.5 pound feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in direction of
arrow.

8005-12
STEP 2
1
1
2
BS03C029

Install new O-rings and thrust rings on main pressure relief valve (14).
STEP 3 STEP 4
2 2
1 2
1 1
1
BS03C025 BS03C026
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RINGS

Install new O-rings and thrust rings on load sense Install new O-rings and thrust rings on load sense
relief valve (22). regulator valve (13).

8005-13
STEP 5 STEP 15
Install main relief valve (14) and torque to 100 Nm
(74 pound feet).
1
STEP 16
2 Install compensators (9) and plugs (10) and torque
plugs to 100 Nm (74 pound feet).
1
STEP 17
Install circuit relief valves (7) and torque to 90 Nm
(66 pound feet).
BS03C027 STEP 18
1. O-RINGS 2. THRUST RING Lubricate unloading spool (18) with hydraulic oil and
Install new O-rings and thrust ring on plug (12). push into housing (20).
IMPORTANT: Do not force spool into housing.
STEP 6
Install new O-rings on housing (20) and install the STEP 19
angle section (11). Install plug (21), spring (17), sleeve (16), and plug
(15). Torque plug 21 to 60 Nm (44 pound feet),
STEP 7 torque plug (15) to 120 Nm (88.5 pound feet).
If equipped, install new O-rings on housing (11) and
install the ripper section (8). STEP 20
Lubricate spools with hydraulic oil and push spools
STEP 8 (34 and 35) into housing (20).
Install new O-rings on housing (8 or 11), install end
IMPORTANT: Do not force spools into housing.
plate (4), washers (2), and nuts (1). Torque nuts to
37 Nm (27 pound feet).
STEP 21
STEP 9 Install ring (44), spring retainers (40), spring retainers
(29), springs (30), spring (33), retainer (31), covers
Install cone (25), spring (26), and plug (27). Torque (42), and screws (43). Torque screws to 6 Nm
plug to 60 Nm (44 pound feet). (53 pound inches).
STEP 10 STEP 22
Install and torque pre-charge valve (24) to 60 Nm Install block cover (39) and screws (38), and torque
(44 pound feet).
screws to 6 Nm (53 pound inches).
STEP 11 STEP 23
Install and torque check valve (23) to 60 Nm
Lubricate spools with hydraulic oil and push spools
(44 pound feet).
(if equipped 28 and 32) into housing (if equipped 8
and 11).
STEP 12
IMPORTANT: Do not force spools into housing.
Install and torque load sense relief valve (22) to
20 Nm (15 pound feet).
STEP 24
STEP 13 Install spring retainers (40), spring retainers (29),
springs (30), covers (42), and screws (43). Torque
Install plugs (12) and tighten.
screws to 6 Nm (53 pound inches).
STEP 14
STEP 25
Install load sense regulator (13) and tighten.
Install covers (45), and bolts (43). Torque bolts to 6
Nm (53 pound inches).

8005-14
STEP 26 Circuit Relief Pressure Test
Install and torque hydraulic valves (5, 36 and 37) to
12 Nm (106 pound inches). STEP 1
Connect the hand pump to the port for circuit relief
STEP 27 valves (7).
Install valve in machine, see section 8001.
STEP 2
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 3
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 4
Compare the reading to the specifications on Page 3.
STEP 5
If the pressure is not correct, adjust the circuit relief
valve.
Circuit Relief Adjustment

STEP 1
Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
STEP 2
Check the pressure again. Repeat the adjustment as
necessary.

Section
8006
CYLINDERS
8006

8006-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALL CYLINDERS EXCEPT THE RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lift Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tilt Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Angle Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REPLACING BUSHINGS FOR TYPICAL CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ripper Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING BUSHINGS FOR THE RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ripper Cylinder Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8006-3
SPECIAL TOOLS
This tool is used to install the buffer seal in the
glands of the cylinders.
BC07F281
CAS1456A Gland Wrench

B795329M
This tool is used to remove and install the gland CAS1039 Torque Multiplier
on the cylinders.
This tool is used to loosen and tighten the piston
bolts or nuts.
B505802M
1. CAS1660 For 32 and 38 mm (1-1/4 and 1-1/2

Inch) Rods
2. CAS1758 For 51 mm (2 Inch) rods

8006-4
ALL CYLINDERS EXCEPT THE RIPPER CYLINDER
Disassembly Inspection
Clean the outside of the cylinder. If hoses were 1. Discard the parts that were removed from the
removed with the cylinder, remove the hoses from piston and the gland.
the cylinder.
1. Fasten the tube (11) in a vise or other holding
3. Check to be sure that the rod is straight. If the
equipment. Do not damage the tube (11).
rod is not straight, install a new rod.
2. Loosen and remove the gland (6) from the tube
4. Illuminate the inside of the tube. Inspect the
(11).
inside of the tube for deep grooves and other
3. Pull the rod (1) straight out of the tube (11) to damage. If there is any damage to the tube, a
prevent damage to the tube (11). new tube must be used.
4. Fasten the rod eye in a vise and put a support 5. Remove small scratches on the rod or inside the
under the rod (1) near the piston (16). Put a shop tube with emery cloth of medium grit. Use the
cloth between the support and the rod (1) to emery cloth with a rotary motion.
prevent damage to the rod (1).
6. Inspect the bushings in the rod eye and the tube,
5. Loosen and remove the nut (13) that holds the and replace the bushings as required.
piston (16) to the rod (1). Use the torque
7. Inspect the gland for rust, clean and remove rust
multiplier for nuts that have a high torque value.
as necessary.
6. Remove the piston (16) from the rod (1).
8. Inspect the gland end of the tube for sharp edges
7. Remove the gland (6) from the rod (1). that will cut the gland O-ring, remove as
necessary.
8. Remove the wear ring (14) and seal (15) from
the piston (16). 9. Inspect the piston for damage and wear. If the
piston is damaged or worn, a new piston must be
9. Remove the O-rings (8 and 10) and backup rings
used.
(7 and 9) from outside of gland (6). Remove the
backup ring (4), rod seal (3), bushing (5), and
wiper (2) from inside the gland.

8006-5
10
9 11
8
7
4
3
12
2
13
1
14
15
17
16
18
BS07F261
1. ROD 6. GLAND 11. TUBE 16. PISTON
2. WIPER SEAL 7. BACKUP RING 12. GREASE FITTING 17. SNAP RINGS
3. SEAL 8. O-RING 13. NUT 18. BUSHING
4. BACKUP RING 9. BACKUP RING 14. WEAR RING
5. BUSHING 10. O-RING 15. SEAL RING
LIFT CYLINDER EXPLODED VIEW

8006-6
5
4
3
2
17
18
17 14
15
17
16
10 18
9
8
7
6 17
11
13
BS07F262
1. ROD 6. GLAND 11. TUBE 16. PISTON
2. WIPER SEAL 7. BACKUP RING 12. NOT USED 17. SNAP RINGS
3. SEAL 8. O-RING 13. NUT 18. BUSHING
4. BACKUP RING 9. BACKUP RING 14. WEAR RING
5. BUSHING 10. O-RING 15. SEAL RING
TILT CYLINDER EXPLODED VIEW

8006-7
17
1
10
9
8
18 17 7
5 17
4
3
2
19
20 11
21
22
23
13
14
18
15
16 17
BS07F263
1. ROD 7. BACKUP RING 13. NUT 19. ‘C’ CLIP
2. WIPER SEAL 8. O-RING 14. WEAR RING 20. RING
3. SEAL 9. BACKUP RING 15. SEAL RING 21. BUSHING
4. BACKUP RING 10. O-RING 16. PISTON 22. SNAP RING
5. BUSHING 11. TUBE 17. SNAP RINGS 23. NUT
6. GLAND 12. NOT USED 18. BUSHING
ANGLE CYLINDER EXPLODED VIEW

8006-8
Assembly 18. Fasten the tube (11) in a vise or other holding

equipment. Be careful to prevent damage to the
NOTE: If a new gland is being used, put the part number tube (11).
of the cylinder on the new gland.
19. Lubricate the inside of the tube (11) and the
1. Install the new bushing (5) into the gland (6). piston (16) with clean oil.
2. Install locking ring on the gland with tab facing 20. Push the piston (16) straight into the tube (11).
towards gland.
21. Lubricate the O-ring (8 and 10) on the gland (6)
3. Install the backup ring (4) in the gland (6). with clean oil.
4. Install the seal (3) in the gland (6). 22. When the piston (16) is in the smooth part of the
5. Press a new wiper (2) into the gland (6). The lips tube (11), start the gland (6) into the tube (11).
of the wiper (2) must be toward the outside end 23. Install the gland (6) and torque to 686 to 784 Nm
of the gland (6). (506 to 578 pound-feet).
6. Install a new backup rings (7 and 9) in the NOTE: Make sure locking ring tab is secured in the slot
grooves on the outside of the gland (6). on the gland.
7. Install the O-rings (8 and 10) next to the backup 24. Secure gland by bending the locking ring into the
rings (7 and 9) in the grooves on the outside of slot on the cylinder.
the gland (6).
8. Fasten the rod eye in the vise.
2
9. Remove any marks and sharp edges on the
chamfer at the end of the rod (1). Make sure that
the rod (1) is clean. 1
10. Lubricate the bore of the gland (6) and the rod
(1) with clean oil.
11. Push the gland (6) onto the rod (1). If necessary,
use a soft hammer to drive the gland (6) onto the
rod (1).
12. Put a support below and near the end of the rod
(1). Use a shop cloth between the support and BD07F075-01
the rod (1) to prevent damage to the rod (1). 1. LOCKING RING TAB 2. CYLINDER SLOT
13. Put the piston (16) on the end of the rod (1). 25. If the hoses were removed with the cylinder,
install new O-rings, if equipped, on the hose
14. Clean the threads on the end of the rod (1) and
fittings. Lubricate the O-rings with clean oil.
the threads of the nut (13) using Loctite cleaning
Install the hoses.
solvent. Allow to dry. Apply Loctite 242 to the
rod threads 6.35mm (1/4 inch) from the end of
the rod (1) so that there is 12.7mm (1/2 inch) of
Loctite on the rod threads. DO NOT apply Loctite
to the first 6.35mm (1/4 inch) of the rod threads.
15. Install the nut (13) and torque on the tilt cylinder
1230 to 1375 Nm (907 to 1014 pound-feet), on
the angle cylinder 1275 to 1373 Nm (940 to
1012.5 pound-feet), on the lift cylinder 657 to
725.5 Nm (484.5 to 535 pound-feet). A torque
multiplier can be used to help tighten the bolt.
16. Install a new seal (15) on the outside of the
piston.
17. Install a new wear ring (14) in the groove on the
outside of the piston (16).

8006-9
REPLACING BUSHINGS FOR TYPICAL CYLINDERS

1. If bushing are held in with a snap ring remove the 5. If the bushing is pressed in start the new bushing
snap ring and bushing. into the bore.
2. If bushings are pressed in use a press and an 6. Use the press and an acceptable driver and
acceptable driver and press the bushings out of press the bushing into the bore until the bushing
the bore. is flush with the outside of the rod eye or tube.
3. Clean the bore for the bushing. NOTE: When two bushings are used in the same bore,
pressing a bushing in too far can close the passage to the
4. If bushings are held in with a snap ring install the
grease fitting.
bushing and the snap ring.
RIPPER CYLINDER
Disassembly Inspection
Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the hoses piston and the gland.
from the cylinder.
1. Fasten the tube (1) in a vise or other holding
3. Check to be sure that the rod is straight. If the
equipment. Do not damage the tube (1).
rod is not straight, install a new rod.
2. Loosen and remove the lock screw (2) from the
4. Illuminate the inside of the tube. Inspect the
gland (3) and the tube (1).
inside of the tube for deep grooves and other
3. Use the gland wrench to loosen and remove the damage. If there is any damage to the tube, a
gland (3) from the tube (1). new tube must be used.
4. Pull the rod (4) straight out of the tube (1) to 5. Remove small scratched on the rod or inside the
prevent damage to the tube (1). tube with emery cloth of medium grit. Use the
emery cloth with a rotary motion.
5. Fasten the rod eye in a vise and put a support
under the rod (4) near the piston (5). Put a shop 6. Inspect the bushings in the rod eye and the tube,
cloth between the support and the rod (4) to and replace the bushings as required.
prevent damage to the rod (4).
7. Inspect the gland for rust, clean and remove rust
6. Loosen and remove the bolt (6) and washer (7) as necessary.
th at ho ld s t he pi sto n ( 5 ). Use th e t or q ue
8. Inspect the gland end of the tube for sharp edges
multiplier for bolts that have a high torque value.
that will cut the gland O-ring, remove as
7. Remove the piston (5) from the rod (4). necessary.
8. Remove the wear rings (8), seal (10) and piston Inspect the piston for damage and wear. If the piston
ring (9) from the piston (5). is damaged or worn, a new piston must be used.
9. Remove the gland (3) from the rod (4).
10. Remove the O-ring (11), backup ring (12), wiper
(13), bushing (14), buffer seal (15), and rod seal
(16) from the gland (3).

8006-10
17
18
17 3
16
15
12
11
8 18
17
5
9
10
8
6 7
17
4
14
13
BC06B024
1. TUBE 6. CAP SCREW 11. O-RING 16. ROD SEAL
2. LOCK SCREW 7. HARDENED WASHER 12. BACKUP RING 17. BUSHING
3. GLAND 8. WEAR RING 13. WIPER 18. GREASE FITTING
4. ROD 9. PISTON RING 14. BUSHING
5. PISTON 10. SEAL 15. BUFFER SEAL
RIPPER CYLINDER EXPLODED VIEW

8006-11
Assembly 14. Clean the threads on the end of the rod (4) and
the treads of the bore (6) using Loctite cleaning
NOTE: If a new gland is being used, put the part number solvent. Allow to dry. Apply Loctite 242 to the rod
of the cylinder on the new gland. threads 6.35 mm (1/4 inch) from the open end of
1. Install the new bushing (14) into the gland (3). the rod so that there is 12.7 mm (1/2 inch) of
Loctite 242 on the rod threads. DO NOT apply
2. Install the buffer seal (15) in the gland (3). If both
Loctite to the first 6.35 mm (1/4 inch) of the rod
sides of the buffer seal are not flat, the lips of the
threads.
buffer seal (15) are toward the small end of the
gland (3). 15. Install the bolt (6). Tighten the bolt (6) to
1355-1627 Nm (1000-1200 pound-feet). A torque
3. Install the rod seal (16) in the gland (3). If both
multiplier can be used to help tighten the bolt (9).
sides of the rod seal are not flat, the side of the
rod seal (16) with the groove must be toward the 16. Install a new piston ring (10) in the center groove
small end of the gland(3). on the outside of the piston (5).
4. Press a new wiper (13) into the gland (3). The 17. Install a new seal (9) on top of the piston ring
lips of the wiper (13) must be toward the outside (10) on the outside of the piston (5).
end of the gland (3). 18. Install new wear rings (8) in the grooves on the
5. Install a new backup ring (12) in the groove on outside ends of the piston (5).
the outside of the gland (3). If both sides of the 19. Fasten the tube (1) in a vise or other holding
backup ring (12) are not flat, the side that is not equipment.
flat must be toward the small end of the gland
20. Lubricate the inside of the tube (1) and the piston
(3).
(5) with clean oil.
6. Install the O-ring (11) next to the backup ring (12)
21. Push the piston (5) straight into the tube (1).
in the groove on the outside of the gland (3). The
O-ring (11) must be toward the small end of the 22. Lubricate the O-ring (11) on the gland (3) with
gland (3). clean oil.
7. Fasten the piston rod eye in the vise. 23. When the piston (5) is in the smooth part of the
tube (1), start the gland (3) into the tube (1).
8. Remove any marks and sharp edges on the
chamfer at the end of the rod (4). Make sure that 24. Install the gland (3) and torque to 135-542 Nm
the rod (4) is clean. (100-400 pound-feet). If the lock screw (2) holes
become aligned, install the lock screw (2).
9. Lubricate the bore of the gland (3) and the rod
Tighten the lock screw (2). If the lock screw (2)
(4) with clean oil.
holes are not aligned, do steps 26 through 27.
10. Push the gland (3) onto the rod (4). If necessary,
25. Install the gland (3) and torque to 135-542 Nm
use a soft hammer to drive the gland (3) onto the
(100-400 pound-feet).Use a No. 26 drill and drill
rod (4).
a hole half in the gland (3) and half in the tube
11. Put a support below and near the end of the rod (1). Drill to a depth of 11 mm (7/16 inch). Do not
(4). Use a shop cloth between the support and drill in line with a hole in the gland (3) for the
the rod (4) to prevent damage to the rod (4). gland wrench.
12. Put the piston (5) on the end of the rod (4). 26. Install the lock screw (2). Tighten the lock screw.
13. Put the hardened washer (7) on the bolt. 27. If the hoses were removed with the cylinder,
install new O-rings, if equipped, on the hose
fittings. Lubricate the O-rings with clean oil.
Install the hoses.
REPLACING BUSHINGS FOR THE RIPPER CYLINDER

1. Use a press and an acceptable driver and press 4. Use the press and an acceptable driver and
the bushings out of the bore. press the bushing into the bore until the bushing
2. Clean the bore for the bushing. is flush with the outside of the rod eye or tube.
3. Start the new bushing into the bore. NOTE: When two bushings are used in the same bore,
pressing a bushing in too far can close the passage to the
grease fitting.

8006-12
1
11 12
2
18
14
17
4
13
3
15 ROD END OF CYLINDER
16 1
8 9 10 8 5
17
18
6
7 CLOSED END OF CYLINDER
BC06B025
1. TUBE 6. BOLT 11. O-RING 16. ROD SEAL
2. LOCK SCREW 7. WASHER 12. BACKUP RING 17. BUSHING
3. GLAND 8. WEAR RING 13. WIPER 18. GREASE FITTING
4. ROD 9. SEAL 14. BUSHING
5. PISTON 10. PISTON RING 15. BUFFER SEAL
RIPPER CYLINDER SECTIONAL VIEW

Section
8010
EQUIPMENT CONTROL VALVE ACCUMULATOR
8010

8010-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8010-3
SPECIFICATIONS
Accumulator Dry Nitrogen Pressure ....................................................................... 10 Bar (145 psi) @ 21° C (70° F)
SPECIAL TOOLS
BS06M002 BC04A001
380001676 NITROGEN REGULATOR VALVE 380001168 ACCUMULATOR VALVE ADDAPTER
BS06M003
380001390 ACCUMULATOR CHARGING HOSE
NOTE: Check your inventory of tools, if you have nitrogen
charging kit CAS10899 use it in place of the above listed
tools.

8010-4
CHECKING THE NITROGEN CHARGE ON AN ACCUMULATOR
B C
D
E
BS06M004
NITROGEN CHARGING KIT
1. Use the Nitrogen Charging Kit to check the 5. Remove the valve cap from the accumulator.
accumulator charge, refer to the illustration
6. Install adapter 380001168 onto the accumulator.
above. The tool can be disconnected from the
nitrogen tank. 7. Connect valve A to the valve stem on the
adapter.
2. Close valve E.
8. Open valve on accumulator using the adapter’s
3. Adjust the regulator D to the minimum pressure
square drive.
setting by turning the knob counterclockwise.
9. Turn the T-handle inward on valve A to engage
4. Turn the T-handle on valve A fully out.
the pin in the valve stem on the adapter.
10. Slowly open valve E.
11. Check the charge pressure on gauge B.

8010-5
CHARGING THE ACCUMULATOR WITH NITROGEN
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
IMPORTANT: The valves A, D, AND E must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the illustration on page 4.
1. Close the shutoff valve D by turning it all the way 11. Fill the accumulator to pressure according to
to the left (counterclockwise), refer to the temperature chart below.
illustration on page 4.
TEMPERATURE CHARGE PRESSURE
2. Close the gauge valve E by turning it all the way 21° C 70° F 10 BAR 145 PSI
to the right (clockwise).
3. Connect the charging gauges to the nitrogen TEMPERATURE/CHARGE PRESSURE CHART
supply tank, open the supply tank valve. 12. Close valve E by turning to the right (clockwise).
4. SLOWLY turn valve D clockwise while watching After a few minutes open valve E and check the
the pressure gauge B. Stop turning valve D when accumulator for leakage.
the needle on the gauge B reaches 10 bar (145 13. Back off the needle valve A on the accumulator
psi). end of the charging hose by turning it
NOTE: If the needle goes over the needed pressure, counterclockwise the maximum amount. This will
quickly open and close valve E and check the pressure p re ve n t n itro g e n fro m esca p ing from th e
setting again. accumulator as the hose is removed.
The charging kit is now ready to be installed on the 14. Close the valve on the nitrogen supply tank.
accumulator. 15. Adjust the regulator D to the minimum pressure
setting by turning the knob counterclockwise.
5. Remove the cap from the accumulator.
6. Loosen the sealing plug with an Allen wrench. 16. Slowly remove the charging hose from the
accumulator pressure valve.
7. Install addapter 380001168.
NOTE: A small amount of nitrogen will escape when
8. Back off the needle valve A on the accumulator
disconnecting the hose.
end of the charging hose by turning it
counterclockwise to the maximum amount. This 17. Snug the sealing plug on the accumulator,
prevents nitrogen from escaping from the remove the addapter from the accumulator.
accumulator when the charging hose is attached 18. Torque the sealing plug to 20 to 25 Nm (15 to
to the accumulator gas charging valve. 18.5 pound feet)
9. Install the charging hose fitting onto the 19. Install the cap on the accumulator.
addapter.
20. Remove the charging gauges from the nitrogen
10. Tighten the needle valve A by turning it supply tank.
clockwise. Slowly open the gauge valve E and
observe the reading on the gauge. This reading NOTE: A small amount of nitrogen will escape when
is the nitrogen pressure level inside the disconnecting the hose.
accumulator.

8010-6
NOTES

SECTION INDEX
MOUNTED EQUIPMENT

Pedals and Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001
Air Conditioning Troubleshooting and System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Removal and Installation of Heater and Air Conditioning Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005
Air Conditioning Compressor and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Dozer Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9008
Air and Mechanical Suspension Seats And Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9009
Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

9001
Section
9001
PEDALS AND LEVERS

9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE PEDAL, HAND THROTTLE, FOOT THROTTLE (DECEL PEDAL)
POTENTIOMETER ADJUSTMENT USING THE INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake and Decelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking Brake Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parking Brake Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

9001-3
SPECIFICATIONS
Engine Speeds
Low Idle ........................................................................................................................... 800 to 1050 r/min (rpm)
High Idle (Full Throttle - No Load) ................................................................................. 2170 to 2270 r/min (rpm)
BRAKE PEDAL, HAND THROTTLE, FOOT THROTTLE (DECEL PEDAL)

POTENTIOMETER ADJUSTMENT USING THE INSTRUMENT CLUSTER
1. Put the master disconnect switch in the on 9. After moving brake pedal and no error message
position and the ignition switch in the run appears on the instrument cluster press both
position. buttons for one second and release, the
instrument cluster will read (CAL HTR).
2. Push and hold both the bump up and bump down
buttons on the directional control. 10. Slowly move the hand throttle from low idle to
high idle two to four times.
3. Start the engine continue to hold the buttons for
5 seconds or until the instrument cluster reads NOTE: During this operation if the instrument cluster
(HP 125-135), release the buttons. reads (ERR RANGE), minimum/maximum values are out of
machine horse power range, (HP 125-135 or
HP 150 - 160). 11. After moving hand throttle and no error message
appears on the instrument cluster press both
NOTE: By selecting a different machine will cause the
buttons for one second and release, the
calibration to be incorrect and machine functions to be
instrument cluster will read (CAL FTR).
impaired.
12. Slowly move the foot throttle (Decel Pedal) from
5. When the machine being calibrated is displayed
high idle to low idle two to four times.
press both buttons for one second and release,
the instrument cluster will read (LT or LGP/WT). NOTE: During this operation if the instrument cluster
machine track gauge, (LT or LGP/WT).
seconds since the start of calibration mode. During this
7. When the machine being calibrated is displayed operation if the instrument cluster reads (ERR SWITCH),
press both buttons for one second and release, the low idle switch is not functioning or is out of
the instrument cluster will read (CAL BRK). adjustment.
8. Slowly move the brake pedal from release to 13. After moving foot throttle (Decel Pedal) and no
applied position two to four times. error message appears on the instrument cluster
press both buttons for one second and release,
NOTE: During this operation if the instrument cluster
the instrument cluster will read (CAL DONE).
Stop and restart the machine, values are stored
in internal memory.
14.If at any time during calibration the instrument
cluster reads (CAL FAIL), stop the engine and
restart the procedure.

9001-4
1 4
2 3 5
BS06K137
1. BRAKE POTENTIOMETER 5. JAM NUT RETURN SPRING

2. ACTUATION ROD 6. DECELERATOR PEDAL
3. BRAKE PEDAL 7. DECELERATOR PEDAL TRAVEL ADJUSTING JAM NUT
4. DECELERATOR POTENTIOMETER
BRAKE AND DECELERATOR PEDAL
BD07K041-01 BD07K040-01
Push down on the idle validation switch you should The idle validation switch should be activated just
be able to hear a click when the switch activates. before the stop bolt contacts the fire wall. Adjust the
stop bolt as needed to activate the switch
Adjust the decelerator potentiometer using the EST
tool, at high idle the voltage reading should be 0.375
to 0.425, at low idle the voltage reading should be
0.75 to 1.25. Adjust potentiometer as needed to get
the correct voltage.
Calibrate the machine using procedures in this
section.

9001-5
2
1
5
6
6 2
5
4
BS06K139
1. BRAKE LEVER 4. ADJUSTMENT BOLT

2. SPRING 5. PROXIMITY SWITCH BRACKET
3. PIVOT MOUNTING BOLT 6. STOP PLATE
PARKING BRAKE LEVERS

9001-6
1. Make sure that the parking brake lever over Parking Brake Proximity Switch
center springs are in place.
Adjustment
2. Loosen the bolt (4) and adjust the stop plate (5)
so the lever (1) does not hit the console.
BD07K039-01
Using a feeler gauge adjust clearance of proximity

switch to 1 to 3 MM. (0.040 to 0.118 in). Recheck
switches.

Section
9003
9003
AIR CONDITIONING TROUBLESHOOTING
AND SYSTEM CHECKS

9003-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem: Erratic Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem: System Makes Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure-Temperature and Louver Air Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Problem - No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Problem - No Cooling or Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Problem - Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
problem - Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Problem - Intermittent Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Problem - Noise in System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9003-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS

MANUAL. WHEN YOU SEE THIS SYMBOL, CREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified by an 1. Always wear safety goggles when doing any
approved training and certification organization may service service work near an air conditioner system.
or repair motor vehicle or mobile air conditioning systems. Liquid refrigerant getting into the eyes can cause
It is mandatory that all refrigerant must be RECOVERED and serious injury. Do the following if you get
RECYCLED when removed from a system during servicing. refrigerant near or in your eyes:
Refrigerant HFC134a is the most stable, and easiest A. Flush your eyes with water for 15 minutes.
to work with of the refrigerants now used in air
B. See a physician immediately.
conditioner systems. Refrigerant HFC134a does not
contain any chlorofluorocarbons (CFC’s) which are 2. A drop of liquid refrigerant on your skin may
harmful to the earth’s ozone layer. cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
Safety procedures must be followed when working
conditioner system. Your skin must be treated for
with Refrigerant HFC134a to prevent possible
frostbite or a physician must be seen if you get
personal injury.
refrigerant on your skin.
3. Keep refrigerant containers in the correct upright
position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
m i x t u r e s of H F C 1 3 4 a a n d a i r c a n f o r m a
combustible gas.

9003-4
SPECIAL TOOLS
299L7C A22094
OEM-1036 Belt Tension Tool OEM-1415 Refrigerant Recovery, Recycling and

Charging Station
A22090
OEM-1437 Electronic Leak Detector 10917
Safety Goggles- Obtain Locally

In the USA and Canada order Service Tools from:
OTC Division/SPX Corporation
655 Eisenhower Drive
Owatonna, Minnesota 55060
phone: 507-455-7000
1-800-533-0492

9003-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core.
tubes and hoses and operate as a closed system.
As the refrigerant flows through the evaporator core
The air conditioner system is charged with HFC134a
the refrigerant is heated by the air around and
refrigerant.
flowing through the evaporator fins. The combination
The compressor receives the refrigerant as a low of increased heat and decreased pressure causes
pressure gas. The compressor then compresses the the air flow through the evaporator fins to become
refrigerant and sends it in the form of a high pressure very cool and the liquid refrigerant to become a low
gas to the condenser. The air flow through the pressure gas. The cooled air then passes from the
condenser then removes the heat from the evaporator to the cab for the operator’s comfort.
refrigerant. As the heat is removed the refrigerant
The electrical circuit of the Air Conditioning System
changes to a high pressure liquid.
consists of a fan speed control, temperature control,
The high pressure refrigerant liquid then flows from two (2) fuzes, one 20 Amp and one 20 Amp, three (3)
the condenser to the receiver-drier. The condenser fan motors, two (2) blower motors, blower
receiver-drier is a container filled with moisture resistor, compressor clutch, low pressure switch,
removing material, which removes any moisture that high pressure switch, and warning light.
may have entered the air conditioner system in order
to prevent corrosion of the internal components of
the air conditioner system.
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER
2. EVAPORATOR 4. CONDENSER

9003-6
TROUBLESHOOTING
1. Perform a visual inspection of the machine. - Are there heavy accumulations of oil, or oily dust
Check the following and correct as necessary: around the fittings, indicating refrigerant leakage?
- - Obtain service history if possible. - Are air ducts undamaged, sealed properly and in
position?
- - Is compressor drive belt in place and tensioned?
- Condensate drain hoses and check valves present
- - Are grille screens, fan blades, condenser, air
and unobstructed?
filter, and evaporator unobstructed?
- Are there any sharp bends or kinks in the hoses?
Problem: No Cooling
COMPRESSOR RUNS COMPRESSOR DOES NOT RUN
INTERNAL SYSTEM PROBLEM MECHANICAL

See Pressure Testing, Page 13. See Mechanical Compressor Check Page 8.
ELECTRICAL
See Blower and Compressor Clutch Check Page 9.

9003-7
Problem: Not Enough Cooling Problem: Erratic Cooling
MECHANICAL
HEATER See Mechanical Compressor Check Page 8.
Make sure the heater control is OFF and that there is
no coolant flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower
Motor Check, Blower Switch Check and Compressor
Clutch Check on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL Problem: System Makes Noise

See Mechanical Compressor Check Page 8. See
Evaporator Heater Core Check Page 12.
MECHANICAL
See Mechanical Compressor Check Page 8.
ELECTRICAL
See Blower Motor Check Page 9.
See Blower and Compressor Clutch Check on Page
9.
ELECTRICAL
See Compressor Clutch Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.
INTERNAL SYSTEM PROBLEM

INTERNAL SYSTEM PROBLEM


9003-8
SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts

1. Loose or broken drive belt - Adjust the tension on
a new belt at 422 to 516 N (95 to 115 lbs) and at
400 to 489 N (90 to 110 lbs) after a minimum of
ten minutes run-in time on the belt. Belt tension
on a used belt must be 400 to 489 N (90 to 110
lbs). See Section 9005.
2. Too much belt wear - replace a worn belt,
because a worn belt will cause too much
slippage.
Compressor Mounting Brackets

1. Loose bracket mounting bolts- tighten the bolts
to the correct torque.
2. Bracket has breaks or cracks - replace the
bracket.
Compressor Clutch
1. The compressor belt will slip on the compressor
pulley if there is compressor seizure. Remove
the compressor for service or replacement. See
Section 9005 of this service manual.
2. Remove the dust cover, if equipped, and check
the air gap on the compressor clutch. The gap
between the front plate and pulley assembly
must be 0.41 to 0.79 MM. (0.016 to 0.031 inch).
See Section 9006.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor rotation
should be smooth and not require much effort.
Pulley and Belt Alignment

1. The compressor pulley and the compressor drive
pulley must be aligned within 1.6 MM. (1/16 inch)
of each other. Use a straight edge to check
pulley alignment. Adjust the compressor
mounting bracket if needed. The drive belt
should be located in the forward clutch groove.

9003-9
Blower and Compressor Clutch

Check
Compressor Clutch
1. If there is electrical system voltage to the clutch,
see Section 9006 and replace the clutch.
High/Low Pressure and Temperature Switches
1. The high pressure switch at the compressor and
the lo w pressur e switch is located at th e
expansion valve and the temperature switch is
located at the receiver-dryer.
Blower Fuse
1. Check for damaged blower fuse.
Blower Fan Switch
1. Check switch operation. Switch must give four
different blower speeds.
2. Check for loose connections or broken wires.
Repair or replace as necessary.
3. Check resistor board.
Blower Motor
1. Check the wiring to the two blower motors. Make
repairs or replace items as necessary.
2. Check motor ground wire. Make sure motor
ground wire is making good contact.
Air Conditioner Switch
1. Turn switch to the AC position. Compressor
clutch must engage.
NOTE: Blower must be operating, since electrical power
to temperature control switch is received from blower
switch.
2. Turn the AC switch on and check for continuity
between the connector. If continuity is not
present, replace the switch.

9003-10
Cab Temperature Check
Air Louvers
1. Make sure louvers and recirculation vents are
fully open for most efficient air conditioning
operation. Defrost louvers must be closed.
2. Check blower; blower must be running.
Air Conditioning
1. Feel the air conditioning hoses. The high
pressure hoses (small line) must be warmer than
the low pressure hose (large line).
2. If no temperature difference, the system is low
on refrigerant, or compressor is not working
correctly.
Duct Temperature
1. Put a thermometer in the air duct behind the seat
and run the compressor for five minutes to make
temperature stable.
2. Duct temperature must not be above the Air
Louver Maximum Temperature for the Ambient
Temperature if the system is operating at
maximum efficiency. See the chart on Page 13.
NOTE: Ambient temperature must be 27 to 43 degrees C
(80 to 110 degrees F).
3. If the duct temperature is above the Air Louver
Maximum Temperature for the Ambient
Temperature (see the Chart on Page 13), the
system is low on refrigerant, there is a restriction
in the system, compressor is not working
correctly, or air ducts are not sealed correctly.
Temperature Sensing Probe Check
1. Turn the engine OFF, key switch ON, blower
switch ON and temperature control switch turned
fully clockwise.
2. Remove the temperature sensing probe from the
evaporator.
3. Put the end of the temperature sensing probe in
a container with ice and water.
4. When the sensing tube has cooled to the
temperature of the ice and water mixture, the
temperature control switch should interrupt the
current flow to the compressor. Check for current
at the control switch terminals as on previous
page. If current is not interrupted then replace
the control switch.

9003-11
Visual and Leak Check
Compressor Hoses
1. Make sure that all hose connections are tight.
2. Check hoses for bends or cracks. Replace all
hoses that have damage.
Leak Finding Check

1. Shut off the engine.
WARNING: When refrigerant comes in

contact with an open flame, it can form
dangerous gas. Never breathe these
fumes. SM109A
2. Use electronic leak detector OEM-1437 to

inspect all connections. Use instructions from
manufacturer of leak finding tool.
NOTE: When checking compressor seal for a leak,
remove the dust cover and rotate the clutch shaft
clockwise.
NOTE: To properly check the expansion valve for leaks,

remove the insulation tape.
3. Repair all leaks and recharge the system.
Condenser
1. Make sure the condenser is clean and the seals
are in place. Make sure condenser fans run
when AC control switch is ON.

9003-12
Evaporator/Heater Core Check
Make sure heater valve is closed.

Evaporator/Heater Core
1. See Section 9005 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater core.
All the fins that have bends or damage must be
made straight.
3. Inspect the evaporator/heater core for
restrictions. If the core is dry, use compressed air
or a brush and vacuum cleaner. If the core is wet
or filled with mud, flush the core with water using
a hose without pressure. Make sure the water
drains freely from the evaporator/heater core.
DO NOT USE STEAM.
WARNING: Do not steam clean any air

conditioning systems parts while the system
is charged. The heat will cause the
refrigerant to rise to a pressure that could
cause the system to explode. SM104A
Evaporator/Heater Core Sealing

1. See Section 9005 for access to the
evaporator/heater core.
2. Make sure seals are in place so blower will pull
air only through the evaporator/heater core and
not around the evaporator/heater core.
Filters
1. Make sure the filters are clean.

9003-13
Pressure Testing
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 0.69 to 2.4 bar (10 to 35
The manifold gauge set is the most important tool psi) after the system has run 10 to 15 minutes.
used to service the air conditioning system. The
manifold gauge set is used to measure the high and HIGH PRESSURE GAUGE - The high pressure
low pressures of the system, the correct refrigerant gauge is used to indicate pressures in the high side
charge, system diagnosis, and operating efficiency. of the system. The gauge must indicate from 0 to
The manifold gauge set can read both the high 27.5 bar (0 to 400 psi) minimum.
(discharge) and low (suction) sides at the same time, During normal operation, the high pressure gauge
since pressure must be compared in order to make a will normally indicate from 120 to 310 psi (8.3 to 21.3
diagnosis of system operation. bar). See pressure-temperature chart.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. Under some conditions, air Pressure Test Connection
conditioning systems can change from a pressure
Connect the manifold gauge set into the air
into a vacuum on the low side. For this reason, it is
conditioning system as shown. Make sure that both
necessary to use a compound gauge that will
valves in the manifold gauge set are closed.
indicate both pressure and vacuum.
Pressure-Temperature and Louver Air Temperature Chart

AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER MAXIMUM
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION TEMPERATURE
°C (°F) kPa (psi) bar (psi) °C (°F)
117.4 to 140.3 821.7 to 919.6

21 (70) 11.4 (53)
(17 to 20) (119 to 133)
117.9 to 188.8 978.1 to 1125.3
27 (80) 16.9 (62)
(17 to 27) (142 to 163)
160.1 to 229.0 1193.8 to 1343.3
32 (90) 20.0 (68)
(23 to 33) (173 to 195)
202.2 to 279.9 1439.2 to 1606.6
38 (100) 24.4 (76)
(29 to 41) (209 to 233)
266.1 to 325.1 1740.2 to 1825.1
43 (110) 28.8 (84)
(39 to 47) (252 to 269)
307.5 to 363.8 1991.3 to 2142.5
49 (120) 31.9 (89)
(45 to 53) (289 to 311)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
1. Engine at 1500 rpm, no load, fan speed &
4. Heater valve at engine closed.
temperature control at maximum setting, A/C
switch ON, all louvers and doors open. 5. Measurements taken 15 minutes after startup.

9003-14
A/C RECOVERY AND CHARGING STATION CONNECTIONS

NOTE: Photos may vary from machine being serviced. Connect the hose from the high pressure gauge to
the port on the discharge hose.
STEP 1
WARNING: Always wear safety goggles
Clean the external surfaces of the compressor and
when working with liquid refrigerant. Liquid
hoses. Remove the caps from the service ports on
refrigerant in your eyes could cause
the suction and pressure hoses.
blindness.
WARNING: Do not steam clean any air SM105A
conditioning system parts while the system is Make sure the charging station manifold gauge
charged. The heat will cause the refrigerant valves are in the closed position.
to rise to a pressure that could cause the
system to explode. STEP 3
SM104A Start the engine and run at 1500 rpm maximum
speed. Operate the air conditioner system at
STEP 2 maximum cooling setting and blower speed for 15
Connect the hoses from the test gauges to the minutes with the cab door open. Observe the test
service ports. gauges and check the chart on Page 13 against the
Connect the hose from the low pressure gauge to the gauge readings.
port on the suction hose. NOTE: The temperature control changes the vent outlet
temperatures by mixing heat with air conditioning. If the
temperature is too cold, the temperature control can be
turned clockwise to increase temperature even though the
air conditioner is on. Any air conditioner tests should be run
with this control all the way counter-clockwise or with the
water valve on the engine turned off.

9003-15
QUICK REFERENCE TROUBLESHOOTING CHART

LOW PRESSURE HIGH PRESSURE SEE
PROBLEM
GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25

9003-16
Problem - No Cooling
See pressure - temperature

VERY LOW VERY LOW chart, Page 13.
476L7
No Refrigerant or Low Refrigerant Charge - 1. Leak test the system, see Page 11. It may be
Indications: necessary to add refrigerant. See Section 9004.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off rapidly
after start-up. 2. Recover the remaining refrigerant from system.
See Section 9004.
3. Repair system leaks as needed. Follow the given

repair procedure.
4. Check level of oil in compressor - possible for

compressor to have an oil loss. See Section
9005.
5. Replace the receiver-drier. The moisture
removing material could be full to capacity with
moisture, refer to Section 9005.
6. Remove air and moisture from the system.

Replace Receiver-Drier. See Section 9004.
7. Charge system with new refrigerant. See Section

9004.
8. Continue performance test for other possible

problems.

9003-17
Problem - No Cooling or Not

Enough Cooling

HIGH HIGH chart, Page 13.
476L7
Air in the System - Indications 1. Leak test system - possible leak permitted air to
enter the system.
A. Suction line warm to hand.
2. Recover the refrigerant from system. See
B. Discharge air from evaporator warm.
Section 9004.
3. Repair leaks as necessary.
4. Replace receiver-drier. See Section 9004.
5. Remove air and moisture from the system. See
Section 9004.
9004.
Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine
fan belt and proper condenser fan operation.
A. Liquid line (between evaporator and
condenser) is very hot. 2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Recover
the refrigerant for system until gauge pressure is
normal. See Section 9004.
4. Remove and check condenser for restrictions
caused by oil or reduced heat transfer.
A. Recover the refrigerant from the system. See
Section 9004.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9004.
5. Continue the performance test for other possible
problems.
(Continued on next page)

9003-18
HFC-134a Stable Saturation

Pressure/Temperature Chart
(No Cooling Continued)
Temperature °C (°F) Pressure Bar (PSIG)
44 (112) 10.5 (152)
Expansion Valve Malfunctioning - Indications: 46 (114) 10.8 (157)
A. Discharge air from heater/evaporator warm. 47 (116) 11.2 (162)
B. Much condensation on suction hose at 48 (118) 11.5 (167)
compressor. 49 (120) 11.9 (172)
C. Much condensation on evaporator outlet.
Refrigerant Contamination - Indications
1. See table below and check stable saturation
pressures at given temperature to determine if 1. Check the expansion valve. Disconnect the low
contamination exists. pressure switch.
A. Measure pressure from gauge on reclamation 2. Test expansion valve:

unit. A. Remove insulation material from top of valve.
B. Measure temperature from refrigerant in With the engine running and the air
reclamation tank. If refrigerant has been in conditioner on maximum cooling, cool the top
reclamation unit for some time, use ambient of the expansion valve with ice and check the
temperature. The numbers in the table low pressure gauge for a decrease.
represent the boiling point for HFC-134a. B. Allow the top of the expansion valve to warm.
C. Pressure readings below range given in chart The valve should open and the pressure
indicate contaminated refrigerant. should rise at the low pressure gauge.
IMPORTANT: Do not use contaminated refrigerant or mix C. Repeat Step A. If there is little or no decrease
with uncontaminated refrigerant. Dispose of in accordance in the low pressure gauge, go to Step 3.
with all applicable laws and local procedure. 3. If the expansion valve did not operate correctly,
recover the refrigerant from the system, refer to
HFC-134a Stable Saturation Section 9004. Remove the expansion valve,
Pressure/Temperature Chart refer to Section 9005.
Temperature °C (°F) Pressure Bar (PSIG) 4. Instal the new expansion valve, refer to section
10 (50) 3.1 (45) 9005. Remove the air and moisture and charge
the system with refrigerant, refer to Section
13 (55) 3.5 (51)
9004.
16 (60) 3.9 (57)
5. Connect the low pressure switch.
18 (65) 4.4 (64)
6. Continue performance test for other possible
21 (70) 4.9 (71)
problems.
24 (75) 5.4 (78)
27 (80) 6.1 (88)
29 (85) 6.6 (95)
32 (90) 7.2 (104)
35 (95) 7.9 (114)
38 (100) 8.6 (124)
39 (102) 8.9 (129)
40 (104) 9.2 (133)
41 (106) 9.5 (138)
42 (108) 9.8 (142)
43 (110) 10.1 (147)

9003-19
Problem - Not Enough Cooling

NORMAL TO
SLIGHTLY NORMAL chart, Page 13.
HIGH
476L7
Heater Control Valve not working - Indications 1. The heater control valve is not closed if the
hoses are hot.
A. Discharge air from evaporator only a little
cool. 2. Shut off coolant flow to heater/evaporator core.
B. Heater hoses to cab are warmer than ambient 3. Check air duct for temperature change.
temperature.
4. Inspect the heater control cable and valve.
5. Continue performance test for possible other
problems.
1. Test system for leaks. See Page 11. Possible

Air in the System - Indications: leak has let air enter; check compressor seal
carefully. See Section 9004.
A. Suction line warm to your hand.
2. Recover the refrigerant from system. See
B. Discharge air from heater/evaporator only a
Section 9004.
little cool.
3. Repair system leak as necessary.
4. Replace receiver-drier. The moisture removing
material in receiver-drier could be full to capacity
with mixture, refer to Section 9005.
5. Check compressor oil level. See Section 9005.
Section 9004.
9004.
Temperature Control Switch sensing tube low on 1. Inspect and repair the temperature control
charge or out of calibration - Indications: switch.
A. Excessive or incorrect compressor cycling.
B. Compressor clutch not engaging.

9003-20
problem - Not Enough Cooling

LOW LOW chart, Page 13.
476L7
Not Enough Refrigerant - Indications: B. If no leak is found, go to Step 6.

A. Discharge air from evaporator cool or warm - 2. Recover the refrigerant from system. See
not cold. Section 9004.
3. Repair system leaks as needed.
4. Check oil level in compressor - It is possible for
compressor to lose oil. See Section 9006.
5. Remove air and moisture from the system.
Replace Receiver-Drier. See Section 9005.
9004.
(Continued on next page)

1. Leak test system - system has a loss of
refrigerant.
NOTE: Normally, the system will lose 14.7 to 29.5 grams
(1/2 to 1 ounce) of refrigerant between seasons.
A. If leak is found, go to Step 2.
9003-21
(Not Enough Cooling
High Side Restriction - Indications: 1. Recover the refrigerant from the system. A
A. Discharge air from heater/evaporator only a restriction in receiver-drier or liquid line must be
little cool. removed.
B. Condensation or frost on receiver-drier. 2. Remove and replace part with restriction.
C. Liquid line to receiver-drier cool, with frost or 3. Remove air and moisture from the system. See
condensation. Section 9004.
NOTE: The frost will form downstream from or at the 4. Charge system with new refrigerant. See Section
point of the restriction 9004.
Expansion Valve Not Operating - Indications: 1. Expansion valve outlet with condensation or frost
is an indication of a restriction in the expansion
A. Discharge air from evaporator warm or cool - valve. Replace expansion valve. See Section
not cold. 9005.
B. Condensation or frost on expansion valve 2. Inlet end of expansion valve is warm, indicating
inlet. expansion valve is not completely open. Replace
C. Inlet end of expansion valve is warm. expansion valve. See Section 9005.

9003-22

HIGH LOW chart, Page 13.
476L7
Compressor turning but not pumping properly -

Indications: 1. Recover the refrigerant from system. See
Section 9004.
A. System is fully charged.
2. Remove the compressor from the machine. See
B. Cool discharge air from evaporator.
Section 9004.
3. Before you start to repair compressor, check and
record compressor oil level. See Section 9005.
4. Remove compressor from machine because
there is indication of internal leak in compressor.
5. Repair or replace compressor as necessary. See
Section 9005 or 9006.
6. Replace receiver-drier if: See Section 9005.
A. System has been opened before.
B. Receiver-drier has been used two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles). See Section 9005 for
receiver-drier replacement.
7. Fill compressor with new refrigerant oil as shown

in Section 9006 and install compressor in
machine.
8. Charge the system with refrigerant. See Section
9004.
Expansion Valve stuck open 1. Replace expansion valve. See Section 9005.

9003-23

VERY LOW VERY LOW chart, Page 13.
476L7
Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and
proper condenser fan operation.
A. Liquid line very hot.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Recover the refrigerant from system until
gauge pressure is below normal. See Section
9004.
B. Add refrigerant until gauge pressures are
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Recover the refrigerant from system. See
Section 9004.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9005.
Air in the System - Indications: 1. Recover the refrigerant from system. See
Section 9004.
A. Warm discharge air from evaporator.
2. Replace receiver-drier.
Section 9004.
9004.

9003-24
Problem - Intermittent Cooling

NORMAL NORMAL chart, Page 13.
476L7
Moisture in System- Indications: 1. Recover the refrigerant from the system. If too
much moisture enters the orifice of the
A. Cooling is acceptable during cool part of day,
expansion valve, the freezing of this moisture
but not acceptable during hot part of day.
can stop refrigerant flow. See Section 9004.
2. Replace receiver-drier. The moisture removing

material could be full to capacity with moisture.
See Section 9005.
Section 9004.
NOTE: The time needed to remove a large amount of
moisture will be two to three hours minimum.

9004.

9003-25
Problem - Noise in System

NORMAL TO HIGH chart, Page 13.
HIGH
476L7
Too much Refrigerant in System - Indications: 1. Recover the refrigerant from system until gauge
readings are below normal. See Section 9004.
A. Cool discharge air from heater/evaporator.
2. Add new refrigerant until gauge readings are
B. Compressor makes noise.

9003-26
NOTES

Section
9004
9004
AIR CONDITIONING SYSTEM SERVICE

9004-2
TABLE OF CONTENTS
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Programming the Recovery/Charging Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Activating Start on Recovery/Charging System Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

9004-3
SPECIFICATIONS
Air conditioning system refrigerant capacity .......................................................................................2041 g (4.5 lbs)
SPECIAL SERVICE TOOLS
A22094 BS03H012
OEM-1415 REFRIGERANT RECOVERY, RECYCLING, AND CAS-10073-3 SAFETY GOGGLES
CHARGING STATION

9004-4
SAFETY PROCEDURES
WARNING: THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS
MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND
BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified by an 2. A drop of liquid refrigerant on your skin may
approved training and certification organization may service cause frostbite. Open the fittings carefully and
or repair motor vehicle or mobile air conditioning systems. slowly when it is necessary to service the air
It is mandatory that all refrigerant must be RECOVERED and conditioner system. Your skin must be treated for
RECYCLED when removed from a system during servicing. frostbite or a physician must be seen if you get
Refrigerant HFC134a is the most stable and easiest refrigerant on your skin.
to work with of the refrigerants now used in air 3. Keep refrigerant containers in the correct upright
conditioning systems. Refrigerant HFC134a does not position. Always keep refrigerant containers
contain chlorofluorocarbons (CFC’s) which are away from heat and sunlight. The pressure in a
harmful to the Earth’s ozone layer. container will increase with heat.
Safety procedures must be followed when working 4. Always reclaim refrigerant from the system, if
with refrigerant HFC134a to prevent possible you are going to weld or steam clean near the air
personal injury. conditioner system.
1. Always wear safety goggles when doing any 5. Always check the temperature and pressure of
service work near an air conditioner system. the air conditioner system before reclaiming
Liquid refrigerant getting into the eyes can cause refrigerant and when you test the system.
serious injury. Do the following if you get
refrigerant near or in your eyes: 6. Dangerous gas can form when refrigerant comes
A. Flush your eyes with water for 15 minutes. fumes to be inhaled.
B. See a physician immediately. 7. Never leak test with compressed air or flame
tester. Tests have indicated that compressed
mixtures of HFC134a and air can form a
combustible gas.

9004-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD02M034
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD02M001
Make sure the charging station manifold gauge

valves are in the closed position. Connect the hose
from the low pressure gauge to the port on the
suction hose. Connect the hose from the high
pressure gauge to the port on the discharge hose.
Turn in both thumbscrews to depress the service
valves.

9004-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. The compressor oil drain valve completely.
will shut OFF automatically when recovery is
complete. Wait for five minutes and observe the STEP 8
manifold pressure gauges for a pressure rise. If
pressure rises above zero PSI, depress the hold/cont
switch. Then wait for the compressor to automatically
shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD02M034
Disconnect the hoses from the service ports and

install the caps.

9004-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or more of Air and moisture are removed from the system by a
the following conditions occurs before you remove the air vacuum pump. A vacuum pump is the only
and moisture from the system. equipment made that will lower the pressure in a
system enough to change the moisture to a vapor so
A. The system has been opened for service
that the moisture can be removed.
before.
NOTE: Refer to the vacuum pump manufacturer’s user
B. Receiver-drier has operated two or more
manual for additional information.
years.
C. Disassembly of compressor shows small Programming the
particles of moisture removing material (gold
or brown particles).
Recovery/Charging Station
D. Large system leak (broken hose, break in STEP 11
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
BD02M001 been accepted.
Make sure the charging station manifold gauge
valves are in the closed position. Connect the hose STEP 12
from the low pressure gauge to the port on the
suction hose. Connect the hose from the high
pressure gauge to the port on the discharge hose.
Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed
from the system after the system has been opened
for maintenance. Air enters the system when the
system is opened. Air has moisture that must be
removed to prevent damage to the system
components.
A22115
Press the Charge key. Program and Charge will

appear on the display.

9004-8
STEP 13 Activating Start on
Recovery/Charging System Station
NOTE: Photos may vary from machine being serviced.
STEP 16
A22113
Program 3.52 lbs (1.6 kg) and press the enter key.
The display will flash once indicating the
programmed data has been accepted.
STEP 14 A22123
Press the Vacuum key. Automatic will show on the

display. Vacuum will appear on the display and after
a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 15 minutes. If the system will not
hold vacuum, a leak exists that must be corrected
before recharging can begin. See Section 9003 for a
A22114
leak test.
Full open the low and high pressure valves.
STEP 17
STEP 15
A22113
A22107
Press the charge key to begin refrigerant charging.
Open the red (vapor) and blue (liquid) valves on the
Automatic and Charge will appear on the display.
tank.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows CPL.

9004-9
STEP 18 IMPORTANT: Check the OEM equipment manual before
performing Step 20 to avoid damaging recovery unit.
Pressure reading should be obtainable with valves closed.
Damage may occur if the machine is started with the valves
accidently open or if either or both valves are opened while
the A/C system operating.
STEP 21
A22114
Completely close the high and low pressure manifold

valves.
STEP 19
Start the engine and run at 1500 rpm. Operate the air
conditioner system at maximum cooling setting and
BD02M001
maximum blower speed with the doors and windows
open. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
NOTE: The compressor will not operate if the system
pressure is too low or too high. If the compressor fails to STEP 22
operate and the condenser blowers also fail to operate
when you actuate the A/C switch, check the system
pressure to determine if refrigerant is present. Check for
continuity at the pressure switch located at the
receiver-dryer and the temperature switch located at the 1
evaporator.
STEP 20
BD02M034
1. SERVICE PORT CAPS
Install the caps on the service ports on the suction

and discharge hoses.
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9003-9 for temperature
and pressure variations.

9004-10
Pressure-Temperature Chart
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER MAXIMUM

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION TEMPERATURE
°C (°F) kPa (psi) kPa (psi) °C (°F)
62 to 83 1000 to 1153
27 (80) 14 (55)
(9 to 12) (145 to 165)
76 to 104 1310 to 1448

32 (90) 18 (61)
(11 to 15) (190 to 210)
110 to 124 1448 to 1586

35 (95) 20 (63)
(16 to 18) (210 to 230)
117 to 131 1620 to 1758

38 (100) 22 (66)
(17 to 19) (235 to 255)
138 to 145 1793 to 1931

41 (105) 23 (68)
(20 to 21) (260 to 280)
193 to 214 2000 to 2137

43 (110) 25 (72)
(22 to 24) (290 to 310)
NOTE: The pressure-temperature chart is based on the 5. A/C switch ON.

following conditions:
6. Both cab doors open.
1. Engine operating at 1500 rpm.
7. All panels and access doors installed and closed.
2. No engine load.
8. Cab filters clean and installed.
3. Fan speed control in maximum position (full
9. Heater valve at engine closed.
clockwise) and all louvers open.
10. Measurements taken 15 minutes after start-up.
4. Cab temperature control set to maximum cooling
(full counterclockwise).

Section
9005
REMOVAL AND INSTALLATION OF HEATER AND

AIR CONDITIONING SYSTEM COMPONENTS
9005

9005-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AIR CONDITIONING THERMAL PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEATER WATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EVAPORATOR CORE AND HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AIR CONDITIONER AND HEATER FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AIR CONDITIONING SYSTEM CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AIR CONDITIONING SYSTEM RECEIVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9005-3
SAFETY PROCEDURES
Refrigerant HFC134a is the most stable, and easiest
conditioner systems. Refrigerant HFC134a does not position. Always keep refrigerant containers
contain any chlorofluorocarbons (CFC’s) which are away from heat and sunlight. The pressure in a
harmful to the earth’s ozone layer. container will increase with heat.
with Refrigerant HFC134a to prevent possible you are going to weld or steam clean near the air
refrigerant near or in your eyes:
testers. Tests have indicated that compressed
m i x t u r e s of H F C 1 3 4 a a n d a i r c a n f o r m a
combustible gas.

9005-4
SPECIAL TOOLS
299L7C A22094-01
OEM-1036 OEM-1415
A22090-01 BS03H012
OEM-1437 SAFETY GOGGLES - OBTAIN LOCALLY

9005-5
AIR CONDITIONING COMPRESSOR
Removal STEP 6
STEP 1
Park the machine on a level surface and lower the
blade to the floor. Apply the parking brake. Stop the
engine and turn the master disconnect switch to
OFF.
STEP 2
Make sure the compressor and engine are clean
before connecting the refrigerant recovery system or
disconnecting any lines. 4
STEP 3 BD06K122-01
Connect the OEM-1415 Refrigerant Recovery, Remove the compressor adjusting bolt (4) and
Recycling and Charging Station to the High and Low washer.
charge ports in the hose fittings connected to the
compressor. Evacuate the system to remove all of STEP 7
the refrigerant, see Section 9004 for the procedure.
STEP 4
Disconnect the compressor clutch wire (1) from the
wiring harness connectors. 5
STEP 5
BD06K121-01
Loosen the compressor pivot bolt (5).
STEP 8
1 Push the compressor down toward the engine.
2 Remove the compressor belt.
BD06K120-01 STEP 9
Disconnect the low pressure line (2) from the suction Remove the compressor pivot bolt (5), nut and
port and the high pressure line (3) from the discharge washers.
p o r t o n t h e c o m p r e s s o r . I m m e d i a t e ly i n s t a l l
protective caps on the open ports and lines. STEP 10
Remove the compressor from the mounting bracket.
See Section 9006 to service the compressor.

9005-6
STEP 11 3
6 5
1
2
7
BD06K120-01
Slowly remove the protective cap, install new O-ring

BD06K121-01
and connect the low pressure line (2) to the inlet port
Install the compressor (6) on the mounting bracket on the compressor.
(7). Install washers on the pivot bolt (5). Install the
pivot bolt, washer, and nut onto the pivot bolt. STEP 16
Carefully remove the protective cap, install new
STEP 12 O-ring and connect the high pressure line (3) to the
discharge port on the compressor.
STEP 17
Connect the OEM-1415 Refrigerant Recovery,
Recycling and Charging Station to the high and low
compressor. Evacuate the system and charge the
system with reclaimed or new refrigerant; see
Section 9004 for the procedure.
BD06K122-01
Install the drive belt on the machine. Install the

adjusting bolts (4), nuts and washers into the
compressor adjusting straps.
STEP 13
Adjust belt tension. See Section 9006 in this service
manual. Tighten pivot bolt (5) nut and compressor
adjusting bolts (4) when complete.
STEP 14
Connect the compressor clutch wire (1) to the wiring
harness connectors.
WARNING: Use caution when removing cap as new
compressors have internal pressure when shipped.

9005-7
EXPANSION VALVE
Removal STEP 6
Remove the rear console cover from the cab.
STEP 1
Park the machine on a level surface and lower the STEP 7
blade to the floor. Apply the parking brake and stop Remove the right arm rest from the cab
the engine.
STEP 8
STEP 2
Turn the master disconnect switch to OFF.
STEP 3 2
Recycling and Charging Station to the High and Low
charge ports in the hose fittings at the compressor.
3 1
Evacuate the system to remove all of the refrigerant,
see Section 9004.
STEP 4
BD06K018-01
Remove two screws (2) mounting the right console,

remove the door catch release knob (1), loosen
console mounting screw (3).
STEP 9
BD06K003-01.
Remove the air filter.

2
STEP 5
BD06K019-01
Remove screws (1) and loosen screw (2).
BD06K004-01
Remove five mounting screws from the center rear

console, two from the front and three are located at
the back glass in the rear.

9005-8
STEP 15
Lubricate the new O-rings with clean refrigerant oil.
STEP 16
Install the new O-rings in the openings in the front of
the expansion valve.
STEP 17
Remove the caps from the tubes and connect the
expansion valve to the tubes.
BD06K020-01
STEP 18
Remove the two mounting screws at the back of the
Use two wrenches and tighten the tubes in
right console, remove the console from the cab.
expansion valve.
STEP 11 STEP 19
Install new insulation tape around the expansion
valve and evaporator lines that are exposed.
STEP 20
Install the cab console covers.
STEP 21
system with reclaimed or new refrigerant, see section
BD06K021-01
9004 for the procedure.
Remove the insulation tape from around the fittings
and the expansion valve.
STEP 12
Use two wenches to loosen and remove the tubes
from the expansion valve.
STEP 13
Remove the expansion valve and install caps on the
tube fittings to the evaporator core.
STEP 14
Remove and discard the O-rings.

9005-9
AIR CONDITIONING THERMAL PROBE
Removal STEP 7
STEP 1
blade to the floor. Apply the parking brake and stop
2
the engine.
STEP 2 3 1
STEP 3
BD06K018-01

STEP 8
BD06K019-01
BD06K003-01
STEP 4 2
BD06K019-01
STEP 9
BD06K004-01

STEP 5
Remove the rear console cover in the cab.
STEP 6 BD06K020-01
Remove the right arm rest from the cab. Remove the two mounting screws at the back of the

9005-10
STEP 10 STEP 13
BD06K007-01 BD06K010-01
Remove the left arm rest from the cab. Remove the two mounting screws at the back of the
left console, remove the console from the cab.
STEP 11
STEP 14
1
2
BD06K008-01
Remove two screws (2) mounting the left console, BD06K005-01
remove the door catch release knob (1), loosen Remove the two screws mounting the electrical
console mounting screw (3). controls.
STEP 12 STEP 15
1
2
BD06K009-01 BD06K022-01
Remove screws (1) and loosen screw (2). Remove the mounting screws for the heater core and
evaporator core cover.

9005-11
STEP 18
BD06K023-01
Remove the cover for the heater core and evaporator

core cover, remove the probe from the evaporator BD06K006-01
core. Install and mount the switch, connect the wires to the
temperature switch.
STEP 17
STEP 19
BD06K006-01
Remove the mounting screws for the temperature BD06K025-01

switch, disconnect the wiring harness connector, Measure over 114 mm (4.5 inches) from the right
remove the switch from the machine. side of the evaporator core.
STEP 20
BD06K024-01
Carefully insert the sensor into the evaporator core.

9005-12
STEP 21 STEP 24
1
2
BD06K022-01 BD06K008
Install the evaporator and heater core cover, install Install and tighten two screws (2) mounting the left
and tighten the mounting screws for the core cover. console, install and tighten the door catch release
knob (1), tighten console mounting screw (3).
STEP 22
STEP 25
1
2
BD06K005-01
Install and tighten the two screws mounting the BD06K009-01
electrical controls. Install and tighten screws (1) and tighten screw (2).
STEP 23 STEP 26
BD06K010-01 BD06K007-01
Install the left console into the cab, install and tighten Install the left arm rest in the cab.
the two mounting screws at the back of the left
console.

9005-13
STEP 27 STEP 30
Install the right arm rest in the cab.
STEP 31
Place the rear console cover in the cab.
STEP 32
BD06K020-01
Install the right console into the cab. Install and

tighten the two mounting screws at the back of the
right console.
STEP 28
BD06K004-01
Install and tighten five mounting screws from the

center rear console, two from the front and three are
located at the back glass in the rear.
STEP 33
2
BD06K019-01
Install and tighten screws (1) and tighten screw (2).
STEP 29
BD06K003-01
2 Install the air filter.
3 1
BD06K018-01
Install and tighten two screws (2) mounting the right

console, install and tighten the door catch release

9005-14
HEATER WATER VALVE
Removal STEP 6
STEP 1
blade to the floor. Apply the barking brake. Stop the
OFF.
STEP 2
Drain 4 liters (1 U.S. gal) from the engine cooling
system.
STEP 3
BD06K007-01
Remove arm rest from the cab.
STEP 7
1
2
BD06K003-01
Remove the air filter. 3
STEP 4
BD06K008-01
Remove two screws (2) mounting the left console,

STEP 8
BD06K004-01

console, two from the front and three are located at 1
the back glass in the rear. 2
STEP 5
Remove the rear console cover from the cab. BD06K009-01

9005-15
STEP 9 Installation
STEP 12
Place the temperature control in the mounting
bracket, install and tighten the mounting screws for
the control. Connect the wiring to the control.
STEP 13
BD06K010-01

STEP 10
BD06K011-01
Connect the heater inlet hose and heater core hose

to the temperature control.
STEP 14
BD06K011-01
Disconnect the heater inlet hose and heater core

hose from the temperature control.
STEP 11
Disconnect the wiring from the control, remove the
mounting screws from the control and remove the
control. BD06K010-01
Install the left console into the cab, install and tighten
console.

9005-16
STEP 15 STEP 18
STEP 19
1
2
BD06K008-01
Install and tighten two screws (2) mounting the left

knob (1), tighten console mounting screw (3). BD06K004-01
Install and tighten five mounting screws into the

STEP 16 center rear console, two are in the front and three are
STEP 20
1
2
BD06K009-01
Install and tighten screws (1) and tighten screw (2).
STEP 17 BD06K003-01
Install the air filter.
STEP 21
Refill the coolant to the proper level.
BD06K007-01
Install the left arm rest in the cab.

9005-17
EVAPORATOR CORE AND HEATER CORE
Removal STEP 5
STEP 1
OFF.
NOTE: If replacing the heater core only do not do step 2.
STEP 2
BD06K004-01
see Section 9004. Remove five mounting screws from the center rear
NOTE: If replacing the evaporator core only do not do the back glass in the rear.
step 3.
STEP 6
STEP 3 Remove the rear console cover in the cab.
Drain 4 liters (1 U.S. gal) from the engine cooling
system. STEP 7
Remove the right arm rest from the cab.
STEP 4
STEP 8
3 1
BD06K003-01

BD06K018-01


9005-18
STEP 9 STEP 12
1
2
3
1
BD06K019-01 BD06K008-01
Remove screws (1) and loosen screw (2). Remove two screws (2) mounting the left console,
STEP 10 console mounting screw (3).
STEP 13
1
2
BD06K020-01

right console, remove the console from the cab. BD06K009-01

STEP 11
STEP 14
BD06K007-01
Remove the left arm rest from the cab. BD06K010-01


9005-19
STEP 15 STEP 18
Use two wrenches to loosen and remove the tubes
from the expansion valve.
STEP 19
Remove the expansion valve and install caps on the
tube fittings to the evaporator core.
STEP 20
BD06K005-01
Remove the two screws mounting the electrical

controls.
STEP 16
BD06K023-01
Remove the probe from the evaporator core.

NOTE: If replacing the evaporator core only it is not
required to do step 21.
STEP 21
BD06K022-01
Remove the mounting screws for the heater core and

evaporator core cover, remove the cover.
NOTE: If replacing the heater core only go to step 21.
STEP 17
BD06K011-01
Disconnect and plug the hoses to the heater core.
BD06K021-01
Remove the insulation tape from around the fittings

at the expansion valve.

9005-20
STEP 23
Install the evaporator core or heater core.
STEP 24
BD06K026-01
It might be required to loosen the guide plate for the

evaporator and heater core to the core housing,
remove the core to be changed.
BD06K026-01
Put the evaporator and heater core in position. If

loosened tighten the screws securing the evaporator
and heater core guide plate.
NOTE: If replacing the heater core only go to step 34.
STEP 25
BD06K025-01
Measure over 114 mm (4.5 inches) from the right

side of the evaporator core.

9005-21
STEP 26 STEP 30
Install the new O-rings in the openings in the front of
the expansion valve.
STEP 31
Remove the caps from the tubes and connect the
expansion valve to the tubes.
STEP 32
Use two wrenches and tighten the tubes in
expansion valve.
STEP 33
BD06K024-01 Install new insulation tape around the expansion
Carefully insert the sensor into the evaporator core. valve and evaporator lines that are exposed.
NOTE: If replacing the evaporator core only it is not
STEP 27
STEP 34
BD06K022-01
Install the evaporator and heater core cover, install

and tighten the mounting screws for the core cover.
BD06K011-01
Remove the plugs from the heater hoses and install

STEP 28
on the heater core.
STEP 35
BD06K005-01
Install and tighten the two screws mounting the

electrical controls.
BD06K010-01
STEP 29
Lubricate the new O-rings with clean refrigerant oil. console.

9005-22
STEP 36 STEP 39
1
2
BD06K008-01 BD06K020-01
Install and tighten two screws (2) mounting the left Install the right console into the cab. Install and
console, install and tighten the door catch release tighten the two mounting screws at the back of the
knob (1), tighten console mounting screw (3). right console.
STEP 37 STEP 40
2
1
2
1
BD06K009-01 BD06K019-01
Install and tighten screws (1) and tighten screw (2). Install and tighten screws (1) and tighten screw (2).
STEP 38 STEP 41
3 1
BD06K007-01 BD06K018-01
Install the left arm rest in the cab. Install and tighten two screws (2) mounting the right

9005-23
STEP 42 STEP 46
Install the right arm rest in the cab. Connect the OEM-1415 Refrigerant Recovery,
STEP 43 charge ports in the hose fittings connected to the
Place the rear console cover in the cab. compressor. Evacuate the system and charge the
system with reclaimed or new refrigerant, see section
9004 for the procedure.
STEP 44
NOTE: If replacing the evaporator core only, it is not
STEP 47
Refill the coolant to the proper level.
BD06K004-01

STEP 45
BD06K003-01

NOTE: If replacing the heater core only it is not required
to do step 46.

9005-24
AIR CONDITIONER AND HEATER FANS
Removal STEP 7
Remove the right arm rest from the cab.
STEP 1
Park the machine on a level surface and lower the STEP 8
blade to the floor. Apply the parking brake and stop
the engine.
STEP 2 2
STEP 3 3 1
STEP 4
BD06K018-01

STEP 9
BD06K003-01

2
STEP 5
BD06K019-01
BD06K004-01

STEP 6
Remove the rear console cover in the cab.

9005-25
STEP 10 STEP 13
1
2
BD06K020-01 BD06K009-01
Remove the two mounting screws at the back of the Remove screws (1) and loosen screw (2).
STEP 14
STEP 11
BD06K010-01
BD06K007-01 Remove the two mounting screws at the back of the

Remove the left arm rest from the cab. left console, remove the console from the cab.
STEP 12 STEP 15
1
2
BD06K008-01 BD06K012-01
Remove two screws (2) mounting the left console, Remove the outer cover mounting screw for the fan
remove the door catch release knob (1), loosen box.

9005-26
STEP 16 STEP 19
BD06K013-01 BD06K016-01
Remove the inner cover mounting screws for the fan Remove the fan motor.
box, remove the fan motor cover.
STEP 20
STEP 17 Repeat the procedure for the right fan.
BD06K014-01
Disconnect the wires to the fan motor.
STEP 18
BD06K015-01
Remove the mounting bolts for the fan motor.

9005-27
STEP 21
BD06K013-01
Install the fan motor cover, install and tighten the

BD06K017-01
inner cover mounting screws.
Install and mount the fan in the air box.
STEP 25
NOTE: Make sure to align the fan bracket into the slot at
the bottom of the air box.
STEP 22
BD06K012-01
Install and tighten the outer cover mounting screw for

the fan box.
BD06K015-01
STEP 26
Install and tighten the mounting bolts for the fan
Repeat the procedure for the right fan.
motor.
STEP 27
STEP 23
BD06K010-01
BD06K014-01
Connect the wires to the fan motor. the two mounting screws at the back of the left
console.
9005-28
STEP 28 STEP 31
1
2
BD06K008-01 BD06K020-01
Install and tighten two screws (2) mounting the left Install the right console into the cab. Install and
console, install and tighten the door catch release tighten the two mounting screws at the back of the
knob (1), tighten console mounting screw (3). right console.
STEP 29 STEP 32
2
1
2
1
BD06K009-01 BD06K019-01
Install and tighten screws (1) and tighten screw (2). Install and tighten screws (1) and tighten screw (2).
STEP 30 STEP 33
3 1
BD06K007-01 BD06K018-01
Install the left arm rest in the cab. Install and tighten two screws (2) mounting the right

9005-29
STEP 34
Install the right arm rest in the cab.
STEP 35
STEP 36
BD06K004-01

STEP 37
BD06K003-01

9005-30
AIR CONDITIONING SYSTEM CONDENSER
Removal STEP 5
STEP 1
OFF.
STEP 2
see section 9004. BD06K125-01
Disconnect electrical connector for the flood light.

STEP 3 Disconnect electrical connector for the fan motors.
STEP 6
BD06K123-01
Disconnect electrical connector for the flood light.

Disconnect the hose and tube from the condenser. BD06K124-01
Remove and discard the O-rings. Support the condenser with suitable lifting device.
Loosen and remove the seven bolts and lock
STEP 4 washers fastening the condenser core to the cab.
Install plugs in the hose and tube. Install caps on the
fittings to the condenser. STEP 7
Remove the condenser and fans.
Installation
STEP 8
Put the condenser in position. Install and tighten the
seven bolts and lock washers securing the
condenser core to the cab
STEP 9
Connect the fan electrical connector and flood light
connector.

9005-31
STEP 10
Remove the caps and plugs from the hose, tube and
fittings.
STEP 11
Lubricate new O-rings with clean refrigerant oil and
install the O-rings.
STEP 12
Connect the hose and tube to the condenser and
tighten the fittings. Connect the flood light connector.
STEP 13
system with reclaimed or new refrigerant, see

9005-32
AIR CONDITIONING SYSTEM RECEIVER DRIER
STEP 1 STEP 8
Park the machine on a level surface and lower the Put the receiver drier and retaining bracket in
blade to the floor. Apply the parking brake. Stop the position. Install and tighten the two bolts securing the
engine and turn the master disconnect switch to mounting bracket for the receiver drier.
OFF.
STEP 9
STEP 2 Remove the caps and plugs from the tubes and
Connect the OEM-1415 Refrigerant Recovery, fittings.
charge ports in the hose fittings at the compressor. STEP 10
Evacuate the system to remove all of the refrigerant, Lubricate new O-rings with clean refrigerant oil and
see Section 9004. install the O-rings.
STEP 3 STEP 11
Open the right cab side panel. Connect the tubes to the receiver drier and tighten
the fittings.
STEP 4
STEP 12
system with reclaimed or new refrigerant, see
STEP 13
Close the cab right side panel.
BD06K119-01
Fasten identification tags on the tubes to the receiver

drier. Disconnect the tubes from the receiver drier.
Remove and discard the O-rings.
STEP 5
Install plugs in the tubes and install caps on the
fittings to the receiver drier.
STEP 6
Loosen and remove the two bolts fastening the
bracket which secures the receiver drier.
STEP 7
Remove the receiver drier.

Section
9006
AIR CONDITIONING COMPRESSOR AND CLUTCH
9006

9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPRESSOR BELT CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPRESSOR OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPRESSOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

9006-3
SPECIFICATIONS
Manufacturer ..............................................................................................................................Sanden International
Manufacturer Model Number................................................................................................................. Sanden 4611
Lubricant...............................................................................................................................................SP-20 PAG oil
Refrigerant Charge .....................................................................................................................1600 grams (3.5 lbs)
Compressor Belt Tension (New Belt) ........................................................................... 578 to 667 N (130 to 150 lbs)
Compressor Belt Tension (Used Belt) ........................................................................... 356 to 534 N (80 to 120 lbs)
Front Plate Air Gap..............................................................................................0.41 to 0.79 mm (0.016 to 0.031 in)
SPECIAL TORQUES
Compressor Rotor Shaft Nut ............................................................................................ 15 to 20 Nm (11 to 15 lb ft)
Oil Filler Plug .................................................................................................................... 15 to 24 Nm (11 to 18 lb ft)
Dust Cover Screws................................................................................................................. 7 to 11 Nm (5 to 8 lb ft)
SPECIAL TOOLS
109L7 A22094
SAFETY GOGGLES, OBTAIN LOCALLY OEM-1415
T81574 299L7
CAS-10747A OEM-1036

9006-4
SAFETY PROCEDURES
Refrigerant HFC134a is the most stable and easiest
conditioning systems. Refrigerant HFC134a does not position. Always keep refrigerant containers
contain chlorofluorocarbons (CFC’s) which are away from heat and sunlight. The pressure in a
harmful to the Earth’s ozone layer. container will increase with heat.
with refrigerant HFC134a to prevent possible you are going to weld or steam clean near the air
refrigerant near or in your eyes:
tester. Tests have indicated that compressed
mixtures of HFC134a and air can form a
combustible gas.

9006-5
COMPRESSOR BELT CHECK AND ADJUSTMENT

NOTE: Photos may vary from machine being serviced.
Check Interval . . . . . . . Every 250 hours of operation WARNING: Rotating fans and belts. Contact
can injure. Keep clear.
NOTE: Check the belt tension after the first 50 hours of M150A
operation and then use the regular check interval.
BD02H035
To adjust the belt tension, loosen the compressor

adjusting bolts and pivot bolt. Push the compressor
up until the correct tension for the belt is reached.
Tighten the compressor adjusting bolts and pivot
bolt.
542L95
Measure the compressor belt for correct tension IMPORTANT: Do not pry on the compressor clutch or
using a belt tension gauge. Check the belt to the body. Apply pressure only on the mounting ears.
following specifications.
New Belt . . . . . . . . . . 578 to 667 N (130 to 150 lbs)
Used Belt . . . . . . . . . . . 356 to 534 N (80 to 120 lbs)
NOTE: Adjust new belts to the used belt specifications
after a 10 minute run-in.
COMPRESSOR OIL LEVEL CHECK

Check the oil level in the compressor when any of the STEP 2
following has occurred. Stop the engine. See Section 9004 for connecting
A. Broken refrigerant hose. the compressor to the A/C charging, recovery and
recycling station and for discharging the system.
B. Large refrigerant leak.
C. Compressor leak. STEP 3
D. Damage to or replaced system components. Check the mounting angle of the compressor. Put the
angle gauge from the service tool set across the flat
E. New compressor installed. surfaces of the two front mounting ears. Adjust the
Use the following procedure to check the compressor gauge so that the bubble is between the center
oil level. marks. Read the mounting angle to the nearest
degree mark. Make a note of the degree reading for
reference later.
STEP 1
Start the engine and run at mid-idle. Operate the air
conditioner for 10 to 15 minutes at maximum cooling
and maximum blower speed.

9006-6
STEP 4 STEP 5
BD02H034 103L7
When all refrigerant has been reclaimed, remove the Remove the dust cover and use a wrench to rotate
oil filler plug. the clutch clockwise until the internal parts are in the
Add back to the compressor an amount of new position shown above. This will permit the dipstick to
SP-20 PAG oil equal to that amount reclaimed with be inserted all the way.
refrigerant. Refer to Section 9004 for complete
instructions. STEP 6
850L0
Put the dipstick in the oil filler hole to the stop

position.
Make sure the dipstick is inserted all the way to the
stop.
NOTE: The illustration shows the front view of the
compressor with the dust cover removed.
IMPORTANT: When compressor is replaced, the old oil
should be drained and this amount of new oil should be put
into the (drained) replacement compressor.

9006-7
STEP 7 STEP 9
Remove the dipstick. Count the oil level marks on the
dipstick. Use the following table to find the correct oil
level for the mounting angle of the compressor.
Compressor Oil Level
MOUNTING ANGLE
DIPSTICK READING
(DEGREES)
0 4 to 6
10 6 to 8
20 7 to 9
30 8 to 10
40 9 to 11
BD02H034
50 9 to 11
Install a new O-ring on the oil filler plug. Install the
plug and tighten to a torque of 15 to 24 Nm (11 to 18
STEP 8 lb ft).
If the oil level is not correct, add or subtract oil to the
correct level shown in the above chart.
IMPORTANT: Use only SP-20 PAG oil.

9006-8
COMPRESSOR REPAIR
Clutch Disassembly STEP 13
STEP 10
A21253
Remove the retaining nut for the front plate. Use the
A21250
special spanner wrench from the service tool set to
See Section 9005 in this service manu al for keep the plate and shaft from turning.
compressor removal. Clean the external surfaces of
the compressor before doing any work on the STEP 14
compressor.
STEP 11
A21254
Install the special puller from the service tool set on

the clutch front plate.
A21251
Remove the mounting bolts for the clutch dust cover. STEP 15
STEP 12
A21255
Turn the center screw to pull the clutch front plate.

A21252
Remove the clutch dust cover.

9006-9
STEP 16 STEP 19
A21256 A21260
Remove the shim(s) from the shaft. Remove the external snap ring for the bearing and
pulley assembly.
STEP 17
STEP 20
A21257
Remove the bearing dust cover. Be careful not to A21261
bend the dust cover. Install the special puller internal collars into the
groove in the pulley. Install the special tool onto the
STEP 18 shaft. Tighten the mounting screws finger tight.
STEP 21
A21258
Remove the key from the rotor shaft.

A21262
Turn the center screw on the puller.

9006-10
STEP 24
A21263
Remove the pulley and bearing assembly. A21266
Remove the clutch coil assembly.
STEP 22
STEP 25
A21265
Remove the snap ring for the clutch coil assembly. A21267
Remove the internal snap ring and remove the

bearing from the pulley.
STEP 23
A21264
Disconnect the clip for the lead wire.

9006-11
3
4 7 8
5
1016L93
1. COMPRESSOR 5. BEARING DUST COVER

2. COIL ASSEMBLY 6. FRONT PLATE
3. PULLEY 7. SHIM(S)
4. BEARING 8. DUST COVER
CLUTCH ASSEMBLY

9006-12
STEP 26 STEP 28
1
2
102L7 A21264
1. AMMETER 2. 12V BATTERY Install the clip for the coil lead wire.
Use a ammeter, voltmeter and a 12 volt battery to
check the amperage of the clutch coil. The current STEP 29
draw must be 3.6 to 4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short
within the coil.
No amperage reading indicates an open circuit in the
coil.
Replace the clutch coil if the amperage reading is not
correct.
Clutch Assembly
STEP 27
A21265
Install the snap ring for the clutch coil assembly.
STEP 30
A21266
Install the clutch coil assembly. Align the detent ball

and socket on the coil and housing.
A21267
Install the bearing in the pulley and install the internal

snap ring.

9006-13
STEP 31 STEP 33
A21268 A21260
Put the pulley and bearing assembly on the front Install the external snap ring on the front housing
housing hub. Install a driver on the pulley assembly. hub.
Make sure that the tool is on the inner race of the
bearing. STEP 34
STEP 32
A21259
Install the key in the rotor shaft.

A21268
Support the compressor on the four mounting ears at STEP 35

the compressor rear. Use a hammer to tap the pulley
assembly onto the front housing hub. As the pulley is
tapped onto the hub you can hear the difference in
sound when the pulley is fully installed. Make sure
the bearing is against the bottom of the hub.
A21269
Place the bearing dust cover in the bore. Place driver

from special tool kit over the dust cover.

9006-14
STEP 36 STEP 39
A21270 A21272
Gently tap the dust cover until it is seated. Use a hammer to tap the plate onto the shaft. Make
sure the plate is against the clutch shims. As the
STEP 37 plate is tapped onto the shaft you can hear the
difference in sound when the plate is fully installed.
STEP 40
A21256
Install the shim(s) on the rotor shaft.
STEP 38 A21253
Install the nut on the rotor shaft. Use the spanner

wrench and a torque wrench to tighten the nut to a
torque of 15 to 20 Nm (11 to 15 lb ft).
A21271
Install the front plate on the rotor shaft. Make sure

the keyway in the plate is aligned with the key in the
shaft. Install the driver over the shaft.

9006-15
STEP 41 STEP 43
T97256 A21251
Use a feeler gauge to measure the gap between the Install and tighten the six bolts that hold the dust
front plate and pulley assembly. The gap must be cover to the compressor to 7 to 11 Nm (5 to 8 lb ft).
0.41 to 0.79 mm (0.016 to 0.031 inch). The gap must
be even all the way around the plate. If necessary,
lightly lift or push down on the plate to make the gap
even.
NOTE: If the gap does not meet the above specifications
remove the front plate and add or subtract clutch shims as
required.
STEP 42
A21252
Install the dust cover.

9006-16
NOTES

Section
9007
DOZER BLADE
9007

9007-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C-FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

9007-3
SPECIFICATIONS
Torques
Hinge pin .........................................................................................................................602 Nm (444 pound feet)
Hinge to blade mounting bolts...................................................................264 to 327 Nm (195 to 241 pound feet)
“C” frame pivot pin retaining bolt ...............................................................202 to 327 Nm (149 to 241 pound feet)
Angle cylinder closed end pin retaining bolt ................................................24 to 38 Nm (17.5 to 28.2 pound feet)
Cylinder pin retaining plate bolts .....................................................................82 to 132 Nm (60 to 97 pound feet)

9007-4
C-FRAME
Removal STEP 7
STEP 1
Put blocks under the rear of the C-frame to hold the
C-frame in place when the pivot pins are removed.
STEP 2
Lower the blade to the floor.
STEP 3
Stop the engine, place the ignition switch in the on
position and the right park brake lever to the operate
position.
BD07K034-01
STEP 4 Remove the bolts and step plates from the angle
Move the blade control lever in all directions to cylinders.
relieve any pressure in the hydraulic circuits, apply
right parking brake lever and turn the ignition switch STEP 8
off.
STEP 5
Remove all dirt and grease from the hose
connections.
STEP 6
BD07K035-01
Tag and disconnect the angle cylinder hoses, install

a plug in each hose and a cap on each fitting.
STEP 9
BD07K033-01
Tag and disconnect the tilt cylinder hoses at the

radiator wrap, install a plug in each hose and a cap
on each fitting.
BD07K036-01
Remove the bolts and hose guard plates from the

C-frame.

9007-5
STEP 10 STEP 12
BD07F116-01
BD07K037-01 Remove the bolts and washers that hold the pivot
Push the hoses through the bracket and secure the pins in place at the rear of the C-frame.
hoses to the machine.
STEP 13
STEP 11
BD07F076-01
BD07F111-01
Use a prybar to remove the pivot pins, observe the
Remove the bolts and pin from the rod end of the lift location and number of shims.
cylinders.
STEP 14
Carefully move the machine out of the C-frame.

9007-6
Connect the hoses to the cylinders.
STEP 15
Carefully move the machine into the C-frame. STEP 21
Install hose guards and step plates.
STEP 16
Replace shims as previously installed. Install the STEP 22
pivot pins that hold the rear of the C-frame to the Start the engine and run the engine at low idle.
main frame.
NOTE: Use shims items 10 as required between the main STEP 23
frame and the C-frame (9) until the C-frame is centered on Raise the blade.
the main frame. Fill the gap between the mounting ear on
the outside of main frame and the C-frame with item 7. STEP 24
Slowly extend and retract the angle and tilt cylinders
STEP 17 four times to remove any air from the hydraulic
circuits.
Install the bolts (3), washers (4) and spacer (5) that
hold the pivot pin. Torque bolts to 202 to 327 Nm
(149 to 241 pound feet). STEP 25
Lower blade to the ground, stop the engine.
STEP 18
Align the piston rod eyes of the lift cylinders with the STEP 26
C-frame and install the pivot pins. Check for leaks, check the oil level in the hydraulic
reservoir. Add oil as required.
STEP 19
Install the plate, bolts, and flat washer. Torque bolts STEP 27
to 82 to 132 Nm (60 to 97 pound feet). Grease all pivot pins.

9007-7
10
8
8
7
5
4
3
BS07H404-01
3. BOLT CSHH10.9P M16X50 5. SPACER 7. SHIM 9. C-FRAME

4. WASHER 6. C-FRAME PIVOT PIN 8. PIN SEAL 10. SHIM

9007-8
BLADE
Removal STEP 8
Remove the pivot pins for the angle cylinders.
STEP 1
Lower the blade to the floor. STEP 9
STEP 2
Put blocks under the center of the C-frame to hold
the C-frame in place.
STEP 3
Connect acceptable lifting equipment to the blade
that will hold the blade in place as the blade is
removed.
STEP 4
Remove all dirt and grease from the hose BD07F114-01
connections. Remove the retaining plate bolts and washers,
remove the retaining plate.
STEP 5
STEP 10
Remove the pivot pin for the blade pitch link.
STEP 11
BD07F115-01
Remove the retaining plate bolts and washers,
remove the retaining plate.
STEP 6 BD07F121-01
Remove the pivot pin from the tilt cylinder. Remove the bolts that fasten the hinge block to the
blade.
STEP 7
STEP 12
Move the blade away from the C-frame and lower the
blade to the floor.
BD07F113-01
Remove the retaining plate bolts and washers,
remove the retaining plates.
9007-9
Installation
2
3 4
7
3
BS07H401-01
1. SLOTTED NUT 4. SNAP RING 7. SPRING PIN

2. WASHER 5. BUSHING 8. PIN
3. SPACER 6. BLADE HINGE SUPPORT 9. BOLT HOLE SPACING
STEP 13 STEP 16
Press bushing (5) into blade hinge support (6). Place spacers (3) with tappers facing the bushing (5).
STEP 14 STEP 17
Install snap ring (4) into blade hinge support (6). Slide the spacers (3) and hinge support (6) into the
C-frame.
STEP 15
Measure bolt hole spacing (9), the holes with a 64 STEP 18
MM (2.5 inch) spacing must be oriented at the Install pin (8) into the C-frame and blade hinge
bottom as shown. support (6).

9007-10
STEP 19 STEP 23
Install washer (2) and slotted nut (1) onto pin (8).
STEP 20
BD07F114-01
Install the blade pitch link to the C-frame, install the
pin.
BS07H403-01
Torque the slotted nut to 602 Nm (444 pound feet), STEP 24

align a slot on the nut with spring pin hole in the pin, Install the plate, bolts, and flat washer. Torque bolts
install a new spring pin (7). to 82 to 132 Nm (60 to 97 pound feet).
NOTE: Do not loosen the nut to align the pin hole. STEP 25
STEP 21
Use acceptable lifting equipment to put the blade in
position on the trunnion block.
STEP 22
BD07F113-01
Install the rod ends of the angle cylinders in position
on the blade. Install the pivot pins that fasten the rod
ends of the angle cylinders to the blade.
STEP 26
BD07F121-01 Install the plate, bolts, and flat washer. Torque bolts
Install the bolts and washers that fasten the blade to 82 to 132 Nm (60 to 97 pound feet).
hinge support to the blade, torque bolts to 264 to 327

9007-11
STEP 27 STEP 28
Install the plate, bolts, and flat washer. Torque bolts
to 82 to 132 Nm (60 to 97 pound feet).
STEP 29
Start the engine and run the engine at low idle.
STEP 30
Raise the blade.
STEP 31
Slowly extend and retract the angle and tilt cylinders
BD07F115-01
to and check for binding.
Install the rod end of the tilt cylinder in position on the
blade. Install the pivot pin that fastens the rod end of STEP 32
the tilt cylinder to the blade. Stop the engine.
STEP 33
Grease all pivot pins and hinge block.

9007-12
CUTTING EDGE
Replacement STEP 3
STEP 1
Remove the old cutting edge.
STEP 2
Clean the surface for the cutting edge on the blade.
BC05H122
Install the cutting edge, dome bolts, spring lock

washers, and nuts. Torque nuts to 461 to 570 Nm

Section
9008
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)
9008

9008-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REFILLING AND BLEEDING THE TILT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TILTING (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(CSF) CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

9008-3

CAB STRUCTURAL FRAME (CSF)
If the machine has rolled over or the ROPS cab or After an accident, check for damage to the ROPS
canopy has been in some type of accident (such as cab or canopy, the operator seat, the seat belts and
hitting an overhead object during transport), the wiring in the ROPS cab or canopy. Before operating
ROPS cab or canopy must be replaced. the machine again, all damaged parts must be
replaced.
DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
REPAIR THE ROPS OR CAB STRUCTURAL
FRAME.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first. WARNING: Adding additional weight
(attachments, etc). to the machine can cause
1. Check to see that the mounting bolts for the injury or death. Do not exceed the gross
ROPS cab or canopy are tight. weight printed on the ROPS label.
2. Check the operator seat and the mounting parts A028
for the seat belts. Check to see that the bolts are
WARNING: Do not modify ROPS in any
tight.
manner. Unauthorized modifications such as
welding, drilling, cutting or adding
attachments can weaken the structure and
reduce your protection. Replace ROPS if
subjected to roll-over or damage. Do not
attempt to repair.
B026
SPECIAL TORQUES
Torques
Support mount bolts .............................................................................................550 to 624 Nm (406 to 460 lb-ft)
Brush guard mount bolts (if equipped) .................................................................570 to 730 Nm (420 to 540 lb-ft)
REFILLING AND BLEEDING THE TILT SYSTEM

1. Make sure that the cylinder rod is fully retracted. 3. Tilt and lower cab two to three times to remove
air from the system.
2. Remove fill check plug and fill with Master-Tran.
4. Fill as needed, use Master-Tran.
5. Install fill check plug.
1
BD02F024-01
1. PUMP FILL CHECK PLUG

9008-4
TILTING (CSF) CAB OR (ROPS) CANOPY

STEP 4
WARNING: Make sure there no loose
objects in the cab or canopy prior to tilting.
Falling objects could cause death and
serious injury.
M853
NOTE: The left and right hand ROPS side panels must be
OPEN to prevent interference with frame components. The
left and right engine compartment panels must be
CLOSED. On cab units the cab doors must be CLOSED.
Tilt
STEP 1
BD02F005-01
Park the machine on a flat surface, lower the blade
and any attachment to the floor, turn the master Tilt the brush guard until the brush guard is free of
disconnect to the off position. the canopy.
NOTE: The removed bolts can be used in the tilting
STEP 2 brackets to hold the brush guard up.
STEP 5
2
BD02F028-01
1. JACK HANDLE 2. LEFT SIDE PANEL

BD02M138-01
Open the right and left side panels under the cab.
Remove the six support mount bolts on the right side
of the cab.
STEP 3
BD02F003-01
If equipped with a brush guard, remove the bolts at

the rear of the brush guard.

9008-5
STEP 6 STEP 8
BD02F024 BD02M139-01
Turn the pump diverter valve into the cab tilt position. Install the six support mount bolts and torque to 550
Actuate the hand pump and tilt the cab slowly. to 624 Nm (406 to 460 lb-ft).
NOTE: Cab travel will be stopped by the safety cable.
STEP 9
Lower If equipped with a brush guard, lower the brush
guard into alignment with the cab.
STEP 7 STEP 10
BD02F024-01
BD06J130-01
Turn the diverter valve to the lower position. Actuate
Install the bolts and torque to 405 to 730 Nm (300 to
the hand pump and lower the cab slowly.
540 lb-ft).
NOTE: Make sure that no wiring or hydraulic lines get
pinched during lowering.

9008-6
ROPS CANOPY
Removal STEP 4
STEP 1
Remove the batteries from the vehicle.
STEP 2
BD02F005-01
Tilt the brush guard until the brush guard is free of

the ROPS canopy.
NOTE: The removed bolts can be used in the tilting
brackets to hold the brush guard up.
BD06J126-01
STEP 5
2 2
1
3
BD06J129-01
4
Disconnect the wiring harness connectors from the BD06J127-01
ROPS.
1. MOUNT BOLTS 3. ENGINE HARNESS
2. FUSE AND RELAY BLOCK 4. ROPS FRAME
STEP 3
Remove the two mounting bolts for the fuse and
relay bracket and lay it in the battery compartment
area.
BD02F003-01
If equipped with a brush guard remove the bolts at
the rear of the brush guard.

9008-7
STEP 6 Installation
3 STEP 10
Carefully lower the ROPS canopy into alignment with
2 the mounts.
STEP 11
1
BD02F031-01
1. TILT CYLINDER 3. PIVOT PIN

2. SAFETY CABLE
Disconnect the tilt cylinder and safety cable.
STEP 7
Install lifting eyes on top of the ROPS canopy. BD02F007-01
Install the twelve support mount bolts and torque to
STEP 8 550 to 623 Nm (406 to 460 lb-ft).
STEP 12
BD02F006-01
Remove the twelve mounting bolts from the mounts.

BD02F031-01
STEP 9 1. TILT CYLINDER 3. PIVOT PIN

Carefully raise and remove the ROPS canopy from 2. SAFETY CABLE
the machine. Connect the tilt cylinder and safety cable.

9008-8
STEP 13 STEP 15
2 2
1
3
4
BD06J127-01 BD07K038-01
1. MOUNT BOLTS 3. ENGINE HARNESS Using a feeler gauge adjust clearance of the tilt
2. FUSE AND RELAY BLOCK 4. ROPS FRAME proximity switch to 1 to 3 MM. (0.040 to 0.118 in).
Mount the fuse and relay bracket to the ROPS,
tighten the mount bolts and install the batteries. STEP 16
If equipped with a brush guard, lower the brush
STEP 14 guard into alignment with the ROPS canopy.
STEP 17
BD06J126-01
BD06J130-01
Install the brush guard mount bolts and torque to 405

to 730 Nm (300 to 540 lb-ft).
BD06J129-01
Connect the wiring harness connectors to the ROPS
connectors.

9008-9
(CSF) CAB
Removal STEP 5
NOTE: The following photos show a ROPS canopy, the
procedures are the same.
STEP 1
Drain 4 liters (1 U.S. gallon) of coolant from the
radiator.
STEP 2
BD06J126-01
BD06J128-01
Disconnect the heater hoses and install a plug in
each heater hose and tighten the clamps.
STEP 3
Remove the batteries from the vehicle. BD06J129-01
Disconnect the wiring harness connectors from the
STEP 4 ROPS cab.
STEP 6
2 2
1
3
4
BD06J127-01

BD02F003-01
2. FUSE AND RELAY BLOCK 4. ROPS FRAME
If equipped with a brush guard, remove the bolts at
Remove the two mounting bolts for the fuse and the rear of the brush guard.
relay bracket and lay it in the battery compartment
area.

9008-10
STEP 7 STEP 12
BD02F005-01 BD02F006-01
Tilt the brush guard forward until the brush guard is Remove the twelve bolts from the mounts.
free of the ROPS cab.
NOTE: The removed bolts can be used in the tilting STEP 13
brackets to hold the brush guard up. The ROPS cab must stay level when raised.
STEP 8 STEP 14
Discharge the air conditioning system according to Carefully raise the ROPS cab until free of the
instructions in Section 9004. machine and remove from the machine.
STEP 9
Disconnect the hoses that go to the evaporator.
Install caps and plugs on the hoses to prevent
moisture from entering the hoses.
STEP 10
BD02F031-01

2. SAFETY CABLE
Disconnect the tilt cylinder and safety cable.
STEP 11
Install lifting eyes on top of the ROPS cab.

9008-11
NOTE: The following photos show a ROPS canopy, the
procedures are the same.
STEP 15
Carefully lower the ROPS cab onto the machine and
into alignment with the mounts.
STEP 16
BD07K038-01
Using a feeler gauge adjust clearance of the tilt
proximity switch to 1 to 3 MM. (0.040 to 0.118 in).
STEP 20
Connect the hoses that go to the evaporator.
STEP 21
BD02F007-01
Install the twelve support mount bolts and torque to 3
550 to 624 Nm (406 to 460 lb-ft).
2
STEP 17
Connect the wiring harness for the ROPS cab to the 1
main wiring harness.
STEP 18
BD02F031-01

2. SAFETY CABLE
2 2 Connect the tilt cylinder and safety cable.
1
STEP 22
3 Tilt the ROPS cab and connect the heater hoses.
4
STEP 23
BD06J127-01
Fill the radiator to the correct level, see section 1002.
2. FUSE AND RELAY BLOCK 4. ROPS FRAME STEP 24
If equipped with a brush guard, lower the brush
Mount the fuse and relay bracket to the ROPS,
guard into alignment with the ROPS cab.
tighten the mount bolts and install the batteries.

9008-12
STEP 25 STEP 26
Charge the air conditioning system according to
BD06J130-01
Install the brush guard mount bolts and torque to 405
to 300 Nm (420 to 540 lb-ft).

Section
9009
AIR AND MECHANICAL SUSPENSION SEATS
9009

9009-2
TABLE OF CONTENTS
AIR SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MECHANICAL SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9009-3
AIR SUSPENSION SEAT
Disassembly STEP 4
STEP 1
BD02N015-01
Remove the plastic pins from the boot assembly.

BD02N012-01
Loosen and remove the 4 cap screws from the seat STEP 5
assembly. Remove the seat assembly from the base.
STEP 2
BD02N016-01
Remove the boot assembly.
BD02N013-01 STEP 6
Remove the washers and spacer blocks.
STEP 3
BD02N017-01
Remove the nut and lock washer from the control

switch.
BD02N014-01
Loosen the Allen set screw for the seat control button
and remove the button.

9009-4
STEP 7 STEP 10
BD02N018-01 BD02N021-01
Disconnect the electrical and air connectors from the Remove the bushing and roller from the suspension
switch. assembly.
STEP 8 STEP 11
BD02N019-01 BD02N022-01
Remove the pivot bolt from the upper plate. Cut the plastic tie holding the wiring harness to the
lower plate.
STEP 9
STEP 12
BD02N020-01
Remove the upper plate. BD02N023-01
Remove the screw for the air spring from the lower
plate.

9009-5
STEP 13 STEP 16
BD02N024-01 BS02N027-01
Remove the pivot bolt from the lower plate. Remove the retainer washer and shock from the
suspension assembly.
STEP 14
STEP 17
BD02N025-01
Pick up on the suspension assembly, twist around BD02N028-01
the rubber bumper to clear the guides and remove Cut the two plastic ties, disconnect the electrical
the lower plate. connector and remove the air hose from the fitting.
STEP 15 STEP 18
BD02N026-01 BD02N029-01
Remove the busing, roller and spacer from the Remove the wiring harness and air hose from the
suspension assembly. retaining clip.

9009-6
STEP 19 Inspection
1. Inspect the seat cushion, backrest cushion, and
lumbar support control for wear and damage.
2. Inspect the slide control, and slide latch for wear
and damage. Use new parts as required.
3. Inspect height adjustment switch, and wire
harness for damage. Use new parts as required.
4. Inspect the boot assembly for damage. Use new
parts as required.
5. Inspect the suspension assembly and roller
BD02N030-01
bearings for wear and damage. Lubricate the
Disconnect the air line from the compressor, remove roller bearings and contact points with
the 2 mounting screws from the compressor, remove molydisulfide grease. Use new parts as required.
the compressor. 6. Inspect the suspension shock and bushings for
wear and damage. Use new parts as required.
STEP 20
7. Inspect the air compressor, air line, and wiring
harness for wear and damage. Use new parts as
required.
8. Inspect the air spring for wear and damage. Use
new parts as required.
9. Insect the lower plate, bearing shaft, and rubber
bumper for wear and damage.Lubricate the
contact points with molydisulfide grease. Use
BD02N031-01
Remove the air spring mounting bolt, remove the air

spring.

9009-7
Assembly STEP 24
STEP 21
BD02N028-01
Connect the electrical connection, connect the air

BD02N031-01
line to the compressor, and replace the plastic ties.
Install the air spring into the suspension assembly,
install the bolt with retaining clip and tighten. STEP 25
STEP 22
BD02N027-01
Install the bushings and suspension shock onto the

BD02N030-01
suspension assembly.
Install the compressor with the two mounting screws,
install the air spring line into the compressor. STEP 26
STEP 23
BD02N026-01
Use molydisulfide grease and install the bushings

BD02N029-01
and rollers on the lower portion of the suspension
Place the air hose and wiring harness into the assembly.
retaining clip.

9009-8
STEP 27 STEP 30
BD02N025-01 BD02N022-01
Place the suspension assembly rollers into the Route the wiring harness to the rear of the seat and
guides, twist around the rubber bumper and lower secure with a plastic tie strap.
into place.
STEP 31
STEP 28
BD02N021-01
BD02N024-01 Use molydisulfide grease and install the bushings

Use molydisulfide grease on the pivot bolt and install and rollers on the upper portion of the suspension
into the lower plate and suspension assembly. Install assembly.
a new self locking nut and tighten.
STEP 32
STEP 29
BD02N020-01
BD02N023-01 Slide the upper plate over the rollers and lower into
Install and tighten the screw into the bottom of the air place.
spring.

9009-9
STEP 33 STEP 36
BD02N019-01 BD02N016-01
Use molydisulfide grease on the pivot bolt and install Slip the rubber boot over the upper plate.
into the upper plate and suspension assembly. Install
a new self locking nut and tighten. STEP 37
STEP 34
BS02N015-01
Slide the rubber boot into position on the upper and

BD02N018-01 lower housing. Install the plastic pins into the
Connect the air hose and electrical wiring to the mounting holes in the rubber boot.
switch.
STEP 38
STEP 35
BD02N014-01
BD02N017-01 Install the control knob onto the switch, tighten the
Install the switch into the upper plate, install the lock Allen set screw.
washer and nut. Tighten the switch.

9009-10
STEP 39 STEP 40
BD02N013-01 BD02N012-01
Place the 4 bushings and washers onto the upper Use new self locking nuts and install the seat
plate. assembly onto the frame assembly.

9009-11
MECHANICAL SUSPENSION SEAT
Disassembly STEP 4
STEP 1
BD02N005-01
Remove the four mounting bolts from the support

BD02N002-01
plate.
Push up on the front of the lower cushion to release
the retaining clip. STEP 5
STEP 2
BD02N006-01
Remove the mounting bolts for the slide controls,

BD02N003-01
remove the slide controls.
Remove the lower cushion from the seat assembly.
STEP 6
STEP 3
BD02N007-01
BD02N004-01
Remove the plastic pins and boot assembly from the
Remove the four mounting bolts from the seat. suspension assembly.

9009-12
STEP 7 Inspection
1. Inspect the seat cushion, backrest cushion, and
lumbar support control for wear and damage.
2. Inspect the slide control, and slide latch for wear
and damage. Use new parts as required.
3. Inspect weight adjustment gears for damage.
4. Inspect the boot assembly for damage. Use new
parts as required.
5. Inspect the suspension assembly and bushings
BD02N009-01
for wear and damage. Lubricate the bushings
Place the suspension assembly in a press, compress and contact points with molydisulfide grease.
the assembly slightly and remove the mounting bolts Use new parts as required.
for the shock assembly. 6. Inspect the suspension shock and bushings for
wear and damage. Use new parts as required.
STEP 8
7. Inspect the spring for wear and damage. Use
BD02N008-01
Remove the shock from the suspension assembly.

9009-13
Assembly STEP 12
STEP 9
BSD2N005-01
Use new self locking nuts and install the support

BD02N009-01
plate.
Install the suspension shock into the suspension
assembly. Install new self locking nuts and tighten. STEP 13
STEP 10
BD02N004-01
Use new self locking nuts and install the seat

BD02N007-01
assembly onto the support plate.
Place the boot assembly into position on the
suspension assembly, install new plastic pins. STEP 14
STEP 11
BD02N010-01
Make sure the retaining clips are in place and install

BD02N006-01
the lower cushion into the seat.
Use new self locking nuts and install the slide rails.

9009-14
NOTES

Section
9010
RIPPER
9010

9010-2
TABLE OF CONTENTS
Hydraulic Hose Routing Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ripper Frame And Mounted Components Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9010-3
2
3
4
5
6
BC06B010
1. CONTROL VALVE 5. MOUNTING CLAMP

2. INSULATED MOUNTING CLAMP 6. RIPPER CYLINDER
3. BULKHEAD 7. RIPPER
4. MANIFOLD TEES
HYDRAULIC HOSE ROUTING ILLUSTRATION

9010-4
8
12
9
10
11
13
17 19 20
16 18 21
15
22
14 23
24
25
26
27
BC06B011
8. PIN UPPER ARM 18. LOWER ARM

9. PIN CYLINDER 19. PIN
10. MOUNTING BOLTS 20. WASHER
11. PIN LOWER ARM 21. RETAINING RING
12. SPACER 22. PIN
13. SPACER 23. WASHER
14. LEFT CYLINDER 24. RETAINING RING
15. LEFT UPPER ARM 25. PIN
16. RIGHT CYLINDER 26. WASHER
17. RIGHT UPPER ARM 27. RETAINING RING
RIPPER FRAME AND MOUNTED COMPONENTS ILLUSTRATION

9010-5
RIPPER
Remove Install
1. Park the machine on a level surface. 1. Align the mounting brackets with the frame.
2. Lower the ripper until the teeth are on the floor. 2. Install the bolts and washers (10) that fasten the
mounting brackets to the frame.
3. Stop the engine and apply the parking brake.
3. Tighten the bolts to 1136 to 1255 Nm (838 to 926
4. Turn ignition switch to the on position, move the
pound-feet).
ripper control lever in both directions to relieve
any pressure in the ripper circuits. Turn off 4. Move the ripper into position, raise the lower arm
ignition. (18) into the brackets.
5. Remove the dirt and grease from the tees (4) on 5. Align and install the pins (11) for the lower arm
the rear cover of the machine. (18).
6. Disconnect the clamps (5) holding the hoses to 6. Place spacers (12 and 13) on the left cylinder
the bulk head. (14), spacer (12) must be towards the center of
the machine.
7. Fasten identification tags to the hoses for each
ripper cylinder so that the connections will be 7. Align the left cylinder (14) in the bracket, install
correct during installation. Disconnect the hoses pin (9).
from the tees.
8. Align the left cylinder with the ripper (7), install
8. Install caps on the tees and plugs in the hoses. pin (22), washer (23), and retaining ring (24).
9. Remove retaining ring (21), washer (20), and pin 9. Repeat steps 6 through 8 for right cylinder (16).
(19) for the right upper arm (17).
10. Align the right upper arm (17) with the bracket,
10. Remove the pivot pin (8) for the right upper arm install the pivot pin (8) for the right upper arm
(17), remove the right upper arm (17). (17).
11. Repeat the procedure for the left upper arm (15). 11. Lower the ripper to the ground and remove the
pin and strap from the right side of the ripper.
12. Place a strap in the channel of the frame where
the upper arms (15 and 17) were removed. 12. Install the pin (19), washer (20), and retaining
ring (21), for the right upper arm (17).
IMPORTANT: Approximate weight of the ripper is 1038
Kg (2288 pounds), use strap(s) that are rated for this 13. Repeat steps 10 through 12 for left upper arm
weight or greater. (15).
13. Install pin (19), washer (20), and retaining ring 14. Install new O-rings, connect the hoses to the
(21) on both sides of the frame. tees (4), reinstall the clamps (5) holding the
hoses to the bulk head.
14. Use acceptable lifting equipment and pick up the
ripper enough to release the pressure on the 15. Start the engine and run the engine at low idle.
cylinder mounting pins.
16. Slowly extend and retract the ripper cylinders
15. Remove retaining ring (24), washer (23), and pin four times to remove any air from the ripper
(22) for the right cylinder (16). circuits.
16. Remove the pivot pin (9) for the right cylinder
(16), remove the right cylinder (16).
17. Repeat the procedure for the left cylinder (14).
18. Support the lower arm (18) to keep it from falling.
19. Remove the pivot pins (11) for the lower arm,
lower the arm to the ground.
20. Carefully move the ripper away from the
machine.
21. If required, remove the mounting bolts (10),
remove the brackets from the frame.
9010-6
NOTES

CHARGING CIRCUIT CRANKING CIRCUIT SOLENOIDS RELAYS FUSE BLOCKS BRAKE, DECELERATOR, DRIVE TRAIN CONTROLLER DRIVE TRAIN CONTROLLER PUMPS AND MOTORS FORWARD-NEUTRAL-REVERSE BRAKES
AND COLD START AND THROTTLE POTENTIOMETER 24A (F-R-N) JOYSTICK 33
AND V25
W (START) 0.8 F5-C4 C3 15 52 LB (252) 0.8 LB (252) 0.8 F28-C17 C18 A BL (V1ACC) 0.8
R (30) 2.0 F14-C2 C2

BR (IGN1) 0.8 51 V (251) 0.8
P (250) 0.8
V (251) 0.8
P (250) 0.8
F28-C14 C17 REVERSE RATIO SWITCH B W (248) 0.8
50 F28-C15 C16
BL (1M) 0.8 F28-C3 C22
R (30) 2.0 4 4 49
BR (50) 2.0 11 11 BR (50) 2.0 BR (50) 2.0 BR (50) 2.0 BR (50) 2.0
10 A
A BR (IGN1) 0.8 48 W (248) 0.8 W (248) 0.8 F11-C4 C15 25 26 27 28 29 30
BL (15) 0.8 12 12 BL (15) 0.8 BL (15) 0.8 BL (15) 0.8 BL (15) 0.8
20 A
BL (V1ACC) 0.8 F11-C1 C22 17 C B (0) 0.8
V (260) 0.8
47
34
B 46
W (START) 0.8 13 13 W (START) 0.8 W (START) 0.8 W (START) 0.8 W (START) 0.8
BL (15) 0.8 BL (15) 0.8 SPL 8 BL (V2ACC) 0.8 F27-C1 C17 45 V24
D1 M1 15 A 44 V (244) 0.8 1 GY (215) 0.8
BL (922) 2.0 F16-C1 C16 W (1003) 0.8 43 W (243) 0.8 2
A
BR (IGN1) 0.8 P5 1 2 3 4 P6 1 2 3 4 P3 1 2 3 4 P4 1 2 3 4 P7 1 2 P8 1 2
BL (ACC) 3.0 BL (ACC) 3.0 BL (ACC) 3.0 BL (ACC) 3.0 10 A
18 C R (1002) 0.8 42
W (START) 0.8
BK (1001) 0.8 41 BR (IGN1) 0.8
BL (V1ACC) 0.8
BL (933) 0.8 F23-C2 C15 B
BR (50) 2.0
BL (15) 0.8
7 B (335) 0.5 Y (335) 0.5 F28-C8 C14
BL (15) 0.8
V (244) 0.8
BL (V1ACC) 0.8
W (243) 0.8
G (218) 0.8
BL (V1ACC) 0.8
O (217) 0.8
R (30) 2.0
40
G (268) 0.8
B (0) 2.0
Y (269) 0.8
B (0) 2.0
B B
V (231) 0.8
P (230) 0.8
LB (204) 0.8
Y (216) 0.8
GY (215) 0.8
10 A
B (0) 0.8
W (248) 0.8
R1 M2 C C 39 W (334) 0.8 G (334) 0.8 F28-C12 C13
R7
30 R (21A) 1.0 F5-C4 C6
15 A
BL (912) 2.0 F16-C2 C14
A A 38 GY (238) 0.8 GY (238) 0.8 F6-C3 C12 31
M14
87 BR (IGN+) 2.0 A GY (1000) 0.8
M7A M7
37 W (237) 0.8 W (237) 0.8 F6-C10 C11 24B
4 D14 1 2 3 4 5 6 A 10 87A BL (953) 0.8 F23-C1 C13 19 C R (1002) 0.8
W (1003) 0.8
36 C1 F17-C10
1 B B (0) 0.8
86
85
BUSS
BR (50) 2.0
10 A B 35
34
80 Y (280) 0.8 F6-C7 C8 A U V V1
79 W (279) 0.8 F6-C1 C7 A U V P10
M6 33
32
74 C G (211) 0.8 F7-C6 C7
R2 M2 BL (800) 2.0 F21-C2 C12 A 279 73 B W (210) 0.8 F7-C5 C6
BL (V1ACC) 0.8
GY (215) 0.8
W (248) 0.8
30 BR (IGN+) 2.0 F7-C4 C6 20 A 20 B P (256) 0.8 31
30
V (231) 0.8
P (230) 0.8
72 LB (272) 0.8 F12-C1 C6 A BL (V1ACC) 0.8 F5-C21 C5
60 A 87 P (21C) 0.8 C Y (265) 0.8 W (271) 0.8
BL (ACC) 3.0 BL (819) 2.0 F21-C1 C11 GY (215) 0.8
71 C7
11 87A 75 25 A M5 SPL 11
29
28 B (0) 2.0
70
86 BUSS A Y (280) 0.8 69 Y (269) 0.8
P (206) 0.8 27 BR (IGN2) 2.0
F7-C4 C6 G (268) 0.8
BATT ACC IGN ST OFF
R (BATT+) 3.0
85
F3-C1 C10
21 B GY (262) 0.8 26
68
67
SPL 2
C LB (219) 0.8 25
R6 SPL 9 66
50 A M3 24 Y (224) 0.8 Y (224) 0.8 F28-C16 C10
2 BR (1N) 0.8 F28-C1 C10 M23 Y (265) 0.8 F6-C8 C5
BL (V1ACC) 0.8
30 P (21C) 0.8 65 9 16 17 P1
23 O (223) 0.8 O (223) 0.8 F6-C4 C9
LB (204) 0.8
10 A O (223) 0.8
W (243) 0.8
LB (264) 0.8
A F6-C2 C4
32
O (217) 0.8
G (218) 0.8
G (268) 0.8
64
V (244) 0.8
Y (216) 0.8
P (230) 0.8
V (231) 0.8
Y (269) 0.8
87 W (210) 1.0 F2-C9 C4 9 16 17 C5
12 R (30) 1.0 22 B Y (280) 0.8 22
R (BATT+) 3.0
W (21D) 1.0 10 10 W (21D) 1.0 F3-C2 C1 87A F2-C2 C10 21
63
R8
5 86 W (317) 0.8 F18-C9 C4 10 A 62 GY (262) 0.8 F6-C6 C3 M9
BL (V1ACC) 0.8
GY (215) 0.8
W (248) 0.8
E1 M11 20
M12
E8 8 9
85 O (337) 0.5 F18-C4 C5 R (21A) 2.0 F3-C2 C10 C6 SPL 8 19 LB (219) 0.8 LB (219) 0.8 F6-C5 C8
61
60 V (260) 0.8 F6-C11 C2
6
5 BR (IGN1) 0.8
GY (262) 0.8
G 20 A
LB (219) 0.8
G (218) 0.8
W (237) 0.8
W (279) 0.8 18
O (223) 0.8
A
Y (280) 0.8
Y (265) 0.8
P (256) 0.8
V (260) 0.8
e 59 P1 7 8 10 11 12 13 14 15 31 32 4 Y (335) 0.8 F28-C7 C4 C1 F9-C10
100 AMP 100 A R5 M2 R (992) 0.8 F14-C3 C9 23 B LB (264) 0.8 17 O (217) 0.8
58 C5 7 8 10 11 12 13 14 15 31 32 3 G (334) 0.8 F28-C11 C3
30 W (332) 0.5 F18-C7 C3 20 A C GY (238) 0.8 16 Y (216) 0.8 F7-C15 C4
B (0) 0.8
279
57 2
O (312) 0.8
B GY (215) 0.8 GY (215) 0.8
V (375) 0.5
Y (329) 0.5 15 F11-C3 C7
LB (204) 0.8
87 F18-C8 C1 R (302) 2.0 F18-C11 C7
W (243) 0.8
P (256) 0.8 BR (IGN1) 0.8
O (217) 0.8
G (218) 0.8
G (268) 0.8
F7-C1 C2
3 F6-C9 C1
V (244) 0.8
Y (216) 0.8
P (230) 0.8
V (231) 0.8
Y (269) 0.8
B+ 56 1
8A 13 87A 30 A 14 SPL 4
C2
F7-C7 C3
6 B G 86 BUSS R (501) 0.8 F20-C2 C5
18 41 36 12 43 20 11 13 19 M10
18 41 36 12 43 20 11 13 19 C4
13
12
BR (IGN1) 0.8
F5-C1 C1
85 W (START) 15 A
E4 E13 11 G (211) 0.8 G (211) 0.8 F10-C7 C6 C12
150 A
GY (262) 0.8
LB (219) 0.8
279
W (237) 0.8
W (210) 0.8 W (210) 0.8 W (271) 0.8
O (223) 0.8
Y (280) 0.8
Y (265) 0.8
P (256) 0.8
V (260) 0.8
W D+ R4
10 F10-C6 C5 A
M2 SPL 4 9 B
30 BR (1N) 0.8 F14-C4 C2 F14-C2 C4 Y (269) 0.8 Y (269) 0.8
BR (IGN3) 0.8 8
P (W) 0.8
P (D+) 0.8
87 BL (1M) 0.8 F14-C4 C2 F18-C3 C3 G (268) 0.8 G (268) 0.8 F10-C5 C21
5A 7
9 14 87A
BR (IGN2) 2.0 F7-C2 C2 F8-C2 C11
6 P (206) 0.8
V (244) 0.8 V (244) 0.8 V (244) 0.8 V (244) 0.8 SPL 3 F13-C1 C19
86 BUSS W (243) 0.8 W (243) 0.8 W (243) 0.8 W (243) 0.8 F20-C1 C18
R (BATT+) 3.0
20 A 5 O (205) 0.8 O (205) 0.8 F17-C1 C3
85 BL (15) 0.8 SPL 2 F7-C11 C10 V (231) 0.8 V (231) 0.8 V (231) 0.8 V (231) 0.8
SPL 10
BR (IGN1) 0.8 4 LB (204) 0.8
F10-C1 C1 F8-C1 C9 P (230) 0.8 P (230) 0.8 P (230) 0.8 P (230) 0.8
R (BATT+) 3.0
BR (IGN1) 0.8
2 2 10 A 3
F8-C5 C8 G (218) 0.8 G (218) 0.8 G (218) 0.8 G (218) 0.8 42 C4
B (0) 0.8
2 B (0) 2.0
O (217) 0.8 O (217) 0.8 O (217) 0.8 O (217) 0.8
BR (IGN1) 0.8
E1 M11 BR (IGN2) 2.0 42 M10
BR (IGN+) 2.0
F8-C8 C7 1
Y (216) 0.8 Y (216) 0.8 Y (216) 0.8 Y (216) 0.8
16 F8-C3 C6 C1 LB (204) 0.8 LB (204) 0.8 LB (204) 0.8 LB (204) 0.8
BL (V1ACC) 0.8
C2 F18-C2 V (375) 0.5 F7-C8 C5 C4 M10
C1 F18-C10 O (312) 0.8 R (BATT+) 3.0 R (BATT+) 3.0 F7-C9 C4
BR (IGN1) 0.8 16 16 BR (IGN1) 0.8 F10-C2 C1
F7-C12 C3 P (206) 0.8 48 48 P (206) 0.8 F3-C6 C4
B (0) 0.8
F3-C1 C1
B (0) 2.0
B (0) 2.0
B (0) 0.8
C1 F28-C2 F8-C4 C2 BR (IGN2) 2.0 BL (V1ACC) 0.8 F11-C1 C1
BR (IGN2) 2.0 7 7 F5-C2 C2
F8-C7 C1 F5-C1 C1
C2 F14-C5 BR (IGN1) 0.8
GND-M4 GND-M4 GND-C19 GND-C19 GND-P2 GND-M4

FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10 FRAME 11
BC07K689-01A BC07K689-02A BC07K689-03A BC07K689-04A BC07K689-05A BC07K689-06A BC07K689-07A BC07K689-08A BC07K689-09A BC07K689-10A BC07K689-11A
BLADE CONTROL JOYSTICK RIPPER CONTROL MENU SWITCHES AND INSTRUMENT CLUSTER SENDING UNITS FRONT AND REAR LAMPS HORN AND BACKUP ALARMS ENGINE CONTROL UNIT RADIO DC CONVERTER ROPS HEATER
JOYSTICK AND AND
47
Y (335) 0.5 F18-C5 C7
12 VOLT POWER SOURCE AIR SUSPENSION
35B 44A 1 BR (IGN3) 0.8 Y (335) 0.5 F10-C4 C6 2 R (302) 2.0 SEAT
LB (133) 0.8 LB (133) 0.8 LB (133) 0.8
2 Y (120) 0.8 D1 M1 M10 C4 6
25
6
25 Y (120) 0.8
31
30
31
30 Y (120) 0.8
6
5
6
5 Y (120) 0.8 M M Y (120) 0.8
3 R (302) 2.0 68
35A 36 3
4
Y (335) 0.5
G (334) 0.5
26 26
16 16
Y (335) 0.5
G (334) 0.5
44 44
45 45
Y (335) 0.5
G (334) 0.5
F28-C6
F28-C10
C7
C6 27 27 W (104) 0.8 46 46 W (104) 0.8 2 2 W (104) 0.8 H H
5
6
B (0) 2.0
B (0) 2.0 R (302) 2.0
C21 1 2 3 4 5 6 7 8 9 10 11 12 P (121) 0.8 33 33 P (121) 0.8 29 29 P (121) 0.8 3 3 P (121) 0.8 K K 63 R (302) 2.0 R (302) 2.0
Y (120) 0.8
5 8
C18 1 2 3 4 5 6 7 8 9 10 11 12
LB (133) 0.8
GY (134) 0.8 GY (134) 0.8 GY (134) 0.8
W (104) 0.8
B (0) 0.8 G (334) 0.5 F18-C6 C7 36 36 34 34 4 4 O O R (302) 2.0
W (104) 0.8
6 9
Y (911A) 2.0 Y(911A) 2.0
O (451) 0.8
P (452) 0.8
W (453) 0.8
G (334) 0.5 35 35 2 2
P (121) 0.8
7 F10-C3 C6 M10 C4 C5 P1 P10 V1 V9 10 B (0) 2.0 B (0) 0.8
P (121) 0.8
G (421) 0.8
G (429) 0.8
LB (422) 0.8
W (423) 0.8
O (424) 0.8
P (425) 0.8
Y (426) 0.8
V (427) 0.8
0 (424) 0.8
Y (911B) 2.0 1 1 V (911B) 2.0
GY (134) 0.8
8 D1 M1 11 B (0) 2.0
GY (134) 0.8
GY (921) 2.0 14 14 GY (921) 2.0 B (0) 0.8 L8
G (103) 0.8
9 12 O (312) 0.8 O (312) 0.8
C17 1 2 3 4 5 6 7 8 9 10 11 12 C10 1 2 3 4 5 6 7 8 9 10 11 12 G (103) 0.8 BL (912) 2.0 5 5 M10 21 22 24 1 1 O (205) 0.8 B B O (205) 0.8 W (317) 0.8 W (317) 0.8 L15 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Y (911A) 2.0
10 17
3 3
11 C4 21 22 24 CS P1 P10 V1 29 Y (329) 0.5 Y (329) 0.5
BL (912) 2.0
28 29 30 C5 SPL 1
R (RADIO) 0.5
R (RADIO) 0.5
B (0) 0.8
R (504) 1.0
LB (505) 1.0
B (RADIO) 0.5
B (RADIO) 0.5
O (205) 0.8
D1 M1
BL (V1ACC) 0.8
B (0) 0.8
LB (415) 0.8
O (416) 0.8
GY (417) 0.8
Y (418) 0.8
W (419) 0.8
O (4111) 0.8
LB (415) 0.8
GY (417) 0.8
O (416) 0.8
12 B (0) 0.8 B (0) 2.0 30

22 23 24 19 20 21 25 26 27 C5
67 L8
BL (922) 2.0
28 29 30 P1
P (135) 0.8
BL (922) 2.0
13 32 W (332) 0.5 W (332) 0.5
GY (921) 2.0
M11 11
V (911B) 2.0
22 23 24 19 20 21 25 26 27 P1 B (0) 0.8
Y(911A) 2.0
14 34 W (334) 0.5 W (334) 0.5 2
E1 11
W (453) 0.8
O (451) 0.8
P (452) 0.8
15 35 B (335) 0.5 E11 69 NO

75
LB (422) 0.8
W (423) 0.8
G (421) 0.8
O (424) 0.8
G (429) 0.8
P (425) 0.8
Y (426) 0.8
V (427) 0.8
0 (424) 0.8
16 1 0 37 O (337) 0.5 R (302) 0.8 3
BL (912) 2.0
71
G (103) 0.8
D12 ENTER
17 40 BR (IGN3) 0.5 B (0) 0.8 2 L17
O (114) 0.8 3
A 13
GY (134) 0.8
18 42 GY (342) 0.8 GY (342) 0.8 1
R (501) 0.8
R (992) 0.8 2 C8 3 2 1
T N F P10 19
W (111) 0.8 1 51 L1 3 2 1 45 B (RADIO) 0.5 BL (V2ACC) 0.8
M
W J L P Q S G E R P10 T N F V1 20 ESCAPE E7 A 75 V (375) 0.5 R (RADIO) 0.5 72 B (0) 0.8
58
P (121) 0.8
W J L P Q S G E R V1 21 0 89 G (389) 0.5 B
GY (921) 2.0
V (911B) 2.0
Y(911A) 2.0
1 2
49
O (993) 0.8
V
22 V10 65 E2
O (451) 0.8
P (452) 0.8
W (453) 0.8
NO L1 6
G (421) 0.8
LB (422) 0.8
W (423) 0.8
O (424) 0.8
P (425) 0.8
Y (426) 0.8
V (427) 0.8
0 (424) 0.8
G (429) 0.8
23 B
66
W (104) 0.8
24 G (103) 0.8 M11 7 C8 6
45 P 60 L16
B (0) 0.8
E10
B (0) 0.8
25 E1 7 A
R (501) 0.8
V20 26 F28-C1 C1
T 1 2 L5 B (RADIO) 0.5
P (452) 0.8 1 D2A
52 76
O (993) 0.8
W (453) 0.8 2 V12 D5 1 B
R (RADIO) 0.5
X V1
B (0) 0.8
1 C4 M10
Y (911A) 2.0
B (0) 2.0
X P10
53
BR (IGN3) 0.5
2 O (114) 0.8 R (501) 2.0
L6 SPL 9 28
28 A 22
W (334) 0.5
W (332) 0.5
W (317) 0.8
W (453) 0.8
70
G (389) 0.5
O (337) 0.5
O (312) 0.8
R (302) 2.0
2
V (375) 0.5
B (335) 0.5
Y (329) 0.5
3 GY (134) 0.8 1 2
BL (922) 2.0
BL (V1ACC) 0.8 BL (V2ACC) 0.8
O (451) 0.8
M
B (0) 0.8
1 M1 8
4 B (0) 0.8
R (501) 2.0
V19 5 LB (133) 0.8
54 D1 8
1 2 B
LB (422) 0.8
W (423) 0.8
W (423) 0.8
46
G (421) 0.8
O (424) 0.8
G (429) 0.8
G (429) 0.8
W (111) 0.8
Y (426) 0.8
P (425) 0.8
Y (426) 0.8
V (427) 0.8
B (0) 0.8
0 (424) 0.8
6 3
61
V (911B) 2.0
37 7 P (125) 0.8 55
O (993) 0.8
29 28 27 26 20 18 25 24 21 23 1 E1
G (118) 0.8 2 D6
LB (505) 1.0
8 29 28 27 26 20 18 25 24 21 23 1
R (504) 1.0
M11
9 Y (911A) 0.8 59 1 2 L7 64 5 4
6 B (0) 0.8
V16 1 2 V15 1 2 V13 1 2 V14 1 2 V18 1 2 V17 1 2 10 D15
R (302) 2.0
G (389) 0.5
V (375) 0.5
BR (IGN3) 0.5
O (337) 0.5
B (335) 0.5
W (334) 0.5
W (332) 0.5
Y (329) 0.5
W (317) 0.8
O (312) 0.8
44B 11 W (104) 0.8 B (0) 2.0
12 GY (921) 0.8
A Y (120) 0.8 2 D13 73
LB (505) 1.0
R (504) 1.0
3
2 1 V21 13 PK (D+) 0.8 1 0 NO L4 NO 8 9 L1
1 2
LB (133) 0.8
P (135) 0.8
B (0) 0.8
C16 1 2 3 4 5 6 7 8 9 10 11 12 14 R (992) 0.8 R (992) 0.8 D11 DOWN 8 9 C8
B (0) 2.0 P (125) 0.8 56 1
B (0) 0.8
LB (272) 0.8
15 3
SPL 1
R (992) 0.8
LB (505) 1.0
16 2 B
38 39 40 41 42 43
BL (V1ACC) 0.8
B (0) 0.8
W (419) 0.8
Y (418) 0.8
57 62
R (504) 1.0
GY (921) 2.0
GY (921) 2.0
GY (921) 2.0
17 W (START) 0.8 G (118) 0.8 1 F5-C7 C11
B (0) 0.8
GY (134) 0.8
LB (133) 0.8
UP
W (104) 0.8
P9 A F4-C1 C10
G (103) 0.8
Y (120) 0.8
P (121) 0.8
18
R (504) 1.0
1 0 M10 39
19
P 1 2 L3 C4 39
F3-C4 C9
20 R (992) 0.8
D V1
D P10 21 BR (IGN3) 0.8
PK (D+) 0.8 F1-C2 C5 50 B B (0) 2.0
F3-C1 C8
F3-C3 C7
G (389) 0.5
SPL 2 W (START) 0.8 F3-C2 C4
W (419) 0.8 W (419) 0.8 22 B (0) 2.0
Y (120) 0.8 F28-C9 C6
Y (418) 0.8 Y (418) 0.8 23 L2
LB (272) 0.8
R (992) 0.8 F5-C9 C3 P (121) 0.8 F17-C2 C1

24 O (4111) 0.8 1 2 F28-C5 C5 74
GY (921) 0.8
BL (V1ACC) 0.8
Y (911A) 0.8
P (135) 0.8
R (501) 2.0
BL (V1ACC) 0.8 BL (V1ACC) 0.8 BL (V1ACC) 0.8 F5-C19 C1
LB (505) 1.0
25 F3-C5 C4
R (504) 1.0
BR (IGN3) 0.8 15 15 BR (IGN3) 0.8 F5-C4 C2 G (103) 0.8
26 F5-C3 C3
B (0) 0.8
B (0) 0.8
B (0) 0.8
O (4111) 0.8 F14-C1 C2 GY (134) 0.8
B (0) 0.8
B (0) 0.8
D1 M1 R (992) 0.8
B (0) 2.0
B (0) 0.8
D2B F5-C8 C2
B (0) 0.8
LB (133) 0.8 F4-C2 C2
P1 C5 10 10 O (4111) 0.8 10 10 O (4111) 0.8 F12-C2 C1
48
B (0) 2.0
Y (911A) 0.8 Y (911A) 0.8 O (205) 0.8 F7-C3 C1
B (0) 0.8
B (0) 0.8
B (0) 2.0
B (0) 0.8
B (0) 0.8
B (0) 0.8
BL (912) 2.0 F28-C13 C1
B (0) 2.0
18 18 LB (272) 0.8 F8-C6 C1 F5-C14 C2
D1 M1 M10 C4 W (104) 0.8 Y (911A) 0.8 LB (505) 1.0 F5-C5 C2
BL (922) 2.0 F5-C16 C1 F5-C18 C1 BL (V2ACC) 0.8 F5-C17 C1
GY (921) 0.8 GY (921) 0.8 GY (921) 0.8 R (504) 1.0
B (0) 0.8 F17-C6 C1
GND-C13 GND-C13 GND-M4 GND-M4 GND-E3 GND-P2 GND-L14 GND-P2 GND-E3 GND-E3 GND-L14 GND-C13 GND-C13 GND-L14 GND-M4 GND-M4
FRAME 12 FRAME 13 FRAME 14 FRAME 15 FRAME 16 FRAME 17 FRAME 18 FRAME 19 FRAME 20 FRAME 21
BC07K689-12A BC07K689-13A BC07K689-14A BC07K689-15A BC07K689-16A BC07K689-17A BC07K689-18A BC07K689-19A BC07K689-20A BC07K689-21A
BLOWER MOTOR AIR CONDITIONING WINDSHIELD WIPER SWITCH WINDSHIELD WIPER DOOR WIPER SWITCH DOOR DIAGNOSTIC AND FLEET GROUND CONNECTIONS COMPONENTS
AND MOTORS SWITCH AND MOTORS WIPER SWITCH (SEE NOTE 1) FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
98
88 D4 AND WASHER AND WASHER FRAME 1 COMPONENTS FRAME 7 COMPONENTS FRAME 13 COMPONENTS FRAME 19 COMPONENTS FRAME 26 COMPONENTS
BL (933) 0.8
1- 1. Batteries 7 - 24A. Drive Train Controller 13- 44A. Ripper Joystick 19- 68. Radio 26- 93. Wiper Motor (Left)
12
11
12
11
G (931) 0.8
93 1- 2. Master Disconnect Switch 13- 44B. Ripper Joystick 19- 69. Right Speaker 26- 94. Wiper Switch (Left/Right)
F15 FRAME 8 COMPONENTS
BRN
10
9
10
9 BL (819) 2.0 BL (933) 0.8 A B C D E F G H I C3
1- 3. Alternator 8 - 24B. Drive Train Controller 13- 45. Ripper Lift Solenoid 19- 70. Left Speaker 26- 95. Wiper Motor (Right)
V (932) 0.8
WHT 8 8 W (818A) 2.0 G (951) 0.8
FRAME 2 COMPONENTS 13- 46. Ripper Lower Solenoid FRAME 20 COMPONENTS FRAME 27 COMPONENTS
V (817) 2.0 84 85 FRAME 9 COMPONENTS
LB (252) 0.8
BLK/WHT 7 7
G (334) 0.5
G (389) 0.5
R (501) 0.5
Y (335) 0.5
V (251) 0.8
P (250) 0.8
Y (224) 0.8
2- 4. Ignition Switch FRAME 14 COMPONENTS 20- 71. Interior Lamp Switch 27- 96. Washer Switch (Left/Right)
B (0) 0.8
PUR 6 6 P (816) 2.0 9 - 25. Left-Hand Motor Speed Sensor
B (0) 0.8
YEL 5 5 G (815) 2.0 V (952) 0.8 2- 5. Starter Solenoid 9 - 26. Right-Hand Motor Speed Sensor 14- 47. Instrument Cluster A 20- 72. Interior Lamp 27- 97. Washer Pump (Left/Right)
BLU 4 4 G (814) 2.0
ORG ORG 3 3 G (813) 2.0 2- 6. Starter 9 - 27. Left-Hand Hydrostatic Pump 14- 48. Instrument Cluster B 20- 73. Converter - 24 Volt DC to 12 Volt DC FRAME 28 COMPONENTS
B (0) 0.8
LB (252) 0.8 F7-C18 C17

M BLK B (0) 2.0 14- 49. Enter/Escape Switch 20- 74. 12 Volt Power Socket
BL (933) 0.8
2 2
91 0 0 Y (224) 0.8 F7-C10 C16 FRAME 3 COMPONENTS 9 - 28. Right-Hand Hydrostatic Pump) 28- 98. Connector - Diagnostic
BL (953) 0.8
V (932) 0.8
BLK GRN BL (811) 0.8 C23 A B E12 A B

1 1
1 1 P (250) 0.8 F7-C16 C15
3- 7. Accessory Relay 9 - 29. Left-Hand Motor Solenoid 14- 50. Up/Down Switch 28- 99. Connector - Fleet Tracker
77 L13 0 89 D8 D10
V (251) 0.8 F7-C17 C14
FRAME 21 COMPONENTS
W (818C) 0.8
W (818A) 2.0
W (818B) 0.8
W (818B) 0.8
1 G (389) 0.5 F18-C1 C13 3- 8. Grid Heater Relay 9 - 30. Right-Hand Motor Solenoid FRAME 15 COMPONENTS FRAME 29 COMPONENTS
3 3 21- 75. Heater - ROPS
V (952) 0.8
ORG D7 1 2 2 F7-C13 C12 3 - 8A. Grid Heater Fuse FRAME 10 COMPONENTS 15- 51. Air Filter Restriction 29- 100. P2 - Located in Battery Compartment
M 2
3
G (931) 0.8 BL (933) 0.8
94 0 SPL 6 F10-C3 C11 3- 9. Grid heater 15- 52. Hydrostatic Filter Restriction Switch 21- 76. Air Suspension Seat
BLK
BL (933) 0.8 1
G (334) 0.5
F14-C6 C10 10- 31. Reverse Ratio Switch (Ground contacts in Frames 9, 14, and
15- 53. Transmission Temperature
O (963) 0.8
86
W(943) 0.8
5 G (934) 0.8 1 D9 96 F18-C6 C9 FRAME 4 COMPONENTS 10- 32. Forward-Neutral-Reverse (F-N-R) FRAME 22 COMPONENTS 17).
C8 4 15 C4 E1 12 E6 4 G (951) 0.8 2
4 - 10. Ignition Relay Joystick 15- 54. Equipment Filter Restriction Switch 29- 101. M4 - Located behind Console (Ground
BL (933) 0.8
A BKW L1 4 15 M10 M11 12

6
BL (953) 0.8
BL (953) 0.8
3 F7-C14 C8
15- 55. Warning Buzzer 22- 77. Blower Motors
78 B WHT W (818B) 2.0 Y (335) 0.5
SPL 5 F10-C4 C7 4 - 11. Vehicle Safety Relay FRAME 11 COMPONENTS 22- 78. Thermostat contacts in Frames 3, 6, 10, 14, 15, 21,
V (935) 0.8 G (954) 0.8 5 15- 56. Fuel Sending Unit
W (818A) 2.0
BL (933) 0.8
BLK
C D1 32 4 D1 18 F14-C7 C6 4 - 12. Starter Relay 11- 33. Brake Pressure Switch 22- 79. Water Valve 24, 26, and 28.)
M1 32 BL (933) 0.8 M1 18 F18-C5 C5
4.- 13. Start Sensing Relay 15- 57. Transmission Charge Pressure Switch 29- 102. L14 - Located top of Cab (Ground
6
R (501) 0.5 F4-C6 C4 11- 34. Brake Solenoid 22- 80. Resistor
V (955) 0.8
1 BRN 4.- 14. Fleet Relay FRAME 16 COMPONENTS 22- 81. Fan Speed Switch contacts in Frames 16, 19, 20, 22, and
O (963) 0.8
BL (933) 0.8
BL (933) 0.8
W(943) 0.8
G (951) 0.8
G (954) 0.8
V (952) 0.8
79
2 GRN D1 23 22 31 D1 21 FRAME 12 COMPONENTS 16- 58. Front Lamp Switch 22- 82. Mode Switch 23.)
3 FRAME 5 COMPONENTS 12- 35A. Blade Joystick
4 BLK
M1 23 22 31 M1 21
5 - 15. Fuse Block A 16- 59. Rear Lamp Switch 22- 83. Temperature Switch 29- 103. E3 - Located at left-hand rear Engine
G (951) 0.8
V (952) 0.8
V (955) 0.8
99 12- 35B. Blade Joystick 16- 60. Front Lamps Mount (Ground contacts in Frames 15,
M11 14 D1 M11 13 5 - 16. Fuse Block B 12- 36. Diagnostic Port FRAME 23 COMPONENTS
7 17 38 28
16- 61. Front Lamps (Optional) 17, 18, 25, and 27.)
BL (819) 2.0
ORG E1 14 E1 13
BL (933) 0.8
1 7 17 38 28 M1
FRAME 6 COMPONENTS 12- 37. Equipment Valve Solenoid 23- 84. Air Conditioner Low Pressure Switch
BL (953) 0.8
80
2 BLU 16- 62. Rear Lamps 29- 104. C19 - Located near Drive Train
BL (953) 0.8
BL (953) 0.8
23- 85. Air Conditioner High Pressure Switch

G (934) 0.8
W (943) 0.8
6 - 17. Right-Hand Brake Proximity Switch 12- 38. Blade Lift Solenoid
V (935) 0.8
O (963) 0.8
YEL
3
92 97 Controller (Ground contacts in Frames
G (954) 0.8
V (955) 0.8
4 PUR
E5 E5 6 - 18. Tilt Proximity Switch 12- 39. Blade Lower Solenoid FRAME 17 COMPONENTS 23- 86. Air Conditioner Clutch
17- 63. Backup Alarm 7, 8, and 28.)
SPL 8
87
1 2 3 4 5 6 7 8 C3
6 - 19. Left-Hand Brake Proximity Switch 12- 40. Tilt Left Solenoid 23- 87. Air Conditioner Condenser 29- 105. C13 - Located near Power Converter
L12 L L11 M10 100 GND-P2
6 - 20. Brake Position Sensor 12- 41. Tilt Right Solenoid 17- 64. Horn Switch
P (816) 2.0 38 47 37
FRAME 24 COMPONENTS (Ground contacts in Frames 12, 13, 20,
BR (1N) 0.8
BL (1M) 0.8
V (817) 2.0
BL (819) 2.0
BL (819) 2.0
B A A B
V (817) 2.0 C 14 8 M10
17- 65. Horn
P (W) 0.5
G (815) 2.0
M1 38 47 37
6 - 21. Decelerator Position Sensor 12- 42. Angle Left Solenoid
B (0) 0.8
B (0) 0.8
C4
B (0) 0.8
81 M2 GY (814) 2.0 BL (819) 2.0 A B 14 8 C4

34 34 GND-F15 24- 88. Front Wiper Motor 24, and 26.)
H B (813) 2.0 GND-M4 39 39 GND-F14 6 - 22. Low Idle Switch 12- 43. Angle Right Solenoid FRAME 18 Components 24- 89. Wiper Switch (Front/Rear)
V (935) 0.8
G (934) 0.8
BL (953) 0.8
G (954) 0.8
V (955) 0.8
1 Y (899) 2.0
95 101
40 40 GND-F24 6 - 23. Throttle Position Sensor 18- 66. Engine Controller 24- 90. Rear Wiper Motor
L8 3 V (817) 2.0
90 C22 M1 D1
18- 67. Water-in-Fuel Sensor
82 2 BL (800) 2.0
C20 GND-M4 FRAME 25 COMPONENTS
BL (953) 0.8
1 Y (899) 2.0
G (934) 0.8
25- 91. Washer Switch (Front/Rear)
102 25- 92. Washer Pump (Front/Rear)
BL (933) 0.8
BL (933) 0.8
BL (933) 0.8
L10 C BL (1M) 0.8 F5-C22 C3 GND-L14

B (0) 2.0
83
B (0) 0.8
B BL (811) 0.8 P (W) 0.5 F1-C1 C2

V (935) 0.8
BL (933) 0.8
W (818A) 2.0
BL (819) 2.0 BR (1N) 0.8 F5-C10 C1

W (818A) 2.0
A
103
BL (953) 0.8
BL (933) 0.8
BL (819) 2.0
BL (953) 0.8 GND-E3

V (817) 2.0
BL (953) 0.8
V (817) 2.0
BL (819) 2.0
BL (933) 0.8
104 GND-C19
B (0) 0.8
B (0) 0.8
B (0) 0.8
BL (953) 0.8 BL (953) 0.8

B (0) 2.0
B (0) 2.0
B (0) 2.0
M10 C4 C8 L1
B (0) 2.0
B (0) 2.0
B (0) 0.8
B (0) 0.8
C2 F5-C12 BL (800) 2.0 23 23 BL (800) 2.0 5 5 BL (800) 2.0 C2 F5-C15 BL (933) 0.8
BL (953) 0.8
BL (933) 0.8
BL (953) 0.8
BL (933) 0.8
BL (953) 0.8
BL (933) 0.8
BL (953) 0.8 BL (953) 0.8 BL (953) 0.8
105 GND-C13
C1 F5-C11 BL (819) 2.0 26 26 BL (819) 2.0 7 7 BL (819) 2.0 C1 F5-C13
GND-L14 GND-L14 GND-M4 GND-C13 GND-E3 GND-C13 GND-M4 GND-E3 GND-C19 GND-M4 GND-M4
FRAME 22 FRAME 23 FRAME 24 FRAME 25 FRAME 26 FRAME 27 FRAME 28 FRAME 29
BC07K689-22A BC07K689-23A BC07K689-24A BC07K689-25A BC07K689-26A BC07K689-27A BC07K689-28A BC07K689-29A
ACTUATORS HOUSINGS FEMALE MALE CIRCUIT CONTINUATION WIRE IDENTIFICATION NOTES

SHOWS SPL-00 SHOWS CIRCUIT B . . . BLACK
V P T CONNECTOR CONNECTOR
NOTE 1 See SECTION 4002 in the REPAIR MANUAL for
ELECTRICAL SCHEMATIC
1 1
M CIRCUIT SPLICE CROSSING Frame Number and Circuit CIRCUIT TAGS BL . . BLUE
VACUUM PRESSURE TEMPERATURE CONNECTION NOT CONNECTED CONNECTOR 2 2
3 3
Number where Circuit F11-C4 C1 BR. . TAN/BROWN
BL (000)-1.0 locations and Troubleshooting information.
NUMBER continues.
LEVER HAND
CONTACT CONFIGURATIONS
FOOT COIL TEMP. DIODE PRESSURE FLOAT LIQUID LEVEL
MISCELLANEOUS SYMBOLS
SWITCH SWITCH LAMP MOTOR SWITCH
INDICATES INDICATES CONNECTOR
45E 45D
RELAY REAR
INDICATES PARTIAL
C1 F19-C7 G. . . GREEN
GY . GREY R . . . RED
WIRE COLOR WIRE SIZE
D150B CRAWLER
WIRE NUMBER
IDENTIFICATION CONNECTOR FRAME - CIRCUIT CIRCUIT
MOMENTARY 54 EXTERNAL INTERNALLY 4 4 LB . . LIGHT BLUE V . . . VIOLET/PURPLE
GROUND GROUNDED CONNECTOR
18 18 NOT ALL O. . . ORANGE W . . WHITE
MAINTAINED VARIABLE CIRCUIT MALE FEMALE COMPONENT
27 27
CONNECTIONS
GROUND COMPONENT NUMBER 32A 32B Circuit Number assigned to Circuit in Frame. P . . . PINK Y. . . YELLOW
S. P. S. T. S. P. D. T. D. P. S. T. D. P. D. T. CONTACTS RESISTOR RESISTOR FUSE BREAKER TERMINAL TERMINAL NUMBER ARE SHOWN
Copyright © 2007. CNH Italia S.p.A. All Rights Reserved. BC07K689-00A
MAIN HYDRAULIC PUMP AND RESERVOIR EQUIPMENT VALVE EQUIPMENT VALVE CYLINDERS LEFT-HAND HYDROSTATIC PUMP ASSEMBLY
C5 F4-C2 C7 F4-C6 C2 F4-C3 C4 F4-C2

C1 F2-C4
C3 F3-C5 C4 F4-C1 C6 F4-C5 C1 F4-C4 C3 F4-C1 C5 F2-C3
C2 F2-C5
14
9 10 11
L1 LS A1 B1 A2 B2 A3 B3 A4 B4
8 8-05 8-06 8-05 8-07 9-01 9-02 10-01 10-02
F11-C5 C6
MLS MP
Ø0.8
F2-C1 C2 P Ø0.8 18-01

C6 F10-C2
C2 F1-C1 C5 F7-C3
F5-C1 C7
F8-C4 C3 8-01 8-03 PST
C6 F2-C7 C4 F10-C1
C1 F2-C2 15 C3 F7-C2
C5 F2-C6 F11-C4 C7
5 7 L
I
3 12
R T2 PS Fa Fe MB
4 18
5-01 F6-C3 C8
7-01 8-02 13 B
P T1
8-08
18-02
13-02
8-04 11-01 18-04
7-02
T C C4 F3-C1
T 16 18-03 18-04 18-06
C1 F1-C2 AC C3 F3-C2
18-07
6
18-05 A
P1 P2 F6-C1 C9
8-09 8-09 8-09 8-09 9-03 9-03 10-03 10-03
1 X1 X2 G G1 MH S MA
MPST
°C
2 C2 F11-C6 F11-C3 C10
L C1 F3-C7
C2 F3-C4
2 17 2 2
C1 F3-C3
19
2-01 2-01
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5

BC07K690-01A BC07K690-02A BC07K690-03A BC07K690-04A BC07K690-05A
LEFT-HAND HYDROSTATIC MOTOR RIGHT-HAND HYDROSTATIC PUMP ASSEMBLY RIGHT-HAND HYDROSTATIC MOTOR BRAKES HYDROSTATIC FILTER TEST PORT PANEL
BP
27
21-01 C3 F5-C5 25 27-01 F5-C2 C6
C3 F7-C5
C3 F5-C8 C2 F6-C2
C2 F5-C3
C4 F8-C5 F11-C2 C4 C5 F6-C4
C2 F8-C2 C4 F1-C3
27-02 F3-C6 C5
B M1 U R T2 PS Fa Fe MB B M1 U 26
BP
20 21 F8-C3 C5
22
B 24 B
20-01 T1 22-01 23 26-01 27-03 F5-C7 C4
20-03 20-05 22-03 22-05

20-06 21-02 22-06 P
21-04 27-04 F5-C10 C3
21-03 21-04 21-06 26-02

21-07
20-02 22-02
27-05 F7-C4 C2
20-04 22-04 P T G P2 P1 P3
21-05 A
F8-C1 C6
C1 F7-C1
27-06 F7-C7 C1
A G T2 X1 X2 G G1 MH S MA A G T2 C1 F5-C4 C2 F5-C6
C1 F5-C9 C1 F9-C1 F11-C1 C7 C1 F7-C6
2 2 2
2 2
2-01
FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10 FRAME 11

BC07K690-06A BC07K690-07A BC07K690-08A BC07K690-09A BC07K690-10A BC07K690-11A
COMPONENTS
FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
FRAME 1 COMPONENTS FRAME 3 COMPONENTS FRAME 5 COMPONENTS

1- 1. Hydraulic Temperature Sending 3- 2. Hydraulic Reservoir 5- 2. Hydraulic Reservoir FRAME 8 COMPONENTS
Unit 3- 9. Angle Section 5- 2-01 Screen 8- 2. Hydraulic Reservoir
1- 2. Hydraulic Reservoir 3- 9-01. Flow Compensator Spool 5- 18. Left-Hand Track Pump 8- 22. Right-Hand Track Motor
1- 2-01. Screen 3- 9-02. Angle Spool 5- 18-01. Proportional Solenoids and Spool 8- 22-01 Speed Sensor
1- 3. Hydraulic Reservoir Vent 3- 9-03. Circuit Relief Valve with 5- 18-02. Hydrostatic Pump 8- 22-02. Hydrostatic Motor
Pressure: 1.3 Bar / 20 psi Anti-cavitation 5- 18-03. Servo Pistion 8- 22-03. Positioning Piston
Vacuum: 0.06 198 Bar / 2872 psi 5- 18-04. Main Pressure Relief 8- 22-04. Proportional Solenoid
Filter: 10 Micron 3- 10. Ripper Section (Optional) 450 Bar / 6527 psi 8- 22-05. Flushing Valve
1- 4. Equipment Hydraulic Pump 3- 10-01. Flow Compensator Spool 5- 18-05. Charge Pump Pressure Relief 8- 22-06. Flushing Orifice
64.5 cc / 4 Cubic Inch 3- 10-02. Ripper Spool 30 Bar / 435 psi
1- 5. Hydraulic Cooler Bypass Valve 3- 10-03. Circuit Relief Valve with 5- 18-06. Override Pressure Relief FRAME 9 COMPONENTS
1- 5-01. 13.8 Bar / 200 psi Anti-cavitation Blocked 9- 2. Hydraulic Reservoir
1- 6. Oil Cooler 198 Bar / 2872 psi 5- 18-07. Charge Pressure Pump 9- 23. Brake Pressure Switch
1- 7. Hydraulic Filter 3- 11. End Cover 19.6 cc / 1.2 Cubic Inch Normally Open (NO)
1- 7-01. Filter Bypass Switch 3- 11-01. ON/OFF Solenoid 5- 19 Charge Pressure Switch Closes at: 11-12.5 Bar / 164-184 psi
1- 7-02. 3.5 Bar / 50 psi 3- 12. Pilot Accumulator Normally Closed (NC) 9- 24. Brake Solenoid
3- 13. Accumulator Charge Valve Opens at 9- 25. Brake Cylinders
FRAME 2 COMPONENTS 17.5-19.5 Bar / 253-281 PSI
2- 8. Equipment Valve FRAME 4 COMPONENTS FRAME 10 COMPONENTS
2- 8-01. Unloading Valve 4- 14. Tilt Cylinder FRAME 6 COMPONENTS 10 - 2. Hydraulic Reservoir
138 liters per minute Bore:125 mm 6- 2. Hydraulic Reservoir 10 - 26. Filter
10-16 Bar / 145-232 psi Rod: 63 mm Diameter 6- 20. Left-Hand Track Motor 10 - 26-01. By-pass Switch
2- 8-02. Main Pressure Relief Stroke: 135 mm 6- 20-01 Speed Sensor 10 - 26-02. 3.5 Bar / 50 psi
185 Bar / 2683 psi 4- 15. Lift Cylinders 6- 20-02. Hydrostatic Motor
2- 8-03. Load Sense Relief Bore: 90 mm 6- 20-03. Positioning Piston FRAME 11 COMPONENTS
163 Bar / 2364 psi Rod: 50 mm Diameter 6- 20-04. Proportional Solenoid 11 - 27. Test Port Panel
2- 8-04. Load Sense Bleed Down Orifice Stroke 826 mm 6- 20-05. Flushing Valve 11 - 27-01. Charge / Pilot Pressure
0.4 liters per minute / 0.1 gpm 4- 16. Angle Cylinders 6- 20-06. Flushing Orifice 11 - 27-02. Equipment Valve Pressure
2- 8-05. Flow Compensator Spool Bore: 110 mm 11 - 27-03. Travel Pressure -Left-Forward
2- 8-06. Tilt Spool Rod: 55 mm Diameter FRAME 7 COMPONENTS 11 - 27-04. Travel Pressure -Left-Reverse
2- 8-07. Lift Spool Stroke: 509 mm 7- 2. Hydraulic Reservoir 11 - 27-05. Travel Pressure -Right-Forward
2- 8-08. Pre-charge Valve 4- 17. Ripper Cylinders (Optional) 7- 2-01 Screen 11 - 27-06. Travel Pressure -Right-Reverse
16 Bar / 232 psi Bore: 125 mm Cylinder 7- 21. Right-Hand Track Pump
2.- 8-09. Circuit Relief Valve with Rod: 70 mm Diameter 7- 21-01. Proportional Solenoids and Spool
Anti-cavitation Stroke: 275 mm 7- 21-02. Hydrostatic Pump
198 Bar / 2872 psi 7- 21-03. Servo Piston
7- 21-04. Main Pressure Relief
450 Bar / 6527 psi
7- 21-05. Charge Pump Pressure Relief
30 Bar / 435 psi
7- 21-06. Override Pressure Relief
Blocked
7- 21-07. Charge Pressure Pump
19.6 cc / 1.2 Cubic Inch
HYDRAULIC SYMBOLS CIRCUIT CONTINUATION NOTES

NOTE: All Pressures and Flows are at Operating RPM.
54
Frame Number and Circuit
Number where Circuit
CIRCUIT TAGS
F4-C3 C10
HYDRAULIC SCHEMATIC
continues.
CHECK VALVE FILTER OR SCREEN CIRCUIT PRESSURE
C6 F1-C3
D150B CRAWLER
20-01 FRAME - CIRCUIT CIRCUIT
SHOWS CIRCUIT SHOWS COMPONENT LOAD SENSE
COMPONENT CROSSING CIRCUIT
RESTRICTOR Circuit Number assigned to Circuit in Frame.
NUMBER NOT CONNECTED CONNECTED OIL COOLER DIRECTION OF FLOW LINE TYPES
Copyright © 2007. CNH Italia S.p.A. All Rights Reserved. BC07K690-00A

SM D150B EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM D150B EN

Uploaded by

Copyright:

Available Formats

Copyright © New Holland

Print No. 87693704 A - EU

Fuel System Tab 3

Copyright © 2007 CNH Italia S.p.A.

Power Train Tab 6

Mounted Equipment Tab 9

Copyright © 2007 CNH Italia S.p.A.

Copyright © 2007 CNH Italia S.p.A.

Section Title Section Number

Copyright © 2007 CNH Italia S.p.A.

GENERAL TORQUE SPECIFICATIONS

Copyright © 2007 CNH Italia S.p.A.

87693704 A - EU Issued 10-07 Printed in E.C.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

87693704 A - EU Issued 10-07 Printed in E.C.

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

87693704 A - EU Issued 10-07 Printed in E.C.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Split Flange Mounting Bolts

87693704 A - EU Issued 10-07 Printed in E.C.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

87693704 A - EU Issued 10-07 Printed in E.C.

FLUIDS AND LUBRICANTS

Copyright © 2007 CNH Italia S.p.A.

87693704 A - EU Issued 10-07 Printed in E.C.

CAPACITIES AND LUBRICANTS

87693704 A - EU Issued 10-07 Printed in E.C.

ENGINE OIL RECOMMENDATIONS

87693704 A - EU Issued 10-07 Printed in E.C.

Specifications for Acceptable No. 2 Diesel Fuel

87693704 A - EU Issued 10-07 Printed in E.C.

87693704 A - EU Issued 10-07 Printed in E.C.

Copyright © 2007 CNH Italia S.p.A.

87693704 A - EU Issued 10-07 Printed in E.C.

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

87693704 A - EU Issued 10-07 Printed in E.C.

Area: square foot 0.092 903 square meter

Force: ounce force 0.278 014 newton

Length: inch 25.4 * millimeter

Mass: pound 0.453 592 kilogram

Mass/Area: ton/acre 2241 702 kilogram/hectare

Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr

Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter

Power: horsepower 0.745 700 kilowatt