2011APACHESERVICEMANUALAS720AS1020AS1220

2011 APACHE
TM
AS720, AS1020 & AS1220 Series
Service Manual
FORM # 580000081
COPYRIGHT 2010
EQUIPMENT TECHNOLOGIES
CONTENTS
Chapter 1: Check Rear Differential for Leaks . . . . . . . 1-26
General Information Re-Phase Steering Cylinders . . . . . . . . . . 1-27
2011 AS720 Specifications. . . . . . . . . . . . . . . . 1-1 After First 100 Hours . . . . . . . . . . . . . . . . . . . 1-27
AS720 Consumables, Capacities, Every 100 Hours. . . . . . . . . . . . . . . . . . . . . . . 1-27
Pressures and Torque ValuesAS720 Optional Grease Driveline Components . . . . . . . . . 1-27
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Torque Axle Extension Brace Bolts. . . . . . 1-28
AS720 Optional Equipment . . . . . . . . . . . . . 1-3 Manual Adjust Axles . . . . . . . . . . . . . . . . 1-28
2011 AS1020 and AS1220 Specifications . . . . 1-5 Adjust On The Go Axles . . . . . . . . . . . . . 1-29
AS1020 Consumables, Capacities, Adjust Poly Tank Straps . . . . . . . . . . . . . . 1-29
Pressures and Torque Values . . . . . . . . . . . 1-6 Replace Fuel Primary Filter. . . . . . . . . . . . 1-30
AS1020 Optional Equipment . . . . . . . . . . . . 1-7 Replace Fuel Separator Filter . . . . . . . . . . 1-30
AS1220 Consumables, Capacities, Every 250 Hours. . . . . . . . . . . . . . . . . . . . . . . 1-31
Pressures and Torque Values . . . . . . . . . . . 1-8 Clean or Replace Engine Primary
AS1220 Optional Equipment . . . . . . . . . . . . 1-9 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
General Information . . . . . . . . . . . . . . . . . . . . 1-10 Replace Differential Fluid . . . . . . . . . . . . . 1-31
Maintenance Precautions . . . . . . . . . . . . . . . . 1-11 Replace Hydraulic Fluid Filter . . . . . . . . . . 1-32
Environmental Precautions. . . . . . . . . . . . . . . 1-12 Clean Hydraulic Fluid Strainer. . . . . . . . . . 1-32
Non-Apache Equipment Maintenance . . . . . . 1-12
Every 500 Hours or Yearly . . . . . . . . . . . . . . . 1-34
Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . 1-13
Mechanical Parts . . . . . . . . . . . . . . . . . . . . 1-13 Check Accumulator Fluid Level. . . . . . . . . 1-34
Electrical Parts. . . . . . . . . . . . . . . . . . . . . . 1-13 Replace Planetary Fluid . . . . . . . . . . . . . . 1-35
Body and Cab Exterior . . . . . . . . . . . . . . . 1-13 Replace Engine Oil and Filter . . . . . . . . . . 1-35
Apache Sprayer Service Interval Chart . . . . . 1-14 Replace Transmission Oil and Filter . . . . . 1-36
Before Initial Use . . . . . . . . . . . . . . . . . . . . . . 1-15 AS720 / ITL Transmission Only . . . . . . . 1-36
After First 10 Hours. . . . . . . . . . . . . . . . . . . . . 1-15 AS1020 and AS1220 / ZF
Adjust Boom . . . . . . . . . . . . . . . . . . . . . . . 1-15 Transmission Only . . . . . . . . . . . . . . . . . 1-38
Boom Lead . . . . . . . . . . . . . . . . . . . . . . . 1-15 Calibration Procedure . . . . . . . . . . . . . . . 1-39
Boom Breakaway . . . . . . . . . . . . . . . . . . 1-16 Recalibrate Raven Radar Gun . . . . . . . . . 1-41
Boom Stabilizer . . . . . . . . . . . . . . . . . . . . 1-16 Inspect and Repack Wheel
Boom Tip and Inter-Flex Bearings . . . . . . . . . . . . . . . 1-41
(80 ft, 90 ft, and 100 ft Booms) . . . . . . . . 1-16 Every Year . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
As Required . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Adjust Toe-In . . . . . . . . . . . . . . . . . . . . . . . 1-42
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Measure Tie Rods . . . . . . . . . . . . . . . . . 1-42
Grease Boom. . . . . . . . . . . . . . . . . . . . . . . 1-18 Measure Toe-in. . . . . . . . . . . . . . . . . . . . 1-42
Boom Stabilizer . . . . . . . . . . . . . . . . . . . . 1-18 Adjust Toe-in. . . . . . . . . . . . . . . . . . . . . . 1-42
Boom Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Replace Engine Safety Air Filter . . . . . . . . 1-42
Boom Fold. . . . . . . . . . . . . . . . . . . . . . . . 1-19 Winterize Wet System . . . . . . . . . . . . . . . . 1-43
Boom Rack . . . . . . . . . . . . . . . . . . . . . . . 1-19 Replace Cab Recirculating Air
Boom Tip. . . . . . . . . . . . . . . . . . . . . . . . . 1-19 and Charcoal Filter . . . . . . . . . . . . . . . . . . 1-45
Boom Inner Breakaway. . . . . . . . . . . . . . 1-19 Check Front Suspension
Boom Outer Breakaway (if equipped). . . 1-19 Accumulator Charge . . . . . . . . . . . . . . . . . 1-46
Flush Wet System . . . . . . . . . . . . . . . . . . . 1-20 Replace Drop Box Fluid . . . . . . . . . . . . . . 1-46
Check Tire Pressure . . . . . . . . . . . . . . . . . 1-20 Every 1000 Hours or Yearly . . . . . . . . . . . . . . 1-47
Check Engine Oil Level . . . . . . . . . . . . . . . 1-20 Inspect Front Accumulator . . . . . . . . . . . . 1-47
Check Cooling System . . . . . . . . . . . . . . . 1-21 Clean Transmission Oil Strainer
Check Transmission Oil Level . . . . . . . . . . 1-22 (AS720/ITL Transmission Only) . . . . . . . . 1-47
AS720 / ITL Transmission Only . . . . . . . 1-22 Replace Hydraulic Fluid . . . . . . . . . . . . . . 1-47
AS1020 and AS1220 / ZF Engine Views . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Transmission Only . . . . . . . . . . . . . . . . . 1-22 Cooling Package . . . . . . . . . . . . . . . . . . . . . . 1-58
Check Hydraulic Fluid Level . . . . . . . . . . . 1-23 Diagnostic Connection . . . . . . . . . . . . . . . . . . 1-58
Every 40 Hours . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Engine Wiring Harness Cummins. . . . . . . . . . 1-59
Torque Lug Nuts . . . . . . . . . . . . . . . . . . . . 1-24
Grease Rear Suspension . . . . . . . . . . . . . 1-24
Grease Steering Components . . . . . . . . . . 1-25
Grease Axle Components . . . . . . . . . . . . . 1-25
Torque Boom Lead Bolts. . . . . . . . . . . . . . 1-26
Check Differential Fluid Level . . . . . . . . . . 1-26
i
CONTENTS
Chapter 2: Individual Clutch Leakage Test . . . . . . . . 2-38
Transmission Fault Finding. . . . . . . . . . . . . . . . . . . . . . . . 2-40
2011 AS720 Apache with Introduction . . . . . . . . . . . . . . . . . . . . . . . 2-40
ITL Transmission . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Coil Combinations . . . . . . . . . . . . . . . . . . . . 2-1 ITL Transmission Symptoms and Solutions2-43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2-2 Chart A. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Operation and Troubleshooting for Chart B. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
PS764 Transmissions Used in the AS720. . . . . 2-2 Chart E. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
AS720 Transmission Pressure and Chart F . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Flow Checks . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Chart G . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Pump Flow Test . . . . . . . . . . . . . . . . . . . . . 2-2 2011 AS1020 and AS1220 Apache
Converter Relief (Safety) Valve with ZF Transmission . . . . . . . . . . . . . . . . . . . 2-49
Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Clutch Combinations . . . . . . . . . . . . . . . . . 2-49
Converter Out Pressure / Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-50
Oil Cooler Flow Rate . . . . . . . . . . . . . . . . . 2-3 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 2-50
Lubrication Pressure . . . . . . . . . . . . . . . . . 2-3 Important Instructions. . . . . . . . . . . . . . . . . 2-51
Converter In Pressure . . . . . . . . . . . . . . . . 2-4 ZF Electronics Protection. . . . . . . . . . . . . 2-51
Mainline Pressure . . . . . . . . . . . . . . . . . . . 2-4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
PS764 Transmission Capacities. . . . . . . . . . 2-5 Driving Preparation and Maintenance . . . . 2-52
Transmission Oil Fill Procedure . . . . . . . . . . 2-5 Driving and Shifting . . . . . . . . . . . . . . . . . . 2-52
ITL Dipstick Details . . . . . . . . . . . . . . . . . . . . 2-5 Neutral Position . . . . . . . . . . . . . . . . . . . . 2-52
Service Schedules . . . . . . . . . . . . . . . . . . . . 2-5 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Technical Data . . . . . . . . . . . . . . . . . . . . . . . 2-7 Upshifting Under Load . . . . . . . . . . . . . . . 2-52
Powershift Gearbox - 4 Speed. . . . . . . . . . 2-7 Downshifting Under Load . . . . . . . . . . . . 2-52
Towing Procedure . . . . . . . . . . . . . . . . . . . . 2-9 Upshifting in Coasting Condition . . . . . . . 2-52
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Downshifting in Coasting Condition . . . . . 2-52
PS764 Transmission . . . . . . . . . . . . . . . . 2-10 Reversing. . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Component Identification . . . . . . . . . . . . . 2-11 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Principle of Operation . . . . . . . . . . . . . . . 2-11 Stopping and Parking . . . . . . . . . . . . . . . . . 2-53
Hydraulic and Electrical Operation. . . . . . 2-12 Towing Procedure . . . . . . . . . . . . . . . . . . . 2-53
Powershift Gearbox . . . . . . . . . . . . . . . . . . 2-15 Oil Temperature . . . . . . . . . . . . . . . . . . . . . 2-53
Drivepaths - 4 Speed . . . . . . . . . . . . . . . . 2-15 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Clutch Operation . . . . . . . . . . . . . . . . . . . 2-19 Oil Level Check . . . . . . . . . . . . . . . . . . . . . 2-54
Propshafts. . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Changing the Oil and Filter. . . . . . . . . . . . . 2-55
Removal and Replacement . . . . . . . . . . . 2-21 Calibration Procedure . . . . . . . . . . . . . . . . . . . 2-56
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-22 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Removal and Replacement . . . . . . . . . . . 2-22 Torque Converter. . . . . . . . . . . . . . . . . . . 2-58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Powershift transmission. . . . . . . . . . . . . . 2-58
Replacement . . . . . . . . . . . . . . . . . . . . . . 2-24 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Torque Converter . . . . . . . . . . . . . . . . . . . . 2-25 Power Take-Off . . . . . . . . . . . . . . . . . . . . 2-58
Removal and Replacement . . . . . . . . . . . 2-25 Transmission Accessories . . . . . . . . . . . . 2-58
Torque Converter Stall Test . . . . . . . . . . . . 2-26 ZF Identification Plate. . . . . . . . . . . . . . . . . 2-58
Pressure and Flow Testing. . . . . . . . . . . . . 2-28 Function of Converter. . . . . . . . . . . . . . . . . 2-59
Test Points: . . . . . . . . . . . . . . . . . . . . . . . 2-29 WK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Clutches: . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Powershift Transmission . . . . . . . . . . . . . . 2-61
Other Items: . . . . . . . . . . . . . . . . . . . . . . . 2-29 Transmission Control . . . . . . . . . . . . . . . . . 2-61
Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Transmission Control Unit TCU . . . . . . . . . 2-63
Mainline Pressure . . . . . . . . . . . . . . . . . . 2-32 Installation Position of the TCU . . . . . . . . 2-63
Converter In Pressure . . . . . . . . . . . . . . . 2-32 Installation Dimensions of the TCU . . . . . 2-63
Converter Relief (Safety) Electronic Control for ZF-Powershift Transmis-
Valve Pressure. . . . . . . . . . . . . . . . . . . . . 2-34 sions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Converter Out Pressure/Oil Cooler Automatic Calibration of the Shifting Elements
Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 (AEB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Lubrication Pressure . . . . . . . . . . . . . . . . 2-34
Pressure Testing - Clutches. . . . . . . . . . . 2-36
ii
CONTENTS
ZF 6 WG-191 Transmission . . . . . . . . . . . . . . 2-65 Chapter 4:
Table 1: Layout View . . . . . . . . . . . . . . . . . 2-65 Wet System Operation
Transmission Diagram/Gearbox Diagram 2-65 Wet System Overview . . . . . . . . . . . . . . . . . . . 4-1
Table 2: Installation View (Front). . . . . . . . 2-66 Fill Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Table 3: Installation View (Rear) . . . . . . . . 2-66 Product Pump and Valves . . . . . . . . . . . . . . . . 4-2
Table 4: Schedule of Measuring Points and Hypro 9306S HM1C . . . . . . . . . . . . . . . . . . . . . 4-3
Connections. . . . . . . . . . . . . . . . . . . . . . . . 2-67 Sump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Table 5: Gearbox Diagram . . . . . . . . . . . . 2-68 Foam Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 5: Oil Circuit Diagram with WK Forward Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
1st Speed. . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 Standard Flow . . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 6: Gearbox Diagram WG191 . . . . . . 2-71 Electronic Boom Valves . . . . . . . . . . . . . . . 4-5
Table 7: Electro-hydraulic Shift Control with Pro- Raven Envizio Pro Monitor . . . . . . . . . . . . . . . . 4-5
portional Valve . . . . . . . . . . . . . . . . . . . . . . 2-72 Side Console . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Spare Parts Orders . . . . . . . . . . . . . . . . . . 2-73 T-Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Data Sheet for WG-191 . . . . . . . . . . . . . . . . . 2-74 Filling Product Tank . . . . . . . . . . . . . . . . . . . . 4-11
Fault Code Information for WG-191 . . . . . . . . 2-75 Filling Rinse Tank . . . . . . . . . . . . . . . . . . . . . . 4-11
Operating Modes . . . . . . . . . . . . . . . . . . . . 2-75 Operating Booms . . . . . . . . . . . . . . . . . . . . . . 4-13
Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 Tilt to Remove Boom from Cradle . . . . . . . 4-13
Substitute Clutch Control . . . . . . . . . . . . 2-75 All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-13
Limp Home . . . . . . . . . . . . . . . . . . . . . . . 2-75 Unfold Booms . . . . . . . . . . . . . . . . . . . . . . 4-13
Transmission Shutdown . . . . . . . . . . . . . 2-75 Unfold Boom Tips . . . . . . . . . . . . . . . . . . . 4-13
TCU Shutdown . . . . . . . . . . . . . . . . . . . . 2-75 All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-13
Fault Code Tables . . . . . . . . . . . . . . . . . . . 2-76 Height Adjustment . . . . . . . . . . . . . . . . . . . 4-14
All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-14
Chapter 3: Tilt to Level Boom . . . . . . . . . . . . . . . . . . . 4-14
Brakes and Differential All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-14
Brakes and Differential . . . . . . . . . . . . . . . . . . . 3-1 Fold Boom Tips . . . . . . . . . . . . . . . . . . . . . 4-14
Rear Differential. . . . . . . . . . . . . . . . . . . . . . 3-2 All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-14
Master Brake Cylinder . . . . . . . . . . . . . . . . . 3-2 Fold Booms . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Brake Accumulator . . . . . . . . . . . . . . . . . . . 3-3 All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-15
Brakes and Bleeding. . . . . . . . . . . . . . . . . . . . . 3-3 Tilt to Return Boom to Cradle . . . . . . . . . . 4-15
General Information . . . . . . . . . . . . . . . . . . . 3-3 All Boom Sizes . . . . . . . . . . . . . . . . . . . . 4-15
Rear Axle Bleeders and Hoses . . . . . . . . . . 3-3 Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Brake Packs. . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operating Foam Marker . . . . . . . . . . . . . . . . . 4-18
Service Brakes - PD70 Axle Auto Foam . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Central Drivehead (Inboard Brakes) . . . . . . 3-5 LandMark Injection Foam Marker . . . . . . . 4-18
Technical Data . . . . . . . . . . . . . . . . . . . . . 3-6 Injection Marker Operation Instructions . 4-19
Standard Retraction Maintenance . . . . . . . . . . . . . . . . . . . . . . 4-19
Disassembly and Assembly . . . . . . . . . . . 3-6 Freezing . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Brake Piston Seal Leakage Test. . . . . . . . 3-8 Flushing Product Tank . . . . . . . . . . . . . . . . . . 4-21
Axle Breather . . . . . . . . . . . . . . . . . . . . . . 3-9 Flushing Booms . . . . . . . . . . . . . . . . . . . . . . . 4-21
Renewing the Pinion Oil Seal . . . . . . . . . 3-10 Cleanload Chemical Eductor . . . . . . . . . . . . . 4-22
Disassemble the Drive Head . . . . . . . . . 3-11 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Assemble Drivehead. . . . . . . . . . . . . . . . 3-12 Loading Liquid or Powdered Chemical into Hop-
Limited Slip Differential (optional) . . . . . . 3-20 per . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Disassembly . . . . . . . . . . . . . . . . . . . . . . 3-21 Loading Liquid and/or Powdered Chemical with
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Suction Lance . . . . . . . . . . . . . . . . . . . . . . 4-23
Friction Plate Wear Limits . . . . . . . . . . . . 3-21 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Differential Axle Shaft Removal . . . . . . . 3-21 Teejet Boom Valves . . . . . . . . . . . . . . . . . . . . 4-24
AS1020 and AS1220 Boom Valve Wiring . . . . . . . . . . . . . . . . . . 4-24
Parking Brake Assembly. . . . . . . . . . . . . . . . . 3-23 Boom Valve Troubleshooting Charts . . . 4-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Agitation Valve . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Agitate Valve Wiring . . . . . . . . . . . . . . . . . 4-35
Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-25 Boom Block . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Troubleshooting. . . . . . . . . . . . . . . . . . . . . 4-36
Boom Block Wiring . . . . . . . . . . . . . . . . . . 4-37
iii
CONTENTS
Flowmeter and Servo Valve. . . . . . . . . . . . . . . 4-40 Axle Adjustment (Optional)
Servo Valve Wiring . . . . . . . . . . . . . . . . . 4-40 (Adjust On The Go,
Flowmeter Wiring . . . . . . . . . . . . . . . . . . . 4-40 AS1020 and AS1220 Only) . . . . . . . . . . . . . . . 5-23
Flowmeter Paper Clip Test . . . . . . . . . . . 4-40 To adjust the axles: . . . . . . . . . . . . . . . . . 5-23
Flowmeter Troubleshooting Chart . . . . . . 4-41 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Servo Valve Troubleshooting Chart . . . . . 4-41 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Radar Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Hydraulic Adjust-On-the-Go
Smucker Injection Foam Marker . . . . . . . . . . . 4-42 Troubleshooting Charts . . . . . . . . . . . . . . 5-25
Autosteer Installation . . . . . . . . . . . . . . . . . . . . 5-33
Chapter 5: Hydraulics Troubleshooting . . . . . . . . . . . . . . . 5-34
Hydraulic System Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . 5-35
Hydraulic Circuit Operation . . . . . . . . . . . . . . . . 5-1
Hydraulic Components . . . . . . . . . . . . . . . . . 5-2 Chapter 6:
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Electrical System
Hydraulic Dump Valve Operation . . . . . . . . . . . 5-3 2011 Apache Electrical System. . . . . . . . . . . . . 6-1
Compensator Adjustments . . . . . . . . . . . . . . . . 5-3 Electrical System (AS720, AS1020 and
Junction Block . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 AS1220). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Front View. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Harness Layout . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuse Block Schematics . . . . . . . . . . . . . . . . . . 6-17
Steering Cylinder Plumbing Fuse Block Diagram . . . . . . . . . . . . . . . . . . . . 6-18
for Adjustable Axles Only. . . . . . . . . . . . . . . . . . 5-4 Fuse Box Right Rear Cab Corner . . . . . . . 6-19
How system works . . . . . . . . . . . . . . . . . . . . 5-4 Circuit Numbers. . . . . . . . . . . . . . . . . . . . . . . . 6-21
Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . 6-27
How to rephase steering. . . . . . . . . . . . . . . . 5-4
CAN Connector Pinouts. . . . . . . . . . . . . . 6-27
If there is no steering . . . . . . . . . . . . . . . . . . 5-4
102-Pin Floor Connector Pinouts. . . . . . . 6-27
If wheels are toeing out while driving . . . . . . 5-4
Console Connector
If wheels are toeing in while driving . . . . . . . 5-5
on Bottom of Console . . . . . . . . . . . . . . . 6-28
If wheels are totally out of phase or
Deutsch Round
pointing in different directions. . . . . . . . . . . . 5-5
Connector Pin Positions . . . . . . . . . . . . . 6-29
Re-Phasing Steering . . . . . . . . . . . . . . . . . . 5-5
Deutsch Pin Insertion
Steering Cylinder Plumbing Instructions. . . . 5-6
and Removal Instructions . . . . . . . . . . . . 6-30
Steering Cylinder Bleeding Instructions . . . . 5-6
Adjusting the Console . . . . . . . . . . . . . . . . 6-31
Boom Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Autoboom . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Removing the Console . . . . . . . . . . . . . . . . 6-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5-9 Disconnecting the Circuit Board . . . . . . . . . 6-31
Suspension Block . . . . . . . . . . . . . . . . . . . . . . 5-12 Apache Sprayer Console. . . . . . . . . . . . . . . . . 6-32
Front View. . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Bottom View . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Console Front. . . . . . . . . . . . . . . . . . . . . . . 6-33
Rack Lift Manifold . . . . . . . . . . . . . . . . . . . . 5-13 Console Back . . . . . . . . . . . . . . . . . . . . . . . 6-33
Rear Suspension . . . . . . . . . . . . . . . . . . . . 5-13 Console Wiring: AS720 . . . . . . . . . . . . . . . 6-34
Front Strut Repair . . . . . . . . . . . . . . . . . . . . . . 5-14 Console Wiring: AS1020 and AS1220 . . . . 6-35
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Inside Console Wiring . . . . . . . . . . . . . . . . 6-36
Removal of Strut Assembly . . . . . . . . . . . . 5-15 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Checking the Pre-charge Pressure . . . . . . 5-15 Console Software Updates. . . . . . . . . . . . . 6-36
Recharging the Accumulator . . . . . . . . . . . 5-16 Membrane Switch Panel Wiring . . . . . . . . . 6-38
Checking/Filling Oil Level . . . . . . . . . . . . . . 5-16 Part Numbers for Console Parts . . . . . . . . 6-39
Using Test Kit 980000419 . . . . . . . . . . . . 5-18 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Cylinder Seal Replacement Procedure . . . 5-18 Cab Nodes . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . 5-19 T-Handle and Raven Envisio Pro Console . . . 6-42
Installing New Rear Suspension Vehicle Direction and Speed . . . . . . . . . . . . . . 6-43
Cylinder Seals . . . . . . . . . . . . . . . . . . . . . . 5-20 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Hydraulic Suppressor . . . . . . . . . . . . . . . . . . . 5-22 To move the Apache Sprayer forward: . . 6-43
Hydraulic Power Brakes . . . . . . . . . . . . . . . . . 5-22 Shifting Gears. . . . . . . . . . . . . . . . . . . . . . . 6-43
Master Cylinder Connections . . . . . . . . . . . 5-22 Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
To move the Apache Sprayer in reverse: 6-45
iv
CONTENTS
Cruise Control . . . . . . . . . . . . . . . . . . . . . . 6-45 AM/FM Radio with
T-Handle . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Weather Band and CD Player . . . . . . . . . . . 6-126
T-Handle Wiring. . . . . . . . . . . . . . . . . . . . . 6-46 Upper Cab Wiring . . . . . . . . . . . . . . . . . . 6-127
Forward Switch . . . . . . . . . . . . . . . . . . . . . 6-47 Apache Sprayer Lighting . . . . . . . . . . . . . . . 6-128
Reverse Switch . . . . . . . . . . . . . . . . . . . . . 6-49 Cab Top Wiring . . . . . . . . . . . . . . . . . . . . 6-129
Throttle Increase . . . . . . . . . . . . . . . . . . . . 6-50 Steering Column. . . . . . . . . . . . . . . . . . . . . . 6-130
Throttle Decrease . . . . . . . . . . . . . . . . . . . 6-54 Climate Control . . . . . . . . . . . . . . . . . . . . 6-130
Transmission Up Shift Switch . . . . . . . . . . 6-57 Steering Column Wiring . . . . . . . . . . . . . 6-131
Transmission Down Shift Switch . . . . . . . . 6-59 All Models General Cab Information. . . . . . . 6-132
Right Tilt Up Switch . . . . . . . . . . . . . . . . . . 6-61 Fault Code Indicator: . . . . . . . . . . . . . . . . 6-132
Right Tilt Down Switch. . . . . . . . . . . . . . . . 6-64 Headliner . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
Left Tilt Up Switch . . . . . . . . . . . . . . . . . . . 6-67 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
Left Tilt Down Switch . . . . . . . . . . . . . . . . . 6-70 Steering Column . . . . . . . . . . . . . . . . . . . 6-133
Boom Rack Up Switch. . . . . . . . . . . . . . . . 6-73 Removal and Service . . . . . . . . . . . . . . 6-133
Boom Rack Down Switch . . . . . . . . . . . . . 6-76 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 6-134
Master Spray Switch . . . . . . . . . . . . . . . . . 6-79
Cruise Control Switch . . . . . . . . . . . . . . . . 6-81 Chapter 7:
Engine Information . . . . . . . . . . . . . . . . . . 6-86
HVAC
Foam Master Switch . . . . . . . . . . . . . . . . . 6-89
HVAC Troubleshooting. . . . . . . . . . . . . . . . . . . 7-1
Left Boom In Switch. . . . . . . . . . . . . . . . . . 6-93 HVAC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Left Boom Out Switch . . . . . . . . . . . . . . . . 6-96 HVAC Wiring . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Left Tip In Switch . . . . . . . . . . . . . . . . . . . . 6-99 Air Compressor . . . . . . . . . . . . . . . . . . . . . . 7-4
Left Tip Out Switch . . . . . . . . . . . . . . . . . 6-102 Air Conditioning Compressor Wiring . . . . . . 7-5
Park Brake Switch . . . . . . . . . . . . . . . . . . 6-105 Basic Troubleshooting for HVAC System. . . . . 7-6
Product Pump Switch . . . . . . . . . . . . . . . 6-109
Right Boom In Switch . . . . . . . . . . . . . . . 6-112
Right Boom Out Switch . . . . . . . . . . . . . . 6-115 Chapter 8:
Right Tip In Switch. . . . . . . . . . . . . . . . . . 6-118 Warranty
Right Tip Out Switch . . . . . . . . . . . . . . . . 6-121 Equipment Technologies Warranty Policy
Agitation Valve Switch . . . . . . . . . . . . . . . 6-124 For all 2011 Model Year . . . . . . . . . . . . . . . . . . 8-1
Light Switches . . . . . . . . . . . . . . . . . . . . . 6-126
v
APACHE 2011 SPECIFICATIONS
Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2400 psi (165 bar) (all models)
A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 lbs (1.47 kg) R134A (all models)
Hypro Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 psi (8.2 bar) dead head (all models)
Raven 1-1/2 in. flow meter (standard) . . . . . . . . . . 60 GPM (227 L/min)
Raven valve cal # . . . . . . . . . . . . . . . . . . . . . . . . . 2123
Raven speed cal# w/ radar gun (approximate) . . . 565
Raven GPS speed cal# . . . . . . . . . . . . . . . . . . . . . 785
Meter cal # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See tag on flow meter
AS720 Front Suspension Accumulators . . . . . . . . 800 psi (55.1 bar)
AS1020 Front Suspension Accumulators . . . . . . . 900 psi (65.5 bar)
AS1220 Front Suspension Accumulators . . . . . . . 900 psi (65.5 bar)
AS720 and AS1020 Rear Suspension Accumulators
Large Accumulators . . . . . . . . . . . . . . . . . . . . . 450 psi (31 bar)
Small Accumulators . . . . . . . . . . . . . . . . . . . . . 400 psi (27.5 bar)
AS1220 Rear Suspension Accumulators
Large Accumulators . . . . . . . . . . . . . . . . . . . . . 500 psi (34.4 bar)
Small Accumulators . . . . . . . . . . . . . . . . . . . . . 450 psi (31 bar)
Boom Wing Accumulators . . . . . . . . . . . . . . . . . . . 200 psi (13.7 bar) (all models)
Boom Center Rack Accumulator . . . . . . . . . . . . . . 200 psi (13.7 bar) (all models)
vii
About this Manual
The graphics and text in this manual generally describe 2011 Model Year Apache Sprayers. Apache Sprayers differ
by model and by optionally installed equipment. Your Apache Sprayer may not exactly match the graphics and/or
text descriptions in this manual. Please contact Equipment Technologies with any questions regarding this manual
or the instructions within.
This manual contains information on:

• General maintenance
• Drive train
• Wet system
• Hydraulic system
• Electrical system
• HVAC system
• Warranty
If you require detailed information on any of the following components please refer to the individual manuals for
these products:
• All Raven components
• Cummins Engines
• ZF Transmission
viii
TORQUE VALUE CHARTS
Fittings
Always tighten fittings to the values below unless a different torque value is specified.
Make sure fitting threads are clean and threads are engaged properly.
All torque values are adopted from SAE J514 and SAE J1453.
Size Chart
SAE SAE (JIC) O-ring Style

Dash 37° Flare Thread Straight Thread Face Seal
Size Size Size Size
2 5/16-24 5/16-24 ----
3 3/8-24 3/8-24 ----
4 7/16-20 7/16-20 9/16-18
5 1/2-20 1/2-20 ----
6 9/16-18 9/16-18 11/16-16
8 3/4-16 3/4-16 13/16-16
10 7/8-14 7/8-14 1-14
12 1 1/16-12 1 1/16-12 1 3/16-12
14 1 3/16-12 1 3/16-12 ----
16 1 5/16-12 1 5/16-12 1 7/16-12
20 1 5/8-12 1 5/8-12 1 11/16-12
24 1 7/8-12 1 7/8-12 2-12
32 2 1/2-12 2 1/2-12 ----
Torque Value Chart

SAE TORQUE
Dash SAE 37° Flare O-ring Straight Thread Face Seal
Size lb-ft N•m lb-ft N•m lb-ft N•m
2 4 5 4 5 ---- ----
3 8 11 9 12 ---- ----
4 12 16 16 22 18 25
5 15 20 22 30 --- ---
6 18 25 35 48 27 37
8 37 50 60 82 40 54
10 48 65 105 143 63 86
12 74 100 140 190 92 125
14 88 120 184 250 ---- ----
16 100 135 221 300 122 165
20 133 180 258 350 147 200
24 166 225 317 430 166 225
32 236 320 ---- ---- ---- ----
xi
TORQUE VALUE CHARTS
Bolts
Always tighten fittings to the values below unless a different torque value is specified. Fasteners must always be
replaced with the same grade. Make sure fitting threads are clean and threads are engaged properly. All torque
values are adopted from SAE J1701 and SAE J1701M.
SAE Series Torque Value Chart
SAE Grade 2 SAE Grade 5 SAE Grade 8

A = Bolt Diameter
(No Markings) (3 Radial Dashes) (6 Radial Dashes)
A GRADE
Wrench
Diameter
Size
SAE 2 SAE 5 SAE 8
(Inches)
lb-ft N•m lb-ft N•m lb-ft N•m
1/4” 7/16” 6 8 10 13 14 18
5/16” 1/2” 12 17 19 26 27 37
3/8” 9/16” 23 31 35 47 49 67
7/16” 5/8” 36 48 55 75 78 106
1/2” 3/4” 55 75 85 115 120 163
9/16” 13/16” 78 106 121 164 171 232
5/8” 15/16” 110 149 170 230 240 325
3/4” 1 1/8” 192 261 297 403 420 569
7/8” 1 5/16” 306 416 474 642 669 907
1” 1 1/2” 467 634 722 979 1020 1383
Metric Series Torque Value Chart
Metric Grade Metric Grade Metric Grade Metric Grade

8.8 10.9 8.8 10.9
Course Thread Fine Thread
Diameter and Wrench Diameter and
Thread Pitch Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9 Thread Pitch
Size
(Millimeters) N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft (Millimeters)
6 x 1.0 10 8 6 11 8 8 6 11 8 6 x 1.0
8 x 1.25 13 20 15 27 20 21 16 29 22 8 x 1.0
10 x 1.5 16 39 29 54 40 41 30 57 42 10 x 1.25
12 x 1.75 18 68 50 94 70 75 55 103 76 12 x 1.25
14 x 2.0 21 109 80 151 111 118 87 163 120 14 x 1.5
16 x 2.0 24 169 125 234 173 181 133 250 184 16 x 1.5
18 x 2.5 27 234 172 323 239 263 194 363 268 18 x 1.5
20 x 2.5 30 330 244 457 337 367 270 507 374 20 x 1.5
22 x 2.5 34 451 332 623 460 495 365 684 505 22 x 1.5
24 x 3.0 36 571 421 790 583 623 459 861 635 24 x 2.0
30 x 3.0 46 1175 867 1626 1199 1258 928 1740 1283 30 x 2.0
xii
Chapter 1
General Information
AS720, AS1020 & AS1220
NOTES
2011 AS720 Specifications

Tank Capacity.............................750 gallons [2839 liters]
Engine ........................................160 hp [119.3 kW] Tier III Cummins
Transmission ..............................ITL/JCB Power shift 4-speed, torque converted
Speed Ranges............................1st 0-5 mph [0-8.04 km/h], 2nd 0-9 mph [0-14.5 km/h],
3rd 0-16 mph [0-25.7 km/h], 4th 0-28 mph [0-45 km/h]
Brakes ........................................Internal, wet disc self adjusting
Suspension.................................Front axle: Center oscillation with independent hydraulic accumulation Rear axle:
Patented hydraulic load suspension with compensating anti-sway control, self-
adjusting for diminishing/increasing load
Cab .............................................ET custom pressurized cab
Crop Clearance ..........................42 in. [106.6 cm] or 50 in. [127 cm]
Axles...........................................120 to 160 in. [304.8 to 406.4 cm], 120 in. [304.8 cm] fixed
Final Drive ..................................ITL/JCB planetary gear set
Weight ........................................17,400 lb [7892.5 kg] dry weight
Fuel Capacity .............................100 gallons [379 liters]
Width ..........................................12 ft [3.6 m]
Length ........................................24 ft [7.3 m]
Height .........................................143 in. [365.7 cm]
Wheel Base ................................15 ft [4.6 m]
Turning Radius ...........................17 ft [5.1 m]
Tires............................................380/80R38 front, 380/90R46 rear, or optional 320/90R50
Booms ........................................80 ft [24.3 m], 90 ft [27.4 m], 100 ft [30.4 m], 60 / 80 ft [18.2 / 24.3 m],
60 / 90 ft [18.2 / 27.4 m]
Boom Height...............................42 in. [106.6 cm] CC: 14 to 74 in. [35.5 to 187.9 cm]
50 in. [127 cm] CC: 22 to 82 in. [55.9 to 208.3 cm]
Product Pump.............................Hypro 9306S HM1C, hydraulically driven centrifugal pump
Roto-Flush..................................Pump pressured
1-1
AS720 Consumables, Capacities,
Pressures and Torque ValuesAS720 Optional Equipment
Capacity
Component Lubrication Filter Part Number
Quarts [Liters]
Engine Oil Lucas 15W-40 Magnum Motor Oil 16 [15] 201450241
KostGuard Universal
Engine Coolant 24 [22.7] ----
Antifreeze 50/50
Engine Primary Air Filter ---- ---- 201300116
Engine Safety Air Filter ---- ---- 201300117
Transmission* Lucas Universal Hydraulic Fluid 16 [15] 300000101
Differential (Rear Axle) Lucas Universal Hydraulic Fluid 11.9 [11.26] ----
Planetary Lucas 80/90 Gear Oil 2.2 [2] ----
Rear Drop Box Lucas 80/90 Gear Oil 21 [20] ----
100 Gallons Filter: 201450242
Engine Fuel Diesel
[379 Liters] Separator: 201450243
Filter: 880000026
Strainer: 840000010
40 Gallons
Hydraulic System Lucas Universal Hydraulic Fluid Hydraulic Filter Kit: K65000209
[151.42 Liters]
Hydraulic Filter Kit with Oil:
K65000210
Front Suspension Lucas Universal Hydraulic Fluid as required ----
A/C System R134a 3.25 lbs ----
Cab Filter Kit: K65000190
Charcoal Filter: 490003651*
Cab Filters ---- ----
Recirculating Filter:
490006661*
* - Included in kit K65000190
NOTE: Any oil and fluid substitutions must meet or exceed recommended fluid specifications.
Tire Pressure (Cold)

320/85 R38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41psi [2.82 bar]
380/80R38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 psi [2.41 bar]
380/90R46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 psi [3.37 bar]
480/70R34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 psi [1.58 bar]
520/85R46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 psi [1.86 bar]
Lug Nut Torque
All Front 38 in. tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 lb-ft [570 N•m]
All Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 lb-ft [570 N•m]
Wet System Capacities
Product Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 gallons [2839 Liters]
Rinse Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 gallons [379 Liters]
Hydraulic Pump Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 psi [165 bar]
1-2
AS720 Optional Equipment
The following chart lists optional kits available for the AS720 Apache Sprayer. The kits include all parts, brackets
and mounting hardware needed for installation.
Part
Description
Number
Rear semi-float tires and rims for

K65000079
42 in. CC AS720, tire size 520/85R46
Rear semi-float tires and rims for
K65000081
50 in. CC AS720, tire size 520/85R46
Front semi-float tires and rims for HD
K65000080
front axles, tire size 480/70R34
Dual rear tire kit, rims, tires, spacers,
K65000106 nuts and studs, for 50 in. CC, tire size
380/90R46
Hypro chemical educator. Mounts near
K65000196
the fill station on left side.
Envizio Pro console. Also order mount-
611000104
ing hardware, cabling and antenna kit.
Viper Pro console. Also order mounting
740000104
hardware, cabling and antenna kit.
K65000193 PowerGlide Plus auto boom kit
K65000194 UltraGlide auto boom kit
K65000195 UltraGlide w/ wheel kit auto boom
K65000199 Antenna kit with Phoenix 200
K65000200 Antenna kit with Phoenix 300
Autosteer kit with Raven SmarTrax.
K65000192
Also order antenna kit.
Accuboom kit. Must have Envizio Pro or
K65000155
Viper Pro and antenna kit
K65000201 Hydraulic Adjust On the Go 2011
K65000202 Fender kit: front tires 42 and 50 in. CC
K65000203 Fender kit: rear axle 42 in. CC only
K65000204 Fender kit: rear axle 50 in. CC
1-3
NOTES
2011 AS1020 and AS1220 Specifications

AS1020 AS1220
Tank Capacity 1000 gallons [3785.4 liters] 1200 gallons [4542.4 liters]
Engine 173 Cummins Tier III 215 Cummins Tier III
Transmission Standard: ZF Powershift 6-speed
with lock-up torque converter
Speeds 1st 0 to 5 mph [8.04 km/h]
2nd 0 to 7 mph [11.27 km/h]
3rd 0 to 11 mph [17.7 km/h]
4th 0 to 17 mph [27.36 km/h]
5th 0 to 27 mph [43.45 km/h]
6th 0 to 35 mph [56.3 km/h]
Brakes Internal, wet disc self-adjusting
Suspension Front Axle: Center oscillation with independent hydraulic accumulation.
Rear Axle: Patented hydraulic load suspension with compensating anti-sway
control, self-adjusting for diminishing/increasing load.
Crop Clearance 42 in. [106.6] or 50 in. [127 cm] 50 in. [127 cm]
Axles 120 in. [304.8 cm] Fixed Width Axle (Standard)
120 to 160 in. [304.8 to 406.4 cm] Adjustable Axle Width

with Optional Hydraulic Adjust
Final Drive ITL/JCB planetary gearset
(42 in. [106.6 cm] CC); Fairfield all gear drop box
Fairfield all gear drop box (50 in. [127 cm] CC)
(50 in. [127 cm] CC)
Cab ET custom pressurized cab
Weight 18,500 lbs [8391.4 kg] dry weight 20,900 lbs [9480.1 kg] dry weight
Width 12 ft [3.65 m]
Height 143 in. [3.63 m]
Length 24 ft. [7.3 m]
Booms 80 ft [24.3 m], 90 ft [27.4 m], 100 ft [30.4 m], 60/80 ft [18.2/24.3 m], 60/90 ft [18.2/27.4 m]
Boom Height 14 to 74 in. [35.5 to 187.9 cm]
(42 in. [106.6 cm] CC); 22 to 82 in. [55.9 to 208.3 cm]
22 to 82 in. [55.9 to 208.3 cm] (50 in. [127 cm] CC)
(50 in. [127 cm] CC)
Wheel Base 15 ft [4.6 m]
Tires Standard Front: 380/80R38
Standard Rear: 380/90R46
Turning Radius 17 ft [5.1 m]
Fuel Capacity 100 gallons [378.5 liters]
Product Pump Hypro 9306S HM1C, hydraulically driven centrifugal pump
1-5
Pressures and Torque Values
Capacity
Quarts [Liters]
KostGuard Universal
Antifreeze 50/50
Transmission Lucas 15W-40 Magnum Motor Oil 27 [25.5] 300000101
Engine Fuel Diesel
Filter: 880000026
Strainer: 840000010
40 Gallons
[151.2 Liters]
K65000210
Cab Filters ---- ---- Charcoal Filter: 490003651*
Recirculating Filter: 490006661*

320/85 R38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41psi [2.82 bar]
380/80R38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 psi [2.41 bar]
380/90R46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 psi [3.37 bar]
480/70R34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 psi [1.58 bar]
520/85R46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 psi [1.86 bar]
Lug Nut Torque
All Front 38 in. tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 lb-ft [570 N•m]
All Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 lb-ft [570 N•m]
Product Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 gallons [3785 Liters]
Hydraulic Pump Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2400 psi [168.9 bar]
1-6
Please contact your Apache dealer or
www.etsprayers.com
for more information on optional equipment.
• 50 in. crop clearance
• 120 to 160 in. [304.8 to 406.4 cm] manual adjust axles
• Hydraulic on the go wheel adjust (only available on 120 to 160 in. [304.8 to 406.4 cm] axles)
• Raven 5000 Rate controller, radar speed pickup
• Raven Envisio Pro Controller (must choose GPS receiver)
• Raven 3D CAN SmarTrax Autosteer**
• Raven GPS receivers 200 and 300
• Raven Autoboom PowerGlide Plus (wheel gauged)
• Raven Autoboom UltraGlide (optical eye)
• Raven Viper Pro Controller (must choose GPS receiver)
• Raven AccuBoom (automatic boom shut off)**
• Smucker Injection Foam Marker
• Fence row nozzles one side or both
• Hypro chemical eductor
• 5-way nozzle bodies
• Front fenders
• Rear fenders
• Narrow front ties 320/85R38
• Narrow rear tires 320/90R50
• Dual rear tires and spacers either 380/90R46 or 320/90R50 (50 in. [127 cm] CC only)
• Product tank fill 3 in. [76.2 mm] (see wet system for more options on product side)
• Wide tires front, either 480/70R34 or 23.1 x 26 in. R-3 TORC TRAC TL*
• Wide tires rear, either 520/85R46 or 30.5 x 32 in. R-3 TORC TRAC TL*
* Only for use on 50 in. [127 cm] crop clearance models

** Must also choose controller and GPS options
1-7
Pressures and Torque Values
Capacity
Quarts [Liters]
KostGuard Universal
Antifreeze 50/50
Transmission Lucas 15W-40 Magnum Motor Oil 27 [25.5] 300000101
Engine Fuel Diesel
Filter: 880000026
Strainer: 840000010
40 Gallons
[151.2 Liters]
K65000210
Cab Filters ---- ---- Charcoal Filter: 490003651*
Recirculating Filter: 490006661*

320/85 R38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41psi [2.82 bar]
380/80R38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 psi [2.41 bar]
380/90R46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 psi [3.37 bar]
480/70R34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 psi [1.58 bar]
520/85R46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 psi [1.86 bar]
Lug Nut Torque
All Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 lb-ft [570 N•m]
All Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 lb-ft [570 N•m]
Product Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 gallons [4542 Liters]
Hydraulic Pump Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 psi [165 bar]
1-8

Please contact your Apache dealer or www.etsprayers.com for more information on optional equipment.
• 120 to 160 in. [304.8 to 406.4 cm] manual adjust axles
• Hydraulic on the go wheel adjust
• Raven 5000 Rate controller, radar speed pickup
• Raven Envizio Pro Controller (must choose GPS receiver)
• Raven SmarTrax Autosteer*
• Raven GPS receivers 200 or 300
• Raven Autoboom PowerGlide Plus (wheel gauged)
• Raven Autoboom UltraGlide (optical eye)
• Raven Viper Pro Controller
• Raven AccuBoom (automatic boom shut off)*
• Smucker Injection Foam Marker
• Fence row nozzles one side or both
• Hypro chemical eductor
• 5-way nozzle bodies
• Front fenders
• Rear fenders
• Dual rear tires 380/90R46
• Wide tires front, either 480/70R34 or 23.1 x 26 in. R-3 TORC TRAC TL
• Wide tires rear, either 520/85R46 or 30.5 x 32 in. R-3 TORC TRAC TL
• Product tank fill 3 in. [76.2 mm] (see wet system for more options on product side)
* Must also choose a controller and GPS option
1-9
General Information
The graphics and text in this manual generally describe the AS1020 and AS1220 Apache Sprayers. Apache
Sprayers differ by model and by optionally installed equipment. Your Apache Sprayer may not exactly match the
graphics and/or text descriptions in this manual. Please contact your dealer or Equipment Technologies with any
questions regarding this manual or the instructions within.
1-10
LUBRICATION AND MAINTENANCE
Maintenance Precautions • Avoid skin contact with high-pressure diesel

fuel spray caused by a fuel system leak such as
To ensure your safety, the safety of others, and the
a broken fuel injection line. High-pressure fuel
safe operation and maintenance of the sprayer, read,
can penetrate your skin and result in serious
follow and practice the following:
injury. If you are exposed to high-pressure fuel
• Any part which is found defective as a result of spray, obtain prompt medical treatment.
inspection or any part whose specifications are not
• NEVER check for a hydraulic leak with your
adequate must be replaced.
hands. ALWAYS use a piece of wood or card-
• ALWAYS tighten components to the specified board.
torque. Loose parts can cause equipment damage
WARNING! Flying Object Hazard.
or cause it to operate improperly.
• ALWAYS wear eye protection when servicing
• Only use Apache-approved replacement parts. the engine or when using compressed air or
Other replacement parts may affect warranty cov- high-pressure water. Dust, flying debris, com-
erage. pressed air, pressurized water or steam may
injure your eyes.
• NEVER attempt to modify the Apache Sprayer
design or safety features. WARNING! Crush Hazards
• ALWAYS make sure the Apache Sprayer is on
• If a warning alarm or indicator activates during
flat, solid ground before getting under the
engine operation, stop the engine and Apache
Apache Sprayer.
Sprayer immediately. Determine the cause and
repair the problem before continuing operation. To • ALWAYS block front and rear axle wheels
ensure your safety, the safety of others, and the before getting under the Apache Sprayer.
safe operation and maintenance of the sprayer,
• If using a hydraulic jack or jack stands, ensure
read, follow and practice the following:
they are of the proper capacity and used in a
WARNING! Exposure Hazards proper manner under the frame of the Apache
• ALWAYS wear appropriate eye protection to Sprayer.
prevent the risk of eye injury. Wear safety
• Use a hoist or use assistance when lifting com-
glasses to prevent eye contact with debris,
ponents that weigh 50 lb [23 kg] or more. Make
chemicals and fluids.
sure all lifting devices such as chains, hooks or
• ALWAYS wear ear plugs when working around slings are in good condition, of the correct
loud noises to prevent hearing loss. capacity, positioned correctly and have cur-
rent, valid inspection labels.
• ALWAYS wear the appropriate gloves to protect
your hands, especially when handling • ALWAYS use lifting equipment with sufficient
extremely hot or cold equipment and fluids. capacity to lift the Apache Sprayer or equip-
ment.
WARNING! Entanglement Hazards
• NEVER leave the key in the key switch when • If transport is needed for repair, acquire assis-
servicing the Apache Sprayer. Attach a “Per- tance when using a hoist and when loading and
son working on vehicle. Do Not Start or Oper- unloading.
ate” tag near the key switch while performing
WARNING! Fire/Explosion Hazards
maintenance on the equipment.
• While the engine is running or the battery is
• ALWAYS stop the engine before beginning ser- charging, hydrogen gas is being produced and
vice. can be easily ignited. Keep the area around the
battery well-ventilated and keep sparks, open
• NEVER operate the engine without the guards
flame and any other form of ignition out of the
in place.
area.
• ALWAYS remove any tools or shop rags used
• ALWAYS turn off the battery switch or discon-
during maintenance from the area before oper-
nect the negative (-) battery cable before ser-
ation.
vicing the equipment
• NEVER engage the transmission or driven
WARNING! Explosion Hazard.
equipment by hand from underneath the
• Batteries contain sulfuric acid. NEVER allow
Apache Sprayer when the engine is running.
battery fluid to come in contact with clothing,
WARNING! Piercing Hazards skin or eyes. Severe burns could result. If bat-
1-11
tery fluid contacts the eyes and/ or skin, imme- Environmental Precautions
diately flush the affected areas with a large
The safety messages that follow have NOTICE level
amount of clean water and obtain prompt medi-
hazards.
cal treatment.
• Thoroughly clean any spilled fluids from the
WARNING! Exposure Hazard.
equipment and/or ground after service is com-
• ALWAYS wear safety goggles and protective
pleted. Dispose of used fluids and filters as
clothing when servicing the battery.
required by law.
WARNING! High-Pressure Compressed Air - Expo- • ALWAYS be environmentally responsible. Fol-
sure and Impact Hazards low the guidelines of the EPA or other govern-
• Pneumatic components store compressed air mental agencies for the proper disposal of
and can separate violently during disassembly hazardous materials such as engine oil, diesel
or removal. Before servicing any part of the fuel and engine coolant. Consult the local
pneumatic (air) system, slowly release all com- authorities or reclamation facility.
pressed air from the system. • NEVER dispose of hazardous materials by
• Never exceed the recommended working air dumping them into a sewer, on the ground, or
pressure. into ground water or waterways.
• Never connect or disconnect a hose or line

containing air pressure. Non-Apache Equipment Mainte-
• ALWAYS wear safety glasses when working
nance
with compressed air systems. NEVER look into Some components and systems of Apache Sprayers
the area of escaping air when draining air tanks are manufactured by companies other than Apache
or disconnecting lines. Dirt or moisture may be and have specific safety, inspection, adjustment and
expelled, causing eye injury. maintenance procedures outlined by their manufac-
turer.
WARNING! Shop Equipment Hazards
• ALWAYS check before starting the engine that NOTICE: ALWAYS perform maintenance procedures
any tools or shop rags used during mainte- for all OEM equipment in addition to procedures for the
nance have been removed from the area. Apache Sprayer.
• ALWAYS use tools appropriate for the task at Some non-Apache equipment operator’s and mainte-
hand and use the correct size tool for loosen- nance manuals are included with the Apache Sprayer.
ing or tightening machine parts. These include, but are not limited to, the Engine
Owner’s Manual, Sprayer Monitor System Manual,
• Always use the proper tools and equipment for Chemical Eductor Manual, Product Pump Instructions
servicing the Apache Sprayer. Ensure the tools and other optional equipment manuals.
are rated and approved for use with this
Apache Sprayer. NOTICE: ALWAYS perform and reference the original
equipment manufacturers’ service information when
• If an Apache Sprayer is to be operated with test performing service or maintenance procedures on
equipment connected, precautions must be equipment manufactured by companies other than
taken to ensure that all equipment and related Apache. Before servicing original equipment manufac-
components are securely attached to prevent turer (OEM) systems or components, properly identify
movement and interference. the OEM model and serial number to ensure correct
• Before performing any maintenance procedure, service and replacement part information is referenced.
have all the correct tools you need to perform
the required tasks.
• Ensure that the work area is adequately illumi-
nated. ALWAYS install wire cages on portable
safety lamps.
1-12
Cleaning Guidelines • Avoid scratching or damaging polished metal fin-

ishes; do not use abrasive cleaners.
The following guidelines are recommended when
cleaning mechanical and electrical parts of the cab. • Never use pressurized water or cleaners to clean
the cab interior.
WARNING! Fire Hazard
• Cleaning solvents can cause death or serious • Never use corrosive cleaning solutions or any type
injury. of abrasives. Part or equipment damage caused by
use of corrosive cleaners or abrasives is not cov-
• Cleaning solvents are extremely flammable and
ered under Apache warranty.
toxic if inhaled.
• Periodically clean the interior dash, gauge panels,
• Do not use near sparks or flame and avoid
floor and seat with a mild cleanser or water-damp-
inhaling.
ened cloth.
• Use in a well-ventilated area and follow the
• Periodically clean all interior glass with a water-
manufacturers’ warnings on use and handling.
dampened cloth or approved glass cleaning mate-
WARNING! Exposure Hazard. rials.
• Wear safety glasses, gloves, and other proper
protective clothing or gear when handling part
cleaners or other hazardous cleaning agents.
The safety messages that follow have NOTICE level
hazards.
• Use caution when using power washers to avoid
damaging rubber, plastic or electrical components.
Mechanical Parts
• Clean mechanical parts with a noncombustible
cleaning agent.
• Clean mating surfaces thoroughly after removing a
part to which an O-ring or gasket is attached. If you
replace a part, always use a new O-ring or gasket.
Electrical Parts
• Never spray water or cleaners directly on electrical
parts.
• Electrical parts are susceptible to water damage
and insulations leaks. Current leakage can develop
if electrical parts become wet or the insulation is
damaged.
Body and Cab Exterior

• The use of a low-pressure water supply system
and mild automotive-type soap is recommended to
wash and rinse the Apache Sprayer.
• Do not use abrasive cleaning materials on the
Apache Sprayer, as brushes, chemicals and clean-
ers may damage the finish or components.
• Do not remove ice or snow from painted surfaces
with a scraper or blade.
• Do not allow diesel fuel, oils, lubricants or anti-
freeze to come in contact with painted surfaces.
• When cleaning chrome, stainless-steel or alumi-
num parts, use clean water and a soft cloth.
1-13
Apache Sprayer Service Interval Chart
Every 1000 Hours

Before Initial Use
Every 100 Hours

Every 250 Hours
Every 500 Hours
Perform and repeat the prescribed
Every 40 Hours
maintenance at each interval
As Required
Every Year
100 Hours
After First
= Conditional Service
After First
10 Hours
or Yearly
or Yearly
= Regular Service
Daily
NOTE: Do not overlook the “After First 100 Hours” interval.
Grease Entire Boom

Torque Lug Nuts
Torque Boom Lead Bolts
Grease Steering Components
Grease Axle Components
Grease Driveline
Adjust Poly Tank Straps
Adjust Boom
Torque Axle Extension Bolts
Adjust Toe-In
Replace Engine Safety Air Filter
Winterize Wet System
Replace Cab Filters
Inspect Front Accumulators
Flush Wet System (including product pump)
Check Tire Pressure
Check Oil Engine Level
Check Coolant Level, Cooling Package, and Hoses
Check Transmission Oil Level
Check Hydraulic Fluid Level
Clean/Replace Primary Engine Air Filter
Grease Rear Suspension
Grease King-pins
Check Differential Fluid Level
Check Differential for Leaks
Re-Phase Steering Cylinders
Replace Fuel Primary Filter
Replace Fuel Separator Filter
Replace Differential Fluid
Replace Hydraulic Fluid Filter
(Immediately if indicator is red.)
Clean Hydraulic Fluid Strainer
Replace Engine Oil and Filter
Replace Transmission Oil and Filter
Check Charge in Front Accumulators
Check Accumulator Fluid Level
Replace Planetary Fluid
Recalibrate Raven Radar Gun
Inspect and Repack Wheel Hub and Flex Bearings
Replace Drop Box Fluid
(AS1220 or AS1020 with 48 in. [121.9 cm] CC)
Clean Transmission Oil Strainer (AS720 Only)
Replace Hydraulic Fluid
1-14
Before Initial Use

The following services must be performed before initial use of the Apache Sprayer and repeated at the interval pre-
scribed in the Apache Sprayer Service Interval Chart. See “Apache Sprayer Service Interval Chart” on page 1-14.
• Grease Boom. See “Grease Boom” on page 1-18.
• Torque Lug Nuts. See “Torque Lug Nuts” on page 1-24.
• Grease Steering Components. See “Grease Steering Components” on page 1-25.
• Grease Axle Components. See “Grease Axle Components” on page 1-25.
• Grease Driveline. See “Grease Driveline Components” on page 1-27.
• Adjust Poly Tank Straps. See “Adjust Poly Tank Straps” on page 1-29.
• Adjust Boom. See “Adjust Boom” on page 1-15.
After First 10 Hours

The following services must be performed after the first 10 hours of operation and repeated at the interval pre-
scribed in the Apache Sprayer Service Interval Chart. See “Apache Sprayer Service Interval Chart” on page 1-14.
• Torque Lug Nuts. See “Torque Lug Nuts” on page 1-24.
Adjust Boom
NOTICE: All boom adjustments should be performed
with the boom fully unfolded and lowered.
Boom Lead
The outermost tip of the booms should lead the boom
rack by 3 to 4 inches [76.2 to 101.6 mm].
To adjust the boom lead:

Loosen the boom lead bolts (1) near the bottom of the
boom rack.
• Turn the jam nuts (2) toward the end of the
boom to increase boom lead.
• Turn the jam nuts (2) toward the center of the
boom rack to reduce boom lead.
Tighten the jam nuts and lead bolts after correct lead is
set.
Torque the boom lead bolts to 420 lb-ft [569 N•m]
Repeat the steps for the remaining boom, as required.
1-15
Boom Breakaway
Each left and right boom is equipped with one or two
boom breakaways depending on boom configuration. A
right, boom tip breakaway is shown.
The breakaways should be adjusted so the boom sec-
tions on both sides of the breakaways are straight and
aligned as they extend from the boom rack.
To adjust the breakaway:
Loosen the jam nut (1) and turn the adjusting screw (2)
to align the booms.
Tighten the jam nut.
Repeat the steps for the remaining breakaways, as
required.
Boom Stabilizer
There are four boom stabilizers mounted to the boom
rack. The upper and lower right-side stabilizers (1) are
shown.
The gap between the nylon wear pads and the steel
frame should be 0.093 to 0.125 in. [2.4 to 3.2 mm] with
the booms unfolded.
To adjust the gap:
Loosen both lock nuts (2) on the stabilizer and equally
adjust the jam nuts (3) until the gap is correct.
Tighten the lock nuts (2).
Repeat the steps for the other stabilizers, as required.
NOTE: For best performance, the jam nuts must be
adjusted so the stabilizer halves are parallel
and provide the 0.093 to 0.125 in. [2.4 to 3.2
mm] gap.
Boom Tip
(80 ft, 90 ft, and 100 ft Booms)
The boom tips should be level with the main boom.
The left boom tip is shown.
To adjust the boom tip level:
Loosen the jam nuts (1) on the leveling bracket.
Turn the leveling bolts (2) clockwise to raise the boom
tip or counter-clockwise to lower the boom tip.
NOTE: When the boom tip is adjusted properly, there
will be some side-to-side movement in the cyl-
inder and in the linkage bars.
NOTE: Adjust the bolts equally for best performance.
Repeat the steps for the other boom tip, as required.
1-16
As Required
The following services will be required at various intervals depending on Apache Sprayer use and environmental
conditions. Repeat these services as prescribed by the Apache Sprayer Service Interval Chart. See “Apache
Sprayer Service Interval Chart” on page 1-14.
• Grease Axle Components. See “Grease Axle Components” on page 1-25.
• Adjust poly Tank Straps. See “Adjust Poly Tank Straps” on page 1-29.
• Adjust Boom. See “Adjust Boom” on page 1-15.
• Check Axle Extension Bolt Torque. See “Torque Axle Extension Brace Bolts” on page 1-28.
• Adjust Toe-In. See “Adjust Toe-In” on page 1-42.
• Clean or Replace the Primary Engine Air Filter. See “Clean or Replace Engine Primary Air Filter” on page 1-31.
• Replace Engine Safety Air Filter. See “Replace Engine Safety Air Filter” on page 1-42.
• Winterize Wet System. See “Winterize Wet System” on page 1-43.
• Replace Cab Air Filters. See “Replace Cab Recirculating Air and Charcoal Filter” on page 1-45.
• Flush Wet System. See “Flushing Booms” on page 4-21.
• Inspect Front Accumulator. See “Inspect Front Accumulator” on page 1-47.
1-17
Daily
The following services must be performed daily, before operation of the Apache Sprayer.
• Clean or Replace Primary Engine Air Filter as needed. See “Clean or Replace Engine Primary Air Filter” on
page 1-31.
Grease Boom
The boom is equipped with seven sets of grease fittings. Apply an ample amount of lithium grease through each of
the grease fittings.
1. Boom Stabilizer 5. Boom Tip

2. Boom Tilt 6. Boom Inner Breakaway
3. Boom Fold 7. Boom Outer Breakaway
4. Boom Rack (if equipped)
Boom Stabilizer
There are two upper (1) and two lower (2) boom stabi-
lizer grease fittings.
1-18
Boom Tilt
There are two boom tilt grease fittings (1).
Boom Fold
There are four boom fold grease fittings (2).
Boom Rack
There are two sets of six boom rack, flag-pin style,
grease fittings (3).
Boom Tip
There are four boom tip grease fittings (1), two on each
boom tip. The left side is shown.
Boom Inner Breakaway

There are six boom inner breakaway grease fittings (1),
three on each boom. The left side is shown.
Boom Outer Breakaway (if equipped)

There are six boom outer breakaway grease fittings (1),
three on each boom tip. The left side is shown.
1-19
Flush Wet System
Drain and flush the product tank and wet system after
use and when changing chemicals. See “Flushing Prod-
uct Tank” on page 4-21.
Check Tire Pressure

Perform the following:
• Check the tires for damage. Replace tires that
have cuts or bubbles.
• Check the tires for proper inflation pressure.
Inflate tires according to the tire manufacturer’s
recommendations. Tire pressures are listed on
the back cover of this manual.
• Check the rims for cracks and other damage.
Replace damaged rims.
Check Engine Oil Level

NOTICE: If the engine has been running, shut off and
wait 10 minutes before checking oil level.
The dipstick is located in the engine compartment, on
the left side of the engine.
Remove the dipstick and check the oil level.
The oil level should be within the hatched area on the
dipstick.
If the oil level is below the ADD mark, add high quality
Lucas 15W-40 Magnum motor oil at the oil fill location
on top of the engine.
Add oil as needed to bring the level to the hatched area
on the dipstick.
Replace the dipstick.
Additional lubricating oil system information is available
in the engine manufacturer’s manual provided with the
Apache Sprayer.
1-20
Check Cooling System
WARNING! Fire Hazard. Coolant may be flammable under certain conditions. NEVER allow coolant to
come into contact with hot surfaces.
WARNING! Exposure Hazard. Wear eye protection and rubber gloves when handling engine coolant. Avoid
skin contact with coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately
with clean water.
WARNING! Burn Hazard. NEVER remove the radiator cap if the engine is hot. Steam and hot engine coolant
will spray out and seriously burn you. Allow the engine to cool down before you attempt to remove the
cap.
Remove the small grille on the top, left of the hood
assembly to gain access to the radiator fill cap.
Remove the radiator cap and check the coolant level.
Remove the radiator cap slowly to relieve internal pres-
sure. The coolant should be level with the bottom of the
fill neck.
Add coolant as necessary. Do not overfill the cooling
system, as this may cause the coolant to spray from the
system during operation.
NOTICE: See the engine manufacturer’s manual for
coolant requirements and additional cooling system
information.
Install the radiator cap.
WARNING! Burn Hazard.
ALWAYS tighten the radiator cap securely after check-
ing the coolant. Steam can spray out during engine
operation if the cap is loose.
Inspect the cooling system components for damage and
debris.
• Check tubes, hoses and other components for damage and leaks.
• Replace damaged components as necessary.
• Clean debris from around or between cooling package components.
1-21
Check Transmission Oil Level
AS720 / ITL Transmission Only
NOTICE: Check the transmission fluid level with the oil at operating temperature and the engine off.
The transmission fluid dipstick is located in the engine
compartment, on the left side of the engine, and toward
the cab.
NOTE: The transmission oil should be at operating
temperature and the engine should be off.
Turn the dipstick handle counter-clockwise to loosen.
Remove the dipstick and check the transmission fluid
level.
The fluid level should be between the two dots on the
dipstick.
NOTICE: DO NOT overfill the transmission fluid. Over-
filling can damage the transmission or cause the trans-
mission to malfunction or overheat.
NOTICE: Use only Lucas Universal Hydraulic Fluid.
If the fluid level is below the lower dot on the dipstick,
use a funnel to add fluid through the dipstick tube.
Add Lucas Universal Hydraulic Fluid to bring the level
between the dots on the dipstick.
Replace the dipstick and turn the handle clockwise to
tighten.
AS1020 and AS1220 / ZF Transmission Only

The transmission oil dipstick is located in the engine
compartment, on the left side of the engine, and toward
the cab.
1-22
Note: All measurements must be taken with the
engine running at low idle.
The transmission oil level check must be carried out as
follows:
• Check transmission oil level weekly
• Machine on level ground
• Transmission in Neutral position
• In the cold start phase, the engine must be running approximately 2 to 3 minutes at idle speed. The trans-
mission oil level must be above the cold start mark “COLD MIN”.
Turn the dipstick handle counter-clockwise to loosen.
Remove the dipstick and check the transmission oil level.
NOTICE: DO NOT overfill the transmission oil. Overfilling can damage the transmission or cause the transmission
to malfunction or overheat.
NOTICE: Use only Lucas 15W-40 Magnum motor oil.
Check Hydraulic Fluid Level

NOTICE: The booms must be folded and in the trans-
port position for an accurate hydraulic fluid level read-
ing.
The hydraulic fluid reservoir is located on the right side
of the Apache Sprayer and a sight glass (1) indicates
the hydraulic fluid level.
NOTICE: Use only Lucas Universal Hydraulic Fluid for
the Apache Sprayer hydraulic system.
If no fluid is visible in the sight glass, remove the fill cap
(2) and add Lucas Universal Hydraulic Fluid until fluid is
visible in the bottom of the sight glass.
NOTICE: Do not fill more than 3/4 up on the sight glass.
1-23
Every 40 Hours
The following services must be performed after every 40 hours of operation of the Apache Sprayer.
Torque Lug Nuts

Torque the 14.9 x 38 in. front wheel lug nuts to:
• 420 lb-ft [570 N•m]
Torque all rear wheel lug nuts to:
• 420 lb-ft [570 N•m]
Grease Rear Suspension

Apply lithium grease to the upper (1) and lower (2)
grease fittings at each end of the suspension cylinder.
1-24
Grease Steering Components
NOTICE: Do not over-grease the ball joints. Damage to
the dust cover will result.
Each steering cylinder has two king-pin grease fittings
(1), two ball joint grease fittings (2), one inter-flex bear-
ing grease fitting (3), and one hub grease fitting (4). The
right wheel is shown.
Apply lithium grease through the two king-pin grease fit-
tings (1).
Apply lithium grease through the two ball-joint grease
fittings (2) on the tie rod ends.
NOTE: The inter-flex (3) and hub (4) bearings are
sealed chambers and once greased require
very little grease to maintain.
Apply lithium grease through the inter-flex bearing
grease fitting (3).
Apply lithium grease through the hub bearing grease fit-
ting (4).
Repeat these steps for the other front wheel.
Grease Axle Components

The rear axle is equipped with 16 grease fittings,
installed in two square-tube axle extension assemblies.
Eight fittings point downward from the bottom faces of
each square tube. Shown are the four rear-most fittings
(1).
The front axle is equipped with eight grease fittings.
Apply an ample amount of lithium grease through each
of the fittings.
1-25
An axle pivot is located under the vehicle on the front
axle. The pivot is equipped with a grease fitting on front
(1) and rear (2) of the front axle.
Apply an ample amount of lithium grease through each
of the fittings.
Torque Boom Lead Bolts

Torque the boom lead bolts (1) on the boom rack to
420 ft-lb [570 N•m]. Torque the bolts on both the right
hand side and left hand side of the boom rack.
Check Differential Fluid Level

The differential is located under the Apache Sprayer, on
the rear axle. The fill/level plug is directly above the
drain plug on the rear of the differential.
Remove the differential fill/level plug (1) and check the
fluid level. The fluid should be level with the bottom of
the fill/level hole.
the differential fluid.
If required, add Lucas Universal Hydraulic Fluid to fill
the differential to the bottom of the fill/level hole.
Install the plug and tighten.
Check Rear Differential for Leaks

Inspect the differential for leaks at the U-joint, near the drop boxes, and between inner and outer housings.
Repair the leaks before operating the Apache Sprayer.
1-26
Re-Phase Steering Cylinders
Start the engine, allow it to reach operating temperature.
Run the engine to 1000 rpm.
Operate the vehicle in a forward direction and turn the steering wheel to the right until the steering cylinder bottoms
out.
After the steering cylinder bottoms out, stop the vehicle, but continue to turn the steering wheel.
Continue to turn the steering wheel toward the right for 5 minutes. This will be approximately 140 revolutions.
Repeat the above steps while turning toward the left to re-phase the left side steering cylinder.
After First 100 Hours

The following services must be performed after the first 100 hours of operation and repeated as prescribed by the
Apache Sprayer Service Interval Chart.
• Replace Differential Fluid. See “Replace Differential Fluid” on page 1-31.
• Replace Hydraulic Fluid Filter. See “Replace Hydraulic Fluid Filter” on page 1-32.
• Replace Engine Oil and Filter. See “Replace Engine Oil and Filter” on page 1-35.
• Replace Transmission Oil and Filter. See “Replace Transmission Oil and Filter” on page 1-36.
• Clean the Transmission Oil Strainer. See “Clean Transmission Oil Strainer (AS720/ITL Transmission Only)” on
page 1-47.
Every 100 Hours

Grease Driveline Components

The Apache Sprayer has a total of ten driveline grease fittings. Three of these fittings are slip joint fittings and
seven are U-joint fittings.
Apply an ample amount of lithium grease through each of the fittings.
One slip joint grease fitting (1) is located under the
Apache Sprayer, between the transmission and the rear
axle.
A U-joint fitting is located at the transmission output U-
joint (not shown) and another fitting (2) is located on the
U-joint connected to the slip joint.
1-27
A U-joint fitting (1) is located at the differential input.
The other two slip joint grease fittings (1) are located
under the Apache Sprayer, between the differential and
each drop box U-joint.
The remaining U-joint fittings (2) are located on the U-
joints at each end of the left and right axles.
The left axle is shown.
Torque Axle Extension Brace Bolts

NOTICE: There are different axle brace bolt torque values for manual and Adjust On The Go axles. Follow the
instructions for your application.
Manual Adjust Axles
There are six axle brace bolts (1) on each front brace.
Loosen all the jam nuts.
Tighten the axle brace bolts (1) to 80 lb-ft [108 N•m].
Tighten the jam nuts.
Repeat the process for the other front axle brace.
1-28
There are twelve axle brace bolts (1) on each rear
brace.
Tighten the bolts (1) to 80 lb-ft [108 N•m].
Repeat the process for the other rear axle brace.
Adjust On The Go Axles

There are six axle brace bolts (1) on each front brace.
Tighten the axle brace bolts (1) to 15 lb-ft [20 N•m].
Repeat the process for the other front axle brace.
There are twelve axle brace bolts (1) on each rear

brace.
Tighten the bolts (1) to 15 lb-ft [20 N•m].
Repeat the process for the other rear axle brace.
Adjust Poly Tank Straps

Tighten the bolts on each tank strap without deforming
the tank, bolts or tank skid. Tighten the bolts evenly
from side to side.
Fill the product tank with water and drive the Apache
Sprayer to allow the tank to settle.
Stop the Apache Sprayer and check the straps.
Adjust the straps as needed.
1-29
Replace Fuel Primary Filter
The fuel filter (1) is located in the engine compartment
on the left side of the engine.
WARNING! Fire Hazard. Wipe up fuel spills immedi-
ately. Fuel will spill from the filter and fuel lines
when loosened or removed. Use a suitable con-
tainer to collect the fuel and dispose of properly.
NOTICE: Always replace the fuel filter with a new fuel
filter.
• Fuel Filter Part Number: 201450242
Fill the new filter with diesel fuel before installing.

NOTE: It is not necessary to bleed the fuel system after
replacing fuel filters.
NOTICE: Do not overtighten the filter. Damage to the
seal can result.
Tighten the filter, by hand, 3/4 to 1-1/4 turns after the seal contacts the filter housing.
Additional fuel system information is available in the engine manufacturer’s manual provided with the Apache
Sprayer.
Replace Fuel Separator Filter

The fuel separator filter (2) is located in the engine compartment on the left side of the engine.
Turn the filter counter-clockwise to remove.
Dispose of the filter properly.
NOTICE: Always replace the fuel separator filter with a new separator filter.
• Fuel Separator Filter Part Number: 201450243.
Fill the new filter with diesel fuel before installing.

NOTICE: Do not overtighten the filter. Damage to the seal can result.
Tighten the filter, by hand, 3/4 to 1-1/4 turns after the seal contacts the filter housing.
NOTE: It is not necessary to bleed the fuel system after replacing fuel filters.
Additional fuel system information is available in the engine manufacturer’s manual provided with the Apache
Sprayer.
1-30
Every 250 Hours

Clean or Replace Engine Primary

Air Filter
NOTICE: When operating in severe conditions, the primary air filter should be cleaned after every 40 hours of use
or when indicated by the console display.
NOTICE: If a “Change Air Filter” fault is indicated on the console display, stop immediately and remove and clean
or replace the primary air filter as needed.
The primary air filter is mounted in the engine compart-
ment, above the engine and toward the cab.
Clean the outside of the air cleaner and surrounding
area to keep dust from entering the cleaner assembly.
Release the four latches (1) and remove the cover from
the air cleaner assembly.
Use a rocking motion to release the primary air filter (2)

from the assembly.
Clean the filter using compressed air. Blow the filter
from the inside-out.
If installing a new primary engine air filter:
• Primary Engine Air Filter Part Number:
201300116.
Install the filter, the air cleaner cover, and engage the
cover latches.
Replace Differential Fluid

The differential is located under the Apache Sprayer, on
the rear axle. The fill/level plug (1) is directly above the
drain plug on the rear of the differential.
Remove the differential drain plug and drain the fluid
into a suitable container. Dispose of the fluid properly.
Install the drain plug and tighten.
the differential fluid.
Remove the differential fill/level plug (1). Add fluid until
it is level with the bottom of the fill/level hole.
• Differential Fluid Capacity:
Approximately 11.9 quarts [11.3 liters].
Install the fill/level plug (1) and tighten.
1-31
Replace Hydraulic Fluid Filter
The hydraulic fluid filter is located between the cab and
product tank on the right side of the Apache Sprayer.
Remove the cover (1) from the filter housing.
Remove the filter from the assembly.
Discard the filter and fluid into an appropriate container.
Install an o-ring on the filter housing and lubricate it with
clean Lucas Universal Hydraulic Fluid.
Install the filter into the filter housing.
Install and tighten the filter housing cover.
Use the sight glass to check the fluid level. See “Check Hydraulic Fluid Level” on page 1-23.
Clean Hydraulic Fluid Strainer

The hydraulic fluid strainer is located under the Apache Sprayer, on the side of the hydraulic fluid reservoir. The
strainer is in line with the hydraulic fluid line.
Remove the hydraulic fluid drain plug (1) from the bot-
tom of the reservoir and drain the fluid into a suitable
container with a capacity of approximately 40 gallons
[151.42 liters].
Install the drain plug.
Remove the hydraulic fluid line (1).

Remove the strainer (2).
Clean the strainer with diesel fuel and allow to air dry.
Dispose of the fuel properly.
NOTICE: If the strainer cannot be cleaned or has holes
in the screen, replace with a new strainer.
Install the hydraulic fluid strainer (2).
• Hydraulic Fluid Strainer
Part Number: 840000010.
Install the hydraulic line (1).
1-32
NOTE: The hydraulic fluid fill location has a screen (1)
in the fill neck. FIll the reservoir slowly to reduce
the possibility of spilling.
Fill the hydraulic fluid reservoir with Lucas Universal
Hydraulic Fluid. The reservoir capacity is approximately
40 gallons [151.42 liters].
Use the sight glass to check the fluid level. See “Check
Hydraulic Fluid Level” on page 1-23.
1-33
Every 500 Hours or Yearly

NOTE: Some services at this interval were performed at the “After First 100 Hours” interval. If the service was per-
formed as prescribed, measurement of 500 hours should begin at the 100 hour mark.
The following services must be performed after every 500 hours of operation or yearly.
• Replace the Primary Fuel Filter. See “Replace Fuel Primary Filter” on page 1-30.
• Replace the Fuel Separator Filter. See “Replace Fuel Separator Filter” on page 1-30.
Check Accumulator Fluid Level

Safely raise the front of the Apache Sprayer so the front
tires are just off of the ground.
Remove the plug (1) from the front of each front accu-
mulator and check the fluid level. The fluid should be
level with the bottom of the fill hole.
NOTICE: If the fluid is foamy, the accumulator has
failed. Contact your dealer for repair.
the accumulator fluid.
If required, add Lucas Universal Hydraulic Fluid to fill
the accumulator to the bottom of the fill hole.
Safely raise the front of the Apache Sprayer so the front
tires are just off of the ground.
Remove the cap (2) and install a nitrogen valve and
gauge on the accumulator.
Open the valve and check the nitrogen pressure.
• AS1020 Accumulator Nitrogen Pressure:
900 psi [62 bar]
900 psi [62 bar]
NOTE: It may be necessary to top off the nitrogen level yearly.
1-34
Replace Planetary Fluid
The planetaries are located on each rear wheel. The
plug (1) on the planetary serves as the drain and fill
location.
To drain the planetary fluid, position the wheel so the
plug on the planetary is in the 6 o’clock position.
Remove the plug in the planetary, drain the fluid into a
suitable container and dispose of the fluid properly.
To fill the planetary fluid, position the wheel so the plug
on the planetary is in the 3 o’clock position.
NOTICE: Use only Lucas 80/90 Gear Oil for the plane-
tary fluid.
Fill each planetary with Lucas 80/90 Gear Oil to the bot-
tom of the fill hole.
• Planetary Fluid Capacity:
Approximately 2.2 quarts [2.0 liters].
Install the plug (1) and tighten.
Replace Engine Oil and Filter

WARNING! Burn Hazard. If you must drain the engine oil while it is still hot, stay clear of the hot engine oil
to avoid being burned. ALWAYS wear eye protection.
Operate the engine for approximately five minutes to warm the engine oil.
Shut off the engine.
The engine oil drain plug is located on the right side of the oil pan. Remove the engine oil drain plug and drain the
oil into a suitable container.
Properly dispose of the used engine oil.
NOTICE: Do not overtighten the oil drain plug. Damage
to the plug or seal may result in leakage.
Install the drain plug and applicable seal and tighten to
the torque value below:
1.Plug with Copper Washer: 52 lb-ft [71 N•m]
2.Plug with O-ring: 37 lb-ft [50 N•m]
1-35
The engine oil filter is located on the right side of the engine.
Turn the engine oil filter counterclockwise to remove.
Dispose of the filter properly.
NOTICE: Do not overtighten the filter. Damage to the seal can
result.
Lubricate the seal on the engine oil filter.
• Engine Oil Filter Part Number: 201450241.
Install and tighten the filter, by hand, 3/4 to 1-1/4 turns after the seal
contacts the filter housing.
NOTICE: Do not overfill the engine oil. Crankcase oil capacity can
vary. ALWAYS use the dipstick to determine if the engine oil is to
the appropriate level.
Fill the engine with high quality Lucas 15W-40 Magnum
motor oil at the oil fill location on the left side of the
engine.
• Engine Oil Capacity:
Approximately 16 quarts [15 liters].
Add oil as needed to bring the level to the hatched area
on the dipstick.
Install the dipstick.
Operate the engine and check for leaks.
Shut off the engine and wait 10 minutes. Check the
engine oil level and add oil as needed to bring the level
to the hatched area on the dipstick.
Additional lubricating oil system information is available
in the engine manufacturer’s manual provided with the
Apache Sprayer.
Replace Transmission Oil and Filter

AS720 / ITL Transmission Only
The transmission drain plug is located under the
machine on the front side of the transmission.
Remove the drain plug (1) and drain the transmission
fluid into a suitable container.
Dispose of the fluid properly.
Remove the strainer (2), clean with diesel fuel, and rein-
stall the strainer and plate.
1-36
The transmission filter is located on the right side of the
transmission, next to the park brake canister.
Turn the filter counter-clockwise to remove. Dispose of
the filter properly.
NOTICE: Do not overtighten the filter. Damage to the
seal can result.
Lubricate the seal on the transmission fluid filter.
• Transmission Fluid Filter
Part Number: 300000101
Install and tighten the filter, by hand, 3/4 to 1-1/4 turns

after the seal contacts the filter housing.
NOTICE: DO NOT overfill the transmission fluid. Over-
filling can damage the transmission or cause the trans-
mission to malfunction.
NOTICE: Use only Lucas Universal Hydraulic Fluid.
Use a funnel to fill the transmission fluid at the transmis-
sion dipstick tube on the left side of the engine.
• Transmission Fluid Capacity:
Approximately 16 quarts [15 liters].
Check the transmission fluid level with the transmission

fluid at normal operating temperature, transmission in
NEUTRAL position, and the engine off.
The fluid level should be between the two dots on the
dipstick.
Install the dipstick and turn the handle clockwise to
tighten.
1-37
AS1020 and AS1220 / ZF
Transmission Only
machine on the back side of the transmission.
Park the machine on firm, level ground and apply the
parking brake. Switch OFF the engine and remove the
starter key. Disconnect the battery.
Note: The transmission should be at operating tem-
perature and the Apache Sprayer on level
ground.
Drain the oil as follows:
• Place a used oil container of suitable size under
the transmission.
• Remove the transmission oil drain plug (1) and drain the used oil.
• The drain plug contains a magnetic insert. Be sure to clean any debris clinging to the plug. Clean the seal-
ing surface on the housing.
• Install the plug with new o-ring.
Unscrew and remove the filter.
Do not allow any dirt or oil sludge to enter the transmis-
sion oil system.
NOTICE: Do not install damaged filters.
The filter differential pressure valve (bypass valve) is
equipped with a filter contamination switch which
informs the driver of ZF-Fine filter contamination. When
the warning lamp is illuminated, the ZF-Fine filter must
be replaced.
NOTICE: The transmission oil filter must be replaced at
every transmission oil change.
Lubricate the seal on the transmission oil filter.
• Transmission Oil Filter
Part Number: 310100001
Install and tighten the filter, by hand, 1/3 to 1/2 turns after the seal contacts the filter housing.
Fill the system with new transmission oil through the
dipstick tube.
• Transmission oil capacity:
27 quarts [25.6 liters]
NOTICE: DO NOT overfill the transmission oil. Overfill-
ing can damage the transmission or cause the transmis-
sion to malfunction.
NOTICE: Use only Lucas 15W-40 Magnum engine oil.
1-38
follows:
Turn the dipstick handle counter-clockwise to loosen and remove the dipstick.
Check the transmission oil level. Add oil as needed.
Install the dipstick and turn the handle clockwise to tighten.
Note: The transmission must be calibrated after the oil and filter are replaced.
Calibration Procedure
1. Move the machine to a safe area.
2. Disconnect the parking brake coil (2-pin Deutsch plug on junction block).
3. Start the machine.
4. Press the 'Cruise Master' button while at the Startup screen to enter the
Service Tools menu (Figure 1).
Figure 1
5. Check to make sure the transmission is in manual mode. If it is not, press
'Foam Left' for manual mode and then return to step 4 (Figure 2).
6. At the Service Tools menu, Press the 'Agitate Down' button to start the cal-
ibration process (Figure 2).
Figure 2
7. Transmission must be hot before the calibration sequence can begin (Fig-
ure 3).
A. Depress the brakes and shift the transmission into 6th gear.
B. While still holding the brakes rev the engine to full throttle and hold for
a maximum of 30 seconds.
C. Idle down and shift into neutral. Wait at least 15 seconds to allow the
hot oil in the torque converter to properly distribute.
D. Repeat steps A through C until the trans temp is in range for calibra- Figure 3
tion. Do not extend step B beyond 30 seconds. Damage to the trans-
mission could occur.
1-39
8. With the engine idling and trans in neutral, check the
trans oil level. It should be within the hot zone. Fill or
drain as required. MEASURED AT LOW
HOT
COLD
MIN
IDLING-NEUTRAL
9. If the trans temp drops more than 5°F during step 8,

repeat step 7. Zone
“HOT”
Figure 4
10. With the transmission hot and the oil topped off the cal
sequence can be started. With the parking brake applied and the engine
idling, press the 'Cruise Master' button to start the cal (Figure 5).
Figure 5
11. The cal sequence will take a few minutes as it runs through 7 clutches; K1,
K2, K3, K4, KV, KR and WK (Figure 6). The current clutch and stage are
displayed on screen.
Figure 6
12. If there is an error during the calibration it will end with the error screen in
Figure 7. Refer to the ZF Fault Code List to determine the error code.
Resolve the error, restart the machine and return to step 4 to rerun the cal.
13
Figure 7
13. If the cal was successful the screen in Figure 8 will be displayed.
14. Turn the machine off.
15. Reconnect the parking brake coil.
16. Start the machine and verify that there are no trans errors on the display.
Figure 8
1-40
Recalibrate Raven Radar Gun
The Raven radar gun should be calibrated every year.
See the Raven manufacturer’s instructions, provided
with the Apache Sprayer.
Inspect and Repack Wheel

and Inter-Flex Bearings
1-41
Every Year
The following services must be performed every year.
Adjust Toe-In
Measure Tie Rods
Measure the rear tie rod ends on the left and right steer-
ing cylinder. The measurements must be equal and
between 4.125 in. [104.7 mm] and 4.5 in. [114.3 mm]
Adjust the tie rods if necessary.
Safely lift the front of the Apache Sprayer so the front
tires are slightly off of the ground and turn the steering
wheel so the front wheels appear to be pointing straight.
Make sure the tie rod ends are fully seated in the taper.
Measure the distance that the steering cylinder ram is
extended on the left and right wheel. The measure-
ments must be equal and between 3.87 in. [98.4 mm]
and 4.125 in. [104.7 mm].
Adjust the steering cylinder rams, if necessary, by turning the steering cylinders all the way to the left, then all the
way to the right.
Measure Toe-in
Safely lift the front of the Apache Sprayer so the front
tires are slightly off of the ground.
Turn the steering wheel so the front wheels are pointing
straight.
Measure and note the distance (1) from the center of
the right hub to the front of the left rim.
Measure and note the distance (2) from the center of
the right hub to the rear of the left rim.
If distance (1) is 0.25 in. [6.35 mm] less than distance
(2), the toe-in is correct for the right wheel. If the toe-in
is not correct, it must be adjusted.
Repeat the steps, measuring from the left hub to the right rim, to measure toe-in for the right wheel.
Adjust the toe-in on each wheel until it meets specification.
Adjust Toe-in
Toe-in adjustments should be made at the ram end of the
steering cylinder.
Loosen the nut and bolt on the tie rod clamp (1).
Use a wrench on the end of the ram (2) to increase or
decrease toe-in.
Replace Engine Safety Air Filter

NOTICE: Do not attempt to clean the engine safety air filter. ALWAYS replace with a new filter.
1-42
The engine safety air filter is mounted in the engine
compartment, above the engine and toward the cab. It
is in the same housing as the primary engine air filter.
Release the four latches (1) remove the cover from the
air cleaner assembly and remove the primary air filter
and set it aside.
NOTICE: Do not leave the intake opening uncovered. If
not replacing the filter immediately, cover the opening to
prevent dirt and debris entering the intake system.
Use a rocking motion to remove the safety air filter (1)

and discard the old filter.
Install the new engine safety air filter.
• Engine Safety Air Filter Part Number:
201300117.
Install the primary filter, air cleaner cover, and engage

the four latches.
Winterize Wet System

The product tank and wet system must be flushed
before winterizing. See “Flushing Product Tank” on
page 4-21.
Open the product tank fill valve, foam marker fill valve,
rinse tank valve, and roto-flush valve to drain any
remaining water in the tanks and roto-flush line.
Close the rinse tank valve, foam marker valve, and
sump valve.
Set all boom section switches to the ON position and
press the agitation decrease button to turn agitation off.
1-43
Connect a compressed air line to the main fill valve (1).
Apply compressed air at 40 psi [2.7 bar] to blow out the
wet system and booms.
Cycle the boom section switches (2) off and on several
times to purge water from around the valves.
Disconnect the air line and close the product fill valve.
NOTICE: Drain the rinse tank and foam tank to prevent
damage during storage.
Remove all boom section strainers (1) and the product

strainer.
Reinstall the strainer bowls.
Store the strainers in a warm, dry location.
Pour approximately 20 gallons [76 liters] of RV anti-

freeze into the product tank.
NOTICE: Boom lengths over 60 ft will require more than
20 gallons [76 liters] of antifreeze.
Pour 1 gallon [4 liters] of RV antifreeze into the rinse
tank.
Repeatedly open and close the sump valve (1) and

rinse tank /product valve (2), to allow the antifreeze to
surround the ball valves.
Close the rinse tank valve (2) and open the sump valve
(1).
Except for one nozzle at the end of each boom section,
turn off all the nozzle bodies.
Open all manual valves halfway and then close to allow
any trapped water to escape.
1-44
NOTICE: DO NOT run the product pump dry. Damage
to the pump seals will result. DO NOT intentionally
dead-head the pump with high pressures. Damage to
the pump seals will result.
Start the engine.
Unfold and lower the booms as far as possible.
Set all boom section switches (2) to the OFF position
and press the agitation increase button (3).
Set the product pump switch (1) to the ON position.
Press the agitation decrease button (3) to turn agitation
off.
One at a time, set the boom section switches (2) to the
ON position until antifreeze flows from the open nozzle
in each boom section.
Turn the boom section switches (2) to OFF.
Set the product pump switch (1) to the OFF position.
NOTE: Excess antifreeze may be left in the sprayer.
Winterize the foamer. See “Freezing” on page 4-19.
Replace Cab Recirculating Air

and Charcoal Filter
NOTICE: Do not attempt to clean the old cab air filters.
Always replace with a new filter.
The recirculating air filter (1) is mounted outside the
cab, in the HVAC box.
Unscrew the five 1/4-turn thumbscrews to open the
cover and use a rocking motion to release the filter.
Discard the old filter.
Insert a new filter into the frame with the air-flow arrow
pointing toward the front of the Apache Sprayer.
• Cab Recirculating Air FIlter Part Number:
490006661
• Charcoal Air Filter Part Number: 490003651
Close the cover and secure the five 1/4-turn thumbscrews.
1-45
Check Front Suspension
Accumulator Charge
Contact your Apache dealer for service.
The charge in the front suspension accumulators must
be checked yearly.
900 psi [62 bar].
900 psi [62 bar].
Replace Drop Box Fluid

The drop box drain, level and fill plugs are located on
the drop box at each rear wheel. The left drop box is
shown.
Remove the drain plug (1) and drain the fluid into a suit-
able container. Dispose of the fluid properly.
NOTICE: Use only Lucas 80/90 Gear Oil for the drop
box fluid.
Remove the drop box fill plug (2) and level plug (3).
Add fluid until it is level with the bottom of the level hole
(3).
• Drop Box Fluid Capacity:
Approximately 21 quarts [20 liters]
Install and tighten the fill plug (2) and the level plug (3).
Repeat the steps for the other drop box.
1-46
Every 1000 Hours or Yearly

The following services must be performed after every 1000 hours of operation or yearly.
Inspect Front Accumulator

Inspect the accumulators and cylinders for hydraulic
leaks and correct operation. Typically, the cylinder
should have 4 to 6 in. [101.6 to 152.4 mm] of the cylin-
der ram showing while the Apache Sprayer is on level
ground.
NOTE: Additional cylinder ram may be exposed when
the Apache Sprayer is new. Several hours of
operation will break in the seals.
Clean Transmission Oil Strainer

(AS720/ITL Transmission Only)
machine on the front side of the transmission.
Remove the drain plug (1) and drain the transmission
fluid into a suitable container.
Remove the strainer (2), clean with diesel fuel, and rein-
stall the strainer and plate.
Fill the transmission to the appropriate level. See
“Check Transmission Oil Level” on page 1-22.
Replace Hydraulic Fluid

The hydraulic fluid drain plug (1) is located on the
hydraulic fluid reservoir, between the cab and the prod-
uct tank.
Remove the hydraulic fluid drain plug (1) from the bot-
tom of the reservoir and drain the fluid into a suitable
container with a capacity of more than 40 gallons
[151.42 liters].
Install the drain plug (1).
1-47
Remove the hydraulic fluid reservoir cap (2) and fill with
Lucas Universal Hydraulic Fluid.
• Hydraulic Fluid Reservoir Capacity:
Approximately 40 gallons [151.42 liters]
Use the sight glass (1) to check the fluid level. See
“Check Hydraulic Fluid Level” on page 1-23.
1-48
CUMMINS ENGINE FAULT CODES
These codes will

display on the
Cummins console Cummins Description
Fault Code
J1939 J1939
SPN FMI
Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal, or
719 22 3
Shorted to High Source
Extended Crankcase Blow-by Pressure Circuit - Voltage Below Normal, or
729 22 4
Shorted to Low Source
Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted
2111 32 3
to High Source
Coolant Temperature 2 Sensor Circuit - Voltage Below Normal, or Shorted
2112 52 4
to Low Source
Coolant Temperature 2 - Data Valid but Above Normal Operational Range
2113 52 16
- Moderately Severe Level
Coolant Temperature 2 - Data Valid but Above Normal Operational Range
2114 52 0
- Most Severe Level
241 84 2 Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect
Vehicle Speed Sensor Circuit tampering has been detected Ð Abnormal
242 84 10
Rate of Change
131 91 3 Voltage Above Normal, or Shorted to High Source
132 91 4 Voltage Below Normal, or Shorted to Low Source
147 91 1 Abnormal Frequency, Pulse Width, or Period
148 91 0 Abnormal Frequency, Pulse Width, or Period
SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error -
287 91 19
Received Network Data In Error
1242 91 2 Data Erratic, Intermittent, or Incorrect
Auxiliary Alternate Torque Validation Switch - Data Erratic, Intermittent, or
528 93 2
Incorrect
268 94 2 Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational
2215 94 18
Range - Moderately Severe Level
Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational
2216 94 1
Range Ð Moderately Severe Level
Water in Fuel Indicator High - Data Valid but Above Normal Operational
418 97 15
Range Ð Least Severe Level
Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to High
428 97 3
Source
Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low
429 97 4
Source
Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High
135 100 3
Source
Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low
141 100 4
Source
143 100 18 Operational Range - Moderately Severe Level
415 100 1 Operational Range - Most Severe Level
1-49
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
435 100 2 Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
Intake Manifold Pressure Sensor Circuit Ð Voltage Above Normal, or
122 102 3
Intake Manifold Pressure Sensor Circuit Ð Voltage Below Normal, or
123 102 4
433 102 2 Erratic, Intermittent, or Incorrect
2973 102 2 Erratic, Intermittent, or Incorrect
Turbocharger #1 Speed High - Data Valid but Above Normal Operational
595 103 16
Turbocharger #1 Speed Low - Data Valid but Below Normal Operational
687 103 18
Turbocharger speed invalid rate of change detected - Abnormal Rate of
2345 103 10
Change
Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or
153 105 3
Intake Manifold Air Temperature Sensor Circuit - Voltage Below Normal, or
154 105 4
Intake Manifold Air Temperature High Ð Data Valid but Above Normal
155 105 0
Operational Range - Most Severe Level
Intake Manifold 1 Temperature - Data Valid but Above Normal Operational
488 105 16
2964 105 15 Severe Level
Barometric Pressure Sensor Circuit Ð Voltage Above Normal, or Shorted to
221 108 3
High Source
Barometric Pressure Sensor Circuit Ð Voltage Below Normal, or Shorted to
222 108 4
Low Source
295 108 2 Barometric Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted to
231 109 3
High Source
Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted to
232 109 4
Low Source
Coolant Temperature Sensor Circuit Ð Voltage Above Normal, or Shorted
144 110 3
to High Source
Coolant Temperature Sensor Circuit Ð Voltage Below Normal, or Shorted
145 110 4
to Low Source
Coolant Temperature High - Data Valid but Above Normal Operational
146 110 16
Coolant Temperature Low - Data Valid but Above Normal Operational
151 110 0
Range - Most Severe Level
1-50
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
Coolant Temperature Sensor Circuit Ð Data Erratic, Intermittent, or
334 110 2
Incorrect
Engine Coolant Temperature High - Data Valid but Above Normal
2963 110 15
Operational Range - Least Severe Level
Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High
195 111 3
Source
Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low
196 111 4
Source
235 111 1 Operational Range - Most Severe Level
422 111 2 Coolant Level - Data Erratic, Intermittent, or Incorrect
Fuel Pressure High - Data Valid but Above Normal Operational Range Ð
449 157 0
Moderately Severe Level
Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above Normal,
451 157 3
or Shorted to High Source
Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below Normal,
452 157 4
or Shorted to Low Source
Injector Metering Rail #1 Pressure High Ð Data Valid but Above Normal
553 157 16
Operational Range - Moderately Severe Level
554 157 2 Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect
Injector Metering Rail #1 Pressure Low Ð Data Valid but Below Normal
559 157 18
Injector Metering Rail 1 Pressure - Data Valid but Above Normal
1911 157 0
Injector Metering Rail 1 Pressure - Data Valid but Below Normal
2249 157 1
Cylinder Power Imbalance Between Cylinders - Data Erratic, Intermittent,
951 166 2
or Incorrect
Electrical Charging System Voltage High Ð Data Valid but Above Normal
596 167 16
Electrical Charging System Voltage Low Ð Data Valid but Below Normal
597 167 18
Electrical Charging System Voltage Low Ð Data Valid but Below Normal
598 167 1
Battery #1 Voltage Low - Data Valid but Below Normal Operational Range
441 168 18
Ð Moderately Severe Level
Battery #1 Voltage High - Data Valid but Above Normal Operational Range
442 168 16
Ð Moderately Severe Level
Ambient Air Temperature Sensor Circuit - Voltage Above Normal, or
249 171 3
1-51
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
Ambient Air Temperature Sensor Circuit - Voltage Below Normal, or
256 171 4
Engine Fuel Temperature - Data Valid but Above Normal Operational
261 174 16
Engine Fuel Temperature Sensor 1 Circuit - Voltage Above Normal, or
263 174 3
Engine Fuel Temperature Sensor 1 Circuit - Voltage Below Normal, or
265 174 4
Engine Oil Temperature Sensor 1 Circuit - Voltage Above Normal, or
212 175 3
Engine Oil Temperature Sensor 1 Circuit - Voltage Below Normal, or
213 175 4
Engine Oil Temperature - Data Valid but Above Normal Operational Range
214 175 0
- Most Severe Level
425 175 2 Engine Oil Temperature - Data Erratic, Intermittent, or Incorrect
Engine Speed High - Data Valid but Above Normal Operational Range -
234 190 0
Most Severe Level
Primary Engine Speed Sensor Error Ð Data Erratic, Intermittent, or
689 190 2
Incorrect
2321 190 2 Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect
319 251 2 Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect
Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Above Normal, or
293 441 3
Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Below Normal, or
294 441 4
431 558 2 Data Erratic, Intermittent, or Incorrect
432 558 13 Out of Calibration
Sensor Supply Voltage #3 Circuit Ð Voltage Below Normal, or Shorted to
238 611 4
Low Source
OEM Intermediate (PTO) Speed Switch Validation - Data Erratic,
523 611 2
Intermittent, or Incorrect
757 611 31 Electronic Control Module data lost - Condition Exists
Sensor Supply Voltage #4 Circuit Ð Voltage Above Normal, or Shorted to
2185 611 3
High Source
2186 611 4
Low Source
2292 611 16 Normal Operational Range - Moderately Severe Level
Expected - Data Valid but Below Normal Operational Range - Moderately
2293 611 18
Severe Level
1-52
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
Engine Speed/Position Sensor Circuit lost both of two signals from the
115 612 2
magnetic pickup sensor - Data Erratic, Intermittent, or incorrect
434 627 2 Power Lost without Ignition Off - Data Erratic, Intermittent, or Incorrect
1117 627 2 Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect
Engine Control Module Critical internal failure - Bad intelligent Device or
111 629 12
Component
Engine Control Module Warning internal hardware failure - Bad Intelligent
343 629 12
Device or Component
351 629 12 Injector Power Supply - Bad Intelligent Device or Component
341 630 2 Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect
342 630 13 Electronic Calibration Code Incompatibility - Out of Calibration
2217 630 31 ECM Program Memory (RAM) Corruption - Condition Exists
2311 633 31 Fueling Actuator #1 Circuit Error Ð Condition Exists
285 639 9 SAE J1939 Multiplexing PGN Time-out Error - Abnormal Update Rate
286 639 13 SAE J1939 Multiplexing Configuration Error Ð Out of Calibration
VGT Actuator Driver Circuit - Voltage Below Normal, or Shorted to Low
2384 641 4
Source
VGT Actuator Driver Circuit - Voltage Above Normal, or Shorted to High
2385 641 3
Source
External Speed Input (Multiple Unit Synchronization) - Data Erratic,
237 644 2
Intermittent, or Incorrect
245 647 4 Fan Control Circuit - Voltage Below Normal, or Shorted to Low Source
2377 647 3 Fan Control Circuit - Voltage Above Normal, or Shorted to High Source
Injector Solenoid Cylinder #1 Circuit Ð Current Below Normal, or Open
322 651 5
Circuit
Injector Cylinder #1 - Mechanical System Not Responding Properly or Out
1139 651 7
of Adjustment
331 652 5
Circuit
1141 652 7
of Adjustment
324 653 5
Circuit
1142 653 7
of Adjustment
332 654 5
Circuit
1143 654 7
of Adjustment
1-53
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
323 655 5
Circuit
1144 655 7
of Adjustment
325 656 5
Circuit
1145 656 7
of Adjustment
584 677 3 Starter Relay Circuit - Voltage Above Normal, or Shorted to High Source
585 677 4 Starter Relay Circuit - Voltage Below Normal, or Shorted to Low Source
Auxiliary PWM Driver #1 - Voltage Above Normal, or Shorted to High
2557 697 3
Source
Auxiliary PWM Driver #1 - Voltage Below Normal, or Shorted to Low
2558 697 4
Source
Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High
527 702 3
Source
Auxiliary Input/Output 3 Circuit - Voltage Above Normal, or Shorted to High
529 703 3
Source
Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) - Root Cause
779 703 11
Not Known
Auxiliary Equipment Sensor Input 3 Engine Protection Critical - Special
2195 703 14
Instructions
731 723 7 Mechanical System Not Responding Properly or Out of Adjustment
Engine Speed/Position #2 Camshaft sync error - Data Erratic, Intermittent,
753 723 2
or Incorrect
778 723 2 Engine Speed Sensor (Camshaft) Erratic, Intermittent, or Incorrect
2322 723 2 Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect
Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High
2555 729 3
Source
Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low
2556 729 4
Source
133 974 3 Circuit Ð Voltage Above Normal, or Shorted to High Source
134 974 4 Circuit Ð Voltage Below Normal, or Shorted to Low Source
SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error -
288 974 19
Received Network Data In Error
Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit -
284 1043 4
Voltage Below Normal, or Shorted to Low Source
Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit -
387 1043 3
Voltage Above Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit -
443 1043 4
Voltage Below Normal, or Shorted to Low Source
1-54
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
Engine Brake Actuator Circuit #1 Ð Voltage Below Normal, or Shorted to
2362 1072 4
Low Source
Engine Brake Actuator Circuit #1 Ð Voltage Above Normal, or Shorted to
2366 1072 3
High Source
Engine Brake Actuator Circuit #2 Ð Voltage Below Normal, or Shorted to
2363 1073 4
Low Source
Engine Brake Actuator Circuit #2 Ð Voltage Above Normal, or Shorted to
2367 1073 3
High Source
Fuel Priming Pump Control Signal Circuit Ð Voltage Above Normal, or
2265 1075 3
Fuel Priming Pump Control Signal Circuit Ð Voltage Below Normal, or
2266 1075 4
352 1079 4
Low Source
386 1079 3
High Source
187 1080 4
Low Source
227 1080 3
High Source
ECM Internal Temperature Sensor Circuit - Voltage Above Normal, or
697 1136 3
ECM Internal Temperature Sensor Circuit - Voltage Below Normal, or
698 1136 4
Turbocharger #1 Compressor Inlet Temperature Sensor Circuit Ð Voltage
691 1172 3
Above Normal, or Shorted to High Source
Turbocharger #1 Compressor Inlet Temperature Sensor Circuit Ð Voltage
692 1172 4
Below Normal, or Shorted to Low Source
Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Above
338 1267 3
Normal, or Shorted to High Source
Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Below
339 1267 4
Normal, or Shorted to Low Source
High Fuel Pressure Solenoid Valve Circuit Ð Voltage Below Normal, or
271 1347 4
High Fuel Pressure Solenoid Valve Circuit Ð Voltage Above Normal, or
272 1347 3
Fuel Pumping Element (Front) Ð Mechanical System Not Responding
275 1347 7
Properly or Out of Adjustment
High Fuel Pressure Solenoid Valve #1 Ð Mechanical System Not
281 1347 7
Responding Properly or Out of Adjustment
1-55
These codes will

display on the
Fault Code
J1939 J1939
SPN FMI
Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or
497 1377 2
Incorrect
649 1378 31 Change Lubricating Oil and Filter Ð Condition Exists
296 1388 14 Auxiliary Pressure Sensor Input 1 - Special Instructions
Auxiliary Pressure Sensor Input # 2 Circuit - Voltage Above Normal, or
297 1388 3
Auxiliary Pressure Sensor Input # 2 Circuit - Voltage Below Normal, or
298 1388 4
211 1484 31 Additional Auxiliary Diagnostic Codes logged - Condition Exists
Control Module Identification Input State Error - Data Erratic, Intermittent,
1256 1563 2
or Incorrect
Control Module Identification Input State Error - Data Erratic, Intermittent,
1257 1563 2
or Incorrect
1239 2623 3 Voltage Above Normal, or Shorted to High Source
Turbocharger Compressor Outlet Temperature (Calculated) - Data Valid
2347 2629 15
but Above Normal Operational Range Ð Least Severe Level
Turbocharger Turbine Inlet Temperature (Calculated) - Data Valid but
2346 2789 15
Above Normal Operational Range Ð Least Severe Level
Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted to High
2115 2981 3
Source
Coolant Pressure 2 Circuit -Voltage Below Normal, or Shorted to Low
2116 2981 4
Source
1-56
ENGINE INFORMATION
Engine Views
Right Side
1. Alternator
2. Lubricating Oil Filter
3. Air Conditioner Compressor
4. Air Conditioner Dryer
ALWAYS replace the air conditioner
dryer if the system is opened for any rea-
son.
ALWAYS follow all government regula-
tions when working on the air conditioner
system.
NOTE: The air conditioner system holds
3.25 lb (1.47 kg) of 134A Freon.
ALWAYS replace the air conditioner
dryer if the system is opened for any
reason.
ALWAYS follow all government
regulations when working on the air
conditioner system.
The blue wire comes from the high
pressure switch for power.
Left Side
1. Secondary Fuel Filter
2. Engine Oil Fill and Dipstick
3. Primary Fuel Filter
4. Battery Disconnect
5. Batteries
6. Windshield Washer Fluid Reservoir
1-57
ENGINE INFORMATION
Cooling Package
1. Engine Radiator
2. Air Conditioner Condenser
3. Charge Air Cooler
The charge air cooler takes air from the turbo-
charger, cools it, then forces it into the engine.
Cooler air in the engine makes it more fuel-efficient
and creates more horsepower.
4. Transmission Fluid Cooler
(integral to radiator)
5. Hydraulic Fluid Cooler
Diagnostic Connection
The diagnostic connection for the Cummins engine is
located in the right rear corner of the cab, on the bottom
of the control console, and above the fuse block.
1-58
ENGINE INFORMATION
Engine Wiring Harness Cummins
1-59
ENGINE INFORMATION
NOTES
1-60
Chapter 2
Transmission
AS720, AS1020 & AS1220
NOTES
APACHE AS720 SERIES
2011 AS720 Apache with

ITL Transmission
Coil Combinations
Gear Coils ET Wire Number
Forward
1F F, H 106, 108
2F E, H 105, 108
3F F, G 106, 109
4F E, G 105, 109
Reverse
1R I, H 107, 108
2R J, H 104, 108
3R I, G 107, 109
4R J, G 104, 109
Pin Positions
Transmission Console P4 Connector

Wire Number Floor Connector
Connector Connector Position
104 3 75 38 1
105 4 74 39 2
106 8 73 40 3
107 9 72 41 4
108 10 71 42 5
109 11 70 43 6
110 12 69 44 ---
111 6 66 45 ---
2-1
APACHE AS720 SERIES
Troubleshooting
If the transmission is not going into gear, follow these steps in order:
1 Check to see if the display shows the gear you have selected. If it does not, the problem could be in the
handle or the circuit board.
2 Check to see if the coils on the transmission are magnetizing. If they are, it could be a problem in the valve
body or an internal component in the transmission.
3 Using the tables above verify the signals are getting through the wiring harness connectors. If not it is a
connection or harness problem.
Operation and Troubleshooting for

PS764 Transmissions Used in the AS720
AS720 Transmission Pressure and
Flow Checks
Pump Flow Test
Remove the filter, then remove the adapter fitting and
replace with the unit in the kit.
Install the pump flow fitting and hoses and flow meter.
2-2
APACHE AS720 SERIES
Converter Relief (Safety) Valve
Pressure
Converter Out Pressure /

Oil Cooler Flow Rate
Lubrication Pressure
2-3
APACHE AS720 SERIES
Converter In Pressure
Mainline Pressure
2-4
APACHE AS720 SERIES
PS764 Transmission Capacities
Item Capacity Fluid/Lubricant
US
Liters
Quarts
Transmission 15.5 13.6 Lucas Universal Hydraulic Fluid

Transmission
3.7 4 Lucas Universal Hydraulic Fluid
Cooler
*† Capacities shown with an asterisk are approximate total system and dependent on vehicle circuit. Use the
maximum and minimum marks on dipstick when filling.
Transmission Oil Fill Procedure

NOTE: When installing a transmission in a machine, whether new or in service, it is extremely important to follow
the correct oil fill procedure to prevent internal damage to the transmission.
1. With the engine stopped, fill the transmission with Lucas Universal Hydraulic Fluid to dipstick maximum mark.
2. Start the engine and run slowly for a period not exceeding five minutes. This allows the oil to fill filter, pump,
torque converter, oil cooler and hoses.
3. Stop the engine, wait approximately one minute. Recheck the oil level and fill to dipstick level.
ITL Dipstick Details

Tube size 1 in. O/D x 16 S.W.G. ERW 1
Locknut and seal required for securing and sealing dip-
stick/filler tube - Part Number 155/10600
Filler tube must sit fully home in transmission casing
counterbore.
NOTE: The figures given below are for transmissions
installed horizontally. Allowance may be needed
if installed at an angle (Front to Rear). ITL
should be consulted if transmission is to be
inclined in vehicle chassis.
Service Schedules
A badly maintained machine is a danger to the operator
and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the ser-
vice schedules are done to keep the machine in a safe and efficient working condition.
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hour-
meter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure
any defects found during the regular maintenance checks are rectified immediately.
Calendar equivalents:
10 Hours = Daily
50 Hours = Weekly
500 Hours = Six Months
1000 Hours = Yearly
2000 Hours = 2 Years
2-5
APACHE AS720 SERIES
* Service checks should be carried out as in the table at whichever time occurs first.
Pre-start Cold Checks Operation 10 50 †100 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
TRANSMISSION
* Transmission Oil Level - Check • •
Transmission Oil - Change • •
Transmission Filter - Change • • • •
Transmission Strainer - Clean • •
Drive Shafts - Security/Grease • • •
Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection Hr Hr Hr Hr Hr Hr
TRANSMISSION
2WD/4WD Selection - Check • • •
Forward/Reverse and Gear Change - Operation - Check • • • •
Transmission Main Line Pressure †† - Check • • •
Clutch Disconnect - Check • • • •
Neutral Start Operation - Check • • • •
Clutch Pack Pressures †† - Check • • • •
BRAKES (Clydesdale and Hayes types)
Parking Brake Operation - Check • • • • • •
† First 100 Hours Service only, to be completed by your Distributor.
†† Indicates jobs which should only be done by a specialist.
2-6
APACHE AS720 SERIES
Technical Data
Powershift Gearbox - 4 Speed
Description Full electro-hydraulic transmission unit with torque con-

verter, input, reverse, layshaft, mainshaft, and 4 wheel drive
clutch packs giving 4 forward and 4 reverse speeds.
Designation Designation PS7644 (4 wheel drive)

2WD Gearbox N/A
4WD Gearbox 678 lb (253 kg)
Gear Ratios XtraLow Ratio (XLR) StdRatio (STD)

1st 7.97:1 6.17:1
2nd 4.29:1 3.32:1
3rd 1.86:1 1.86:1
4th 1.00:1 1.00:1
Torque Converter
Dia. 12.2 in (310 mm)
Part No. 04/600580 04.600581
Torque Multiplication at Stall 2.52:1 3.01:1
Converter Pressures - in neutral bar kgf/cm2 lbf/in2

Converter in at 122°F (50°C) 1000 rev/min 1.4 - 2.2 1.4 - 2.2 20.3 - 31.9
2000 rev/min 5.8 - 6.9 5.9 - 7.0 84.1 - 100.0
Converter in at 212°F (100°C) 1000 rev/min 0.5 - 1.3 0.5 - 1.3 7.2 - 18.9
2000 rev/min 2.5 - 3.5 2.5 - 3.7 36.2 - 50.8
Converter out at 50°C 1000 rev/min 0.6 - 1.6 0.6 - 1.6 8.7 - 23.2
2000 rev/min 2.8 - 3.8 2.9 - 3.9 40.6 - 55.1
Converter out at 212°F (100°C) 1000 rev/min 0.2 - 1.0 0.2 - 1.0 2.9 - 14.5
2000 rev/min 1.0 - 1.9 1.0 - 1.9 14.5 - 27.6
Converter Inlet Relief Valve Pressure - max. 7.1 7.2 103.0
Lubrication Pressure - in neutral bar kgf/cm2 lbf/in2

Oil at 122°F (50°C) 1000 rev/min 0.2 - 0.9 0.2 - 0.9 2.9 - 13.1
2000 rev/min 1.1 - 2.1 1.1 - 2.1 16.0 - 30.5
Oil at 212°F (100°C) 1000 rev/min 0.1 - 0.4 0.1 - 0.4 1.5 - 5.8
2000 rev/min 0.4 - 1.4 0.4 - 1.4 5.8 - 20.3
2-7
APACHE AS720 SERIES
Mainline Pressure - in neutral* bar kgf/cm2 lbf/in2

Oil at 122°F (50°C) 1000 rev/min 11.0 - 13.0 11.2 - 13.3 159.5 - 188.8
2000 rev/min 13.0 - 15.2 13.3 - 15.5 188.5 - 220.5
Oil at 212°F (100°C) 1000 rev/min 10.2 - 12.2 10.4 - 12.4 147.9 - 176.9
2000 rev/min 11.4 - 14.5 11.6 - 14.8 165.3 - 210.3
* Clutch Pressure All clutch pressures should be the same as mainline pres-
sure to within 10 lbf/in2 (0.7 bar)
[4WD clutch pressure within 20 lbf/in2 (1.4 bar)]
Flow Rates (in neutral) liters/min US gal/min UK gal/min

Cooler oil flow at 122°F (50°C) 1000 rev/min 8.5 - 11.0 2.1 - 2.9 1.9 - 2.4
2000 rev/min 17.0 - 25.1 4.5 - 6.6 3.7 - 5.5
Cooler oil flow at 212°F (100°C) 1000 rev/min 6.2 - 9.5 1.6 - 2.5 1.4 - 2.1
2000 rev/min 15.0 - 19.5 4.0 - 5.2 3.3 - 3.4
Pump at 122°F (50°C) 1000 rev/min 11.5 - 15.6 3.0 - 4.1 2.5 - 3.4
2000 rev/min 24.0 - 33.0 6.3 - 8.7 5.3 - 7.3
Control Solenoid Valves 3 way, 2 position, normally closed, integral suppression

diode
Initial Coil Current Draw 1.68 amps @ 12 volts @ 68°F (20°C)
2-8
APACHE AS720 SERIES
Towing Procedure
If there is no transmission damage, the machine may be towed for a distance of approximately 1 mile (1.5 kilome-
ters). Always use a rigid tow bar. Restrict towing speed to 15 mph (25 km/h).
If it is necessary to tow the machine for a distance in excess of 1 mile (1.5 kilometers) the propshafts should be dis-
connected to prevent damage to the transmission system.
WARNING! Removal or disconnection of the propshaft(s) will disable the parking brake. It is essential that
the following procedure be adopted.
Position the machine on firm level ground and block the wheels securely to prevent any movement. Release the
parking brake.
Disconnect the propshaft(s) from the axle(s), and tie up the shaft securely well clear of the rotating axle yoke. Alter-
natively remove the shaft(s) completely.
Connect the towing vehicle via the towbar BEFORE removing the blocks from the wheels. Restrict the towing
speed to 15 mph (25 km/h).
When towing is complete, block the wheels securely BEFORE removing the towbar and reconnecting the prop-
shafts.
NOTICE: In some countries, neither of the above procedures may be legally acceptable for towing on public
highways.
2-9
APACHE AS720 SERIES
Descriptions
PS764 Transmission
746950
G
1
M
N
K
H
3
5
C
Q2
A439080
F
E
A
J 2
B
C
D
2-10
APACHE AS720 SERIES
Component Identification
A Torque Converter
B Forward/input clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive clutch assembly
G Torque converter relief valve
H Oil pressure maintenance valve
J Transmission oil pump
K 6 speed assembly (if fitted)
L 4WD output yoke
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P Oil strainer
Q Oil filter
R Driveshaft (drives machine main hydraulic pump)
Principle of Operation
The Powershift gearbox is an electro-hydraulic transmission unit. Gear shifting and direction selection are con-
trolled using multi-disc clutch packs.
Electrically operated solenoid valves 5 divert pressurized oil (provided by pump J) to the selected clutch packs. A
combined lever/swivel switch 4 on the steering column actuates both gear ratio and direction solenoids.
The Powershift unit consists of a torque converter A, forward clutch assembly B, reverse clutch assembly C, lay-
shaft assembly E, mainshaft assembly D, 2/4 wheel drive clutch assembly F.
6 speed gearboxes incorporate a ‘6 speed’ shaft and clutch assembly K.
The forward clutch assembly B is driven by the torque converter A. The reverse clutch assembly C is permanently
driven via constant meshing of spur gears 2. On 6 speed gearboxes the 6 speed assembly is also driven via mesh-
ing gears 2.
Driveshaft R is permanently driven by the engine and runs through the hollow forward/reverse unit shaft to the
back of the gearbox. The shaft (R) drives the gearbox mounted machine main hydraulic pump.
Strainer P and filter Q are used to prevent potential system contamination by filtering dirt particles.
Gearbox oil is cooled by an air blast cooler 6. The cooler is part of the front mounted machine ‘cooling pack’.
2-11
APACHE AS720 SERIES
Hydraulic and Electrical Operation
747560
A
M
J
P
Q
G
L
B
H
F
1
C
K
N
1
2
Ws
3
Us
Xs
Ss
Vs
Ys
Ts
Zs
3
2
1
5
2-12
APACHE AS720 SERIES
Oil pump J is directly driven by the engine via the torque converter.
Oil from the pump J is fed through an internal passage via the filter Q to the pressure maintenance valve H, which
maintains pressure to the solenoid valve block for clutch selection. Excess oil from the maintenance valve flows
back through the casing to the torque converter A. Pressure in the converter is controlled by a relief valve G which
dumps oil from the converter line back to the sump.
Oil from the torque converter A flows out of the gearbox at position M to the external oil cooler 6, returning to the
solenoid valve manifold block 5 at position N. The oil then flows through internal oilways providing lubrication for
clutches and bearings before returning to the gearbox sump.
The torque converter A is a fluid coupling bolted to a drive plate which in turn is bolted to the engine flywheel. As
the engine starts to rotate, the converter gives smooth power take off gradually increasing the torque transmitted.
This torque is transferred from the converter assembly to the clutch/gear assemblies via input shaft on the forward
clutch assembly B.
Forward clutch assembly B contains two hydraulically operated clutches; one clutch (T) provides a forward low
ratio drive and the other (U) a forward high ratio drive. Each clutch is controlled by a 2-position solenoid valve.
When the applicable solenoid is energized, pressurized oil is directed to either the forward low (solenoid Ts) or for-
ward high (solenoid Us) clutch.
The reverse clutch assembly C is similar to the forward clutch assembly. It contains two hydraulically operated
clutches; one clutch (W) provides a reverse low ratio drive and the other (V) a reverse high ratio drive. 2-position
solenoid valves when energized, direct pressurized oil to either the reverse low (solenoid Ws), or reverse high
(solenoid Vs) clutch.
Both the mainshaft and the layshaft assemblies have a single clutch each. Solenoid valve Zs, when energized,
directs pressurized oil to the layshaft clutch Z. Solenoid valve Ys, when energized, directs pressurized oil to the
mainshaft clutch Y.
On 6 speed gearboxes, the 6 speed clutch X is controlled via solenoid valve Xs.
NOTE: The 6 speed clutch assembly is so called as it is fitted to 6 speed, and not 4 speed gearboxes. However,
the clutch is NOT engaged when 6th gear is selected. See the adjacent table.
NOTE: All the clutches work on the same principle. For a full description of operation see Clutch Operation.
The 2/4 wheel drive unit F also has a single clutch S. When 4WD is selected, pressurized oil is directed via sole-
noid valve Ss to the 4WD clutch. When 2WD is selected a connection from the clutch to the transmission sump is
made. For a full description of 2/4 wheel drive clutch operation see Systems Description, 2/4WD Clutch Operation
When a gear is selected via the control switch in the cab, 2 clutches are always engaged. By selecting different
pairs of clutches different gear ratios are engaged. On 4 speed gearboxes the solenoids are electrically controlled
using relays. On 6 speed gearboxes the solenoids are controlled by an electronic control unit (ECU). Speed sensor
1 is used to enable the gear selection to be managed automatically as required.
Example - 2nd gear forward 4WD (6 speed gearbox)
In the schematic, the gearbox is shown with 2nd gear forward engaged. 2nd gear forward requires the forward low
clutch T and layshaft clutch Z to be engaged. When the gear selection switch is moved to 2nd gear forward, the
electrical control system energizes solenoid valves Ts and Zs. pressurized oil is diverted to the back of pistons in
both clutches to engage the drive. At the same time all other solenoids are de-energized, diverting oil from the back
of the other clutch pistons to the gearbox sump. 4WD clutch S is also energized to give 4 wheel drive.
The tables show which clutches and solenoids are engaged for each gear selection.
NOTE: Solenoid valve Xs controls clutch X, solenoid valve Zs controls clutch Z and so on.
2-13
APACHE AS720 SERIES
A Torque Converter
4 Speed Powershift B Forward clutch assembly
C Reverse clutch assembly
Gear Clutches Engaged
D Mainshaft assembly
Forward Reverse E Layshaft assembly
1st T, Z W, Z F 2/4 wheel drive clutch assembly
2nd U, Z V, Z G Torque converter relief valve
H Oil pressure maintenance valve
3rd T, Y W, Y
J Transmission oil pump
4th U, Y V, Y
K 6 speed assembly (if fitted)
L 4WD output yoke
M Hose connection - to oil cooler
N Hose connection - from oil cooler
6 Speed Powershift P Oil strainer
Gear Clutches Engaged Q Oil filter
R Driveshaft (drives machine main hydraulic
Forward Reverse pump)
1st X, Z W, Z S 2/4WD clutch
2nd T, Z V, Z Ss 2/4WD clutch solenoid
3rd U, Z W, Y T Forward low ratio clutch
Ts Forward low ratio clutch solenoid
4th X, Y V, Y
U Forward high ratio clutch
5th T, Y - Us Forward high ratio clutch solenoid
6th U, Y - V Reverse high ratio clutch
Vs Reverse high ratio clutch solenoid
W Reverse low ratio clutch
Ws Reverse low ratio clutch solenoid
X 6 speed clutch (6 speed gearbox only)
Xs 6 speed clutch solenoid (6 speed gearbox only)
Y Mainshaft clutch
Ys Mainshaft clutch solenoid
Z Layshaft clutch
Zs Layshaft clutch solenoid
1 Speed sensor
5 Solenoid valve manifold block
6 Gearbox oil cooler
2-14
APACHE AS720 SERIES
Powershift Gearbox
Drivepaths - 4 Speed
1F
1st Gear Forward (4 wheel drive) Ts Us
Ws
Clutches Engaged Solenoids Energized Vs
T Forward Low Ts
Z Layshaft Zs
S 2/4 Wheel Drive Ss
2F
2nd Gear Forward (4 wheel drive)
Clutches Engaged Solenoids Energized
Ss
U Forward High Us Ys
Z Layshaft Zs Zs
3F
3rd Gear Forward (4 wheel drive)
T Forward Low Ts
Y Mainshaft Ys
4F
4th Gear Forward (4 wheel drive)
U Forward High Us
Y Mainshaft Ys
2-15
APACHE AS720 SERIES
Drivepaths - 4 Speed (continued)
1F W V 2F W V
T U T U
Y Y
Z Z
S S
3F W V
4F W V
T U T U
Y Y
Z Z
S S
2-16
APACHE AS720 SERIES
1R
1st Gear Reverse (4 wheel drive) Ts Us
Clutches Engaged Solenoids Energized Ws
Vs
W Reverse Low Ws
Z Layshaft Zs
2R
2nd Gear Reverse (4 wheel drive)
V Reverse High Vs Ss
Ys
Z Layshaft Zs Zs
3R
3rd Gear Reverse (4 wheel drive)
T Reverse Low Ts
Y Mainshaft Ys
4R
4th Gear Reverse (4 wheel drive)
V Reverse High Vs
Y Mainshaft Ys
2-17
APACHE AS720 SERIES
1R 2R
W V W V
T U T U
Y Y
Z Z
S S
3R 4R
W V W V
T U T U
Y Y
Z Z
S S
2-18
APACHE AS720 SERIES
Gearbox
Clutch Operation
Forward, Reverse
The forward and reverse clutch units are very similar in design and operate in the same way. The following descrip-
tion refers to one unit and can be applied to either the forward or reverse clutch units.
The clutch 1 transfers drive from the input shaft A3 to either gear G1 or gear G2 depending on which of the two
clutches (A1 or A2) is engaged, transferring drive to the mainshaft. When neither clutch is engaged, neutral is
selected.
The clutches are of the wet, multi-plate type.
The clutch housings and input shaft are a one piece assembly A3. The assembly is permanently driven by the
engine via the torque converter. Clutch counter plates 3 are also permanent driven via meshing teeth inside the
clutch housings. Clutch friction plates 4 are meshed with the gear/plate carriers (G1 and G2).
In the diagram, clutch A1 is engaged. The counter plates 3 and friction plates 4 are pressed together by hydrauli-
cally actuated piston 5. Drive is then transmitted from the input shaft to the gear G1. Clutch A2 is disengaged and
no drive is transmitted to gear/plate carrier G2. The gear is also free to rotate on the input shaft assembly.
Actuation of the hydraulic pistons 10 and 5 is controlled via two position solenoid valves E1 and E2†. When neutral
is selected, solenoids E1 and E2 are deactivated and the flow of pressurized oil to the clutches is blocked. Springs
8 and 9 move the pistons away from the clutch plates and oil from both pistons is vented to the sump. When for
example clutch A1 is selected to be engaged, solenoid valve E1 is energized and solenoid valve E2 is de-ener-
gized. Pressurized oil is diverted via cross drillings inside the input shaft A3 to the clutch piston 5. Pressure from
clutch A2 is vented to the sump via the solenoid valve spool E2. Oil is prevented from leaking by seals 6 on the pis-
tons and ring seals 7 on the input shaft A3.
† The valve E is shown using symbols.
Mainshaft, Layshaft, 6 Speed
The mainshaft, layshaft and 6 speed units all incorporate one clutch and not two, as in the forward and reverse
units. The operation of the single clutches is the same as for one clutch in the forward or reverse units.
2-19
2-20
E1
1
A3 G1 A1 6 5 6 10 A2 G2
APACHE AS720 SERIES
E2
8 9
4 3
APACHE AS720 SERIES
Propshafts
Removal and Replacement
Removal
Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.
Replacement
Upon reassembly, after lubricating sliding joints with
Lucas X-tra Heavy Duty grease, align the shafts
against identification marks previously made or, in the
case of a shaft being renewed, use the manufac-
turer’s alignment markings.
Apply Loctite 242 to threads of all flange bolts.
Retaining straps C stretch with use, therefore these
straps must always be replaced with new ones.
A B
A396840
The propshaft must have both ends exactly on the

same plane as shown at X. The yokes must not be at right angles as
at Y or at an intermediate angle as at Z.
Torque Settings
Item N•m kgf m lbf ft

C
A
A 75 - 85 7.7 - 8.7 55 - 63
B 118 12 87
A
Y
A
Z
2-21
APACHE AS720 SERIES
Transmission
NOTE: This illustration shows a typical machine.
J H H
K
R c
R
M
P N
S
L
a b
Y Z
D
B
NOTICE: The gearbox is heavy. Unless it is safely supported during removal and replacement it could fall and
cause injury. Make sure that you have access to suitable jacks and a gearbox locating ‘cradle’ before attempting to
remove the gearbox.
The following procedures do not relate to any specific gearbox installation. For details of specific gearbox removal
and replacement procedures refer to the relevant vehicle manufactures documentation.
WARNING! A raised and badly supported machine can fall on you. Position the machine on a firm, level
surface. Before raising one end ensure the other end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine when working under it.
WARNING! Disconnect the battery, to prevent the engine being started while you are beneath the machine.
Removal
1. Park the machine on firm level ground. The gearbox is heavy. If the ground is soft or uneven it will not be pos-
sible to remove the gearbox safely.
2. Note that at least 31.5 in. (800 mm) clearance will be required between the ground and machine underside to
allow the gearbox to be pulled clear.
3. Remove the propshafts from the gearbox - see Propshafts.
4. If the gearbox is fitted with a hydraulic pump, Drain the hydraulic system and remove the pump. See the
machine manufacturers documentation.
2-22
APACHE AS720 SERIES
5. Drain the gearbox oil, see Section 3, Routine Maintenance.
6. Remove the access bung/plate at the bottom of the torque converter housing. Through the access hole, loosen
and remove the torque converter to engine flywheel retaining bolts D.
J H H
K
R c
R
M
P N
S
L
a b
Y Z
D
B
7. Support the gearbox using a suitable trolley jack and cradle. The gearbox must be securely located on the cra-
dle as shown at Y.
8. Make sure that the weight of the gearbox is supported by the trolley jack and then remove the gearbox mount-
ing bolts H.
9. Pull off the breather tube K. Undo the gearbox dipstick fixing nut L and then remove the dipstick tube.
10. Label and then uncouple the solenoid control valve electrical connectors M, oil pressure sender N and temper-
ature sender P (if fitted). Uncouple the electrical connector at the speed sensor S.
11. Disconnect the gearbox oil cooler hoses R.
12. Support the engine as required - see the machine manufacturers documentation. Undo the torque converter
housing bolts J.
13. Manoeuvre the gearbox with the torque convertor clear of the engine housing.
14. Lower the trolley jack and pull the gearbox and torque convertor clear of the machine.
2-23
APACHE AS720 SERIES
Replacement
Replacement is a reversal of the removal procedure but note the following:
1. Before replacing the gearbox remove circlip 5 and with-
draw the pump driveshaft 6 together with its bearing 7
approximately 2 in. (50 mm). The shaft can then be
engaged after the gearbox has been fitted, making
replacing the gearbox easier. Remember to engage the
pump drive shaft, refit the bearing and circlip after the
gearbox has been fitted.
2. Set the torque converter as described in Torque Con- 6
verter, Removal and Replacement.
5
3. Align the Torque Converter

It is vitally important that the torque converter is fitted at the
gearbox and engine flywheel correctly. Failure to locate the
converter correctly will result in damage to the gearbox oil pump
on engine start up. Proceed as follows:
Make sure that the torque converter drive dogs 1 are correctly
engaged with the pump 2 on the gearbox. Temporarily tie the
converter onto the gearbox. Use wire tied at a drive plate bolt 8
hole to a convenient point on the outside of the gearbox.
Take note of the flywheel and drive plate fixing hole phasing.
The heads of the bolts 3 will foul the flywheel if phasing is incor-
rect.
Before bolting the torque converter housing to the engine make
sure the mating faces are fully together (DO NOT USE
FORCE). The drive plate 8 should also be mated close to the
flywheel. Do not force the components together with the fixing
1
bolts.
Make sure that the torque converter is free to rotate slightly
within the clearance of the location bolt holes. If you cannot
rotate the converter it is trapped either by bolt heads 3 or by
incorrectly located pump drive dogs. Make sure that all is well
before tightening the bolts.
4. Fill the gearbox with the specified amount and type of oil (see
Section 3, Routine Maintenance). Leave hose R off until the fill-
ing operation is complete. After filling refit hose R. 2
Torque Settings
B 79 8 58
D 44 4.5 32
H 237 24 55 - 63
J, T 98 10 72
2-24
APACHE AS720 SERIES
Torque Converter
NOTICE: Two sizes of torque converter are available: 11
Inch and 12.2 Inch (280 mm and 310 mm) (see X and Y).
These dimensions refer to the internal section of the
converter in inches. Ensure the correct tightening torques
and procedures are selected.
11 Inch (280 mm) dia Torque Converter
Removal
See Transmission - Removal and Replacement for
transmission/torque converter removal.
Replacing (Using Alignment Tool)
Ensure that flywheel face, drive plate, and hardware are
clean and free from burrs or other surface imperfections.
X 11 in. Ø (280 mm) Y 12.2 in. Ø (310 mm)

1. Offer drive plate and annulus 1 to the torque con-
verter.
2. Place the torque converter alignment tool A over the
torque converter spigot, making sure that the tool
locates in two of the converter bolt holes as shown. It
is important to note that the converter drive tube must
be protected against damage or contamination at all
times.
3. Apply Loctite 242 to the threads and fit four new spe-
cial drive plate retaining bolts 2; torque tighten to 30
lb-ft (40 N•m). Remove the alignment tool and fit the
remaining two retaining bolts 2.
4. Offer the torque converter and drive plate/annulus

assembly to the flywheel, bolt the drive plate annulus
to the flywheel (use only 3 bolts). Check the converter
runout as shown at B, which should not exceed 0.015
in. (0.38 mm).
NOTE: In the unlikely event that the run-out exceeds
0.015 in. (0.38 mm), remove the converter and
check the spigot for burrs, remove the drive plate
and rotate it 180 degrees on the torque converter.
Repeat steps 2 to 4.
5. Remove the torque converter and drive plate/annulus
assembly from the flywheel.
6. Install the converter assembly to the transmission/
engine:
2-25
APACHE AS720 SERIES
6.1. Install the torque converter with its drive plate/annulus sub-assembly
onto the transmission input shaft, making sure that the dogs on the
converter pump drive shaft engage with the recesses in the pump.
Also take care not to damage the oil seal.
6.2. Rotate the engine flywheel so that one bolt hole is in the six o’clock
position.
6.3. Rotate the torque converter and drive plate assembly so that one bolt
hole is in the six o’clock position.
6.4. Install the transmission/torque converter assembly to the engine.
6.5. Remove the access plate from the bottom of the engine flywheel
housing and, through the access hole, fit and hand tighten one bolt 3
in the sex o’clock position.
NOTE: It is important to mount washers 4 with the outside diameter radius
against the drive plate, i.e. facing towards the flywheel.
6.6. Rotate the flywheel until the next bolt hole is accessible. Apply Loctite
242 to the threads of the next bolt 3 then fit and hand-tighten. Repeat
this operation until all bolts 3 are fitted. Finally, torque tighten bolts 3
to 14 lb-ft (19 N•m; 1.9 kg•m), rotating the flywheel each time to align the bolts with the access hole.
Refit access plate.
Torque Settings (11Inch (280 mm) Only)
2 40 5 30
3 19 2 14
Replacing 11 Inch (280 mm) Converter (Without Alignment Tool)

If the torque converter alignment tool A is not available, the following
method should be used to replace the convertor.
Offer drive plate and drive plate annulus 1 to torque converter, tighten-
ing bolts 2 finger tight only.
Bolt drive plate to flywheel and check that un-out of pump drive shaft B
does not exceed maximum permissible 0.015 in. (0.38 mm). If incorrect,
tap torque converter by hand to reposition.
When correct, mark position of flywheel and drive plate, then remove drive plate and annulus from flywheel.
Tighten bolts 2 to 30 lb-ft (40 N•m; 4.1 kg•m) after applying Loctite 242 to the threads.
Fit torque converter/drive plate sub-assembly to flywheel; align marks, then fit washers 4 and bolts 3. Tighten bolts
3 to 14 lb-ft (19 N•m; 1.9 kg•m) after applying Loctite 242 to the threads.
NOTE: It is important to mount washers 4 with the outside diameter radius against the drive plate (i.e. facing
towards the flywheel).
NOTE: When installing transmission to washers converter assembly, ensure that the dogs on the converter oil
seal spigot engage with the recesses on the transmission input. Take care not to damage the oil seal.
Torque Converter Stall Test

NOTE: DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat. Make sure
that the oil level is correct and at normal operating temperature.
2-26
APACHE AS720 SERIES
Before completing the following test, remove the transmission dipstick. If there is any sign of smoke emitting from
the dipstick tube STOP THE TEST IMMEDIATELY and dismantle the transmission for servicing.
1. Ensure that the engine and transmission are at normal working temperature. Run engine at maximum speed
and check the No Load Speed (High Idle Speed - U.S.A.). See Engine Technical Data for correct figure;
adjust if necessary.
2. Apply the footbrake firmly. If necessary, set the machine against a fixed obstruction.
3. Select 2nd speed forward drive and open throttle fully. Record the engine speed from the tachometer. Repeat
the test for 3rd speed forward and record the reading.
4. Repeat step 3 except this time select 2nd and 3rd gear reverse drive respectively. Record the readings.
NOTE: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energized during
the test.
5. All recorded readings should be specified at Torque Converter Stall in Transmission Technical Data.
Record the rpm readings after 2 seconds of full throttle. After 3 seconds, the rpms will increase as the machine
tries harder to move. Rpm readings of 2450 or lower are within normal operating specifications. If rpms are higher
than 2450, please contact the factory for further testing and instruction.
Clutch control valves fitted to the PS764 gearbox may be an assembly of 5 or 6 solenoids. The following details
describe both systems:
WARNING! DO NOT go underneath the machine with the engine running. Switch off the engine, apply the
parking brake and chock both sides of all wheels before going underneath the machine.
2-27
APACHE AS720 SERIES
Pressure and Flow Testing
B1
V M
S
S
Z
Y
X
C004190-C1
2-28
APACHE AS720 SERIES
Before completing any of the transmission pressure/flow tests, make sure that the oil level is correct and at normal
operating temperature (not less than 50°C (122°F)).
WARNING! Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to
check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard
close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.
WARNING! DO NOT go underneath the machine with the engine running. Switch off the engine, apply the
parking brake and chock both sides of all wheels before going underneath the machine.
WARNING! If a 4 wheel drive machine is to be raised and the engine/transmission run, make sure all four
wheels are off the ground and supported by axle stands. If only one pair of wheels is raised, the machine
could still drive through the other axle.
WARNING! Under no circumstances must the engine be run with the transmission in gear and only one
driving wheel jacked clear of the ground, since the wheel on the ground will move the machine.
Test Points:
A Mainline pressure
B Converter inlet and converter relief valve
pressure
B1 Converter inlet and converter relief valve
pressure - Lock up torque converter vari-
ant
C Converter outlet pressure
F Pump flow (remove filter and fit adapters)
J Lubrication pressure
Clutches:
S 2 and 4 wheel drive clutch pressure
T Forward low ratio clutch pressure
U Forward high ratio clutch pressure
V Reverse high ratio clutch pressure
W Reverse low ratio clutch pressure
X 6 speed clutch pressure (6 speed gear-
box only)
Y Mainshaft clutch pressure
Z Layshaft clutch pressure
Other Items:
L Torque converter relief valve
M Pressure maintenance valve
2-29
APACHE AS720 SERIES
Test Procedures:
Pump Flow
Mainline Pressure
Converter in Pressure
Converter Relief (Safety) Valve Pressure
Converter Out Pressure and Oil Cooler Flow Rate
Clutches:
Isolating a Suspect Clutch
Individual Clutch Leakage Test
Record the test results carefully. Make a copy of the Transmission Technical Data Check List and fill in the test
results, see Fault Finding. Correct completion of the checklist will assist the engineer in diagnosing gearbox abnor-
malities. Alternatively the check list can be emailed to the Transmission Service Technical Service Team should
and further assistance be required.
2-30
APACHE AS720 SERIES
Pressure and Flow Testing (continued)
B1
B
C004210-C1
2-31
APACHE AS720 SERIES
Pump Flow
1. Stop engine, remove the gearbox oil filter and fit adapter X (460/
15708) into the gearbox casing. Connect flowmeter W (892/
W
00268).
2. Start engine and run at 1000 rev/min. With the transmission in
neutral the flowmeter will show the Pump Flow which should be
as shown in Technical Data - Section 4. A low reading indicates a
worn pump or blocked suction strainer.
3. Repeat Step 2 and note gauge readings with engine running at
2000 rev/min.
717890
4. Stop engine and remove test adapters, refit filter.
Mainline Pressure X
1. Stop engine, connect a 0 - 300 lbf/in2 (0 - 20 bar) pressure gauge
to test connector A.
2. Start engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show the Main
Line Pressure which should be as shown in Technical Data - Section 4. A low reading can be caused by either
a faulty pressure maintenance valve or a worn pump. A high or low reading may indicate a faulty pressure
maintenance valve.
3. Repeat Step 2, with engine running at 2000 rev/min note gauge readings which should be as shown in Techni-
cal Data - Section 4.
4. Stop engine and remove test gauge.
Converter In Pressure
Note that the converter in pressure is affected by the torque converter relief valve operation. Before carrying out
tests check the operation of the relief valve (see Converter Relief (Safety) Valve Pressure).
1. Stop engine, connect a 0 - 300 lbf/in2 (0 - 20 bar) pressure gauge to test point B or B1 as applicable.
NOTE: A pressure test kit (998/10650) is available to enable easier pressure gauge connection.
2. Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show Con-
verter In Pressure which should be as shown in Technical Data - Section 4. A high or low reading could indi-
cate a faulty converter relief valve.
3. Stop engine and remove pressure test gauge.
2-32
APACHE AS720 SERIES
Pressure and Flow Testing (continued)
B1
C004230-C1
2-33
APACHE AS720 SERIES
Converter Relief (Safety)
Valve Pressure
The purpose of the torque converter relief valve is to protect the torque converter from excessive oil pressure.
Excessive oil pressure can be generated when the transmission oil temperature is below 122°F (50°C) and/or the
engine is run at over 2000 rev/min. In this event the relief valve opens and returns oil directly to the transmission
sump, bypassing the torque converter, cooler and clutch lubrication circuits, protecting against damage due to
excessive pressure. For this reason it is essential that the transmission oil is above 122°F (50°C) and the engine is
run between idle and 1000 rev/min when testing the relief valve.
1. Connect a 0 - 300 lbf/in2 (0 - 20 bar) pressure gauge to test point B or B1 as applicable.

NOTE: A pressure test kit (998/10650) is available to enable easier pressure gauge connection.
2. Fit a load valve P into the converter out line.
Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT),
before starting the following pressure test. Failure to do this could damage the pump.
DO NOT allow the pressure to exceed 120 lbf/in2 (8.3 bar) or damage to the converter seals will be caused.
3. Start the engine and run at 1000 rev/min. With the transmission in neutral, slowly screw down the load valve P
whilst observing the gauge reading which should rise to the Converter Relief (Safety) Valve setting as specified
in Technical Data - Section 4.
Note that the gauge pressure will fall once the valve has opened. This is normal relief valve operation and does not
indicate a fault. If necessary reset the load valve P and perform the test again, watching the pressure gauge care-
fully.
4. If the converter relief valve opens at a pressure higher than specified then the valve is faulty. A low opening
pressure indicates a leaking pump to casing seal or a faulty converter relief valve.
5. Stop engine, remove test gauges and load valve. Refit hoses to original position.
Converter Out Pressure/Oil Cooler
Flow Rate
Note that the converter out pressure and oil cooler flow rate are affected by the torque converter relief valve opera-
tion. Before carrying out tests check the operation of the relief valve (see Converter Relief (Safety) Valve Pressure.
1. Stop engine, connect a 0 - 300 lbf/in2 (0 - 20 bar) pressure gauge and flowmeter into the converter out line as
shown at C and K respectively.
2. Run the engine at 1000 rev/min with transmission in neutral. The pressure gauge indicates the Converter Out
Pressure and the flowmeter indicates the Oil Cooler Flow Rate, both readings should be as specified in Tech-
nical Data - Section 4. A high pressure together with low flow could be caused by a blocked oil cooler or inter-
nal leakage.
3. Repeat Step 2, with engine running at 2000 rev/min note gauge readings which should be as shown in Techni-
cal Data - Section 4.
4. Stop engine, remove test gauges and refit hoses to original position.
Note that the lubrication pressure is affected by the torque converter relief valve operation. Before carrying out
tests check the operation of the relief valve (see Converter Relief (Safety) Valve Pressure.
1. Stop engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as
shown at J.
2. Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will indicate the
Lubrication Pressure which should be as specified in Technical Data - Section 4.
3. Repeat Step 2 and note gauge readings with engine running at 2000 rev/min. If the pressure is high the oil
cooler may be blocked, (see Converter Out Pressure/Oil Cooler Flow Rate).
4. Stop engine and remove pressure gauge.
2-34
APACHE AS720 SERIES
W
V
T U
Z
Y
2-35
APACHE AS720 SERIES
Pressure Testing - Clutches
Isolating a Suspect Clutch
By performing the tests in the first 3 gears in forward and reverse all the clutches in the gearbox will be engaged,
ensuring any clutch leakage will be easy to identify. Draw a table as shown so that you can record the results.
Clutch Pressure Test Results - 6 Speed Powershift

Clutches Engaged
Gear
Forward bar lbf/in2 Reverse bar lbf/in2
1st X, Z W, Z
2nd T, Z V, Z
3rd U, Z W, Y

Clutches Engaged
Gear
1st T, Z W, Z
2nd U, Z V, Z
3rd T, Y W, Y
1. Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A (mainline pressure test
point).
2. Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.
NOTE: When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the
machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the
parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position
for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be
fully operational. Alternatively, disconnect the switch at the park brake.
3. Start engine and run at 1000 rev/min, engage 1st gear forward. Record the pressure reading. Repeat the test
for 2nd and 3rd gears forward and 1st, 2nd and 3rd gears reverse. Record the pressure readings as shown in
the example below:
Example:

Clutches Engaged
Gear
1st T, Z 13.4 194 W, Z 13.4 194
2nd U, Z 12.0 175 V, Z 13.6 197
3rd T, Y 13.5 195 W, Y 13.5 195
Readings should not vary between clutches by more than 0.7 bar (10 lbf/in2). In the example shown, we can see
that pressure is low when 2nd gear forward is selected, indicating clutch leakage.
2-36
APACHE AS720 SERIES
From the table we can see that the layshaft clutch Z is working normally (1st gear forward, 1st and 2nd gears
reverse all show normal operating pressure). We can assume that the forward high clutch U is leaking.
By carrying out ‘Individual Clutch Leakage Tests', (see next page) we can confirm that the forward high clutch U is
leaking.
W
V
T U
Z
Y
2-37
APACHE AS720 SERIES
Individual Clutch Leakage Test
When testing individual clutch pressures it is necessary to isolate the clutch being tested. So for instance, on a 6
speed gearbox, to check the forward low clutch T we must select 2nd gear forward - this would energize the for-
ward low (T) and layshaft (Z) clutches. Because we only want to check the forward low (T) clutch pressure and not
the layshaft (Z) clutch pressure, remove the electrical connector to the 6 speed clutch solenoid Xs BEFORE select-
ing 2nd gear.
On a 4 speed gearbox, to check the forward high clutch (U) we must select 2nd gear forward - this would energize
the forward high (U) and layshaft (Z) clutches. Because we only want to check the forward high (U) clutch pressure
and not the layshaft (Z) clutch pressure, remove the electrical connector to the layshaft clutch solenoid Zs
BEFORE selecting 2nd gear.
Use the table below to determine which solenoid electrical connectors should be removed when pressure testing
individual clutches. Note that as the first 3 forward and reverse gears utilize all clutches, there is no need to select
other gears when testing for leakage.
6 Speed Gearbox
Gear Selected Clutches Engaged Solenoids Energized
1st Forward 6 Speed and Layshaft - X, Z Xs, Zs
2nd Forward Forward Low and Layshaft - T, Z Ts, Zs
3rd Forward Forward High and Layshaft - U, Z Us, Zs
1st Reverse Reverse Low and Layshaft - W, Z Ws, Zs

2nd Reverse Reverse High and Layshaft - V, Z Vs, Zs
3rd Reverse Reverse Low and Mainshaft - W, Y Ws, Ys
4 Speed Gearbox
Gear Selected Clutches Engaged Solenoids Energized
1st Forward Forward Low and Layshaft - T, Z Ts, Zs
2nd Forward Forward High and Layshaft - U, Z Us, Zs
3rd Forward Forward Low and Mainshaft - T, Y Ts, Ys
1st Reverse Reverse Low and Layshaft - W, Z Ws, Zs

2nd Reverse Reverse High and Layshaft - V, Z Vs, Zs
3rd Reverse Reverse Low and Mainshaft - W, Y Ws, Ys
.In the following procedures the forward low clutch T is tested on a 4

speed gearbox, therefore in step 2 a pressure gauge is connected to
Ts Us
the forward low clutch test point. Ws
Vs
When testing other suspect clutches connect a gauge to the relevant
suspect clutch test point. Because the forward low clutch is suspect, a
gear must be selected that will use the forward low clutch, in this
instance 2nd gear forward on a 4 speed gearbox.
NOTE: When testing the 2/4WD clutch remove the feed pipe R and fit
service tool. This pipe incorporates a test point. Replace the
original pipe when testing is complete. Ss
Ys Note:
1. Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to Zs No Xs on 4
test connector A, (mainline pressure test point). Xs Speed Box.
2. Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connec-

tor T (forward low ratio clutch test point).
2-38
APACHE AS720 SERIES
3. Remove the layshaft clutch solenoid feed connector Zs, at the solenoid control valve. This ensures that only
the forward low clutch T is energized when 2nd gear forward is selected.
4. Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.
NOTE: When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the
machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the
parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position
for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be
fully operational. Alternatively, disconnect the switch at the park brake.
5. Start engine and run at 1000 rev/min, select 2nd gear forward. Note the pressure readings on both gauges,
which should not vary by more than 0.7 bar (10 lbf/in2). If the difference on the gauges is greater than 0.7 bar
(10 lbf/in2) do the following:
a. Stop the engine and interchange the gauges.
b. Start the engine and run at 1000 rev/min, select 2nd gear forward. If the difference on the gauges is still
greater than 0.7 bar (10 lbf/in2) dismantle the forward low clutch for servicing.
c. If after interchanging the gauges, the readings are different than at step 5, have the gauges calibrated and
repeat the testing procedure
2-39
APACHE AS720 SERIES
Fault Finding
Introduction
The Powershift fault finding procedures concern themselves with general problems normally associated with this
type of transmission system, and so the layout is a ‘Possible Cause and Remedy’ type.
For testing procedures for the Powershift transmission refer to Flow Pressure and Stall Tests.
Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been
used (Lucas Universal Hydraulic oil) or approved equivalent.
2-40
APACHE AS720 SERIES
General
LACK OF POWER Remedy

Possible Cause
1. Check and if necessary repair engine.
1. Poor engine condition. 2. Top up system.
2. Low oil level. 3. Check and if necessary repair or renew pump.
3. Worn pump. 4. Check and if necessary repair or renew torque
4. Torque converter damage. converter.
5. Low mainline pressure. 5. See fault ‘Low Mainline Pressure’.
6. Clutches slipping. 6. Check clutch pressures, check clutch piston
7. Internal leakage. rings.
8. High stall speeds. 7. Check internal cored galleries and the casting
9. Low stall speeds. for porosity.
10. Overheating. 8. See fault ‘High Stall Speeds (on ALL
clutches)’.
9. See fault ‘Low Stall Speeds (on All clutches).
10. See fault ‘Overheating’.
LOW MAINLINE PRESSURE Remedy

Possible Cause
1. Check and if necessary repair or renew pump.
1. Worn pump. 2. Clean suction strainer.
2. Blocked suction strainer. 3. Free off or renew valve.
3. Pressure maintaining valve sticking/leaking. 4 a. Internal leakage (cored galleries) - inspect/
4. Oil aerated (foaming). repair transmission.
5. Oil leak thru 2/4 WD circuit. b. Dirty suction strainer - clean strainer.
c. High oil level - drain to proper level.
d. Incorrect grade of oil - drain then refill with
correct oil.
5 a. Check external pipework for 2/4 WD circuit
b. Check 2/4 WD (pressure) circuit. Refer to
Fault Finding - 2/4 Wheel Drive Clutch.
HIGH STALL SPEEDS (ON ALL CLUTCHES) Remedy

Possible Cause
1. Check and if necessary repair or renew con-
1. Damaged converter blades. verter.
2. Clutches slipping. 2. Strip, inspect and fit new clutch friction/counter
3. Internal leakage. plates.
3. Check internal cored galleries and the casting
for porosity.
LOW STALL SPEEDS (ON ALL CLUTCHES) Remedy

Possible Cause
1. Check and if necessary repair engine.
1. Poor engine condition. 2. Check and if necessary repair torque con-
2. Torque converter reaction member clutch verter.
slipping.
LOW CONVERTER OUT PRESSURE Remedy

Possible Cause
1. See fault heading ‘Low Mainline Pressure’.
1. Low mainline pressure. 2. Check and if necessary renew converter.
2. Converter internal leakage. 3. Check and if necessary repair relief valve.
3. Converter relief valve faulty. 4. See item 10 in fault ‘Overheating’.
4. Restriction in converter feed.
2-41
APACHE AS720 SERIES
LOW PUMP FLOW Remedy

Possible Cause
1. Top up system.
1. Low oil level. 2. Clean suction strainer.
2. Blocked suction strainer. 3. Repair or renew pump.
3. Worn pump.
HIGH CONVERTER OUT PRESSURE Remedy

Possible Cause
1. Clean cooler, free blockage.
1. Oil cooler/lines blockage.
LOW LUBRICATION PRESSURE Remedy

Possible Cause
1. See fault ‘Low Mainline Pressure’.
1. Low mainline pressure. 2. Clean cooler, free blockage.
2. Oil cooler/lines blockage. 3. Repair line.
3. Ruptured lubrication line. 4. Check and if necessary renew converter.
4. Converter internal leakage. 5. Check and if necessary repair or renew relief
5. Converter relief valve faulty. valve.
6. Leak at pump to case joint (indicated by low 6. Check and if necessary repair or replace as
cooler flow). necessary.
7. Restriction in converter feed. 7. See item 10 in ‘Overheating’.
LOW CLUTCH PRESSURE AND/OR CLUTCH Remedy

SLIPPING
Possible Cause 1. See fault ‘Low Mainline Pressure’.
2. Check flow and if necessary repair or renew
1. Low mainline pressure. pump.
2. Worn pump. 3. Remove solenoid(s) and clear restriction in
3. Blocked restrictor orifice in solenoid valve solenoid valve block.
block. 4. Confirm with a clutch leak test, if required
4. Clutch seals worn. renew clutch seals.
5. Clutch piston rings worn. 5. Confirm with a clutch leak test, renew piston
6. Mechanical failure. rings.
6. Strip and rebuild clutch, renew parts as
required.
OVERHEATING Remedy
Possible Cause
1. Top up system.
1. Low oil level. 2. Drain oil to correct level.
2. High oil level. 3. Renew or repair hoses.
3. Trapped or kinked hoses in cooler system. 4. Repair or renew the converter relief valve.
4. Low converter out pressure and flow rate. 5. Clean cooler.
5. Oil cooler blockage. 6. Select correct gears to suit working conditions.
6. Operating in wrong gear range usage. 7. Rectify water system problems, e.g. radiator,
7. Water system overheating. cooler lines, low water level etc.
8. Oil aerated (foaming). 8. See fault ‘Low Mainline Pressure’, item 4.
9. Clutch piston(s) sticking on return stroke. 9. Check and repair clutch piston(s) and seal(s).
10. Cored galleries on front housing pump 10. Replace front housing (or rectify existing hous-
mounting face wrong depth (indicated with ing).
an excessively low pressure and flow on the 11. Check for damaged surface on both compo-
converter out cooling line). nents and loose pump mounting bolts.
11. Leakage across pump mounting face and
front case.
2-42
Chart A
Chart A - Machine drives but lacks power in all gears. Gearbox oil may also be overheating
START Top up oil level
Is gearbox oil level low? YES

Check reason for contamination.
Rectify as applicable Drain and flush
the oil.
NO
Is gearbox oil the correct type and Check the operation of the parking
YES
free from contamination? and service brakes.
YES NO NO
Torque converter reaction member

Carry out a Torque Converter Stall Test Is the engine performance normal?
YES Are all the stall speeds too low? YES YES
clutch slipping. Remove the gearbox
in all gears. Are all the stall speeds See Checking the Engine Power. and renew the torque converter.
outside specifications?
NO
ITL Transmission Symptoms and Solutions
Carry out Mainline Oil Pressure Test Carry out Torque Converter In Check condition of torque
YES Pressure Test. Is torque converter in NO
Is mainline oil pressure correct? converter relief valve.
pressure correct? Clean or renew as applicable.
NO
YES
Check condition of pressure

maintenance
valve. Clean or renew as applicable.
Check for signs of excessive external
Machine drives but lack power in all gears. Gearbox may also be overheating.
Too high?
YES
Cooler lines restricted or blocked. Oil
oil leakage.
cooler blocked.
Carry out Torque Converter Out

Pressure Test. Is torque converter out NO
Carry out Mainline Oil Pressure and pressure correct?

Flow Tests YES Cooler lines or cooler leaking. Internal
Is mainline oil pressure /flow correct? Too low? leakage. Remove the gearbox, torque
YES
YES converter housing and pump, check
NO
all sealing faces for damage.
It may be that another fault may have

Remove and dismantle gearbox. been overlooked. Go back to the start
Check condition of pump, casings for of the fault finding and re-check.
internal/external leakage.The clutches
will have been slipping due to low oil
pressure - dismantle all clutches and
715610
renew as required.
2-43
ITL TROUBLESHOOTING
2-44
Chart B - Machine does not drive in any gear. Chart B
START
Is gearbox oil level low? YES Top up oil level.
NO
Are the park brake and transmission NO Renew switch or repair wiring as
dump switches working correctly? applicable.
Machine does not drive in any gear.
ITL TROUBLESHOOTING
YES
Is the gear selection column switch

NO Renew switch or repair wiring as
working correctly. See Powershift
Electrical System Tests. applicable.
NO
YES Carry out Torque Converter In Check condition of torque

Carry out Mainline Oil Pressure Test Pressure Test
Is mainline oil pressure correct? NO converter relief valve.
Is torque converter in pressure Clean or renew as applicable.
correct?
NO
YES
Check condition of pressure Are the clutch control solenoids

maintenance working? Check control valve
valve. Clean or renew as applicable. solenoids for correct resistance
and wiring continuity - check Renew solenoid or repair wiring as
Check for signs of excessive external NO
forward and reverse solenoids applicable.
oil leakage.
first.
YES
Carry out Mainline Oil Pressure and
Flow Tests YES
Is mainline oil pressure /flow correct? 6 Speed - Is the gearbox ECU connected
correctly? Clean connectors and fit securely.
NO
4 Speed - Are the Powershift relays
NO
connected correctly?
YES
Remove and dismantle gearbox.
Check condition of pump, casings for
internal/external leakage. Check 6 Speed - Renew the ECU.
pump drive dogs on torque converter 4 Speed - Renew the relays as
are undamaged. applicable. A396290
Chart E
Chart E - Gearbox oil overheats.

START
Is the gearbox oil cooler heat Clean the matrix.

exchanger matrix clogged with YES
Gearbox oil overheats.
dirt/chaff?
Adjust oil to correct level.
Is gearbox oil level incorrect (too low YES

or too high)?
NO Rectify as applicable. Drain and flush
oil.
Is gearbox oil the correct type and

free from contamination, especially YES
water contamination?
Rectify routing/renew hoses as

NO
applicable
Are the cooler lines kinked, or

trapped? YES
Educate operator.
NO
Is the machine being operated NO

correctly - in the correct gear range?
YES
Carry out Torque Converter Out Check condition of torque

NO
Pressure/Flow Test. Is the pressure converter relief valve.
correct? Clean or renew as applicable.
YES
YES
Is oil flow correct? NO

Is the cooling circuit restricted or Rectify as applicable.
YES
blocked internally? Remove cooler,
check lines and cooler for internal
YES blockages.
NO
Remove gearbox. Check condition of
pump, casings for internal/external
leakage. Inspect clutches for signs of
jammed pistons. Repair clutches as
applicable. 715630
2-45
ITL TROUBLESHOOTING
2-46
Chart F - External oil leakage. Chart F
START
External oil leakage.
Is the oil leaking from the gearbox or

from another source? Remember that
the main machine hydraulic pump Rectify as applicable.
YES
may be mounted on the gearbox. Oil
leakage from inside the torque
converter housing may be engine oil.
NO
ITL TROUBLESHOOTING
Drain oil to correct level.

Is gearbox oil level too high? YES Check oil for water contamination.
NO
YES Rectify as applicable.
NO
Remove valve manifold, check sealing

Is oil leaking from the solenoid control faces for damage. Renew gaskets,
valve manifold/solenoid valve stem? YES
solenoids and components as
applicable.
NO
Remove gearbox. Remove the torque

converter housing. Check the sealing
Is oil leaking between the torque faces for signs of damage. Rectify as
converter housing to front case joint? YES
applicable. Re-seal casings, See
Powershift Gearbox - Assembly step 10.
NO
Carefully check casings for signs of

damage. If damage is evident, remove
the gearbox and renew components
as required.
A396330
Chart G
Chart G - Noisy operation.

Noisy operation.
START
Is gearbox oil level low? YES Top up oil level.
NO

Is gearbox oil the correct type and
NO Rectify as applicable Drain and flush
free from contamination?
oil.
NO
Carry out Torque Converter Out

YES
Pressure Test. Is the pressure correct?
NO NO YES
Check the condition of the torque

converter relief valve. Make sure that
the cooler lines are not restricted.
Rectify as applicable.
Remove and dismantle gearbox.

Check all components for signs of
wear or damage, especially shaft
seals and bearings. Rectify as
applicable.
715640
2-47
ITL TROUBLESHOOTING
NOTES
ZF TRANSMISSION (AS1020 AND AS1220 ONLY)
2011 AS1020 and AS1220 Apache

with ZF Transmission
Clutch Combinations
Gear Engaged Clutch ZF Wire Number
Forward
1F K1, KV 432, 409
2F K4, K1 456, 432
3F KV, K2 409, 451
4F K4, K2 456, 451
5F K3, KV 455, 409
6F K4, K3 456, 455
Reverse
1R KR, K1 410, 432
2R KR, K2 410, 451
3R KR, K3 410, 455
1. “K4” - Clutch Shaft 5. “K2” - Clutch Shaft

2. “KV” - Clutch Shaft 6. “K3/AB” - Clutch Shaft/Output
3. “AN/PTO” - Input Shaft/Power Take-off 7. “K1” - Clutch Shaft
4. “KR” - Clutch Shaft 8. Electro-hydraulic Control with Intermedi-
ate Sheet and Duct Plate
2-49
Pin Positions
Wire Number ZF TCU ZF Console ZF Floor ZF Manifold
409 9 15 15 5
410 10 12 12 2
432 32 13 13 3
451 51 16 16 6
455 55 14 14 4
456 56 11 11 1
ZF Power
C3 Bussman C4 Ignition
Wire Number C5 Converter C2 ZF Console ZF TCU
Connector Trip
07 C 1 12 - -
423 A - - 22 23
900 D - - 27 45
990 F - 7 - -
992 B - 10, 11 - -
Troubleshooting
If the transmission is not going into gear, follow these steps in order:
1. Check to see if the display shows the gear you have selected. If it does not, the problem could be in the
handle or the circuit board.
1. Remove the console plastic and by using the tables above verify the transmission computer is getting and
sending the signals through it. If not, it could be a computer problem or a connection problem.
1. Using the tables above, verify that the power in and out of the converter is correct.
Abbreviations
The following abbreviations are used in this section:
WK Converter Lockup Clutch
EST-37-A Ergocontrol
AEB Automatic determination of the filling parameters
TCU Transmission Control Unit
PTO Power Take-Off
2-50
Important Instructions
• Oil Level Check. See “Oil Level Check” on page 2-54.
• In the cold start phase, the engine must be running about 2 to 3 minutes at idling speed and the marking
on the oil dipstick must then be lying above the cold start mark.
• The oil level check in the transmission must be carried out at engine idling speed and operating
temperature of the transmission 176 to 194°F [80 to 90°C].
• At stationary engine, the oil level in the transmission is rising essentially, according to the installation
conditions.
• At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF recommends to start the
autonomous calibration of the shifting elements (AEB).
• The autonomous calibration of the shifting elements (AEB) must be started after the initial installation of
the transmission and the electronics in the vehicle at the vehicle manufacturer and after every replacement
of the transmission, the electrohydraulic control or the TCU in case of a failure.
• Put the controller at the starting of the engine always to the NEUTRAL position.
• At running engine and transmission in NEUTRAL, the parking brake must be engaged or the service brake
be actuated, to prevent the vehicle from rolling.
• Prior to every start off, loosen the parking brake.
• The engagement of the speed out of neutral is only possible under the programmed transmission input
speed (turbine speed).
• NEUTRAL position of the selector switch at higher vehicle speeds (above stepping speed) is not
admissible. Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.
• At stopped engine, there is on the controller, despite a preselected gear, no power flow between
transmission and engine, i.e. the transmission is in the idling position. The parking brake must therefore be
completely actuated.
• When leaving the vehicle, secure it additionally by brake blocks.
• The towing speed must in no case be higher than 6 mph [10 km/h], the towing distance not longer than 6
mi [10 km]. It is imperative to observe this specification because otherwise the transmission will be
damages due to insufficient oil supply. At a longer distance, the best solution would be to transport the
vehicle with a low loader.
• Operating temperature after the converter is at least 149 and 212°F [65 and 100°C] in continuous
operation, a short-term increase to a maximum of 248°F [120°C] is permitted.
• Sump temperature is 140°F to 194°F [60 to 90°C]. If exceeded, "WS" is displayed at 105°C.
• In case of irregularities on the transmission, put the vehicle out of service and contact your dealer.
ZF Electronics Protection
At the following operations, the ignition must be switched off and the control unit plug must be pulled off from the
ZF Electronics:
• At any kind of electrical operations on the vehicle.
• At welding operations on the vehicle.
• At insulation tests on the electric system.
2-51
Operation
Driving Preparation and Maintenance
Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the cor-
rect quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter as
well as the pipes must get filled with oil.
According to these cavities, the quantity of oil to be filled in, is greater than at the later oil fillings in the course of the
usual Maintenance service.
NOTE: Because the converter and also the oil cooler, installed in the vehicle, as well as the pipes can empty at
standstill into the transmission, the Oil level check must be carried out at engine idling speed and operating
Temperature of the transmission. See “Oil Level Check” on page 2-54.
CAUTION! At the oil level check, the prescribed safety directions according to # 6 of the regulations for the
prevention of accidents for power plants in Germany, and in all other countries, the respective national
regulations have to be absolutely observed.
CAUTION! For example, the vehicle has to be secured against rolling by blocks, articulated vehicles
additionally against unintended turning-in.
Driving and Shifting

NOTE: Which control lamps in the INFOCENTER (dashboard) are illuminated for the functional check, can be
different from vehicle manufacturer to vehicle manufacturer.
NOTE: Control elements and displays can be from the ZF, however can be also customize specific products; the
precise specifications must therefore be taken from the operating instructions of the respective vehicle
manufacturer.
Neutral Position
Neutral position will be selected via the controller.
After the ignition is switched on, the electronics remains in the waiting state.
By the position NEUTRAL of the controller, resp. by pressing the push button NEUTRAL, the EST-37-A becomes
ready for operation.
Now, a gear can be engaged.
Starting
The starting of the engine has to be always carried out in the NEUTRAL POSITION of the controller.
For safety reasons, it is to recommend to brake the vehicle securely in position with the parking brake prior to start
the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the vehicle can be set in
motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
Upshifting Under Load
Upshifting under load will be then realized if the vehicle can continue to accelerate by it.
Downshifting Under Load
Downshifting under load will be then realized if more traction force is needed.
Upshifting in Coasting Condition
In the coasting mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehi-
cle on a downgrade should not be further increased.
Downshifting in Coasting Condition
Downshifting in the coasting mode will be then carried out if the vehicle should be retarded.
2-52
Reversing
See “Important Instructions” on page 2-51.
If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be
stalled. On a level and horizontal roadway it is possible that the vehicle begins to crawl, because the engine is cre-
ating at idling speed a slight drag torque via the converter.
It is convenient to brake the vehicle at every stop securely in position with the parking brake. At longer stops, the
controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a converter transmission it
might not immediately be noted to have forgotten this quite normal operating step because a converter, due to its
high ratio, can easily overcome the braking torque of the parking brake.
Temperature increases in the converter oil as well as overheated brakes will be the consequences to be find out
later.
Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible. Either a
suitable gear is to be shifted immediately, or the vehicle must be stopped at once.
Cold Start
At an oil temperature in the shifting circuit of less than 10°F [-12°C], the transmission must be warmed-up for some
minutes.
This must be carried out in neutral with an increased engine speed (about 1500 min-1). Until this oil temperature is
reached, the electronics remains in neutral, and the symbol of the cold start phase will be indicated on the ZF dis-
play.
After the indication on the ZF-Display is extinguished, the full driving program can be utilized out of “NEUTRAL”.
Stopping and Parking

Since due to the converter there is no rigid connection existing from the engine to the axle, it is recommended to
secure the vehicle on upgrades, resp. downgrades against unintended rolling not only by applying the parking
brake but additionally by a block on the wheel, if the driver has the intention to leave the vehicle.
Towing Procedure
See “Important Instructions” on page 2-51.
Oil Temperature
The oil temperature in the transmission sump is monitored by a temperature sensor in the electrohydraulic control
unit.
The service temperature in the sump of 140 to 194°F [60 to 90°C] must not be exceeded.
NOTICE: By overstepping results by 221°F [105°C] notice "WS" on the display in the cabin.
At a trouble-free unit and an adequate driving mode, a higher temperature will not occur.
The notice “WS” results at the display, the vehicle has to be stopped and controlled for external oil loss and the
engine must run with a speed of 1200 to 1500 min-1 at NEUTRAL POSITION of the transmission.
Now, the temperature must drop quickly (in about 2 to 3 minutes) to normal values. If this is not the case, there is a
trouble pending, which must be eliminated prior to continue working.
The monitoring of the oil temperature is additionally realized behind the converter with an indication on the ZF dis-
play or analog in the INFOCENTER.
Operating temperature behind the converter at least 149°F and 212°F [65°C and 100°C] in continuous operation,
a short-time increase up to a maximum of 248°F [120°C] is permitted.
NOTE: The temperature is measured on the measuring point “63”. See “Table 4: Schedule of Measuring Points
and Connections” on page 2-67.
2-53
Maintenance
Oil Grade
NOTE: Permitted for the Powershift transmissions 6 WG-191 are oils according to ZF-List of lubricants TE-ML 03.
NOTICE: The list of lubricants is being continuously updated and can be obtained or viewed as follows:
• At all ZF Plants
• At all ZF Service Stations
• Internet http://www.zf.com Service/Technical Information
Oil Level Check

NOTICE: Check measurements only with running engine.
At the oil level check, the prescribed safety directions according to # 6 of the rules for accident preven-
tion for power plants in Germany, and in all other countries the respective national regulations have to
be absolutely respected.
For example, the vehicle has to be secured against rolling with blocks, articulated vehicles additionally
against unintended turning-in.
The oil level check must be carried out as follows:
• Oil level check (weekly)
• At horizontally standing vehicle
• Transmission in Neutral position “N”
• In the cold start phase, the engine must be running about 2 to 3 minutes at idling speed, and the marking
on the oil dipstick must then be lying above the cold start mark “COLD MIN“
• At operating temperature of the transmission (about 176 to 194°F [80 to 90°C])
NOTE: With engine idling speed all measurements must be carried out with low engine idling speed.
• Loosen oil dipstick by counterclockwise rotation, remove and clean it.
• Insert oil dipstick slowly into the oil level tube until contact is obtained, and pull it out again.
• On the oil dipstick, the oil level must be lying in the zone “HOT”.
• Insert the oil dipstick again, and tighten it by clockwise rotation.
NOTE: If the oil level has dropped in operating temperature condition below the “HOT” Zone, it is absolutely
necessary to replenish oil according to the ZF List of lubricants TE-ML-03. An oil level above the “HOT”
marking, is leading to a too high oil temperature.
NOTE: The oil dipstick and the oil filler tube can have different lengths and shapes, according to the transmission
version. Additionally, the mounting on the transmission can be on the converter side or on the output side.
(In this Illustration, the mounting of the oil dipstick is illustrated on the output side).
2-54
Changing the Oil and Filter
For service interval, see the Service Interval Chart on Page page 1-14.
machine on the back side of the transmission.
Park the machine on firm, level ground and apply the
parking brake. Switch OFF the engine and remove the
starter key. Disconnect the battery.
Note: The transmission should be at operating tem-
perature and the Apache Sprayer on level 3
ground.
Drain the oil as follows:
• Place a used oil container of suitable size 2
under the transmission.
• Remove the transmission oil drain plug (1) and
drain the used oil.
• The drain plug contains a magnetic insert. Be
sure to clean any debris clinging to the plug. 1
Clean the sealing surface on the housing.
• Install the plug with new o-ring.
Unscrew and remove the filter (2).

Do not allow any dirt or oil sludge to enter the transmission oil system.
NOTICE: Do not install damaged filters.
The filter differential pressure valve (bypass valve) is equipped with a filter contamination switch which informs the
driver of ZF-Fine filter contamination. When the warning lamp is illuminated, the ZF-Fine filter must be replaced.
NOTICE: The transmission oil filter must be replaced at every transmission oil change.
Lubricate the seal on the transmission oil filter (2).
• Transmission Oil Filter Part Number: 310100001
Install and tighten the filter (2), by hand, 1/3 to 1/2 turns after the seal contacts the filter housing.
Fill the system with new transmission oil through the dipstick tube (3).
• Transmission oil capacity: 27 quarts [25.6 liters]
NOTICE: DO NOT overfill the transmission oil. Overfilling can damage the transmission or cause the transmission
to malfunction.
NOTICE: Use only Lucas 15W-40 Magnum engine oil.
2-55
follows:
Turn the dipstick handle counter-clockwise to loosen and remove the dipstick.
Check the transmission oil level. Add oil as needed.
Install the dipstick and turn the handle clockwise to tighten.
NOTICE: ZF RECOMMENDS TO START THE AEB AT EVERY OIL CHANGE.
Calibration Procedure
1. Move the machine to a safe area.
2. Disconnect the parking brake coil (2-pin Deutsch plug on junction block).
3. Start the machine.
4. Press the 'Cruise Master' button while at the Startup screen to enter the
Service Tools menu (Figure 1).
Figure 1
5. Check to make sure the transmission is in manual mode. If it is not, press
'Foam Left' for manual mode and then return to step 4 (Figure 2).
6. At the Service Tools menu, Press the 'Agitate Down' button to start the cal-
ibration process (Figure 2).
Figure 2
7. Transmission must be hot before the calibration sequence can begin (Fig-
ure 3).
A. Depress the brakes and shift the transmission into 6th gear.
B. While still holding the brakes rev the engine to full throttle and hold for
a maximum of 30 seconds.
C. Idle down and shift into neutral. Wait at least 15 seconds to allow the
hot oil in the torque converter to properly distribute.
D. Repeat steps A through C until the trans temp is in range for calibra- Figure 3
tion. Do not extend step B beyond 30 seconds. Damage to the trans-
mission could occur.
2-56
8. With the engine idling and trans in neutral, check the
trans oil level. It should be within the hot zone. Fill or
drain as required. MEASURED AT LOW COLD
IDLING-NEUTRAL HOT MIN
9. If the trans temp drops more than 5°F [3°C] during

step 8, repeat step 7. Zone
“HOT”
Figure 4
10. With the transmission hot and the oil topped off the cal
sequence can be started. With the parking brake applied and the engine
idling, press the 'Cruise Master' button to start the cal (Figure 5).
Figure 5
11. The cal sequence will take a few minutes as it runs through 7 clutches; K1,
K2, K3, K4,KV, KR and WK (Figure 6). The current clutch and stage are
displayed on screen.
Figure 6
12. If there is an error during the calibration it will end with the error screen in
Figure 7. Refer to the ZF Fault Code List to determine the error code.
Resolve the error, restart the machine and return to step 4 to rerun the cal.
Figure 7
13. If the cal was successful the screen in Figure 8 will be displayed.
14. Turn the machine off.
15. Reconnect the parking brake coil.
16. Start the machine and verify that there are no trans errors on the display.
Figure 8
2-57
Description
The ZF 6 WG-191 transmission is composed of a hydrodynamic torque converter and a rear-mounted multi-speed
powershift transmission with integrated transfer case (see Table 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself to the required situa-
tions (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via universal shaft) with DIN-,
Mechanic-or Spicer-input flange.
Torque Converter
Unit size W 300 and 340 with torque multiplication according to the version and a WK.
Powershift transmission
6 Forward speeds and 3 Reverse speeds.
Output
The powershift transmission has between input and output shaft a center distance of 190 mm, and can be
equipped with output flanges (rear-side) for different universal shafts
Power Take-Off
For the drive of an external hydraulic pressure pump, an engine-dependent, coaxial power take-off is existing,
upon request also disconnectable.
It allows the mounting of pumps with SAE-C connection.
Transmission Accessories
Upon request, the transmissions can be additionally equipped with the following components:
• Electronic speedometer signal for:
- Construction site vehicles here, the electronic unit EST-37-A offers a speedometer signal.
- Road vehicles, the signal required for the speedometer interpretation will be picked-up on the output
side by a pulse generator (e.g. is needed for trip recorders). For this, a frequency divider from the
customer side is necessary.
• Inching device
• Separate mounting of the ZF-Fine filter.
ZF Identification Plate
1. Gearbox Type
2. Gearbox Serial-Number
3. ZF-Parts List-Number
4. Total Ratio of the Gearbox
5. Oil (oil specification)
6. List of Lubricants
7. Oil Capacity
8. Customer Number
2-58
Function of Converter
Hydrodynamic Torque Converter
The converter is working according to the Trilok-System, i.e. it assumes at high turbine speed the characteristics,
and with it the favorable efficiency of a fluid clutch.
The converter is designed according to the engine power so that the most favorable operating conditions are
obtained for each installation case.
The torque converter is composed of 3 main components:
• Impeller
• Turbine wheel
• Stator (reaction member)
These 3 impellers are arranged in such a ring-shaped system that the fluid is streaming through the circuit compo-
nents in the indicated order.
Pressure oil from the transmission pump is constantly streaming through the converter. In this way, the converter
can fulfill its task to multiply the torque of the engine and at the same time, the heat created in the converter is dis-
sipated via the escaping oil.
The oil which is streaming out of the impeller, enters the turbine wheel and is there reversed in the direction of flow.
According to the rate of reversion, the turbine wheel and with it also the output shaft is receiving a more or less
high reaction torque.
The stator (reaction member) following the turbine, has the task to reverse the oil, which is streaming out of the tur-
bine once more and to deliver it under the suitable discharge direction to the impeller.
Due to the reversion, the stator is receiving a reaction torque. The relation turbine torque/pump torque is called
torque multiplication. This is the higher, the greater the speed difference of impeller and turbine wheel will be.
2-59
Therefore, the maximum torque multiplication is created at stationary turbine wheel. With increasing output speed,
the torque multiplication is decreasing. The adaption of the output speed to a certain required output torque will be
infinitely variable and automatically achieved by the torque converter.
When the turbine speed reaches approximately 80 percent of the pump speed, the torque multiplication becomes
1.0. i.e. the turbine torque becomes equal to that of the pump torque. From this point on, the converter is working
similar to a fluid clutch.
A stator free wheel serves to improve the efficiency in the upper driving range; In the torque multiplication range it
is backing up the torque upon the housing and is released in the clutch range. In this way, the stator can rotate
freely.
WK
1. Cup spring 4. Circuit cover / Impeller

2. Plate pack 5. Turbine wheel
3. Stator 6. Piston
At closed WK, the slip between impeller and turbine wheel, and with it the hydraulic loss in the converter is equal to
zero. See the figure above.
The WK will be automatically shifted dependent on the turbine speed.
The pressure oil (15+1 bar) for the closing of the WK, is directed via a solenoid shift valve (See WK Solenoid Shift
Valve on page 2-61.) to the piston (6), which is compressing the plate pack.
2-60
WK Solenoid Shift Valve
Powershift Transmission
The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated multi-
disk clutches.
All gears are constantly meshing and carried on antifriction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 6-speed reversing transmission is equipped with 6 multi-disk clutches.
At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is pressurized by
pressure oil.
A compression spring takes over the pushing back of the piston, thus the release of the plate pack. As to the layout
of the transmission as well as the specifications of the closed clutches in the single speeds, see Tables 1, 4 and 5.
See “Table 1: Layout View” on page 2-65. See “Table 4: Schedule of Measuring Points and Connections” on
page 2-67. See “Table 5: Gearbox Diagram” on page 2-68.
Transmission Control
See tables 4, 5 and 7 for transmission control. See “Table 1: Layout View” on page 2-65. See “Table 4: Schedule of
Measuring Points and Connections” on page 2-67. See “Table 7: Electro-hydraulic Shift Control with Proportional
Valve” on page 2-72.
The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is located in
the transmission on the engine-dependent input shaft.
The feed rate of the pump is Q = 105 l/min, at nEngine = 2000 min -1.
2-61
This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF-Fine filter — the filter
can be fitted also externally from the transmission — to the main pressure valve.
If because of contamination, resp. damage, the through-flow through the ZF-Fine filter is not ensured, the oil will be
directly conducted via a filter differential pressure valve (bypass valve ∆p=5.5+3 bar) to the lubrication. In this
case, an error indication is shown on the ZF display.
• ZF-Fine Filter
- Filtration ratio according to ISO 4572: ß30 > 75 ß15 = 25 ß10 = 5.0
- Filter surface at least: 6700 cm2
- Dust capacity according to ISO 4572 at least: 17g
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6.
The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6), follow-on slide and
vibration damper.
The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressure reducing valve.
The hydraulic oil (16+2 bar) is directed via the follow-on slide to the respective clutch.
Due to the direct proportional selection with separate pressure modulation for each clutch, the pressures to the
clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic intersection of the
clutches to be engaged and disengaged becomes possible.
This is creating spontaneous shiftings without traction force interruption.
At the gear change, the following criteria will be considered:
• Speed of engine, turbine, central gear train and output.
• Transmission temperature.
• Shifting mode (up-, down-, reverse shifting and speed engagement out of neutral).
• Load condition (full and part load, traction, overrun inclusive consideration of load cycles during the gear
change).
The main pressure valve is limiting the max. control pressure to 16+2.5 bar and releases the main flow to the con-
verter and lubricating circuit.
In the inlet to the converter, a converter safety valve is installed which protects the converter from high internal
pressures (opening pressure 11+2 bar).
Within the converter, the oil serves to transmit the power according to the well-known hydrodynamic principle. See
“Function of Converter” on page 2-59.
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter pressure back-up valve, rear-mounted to the converter, with an opening pressure
of about 4.3+3 bar.
The oil, escaping out of the converter, is directed to a heat exchanger.
The selection and definition of the heat exchanger must be carried out according to our Installation Specification for
hydrodynamic powershift transmissions by the Customer on his own responsibility.
The heat exchanger is not within the scope of supply of the ZF Passau GmbH.
From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil circuit so that all
lubricating points are supplied with cooled oil.
In the Electrohydraulic control unit, are 6 pressure regulators installed. See “Table 7: Electro-hydraulic Shift Control
with Proportional Valve” on page 2-72.
The allocation of the pressure regulators to the single gears can be seen on the Tables 4 and 5. See “Table 4:
Schedule of Measuring Points and Connections” on page 2-67. See “Table 5: Gearbox Diagram” on page 2-68.
2-62
Transmission Control Unit TCU
The electrohydraulic transmission control can be automated by connection on the electronic TCU.
The basic functions of the automatic system are the automatic shifting of speeds, adaption of the optimum shifting
points, the comfortable kickdown function as well as comprehensive safety functions in relation to operating errors
and overloading of the power-transmitting components with a comprehensive fault storage.
The control units can be programmed — customer-and vehicle-specific — in a wide spectrum, control parameters
can be logically linked, and also special functions such as gear limitation, converter or retarder functions can be
integrated.
NOTICE: Due to the great number of the available TCU, the exact Technical Data must be taken from the
respective installation drawing.
Installation Position of the TCU
Installation Dimensions of the TCU
NOTICE: The installation position of the TCU can vary. For best performance, ZF recommends using the above
illustrations as a guide for placement and orientation. The TCU must be installed in a protected point in the cabin
with proper clearance to disconnect the unit. The TCU must not be exposed to flowing water.
2-63
Electronic Control for ZF-Powershift Transmissions
NOTE: Because of the different configurations of the electronic transmission controls at the various vehicles, the
corresponding documentation must be taken from the operating Instructions of the vehicle manufacturer or
from the data sheets of the respective parts list versions. In these are also indicated the corresponding
circuit diagram and the connection diagram (upon request, these informations can be asked for at the ZF
Passau).
According to the type of vehicle, the wiring will be performed according to the wiring diagrams. Variations
such as double cabin Version (e.g. RT-Crane vehicles) are possible. The cabin change-over is not scope
of supply of the ZF.
The corresponding electric circuit diagrams (proposals) will be realized by ZF.
Upon request, the wiring can be also supplied by ZF.
If the wiring is realized by the Vehicle Manufacturer, it must be in accordance with the ZF requirements
(see Installation Specification).
Automatic Calibration of the Shifting Elements (AEB)
The AEB serves to compensate tolerances (plate clearance and pressure level), which are influencing the filling
procedure of the clutches. For each clutch, the correct filling parameters for:
• Period of the rapid-filling time
• Level of the filling equalizing pressure are defined in a test cycle.
The filling parameters are stored, together with the ABE-Program and the driving program in the transmission elec-
tronics. Because the electronics will be separately supplied, the AEB cycle must be started only after the installa-
tion of both components in the vehicle, thus ensuring the correct mating (Transmission and Electronics).
NOTE: At any rate, the AEB-Cycle must be carried out at the Vehicle Manufacturer prior to the commissioning of
the vehicles.
It is imperative, to respect the following Test conditions:
• Shifting position Neutral
• Engine in idling speed
• Parking brake applied
• Transmission in operating temperature
NOTE: After a replacement of the transmission, the electrohydraulic control or the TCU in the vehicle, the AEB-
Cycle must be as well carried out again.
The AEB-Cycle continues for about 3 to 4 minutes. The determined filling parameters are stored in the EEProm of
the Electronics. In this way, the error message F6 shown on the Display will be cancelled also at non-performed
AEB.
NOTICE: Due to the operation of the transmission, the paper friction linings, installed in the Ergopower
transmissions are settling, i.e. the plate clearance becomes greater.
Because these settling appearances can interfere the shifting quality, ZF recommends to repeat the AEB cycle at
the maintenance intervals.
NOTICE: ZF recommends likewise at a reduced shifting quality as first measure to repeat the AEB-Cycle.
2-64
ZF 6 WG-191 Transmission
Table 1: Layout View
Transmission Diagram/Gearbox Diagram
1. “K4” - Clutch Shaft 5. “K2” - Clutch Shaft

2. “KV” - Clutch Shaft 6. “K3/AB” - Clutch Shaft/Output
3. “AN/PTO” - Input Shaft/Power Take-off 7. “K1” - Clutch Shaft
4. “KR” - Clutch Shaft 8. Electro-hydraulic Control with Intermedi-
ate Sheet and Duct Plate
2-65
Table 2: Installation View (Front)
1. Electro-hydraulic Control
2. Converter Bell
3. Lifting Lugs
4. Gearbox Housing
(front and rear sections)
5. Oil Level Tube and Dipstick
(rear side)
6. Transmission Suspension Holes
(M20)
7. Plate
8. Converter with Diaphragm
Table 3: Installation View (Rear)

1. Power Take-off
(coaxial, engine-dependent)
2. Oil Pressure Line
(WK-Valve to the WK)
3. Gearbox Housing
(front and rear section)
4. Lifting Lugs
5. Converter Bell
(direct mounting)
(with WK)
8. Annex Area for Exchange Filter
(ZF-fine filter)
9. Oil Pressure Line
(system pressure to the WK)
10. Transmission Suspension Holes
(M20)
11. Oil Drain Plug (M38x1.5)
12. Type Plate
13. Output Flange
14. Oil Level Tube with Dipstick (rear side)
2-66
Table 4: Schedule of Measuring Points and Connections
Refer to the diagram on the following page.
Marking On
Item Number Position Connection
Valve Block
Measuring points for hydraulic oil and temperature:

51 In front of the converter - opening pressure 11+2 bar M10x1 H
53 Clutch forward - 16+2 bar - KV M10x1 B
55 Clutch reverse - 16+2 bar - KR M10x1 E
56 Clutch - 16+2 bar - K1 M10x1 D
57 Clutch - 16+2 bar - K2 M10x1 A
58 Clutch - 16+2 bar - K3 M10x1 C
60 Clutch - 16+2 bar - K4 M10x1 F
Behind the converter

63 M14x1.5
Temperature 212°F [100°C]; Short time 248°F [120°C]
65 System pressure - 16+2.5 bar M10x1 K
67 WK shift pressure - 15+1 bar M10x1
Measuring points for delivery rates:

15 Connection to the heat exchanger M33x2
16 Connection from the heat exchanger M33x2
Inductive transmitter-impulse-speed sensor and switch:

21 Inductive transmitter - n Turbine M18x1.5
34 Speed sensor - n Output speedometer n/a
47 Inductive transmitter - n Central gear train M18x1.5
48 Inductive transmitter - n Engine M18x1.5
54 Filter combination switch M14x1.5
Connections:
10 Breather
49 Plug connection on the electro-hydraulic control unit
68 WK-Valve
2-67
Table 5: Gearbox Diagram
48 10 47
21
49
68 65 51 48 54
60
57 55
67 56
53 Detail-B
34 63 63
(See Detail-A) (See Detail-B)
Detail-A 15
15
16
58 Coding
Pressure regulator under voltage Engaged clutch
Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
34 Forward 1 K1 KV
2 K4 K1
3 KV K2
4 K4 K2
5 K3 KV
6 K4 K3
Reverse 1 KR K1
2 KR K2
3 KR K3
Neutral
Engaged clutch K4 KR K1 K3 KV K2
Position on valve block F E D C B A
Consec. No. Of measuring points 60 55 56 58 53 57
2-68
Table 5: Oil Circuit Diagram with WK Forward 1st Speed
The marked positions correspond with the positions on Table 4. Additional explanation for this schematic is on the
following page.
RV-9
FDV
HDV
WK
F
control circuit
Valve block
2-69
Oil Circuit Schematic Definitions
WT = Heat Exchanger
WK-M = WK - Proportional Valve 15+1 bar
WSV = Converter Safety Valve 11+2 bar
HDV = Main Pressure Valve 16+2 bar
RV-9 = Pressure Reducing Valve 9±0.5 bar

NFS = Follow-on Slide
D = Vibration Damper
B = Orifice
P1 = Proportional Valve - Clutch KR
P2 = Proportional Valve - Clutch K4
P5 = Proportional Valve - Clutch KV
Y1 - Y6 =Pressure Regulator
TEMP = Temperature Sensor
FDV = Filter Differential Pressure Valve ∆p = 5.5+3 bar

WS = Maintenance Switch
Coding
Pressure regulator under voltage Engaged clutch
Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
Forward 1 K1 KV
2 K4 K1
3 KV K2
4 K4 K2
5 K3 KV
6 K4 K3
Reverse 1 KR K1
2 KR K2
3 KR K3
Neutral
Engaged clutch K4 KR K1 K3 KV K2
Position on valve block F E D C B A
Consec. No. Of measuring points 60 55 56 58 53 57
2-70
Table 6: Gearbox Diagram WG191
K1 Gearbox diagram
K4
KR
Converter
KV
KV K4
AN PTO AN/PTO
KR K1
K2
K3/AB
K2
K3/AB
Legend: Diagram Clutches

Driving direction Speed Clutch
KV = Clutch forward
Forward 1 KV/K1
KR = Clutch reverse
K1 = Clutch 1st speed 2 K4/K1
K2 = Clutch 2nd speed 3 KV/K2
K3/AB = Clutch 3rd speed / Output 4 K4/K2
K4 = Clutch 4th speed 5 KV/K3
AN/PTO = Input / Power take-off 6 K4/K3
Reverse 1 KR/K1
2 K / R 2K
3 KR/K3
2-71
Table 7: Electro-hydraulic Shift Control with Proportional Valve
Pressure reducing valve 9 bar
Main pressure valve 16+2,5 bar
Housing Plug
(Cable harness)
A Y6 Y1 A
Y5 Y2
B B
Y4 Y3
Cover
Cover
Housing Valve block
Valve block
Pressure reducing valve 9 bar
Intermediate plate
Y5 Vibration damper
2-72
Table 8: WK Valve with Electro-Hydraulic Shift Control
1 2 3 4 5
9
1. Cover 6. Oil Pressure Line System Pressure to
2. Housing the WK
3. Valve Block 7. Connection Housing
4. Messing Point WK 8. Oil Pressure Line from WK Valve to

the WK
5. Housing
9. Pressure Regulator (WK Valve)
Spare Parts Orders

When ordering genuine ZF spare parts, please provide the following information to reduce errors in parts delivery:
• Gearbox type (See model identification plate.)
• Serial number (See model identification plate.)
• ZF parts list number.
• Make and type of vehicle
• Denomination of the spare part
• Spare parts number
• Way of transport
2-73
Data Sheet for WG-191

Data for Inductive Transmitter of Engine, Turbine and Central Gear Train
• Resistance: 1050 Ohm (±10%) at 68°F [20°C]
• Temperature Range: -40°F to 302°F [-40°C to 150°C]
• Torque Limit: 30 Nm
Data for Hall Sensor Output
• Temperature Range: -40°F to 302°F [-40°C to 150°C]
• Working Range: 2Hz to 5 kHz
• Supply Voltage: 24V
Data for Proportional Valves
• Resistance: 19 Ohm (±10%) at 68°F [20°C]
• Current: 100 to 500 mA
• Pressure Range: 0 to 15 bar
Data for Lock-up Solenoid Valve
• Resistance: 60 to 80 Ohm
• Current: 0.25 to 0.35 A
• Voltage: 24V
Data for Lock-up Proportional Valve
• Resistance: 10.5 Ohm (±10%) at 68°F [20°C]
• Current: 0 to 926 mA
• Pressure Range: 0 to 15 bar
Data for Temperature Sensors
• Sump: 1000 to 1500 Ohms
• Retarder: 800 to 1500 Ohms
Data for Lock-up Clutch Solenoid Valve
• Resistance: 60 to 80 Ohm
• Current: 0.25 to 0.35 A
• Voltage: 24V
Control Pressure
• 16+2 bar
• 0.2 to 1.5 bar
Pressure Before the Converter
• 130/160: 9 bar (Max)
• 190/210: 9 bar (Max)
• 260/310: 8.5 bar (Max)
Pressure Behind the COnverter
• 130/160: 3.5 bar (Max)
• 190/210: 3.5 bar (Max)
• 260/310: 5 bar (Max)
Oil Flow from the Pump
• 130/160: 80 l/min @ n = 2000 min-1
• 190/210: 105 l/min @ n = 2000 min-1
• 260/310: 115 l/min @ n = 2000 min-1
2-74
Fault Code Information for WG-191

If a fault code is detected, the Apache display
will show “Trans Fault” and the SPN and FMI
numbers. If more than one fault is detected,
each fault is shown for approximately 1 second.
The following abbreviations are used in the ZF
fault code tables:
o.c. open circuit
s.c. short circuit
OP-Mode Operating Mode
TCU Transmission Control Unit
EEC Electronic Engine Controller
PTO Power Take-Off
Operating Modes
Normal
There's no failure detected in the transmission-system or the failure has no or slight effects on transmission con-
trol. TCU will work without or in special cases with little limitations. See “Fault Code Tables” on page 2-76.
Substitute Clutch Control
TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the sub-
stitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25)
Limp Home
The detected failure in the system has strong limitations to transmission control. TCU can engage only one gear in
each direction. In some cases only one direction will be possible. TCU will shift the transmission into neutral at the
first occurrence of the failure. First, the operator must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or
reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and the
operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to slow
down the vehicle and must shift the gear selector into neutral position.
Transmission Shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission
shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU Shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2).
The park brake will engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
2-75
Fault Code Tables
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code
(hex)
10 5001 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to •
SIGNAL 3RD SHIFT LEVER neutral if selector activ 3 a valid neutral signal for the
OP-Mode: transmission • direction at the shift lever
for the direction shutdown if selector activ positions F-N-R
• cable from shift lever 3 to TCU is •
broken CAN cable/shifter/device
•
battery voltage or vehicle ground
• shift lever is defective
11 5000 12 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to •

fault is taken back if TCU
neutral •
for the gear range OP-Mode: transmission positions for gear range position
• shutdown
•
12 5010 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • fault is taken back if TCU
SIGNAL neutral •
OP-Mode: transmission positions F-N-R direction at the shift lever
for the direction shutdown
•
•
13 5020 12 LOGICAL ERROR AT ENGINE DERATING after selecting neutral, TCU • check engine derating device
DEVICE up of TCU
derating device activ
Code
(hex)
14 5030 12 LOGICAL ERROR AT PARKBRAKE STATUS •

State to status switches
OP-Mode: normal • check signals of the status switches
don't fit
•
electronic box is broken
•
15 5040 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • fault is taken back if TCU
SIGNAL 2. SHIFT LEVER neutral if selector activ 2
OP-Mode: transmission • for the direction at the shift
for the direction shutdown if selector activ positions F-N-R lever
• cable from shift lever 2 to TCU is
broken
•
16 5050 12 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal •

feedback axle connection measured by axle connection switch
TCU and output signal axle connection • check signals of the feedback axle
don't fit connection switch
• axle can’t be connected or
disconnected due to mechanical
problem
•
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, •

TRANSMISSION SUMP TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
•
2-76
Code
(hex)
battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
defect
•
voltage or is broken
26 5110 4 S.C. TO GROUND AT TRANSMISSION SUMP no reaction, •

TEMPERATURE SENSOR INPUT TCU uses default temperature • check the connectors
the measured voltage is too low: OP-Mode: normal • check the temperature sensor
•
vehicle ground
defect
•
ground
27 5120 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, •

RETARDER / TORQUECONVERTER TCU uses default temperature • check the connectors
TEMPERATURE SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
•
battery voltage
defect
•
28 5120 4 S.C. TO GROUND AT RETARDER/ no reaction, •

TORQUECONVERTER TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too low:
•
vehicle ground
Code
(hex)
defect
•
ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value •

PARKING BRAKE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the parking brake sensor
•
battery voltage
• sensor has an internal defect
•
2A 5130 4 S.C. TO GROUNDPARKING BRAKE SENSOR TCU uses default value •

INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the parking brake sensor
•
vehicle ground
•
ground
2B 5313 12 INCHSENSOR -SIGNAL MISMATCH •

the measured voltage from CCO and to neutral • check the connectors
CCO2 signal don’t match: While not inching: no change • check sensor
• cable is defective OP-Mode: normal
2C 5135 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value •

DLM TRACTION A DJUST DASHBOARD OP-Mode: normal • check the connectors
DEVICE INPUT • check the DLM Traction Adjust
the measured voltage is too high: dashboard device
2-77
Code
(hex)
•
battery voltage
•
2D 5135 4 S.C. TO GROUNDDLM TRACTION A DJUST TCU uses default value •

DASHBOARD DEVICE INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM Traction Adjust
• dashboard device
vehicle ground
•
ground
2E 5137 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value •

DLM STEERING A NGLE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the DLMSTEERING A NGLE
• SENSOR
battery voltage
•
2F 5137 4 S.C. TO GROUNDDLM STEERING A NGLE TCU uses default value •

SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLMSTEERING A NGLE
• SENSOR
vehicle ground
•
ground
Code
(hex)
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch •
ENGINE SPEED INPUT control • check the connectors
• check the speed sensor
V at speed input pin
•
battery voltage
•
•
voltage or has no contact
32 5140 4 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch •

control • check the connectors
at speed input pin • check the speed sensor
•
contacted to vehicle ground
•
33 5140 12 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch •

TCU measures a engine speed over a control • check the connectors up of TCU
threshold and the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
•
bad contact
•
• sensor gap has the wrong size
34 5150 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch •

TURBINE SPEED INPUT control • check the connectors
if a failure is existing at output • check the speed sensor
V at speed input pin speed,
• TCU shifts to neutral
battery voltage OP-Mode: limp home
•
2-78
Code
(hex)
•
35 5150 4 S.C.TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch •

at speed input pin if a failure is existing at output • check the speed sensor
• speed,
contacted to vehicle ground TCU shifts to neutral
• OP-Mode: limp home
36 5150 12 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch •

TCU measures a turbine speed over a control • check the connectors up of TCU
threshold and at the next moment the if a failure is existing at output • check the speed sensor
measured speed is zero speed, • check the sensor gap
• TCU shifts to neutral
bad contact OP-Mode: limp home
•
37 5160 3 S.C.TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch •

INTERNAL SPEED INPUT control • check the connectors
• check the speed sensor
•
battery voltage
•
•
38 5160 4 S.C. OP-Mode: substitute clutch •

at speed input pin • check the speed sensor
•
Code
(hex)
• speed sensor has an internal defect
OP-Mode: substitute clutch •

control • check the connectors up of TCU
threshold and at the next moment the • check the speed sensor
•
bad contact
•
3A 5170 3 S.C
. TO BATTERY VOLTAGE OR O.C. AT •
OUTPUT SPEED INPUT OP-Mode: substitute clutch • check the connectors
control • check the speed sensor
• speed,
battery voltage TCU shifts to neutral
• cable has no connection to TCU OP-Mode: limp home
• connector pin is contacted to battery
3B 5170 4 S.C
. TO GROUND AT OUTPUT SPEED INPUT •
OP-Mode: substitute clutch • check the connectors
at speed input pin control • check the speed sensor
• cable / connector is defective and is
contacted to vehicle ground speed,
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
LOGICAL ERROR AT OUTPUT SPEED INPUT •
TCU measures a output speed over a OP-Mode: substitute clutch • check the connectors up of TCU
threshold and at the next moment the control • check the speed sensor
• speed,
bad contact TCU shifts to neutral
2-79
Code
(hex)
• speed sensor has an internal defect OP-Mode: limp home
3E 5180 2 ’ T FIT TO
OUTPUT SPEED ZERO DOESN •
OTHER SPEED SIGNALS OP-Mode: substitute clutch sensor up of TCU
if transmission is not neutral and the control • check the sensor gap of output speed
shifting has finished, if a failure is existing at turbine sensor
TCU measures outputspeed zero and speed, •
TCU shifts to neutral
to zero. OP-Mode: limp home
54 5260 9 DCT1 TIMEOUT OP-Mode: normal • check display computer

Timeout of CAN-message DCT1 from • check wire of CAN-Bus
display computer • check cable to display computer
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
55 5270 9 JSS TIMEOUT TCU shifts to neutral while • check Joystick steering controller
Timeout of CAN-message JSS from Joystick Steering is active • check wire of CAN-Bus
Joystick Steering Controller OP-Mode: normal • check cable to Joystick steering
• interference on CAN-Bus controller
• CAN wire/connector is defective and
battery voltage
56 5280 9 ENGINE CONF TIMEOUT OP-Mode: substitute clutch • check engine controller
Timeout of CAN-message ENGINE control • check wire of CAN-Bus
CONF from engine controller • check cable to engine controller
Code
(hex)
•
defect
•
ground
95 5570 3 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • 1)

see chapter 4
STARTER INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the • check the connectors from starter
interlock relay to TCU
voltage • check the resistance1)
of starter
• interlock relay
battery voltage
•
defect
•
voltage
96 5570 5 O.C. AT RELAY STARTER INTERLOCK no reaction • 1)

see chapter 4
TCU detected a wrong voltage at the OP-Mode: normal interlock relay
output pin, that looks like a o.c. for this • check the connectors from starter
output pin interlock relay to TCU
• cable is defective and has no • check the resistance1)
of starter
connection to TCU interlock relay
•
defect
•
A4 5620 4 S.C. TO GROUND AT WARNING SIGNAL no reaction • check the cable from TCU to the 1)
see chapter 4
OUTPUT OP-mode: normal warning device
TCU detected a wrong voltage at the • check the connectors from warning
device to TCU
ground • check the resistance
1)
•
vehicle ground
•
2-80
Code
(hex)
•
ground
A5 5620 5 O.C. AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the 1)
see chapter 4
TCU detected a wrong voltage at the OP-mode: normal warning device
output pin, that looks like a o.c. for this • check the connectors from warning
output pin device to TCU
• cable is defective and has no • 1)
connection to TCU
•
•
A6 5620 3 S.C. TO BATTERY VOLTAGE AT WARNING no reaction • check the cable from TCU to the 1)
see chapter 4
SIGNAL OUTPUT OP-mode: normal warning device
TCU detected a wrong voltage at the • check the connectors from warning
device to TCU
voltage • 1)
•
battery voltage
•
•
voltage
B1 5660 2 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1

TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
if failure at another clutch is • check sensor gap at internal speed
out of range, TCU interprets this as pending sensor
slipping clutch. TCU shifts to neutral •
• low pressure at clutch K1 OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at output speed sensor
• • replace clutch
•
• wrong size of the sensor gap
• clutch is defective
Code
(hex)
• low pressure at clutch K2 OP-Mode: TCU shutdown •
•

• low pressure at clutch K3 OP-Mode: TCU shutdown •
•

OP-Mode: limp home • check main pressure in the system
pending sensor
range, TCU interprets this as slipping TCU shifts to neutral •
clutch. OP-Mode: TCU shutdown •
• low pressure at clutch K4 • check signal at turbine speed sensor
• low main pressure • replace clutch
•
•
2-81
Code
(hex)
B5 5680 2 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV

is out of range, TCU interprets this as pending sensor
• low pressure at clutch KV OP-Mode: TCU shutdown •
• low main pressure • check signal at turbine speed sensor
•
B6 5685 2 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR

is out of range, TCU interprets this as pending sensor
• low pressure at clutch KR OP-Mode: TCU shutdown •
• low main pressure • check signal at turbine speed sensor
•
B7 5700 0 OVERTEMP SUMP no reaction • cool down machine

OP-Mode: normal • check oil level
• check temperature sensor
BA 5730 0 DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter

TCU measured a voltage at differential OP-Mode: normal • check wiring from TCU to differential
pressure switch
• oil filter is polluted • check differential pressure switch
• cable/connector is broken or (measure resitance)
Code
(hex)
voltage or vehicle ground

•
BB 5740 2 SLIPPAGE AT CONVERTER LOCKUP CLUTCH Lockup Clutch is disabled • check pressure at converter lockup
TCU calculates a differential speed at immediately. After fault code clutch
closed converter lockup clutch. If this • check main pressure in the system
calculated value is out of range, TCU •
interprets this as slipping clutch. will be enabled again. •
• low pressure at converter lockup • check signal at engine speed sensor
clutch • check signal at turbine speed sensor
• low main pressure • replace clutch
•
•
BC 5745 15 OVERSPEED OUTPUT No reaction

TCU messures an transmission output OP-Mode: normal
speed above the defined threshold
C0 5751 0 ENGINE TORQUE OR ENGINE POWER OP-Mode: normal
OVERLOAD
power above the defined thresholds

C1 5752 0 TRANSMISSION OUTPUT TORQUE OP-Mode: normal
OVERLOAD
TCU calculates an transmission output
torque above the defined threshold
C2 5755 15 T T programmable: No reaction or
TCU calculates a transmission input shift to neutral
torque above the defined threshold OP-Mode: normal
C3 5760 0 OVERTEMP CONVERTER OUTPUT no reaction • cool down machine
OP-Mode: normal • check oil level
• check temperature sensor
threshold.
2-82
Code
(hex)
C4 5770 4 S.C. TO GROUND AT JOYSTICKSTATUS no reaction • check the cable from TCU to joystick
INDICATOR OP-Mode: normal status indicator
TCU detected a wrong voltage at the • check the connectors from joystick
status indicator to TCU
ground • check the resistance 1)
• indicator
vehicle ground
• joystick status indicator has an
internal defect
•
ground
C5 5770 3 S.C. TO BATTERY VOLTAGE AT

JOYSTICK no reaction • check the cable from TCU to joystick
STATUS INDICATOR OP-Mode: normal status indicator
status indicator to TCU
voltage • check the resistance 1)
• indicator
battery voltage
internal defect
•
voltage
C6 5770 5 O.C. ATJOYSTICK STATUS no reaction • check the cable from TCU to joystick
INDICATOR OP-Mode: normal status indicator
output pin, that looks like a o.c. for this status indicator to TCU
output pin • check the resistance 1)
• cable is defective and has no indicator
connection to TCU
internal defect
•
Code
(hex)
C7 5780 4 S.C. TO GROUND AT OVERTEMP no reaction • check the cable from TCU to
NEUTRAL INDICATOR OP-Mode: normal OVERTEMP NEUTRAL I NDICATOR
TCU detected a wrong voltage at the •
NEUTRAL I NDICATOR to TCU
1)
ground • of OVERTEMP
• NEUTRAL I NDICATOR
vehicle ground
•
internal defect
•
ground
C8 5780 3 S.C. TO BATTERY VOLTAGE AT no reaction • check the cable from TCU to
OVERTEMP NEUTRAL INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
NEUTRAL I NDICATOR to TCU
voltage • 1)
of OVERTEMP
• NEUTRAL I NDICATOR
battery voltage
•
internal defect
•
voltage
C9 5780 5 O.C. ATOVERTEMP NEUTRAL no reaction • check the cable from TCU to
INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
output pin, that looks like a o.c. for this NEUTRAL I NDICATOR to TCU
1)
output pin • of OVERTEMP
• cable is defective and has no NEUTRAL I NDICATOR
connection to TCU
• OVETEMP status indicator has an
internal defect
•
2-83
Code
(hex)
CA 5790 9 ENGINE _RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message control • check wire of CAN-Bus
ENGINE_RETARDER CONFIG from EEC • check cable to EEC controller
controller
• CAN wire/connector is defective an
battery voltage
CB 5800 9 ERC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message ERC1 from control • check wire of CAN-Bus
EEC controller • check cable to EEC controller
• CAN wire/connector is defective an
battery voltage
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C •

SUPPLY FOR SENSORS which are supplied from AU1
•
AU1 (5V sensor supply) (should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY FOR see fault codes no. 21 to 2C •
SENSORS which are supplied from AU1
TCU measures less than 4V at the pin •
AU1 (5V sensor supply) (should be appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery
OP-Mode: TCU shutdown • check cables from batteries to TCU
than 10 V (12V device) •
lower than 18 V (24V device)
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
Code
(hex)
measured voltage at power supply is OP-Mode: TCU shutdown • check cables from batteries to TCU
higher than 18 V (12V device) •
higher than 32.5 V (24V device)
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 •
and measured VPS1 is still on • replace TCU
•
contacted to battery voltage
•
•
• TCU has an internal defect
D6 5840 2 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 •
and measured VPS2 is still on • replace TCU
•
contacted to battery voltage
•
•
• TCU has an internal defect
D7 5545 4 S.C. TO GROUND AT DLM L ONGITUDINAL output will be on until TCU • 1)

see chapter 4
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the vanishes (loose connection) • check the resistance of valve
OP-Mode: normal
ground
•
vehicle ground
• device has an internal defect
•
ground
2-84
Code
(hex)
D8 5545 3 S.C. TO BATTERY VOLTAGE AT DLM no reaction • 1)

see chapter 4
L ONGITUDINAL OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the • check the resistance of valve
voltage
•
battery voltage
•
voltage
D9 5545 5 O.C. ATDLM L ONGITUDINAL OUTPUT no reaction • 1)

see chapter 4
TCU detected a wrong voltage at the OP-Mode: normal • check the connectors
output pin, that looks like a o.c. for this • check the resistance of valve
output pin
• cable is defective and has no
connection to TCU
•
E3 5860 3 S.C. TO BATTERY VOLTAGE AT DISPLAY no reaction •

OUTPUT OP-Mode: normal • check the connectors at the display
TCU sends data to the display and • change display
the connector
•
are contacted to battery voltage
• display has an internal defect
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction •

TCU sends data to the display and OP-Mode: normal • check the connectors at the display
• change display
the connector
•
Code
(hex)
are contacted to vehicle ground
• display has an internal defect
E5 5270 9 DISPID1_ TIMEOUT • check display controller

ID0 • check wire of CAN-Bus
display controller OP-Mode: Limp Home • check cable to display controller
•
battery voltage
E6 5880 2 ILLEGAL ID REQUEST VIACAN transmission stay neutral

OP-Mode: TCU shutdown
F1 5890 2 GENERAL EEPROMFAULT no reaction • replace TCU often shown together with
TCU can't read non volantile memoy OP-Mode: normal fault code F2
• TCU is defective
F2 5900 13 CONFIGURATION LOST transmission stay neutral •

OP-Mode: TCU shutdown for the vehicle (e.g. with cluster
can't control the transmission. controller,...)
•
volatile memory
• TCU is brand new or from another
vehicle
F3 5910 13 APPLICATION ERROR transmission stay neutral • replace TCU !! This fault occurs only if an
something of this application is wrong OP-Mode: TCU shutdown
wrong in the application of
the vehicle
F5 5930 7 CLUTCH FAILURE transmission stay neutral • check clutch
OP-Mode: TCU shutdown clutch on the Display
parameters
•
2-85
Code
(hex)
F6 5930 13 CLUTCH A DJUSTMENT DATA LOST OR default values = 0 for AEB • execute AEB
I NCHPEDAL CALIBRATION DATA L OST offsets used
OP-Mode: normal
adjustment parameters no Inchmode available
•
volatile memory
• TCU is brand new
2-86
Chapter 3
Brakes and Differential
AS720, AS1020 & AS1220
NOTES
BRAKES AND DIFFERENTIAL
Brakes and Differential
Are the rest of the

START Are both brake pedals weak? yes hydraulics working no Contact Factory
on the machine?
no
yes
Inspect for leaks or kinks in
the pressure lines going to
Repair leak and bleed brakes. yes the differential from the
master cylinder. Is there any
visible oil?
no
Bleed brake line by holding

Tee a pressure gauge at
brake down and open
differential and push brake.
no bleeder valve on differential. Tighten
Is the pressure close to
bleeder, did the brake
1200 psi?
improve quality?
yes
yes
no
Remove gauge from

If brake performance is still Hold pedal down for 1
tee and install directly
inadequate, contact factory minute. Does pressure Monitor system for next week to
no yes onto end of brake hose.
for brake pack replacement bleed off more than make sure all air is gone.
Push brake, is pressure
verification. 300 psi?
close to 1000 psi?
no yes
Replace piston seals in

Replace master cylinder.
differential. Bleed
Bleed brake line.
both brake lines.
3-1
Rear Differential
The illustration shows the pressure gauge installed in
the brake line.
The pressure should be 1200 psi (82.7 bar) in each line
when applying brakes.
Master Brake Cylinder

1. Master brake cylinder
2. Springs on brake plungers
3. Springs at front of master brake
3-2
Brake Accumulator
1. Brake accumulators
Nitrogen charged to 1200 psi (82.7 bar)
2. Pressure hose from junction block
3. Shuttle valve
Brakes and Bleeding

General Information
When bleeding the brakes on an Apache, use the following procedure:
1. Start the machine and hold the right brake pedal down.
2. Loosen the bleeder screw on the right side of the differential; the brake pedal will fully depress.
3. Hold the pedal down and tighten the bleeder screw.
4. Repeat steps 1 through 3 until there are no signs of air present at the bleeder screw.
5. Couple the right and left brake pedals together, pump both pedals, and hold.
6. Loosen the left side bleeder screw on the differential; both pedals will fully depress.
7. Hold the pedals down and tighten the bleeder screw.
NOTE: It is important to follow the above steps as outlined to make sure all the air is bled from the circuit.
Rear Axle Bleeders and Hoses

1. Bleed screw for right side
2. Bleed screw for left side
3. Brake hose to right side brakes from the master
cylinder under cab
4. Brake hose to left side brakes from the master
cylinder under cab
3-3
Brake Packs
The brake packs have 5 fiber and 6 steel discs per side.
The disc types are alternated, beginning with a steel
disc. Brake pack kit part number 350000155.
3-4
Service Brakes - PD70 Axle
Central Drivehead (Inboard Brakes)
3-5
Technical Data
Type Oil-immersed multi-plate inboard disc braking

Actuation Hydraulic
Location Inboard - Axle Centre Casing (2 brake packs)
Friction Plates 3 or 5 pack
Outside diameter 220 mm (8.66 in.)
Inside diameter 180 mm (7.09 in.)
Nominal facing area/plate 12,616 mm2 (19.5 in2)

Hydraulic Piston Diameter 216 mm (8.5 in.)
Piston Operation Standard Retraction
Standard Retraction
Disassembly and Assembly
WARNING! A raised and badly supported machine can fall causing serious personal injury. Position the
machine on a firm, level surface before raising one end. The other end must be securely chocked. Do not
rely solely on the machine hydraulics or jacks to support the machine when working under it.
WARNING! Disconnect the battery before working under the machine to prevent the engine from starting.
Disassembly:
1. It is recommended that the axle be removed from the machine when dismantling the brakes.
2. Drain the oil from the axle and hub.
3. Support the axle arm and remove the bolts (1) using a heavy-duty socket.
4. Separate the axle arm from the drivehead by tapping the flange with a soft-faced hammer. Remove all traces
of gasket from the mating faces.
5. There are two counterplates (2), one at each end of the brake pack, which are not secured to the plate carrier
(3). If the plates are to be reused, note their positions, then withdraw the brake pack.
6. Remove the circlip (4). If the brake pack is to be reused, note the positions of the plates before removing them.
NOTE: The plate carrier (3) has in internal chamfer at the end which faces away from the drivehead.
3-6
7. The wear limit of friction plates is to the depth of the crosshatching. Check all plates for flatness and damage.
Wear and polishing of the counterplates is normal. Replace the complete brake pack if excessively worn or
damaged. Do not replace individual plates.
8. Remove the three reaction pins (5) and inspect them for damage.
9. Carefully withdraw the brake piston (6) from the housing, if removal is necessary. A hydraulic hand pump can
be used to force the piston out of the housing.
10. Remove and discard the seals (7 and 8). Inspect the housing bore for damage and scoring. Nicks or cuts in the
seals can cause loss of brake fluid.
Assembly:
1. Install the new seals (7 and 8). They must be squarely seated in the grooves.
2. Carefully press the piston (6) all the way into the housing.
3. Install the friction plates and counterplates (2) onto the carrier (3). If the original brake pack is being reused,
return the plates to their original positions (see Disassembly, Step 4). Soak new friction plates in gear oil before
assembly. Fit the circlip (4).
4. Install the three reaction pins (5) into the grooves, securing them with grease. Push the pins fully into the loca-
tion holes in the housing.
5. Install one counterplate (2) into the axle arm housing, then the brake pack, then the other counterplate. The
chamfered end of the brake carrier (3) must face away from the drivehead. Return reused counterplates to
their original positions. Push the brake pack in fully.
6. Apply Loctite 275 to the mating face of the drivehead and to the threads of the bolts (1). Install the axle arm
onto the drivehead. The embossed word “TOP” must be on the uppermost axle arm.
7. Fit bolts (1) and torque tighten.
Torque:
Grade 8.8 Bolts: 175 lb-ft (237 N•m; 24.2 kg•m)
Grade 12.9 Bolts: 295 lb-ft (400 N•m; 40.8 kg•m)
8. Refill the differential with the correct grade of oil.
3-7
Brake Piston Seal Leakage Test
WARNING! Before working on the brake system, the

machine must be on level ground with all four wheels
chocked.
WARNING! Do not drive the machine with any part of
the brake system disconnected. When the following
test is complete, reconnect all brake pipes and bleed
the brake system using the recommended procedure.
The following procedure describes how to check for a
severely damaged, cut, or nicked piston seal. The test must
be done when the axle is COLD.
1. Remove and cap the brake piston feed pipe (A).
2. Fill the brake piston housing with Light Hydraulic Fluid.
3. Check for severe piston seal damage:
3.1 Install a hand pump (see note below) fitted with a 0
to 600 lb-ft/in2 (0 to 40 bar) pressure gauge to port
(B), as shown at X.
NOTE: The hand pump must be filled with Light Hydraulic
Fluid. Do not exceed 1000 lb-ft/in2 (69 bar).
3.2 Use the hand pump to generate pressure in the
brake piston housing.
3.3 If the pressure falls off rapidly, or if no pressure
reading can be read, the seal is severely damaged
and must be replaced with a new one.
4. Check for small cuts or nicks in the piston seal:
4.1 Install an adapter fitted with a piece of clear tube
(approximately 4.8 in. (122 mm) long) to the brake
piston port (B), as shown at Y (see note below).
NOTE: The tube must be kept vertical during the test, use
tape to attach the tube to the side of the machine.
4.2 Fill the tube approximately three quarters full with
Light Hydraulic Fluid.
4.3 Mark the level line of the brake fluid on the tube
(C), using a suitable pen.
4.4 If the brake fluid level drops below the original
marked line after 1/2 hour, check the brake piston
seal for slight nicks, cuts, and for general wear.
5. Repeat Steps 1 to 4 for the opposite brake piston seal.
6. Connect all brake pipes and bleed the brake system.
3-8
Axle Breather
Later axles, having inboard brakes, are fitted with
extended breathers (A), as shown in the illustration.
Original breathers fitted to earlier units should be
replaced using the following procedure:
The extended breather (A) is now available in either
metal or plastic construction and is now fitted as stan-
dard to all inboard braked axles. Both metal and plastic
breathers are fully interchangeable if the correct fitting
procedure is followed.
Service Procedure:
1.Park the vehicle on firm level ground, engage the
parking brake, and set the transmission to neutral.
Lower all hydraulically operated fittings to the ground.
2.Remove debris and loose material from the top of the
axle.
3.Remove existing breathers or degrease the breather
hole, as applicable.
4.Refer to the illustration and fit plug (B) (if not already
fitted) and the extended breather after ensuring hole (C)
in the breather is pointing toward the center of the differ-
ential.
For plastic breathers, either a suitable plastic to metal
bonding sealant or bonding, part number 4103/0955 is
required, with sufficient preparation and cure time as
specified in the manufacturer’s instructions.
For the axle location of the plug (B) and breather (A),
refer to the Machine Operator Handbook.
NOTE:Under no circumstances should an axle fitted
with oil immersed brakes be operated without an
approved breather.
3-9
Renewing the Pinion Oil Seal
The pinion seal (3) may be renewed without removing axle from the machine.
WARNING! A raised and badly supported machine can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine when working under it.
WARNING! Disconnect the battery, to prevent the engine being started while you are beneath the machine.
NOTE: These axles are fitted with a brake disc/drive flange in place of the yoke. For Brake Disc Removal
procedure see Brakes, Service Procedures, Section 5.
1. Remove the roadwheels and
uncouple the axle driveshaft.
Measure the axle rolling torque
and record reading. Mark the rel-
ative positions of the pinion shaft
(4) and nut (2) with a scriber.
2. Using Service Tool 892/00812,
remove the drive yoke (1)
together with its stake nut (2).
3. Remove seal (3) and fit a new
one. Be sure not to damage the
seal housing. Pack between the
lips of the new seal with grease
before fitting.
4. Check the sealing surface on the
yoke for wear or damage. Renew
the yoke if necessary. Check the
brake disc for damage or wear.
5. Fit the yoke and temporarily fit
the old stake nut (2). Tighten the
nut with a torque wrench, aligning the scriber marks. Note the tightening torque required.
6. Remove and discard the old nut. Fit a new nut and tighten to the torque determined at step 5.
6.1 Measure the rolling torque. The reading should be 0.37 to 0.74 lb-ft (0.5 to 1 N•m) more than that recorded
in Step 1 (see Note).
6.2 If necessary, progressively torque tighten nut to a maximum of 221 lb-ft (300 N•m) to achieve correct roll-
ing torque.
NOTE: If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in Step 1 by 0.74 lb-ft (1
N•m) or more, or a minimum torque of 184 lb-ft (250 N•m) cannot be achieved then the pinion assembly
must be re-built using a solid spacer, see the appropriate axle assembly procedure.
6.3 Stake the nut using a square ended staking tool.
7. Refit the roadwheels and couple the propshaft.
NOTE: All axles with Parking Brake Disc will have a solid spacer and NOT a collapsible spacer. This also applies
to Differential Lock versions.
3-10
Disassemble the Drive Head
As the drivehead cannot be dismantled whilst fitted on
the machine, we recommend that the complete axle is
removed. See Removal and Replacement for axle arm
removal procedure.
The crownwheel and pinion are matched and should
be renewed as a pair if either one is damaged or
excessively worn. The two differential case halves are
also matched as are the differential side gears and
planet gears, do not use unmatched halves or gears.
NOTE: Drain oil from the axle before dismantling.
NOTE: For axles with limited slip differential, see
Limited Slip Differential.
NOTE: * For axles with soft engage differential lock,
see Soft Engage Differential Lock.
1. Position the drive head as shown, with the crown-
wheel at the top. (For coupling removal see Renewing the Pinion Oil Seal.) Remove capscrews.
2. * Match - mark the brake piston housing and drive head. Pull off the brake piston housing. After removing bolts
1 pull off dowels.
3. Drive out the differential side nut locking pin (3), to
allow readjustment on assembly. Remove the other
brake piston housing only if damaged, but remove
its locking pin regardless (to allow sideload adjust-
ment on assembly).
4. Lift out the crownwheel/differential assembly.

NOTE: If both brake piston housings are to be
removed, mark the crownwheel end of the drive
head casing to ensure that the assembly is
returned to its original position.
3-11
5. Using a soft faced hammer, hit the pinion end shaft
until the pinion is free from its front bearing, then
withdraw the pinion.
6. Withdraw the pinion seal and outer bearing cone.
7. If necessary, drive out the pinion inner bearing cup
and shims. Discard the shims. Repeat for the outer
bearing cup if required. Note that there are no shims
for the outer bearing cup.
8. * Remove and discard the pinion collapsible spacer

(8). If fitted keep the solid spacer.
9. Pull off the bearing cone (9).
10. To dismantle the differential assembly, first remove

bolts (10).
11. Lift off the top half housing (11).
12. Remove the differential gears and spherical wash-
ers. Pull off both differential bearing cones.
NOTE: If required, remove the crownwheel to differential
case-half retaining bolts and remove the
crownwheel.
NOTE: * If a yoke is fitted to the drivehead, then an M24
pinion (hence an M24 stake nut), if a brake disc
is fitted then an M30 pinon is used (hence an
M30 stake nut). Torque figures when assembling
will vary as stated in Drivehead -Assembly.
Assemble Drivehead
Pinion Depth
Determine the pinion depth setting as follows:
NOTE: See page 4/6-6 for general guidance on
crownwheel and pinion adjustment.
1. Assemble the pinion inner bearing and its cup on a
flat surface.
2. Place Service Tool 892/00174 over the bearing
assembly. Measure gap (A). Add tool depth 30.01
mm to gap (A) to give bearing depth.
3-12
3. Note the mounting distance figure (B) etched on the
pinion and the deviation figure (C) on the drive head
housing. Both figures are in units of 0.01 mm.
4. If dimension (B) is positive, add it to the bearing
depth. If dimension (B) is negative, subtract it from
the bearing depth.
5. If dimension (C) is positive, subtract it from the total.
If dimension (C) is negative, add it to the total.
6. Subtract the result from the standard value of 31.19
mm to give the required shim thickness.
Example (Dimensions in mm)

Dimension A 0.25
Add tool depth +30.01
Total 30.26
Add dimension B if
positive. (Subtract +0.01
if negative.)
Total 30.27
Add dimension C if
negative. (Subtract +0.01
if positive.)
Total 30.28
Standard Value 31.19

Less calculated
-30.28
total from above
Shim Thickness 0.91
NOTE: The crownwheel and pinion are matched and

should be renewed as a pair if either one is
damaged or excessively worn. The two
differential housing halves are also matched. Do
not use unmatched halves. If required, fit a new
crownwheel to the differential case half, torque
tighten crownwheel retaining bolts to 122 lb-ft
(166 N•m).
7. Assemble the differential gears and their spherical
washers into the bottom half housing. Fit the differen-
tial bearing cones.
8. Position the top half housing onto the differential,
aligning the match mark letters (see Note above).
Apply Loctite 242 to the threads of bolts, then fit and
torque - tighten to 42 lb-ft (56 N•m). Check the gears
for free rotation.
3-13
9. * Fit the pinion inner bearing cone and a new 14.20 mm
solid spacer from the Service Kit.
NOTE: * It should be noted that the axle should be
assembled using a solid spacer. However, in the
absence of the special tools required or the correct
size solid spacer it IS acceptable to fit a collapsible
spacer.
10. Fit the pinion inner bearing cup, together with the
required thickness of shims to give correct pinion depth, see
Pinion Depth, Steps 1 to 6. To ensure that the cup is fitted
square, use a suitable puller assembly. Do not use a ham-
mer. Fit the outer bearing cup.
11. Insert the pinion Into its bore. (Before inserting, ensure that
the pinion matches the crownwheel. The code numbers
etched on the pinion end face and the crownwheel perimeter
should be the same.)
12. * Fit the pinion outer bearing cone.
NOTE: * If a collapsible spacer has to be used then items (13)
to (21) must be changed. See Collapsible Spacer
Assembly, Section 4.
13. Fit special tool sleeve (B) and special pinion shaft
adapter (C). Tighten adapter (C) to approximately 37
lb-ft (50 N•m; 5 kg•m), making sure the pinion is free to
rotate and there is end float, this will prevent any dam-
age to the bearing. If the pinion is not free to rotate or
there is no end float at this stage check the bearing is
fitted correctly. Also check the correct size spacer has
been fitted.
14. * Fit special bracket (D) to the drive-head housing
using two M16 x 30 bolts. Fit special tool support pillar
(E) to bracket (D) so that the fork end engages in
adapter (C). Ensure that fork (E) is centrally located on
adapter (C). If necessary, re-align bracket (D) to suit.
Fit dial test indicator (F). Ensure that the dial test indi-
cator is mounted on the drive head and not on bracket
(D).
3-14
15. * Set torque wrench (G) to 25.8 lb-ft (35 N•m; 3.5 kg•m)
and measure the end float while rotating the shaft.
16. * To select the right size spacer, subtract the end float
obtained at Step 14 from the solid spacer size (14.20
mm). Also subtract (0.04 mm) to allow for theoretical
bearing tolerance and pre load. The result is the size of
spacer to be fitted from the solid spacer setting kit. If
there is no spacer of this size, fit the next nearest size
spacer.
Example (Dimensions in mm)
Temporary spacer size 14.20
Subtract end-float -0.25
Total 13.95
Subtract tolerance and preload -0.04

Total 13.91
(No spacer available this size, use next nearest size spacer
i.e. 13.900 mm)
17. * Remove sleeve (B) and bearing and temporary spacer. fit correct size spacer from solid spacer setting kit,
refer to Service Tools - Section 1. During removal take care to avoid damaging the outer bearing.
18. * Fit sleeve (B). Tighten adapter (C) to no more than 37 lb-ft (50 N•m; 5 kg•m) to protect against bearing dam-
age while spacer selection is verified making sure the pinion IS free to rotate. Check there is no end float and
pinion is free to turn smoothly by hand. Remove adapter (C) and fit nut (16) and torque tighten to 37 lb-ft (50
N•m; 5 kg•m). Then check that rolling torque is less than 1.5 lb-ft (2.0 N•m; 0.2 kg•m). If the rolling torque
exceeds 1.5 lb-ft (2.0 N•m; 0.2 kg•m), check that the shaft has been assembled correctly.
NOTE: * If the pinion is not free to rotate check the correct size spacer has been fitted.
3-15
19. * If rolling torque measured at Step 18 is too high, fit
the next larger size spacer. If rolling torque is too low,
fit the next smallest size spacer. If a correct spacer is
not available from the range, check that drive head is
assembled correctly.
NOTE: *A yoke or brake flange may be fitted.
20. * Remove adapter (C) and sleeve (B). Fit a new oil
seal, grease between seal lips before fitting. Fit the
brake calliper bracket (D) if a park brake is fitted to
this axle. Fit a Verbus Ripp bolt (E) and torque
tighten to 37.32 lb-ft (166 N•m; 16.9 kg•m). Fit the
brake disc/coupling and a NEW stake nut (16).
21. Progressively torque tighten the stake nut, occasion-
ally rotating coupling yoke, up to 184 lb-ft (250 N•m;
25.5 kg•m). Providing the correct size spacer has
been selected the rolling torque should be between
1.7 and 2.5 lb-ft (2.3 and 3.4 N•m; 0.23 and 0.35
kg•m) including seal drag.
NOTE: The nut tightening torque can be increased to a
maximum of 221 lb-ft (300 N•m; 31 kg•m)
provided that the pinion rolling torque does not
exceed the maximum of 2.5 lb-ft (3.4 N•m; 0.35
kg•m).
22. Finally stake the nut 16 into the slot.
NOTE: Step 21 uses an M24 stake nut (for a yoke), for a
brake disc type. Item (16) would be M30. Torque
tighten to 273 lb-ft (370 N•m; 37 kg•m).
23. If both brake piston housings were removed, fit the
one at the opposite end to the crownwheel, using the
procedure in Step 24. Then install the crownwheel
differential assembly into the drive head.
24. Apply Loctite 574 to the drive head mating face, then
fit the brake piston housing. Ensure that the match -
marks made during dismantling are aligned. Fit cap-
screws (14). Torque - tighten to 42 lb-ft (56 N•m; 5.7
kg•m). (Applies to both piston housings.)
25. Adjust differential side nuts (17) to give a bearing
preload of 0.8 to 1.6 lb-ft (1.13 to 2.26 N•m; 0.1 to 0.2
kg•m). (Measure the preload by taking another rolling
torque reading and subtracting the torque figure
measured at Step 21. The difference is the bearing
preload.)
3-16
26. Measure the crownwheel backlash, which should be
0.006 to 0.010 in. (0.17 to 0.28 mm). Adjust the differ-
ential side nuts by equal amounts when altering back-
lash. When backlash and preload are both correct, fit
the side nut locking pins, see Step 25.
3-17
Crownwheel and Pinion Adjustment
Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound
and rotating the pinion.
The marking will then be transferred to the crown wheel teeth.
Correct tooth marking.
Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner
bearing cup and the axle casing. Move the crown wheel
towards the pinion to correct the backlash.
Pinion too far out of mesh.

Increase the shim thickness between-the pinon inner
bearing cup and the axle casing. Move the crown wheel
away from the pinon to correct the backlash.
3-18
Collapsible Spacer Assembly
When assembling the axle, if the special tools listed in the Service Tools - Section 1 or if the correct size solid
spacer is not available it is acceptable to fit a collapsible spacer using the procedure below. The illustration shows
a typical axle, note that rear axle brake disc, or the yoke (22) shown.
1. Fit NEW collapsible spacer (24), after smearing with Mobil HP222 fit outer bearing (26) followed by a new oil
seal (25). Grease between seal lips before fitting. Assemble yoke (22) or brake disc and NEW stake nut (20)
with integral washer.
2. Tighten stake nut (20) to achieve a rolling torque of 1.1 to 2.1 lb-ft (1.5 to 2.8 N•m), inclusive of seal drag.
NOTE: If this figure is accidentally exceeded the output shaft must be dismantled and the collapsible spacer (24)
renewed.
3. Finally stake nut into slot.
3-19
Limited Slip Differential (optional)
NOTE: The number of friction and counter plates shown in the illustration is typical only. The actual number of
plates is specified by the manufacturer and must not be altered without approval. Refer to parts
information.
3-20
The numerical sequence shown on the illustration is intended as a guide to disassembly.
Disassembly
Mark the two differential halves before disassembly, for subsequent assembly.
Note the relative positions of the friction and counter plates before disassembly, they must be fitted in the same
positions.
If worn, the friction and counter plates must be replaced as a complete set.
Assembly
1. Assemble trunnion pins (12), side gears (11) with pressure plates (10), counter plates (8), friction plates (9),
planet gears (13), and thrust washers (14) into the “crownwheel” half of the differential assembly (5).
NOTE: Do not fit the shims (6) at this point.
2. Align the two halves of the differential assembly with the marks made during disassembly. Assemble using
bolts (3).
Determine the shim value by either a dial test indicator or feeler gauges, refer to the illustration.
3. Gently apply pressure to the side gear (11) away from the trunnion pins (12) with two screwdrivers or suitable
levers, as shown. Measure and note the end-float of the side gear.
4. Turn the differential assembly over and repeat Step 3 for the second side gear.
5. Dismantle the differential assembly. Add shims (6) to give an end-float between 0.004 and 0.008 in. (0.1 and
0.2 mm).
NOTE: Shimming must be carried out whenever the differential is dismantled, however the end float 0.004 and
0.008 in. (0.1 and 0.2 mm) can be exceeded on previously assembled differential as this is only an initial
setting figure.
6. Repeat Steps 2, 3 and 4. If the end float is correct, tighten the bolts (3) to 41 lb-ft (56 N•m).
7. Fit the crownwheel (2) using new Verbus Ripp bolts (1) tightened to 70 lb-ft (94 N•m).
Friction Plate Wear Limits
Measure and note the thickness of the friction plate. The result must not be less than 0.049 in. (1.25 mm).
Check the condition of the friction material, which should be even over both surfaces.
If in doubt, discard the set of friction and counter plates.
Differential Axle Shaft Removal
Remove the U-joint to separate the output shaft from
the differential.
3-21
Remove all but a few of the bolts holding the brake
housing to the differential.
Support the brake housing and remove the remaining
bolts.
The differential will remain in the axle, and the brake
housing can then be removed from the differential.
Once the brake housing is removed, the axle shaft can

then be removed from the brake pack.
Before installing the brake housing back onto the differ-
ential, be sure to insert the dowel pin into the end of the
shaft and secure it with Loctite.
3-22
AS1020 and AS1220

Parking Brake Assembly
The fail-safe brake is spring loaded to apply the brake;
hydraulic pressure is required to release the brake.
Normal operation is to have the brake pressurized while
running. Any function which reduces the hydraulic sys-
tem pressure below the release pressure of the brake
will cause the brake to be applied.
Installation
Move the brake assembly into position and align the
mounting bolt holes.
Install four 5/8-16x3 ½” (grade 8) bolts through holes in
each mounting foot.
Tighten the bolts to 160 to 175 lb-ft [217 to 237 N•m].
Install a yoke, washer and nut onto the brake shafts.

Tighten the nut on each shaft to 275 to 325 lb-ft [373 to
441 N•m.
3-23
Connect the machine driveline (1) to the brake yokes
(2).
Remove the oil fill/level plug (1) from the side of the
brake.
Fill the brake cavity with hydraulic oil until oil overflows
from the fill hole.
3-24
FRONT AXLE
Front Axle
Replacement
Before removing the front axle:
• Be sure to locate the machine on a hard, level surface.
• Turn off machine
• Set the parking brake
• Remove the keys from the ignition
• Place wheel chocks in the front and rear of one of the rear tires
• Support the left and right frame rails
• Support the front axle.
Remove all eight bolts from the two pillow blocks.
Note the position of any spacers or shims on the axle.
Remove the axle.
Reinstall any shims (1) or spacers (2) removed with the

axle.
NOTICE: When installing the pillow blocks (5), it is
important to recoat each bolt with a high strength
threadlocker.
Install a flat washer (4) onto each bolt (3) and install the
pillow blocks (5) using the following torque sequence.
Tighten the bolts to 420 lb-ft (569 N•m). Tighten the
bolts starting on the inside and work toward the outside.
Repeat the torque sequence to ensure all bolts are
tightened to the proper torque.
3-25
NOTES
Chapter 4
Wet System Operation
AS720, AS1020 & AS1220
NOTES
WET SYSTEM OPERATION
Wet System Overview
1. Fill Station 5. Rinse Tank

2. Boom Cradle 6. Product Tank
3. Boom Rack 7. Left Boom Tip
4. Flowmeter 8. Left Boom
4-1
Fill Station
1. Hand Rinse Valve
This valve allows water from the rinse tank on the
right side to be used for hand rinsing.
2. Rinse Tank Quick Fill
3. Product Valve (shown in CLOSED position)
This valve directs flow from the product tank to the
pump or from the rinse tank to the pump.
4. Product Tank Quick Fill
5. Roto-Flush/Agitate Valve
Directs flow between the roto-flush and agitation.
6. Fill Station Light Switch
7. Remote Product Pump Switch
This switch turns the product pump while outside of the cab.
8. Increase/Decrease Agitation Switch
Used to increase or decrease agitation while outside of the cab.
9. Activate Agitation Switch
Use to turn on agitation from outside the cab. Must hold down while increasing or decreasing agitation.
10. Agitation Valve
This valve is electronically actuated and controlled by a switch on the side console in the cab.
11. Fill Station Light
Product Pump and Valves

1. Product Pump
4-2
Hypro 9306S HM1C

(breakdown of Hypro pump)
Sump Valve
1. Product Tank Sump Valve
Shown in the OPEN position.
4-3
Foam Tank
1. Foam Concentrate Bottle
Flow Control
Standard Flow
1. Raven Flowmeter
2. Raven Servo Valve
4-4
Electronic Boom Valves
The strainers (1) on the five electronic boom valves
have 50 mesh screens, which must be cleaned periodi-
cally.
Raven Envizio Pro Monitor

1. Raven Envizio Pro Monitor and Switchbox
On equipped Apache Sprayer models, the Raven
Envizio Pro Monitor and Switchbox are located on
the right side of the cab.
See the manufacturer’s instructions, provided with
the Apache Sprayer, for complete operating, cali-
bration, and service information.
Monitor Calibration Information
Valve cal - 2123
Speed cal (radar gun equipped) - 565
Speed cal (GPS for speed) - 785
Meter cal - See tag on the flowmeter, located on the rear
boom rack. Record this number in a convenient location
for future use.
NOTE: These are factory presets. All Raven controls must be calibrated before applying chemicals.
NOTE: The Raven radar gun is not factory-calibrated. See the manufacturer’s instructions, provided with the
Apache Sprayer, for proper calibration.
NOTE: The Raven 5000 Monitor, Envisio Pro and Viper
Pro are the only consoles installed by Equip-
ment Technologies. If your Apache Sprayer has
a different console, please contact your Apache
dealer for information.
4-5
Side Console
1. Switchbox 10. Cigarette Lighter

2. Raven Envisio Pro Controller 11. Foam Switch for Left and Right Side
3. Cruise Control Master Switch 12. Foam Master Switch
4. Left Boom Fold In and Out 13. Foam Auto
When switched on, foam can be switched
5. Right Boom Fold In and Out
from left to right using the yellow Master
6. Left Boom Tip In and Out Switch on the T-handle.
7. Right Boom Tip In and Out 14. Agitate Increase and Decrease
8. Axle Width Adjustment Switches 15. Product Pump Switch
(Optional Adjust on the Go)
16. Parking Brake Switch
9. Auxiliary Power Point A red light indicates when the parking brake
is applied.
4-6
T-Handle
1. Boom Center Rack Up/Down
Press to raise or lower the boom mast. Press the top of the switch to raise
and press the bottom of the switch to lower.
2. Left Boom Tilt
Press to tilt the left boom up or down. Press the top of the switch to raise
3. Right Boom Tilt
Press to tilt the right boom up or down. Press the top of the switch to raise
4. Master Spray Switch
Press to turn all spray sections on or off at the same time. This function
requires that all boom sections be turned on.
4-7
4-8
4-9
4-10
Filling Product Tank

Open the sump valve (1) on the underside of the prod-
uct tank.
Remove the cap from the product quick fill inlet (1) and
connect the hose from the nurse tank to the inlet.
Open the product fill valve (2), shown in the OPEN posi-
tion, and fill tank to desired level.
When filling is complete, close the valve on the nurse
tank, then close the product fill valve.
Disconnect the hose from the inlet and install the quick
fill inlet cap.
Filling Rinse Tank

Remove the cap from the foam/rinse quick fill inlet (1)
and connect the hose from the nurse tank to the inlet.
Open the rinse valve (2), shown in the CLOSED posi-
tion and fill to the desired level.
IMPORTANT: Fill the tank slowly. Rapid filling or overfill-
ing may rupture the tank.
When filling is complete, close the valve on the nurse
tank, then close the rinse fill valve.
Disconnect the hose from the inlet and install the quick
fill inlet cap.
4-11
1. Optional Fence Row Nozzle
If your Apache Sprayer has optional fence row noz-
zles, they are located near the end of each boom.
2. The electric control valve for nozzles is located
near the end of each boom.
1. Optional Foam Marker Boot and Drop

If your Apache Sprayer is equipped with the Land-
Mark injection foam marker, then the boot is located
near the end of each boom.
2. Foam Marker Mixing Chamber
The foam marker mixing chamber is located near
the end of each boom.
4-12
Operating Booms
Before performing any boom operations, read all the following safety messages and take all necessary precautions
to avoid personal injury and equipment damage.
WARNING! Electrocution Hazard. Do not fold or unfold the booms near power lines.
WARNING! Control Hazard. NEVER fold or unfold the booms while the Apache Sprayer is moving over 5
mph [8.04 km/h] or with the optional Auto Boom height control turned ON.
NOTICE: The boom tips must be folded before the booms can be retracted. The cab can be damaged if the boom
tips are not folded properly.
Tilt to Remove Boom from Cradle

All Boom Sizes
On the T-handle, press the top of the left (1) and right
(2) boom tilt raise/lower switches to tilt the boom and
boom hangers (3) off of the boom cradles (4).
Unfold Booms
IMPORTANT: Do not fold or unfold the booms near
power lines.
NOTE: The boom hangers must be tilted off of the
boom cradles before they can be unfolded.
On the side console, press the top of the left and right
boom fold switches (1) until the booms are fully
extended. After the booms are fully extended, the boom
tips can be unfolded.
Unfold Boom Tips

All Boom Sizes
NOTICE: The booms must be unfolded before the boom
tips can be extended. The cab can be damaged if the
booms are not unfolded properly.
On the side console, press the bottom of the left and
right boom tip fold switches (1) until the boom tips are
fully extended.
4-13
Height Adjustment
All Boom Sizes
On the T-handle, press the bottom of the boom rack
raise/lower switch (1) to lower the boom rack (2) to the
desired height.
Press the top of the switch to raise the boom rack.
Tilt to Level Boom

All Boom Sizes
On the T-handle, use the left (1) and/or right (2) boom
tilt raise/lower switches to adjust the booms to level.
Press the top of the switches to tilt the boom up and the
bottom of the switches to tilt the boom down.
Fold Boom Tips

All Boom Sizes
right boom tip fold switches (1) until the boom tips are
fully folded.
After the boom tips are fully folded, the booms can be
folded.
4-14
Fold Booms
NOTICE: Fold the booms slowly to reduce the possibil-
ity of the booms hitting the cab.
NOTICE: Always tilt the booms up before folding.
All Boom Sizes
right boom fold switches (1) until the booms are fully
folded.
Tilt to Return Boom to Cradle

All Boom Sizes
On the T-handle, press the bottom of the left (1) and
right (2) boom tilt raise/lower switches to tilt the booms
(3) onto the boom cradle (4).
With the booms properly stored, the Apache Sprayer is
ready for transport.
Spraying
Make sure the product, rinse, and foam marker tanks
are filled. See “Filling Rinse Tank” on page 4-11.. See
“Filling Product Tank” on page 4-11..
Level the booms and boom tips using the tilt and unfold
switches. See “Operating Booms” on page 4-13.
Set the boom height using the boom rack switch. See
“Height Adjustment” on page 4-14..
Open the sump valve (1) on the underside of the prod-
uct tank.
NOTICE: ALWAYS read and follow all chemical labels
and follow all federal and state laws when applying
chemicals.
4-15
Set the product valve (1) to PRODUCT TO PUMP.
Set the flush/agitation knob (2) to AGITATION.
Open the product valve (3).
The product strainer features 50 mesh screens, which

should be checked and cleaned after every 50 hours of
operation or as needed.
NOTE: Depending on the chemicals being applied, it
may be necessary to substitute the 50 mesh
screen with a more coarse strainer. See the
chemical manufacturer’s instructions for com-
plete details.
Set the Raven 5000 Monitor power switch to the ON

position and check the settings. Select a saved flow rate
or enter the desired rate. See the Raven manual sup-
plied with the Apache Sprayer for complete operating
instructions.
4-16
Set the desired boom section switches (2) to the ON
position.
IMPORTANT: DO NOT run the product pump dry. Dam-
age to the pump seals will result. DO NOT intentionally
dead-head the pump with high pressures. Damage to
the pump seals will result.
The agitation (1) and boom (2) pressure gauges are

mounted outside at the lower right of the cab.
• The agitation gauge reads pressure at the agi-
tation valve.
• The boom pressure gauge reads pressure from
the five bank boom valves.
NOTE: When the agitation valve is fully open, the agi-
tation pressure gauge and the boom pressure
gauge should show approximately the same
pressure.
IMPORTANT: Selecting the correct spray tip is critical to
obtain proper application. See the spray tip manufac-
turer’s instructions for proper selection.
4-17
Select an appropriate gear for the desired Apache
Sprayer speed during spraying. Under typical operating
conditions, second or third gear is recommended.
Use the master product on/off switch (1) on the T-han-
dle to start and stop spraying.
Use the Raven Sprayer Control boom switches on the
switchbox (2) to start and stop product flow to individual
boom sections. The Raven Sprayer Control will auto-
matically adjust the product flow for the remaining sec-
tions.
Operating Foam Marker

To turn on the foam marker, push the Foam Master but-
ton (1) on the console.
• Push the Foam Left button (2) to drop foam on
the left.
• Push the Foam Right button (2) to drop foam on
the right.
If the Apache Sprayer has the optional split boom, open
the foam valves on each of the booms to drop foam at
60’. The valves are located at the midpoint of each
boom.
NOTE: When the foam marker is turned on, foam will drop from the left side until the right side is chosen.
Auto Foam
To use the Auto Foam feature, turn on the Foam Master switch (1), then turn on the Auto Foam button (3). Foam
will drop from whichever side was used last.
When you turn the boom section switches on or off with the yellow master spray switch on the T-handle, the foam
will switch from left to right.
NOTE: The yellow master spray switch on the T-handle must be turned on before the Auto Foam feature is acti-
vated.
NOTE: The LandMark injection foam marker is the only factory-installed foam marker. If your Apache Sprayer is
equipped with a different foam marker, contact your dealer.
NOTE: After filling the foam tank, the foam marker may need to run for 1 to 2 minutes before the foam begins.
LandMark Injection Foam Marker

Your new foam marker is designed to produce the longest lasting foam, and provide you with the convenience of
not having to mix your foam concentrate and fill the foam marker tank as often. Accuracy in spraying is critical to
your operation.
NOTICE: The LandMark injection marker draws fresh water in one line and soap concentrate in the other before it
reaches the liquid pump. It is very important that when you first begin, or if you change brands of foam concentrate,
4-18
that you properly set the “soap injection valve” and the “output valve”. This will produce the best results in foam
quality and ensure the proper amount of soap concentrate is used.
Injection Marker Operation Instructions
See page page 4-20 for injection marker feature loca-
tion.
Turn on the injection marker and allow the liquid pump
to prime. If the liquid pump does not prime, open the
priming valve until liquid begins to flow, then close the
priming valve.
To adjust the foam quality, open the soap injection valve
(1) by turning the knob counterclockwise. Adjust the
foam quality until foam is rich and thick.
To adjust the total foam output, open the output valve
(2) by turning the knob counterclockwise. Adjust as
needed.
• Opening the valve too far will flood the cham-
bers and produce soupy foam.
• Closing the valve too far will not produce
enough foam.
The water pump and air compressor are located behind
the panel (3).
When the foam marker is set properly, quality foam will
be produced at 60 drops per minute. See the following
table.
NOTE: This foam should stick to your hand when turned upside down.
NOTE: The foam marker pulls water from the rinse tank to create foam.
Drops per Minute Foam Spacing @ Foam Spacing @ Foam Spacing @

Output (based on
3 in. [7.6 cm] boot) 5 mph [8.04 km/h] 10 mph [16 km/h] 15 mph [24.1 km/h]
5 gpm
[18.9 lpm] 62 7.1 [2.16 m] 14.2 [4.32 m] 21.3 [6.9 m]
Maintenance
Clean and replace the air pump and in-line solution filters regularly to extend the lift of the pump. The air pump has
one sponge and one felt filter.
Freezing
When operating in temperatures at or below freezing, ethylene-glycol-based antifreeze may be added to the water
and soap tanks.
If the system will be exposed to freezing temperatures overnight:
1. Pull the suction tube out of the tank and expose it to the air.
2. Close the soap valve and run the system for 10 to 15 seconds to clear the foam solution from the pump and
solenoids.
For long-term storage:
1. Drain the tank of the foam solution and run fresh water through the entire system.
2. While the unit is running, blow air through the suction tube until the system is dry.
3. Flip the power switch to dry the other side.
4-19
1. Output Valve 4. Air Solenoid

Labeled “More Foam Less Foam”
5. Soap Solenoid
2. Soap Injection Valve
6. Liquid Pump
3. Priming Valve
7. Thomas Air Compressor
4-20
Flushing Product Tank

NOTICE: Read and follow chemical labels for flushing, disposal, and protective clothing requirement instructions.
NOTICE: DO NOT run the product pump dry. Damage to the pump seals will result. DO NOT intentionally dead-
head the pump with high pressures. Damage to the pump seals will result.
Fill the rinse tank with clean, fresh, water. See “Filling Rinse Tank” on page 4-11..
Turn the product valve to RINSE TO PUMP (1).
Turn the Agitate/Roto-Flush knob to ROTO-FLUSH (2).
Start the engine.
NOTICE: The rinse tank will empty quickly. Monitor the
process closely to reduce the possibility of running the
product pump dry.
After the tank is rinsed:
• Return the T-handle to IDLE.
• Set the product pump switch (4) to OFF.
• Turn the product lever (1) to PRODUCT TO PUMP.
• Turn the Agitate/Roto-Flush knob (2) to OFF.
Flushing Booms
NOTICE: Read and follow chemical labels for proper usage, flushing, disposal and protective clothing requirement
instructions. ALWAYS dispose of chemicals and contaminated rinse water in a safe location in accordance with
chemical label recommendations and local laws.
NOTICE: Some chemicals may require multiple tank flushings.
NOTICE: DO NOT run the product pump dry. Damage to the pump seals will result. DO NOT intentionally dead-
head the pump with high pressures. Damage to the pump seals will result.
To flush the booms:
• Unfold the booms.
• Set the product valve (1) to RINSE TO PUMP.
• Set the product pump switch (4) to the ON posi-
tion.
• Increase engine speed to 1800 rpm.
• Turn the agitate/roto-flush knob (2) to ROTO-
FLUSH.
• Set the boom section switches to the ON posi-
tion.
NOTE: If the Apache Sprayer is equipped with an
optional chemical eductor, flush the eductor at
the same time as the booms.
After the booms are flushed:
• Return the engine speed to IDLE.
• Set the boom section switches to OFF.
• Set the product pump switch (4) to OFF.
• Set the product valve (1) to PRODUCT TO PUMP.
• Set agitate/roto-flush knob (2) to AGITATE.
• Return agitate switch (3) to original setting.
• Fold the booms, and turn off the engine.
4-21
Cleanload Chemical Eductor

Startup
1. All Cleanload valves must be closed prior to start-
ing. Close the inlet ball valve (1) and the hopper ball
valve (2).
2. Open the lid to check for foreign objects which may
hinder performance or contaminate the system.
3. Close and lock the lid by turning the cover clock-
wise.
4. Divert pump flow to the Cleanload inlet line.
NOTICE: A pressure of 30 psi [2.06 bar] minimum and
150 psi [10.3 bar] maximum must be used. Highest
pressures increase eduction rate and available wand
suction.
5. Turn the yellow handle of the inlet ball valve (1) to
the open position.
6. Open the hopper ball valve (2), located on the bot-
tom of hopper, by rotating the handle into a vertical
position.
7. Unlock and open the lid slowly by turning the cover
counterclockwise.
8. Load the eductor. Loading instructions differ for
eductors equipped with an optional suction lance.
Use the procedure that is appropriate for your appli-
cation.
Loading Liquid or Powdered Chemical into Hopper

NOTICE: Do not at any point put your face directly over the hopper.
NOTICE: Avoid splashing liquids or powdered chemicals outside of the hopper.
1. Pour required amount of chemical into the hopper.
2. Rinse empty chemical containers if applicable. Place container opening over the container rinse valve and
press down. This will activate the rinse valve and rinse the container.
3. Rinse the Cleanload hopper.
4. Close and lock the lid by turning the cover clockwise.
5. Release the safety locking band on the hopper rinse ball valve and open the valve for 20 seconds.
6. Close the ball valve and return the locking band to the locked position.
7. Open the lid and inspect for chemical residue. Repeat steps 3 to 6 as necessary.
8. Close the hopper ball valve (2) by rotating the handle into a horizontal position (shown). Turn the inlet valve (1)
(yellow handle) off.
NOTE: The eductor hoses are flexible and may be kinked while in the up position. This is normal and will not
cause any damage to the hoses or equipment.
4-22
Loading Liquid and/or Powdered Chemical with Suction Lance
NOTE: The suction lance must be purchased sepa-
rately. It is not included with the chemical educ-
tor.
NOTE: Lance suction is dependent on eductor pres-
sure and flow. For best results, use highest
pressure available (up to 150 psi [10.3 bar]
maximum).
1. Insert lance body with o-ring into eductor until the o-
ring is sealed.
2. Use the free end of the lance to pierce bag or con-
tainer to vacuum powdered or liquid chemical.
3. Rinse lance. Place lance end into a clean container
of water to rinse lance assembly.
4. Remove lance body from eductor and drain any
remaining fluid into hopper.
5. Close hopper ball valve. Turn inlet valve (yellow
handle) off.
Shutdown
1. Before shutdown, make sure:
• All valves are closed. Be sure to close the hop-
per ball valve first. (Close by moving handle into
a horizontal position.)
• Chemical residue has been cleaned.
• Hopper lid is closed and locked by turning cover
clockwise.
2. Divert pump flow back to normal operation.
3. Raise eductor to up positions and insert latch pin.
NOTICE: Do not store a contaminated lance in the
Apache Sprayer cab.
4-23
Teejet Boom Valves

The Teejet boom valves are 1” flanged ball valves. The
strainers are equipped with 50 mesh from the factory.
A 5 valve system is shown at right
The valve for boom section 1 is on the far left (1) and
the valve for section 5 is toward the far right (2).
The valve for the product rinse valve (flow back) is
always on the far right (3). This valve is part of the flow
back system and allows you to rinse the flow back line
(4).
On the 8 and 10 section booms, all the valves are
located on the rack with the product rinse valve on the
far right. The 8 and 10 section booms are an available
option.
The boom pressure hose is connected to a gauge on
the outside, right of the cab.
The boom valve wiring is routed from each valve to the 31-Pin connector on the left frame rail, near the suspension
block. From the 31-Pin connector the valve wiring runs to the 102-Pin connector in the cab floor. Refer to the Elec-
trical Section for 102-Pin connector pin-outs.
Boom Valve Wiring

The wiring for the boom valves is shown below.
(77) RED
(77) RED
(77) RED
(77) RED
(77) RED
(77) RED
(77) RED
(77) RED
(77) RED
(77) RED
4-24
Boom Valve Troubleshooting Charts
Boom Valve Troubleshooting Chart (Boom Section #1)
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
4-33
4-34
Agitation Valve
The agitation valve (1) is located behind the quick fill
station.
The agitation valve wiring is routed from the valve to the
102-Pin connector on the cab floor. From the 102-Pin
connector, the wiring runs to pin 8 and pin 9 of the round
37-Pin connector in the side console. The wiring then
terminates at a circuit board.
The external product pump switch is located on the
quick fill station.
The external product pump switch wiring is routed from
the switch to the 102-Pin connector on the cab floor and
then to fuse F11 for power.
Agitate Valve Wiring

The wiring for the agitate valve is shown at right.
4-35
Boom Block
The electrical over hydraulic boom block is located on the rear of the boom rack.
1. Right Boom Tilt “Down” 9. Left Boom Fold “In”

2. Right Boom Tilt “Up” 10. Left Boom Fold “Out”
3. Left Boom Tilt “Down” 11. Left Boom Tip Fold “In”
4. Left Boom Tilt “Up” 12. Left Boom Tip Fold “Out”
5. Right Boom Fold “In” 13. Check Valves
6. Right Boom Fold “Out” 14. Pressure Hose (shown connected to
7. Right Boom Tip Fold “In” autoboom hose with a tee)
8. Right Boom Tip Fold “Out” 15. Return Hose (shown connected to
autoboom hose with a tee)
Each coil must have 12 volts to energize. Make sure to check both power and ground at each coil when trouble-
shooting a problem. When replacing or reinstalling a coil make sure not to over tighten the nut holding the coil on.
If the nut is over tightened it could bend the stem and cause the spool valve not to open. Torque the nut to 18 lb-in
(2 N•m).
Troubleshooting
If there is a boom function that is not working properly, check the following:
1. With the ignition key turned to the “on” position, push the button on the console for the boom function that is not
working properly. Then using a voltage meter, check both power and ground at the coil. If power is present,
then go to Step 2. If power is not present, check the electrical connections at the 31-Pin boom harness connec-
tor, the 102-Pin connector on cab floor, the round 37-Pin connector at the bottom of the console and then at the
back of the circuit board. Refer to the Electrical section for more details on pin locations.
2. Pull the coil back in and using a paper clip or small screwdriver determine if the coil is magnetized. If energized
properly, then the coil will be magnetized. If the coil is not magnetized then replace the coil with a new one. If
the coil is magnetized go to Step 3.
3. Remove the coil from the spool valve, check the stem of spool valve for rust or debris; If found, clean with
emery cloth. If the stem is clean, then remove spool valve from block, inspect o-rings and clean the inside of
4-36
the valve with brake cleaner. Install the coil on the spool valve before installing it into the block. Energize the
coil. If the spool shifts, then reinstall into block and check the operation of the boom function.
4. If still not working check for hydraulic pressure at cylinder for that function. If you have hydraulic pressure then
replace cylinder.
Boom Block Wiring

The boom block wiring is shown at right.
The 31-Pin boom harness connector, located near the suspension

block, is shown below.
4-37
The 102-Pin connector, located on the cab floor, is shown below.
4-38
The 70-Pin connector, located at the bottom of the side console, is shown below.
4-39
Flowmeter and Servo Valve

The Raven 1½ inch flowmeter (1) and 1½ inch servo
valve (2) are located on the boom rack.
If the Apache is equipped with the optional high-flow
plumbing, then the flowmeter and servo valve are config-
ured with 2 inch connections instead of 1½ inch connec-
tions. High-flow component location and wiring are the
same as standard flow.
Servo Valve Wiring
The voltage at the servo valve is +12 VDC. The wire, Yel-
low #236, is routed from the valve to pin #7 in the product
node harness. This wire is powered when the valve is
opening. The wire, Green #235 is routed from the valve to
pin #6 in the product node harness. From the 102-Pin
connector the wiring runs to pin #37 of the 37-Pin con-
nector at the back of the Raven console. This wire is pow-
ered when the valve is closing. The wires switch between
power and ground depending upon whether the valve is
opening or closing.
By design, the servo valve will neither completely close or completely open.
Flowmeter Wiring
The voltage at the flowmeter connector is 5 volts on the power and 5 volts on the signal and ground on the shield.
These wires run from the flowmeter to the product node.
The flowmeter monitors product flow The meter functions using an impeller and magnetic sensor; pulses are
sensed at the meter and a signal is sent to the Raven console, indicating how much product is being used. All 2011
Apaches, regardless of flowmeter size, use the same wiring.
Flowmeter Paper Clip Test
Disconnect the 3-Pin harness connector from the flowmeter connec-
tor. Orient the harness connector with the keyway in the 12 o’clock
position. The pin at the 2 o’clock position is the ground wire, the pin at
the 6 o’clock position is the signal wire and the pin at the 10 o’clock
position is the power wire.
Step 1. Enter a METER CAL number of 1 on the console.
Step 2. Depress the TOTAL VOLUME key.
Step 3. Place the boom switches and master switch to the “on” posi-
tions.
Step 4. Use a paper clip or small jumper wire to create an intermittent short between the 2 o’clock and 6 o’clock
positions on the cable connector. Each time contact is made, the TOTAL VOLUME should increase in
increments of 1 or more counts.
Step 5. If TOTAL VOLUME does not increase, repeat the test on the flowmeter cable connector that is next closest
to the console. Replace defective cables as required.
Step 6. Perform a voltage check. Measure between the 2 o’clock and 6 o’clock positions on the cable connector;
the voltage should read +5 VDC. Measure between the 2 o’clock and 10 o’clock positions on the cable
connector; the voltage should read +5 VDC.
Step 7. If all the cables tested are good, replace the flowmeter.
NOTE: After testing is complete, reset METER CAL values before applying product.
4-40
Flowmeter Troubleshooting Chart
Following directions on previous

START pages, perform paperclip test.
Does the value increase?
no yes
Remove backshell on
harness side of flow
Replace sensor
yes meter connector. Are
or entire flow meter.
any wires pulled out
of the pins?
5 Volts
Ground
Power
ground 5 volts
Repair connection or no
install new connector.
5 Volts Signal
Using a voltmeter check 5 volts
voltages per diagram at Verify a good
yes
right. Are the voltages connection at plug.
correct?
no
Check voltages at Raven

connector
Inspectand floor
wiring forconnector.
rubs or
InspectIfwiring
pinches. signal for
wirerubs or
or power
pinches. If signal wire
wire is grounded it will orshow
power
wire is grounded it will show
0 volts.
0 volts.
Servo Valve Troubleshooting Chart

Turn Raven Controller 5000 on.
Set switch to manual, hold Check other wet system
START yes
increase switch up. Does componets to correct problem.
control valve motor turn?
no
Unplug control valve, using

a voltmeter on the two wires
in the plug, check for 12 volts
yes no
while holding increase switch
up and then down. Is there
power?
Check for power on wires 236

Remove control valve and and 235 at the product
chck inside for obstrucutions. no control node.
Is it obstructed? Is there power while holding
yes no
the increase switch up then down?
yes
Clean out control valve. Replace control valve.
Repair connection at floor plug Contact factory to verify Raven

or problem in wiring harness. controller replacement.
4-41
Radar Gun
The radar gun is located on the right side of the vehicle,
under the battery box. The radar uses a 12 volt power
source.
The power wire, Black CBL 2 is routed from the radar
plug connection position 2, to pin 27 of the Precision Ag
harness floor connector. From there it runs to pin 12 of
the black boom/ speed node connector. This wire is 12
volts.
The ground wire, shield CBL2, has a yellow heat shrink
covering on it and is routed from the radar connection
position 1, to pin 24 of the Precision Ag harness floor
connection. From there it runs to pin 4 of the black
boom/speed node connector.
The signal wire, Clear CBL 2, is routed from the radar
plug connection position 3, to pin 29 of the Precision Ag
harness floor connector. From there it runs to pin 3 of
the black boom/speed node connector. This wire is 5
volts.
Smucker Injection Foam Marker

The Smucker injection foam marker control box (1) is
located on the frame, near the left rear tire. The com-
pressor and water pump are also located here; refer to
the Operation section for complete details.
The wiring for the Smucker foam marker is routed from
the marker components to a 4-Pin connector and then
to the 102-Pin connector on the cab floor. From the 102-
Pin connector, the wires run to the round 37-Pin con-
nector at the bottom of the side console. The blue #71
wire supplies power to the foam solenoid. The blue #70
wire supplies power to the compressor and water pump.
When the master foam switch is activated, the left side
will be energized until the right side “on” is selected.
4-42
The foam concentrate bottle (1) is located on the frame,
near the left rear tire.
The foam mixing chambers (2), drop tubes (3) and drop
boots (4) are located on the booms.
Three-way valves are used on combination booms such

as the 60/90 foot booms.
4-43
NOTES
4-44
Chapter 5
Hydraulic System
AS720, AS1020 & AS1220
NOTES
HYDRAULICS OPERATION AND TROUBLESHOOTING
Hydraulic Circuit Operation

The hydraulic system on all 2011 Apache models is the same circuit. Refer to the following diagram and the
Hydraulic System Circuit Schematic on page 5-35.
5-1
The gear pump has two sections. The rear half pulls oil through a suction screen in the hydraulic tank and then
supplies oil to run the hydraulic motor that turns the fan to cool the radiator. The return oil from the fan motor is sent
to the junction block and then to the cooler and back into the hydraulic tank return filter. The front half of the gear
pump pulls oil from the filter in the tank and supplies oil to the steering motor. The return oil is then sent to the junc-
tion block and to the cooler then back to the hydraulic tank return filter. The steering circuit and the fan circuit are
open center. The pressure compensated piston pump pulls the oil that is returned into the hydraulic tank filter and
supplies oil to the junction block. Where the oil can be used to release the parking brake, raise the ladder, or flow
through the block and back to the rear suspension block. The oil can be used in the rear suspension block to oper-
ate rear suspension, product pump, boom rack up/down, or flow through the block to the boom manifold block. The
boom manifold block operates boom fold in/out, boom tilt up/down, or boom tip fold in/out. The excess oil not used
in the hydraulic blocks and all return oil goes back to the return filter on the left frame rail then back to the junction
block, and then back through the cooler and into piston pump. The hydraulic system through the piston pump acts
as a closed loop system.
Hydraulic Components
ET Part Number Description Model
860000035 Hydraulic pump (piston and gear) AS720 with ITL Transmission
860000036 Hydraulic pumps (piston and gear) AS720, AS1220 and AS1020 with
ZF Transmission
810000006 Junction block under cab All
810000010 Suspension manifold All
810000015 Boom manifold All
810000016 Boom manifold with Autoboom All
840000010 Suction strainer (large) All
880000024 Return filter assembly All
880000026 Return filter element All
600901510 Boom tilt up\dn cylinder All
600901510 Boom fold in\out cylinder All
600901511 Boom tip fold in\out All
600901406 Boom rack up\dn cylinder All
100106514 Front suspension assembly All
100106052 Rear suspension cylinder (small) All
100106063 Rear suspension cylinder (large) All
Hydraulic Pump
1. Hydraulic Dump Valve
2. Piston Pump
3. Case Drain Hose
4. Piston Pump Suction
5. Compensator for Pressure Adjustment
6. Pressure to Steering Motor
7. Pressure to Fan motor
8. Gear pump Suction Hoses
9. Piston Pump Pressure
5-2
Hydraulic Dump Valve Operation

The hydraulic pump contains a dump valve attached to the compensator to relieve the pressure of the hydraulic
system while cranking the engine. The valve is energized only when the engine is cranking.
Compensator Adjustments
The pressure adjustment screw is located on the front left side of the hydraulic pump.
To adjust the pressure, loosen the set screw, then turn the pressure adjustment screw “in” to turn the pressure up
and “out” to turn the pressure down. Always go one-quarter turn at a time and check the pressure. Do not turn it
above 2500 psi (172 bar).
The remaining screw is preset and is not to be adjusted.
NOTE: If one or both pumps fail, then it will be necessary to replace both pumps. The new pumps will not be
factory set for the correct hydraulic pressure. Once you have installed the new pumps and changed the
return filter and flushed and cleaned the suction strainers, then crack the suction fitting on the gear pump
to bleed air. Once you have good clean oil, then check your pressure on the junction block and using the
adjustment settings above adjust the pressure to 2400 psi (165 bar).
Junction Block
The junction block is located under the cab.
Front View
1. Return Hose from Rear Manifolds
2. Pressure to Rear Manifolds
3. Pressure to Brake Master Cylinders
4. Ladder Raise and Lower
5. Fan Motor Return
6. Return to Tank
7. 100 PSI Check Valve
8. Return from Brake Master Cylinders
9. Pressure Test Port
10. Right Turn Hose to Steering Cylinder
11. Left Turn Hose to Steering Cylinder
12. Pressure to Release Brake
Bottom View
1. Junction Block Return to Tank
2. Steering Motor Return / Autosteer Return
3. Piston Pump, Fan Motor Case Drain and Ladder
Vent
4. Pressure from Piston Pump
5. Left Turn Hose from Steering Motor / Autosteer
Tie In
6. Right Turn Hose from Steering Motor / Autosteer
Tie In
7. Outlet of Junction Block to Hydraulic Oil Cooler.
5-3
Side View
1. Brake Set Speed Adjustment
2. Steering Counterbalance Valve
3. Steering Counterbalance Valve
4. Ladder Speed Adjustment
5. Ladder and Brake Solenoid Valve
Steering Cylinder Plumbing

for Adjustable Axles Only
For 2005 and Newer Apaches: AS500, AS510, AS710, AS850, AS1000, AS1200, AS1010, AS1210, AS720,
AS1020, or AS1220.
How system works

Oil is supplied to the open center 5 gpm (18.9 L/min) steering motor from the hydraulic gear pump that is attached
to the main hydraulic pump. When the operator turns the steering wheel, the motor sends oil through a counterbal-
ance valve to the rod end of the steering cylinder. The oil from the base end of the cylinder is then pushed out of
this cylinder and into the base end of the cylinder on the other side pushing the rod out. The counterbalance valves
are cross-ported and remain closed until the operator turns the steering wheel. To keep the wheels in phase, or
steering together, the cylinders have rephasing valves built in to them. Once the cylinder reaches the end of stroke
the rephasing valve opens allowing oil to circulate through the system to remove air and to bring the wheels back in
to phase if needed.
How to rephase steering

1. Start machine and turn the steering wheel all the way one direction. Continue turning steering wheel even
though the front wheels have stopped turning. You will need to move the machine forward a couple feet to
allow the wheels to turn all the way.
2. Continue turning steering wheel for 100 complete revolutions; this will circulate the oil through both cylinders.
3. After you have done this in one direction, turn the steering wheel the opposite direction and repeat the proce-
dure.
If there is no steering
• If the steering wheel will not turn or is hard to turn, the hydraulic pump may not be supplying any or enough
flow.
• If the wheel will turn there could be a problem in the steering motor, or the steering arm on the front axle.
If wheels are toeing out while driving

• The oil is compressing air in the barrel side, the oil is leaking out of the barrel side of the cylinder internally or
externally, or oil is leaking over the counterbalance valves.
• Inspect hoses and cylinders for leaks. Also, make sure hoses are not looped above cylinders.
• Rephase steering to purge air from the system. (See above rephase instructions)
• Remove counterbalance valves, clean and inspect o-rings
5-4
• Adjust counterbalance valves to the proper setting. The 2009 and current model year valves are marked with
the word “SUN” on the wrench flats. The 2005 to 2008 valves are marked with a number, either “50/” or “30/”,
on the wrench flats of valve.
• SUN - Adjust to 1.5 turns in from all the way backed out.
• 50/ - Adjust to 2 turns in from all the way backed out.
• 30/ - Adjust to ½ turn in from all the way backed out.
• If wheels are still toeing out, replace cylinders.
If wheels are toeing in while driving

• The oil is leaking internally or externally from the rod end of the cylinder, air is trapped in the crossover hose, or
a piece of debris is stuck in the counterbalance valve.
• Inspect hoses and cylinders for leaks. Also, make sure hoses are not looped above cylinders.
• If wheels are still toeing in, replace cylinders
If wheels are totally out of phase or

pointing in different directions
• The counterbalance valve is stuck open, or the cylinder is internally or externally leaking oil.
• Inspect hoses and cylinders for leaks.
• If wheels are still out of phase, replace cylinders.
Re-Phasing Steering
Use the procedure below to align or replace a steering cylinder.
WARNING! Make sure the tractor is off and the park brake set.
NOTE: To ease this procedure, raise the axle 3 to 5 in. (76 - 127 mm) to reduce the force on the wheels.
1. Disconnect the steering arm ball joint from the steering arm on both sides.
2. Start the engine and steer to the left extreme and continue to turn the steering wheel 100 complete revolutions
to remove air from the new cylinders.
3. Steer to the right extreme and continue to turn the steering wheel 100 complete revolutions to remove air from
the new cylinders
4. Steer back left until both cylinder rods protrude an equal distance from each cylinder. Use a tape measure to
verify both rods are the same length.
5-5
5. Manually turn the left front wheel until it points in a straight forward direction.
6. Thread ball joints into the left steering cylinder with equal thread engagement to where the ball joint tapers will
drop into the tapered holes in the steering arm and steering cylinder support without turning the left front wheel.
7. Measure from the parting flash on the front of both front tires, then the back. Manually turn the right front wheel
until the front measurement (parting line to parting line) is 1/8 in. (3.175 mm) less than the measurement
between the rear of the wheels (parting line to parting line).
8. Thread ball joints into the right steering cylinder with equal thread engagement to where the ball joint tapers
will drop into the tapered holes in the steering arm and steering cylinder support without turning the right front
wheel.
9. Torque all four ball joints to 75 ±8 lb-ft (101.7 ±10 N•m) and install the cotter pins.
10. Torque rear jam nut on both cylinders (head end only) to 150 ±10 lb-ft (203.4 ±13 N•m).
11. Re-measure the front of the wheels (parting line to parting line), then the rear of the wheels (parting line to part-
ing line). Make fine adjustments by turning one or both of the steering cylinder rods until the front measurement
is 1/8 in. (3.175 mm) less than the rear measurement.
12. Torque the clamp bolts on both female ball joints that clamp the cylinder rods to 75 ±5 lb-ft (101.7 ±6 N•m).
13. Lower machine, start, and check steering operation.
Steering Cylinder Plumbing Instructions

On all 2005 and newer Apaches: AS500, AS510, AS710, AS720, AS850, AS1000, AS1200, AS1020, or AS1220
Follow these instructions when installing steering cylinder part # 850000129 in place of steering cylinder part #
850000118 or 850000126.
1. Remove steering supply hoses from the bolster bulkhead fittings and reverse the connections. The right supply
hose connects to the rear most fitting and the left to the front most fitting.
2. Reverse the hoses on both the right and left steering cylinders, so that the crossover hose is tied to the rod end
of each steering cylinder and the supply hoses are tied to the base end of each cylinder.
3. Refer to Figure 5-5. The line labeled (1) below is the pressure hose to the right steering cylinder, the line
labeled (2) is the pressure hose to the left cylinder, and the line labeled (3) is the cross over between the cylin-
ders.
When the installation is complete the hose routings should be as shown in the following illustration.
Steering Cylinder Bleeding Instructions

1. Start machine, bring to operating temperature, rev the engine to 1000 RPM.
2. Start moving the machine forward; turn the wheel to the right until the steering cylinder bottoms out. Once the
cylinder is bottoms out, then stop moving the machine. Continue turning the wheel for 5 minutes in this direc-
tion. This will be approximately 140 revolutions.
3. Repeat Steps 1 and 2 for the left side.
NOTE: It is very important to follow the above steps as outlined to insure the cylinders will operate properly and it
is not necessary to loosen any fittings when bleeding the steering circuit.
NOTE: Service Update 26005 is a reference for the correct counter balance valve settings for the 2005 and Newer
Apaches.
5-6
Steering Plumbing Diagram
5-7
Boom Block
1. Right Boom Tilt “Down” 9. Left Boom Fold “In”

2. Right Boom Tilt “Up” 10. Left Boom Fold “Out”
3. Left Boom Tilt “Down” 11. Left Boom Tip Fold “In”
4. Left Boom Tilt “Up” 12. Left Boom Tip Fold “Out”
5. Right Boom Fold “In” 13. Check Valves
6. Right Boom Fold “Out” 14. Pressure Hose (shown connected to
7. Right Boom Tip Fold “In” autoboom hose with a tee)
8. Right Boom Tip Fold “Out” 15. Return Hose (shown connected to
autoboom hose with a tee)
The electrical over hydraulic boom block (shown above) is located on the rear of the boom rack.
Each coil must have 12 volts to energize. Make sure to check both power and ground at each coil when trouble-
shooting a problem. When replacing or reinstalling a coil make sure not to over tighten the nut holding the coil on.
If the nut is over tightened it could bend the stem and cause the spool valve not to open. Torque the nut to 18 in-lb
(2 N•m).
Autoboom
1. Left Proportional valve
2. Right Proportional valve
3. Left Boom up
4. Left Boom down
5. Right Boom down
6. Right boom up
When Autoboom is installed on the machine at the fac-
tory, a different manifold is used that contains the valves
for the autoboom instead of using a separate block. The
hydraulic connections are the same.
5-8
Troubleshooting
The boom block wiring is shown at right.
If there is a boom function that is not working properly, check the
following:
1. With the ignition key turned to the “on” position, push the but-
ton on the console for the boom function that is not working
properly. Then using a voltage meter, check both power and
ground at the coil. If power is present, then go to Step 2. If
power is not present, check the electrical connections at the
31-Pin boom harness connector, the 102-Pin connector on
cab floor, the round 37-Pin connector at the bottom of the con-
sole and then at the back of the circuit board. Refer to the
Electrical section for more details on pin locations.
2. Pull the coil back in and using a paper clip or small screw-
driver determine if the coil is magnetized. If energized prop-
erly, then the coil will be magnetized. If the coil is not
magnetized then replace the coil with a new one. If the coil is
magnetized go to Step 3.
3. Remove the coil from the spool valve, check the stem of spool
valve for rust or debris; If found, clean with emery cloth. If the
stem is clean, then remove spool valve from block, inspect o-
rings and clean the inside of the valve with brake cleaner.
Install the coil on the spool valve before installing it into the
block. Energize the coil. If the spool shifts, then reinstall into
block and check the operation of the boom function.
4. If still not working check for hydraulic pressure at cylinder for
that function. If you have hydraulic pressure then replace cyl-
inder.
The 31-Pin boom harness connector, located near the suspension
block, is shown below.
5-9
The 102-Pin connector, located on the cab floor, is shown below.
5-10
The 70-Pin connector at the console, is shown below.
5-11
Suspension Block
The rear suspension block is located near the rear of the Apache.
Front View
1. Pressure Hose From Junction Block 8. Right Side Suspension “Up”

2. Return Hose Back Into The Junction Block Power wire is brown #83.
3. Product Pump Adjustment 9. Right Side Suspension “Down”

This regulates the flow of oil to the product pump. Power wire is brown #84.
It is factory set so the product pump is set at maxi- 10. Hose to Right Side Leveling Cylinder
mum deadhead pressure of 120 psi (827 kPa) with 11. Hose to Large Suspension Cylinder Right Side
the agitation valve closed.
12. Boom Rack “Up” Hose
4. Boom Rack “Up”
Power wire is brown #19. 13. Return from Product Pump
5. Boom Rack “Down” 14. Pressure to Product Pump

Power wire is brown #20. 15. Small Left Side Leveling Cylinder
6. Left Side Suspension “Up” 16. Large Left Side Leveling Cylinder
Power wire is brown #81. 17. Right Suspension Cylinder Return
7. Left Side Suspension “Down” 18. Left Suspension Cylinder Return
Power wire is brown #82.
Bottom View
1. Pressure to Boom Manifold
2. Product Pump Solenoid Valve
3. Return From Boom Valve
5-12
The rear suspension block wiring is shown at right.
Rack Lift Manifold

1. Left Rack Cylinder Pressure
2. Left Rack cylinder Vent
3. Rack Lift Accumulator
4. Right Rack Cylinder Vent
5. Right Rack Cylinder Pressure
6. Rack Lift Pressure from Suspension Block
7. Rack Lift Cylinder Vent to Return on Suspen-
sion Block
Rear Suspension
1. Rear Suspension Accumulator Block
2. Rear Suspension Accumulator
3. Rear Suspension Leveling Cylinder
4. Rear Suspension Load Cylinder
5. Rear Suspension Switch
5-13
Front Strut Repair

This set of instructions will guide you through service on the front strut assembly. This procedure should also be
used for preventive maintenance. The following areas will be covered:
• Inspection
• Removal of the strut assembly
• Checking the pre-charge pressure
• Replacing the old-style Schrader valve
• Recharging the accumulator
• Checking/filling oil level
NOTE: Before performing any maintenance, be sure to locate the Apache on a hard level surface, place the
Apache in neutral, set parking brake, turn off the Apache, remove key from ignition and keep the key with
person making repairs.
Inspection
Visually inspect for external leaks at the following locations. If leaks are present replace entire unit with a new strut
and send the unit back for repair or replacement.
Rod Seal Small Plug #1.
Fill Plug Small Plug #2.
Cylinder Tube Weld Cap End Weld.
5-14
Strut Assembly Welds Union.
Check the cylinder rod extension. The minimum

extension should be 3 in. (76 mm).
Removal of Strut Assembly

Lift the Apache so the front wheels are off the ground and the strut cylinder rod is fully extended. When the rod is
extended, the length should be 12-3/4 in. (324 mm).
Remove the strut from the Apache and put the unit in a vise vertically so the accumulator and gas valve are facing
up.
Checking the Pre-charge Pressure

1. Check accumulator nitrogen pre-charge by putting the charge valve on, shut off the bleed valve and check the
gauge.
2. This pre-charge should not be more than 50 psi (3.4 bar) below the original pre-charge. The proper pre-charge
is shown in the Apache manual for your specific tractor.
3. There can be a great amount of pressure in the accumulator, so relieve the pressure by depressing the center
pin with a suitable tool, such as a center punch.
4. Remove the valve with a wrench.
5. Install the new adapter fitting and tighten with a wrench. Be careful not to over-tighten the fitting so the O-ring
will not split.
6. Install the valve into the adapter fitting. Hand tighten, then tighten with a wrench. Be careful not to over-tighten
the fitting so the O-ring will not split.
5-15
Recharging the Accumulator
Charge the accumulator to 1100 psi (76 bar).
Let the accumulator settle to around 1000 psi (69

bar), this should take approximately 30 to 40 sec-
onds.
Bleed down the accumulator to the desired pres-
sure (proper pressure can be obtained from the
Apache manual for your specific tractor) by open-
ing the bleed valve very slowly.
NOTE: ALWAYS BLEED DOWN TO THE
REQUIRED PRESSURE. Do not charge
up to the required pressure.
Close the accumulator, bleed off the excess gas in
the valve and remove the valve.
Install the new cap to complete the process.
Checking/Filling Oil Level

1. Slowly remove the 1/4 in. SAE plug at the very top of the strut cylinder. Cover with a rag as you loosen the
plug, the oil may be very foamy and aerated due to the cylinder being under pressure.
2. Reinstall the plug after all aerated oil has been released from the cylinder.
3. Check to see if the accumulator charge valve has a cap, if so remove the cap and verify that the cap has a
working seal. Provide new accumulator cap if it is damaged or does not have a working seal.
4. Position strut assembly in horizontal position in vice with accumulator and cylinder block facing up.
5. Remove top 1/4 in plug and 1-1/4 in. plug and observe oil level inside the piston/spring cavity.
5-16
6. If oil level is above the bottom of piston, follow
Steps “a” through “f” below. If it is below the
piston, then proceed to Step 7.
a. Fill the piston cavity to 1/4 in. from top

with new oil.
b. Hold rag over 1/4 in. plug hole and re-
install 1-1/4 in. plug. Some oil will
come out of the 1/4 in. plug hole.
c. Install 1/4 in. plug and wipe off any oil
from piston block and plugs.
d. Remove the strut from the vice.
Attempt to compress the cylinder rod
by putting the rod end down on the
floor and pushing on the assembly.
e. If no compression happens, the strut
is ready to be reinstalled.
f. If the rod does compress then go back
to Step 4.
7. If oil level is below the bottom of piston:
a. Remove the spring.
b. Remove the strut from the vice and turn it over to drain the oil into a drain pan or bucket. Let the piston
fall out and drain all the oil from the unit.
c. Reposition the strut in a horizontal position in the vice.
d. Fill the cylinder with new oil to just above the piston seat. Let the unit sit for 5 minutes to allow air to
escape from the cylinder.
e. Install piston and spring.
f. Fill piston cavity to 1/4 in. from top with new oil.
g. Hold rag over 1/4 in. plug hole and re-install 1-1/4 in. plug. Some oil will come out of the 1/4 in. plug
hole.
h. Install 1/4 in. plug and wipe off any oil from piston block and plugs.
i. Remove the strut from the vice. Attempt to compress the cylinder rod by putting the rod end down on
the floor and pushing on the assembly
j. If no compression happens, the strut is ready to be reinstalled.
k. If the rod does compress then go back to Step 4.
5-17
.
PSI Charge Model Year Model Number

800 2004 - 2006 500, AS500, AS510
850 2001 - 2003 760, 780, 790, 7100
850 2004 - 2009 850, AS850, AS710, AS720
900 2001 - 2003 875, 880, 890, 8100, 1080, 1090
900 2004 - 2009 1000, AS1000, AS1020
950 2002 - 2009 1280, 1290, 1200, AS1200, AS1220
800 1999 - 2000 All Apaches with Suspension
800 2010 715, 1010
900 2010 1210
800 2011 720
900 2011 1020, 1220
Using Test Kit 980000419

Install the test kit gauge (A) onto the accumulator as
shown and snug the fitting (1) with a wrench onto the
accumulator.
Slowly open tee handle (2) (left hand thread) on the
valve all the way open and the gauge (3) will show the
psi charge of the accumulator.
To charge the accumulator leave the tee handle open
and connect a hose to fitting (4) as shown. Connect the
other end of the hose to the nitrogen tank. Slowly open
the nitrogen tank valve and watch gauge on accumula-
tor. Once you have reached the correct charge on accu-
mulator then close the valve on the nitrogen tank and
the tee handle the connected to the accumulator.
Remove the hose from gauge and reinstall cap. Then
remove test kit gauge (A) from accumulator and install
the new cap (100106503).
If you over charge the accumulator use the bleeder valve (5) to let the excess charge out.
NOTE: The accumulator is not rebuildable.
NOTE: Dealer must supply nitrogen, tank, gauge, and adaptor for tank.
Cylinder Seal Replacement Procedure

The following is the seal replacement procedure provided by Columbus Hydraulics:
1. Drain all oil from the cylinder.
2. Clean all dirt and grit from the outside of the cylinder.
3. Insert the cylinder into a vise.
4. Turn the shaft until the split in the retaining ring is facing the oil opening in the tube. Then move the round cyl-
inder retainer from the groove on the shaft into the relieved area on the shaft using a long thin screwdriver. It
may be necessary to use two screwdrivers to move the ring.
5. Remove the shaft assembly from the barrel, pulling in a straight line, so as not to scar the internal parts.
6. Remove all seals from the barrel assembly using a non-sharp seal tool. These tools are available from various
seal suppliers.
5-18
7. Clean all oil and debris from the shaft and the inside and outside diameter of the barrel using solvent, rags, and
an air hose.
8. Inspect all parts for wear or damage. If damage is found, replace with new.
9. Reinstall all seals in the barrel assembly using the non-sharp seal tools.
10. Place a small amount of oil on the inside of the seals and install the shaft. Carefully place it back into the barrel
assembly, being very careful not to damage the seals inside.
11. Turn the shaft until the split in the retaining ring is facing the oil opening in the tube. Then move the round cyl-
inder retainer from the relieved area on the shaft into the groove on the shaft using a long thin screwdriver. It
may be necessary to use two screwdrivers to move the ring. It is import to make sure that the retaining ring is
properly seated in the retaining groove before putting any pressure on the cylinder.
12. Cycle the cylinder using air to check for proper operation.
NOTE: It is very important to keep all parts clean when working with hydraulic cylinders; even one small piece of
dirt or grit can damage the cylinder.
Rear Suspension
The operating pressure may be measured at the inlet pressure hose coming into the suspension block. The normal
operating pressure is 2400 psi (165 bar) for all Apache models.
Oil flows into the block through the check valves, then out to the 4 inch suspension cylinders. The hoses connected
to each suspension cylinder are connected to a T connector. One side goes to the small leveling cylinders on the
opposite side of the vehicle from the suspension cylinder receiving oil. This allows oil to flow into the cylinder to
give the Apache the ride. When the vehicle is making a left turn, oil flows out of the cylinder on the left and into the
small leveling cylinder on the right. The leveling cylinder on the right will then pull down. This helps to keep the rear
axle even with the frame. The opposite occurs when the vehicle turns right.
The ride of the Apache is achieved with the large suspension cylinder. The limit switch activates when the cylinder
collapses. The limit switch then activates the coil on the suspension block for that cylinder. This shifts the spool in
the suspension block allowing oil to flow to the suspension cylinder. This raises the cylinder back up to maintain the
Apache ride.
The rear accumulators are charged with nitrogen. As the vehicle goes across the field, the suspension cylinders
move up and down. When the cylinder moves down, this pushes oil out of the cylinder and into the accumulators.
Oil flows into the accumulator through a machined block with a throttle valve orifice assembly. Oil flows in and
pushes against the nitrogen, then the nitrogen pushes the oil back into the machined block.
Before working on the rear suspension, remove the rods from the switch to the axle and activate the switch so the
suspension collapses. This will take the hydraulic pressure off the cylinders.
5-19
NOTE: Check the accumulator charge with the suspension lowered all the way down.
1. Rear Suspension Block
Part number 100106140
2. Rear Suspension Accumulators
AS720 and AS1020
Large 450 psi (28 bar) nitrogen,
Part number 100106155.
Small 400 psi (31 bar) nitrogen,
AS1220
Large 500 psi (34 bar) nitrogen,
Small 450 psi (38 bar) nitrogen,
3. Rear Suspension Leveling Cylinder
Seal Kit part number 100106056.
4. Rear Suspension Load Cylinder
Seal Kit part number 100106062.
5. Rear Suspension Switch
(Refer to Chapter 6, Electrical).
Installing New Rear Suspension Cylinder Seals

If any of the suspension cylinders begin to leak, a seal kit may need to be installed.
Follow the following instructions when replacing the seals:
1. Drain all oil from the cylinder.
2. Clean all dirt and grit from the outside of the cylinder.
3. Insert the cylinder into a vise.
4. Remove the cylinder retainer using a spanner wrench inserted into the holes on the head. It may be necessary
to use a sharp object to start the retainer removal through the slotted barrel.
5. Remove the shaft assembly from the barrel. Hold it straight when pulling it out to reduce the possibility of scar-
ring the internal parts.
6. Insert the shaft into a soft-jawed vise so the head and piston can be removed. The shaft and vise must be
clean before using.
7. Remove the nut at the end of the shaft and pull the head and piston off the rod.
8. Remove all seals from the head and piston using a non-sharp seal tool. These tools are available from various
seal suppliers and tool trucks.
9. Clean all oil and debris from the head, piston, shaft, collar, and barrel using solvent, rags, and an air hose.
10. Inspect all parts for wear or damage. If damage is found on any parts, replace the part.
11. Install all seals on the head and piston using a non-sharp seal tool.
12. Place a small amount of oil on the inside seals of the head. Install it on the shaft by slipping the head over the
position of the shaft. Use extreme caution not to damage the inside seals.
13. Place a small amount of oil on the inside seals of the piston. Install it on the shaft by slowly twisting the piston
over the threads of the shaft. Use extreme caution not to damage the inside seals.
14. Install the shaft nut and tighten with a wrench.
5-20
15. Grease the outside seals of the head and piston.
16. Install the shaft into the barrel of the cylinder and push it until the groove of the head lines up with the slot in the
barrel.
17. Install the cylinder retainer using a spanner wrench.
18. Use air to cycle the cylinder and check its operation.
NOTE: It is very important to keep all parts clean when working with hydraulic cylinders. One piece of dirt can
damage the seal and/or cylinder.
Hydraulic Tank
1. Hydraulic Tank Fill Cap
Located behind the cab, on the right side.
2. Return Hose from Cooler

3. Hydraulic Temperature Sensor
4. Pressure Comp. Pump Suction
5. Gear Pump Steering Suction
6. Cooler Bypass from Junction Block
7. Gear Pump Suction for Radiator Fan
8. Hydraulic Tank Strainer
Part Number 840000010
9. Hydraulic Tank Filter

The Apache uses a combination open loop return
and closed loop suction boost filter in one housing.
The return line flow from the gear pump is fed to the
filter and is cleaned by the filter element. A pressure
is applied by the back pressure valve. This insures
that the filtered, precharged gear pump return flow
is available to the pressure compensated pump.
5-21
Hydraulic Suppressor
The hydraulic suppressor is mounted to the hydraulic
pump pressure port and is used to reduce the hydraulic
whine common in most hydraulic systems. The sup-
pressor accumulator is charged with nitrogen, but
should not require regular service.
• Hydraulic Suppressor Nitrogen Charge
1200 psi (83 bar)
Hydraulic Power Brakes

The hydraulic power brakes connect to the hydraulic
system at the back of the junction block and use a shut-
tle valve block to maintain constant pressure to each
brake master cylinder.
1. Brake Accumulators
Nitrogen Charge 1200 psi (83 bar)
2. Pressure Hose from Junction Block
3. Shuttle Valve
The power brake system also uses two accumulators to
hold a charge of oil in the system in case of a loss of
hydraulic pressure in the main system. The accumula-
tors will enable several stops if pressure is lost in the main system.
Master Cylinder Connections

1. Master Cylinder Return Hose
2. Brake Pressure Out Hoses
3. Pressure from Hydraulic System.
5-22
Axle Adjustment (Optional)

(Adjust On The Go,
AS1020 and AS1220 Only)
The front and rear axles on the AS1020 and AS1220 are adjustable from 120 to 160 in. (305 to 406 cm) (center of
left tire to center of right tire). The Adjust On The Go system will not allow the axle to be adjusted beyond 144 in.
(366 cm).
To adjust the axles:
While the engine is idling, operate the vehicle in the forward direction at approximately 3 mph (4.8 km/h).
Press the desired switch(es) (1) on the console to move
the wheels in or out.
The axles can be adjusted individually, in combination,
or all together.
Front
When activated, the Adjust On The Go cylinder (1)
adjusts the axle inward or outward as desired. The front
wheels/axles are actuated by one cylinder per wheel.
The left front Adjust On The Go axle is shown.
The socket-head bolts (2) should be torqued to 18 lb-ft
(24 N•m) at all times. Check and adjust the torque
weekly. See “Adjust On The Go Axles” on page 5-19.
Grease the axles daily when using the Adjust On The
Go feature. See “Grease Axle Components” on page 5-
16.
Rear
When activated the Adjust On The Go cylinders (1)
adjust the axle inward or outward as desired. The rear
wheels/axles are actuated by two cylinders per wheel.
The left rear Adjust On The Go axle is shown.
5-23
The Adjust On The Go harness wiring is shown at
right.
Adjust-On-the-Go wiring on the 102-Pin connector at

the cab floor is shown below.
5-24
Hydraulic Adjust-On-the-Go
Troubleshooting Charts
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Left Front Wheel In
START
Shift machine into first gear,

Check hoses and fittings for
increase speed to 3 mph,
no leaks, replac e or tighten as
activ ate function. Does
neces sary. Does wheel move?
wheel move?
no no
Is the front axle damaged? no Is axle properly lubricated? no Lubric ate axle, recheck
yes yes
Contact factory Remove bolt from base

Is coil magnetized when
yes end of cylinder, activ ate function. y es
button is pressed?
Does the cylinder move?
no no
Install new touch pad, Pull controller as sembly out of Torque axle clamp bolts.
Loosen coil, retighten to
activate function. Does no console plasitc. Activate functions. y es Reinstall cy linder bolt and
5 ft-lbs. Does c ylinder move?
the LED turn on? Does the indicator LED turn on? recheck. Does wheel move?
no yes no no
Replac e sprayer ECU Is P3 sec urely connec ted in ECU

Remove valve and clean. Check pressure on rod side of
and wire #124 properly inserted
Reinstall, does cylinder move? left front c ylinder. Consult factory
c avity 14 of P3?
no
yes no
Activ ate function. Is

Correct connection Replace valve.
no there power at cavity 31
problem. Does function operate?
in the console connector?
yes
Activate function. Is
no there power at cavity
13 of the cab connector?
yes no
no
there power at cavity
4 of the AOG connector?
yes
Does func tion

no Consult Factory .
operate properly?
5-25
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Left Front Wheel Out
START

wheel move?
no no
yes yes

button is pressed?
Does the cy linder move?
no no
no yes no no

c avity 15 of P3?
no
yes no

Correc t connection Replace valve.
yes
no yes no
yes
Does func tion

operate properly?
5-26
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Left Rear Wheel In
START

wheel move?
no no
yes yes

button is pressed?
no no
no yes no no

c avity 18 of P3?
no
yes no

yes
yes
no no
yes
Does func tion

operate properly?
5-27
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Left Rear Wheel Out
START

wheel move?
no no
yes yes

button is pressed?
no no
no yes no no

c avity 11 of P3?
no
yes
no
Ac tivate Function. Is
Correc t connection
problem. Replace valve.
Does function operate?
yes
no yes
no
yes
Does func tion
operate properly?
5-28
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Right Front Wheel In
START

wheel move? neces sary. Does wheel move?
no no
yes yes

button is pressed?
no no
no yes no no

c avity 16 of P3?
no
yes no

yes
yes
no
no
yes
Does func tion

operate properly?
5-29
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Right Front Wheel Out
START

increase speed to 3 mph, Check hoses and fittings for
no leaks, replace or tighten as
no no
yes yes

button is pressed? yes end of cylinder, activate function. yes
no no
activate function. Does no console plasitc. Activate functions. 5 ft-lbs. Does cylinder move? y es Reinstall cylinder bolt and
no yes no no
Replace sprayer ECU Is P3 securely connected in ECU

and wire #127 properly inserted Reinstall, does cylinder move? left front cylinder. Consult factory
cavity 17 of P3?
no
yes no
problem. in the console connector? Does function operate?
yes
no yes
no
yes
Does func tion

operate properly? no Consult Factory.
5-30
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Right Rear Wheel In
START

wheel move?
no no
yes yes

button is pressed?
no no
no yes no no

c avity 12 of P3?
no
yes no
yes
no no
yes
yes
Does func tion
operate properly?
5-31
Hydraulic Adjust-On-the-Go Troubleshooting Chart - Right Rear Wheel Out
START

increase speed to 3 mph, Check hoses and fittings for
no leaks, replace or tighten as
no no
yes yes

button is pressed? yes end of cylinder, activate function. yes
no no
activate function. Does no console plasitc. Activate functions. 5 ft-lbs. Does cylinder move? y es Reinstall cylinder bolt and
no yes no no
Replace sprayer ECU Is P3 securely connected in ECU

and wire #123 properly inserted Reinstall, does cylinder move? left front cylinder. Consult factory
cavity 13 of P3?
no
yes no
yes
yes
no no
yes
Does func tion

no Consult Factory.
operate properly?
5-32
Autosteer Installation
1. Left Turn
2. Right Turn
3. Return
4. To Steering Motor P Port
5. Pressure From Steering Section of Gear Pump
6. Right Turn Hose to Autosteer Block

7. Left Turn Hose to Autosteer Block
8. Return from Autosteer block. Port on Block is
labeled GPS
9. Pressure from Steering Section of Gear Pump

Goes to P Port on Autosteer Block.
Mount the Autosteer hydraulic block on the left inner
frame rail under the front left corner of the cab.
Discard the hose from the steering section of the gear
pump to the steering motor and replace it with a shorter
hose (9) connecting it to the Autosteer block P port.
Install hose (4) from EF port on Autosteer block to the
pressure port on the steering motor.
Install a Tee in the lines at the junction block labeled LT
and RT and also in the return port labeled GPS.
Connect the hoses (1 through 7) from the tees to the autosteer block.
A goes to Left Turn and B goes to Right Turn. The T port on autosteer block goes to GPS on the junction block.
5-33
Hydraulics Troubleshooting
Problem Solution
Boom will not fold or unfold Check that the electrical coil on boom block is energized.
Check for power to the coil.
Check the hydraulic fluid level.
Remove the spool valve, clean, and check operation.
Check the operation of the switch and for power.
No steering Crack the hose at the rod end of the steering cylinder for
hydraulic fluid flow to the cylinder.
Install a pressure gauge to check for hydraulic pressure.
Check the coupler in the steering column.
Hydraulic functions are slow or sluggish Check for a suction leak to the hydraulic pumps.
Check for water in the hydraulic tank.
Bleed air from the hydraulic system by cracking a hose.
Check the hydraulic filter indicator for a clean filter.
Hydraulic fluid overheating Check the hydraulic cooler and radiator for cleanliness.
Check for a hydraulic function that may be operating at all
times.
Check the temperature with a heat gun to make sure the sen-
sor is good.
Rear suspension will not raise Check that the coil is energized when the switch is active.
Lower the suspension completely and remove and clean the
spool valves.
Rear suspension leaks down Lower the suspension completely and clean the spool valves.
No product pump pressure Make sure all tank valves are open.
Make sure the rinse tank valve is closed.
Inspect the impeller in the product pump.
Check for obstructions in the product hose going to the pump.
Check the hydraulic pressure at the junction block under the
cab.
Front wheels will toe in or out Rephrase the front wheels by driving the vehicle in figure
eights.
Bleed the air from the steering circuit.
5-34
HYDRAULIC SYSTEM OPERATION AND TROUBLESHOOTING
Hydraulic System
LH BRAKE RH BRAKE
2.50" bore x 7.00" stroke, 1.125"
rod piloted rephasing ports,
MPI Piston Sleeve
P-BRAKE SAHR
LADDER FOLD
1.00"x6.00"x0.63" rod
LHC RHC P1 BRK LDR T1
SW
OC1
3000psi
2x 2.00"x7.00"x1.00" rod
P 2x 4.00"x6.00"x3.50" rod
SUSPENSION LEFT SUSPENSION RIGHT
4x 3.00"x10.00"x1.25" rod
2x 3.00"x16.00"x1.25" rod
LEFT TILT RIGHT TILT
RES 2
LEFT TIP LEFT FOLD RIGHT TIP RIGHT FOLD
RES 2x 2.50"x17.13"x1.50" rod

PRODUCT PUMP .125 .125 .125 .125 BOOM UP/DOWN
LH ST RH ST P SYS PSI P2 T2 CD GT
LTR LTB LFB LFR RTR RTB RFB RFR LT RT T2
T4 T3
.046 .046 .046 .046 .06 .06
PP-P PP-T R1 L2 R2 L2 RACK
.06 .046 .046 .046 .046

.028 .028
SAE -12 P1 SAE-6 P
SAE -16 SAE-8 T

T1
FAN MOTOR
#6 #6
G4
#4 #6 #6 #6 #6 #6 #6 #6 #6
PSR
LT RT RFB RFR RTR RTB LFB LFR LTR LTB
2400 PSI G1
PSL
(8) 1/4-20UNC ORIFICE (0.046") DIA
BELOW CORRESPONDING PORTS
Eaton 420 #4
3 3
2 2 2 2 2 2 2 2
2 2 2 2 2
(4) WS08W-01M-C-N-12DN 1 1 1 1 1 1 1
1
1 FC08-2 1 1 1
4A 4B 4 4
L R LD RD LU RD
2
10
4 2 4 2 4 2 4
3 1 3 1 3 1 3 1
11
5A 13A
LPV RPV
1 1
(4) WK06J-01-C-N-12DN01
1.48in3/r 1.20in3/r 3.80in3/r 2 3 (2) PDR08P-01M-C-N-330-12PN 2 3

FC06-4
FC08-3
3A 3B
-6 -6 #6
A B
T
1
1 1
Eaton 26 DESTROKE 2
8
AT START 2400 PSI 9
#6
P
AutoBoom Combo
063-0131-130-A
OSPC 125 ON 150N2234
PS
063-0131-134-A
SmartTrax
-4
-10
EF
-10 P T -10
P T
FLOW EZY #ST15-100-RV3
5-35
Chapter 6
Electrical System
AS720, AS1020 & AS1220
NOTES
ELECTRICAL SYSTEM
2011 Apache Electrical System

The electrical system is standard 12-volt system.
Power comes from the batteries on right side of
sprayer to the fuse box inside cab. Everything on the
Apache is powered through the fuse box. The fuse box
also grounds everything except radio, lights, and
HVAC they are ground on an external ground under
the right rear corner of cab. The wiring is color coded
as follows:
Wire Color Function

Tan Cab
Orange Transmission
Blue Product (wet system)
Brown Hydraulics
Yellow Signal (sensors)
White Engine
Green Lights
NOTE: Always disconnect the batteries prior to

performing any welding on the Apache and
ground the welder as close to the welding to be
performed as possible.
6-1
NOTES
SYSTEM SCHEMATICS
Electrical System (AS720, AS1020 and AS1220)
Page
6-9
Page
6-10
Page
6-10
AS720 Only Page 6-2

AS1020 AS1220 Page 6-3
6-1
Electrical System (AS720 Only)
Page
6-1
Page
6-10
6-2
Electrical System (AS1020 and AS1220)
Page
6-1
Page
6-10
6-3
Electrical System (AS720 Only)
Page
6-9
6-4
Page
6-9
Page
6-14
6-5
Page
6-8
6-6
Page
6-8
6-7
Page
6-7
Page
6-6
Page
6-9
6-8
Page
6-8
AS720
Only Page
Page 6-4 6-11
AS1020/
AS1220
Page
6-5
Page
6-1
6-9
AS720 Only Page 6-2 Page

AS1020/AS1220 Page 6-3 6-1
Page
6-1
6-10
Page
6-9
Page
6-12
6-11
Page
6-11
Page
6-11
6-12
Page
6-12
6-13
Page
6-5
6-14
Harness Layout
6-15
Fuse Block
6-16
ELECTRICAL SYSTEM
Fuse Block Schematics
15712 ATC DVEC

FUSE BLOCK FUSE BLOCK
(207) RED F23 (180) RED
4
4
(08) RED F22

2 3
2 3
F21
(78) RED F20

1
1
F39 (77) RED
A B C D E F G H J K L M N P R S
A B C D E F G H J K L M N P R S
F38
F37 (80) RED
Page 6-14
F36 (06) RED
Refer to
F35 (201) RED
F34 (204) RED
F33 (05) RED

F32 (208) RED
F31 (12) RED
F30 (43) RED
F29 (32) RED
F28 (14) RED

F27 (02) RED
F26 (48) RED
F25 (68) RED
F24 (72) RED
6-17
6-18
BAT (+) BAT (-)
Fuse Block Diagram
ELECTRICAL SYSTEM
- 10 - - 5 -
- 20 - - 15 -
- 5 - - 30 -
- 30 -
- 30 -
- 20 - - 20 -
- 2 - - 30 -
- 10 - - 10 -
- 20 - - 20 -
- 30 - - 20 -
- 20 -
- 20 -
- 25 -
- 10 -
- 25 -
- 20 -
- 30 -
- 20 -
- 20 -
- 20 -
- 20 -
- 20 -
- 5 -
- 20 -
- 7.5 -
- 7.5 -
- 25 - - 30 -
- 20 - - 30 -
ELECTRICAL SYSTEM
Fuse Box Right Rear Cab Corner
The fuses are mini automotive fuses. The relays are also automotive relays.
DVEC Block 2011
Source Function Circuit
Pwr Source To Cir #

F1 (30A) DC-DC Converter 12V Pwr In Batt Converter 990
F2 (7.5A) 24 Volt Ignition Pwr Converter TCU 900
F3 (7.5A) 24 Volt Permanent Pwr Converter TCU/Trans 423/468
Boom Support Light

F4 (20A) Not Used Support Lt Plg ***
Relay 12
F5 (30A) Aux Boom Pwr Aux Relay 13 Aux Boom Pwr Plg 100 GN
Console Backup, Rt
F6 (20A) Console Backup, Chassis Ign Relay 4 Sus, Lt Sus, Brake 42 RD
Sw
F7 (20A) Aux Acc Pwr Ign Relay 4 Aux Acc Plg 73 RD
F8 (7.5A) Engine Ign Pwr Ign Relay 4 Engine ECU 11 RD
F9 (10A) Radio, Overhead Pwr Pnt, Pann Lt Acc Relay 3 Radio, Pwr Pnt 09 RD
F10 (25A) Horn, Washer, Wiper Batt Pwr Acc Relay 3 Turn Signal Lever 04 RD
F11 (20A) Foamer Foam Relay 2 Foamer Plgs 70 BL

F12 (30A) Front Hood Lights Driving Lights Relay 5 Driving Lt Plugs 33 GN
F13 (20A) Rear Outer Cab Lights Rear Field Lt Relay 8 Rear Outer Lt Plgs 69 GN
F14 (20A) Front Outer Cab Lights Frt Field Lt Relay 6 Front Outer Lt Plgs 58 GN
F15 (20A) Rear Inner Cab Lights Rear Field Lt Relay 9 Rear Inner Lt Plgs 59 GN
F16 (20A) Front Inner Cab Lights Frt Field Lt Relay 7 Front Inner Lt Plugs 79 GN
F17 (20A) Node Logic Node Logic Relay 10 Node Pwr 200 RD
F18 (5A) Boom Node Node Logic Relay 10 Node Pwr 209 RD
F19 (20A) Master Spray Control Mast Spry Relay 11 Switch Box 51 BL
Relay 1 Start Relay Ignition Switch Crank Start Relay 01 TN/10 WH

Relay 2 Foam Comp Relay Foam Switch Board F11 70 BL
Relay 3 Acc Relay Acc Pwr Board out F9/F10 03 TN/04,09 RD
Relay 4 Ign Relay Ignition Switch Ign F6/F7/F8 07 TN/42,73,11 RD
Relay 5 Front Hood Lights Driving Switch F12 142 YL / 33 GN
Relay 6 Front Cab Field 1 Outer Field Front Switch F14 143 YL / 58 GN
Relay 7 Front Cab Field 2 Inner Field Front Switch F16 143 YL / 79 GN
Relay 8 Rear Cab Field 1 Outer Field Rear Switch F13 144 YL / 69 GN
Relay 9 Rear Cab Field 2 Inner Field Rear Switch F15 144 YL / 59 GN
Relay 10 Node Logic Relay Raven Console F17/F18 206 RD/200,209 RD
Relay 11 Master Spray Relay Master Switch F19 51 BL
Relay 12 Not used Field Rear Switch F4 ***
Relay 13 Aux Boom Power Relay Auxiliary Switch F5 145 YL / 100 GN
Relay 14 Key Pwr Relay Ignition Switch Ign F20/F21/F22/F23 180 RD
Relay 15 DC-DC Converter Converter F2
Ground Function
Gnd G1 Seat, Steering Column
Gnd G2 Chassis
Gnd G3 Air System
Gnd G4 Upper Cab
Gnd G5 Cab Roof
Gnd G6 Aux Pwr Batt, Aux Pwr Key, Raven Console, Switch Box, Antenna
Gnd G7 Console
Gnd G8 Power Point and Lighter
Gnd 202 Node Logic
Gnd 203 Node High Current
Gnd 205 Raven CAN
Gnd 902,3 & 4 TCU
Gnd 995 DC-DC Converter
6-19
ELECTRICAL SYSTEM
6-20
ELECTRICAL SYSTEM
Circuit Numbers
CIRCUIT
FUNCTION COLOR
NUMBER
1 START SWITCH POWER Tan
2 BATTERY POWER (F27) Wiper Batt Red
3 ACCESSORY SWITCH POWER Tan
4 ACCESSORY POWER (F10) Red
5 BATTERY POWER (F33) Red
6 BATTERY POWER (F36) Booster Blower Relay Red
7 IGNITION SWITCH POWER Tan
10 STARTER RELAY White
11 ENGINE IGNITION POWER (F8) Red
12 ENGINE ECU POWER (F31) Red
13 FUEL SENDER Yellow
14 BATTERY POWER (F28) Seat, Radio Batt, Lighter Red
15 LEFT BOOM UP Brown
16 LEFT BOOM DOWN Brown
17 LEFT BOOM IN Brown
18 LEFT BOOM OUT Brown
19 RACK UP Brown
20 RACK DOWN Brown
21 RIGHT BOOM IN Brown
22 RIGHT BOOM OUT Brown
23 RIGHT BOOM UP Brown
24 RIGHT BOOM DOWN Brown
25 AGITATE FROM BOARD Blue
26 AGITATE FROM BOARD Blue
27 BOOM SECTION 6 Blue
27R BOOM SECTION 7 Blue
28 PRODUCT PUMP Blue
32 BATTERY POWER (F29) Dome Light, Hazard Red
33 HEADLIGHT/PARKING LIGHTS (F12) Green
34 HAZARD SIGNAL OUTPUT Tan
35 HAZARD SIGNAL INPUT Tan
36 WIPER HIGH SPEED Tan
37 WIPER LOW SPEED Tan
38 WIPER PARK Tan
39 WIPER INTERMITTENT Tan
40 PARKING BRAKE HIGH SIDE Brown
41 HYDRAULIC TEMPERATURE SENDER Yellow
42 IGNITION POWER (F6) Red
43 BATTERY POWER (F30) Console Red
6-21
ELECTRICAL SYSTEM
CIRCUIT
FUNCTION COLOR
NUMBER
44 RIGHT TURN SIGNAL Green
45 LEFT TURN SIGNAL Green
46 RIGHT TURN SIGNAL INPUT Tan
47 LEFT TURN SIGNAL INPUT Tan
48 OVERHEAD SWITCH BATT POWER (F26) Red
49 A/C PRESSURE SWITCH White
50 PARKING BRAKE LOW SIDE Brown
51 MASTER ON/OFF Blue
52 TRANSMISSION TEMPERATURE SENDER Yellow
53 WASHER BOTTLE Tan
56 REMOTE PRODUCT PUMP SWITCH Blue
57 BOOM SUPPORT LIGHT SWITCH OUTPUT Green
58 FRONT OUTER WORK LIGHTS Green
59 REAR INNER WORK LIGHTS Green
60 LEFT TIP IN Brown
61 LEFT TIP OUT Brown
62 RIGHT TIP IN Brown
63 RIGHT TIP OUT Brown
64 RIGHT REAR SPEAKER + Tan
65 RIGHT REAR SPEAKER - Tan
66 LEFT REAR SPEAKER + Tan
67 LEFT REAR SPEAKER - Tan
68 BATTERY POWER (F25) HVAC High/Med Relay Red
69 REAR OUTER WORK LIGHTS Green
70 FOAMER PUMP/COMPRESSOR F11 Blue
71 FOAMER SOLENOID Blue
72 AUX POWER BATT F24 Red
73 AUX POWER KEY (F7) Red
74 CONTROL VALVE
75 CONTROL VALVE
76 WATER VALVE Tan
77 BATTERY POWER (F39) Boom Valve Power Red
78 KEY POWER (F20) Red
79 FRONT INNER WORK LIGHTS Green
80 BATTERY POWER (F37) Boom Supp Sw Red
81 LEFT SUSPENSION DOWN Brown
82 LEFT SUSPENSION UP Brown
83 RIGHT SUSPENSION DOWN Brown
84 RIGHT SUSPENSION UP Brown
85 ALTERNATOR CHARGE WIRE Red
86 JD GRID HEATER POWER
87 THROTTLE +5 Red
88 THROTTLE SIGNAL White
6-22
ELECTRICAL SYSTEM
CIRCUIT
FUNCTION COLOR
NUMBER
89 THROTTLE REFERENCE Black
90 FAN HIGH SPEED Tan
91 FAN MEDIUM SPEED Tan
92 FAN LOW SPEED Tan
93 A/C ON/OFF Tan
94 TEMPERATURE CONTROL POWER Tan
95 NEUTRAL SAFETY Tan
96 DIFF LOCK Red
97 HORN Tan
98 15712 BATT POWER Red
99 AIR FILTER INDICATOR Yellow
100 AUX SWITCH OUTPUT Green
101 WAIT TO START Yellow
102 RAVEN CAN LOW Green
103 RAVEN CAN HIGH Yellow
104 TRANSMISSION COIL 1 Orange
111 TRANS SPEED SENSOR Orange
112 TRANS SPEED SENSOR Orange
113 TRANSMISSION GROUND Black
114 TRANSMISSION OIL PRESSURE Orange
115 ECU GROUND/DIAGNOSTIC PLUG GND Black
116 ECU POWER Red
117 CAN BUS POWER Green
118 CAN BUS SIGNAL Yellow
119 CAN BUS SHIELD Black
120 LEFT REAR IN Brown
121 LEFT REAR OUT Brown
122 RIGHT REAR IN Brown
123 RIGHT REAR OUT Brown
124 LEFT FRONT IN Brown
125 LEFT FRONT OUT Brown
126 RIGHT FRONT IN Brown
127 RIGHT FRONT OUT Brown
128 CUMMINS ENGINE POWER Red
129 CUMMINS COLD START RETURN Black
130 BINARY SWITCH TO A/C COMPRESSOR Yellow
131 CUMMINS COLD START WIRE White
132 CUMMINS COOLANT LEVEL White
133 BRAKE SWITCH Yellow
6-23
ELECTRICAL SYSTEM
CIRCUIT
FUNCTION COLOR
NUMBER
134 ALTERNATOR GROUND Black
135 ECM GROUND Black
136 ENGINE BLOCK GROUND Black
137 STARTER SOLENOID White
138 AGITATION VALVE SWITCH SIGNAL Blue
139 AGITATION VALVE SWITCH SIGNAL Blue
140
160 LEFT BREAKAWAY FOLD IN
161 LEFT BREAKAWAY FOLD OUT
162 RIGHT BREAKAWAY FOLD IN
163 RIGHT BREAKAWAY FOLD OUT
164 RIGHT FRONT SPEAKER + Tan
165 RIGHT FRONT SPEAKER Tan
166 LEFT FRONT SPEAKER + Tan
167 LEFT FRONT SPEAKER Tan
171 AUXILIARY LIGHT POWER
172 AUXILIARY LIGHT BREAKER
173 AUXILIARY LIGHT BREAKER
174
175
176 RAVEN SWITCH POWER
177 LEFT FENCEROW NOZZLE Blue
178 RIGHT FENCEROW NOZZLE Blue
179
180 KEY POWER IGN RELAY 14 OUTPUT 15712 Red
200 NODE LOGIC POWER Red
201 NODE HIGH CURRENT POWER (F35) Red
202 NODE LOGIC GROUND Black
203 NODE HIGH CURRENT GROUND Black
204 RAVEN CAN PWR (F34) Red
205 RAVEN CAN GROUND Black
206 RAVEN CONSOLE SWITCHED POWER Red
207 RAVEN ANTENNA POWER KEY Red
208 RAVEN CONSOLE BATTERY POWER (F32) Red
209 BOOM NODE POWER Red
210
211 SMARTRAX COIL POWER Red
212 SMARTRAX DOUBLE BLOCKER GND White
213 SMARTRAX +12 VOLTS Red
214
215
216
6-24
ELECTRICAL SYSTEM
CIRCUIT
FUNCTION COLOR
NUMBER
217 SMARTRAX RIGHT SIGNAL Yellow
218 SMARTRAX LEFT SIGNAL Brown
219 SMARTRAX DOUBLE BLOCKER POWER Red
220
221 SMARTRAX PSI SIGNAL Violet
400
401
402 ZF VM2 TRANSMISSION GROUND Black
404 ZF VMG2 SPEED SENSOR OUTPUT Black
405 ZF ADM4 YL/BK 406 ZF ADM3 YL/BK
407 ZF ADM2 REVERSE LIGHT YL/BK
409 ZF AIP5 CLUTCH KV OR/RD
410 ZF AIP2 CLUTCH KR OR/RD
411
412
413
414 ZF SD1 DISPLAY SIGNAL YL/BK
415 ZF SDDK DIAGNOSTIC INTERFACE YL/BK
417 ZF ER3 FILTER RESTRICTION SWITCH YL/BK
418 ZF EUPR DIAGNOSTIC INTERFACE YL/BK
419 ZF EF1 SPEED PICK-UP ENGINE YL/BK
420 ZF ED3 YL/BK
421 ZF ED10 REGISTRATION SWITCH PARK BRAKE YL/BK
422 ZF ED7 SELECT AUTOMATIC (1) / MANUAL (0) YL/BK
423 ZF VPE1 24 VOLT PERMANENT POWER F3 Red/White
424 ZF VMGA1 Black
425 ZF CANF_H Yellow
426
427
428 ZF VGS CAN B- Black
429 ZF ED11 KICKDOWN SIGNAL YL/BK
430 ZF ED12 GEAR LIMITATION 1-5F/1-3R YL/BK
431 ZF ED13 YL/BK
432 ZF AIP3 CLUTCH K1 OR/RD
433 ZF ADM8 YL/BK
434 ZF ADM7 YL/BK
435 ZF ED14 YL/BK
436 ZF SD4 SPEED OUTPUT FROM TRANSMISSION YL/BK
438 ZF EU1 YL/BK
439 ZF ER1 SUMP TEMP SIGNAL YL/BK
441 ZF EF2 SPEED PICK-UP TURBINE YL/BK
442 ZF EF3 SPEED PICK-UP INTERNAL YL/BK
443 ZF ED4 GEAR SELECTOR FORWARD SIGNAL YL/BK
444 ZF ED8 YL/BK
445
6-25
ELECTRICAL SYSTEM
CIRCUIT
FUNCTION COLOR
NUMBER
446
447
448
449 ZF ER2 CONVERTER TEMP SENSOR YL/BK
450 ZF AIP7 VALVE LOCKUP CLUTCH OR/RD
452 ZF ADM1 WARNING LAMP YL/BK
453
454
457 ZF ADM5 YL/BK
458
459 ZF ED15 YL/BK
460
461 ZF EU2 YL/BK
462 ZF EF4 SPEED SENSOR OUTPUT YL/BK
463 ZF ED1 GEAR SELECTOR B1 SIGNAL YL/BK
464 ZF ED5 GEAR SELECTOR REVERSE SIGNAL YL/BK
465 ZF ED2 GEAR SELECTOR B2 SIGNAL YL/BK
466 ZF ED9 YL/BK
468 ZF VPE2 24 VOLT PERMANENT POWER F3 Red/White
900 ZF VPI 24 VOLT IGNITION POWER F2 Red/White
902 ZF VM1 GROUND ECU Black
903 ZF VMG1 GROUND Black
904 ZF VMGA2 GROUND Black
906 ZF VPS1 SHIFT/ TRANSMISSION POWER Red/White
911 ZF ED6 GEAR SELECTOR NEUTRAL SIGNAL YL/BK
913 ZF CANF_L & CANF_T Green
940 ZF ADM6 YL/BK YL/BK
944 ZF VPS2 TRANS POWER Red/White
948 ZF AU1 YL/BK
990 12V POWER OUT TO CONVERTER F1 Red
992 24V POWER FROM CONVERTER Red/White
995 CONVERTER GROUND Black
6-26
ELECTRICAL SYSTEM
Connector Pinouts
CAN Connector Pinouts
102-Pin Floor Connector Pinouts
6-27
ELECTRICAL SYSTEM
Console Connector
on Bottom of Console
6-28
ELECTRICAL SYSTEM
Deutsch Round
Connector Pin Positions
6-29
ELECTRICAL SYSTEM
Deutsch Pin Insertion
and Removal Instructions
6-30
ELECTRICAL SYSTEM
Adjusting the Console
The illustration is shown with the seat cushion removed.
Lift the left front corner of the seat cushion to remove.
Loosen bolts (1) to adjust the console up or down and/
or front to back.
The holes in the front plate are slotted front to back and
the rear plate is slotted up and down.
Removing the Console

To remove the console, remove the four screws (1) and
pull the panel forward.
When installing the panel, make sure not to pinch the
wires in the plastic.
Disconnecting the Circuit Board

To disconnect the circuit board, unplug the following
connectors:
1. 24-Pin Plug
2. 20-Pin Plug
3. 22-Pin Plug
4. Handle Plug
5. Screen Plug (2 yellow wires under board, not
shown)
6. SD Board Plug (not shown)
7. Display Connector (white tape)
8. Switch Panel Connector (green tape)
6-31
ELECTRICAL SYSTEM
Apache Sprayer Console
1. MPH Readout 12. Right Boom Fold In and Fold Out

2. Engine RPM 13. Left Boom Tip In and Fold Out
3. Engine Oil Pressure 14. Right Boom Tip In and Fold Out
4. Engine Water Temperature 15. Product Pump On/Off Switch
5. Voltage Level 16. Agitation Pressure Increase and
6. Fuel Level Decrease
7. Direction and Gear Indicator 17. Foam Auto On/Off
8. Park Brake Switch 18. Foam Master On/Off Switch
9. Cruise Control Master Switch 19. Turn Foam Drop On for Right Side
and Left Side
10. Axle Hydraulic Adjust Switches In and
Out (Optional) 20. Cigarette Lighter
11. Left Boom Fold In and Fold Out 21. Auxiliary Power Outlet
6-32
ELECTRICAL SYSTEM
Console
Console Front
Console Back
1. Power outlet
2. Ribbon to LCD display
3. Ribbon cable to membrane switches
4. 18-pin connector to tee handle
5. 22-pin connector: board power and ground,
neutral safety, boom fold, agitate, parking brake
and CAN bus
6. 20-pin connector: boom, foam comp, AOG,
spray master, wait to start (Deere)
7. 24-pin connector transmission plug, turn sig-
nals/flashers, brake switches, air filter, hydrau-
lic pump, pump switch
8. Cigarette lighter
6-33
ELECTRICAL SYSTEM
Console Wiring: AS720
6-34
ELECTRICAL SYSTEM
Console Wiring: AS1020 and AS1220
6-35
ELECTRICAL SYSTEM
Inside Console Wiring
1. Transmission ECU (ITL 6-speed transmission
shown)
Inverter
The inverter’s job is to supply power to the LCD display and communi-
cate software to the circuit board.
1. Power going out to LCD display
2. Power coming in to board from circuit board
3. These wires send information (software) to circuit board
4. Insert SD card here with software installed for circuit board to install
new or updated software. The card slot is located on the side of the
console, facing the right cab window.
Console Software Updates

To update the software on the 2011 Apache perform the following:
• Ensure keyswitch is OFF
• Insert The SD card into the slot (contacts
down).
6-36
ELECTRICAL SYSTEM
• Turn the keyswitch to the ON position. The
console will display “Updating”.
• The screen will then prompt you to select a

transmission. Press the appropriate button on
the console for the model of Apache that you
are in.
• The screen will then ask you to select MPH or

KPH. Select the desired setting by pushing
either the cruise control button or the park
brake button.
• The screen will then tell you to remove the SD

card and turn the key off and restart the
Apache.
6-37
ELECTRICAL SYSTEM
Membrane Switch Panel Wiring
.
6-38
ELECTRICAL SYSTEM
Part Numbers for Console Parts
Part Number 420301022: Membrane panel with rib-
bon. This does not include the metal plate.
Part Number 700300088: LCD display.
Part Number 700300091: Inverter/SD driver circuit

board and wiring only. This does not include metal plate.
6-39
ELECTRICAL SYSTEM
Part Number 700300100: Circuit board.
When replacing a circuit board the current software will
need to be loaded.
Fuse Block
The fuse block is located under a service cover inside the
right, rear, of the cab.
Turn the knob on top of the cover, then lift cover to
remove.
Cab Nodes
In the right rear corner of the cab behind where the fuse
box is located is the location for the Raven Nodes and a
power inverter for the ZF transmission.
1. ZF Transmission Power Inverter
2. Smartrax Node
3. Boom Sense Node
6-40
ELECTRICAL SYSTEM
The console displays the machine hours and software
revision when the key is in the ON position and for five
seconds at startup.
1. Number of Hours on Machine
2. Software Revision Number
3. Console Display Contrast Adjust
To adjust the contrast of the console display, press
the agitate increase button and hold to increase the
contrast of display, press the agitate decrease but-
ton to decrease the contrast of display. Both must
be down before start up of Apache Sprayer while
the display is in this mode.
4. Speed Calibration
To calibrate the speed of the vehicle: Press the
cruise master button (while the board is in this
state), press the cruise master a second time, and
drive a measured mile (5,280 feet), drive through
the mark at end of measure mile, pushing the cruise
master when the front wheels are crossing the mile
mark. This will automatically reset the speed read-
ing on the vehicle.
6-41
ELECTRICAL SYSTEM
T-Handle and Raven Envisio Pro Console
1. T-Handle 7. Set Button for Cruise

Press to set cruise control.
2. Raven Envisio Pro Console
8. Resume Button for Cruise
3. Boom Switch Box
Press to resume cruise control.
4. Boom Rack
9. Master Spray Switch
Press to move the boom rack up or down.
Press to turn all five spray sections on or off.
5. Left Boom Tilt
10. Forward Trigger Button
Press to tilt the left boom up or down.
11. Reverse Trigger Button
6. Right Boom Tilt
Press to tilt the right boom up or down.
6-42
ELECTRICAL SYSTEM
Vehicle Direction and Speed

IMPORTANT: DO NOT leave the operator’s seat with the Apache Sprayer in gear. Place the transmission in
neutral and apply the parking brake before exiting the cab.
IMPORTANT: ALWAYS bring the vehicle to a complete stop before changing directions. Place the transmis-
sion in the neutral position and apply the vehicle brake before changing directions.
IMPORTANT: DO NOT shift transmission into neutral while the vehicle is in motion. The transmission is
only lubricated while in gear. “Coasting” will cause damage to the transmission.
Neutral
At start up, the Apache Sprayer transmission is reset to
neutral and an indicator lamp on the console will indicate
“N” (1). Squeeze and hold either one of the trigger but-
tons to put into gear. Use the top button for forward and
the bottom button for reverse. Once the transmission is
in gear, the gear indicator will show the current gear.
Return to neutral by squeezing either of the trigger but-
tons; the transmission will immediately shift to neutral.
NOTE: The T-handle will not shift the transmission into
neutral. To obtain neutral from a forward gear, squeeze
either trigger button on the T-handle. To obtain neutral
from a reverse gear, release the bottom trigger button on
the T-handle.
Forward
To move the Apache Sprayer forward:
Apply the vehicle brakes and release the parking brake.
NOTE: The transmission will not shift if the parking
brake is applied.
To move forward, release the park brake, apply the vehi-
cle brakes, and squeeze and hold the top trigger button
(1) on the T-handle until the transmission shifts into first
gear forward. The vehicle will begin rolling forward at
this time. Once the vehicle is in first gear forward,
release the button. Push the T-handle forward to
increase the engine rpm and ground speed. Pull the T-
handle back to decrease the engine rpm.
neutral. To obtain neutral from a forward gear, squeeze
either trigger button (1 or 2) on the T-handle.
NOTE: If the vehicle is moving forward and either trigger
button on the T-handle is squeezed, the machine will
shift to neutral. Once the vehicle is below 1400 rpm and
4 mph, squeezing and holding the top trigger button on
the T-handle shifts the vehicle into the gear the transmission was in before neutral.
Shifting Gears
The Apache Sprayer is equipped with a torque converter. This allows the Apache Sprayer to take off in any gear.
Once the vehicle is moving, you may up shift or down shift without returning the transmission to the neutral posi-
tion. The Apache Sprayer is equipped with six forward gears. Be aware of speed ranges for each gear. Refer to the
Gear Speed Range chart.
6-43
ELECTRICAL SYSTEM
Upshifting and downshifting are achieved with a sideways rock and release movement or “bump” of the T-handle.
The T-handle should return to the center (side-to-side) position between shifts and some time must be allowed for
the transmission to respond.
Upshifting: While the vehicle is in either the forward or

reverse direction, bump the T-handle to the right one
time to shift up to the next highest gear. Repeat this
motion to upshift the transmission one gear at a time.
Downshifting: Pull back on the T-handle slightly to
decrease engine rpm, lightly apply the vehicle brakes,
then bump the T-handle to the left one time to downshift
to the next lowest gear. Repeat this motion to downshift
the transmission one gear at a time.
NOTE: The ITL transmission is equipped with shift pro-
tect; the transmission will not downshift, even if the dis-
play readout changes on the console, until the engine
rpm’s drop down to the appropriate speed range.
IMPORTANT: DO NOT shift the transmission into
neutral while the vehicle is in motion. The transmis-
sion is only lubricated while in gear. “Coasting” will
cause damage to the transmission.
6-44
ELECTRICAL SYSTEM
Reverse
To move the Apache Sprayer in reverse:
Apply the vehicle brakes and release the parking brake.
NOTE: The transmission will not shift if the parking
brake is applied.
To shift into reverse from neutral, squeeze and hold the
bottom trigger button (2) on the T-handle. Push the T-
handle forward to increase the engine rpm and ground
speed. Pull the T-handle back to decrease the engine
rpm.
The reverse button (2) must be held in at all times to
move in reverse.
neutral. To obtain neutral from a reverse gear, release
the bottom trigger button (2) on the T-handle.
NOTE: If the vehicle is moving in reverse and the
reverse button (2) is released, the transmission will shift
to neutral. Once the vehicle is below 1400 rpm and 4
mph, squeezing and holding the bottom trigger button
(2) shifts the transmission into the gear the transmission
was in before neutral.
Cruise Control
To use the cruise control function, turn the master cruise
button (1) located on the console ON. Once the desired
speed is reached, push and release the SET button (2)
on the T-handle.
If the engine rpm’s are decreased or increased, cruise
control will disengage. to resume cruise speed, press
the resume (RES) button (3) on the joystick to return to
the previously set cruise control speed.
If the transmission is up- or down-shifted, the cruise
control will disengage.
The cruise control will operate between 4 and 20 mph. If
the SET button (2) is pressed while the speed is out of
range, the command will be ignored.
When the cruise is set, the RES button (3) increases
vehicle speed by one mph for each time it is pressed;
pressing the SET button (2) when cruise control is set,
decreases speed by one mph for each time it is
pressed.
6-45
ELECTRICAL SYSTEM
T-Handle
1. Apache T-Handle
T-Handle Wiring
6-46
ELECTRICAL SYSTEM
Forward Switch
The operator presses the forward button (1) on the T-handle
sending a signal to the sprayer ECU.
The ECU turns on the output FET’s needed for first gear on
the transmission, which supplies power to two output pins in
connector P4.
The signal is transmitted through the wiring harnesses to the
transmission, where it powers the shift coils to select first
gear.
6-47
ELECTRICAL SYSTEM
Forward Switch Troubleshooting
Circuit Number: 1st, Forward
Wire Color: White/Red, Orange
6-48
ELECTRICAL SYSTEM
Reverse Switch
The operator presses the reverse button (1) on the T-handle
which sends a signal to the sprayer ECU.
The ECU turns on the output FET’s needed for the first-gear-
reverse on the transmission; this supplies power to two output
pins in connector P4.
The signal is then transmitted through the wiring harnesses to
the transmission, where it powers the shift coils to select first-
gear-reverse.
6-49
ELECTRICAL SYSTEM
Reverse Switch Troubleshooting

Circuit Number: 1st, Reverse
Wire Color: White, Orange
Throttle Increase
The operator starts the machine and moves the T-handle for-
ward, increasing RPM.
6-50
ELECTRICAL SYSTEM
The T-handle sends a voltage signal between 0.5 and 4.5
volts the to the sprayer ECU.
The ECU processes this information and sends it to the

engine ECU on the CAN bus line.
6-51
ELECTRICAL SYSTEM
A signal is then sent from the engine ECU to the fuel system
to increase the engine RPM.
6-52
ELECTRICAL SYSTEM
Throttle Increase Troubleshooting

Circuit Number 117, 118
Wire Color: Green, Yellow
6-53
ELECTRICAL SYSTEM
Throttle Decrease
The operator starts the machine and moves the T-handle for-
ward, increasing RPM. The operator then moves the T-handle
back, which sends a voltage signal between 0.5 and 4.5 volts the
to the sprayer ECU.
The sprayer ECU processes this information and sends it to

the engine ECU on the CAN bus line.
6-54
ELECTRICAL SYSTEM
A signal is then sent from the engine ECU to the fuel system
to decrease the engine RPM.
6-55
ELECTRICAL SYSTEM
Throttle Decrease Troubleshooting

Circuit Number 117, 118
6-56
ELECTRICAL SYSTEM
Transmission Up Shift Switch

The operator presses the forward button on the T-handle which
puts the machine into first gear forward. The operator then
pushes the T-handle to the right which sends an up shift signal
to the sprayer ECU.
The ECU turns on the output FET’s needed for second gear
on the transmission, which supplies power to two output pins
in connector P4.
The signal is then transmitted through the wiring harnesses

to the transmission, where it powers the shift coils to select
second gear.
6-57
ELECTRICAL SYSTEM
Transmission Up Shift Switch Troubleshooting
Wire Color: Blue
6-58
ELECTRICAL SYSTEM
Transmission Down Shift Switch

The operator presses the forward button on the T-handle putting
machine into first gear forward. The operator then pushes the
handle to the right sending an up shift signal to the sprayer ECU.
The operator then pushes the handle to the left sending a down-
shift signal to the sprayer ECU.
The ECU turns on the output FET’s needed for first gear on
the transmission, which supplies power to two output pins in
connector P4.
transmission, where it powers the shift coils to select first
gear.
6-59
ELECTRICAL SYSTEM
Transmission Down Shift Switch Troubleshooting
Wire Color: Violet
6-60
ELECTRICAL SYSTEM
Right Tilt Up Switch

The operator presses the touch pad or the button (1) on the
T-handle which sends a signal to the sprayer ECU.
The ECU turns on the output FET, which supplies power to

an output pin in connector P3 or P2.

boom harness, where it powers the hydraulic coils.
6-61
ELECTRICAL SYSTEM
The coil shifts the spool valve, sending hydraulic oil to the
selected cylinder.
6-62
ELECTRICAL SYSTEM
Right Tilt Up Switch Troubleshooting

Circuit Number: 23
Wire Color: Brown
6-63
ELECTRICAL SYSTEM
Right Tilt Down Switch

T-handle which sends a signal to the sprayer ECU.


6-64
ELECTRICAL SYSTEM
selected cylinder.
6-65
ELECTRICAL SYSTEM
Right Tilt Down Switch Troubleshooting

Circuit Number: 24
Wire Color: Brown
6-66
ELECTRICAL SYSTEM
Left Tilt Up Switch

T-handle, sending a signal to the sprayer ECU.

6-67
ELECTRICAL SYSTEM
selected cylinder.
6-68
ELECTRICAL SYSTEM
Left Tilt Up Switch Troubleshooting
Circuit Number: 15
Wire Color: Brown
6-69
ELECTRICAL SYSTEM
Left Tilt Down Switch

The operator presses the touch pad or the button on the T-
handle, sending a signal to the sprayer ECU.

6-70
ELECTRICAL SYSTEM
selected cylinder.
6-71
ELECTRICAL SYSTEM
Left Tilt Down Switch Troubleshooting
Circuit Number: 16
Wire Color: Brown
6-72
ELECTRICAL SYSTEM
Boom Rack Up Switch


6-73
ELECTRICAL SYSTEM
selected cylinder.
6-74
ELECTRICAL SYSTEM
Boom Rack Up Switch Troubleshooting
Circuit Number: 19
Wire Color: Brown
6-75
ELECTRICAL SYSTEM
Boom Rack Down Switch


6-76
ELECTRICAL SYSTEM
selected cylinder.
6-77
ELECTRICAL SYSTEM
Boom Rack Down Switch Troubleshooting
Circuit Number: 20
Wire Color: Brown
6-78
ELECTRICAL SYSTEM
Master Spray Switch
The operator presses the yellow button (1) on the T-handle
while spraying.
This sends a signal to an input pin in connector P1 on the

sprayer ECU. The ECU carries the signal through an output
pin in connector P3.
The signal is transmitted to a relay in the console harness

that energizes and sends power to the switch box.
The switch box then sends a signal to all boom sections and
to the boom sense node that are in use and turns them on or
off.
6-79
ELECTRICAL SYSTEM
Master Spray Switch Troubleshooting
Circuit Number: 51
Wire Color: Blue
6-80
ELECTRICAL SYSTEM
Cruise Control Switch

The operator drives machine between 4 and 20 mph and
presses the Cruise Control button (1), sending a signal to the
processor on the sprayer ECU.
The operator then pushes the set button (2) on the handle.
The signal is transmitted to the throttle control on the engine
ECU and the throttle is then regulated to maintain the chosen
speed.
6-81
ELECTRICAL SYSTEM
If the operator pushes the brakes, a power signal is transmit-
ted through the wiring harnesses to the P4 connector on the
sprayer ECU and the cruise control is disengaged. The
cruise control can also be disengaged by increasing or
decreasing the throttle. The operator can then push the
resume button (3) on the handle and regain the previously
selected speed.
When the cruise control disengages, the engine will remain
at the current rpm and stops correcting to maintain speed.
The engine will not go to an idle to reduce speed.
6-82
ELECTRICAL SYSTEM
Cruise Control Switch Troubleshooting

Circuit Number: 133
Wire Color: Yellow
6-83
ELECTRICAL SYSTEM
Cruise Control Resume Troubleshooting
6-84
ELECTRICAL SYSTEM
Cruise Control Disengage Troubleshooting
6-85
ELECTRICAL SYSTEM
Engine Information
The operator starts the machine. The engine ECU sends low
voltage signals ranging from 1.5 to 3.5 volts through the CAN
bus line to the sprayer ECU. The sprayer ECU then pro-
cesses these signals and displays them on the console
screen.
6-86
ELECTRICAL SYSTEM
6-87
ELECTRICAL SYSTEM
Engine Information Troubleshooting
Circuit Number: 117,118
6-88
ELECTRICAL SYSTEM
Foam Master Switch

The operator presses the Foam Master button (1), sending a
signal to the sprayer ECU.
The sprayer ECU turns on the output FET, which supplies

power to an output pin in connector P3.

foam marker, where it powers the water pump and air com-
pressor. The foam marker automatically starts sending foam
to the left side until the operator presses the foam right but-
ton (2), then it switches to the right side. When the Auto
Foam feature is pressed the foam will alternate left to right
whenever the master spray button is pressed twice.
6-89
ELECTRICAL SYSTEM
6-90
ELECTRICAL SYSTEM
Foam Master Switch Troubleshooting
Circuit Number: 70, 71
Wire Color: Blue
6-91
ELECTRICAL SYSTEM
Auto Foam Control Troubleshooting
6-92
ELECTRICAL SYSTEM
Left Boom In Switch

The operator presses the touch pad (1) or the button on the

6-93
ELECTRICAL SYSTEM
selected cylinder.
6-94
ELECTRICAL SYSTEM
Left Boom In Switch Troubleshooting
Circuit Number: 17
Wire Color: Brown
6-95
ELECTRICAL SYSTEM
Left Boom Out Switch


6-96
ELECTRICAL SYSTEM
selected cylinder.
6-97
ELECTRICAL SYSTEM
Left Boom Out Switch Troubleshooting
Circuit Number: 18
Wire Color: Brown
6-98
ELECTRICAL SYSTEM
Left Tip In Switch


6-99
ELECTRICAL SYSTEM
selected cylinder.
6-100
ELECTRICAL SYSTEM
Left Tip In Switch Troubleshooting
Circuit Number: 60
Wire Color: Brown
6-101
ELECTRICAL SYSTEM
Left Tip Out Switch


6-102
ELECTRICAL SYSTEM
selected cylinder.
6-103
ELECTRICAL SYSTEM
Left Tip Out Switch Troubleshooting
Circuit Number: 61
Wire Color: Brown
6-104
ELECTRICAL SYSTEM
Park Brake Switch

The operator presses the Park Brake button (1) on the touch
pad sending a signal to the sprayer ECU.
The ECU turns on the output FET, which supplies a power

and a ground signal to output pins in connector P2.
6-105
ELECTRICAL SYSTEM
The signals are transmitted through the wiring harnesses to
the junction block under the cab, where it powers the hydrau-
lic coil.
The coil shifts the spool valve, sending hydraulic oil through
an adjustable restrictor valve to the Park Brake spring can
and the ladder cylinder.
1. Steering counter balance valve
2. Steering counter balance valve
3. Park brake speed adjustment
4. Ladder speed adjustment
5. Brake and ladder spool valve
6-106
ELECTRICAL SYSTEM
Park Brake Switch Electrical Troubleshooting
NOTE: For Park Brake Mechanical Troubleshooting, See “Brakes and Differential” on page 3-1.
Circuit Number: 40 is Power, 50 is Ground
Wire Color: Brown
6-107
ELECTRICAL SYSTEM
Park Brake Continued
Start machine. Press park

START
brake button.
Ladder comes up but park brake Park brake releases but ladder
does not release. does not come up.
IsIsthe
the second
bottom adjustable valvevalve Inspect hose going from
in thein hydraulic
the hydraulic
line block open
from the block block to ladder cylinder. yes
at least
open three
at least turns?
three turns? Is it kinked or linking?
yes no no
Remove cover plate from

transmission to expose the Is ladder or cylinder
Open restrictor valve yes Replace hydraulic hose.
park brake clevis. Are the pin a binding in any way?
and clevis attached properly?
no
yes
no
Replace park brake

Replace cylinder. Does the Repair binding or replace
spring can. Does it Repair pin and clevis
ladder come up now? ladder if needed.
work now?
no no
Consult Factory Consult Factory
6-108
ELECTRICAL SYSTEM
Product Pump Switch

The operator presses the product pump button on the touch
pad, sending a signal to the sprayer ECU.

an output pin in connector P2.
product pump valve, where it powers the hydraulic coil.
6-109
ELECTRICAL SYSTEM
product pump.
6-110
ELECTRICAL SYSTEM
Product Pump Switch Troubleshooting
Circuit Number: 28
Wire Color: Blue
6-111
ELECTRICAL SYSTEM
Right Boom In Switch

The operator presses the touch pad or the button on the T-
handle, sending a signal to the sprayer ECU.

6-112
ELECTRICAL SYSTEM
selected cylinder.
6-113
ELECTRICAL SYSTEM
Right Boom In Switch Troubleshooting
Circuit Number: 21
Wire Color: Brown
6-114
ELECTRICAL SYSTEM
Right Boom Out Switch


6-115
ELECTRICAL SYSTEM
selected cylinder.
6-116
ELECTRICAL SYSTEM
Right Boom Out Switch Troubleshooting
Circuit Number: 22
Wire Color: Brown
6-117
ELECTRICAL SYSTEM
Right Tip In Switch


6-118
ELECTRICAL SYSTEM
selected cylinder.
6-119
ELECTRICAL SYSTEM
Right Tip In Switch Troubleshooting
Circuit Number: 62
Wire Color: Brown
6-120
ELECTRICAL SYSTEM
Right Tip Out Switch


6-121
ELECTRICAL SYSTEM
selected cylinder.
6-122
ELECTRICAL SYSTEM
Right Tip Out Switch Troubleshooting
Circuit Number: 63
Wire Color: Brown
6-123
ELECTRICAL SYSTEM
Agitation Valve Switch
The operator presses the agitation increase (1) or agitation
decrease (2) on the touch pad sending a signal to the
sprayer ECU.
The ECU supplies a ground to an output pin in connector P2.
The signal is transmitted through the wiring harness to the

agitation valve.
6-124
ELECTRICAL SYSTEM
At the agitation valve, the signal powers the motor to turn the
ball valve.
If the pump is running, product from the tank is circulated
through the pump back into the tank, stirring the mixture.
Agitation Switch Troubleshooting

Circuit Number: 25, 26
Wire Color: Blue
6-125
ELECTRICAL SYSTEM
Light Switches
1. Headlights
• Press the switch down to turn on the hood-
mounted headlights.
• Press the switch up to turn off the lights.
2. Cab Front Lights
• Press the switch down to turn on the cab-
mounted, front-facing work lights.
3. Cab Rear Lights
• Press the switch down to turn on the cab-
mounted, rear-facing work lights.
4. Boom Lights
• Press the switch down to turn on the signal and
tail lights.
5. Product Rinse (Flow Back)
6. Auxiliary Power Outlet
7. Dome Light
• Press the switch to turn the light on and off.
NOTICE: The dome light can drain the battery if left on
without the engine running.
AM/FM Radio with

Weather Band and CD Player
1. AM/FM Radio with Weather Band and CD Player
See manufacturer instructions for operation.
6-126
ELECTRICAL SYSTEM
Upper Cab Wiring
(38 PIN 4) TAN

(37 PIN 5) TAN
(36 PIN 6) TAN
(59) GREEN
(79) GREEN
(58) GREEN
(69) GREEN
(02) RED
A B C D E F GH J K L M N P R S
CAB ROOF
(38 PIN 4) TAN

(37 PIN 5) TAN
(36 PIN 6) TAN
(58) GREEN
(79) GREEN
(69) GREEN
(59) GREEN
(02) RED
1 2 3 4 5 6 7 8
(48) RED
(142) YELLOW
DRIVING
LIGHTS
(G4 CAB GND) BLACK (G4)BLACK
1 2 3 4 5 6 7 8
(48) RED
(143) YELLOW
FIELD
FRONT
(G4) BLACK
LIGHTS
1 2 3 4 5 6 7 8
(48) RED
(144) YELLOW
FIELD
REAR
(G4) BLACK LIGHTS
1 2 3 4 5 6 7 8
(80) RED
(57) GREEN
BOOM
(G4) BLACK
LIGHT
1 2 3 4 5 6 7 8
(48)RED
(145)YELLOW
AUXILIARY
(G4)BLACK
(G4 DOME) BLACK
DOME
LIGHT (32 DOME) RED
(167) TAN
LEFT FRONT
SPEAKER (166) TAN
(165) TAN
RIGHT FRONT
SPEAKER (164) TAN
(67) TAN
LEFT REAR
SPEAKER (66) TAN
(65) TAN
RIGHT REAR
SPEAKER (64) TAN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(09 PIN 4) RED

(09 PIN 5) RED
(14 PIN 7) RED
(09) RED
(64 PIN 9) TAN
RADIO (65 PIN 10) TAN
PWRPOINT
(G4) BLACK
(164) TAN
(165) TAN (09) RED
(166) TAN
(167) TAN (G4) BLACK

PANNLT.
(66 PIN 15) TAN
(67 PIN16) TAN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
UPPER CAB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
(38 PIN 4) TAN
(37 PIN 5) TAN
(36 PIN 6) TAN
(58) GREEN
(57) GREEN
(79) GREEN
(69) GREEN
(59) GREEN
(14 PIN 2) RED
(48 PIN 3) RED
(09) RED
(32) RED
(02) RED
(80) RED
(145) YELLOW
(144) YELLOW
(142) YELLOW
(143) YELLOW
6-127
ELECTRICAL SYSTEM
Apache Sprayer Lighting

1. Headlights
2. Cab Front Work Lights
3. Front Hazard and Turn Signal Lights
4. Cab Rear Work Lights
5. Side Hazard and Turn Signal Lights
6. Side Work Lights
7. Rear Hazard and Turn Signal Lights
(Mounted to back rack - not shown)
8. Brake Lights
(Mounted to back of chassis - not shown)
Turn Signal and Hazard Light Function:
• When the hazard lights are turned on, light sets #5, #3 and #7 will all flash.
Turn Signal Function:
• When the left turn signal is turned on, the left side of light sets #5, #3 and #7 will all flash.
• When the right turn signal is turned on, the right side of light sets #5, #3 and #7 will all flash.
If the hazard lights are already flashing when the turn signal is activated, the lights opposite the turn indicator will
glow steady while the lights on the side of the turn will flash.
6-128
ELECTRICAL SYSTEM
Cab Top Wiring

CAB GND
(G5 CAB GND) BLACK
LR BULKHEAD RR BULKHEAD
(69) GREEN (69) GREEN
A B C D E F GH
A B C D E F GH
1
(G5) BLACK (G5) BLACK
2
(59) GREEN
(G5)BLACK (59) GREEN
1
(G5) BLACK
2
A B C D E F GH
A B C D E F GH
1
2
(59) GREEN
(G5)BLACK (59) GREEN
1
(G5) BLACK
2
LF BULKHEAD RF BULKHEAD
A B C D E F GH
A B C D E F GH
1
2
(79) GREEN
(G5) BLACK (79) GREEN
1
(G5) BLACK
2

A B C D E F G H
A B C D E F G H
1
2
(79) GREEN
(G5) BLACK (79) GREEN
1
(G5) BLACK
2
(37 PIN 1) TAN

1 2 3 4 5
WIPER (36 PIN 2) TAN

(02) RED
MOTOR (38 PIN 4) TAN

(38 PIN 4) TAN
(37 PIN 5) TAN
(36 PIN 6) TAN
(59) GREEN
(79) GREEN
(58) GREEN
(69) GREEN
(02) RED
CAB ROOF
(38 PIN 4) TAN
(37 PIN 5) TAN
(36 PIN 6) TAN
(58) GREEN
(79) GREEN
(69) GREEN
(59) GREEN
(02) RED
6-129
ELECTRICAL SYSTEM
Steering Column
NOTE: Do not drill or alter in any way, the plastic of the steering column.
1. Steering Column Tilt Adjustment Lever
• Step forward on the foot lever.
• Adjust the tilt to the desired position.
• Release the foot lever to lock the column.
2. Steering Wheel
3. Steering Wheel Telescope Adjustment Knob
• Turn center knob counterclockwise to unlock.
• Position steering wheel to desired height.
• Turn center knob clockwise to lock.
4. Hazard Flasher Button
5. Horn Button
Push to sound horn.
6. Turn Signal Lever
• Push lever up for right turn signal.
• Push lever down for left turn signal.
7. Windshield Washer
• Push ring to operate washer.
8. Windshield Wiper Switch
• Turn lever to the “I” position for low speed wiper.
• Turn lever to the “II” position for high-speed
wiper.
9. Key Switch
Shown in the “OFF” position.
Climate Control
1. A/C On/Off Switch
2. Cab Temperature Control
Turn the switch toward blue (counter-clockwise) for
cool. Turn the switch toward red (clockwise) for
warm.
3. Blower Fan Control
Turn the switch counter-clockwise for “OFF” and
clockwise for “ON”.
6-130
ELECTRICAL SYSTEM
Steering Column Wiring
POTENTIOMETER
DIFF LOCK
STEERING COLUMN
TEMP CONTRL
FAN SWITCH
AC ROCKER
SWITCH
H M L C B 3 2 1
(G3) BLACK
1 2
(78) RED
(78) RED
(76) TAN
(92) TAN
(93) TAN
(90) TAN
(91) TAN
(93) TAN
(93) TAN
(G1) BLACK
(56a) RED
(46) TAN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(46) TAN
(47) TAN (47) TAN
(38 PIN 3) TAN (38 PIN 3) TAN
(37-PIN 5) TAN (37 PIN 5) TAN
(04 PIN 7) RED (04 PIN 7) RED
(35) TAN (35) TAN
(78) RED (78) RED
(93) TAN (93) TAN
(76) TAN (76) TAN
STEERINGCOLUMN
(92) TAN (92) TAN
(91) TAN (91) TAN
(90) TAN (90) TAN
(53-PIN 16) TAN (53 PIN 16) TAN
(05) RED (05 PIN 17) RED
(07) TAN (07 PIN 18) TAN
(01) TAN (01 PIN 19) TAN
(97) TAN (97) TAN
(34) TAN (34) TAN
1 2 3 4 5 6 7 8 9 10 11 12 13
(53) GREEN
(30) GRAY/RED
(J) RED
(53b) BLUE
(53c) PURPLE
(Dx) L.BLUE
(31b) ORANGE
(56) GRAY
(56b) GRAY/BLACK
(56a) GREEN/BLACK
(H) BLACK
(Sx) L.BLUE/BLACK
(L) WHITE/BLACK
(03 PIN 28)TAN
IGNITION
CRANK
58 15 19 50
P0 1 23
30 30
L
49
56 30 Dx Sx 53 J H 49A
15
R
6-131
ELECTRICAL SYSTEM
All Models General Cab Information

Fault Code Indicator:
1. Fault Code Indicator on Console
When a fault code is logged, the ET logo will disap-
pear on the right side of the console display and
one or more of the following fault codes will appear:
• Stop Engine
• Check Engine
• Water In Fuel
• Wait To Start
• Water Temperature
• Low Oil Pressure
• Change Air Filter
• High Hyd Temp
• High Trans Temp
• Low Coolant
• ECU Failure
• SPN 00000 FMI 00
• Transmission Fault Code
Refer to Fault Codes in the Maintenance Section.
Headliner
The headliner can be removed by taking all the screws out around the outside edge.
Fuse Box
The fuse box is located in the right rear corner of the
cab.
6-132
ELECTRICAL SYSTEM
Steering Column
Removal and Service
After the plastic cowling is removed, the steering tilt col-
umn can be removed or serviced.
The tilt is operated by a foot pedal attached to a cable
that goes to the lock on the tilt column.
Remove column by removing the four bolts connecting
the column to the cab.
The removed assembly is shown here.
6-133
ELECTRICAL SYSTEM
Troubleshooting
Problem Solution
Check the battery charge and connections.

Engine will not crank over
Check the operation of start relay.
Release the parking brake.

Vehicle will not move forward Make sure a gear is selected on the display.
Check for power at the transmission coils or computer.
Release the parking brake.
Vehicle will not move in reverse Make sure a gear is selected on the display.
Check for power at the transmission coils or computer.
Check the wire connection on the alternator.
Alternator not charging Check battery ground.
Test the alternator.
Check fuse.
Head lights not working Check for power at the switch.
Check for power at the lights.
Check the connections from the switch to the lights.
Check fuse.
Work lights not working Check for power at the switch.
Check for power at the lights.
Check the connections from the switch to the lights.
Check fuse.
Turn signals not working
Check all wire connections.
Check for power on the temperature switch.

Air conditioner not working
Check that the water valve is closing properly.
Check to make sure the solenoid is magnetized.

Hydraulic boom function not working Check for power to the solenoids.
properly Remove the spool valves and clean and inspect the o-
rings for cuts or breaks.
Check for hydraulic pressure at the cylinder.
Make sure all valves are in the correct positions.
Booms will not spray Make sure the boom switches and raven are turned on.
Make sure the master spray switch on the tee handle is
turned on.
Make sure the product pump is turned on.
Make sure the strainers are clean.
Make sure the meter cal number is entered correctly.
Raven not reading flow Check the wire connections at the flowmeter.
Perform a paper clip test on the flowmeter.
Clean the flowmeter with a garden hose.
Make sure there is power to both wires while attempting

Raven servo valve not opening
to open.
Check fuse.
Raven controller will not come on
Check the connections at the raven console.
6-134
ELECTRICAL SYSTEM
Problem Solution
Check for power and ground at the air compressor and

Foam marker not turning on water pump.
Check for power and ground at the air solenoid and
water solenoid.
Make sure the screens are not plugged at the mixing
chambers.
Check the calibration numbers in the raven console.

No speed reading on raven
Check the wire connections at the speed source.
Check the yellow and green CAN bus wires on engine

Gauges not working on display
and circuit board.
Check the transmission fluid level.

Constraint alarm sounds when moving Check to make sure the transmission cooler is clean.
forward or in reverse Check the temperature of the transmission with a heat
gun.
Check the sensor.
Speedometer on display not working Check the wire connections on the sensor and at the
gauge.
Check fuse.
Seat will not raise Check the wire connection at the seat.
Check for power to the seat.
6-135
ELECTRICAL SYSTEM
NOTES
6-136
Chapter 7
HVAC
AS720, AS1020 & AS1220
NOTES
HVAC
HVAC Troubleshooting
7-1
HVAC
HVAC Unit
1. Blower Motor
2. Evaporator
3. Water Valve
The water valve for all 2011 Apaches is located on
the left rear of the battery tray, directly in front of the
cab. The water valve wiring includes the water
valve connector and the 102-Pin connector at the
cab floor.
7-2
HVAC
4. Cold Control Thermostat
5. Medium Blower Motor Speed Relay
6. High Blower Motor Speed Relay
7. Low Blower Motor Speed Circuit Breaker
8. Blower Motor
Since the elimination of the cab pressurization fan the
cab blower motor will now function as both the blower
motor and pressurization fan. The blower motor will run
with the key on and the fan switch off.
HVAC Wiring
HVAC wiring at top of cab.
7-3
HVAC
Air Compressor
1. Low Pressure Hose
2. High Pressure Hose
3. Air Conditioner High Pressure Switch

4. Air Conditioner Receiver/Dryer (replace any
time the air conditioning system is opened)
Power comes from the high-pressure switch to the air
conditioner compressor, then from the compressor to
the HVAC unit under the seat on white wire #49. Check
for power at the high-pressure switch and at the com-
pressor if the compressor is not running.
The compressor should cycle on and off if working prop-
erly.
NOTE: The A/C system holds 3.25 lbs of freon.
7-4
HVAC
Air Conditioning Compressor Wiring
7-5
HVAC
Basic Troubleshooting for HVAC System

1. Is there noise from a loose drive belt?
• A loose or worn drive belt makes various squeaking and slapping noises. If such noises are heard, check
and adjust the drive belt tension. Replace the drive belt if it is worn.
2. Is there noise from the compressor area?
• Check the compressor and bracket for loose bolts and tighten them, if necessary.
3. Is there noise from the compressor?
• Damage and internal wear of the suction/discharge valve are possible sources of noise from within the
compressor.
4. Has mud or dirt adhered to the condenser?
• Remove any mud and dirt from the condenser. Mud and dirt can drastically reduce heat radiation, which
adversely affects cooling performance. Do not scratch or bend the condenser fins.
5. Are the condenser/radiator fans operating properly?
• Check the drive belts, viscous drives and/or fan motors.
6. Is there oil contamination on pipe unions or the compressor?
• Oil contamination on pipe unions or on the compressor indicates that refrigerant from the system is leaking
together with compressor oil. If oil contamination is discovered, check for leaks using a leak detector and
replace parts as necessary.
• Carefully check the compressor gaskets, o-rings, and shaft seals.
7. Is there noise from the blower motor?
• If the fan motor is noisy or does not operate correctly, disassemble the fan motor and repair or replace
parts as necessary.
• The fan will also be noisy if not properly tightened or when foreign matter has adhered to it.
7-6
Chapter 8
Warranty
AS720, AS1020 & AS1220
NOTES
WARRANTY
Equipment Technologies Warranty Policy

For all 2011 Model Year
NEW APACHE LIMITED WARRANTY POLICY
Equipment Technologies (hereinafter called ET) warrants each new Apache to be free from defects in materials
and workmanship for a period of five (5) years or two thousand (2000) hours, whichever occurs first, from the date
of delivery to the original purchaser, with the exclusions listed herein. Under no circumstances does this limited
warranty cover any merchandise or component parts, which, in the sole opinion of ET, have been subject to negli-
gent, misuse, improper storage, alteration, accident, or if repairs have been made with parts other than those man-
ufactured, supplied, and/or authorized by ET. Under no circumstances are component parts warranted against
normal wear and tear. There is no warranty on glass, parking brake pads, brake linings, filters, oils, product pump
seals, product pump bearings, rubber product hoses, or pressure gauges.
First Year - Limited warranty covers the total machine for the first year from the date of delivery to the original pur-
chaser or one thousand (1000) hours whichever occurs first, for both parts and labor. Under no circumstances
does this limited warranty cover any merchandise or component parts, which, in the opinion of ET, have been sub-
ject to negligent, misuse, improper storage, alteration, accident, or if repairs have been made with parts other than
those manufactured, supplied, and/or authorized by ET. For engine, tire, and battery warranty please see below.
Second Year - Limited warranty covers the driveline and chassis components for both parts and labor from the
date of delivery to the original purchaser or one thousand (1000) hours which ever comes first. The following com-
ponents are covered under the second year of warranty. Transmission and its internal components, rear differential
and its internal components, front axle assembly (excludes seals, bearings, wear pads, suspension cylinder, accu-
mulator, and steering cylinders), frame rails, engine bolster, rear axle assembly (excludes wear pads, drive shafts,
and rear suspension components), planetaries and their internal components (excludes bearings, seals, and o
rings), drop boxes and their internal components, and frame cross members and any bracket that bolts directly to
the frame rails. This portion of coverage is subject to all listed conditions but further excludes oil, seals, gaskets
and leakage.
Years Three through Five - Limited warranty covers the driveline and chassis components for parts only from the
date of delivery to the original purchaser or two thousand (2000) hours which ever comes first. The following com-
ponents are covered under years three through five of warranty. Transmission and its internal components, rear dif-
ferential and its internal components, front axle assembly (excludes seals, bearings, wear pads, suspension
cylinder, accumulator, and steering cylinders), frame rails, engine bolster, rear axle assembly (excludes wear pads,
drive shafts, and rear suspension components), planetaries and their internal components (excludes bearings,
seals, and o rings), drop boxes and their internal components, and frame cross members and any bracket that
bolts directly to the frame rails. This portion of coverage is subject to all listed conditions but further excludes oil,
seals, gaskets and leakage.
Engine Warranty - The limited engine warranty is covered by engine manufacturer for two (2) years or two thou-
sand (2000) hours from the date of delivery to the original purchaser, whichever comes first. ET does warranty the
a/c compressor, a/c belt, alternator, and engine belt for the first year only. The engine manufacturer warrants all
other bolt on and engine components. See engine warranty for complete details.
Tires - The tire manufacturer (Titan) covers the tire warranty. Contact your local authorized Titan dealer for com-
plete warranty details.
Batteries - Batteries are warranted for thirty (30) months. Batteries are warranted through NAPA auto part stores.
If you have no authorized NAPA auto part stores, then contact ET for warranty replacement information.
ET’s obligation under this limited warranty is limited to repairing or replacing free of charge to the original pur-
chaser, at a location designated by ET, any part that in ET’s sole judgment, shows evidence of defect or improper
workmanship, provided that the part is returned to ET within thirty (30) days of repair date. Parts must be returned
through the authorized selling dealer, transportation charges prepaid. All returned parts must be clean from all
chemicals and/or oils.
ET’s obligation under this limited warranty is in lieu of all other warranties or representations, expressed or implied,
and specifically excludes any obligations or liability for loss of crops, losses caused by harvest delays or any
expense or loss of labor, supplies, rental equipment, and all incidental or consequential damages. The replace-
8-1
WARRANTY
ment of parts and/or repair is the exclusive remedy under this limited warranty. ET reserves the right to repair or
replace any defective part or parts. No person is authorized to give any other warranties or to assume any other lia-
bility on ET’s behalf. This limited warranty is void if ET’s limited warranty policy maintenance standards are vio-
lated.
ET makes NO warranty of merchantability or fitness for a particular purpose.
This machine must be registered to both ET and engine manufacture within ten (10) working days from the date of
delivery to the original purchaser.
All inquires about this warranty policy should be addressed to:
Warranty Department • 2201 Hancel Parkway • Mooresville, IN • 46158

Telephone: 317-834-4500.
Apache Machine Warranty Registration

In the cab of each new Apache is a warranty registration sheet that is in triplicate. When the Apache is delivered to
the end user this registration sheet must be completed, signed, and dated by both the dealer representative and
the end user. This completed form starts the warranty period for this machine. The completed registration sheet
one copy is for the end user, one copy for the dealer, and the white copy is to be faxed, emailed, or mailed to (ET)
within ten (10) business days of it being signed. These forms are also on our web site www.apachesprayer.com
under the dealer login. On the web site you can either download the registration form in PDF print it or complete or
you may enter the information under warranty registration and submit it through our web site. If you submit through
the web site, then we will still need the signed form by the customer fax or mailed to us at ET.
Engine Warranty Registration

There are two ways to register the engine warranty for Cummins. The first is a mail-in warranty registration card. In
the cab of each new Apache with the engine book is a warranty registration card. This card needs to be completed
and mailed or fax to the engine manufacture as directed on the card. The second registration method is to go
online and register the engine for warranty.
To register the Cummins engine for warranty online: go to www.cummins.com, click on “product registration” and
read the terms and conditions, if you agree with the terms and conditions, then click on “I accept”, and follow the
instructions to register.
8-2

2011APACHESERVICEMANUALAS720AS1020AS1220

Uploaded by

Document Information

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

2011APACHESERVICEMANUALAS720AS1020AS1220

Uploaded by

Copyright:

Available Formats

2011 APACHE

AS720, AS1020 & AS1220 Series

This manual contains information on:

SAE SAE (JIC) O-ring Style

Torque Value Chart

SAE Grade 2 SAE Grade 5 SAE Grade 8

Metric Series Torque Value Chart

Metric Grade Metric Grade Metric Grade Metric Grade

2011 AS720 Specifications

Tire Pressure (Cold)

Rear semi-float tires and rims for

2011 AS1020 and AS1220 Specifications

120 to 160 in. [304.8 to 406.4 cm] Adjustable Axle Width

Tire Pressure (Cold)

* Only for use on 50 in. [127 cm] crop clearance models

Tire Pressure (Cold)

AS1220 Optional Equipment

* Must also choose a controller and GPS option

Maintenance Precautions • Avoid skin contact with high-pressure diesel

• Never connect or disconnect a hose or line

Cleaning Guidelines • Avoid scratching or damaging polished metal fin-

Body and Cab Exterior

Apache Sprayer Service Interval Chart

Every 1000 Hours

Every 100 Hours

Grease Entire Boom

Before Initial Use

After First 10 Hours

To adjust the boom lead:

1. Boom Stabilizer 5. Boom Tip

Boom Inner Breakaway

Boom Outer Breakaway (if equipped)

Check Tire Pressure

Check Engine Oil Level

AS1020 and AS1220 / ZF Transmission Only

Check Hydraulic Fluid Level

Torque Lug Nuts

Grease Rear Suspension

Grease Axle Components

Torque Boom Lead Bolts

Check Differential Fluid Level

Check Rear Differential for Leaks

After First 100 Hours

Every 100 Hours

Grease Driveline Components

Torque Axle Extension Brace Bolts

Adjust On The Go Axles

There are twelve axle brace bolts (1) on each rear

Adjust Poly Tank Straps

Fill the new filter with diesel fuel before installing.

Replace Fuel Separator Filter

Fill the new filter with diesel fuel before installing.

Every 250 Hours

Clean or Replace Engine Primary

Use a rocking motion to release the primary air filter (2)

Replace Differential Fluid

Clean Hydraulic Fluid Strainer

Remove the hydraulic fluid line (1).

Install the hydraulic line (1).

Every 500 Hours or Yearly

Check Accumulator Fluid Level

Replace Engine Oil and Filter

Replace Transmission Oil and Filter

Install and tighten the filter, by hand, 3/4 to 1-1/4 turns