17710-Case 1150k Series 3 Tier 3-1 PDF

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1150K
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1150K
Crawler Dozer
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Crawler Dozer
Repair Manual
Repair Manual
87364101
87364101
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1150K
CRAWLER
87364101
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SECTION INDEX
GENERAL
Section Title Section Number

General Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
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Copyright © 2007 CNH America LLC.

CNH America LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 5-4120 Issued February, 2007
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Copyright ©
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS
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CASE, LLC. All rights reserved.
Racine, WI 53404 U.S.A. Bur 8-71603 Issued April, 2003 Revised July, 2005
Copyright ©
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Bur 8-71603 Revised 7-05 Printed in U.S.A.

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1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

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

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/8 inch 220 to 264 298 to 358
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Pound- Newton 3/4 inch 380 to 456 515 to 618
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Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
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1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
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3/4 inch 270 to 324 366 to 439

1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
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NOTE: Use thick nuts with Grade 8 bolts.

1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
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1-3/8 inch 1460 to 1680 1980 to 2278

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1-1/2 inch 1940 to 2200 2631 to 2983

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1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or 10.9
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is Pound- Newton
used. Size Inches metres
M4 36 to 48 4 to 5
Grade 8.8 Bolts, Nuts, and Studs M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
8.8
M8 324 to 384 37 to 43
Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres
M5 60 to 72 7 to 8 M10 54 to 64 73 to 87
M6 96 to 108 11 to 12 M12 93 to 112 125 to 150
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M8 228 to 276 26 to 31 M14 149 to 179 200 to 245
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M10 456 to 540 52 to 61 M16 230 to 280 310 to 380
M20 450 to 540 610 to 730
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Pound- Newton M24 780 to 940 1050 to 1275
Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
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Grade 12.9 Bolts, Nuts, and Studs

M16 160 to 200 217 to 271
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M20 320 to 380 434 to 515

12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600
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fasteners can be used satisfactorily on grade 12.9

fasteners.
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1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting Straight Threads with O-ring

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

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Pound- Newton
Size Inches metres
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5/16-18 180 to 240 20 to 27

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3/8-16 240 to 300 27 to 34

7/16-14 420 to 540 47 to 61
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

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1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Boss End

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

Size Feet metres
-10 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
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15.9 mm
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Nom. 1-1/16-12 85 to 90 115 to 122
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SAE
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Feet metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
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-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
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22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
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31.8 mm
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-24 1-1/2 inch 2-12 150 to 180 200 to 254

38.1 mm
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1002
Section
1002
FLUIDS AND LUBRICANTS
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1002-2
TABLE OF CONTENTS
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Bur 5-4130 Issued 2-07 Printed in U.S.A.

Copyright ©
1002-3
CONVERSION FORMULAS
Imperial quart = litres x 0.879877
Imperial gallon = litres x 0.219969
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ..................................................................................... 16.4 Litres (17.3 U.S. Quarts)
Capacity without Filter Change ................................................................................ 15.6 Litres (16.5 U.S. Quarts)
Type of Oil ..................................................................................... See Engine Oil Recommendations on page 4
Engine Cooling System
Capacity without Heater ..........................................................................................32.47 Litres (8.6 U.S. Gallons)
Type of Coolant .......................................... Ethylene glycol and water mixed for the lowest ambient temperature
(at least 50/50 mix)
Fuel Tank
Capacity ......................................................................................................................246 Litres (65 U.S. Gallons)
Type of Fuel .......................................................................................... See Diesel Fuel Specifications on page 5
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Transmission and Hydraulic System
Hydraulic Reservoir Refill Capacity ............................................................................98.4 Litres (26 U.S. Gallons)
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Type of Oil ..................................................................................................................... MS-1209, Hy-Tran Ultra
Final Drives
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Capacity ...................................................................................................................... 14.2 Litres (15 U.S. Quarts)
Type of Lubricant ..................................................................................... Case AKCELA 135H EP Gear Lubricant
Track Rollers
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Capacity ............................................................................................................... 450 mL (15.2 U.S. fluid ounces)

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Front Idlers
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Carrier Rollers
Capacity ................................................................................................................. 290 mL (9.8 U.S. fluid ounces)
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CLT and CELT track pins
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Capacity .............................................................................................................. 28.1 mL (0.95 U.S. fluid ounces)

CAB/ROPS Tilt System
Reservoir Refill Capacity .......................................................................................... 0.36 Litres (0.38 U.S. Quarts)
Type of Oil .............................................................................................Case AKCELA MS-1209, Hy-Tran Ultra
ENVIRONMENT
Before you service this machine and dispose of oil, fluids and lubricants, always remember the environment. Do
not put oil or fluids into the ground or into containers that can leak. Check with your local environmental, recycling
center or your Case dealer for correct disposal information.
NOTE: See operators manual and equipment lubrication chart for service intervals.

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1002-4
ENGINE OIL RECOMMENDATIONS

Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CH-4 (preferred) or CG-4.
S e e t h e c h a r t b e l ow fo r
recommended viscosity at
ambient air temperature
ranges.
BD03A102
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
RH99K130
intervals given in this manual
are according to tests with Case
AKCELA lubricants.
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BC02N250

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

API gravity, minimum ..............................................................................................................................................34
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Flash point, minimum ........................................................................................................................ 60° C (140° F)
Cloud point (wax appearance point), maximum ....................................................... -20° C (-5° F) See Note above
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Pour point, maximum .............................................................................................. -26° C (-15° F) See Note above
Viscosity, at 88° C (100° F)
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Centistokes ..................................................................................................................................................2.0 to 4.3
Saybolt Seconds Universal ............................................................................................................................32 to 40
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1002-6
NOTES
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Section
1003
1003
METRIC CONVERSION CHART
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Copyright © 2003 Case, LLC. All rights reserved.

CASE, LLC. Case is a registered trademark of Case, LLC.
Racine, WI 53404 U.S.A. Bur 7-52590 Issued April, 2003
Copyright ©
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

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

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Pressure: kilopascal 0.145 038 lb/sq. inch
bar 14.50385 lb/sq. inch
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Temperature: degree C 1.8 x C +32 degree F

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Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.

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Volume: cubic centimeter 0.061 024 cubic inch

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cubic meter 35.314 66 cubic foot

cubic meter 1.307 950 cubic yd.
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milliliter 0.033 814 ounce (US fluid)

litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

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

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

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

ounce 28.35 gram
Mass/Area: ton/acre 2241 702 kilogram/hectare
Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr
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Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter
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Power: horsepower 0.745 700 kilowatt
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Pressure: lbs/sq. in. 6.894 757 kilopascal
lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
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Temperature: degree F 1.8 F - 32 degree C

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Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.

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Volume: cubic inch 16.387 06 cubic centimeter

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cubic foot 0.028 317 cubic meter

cubic yard 0.764.555 cubic meter
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ounce (US fluid) 29.573 53 milliliter

quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact

Copyright ©
SECTION INDEX
ENGINE

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000
After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003
For Engine Repair, see the Engine Repair Manual 87519803
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Copyright ©
Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
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2000

Copyright ©
2000-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2000-3
SPECIFICATIONS
Torques
Engine mount bolts ...................................................................................205 to 230 Nm (151 to 170 pound-feet)
Radiator mount bolts .........................................................................................68 to 82 Nm (50 to 60 pound-feet)
Drive shaft to flywheel mount bolts............................................................335 to 375 Nm (245 to 275 pound-feet)
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2000-4
RADIATOR
Removal STEP 7
STEP 1
Park the machine on a level surface. Lower the blade
to the floor and stop the engine.
STEP 2
Put the master disconnect switch in the OFF position.
STEP 3
Open and remove the engine side panels.
STEP 4
BD05H153
Make sure the engine is cool and slowly remove the
radiator cap. Attach a hose to the drain cock and Lower the grille to gain access to the three bolts
drain the radiator into a suitable container. securing the grille hinge to the machine. Loosen the
three bolts. Raise the grille and remove the three
STEP 5 bolts. Remove the grille from the machine.
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STEP 8
IN 1
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BD05H158
3
Remove the two bolts securing the grille. Lower the
grille.
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BD05H152
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STEP 6 NOTE: Have another person assist you, the plates

are heavy and have no lifting point.
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Remove the upper mount bolt (1), the middle mount

bolt (2), the step up handle on the side you are
working, the lower bolt (3 not shown) and the radiator
front wrap plate (4). Repeat the procedure for the
opposite side.
STEP 9
Remove the horn and place on the back side of the
radiator.
BD05H154
Connect suitable lifting equipment to the grille. Raise

the grille to get slack in the cable. Disconnect the
hook from the grille.

Copyright ©
2000-5
STEP 10 STEP 13
BD05H156 2
Remove the nuts from the two lower radiator wrap BD05H159
mounting bolts, remove the bolts so the radiator will Loosen the clamp (1) and disconnect the lower hose
have clearance during removal. (2).
NOTE: Radiator is shown removed for clarity only.
STEP 14
STEP 11 Connect a vacuum pump to the hydraulic reservoir,
Disconnect and remove the coolant recover hose. turn on the vacuum pump.
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STEP 15
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STEP 12 PR
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BD05H160
BD05H151
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Loosen the clamp (1) and disconnect the radiator Place a container beneath the machine to catch
hose. Remove the bolt (2) and two washers securing hydraulic oil that will drain when the oil cooler line is
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the mounting straps (3) to the machine. Remove the disconnected from the oil cooler. Disconnect the lines
bolt and washers from the strap on the other side of and install plugs and caps.
the machine.

Copyright ©
2000-6
STEP 16 Installation
STEP 20
If mounting straps were removed from the radiator,
install using bolt, two washers, and lock nut. Repeat
to install mounting straps on opposite side of radiator.
STEP 21
BD05H157
Connect suitable lifting equipment to the radiator.

Remove the bolts and washers from the radiator.
STEP 17
Carefully move the radiator forward until the fan
shroud is clear of the fan. Pull the radiator forward BD05H155
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until clear of the radiator cover. If radiator mounts were removed for replacement,
apply a light coat of water from bottom of shank to 3
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STEP 18 mm (1/8 inch) up from bottom. Inser t mount in
Remove the radiator from the machine. welded bracket by rotating and pushing mount until
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partially positioned. Install bolt making sure that bolt
STEP 19 head does not overhang the outside diameter of the
mount metal insert; if it does, use a smaller bolt.
Remove radiator mounts only if replacement is
Push the mount into the bracket with enough force to
necessary. If radiator is being replaced, remove lock
ensure there is no gap between bottom surface of
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nut, bolt, two washers, and mounting straps from the

mount head and surface of bracket.
top of the radiator.
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STEP 22
Push the radiator into position on the mounts. Be
careful not to damage the engine fan by hitting it with
the fan shroud.
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STEP 23
Raise one end of the radiator slightly and install two
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washers on top of the mount. Do the same on the

other mount. Put two washers on a bolt and install
the bolt from bottom. Install washers and bolt on
other side of radiator. Tighten bolts to a torque of 68
to 82 Nm (50 to 60 pound-feet).

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2000-7
STEP 24 STEP 28
BD05H151 BD05H159
Install two washers and a bolt (2) to secure the Install the lower hose. Position clamps and tighten to
mounting straps (3). Repeat procedure for the other a torque of 11 to 12 Nm (97 to 106 lb-inch).
side of the radiator. Install radiator hose and tighten
hose clamps (1) to a torque of 11 to 12 Nm (97 to STEP 29
106 lb-inch). Route the horn wires on the hose and Close the drain valve.
secure using new tie strap (1).
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STEP 30
STEP 25
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Carefully pull the horn and wires over the radiator.
Install the coolant recover hose and the upper oil Mount the horn.
cooler line.
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STEP 31
STEP 26
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BD05H156
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Install the two lower radiator wrap mount bolts into

BD05H160 place. Install the washer and self locking nuts.
Connect the oil cooler lines to the oil cooler. Tighten the nuts.
NOTE: Radiator is shown removed for clarity only.
STEP 27
Stop and disconnect the vacuum pump from the
reservoir.

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2000-8
STEP 32 STEP 35
1
3
BD02H031
NOTE: Have another person assist you, the plates BD05H154
are heavy and hove no lifting point. Raise the grille enough to connect the cable hook to
the grille. Disconnect the lifting equipment from the
Hold the plate (4) in place and install the lower bolt,
grille.
nut and washer (3 not shown), do not tighten at this
time. Install the upper bolt (1) through the plate,
radiator wrap and into the top of the step up handle STEP 36
on the side you are working, install the middle bolt. Fill the radiator with a mixture of 50% ethylene glycol
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Repeat the procedure for the other side. Tighten the and 50% water. Install the radiator cap. Fill the
bolts. coolant reser voir up to the FULL mark on the
IN
reservoir.
STEP 33
STEP 37
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Attach lifting equipment to the grille, move the grille
into position in front of the machine. Raise the grille Put the master disconnect switch in the ON position.
and install the three bolts finger tight.
STEP 38
STEP 34
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Start the engine and run the engine at low idle.

Check for leaks. When the coolant is at operating
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temperature, stop the engine. When engine has

cooled, check the coolant level at the reservoir.
STEP 39
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Install the engine side panels, close and secure the

grille.
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BD05H153
Lower the grille to gain access to the three bolts.

Tighten the three bolts.

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2000-9
ENGINE
Removal STEP 6
STEP 1
Remove the radiator.
NOTE: If machine is equipped with a brush guard do
Step 2 otherwise go to Step 3.
STEP 2
Connect suitable lifting equipment to brush guard.
Remove two lower bolts and lock nuts, remove the
two upper bolts and washers securing the brush
guard. Remove brush guard.
BD05H168
STEP 3
Loosen the hose clamp for the after cooler at the
Remove the engine compartment side doors. turbocharger outlet, remove the after cooler tube.
STEP 4 STEP 7
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BD05H169
BD05H165
Loosen the clamps on the air cleaner hose, remove Loosen the hose clamp at the engine intake.
the hose. Disconnect the electrical connectors from
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the air cleaner restriction indicator switch.

STEP 8
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STEP 5
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BD05H166
Loosen the hose clamp at the after cooler outlet,

BD05H167 remove the after cooler tube.
Loosen the hose clamp on the after cooler inlet.

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2000-10
STEP 9 STEP 14
Attach lifting equipment to the hood.
STEP 10
BD05H104
Disconnect the wires from the alternator.
BD05H163 STEP 15
Remove the two nuts and washers (2) from the rear
of the engine hood.
STEP 11
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2 BD05H103
Disconnect the battery cable and the wiring harness

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wires from the starter.

BD05H164
Remove the four bolts (1), hood mounting bolts (2), STEP 16
and the radiator wrap brace (3).
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STEP 12
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Remove the hood, air filter, and after cooler from the
machine.
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STEP 13
If machine is equipped with a heater, loosen the
clamp and disconnect heater hoses, plug the hose to
prevent loss of coolant.
BD05H172
Discharge the air conditioning system, see section

9004. Disconnect the electrical connector for the
clutch and the compressor hoses. Plug the hoses
and cap the fittings.

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2000-11
STEP 17 STEP 22
BD05H170 BD05H162
Disconnect the electrical connector from the engine Remove the rear engine mounting bolts.
controller.
STEP 23
STEP 18
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BD05H161
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BD05H171
Remove the front engine mounting bolt.
Shut off the fuel valve (1). Disconnect the fuel line
from the valve (2) and the engine (3). STEP 24
Raise the engine slightly. Move engine forward, slip
STEP 19
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the drive shaft off of the hydrostat pumps and until

NOTE: Tilt the ROPS cab or canopy, see section engine clears the fire wall.
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9008.
STEP 25
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Disconnect grounding cable from the bell housing.

Remove the engine from the machine.
STEP 20
The wiring harnesses and the heater hoses (if
e q u i p p e d ) c a n b e p u l l e d i n t o t h e hy d r o s t a t
compartment and moved out of the way.
STEP 21
Attach lifting equipment to the engine.

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2000-12
Installation STEP 30
STEP 26
Connect suitable lifting equipment to lifting eyes on
the engine. Raise the engine and move into position
on machine. Move engine rearward, slip the drive
shaft onto the hydrostat pumps. Carefully lower the
engine into machine.
STEP 27
BD05H172
Connect the compressor hoses and clutch electrical

connector.
STEP 31
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Install the front engine mount bolt and nut, torque to

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205 to 230 Nm (151 to 170 pound-feet).
STEP 28
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BD05H103
Connect the battery cable to the starter solenoid and

torque to 22.5 to 29.4 Nm (16.5 to 21.6 pound-feet).
Push the rubber boot onto the terminal. Connect the
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ignition switch wire to the bottom of the star ter

solenoid and torque to 2.6 to 4.6 Nm
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(23 to 41 lb-in).
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STEP 32
BD05H162
Install the rear motor mounting bolts and nuts, torque

t o 2 0 5 t o 2 3 0 N m ( 1 5 1 t o 1 7 0 p o u n d - fe e t ) .
Disconnect lifting equipment from engine lifting eyes.
STEP 29
Install the grounding cable to the bell housing.
NOTE: Lower the ROPS cab or canopy, see section
9008.
BD05H104
Connect the wires to the alternator.

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2000-13
STEP 33 STEP 37
1 1
3
2
2
3
BD05H171 BD05H164
Connect the fuel line to the valve (2) and the engine Install the radiator wrap brace (3), four mounting
(3). Turn the fuel valve (1) on. bolts (1), hood mounting bolts (2), tighten the bolts.
STEP 34 STEP 38
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BD05H163
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BD05H170 Install the two nuts and washers for the rear of the
Connect the electrical connector from the engine engine hood, tighten the nuts.
controller.
STEP 39
STEP 35
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Remove the plug from the heater hoses (if equipped)

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and connect the heater hoses and tighten the

clamps.
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STEP 36
Install the hood, air filter, and after cooler on the
machine. Align the rear mounting bolts into the
bushings.
BD05H167
Install the after cooler tube, tighten the hose clamp

on the after cooler inlet.

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2000-14
STEP 40 STEP 43
BD05H168. BD05H169
Tighten the hose clamp for the after cooler at the Install and the air cleaner hose, tighten the hose
turbocharger outlet. clamps. Connect the electrical connectors to the air
cleaner restriction indicator switch.
STEP 41
STEP 44
Install the engine compartment side doors.
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STEP 45
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Install the radiator, see procedures this section.
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STEP 46
If equipped with a brush guard, connect suitable
lifting equipment to brush guard and move into
position. Install the two lower bolts, lock nuts, and
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washers. Install the two upper bolts and washers.

Torque the upper bolts to 570 to 730 Nm
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BD05H165 (420 to 540 pound-feet).

Install the after cooler tube, tighten the hose clamp at
the engine intake. STEP 47
Check and ensure that the engine has been filled
STEP 42
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with the correct engine oil, see section 1002.

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STEP 48
Start engine and run at low idle. Check for leaks.
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Check that gauges show the correct indications.
STEP 49
If equipped, see section 9004 and charge the air
conditioning system.
BD05H166
Tighten the hose clamp at the after cooler outlet.

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

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

holes and insure that the clamps are tight.
STEP 5
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BD05H102
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Inspect the turbocharger flex hose for leaks or holes
and insure that the clamps are tight.
STEP 4
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BD05H097
Inspect the intake manifold flex hose for leaks or

STEP 6
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Visually inspect top of after cooler for damage or

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leaks
NOTE: If the leak source has not been located,
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remove and test the after cooler.

BD05H101
Inspect the after cooler inlet flex hose for leaks or


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

BD05H102
Loosen clamps on the turbocharger outlet hose. STEP 5

Have an assistant hold the after cooler in place while
STEP 2 removing the mounting bolts.
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STEP 6
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BD05H101
Loosen clamps and remove air cooler inlet hose.

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STEP 3 BD05H099
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Remove the two bolts on the left side of the after

cooler.
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BD05H097
Loosen clamps and remove Intake hose.

Copyright ©
2003-5
STEP 7 Leak Test
BD05H100
Remove two bolts from the right side of the after

cooler.
BS03B028
STEP 8 Check the core for leaks by closing off the outlet tube
Lower the after cooler and remove it from the and attaching regulated air pressure 550kPa (80psi)
machine. to the inlet tube. Submerge the cooler in water and
watch for air leakage.
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NOTE: If leakage is detected replace the after
IN
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2003-6
Installation STEP 5
STEP 1
Have an assistant hold the after cooler in place while
installing the mounting bolts.
STEP 2
BD05H101
Tighten clamps at air cooler inlet.
STEP 6
BD05H099
Install two left side mounting bolts
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STEP 3
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BD05H097
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Install air cooler outlet hose and tighten clamps at

engine intake.
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STEP 7
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BD05H100
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Install two right side mounting bolts.
STEP 4
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BD05H098
Tighten clamps at air cooler outlet.
BD05H102
Install air cooler inlet hose. Tighten clamps at

turbocharger outlet.

Copyright ©
SECTION INDEX
FUEL SYSTEM

For Fuel System Repair, See the Engine Repair Manual 87519803
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Copyright ©
SECTION INDEX
ELECTRICAL SYSTEM

Removal and Installation of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001
Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
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Copyright ©
4001
Section
4001
REMOVAL AND INSTALLATION OF

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

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

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of the way while installing the drive belt on the

alternator pulley. Make sure that the drive belt is
BD05H105
seated in the grooves in each of the pulleys.
10. Lift up on the breaker bar to release the belt
tension, and remove the drive belt from the 7. Install the right-hand side lower panel.
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alternator pulley.
8. Close the right-hand engine side panel.
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9. Put the battery disconnect switch in the on

position.
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1
10. Close the left rear ROPS door.
instrument panel.
BD05H104
11. Remove the nut (1) and lock washer. Disconnect

the wire from the terminal.
12. Lift the lever and disconnect the wiring harness
wire from the alternator.

Copyright ©
4001-5
DRIVE BELT REPLACEMENT

1. Park the machine on a level surface. 10. Lift up on the breaker bar to release the belt
tension while removing the old drive belt.
2. Lower the attachments to the floor.
11. Use the breaker bar to hold the tension pulley out
of the way while installing the new drive belt on
remove the key from the ignition switch.
the pulleys. Make sure that the drive belt is
4. Fasten a Do Not Operate tag to the instrument seated in the grooves in each of the pulleys.
panel.
12. Install the right-hand side lower panel.
5. Open the left rear ROPS door.
13. Close the right-hand engine side panel.
position.
instrument panel.
7. Open right-hand side engine panel.
8. Remove the right-hand side lower panel.
9. Put a 12.7 (1/2 inch) drive breaker bar in the
bracket for the automatic belt tensioner.
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BD05H105
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4001-6
PARKING BRAKE PROXIMITY SWITCH ADJUSTMENT
BD02H047
Using a feeler gauge adjust clearance of proximity

switch to 1 to 3 MM. (0.040 to 0.118 in). Recheck
switches.
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4002
Section
4002
ELECTRICAL SPECIFICATIONS
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4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL SYSTEM WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MAIN ELECTRICAL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ignition Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Start Sensing Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fleet Relay (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Accessory Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuse Block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
T
Fuse Block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
IN
Decelerator Pedal Low Idle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Decelerator Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PR
Brake Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Tilt Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Left Parking Brake Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Right Parking Brake Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Drivetrain Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
R
Left Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Right Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FO
Left Motor Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Right Motor Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Right Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Left Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
T
Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Reverse Ratio Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
O
Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
N
Equipment Valve Hydraulic Safety Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Equipment Valve Blade Control Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Equipment Valve Blade Lift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Equipment Valve Blade Lower Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Equipment Valve Tilt Left Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Tilt Right Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Twist Left Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment Valve Twist Right Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Ripper Joystick (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Ripper Lower Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Valve Ripper Lift Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Enter Escape Instrument Cluster Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Up Down Menu Instrument Cluster Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Instrument Cluster Connector A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Instrument Cluster Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Copyright ©
4002-3
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydrostat Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Transmission Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front Floodlight/Monitor Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rear Floodlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Front Floodlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Front Floodlights (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Rear Floodlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Injector Driver Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Injector Number 1 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
T
IN
Engine Sensors Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Crankshaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PR
Camshaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
R
Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FO
Optional ROPS Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Optional Air Suspension Seat - Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fleet Tracker Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
T
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

O
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Accessory Power Jack 12 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power Converter 24 volts to 12 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
N
Cab Interior Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cab Interior Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Temperature Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
HVAC Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Blower Motor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Condenser Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Low Pressure AC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
High Pressure AC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Front and Rear Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Front Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rear Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Front and Rear Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Front and Rear Windshield Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Left and Right Hand Door Windshield Wiper Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Copyright ©
4002-4
Left Hand Door Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Right Hand Door Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Left and Right Hand Door Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Left and Right Hand Door Windshield Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
USING BOOSTER BATTERIES TO START THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Copyright ©
4002-5
SPECIFICATIONS
Electrical System ..................................................................................................................24 Volt Negative Ground
Battery (Two Batteries Connected in Parallel)
Group Size .......................................................................................................................................... 31-700CCA
Reserve Capacity ............................................................................................................................... 170 Minutes
Cold Cranking Capacity
at 0° F (-17° C) ............................................................................................................................ 700 Amperes
at -20° F (-29° C) ........................................................................................................................ 520 Amperes
Load for Capacity (load) Test ................................................................................................................ 350 Amperes
Alternator ......................................................................................................................................24 Volt 65 Amperes
Starter.................................................................................................................................24 Volt Solenoid Actuated
NOTE: During inspection of connectors look for moisture, burnt, corroded or bent pins. For troubleshooting
procedures on the drivetrain control module and hydrostat controlling components see Section 6003.
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IN
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Copyright ©
4002-6
ELECTRICAL SYSTEM WIRE IDENTIFICATION
Wire and Connector Identification Codes

Wire Identification
M3/A7 A7 is pin ID in the connector
100 - Cluster 500 - 12 Volt
Connector Identification 200 - Drivetrain 800 - A/C
C - Micro M - Main 300 - Engine 900 - Menu Sw
D - Dash P - Pumps and Motors 400 - Joysticks
M3 connector ID E - Engine V - Valve
L - Lighting SA - Splice
Wire
From To
Identification
ACC M18 M19
ACC M19 RESISTOR
BATT+ M17 SA-9
BATT+ SA-9 M3/AA1
BATT+ SA-9 M3/AA2
BATT+ SA-9 M3/AA3
T
BATT+ SA-9 M3/AA4
IN
BATT+ SA-9 M3/AA5
BATT+ SA-9 M3/AA6
PR
IGN+ M2/B3 SA-10
IGN+ SA-10 M2/D2
IGN+ SA-10 M3/AA8
IGN+ SA-10 M3/AA9
R
IGN+ SA-10 M3/AA1

FO
IGN 1 C1/13 SA-7

IGN 1 C1/41 SA-7
IGN 1 C1/42 SA-7
IGN 1 SA-7 C4/7
T
IGN 1 M10/7 SA-2

O
IGN 1 SA-2 M7/A

IGN 1 SA-2 M8/A
N
IGN 1 SA-2 M3/A1

IGN 1 SA-2 M9/1
IGN 1 SA-2 M9/5
IGN 2 M3/A9 M10/16
IGN 2 C4/16 SA-2
IGN 2 SA-2 C1/27
IGN 2 SA-2 C1/1
IGN 2 SA-2 C9/A
IGN 3 M1/15 SA-4
IGN 3 SA-4 M3/A8
IGN 3 SA-4 M11/27
IGN 3 E1/27 E2/40
START D2B/17 D14

Copyright ©
4002-7

Wire Identification
Wire
From To
Identification
START D14 D1/13
START M1/13 M2/B10
V1acc M2/A2 M10/42
V1acc C4/42 SA-10
V1acc SA-10 C5/9
V1acc SA-10 C7/A
V1acc SA-10 C16/1
T
V1acc SA-10 C14/2
V1acc SA-10 C17/1
IN
V1acc P1/9 SA-2
V1acc SA-2 P5/2
PR
V1acc SA-2 P6/2
V1acc SA-2 P10/A
V1acc V1/A V25/A
R
V2acc M2/A3 SA-3

V2acc SA-3 M13/A
FO
V2acc SA-3 M22/A

W E4 E1/16
W M11/16 M16/5
T
0-D D15 SA-1

0-D SA-1 D1/34
O
0-D M1/34 M4
N
0-D M4 SA-1
0-D SA-1 M16/6
0-D 2A/6 SA-1
0-D SA-1 D1/39
0-D M1/39 M4
0-D SA-1 M16/8
0-D 2A/12 SA-1
0-D SA-1 D1/40
0-D M1/40 M4
0-D SA-1 M9/2
0-D 2B/15 SA-1
0-D SA-1 M22/B
0-D 2B/22 SA-1
0-D SA-1 M7/C

Copyright ©
4002-8

Wire Identification
Wire
From To
Identification
0-D SA-1 M8/C
0-D SA-1 M13/B
0-D SA-1 M15
0-D SA-1 M14/B
0-D SA-1 M20
0-E E2/5 SA-1
0-E SA-1 SA-3
T
0-E SA-3 E7/8
0-E SA-4 E10/B
IN
0-E E2/6 SA-1
0-E SA-3 E3
PR
0-E E3 SA-4
0-E SA-4 E5/B
0-E E2/10 SA-1
R
0-E SA-4 E5/A

0-E E2/11 SA-1
FO
0-E E11/3 SA-1

0-L SA-6 L1/10
0-L C8/10 C19
T
0-L C19 C9/B

0-L C13 C22
O
0-L SA-6 L1/11

N
0-L C8/11 C19

0-L C19 C12/B
0-L C13 C17
0-L L3/2 L14
0-L L14 SA-6
0-L SA-6 L1/12
0-L C8/12 C19
0-L C19 C3/A
0-L C13 C16
0-L L2/2 SA07
0-L DA07 L14
0-L L14 SA-1
0-L SA-1 L4/2
0-L C19 C1/2

Copyright ©
4002-9

Wire Identification
Wire
From To
Identification
0-L C13 C15
0-L L11/B SA-7
0-L SA-1 L5/2
0-L C19 C1/28
0-L C13 C20
0-L L8 SA-7
0-L SA-1 L6/2
T
0-L C19 C13
0-L C13 C14
IN
0-L SA-1 L7/2
0-L C13 C14
PR
0-L SA-1 L15/5
0-L SA-1 L10/C
0-P+V P9/B P2
R
0-P+V P2 P1/X
0-P+V V1/X SA-1
FO
0-P+V SA-1 V21/2

0-P+V P8/2 SA-1
0-P+V SA-1 P2
T
0-P+V SA-1 V24/2

0-P+V P3/1 SA-1
O
0-P+V SA-1 V23/B

N
0-P+V P3/4 SA-1

0-P+V SA-1 V9
0-P+V P4/1 SA-1
0-P+V P4/4 SA-1
0-P+V P7/2 SA-1
15 D14 D1/12
15 M1/12 SA-8
15 SA-8 M2/B8
15 SA-8 M14/A
30 D14 D1/4
30 M1/4 M3/A2
50 D14 D1/11
50 M1/11 M2/B2
103 D2A/24 D1/35

Copyright ©
4002-10

Wire Identification
Wire
From To
Identification
103 M1/35 M11/11
103 E1/11 E7/A
104 D2B/11 D1/27
104 M1/27 M10/46
104 C4/46 C5/2
104 P1/2 P10/H
104 V1/H V12
T
111 D2B/6 D12/1
114 D2B/2 D12/3
IN
118 D2B/8 D11/1
120 D2A/2 D1/25
PR
120 M1/25 M10/30
120 C4/30 C5/5
120 P1/5 P10/M
R
120 V1/M V23/A

121 D2A/5 D1/33
FO
121 M1/33 M10/29

121 C4/29 C5/3
121 P1/3 P10/K
T
121 V1/K V11

125 D2B/7 D11/3
O
133 D2B/5 D1/6

N
133 M1/6 M10/31

133 C4/31 C5/6
133 P1/6 P9/A
134 D2B/3 D1/36
134 M1/36 M10/34
134 C4/34 C5/4
134 P1/4 P10/O
134 V1/O V10
135 D2A/13 D15
204 C1/4 C5/12
204 P1/12 P4/2
205 C1/5 C5/1
205 P1/1 P10/B
205 V1/B V9

Copyright ©
4002-11

Wire Identification
Wire
From To
Identification
206 C1/6 C4/48
206 M10/48 M2/B4
210 C7/B C1/10
211 C7/C C1/11
215 V24/1 V1/U
215 P10/U P1/16
215 C5/16 SA-4
T
215 SA-4 C1/15
215 SA-4 C1/29
IN
216 C1/16 C5/13
216 P1/13 P4/3
PR
217 C1/17 C5/10
217 P1/10 P6/3
218 C1/18 C5/11
R
218 P1/11 P6/1

219 M5/C M10/36
FO
219 C4/36 C1/19

223 M23/A M10/41
223 C4/41 C1/23
T
224 C3A/H C1/24

230 C1/30 C5/14
O
230 P1/14 P3/3

N
231 C1/13 C5/15

231 P1/15 P3/2
237 C1/37 C4/13
237 M10/13 M7/B
238 C6/C C1/38
243 C1/43 C5/8
243 P1/8 P5/3
244 C1/44 C5/7
244 P1/7 P5/1
248 C1/48 C5/17
248 P1/17 P10/V
248 V1/V V25/B
250 C3A/G C1/50
251 C3A/F C1/51

Copyright ©
4002-12

Wire Identification
Wire
From To
Identification
252 C3A/J C1/52
256 C2/56 C4/11
256 M10/11 M6/B
260 C2/60 C4/19
260 M10/19 M8/B
262 C2/62 C4/12
262 M10/12 M5/B
T
264 C2/64 C6/B
265 C2/65 C4/20
IN
265 M10/20 M6/C
268 C2/68 C5/31
PR
268 P1/31 P7/1
269 C2/69 C5/32
269 P1/32 P8/1
R
271 C12/A C2/71

272 C2/72 C5/18
FO
272 P1/18 P10/D

272 V1/D V21/1
279 M6/A M10/18
T
279 C4/18 SA-8

279 SA-8 C2/79
O
279 SA-8 C6/A

N
280 C2/80 C4/43

280 M10/43 SA-11
280 SA-11 M23/B
280 SA-11 M5/A
302 M3/A5 M11/1
302 E1/1 SA-2
302 SA-2 E11/2
302 SA-2 E2/2
302 SA-2 E2/3
302 SA-2 E2/8
302 SA-2 E2/9
312 M12 M11/23
312 E1/23 E2/12
317 M3/D1 M11/21

Copyright ©
4002-13

Wire Identification
Wire
From To
Identification
317 E1/21 E2/17
329 M2/D10 M11/24
329 E1/24 E2/29
332 M2/B9 M11/25
332 E1/25 E2/32
334 D2A/4 D1/16
334 M1/16 SA-6
T
334 SA-6 M10/45
334 C4/45 SA-6
IN
334 SA-6 C1/39
334 SA-6 C3/D
PR
334 SA-6 M9/3
334 SA-6 M11/18
334 E1/18 E2/34
R
335 D2A/3 D1/26

335 M1/26 SA-5
FO
335 SA-5 M11/20

335 SA-5 M10/44
335 SA-5 M9/4
T
335 E1/20 E2/35

335 C4/44 SA-5
O
335 SA-5 C1/40

N
335 SA-5 C3A/E

337 M3/B2 M11/26
337 E1/26 E2/37
342 E11/1 E2/42
375 M12 M11/28
375 E1/28 E2/75
389 C3A/E C4/39
389 M10/39 M11/29
389 E1/29 E2/89
415 C10/7 C17/5
416 C10/12 C17/6
417 C10/11 C17/7
418 C17/8 C16/6
419 C17/9 C16/5

Copyright ©
4002-14

Wire Identification
Wire
From To
Identification
421 C18/1 C5/22
421 P1/22 P10/W
421 V1/W V16/1
422 C18/2 C5/23
422 P1/23 P10/J
422 V1/J V15/1
423 C18/3 C5/24
T
423 P1/24 P10/L
423 V1/L SA-2
IN
423 SA-2 V15/2
423 SA-2 V16/2
PR
424 C18/4 C5/19
424 P1/19 P10/P
424 V1/P V13/1
R
425 C18/5 C5/20

425 P1/20 P10/Q
FO
425 V1/Q V14/1

426 C18/6 C5/21
426 P1/21 P10/S
T
426 V1/S SA-5

426 SA-5 V13/2
O
426 SA-5 V14/2

N
427 C18/7 C5/25

427 P1/25 P10/G
427 V1/G V17/1
428 C18/8 C5/26
428 P1/26 P10/E
428 V1/E V18/1
429 C18/9 C5/27
429 P1/27 P10/R
429 V1/R SA-3
429 SA-3 V17/2
429 SA-3 V18/2
451 C21/1 C5/28
451 P1/28 P10/T
451 V1/T V19/1

Copyright ©
4002-15

Wire Identification
Wire
From To
Identification
452 C21/2 C5/29
452 P1/29 P10/N
452 V1/N V20/1
453 C21/3 C5/30
453 P1/30 P10/F
453 V1/F SA-4
453 SA-4 V19/2
T
453 SA-4 V20/2
501 M3/A6 M10/28
IN
501 C4/28 SA-9
501 SA-9 C8/6
PR
501 L1/6 L8
501 SA-9 C14/1
501 SA-9 C3A/B
R
504 C15 SA-12

504 SA-12 C8/8
FO
504 L1/8 L15/17

504 SA-12 C14/4
505 C14/5 C8/9
T
505 L1/9 L15/12

800 L9 L13/10
O
800 L9 L1/5
N
800 C8/5 C4/23

800 M10/23 M2/A9
811 L10/B L13/1
813 L12 L13/3
814 L12 L13/4
815 L12 L13/5
816 L12 L13/6
817 L11/3 SA-5
817 SA-5 L9
817 SA-5 L13/7
818A L13/8 L1/4
818A C8/4 C23/A
818B E12/A E1/12
818B M11/12 M10/15

Copyright ©
4002-16

Wire Identification
Wire
From To
Identification
818B C4/15 C23/B
818C E12/B E6
819 L10/A SA-8
819 L13/9 SA-8
819 L11/A SA-8
819 SA-8 L1/7
819 C8/7 C4/26
T
819 M10/26 M2/A1
899 L9 L12
IN
912 D5/2 D1/5
912 M1/5 M2/A6
PR
921 D2B/12 D6/1
921 D6/1 D1/14
921 M1/14 M10/21
R
921 C4/21 C8/3

921 L1/3 SA-2
FO
921 SA-2 L2/1

921 SA-2 L3/1
922 D6/2 D1/3
T
922 M1/3 M2/A4

931 D7/1 D4
O
932 D7/2 D4
N
933 D4 D9/6
933 D9/6 D8/2
933 D8/2 D7/3
933 D7/3 D1/21
933 M1/21 SA-7
933 SA-7 M15
933 SA-7 M2/A5
934 D7/4 D1/22
934 M1/22 M10/47
934 C4/47 C20
935 D7/5 D1/23
935 M1/23 M10/38
935 C4/38 C20
943 D8/3 D1/32

Copyright ©
4002-17

Wire Identification
Wire
From To
Identification
943 M1/32 M11/14
943 E1/14 E5A/1
951 D9/1 D1/17
951 M1/17 M15
952 D9/2 D1/7
952 M1/7 M15
953 D10/2 D9/3
T
953 D9/3 D7/6
953 D7/6 D1/31
IN
953 M1/31 SA-12
953 SA-12 M10/3
PR
953 SA-12 M2/A7
953 C4/37 SA-11
953 SA-11 C22
R
953 SA-11 C20

954 D9/4 D1/38
FO
954 M1/38 M10/14

954 C4/14 C22
955 D9/5 D1/28
T
955 M1/28 M10/8

955 C4/8 C22
O
963 D10/3 D1/18

N
963 M1/18 M11/13

963 E1/13 E5B/1
992 M3/A4 M1/37
992 D1/37 D11/2
992 D11/2 D12/2
992 D11/2 D2B/14
992 D12/2 D13/2
992 D13/2 D2B/2
993 D13/3 D1/8
993 M1/8 M11/7
993 E1/7 E10/A
4111 D2B/10 D1/10
4111 M1/10 M10/10
4111 C4/10 C17/11

Copyright ©
4002-18

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

911B SA-4 L7/1
FO
T
O
N

Copyright ©
4002-19
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Example 1
Front, right side of the engine. 2
Check Points Reading Possible Cause of Bad Reading
3
Check the 10 ampere fuse at
4 5
location 3 and 4C in the fuse block.
Good Bad fuse.
(See fuse and relay location on
page 4.)
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 24 Volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the alternator.
6
1. This title is the component name.

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

Copyright ©
4002-20
MAIN ELECTRICAL SYSTEM TROUBLESHOOTING

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

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

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

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


T
Bad wire 1A between the alternator and the battery terminal of

O
B+ terminal for wire 1A to ground. 24 Volts the starter (5). Bad cable between the battery terminal of the
starter and the positive post of the battery (1).
N
NOTE: Put the ignition switch in the RUN position.
D+ terminal to ground. 24 Volts Bad wire from instrument cluster to the alternator.

Copyright ©
4002-21
4 – Ignition Switch
Dash panel.
NOTE: Disconnect the connector from the ignition switch. Turn the ignition switch to the RUN position.
Between the BATT and the RUN
Continuity Bad ignition switch.
terminals of the ignition switch.
Between the BATT and the ACC
NOTE: Hold the key switch in the START position.

Between the BATT and all other
5 – Starter
Lower right side of the engine.
T
Terminal for battery positive wire to Bad cable between the battery terminal of the starter and the
24 Volts
ground. positive post of the battery (1).
IN
NOTE: Put the directional control in the neutral position and the parking brake control levers in the applied
position. Have another person hold the ignition switch in the START position.
PR
Bad wire 21D between the starter and the starter relay. Bad
Terminal for wire W (21D) to ground. 24 Volts
starter relay (9).
R
6 – Starter Solenoid
FO
Right rear side of the engine compartment.


T
Terminal e to ground. Continuity Bad ground circuit.

O
NOTE: Put the directional control in the neutral position and the parking brake control levers in the applied
position. Have another person hold the ignition switch in the START position.
N
Bad wire 21D between the starter solenoid and the starter relay
Terminal for wire W (21D) to ground. 24 Volts
(9).
Terminal B to ground. 24 Volts Bad starter solenoid.

Copyright ©
4002-22
7 – Ignition Relay
Left ROPS side panel.
Terminal 86 to ground. Continuity Bad ground circuit.
Bad fuse F13, bad wire 21A between the relay and fuse panel
Terminal for wire R (21A) to ground. 24 Volts
B.
NOTE: Place the ignition switch in the ON position.
Terminal for wire BR (50) to ground. 24 Volts Bad wire BR (50) to ignition switch, bad ignition switch (4).
Terminal 87 to ground. 24 Volts Bad ignition relay.
8 – Safety Relay
T
IN
PR
NOTE: Put the ignition switch in the RUN position and the parking brake control levers in the APPLIED position.
Bad wire to drivetrain control module, bad drivetrain control
Terminal for wire P (206) to ground. 24 Volts
module (24), bad proximity switches (21, 22, and 23).
NOTE: If power is not present check fuse F19 and F20.

R
FO
9 – Starter Relay
T

O

N
NOTE: Put the ignition switch in the RUN position and the parking brake control levers in the APPLIED position.
Terminal for wire P (21C) to ground. 24 Volts Bad wire 21C to safety relay, bad safety relay (8).
NOTE: Put the ignition switch in the START position.
Terminal for wire O (337) to ground. 24 Volts Bad wire 337 to engine controller, bad engine controller.
NOTE: If power is not present check fuse F15 and F18.

Copyright ©
4002-23
10 – Start Sensing Relay

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

T
IN

PR
Check fuse F12. Bad wire between fleet relay and ignition switch
Terminal for wire BL (15) to ground. 24 Volts
Bad ignition switch (4).
R
12 – Accessory Relay
FO


T
Terminal for wire 0 to ground. Continuity Bad ground circuit.

O

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

Copyright ©
4002-24
13 – Grid Heater Relay

Engine compartment.

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

PR
Negative terminal to ground Continuity Bad ground circuit.
Positive terminal of grid heater to Resistance If an open or short circuit is obtained, replace the grid heater.
ground
R
FO
15 – Fuse Block A
Left side ROPS access panel.
T
Check and replace fuses as required.

O
16 – Fuse Block B
N
Left side ROPS access panel.

Check and replace fuses as required.

Copyright ©
4002-25
17 – Throttle Potentiometer
Left console.
NOTE: The purpose of this check is only for the power and grounding circuit. For additional adjustments of the
throttle potentiometer see Section 9001.
NOTE: Disconnect the connector at the throttle potentiometer, put the master disconnect in the ON position and
the ignition switch in the RUN position.
Bad wire GY (238) to drivetrain controller, bad drivetrain
Terminal for wire GY (238) to ground. Continuity
controller, bad ground circuit.
Bad wire W (279) to drivetrain controller, bad drivetrain
controller, bad power circuit, check fuse F20.
18 – Decelerator Pedal Low Idle Switch

Right foot pedal.
throttle potentiometer see Section 9001.
T
IN
NOTE: Disconnect the connector at the pedal low idle switch, put the master disconnect in the ON position and
the ignition switch in the RUN position.
PR
Bad wire 0 (223) to drivetrain controller, bad drivetrain
Terminal for wire 0 (223) to ground. Continuity
Bad wire Y (280) to drivetrain controller, bad drivetrain
Terminal for wire Y (280) to ground. 5 Volts
R
FO
19 – Decelerator Pedal Potentiometer

Right foot pedal.
T
decelerator potentiometer see Section 9001.

O

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

Copyright ©
4002-26
20 – Brake Pedal Potentiometer

Center foot pedal.
brake potentiometer see Section 9001.
NOTE: Disconnect the connector at the brake pedal potentiometer, put the master disconnect in the ON position
and the ignition switch in the RUN position.
Bad wire P (256) to drivetrain controller, bad drivetrain
Terminal for wire P (256) to ground. Continuity
Bad wire W (279) to drivetrain controller, bad drivetrain
21 – Tilt Proximity Switch

Left side ROPS panel.
T
NOTE: Lower ROPS, disconnect proximity switch.
Between the cavities of switch Continuity Switch out of adjustment, bad proximity switch
IN
NOTE: Using a feeler gauge, adjust clearance of proximity switch to 1 to 3 MM. (0.040 to 0.118 in). Recheck
switch.
PR
Terminal for wire R (1002) to ground. Continuity Bad ground circuit.
R

Terminal for wire GY (1003) to Bad wire GY (1003) between the tilt proximity switch and fuse
FO
24 Volts
ground. F19, bad fuse F19.
Terminal for wire BL (1001) to
24 Volts Bad tilt proximity switch.
ground.
T
O
22 – Left Parking Brake Proximity Switch

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

switch.


Terminal for wire BL (1001) to Bad wire BL (1001) between the brake proximity switch and tilt
24 Volts
ground. proximity switch, bad tilt proximity switch (21).
Terminal for wire W (237) to ground. 24 Volts Bad brake proximity switch.

Copyright ©
4002-27
23 – Right Parking Brake Proximity Switch

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

switch.


Terminal for wire BR (IGN) to Bad wire BR (IGN) between the brake proximity switch and fuse
24 Volts
ground. F19, bad fuse F19.
Terminal for wire V (260) to ground. 24 Volts Bad brake proximity switch.
24 – Drivetrain Control Module
T
IN
Left console access panel.
PR
NOTE: Disconnect the connector at the drivetrain controller, put the master disconnect switch in the ON position.
Terminal for wire 0, pin 2 and 28, to
Continuity Bad ground circuit.
ground.
R

Terminal for wire BR (IGN2), pin 1
FO
24 Volts Bad wire BR (IGN2) to fuse F20, bad fuse.

and 27, to ground.
NOTE: If all tests are good, replace drivetrain controller.

T
25 – Left Pump Solenoid

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

Copyright ©
4002-28
26 – Right Pump Solenoid

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

5.75 ±0.75
Between terminals 1 and 2 Ohm at Bad forward solenoid
25° C (77° F)
5.75 ±0.75
Between terminals 3 and 4 Ohm at Bad reverse solenoid
25° C (77° F)
27 – Left Motor Solenoid
T
Left motor.
IN
NOTE: Disconnect the connector at the left motor solenoid, on connector to the main harness.
PR
Less than 10
Terminal for wire 0, pin 2, to ground. Ohm at Bad ground circuit.
25° C (77° F)

R
5.75 ±0.75
FO
Between terminals 1 and 2 Ohm at Bad solenoid

25° C (77° F)
28 – Right Motor Solenoid

T
Right motor.
O

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

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

Copyright ©
4002-29
29 – Right Motor Speed Sensor

Right motor.
NOTE: Speed sensor can only be tested by the drivetrain controller, see section 6003 fault 4312.
30 – Left Motor Speed Sensor

Left motor.
NOTE: Speed sensor can only be tested by the drivetrain controller, see section 6003 fault 4311.
31 – Directional Control
Left console.
NOTE: The purpose of this check is only for the START circuit of the machine. For additional tests of the
directional control see Section 6003.
T
IN
NOTE: Disconnect the connector at the directional control. Put the directional control in the NEUTRAL position.
Between connectors 5 and 6 on
PR
Continuity Bad directional control.
directional control.
NOTE: DO NOT reconnect the directional control. Put the master disconnect switch in the ON position and the
ignition switch in the RUN position. Put the parking brake control levers in the applied position.
R
Cavity 1 and 5 of connector to Check fuse F19. Check wire BR (IGN) from directional control
24 Volts
ground. to fuse F19.
FO
32 – Reverse Ratio Switch

Left console.
T

O
NOTE: Disconnect the connector at the reverse ratio switch. Put the master disconnect switch and ignition switch
in the ON position.
N
Terminal for wire BL (V1ACC) to

24 Volts Check fuse F2.
ground.
NOTE: Place reverse ration switch in the second position.

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

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

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

Copyright ©
4002-30
33 – Brake Pressure Switch

Left ROPS side panel behind ROPS tilt cylinder.
NOTE: Put the master disconnect switch and ignition switch in the ON position. Disconnect the harness
connector for the brake pressure switch.
Terminal for wire BL (V1ACC) to
24 Volts Check fuse F2.
ground.
Between the connector pins of the
Open Bad pressure switch.
pressure switch connector.
WARNING: Start the engine, DO NOT place the directional control in the F or R position, move hand throttle to
½ throttle position.
Continuity Bad pressure switch.
NOTE: Hydrostatic charge pressure must be checked to make sure it is at proper pressure, see section 6002.
The pressure switch is normally open and closes at 11.4 to 12.8 Bar (165 to 185 psi).
T
34 – Brake Solenoid
IN
Left ROPS side panel behind ROPS tilt cylinder.
PR
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector for the brake
solenoid.
Check brake solenoid coil resistance 9 to 10 Ohm

R
between the connector cavities of the at 25° C Bad brake solenoid.

solenoid connector. (77° F)
FO
Main harness terminal for wire 0 to

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

Copyright ©
4002-31
35 – Equipment Valve Hydraulic Safety Solenoid Valve

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

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

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

FO
37 – Equipment Valve Blade Lift Solenoid

Right ROPS side panel.
T

O
NOTE: Disconnect the harness connector for the blade lift solenoid.
N
Check solenoid coil resistance

12 Ohm at 20°
between the connector cavities of the Bad solenoid.
C (68° F)
solenoid connector.
38 – Equipment Valve Blade Lower Solenoid

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

Copyright ©
4002-32
39 – Equipment Valve Tilt Left Solenoid

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

NOTE: Disconnect the harness connector for the blade tilt right solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.
T
41 – Equipment Valve Diagnostic Port
IN
PR
NOTE: Disconnect the harness connector C17 for the blade control joystick.
From pin 5 at joystick connector to
Ohm Bad wire or bad connector.
pin 12 of diagnostic port
R

FO

T
42 – Equipment Valve Twist Left Solenoid

O

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

Copyright ©
4002-33
43 – Equipment Valve Twist Right Solenoid

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

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

24 Volts Bad fuse F2, bad wire from joystick to fuse F2.
T
to ground
IN
NOTE: If joystick still does not function, replace joystick.
PR
45 – Equipment Valve Ripper Lower Solenoid (Option)
R
NOTE: Disconnect the harness connector for the ripper lower solenoid.
FO

12 Ohm at 20°
C (68° F)
solenoid connector.
T
46 – Equipment Valve Ripper Lift Solenoid (Option)

O

N
NOTE: Disconnect the harness connector for the ripper lift solenoid.
12 Ohm at 20°
C (68° F)
solenoid connector.

Copyright ©
4002-34
47 – Enter Escape Instrument Cluster Switch

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

Dash panel.
T
Terminal for wire R (992) to ground. 24 Volts Check fuse F14, bad wire from switch to fuse.
IN
NOTE: Push and hold switch in up or down position.

PR
49 – Instrument Cluster Connector A

R
Located on back of instrument cluster.

FO
Correct
Reading
NOTE: Disconnect the connector AIC-A from the instrument cluster.

T
Check fuse F18, bad ignition switch (4), bad wire from AIC-A to
Connector terminal 1 to ground 24 Volts
O
fuse F18.
Connector terminal 6 and 12 to

N

ground
50 – Instrument Cluster Connector B

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

ground

Copyright ©
4002-35
51 – Fuel Level Sender

Top of the fuel tank.
NOTE: Disconnect the wiring harness connector from the fuel level sender connector. Put the master disconnect
switch in the ON position.
Terminal of wire 0 to ground. Continuity Bad ground connection.

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

Bad fuel level sender.
level sender connector to ground. Ohm
T
NOTE: Connect connector to fuel level sender.
IN
7.0 to 9.0
volts (fuel
PR
Cavity for wire Y (120) at fuel level tank empty) -
Bad fuel level sender.
sender to ground. 1.5 to 3.5
volts (fuel
tank full)
R
FO
52 – Transmission Temperature Sender

Right rear ROPS filter access panel, lower hydraulic reservoir.
T
Check between the housing of the

transmission temperature sender Continuity Bad ground connection.
O
and housing hydraulic reservoir.

N
NOTE: Disconnect wire P (121) from the transmission temperature connector. Put the master disconnect switch
in the ON position and the ignition switch in the RUN position.
Bad wire P (121) between the transmission temperature sender
Wire P (121) to ground. 5 Volts and the instrument cluster connector A 5. Bad connectors.
Check the oil temperature gauge.
Check oil temperature gauge reading Low

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

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

Copyright ©
4002-36
53 – Air Filter Restriction Switch

Air cleaner outlet to the engine.
NOTE: Disconnect the wires from the air filter restriction switch.
Between terminals of air filter
Open Bad air filter restriction switch.
restriction switch.

Bad wire G (103) between air filter restriction switch and
Wire G (103) to ground. 24 Volts
instrument cluster connector A 24. Bad connector.
54 – Hydrostat Filter Restriction Switch

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

T
Right rear of hydrostat pumps.

O

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

Copyright ©
4002-37
56 – Hydraulic Filter Restriction Switch

Hydraulic filter housing behind right rear ROPS access panel.
Check between the hydraulic filter
restriction switch housing and the Continuity Bad ground connection.
filter housing.
NOTE: Disconnect wire W (104) from the hydraulic filter restriction switch terminal.
Hydraulic filter restriction switch
Open Bad hydraulic filter restriction switch.
terminal to ground.
Bad wire W (104) between hydraulic filter restriction switch and
Wire W (104) to ground. 24 Volts
the instrument cluster connector B 11. Bad connectors.
57 – Warning Buzzer
Front console.
T
IN
PR
NOTE: Put the ignition switch in the RUN position. If the buzzer does not sound, do the following checks.
Terminal for wire P (135) at warning
24 Volts Bad instrument cluster (49).
buzzer to ground.
R
NOTE: Turn the ignition switch OFF. Disconnect wires from warning buzzer terminals.
Between terminals of warning
FO
30 Ohm Bad warning buzzer

buzzer.
NOTE: If all readings are good, replace the warning buzzer.

T
58 – Front Floodlight/Monitor Light Switch

O
Dash panel.
N
NOTE: Put the master disconnect switch in the ON position, put the ignition switch in the RUN position.
Bad wire BL (912) between front floodlight/monitor light switch
and fuse F6, bad fuse. Bad accessory relay (12).
NOTE: Turn the front floodlight/monitor switch ON.

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

Copyright ©
4002-38
59 – Rear Floodlight Switch

Dash panel.
Bad wire BL (922) between front floodlight/monitor light switch
and fuse F4, bad fuse. Bad accessory relay (12).
NOTE: Turn the front floodlight/monitor switch ON.

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

PR
61 – Front Floodlights (Option)
R
Front of ROPS or CSF.

FO

T

O
62 – Rear Floodlights
N
Rear of ROPS or CSF.


Copyright ©
4002-39
63 – Backup Alarm
Right rear ROPS access panel for hydraulic filter.

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

PR
65 – Horn
Front RH side of the radiator.
R

FO
NOTE: Disconnect the wire 0 from the horn. Have another person hold down the horn button.
T
Horn terminal for wire 0 to ground. 24 Volts Bad horn.

O
Horn terminal for wire O (993) to Bad wire O (993) between the horn and horn button, bad horn
24 Volts
N
ground. button (64).

Copyright ©
4002-40
66 – Electronic Diesel Control

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

Located in the left side of the engine compartment on water separator housing, open engine compartment to gain access.
Correct
T
Reading
IN
Terminal for wire 0 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
PR
Terminal for wire R (302) to ground 24 volts Bad fuse F15, bad wire R (302).
NOTE: Remove sensor from filter and place probes in water.

R
Terminal for wire GY (342) to ground 24 volts Bad water separator sensor.
FO
68 – Injector Driver Connector

Located in the left side of the engine, open engine compartment to gain access.
T
Correct
Reading
O
NOTE: Disconnect connector from EDC-7 controller.

N
Check for moisture, burnt, corroded Repair as needed

or bent pins
69 – Injector Number 1 Cylinder

Correct
Reading
NOTE: Disconnect injector driver connector from EDC-7 controller
0.56 to 0.57
Between pins 13 and 4 Bad injector, bad wires from connector to injector.
Ohm

Copyright ©
4002-41

Correct
Reading
0.56 to 0.57
Ohm

Correct
Reading
0.56 to 0.57
Ohm
T
IN
PR
Correct
Reading

R
0.56 to 0.57
FO
Ohm

T
O
Correct
Reading
N
0.56 to 0.57
Ohm

Correct
Reading
0.56 to 0.57
Ohm

Copyright ©
4002-42
75 – Engine Sensors Connector

Correct
Reading
NOTE: Disconnect connector from EDC-7 controller.
Check for moisture, burnt, corroded Repair as needed

or bent pins
76 – Crankshaft Speed Sensor

Located on the front of the engine.
Correct
Reading
NOTE: Disconnect engine sensors connector from EDC-7 controller
Between pins 19 and 23 900 Ohm Bad sensor, bad wires from connector to sensor.
T
IN
77 – Camshaft Speed Sensor
Located on the left rear of the engine.
PR
Correct
Reading

R
Between pins 9 and 10 900 Ohm Bad sensor, bad wires from connector to sensor.
FO
78 – Rail Pressure Sensor

Located on the common rail of the engine.
T
Correct
Reading
O
NOTE: No information available at time of print.

N
79 – Coolant Temperature Sensor

Located on the front of the engine.
Correct
Reading
Between pins 15 and 26 2.50 Ohm Bad sensor, bad wires from connector to sensor.

Copyright ©
4002-43
80 – Oil Pressure Sensor

Located on the right front of the engine.
Correct
Reading
81 – Boost Pressure Sensor

Located on the right front of the engine.
Correct
Reading
82 – Fuel Temperature Sensor

Located on the left side of the engine.
T
Correct
IN
Reading

PR
Between pins 18 and 35 2.50 Ohm Bad sensor, bad wires from connector to sensor.
83 – Optional ROPS Heater

R
Operator’s compartment.
FO

T

O
Terminal for wire BL (V2ACC) to Bad wire BL (V2ACC) between ROPS heater and fuse F3, bad
24 Volts
N
ground. fuse.
NOTE: If readings are good, replace the ROPS heater.

Copyright ©
4002-44
84 – Optional Air Suspension Seat - Air Compressor

Operator’s compartment.

Terminal for wire BL (V2ACC) to Bad wire BL (V2ACC) between ROPS heater and fuse F3, bad
24 Volts
ground. fuse.
NOTE: If readings are good, replace the seat air compressor.
85 – Diagnostic Port
Left consule access panel for drive train controller.
T
Terminal for pin A to ground Continuity Bad ground circuit
IN
Bad wire R (501) between diagnostic port and fuse F15, bad
Terminal for wire R (501) to ground 24 volts
fuse.
PR
86 – Fleet Tracker Port
Left consule access panel for drive train controller.
R

FO
Terminal pin 6 and 8 to ground Continuity Bad ground circuit
Bad wire between fleet tracker port and fuse F1 and F10, bad
Terminal pin 1 and 7 to ground 24 volts
T
fuse.
O
87 – Right Speaker (Option)

N
Located in the cab.

Correct
Reading
NOTE: Disconnect connector from right speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (89) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the right speaker and the radio or a bad
Voltage
RSPK to ground radio (89).
Pin 2 in wiring harness connector Continuity Bad circuit between the right speaker and the radio (89).
RSPK to ground
NOTE: If the readings are good, replace the right speaker.

Copyright ©
4002-45
88 – Left Speaker (Option)

Located in the cab.
Correct
Reading
NOTE: Disconnect connector from left speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (89) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the left speaker and the radio or a bad
Voltage
LSPK to ground radio (89).
Pin 2 in wiring harness connector Continuity Bad circuit between the left speaker and the radio (89).
LSPK to ground
NOTE: If the readings are good, replace the left speaker.
89 – 12 Volt Radio Ready (Option)

Located in the cab.
Correct
T
Reading
IN
Terminal in radio connector for wire Continuity Bad ground circuit.
0 to ground
PR
NOTE: Put master disconnect switch and ignition switch in ON position.
Terminal in radio connector for wire Check fuse F2, also check circuit 12V. Also check the remote
12 volts
LB (505) to ground radio power converter (91).
R
Terminal in radio connector for wire Check fuse F2, also check circuit 12V. Also check the remote
12 volts
R (504) to ground radio power converter (91).
FO
90 – Accessory Power Jack 12 Volt

Left side console.
T

O

N
Terminal for wire R (504) to ground. Check fuse F2, also check circuit 12V. Also check the remote
12 Volts
power converter (91).

Copyright ©
4002-46
91 – Power Converter 24 volts to 12 volts

Located in the cab under right console cover.
Correct
Reading
Terminal for wires 0 to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position.
Terminal for wire R (501) to ground 24 volts Bad fuse F16, also check circuit R (501)
Terminal for wire R (504) to ground 12 volts Bad power converter
NOTE: Put ignition switch in ON position.
Terminal for wire BL (V1ACC). to Bad fuse F2, bad accessory relay (12), also check circuit BL
24 volts
ground (V1ACC).
Terminal for wire LB (505) to ground 12 volts Bad power converter
92 – Cab Interior Lamps Switch
T
Left and right headliners in cab.
IN

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

R
Positive connector at light to ground. 24 Volts Bad wire between light and switch. Bad switch.
FO
93 – Cab Interior Lamps

Left and right headliners in cab.
T

O
Between bulb contacts. Continuity Bad bulb.

N
NOTE: Turn the interior light switch on.
Terminal R (501) to ground. 24 Volts Bad wire R (501) to lamp switch, bad interior lamp switch (92).

Copyright ©
4002-47
94 – Temperature Control Switch

Top of cab.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the RUN position.
Bad wire BL (819) to fuse F9, bad fuse, bad accessory relay
(12).
NOTE: Turn the temperature control switch while measuring voltage.
Will this work?

Terminal for wire BL (811) to ground. Bad temperature control switch.
Varying Volts
95 – HVAC Mode Switch

Top of cab.
T
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the RUN position. Turn the
blower switch to the HIGH position.
IN
(12).
PR
NOTE: Turn the AC switch on.
Terminal for wire V (817) to ground. 24 Volts Bad HVAC mode switch.
R
96 – Blower Switch
FO
Top of cab.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the RUN position.
T
Terminal for wire Y (899) to ground. 24 Volts Bad wire Y (899) to mode switch, bad mode switch (95).
O
NOTE: Turn the blower switch to the LOW position.

N
Terminal L to ground. 24 Volts Bad blower switch.
NOTE: Turn the blower switch to the MEDIUM 1 position.
Terminal M 1 to ground. 24 Volts Bad blower switch.
NOTE: Turn the blower switch to the MEDIUM 2 position.
Terminal M 2 to ground. 24 Volts Bad blower switch.
NOTE: Turn the blower switch to the HIGH position.
Terminal H to ground. 24 Volts Bad blower switch.

Copyright ©
4002-48
97 – Blower Motor Housing

Rear of cab under consoles.
NOTE: No information at time of print.
98 – Condenser Blower Motor

Top rear of cab.

(12).
NOTE: Put the AC switch in the ON position. Put the blower switch in the HIGH position and turn the thermostat
T
switch to maximum cool.
IN
Terminal for wire V (817) to ground 24 volts Bad wire V (817) to mode switch, bad mode switch (95).
NOTE: If the tests are good and the condenser blower motor(s) do not work, replace the motor(s).
PR
99 – Low Pressure AC Switch
Located under right side rear conole in cab.
R

FO
NOTE: Switch opens at 14 to 42 kPa (2 to 6 psi) falling, switch closes at 117 to 159 kPa (17 to 23 psi) and rising.
Make sure AC system is at operating pressure.
Between terminal of switch Continuity Bad switch.

T
O
100 – High Pressure AC Switch

N
Located on the compressor output hose left sied of engine.

NOTE: Switch opens at 2689 to 2827 kPa (390 to 410 psi) rising, switch closes at 1654 to 1792 kPa (240 to 260
psi) and falling. Make sure AC system is at operating pressure.
Between terminal of switch Continuity Bad switch.

Copyright ©
4002-49
101 – Compressor Clutch

Air compressor on the left side of the engine.
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the RUN position and the
AC switch in the ON position. Put the blower switch in the HIGH position and turn the thermostat switch to
maximum cool.
+ terminal on compressor clutch to Bad wire between clutch and high/low pressure switches, bad
24 Volts
ground. switches.
NOTE: If the test is good and the clutch does not work, replace the clutch coil.
102 – Front and Rear Windshield Wiper Switch

Front dash panel.
Terminal for wire BL (933) and wire Bad wire BL (933) or wire BL (953) to fuses F5 and F7, bad
24 Volts
T
BL (953) at wiper switch to ground. fuse. Bad accessory relay (12).
IN
NOTE: Turn the wiper switch ON.
Terminal for pin 2 and pin 5, to
24 Volts Bad wiper switch.
ground.
PR
103 – Front Windshield Wiper
R
Front windshield.
FO

T

O
Bad wire BL (933) to fuse F5, bad fuse. Bad accessory relay
Terminal for wire BL (933) 24 Volts
(12).
N

Terminal for wire V (932) at wiper Bad wire from wiper switch to wiper motor, bad wiper switch
24 Volts
motors to ground. (102).
NOTE: If the tests are good and the wiper does not work, repair or replace the wiper motors.

Copyright ©
4002-50
104 – Rear Windshield Wiper

Rear windshield.

(12).

24 Volts
105 – Front and Rear Windshield Washer Switch
T
Front dash panel.
IN
PR
(12).
NOTE: Have another person push and hold the washer switch in the ON position.
R
Terminal for wire B (943) at washer

24 Volts Bad washer switch.
switch to ground.
FO
106 – Front and Rear Windshield Washer

Left engine compartment door.
T

O

N
Terminal for wire O to ground. Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have another person push and hold the washer switch in the
ON position.
Terminal for wire B (943) at washer
24 Volts Bad wire B (943), bad washer switch (105).
motor to ground.
NOTE: If the tests are good and the washer pump does not work, repair or replace the washer pump.

Copyright ©
4002-51
107 – Left and Right Hand Door Windshield Wiper Switch Assembly
Front dash panel.
Terminal for wire BL (933) and wire Bad wire BL (933) or wire BL (953) to fuses F5 and F7, bad
24 Volts
BL (953) at wiper switch to ground. fuse. Bad accessory relay (12).

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

Left hand door.
T
IN
(12).
PR
24 Volts
R
FO
109 – Right Hand Door Windshield Wiper

Right hand door.
T

O

N

(12).

24 Volts

Copyright ©
4002-52
110 – Left and Right Hand Door Windshield Washer Switch

Front dash panel.
(12).
NOTE: Have another person push and hold the washer switch in the ON position.
Terminal for wire O (963) at washer
24 Volts Bad washer switch.
switch to ground.
111 – Left and Right Hand Door Windshield Washer

Left engine compartment door.
Terminal for wire O to ground. Continuity Bad ground circuit.
T
IN
NOTE: Put the ignition switch in the RUN position. Have another person push and hold the washer switch in the
ON position.
Terminal for wire O (963) at washer
PR
24 Volts Bad wire O (963), bad washer switch (110).
motor to ground.
NOTE: If the tests are good and the washer pump does not work, repair or replace the washer pump.
R
FO
USING BOOSTER BATTERIES TO START THE ENGINE

5. Connect the negative (−) jumper cable to a good
WARNING: Batteries produce explosive frame ground away from the battery.
T
gases. Keep sparks, flame, and cigarettes

6. Put the master disconnect switch in the ON
O
away. Ventilate when charging or using in an

position.
enclosed space. Always shield eyes when
N
working near batteries. 7. Start the engine and have the other person
SA031 disconnect the negative (−) jumper cable first and
Two persons are required for this procedure. Make the positive (+) jumper cable last.
sure the person making the connection is wearing
face protection.
1. Sit in the operators seat and have the other
person make the connections. Make sure the
booster battery is 24 Volts.
2. If you are using another machine for power,
make sure the two machines do not touch.
3. Put the master disconnect switch in the OFF
position.
4. Connect the positive (+) jumper cable to the
positive (+) battery terminal.

Copyright ©
4002-53
CONNECTORS
CONNECTOR FRLWL - FRONT RIGHT LOWER CONNECTOR FLLWL - FRONT LEFT LOWER
WORK LIGHT WORK LIGHT
225316C1 225316C1
CAV CIRCUIT CAV CIRCUITT

1 911B 1 911B
2 0 2 0
CONNECTOR FRU WL - FRONT RIGHT UPPER CONNECTOR RR WL - REAR RIGHT WORK
T
WORK LIGHT LIGHT
IN
PR
R
FO
225316C1 225316C1
CAV CIRCUIT CAV CIRCUIT
1 911A 1 921
T
2 0 2 0
O
CONNECTOR RL WL - REAR LEFT WORK LIGHT

N
CONNECTOR FLU WL - FRONT LEFT UPPER

WORK LIGHT
225316C1
225316C1 CAV CIRCUIT

CAV CIRCUIT 1 921
1 911A 2 0
2 0

Copyright ©
4002-54
CONNECTOR CWL - CANOPY WORK LIGHTS CAV CIRCUIT
30 230
31 231
37 237
38 238
39 334
40 335
41 IGN1
42 IGN2
225316C1 43 243
CAV CIRCUIT 44 244
1 911A 48 248
2 911B 50 250
3 921 51 251
4 Not Used 52 252
5 Not Used
6 Not Used CONNECTOR C2 - MICRO CONTROLLER
T
7 Not Used
IN
8 Not Used
?
9 Not Used
CAV CIRCUIT
10 0
PR
56 256
11 0
60 260
12 0
62 262
R
64 264
CONNECTOR C1 - MICRO CONTROLLER 65 265
FO
68 268
?
69 269
CAV CIRCUIT 71 271

72 272
T
1 IGN2
2 0 79 279
O
4 204 80 280
N
5 205
6 206
10 210
11 211
13 IGN1
16 215
17 217
18 218
19 219
23 223
24 224
27 IGN2
28 0
29 215

Copyright ©
4002-55
CONNECTOR C3 - DIAGNOSTIC CONNECTOR C4 - FROM MICRO CONTROLLER
TO DASH HARNESS
CAV CIRCUIT
7 IGN1
8 955
9 4112
10 4111
11 256
12 262
DE_HD10-9-1939P 13 237
CAV CIRCUIT 14 954
A 0 15 61C
B 501 16 IGN2
C 335 18 279
D 334 19 260
T
E 389 20 265
F 251
IN
21 921
G 250 22 911B
H 224 23 811
PR
J 252 24 911A
26 582
28 501
R
29 121
30 120
FO
31 133
34 134
36 219
T
37 953
38 935
O
39 389
N
41 223
42 V1acc
43 280
44 335
45 334
46 104
47 934
48 206

Copyright ©
4002-56
CONNECTOR C5 - FROM MICRO CONTROLLER CONNECTOR C6 - THROTTLE POSITION
TO PUMPS AND MOTORS SENSOR
CAV CIRCUIT
1 205
2 104
3 121
4 134
5 120
7 133
8 244
9 V1acc DEU_DT04-3P
10 217 CAV CIRCUIT

11 218 A 279
12 204 B 264
13 216 C 238
T
14 230
IN
15 231
CONNECTOR C7 - REVERSE RATIO SWITCH
16 215
17 248
PR
18 272
19 424
20 425
R
21 426
22 421
FO
23 422
24 423
25 427
T
26 428
27 429
O
DEU_DT06-3S
28 451 CAV CIRCUIT

N
29 452 A V1acc
30 453 B 210
31 268 C 211
32 269
33 Not Used

Copyright ©
4002-57
CONNECTOR C8 - FROM MICRO CONTROLLER CONNECTOR C10 - FROM MICRO CONTROLLER
TO LIGHT HARNESS TO DIAGNOSTIC PORT
DEU_DT04-12P DEU_DT06-12S

1 911A 1 Not Used
2 911B 2 Not Used
3 921 3 Not Used
T
4 61C 4 Not Used
IN
5 811 5 Not Used
6 501 6 Not Used
PR
7 852 7 416
8 504 8 Not Used
9 505 9 Not Used
10 0 10 Not Used
R
11 0 11 417
FO
12 0 12 415
CONNECTOR C9 - INDICATOR LIGHT CONNECTOR C12 - INDICATOR LIGHT

T
O
? ?

N
A IGN2 A 271
B Not Used B Not Used
C 0 C 0

Copyright ©
4002-58
CONNECTOR C14 - DC CONVERTER CONNECTOR C16 - RIPPER POWER AND
DIAGNOSTICS
CAV CIRCUIT
1 V1acc
2 0
3 Not Used
4 Not Used
5 419
6 518
DEU_DT06-6S 7 Not Used
CAV CIRCUIT 8 Not Used
1 501 9 Not Used
2 V1acc 10 Not Used
3 0 11 Not Used
4 504 12 Not Used
T
5 505
IN
6 0
CONNECTOR C17 - BLADE POWER AND
DIAGNOSTICS
PR
CONNECTOR C15 - CIGAR LIGHTER
R
FO
T
O
DEU_DT06-12S
N
PAC_2973781 CAV CIRCUIT
CAV CIRCUIT 1 V1acc
? 504 2 0
? 0 3 Not Used
4 Not Used
5 415
6 416
7 417
8 418
9 419
10 4112
11 4111
12 Not Used

Copyright ©
4002-59
CONNECTOR C18 - BLADE CONTROLLER CONNECTOR C21 - RIPPER CONTROL
DEU_DT04-12P DEU_DT04-12P

1 421 1 451
2 422 2 452
3 423 3 453
4 424 4 Not Used
T
5 425 5 Not Used
IN
6 426 6 Not Used
7 427 7 Not Used
PR
8 428 8 Not Used
9 429 9 Not Used
10 Not Used 10 Not Used
R

FO
CONNECTOR C20 - REAR WIPER CONNECTOR C22 - RIGHT DOOR WIPER

T
? ?
O

? 0 ? 0
N
? 953 ? 953
? 935 ? 954
? 934 ? 955

Copyright ©
4002-60
CONNECTOR D1 - FROM MAIN HARNESS TO CONNECTOR D2A - INSTRUMENT CLUSTER A
DASH
CAV CIRCUIT
1 911B
2 911A
3 922
4 30
5 912
6 133
87419488
7 952
CAV CIRCUIT
8 993
1 IGN3
9 Not Used
2 120
10 4111
3 335
11 50
4 334
12 15
5 121
T
13 START
6 0
IN
14 921
7 4112
15 IGN3
8 Not Used
16 334
PR
9 Not Used
17 951
10 Not Used
18 963
11 Not Used
19 Not Used
12 0
R
20 Not Used
13 135
21 933
FO
14 Not Used
22 934
15 Not Used
23 935
16 Not Used
24 Not Used
17 Not Used
T
25 120
18 Not Used
26 335
O
19 Not Used
27 104
20 Not Used
N
28 955
21 Not Used
29 4112
22 Not Used
30 Not Used
23 Not Used
31 953
24 103
32 943
25 Not Used
33 121
26 Not Used
34 0
35 103
36 134
37 992
38 954
39 0
40 0

Copyright ©
4002-61
CONNECTOR D2B - INSTRUMENT CLUSTER B CONNECTOR D4 - FRONT WIPER
CAV CIRCUIT
? 0
? 933
? 932
? 931
CONNECTOR D5 - FRONT HEADLAMPS SWITCH

87410948
CAV CIRCUIT
1 Not Used
2 114
3 134
4 Not Used
5 133
T
6 111
IN
7 125
8 118
PR
9 911a 245781C1
10 4111 CAV CIRCUIT
11 104 1 911B
12 921 1 911A
R
13 Not Used 1 911A

FO
14 992 2 912
15 0 3 Not Used
17 START 5 Not Used

T

O
19 Not Used
20 992
N
21 IGN3
22 0
23 Not Used
24 Not Used
25 Not Used
26 Not Used

Copyright ©
4002-62
CONNECTOR D6 - REAR HEADLAMPS SWITCH CONNECTOR D8 - FRONT/REAR WASHER
SWITCH
245781C1
245781C1
CAV CIRCUIT
1 921 CAV CIRCUIT
1 921 1 Not Used
2 922 2 933
3 Not Used 2 933
4 Not Used 3 943
T
IN
6 Not Used
PR
CONNECTOR D7 - FRONT/REAR WIPER SWITCH
CONNECTOR D9 - DOOR WIPER SWITCH
?
R
?
CAV CIRCUIT
CAV CIRCUIT
FO
1 931
2 932 1 951
3 933 2 952
3 933 3 953
T
4 934 3 953
O
5 935 4 954
6 953 5 955
N
6 953 6 933
6 933

Copyright ©
4002-63
CONNECTOR D10 - DOOR WASHER SWITCH CONNECTOR D12 - ENTER/ESC SWITCH
245781C1 245781C1

1 Not Used 1 111
2 953 2 992
3 963 2 992
4 Not Used 3 993
T
IN
6 Not Used
CONNECTOR D11 - UP/DOWN SWITCH

PR
CONNECTOR D13 - HORN SWITCH
R
FO
T
O
245781C1
CAV CIRCUIT 245781C1

N
1 118 CAV CIRCUIT

2 992 1 Not Used
2 992 2 992
2 992 2 992
3 125 3 993

Copyright ©
4002-64
CONNECTOR D14 - IGNITION SWITCH CAV CIRCUIT
20 335
21 317
22 Not Used
23 312
24 329
25 332
26 337
27 IGN3
28 375
225253C1
29 389
CAV CIRCUIT
1 30
2 START
2 START
3 50
4 15
5 Not Used
T
6 Not Used
CONNECTOR E1 - FROM ENGINE TO FRONT

IN
PR
CONSOLE
v
?
R
CAV CIRCUIT
FO
1 302
2 Not Used
3 Not Used
4 Not Used
T
5 Not Used
O
6 Not Used
7 993
N
8 Not Used
9 Not Used
10 Not Used
10 21D
11 103
12 818B
13 963
14 943
15 Not Used
16 W
17 Not Used
18 334
19 Not Used

Copyright ©
4002-65
CONNECTOR E2 - ENGINE CONTROLLER CAV CIRCUIT
42 342
75 375
89 389
CONNECTOR E5/A - WINDSHIELD WASHER 2
T
PAC_2973781
CAV CIRCUIT
IN
? 943
? 0
PR
CONNECTOR E5/B - WINDSHIELD WASHER 1
R
BOSCH-89-POLE
FO
CAV CIRCUIT
2 302
3 302
T
5 0
O
6 0
8 302
N
9 302
10 0
PAC_2973781
11 0
CAV CIRCUIT
12 312
? 963
17 317
? 0
29 329
32 332
34 334
35 335
37 337
40 OGN3

Copyright ©
4002-66
CONNECTOR E11 - WATER IN FUEL SENSOR CONNECTOR L1 - FROM LIGHT HARNESS TO
MICRO CONTROLLER
CAV CIRCUIT
1 342
2 302
3 0
CONNECTOR E12 - A/C HIGH PRESSURE

SWITCH
DEU_DT06-12S
CAV CIRCUIT
1 911A
2 911B
3 921
T
4 61C
5 811
IN
6 501
7 852
PR
PAC_12065863 8 504
CAV CIRCUIT 9 505
A 818b 10 0
R
B 818C 11 0
12 0
FO
CONNECTOR L2 - LEFT REAR LIGHT

T
O
N
DEU_DT06-2S
CAV CIRCUIT
1 921
2 0

Copyright ©
4002-67
CONNECTOR L3 - RIGHT REAR LIGHT CONNECTOR L5 - CENTER FRONT LIGHT
DEU_DT06-2S DEU_DT06-2S

1 921 1 911A
2 0 2 0
CONNECTOR L4 - LEFT FRONT LIGHT CONNECTOR L6 - CENTER FRONT LIGHT
T
IN
PR
R
FO
T

O
1 911B 1 911A
2 0 2 0
N

Copyright ©
4002-68
CONNECTOR L7 - RIGHT FRONT LIGHT CONNECTOR L11 - CONDENSER
CAV CIRCUIT
1 61C
2 852
3 0
4 804
CONNECTOR L12 - HEATER A/C UNIT
DEU_DT06-2S
?
CAV CIRCUIT
1 911B CAV CIRCUIT
2 0 1 822
2 0
3 813
CONNECTOR L9 - CONTROL PANEL
T
4 814
IN
5 815
? 6 816
PR
CAV CIRCUIT
A 811 CONNECTOR L13 - HEATER A/C UNIT
B 812
C 813
R
?
D 814
CAV CIRCUIT
FO
E 815
F 816 A 804
G Not Used B 812
H Not Used C 18L

T
O
CONNECTOR L10 - PDT

N
CAV CIRCUIT
A 811
B 822
C 0

Copyright ©
4002-69
CONNECTOR L15 - RADIO CONNECTOR M1 - FROM DASH TO MAIN
HARNESS
?
CAV CIRCUIT
1 Not Used CAV CIRCUIT
2 Not Used 1 911B
3 Not Used 2 911A
4 Not Used 3 922
5 Not Used 4 30
6 Not Used 5 912
7 505 6 133
8 Not Used 7 952
9 Not Used 8 993
11 Not Used 10 4111
12 504 11 50
13 Not Used 12 15
T
14 Not Used 13 START
IN
14 921
15 IGN3
16 334
PR
17 951
18 963
19 Not Used
R
20 Not Used
21 933
FO
22 934
23 935
24 Not Used
T
25 120
26 335
O
27 104
N
28 955
29 4112
30 Not Used
31 953
32 943
33 121
34 0
35 103
36 134
37 992
38 954
39 0
40 0

Copyright ©
4002-70
CONNECTOR M2 - FUSE PANEL
T
IN
87315249
PR
CAV CIRCUIT
CAV CIRCUIT
C5 Not Used
A1 1M
C6 Not Used
A2 V1acc
C7 Not Used
R
A3 V2acc
C8 Not Used
A4 922
FO
C9 Not Used
A5 933
C10 Not Used
A6 912
D1 Not Used
A7 953
D2 IGN+
A8 Not Used
T
D3 Not Used
A9 811
O
D4 21C
A10 852
D5 Not Used
B1 21A
N
B2 50 D6 Not Used
B3 IGN+ D7 Not Used
B4 206 D8 1N
B5 Not Used D9 Not Used
B6 Not Used D10 329
B7 1N
B8 15
B9 332
B10 START
C1 Not Used
C2 Not Used
C3 Not Used
C4 Not Used

Copyright ©
4002-71
CONNECTOR M3 - FUSE AND RELAY PANEL
T
IN
PR
87312843
CAV CIRCUIT
CAV CIRCUIT B3 Not Used

B4 Not Used
R
AA1 BATT+
AA2 BATT+ B5 Not Used
FO

T
AA7 Not Used B10 Not Used

O
AA8 IGN+ C1 -
Not Used
10
N
AA9 IGN+
D1 317
AA10 IGN+
D2 21D
A1 1N
D3 Not Used
A2 30
D4 Not Used
A3 21A
D5 Not Used
A4 992
D6 Not Used
A5 302
D7 Not Used
A6 501
D8 Not Used
A7 Not Used
D9 Not Used
A8 IGN3
D10 Not Used
A9 IGN2
A10 IGN1
B1 21C
B2 337

Copyright ©
4002-72
CONNECTOR M5 - DECELERATOR PEDAL CONNECTOR M7 - PROXIMITY SWITCH LEFT
DEU_DT04-3P DEU_DT06-3S

A 280 A IGN1
B 262 B 237
C 219 C 0
T
CONNECTOR M5A - LOW IDLE SWITCH CONNECTOR M8 - PROXIMITY SWITCH RIGHT
IN
PR
?
CAV CIRCUIT
A 223
B 280
R
FO
CONNECTOR M6 - BRAKE PEDAL

T
DEU_DT06-3S
O
CAV CIRCUIT
A IGN1
N
B 260
C 0
DEU_DT06-3S
CAV CIRCUIT
A 279
B 256
C 265

Copyright ©
4002-73
CONNECTOR M9 - JOYSTICK CONNECTOR M10 - FROM DASH HARNESS TO
MICRO CONTROLLER
CAV CIRCUIT
7 IGN1
8 955
9 4112
10 4111
11 256
12 262
13 237
DEU_DT06-6S
14 954
CAV CIRCUIT
15 61C
1 IGN1
16 IGN2
2 0
18 279
3 334
19 260
4 335
T
20 265
5 IGN1
IN
21 921
6 Not Used
22 911B
23 811
PR
24 911A
26 582
28 501
R
29 121
30 120
FO
31 133
34 134
36 219
T
37 953
38 935
O
39 389
N
41 223
42 V1acc
43 280
44 335
45 334
46 104
47 934
48 206

Copyright ©
4002-74
CONNECTOR M11 - FROM FRONT CONSOLE TO CONNECTOR M12 - GRID HEATER RELAY
ENGINE
CAV CIRCUIT
1 302
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 993 PAC_2973781
8 Not Used CAV CIRCUIT

9 Not Used ? 375
10 Not Used ? 312
10 21D
11 103
CONNECTOR M13 - ROPS HEATER
T
12 818B
IN
13 963
14 943
15
PR
16 W
17 Not Used
18 334
R
19
20 335
FO
21 317
22 Not Used
23 312 PAC_12015792
T
24 329 CAV CIRCUIT

25 332
O
A V2acc
26 337 B 0
N
27 IGN3
28 375
CONNECTOR M14 - ACC POWER RELAY
29 389
CAV CIRCUIT
A 15
B 0

Copyright ©
4002-75
CONNECTOR M15 - LEFT DOOR WIPER CONNECTOR P1 - FROM PUMPS AND MOTORS
v
TO MICRO CONTROLLER
?
CAV CIRCUIT
? 952 CAV CIRCUIT
? 951 1 205
? 0 2 104
? 933 3 121
4 134
5 120
CONNECTOR M16A -
7 133
8 244
9 V1acc
?
10 217
CAV CIRCUIT
11 218
1 1N
12 204
2 Not Used
13 216
3 Not Used
T
14 230
4 Not Used
IN
15 231
5 W
16 215
6 0
17 248
PR
7 1M
18 272
8 0
19 424
20 425
CONNECTOR M22 - POWER SEAT
R
21 426
22 421
FO
23 422
24 423
25 427
T
26 428
27 429
O
28 451
N
29 452
30 453
31 268
PAC_12015792 32 269
CAV CIRCUIT 33 not used
A V2acc
B 0

Copyright ©
4002-76
CONNECTOR P3 - LEFT HAND PUMP CONNECTOR P5 - LEFT HAND MOTOR SPEED
SENSOR
DEU_DT06-4S
DEU_DT06-4S
CAV CIRCUIT
1 0 CAV CIRCUIT
2 231 1 244
3 230 2 V1acc
4 0 3 243
T
4
IN
CONNECTOR P4 - RIGHT HAND PUMP
CONNECTOR P6 - RIGHT HAND MOTOR SPEED
PR
SENSOR
R
FO
T
O
DEU_DT06-4S
CAV CIRCUIT
N
DEU_DT06-4S
1 0
CAV CIRCUIT
2 204
1 218
3 216
2 V1acc
4 0
3 217
4

Copyright ©
4002-77
CONNECTOR P7 - LEFT HAND MOTOR CONNECTOR P10 - FROM PUMPS TO
SOLENOID HYDRAULIC VALVE
CAV CIRCUIT
A V1acc
B 205
C Not Used
D 272
E 428
F 453
G 427
DEU_DT06-2S H 104
CAV CIRCUIT J 422
1 268 K 121
2 0 L 423
M 120
T
N 452
CONNECTOR P8 - RIGHT HAND MOTOR
IN
SOLENOID O 134
P 424
PR
Q 425
R 429
S 426
T 451
R
U 215
FO
V 248
W 421
X 0
T
O
DEU_DT06-2S
CAV CIRCUIT
N
1 269
2 0
CONNECTOR P9 - CHARGE PRESSURE SONSOR
CAV CIRCUIT
A 133
B 0

Copyright ©
4002-78
CONNECTOR V1 - TO HYDRAULIC VALVE CONNECTOR V14 - BLADE TILT RIGHT
CAV CIRCUIT
A V1acc
B 205
C Not Used
D 272
E 428
F 453
G 427
H 104 DEU_DT06-2S
J 422 CAV CIRCUIT

K 121 1 425
L 423 2 426
M 120
N 452
CONNECTOR V15 - BLADE LOWER
T
O 134
IN
P 424
Q 425
PR
R 429
S 426
T 451
U 215
R
V 248
FO
W 421
X 0
DEU_DT06-2S
T
CONNECTOR V13 - BLADE TILT LEFT

CAV CIRCUIT
O
1 422
2 423
N
DEU_DT06-2S
CAV CIRCUIT
1 424
2 426

Copyright ©
4002-79
CONNECTOR V16 - BLADE RAISE CONNECTOR V18 - BLADE ANGLE LEFT

1 421 1 428
2 423 2 429
CONNECTOR V17 - BLADE ANGLE RIGHT CONNECTOR V19 - RIPPER LOWER
T
IN
PR
R
FO
T

O
1 427 1 451
2 429 2 453
N

Copyright ©
4002-80
CONNECTOR V20 - RIPPER RAISE CONNECTOR V24 - BRAKE RELEASE SOLENOID

1 452 1 215
2 453 2 0
CONNECTOR V21 - POWER TO VALVE CONNECTOR V25 - BRAKE RELEASE SWITCH
T
IN
? ?
PR
1 272 1 V1acc
2 0 2 248
R
CONNECTOR V23 - FUEL LEVEL SENDER

FO
CAV CIRCUIT
T
1 120
O
2 0
N

Copyright ©
4002-81
INDEX
Symbols Brake Release Sonenoid ..................................80
12 Volt Radio .........................................................45 Brake Release Switch .......................................80
Canopy Work Lights ..........................................54
A Center Front Light .............................................67
Accessory Power Jack 12 Volt ..............................45 Charge Pressure Sensor ...................................77
Accessory Relay ....................................................23 Cigar Lighter ......................................................58
Air Conditioner Condenser ........................................................68
Compressor Clutch ...........................................49 Control Panel ....................................................68
Condenser Blower Motor ..................................48 DC Converter ....................................................58
High Pressure Switch ........................................48 Decelerator Pedal .............................................72
Low Pressure Switch .........................................48 Diagnostic .........................................................55
Air Filter Restriction Switch ....................................36 Door Washer Switch .........................................63
Air Suspension Seat-Air Compressor ....................44 Door Wiper Switch ............................................62
Alarm Engine Controller ..............................................65
Backup ..............................................................39 Enter/ESC Switch ..............................................63
Oil Pressure/Coolant Temperature ...................37 From Dash Harness to Micro Controller ............73
Alternator ...............................................................20 From Dash to Main Harness .............................69
From Engine to Front Console ..........................64
B From Front Console to Engine ..........................74
T
Backup From Light Harness to Micro Controller ............66
Alarm .................................................................39 From Main Harness to Dash .............................60
IN
Battery ...................................................................20 From Micro Controller to Dash Harness ............55
Blower From Micro Controller to Diagnostic Port ..........57
From Micro Controller to Light Harness ............57
PR
Switch ................................................................47
Blower Motor Housing ...........................................48 From Micro Controller to Pumps and Motors ....56
Boost Pressure Sensor ..........................................43 From Pump to Hydraulic Valve .........................77
Boosting Batteries to Start the Engine ...................52 From Pumps and Motors to Micro Controller ....75
Brake Front Headlamps Switch ...................................61
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Pedal Potentiometer ..........................................26 Front Left Lower Work Light ..............................53

Pressure Switch ................................................30 Front Left Upper Work Light ..............................53
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Solenoid ............................................................30 Front Right Lower Work Light ...........................53

Buzzer Front Right Upper Work Light ...........................53
High Temperature .............................................37 Front Wiper .......................................................61
Low Oil Pressure ...............................................37 Front/Rear Washer Switch ................................62
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Front/Rear Wiper Switch ...................................62

C Fuel Level Sender .............................................80
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Cab Fuse and Relay Panel .......................................71

Interior Lamps ...................................................46 Fuse Panel ........................................................70
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Interior Lamps Switch ........................................46 Grid Heater Relay .............................................74

Camshaft Speed Sensor .......................................42 Heater A/C Unit .................................................68
Cluster, Instrument Connector A ...........................34 Horn Switch .......................................................63
Cluster, Instrument Connector B ...........................34 Ignition Switch ...................................................64
Connector Ignition switch ....................................................64
A/C High Pressure Switch .................................66 Indicator Light ...................................................57
ACC Power Relay .............................................74 Instrument Cluster A .........................................60
Blade Angle Left ................................................79 Instrument Cluster B .........................................61
Blade Angle Right .............................................79 Joystick .............................................................73
Blade Controller ................................................59 Left Door Wiper .................................................75
Blade Lower ......................................................78 Left Front Light ..................................................67
Blade Power and Diagnostics ...........................58 Left Hand Motor Speed Sensor .........................76
Blade Raise .......................................................79 Left Hand Pump ................................................76
Blade Tilt Left ....................................................78 Left Hand Solenoid ...........................................77
Blade Tilt Right ..................................................78 Left Rear Light ..................................................66
Brake Pedal .......................................................72 Low Idle Switch .................................................72
Micro Controller .................................................54
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4002-82
PDT ...................................................................68 Connector D5 ........................................................ 61
Power Seat ........................................................75 Connector D6 ........................................................ 62
Power to Valve ..................................................80 Connector D7 ........................................................ 62
Proximity Switch Left .........................................72 Connector D8 ........................................................ 62
Proximity Switch Right ......................................72 Connector D9 ........................................................ 62
Radio .................................................................69 Connector E1 ........................................................ 64
Rear Headlamps Switch ....................................62 Connector E11 ...................................................... 66
Rear Left Work Light .........................................53 Connector E12 ...................................................... 66
Rear Right Work Light .......................................53 Connector E2 ........................................................ 65
Rear Wiper ........................................................59 Connector E5A ...................................................... 65
Reverse Ratio Switch ........................................56 Connector E5B ...................................................... 65
Right Door Wiper ...............................................59 Connector FLL WL ................................................ 53
Right Front Light ................................................68 Connector FLR WL ................................................ 53
Right Hand Motor Speed Sensor ......................76 Connector FRL WL ................................................ 53
Right Hand Pump ..............................................76 Connector FRU WL ............................................... 53
Right Hand Solenoid .........................................77 Connector L1 ......................................................... 66
Right Rear Light ................................................67 Connector L10 ....................................................... 68
Ripper Control ...................................................59 Connector L11 ....................................................... 68
Ripper Lower .....................................................79 Connector L12 ....................................................... 68
Ripper Power and Diagnostics ..........................58 Connector L13 ....................................................... 68
Ripper Raise .....................................................80 Connector L15 ....................................................... 69
ROPS Heater ....................................................74 Connector L2 ......................................................... 66
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Throttle Position Sensor ....................................56 Connector L3 ......................................................... 67
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To Hydraulic Valve ............................................78 Connector L4 ......................................................... 67
Up/Down Switch ................................................63 Connector L5 ......................................................... 67
Water in Fuel Sensor ........................................66 Connector L6 ......................................................... 67
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Windshield Washer 1 ........................................65 Connector L7 ......................................................... 68
Windshield Washer 2 ........................................65 Connector L9 ......................................................... 68
Connector C1 ........................................................54 Connector M1 ........................................................ 69
Connector C10 ......................................................57 Connector M10 ...................................................... 73
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Connector C18 ......................................................59 Connector M16A ................................................... 75
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Connector C21 ......................................................59 Connector M3 ........................................................ 71

Connector C22 ......................................................59 Connector M5 ........................................................ 72
Connector C3 ........................................................55 Connector M5A ..................................................... 72
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Connector C8 ........................................................57 Connector P1 ........................................................ 75
Connector C9 ........................................................57 Connector P10 ...................................................... 77
Connector CWL .....................................................54 Connector P3 ........................................................ 76
Connector D1 ........................................................60 Connector P4 ........................................................ 76
Connector D10 ......................................................63 Connector P5 ........................................................ 76
Connector D2A ......................................................60 Connector RL WL .................................................. 53
Connector D2B ......................................................61 Connector RR WL ................................................. 53
Connector D4 ........................................................61 Connector V1 ........................................................ 78

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4002-83
Connector V13 .......................................................78 Level Sender .....................................................35
Connector V14 .......................................................78 Fuel Temperature Sensor .....................................43
Connector V15 .......................................................78 Fuse Block A .........................................................24
Connector V16 .......................................................79 Fuse Block B .........................................................24
Connector V17 .......................................................79
Connector V18 .......................................................79 G
Connector V19 .......................................................79 Grid Heater ............................................................24
Connector V20 .......................................................80 Grid Heater Relay ..................................................24
Connector V21 .......................................................80
Connector V23 .......................................................80 H
Connector V24 .......................................................80 Heater
Connector V25 .......................................................80 Grid ...................................................................24
Coolant Temperature Sensor ................................42 ROPS ................................................................43
Cranckshaft Speed Sensor ....................................42 Horn .......................................................................39
Horn Button ...........................................................39
D HVAC Mode Switch ...............................................47
Decelerator Pedal Low Idle Switch ........................25 Hydraulic Filter Restriction Switch .........................37
Decelerator Pedal Potentiometer ..........................25 Hydrostat Filter Restriction Switch ........................36
Diagnostic Port ......................................................44 Hydrostatic Charge Pressure Switch .....................36
Directional Control .................................................29
Door I
Windshield Wiper, Left and Right Hand ............51 Ignition Relay .........................................................22
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Windshield Wiper, Left Hand .............................51 Ignition Switch .......................................................21
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Windshield Wiper, Right Hand ..........................51 Injector
Drivetrain Control Module ......................................27 Number 1 Cylinder ............................................40
Number 2 Cylinder ............................................41
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E Number 3 Cylinder ............................................41
Electrical System Wire Identification .......................6 Number 4 Cylinder ............................................41
Electronic Diesel Control .......................................40 Number 5 Cylinder ............................................41
Engine Sensors Connector ....................................42 Number 6 Cylinder ............................................41
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Enter Escape Instrument Cluster Switch ...............34 Injector Driver Connector ......................................40
Equipment Valve Instrument Cluster Connector A ............................34
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Blade Control Joystick .......................................31 Instrument Cluster Connector B ............................34

Blade Lift Solenoid ............................................31
Blade Lower Solenoid .......................................31 J
Diagnostic Port ..................................................32 Jump Starting the Vehicle .....................................52
Ripper Joystick (Option) ....................................33
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Ripper Lift Solenoid (Option) .............................33 L

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Ripper Lower Solenoid (Option) ........................33 Left

Safety Solenoid .................................................31 Motor Solenoid ..................................................28
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Tilt Left Solenoid ...............................................32 Motor Speed Sensor .........................................29

Tilt Right Solenoid .............................................32 Parking Brake Proximity Switche ......................26
Twist Left Solenoid ............................................32 Pump Solenoid ..................................................27
Twist Right Solenoid .........................................33 Left and Right Hand Door
Windshield Washer ...........................................52
F Windshield Washer Switch ................................52
Fleet Relay (Option) ..............................................23 Left Speaker ..........................................................45
Fleet Tracker Port ..................................................44 Lights
Front Cab Interior .......................................................46
And Rear Windshield Washer ...........................50 Front Floodlights ...............................................38
And Rear Windshield Washer Switch ...............50 Rear Floodlights ................................................38
Floodlight/Monitor Light Switch .........................37
Floodlights .........................................................38 M
Windshield Wiper ..............................................49 Main
Front and Rear Electrical System Troubleshooting ....................20
Windshield Wiper Switch ...................................49 Master Disconnect Switch .....................................20
Fuel Monitor Light Switch ..............................................37
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4002-84
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Oil Pressure Sensor ..............................................43 Left .................................................................... 45
Right .................................................................. 44
P Specifications .......................................................... 5
Potentiometer Start Sensing Relay ............................................... 23
Brake .................................................................26 Starter .................................................................... 21
Deceleratior Pedal .............................................25 Starter Relay ......................................................... 22
Throttle ..............................................................25 Starter Solenoid ..................................................... 21
Power Converter (24 volts to 12 volts) ..................46 Switch
Air Filter Restriction ........................................... 36
R Blower ............................................................... 47
Radio Brake Pressure ................................................. 30
12 Volt ...............................................................45 Cab Interior Lights ............................................. 46
Rail Pressure Sensor .............................................42 Enter Escape Instrument Cluster Switch .......... 34
Rear Front And Rear Windshield Washer ................. 50
And Front Windshield Washer ..........................50 Front and Rear Windshield Wiper ..................... 49
And Front Windshield Washer Switch ...............50 Front Floodlights ............................................... 37
Floodlight Switch ...............................................38 Horn Button ....................................................... 39
Floodlights .........................................................38 HVAC Mode ...................................................... 47
Windshield Wiper ..............................................50 Hydraulic Filter Restriction ................................ 37
Rear and Front Hydrostat Filter Restriction ................................ 36
Windshield Wiper Switch ...................................49 Ignition .............................................................. 21
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Relay Left and Right Hand Door Windshield Washer . 52
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Accessory ..........................................................23 Left and Right Hand Door Windshield Wiper .... 51
Fleet (Option) ....................................................23 Left Parking Brake Lever .................................. 26
Grid Heater ........................................................24 Master Disconnect ............................................ 20
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Ignition ...............................................................22 Monitor Lights ................................................... 37
Safety ................................................................22 Rear Floodlights ................................................ 38
Start Sensing Power .........................................23 Reverse Ratio ................................................... 29
Starter ...............................................................22 Right Parking Brake Lever ................................ 27
Temperature Control ......................................... 47
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Reverse Ratio Switch ............................................29

Right Transmission Charge Pressure ........................ 36
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Motor Solenoid ..................................................28 Up Down Menu Instrument Cluster Switch ....... 34

Motor Speed Sensor .........................................29
Parking Brake Proximity Switche ......................27 T
Pump Solenoid ..................................................28 Temperature
Right Speaker ........................................................44 Transmission Sender ........................................ 35
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ROPS Heater .........................................................43 Temperature Control

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Switch ............................................................... 47
S Throttle Potentiometer ........................................... 25
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Safety Relay ..........................................................22 Tilt Proximity Switch .............................................. 26

Sensor Transmission Charge Pressure Switch ................. 36
Boost Pressure ..................................................43 Transmission Temperature Sender .......................35
Camshaft Speed ...............................................42
Coolant Temperature ........................................42
Crankshaft speed ..............................................42
Fuel Temperature ..............................................43
Oil Pressure ......................................................43
Rail Pressure .....................................................42
Water In Fuel .....................................................40
Shifter
Directional control .............................................29
Solenoid
Brake .................................................................30
Hydraulics Safety ..............................................31
ON OFF Hydraulics ...........................................31
Starter ...............................................................21
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4002-85
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Understanding the Troubleshooting Tables ...........19 Warning Buzzer .....................................................37
Up Down Menu Instrument Cluster Switch ............34 Water In Fuel Sensor ............................................40
Windshield Washer
Front And Rear ..................................................50
Left and Right Hand Door .................................52
Windshield Washer Switch
Front And Rear ..................................................50
Left and Right Hand Door .................................52
Windshield Wiper
Front ..................................................................49
Left Hand Door ..................................................51
Rear ..................................................................50
Right Hand Door ...............................................51
Wire Identification ....................................................6
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NOTES
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Section
4003
4003
BATTERIES
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Racine, WI 53404 U.S.A. Bur 6-47960 Issued December, 2002
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4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4003-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or milk. Follow with milk of magnesia, beaten
have been recently charged. egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
WARNING: Some batteries have a Keep out of reach of children.

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

released when the battery is turned upside
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down. If you turn the battery upside down,
make sure that the end of the ventilation tube
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is away from you and away from any other
people in the area. Battery acid can cause
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severe burns.
48-57B
SPECIAL TOOLS
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B799328
The CAS10147 tester is used to do the Capacity

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

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4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

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

the cell opening. Do not add more water than is
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n e e d e d . To o m u c h w a t e r c a n c a u s e b a d
performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.
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4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check 1. TEMPERATURE IN F 2. TEMPERATURE IN C

B790863
A hydrometer is used to check the specific gravity SPECIFIC GRAVITY CHART
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(weight) of the electrolyte. The specific gravity is an 4. Make a record of the corrected specific gravity
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indication of the level of charge for each cell. reading for each cell.
Hydrometers are made to show the correct specific 5. If the difference between the high reading and
gravity when the temperature of the electrolyte is
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the low reading is 0.050 or more, charge the
26.7°C (80°F). battery and check the specific gravity again. If
When you check the specific gravity, you must know after charging, the difference is still 0.050 or
the temperature of the electrolyte. If your hydrometer more, install a new battery.
does not have a thermometer, get a thermometer to
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6. The corrected specific gravity reading shows the

check the temperature of the electrolyte. The level of charge for the cell. The level of charge
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thermometer must indicate a high temperature of at must be at least 75% in each of the cells. ln
least 52°C (120°F). maintenance free batteries the level of charge is
1. Remove enough electrolyte from a cell so that at least 75% if the corrected specific gravity
the float is free in the tube. reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
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NOTE: If the specific gravity cannot be checked specific gravity reading is 1.230 or higher.
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without first adding water to the cell, the battery must

be charged for 15 minutes at 15 to 25 amperes to mix 7. If the difference between the high reading and
the water with the electrolyte. Then check the specific the low reading is less than 0.050, and the level
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gravity. of charge is at least 75% in all of the cells, do the

Capacity (Load) Test.
2. Read the float.
8. If the difference between the high reading and
3. Read the thermometer. If the reading is above the low reading is less than 0.050, but the level of
26.7°C (80°F) add specific gravity points to the charge is less than 75% in any of the cells,
reading for specific gravity. If the reading is below charge the battery and check the specific gravity
26.5°C (80°F) subtract specific gravity points again. If after charging:
from the reading for specific gravity. See the
following illustration and add or subtract specific A. The level of charge is less than 75% in any of
gravity points as needed. the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.

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

1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
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A. If the test result is equal to or more than the

vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d
condition.
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B. If the test result is less than the voltage

shown, discard the battery.
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B790499
1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF

ARROW AWAY FROM
BATTERY)

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

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See
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Reserve Capacity under Slow Charge Fast Charge
Specifications
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10 Hours at 5 Amperes 2.5 Hours at 20 Amperes
80 Minutes or Less
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Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1 .5 Hours at 50 Amperes
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20 Hours at 5 Amperes 5 Hours at 20 Amperes

Above 125 to 170 Minutes 10 Hours at 10 Amperes 2 Hours at 50 Amperes
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*lnitial rate for standard taper charger.

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NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
Continued on next page

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4003-8
Charging Guide For Batteries Other Than Maintenance Free

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

Reserve Capacity under Slow Charge Fast Charge
Specifications

80 Minutes or Less 5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1 .5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes


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6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
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*lnitial rate for standard taper charger.
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PREPARING A DRY CHARGED BATTERY FOR USE
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1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
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spe cific gravity is 1 .25 0 or m ore a nd the

2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will per mit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
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electrolyte is just below split ring at the bottom of

3. Install the caps on the battery.
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the cell opening.

4. Connect a battery charger to the battery.
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Section
4005
INSTRUMENT CLUSTER
4005
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4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Erasing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DRIVE TRAIN FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ELECTRO-HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EST Fault Retrieval for Electro-Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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4005-3
INSTRUMENT CLUSTER
6
5 7 8 9 10
3 4 11
2
1
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20 12
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19 18 17 13
16 15 14
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BD06G107
1. SERVICE SOON LAMP 11. ALTERNATOR
2. TRANSMISSION FILTER CLOG WARNING LAMP 12. HYDRAULIC FILTER CLOG WARNING LAMP
3. CHARGE PRESSURE LOW WARNING LAMP 13. FUEL GAUGE
4. TRANSMISSION TEMPERATURE GAUGE 14. TRANSMISSION FAULT WARNING LAMP
5. FAULT WARNING LAMP 15. FUEL LEVEL LOW WARNING LAMP
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6. DIGITAL DISPLAY 16. AIR FILTER RESTRICTION WARNING LAMP

7. STOP MACHINE OPERATIONS WARNING 17. ENGINE COOLANT TEMPERATURE WARNING LAMP
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8. BATTERY CHARGE GAUGE 18. TRANSMISSION TEMPERATURE WARNING LAMP

9. LOW ENGINE OIL PRESSURE WARNING LAMP 19. ENGINE COOLANT TEMPERATURE GAUGE
10. PARKING BRAKE ENGAGED LAMP 20. FRONT WORK LAMP INDICATION LAMP
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The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
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possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:
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4005-4
Self-Test Power Circuit Test

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

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

d i s p l aye d . M a c h i n e h o u r s w i l l a l way s b e
displayed briefly, on start up. After, the machine
is started, the display will show engine rpm’s.
After, beginning travel, the machine will display
travel speed, if default settings were not changed
by the operator.
2. This example, shows that the Transmission
Control Lever is in Neutral. The display will show
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is
positioned.
3. This example shows the transmission at 60%.
60% is the default speed. When the ignition
BD06G111 switch has been shut off it will default the
The LCD Multi-Function Display is located at the transmission to this setting.
center of the modular dashboard. On start up the 4. This zone will display fault codes when an error
cluster will flash the instructional lamps and the LCD has accord in the engine controller, drivetrain
Multi-Display will display, CASE, with the machine controller, or blade controller.
model and current hour reading. 5. This zone will display additional and optional
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information.
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BD06G113
LCD MULTI-FUNCTION DISPLAY
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Information will be displayed in different zones on the

LCD, as directed by the operator or machine. In
most situations the operator or technician will be
given specific information to follow if conditions are
not correct.

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4005-6
Navigating Through The LCD Using The Arrow Keys
Multi-function Display Screens At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
keys. These five screens are in a circular loop and
1 3 may be reached by pressing the up or down key. The
following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD
back to the normal driving screen.
2 4
BD06G112
Located on the dash panel are the operating
switches for the instrument cluster. Use the switches
to move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
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the same basic manner.
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1. Up arrow key: Use this key to scroll up to
BD06G112
selections.
From the driving screen push the down arrow.
2. Down arrow key: Use this key to scroll down to
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selections.
3. Escape key: Use this key to exit and return to
the driving screen. Use this key anytime you
would like to start over and begin again, plus use
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to check active, acknowledge errors.

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4. Enter key: Use this key to confirm, yes, this is

the desired function.
NOTE: Arrows on the screen will indicate if
selections are up or down from the current selection.
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NOTE: Display units can be changed by the

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operator.
BD06N046
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Info 1 is the first information screen using the down

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

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4005-7
BD06F169
Press the down button again and the Trip 1 screen
BD06F027
will display. The LCD provides two trip computers.
Info 2 will be displayed next. The Info 2 screen will These will display since last reset the total time in
display coolant temperature, turbocharger air h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l
temperature, engine oil temperature in either consumption per hour.
Fahrenheit or Celsius, as well as oil pressure PSI.
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BD06F170
By continuing to scroll down, the fifth screen will
display the Trip 2 screen. Trip 1 and Trip 2 screens
can be reset independently. The previous screen can
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be accessed by using the up arrow key.

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4005-8
Reset The Trip Information
BD06F172
BD06F170 The trip screen will indicate a reset message. At this

Highlight the trip screen you wish to set. screen, press confirm to clear the numbers and reset
the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.
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BD06G112
Press the confirm button.
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BD06G112
Press the confirm button to reset the trip selection to

zero.
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4005-9
Adjusting Steering Sensitivity
The direction control lever has three sensitivity
settings.
● Smooth
● Normal
● Fast
To change the sensitivity:
BD06G112
3. Select the SETTINGS menu by pressing the
enter button. The display will show SETTINGS at
the top followed by:
● Max Spd
● Shuttle
● Steer
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4. Push the down arrow and go to steer.
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BD06G112
NOTE: Normal is the setting from the factory.
1. Press and hold the enter button for 2 to 3
seconds until the screen shows SERVICE at the 5. Press the enter button.
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top. 6. Use the up or down arrow button until the desired
choice is blinking.
7. Push the enter button to confirm the selection
and store the choice.
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NOTE: The setting menu may be hidden entirely

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with the EST.

Adjusting Shuttle Parameter
To adjust the shuttle parameter follow the same
steps as for steering sensitivity.
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The shuttle choices are the same:

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● Smooth
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BD06G112 ● Normal
2. Press the down arrow until SETTINGS is on
● Fast
displayed.
After selecting desired value press the enter button
to confirm the selection and store the choice.
Adjusting Maximum Transmission Speed
Parameter
To adjust the maximum transmission speed follow
the same steps as for steering sensitivity.
The transmission speed choices will be 70, 80, 90 or
100 per cent.
After selecting the desired value press the enter
button to confirm and store the choice.

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

control lever must be returned to neutral before
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4005-11
RETRIEVING FAULT CODES
General Fault Code Identification Fault Code Grouping

1. Press and hold the escape key and up arrow key 1. 1000 to 1999 vehicle errors.
for more than 2 seconds to access the fault
2. 2000 to 2999 not used.
codes.
3. 3000 to 3999 engine errors.
NOTE: If a fault is active and a warning lamp is
illuminated the escape key (3) will only need to be 4. 4000 to 4999 transmission errors.
pressed once to display the fault.
5. 5000 to 5999 eltro-hydraulic system errors.
6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
1 3
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.
NOTE: Fault codes will show the number of
occurrences, this can be used to see if a yellow or
white fault is recurring on a regular basis and needs
repaired.
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Erasing Faults
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BD06G112
1. UP KEY 1. Hold the enter button until the display shows
SERVICE.
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2. DOWN KEY
3. ESCAPE KEY
2. Press the down arrow until RESET is highlighted.
4. ENTER KEY
3. Press enter, the display shows CLEAR ERRORS
2. Yellow Faults, buzzer will beep once every 2
AND RESTORE FATORY SETTINGS.
seconds:
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4. Highlight CLEAR ERRORS and press enter to

A. Operator can acknowledge it by pressing the
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erase active errors.

enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
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D. Yellow lamp will stay ON.

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E. Fault will remain in yellow list until it is closed.

3. Red Faults, buzzer will be continuous,
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alternating sounds:
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.

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4005-12
ENGINE FAULT CODES
DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR
Idle switch defect or wiring of idle switch broken

or accelerator pedal defect.
3001 Foot throttle sensor signal not plausible
Check wiring, replace idle switch or replace
accelerator pedal.
3002 Short circuit in wiring or in accelerator pedal.

Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3003 Foot throttle sensor signal below range min.
Check wiring or replace accelerator pedal.
3004 Foot throttle sensor - no signal Check wiring or replace accelerator pedal
3006 Coolant temperature sensor signal not See OTS (Oil Temperature Sensor) plausibility
plausible check (Fault 3033)
Sensor defective or short circuit to external
3007 Coolant temperature sensor signal above
source.
range max.
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Check wiring or replace sensor.
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Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
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No CAN plausibility check performed, restart
3009 Coolant temperature sensor null (via CAN) system, if problem reoccurs.
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3015 Fuel temperature signal above range max. source.

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Sensor defective or short circuit to ground.

3016 Fuel temperature signal below range min.
Boost pressure sensor signal above range
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3019 source.
max.
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3021
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Boost pressure sensor null (via CAN) system, if problem reoccurs.

Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal not plausible of range.
Atmospheric pressure sensor signal not
3023
plausible
Ambient pressure sensor inside ECU is defect.
Atmospheric pressure sensor signal above
3024 Replace ECU (not necessary if never running in
range max.
high altitude and if turbocharger is without VGT)
Atmospheric pressure sensor signal below
3025
range min.

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4005-13

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

low oil level, leakage...) in the oil system.
3028 Oil pressure sensor pressure too low
Check oil pressure sensor for accuracy and
check oil system.
3029 Oil pressure sensor short-circuit to battery source.
3030 Oil pressure sensor short-circuit to ground
Inaccurate oil pressure sensor or defect (e.g.
short to ground).
3031 Oil pressure sensor ADC conversion error
check oil system.
Inaccurate oil pressure sensor or defect (e.g.
blocked piping) in the oil system.
3032 Oil pressure sensor pressure too high
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check oil system.
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Inaccurate oil or coolant temperature sensors or
insufficient oil or coolant recirculation (low
coolant level etc.).
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3033 Oil temperature sensor signal not plausible
Check oil and coolant temperature sensor for
accuracy and check oil and coolant system for
proper functioning.
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Oil temperature sensor signal above range

3034 source.
max.
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3035 Oil temperature sensor signal below range Sensor defective or short circuit to ground.
min. Check wiring or replace sensor.
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3036 Oil temperature sensor signal CAN

system, if problem reoccurs.
transmission disturbed
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3037 Boost pressure sensor signal low

Alternator voltage governor defect.
3051 Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3060 Cylinder 1 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU

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4005-14

CODE DEFINITION
STEPS FOR REPAIR
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
3062 Check the wiring and the injection signals,

Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to low side
Check the wiring and replace injector
replace ECU
3065
3066 Cylinder 5 signal low
replace ECU.
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replace ECU
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3069
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replace ECU.
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replace ECU
3073
replace ECU.
replace ECU

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4005-15

CODE DEFINITION
STEPS FOR REPAIR
3077
3078 Check the wiring and the injection signals,

Cylinder 2 signal low
replace ECU.
replace ECU
3081
replace ECU.
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Signal interrupted do to wiring problem, defective
or incorrectly installed crankshaft speed sensor.
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3088 Crankshaft sensor lost synchronization Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
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Check wiring, sensor installation and proper

3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
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signals).
or incorrectly installed camshaft phase sensor.
3090 Camshaft sensor lost phase Check wiring, sensor installation and proper
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functioning of camshaft phase sensor (evaluate

raw signals)
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Camshaft sensor phase synchronization
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3091 functioning of camshaft phase sensor (evaluate

failure
raw signals).
or incorrectly installed camshaft or crankshaft
3093 Offset between camshaft and crankshaft sensor.
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor

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4005-16

CODE DEFINITION
STEPS FOR REPAIR
Defective rail pressure sensor, defect in other

injection relevant component.
3104 Rail pressure relief valve open Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components
PRV does not open once the pressure limit is
reached: Mechanical defect or wrong application
Rail pressure relief valve pressure shock
3105 parameter.
requested
Check application value of maximum rail
pressure, check functioning of the PRV
PRV does not open even after pressure shock:
Rail pressure relief valve did not open after Stuck PRV or wrong application parameter.
3106
pressure shock Check application value of maximum rail
pressure, check functioning of the PRV
Short circuit of wiring to external source or inside
Metering unit output short-circuit to battery on
3107 relay.
low side
Check wiring or replace relay
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Rail pressure sensor offset monitoring signal
IN
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
Rail pressure sensor offset monitoring signal
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3111 rail pressure sensor, replace sensor
below range min.
Short circuit of wiring to external source or
defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
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max.
Check wiring and proper functioning of rail
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pressure sensor
Short circuit of main relay to external source or
Grid heater battery switch relay short-circuit to defective main relay.
3113
battery Check the wiring connecting the battery to the
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EDC or replace main relay

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Short circuit to ground of main relay or defective

Grid heater battery switch relay short-circuit to main relay.
3114
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ground Check the wiring connecting the battery to the

EDC or replace main relay
3118 ECM 12V sensor supply voltage high Ambient pressure sensor inside ECU is defective.
Replace ECU (not necessary if never running in
3119 ECM 12V sensor supply voltage low high altitude and if turbocharger without VGT)
3131 Short circuit to ground of grid heater.

Grid heater always switched on
Check grid heater switch and replace it
Broken or disconnected wiring or defective relay.
3137 Metering unit open load
Check of wiring or replace relay
Defective wiring, ECU, power stage or metering
unit.
3138 Metering unit signal not plausible
Check wiring, ECU, power stage and metering
unit

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4005-17

CODE DEFINITION
STEPS FOR REPAIR
High pressure system: Rail pressure sensor

inaccurate, high pressure pump defective.
Set point of fuel volume flow through metering
3141 Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
3147
range check oil system.
3154 Grid heater relay short-circuit to battery relay.
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
3156 Broken or disconnected wiring or defective relay.

Grid heater relay no load
High pressure side: Leakage in high pressure
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section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
IN
3171 Fuel rail/system pressure - too low pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
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clogged, leakage in low pressure side).
Metering unit stuck in open position,
zero-delivery throttle clogged, metering unit
without power due to electrical error.
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3172 Fuel rail/system pressure - too high

Low pressure side: Pressure before gear pump
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too high (e.g. by pressure relieve valve), pressure

after zero-delivery throttle too high.
3173 Fuel rail/system pressure - too low See fault 3171
3174 Fuel rail/system pressure - too high See fault 3172
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Leakage in the high pressure section, injection

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nozzle stuck in open position, worn high pressure

3175 Fuel system leak detected – large leak
pump, worn injector, leaking pressure relieve
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valve, injector reflux too high.

High pressure system: Leakage in the high
pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
3176
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.

Copyright ©
4005-18

CODE DEFINITION
STEPS FOR REPAIR
Defective CAN controller of Body Computer,

3178 Time-out of CAN message BC2EDC1 undervoltage of BC, missing BC, CAN cable
connecting the BC is disconnected or broken.
Short circuit in wiring. Check presence and
correct connection of the BC to the network,
3179 Time-out of CAN message BC2EDC2 Check correct functioning of the BC CAN
controller and its voltage supply. Check wiring.
Defective CAN controller of Vehicle Control
Module, undervoltage of VCM, missing VCM,
CAN cable connecting the VCM is disconnected
or broken. Short circuit in wiring. Check presence
3180 Time-out of CAN message VCM2EDC
and correct connection of the VCM to the
network, Check correct functioning of the VCM
CAN controller and its voltage supply. Check
wiring.
3188 Cylinder 1 open load
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3196 Cylinder 3 open load Broken wire or disconnection of wiring or inside
IN
injector.
3200 Cylinder 4 open load Check the wiring or replace injector.
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Short circuit of high-side to battery or ground.
3210 Bank 1 general short-circuit on injection cable
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Check the wiring or replace injector.

Short circuit of low-side to ground in injector
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3211 Bank 1 injection cable short-circuit low side to

cable.
ground
cause the defect, internal ECU problem.
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3213 Bank 1 unclassified error

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replace ECU
Short circuit of high-side to battery or ground.
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3218 Bank 2 general short-circuit on injection cable

Short circuit of low-side to ground in injector
Bank 2 injection cable short-circuit low side to
3219 cable.
ground
3221 cause the defect, internal ECU problem.
Bank 2 unclassified error
replace ECU
Clock error or interruption of the power supply
voltage.
3227 Injection processor error - stop engine
Check the power supply or replace ECU if
problem reoccurs.
Defective ECU, reset ECU.
If no recovery, replace ECU.
Copyright ©
4005-19

CODE DEFINITION
STEPS FOR REPAIR
Internal failure of ECU or 'TESTMODE' takes too

long.
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
due to software bug.
Replace ECU if problem reoccurs (Send in ECU
for investigation)
3232 Injection processor error - stop engine Defective ECU.
3233 Injection processor error - stop engine Replace ECU if problem reoccurs

Electric disturbances, internal defect of the ECU
3238 Communication error of CJ940 processor leading to a SPI bus communication error.
Replace ECU if failure remains present
T
3242 Recovery which is locked Electronic disturbances, various hardware
IN
defects (ECU internal) or configuration problems.
3243 Recovery which is suppressed
Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
PR
the value with the according table). If error occurs
3244 Recovery which is visible
repeatedly, reprogram EDC. If error remains,
replace EDC.
R
Defective monitoring module or CPU (e.g.

impaired functioning of the CPU clock) of the
FO
EDC. Disturbed SPI-Bus.

Communication supervision watchdog control If error exists only temporary (i.e. injection
3245
flag reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
T
be replaced
O
Watch dog switch off path defect.

3246 Redundant shutoff paths during initial If failure remains after ECU initialization: replace
N
ECU
3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem.
If failure remains after ECU initialization: replace
3248 Redundant shutoff paths during initial ECU
3253 Error status ADC monitoring
3254 Error status ADC monitoring Buffer overrun
3255 Error status ADC monitoring No additional information available at time of print
3256 Error status ADC monitoring

Short-circuit to battery at high side power
3258 relay.
stage

Copyright ©
4005-20

CODE DEFINITION
STEPS FOR REPAIR
Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
3259
stage Check of wiring or replace relay
3260 Broken or disconnected wiring or defective relay.

Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
Electronic disturbances, requested torque
increase via tester, wrong application of injection
Energizing time exceeds limit of over run
3265 relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
Electronic disturbances, internal ECU problem.
3266 Plausibility error in engine speed check
T
If failure persists after reinstallation replace ECU
IN
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
PR
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Insufficient voltage supply of a CJ940
R
component: Low battery voltage, defective wiring,

internal defect of the EDC.
FO
3279 Supply voltage CJ940 lower limit

Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Excessive battery voltage, defect in wiring
T
harness, electrical failure in connected sensors

O
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
N
voltage supply of the sensor and the EDC,

replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
in the EDC.
3281 Sensor supply voltage 1 low
replace EDC
or in the EDC.
replace EDC

Copyright ©
4005-21

CODE DEFINITION
STEPS FOR REPAIR

in the EDC.
replace EDC
or in the EDC.
replace EDC
in the EDC.
T
replace EDC
IN
PR
R
FO
T
O
N

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

4121
current
Right forward pump solenoid circuit open or over

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

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

4324 Hand throttle out of range

T
4331 Brake pedal potentiometer out of range

O
Check for power at the solenoid when the safety lever

are down and joystick is in F or R position. Check if
4332
N
Brake release pressure switch open

there is 200 psi at port P at the solenoid valve. Check
the resistance of the solenoid.
into connector fully, bent pin or broken wire at
rear of connector.
4341 No engine speed
3. Wiring or sensor circuits shorted
rear of connector.
4421 Backup alarm circuit open or over current 2. Water in connectors
3. Wiring or relay circuits open
4. Wiring or relay circuits shorted

Copyright ©
4005-23

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

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

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

5109 Blade joystick EEPROM write error
joystick
T
5110 Blade joystick memory fault No information at time of print.
IN
5111 Ripper joystick EEPROM read error Turn machine off and restart, if fault reoccurs replace
5112 Ripper joystick EEPROM write error joystick
PR
Ripper joystick PWM output fault for lift/lowering into connector fully, bent pin or broken wire at
5113
function
rear of connector.
2. Water in connectors
R

5114 Ripper joystick sensor fault for lift/lowering function 4. Wiring or sensor circuits shorted
FO

5115 Blade joystick memory fault No information at time of print.
T
O
N

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

9. On the error menu selection 1, STATUS, the
1
current error status can be retrieved from the
2 joysticks.
10. On the error menu selection 2, CLEAR, the
errors can be cleared form the joysticks.
11. Press 1 to get a complete error list, if a ripper
T
joystick is connected, the blade joystick will now
download the saved error from the ripper joystick
IN
BS07B023
which will take a couple of seconds.
5. After entering the configuration page the joystick
is shown in the item selection box. Select the 12. If no ripper is on the machine the display will
PR
joystick and press the “Configure Selected Item” read, RIPPER NOT FOUND, press 0 to continue.
(2).
13. If a ripper is installed on the machine the EST will
6. An emulation of the Rexroth BB3 will appear on automatically move to the joystick.
the monitor.
14. An ERROR STATUS screen will be displayed.
R
15. There are two entry types ACTIVE ERRORS and

FO
PASSIVE ERRORS.
16. ACTIVE ERRORS are fault which are not
resolved in the system.
T
17. PASSIVE ERRORS are faults which are

resolved in the system and are stored for
O
analyses.
18. Errors will include the error code, CODE, number
N
of occurrences, OCC, and timestamp when the

error was last detected, TIME.
BS07B024
NOTE: Fault code cross reference from EST faults
to instrument cluster electro-hydrualic system faults.
EST AIC EST AIC

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

Copyright ©
4005-26
INSTRUMENT CLUSTER FAULT CODES
9129 CAN timed out during operation If error is permanent or repeats often, check CAN
wiring harness and connections on the CAN bus
9130 CAN timed out during operation circuits.
T
IN
PR
R
FO
T
O
N

Copyright ©
SECTION INDEX
TRACK

Undercarriage Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001
Inspection of Track System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5502
Case Lubricated Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5504
Track Frame and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5506
Idler, Track Adjuster, and Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5508
Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5509
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5511
T
IN
PR
R
FO
T
O
N

Copyright ©
T
IN
PR
R
FO
T
O
N
Copyright ©
5001
Section
5001
UNDERCARRIAGE FUNDAMENTALS
T
IN
PR
R
FO
T
O
N

Copyright ©
5001-2
TABLE OF CONTENTS
UNDERCARRIAGE WEAR AND MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Track Measuring Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Record Keeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rebuilding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repositioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UNDERCARRIAGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNDERSTANDING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wear You Cannot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wear You Can Partially Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wear You Can Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXTENDING UNDERCARRIAGE LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track Adjustment and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPROCKET WEAR AND MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clean Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sprocket Wear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Measuring Sprocket Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
T
Bushing Off-Center Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
IN
Roller Flange Wear on the Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bushing Vertical Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bushing Reverse Drive Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PR
Bushing Forward Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bushing Cracks (Non-Lubricated Track) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Bushing Cracks (Case Lubricated Track) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pins and Bushings (Pitch Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
R
TRACK PIN WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pin Surface Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FO
Pin Spalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pins Breaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pin End Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TRACK LINK WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Link Uneven Top Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
T
Side Wear of the Link Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

O
Wear on the Inside Surface of the Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pin Boss Top Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
N
Sprocket Wear on the Inside of the Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Wear in the Counterbore (Non-Lubricated Track) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Link Rail Spalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pin Boss End Wear of the Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Counterbore Extension of the Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Link Crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
IDLER WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Idler Tread Surface Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Idler Flange Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRACK ROLLER AND TRACK CARRIER ROLLER WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tread Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Flange Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Track Rollers and Carrier Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRACK SHOE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Copyright ©
5001-3
Grouser Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cracked or Broken Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bolt Holes Too Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CASE NON-LUBRICATED TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Turning Pins and Bushings (Non-Lubricated Track) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CASE LUBRICATED TRACK (C.L.T.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Turning Pins and Bushings (Case Lubricated Track) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Marking the Pins and Bushings (Case Lubricated Track) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Track Bushings (Forward and Reverse Wear) - Sealed and C.L.T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Track Bushings (Vertical Wear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CASE EXTENDED LIFE TRACK (C.E.L.T.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TRACK TENSION - C.L.T., C.E.L.T., AND NON-LUBRICATED TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Extended Track Pitch (Length) - Non-Lubricated Track Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Other Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Correct Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Bushing and Sprocket Wear Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Track Link Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Procedure to Adjust the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
To Tighten the Track Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
To Loosen the Track Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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5001-4
NOTES
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5001-5
UNDERCARRIAGE WEAR AND MEASUREMENT

This section is to help you understand how track Record Keeping
wear occurs and what you can do to get the most out
of your undercarriage components. The undercarriage parts are measured to determine
the amount of wear and to tell when repairs or
Monitoring wear is one of the three main elements in replacement of parts is required. Keeping a good
maximizing an undercarriage investment. Monitoring record of these measurements can tell you when
wear helps anticipate when to make the pin and your machine will be taken out of production for
bu s h i n g t u r n a n d w h e n t o s e r v i c e o r r o t a t e service.
components.
The special forms for recording measurements and
Also, by measuring wear and using the wear charts other information are available from your Case dealer
that are available for your machine, you will be able to (form number Bur 8-18791).
determine the remaining life of all the components.
When a customer buys a new piece of tracked
e q u i p m e n t, a p p r ox i m a t e l y 2 0 p e r c e n t o f t h e
purchase price is in the undercarriage. As repairs
become necessary, approximately 50 percent of the
overall maintenance cost will be maintaining the
undercarriage. With this type of expense, the owner
or end user will greatly benefit from a detailed
explanation of how undercarr iage life can be
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extended.
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Track Measuring Tool Kit
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8-18791
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B4007091
CAS-1950A MEASURING TOOLS KIT
The special tools shown are used to measure the
wear of track system components.

Copyright ©
5001-6
Before Measuring Repositioning

Make sure that you clean each component before Repositioning is a method of extending the life of
you make the measurement. Use the scraper tool worn components. In addition to turning the pins and
that is provided with the kit and a piece of emery bushings, you can also change the sprockets from
cloth is necessary. side to side. This is only if the reverse wear is much
greater than the forward wear.
Each time you measure an undercarriage, carefully
record all measurements on the Track Component The front and rear track rollers will generally wear
Appraisal Form. Complete the report by comparing faster than the middle rollers. If they are all the same
your measurements with the percent worn charts. type (single flange or double flange), it is possible to
Then record the wear life percentage remaining. rotate the rollers. See the service manual for your
machine for the correct procedure.
Replacement of worn components with new parts is
one solution to undercarriage wear. However, there If the machine has been run on a side slope for an
are other methods to prolong the life of your extended period of time, the wear patterns can differ
undercarriage. from one side of the machine to the other. The same
can be true of the undercarriage that is not aligned
Rebuilding correctly. Additional life can be obtained by moving
undercarriage components from one side to the
Rebuilding is the process of welding or adding other.
material to the worn surfaces of a component. Then
the component is machined to original dimensions. Track Simulator
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Rebuilding is an alternative to replacing with new
parts. While rebuilding is an inexpensive way of We will be using the Case Track Simulator to
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gaining additional life from worn components, this is demonstrate the varying conditions of track wear.
not a recommended practice for small undercarriage
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parts. The extreme heat created by welding can
cause warping or changes in the molecular structure.
Always use an experienced rebuild shop.
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B921008
CASE TRACK SIMULATOR
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New track components must never be used or mixed

with wor n track components. Mixing new
undercarriage components with worn ones will
greatly decrease the life of the new components and
accelerate the wear of the worn parts.

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5001-7
UNDERCARRIAGE COMPONENTS
2 2 4
1
5
13
12 6 11 10 9 8 7 6
BD06G106
To fully understand the undercarriage, it is important 8. RECOIL SPRING - The recoil spring is used as a
to understand the purpose of each component. It is shock absorber that cushions large impact loads
also very important to know how that component and also aids in maintaining correct track
functions with the other components in the system. tension.
1. DRIVE SPROCKET - The drive sprockets 9. TRACK ROLLERS - The track rollers are
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transmit engine power to the tracks. The drive mounted to the bottom of the track frame. These
sprockets do not suppor t the weight of the rollers carry the weight of the machine on the
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machine. track chain.
2. CARRIER ROLLER/S - The carrier roller/s are 10. TRACK FRAME - The track frames are attached
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mounted on the top of the track frame to support to the machine chassis on each side. All of the
the track chain between the drive sprocket and track components except the drive sprockets are
idler. This roller also helps to maintain alignment attached to the track frames.
of the chain between the idler and drive sprocket. 11. PIVOT SHAFT - Allows track frames to pivot do
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3. TRACK CHAIN - The track chain includes a to terrain changes and supports the tractor.
number of link assemblies that are connected 12. TRACK LINKS - A number of track links make up
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together to form a complete chain. Shoes are the track chain assembly. Each link assembly
bolted to the track chain to provide traction for consists of a right-hand and a left-hand link, a
the machine. The drive sprocket rotates the track track pin (solid with sealed track chains and
chain around the undercarriage assembly. hollow with C.L.T track chains), bushings and
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4. IDLER - The idler carries the track chain around seals. Each link assembly is bored at both ends
the front of the track frame. This assembly can to hold the pins and bushings that connect the
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slide forward or rearward on the track frame two links. The bushing is pressed into each link.
against the recoil spring to absorb any shock A pin is inserted through the bushing and the
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loads. These shock loads can be from changes next set of links is pressed onto the pin. Sealed
in the terrain or temporary material buildup on track and Case Lubricated Track chains are
the track chain or sprockets. illustrated on Page 32. Case Extended Life Track
5. TRACK ADJUSTER - The track adjuster is a chain is illustrated on Page 34.
grease filled hydraulic cylinder used to maintain 13. TRACK SHOES - The track shoes are installed
or adjust track tension. To change track tension, on the track chain to give traction and flotation for
add grease or remove grease from the track the machine.
adjuster.
NOTE: The pins and bushings of the sealed track
6. TRACK GUIDES - The track guides help to are generally the first items of the undercarriage to
maintain alignment of the track chain and protect wear. This wear can (and will) affect the rest of the
the track. components in the system. This will be further
7. EQUILIZER BEAM - Allows track frames to pivot discussed in the section Wear Patterns.
do to terrain changes and supports the tractor. Your CASE dealer has six VISTA video tapes that
are very helpful when learning the basics of the
undercarriage system.

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5001-8
UNDERSTANDING UNDERCARRIAGE WEAR

The factors that affect wear are very diverse. The PACKING
most important wear factor is track tension, but other
Packing materials are any materials that stick to or
factors like speeds, soil conditions, the operator, the
pack around the moving components. To maintain
size of the machine, and high or low impact ground
correct track tension, the tracks must be adjusted as
surface are also variables that affect wear.
often as required when working in this type of soil
You cannot stop undercarriage wear - even if you condition.
have the best design and top quality parts. You can,
Packing materials cause a mismatch between
however, extend the undercarr iage life if you
components, particularly between the chain and
understand the causes of wear.
sprocket. The packing materials tighten the chain.
This causes increased stress and strain on links,
Wear You Cannot Control pins, bushings and the contact surfaces between
Soil and underfoot conditions cannot be controlled. mating parts. For example, as mismatch occurs due
These include abrasive soils, impact, packing, and to packing in the sprocket root, each track bushing
moisture. rides higher in the sprocket. This condition causes
rapid and severe forward and reverse wear and
ABRASIVE SOILS chain-to-sprocket “jumping” that is indicated by a
Each type of soil a machine works in has a different loud “banging” noise. This results in high impact
level of abrasiveness. Generally, the higher the loads that cause additional wear and cracking.
abrasiveness, the higher the wear rate.
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Moisture also plays a major roll in abrasiveness of
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soils. A sand slurry will be less abrasive than a damp
sand, especially if that sand is packing in the
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sprocket roots and around the bushings. Wet
abrasives act like grinding compounds.
LOW ABRASIVES - Silts and clays are in this
category. When wet, this type of soil feels slick and
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can be easily molded.

MODERATE ABRASIVE - Silts or clays that contain
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a low amount of rounded sand particles and enough

moisture to stick together are in this category. B408629V
HIGH ABRASIVE - These soils contain a high This packing condition can also stop rollers from
amount of sharp, irregular shaped sand particles. turning. When this happens, the track chain slides
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over that spot on the roller. This sliding causes a flat

IMPACT
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spot on the roller.

Impact is best described as the amount of grouser Packing materials increase the abrasive effect of
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penetration in the ground. The effect of high impact most material by not allowing the material to escape.
loads can be reduced by reducing the machine Wear is then accelerated. Open center grousers or
speed and by using the smallest track shoes special relieved sprockets may help alleviate this
possible. problem.
LOW IMPACT - Track shoe grousers will completely
penetrate the ground surface with little or no rock or
other irregularities.
HIGH IMPACT - Track shoe grousers will not
penetrate the ground surface. Large rock or large
irregular ities cause high impact loads on the
undercarr iage system. Rocky terrain causes
bending, breaking and chipping of the components.
Reduce the machine speed and use the smallest
track shoes possible.

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5001-9
Wear You Can Partially Control Terrain

APPLICATIONS - The term “Applications” is often Changes in the terrain change the attitude of your
used to describe underfoot conditions. In this section machine. This condition shifts the center of gravity
we will describe what the machine is doing without and increases the weight of the machine on different
regarding the applications. parts of the undercarriage.
DOZING - This operation shifts the machine weight WORKING UPHILL

to the front causing a faster wear rate on the front
rollers and idlers.
SPEED - Unnecessary speed directly affects the
wear rate on pins, bushings and sprockets. The
faster the speed, the faster the wear rate. High speed
reverse accelerates bushing and sprocket wear.
Wear rate is a function of speed and distance
traveled, not just hours worked.
BS97N011
IMPACT - High speed will increase impact loading
when there is low grouser penetration on hard This condition moves the weight of the machine
surfaces or when working in rock. rearward causing increased wear of the rear rollers
and increased forward drive wear of the sprockets
Impact can cause structural problems such as and bushings.
bending, cracking or breakage of components. This
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can also affect pin and bushing retention and WORKING DOWNHILL
bushing cracking. And, if a chain is worn, can cause
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fractures.
TURNING - Wear rate increases when tracks are
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slipping. Track shoe grousers are affected due to
increased sliding between grouser and the ground.
T R AC K S L I P - We a r ra t e o n a l l c om p o n en t s
increases when tracks are slipping. Track shoe
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grousers are affected due to increased sliding

between the grouser and the ground.
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FAVORED SIDE OPERATION - Wear rates will BS97N012
increase on all components when only one side of The machine weight is moved forward causing
the machine is favored. Wear increases as more increased wear of the front rollers. However, due to
power is applied to the favored side. Also, more the design of the track system, working downhill
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packing and slipping will occur on the favored side. reduces the wear of the sprockets and bushings.
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REVERSE OPERATION - Avoid excessive use of WORKING ON THE SIDE OF THE HILL
reverse operation. This is not only non-productive
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use of the machine, but it also accelerates bushing

and sprocket wear.
RIPPING, PULLING IMPLEMENTS, OR USING A
H I T C H O R W I N C H TO P U L L L OA D S - T h i s
operation will shift the machine weight toward the
rear, causing a faster wear rate on the rear rollers.
Then, during severe applications, the sprockets and
track bushings wear much faster.
BS97N013
This moves the weight of the machine toward the

downhill side of the machine. Wear is increased on
the rail sides, roller and idler flanges, bushing ends,
and track shoe ends that are on the downside of the
hill.

Copyright ©
5001-10
WORKING ON A CROWN Wear You Can Control
Good operating techniques and a good maintenance
program will help you to get the longest life from your
undercarriage.
TRACK TENSION
Check the track tension frequently when you operate.
When wor king in mud, snow and some sandy
conditions, check the track tension more often.
Material will pack on the undercarriage parts and
cause the tracks to become too tight. Always
BS97N014
maintain the correct track tension and always clean
The inner components carry the heaviest load. The the undercarriage when you are done for the day.
wear is increased on the inner links, roller treads, See Page 36 for complete information on track
idler treads, and track plate ends. In extreme tension and track adjustment.
situations, the inner sprocket/bushing wear is greatly
increased.
WORKING IN A DEPRESSION
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BS97N015 BD06E024
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The outer components carry the heaviest load. The TRACK SHOES
wear is increased on the outer links, roller treads, The shoes must provide adequate traction and
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idler treads, and track plate ends. In extreme flotation but must be no wider than absolutely
situations, the outer sprocket/bushing wear is greatly necessary. Flotation is the ability to stay on the
increased. surface of soft ground or mud. Correct flotation
CLEAN TRACKS occurs when the grousers penetrate fully into the
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ground without letting the track shoes go below the

W h e n t h e d ay i s f i n i s h e d , a l way s c l e a n t h e
surface.
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undercarriage. Park the machine on a level surface to

p r eve n t d i s t o r t i o n o f t h e t r a ck s e a l s. I f t h e Track shoes that are too wide can have a damaging
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temperature is cold, park the machine on a surface effect on many of the undercarriage components.
that will not freeze to the track shoes. Because the middle of the track shoe is fastened to
the track links, the links act as a fulcrum and must
absorb or transmit any leverage or twisting forces
that occur as the machine moves over uneven or
rocky terrain. All of the other components (sprockets,
track rollers and idlers) resist and restrict the twisting
forces of the links. As a result, most of the wear and
damage caused by the twisting action affects the
links, pins, bushings and track plate mounting
hardware.
Listed below are some of the effects of wide track
shoes:
● Resistance to turning - results in wear on the shoe
corners and twists the track chain.

Copyright ©
5001-11
● Bending, cracking or breaking the track shoes, Misalignment problems will affect more of the
shoe hardware and links. undercarriage components than any other cause of
wear. Misalignment will cause accelerated wear on
● Constant problems with loose shoe hardware that
the track links, idler flanges, track and carrier roller
makes the bolt holes larger.
flanges, sprockets and rock guards. Alignment
● Increased wear on links, roller flanges and idler problems can be caused by all of the following:
flanges caused by constant twisting of the track
● Bent or twisted track frames that are not parallel or
chain.
perpendicular to the centerline of the machine.
● Decreased pin and bushing life, or decreased link Realign, repair or replace damaged or misaligned
life due to elongated pin and bushing bores. This is track frames as required.
a result of the twisted links.
● Idlers that are misaligned vertically or horizontally
● Possible loss of lubricant in the Case Lubricated or are not in line with the sprocket and carrier
Track or Case Extended Life Track pins. This will rollers. Realign the idlers.
result in early pin and bushing wear.
● Sprockets that are not in line with the track and
TRACK ALIGNMENT carrier rollers. Realign the track frame to the
sprockets.
Correct track alignment is required to prevent early
wear of the undercarriage components. When you ● Carrier rollers that are not in line between the
replace parts of the track system, always see the sprocket and idler. Realign the carrier rollers.
service manual for your machine and check the
IMPORTANT: Tight tracks will greatly increase the
alignment of the undercarriage components.
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effect of misalignment by causing an increase in load
between the components. Track tension must be
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checked on a regular basis - more often during
packing conditions. See Page 36 for the correct
procedure to check and adjust the track tension.
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5001-12
EXTENDING UNDERCARRIAGE LIFE
Track Adjustment and Inspection ● If possible, avoid reverse operation, especially

high speed reverse operation.
Eliminating or reducing the controllable causes of
● Avoid long runs at high speed and limit the amount
wear is a primary factor in extending the life of the
of reverse travel.
undercarriage.
● Avoid frequent reverse operation. If necessary to
Proper care and maintenance is the simplest and work in reverse, keep travel speed to a minimum.
m o s t c o s t e f fe c t i v e m e t h o d o f ex t e n d i n g
und erca rr ia ge life. Conscie ntious sche duled ● Constantly turning the crawler in the same
maintenance and good operating habits will help direction will cause uneven wear.
keep operating costs and downtime to a minimum. ● Make sure that rock guards are installed before
you operate in rocky conditions. Remove the rock
Now that you know the major factors contributing to
guards before operating in packing conditions.
t r a c k w e a r, h e r e a r e a fe w o p e r a t i n g a n d
maintenance tips to help you get the most life from ● In freezing temperatures, clean the undercarriage
your machine’s undercarriage. more frequently and park the machine on planks
or on a surface that will not freeze to the machine.
Undercarriage wear is an inevitable part of owning a
track machine. Sooner or later, even the best ● Keep the machine turns to a minimum. Turning
undercarriage will need to be replaced. adds stress and side wear to the components.
● If possible, match the track shoes to the underfoot
You can prolong undercarriage life by understanding
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conditions. Use the smallest track shoe possible
the factors that contribute to wear.
that will give good traction and flotation.
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Operating techniques and maintenance also greatly ● Soil conditions are a major factor in determining
affect undercarriage life. Unlike the other wear the amount of life you can expect from an
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fa ctors that you can no t control, you can do undercarriage. Nonabrasive soils, such as silt and
something about the way you operate and maintain clay, cause the least amount of wear. Wet, sandy
the machine. soils are the most abrasive and cause the most
If you are serious about reducing the maintenance wear.
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and repair of your undercarriage, follow these tips. ● Working in rocky conditions and other surfaces,
● Visually inspect the machine each day for leaking where the grouser bars do not penetrate, causes
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rollers and track pins. high impact and twisting loads on the track chains.
● Check and adjust the track tension on a regular ● Minimize the effects of packing by checking track
basis, especially as job and soil conditions sag frequently when working in mud, snow, and
change. wet sand. Packing can cause track jumping and
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banging.
● Keep the tracks as clean as possible. Packing
●
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materials and abrasives will both accelerate the Severe packing of materials between
wear process. undercarriage components causes wear by
increasing track tension.
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● Check for loose or missing hardware on a regular

basis and replace all missing or damaged parts. ● Running tracks that are too tight reduces bushing
Tighten all bolts to the recommended and sprocket life 2.5 to 3 times.
specifications. ● When possible, work up and down a slope instead
● Tracks that are too tight rob power and cause early of across it. This decreases wear on roller flanges
bushing and sprocket wear. Periodically check and link side rails.
tracks for correct tension. ● Check track tension and clean the undercarriage
● Speed, impact, turning and direction of operation more frequently when working in high packing
greatly affect wear. conditions.
● Avoid high speed operation whenever possible, ● Use the smallest track shoes possible to minimize
particularly in rough terrain. track chain twisting. Limit the use of wide track
shoes to high flotation applications.
● Avoid spinning the tracks as much as possible,
especially in abrasive soil conditions. ● Park the machine on level ground to prevent seal
distortion (Case Lubricated Track and Case
● Do not spin or slide the tracks. Apply the power
Extended Life Track).
and stop the machine gradually.

Copyright ©
5001-13
● Turn the pins and bushings at the 100% wear limit. ● Letting the pins and bushings run to destruction
Operating past the 100% wear limit can cause the results in accelerated wear of other components.
bushings to crack or to wear completely through to Turn the pins and bushings to extend track life.
the pin.
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5001-14
SPROCKET WEAR AND MEASUREMENT

Sprocket tooth wear is the most obvious of all wear
patterns. Track bushing wear is not as obvious but
still must be considered when evaluating corrective
action.
5
Clean Track
When the undercarriage is clean, each bushing seats
against a sprocket tooth. The bushing is engaged at
the 6 o’clock position and carries approximately 85%
of the driving load. At 5 o’clock the load is reduced on 2
this bushing to 10% and at 4 o’clock down to 5% of
the drive load.
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B912376
3 1. BUSHING AND DRIVE TOOTH ENGAGED (AT 3 O’CLOCK)
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2. PACKING ON THE DRIVE SPROCKET
3. ORIGINAL CHAIN PITCH
4. CHAIN PITCH WHEN PACKING STARTS
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5. LEFT DRIVE SPROCKET
SEVERE PACKING
2 1 When severe packing occurs, bushing engagement
starts much later in the sprocket rotation, around 1 to
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2 o’clock. The chain pitch is increased to the

maximum. As a result, (1) the chain is tightened, (2)
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the recoil spring is compressed and, (3) bushing

engagement moves out to the tip of the sprocket
B912375 tooth. The driven bushing continues to receive full
1. TRACK CHAIN AND SPROCKET ARE ON THE SAME
PITCH DIAMETER
load until this bushing leaves the sprocket tooth. At
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2. BUSHING AND DRIVE TOOTH ENGAGED (AT 6 O’CLOCK) that time the track chain seats again on the sprocket.
3. LEFT DRIVE SPROCKET At the same time, the recoil spring is released
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against the stop and a loud noise is heard.

SPROCKET BEGINS TO PACK
This severe packing condition can also cause the
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A material begins to pack into the sprocket teeth, the chain bushing to climb up and go over the top of the
bushing must be engaged at a higher position on the sprocket tooth. This condition, called jumping, will
tooth. See the following illustration. The first bushing also cause a loud noise.
will be seated against a tooth and there will be a
space between the next bushing and tooth. As the The best action to take is to loosen the tracks to the
sprocket rotates, each bushing that is to be engaged correct tension. Or, you can install special relieved
will be progressively further from the driving tooth. drive sprockets if the packing material is extrudable.
The special relieved drive sprockets will help to clean
The first bushing continues to receive the full load as material from the sprocket root.
the sprocket rotates. When this bushing leaves the
sprocket, the track chain will re-seat on the sprocket. NOTE: Special relieved drive sprockets can reduce
This re-seating results in the bushing impacting the life of the track chain bushings as there is less
against the sprocket tooth. At the same time, the contact area on the sprocket.
increased track tension causes the track recoil spring
to be compressed. As the bushing re-seats, the
impact of the bushing along with the release of the
recoil spring causes a loud “banging” noise.

Copyright ©
5001-15
All Case Sealed and the Case Lubricated track EXTREME REVERSE LOADING - Dur ing this
(C.L.T) chains use a “hunting-tooth” design drive operation the machine is backing up a hill and the top
sprocket with an odd number of teeth. This design of both track chains are tight compressing the recoil
causes each tooth to make contact on every other springs. You suddenly drive the machine forward.
r e v o l u t i o n . We u s e t h e s a m e s p r o c k e t fo r The loud “banging” noise that you hear can be from
non-lubricated track as well as the Case lubricated one or both recoil springs releasing.
track.
Sprocket Wear Patterns
1 FORWARD DRIVE SIDE WEAR OF SPROCKET,
BUSHINGS, AND PINS
4 3
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IN
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B921009
5 1. With new sprocket, pins and bushings, there is a

PR
correct match between the sprocket and the
bushings in the 6 o’clock position.
2. The track bushing to sprocket contact area is
60%.
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3. There is not any movement between the

FO
sprocket and bushing until the bushing leaves

the sprocket. At that point, wear is very small.
4. In the forward drive direction, the track pin is in
the hinge point. Internal wear occurs between
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the outside diameter of the pin and the inside

diameter of the bushing. This wear is greatly
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reduced with the C.L.T. and C.E.L.T. track chain.

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5 5. With Case Extended Life track, forward, reverse,

B920084
and vertical wear are evenly distributed on the
1. BUSHING AND DRIVE TOOTH ENGAGED (AT 1 O’CLOCK) bushing because of its ability to rotate, giving
2. CHAIN PITCH WHEN PACKING IS SEVERE greater life to the external bushing surfaces.
3. ORIGINAL CHAIN PITCH
4. SEVERE PACKING
5. TOOTH MOVING OVER BUSHING
6. LEFT DRIVE SPROCKET
INTERMITTENT PACKING - Packing can also occur

between some of the sprocket teeth. When this
happens, the track is tightened and released rapidly
causing the recoil spring to compress and release. A
loud “banging” noise will result.

Copyright ©
5001-16
B921010 B921012
In the forward drive direction, the track bushings ● There are three wear/movement points in the
carry: REVERSE direction as opposed to one in
FORWARD:
1. 85% of the load at the 6 o’clock position.
A. Sprocket scuffing from the bushing
B. Bushing scuffing and rotation
C. Internal pin and bushing wear
REVERSE DRIVE SIDE WEAR OF THE
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SPROCKET AND BUSHINGS VERTICAL WEAR OF THE BUSHINGS AND
IN
SPROCKETS
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B921011
● This is the most severe of all bushing and sprocket

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B921013
wear. The sprocket teeth make contact with the ● This wear results when the bushing slides back
bushings at 12 o’clock. Most of the torque required and fourth in the sprocket.
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to move the machine is transferred at this point.

● With Case Extended Life Track, forward, reverse
● The track chain bushing becomes the hinge point and vertical wear are evenly distributed on the
in reverse drive operation. bushing because of its ability to rotate, giving
greater life to the external bushing surfaces.
● Reverse drive must be kept to a minimum. If
reverse drive is required, reduce the speed.
● With Case Extended Life Track, forward, reverse
and vertical wear are evenly distributed on the
bushing because of its ability to rotate, giving
greater life to the external bushing surfaces.

Copyright ©
5001-17
B921014 B921016
● Frequent forward and reverse shifting accelerates ● The pitch of the track chain no longer matches the
this wear. pitch of the sprocket and “snapping” or “popping”
of the track occurs.
REVERSE TIP WEAR
NEW SPROCKET WITH WORN TRACK PINS AND
BUSHINGS
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IN
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B921015
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● This is the most severe of all outer diameter

bushing wear situations. B921017
● The sprocket pitch no longer matches the track pin

● This only occurs in the forward drive direction.
and bushing pitch.
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● The bushing outer diameter contacts the reverse

● This is a result of the contact area being moved
tip of the sprocket.
farther up on the sprocket tooth.
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● This wear occurs due to packing of the sprocket

root.
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B921018
● Again, never interchange old undercarriage

components with new to try to correct any
condition.

Copyright ©
5001-18
TURNED TRACK PINS AND BUSHINGS WITH
NEW SPROCKET (SEALED AND C.L.T. ONLY)
B921023
● Worn sprocket teeth can be seen as pointed teeth.

B921020
● Again, never interchange old undercarriage
● Turned track pins and bushings will create an components with new to try to correct any
almost new condition. condition.
WORN PINS AND BUSHINGS WITH WORN
SPROCKET
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IN
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R
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B921021
● This returns the sprocket pitch and track chain

pitch to a correct match.
B921019
NEW PINS AND BUSHINGS WITH WORN ● The surface contact is greatly reduced.
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SPROCKET
● Accelerated wear will occur due to lack of contact
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area until the track pins, bushings and sprockets

are destroyed.
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You must now decide whether to turn the pins and

bushings and install new sprockets or run the
undercarriage to destruction.
B921022
● The new track pins and bushings will not match the
worn sprocket pitch.
● The worn sprocket teeth no longer match the track
pitch - this accelerates wear.

Copyright ©
5001-19
SPROCKET REVERSE TIP WEAR (MACHINE SPROCKET REVERSE DRIVE SIDE WEAR
TRAVELING FORWARD) (MACHINE TRAVELING IN REVERSE)
R eve r s e t i p we a r i s d u e t o m a t e r i a l p a ck i n g Reverse drive side wear can be the most severe
conditions. As the material builds up on the sprocket, wear you can have with the sprocket teeth and
the chain pitch no longer matches the sprocket teeth. bushings. When moving in reverse, the sprocket
The sprocket tooth contacts the bushing as the chain teeth contact the chain bushings at about 12 o’clock.
moves into the sprocket. Wear is on the reverse side Most of the torque required to move the machine is
tip of the sprocket tooth and the bushing. transferred to the track chain between 12 and 11
o’clock. During this time, the bushing is rotating
against the sprocket. A pocket forms on the reverse
side of the sprocket tooth where the rotating bushing
is making contact. This contact causes accelerated
wear, especially when the machine is moving at high
speed.
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IN
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FO
2
T
O
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3
1
B912293
1. REVERSE TIP WEAR OF THE SPROCKET CAUSED BY
PACKING B912297
2. BUSHING WEAR CAUSED BY THE SPROCKET TOOTH 1. REVERSE WEAR OF THE SPROCKET
3. MATERIAL PACKING IN THE SPROCKET ROOT 2. REVERSE WEAR OF THE BUSHING

Copyright ©
5001-20
SPROCKET FORWARD OPERATION WEAR SPROCKET ROOT WEAR (VERTICAL WEAR)
(MACHINE TRAVELING FORWARD)
This type of wear occurs as the track bushings slide
When driving forward, the sprocket teeth contact the through the sprocket root. Accelerated wear occurs
bushings at about 6 o’clock. Most of the torque with frequent forward and reverse shifting. This
required to move the machine occurs at this point. moves the bushing back and for th between the
The bushing does not rotate against the sprocket sprocket teeth, though wear is even greater if track
u n t i l l e av i n g t h e s p r o cke t a t a b o u t 1 1 t o 1 2 tension is too tight. This type of wear is also called
o’clock.This is normally not a critical wear factor vertical wear.
because the torque was transmitted at the 6 o’clock
position. It becomes a problem only when track
tension is too tight.
2
2 1
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B912299
1. SPROCKET WEAR
IN
2. BUSHING WEAR
SPROCKET SIDE WEAR

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Sprocket side wear is caused by contact with the
1 sides of the track links and is a result of excessively
loose track, back bending, jamming or misalignment
of the sprocket and rear roller.
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FO
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1
O
N
B912298
1. FORWARD WEAR OF THE SPROCKET
2. FORWARD WEAR OF THE BUSHING
B912300
1. SPROCKET SIDE WEAR

Copyright ©
5001-21
Measuring Sprocket Wear SPROCKET WEAR
The purpose of this section is to help you measure Sprocket tooth wear is not measurable. The sprocket
the wear of undercarriage components as accurately teeth have no clear reference point from which to
as possible. take a measurement. The wear on the sprocket teeth
is due to (1) the contact with the track chain bushings
Also, by measuring wear and using the charts that and (2) any material trapped (packed) between the
are available for your machine, you will be able to components. As the components wear, certain wear
determine the remaining life of all the components. patterns develop on the sprockets.
A visual examination of the sprocket teeth along with
the bushing outside diameter measurements will give
you a good idea of the sprocket condition.
When replacing the track chain or turning the pins
and bushings, always replace the sprockets or
sprocket segments (sections). Never mix old
components with new.
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IN
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R
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Copyright ©
5001-22
BUSHING WEAR
Bushing Off-Center Wear Bushing Vertical Wear

This type of wear is caused by misalignment of any Vertical wear occurs as the track bushings slide
of the undercarriage components. The track chain is through the sprocket root. Accelerated wear occurs
pushed against the side of the rollers or idler flanges with frequent forward and reverse shifting. This wear
or against the side of the sprocket. Off-center wear is is even greater if track tension is too tight. This
also caused by continuous side hill operation. If you moves the bushing back and for th between the
must operate the machine sideways on a hill, operate sprocket teeth, see Page 16, Sprocket Root Wear.
in both directions. If side hill operation is
unavoidable, changing component parts from side to Bushing Reverse Drive Side Wear
side will lengthen undercarriage life. The use of rock
guards/track guides also help to maintain alignment. Reverse drive side wear can be caused by sprocket
reverse tip wear or machine reverse travel, see Page
15, Sprocket Reverse Tip Wear or Sprocket Reverse
Drive Side Wear. Reverse drive side wear is a major
wear pattern for bushings in all track chains and is
accelerated with tight track and high speed reverse
operation.
Bushing Forward Wear
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Forward wear is the normal wear which occurs as the
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machine is driven forward, see Page 15. Forward
1 drive side wear will generally show less wear than
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reverse or ver tical wear because of the lack of
bushing rotational movement when the machine is
B912301 driven forward.
1. OFF-CENTER BUSHING WEAR
RIGHT-HAND TRACK
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Roller Flange Wear on the Bushing

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If the track rollers, carrier rollers, and/or links are

2
allowed to wear excessively, the roller flanges will
begin to rub against the bushings. If not corrected,
the bushings can crack or break. 1
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Do not use worn rollers with a new chain or with

turned pins and bushings. Also, do not use worn links
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and new rollers. 3

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B900594X
1. VERTICAL WEAR
2. FORWARD WEAR
3. REVERSE WEAR
C.E.L.T. - The above wear characteristics are

reduced with the Case Extended Life Track design.
The rotating bu shings will wear under these
conditions, but the wear will be spread evenly over
1
the circumference of the bushing. Thereby, providing
significantly greater life.
B912302
1. ROLLER FLANGE WEAR ON BUSHING

Copyright ©
5001-23
LEFT-HAND TRACK Pins and Bushings (Pitch
Extension)
2 To measure the internal bushing and pin wear,
measure the track pitch in three places on each
track. This measurement is the distance between five
1 track pins. Make sure the measurement is taken at
least four track links away from the master pin
(non-lubricated track). The master pin has a hole in
3 each end. Tighten the track to remove all slack and
measure from the front of one pin to the front of the
5th pin. See the following illustration. Make a record
of the measurements on the Track Component
Appraisal Form.
B900594
1. VERTICAL WEAR
2. REVERSE WEAR
3. FORWARD WEAR
Bushing Cracks (Non-Lubricated

Track)
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Excessive external bushing wear with excessive
internal wear will cause thin bushing sides, reducing
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the bushing strength. Impact loads can then cause
cracks in the bushings. B800707
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IMPORTANT: The Case lubricated track will have
Bushing Cracks (Case Lubricated little pitch wear unless the seals are damaged and
Track) the lubricant lost in individual joints. The dry joint will
feel hot after operation.
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Excessive external bushing wear and high impact

loads will cause the bushings to crack. Prevent this
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problem by turning the pins and bushings at the

recommended time.
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B4086391
1. CRACK
Bushing cracks can also result when you run the

undercarriage to destruction. When this happens,
you prevent the possibility of turning the pins and
bushings (sealed and C.L.T.).
P r e ve n t t h i s p r o b l e m b y p e r fo r m i n g w e a r
measurements and turning the pins and bushings at
the recommended time.

Copyright ©
5001-24
TRACK PIN WEAR
Pin Surface Wear Pin Spalling
B912307
B912305
C A S E L U B R I C AT E D T R AC K A N D C A S E
NON-LUBRICATED TRACK - Track pin wear is
EXTENDED LIFE TRACK - If you operate the
accelerated by tight track, high speed operation, and
machine with tight tracks, heavy packing, or flexing of
abrasives between the pins and bushings. As the
the chain caused by shoes that are too wide, cracks
tracks turn around the sprocket and idler, the pins
can begin to form at the oil reservoir hole and spread
and bushings pivot internally. This pivoting action
out.
wears the outside surface of the pins and the inside
surface of the bushings. But, because the chain is
under tension, this wear occurs only on one side of Pins Breaking
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the pins and bushings (regardless of forward or
reverse direction of the tracks). The pin and bushing
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wear, called “pitch wear”, eventually increases the
length of the chain.
PR
R
B912308
C A S E L U B R I C AT E D T R AC K A N D C A S E
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EXTENDED LIFE TRACK - This condition can be

B912306
caused by tight track, high impact loads, severe
C A S E L U B R I C AT E D T R AC K A N D C A S E packing, and using track shoes that are too wide.
EXTENDED LIFE TRACK - Track pin wear is greatly This problem can also be caused by not installing the
pins correctly at assembly.
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reduced with the C.L.T. and C.E.L.T. However, tight

tracks with high speed operation, operating in Cracks start at the outer surface at the reservoir hole
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packing conditions, or using track shoes that are too and spread through the pin at a rapid rate. This
wide will cause the pins to gall (score marks on the condition is not common with sealed track pins.
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surface).
Pin End Wear guards.
B912309
Pin end wear is caused by misalignment, track shoes

that are too wide, worn idlers or worn roller flanges.
This condition can also result from hillside operation.
The pin ends rub against the track guides/rock
Copyright ©
5001-25
TRACK LINK WEAR
Link Uneven Top Wear Wear on the Inside Surface of the

Link
B900597
As the tracks rotate, the rail surfaces of the link B912314

contact the idler, rollers and carrier rollers. The wear Wear on the inside surface of the link is caused by
pattern that develops eventually becomes “wavy” or rotating contact with the next link when seal failure
“scalloped”. See the illustration that follows. These occurs. Bushing end wear and lack of link separation
wear patterns are normal. occurs. If the link rails are not worn excessively, turn
The forward and rearward surfaces wear faster the pins and bushings and reseal.
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because of the narrow link overlap. The center wear
surface is sliding wear due to a reduced contact area Pin Boss Top Wear
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with the idler wheel.
This wear is caused by contact with the roller flanges
due to link rail surface wear and roller tread surface
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Side Wear of the Link Rail wear. This condition must be corrected or track chain
rebuild will not be possible. Your machine will start to
vibrate.
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FO
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B900598
This wear occurs because of contact with the rollers

and idler flanges. Wear increases with side hill B900599
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operation, turning, uneven terrain, misalignment or

track shoes that are too wide. Looseness due to
increased track pitch (bushing to pin wear) allows the
track chain to flex from side to side increasing side
loads and side wear.

Copyright ©
5001-26
Sprocket Wear on the Inside of the Link Rail Spalling

Links
B900600 B912311J
The following illustration shows wear caused by the This condition occurs with repeated high impact
tips of the sprocket teeth on the inside of the link. loading with the track rollers. Machine speed, weight,
This occurs due to misalignment between the tracks that are too tight, or track shoes that are too
sprocket and rear roller. Other causes can be a chain wide can also cause the problem. If the area of
that has worn pins and bushings, side hill operation damage is over 25 to 30%, wear life and rebuild
or track shoes that are too wide. ability may be reduced.
Wear in the Counterbore Pin Boss End Wear of the Link
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(Non-Lubricated Track)
IN
PR
R
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B912312
Wear of the pin boss is caused by sliding contact with

B912310
the track guides/rock guards. This condition is
This wear is caused by the same condition as was
caused by side hill operation or track shoes that are
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stated under Wear on the Inside Surface of the Link -

too wide.
wear caused by rotating contact with the next link
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when seal failure occurs. Bushing end wear and lack

of link separation occurs. Other kinds of causes can
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be side hill operation, turning and high impact.
Counterbore Extension of the Link result of pitch extension and usually occurs after the
pins and bushings have been turned. Track shoes
that are too wide can also cause this condition.
B921123
This condition is caused by seal failure that causes

the bushing to rotate in the bore. This is a direct
Copyright ©
5001-27
Link Crack
B900601
Link cracking is caused by twisting track chain. This

is usually caused by track shoes that are too wide,
high impact, or tight tracks. If you see this type of
damage, replace the links immediately to prevent
further damage.
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PR
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Copyright ©
5001-28
IDLER WEAR
Idler Tread Surface Wear Idlers

Normal wear occurs between the tread surface and The only wear that can be measured on the idlers is
track links. Acceleration of this wear can occur with the treads. This wear is normal and is caused by the
applications that put more weight on the idlers, track links moving around the idler. Assemble the
speed, high impact, turning, tight tracks, packing and rules in the kit to make a depth gauge. See the
abrasive soils. following illustration. Make sure the treads are clean.
Measure the center of the treads because this is the
area of greatest wear. Measure both sides of the
idler. Make a record of the idler measurements on
the Track Component Appraisal Form.
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B912318
IN
Idler Flange Side Wear
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This wear is caused by contact with the inner rail of
B900608
the track links. Misalignment, side hill operation,
excessive turning, tight track, worn track guides/rock
guards, and track shoes that are too tight all
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contribute to this wear.

FO
T
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B900609

Copyright ©
5001-29
TRACK ROLLER AND TRACK CARRIER ROLLER WEAR

Rollers will show wear on the tread surfaces and the Track Rollers and Carrier Rollers
sides of the flanges. These are normal wear patterns
caused by contact with the track chain links. The only wear that can be measured on these rollers
is the treads. Use the large caliper from the kit and
Tread Wear measure both treads of each roller. If required,
remove the rock guards/track guides. When installing
Wear will occur between the tread surface (1) and the rock guards/track guides, use Loctite 242 on the
the top of the track link rails. This wear is normal and threads of the mounting bolts. When the middle track
unavoidable. However, this wear is accelerated by rollers are 40% worn, it is recommended that the
high speeds, impact loads due to rough terrain, track rollers be rotated. Make a record of the roller
packing, and the use of track shoes that are too wide. measurements on the Track Component Appraisal
When packing prevents the roller from turning, flat Form.
spots on the tread surface will occur.
Make sure that you hold the caliper in the center of
the treads as this is the area of most wear. Care
Flange Wear must be taken to find the smallest worn diameter.
Wear on the flange tops (2) shows that the roller Measure both treads of each roller.
treads and/or the link rails are worn past the wear
limits. The flanges are contacting the link pin bosses. 2
Side flange wear (3) shows misalignment, side hill
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operation, excessive turning, worn track, or track.
IN
PR
3
R
1
B900602
FO
1. TREAD WEAR 3. FLANGE SIDE WEAR

2. FLANGE TOP WEAR
BS98H051
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Copyright ©
5001-30
TRACK SHOE WEAR
Track Shoes
The wear that is measured on the track shoes is the
height of the grouser. There are three types of track
shoes (1) one bar, (2) two bar, or (3) three bar
grouser. Assemble the rulers in the kit to make a
depth gauge. If your machine has single bar
grousers, tighten the track chain before measuring.
Refer to the following illustration and measure
B900612
several track shoes on each side of the machine.
Measure the wear 1/3 the distance from the outer
e n d o f t h e t ra ck s h o e. M a ke a r e c o r d o f t h e
Cracked or Broken Shoes
measurements on the Track Component Appraisal Cracked or broken shoes can be caused by various
Form. When finished, adjust the track for correct conditions. Some of the causes can be terrain,
tension. impact loads, speed, shoes that are too wide for the
conditions, or structural problems for a track shoe
that has lost most of the grouser bar/s. Always try to
use the narrowest track shoe possible.
T
IN
PR
B900611
Grouser Wear
B900613
The following illustration shows wear of the grouser.
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This wear is normal and unavoidable. The greatest Bolt Holes Too Large
cause of grouser wear is track slipping. This is
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If the mounting bolts are loose, the bolt holes can

non-productive and can be controlled by reducing
become larger. If this happens, the track shoes and
track speed and using the correct type track shoe for
mounting hardware must be replaced. Conditions
the job. Excessive wear of the grousers will reduce
that cause hardware to loosen can be (1) hardware
the strength of the track shoes increasing the
that was not torqued correctly, (2) track shoes that
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probability of track shoe bending.

are too wide, or (3) turning resistance in rocky
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terrain.
W h e n in s t a l l i n g n ew t ra ck s h o e s, l i n k s, a n d
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hardware, always clean the mating surface of all

paint, rust and dirt. Always use the recommended
bolt torque. (Don’t over torque.)
B912322
Wear on the corners of the grousers usually indicates

rough terrain with high impact conditions. If the shoes
are too wide, the corners can chip or bend.
B900614

Copyright ©
5001-31
CASE NON-LUBRICATED TRACK

Case Lubr icated Track (C.L.T.) and the Case Turning Pins and Bushings
Extended Life Track (C.E.L.T.) provide substantially
m o r e s e r v i c e l i fe t h a n t h e s e a l e d t r a c k o r
(Non-Lubricated Track)
non-lubricated track. Turning the pin/bushing assembly in the track link
Because of the greatly reduced internal wear of the returns the track chain to the original length and puts
(C.L.T. & C.E.L.T.) pins and bushings, the wear fresh bushing material in contact with the sprocket
patterns of the undercarriage will be somewhat teeth.
different from those of the sealed track.
This track is assembled with pins, bushings and
Belleville seals on each side to reduce the amount of
dirt entering the bushings. Parts are lubricated at
assembly.
1
2
3
2
1
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5
IN
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1
3
4
1
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B900615
1. BELLEVILLE SEALS 4. PIN

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2. SPACERS AT MASTER LINK 5. MASTER PIN

3. BUSHINGS
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Copyright ©
5001-32
CASE LUBRICATED TRACK (C.L.T.)

The Case lubricated track design begins with a link DRY TURN - A dry turn can be made when the pins,
joint that seals out abrasives and keeps the lubricant bushings, and seals are in condition to be used again
in. Pin and inter nal bushing wear is vir tually but not good enough to be used as a sealed
eliminated by constant lubrication from the oil assembly. Lubricant is not added to this joint after
reservoir in each pin. External bushing life is also turning. See the service manual for your machine for
extended due to a larger bushing outer diameter and more information.
deeper case hardening.
IMPORTANT: If hollow pins are used in a dry turn,
Sealed and lubricated pins and bushings means less make sure the lubrication hole is put in the vertical
track friction. The machine actually has more position and the oil passage hole is toward the link
horsepower available for machine work. rail wear surface. Installing the pin wrong can cause
the pin to break.
3 IMPORTANT: After turning the pins and bushings, it

is recommended that you use new track shoe
mounting bolts. Be sure to torque bolts as specified
and recheck bolt torque daily until they stabilize.
(Don’t over torque.)
Marking the Pins and Bushings

(Case Lubricated Track)
T
IN
4 Before you turn the pins and bushings, mark each
6 1 pin and bushing with a little paint as shown below.
2 5 This will give good identification reference points as
PR
you reassemble the track chain.
B900616J
1. BUSHING 4. RUBBER PLUG IMPORTANT: If hollow pins are used in a dry turn,
2. LUBRICANT 5. SEAL make sure the lubrication hole is put in the vertical
3. PIN 6. OIL PASSAGE HOLE position as shown below (3). Installing the pin wrong
R
(lubrication hole horizontal or vertical with lubricating

Turning Pins and Bushings (Case hole toward the shoe mounting surface) can cause
FO
the pin to break.

Lubricated Track)
CASE lubricated track has vir tually eliminated 6
inter nal pin and bushing wear. Only the outer 4
T
bushing to sprocket wear is the main concern. This

track system is very dependent on the seals. If a joint
O
fails and loses oil, that joint will wear rapidly.

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Bolt-on sprocket segments or new sprockets must be

installed when you turn the pins and bushings. The
bushings in the newly restored track chain will
continue to ride high on the worn sprocket teeth 5
causing faster wear.
2
Because there is virtually no internal wear of the pins 1
and bushings with this type of track, measure the 3
outside wear of the bushings. If the bushings are B920937
turned, it is recommended that you replace both drive 1. PIN
sprockets at the same time. 2. BUSHING
3. OIL PASSAGE
WET TURN - A wet turn can be made when the pins,
4. SPROCKET WEAR ON BUSHING BEFORE TURN
bushings and seals are in condition to be used again 5. PAINT ON PIN AND BUSHING
to make a sealed and lubricated joint. Refer to 6. SPROCKET WEAR ON BUSHING AFTER TURN
s e r v i c e m a n u a l fo r y o u r m a c h i n e fo r m o r e
NOTE: Turn pin “around or 180° “but do not rotate
information.
pin and change position of oil passage No. 3.

Copyright ©
5001-33
Track Bushings (Forward and Track Bushings (Vertical Wear)

Reverse Wear) - Sealed and C.L.T. SEALED AND C.L.T. - Use the depth gauge to
Use the small caliper from the kit and measure the measure the vertical wear of a bushing as shown.
wear on the track bushing as shown. Make several Make several measurements across the worn area to
measurements across the worn area to find the most find the most wear. Make sure that the bushing and
wear. Make sure that the caliper is 90° to the track shoe are clean and that the depth gauge is
bushing. Record the measurements on the Track pe r pe n d icular to the tra ck sh o e. R ecord the
Component Appraisal Form. Measure three bushings measurement on the Track Component Appraisal
at 0.9 to 1.2 m (3 to 4 foot) intervals and record the Form. Measure two more bushings at 0.9 to 1.2 m (3
measurements on the Track Component Appraisal to 4 foot) intervals and record the measurements on
Form. Measure the bushings on both sides of the the Track Component Appraisal Form.
machine.
2
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B900594X
IN B900595
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RIGHT-HAND TRACK C.E.L.T. - Be ca u se the C. E.L.T has rotatin g
bushings, the bushings will wear evenly over the
1. FORWARD WEAR 2. REVERSE WEAR
entire circumference of the bushing. No pin and
bushing turn is required, but measurements should
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be taken to determine remaining bushing wear life.

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B900594X
LEFT-HAND TRACK
1. REVERSE WEAR 2. FORWARD WEAR

Copyright ©
5001-34
CASE EXTENDED LIFE TRACK (C.E.L.T.)

The Case extended life track (C.E.L.T.) is a sealed
and lubricated track and incor porates a large
diameter bushing that is free to rotate on the
standard track bushing. This allows wear to be
distributed over the entire circumference of the
bushing and because it is free to rotate, it does not
create the scrubbing wear between the sprocket and
the bushing as the conventional track does.
The Case Extended Life Track provides the long 4 2
service life that the Case Lubricated Track provides
with the internal lubrication. It also provides up to 3 1 5
twice the bushing wear life on the external surface of BS96A027
the bushing, because of the rotating bushing and
1. BUSHING 4. RUBBER PLUG
greater wear material.
2. LUBRICANT 5. ROTATING BUSHING
The rotating bushing can make a clanging noise 3. PIN
“when worn” during Hi speed operation. The bushing
will make less noise when crawler is dozing.
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5001-35
TRACK TENSION - C.L.T., C.E.L.T., AND NON-LUBRICATED TRACK
Extended Track Pitch (Length) - Correct Tension

Non-Lubricated Track Only Correct track adjustment is the most important
For maximum track life, always maintain correct track factor that helps to control undercarriage wear. Track
tension. The track chain must match the pitch of the sag of 1-1/2 to 2 inches must be maintained for all
drive sprockets. If the pitch (length) of the track chain Case crawlers.
increases, the chain pitch no longer matches the IMPORTANT: When operating in packing conditions
drive sprocket pitch. Increased wear will occur. (mud, snow, etc.) material will stick to the track parts
and cause the track tension to be too tight. Check
2 and adjust the track tension often during these
conditions.
The following char t shows track tension (% of
tightness). A tight track requires more horsepower to
move the machine, increases fuel consumption, and
3 can reduce bushing and sprocket life up to 2.5 to 3
times.
100%
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90%
1
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75%
B920820
1. PITCH (LENGTH) OF NEW TRACK CHAIN 60% 1
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2. PITCH (LENGTH) OF WORN TRACK CHAIN
3. INCREASE OF PITCH (LENGTH) OF WORN TRACK CHAIN 45%
30%
Track Tension
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15%
The life of the Case Lubricated Track, the Case
Extended Life Track and the non-lubricated track is 0%
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directly controlled by track tension. This single factor

13 mm 38 mm 51 mm
is the most important in controlling the track life. (0.5 inch) (1.5 inch) (2 inch)
Other Conditions B912346

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TRACK SAG ADJUSTMENT CHART

If the Case Lubricated Track or the Case Extended 1. TRACK TENSION (PERCENT TIGHT)
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Life Track does not show improved life when

compared with the non-lubricated track, one or more
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of the following conditions has occurred:

1. The track tension was too tight.
2. The track pins lost lubricant. This can be caused
by having track shoes that are too wide for the
conditions or by high impact conditions.
3. Soil or operating conditions have changed.

Copyright ©
5001-36
Bushing and Sprocket Wear Chart Procedure to Adjust the Track

The tighter you have the tracks, the faster the wear. 1. Park the machine on a level surface and do not
The following char t illustrates the relationship clean the tracks.
between wear rate and track sag.
2. Drive the machine forward the length of the
NOTE: It is recommended that you turn the pins and track. Do not use the brakes to stop the machine.
bushings at the 100% wear limit, or before.
3. Stop the machine so that a track pin is over the
front carrier roller.
20% 40% 60% 80% 100% 120%
B912347
1. 38 TO 51 MM (1.5 TO 2 INCH) TRACK SAG
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2. 25 MM (1 INCH) TRACK SAG BD02H010
IN
3. 13 MM (0.5 INCH) TRACK SAG 4. Put a straightedge over the track and measure
4. HOURS OF USEFUL TRACK LIFE the track deflection midway between the carrier
NOTE: 120% Wear is Running the Track to roller and the idler wheel. The correct
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Destruction. adjustment is 38 to 51 mm (1-1/2 to 2 inches).
Track Link Height

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The only wear that can be measured is wear of the

rail on the track links. To measure the height of the
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track links, assemble the rulers in the kit to make a

depth gauge. Make sure the areas to be measured
are clean. Make the measurement in the area shown
in the following illustration. Make sure you hold the
ruler 90° to the track shoe. Measure 3 track links 0.9
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to 1.2 m (3 to 4 feet) apart. Record the smallest

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measurement on the Track Component Appraisal

Form.
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BDO2H013
5. If you must adjust the track, see the two following

instructions.
B900596

Copyright ©
5001-37
To Tighten the Track Chain To Loosen the Track Chain
BD02H015 BD02H016
1. Put grease into the adjuster grease fitting until 1. Use a deep socket to loosen the large adapter
the deflection is between 38 to 51 mm (1-1/2 to 2 two turns. Do not remove the large adapter. Let
inches). the grease come out until the track deflection is
38 to 51 mm (1-1/2 to 2 inches).
2. Adjust the other chain.
2. Tighten the large adapter to a torque of 60 to 75
3. Move crawler again and check track deflection.
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Nm (44 to 55 pound feet).
IN
3. Adjust the other chain.
4. Move crawler again and check track deflection.
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5001-38
NOTES
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Copyright ©
5001-39
GLOSSARY
Gritty or abrasive types of soils that accelerate wear on the undercarriage parts. Wear is
ABRASIVES
accelerated with moist abrasives and tight tracks.
A Case publication (Form Number BUR 8-17960) that has charts for finding the wear
APPRAISAL MANUAL
percentage after measuring an undercarriage component.
A pushing together of the track chain parts between the bottom of the sprocket and the
BACK-BENDING rear track roller. This occurs during reverse travel with excessively loose track. The
condition is sometimes called Back Jamming.
A component of the track link assembly through which the pin of the next assembly
BUSHING
passes. The pin of the next assembly then pivots on the bushing.
The carrier roller guides and supports the upper part of the track chain between the
CARRIER ROLLER
sprocket and the idler wheel.
A track chain assembly that is sealed and lubricated with an oil reservoir in each pin. It
CASE EXTENDED LIFE
incorporates a large diameter rotating bushing that rotates on the standard bushing. Each
TRACK (C.E.L.T.) link is sealed to keep contaminants out and the lubricant in.
CASE LUBRICATED A track chain assembly that is sealed and lubricated with an oil reservoir in each pin. Each
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TRACK (C.L.T.) link is sealed to keep contamination out and lubricant in.
IN
This is a Case Lubricated Track (C.L.T.) track joint that has lost all lubricant. Internal wear
DRY JOINT
begins after loss o lubricant.
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A procedure to turn the track pins and bushings without putting new oil in each pin. This
DRY TURN
reduces the service cost but results in shorter track life.
EXTERNAL WEAR Wear that occurs on the outside surface of track bushings.
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EXTRUDABLE Material that squeezes out from between undercarriage parts instead of lodging and
MATERIAL becoming compressed.
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The ability to stay on the surface of the ground. Correct flotation occurs when the track
FLOTATION
shoes penetrate fully into the ground without sinking below the surface.
FORWARD DRIVE SIDE The wear pattern of the sprocket teeth that results from the bushings wearing into the
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WEAR sprocket tooth during forward travel.

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GROUSER The metal bars on the track shoes that give traction to the machine.
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HOURS OF USE The number of hours a machine has worked according to the hour-meter.
IDLER The wheel that guides the track chain around the front of the track frame.
INTERNAL WEAR The wear between a track pin and bushing. This is also called pitch wear.
This refers to a part that is filled with lubricant and then sealed. No maintenance is
LIFETIME LUBRICATED
required.
Component parts of a track link assembly. One inner link and one outer link are required
LINKS
for one assembly.
The distance from the link wear surface to the track shoe mounting surface. This distance
LINK HEIGHT
is measured to determine link surface wear.

Copyright ©
5001-40
A special link that provides for easy separation of the track chain. Conventional master
links use a pin that has a smaller diameter than normal pins except for an oversized
MASTER LINK
shoulder at one end. Master pins are identified by a large, deep counterbore at one or both
ends. (Also see Split Master Link).
Conditions such as snow, wet sand, or clay cause material to stick to the undercarriage
PACKING MATERIALS
parts.
A component part of a track link assembly. The pin from one link assembly rotates in the
PIN
bushing of the next assembly and allows the track chain to hinge.
POTENTIAL HOURS An estimate of the total remaining life of a component.
RAIL The surface of the track link upon which the track rollers travel
REVERSE DRIVE SIDE The wear that occurs to the sprocket and external surface of the bushings when traveling
WEAR in reverse.
Guards that are used to keep rocks or debris from getting caught between the track chain
ROCK GUARDS
and track rollers.
A component of the track link assembly which rotates over the standard bushing. Used
ROTATING BUSHING
only on the Case Extended Life Track (C.E.L.T.).
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This is a term that is used to describe the complete destruction of undercarriage
RUN TO DESTRUCTION
IN
components. When this occurs, the crawler can no longer function.
This is the side flex and motion of the track chain. This will occur when the pins and
SNAKY TRACK
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bushings become worn.
SPLIT MASTER LINK

This special track link assembly allows the track chain to be separated without using a
(C.L.T.andC.E.L.T.
track press. The design allows easy separation.
CHAIN)
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The sprocket is the driving part of the undercarriage system. The teeth on the sprocket
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SPROCKET engage the bushings of the track chain and propel the machine forward or rearward. The
sprockets are connected to the final drives on each side of the transmission.
This specail sprocket is designed to reduce the amount of material that can build up and
SPROCKET, RELIEVED stick in the root of the sprocket. This sprocket must only be used when operating in
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packing materials.
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The track adjuster is used to increase or decrease track tension. Grease is added or
TRACK ADJUSTER removed to make the adjustment. The rubber track uses an automatic adjusting system
N
which uses hydraulic oil.
The track chain assembly is a continuous rail system on which the machine moves. This
TRACK CHAIN assembly includes links, pins, and bushings. The track shoes are attached to this
assembly.
TRACK CHAIN, SEALED A track chain assembly (non-lubricated track) that has metal seals (Belleville Washers) on
TYPE both sides of each bushing.
TRACK CHAIN, CASE A track chain assembly that is sealed and lubricated with an oil reservoir in each pin. Each
LUBRICATED TRACK link is sealed to keep contamination out and the lubricant in.
TRACK CHAIN, CASE A chain assembly that is sealed and lubricated with an oil reservoir in each pin. It
EXTENDED LIFE incorporates a large diameter rotating bushing that rotates on the standard bushing. Each
TRACK link is sealed to keep contaminants out and the lubricant in.

Copyright ©
5001-41
This is the distance from the centerline of the right track chain to the centerlink of the left
TRACK GAUGE track chain. Sometimes referred to as the distance between the centerline of each
sprocket.
TRACK PITCH This is the distance from the center of one track pin to the center of the next track pin.
TRACK ROLLER The track rollers support the weight of the machine and guide the track chain.
Track sag is the amount of track chain deflection of the upper part of the track chain. This
TRACK SAG
deflection is measured when you adjust the track tension.
TRACK STRETCH -
This is the increase of the track pitch due to internal bushing wear and pin wear.
SEALED TRACK
TRACK TENSION Track tension is the measurement of how tight or loose the track chain is on your machine.
TURNING PINS AND

BUSHINGS
This is the rotation of the pins and bushings 180 degrees in each chain link to give new
SEALED TRACK
wear surfaces.
WET TURN- A wet turn can be made when pins, bushings, and seals are in condition to
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be used again to make a sealed and lubricated joint. Lubricant is added after assembly
CASE LUBRICATED
DRY TURN- A dry turn can be made when pins, bushing, and seals are in condition to be
IN
TRACK used again but not good enough to make a sealed joint. Lubricant is not added after
assembly.
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IMPORTANT: If hollow pins are used in a dry turn, the lubrication hole must be positioned
vertically - 180 degrees to the track shoe mounting surface.
IMPORTANT: A joint that shows leakage can be assembled only as a dry turn if new parts
are not used.
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UNDERCARRIAGE A teaching aid that is used to demonstrate concepts and causes of track pin, bushing, and
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SIMULATOR sprocket wear.
The rate at which a component or system of components wears. This wear rate is
WEAR RATE
controlled directly by service methods, ground conditions, and operating methods.
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5001-42
NOTES
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5001-43
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5001-44
NOTES
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Copyright ©
5502
Section
5502
INSPECTION OF TRACK SYSTEM COMPONENTS
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5502-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Impact and Low Impact Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PIN AND BUSHING WEAR FOR SEALED TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PIN AND BUSHING WEAR FOR CASE LUBRICATED TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Case Extended Life Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRACK LINK WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRACK SHOE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRACK AND CARRIER ROLLER WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IDLER WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WEAR CHART FOR PIN AND BUSHING WEAR (PITCH EXTENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WEAR CHART FOR VERTICAL BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WEAR CHART FOR FLOATING BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WEAR CHART FOR VERTICAL BUSHING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WEAR CHART FOR TRACK LINK WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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WEAR CHART FOR ONE BAR TRACK SHOE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
IN
WEAR CHART FOR TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WEAR CHART FOR CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WEAR CHART FOR IDLER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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TRACK COMPONENT APPRAISAL FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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5502-3
SPECIAL TOOL
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B4007091
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CAS-1950A MEASURING TOOLS KIT
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Copyright ©
5502-4
INTRODUCTION
The purpose of this section is to help you measure 3. Case Extended Life Track (CELT) is a sealed
the wear of track system components, and to and lubricated track and incorporates a large
understand the cause of the wear. diameter bushing that is free to rotate on the
standard track bushing. This allows wear to be
Also, by measuring wear and using the charts in this
distributed over the entire circumference of the
section you will be able to determine the remaining
bushing and because it is free to rotate, it does
life of many of the components.
not create the scrubbing wear between the
Three types of track systems are used on this sprocket and the bushing as the conventional
machine: track does.
1. Sealed track which is assembled with grease.
Two Belleville springs are installed at each end
of the bushings to keep dirt out of the bushings.
1
2
3
4 2
3
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1 5
IN
BS96A027
1. BUSHING 4. RUBBER PLUG

2. LUBRICANT 5. ROTATING BUSHING
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3. PIN
The remainder of the track system components are
4 1 the same for the sealed track, Case Lubricated
B900615 Track, and Case Extended Life Track.
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1. BELLEVILLE SPRINGS 3. MASTER BUSHING

2. SPACER 4. BUSHING High Impact and Low Impact
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2. Case Lubricated Track (CLT) which is Conditions

assembled with oil. Seals are installed at each
end of the bushings to keep the lubricant in the To determine if the machine is being used in a low or
bushing. high impact working condition, see the following
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definitions.
A low impact condition is when the bar(s) on the track
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shoe completely engage the ground and the ground

is free of bumps.
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A high impact condition is when the bar(s) on the

track shoe do not completely engage the ground and
there is constant contact with rocks or large
1
irregularities.
4
2
3
B900616
1. PLUG 3. BUSHING
2. PIN 4. LUBRICANT

Copyright ©
5502-5
PIN AND BUSHING WEAR FOR SEALED TRACK

Because of the constant force applied to the pins and Use the small caliper from the CAS-1950A kit and
bushings in forward and reverse, wear occurs on the measure the wear on the front and rear of a bushing
ID of the bushing and the OD of the pin surface as shown. Make several measurements across the
inside the bushing. This wear is nor mal. The worn area to find the most wear. Make sure that the
deflection of the track chain is important because the bushing is clean and that the caliper is 90 degrees to
tighter the track chain, the faster the wear. the bushing. Record the measurements on the Track
Component Appraisal Form. Measure two more
To measure internal bushing and pin wear, measure
bushings at 0.9 to 1.2 M (3 to 4 feet) intervals and
the track pitch in three places. When measuring the
record the measurements on the Track Component
track pitch, the measurement must be taken at least
Appraisal Form. See the chart on Page 13 to find the
four track links away from the master link and master
percent of wear.
pin. The master pin has a hole in each end. Use the
track adjuster to tighten the track chain. Measure
from the front of a track pin to the front of the fifth
track pin. If using a tape measure, do not use the
hook to hold the tape measure. Make a record of the
measurements on the Track Component Appraisal
Form.
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IN
B900594
1. FORWARD OR REVERSE WEAR
2. VERTICAL WEAR
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Use the depth gauge to measure the vertical wear of
B900593 a bushing as shown. Make several measurements
See the chart on Page 12. If the measurement was across the worn area to find the most wear. Make
equal to 70% worn or less turn the pins and bushings sure that the bushing and track shoe are clean and
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for maximum life of these parts. that the depth gauge is perpendicular to the track
shoe. Record the measurement on the Track
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As the bushings move around the sprocket, the Component Appraisal Form. Measure two more
bushings also wear on the OD of the bushings. The bushings at 0.9 to 1.2 M (3 to 4 feet) intervals and
faster the speed of the machine and excessive use of record the measurements on the Track Component
reverse, the faster the wear of the bushings. Appraisal Form. See the chart on Page 14 to find the
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Increased track pitch is also a cause of wear on the percent of wear.

OD of the bushings. As the track pitch increases, the
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bushings come into contact with the sprocket teeth

nearer the ends of the sprocket teeth and slide to the
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bottom of the sprocket teeth. This wear occurs on the

rear of the bushings.
B900595

Copyright ©
5502-6
PIN AND BUSHING WEAR FOR CASE LUBRICATED TRACK

Because the lubricant in the bushing decreases wear
on the ID of the bushings and the OD of the pin to a
minimum amount, the track pitch does not increase
to cause faster wear on the OD of the bushings.
As the bushings move around the sprocket, wear 1 1
occurs on the OD of the bushings. The wear occurs
on the front and rear of the bushings. The faster the
speed of the machine and excessive use of reverse,
the faster the wear of the bushings. 2
Rapid wear of the bushings is caused by operating
B900594
the machine when the tracks are too tight. The tight
track chain increases the pressure between the 1. FORWARD OR REVERSE WEAR 2. VERTICAL WEAR
bushings and sprocket teeth which causes more Use the depth gauge to measure the vertical wear of
friction and rapid wear on the bushing OD. Tight a bushing as shown. Make several measurements
tracks are caused by wrong adjustment and mud or across the worn area to find the most wear. Make
other debris filling the sprocket teeth. sure that the bushing and track shoe are clean and
To help prevent wear caused by tight tracks, adjust that the depth gauge is perpendicular to the track
the deflection of the track according to instructions in shoe. Record the measurement on the Track
Section 5504. Remember, if the sprocket teeth are Component Appraisal Form. Measure two more
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filled with mud or other debris, adjust the track bushings at 0.9 to 1.2 M (3 to 4 feet) intervals and
IN
deflection without cleaning the sprocket teeth. record the measurements on the Track Component
Appraisal Form. See the chart on Page 16 to find the
Vertical wear of the bushings is caused by changing percent of wear.
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directions. Each time the machine changes direction
the bushings slide across the bottom of the teeth
before touching the forward or reverse drive side of
the sprocket teeth. Another cause of vertical wear is
track chains that are too tight because the track
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chain is not adjusted correctly or because of packing.

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Internal wear of the bushing will occur when the

lubricant has been lost. Dry bushings will feel warm.
B900595
One of two methods can be used to measure the
wear of the bushings. Both are shown. Case Extended Life Track
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Use the small caliper and measure the wear on the This system uses lubricated track with a large
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front and rear of a bushing as shown. Make several diameter bushing that is free to rotate on the
measurements across the worn area to find the most standard bushing. This allows wear to be distributed
N
wear. Make sure that the bushing is clean and that over the entire circumference of the outer bushing.
the caliper is 90 degrees to the bushing. Record the Because the bushing is free to rotate, it does not
measurements on the Track Component Appraisal create the scrubbing action between the sprocket
Form. Measure two more bushings at 0.9 to 1.2 M (3 and bushing as the conventional crawler track chain
to 4 feet) intervals and record the measurements on does. The service life has up to doubled (Case Test)
the Track Component Appraisal Form. See chart on with this design and is recommended for HIGH
Page 15 to find the percent wear. ABRASIVE AND LOW IMPACT applications where
bushing and sprocket wear may be severe.

Copyright ©
5502-7
TRACK LINK WEAR

The only wear that can be measured is wear of the Shown below is wear on the side of the rail. This
rail (top) on the track links. This wear is caused by wear occurs because of contact with the flanges on
the rolling and sliding contact with the track and the rollers and the idler. This wear will occur faster
carrier rollers and the idler. Other causes of wear are during side hill operation, turning, and with increased
speed, a tight track chain, track shoe width, the work track pitch which makes the track flexible.
environment and increased track pitch.
To measure the height of the track links (wear of rail),
assemble the rulers in the CAS-1950A kit. Make sure
that the rail and the bottom of the track shoe are
clean. Make the measurement in the areas shown in
the illustration at the bottom of this column. Make
sure that the vertical ruler is at 90 degrees to the
track shoe. Record the smallest measurement on the
Track Component Appraisal Form. Measure two
more track links at 0.9 to 1.2 M (3 to 4 feet) intervals B900598
a n d r e c o r d t h e m e a s u r e m e n t s o n t h e Tr a ck Shown below is wear on the top of the boss for the
Component Appraisal Form. See the chart on Page pin. This wear is caused by the flanges on the track
17 to find the percent of wear. links and the decreased diameter of the track rollers.
This is the result of bad maintenance and track
T
system management.
IN
PR
R
B900596
FO
Shown below is uneven wear on the rail. Wear over B900599

the pins will occur faster because of the narrow width Shown below is wear on the inside of the track link.
of the rail and contact with the rollers. This wear can This wear is caused by contact with the tips of the
also be caused by working on an uneven surface sprocket teeth. This wear occurs because the
(rocks) which can cause the track rail to hit the sprocket is not aligned with the track and rear track
T
roller(s). roller, increased track pitch which makes the track

O
flexible, side hill operation and wide track shoes.

The wear in the center of the rail is caused by contact
with the idler and carrier and track rollers.
N
B900600
B900597

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

The only wear that can be measured is the wear of Shown below is a cracked grouser and a broken
the grouser on the track shoe. This wear is normal. corner on the track shoe. This is caused by using
track shoes that are too wide for use on rough
To measure the height of the grouser, use the track
terrain.
adjuster to tighten the track chain. Use the depth
T
gauge in the CAS-1950A kit to measure the height of
the grouser 1/3 of the way from the end of the track
IN
shoe as shown. Record the measurement on the
Track Component Appraisal Form. See the chart on
Page 18 or 19 to find the percent of wear.
PR
B900613
R
Shown below are worn bolt holes in a track shoe.

This is caused by loose bolts. Make sure that the
FO
bolts are tightened to the specified torque.

B901624
Shown below are worn or broken corners on the

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

Copyright ©
5502-9
TRACK AND CARRIER ROLLER WEAR

The only wear that can be measured is wear on the If the track rollers are to be rotated, see the diagram
treads of the roller. This wear is normal and occurs below.
as the track links move under or over the rollers. The
front and rear track roller wear faster than the track
rollers between them. Measure the middle track
rollers first and more often. The reason for this is that
w h e n t h e m i d d l e r o l l e r s a r e 4 0 % wo r n , i t i s
recommended that the track rollers be rotated to
increase the life of all the track rollers.
If equipped with track guides (rock guards) loosen
and remove the cap screws that hold the track
B900603
guides and remove the track guides. It is important to
Shown below is normal tread wear.
measure both treads for an accurate indication of
wear. When installing the track guides, apply Loctite
242 to the threads on the cap screws.
Use the large caliper from the CAS-1950A kit and
measure both treads as shown. Make sure that the
treads are clean. Measure at the center of the treads
because this is the area of the most wear. Record the
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measurements on the Track Component Appraisal
Form. See the chart on Pages 20 or 21 to find the
IN
percent of wear.
PR
B900604
R
FO
B900602
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Copyright ©
5502-10
Shown below is wear on the side of the flanges. This Shown below are flat areas on the treads of a carrier
wear is caused by side hill operation, extended track roller. This wear is caused by the track links sliding
pitch which makes the track flexible, the front and on the tread because the roller does not rotate. The
rear track rollers not aligned with the idler and same wear can occur on the track rollers. Keep the
sprocket, and the carrier roller not aligned with the area around the rollers clean to prevent this wear.
track.
B900607
B900605
Shown below is wear on the OD of the flanges. This

wear is caused by wear on the rail on the track links
T
and wear on the tread of the roller which causes the
flanges to touch the bosses for the pins in the track
IN
links. This is the result of bad maintenance and track
system management.
PR
R
FO
T
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B900606
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Copyright ©
5502-11
IDLER WEAR
The only wear measured on the idler is the tread Shown below is wear on the side of the flange. This
wear. This wear is normal and is caused by the track wear is caused by side hill operation, extended track
links moving around the idler. pitch which makes the track flexible and the carrier
roller not aligned with the track. Check the idler
Use the depth gauge to measure tread wear as
alignment according to instructions in Section 5508.
shown. Make sure that the treads are clean. Measure
at the center of the treads because this is the area of
the most wear. Record the measurements on the
Track Component Appraisal Form. See the chart on
Page 22 to find the percent of wear.
B900609
Wear on the OD of the flange is caused by packing

between the track links and packing behind the idler
roller. This wear is of little importance except when
measuring tread wear.
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B900608
IN
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B900610
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Copyright ©
5502-12
WEAR CHART FOR PIN AND BUSHING WEAR (PITCH EXTENSION)

For sealed track with 175.41 mm (6.906 in) pitch.
Measured across 5 pins
Length Measurement
Percent Worn
mm Inches
702.31 27.65 0
703.33 27.69 10
704.34 27.73 20
705.36 27.77 30
706.37 27.81 40
707.39 27.85 50
708.66 27.90 60
T
709.93 27.95 70
IN
711.45 28.01 80
713.49 28.09 90
PR
715.01 28.15 100**
** Turn pins and bushings before this point. It is
recommended the pins and bushings be replaced if
the wear exceeds this point.
R
BS97N004
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Copyright ©
5502-13
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR

Caliper Measurement Percent Worn

mm Inches High Impact* Low Impact*
62.0 2.44 0 0
61.46 2.42 20 10
60.96 2.40 33 20
60.45 2.38 58 30
59.94 2.36 72 40
59.43 2.34 82 50
58.67 2.31 88 60
T
58.16 2.29 96 70
IN
57.15 2.25 100** 80
56.64 2.23 110 90
PR
55.88 2.20 120 100**
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* A Low Impact condition is when the grousers on the track shoe

completely engage the ground and the ground is free of bumps.
* A High Impact condition is when the grousers on the track
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shoe do not completely engage the ground and there is

constant contact with rocks or large irregularities.
BS97N001
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Copyright ©
5502-14
WEAR CHART FOR VERTICAL BUSHING WEAR

Depth Gauge
Percent Worn
Measurement
74.30 2.93 0 0
73.91 2.91 20 10
73.40 2.89 33 20
72.89 2.87 58 30
72.39 2.85 72 40
71.88 2.83 82 50
71.12 2.80 88 60
T
70.61 2.78 96 70
IN
69.59 2.74 100** 80
69.08 2.72 110 90
PR
68.32 2.69 120 100**
R
* A Low Impact condition is when the grousers on the track shoe

completely engage the ground and the ground is free of bumps.
FO
* A High Impact condition is when the grousers on the track

shoe do not completely engage the ground and there is
constant contact with rocks or large irregularities.
BS97N002
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Copyright ©
5502-15
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR

For Case lubricated track with 174.41 mm (6.906 in) pitch.

62.00 2.44 0 0
61.21 2.41 12 10
60.45 2.38 24 20
59.94 2.36 38 30
59.18 2.33 50 40
58.67 2.31 60 50
57.91 2.28 72 60
56.90 2.24 88 70
56.13 2.21 100** 80
T
54.36 2.14 112 90
IN
52.58 2.07 122 100**
PR
BS97N001
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Copyright ©
5502-16
WEAR CHART FOR FLOATING BUSHING

For extended life track with 175.41 mm (6.906 inch) pitch chain.

mm Inches
PERCENT
MM WORN (INCH)
79.25 0 3.12
78.74 4 3.10
78.23 9 3.08
77.72 13 3.06
77.22 17 3.04
76.71 22 3.02
T
76.20 27 3.00
IN
75.69 33 2.98
75.18 38 2.96
PR
74.68 43 2.94
74.17 48 2.92
73.66 52 2.90
73.15 57 2.88
R
72.64 62 2.86
FO
72.14 67 2.84
71.63 72 2.82
71.12 78 2.80
T
70.61 84 2.78
O
70.10 92 2.76
69.60 96 2.74
N
69.09 100 2.72

BS98G005

Copyright ©
5502-17
WEAR CHART FOR VERTICAL BUSHING WEAR

For Case lubricated track with 175.41 mm (6.906 in) pitch.
Depth Gauge
Percent Worn
Measurement
74.30 2.93 0 0
73.66 2.90 12 10
72.89 2.87 24 20
72.39 2.85 38 30
71.62 2.82 50 40
71.12 2.80 60 50
70.35 2.77 72 60
69.32 2.73 88 70
T
68.58 2.70 100** 80
IN
66.80 2.63 112 90
65.02 2.56 122 100**
PR
BS97N002
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Copyright ©
5502-18
WEAR CHART FOR TRACK LINK WEAR

For track with 175.41 mm (6.906 in) pitch.
Depth Gauge
Measurement Percent Worn
mm Inches
103.9 4.09 0
103.37 4.07 7
102.87 4.05 14
102.36 4.03 21
101.85 4.01 27
101.34 3.99 33
100.83 3.97 39
T
100.33 3.95 45
IN
99.82 3.93 50
99.31 3.91 55
PR
98.80 3.89 60
98.29 3.87 65
97.79 3.85 70
R
97.28 3.83 75
96.77 3.81 79
FO
96.26 3.79 83
95.75 3.77 87
95.25 3.75 91
T
94.74 3.73 94
O
94.23 3.71 97
93.72 3.69 100
N
BS97N003

Copyright ©
5502-19
WEAR CHART FOR ONE BAR TRACK SHOE WEAR
Depth Gauge
mm Inch
52.32 2.06 0
51.31 2.02 4
50.29 1.98 8
49.02 1.93 12
48.01 1.89 16
46.99 1.85 20
45.97 1.81 24
44.70 1.76 28
T
43.69 1.72 32
IN
42.67 1.68 36
41.66 1.64 40
PR
40.39 1.59 44
39.37 1.55 48
38.35 1.51 52
R
37.34 1.47 56
36.07 1.42 60
FO
35.05 1.38 64
34.04 1.34 68
33.02 1.30 72
T
31.75 1.25 76
O
30.73 1.21 80
29.72 1.17 84
N
28.70 1.13 88
27.43 1.08 92
26.42 1.04 96
25.40 1.00 100
BS97N008

Copyright ©
5502-20
WEAR CHART FOR TRACK ROLLER
Caliper Measurement
Percent Worn
mm Inches
190.00 7.48 0
189.23 7.45 6
188.47 7.42 12
187.71 7.39 18
186.94 7.36 24
186.18 7.33 29
185.42 7.30 34
184.66 7.27 39
T
183.90 7.24 44
183.13 7.21 49
IN
182.37 7.18 54
181.61 7.15 59
PR
180.85 7.12 63
180.09 7.09 67
179.32 7.06 71
R
178.56 7.03 75
FO
177.80 7.00 79
177.04 6.97 83
176.28 6.94 87
175.51 6.91 91
T
174.75 6.88 94
O
173.99 6.85 97
N
173.23 6.82 100

BS97N005

Copyright ©
5502-21
WEAR CHART FOR CARRIER ROLLER
Caliper Measurement
Percent Worn
mm Inches
140.00 5.51 0
139.45 5.49 6
138.94 5.47 12
138.43 5.45 18
137.92 5.43 23
137.41 5.41 28
136.91 5.39 33
136.40 5.37 38
T
135.89 5.35 43
135.38 5.33 47
IN
134.87 5.31 51
134.37 5.29 55
PR
133.86 5.27 59
133.35 5.25 63
132.84 5.23 67
R
132.33 5.21 71
FO
131.83 5.19 75
131.32 5.17 79
130.81 5.15 82
130.30 5.13 85
T
129.79 5.11 88
O
129.29 5.09 91
N
128.78 5.07 94
128.27 5.05 96
127.76 5.03 98
127.25 5.01 100
BS97N006

Copyright ©
5502-22
WEAR CHART FOR IDLER WHEEL
Depth Gauge
mm Inch
19.50 0.77 0
20.07 0.79 8
20.57 0.81 16
21.08 0.83 23
21.59 0.85 30
22.10 0.87 37
22.61 0.89 44
23.11 0.91 50
T
23.62 0.93 56
IN
24.13 0.95 62
24.64 0.97 68
PR
25.15 0.99 74
25.65 1.01 80
26.16 1.03 85
R
26.67 1.05 90
27.18 1.07 95
FO
27.69 1.09 100

BS97N007
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Copyright ©
5502-23
TRACK COMPONENT APPRAISAL FORM
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BC05J151

Copyright ©
5502-24
NOTES
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Copyright ©
Section
5504
5504
CASE LUBRICATED TRACK
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Copyright ©
5504-2
TABLE OF CONTENTS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Assembly and Track Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
When to Turn the Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing to Turn the Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing the Track Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Usage Guide for Pins, Bushings, Spacers, Links, and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRACK CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
T
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
IN
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Copyright ©
5504-3
SPECIFICATION
Torque
Master link bolts........................................................................................................430 to 470 Nm (318 to 346 lb-ft)
Standard link shoe bolts ...........................................................................................406 to 447 Nm (300 to 330 lb-ft)
Track Adjustment
Track deflection .........................................................................................................38 to 50 mm (1-1/2 to 2 inches)
Track Assembly and Track Press
T
IN
B860492J B860491J
DRIVER HOUSING OFFSET BUSHING PROJECTION
36.8 MM (1.449 INCH) 3.95 MM (0.156 INCH)
PR
Maximum Pressure OTC 180 Metric ton (200 US ton) only .....................................................40 825 kPa (5921 psi)
Lubricant ..................................................................................................................... Case IH 135-H gear lubricant
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Special Tools
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B866032U
The track press is a dual ram 180 Metric ton (200

US ton) press used to disassemble and assemble
the track links.
B866034U
The lubricator uses a vacuum function to make sure

that the seals are seated, and a pressure system to
fill the reservoir in the track pins. The part number of
the lubricator is CAS10762

Copyright ©
5504-4
B614342M B614336M
The nozzle shown MUST be used when lubricating The brush must be used to clean the bore of all pins
Case Lubricated Track. The use of any other nozzle that are to be used for a wet turn. The part number of
will damage the seal in the rubber plug. The part the brush is CAS1853.
number of the nozzle is CAS10762-1.
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IN
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B614340M
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B616311M The wood drill shown is used to remove the plug from
The tools shown are used to install the plug in each the track pins. The drill is 12.5 mm (1/2 inch) in
FO
track pin. The part number is CAS1851. diameter. Buy the wood drill at a local store.
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Copyright ©
5504-5
Track Adjustment 4. If the deflection is not correct, remove the cap at

the front of the track adjuster.
Tracks that are too tight will cause increased track
and sprocket wear, increased fuel consumption and
5. To tighten the track:
decreased power. Use the following procedure to
adjust the track. A. Add grease to the track adjuster to decrease
the deflection of the track.
1. Do not clean the track. Adjust the track tension
for the ground conditions in which you will be
working. If you are working in mud, adjust with
mud on the tracks.
2. Drive the machine forward the length of the
machine and stop the machine with a pin over
the front carrier roller. Do not use the brakes to
stop the machine.
BD02H015
B. When the deflection is correct, install the cap.
T
6. To loosen the track:
IN
A. Loosen the valve in the track adjuster two
turns only, with a socket to allow grease to
PR
flow from the track adjuster.
BD02H010
3. Put a straightedge over the track and measure

R
the track deflection. The measurement must be

38 to 51 mm (1-1/2 to 2 inches).
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BD02H016
B. When the deflection is correct, tighten the

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

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

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

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

Copyright ©
5504-8
STEP 7 STEP 15
Make sure that the track chain mounting surface and
the track shoe mounting surface are free of dirt and
rust. Use 36 grit sandpaper to clean the mounting
surfaces.
STEP 16
Carefully lower the machine onto the track, making
sure that the teeth on the sprocket engage the track
links.
STEP 17
Use the lifting equipment to carry the track over the
B94040108M idler and the carrier roller and onto the sprocket.
Use a pry bar to completely separate the halves of
the master link. STEP 18
Use the lifting equipment to raise the bottom part of
STEP 8 the track and use the blocks to hold the track in place
Fasten acceptable lifting equipment to the bottom as during removal
part of the track.
STEP 19
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STEP 9
IN
Remove the blocks and lower the track to the floor.
STEP 10
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Fasten acceptable lifting equipment to the top of the
track and carry the track to the front of the machine
and lower the track to the floor.
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STEP 11
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Use acceptable lifting equipment to raise the

machine until the track rollers are free of the track.
STEP 12 B9400108M
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Use acceptable supports to hold the machine in Use a pry bar to put the top link in position on the
place. bottom link.
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STEP 13 STEP 20
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Remove the track from under the machine.
Installation
STEP 14
FRONT OF MACHINE
866L95
Put the track under the track rollers so that the track
shoes are in the position shown. B94040106M
Put the track shoe in position on the master link.

Install the top bolts to hold the track shoe in place.

Copyright ©
5504-9
STEP 21 STEP 22
3 2
1 4
B94040110M Tighten the bolts as shown in illustration to 430 to

Start the bottom bolts into the master link. Tighten 470 Nm (318 to 346 pound-feet). Do not over tighten
the top bolts to pull the halves of the master link the bolts.
together.
STEP 23
Adjust the track according to the instructions in this
section.
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5504-10
When to Turn the Bushings

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

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leakage. A joint that shows leakage can be

assembled only as a dry turn if new parts are not
used.
Preparing the Track Chain

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1. Loosen and remove the bolts, nuts and track

shoes.
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2. If a wet turn is to be made, use a 12.5 mm (1/2

inch) wood drill and a low RPM electric drill and
remove the plugs from the pins. The plugs can
also be removed as shown after the track has
been disassembled.

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

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

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

removed from the surface of the pin. A pin like
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this MUST NOT be used again.

B860750J
4. The pin shown has a wear ridge. This pin can

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

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

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

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

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is not centered on the end of the bushing. This

busing CANNOT be used for a wet turn. The
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bushing can be used for a dry turn.

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B865382M
The pins show rust, pitting and discoloration. Each

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

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

two or more fine cracks or one large and rough
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crack can only be used for a dry turn.

B865375M
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8. The bushing shown has rust in the bore. This

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

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

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

Be cause t he s p ac er h as b ot h l u b r i c a t ion
notches, the spacer can be used for a wet turn.
The spacer is acceptable for a dry turn.

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5504-15
TRACK CHAIN
Disassembly 5. Actuate the other ram and press the pin out of
the other link.
1. Install the carrier and driver needed to
disassemble the track chain.
B604120M
6. Retract the ram and remove the link from the

B604112M driver and the pin from the bushing.
2. Put the track chain on the table so that the track
7. Move the track chain forward one bushing.
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shoe surface is up and pin half of the master link
will be the first link disassembled. 8. Actuate one of the rams to press the pin and
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IMPORTANT: Before pressing a bushing and pin out bushing out of a link.
of the link, make sure that the drivers are aligned with
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the pin and bushing to prevent damage to the bores
in the link.
3. Put the bushing in the first notch in the carrier
and actuate one of the rams to press that pin out
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of a link.
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B604112M

driver.
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B604116M

driver.

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5504-16
10. Actuate the other ram to press the pin and C. Put the guide (CAS1851-1 or CAS1851-2) on
bushing out of the other link. the end of the pin and lubricate the bore of the
guide.
B604124M
11. Retract the ram and remove the link from the B616316M
driver and the pin from the bushing. D. Use the driver CAS1851 and drive the plug
into the pin. The plug must be approximately
12. Repeat steps 7 through 11 until the track chain is
10 mm (0.39 inch) below the end of the pin.
disassembled.
5. Make sure that there is a good chamfer on both
13. Remove the spacers from the pins and seals.
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ends of all the pins so that metal will not be
14. Remove the seals and rubber rings from the removed from the bores in the links when the
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links. links are pressed onto the pins.
15. Clean all parts in cleaning solvent. 6. The first link assembly to be assembled is the
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bushing half of the master link.
16. Use a wire brush and clean the seal bore in each
link. 7. Install a bushing in the far notch. If the bushings
are being turned, put the bushing in the carrier
17. Use a wire brush and clean the reservoir in each
so that the mark made before disassembly is on
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pin.
top.
See Usage Guide for Pins and Bushings.
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8. Install a link half on one of the drivers and

actuate the ram to hold the link half against the
Assembly carrier.
IMPORTANT: If a wet turn is being made, the parts 9. Install the other link half on the other driver and
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of the track must be clean. actuate the other ram until the link half touches
the bushing. Check to make sure that the parts
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1. Remove the drivers used for disassembly and

install the drivers used to assemble the track are even with each other.
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chain. The same carrier is used.

2. Use a straightedge and measure the offset of the
drivers. The offset of the drivers must be 36.8
mm (1.449 inches). Add or remove shims
between the long driver and base as required.
3. Adjust the relief valve for the track press to 40
539 kn (119.250 psi).
4. If a wet turn is being made, install a new plug in
each pin.
A. Make sure that the bore in the pin is clean and
free of any lubricant.
B604140M
B. Lubricate the bore in the pin with Loctite
10. Actuate the ram to press the bushings into both
Safety Solvent or water and soap.
link halves.

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

14. Install a pin in the bushing so that the mark is on
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B604208M
top. The remainder of the pins must be installed
18. Hold the master link level and actuate the rams
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so that the plugs are all on the same side. Apply

until the drivers touch the links.
Molykote Type G to both ends of two spacers
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according to the instructions on the container.

Then install spacers on both ends of the pin.
B604212M
19. Press the links onto the pin and bushing.

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5504-18
C. Push the nozzle all the way into the plug.
D. Push down and hold the vacuum button until
the gauge reads 68 to 91 kPa (20 to 27
inches) vacuum.
E. Release the vacuum button. The reading must
not decrease for a minimum or 5 seconds.
F. If the joint will not hold the vacuum for 5
seconds, push down and hold the vacuum
button for a long time to see if the joint will
hold vacuum as specified.
G. Before disassembling the links, use a pry bar
B604215M
and move the link in both directions to seat the
20. Use the gauge and pin to check the spacing seal(s). Do the vacuum check again. If the
between the links. joint still does not hold the vacuum, the links
must be removed and the cause found.
21. Measure the bushing projection at each end of
the bushing. The bushing projection must be H. Push down and hold the oil button until gauge
3.95 mm (0.156 inch). reads 551 to 586 kPa (80 to 85 psi) then
release the oil button.
22. If the bushing projection is not as specified, add
or remove shims as required for the long driver. I. After the oil button is released, the reading of
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the pressure gauge must be 140 to 205 kPa
23. Repeat steps 14 through 17 and step 19 and
IN
(20 to 30 psi).
install the second set of links.
28. Make sure the mounting surfaces on the track
24. Check the end play of the outside links at the pin shoes and track chain are clean and smooth.
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joint.
29. Install the track shoes and new nuts and bolts.
A. Use a dial indicator against one of the outside
links or the end of the pin. 30. Tighten the bolts to 406 to 447 Nm (300 to 330
lb-ft).
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B. Set the dial indicator to 0 (zero).

31. Tighten master link bolts to 430 to 470 Nm (318
C. Use a screwdriver between the inside the
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to 346 lb-ft).
outside link to move the outside link and read
the dial indicator.
D. Check the end play several times to make
sure that the reading is correct.
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E. The end play must not be more than 0.13 mm

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(0.005 inch). Zero end play is the best, but not

required.
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25. If the end play is not as specified, add shims as

required for the short driver.
26. Repeat steps 14 through 17 and step 19 until the
track chain is assembled.
27. As soon as possible, begin to fill the pins with
gear lubricant.
A. Make sure that the nozzle CAS10762-1 is
installed on the tube on the control handle.
B. Prepare the lubrication equipment according
to the instructions of the manufacturer.

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Section
5506
TRACK FRAME AND SUSPENSION
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5506
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5506-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EQUALIZER BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing the Center Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Self-Aligning Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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5506-3
SPECIAL TORQUES
Pivot shaft mounting bolts ...........................................................................815 to 1045 Nm (600 to 770 pound-feet)
Equalizer beam bracket to the track frame bolts ............................................................ 515 to 618 Nm (380 to 456 pound feet)
Pivot shaft retainer plate bolts ....................................................................... 146 to 180 Nm (107 to 133 pound feet)
Equalizer beam pivot pin retaining bolts............................................................................ 515 to 618 Nm (380 to 456 pound feet)
SPECIAL TOOLS
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BS06J412
BS06J411
TRACK FRAME ALIGNMENT PLATE 380500002
IN
TRACK ALIGNMENT PLATE AND PIN ASSEMBLY 380500001 PR
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5506-4
TRACK FRAME
2
7
3 23
5 6
23
4
8 4
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10 4
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22
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12 11 9
24
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14
4 15
16
19
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20 21
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13 17
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24
18
BC05H098
1. EQUALIZER BEAM 9. TRACK FRAME 17. SHIMS

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

Copyright ©
5506-5
NOTE: If pivot shaft is being replaced do steps 9
STEP 1 through 14, if pivot shaft is not being replaced go to
Remove the track, see section 5504. step 15.
STEP 2 STEP 9
Attach lifting equipment to the track frame (9). Support the pivot shaft in the frame brackets.
NOTE: The track frame subassembly weighs
approximately 950 Kg (2100 pounds). STEP 10
STEP 3
Remove the cover (21) and gasket (20).
10
STEP 4
Loosen and remove cap screws (19). 22
STEP 5
Remove the retainer (18) and shims (17). 12
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STEP 6
Loosen the seal clamp (14) for seal (16).
IN
BC05K073
Place spacers (22) on the front bolts between the

STEP 7 block (12) and the frame (10), hand tighten the bolts
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Loosen and remove the cap screws (8) and washers
that mount the mounting bracket (5) to the track STEP 11
frame (9).
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STEP 8
Carefully move the track frame from the pivot shaft.
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BD05H121
Install the alignment tools, 380500001, to the

sprocket mounting surface on the final drive.

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5506-6
STEP 12 STEP 15
BD05H121 BD05H112
Orient a hole in the pivot shaft (11) to the top as Bolt the track frame alignment gauge, 380500002, to
shown. the 3 holes at the rear of the rack frame (9).
STEP 13 STEP 16
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BD05H122 BD05H106
Measure the distance on each side of the machine Attach suitable lifting equipment to track frame (9), lift
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and center the pivot shaft (11) on the frame (10). and make sure that the track frame will set level
during installation.
NOTE: Center pivot shaft within 1 mm (0.040 inch).
NOTE: The track frame subassembly weighs
STEP 14 approximately 950 Kg (2100 pounds).
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STEP 17
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1 2
BC05K073
Torque the front pivot shaft mounting bolts (1) first

then the rear mount bolts (2) to 815 to 1045 Nm BD05H123
(600 to 770 pound-feet). Use caution when installing the track frame (9), do
not damage the pivot seal (16).
NOTE: Apply a thin film of grease on the pivot shaft
(11) to help the pivot shaft seal (16) slide over the
shaft (11).
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5506-7
STEP 18 STEP 22
Install the cap screws (19) and torque to 146 to 180
Nm (107 to 133 pound feet).
STEP 23
BD05H109
Carefully slide the track frame (9) assembly over the

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

STEP 19 and measure the gap between the cover (21) and the
track frame (9) pivot housing.
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STEP 24
IN
Add 0.8 mm (0.030 inch) to this measurement, this
will be the amount of shims that will be required.
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NOTE: A minimum of one gasket is required for a
proper seal.
STEP 25
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Install required shims, gasket (20), cover (21), and

cap screws onto track frame (9), tighten cap screws.
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BD05H108
Slide the track frame over the pivot shaft so the STEP 26
alignment gauge is flush with the sprocket final drive
mounting surface.
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STEP 20
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24
9
B A
21 24
BC05K074
Remove the lubrication plugs (24). Fill the pivot

housing with grease, pump grease in the hole in the
BD05H107 track frame (9) until grease comes out of the hole in
Measure the distance from the track frame retaining the cover (21).
plate surface (A) to the pivot shaft end (B). NOTE: Exercise caution while greasing to prevent
the seals (16) from being damaged.
STEP 21
Install shims (17) and retainer plate (18).
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5506-8
STEP 27 STEP 32
BD05H110
Position alignment tools, 380500001, on the lower

portion of the sprocket mounting surface of the final
drives. Place a straight edge on the tools that is long
enough to reach the front of the track frame (9).
NOTE: The straight edge should be positioned
directly in line with the track rollers shafts.
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STEP 28
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B
A
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BC05H101
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HORIZONTAL MEASUREMENT
NOTE: The views are from the top looking down.
Track frame (9) alignment can be checked after the
BD05H111
unit is assembled. Measure track rollers parallel and
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Measure distance from the straight edge to the end diagonal alignment as shown.
of the roller shaft that is located below the equalizer
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beam (A). NOTE: Alignment should be within 3 mm (0.12 inch).

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STEP 29 STEP 33
Measure distance from the straight edge to the end If parallel alignment is out of tolerance, check
of the roller shaft that is located in front of the alignment of the rear track roller to the sprocket by
equalizer beam (B). projecting a straight edge on each side of the
sprocket to the track roller.
STEP 30
Move the front of the rack frame in or out until the
rollers are parallel within 1.5 mm (0.060 inch).
STEP 31
Torque the cap screws on the equalizer beam
mounting bracket (5) to 515 to 618 Nm
(380 to 456 pound feet) to the track frame (9).

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5506-9
STEP 34
To center the roller add or remove shims between
the end of the pivot shaft and retainer.
STEP 35
After rear roller to sprocket alignment is established
re-measure parallel and diagonal alignment.
STEP 36
If frames need adjusted loosen the cap screws (8) on
the bracket (5) and repeat steps 27 through 31.
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BC05H102
DIAGONAL MEASUREMENT
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5506-10
EQUALIZER BEAM
Removal STEP 42
STEP 37
Remove the track from one side of the machine, see
section 5504.
STEP 38
BD05H115
Remove the hose and elbow from the pivot pin.
STEP 43
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BD05H120
IN
Remove the covers from the track frames.
STEP 39
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Raise the front of the machine just enough to remove
the weight of the machine from the center pivot for
the equalizer beam.
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STEP 40
Block the machine. BD05H114
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Remove the cap screws, washers and bushings from

STEP 41 the center pivot pin.
STEP 44
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Install the cap screws in the threaded holes in the

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center pivot pin retainer plate.
STEP 45
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Tighten the cap screws to start the pivot pin out of

the frame.
STEP 46
Remove the pivot pin.
BD05H119
Remove the grease fitting and nut from the hose.

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5506-11
STEP 54
Install new seals in the equalizer beam.
STEP 55
Apply clean grease to the pivot pin and the bore of
the self-aligning bearing for the side of the equalizer
that will be mounted into the removed mounting
bracket.
STEP 56
BD05H118 Install the pin, bushing, washer and cap screw into
On the side of the machine that the track was not the mounting bracket and equalizer bar, tighten the
removed, loosen and remove the cap screw, washer cap screw.
and bushing from the pivot pin.
NOTE: Track is shown removed for clarity only. STEP 57
Attach lifting equipment to the equalizer and carefully
STEP 48 place the equalizer in position on the track frames.
Remove the pivot pin from the bracket.
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STEP 58
STEP 49
IN
Apply clean grease to the pivot pin and the bore of
the self-aligning bearing for the mounting bracket.
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STEP 59
Install the pin, bushing, washer and cap screw into
the mounting bracket and equalizer bar, tighten the
cap screw.
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STEP 60
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BD05H117
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From the side of the machine that the track was

removed, remove the cap screws that mount the
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equalizer mounting bracket to the track frame.

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STEP 50
Raise the machine enough to allow for clearance to
remove the equalizer beam.
BD05H113
STEP 51
Lower the frame into alignment with the equalizer
Block the machine.
beam.
STEP 52
Attach lifting equipment to the mounting bracket.
STEP 53
Carefully remove the equalizer beam from the
machine.
IMPORTANT: Support the opposite side of the
equalizer, it will fall from the track frame.

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5506-12
STEP 61 Replacing the Self-Aligning
Bushing
STEP 71
Remove the snap rings and seals from each side of
the self-aligning bearing.
STEP 72
Remove the sna p r ing from e ach sid e of the
self-aligning bearing.
STEP 73
BD05H114
Press the self-aligning bearing out of the equalizer.
Install the pivot pin, bushings, washers and cap
screws. Torque the cap screws to 515 to 618 Nm
(380 to 456 pound feet). STEP 74
Clean the bore for the self-aligning bearing.
STEP 62
Connect the grease hose to the center pivot pin. STEP 75
Install a snap ring in one of the grooves in the bore
for the self-aligning bearing.
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STEP 63
Check the alignment of the track frames, see track
IN
frame installation this section. STEP 76
Align the fracture (6) within ± 5° on outer bearing face
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STEP 64 as shown in illustration on page 13.
Install the guards on the track frames.
STEP 77
STEP 65 Press the bearing into the bore until the self-aligning
bearing touches the snap ring.
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Install the track, see section 5504.

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STEP 78
STEP 66
Install the other snap ring.
Grease all pivot pins.
STEP 79
Replacing the Center Bushing
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Install the seal on each side of the self-aligning

bushing.
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STEP 67
Press the bushing and seals out of the equalizer NOTE: The seal must be assembled with rubber
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beam. side towards the bearing, metal side to the outside of

the beam assembly.
STEP 68
STEP 80
Clean the bore for the bushing.
Install the outer snap rings.
STEP 69
Press the bushing into the bore of the equalizer
beam until it is 8 mm (0.30 inch) below the side of the
equalizer beam.
STEP 70
Press new seals into the bore so that the lip of the
seal is toward the outside.
NOTE: The seal must be assembled with the metal
side towards the bushing.

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5506-13
1
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2 6
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BC05H099
1. EQUALIZER BEAM 4. BEARING 7. BUSHING

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

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5506-14
NOTES
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Section
5508
IDLER, TRACK ADJUSTER, AND RECOIL HOUSING
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5508

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5508-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IDLER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
RECOIL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Destroying the Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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5508-3
SPECIFICATIONS
Idler Lubricant ........................................................................................................... Case 135H EP Gear Lubricant
Capacity ...................................................................................................................... 680 ml (23 U.S. fluid ounces)
SPECIAL TORQUES
Idler Bracket Springs Preload Bolts ....................................................................................................48 Nm (35 lb-ft)
Bolts Securing Track Adjuster to Idler.......................................................................183 to 223 Nm (135 to 165 lb-ft)
Recoil Housing Mounting Bolts.................................................................................183 to 223 Nm (135 to 165 lb-ft)
Track Adjuster Valve .........................................................................................................61 to 74 Nm (45 to 55 lb-ft)
SPECIAL TOOLS
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B914933M B407315M
CAS-1755 SEAL INSTALLATION TOOL CAS-1450
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4 3
2
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B820200J
3. OPTIONAL 6 MM (1/4
INCH) PLATE WELDED TO
1. 63.5 MM (2-1/2 INCHES) SLEEVE WITH OUSTIDE
DIAMATER OF 71 TO 72 B407317M
MM (2.80 TO 2.83 INCHES) CAS-1682

2. 63.5 MM (2-1/2 INCHES) 4. OPTIONAL 6 MM (1/4 These tools are used to do the leakage test on the
INCH) PLATE WELDED TO
idler.
SLEEVE
This tool is used to install the wiper in the track
adjuster. Make the tool according to the dimensions
shown in the illustration. A longer sleeve can be used
if the sleeve has the correct OD and ID.

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5508-4
IDLER LEAKAGE TEST

1. Connect the shutoff valve to the pressure 3. Turn the knob counterclockwise to close the
regulator valve. Connect a fitting for the air pressure regulator valve.
supply hose to the shutoff valve.
4. Connect the line from the pressure gauge to the
quick disconnect fitting in the idler wheel.
1 5. Make sure that the shutoff valve is open.
6. Open the pressure regulator valve until the
pressure gauge indicates 172 kPa (25 psi).
7. Use the bracket and turn the shaft three to ten
revolutions.
8. Close the pressure regulator valve until the
pressure gauge indicates 110 kPa (15 psi).
9. Close the shutoff valve. The idler must hold this
2 pressure for 10 seconds. Loss of air pressure
B407320M
during this time indicates a bad part or wrong
assembly.
1. SHUT OFF VALVE 2. PRESSURE REGULATOR VALVE
2. Install the adapter and quick disconnect fitting in
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the oil drain hole in the idler wheel. Use a seal
washer with the adapter.
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5508-5
IDLER
Removal 8. Remove two nuts (12) and washers (13) from

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

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

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5508-6
Disassembly STEP 7
STEP 1
Remove all dirt and grease from the idler.
STEP 2
Fasten acceptable lifting equipment to the idler so
that the idler will be in a horizontal position. Make
sure the drain plug is on the bottom.
STEP 3
Remove the plug from the idler wheel. Drain the oil
from the idler.
B509840M
STEP 4 For the 750K and the 850K. Remove the metal rings
(7) and rubber rings (8) from the idler wheel. Refer to
Use a roll pin punch and a hammer to drive the roll
illustration on page 12.
pin out of the top bracket and shaft.
STEP 8
STEP 5
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B509840M
B509838RM
For the 650K. Remove the metal rings (7) and rubber
Remove the roll pins and the bracket from the shaft.
rings (8) from the idler wheel. Refer to illustration on
NOTE: The bracket can be difficult to remove. If page 11.
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required, use a press to press the shaft from the

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bracket. STEP 9
If necessary, do steps 10 through 16 to remove the
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STEP 6 bushings from the idler wheel.
B509920M
Use lifting equipment to remove the idler wheel from

the shaft.
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5508-7
STEP 10 STEP 13
B150637M B509915M
Put the idler wheel in a press. Put the idler wheel on Press the bushing out of the idler wheel.
blocks that will support the hub of the idler wheel.
STEP 14
STEP 11
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B150637M
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B150639M Put the idler wheel in the press for removal of the
Install a puller as shown in the bottom bushing and other bushing.
from the bottom of the idler wheel.
STEP 15
STEP 12
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B150528M
B150640M Install an acceptable driver on top of the bushing.

Put an acceptable driver on top of the bushing.

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5508-8
STEP 16 STEP 20
B150530M B509806M
Press the bushing out of the idler wheel. For the 750K and the 850K. Use a hammer and
punch and remove the small roll pin from the large
STEP 17 roll pin. Be careful not to damage the shaft.
STEP 21
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B509844M
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Remove the metal ring and the rubber ring from the
bracket and shaft assembly. B509902M
For the 750K and the 850K. Use a hammer and

STEP 18 punch and remove the large roll pin that fastens the
bracket to the shaft.
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STEP 22
For the 650K. Use a hammer and punch and remove
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the tapered grooved pin that fastens the bracket to

the shaft.
NOTE: The pin must be driven out from the track
frame rail side of the idler bracket.
B509802M
Remove the metal ring and rubber ring from the other
bracket.
STEP 19
Fasten the bracket and shaft assembly in a vise with
soft jaws.

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5508-9
STEP 23 STEP 24
1. O-RINGS
B509909M B509912M
Remove the bracket from the shaft. Remove the O-rings from the shaft.
NOTE: The bracket can be difficult to remove. If
required, use a press and press the shaft from the
bracket.
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5508-10
2
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8 10
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B9402090A
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1. IDLER WHEEL 3. SMALL ROLL PIN 5. SHAFT 7. BUSHING 9. RUBBER RING

2. PLUG 4. LARGE ROLL PIN 6. O-RING 8. METAL RING 10. IDLER BRACKET
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Inspection
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1. Clean all parts of the idler in cleaning solvent. 4. Inspect the bushing surfaces on the shaft for
Make sure that the lubricant cavity in the idler is scoring, pitting and other damage.
clean.
5. Inspect the bores for the rubber rings in the
2. Discard the O-rings. brackets and in the idler for damage that will
result in leakage. Use new parts as required.
3. Discard the bushings and the rubber rings. New
bushings and rubber rings must be used during
assembly.

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5508-11
Assembly STEP 27
STEP 25
B509924M
For the 750K and the 850K. Make sure that the seal
B509916M
area of the idler wheel is clean and dry. Use soap
Use Loctite 680 on the bushing outer surface. Put the and water or a fast drying oil free compound on the
idler wheel in a press and start a new bushing into rubber seal. Do not twist the seal during installation.
the hub. Use an acceptable driver to press the Use the tool CAS-1755 to install rubber rings and
bushing into the hub until the bushing stops moving. seals in each side of the idler wheel. Refer to
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Repeat for the other bushing.
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STEP 26 PR
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B509924M
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For the 650K. Make sure that the seal area of the
idler wheel is clean and dry. Use soap and water or a
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fast drying oil free compound on the rubber seal. Do

not twist the seal during installation. Use the tool
CAS-1755 to install rubber rings and seals in each
side of the idler wheel. Refer to illustration on page
10.

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5508-12
STEP 28 STEP 31
1. O-RINGS
B509912M B509904M
Install the O-rings on the shaft. Lubricate the O-rings Use a punch to hold the bracket in position on the
with petroleum jelly. shaft.
STEP 29 STEP 32
Fasten the shaft in a vise with soft jaws. Be careful
not to damage the shaft or the O-rings.
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STEP 30
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B509906M
For the 650K. Install the grooved pin that fastens the
bracket to the shaft.
STEP 33
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B509909M
Put the bracket on the shaft. Align the hole in the

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shaft with the hole in the bracket.

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B509906M
For the 750K and the 850K. Install the large roll pin
that fastens the bracket to the shaft.

Copyright ©
5508-13
STEP 34 STEP 38
For the 750K and the 850K. Install the small roll pin in
the large roll pin so that the slots in the roll pins are
90 degrees from each other. Make sure that the roll
pins do not protrude from the idler bracket.
STEP 35
B509922M
Put the bracket and shaft assembly in the press.

Lower the idler wheel onto the shaft, install the O-ring
shown after the shaft is through the idler wheel.
STEP 39
B509804M
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Make sure that the seal area in the brackets is clean
and dry. Use soap and water or a fast drying oil free
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compound on the rubber ring. Use the tool CAS-1755
to install the metal ring and rubber ring in the bracket.
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STEP 36
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B509838RM
Put the other bracket on the shaft. Make sure that the
brackets are aligned correctly.
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B509842M
Use soap and water or a fast dr ying oil free

compound on the rubber ring. Use the tool CAS-1755
to install the metal ring and rubber ring in the bracket
and shaft assembly.
STEP 37
Lubricate the O-rings on the shaft with petroleum
jelly.

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5508-14
STEP 40 STEP 42
B509926M B509901M
Use an acceptable driver and a press to press the For the 750K and the 850K. Install the large roll pin
bracket onto the shaft until the hole in the shaft and and then the small roll pin so that the slots in the roll
the hole in the bracket are aligned. pins are 90 degrees from each other. Make sure the
roll pins do not protrude from the idler bracket.
STEP 41
STEP 43
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Do the leakage test according to the instructions in
this section. Make sure the idler has been assembled
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correctly and there are no defects in the metal parts
that will result in leakage.
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STEP 44
Fill the idler with the amount of oil specified on page
3.
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STEP 45
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Apply thread sealant to the threads on the plug.

B509901M
For the 650K. Install the grooved pin. Make sure that STEP 46
the pin does not protrude from the idler bracket. Install and tighten the plug.
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5508-15
NOTE: Refer to Section 5501 for wear specifications
STEP 47
BD05H126
Install the bottom wear bar (14) with new bolts (16),
washers (13) and nuts (12). Do not install shim(s)
(15) at this time.
BD05H124
STEP 51
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BD05H125
Scribe a line across the forward end of each of the BD05H127

top wear plates (23), at half the thickness of the wear Install the washers (10) and bolts (9) in the idler
plate as shown. bracket (22). Tighten the bolts to a torque of 48 Nm
(35 lb-ft) to preload the springs (24).
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STEP 48
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Connect lifting equipment to the idler (21) using the

same method used for removal.
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STEP 49
Align the idler (21) in the track frame (27). Install the
spring seats (25), springs (24) and wear plates (23)
in the idler bracket (22). Slide the idler bracket into
the track frame. Remove the lifting equipment.

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5508-16
STEP 52 STEP 56
A A
BD05H128
Select the number of shims (15) to fill the distance

between the scribed line on the wear plate (23) and
the bottom of the idler bracket (22). This will
determine the number of shim(s) (15) required for the C
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bottom wear bar (14).
STEP 53
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Completely loosen the bolts (9).
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STEP 54
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B771113A
A.BOTH MEASUREMENTS MUST BE EQUAL WITHIN 3.2 MM

(1/8 INCH)
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B.THE SQUARE MUST BE EVEN WITH THE INSIDE SURFACE

OF THE TRACK FRAME
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C.SHIMS
Hold a square against the idler bracket (22) and even
with the inner edge of the track frame (27) as shown.
Measure from the edge of the square to the outer
edge of the idler (21). Make a record of this
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measurement.
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BD05H129
Install the shims (15) from Step 48 between the STEP 57

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bottom wear bar (14) and the track frame (27). Repeat Step 52 on the other side of the idler (21).
NOTE: The two measurements must be equal within
STEP 55 3.2 mm (1/8 inch)
Connect lifting equipment to the idler bracket (22)
and raise the idler (21) so that the idler brackets (22) STEP 58
touch the bottom of the bottom wear bar (14). If the measurements are not as specified, add or
remove shims (15) as required between the bottom
wear bar (14) and the track frame (27).
STEP 59
Remove the lifting equipment from the idler (21).

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5508-17
STEP 60 STEP 64
BD05H127 BD05H131
Tighten the bolts (9) to a torque of 48 Nm (35 lb-ft). Install the original shim(s) (20), thrust plates (19),
washers (18), and bolts (17). Tighten the bolts (17).
STEP 61
STEP 65
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BC05H105
BD05H130 E. IDLER MUST BE CENTERED IN TRACK FRAME

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Make sure the scribed line on the wear plate (23) is F. 0.8 MM (1/32 INCH) MAXIMUM CLEARANCE
flush with or slightly recessed with the bottom of the Measure from the center of the idler (21) to the inside
idler bracket (22). edge of the track frame (27). The idler must be
centered in the track frame. If the idler is not centered
STEP 62
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in the track frame, remove or add shims (20) between

Put 242 Loctite on the threads in the holes in the idler the thrust plates (19) and idler brackets (22) as
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brackets (22) for the bolts (7) that fasten the idler (21) necessary so that the idler is centered in the track
to the track adjuster (26). frame.
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STEP 63
Place the original shims (11) on the idler brackets
(22). Install the washers (8) and bolts (7) to secure
the track adjuster (26) to the idler (21). Tighten the
bolts (7) to a torque of 183 to 223 Nm (135 to 165
lb-ft).

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5508-18
STEP 66 STEP 68
After the idler (21) has been centered, check the Position the track adjuster cover (6) and secure using
clearance between the thrust plates (19) and track four washers (5) and bolts (4).
frame (27). The clearance must be as little as
possible and not more than 0.8 mm (1/32 inch). STEP 69
Remove shims (20) as required. Position the yoke cover (3) and secure using four
washers (2) and bolts (1).
STEP 67
When the idler (21) is in the correct position,
assemble the track according to the instructions in
Section 5504.
3 9 10
21
6 2 20
1
5 18
11
4 17
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14
27
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BC05H103
1. BOLT 8. WASHER 15. SHIM(S) 22. IDLER BRACKET

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2. WASHER 9. BOLT 16. BOLT 23. WEAR PLATE

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

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5508-19
TRACK ADJUSTER
2 3
5
7
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10
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BS02H052
1. YOKE 5. SEAL 9. WEAR RING

2. CHECK VALVE 6. BUSHING 10. PACKING RING
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3. GREASE FITTING 7. BACKUP RING 11. SPACER

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

Copyright ©
5508-20
Disassembly Inspection
1. Discard the seal.
STEP 1
Tighten the valve (2) in the track adjuster. 2. Clean all parts in cleaning solvent.
3. Check the bushing and wear ring for damage.
STEP 2
4. Check the cylinder bore for scratches and rust.
Use a grease gun to inject grease into the track
adjuster to push the piston out of the cylinder. 5. Check the piston for scratches and rust.
WARNING: The piston takes a lot of pressure to 6. Clean the valve and check for damage.
remove and will come out with force. 7. Check the tube spacer for damage.
STEP 3
Remove the packing ring (10) from the piston.
STEP 4
Remove the wear ring (9) from the piston.
STEP 5
Remove the snap ring (4) from the piston.
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STEP 6
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Remove the seal (5) from the piston.
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STEP 7
Remove the bushing (6) from the piston.
STEP 8
R
Remove the backup ring (7) from the piston.

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STEP 9
Remove the valve (2).
STEP 10
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Remove the grease from the bore of the cylinder.

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5508-21
Assembly Installation
1. Be sure that the piston is pushed all the way into
STEP 11 the track adjuster.
Put the backup ring (7) on the piston.
2. Install the tube spacer in the recoil housing.
STEP 12 3. Place the track adjuster in place on the track
Put the bushing (6) on the piston. frame.
4. Put 242 Loctite (blue) on the threads of the holes
STEP 13 in the idler brackets for the bolts that hold the
Install the seal (5) on the piston so that the lips are track adjuster in place.
toward the snap ring.
5. Align the track adjuster with the idler.
STEP 14 6. Install the bolts and washers that fasten the track
Install the snap ring (4) in the groove on the end of adjuster to the idler. Tighten the bolts to 183 to
the piston. 223 Nm (135 to 165 lb-ft).
7. Push the idler to the rear to engage the track
STEP 15 adjuster with the recoil housing.
Lubricate the backup ring, bushing and seal with 8. Install the front covers.
clean oil. Install the piston into the cylinder. Be
careful not to damage the seal. 9. Connect the track according to the instructions in
T
Section 5504.
IN
STEP 16
Use a soft hammer to drive the piston into the
cylinder.
PR
STEP 17
Install the wear ring (9), use a soft hammer to drive
the wear ring into the cylinder.
R
STEP 18
FO
Put 601 Loctite (green) on the OD of the packing ring

(10).
STEP 19
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Put the packing ring (10) on the piston. Be sure the

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metal part of the packing ring is toward the cylinder.

Use the tool shown on page 3, and a hammer to
N
drive the wiper into the cylinder.
STEP 20
Install the valve (2) into the track adjuster yoke.
Tighten the valve to 61 to 74 Nm (45 to 55 lb-ft).

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5508-22
RECOIL HOUSING
1. Install the tube spacer inside the recoil housing.
WARNING: The recoil spring in the recoil
housing is highly compressed. Using the 2. Put the recoil housing on the track frame.
wrong method to release this 3. Install the bolts and washers that hold the recoil
compression will result in personal injury. housing in place. Tighten the bolts to 183 to 223
Release (destroy) the compression of the Nm (135 to 165 lb-ft).
recoil spring according to instructions in
this section. 4. Install the valve in the track adjuster. Tighten the
48-70 valve to 61 to 74 Nm (45 to 55 lb-ft).
1. Loosen the valve in the track adjuster to release 5. Remove the hydraulic ram.
the pressure in the track adjuster.
6. Install the covers on the track frame.
2. Use acceptable lifting equipment to lift the top of
the track and push the piston into the track 7. Adjust the tension of the track according to the
adjuster as far as possible. instructions in Section 5504.
3. Disconnect the lifting equipment from the track.

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

FO
NOTE: If the recoil housing is not to be used again,

the recoil spring must be cut to release the tension of
the recoil spring.
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1. Use an acetylene cutting torch through the hole

in the bottom of the recoil housing and cut
O
through as much of the recoil spring as can be

seen. This will remove the tension of the recoil
N
spring and the recoil housing can be safely

discarded.

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Section
5509
SPROCKETS
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5509

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5509-2
TABLE OF CONTENTS
REMOVAL FOR CELT TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION FOR CELT TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL FOR CLT TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION FOR CLT TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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5509-3
REMOVAL FOR CELT TRACK

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

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

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5509-4
INSTALLATION FOR CELT TRACK

1. Install the sprocket bolts in the final drive hub, 5. Check to see that the sprocket is centered on the
mount the sprocket. rear track roller within 3 mm (1/8 inch), see item
6 in illustration on page 3.
2. Use Loctite No. 242 and install the washers and
nuts on the bolts. NOTE: If the sprocket is not centered as specified,
NOTE: Do not get loctite on the surface between nut see section 5506 and align track frame to the
and washer. This will change the co-efficiency of the sprocket.
friction and will effect the bolt torque and clamp load. 6. Use Loctite No. 242 and install the outer cover at
3. Torque the nuts to 576 Nm (425 pound-feet) in the rear of the track frame.
the sequence shown. 7. Install the bolts and washers that hold the outer
4. Repeat the torque sequence. cover in place. Tighten the bolts.
8. Refer to Section 5504 and connect the track.
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10 1
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5 13
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12 8
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14 6
2 9
BC05H062

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5509-5
REMOVAL FOR CLT TRACK

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

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2. BOLT (27) 4. NUT (27) 6. ALIGNMENT MEASUREMENT

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5509-6
INSTALLATION FOR CLT TRACK

1. Install the sprocket segment. 3. Torque the nuts to 813 Nm (600 pound-feet) in
the sequence shown.
2. Use Loctite No. 242 and install the nuts on the
bolts. 4. Check to see that the sprocket is centered on the
rear track roller within 3 mm (1/8 inch), see item
NOTE: Do not get loctite on the surface between nut
6 in illustration on page 5.
and segment. This will change the co-efficiency of
the friction and will effect the bolt torque and clamp NOTE: If the sprocket is not centered as specified,
load. see section 5506 and align track frame to the
sprocket.
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BC05H064

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5511
Section
5511
TRACK ROLLER
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5511-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FILLING THE TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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5511-3
SPECIFICATIONS
Lubricant
Type.................................................................................................................... Case IH 135-H EP gear lubricant
Special Torques
Bolts for mounting bracket..................... Apply Loctite 242 then torque to 434 to 447 Nm (320 to 330 pound-feet)
Valve in track adjuster ............................................................................................. 61 to 74 (45 to 55 pound-feet)
SPECIAL TOOLS
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CAS-1283, SEAL INSTALLATION TOOL CAS-1450, AIR TEST TOOL SET
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B914826
CAS-1313, ROLLER BUSHING TOOL
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B407317
CAS-1682, PRESSURE TEST ADAPTER KIT
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5511-4
TRACK ROLLER
Removal 3. Use acceptable lifting equipment to lift the top of

the track and push the piston into the track
1. If equipped with track guards, remove the track adjuster as far as possible.
guards as required to remove a track roller.
4. Disconnect the lifting equipment from the track.
A. To remove one of the middle track rollers,
remove both center rock guards. 5. Raise the machine to get as much clearance as
possible between the track chain and the track
B. To remove a front or rear track roller, remove rollers (1).
both middle track guards, and the front or rear
track guard as required. 6. Put blocks under the machine to hold the
machine in place.
C. Loosen and remove the nuts and bolts that
hold the spacers between the track guards. 7. Loosen and remove the self-locking bolts (3) that
fasten the inside of the track roller (1) to the track
D. Loosen and remove the cap screws that frame (2).
fasten the front and rear track guards to the
middle track guards. NOTE: The weight of a track roller is approximately
35 kg (77 pounds). Be careful when removing the
E. As required, loosen and remove the cap track roller to prevent personal injury.
screws that fasten the center rock guards to
the track frame.
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F. Remove the track guards.
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G. Remove the spacers that fell onto the track
chain.
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2. Loosen the valve in the track adjuster two turns.
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BD02H016
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5511-5
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B900332
1. TRACK ROLLER 2. TRACK FRAME 3. SELF-LOCKING BOLT

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5511-6
Disassembly STEP 5
STEP 1
Clean the track roller with cleaning solvent.
STEP 2
B205002
Remove the end cap from the shaft.
STEP 6
B205043
Loosen and remove the plug from the track roller.
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STEP 3
IN
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B205004
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Remove the O-ring from the groove in the shaft.

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STEP 7
B205044
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Drain the oil from the track roller.

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STEP 4
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B205005
Remove the shaft from the track roller.
B205001
Use a hammer and punch and remove one of the roll

pins that hold the end caps in place.

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5511-7
STEP 8 STEP 11
B205006 B205013
Remove the metal ring from the rubber ring. Use a Put the shaft and end cap in a vise and use the driver
screwdriver if necessary. and hammer to drive the shaft out of the end cap. If
the shaft is used again, do not let the shaft fall.
STEP 9
STEP 12
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B205007
Remove the rubber ring from the track roller.

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B205014
Remove the O-ring from the shaft.

STEP 10
STEP 13
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B205011
Support the shaft and end cap and remove the roll B205008
pin that holds the end cap in place. Remove the metal ring from the rubber ring in each
end cap. Use a screwdriver if necessary.

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5511-8
STEP 14 STEP 17
B205009 B921324
Remove the rubber ring from each end cap. Use an acceptable driver and press the bushing out
of the roller.
STEP 15
STEP 18
Repeat Steps 15 through 17 for the other bushing.
Inspection
T
1. Discard the O-rings. New O-rings must be used
IN
during assembly.
2. Discard the rubber rings and metal rings. New
PR
parts must be used during assembly.
3. Inspect the bushings and the bushing surfaces of
the shaft for scoring, pitting and other damage.
B921322 Use new parts as required.
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Put the track roller in the press for removal of the

bushings.
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STEP 16
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B921323
Put the tool CAS-1313 on top of the bottom bushing

as shown.

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5511-9
7
6
6
4
5 3
4
2
4
5
4
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B900333
1. TRACK ROLLER 4. RUBBER RING 7. PLUG

2. END CAP 5. METAL RINGS 8. O-RING
3. ROLL PIN 6. BUSHING 9. SHAFT
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5511-10
Assembly STEP 22
STEP 19
B921312
Put a rubber ring on each metal ring.

B921329
Put the roller in the press for installation of a new STEP 23

bushing.
STEP 20
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B914911
Put the metal ring in the tool CAS-1283 as shown.

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B921330
STEP 24
Start the new bushing into the track roller.
STEP 21
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B205018
Make sure all oil is removed from the bore for the
rubber ring at each end of the track roller.
B921331
Install tool CAS-1313. Use an acceptable driver and

press the bushing into the track roller until the
bushing stops moving. Repeat Steps 19 through 21
for the other bushing.

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5511-11
STEP 25 STEP 29
B914914
Apply soap and water or a fast dr ying oil free B914911
lubricant on the rubber ring. Start the rubber ring into Install a metal ring in the tool CAS-1283 as shown.
one end of the track roller
STEP 30
STEP 26
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B914919
Apply soap and water or a fast dr ying oil free

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B914915
Push down on the tool CAS-1283 to push the rubber lubricant on the rubber ring. Start the rubber ring into
ring into the track roller. an end cap.
STEP 27 STEP 31
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Repeat Steps 24 through 26 for the other rubber ring

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and metal ring.

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STEP 28
B915006
Push down on the tool CAS-1283 until the rubber

ring is seated in the end cap.
B205016
STEP 32
Make sure all oil is removed from the bore for the Repeat Steps 29 through 31 for the other end cap.
rubber ring in each end cap.

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5511-12
STEP 33 STEP 36
B205125 B205129
Install an O-ring in the groove at one end of the shaft. Start the end cap onto the shaft so that the flat
surface of the end cap the flat surface on the shaft
STEP 34 are aligned.
STEP 37
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B205126
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Lubricate the O-ring with clean oil.

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B921319
STEP 35 Use a soft hammer and drive the end cap onto the
shaft.
STEP 38
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B205127
Lubricate the bore of the end cap with clean oil.
B205132
Install the roll pin that fastens the end cap to the
shaft.

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5511-13
STEP 39 STEP 42
B205133 B205137
Lubricate the face of a metal ring in the track roller Put the track roller in the press for the installation of
with clean oil. the other end cap.
STEP 40 STEP 43
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B205134 B205139
Install the shaft in the track roller. Lubricate the O-ring with clean oil.
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STEP 41 STEP 44
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B205135 B205140
Install a new O-ring in the groove in the shaft. Lubricate the face of the metal ring with clean oil.

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5511-14
STEP 45 STEP 48
B205127 B205101
Lubricate the bore of the other end cap with clean oil. Install the roll pin that fastens the end cap to the
shaft.
STEP 46
STEP 49
Do the leakage test according to the instructions on
Page 18.
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STEP 50
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Fill the track roller with lubricant according to the
instructions on Page 15.
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B205141
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Start the end cap onto the shaft so that the flat
surface is aligned with the flat surface of the other
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end cap.
STEP 47
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B205143
Press the end cap onto the shaft until holes are
aligned.

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5511-15
FILLING THE TRACK ROLLER

1. Turn the shaft so that the fill opening is on top 4. Open the valve for the air line to push the
and the mounting surface on the end cap is at lubricant into the outer ends of the track roller.
the bottom.
5. Close the valve and disconnect the air line from
2. Fill the track roller with Case IH 135-H EP gear the track roller.
lubricant.
6. Use blocks to hold the track roller in place with
3. Connect an air line that can be controlled to a the fill opening 45 degrees from vertical.
maximum pressure of 275 kPa (40 psi) to fill the
7. Add lubricant until the lubricant begins to flow out
opening in the track roller.
of the fill opening.
8. Install and tighten the plug.
LEAKAGE TEST
STEP 51 STEP 54
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B407320 B407323
Connect the shutoff valve to the pressure regulator Connect the line from the pressure gauge to the track
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valve. Connect a fitting for the air supply hose to the roller.
shutoff valve. Connect this assembly to an air hose.
STEP 55
STEP 52
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B407324
B407322 Make sure that the shutoff valve is open.

Install the adapter and quick disconnect fitting. Use a
seal washer with the adapter.
STEP 53
Tur n the knob counterclockwise to close the
pressure regulator valve.

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5511-16
STEP 56 STEP 58
B407326 B407332
Open the pressure regulator valve until the pressure Close the pressure regulator valve until the pressure
gauge indicates 172 kPa (25 psi). gauge indicates 110 kPa (15 psi).
STEP 57 STEP 59
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B407328 B4073334
Turn the shaft four revolutions. Close the shutoff valve. The track roller must hold
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this pressure for 10 seconds. Loss of air pressure

during this time indicates a bad par t or wrong
assembly.
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5511-17
INSTALLATION
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3
B900332
1. TRACK ROLLER 3. SELF-LOCKING BOLT

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

Copyright ©
5511-18
9. Apply 242 Loctite to the threads in the holes in 18. If the machine is equipped with track guards:
the track frame (2) for the self-locking bolts (3)
A. Apply 242 Loctite to the threads in the holes
that hold the track roller (1) in place.
on the inside of the track frame for the bolts
10. Hold the track roller (1) in alignment with the that hold the track guards in place.
track frame (2) and install two self-locking bolts
B. As required, hold the track guard in alignment
(3) to hold the track roller (1) in place.
with the track frame and install the hardened
11. Install the other self-locking bolts (3) that hold the washers and bolts that hold the track guards in
track roller (1) in place. place.
12. Tighten the self-locking bolts (3) to 434 to 447 C. Tighten the bolts.
Nm (320 to 330 pound-feet).
D. Apply 242 Loctite to the threads in the holes
13. Install the valve in the track adjuster. on the outside of the track frame for the cap
screws that hold the track guards in place.
14. Tighten the valve to 61 to 74 Nm (45 to 55
pound-feet).
15. Raise the machine and remove the blocks.
16. Lower the machine.
17. Adjust the tension of the track according to the
instructions in Section 5504.
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SECTION INDEX
POWER TRAIN

Hydrostatic Pumps and Motors System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6000
Removal and Installation of Hydrostatic Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001
Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
Transmission Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
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Copyright ©
Section
6000
HYDROSTATIC PUMPS AND MOTORS
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6000

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

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

If the machine were to become disabled, the drive wheels would lock because they are directly coupled to the
hydrostatic drive system through the final drives. A pair of bypass (tow) valves in each pump will allow the machine
to be moved for service. Once the brakes are released The bypass valve separates the forward and reverse side of
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the closed loop. When the valves are opened approximately two turns, the loop oil can bypass the pump and the
unit can be moved. Use caution when the bypass valves are opened to prevent the machine from moving out of
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6000-4
HOW IT WORKS
The 1150K crawler utilizes a dual path closed loop hydrostatic drive system to operate both tracks independently.
The engine provides power for two hydrostatic pumps, one for each track, to supply oil to the drive motor for each
track. The drive motors are directly coupled to the left or right final drive assembly. The tracks are then controlled
via a joystick from the left side of the operator’s platform. The two tracks being powered individually allow for power
turns and counter rotation.
The hydrostatic pump is a piston pump design that allows for the variable displacement of oil. The amount of oil
flow from the pump to the drive motor controls the speed of the vehicle in the forward and reverse directions. As the
amount of oil being pumped increases so does the vehicle speed. As one might expect as the amount of oil being
pumped decreases the vehicle speed decreases and the amount of torque or pulling power the vehicle has
increases. The swash plate is controlled by the operator electronically and changes the angle of the rotating piston
group. As the angle of the swash plate gets larger the amount of oil pumped and the pressure of that oil increases.
As the swash plate goes to a neutral position the flow of oil stops and the vehicle comes to rest. The direction of the
swash plate is what controls the directional flow of oil. Therefore the pump always turns the same direction but the
swash plate angles determine which way the flow available to do work travels.
The piston motors then receives oil from the pump, which causes a piston group to rotate. The motors are used to
power the final drives. The variable motor also has a swash plate which can rotate to increase or decrease speed.
With variable pumps and motors the operator can select an appropriate speed for operation. Oil leaving the motors
goes directly back to the pump and the cycle starts again.
Not all of the original oil returns to the hydrostatic pump. Some of the oil is lost to the reservoir through internal
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leakage of the pumps and motors. This oil is then picked up by the hydraulic pump, cooled, filtered, and put back
into the closed loop via the charge pump. The oil that leaks from the pump and motors is not enough to keep the
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closed loop oil cool, therefore a shuttle valve is incorporated into the motor to direct some additional oil back to the
reservoir.
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If the system continued to operate without a charge pump it would only operate for a few cycles before pump
cavitation and failure would occur. For that reason a charge pump supplies cool and filtered oil to replenish oil lost
from the internal leakage of the pump and motors as well as the oil that is drained off from the shuttle valve for
cooling. The charge pump also provides oil to release the parking brake.
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6000-5
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BS06K191
1. CHARGE FILTER 2. BENT AXIS MOTOR 3. TANDEM PUMP

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6000-6
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BS06M468
BENT AXIS DRIVE MOTOR

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

2. CHARGE PUMP 4. CIRCUIT RELIEFS 6. ELECTRONIC CONTROLS
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6000-8
FUNCTIONALITY
The variable displacement hydrostatic pump and the charge pump are driven by the diesel engine.
The charge pump, pumps oil through the charge filter. If the charge filter cartridge is excessively dirty, the charge
filter restriction indicator will alert you of this problem. If back pressure is too high in front of a dirty charge filter
cartridge, the charge circuit bypass valve opens and directs part of the charge oil back to the inlet side of the
charge pump after going through the charge circuit strainer.
The charge pressure is limited to 425 PSI by two charge pressure relief valves and can be checked at the test port
located on the test panel. Charge pressure oil is directed to the appropriate low pressure side of the variable
displacement pump (dependent upon travel direction) by way of the check/replenishing valves. The
check/replenishing valves are integrated into the high pressure circuit relief valves. Charge oil compensates for
leakage in our closed loop system.
The charge pump generates a variable flow dependent upon the speed of the engine. The faster the engine speed,
the higher the charge pump flow. The charge flow is directed to the directional control valve. The directional control
valve (which is controlled by electro proportional valves which receive a signal from the controller) uses the charge
flow to create control pressure and sends it out to the required side of the servo cylinder. The servo cylinder then
creates the angular movement of the swash plate.
The directional control valve is defaulted to its neutral position. While in neutral oil from both sides of the servo
cylinder has a path to tank. When forward movement is requested by the operator the joystick sends a signal to the
controller stating which direction the operator would like to travel and at what speed. Based upon this input from the
operator the controller opens the forward electro proportional valve and sends charge pressure to the
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corresponding side of the servo cylinder. A sensor measuring track speed communicates with the controller and
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allows for closed loop control. The EP valve then shifts as necessary to maintain the desired speed.
When the machine is traveling, high pressure oil is pumped to the hydraulic motors by the travel pumps. In the
event the oil pressure exceeds 6000 PSI the travel circuits are protected by circuit relief valves which are set at
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6000 PSI and protect the forward and reverse directions.
The pump and motor swash plate angles have ten preset positions. These positions are controlled by the
micro-controller and EP valves and toggled between by the operator with bump_up and bump_down buttons
located on the travel joystick. By toggling between these preset positions the speed of the vehicle is changed. The
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motor EP valves control the swash plate by allowing a certain amount of drive side high pressure oil to energize the
appropriate side of the adjusting cylinder. The adjusting cylinder will either retract or extend based upon how the
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EP valve is set. The swash plate angle is increased or decreased by retracting and extending the adjusting
cylinder. As the angle increases CRAWLER speed decreases and torque increases. As the angle decreases speed
increases and torque decreases.
A shuttle spool is also integrated into the motor housing. The spool reacts to drive side high pressure oil and allows
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return side low pressure hot oil to exit the motor and return to the hydraulic reservoir.
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Direction and speed are both controlled by a joystick located in the left hand console. As the joystick is moved
forward the machine begins forward movement. Once in the forward detent track speed is controlled by bump_up
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and bump_down buttons located on the joystick. These buttons change the speed by a predetermined amount and
display the selected speed on the dash. There are 10 preset operating positions that the operator can bump up and
down between. The speed defaults to 3 MPH every time the engine is started. Holding the bump_up and
bump_down buttons for a continuous time will continue to shift up or down through the preset operating speeds.
This same process also holds true for the reverse direction.
For greater working efficiency the speed of reverse is variable based upon maximum speed in the forward
direction. The maximum reverse speed can be 80% to 130% of the maximum forward speed. The forward to
reverse ratio is controlled by the forward speed set by the bump_up and bump_down buttons as well as the setting
selected on the reverse speed knob.
Steering is also commanded by the joystick located in the left hand console. When the operator commands turning
(must be in forward or reverse to turn) the inside track decreases in speed and the outside track remains at the
same speed (Pivot Turn). Counter rotation is possible when a pivot turn is not adequate (NOTE: Control lever must
be in the forward or reverse direction). When the operator moves the joystick past the pivot turn position, counter
rotation will take place. The inside track shall begin to move in the reverse direction of the outside track. As the
joystick is stroked against its stop the tracks will be driven at commanded speed for the forward or reverse direction
with both tracks being driven in opposite directions.

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6001
Section
6001
REMOVAL AND INSTALLATION OF

HYDROSTATIC PUMPS AND MOTORS
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6001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HYDROSTATIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PUMP AND MOTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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6001-3
SPECIFICATIONS
Manufacture.................................................................................................................................................... Rexroth
NOTE: For additional torques see illustrations at the rear of this section.
Torques
Pump mount bolts to frame ..........................................................................................68 to 81 Nm (50 to 60 lb-ft)
Motor mount bolts to brake housing .....................................................................250 to 280 Nm (183 to 210 lb-ft)
Pump to motor hoses split flange clamps ..................................................................90 to 100 Nm (66 to 74 lb-ft)
Inlet hose clamps ...................................................................................................... 6.5 to 7.6 Nm (58 to 68 lb-in)
Drive shaft to flywheel mount bolts.......................................................................285 to 305 Nm (210 to 225 lb-ft)
Center Housing Rear Cover
30mm hex bolts ....................................................................................................430 to 485 Nm (315 to 355 lb-ft)
18mm hex bolts ......................................................................................................... 77 to 100 Nm (57 to 74 lb-ft)
NOTE: For final drive removal and repair see section 6007.
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6001-4
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BD06E012

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6001-5
1. FROM EQUIPMENT VALVE 8. FROM FRONT CHARGE PUMP 15. DIAGNOSTIC LINES (3)
2. RESERVOIR TO HYDRAULIC PUMP 9. LEFT PUMP 16. CHARGE PUMP CROSS OVER
3. HYDRAULIC PUMP 10. MOUNT BRACKET 17. RIGHT PUMP
4. TO HYDRAULIC FILTER 11. CLAMP MOUNTING BOLTS 18. “T” FITTING
5. FROM HYDROSTAT FILTER 12. CASE DRAIN CROSS OVER 19. TO HYDROSTAT FILTER
6. “T” FITTING 13. FRONT CHARGE PUMP INLET HOSE 20. CASE DRAIN TO RESERVOIR
7. LEFT MOTOR HIGH PRESSURE 14. CHARGE PRESSURE SENSOR 21. RIGHT MOTOR HIGH PRESSURE
HYDROSTATIC PUMP
Removal STEP 5
Disconnect the hydraulic pump inlet line (2) and
NOTE: After removal of lines, cap and plug lines and
pressure line.
fittings to prevent foreign material from entering the
hydraulic system.
STEP 6
STEP 1 Disconnect the front charge pump inlet line (13).
Park the machine on a level surface, lower the blade
and any attachment to the floor, apply the parking STEP 7
brake levers and turn off the master disconnect. Disconnect the case drain to reservoir line (20).
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STEP 2 STEP 8
Disconnect the hydrostat filter output line (5) and
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Tilt the ROPS cab or canopy, see section 9008.
input line (19).
STEP 3
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Remove both rear belly pans from the machine. STEP 9
STEP 4
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BD06E003
Disconnect the rear charge pump inlet hose at the

reservoir, position the hose so it can be removed with
BD06E002
the hydrostatic pumps.
1. RESERVOIR VENT 3. TRANSMISSION FILTER
2 HYDRAULIC FILTER 4. BACK UP ALARM
STEP 10
Remove the vent from the hydraulic reservoir and
Disconnect the equipment valve return line (1).
connect a vacuum pump to the reservoir. Turn on the
vacuum pump.
STEP 11
IMPORTANT: DO NOT disconnect two lines at the Disconnect the thermal valve to filter line (4).
same time going to the hydraulic reservoir. Plug or
cap any line prior to disconnecting another.
NOTE: Tag all lines and wires before disconnecting
for proper identification for assembly. See page 4 for
locations.

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6001-6
STEP 12 STEP 17
Disconnect the right motor pressure lines (21).
STEP 18
Remove two bolts (11) and clamps from front
mounting bracket.
STEP 19
NOTE: Line 8, 12, and 16 do not need to be
removed prior to pump removal.
Attach suitable lifting equipment to the pumps,
ensure proper balance of the pumps to keep from
tilting during removal.
BD06E013
Disconnect the solenoids from under the machine.

STEP 20
Remove the two front mounting bolts.
STEP 13
Disconnect pressure switch (14) harness.
STEP 21
STEP 14
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Disconnect the three diagnostic center lines (15).
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STEP 15
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BD06E013
Remove the two rear mount bolts, the hose seen in

3 the center of the photo was disconnected in step 9
2 and can be removed with the pump.
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STEP 22
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BD06E001
1. BRAKE PRESSURE LINE Raise the pumps slowly, move the pumps to the rear
2. DIAGNOSTIC CENTER LINES and slip the input shaft off of the pump splines.
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3. HYDRAULIC PUMP Carefully remove the pumps from the machine.

Disconnect the brake solenoid pressure line and two IMPORTANT: When removing and installing lines
diagnostic lines from the rear charge pump. and fittings from the old pump to the new pump,
replace all O-rings and install the lines and fittings at
STEP 16 the same angles as when removed.
Disconnect the left motor pressure lines (7).

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6001-7
NOTE: Remove caps and plugs for lines and fittings
just prior to the connection of that line.
IMPORTANT: DO NOT remove plugs or caps from
two lines at the same time going to the hydraulic
reservoir.
STEP 23
BD06E007
Install the front wiper seal, do not drive the seal in

flush but leave it raised as shown. Coat the shaft
splines with high pressure grease.
STEP 26
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BD06E004
Install and tighten the drive shaft mounting bolts to
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285 to 305 Nm (210 to 225 lb-ft).
STEP 24
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BD06E008
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Carefully lower the pumps into the machine. Slide the

pumps forward onto the shaft until the shaft engages
the seal, as shown. Align the mounting bolt holes and
install the mounting bolts.
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STEP 27
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BD06E005 Remove the lifting equipment from the pumps.

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STEP 28
BD06E006
Install the front and rear mounting bushings.

BD06E013
Torque the rear mount bolts to 68 to 81 Nm

(50 to 60 lb-ft). Connect the hose to the reservoir.

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6001-8
STEP 29 STEP 33
Torque the two front mounting bolts to 68 to 81 Nm Connect the left motor pressure lines (7). Snug the
(50 to 60 lb-ft). split flange clamps down evenly and then torque to
90 to 100 Nm (66 to 74 lb-ft).
STEP 30
STEP 34
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BD06E009
Install the flywheel covers. 1. BRAKE PRESSURE LINE

BD06E001
2. DIAGNOSTIC CENTER LINES
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STEP 31 3. HYDRAULIC PUMP
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Install the two bolts (11) and clamps to the front Connect the brake solenoid pressure line and two
mounting bracket. diagnostic lines to the rear charge pump.
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STEP 32 STEP 35
Connect the right motor pressure lines (21). Snug the Connect the remaining three lines to the diagnostic
split flange clamps down evenly and then torque to center (15). Three lines are located on the right side
90 to 100 Nm (66 to 74 lb-ft). of the pump.
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Connect the pressure switch wiring (14).
STEP 37
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BD06E013
Connect the solenoids from the under side of the

machine.
STEP 38
Connect the thermal valve to filter line (4).

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6001-9
STEP 39 STEP 45
Connect the equipment valve return line (1).
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STEP 40
Connect hydraulic pump (3) inlet line (2) and outlet 2
line. Torque the clamp on the inlet line to a torque of
6.5 to 7.6 Nm (58 to 65 lb-in).
STEP 41 3
Connect the hydrostat filter output line (5) and output 4
line (19).
STEP 42
Connect the case drain to reservoir line (20). BD06E002

STEP 43 2 HYDRAULIC FILTER 4. BACK UP ALARM
Connect the front charge pump inlet line (13). Torque Turn off the vacuum pump. Disconnect the vacuum
to 6.5 to 7.6 Nm (58 to 65 lb-in). pump from the reservoir, install the vent in the
hydraulic reservoir.
STEP 44
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STEP 46
Lower the ROPS cab or canopy, see section 9008.
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STEP 47
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Check the oil level in the reser voir and fill as
necessary with MS-1209, see section 1002.
STEP 48
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Start and run the engine at low idle for 3 minutes, run
the machine at full throttle for 5 minutes while moving
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the machine in forward, reverse, left and right

steering positions.
BD06E003
Connect the rear charge pump inlet hose to the STEP 49

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reservoir. Torque the clamp on the inlet line to a Shut the engine off and tilt the ROPS cab or canopy,
torque of 6.5 to 7.6 Nm (58 to 65 lb-in). see section 9008, and check for leaks.
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STEP 50
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Check for leaks from the under side of the machine,

repair leaks as required. Install the belly pans.

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6001-10
HYDROSTATIC MOTORS
Removal STEP 5
NOTE: After removal of lines, cap and plug lines and
fittings. 2 3
STEP 1
and any attachment to the floor, apply the parking 1
brake levers and turn off the master disconnect.
STEP 2
Tilt the ROPS cab or canopy, see section 9008. 4
STEP 3 BD06E011
1. CASE DRAIN 3. SOLENOID

2. SPEED SENSOR 4. BRAKE RELEASE
Disconnect the rear case drain hose, solenoid and
speed sensor wiring harness.
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NOTE: Brake release hose (4) does not need to be
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disconnected but should be disconnected and moved
out of the area of the motor to prevent damage
during removal.
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STEP 6
Disconnect high pressure hoses from the motor.
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BD06E010
Remove the rear cover plate from the center box, use STEP 7
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suitable lifting equipment to lower the plate. Disconnect the front case drain hose.
STEP 4 STEP 8
Remove all but one mount bolt to the brake housing.
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Support the motor with blocks of wood and remove

the last mounting bolt.
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Carefully work the motor out of the brake housing

and remove it from the machine.
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4 IMPORTANT: When removing and installing fittings
from the old motor to the new motor, replace all
O-rings and install the fittings.
BD06E002

vacuum pump.

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6001-11
Turn off the vacuum pump. Disconnect the vacuum
STEP 10 pump from the reservoir, install the vent in the
Lubricate the splines on the motor with Loctite 767 hydraulic reservoir.
anti-seize.
STEP 17
STEP 11 Lower the ROPS cab or canopy, see section 9008.
Carefully work the motor into the machine and into
the brake housing. STEP 18
Check the oil level in the reser voir and fill as
STEP 12 necessary, see section 1002.
Start all four mounting bolts to the final drive and
snug them up evenly. Torque the mounting bolts to STEP 19
250 to 280 Nm (183 to 210 lb-ft). Start and run the engine at low idle for 3 minutes, run
the machine at full throttle for 5 minutes while moving
STEP 13 the machine in forward, reverse, left and right
steering positions.
Connect the front case drain hose.
STEP 20
STEP 14
Shut the engine off and check for leaks.
Connect high pressure hoses to the motor. Snug the
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split flange clamps down evenly and then torque to
STEP 21
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90 to 100 Nm (66 to 74 lb-ft).
STEP 15
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Install the rear cover and torque the 30mm hex bolts
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to 430 to 485 Nm (315 to 355 lb-ft), the 18mm hex

BD06E011 bolts to 77 to 100 Nm (57 to 74 lb-ft).
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1. CASE DRAIN 3. SOLENOID

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

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6001-12
PUMP AND MOTOR MOUNTING
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BS06K191
RIGHT SIDE VIEW
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1. HOSE TO FILTER TORQUE TO 90 - 95 NM (65 - 70 FT-LBS) 7. MOUNTING NUTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)
2. MOTOR CASE DRAIN TORQUE TO 90 - 95 NM (65 - 70 FT-LBS) 8. HOSE FLANGE TORQUE TO 90 - 95 NM (65 - 70 FT-LBS)
3. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 70 FT-LBS) 9. CONNECTOR TORQUE TO 35 - 54 NM (25 - 40 FT LBS)
4. CLAMP TORQUE TO 6.5 - 7.6 NM (58 - 68 INCH-LBS) 10. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
5. STEM 45° TORQUE TO 163 - 224 NM (120 TO 165 FT-LBS) 11. CONNECTOR LONG TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
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6. BOLT USE LOCTITE 243 TORQUE TO 285 - 305 NM (210 - 225 FT LBS)
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6001-13
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BS06K190
LEFT SIDE VIEW
1. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS) 7. CONNECTOR TORQUE TO 35 - 54 NM (25 - 40 FT-LBS)

2. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS) 8. MOUNTING NUTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)
3. STEM 45° TORQUE TO 163 - 224 NM (120 TO 165 FT-LBS) 9. CHARGE PUMP OUT TORQUE TO 90 - 95 NM (65 - 70 FT LBS)
4. BOLT APPLY LOCTITE 243 TORQUE TO 250 - 280 NM 10. HOSE CASE DRAIN TORQUE TO 90 - 95 NM (65 - 700 FT-LBS)
(183 - 210 FT-LBS) 11. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 700 FT-LBS)
5. CONNECTOR LONG TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
12. HOSE FLANGE TORQUE TO 125 - 135 NM (92 - 100 FT-LBS)
6. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 70 FT LBS)

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6001-14
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BOTTOM VIEW
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4. HOSE PUMP CASE DRAIN TORQUE TO 90 - 95 NM
1. BOLT TORQUE TO 90 - 100 NM (66.4 - 74.8 FT-LBS)
(65 - 70 FT-LBS)
5. SUCTION HOSE CHARGE PUMP TORQUE TO 170 - 190 NM
2. CONNECTOR TORQUE TO 263 - 224 NM (120 - 165 FT-LBS)
(125 - 140 FT LBS)
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6. BOLT APPLY LOCTITE 243 TORQUE TO 118 - 132 NM

3. CONNECTOR TORQUE TO 90 - 95 NM (65 TO 70 FT-LBS)
(87 - 98 FT-LBS)
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6002
Section
6002
HYDROSTATIC DRIVE SPECIFICATIONS
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PRESSURE CHECKS AND TROUBLESHOOTING
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6002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKS TO DO BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDROSTATIC SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDROSTATIC LINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RELIEF VALVE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING CHARGE PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting Charge Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Checking the Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CHECKING PRESSURE OF RIGHT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKING PRESSURE OF LEFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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SPECIFICATIONS
Charge Pump Pressure .....................................................................................................................30 bar (435 psi)
Left Pump Pressure Override Valve ............................................................................................390 bar (5656.5 psi)
Left Forward Pump Port MA ...........................................................................................................420 bar (6092 psi)
Left Reverse Pump Port MB ...........................................................................................................420 bar (6092 psi)
Right Pump Pressure Override Valve ..........................................................................................390 bar (5656.5 psi)
Right Forward Pump Port MB.........................................................................................................420 bar (6092 psi)
Right Reverse Pump Port MA.........................................................................................................420 bar (6092 psi)
NOTE: The hydraulic and hydrostatic oil must be at an operating temperature of 49° to 63° C (120° to 145° F)
when checking pressure specifications.
SPECIAL SERVICE TOOLS
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B877558M
CAS-1804 PRESSURE TEST FITTING KIT
CHECKS TO DO BEFORE TROUBLESHOOTING

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1. Check the oil level, type, and grade in the 3. Check controls for correct operation. See section
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hydraulic reservoir. See Section 1002 for correct 9001 for adjustment.
hydraulic oil specifications.
4. Check engine r/min (rpm).
2. Check hydrostatic oil filter condition and change
as necessary. See Section 8002 for procedure.
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6002-4
HYDROSTATIC SYSTEM COMPONENT LOCATIONS
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21
20
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BD06E012

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6002-5
1. FROM EQUIPMENT VALVE 8. FROM FRONT CHARGE PUMP 15. DIAGNOSTIC LINES (3)
2. RESERVOIR TO HYDRAULIC PUMP 9. LEFT PUMP 16. CHARGE PUMP CROSS OVER
3. HYDRAULIC PUMP 10. MOUNT BRACKET 17. RIGHT PUMP
4. TO HYDRAULIC FILTER 11. CLAMP MOUNTING BOLTS 18. “T” FITTING
5. FROM HYDROSTAT FILTER 12. CASE DRAIN CROSS OVER 19. TO HYDROSTAT FILTER
6. “T” FITTING 13. FRONT CHARGE PUMP INLET HOSE 20. CASE DRAIN TO RESERVOIR
7. LEFT MOTOR HIGH PRESSURE 14. CHARGE PRESSURE SENSOR 21. RIGHT MOTOR HIGH PRESSURE
NOTE: The reverse pressure relief valves are located on the directly below the forward pressure relief valves. The
rear pump POR valve is located in the left rear bottom of the rear pump.
HYDROSTATIC LINE INSTALLATION
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BS06K191
RIGHT SIDE VIEW
1. HOSE TO FILTER TORQUE TO 90 - 95 NM (65 - 70 FT-LBS) 7.

MOUNTING NUTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)
2. MOTOR CASE DRAIN TORQUE TO 90 - 95 NM (65 - 70 FT-LBS) 8.
HOSE FLANGE TORQUE TO 90 - 95 NM (65 - 70 FT-LBS)
3. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 70 FT-LBS) 9.
CONNECTOR TORQUE TO 35 - 54 NM (25 - 40 FT LBS)
4. CLAMP TORQUE TO 6.5 - 7.6 NM (58 - 68 INCH-LBS) 10.
CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
11.
CONNECTOR LONG TORQUE TO 75 - 108 NM (55 - 80
5. STEM 45° TORQUE TO 163 - 224 NM (120 TO 165 FT-LBS)
FT-LBS)
6. BOLT USE LOCTITE 243 TORQUE TO 285 - 305 NM (210 - 225 FT LBS)

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6002-6
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BS06K190
LEFT SIDE VIEW
1. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS) 7. CONNECTOR TORQUE TO 35 - 54 NM (25 - 40 FT-LBS)

2. CONNECTOR TORQUE TO 75 - 108 NM (55 - 80 FT-LBS) 8. MOUNTING NUTS TORQUE TO 68 - 81 NM (50 - 60 FT-LBS)
3. STEM 45° TORQUE TO 163 - 224 NM (120 TO 165 FT-LBS) 9. CHARGE PUMP OUT TORQUE TO 90 - 95 NM (65 - 70 FT LBS)
4. BOLT APPLY LOCTITE 243 TORQUE TO 250 - 280 NM 10. HOSE CASE DRAIN TORQUE TO 90 - 95 NM (65 - 700 FT-LBS)
(183 - 210 FT-LBS) 11. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 700 FT-LBS)
5. CONNECTOR LONG TORQUE TO 75 - 108 NM (55 - 80 FT-LBS)
12. HOSE FLANGE TORQUE TO 125 - 135 NM (92 - 100 FT-LBS)
6. ‘T’ FITTING TORQUE TO 90 - 95 NM (65 - 70 FT LBS)

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6002-7
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BS06K189
BOTTOM VIEW
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4. HOSE PUMP CASE DRAIN TORQUE TO 90 - 95 NM
1. BOLT TORQUE TO 90 - 100 NM (66.4 - 74.8 FT-LBS)
(65 - 70 FT-LBS)
5. SUCTION HOSE CHARGE PUMP TORQUE TO 170 - 190 NM
2. CONNECTOR TORQUE TO 263 - 224 NM (120 - 165 FT-LBS)
(125 - 140 FT LBS)
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6. BOLT APPLY LOCTITE 243 TORQUE TO 118 - 132 NM

3. CONNECTOR TORQUE TO 90 - 95 NM (65 TO 70 FT-LBS)
(87 - 98 FT-LBS)
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RELIEF VALVE LOCATIONS
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PUMP RELIEF VALVES
1. MAIN RELIEF 3. MAIN RELIEF

2. CHARGE PRESSURE RELIEF 4. PRESSURE OVERRIDE VALVE (NOT SHOWN)
NOTE: The rear charge pump will be rotated 180° and the the location of the pressure relief valves will be on the
opposite side.

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6002-9
CHECKING CHARGE PUMP PRESSURE

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

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17. Compare the pressure readings recorded to the
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specifications on page 3.
NOTE: If charge pressure readings dropped more
BD06K126 than 1.8 bar (25 psi) between N and F or R during
procedures 12 or 15 it will be required to determine if
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4. Direct the gauge into the ROPS or cab to view

them from the operators seat. the leakage is in the brake release system or the
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hydrostat system.
WARNING: Always know the location of all
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workers in your area. Warn them before you Understanding Results of the Test
start working the machine. Always keep all
other persons away from your area. Serious NOTE: Charge pressure is used to shift the servo
injury or death can result if you do not follow control pistons, hydraulic blade control systems, and
these instructions. release the brakes. Low charge pressure may be the
SA015
result of a failure in either of these systems.
5. Start the engine, select engine r/min (rpm) on the 18. If pressure is not within specification on page 3
instrument cluster display. during procedure 7 go to procedure 19, if the
pressure dropped during procedure 13 or 15 go
6. Raise and maintain engine r/min (rpm) at 2000.
to procedure 23.

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6002-10
Adjusting Charge Pressure 19. Remove the vent from the hydraulic reservoir and
connect a vacuum pump to the reservoir. Turn on
Settings the pump.
IMPORTANT: Adjust both front and rear charge 20. Disconnect the filter bypass return line, plug the
pumps at the same time with the same amount of line and cap the fitting.
turns of the adjusting screws.
21. Turn off the vacuum pump, repeat procedures 2
through 8 and check the pressure.
NOTE: If pressure increased replace the filter head,
if pressure did not increase, reconnect the filter
1 bypass line and go to the next procedure.
22. Adjust the pressure settings of the charge pump
relief valves by doing the following procedure:
A. Tilt the ROPS cab/canopy, see section 9008.
2
BD06E002
1. RESERVOIR VENT 2. BYPASS LINE
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6002-11
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BD06E012

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6002-12
Checking the Brake Circuit

NOTE: Rear charge pump pressure relief valve is NOTE: Check oil levels in both final drives to
located below the pump feed cross over line and determine if hydraulic system oil is present.
fitting, the front charge pump pressure relief valse is
located under the charge pump pressure switch. 24. The brake system can be isolated by plugging
the feed line to the brake solenoid.
B. Remove the adjusting screw cover.
C. Loosen the adjusting screw jam nut.
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D. Turn the adjusting screw clockwise to increase
pressure and counterclockwise to decrease
pressure.
NOTE: One turn will result in a pressure change of
approximately 3.8 Bar (55 psi). 2
E. Lower the ROPS cab/canopy, see section
9008.
F. Turn off the vacuum pump, repeat procedures
2 through 8 to check the pressure setting. BD06K044
23. Adjust the charge pressure relief valves again if 1. FEED LINE 2. RESERVOIR RETURN LINE
necessary. A. Tilt the ROPS cab/canopy, see section 9008.
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B. Remove the vent from the hydraulic reservoir
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and connect a vacuum pump to the reservoir.
Turn on the pump.
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C. Disconnect the feed line from the brake
solenoid, plug the line and cap the fitting.
D. Lower the ROPS cab/canopy, see section
9008.
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E. Turn off the vacuum pump and repeat

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procedures 2 through 17.

25. If the pressure increases do the following to
further isolate the problem.
A. Tilt the ROPS cab/canopy, see section 9008.
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B. Turn on the vacuum pump.

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C. Connect the feed line to the brake solenoid.

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D. Disconnect the reservoir return line from the

brake solenoid, plug the line and cap the
fitting.
E. Lower the ROPS cab/canopy, see section
9008.
F. Turn off the vacuum pump and repeat
procedures 2 through 17.

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6002-13
26. If the pressure increases replace the brake 27. If the pressure did not increase during
solenoid, see section 7001, if the pressure still procedures 19 through 28 there is an internal
remains low during procedure 12 or 15 replace problem in the hydrostatic pump system. Do the
the brake piston O-rings, see section 7001. following procedures to isolate the problem.
A. Tilt the ROPS cab/canopy, see section 9008. A. While moving the machine forward at low
speed, note the pressure reading, make a
B. Turn on the vacuum pump.
slow right turn, note the pressure reading,
C. Connect the reservoir return line from the make a slow left turn, note the pressure
brake solenoid. reading.
D. Lower the ROPS cab/canopy, see section B. While moving the machine in reverse at low
9008. speed, note the pressure reading, make a
slow right turn, note the pressure reading,
E. Turn off the vacuum pump and disconnect it
make a slow left turn, note the pressure
from the reservoir. Install the vent in the
reading.
hydraulic reservoir.
28. If the pressure did not recover during straight
forward motion check both right and left forward
pumps. If pressure did not recover during right
turn check the left forward pump, during left turn
check the right forward pump.
29. If the pressure did not recover during straight
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reverse motion check both right and left reverse
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pumps. If pressure did not recover during right
turn check the left reverse pump, during left turn
check the right reverse pump.
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NOTE: See procedures in this section for checking
forward and reverse pumps.
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6002-14
CHECKING PRESSURE OF RIGHT PUMP

Equipment Required 10. Move the Hand throttle to the IDLE position.
CAS-1804 Pressure test and fitting kit. 11. Place the directional control in the R position.
Right Pump Pressure Test When the pressure stops increasing, record the
pressure readings.
Make sure the hydraulic and hydrostatic oil is at
operating temperature. 13. Move the Hand throttle to the IDLE position,
place the directional control in neutral and apply
1. It will be necessary to operate the machine the parking brakes, stop the engine.
against an immovable object or into a spoil pile.
The surface must be one that will allow the track 14. Compare the pressure readings recorded to the
to dig in, in both FORWARD and REVERSE. specifications on page 3.
15. If pressures are not within specification on page
WARNING: Always know the location of all 3, tilt the ROPS cab/canopy, see section 9008.
workers in your area. Warn them before you
16. Adjust the pressure reliefs of the right pump by
doing the following procedure:
other persons away from your area. Serious
injury or death can result if you do not follow A. Check the torque of the pressure relief valves
these instructions. in the pump body, 150 Nm (110 lb-ft).
SA015 B. Remove the plastic cap from the pressure
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2. Connect two 414 to 690 bar (6000 to 10,000 psi) relief valve, loosen the jam nut and turn the
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adjusting screw in to increase the pressure
Right Reverse Pump Por t MA (1) and Right and out to decrease the pressure. Pressure
Forward Pump Port MB (2). The hose for the setting of 414 bar (6000 psi).
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pressure gauge must have at least a 690 bar
(10,000 psi) rating. NOTE: The forward directional pressure relief valve
is located on the bottom and the reverse relief valve
is located on the top.
17. Lower the ROPS cab/canopy, see section 9008.
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18. Repeat Steps 3 through 14 to check the pressure

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setting.
19. If pressure is still not within specification on page
3, tilt the ROPS cab/canopy, see section 9008.
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20. Adjust the pressure over ride valve by doing the
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following procedure:
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A. Remove the plastic cap from the POR valve,

loosen the jam nut and turn the adjusting
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BD06K126 screw in until it just seats, tighten the jam nut.

3. Direct the gauges into the ROPS or cab to view
them from the operators seat. IMPORTANT: DO NOT over tighten the adjusting
screw in the POR valve, this WILL damage internal
4. Start the engine.
components of the POR valve.
5. Make sure the Hand Throttle is in the idle 21. Lower the ROPS cab/canopy, see section 9008.
position.
22. Repeat procedures 3 through 14 to check the
6. Use the UP range button to place the machine in pressure setting.
its highest range. The instrument cluster will
reflect the hydrostat range. NOTE: If the pressure reading is not within
specifications see section 6001 removal and
7. Make sure both parking brakes are in the OFF
installation of power train components, replace the
position.
pumps.
8. Place the directional control in the F position.
When the pressure stops increasing, record the
pressure reading.

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6002-15
CHECKING PRESSURE OF LEFT PUMP

Equipment Required 10. Move the Hand throttle to the IDLE position.
CAS-1804 Pressure test and fitting kit. 11. Place the directional control in the R position.
Left Pump Pressure Test When the pressure stops increasing, record the
pressure readings.
Make sure the hydraulic and hydrostatic oil is at
operating temperature. 13. Move the Hand throttle to the IDLE position,
place the directional control in neutral and apply
1. It will be necessary to operate the machine the parking brakes, stop the engine.
against an immovable object or into a spoil pile.
The surface must be one that will allow the track 14. Compare the pressure readings recorded to the
to dig in, in both FORWARD and REVERSE. specifications on page 3.
15. If pressures are not within specification on page
WARNING: Always know the location of all 3, tilt the ROPS cab/canopy, see section 9008.
workers in your area. Warn them before you
16. Adjust the pressure reliefs of the left pump by
doing the following procedure:
other persons away from your area. Serious
injury or death can result if you do not follow A. Check the torque of the pressure relief valves
these instructions. in the pump body, 150 Nm (110 lb-ft).
SA015 B. Remove the plastic cap from the pressure
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2. Connect a 414 to 690 bar (6000 to 10,000 psi) relief valve, loosen the jam nut and turn the
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adjusting screw in to increase the pressure
Left Reverse Pump Port MB (2) and Left Forward and out to decrease the pressure. Pressure
Pump Port MA (1). The hose for the pressure setting of 414 bar (6000 psi).
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gauge must have at least a 690 bar (10,000 psi)
rating. NOTE: The forward directional pressure relief valve
is located on the bottom and the reverse relief valve
is located on the top.
1 2 17. Lower the ROPS cab/canopy, see section 9008.
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18. Repeat Steps 3 through 14 to check the pressure

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setting.
19. If pressure is still not within specification on page
3, tilt the ROPS cab/canopy, see section 9008.
20. Adjust the pressure over ride valve by doing the
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following procedure:
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A. Remove the plastic cap from the POR valve,

loosen the jam nut and turn the adjusting
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BD06K126 screw in until it just seats, tighten the jam nut.

3. Direct the gauges into the ROPS or cab to view
them from the operators seat. IMPORTANT: DO NOT over tighten the adjusting
screw in the POR valve, this WILL damage internal
4. Start the engine.
components of the POR valve.
5. Make sure the Hand Throttle is in the idle 21. Lower the ROPS cab/canopy, see section 9008.
position.
22. Repeat procedures 3 through 14 to check the
6. Use the UP range button to place the machine in pressure setting.
its highest range. The instrument cluster will
reflect the hydrostat range. NOTE: If the pressure reading is not within
specifications see section 6001 removal and
7. Make sure both parking brakes are in the OFF
installation of power train components, replace the
position.
pumps.
8. Place the directional control in the F position.
When the pressure stops increasing, record the
pressure reading.

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6002-16
NOTES
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Section
6003
6003
DRIVETRAIN CONTROLLER
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6003-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE DRIVETRAIN CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE, HAND, AND FOOT THROTTLE POTENTIOMETER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RETREIVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Erasing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Steering Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Shuttle Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Maximum Transmission Speed Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL AND INSTALLATION OF THE PUMP SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FAULT 4121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FAULT 4131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FAULT 4141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FAULT 4151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FAULT 4212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FAULT 4222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FAULT 4311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FAULT 4312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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FAULT 4321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FAULT 4322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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FAULT 4323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FAULT 4324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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FAULT 4331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FAULT 4332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FAULT 4341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FAULT 4421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
R
FAULT 4431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
FO
FAULT 4521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FAULT 4522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FAULT 4531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FAULT 4532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
T
FAULT 4533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
FAULT 4622 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
O
FAULT 4721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
N

Copyright ©
6003-3
REMOVAL AND INSTALLATION OF THE DRIVETRAIN CONTROL MODULE

STEP 1 STEP 5
Park the machine on a level surface, lower blade and
any attachments.
STEP 2
Apply parking brakes, turn ignition switch and master
disconnect off.
STEP 3
BD06M024
Unsnap connector lock tab.
STEP 6
T
IN
BD06K007
Remove left arm rest.

PR
STEP 4
R
BD06M025
FO
Continue to push locking tab until the connector

disconnects from the controller.
STEP 7
T
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N
BD06K008
Remove four mounting screws, remove the cover for

the controller.
BD06M026
Check connector for corrosion, check seal for

damage.

Copyright ©
6003-4
STEP 8 STEP 10
BD06M027 BD06K008
Repeat the procedure for the other connector. Install the cover and mounting screws.
STEP 9 STEP 11
T
IN
PR
BD06M024 BD06K007
R
Install the mounting bolts, start the connectors into Install the left arm rest.
the controller with the locking bar slid completely out
FO
of the connector. Slide the locking bar into the

connector to draw the connector into place on the
controller.
NOTE: Make sure the locking bar snap’s into the
T
locked position.
O
N

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

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

internal memory.
applied position three times.
14.If at any time during calibration the instrument
NOTE: During this operation if the instrument cluster
cluster reads (CAL FAIL), stop the engine and
reads (ERR RANGE), minimum/maximum values are
restart the procedure.
T

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Copyright ©
6003-6
RETREIVING FAULT CODES

NOTE: If you have and active fault the fault menu Erasing Faults
can be accessed by pressing service/enter (4) on the
dash rocker switch. If there are no active faults, you 1. Hold the enter button until the display shows
must press the up arrow (1) and the escape button SERVICE.
(3) to access the fault menu, if no faults are recorded 2. Press the down arrow until RESET is highlighted.
the monitor will display (NONE).
3. Press enter, the display shows CLEAR ERRORS
AND RESTORE FATORY SETTINGS.
1 4. Highlight CLEAR ERRORS and press enter to

3
erase active errors.
NOTE: This will clear only the faults from the drive
train controller, the engine controller will hold faults in
memory an can be recovered by the EST.
2 4
BD06G112
1. Press and release the service/enter button (4).
T
Use up or down arrows (1 or 2) to display fault
IN
codes menu, (FAULTS). Press the service/enter
button (4) to select the faults menu then the
down arrow (2) to retrieve the faults.
PR
2. The first fault code display will be the fault code
number. (1 #####F).
3. Press the down arrow (2), the second part of the
R
fault code display will be the hours when the fault

was recorded. (1 #####.#).
FO
4. Press the down arrow (2), the third part of the

fault code display will be the number of times the
fault has occurred. (1 ##X).
5. Press the down arrow (2), if there is a second
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fault recorded the display will read (2 #####F),

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repeat steps two through four to retrieve all fault

codes.
N
6. Continue to toggle the down arrow (2) until all

fault codes are recorded for repair or repairs are
completed.
7. Press the down arrow (2) until the clear fault
code menu is displayed, (CLEAR FC). Select the
clear fault code menu by press ing the
service/enter button (4), the item will flash and
display (CLEAR?). Pressing the service/enter (4)
button again will confirm this selection and faults
codes will be removed.
NOTE: If a reset is not desired at this time, press the
down arrow (2) again and (NO CLEAR) will be
displayed.

Copyright ©
6003-7
ADJUSTING PARAMETERS
Adjusting Steering Sensitivity

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

FO
and store the choice.

NOTE: The setting menu may be hidden entirely
with the EST.
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Adjusting Shuttle Parameter

O
To adjust the shuttle parameter follow the same

steps as for steering sensitivity.
N
The shuttle choices are the same:

● Smooth
BD06G112
● Normal
2. Press the down arrow until SETTINGS is on
displayed. ● Fast
After selecting desired value press the enter button
to confirm the selection and store the choice.

Copyright ©
6003-8
Adjusting Maximum Transmission NOTE: When the crawler engine is shut off the
transmission speed will default to 60%.
Speed Parameter
To adjust the maximum transmission speed follow
the same steps as for steering sensitivity.
The transmission speed choices will be 70, 80, 90 or
100 per cent.
After selecting the desired value press the enter
button to confirm and store the choice.
Transmission Speed Controls
BD06G113
The transmission speed gauge will allow the operator
to know which speed is selected. When the crawler
T
engine is shut off the transmission speed will default
IN
to 60% as shown.
The digital display will reflect the position of the
direction control lever as “F” forward, “N” neutral, or
PR
BD02M166
1. Transmission speed up button “R” reverse.
2. Transmission speed down button NOTE: The crawler will not move unless the engine
The CASE K Series crawlers have infinitely variable rpm is above 1000.
R
speeds in forward and revers from 0 to 9.7 km/h (0 to

NOTE: A flashing F or R indicates the directional
6.0 mph). The maximum speed is selectable in a
control lever must be returned to neutral before
FO
range of 10 increments. To move from on speed to

movement is allowed.
another press the UP (1 for DOWN (2) button. The
operator may increment up one touch at a time or
hold the button to move through the transmission
speeds.
T
NOTE: The speed can only be increased to the

O
maximum transmission speed setting which can be

adjusted. See Adjusting Maximum Transmission
N
Speed Parameter on page 8. From the factory 90%

is the highest speed.

Copyright ©
6003-9
REMOVAL AND INSTALLATION OF THE PUMP SOLENOIDS

STEP 1 STEP 6
Park the machine on a level surface, lower blade and Slide the solenoids onto the control valve shaft,
any attachments. install the retaining nut and tighten.
NOTE: Make sure the wires are routed in such a
STEP 2 manner that they will not rub against the pump
Apply parking brakes, turn ignition switch and master housings.
disconnect off.
STEP 7
STEP 3 Connect the electrical connector.
Remove the center belly plate for the right pump
solenoids, rear belly plate for the left pump solenoids. NOTE: Make sure the connector seal is in place and
serviceable.
STEP 4
STEP 8
Install the belly plates.
T
IN
PR
BD06E013
Disconnect the electrical connector for the solenoids

R
being replaced.
FO
STEP 5
T
O
N
BD06M021
Remove the retaining nut for the solenoids, remove

the solenoids.
NOTE: Remove and replace both solenoids as a
unit.

Copyright ©
6003-10
FAULT 4121
Left Forward Pump Solenoid Circuit STEP 2
Open or Over Current
Condition:
Crawler will not move forward. 1
Possible Failure Modes:
1. Connectors not mated fully, pins not pushed into
connector fully, bent pin or broken wire at rear of 2
connector.
BD06E013
3. Wiring or solenoid circuits shorted.
1. CONNECTOR P3 2. CONNECTOR P4
4. Failed Drivetrain Control Module.
Clean and inspect the Left Forward Pump Solenoid
NOTE: Go to the electrical schematic for a complete Connection.
view of the controller circuit.
A. Turn ignition switch and master disconnect off.
T
STEP 1 B. Remove rear belly plate.
IN
Find out if the fault code is still active. C. Disconnect the Left Forward Pump Solenoid,
Connector P3.
A. Turn ignition switch to RUN position to power
PR
drivetrain controller. D. Inspect pins 1 through 4. Clean connections.
B. Clear all fault codes from the controller. E. Clean female pins by installing and removing.
NOTE: Prior to clearing fault codes write down all F. Measure the resistance of the coil at the Left
fault codes, number of occurrences, and engine Forward Pump Solenoid, Connector P3 pins 1
R
hours at last occurrence. and 2. The resistance should be 23.75 Ohms

± 0.75 Ohms.
FO
C. To check for fault code: Move directional

control to neutral, ignition switch to run NOT OK – Replace the solenoid. Return to Step 1 to
(engine does not need to be running), move confirm elimination of fault.
both parking levers to down position, move
OK – Go to Step 3.
hand throttle to high idle position, and push
T
directional control to forward position.

STEP 3
O
NOT OK – Fault code 4121 is recorded again. Go to

Check the Left Forward Pump Solenoid Ground
Step 2.
N
Connection.
OK – Fault is not recorded again. Ok for return to
A. Measure the resistance between Connector
service.
P3, pin 1 and battery ground, must be less
than 10 Ohms.
NOT OK – Determine break in ground connection
and repair. Return to Step 1 to confirm elimination of
fault.

Copyright ©
6003-11
STEP 4 STEP 5
2
1 2
BD06M022 BD06M028
1. CONNECTOR C5 1. CONNECTOR C2
2. CONNECTOR P1 2. CONNECTOR C1
3. LEFT ROPS STRUT
Check for open circuit in the Left Forward Pump
Check for open circuit in the Left Forward Pump Solenoid control wire between connectors C5 and
Solenoid circuit between P3 and P1. C1.
A. Disconnect Connector P1. A. Disconnect the Main Drivetrain Controller,
Connector C1.
T
B. Inspect pin 15 on Connector P1. Clean
Connections. B. Inspect pin 31 on Connector C1. Clean
IN
connections.
C. Clean female pins by installing and removing.
D. Check for open circuit between pin 2 of the
PR
Left Forward Pump Solenoid, Connector P3, D. Check for open circuit between pin 15 of
and pin 15 of Connector P1. Connector C5,and pin 31 of the Main
Drivetrain Controller, Connector C1.
NOT OK – Determine the break between connector
P1 and P3 and repair. Return to Step 1 to confirm NOT OK – Determine break between connector C1
R
elimination of fault. and C5 and repair. Return to Step 1 to confirm

FO
elimination of fault.
STEP 6
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Replace the Drivetrain Control Module.

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A. Remove and replace Drivetrain Control

Module.
N
B. Write symptom on failed Drivetrain Control

Module.
C. Install program with Electronic Service Tool
(EST) and recalibrate system.

Copyright ©
6003-12
FAULT 4131
Right Forward Pump Solenoid Circuit STEP 2
Condition:
Crawler will not move forward. 1
connector.
BD06E013
3. Wiring or solenoid circuits shorted.
Clean and inspect the Right Forward Pump Solenoid
NOTE: Go to the Electrical Schematic for a Connection.
complete view of the controller circuit.
T
STEP 1 B. Remove center belly plate.
IN
Find out if the fault code is still active. C. Disconnect the Right Forward Pump Solenoid,
A. Turn ignition switch to RUN position to power Connector P4.
PR
NOTE: Prior to clearing fault codes write down all F. Measure the resistance of the coil at the Right
fault codes, number of occurrences, and engine
R
Forward Pump Solenoid, Connector P4 pins

hours at last occurrence. 1 and 2. The resistance should be 23.75
FO
C. To check for fault code: Move directional Ohms ± 0.75 Ohms.

hand throttle to high idle position, and push OK – Go to Step 3.
T

O
STEP 3
Step 2. Check the Right Forward Pump Solenoid Ground
N
Connection.
service. A. Measure the resistance between Connector
P4, pin 1 and battery ground, must be less
than 10 Ohms.
fault.

Copyright ©
6003-13
STEP 4 STEP 5
2
1 2
BD06M022 BD06M028
1. CONNECTOR C5
1. CONNECTOR C2
2. CONNECTOR P1
2. CONNECTOR C1
3. LEFT ROPS STRUT
Check for open circuit in the Right Forward Pump
Check for open circuit in the Right Forward Pump Solenoid control wire between connectors C5 and
Solenoid circuit between P4 and P1. C1.
Connector C1.
T
Connections. B. Inspect pin 4 on Connector C1. Clean
IN
C. Clean female pins by installing and removing. connections.
D. Check for open circuit between pin 2 of the C. Clean female pins by installing and removing.
PR
Right Forward Pump Solenoid, Connector D. Check for open circuit between pin 13 of
P4, and pin 13 of Connector P1. Connector C5,and pin 4 of the Main
NOT OK – Determine break between connector P1 Drivetrain Controller, Connector C1.
and P4 and repair. Return to Step 1 to confirm
R
NOT OK – Determine break between connector C1

FO
OK – Go to Step 5. elimination of fault.

STEP 6
T

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Module.
N

Module.

Copyright ©
6003-14
FAULT 4141
Left Reverse Pump Solenoid Circuit STEP 2
Condition:
Crawler will not move in reverse. 1
connector.
2. Wiring or solenoid circuits open
BD06E013
3. Wiring or solenoid circuits shorted
Inspect the Left Reverse Pump Solenoid connection
NOTE: Go to the Electrical Schematic for a and Resistance.
T
STEP 1 B. Remove rear belly plate.
IN
Find out if the fault code is still active. C. Disconnect the Left Reverse Pump Solenoid,
A. Turn ignition switch to RUN position to power Connector P3.
PR
Drivetrain Controller. D. Inspect pins 1 through 4. Clean connections.
NOTE: Prior to clearing fault codes write down all F. Measure the resistance of the coil at the Left
R
Reverse Pump Solenoid, Connector P3 pins

FO

both parking levels to down position, move
hand throttle to high idle position, and pull OK – Go to Step 3.
T
directional control to reverse position (backup

O
alarm should sound). STEP 3

NOT OK – Fault code 4141 is recorded again. Go to C h e ck L e f t R eve r s e P u m p S o l e n o i d G r o u n d
N
Step 2. Connection.
OK – Fault is not recorded again. Ok for return to A. Measure the resistance between Connector
service. P3, pin 4 and battery ground, must be less
than 10 Ohms.
fault.

Copyright ©
6003-15
STEP 4 STEP 5
2
1 2
BD06M022 BD06M028
1. CONNECTOR C5
1. CONNECTOR C2
2. CONNECTOR P1
2. CONNECTOR C1
3. LEFT ROPS STRUT
Check for open circuit in the Left Reverse Pump
Check for open circuit in the Left Reverse Pump Solenoid control wire between connectors C5 and
Solenoid Circuit between connectors P3 and P1. C1.
Connector C1.
T
connections. B. Inspect pin 30 on Connector C1. Clean
IN
PR
Left Reverse Pump Solenoid, Connector P3, D. Check for open circuit between pin 14 of
and pin 14 of the Dr ivetrain Controller, Connector C5, and pin 30 of the Main
Connector P1. Drivetrain Controller, Connector C1.
NOT OK – Determine break between connector P1
R

and P3 and repair. Return to Step 1 to confirm and C5 and repair. Return to Step 1 to confirm
FO
OK – Go to Step 5. OK – Go to Step 6.
STEP 6
T

O

Module.
N

Module.

Copyright ©
6003-16
FAULT 4151
Right Reverse Pump Solenoid Circuit STEP 2
Condition:
Crawler will not move in reverse. 1
connector.
BD06E013
3. Wiring or solenoid circuits shorted
I n s p e c t t h e R i g h t R ev e r s e P u m p S o l e n o i d
NOTE: Go to the Electrical Schematic for a Connection and Resistance.
T
STEP 1 B. Remove center belly plate.
IN
Find out if the fault code is still active. C. Disconnect the Right Reverse Pump
A. Turn ignition switch to RUN position to power Solenoid, Connector P4.
PR
NOTE: Prior to clearing the fault codes write down F. Measure the resistance of the coil at the Right
all fault codes, number of occurrences, and engine
R
Reverse Pump Solenoid, Connector P4 pins

FO

hand throttle to high idle position, and pull OK – Go to Step 3.
T
directional control to reverse position (backup

O
alarm should sound). STEP 3

NOT OK – Fault code 4151 is recorded again. Go to Check Right Reverse Pump Solenoid Ground
N
Step 2. Connection.
OK – Fault is not recorded again. Ok for return to A. Measure the resistance between Connector
service. P4, pin 4 and battery ground, must be less
than 10 Ohms.
fault.

Copyright ©
6003-17
STEP 4 STEP 5
2
1 2
BD06M022 BD06M028
1. CONNECTOR C5
1. CONNECTOR C2
2. CONNECTOR P1
2. CONNECTOR C1
3. LEFT ROPS STRUT
Check for open circuit in the Right Reverse Pump
Check for open circuit in the Right Reverse Pump Solenoid control wire between connectors C5 and
Solenoid Circuit between connectors P4 and P1. C1.
Connector C1.
T
connections. B. Inspect pin 16 on Connector C1. Clean
IN
PR
Right Reverse Pump Solenoid, Connector D. Check for open circuit between pin 13 of
P4, and pin 13 of Connector P1. Connector C5, and pin 16 of the Main
NOT OK – Determine break between connectors P1 Drivetrain Controller, Connector C1.
R
NOT OK – Determine break between connectors C1

FO
OK – Go to Step 5. elimination of fault.

STEP 6
T

O

Module.
N

Module.

Copyright ©
6003-18
FAULT 4212
Left Motor Solenoid Circuit Open or Over NOTE: Go to the Electrical Schematic for a complete
Current view of the controller circuit.
Condition: STEP 1
Find out if the fault code is still active.
Crawler will not operate at full speed.
Possible Failure Modes: drivetrain controller.
1. Connectors not mated fully, pins not pushed into B. Clear all fault codes from the controller.
connector fully, bent pin or broken wire at rear of NOTE: Prior to clearing fault codes write down all
connector. fault codes, number of occurrences, and engine
2. Wiring or solenoid circuits open hours at last occurrence.
3. Wiring or solenoid circuits shorted C. To check for fault code the machine needs to
be dr iven at a speed above the 50%
4. Failed Drivetrain Control Module transmission speed range.
Step 2.
T
service.
IN
PR
STEP 2
R
FO
T
O
2
N
BD06M031

Copyright ©
6003-19
1. LEFT MOTOR SPEED SENSOR 3. LEFT MOTOR SPEED SENSOR CONNECTOR P5

2. LEFT MOTOR SOLENOID 4. LEFT MOTOR SOLENOID CONNECTOR P7
Inspect the Left Motor Solenoid Connection and STEP 3

Resistance. Check Left Motor Solenoid Ground Connection.
A. Turn ignition switch and master disconnect off. A. Measure the resistance between Connector
B. Remove rear access cover to hydrostat P7, pin 2 and Battery ground, must be less
motors. than 10 Ohms.
C. Disconnect the Left Motor Solenoid, NOT OK – Determine break in ground connection
Connector P7. and repair. Return to Step 1 to confirm elimination of
fault.
D. Inspect pins 1 and 2. Clean connections.
E. Clean female pins by installing and removing.
F. Measure the resistance of the coil at the Left STEP 4
Motor Solenoid, Connector P7 pins 1 and 2.
The resistance should be 22.70 Ohms ± 0.75
1
Ohms.
NOT OK – Replace the solenoid. Return to Step 1 to
confirm elimination of fault. 2
T
IN 3
PR
BD06M022
1. CONNECTOR C5
2. CONNECTOR P1
R
3. LEFT ROPS STRUT

FO
Check for open circuit in the Left Motor Solenoid

Circuit between connections P7 and P1.
A. Disconnect Connector P1.
T
connections.
O
C. Clean female pin by installing and removing.

N

Left Motor Solenoid, Connector P7, and pin
31 of Connector P1.

Copyright ©
6003-20
STEP 5
1 2
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit in the Left Motor Solenoid
control wire between connectors C5 and C2.
A. Disconnect the Main Drivetrain Controller,
Connector C2.
T
B. Inspect pin 68 on Connector C2. Clean
connections.
IN
PR
D. Check for open circuit between pin 31 of
Connector C5, and pin 68 of the Main
R
and C5 and repair. Return to Step 1 to confirm

FO
STEP 6
T

O
Module.
N
Module.
STEP 7
bolts to 77 to 100 Nm (57 to 74 lb-ft).

Copyright ©
6003-21
FAULT 4222
Right Motor Solenoid Circuit Open or NOTE: Go to the Electrical Schematic for a complete
Over Current view of the controller circuit.
Condition: STEP 1
Crawler will not operate at full speed.
Possible Failure Modes: drivetrain controller.
1. Connectors not mated fully, pins not pushed into B. Clear all fault codes from the controller.
connector fully, bent pin or broken wire at rear of NOTE: Prior to clearing fault codes write down all
connector. fault codes, number of occurrences, and engine
2. Wiring or solenoid circuits open hours at last occurrence.
3. Wiring or solenoid circuits shorted C. To check for fault code the machine needs to
4. Failed Drivetrain Control Module transmission speed range.
Step 2.
T
service.
IN
PR
STEP 2
R
FO
1
T
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3
N
4
2
BD06M030

Copyright ©
6003-22
1. RIGHT MOTOR SPEED SENSOR CONNECTOR P6 3. RIGHT MOTOR SOLENOID CONNECTOR P8

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

Resistance. Check Right Motor Solenoid Ground Connection.
A. Turn ignition switch and master disconnect off. A. Measure the resistance between Connector
B. Remove rear access cover to hydrostat P8, pin 2 and Battery ground, must be less
motors. than 10 Ohms.
C. Disconnect the Right Motor Solenoid, NOT OK – Determine break in ground connection
Connector P8. and repair. Return to Step 1 to confirm elimination of
fault.
D. Inspect pins 1 and 2. Clean connections.
F. Measure the resistance of the coil at the Right
Motor Solenoid, Connector P8 pins 1 and 2.
The resistance should be 22.70 Ohms ± 0.75
Ohms.
NOT OK – Replace the solenoid. Return to Step 1 to
confirm elimination of fault.
T
IN
PR
R
FO
T
O
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6003-23
STEP 4 STEP 5
2
1 2
BD06M022 BD06M028
1. CONNECTOR C5
1. CONNECTOR C2
2. CONNECTOR P1
2. CONNECTOR C1
3. LEFT ROPS STRUT
Check for open circuit in the Right Motor Solenoid
Check for open circuit in the Right Motor Solenoid control wire between connectors C5 and C2.
A. Disconnect Connector P1. Connector C2.
T
B. Inspect pin 32 on Connector P1. Clean B. Inspect pin 69 on Connector C2. Clean
connections. connections.
IN
C. Clean female pin by installing and removing. C. Clean female pins by installing and removing.
PR
Right Motor Solenoid, Connector P8, and pin Connector C5, and pin 69 of the Main
32 of Connector P1. Drivetrain Controller, Connector C2.
NOT OK – Determine break between connector P1 NOT OK – Determine break between connector C2
R

elimination of fault. elimination of fault.
FO
OK – Go to Step 5. OK – Go to Step 6.
STEP 6
T

O
Module.
N
Module.
STEP 7

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6003-24
FAULT 4311
Left Speed Sensor Out of Range NOTE: Go to the Electrical Schematic for a complete
Condition:
STEP 1
Tra ck s p e e d i n p u t i s a t ze r o w h e n m o t i o n i s
commanded and engine speed is non-zero, for a
long period. A. Turn ignition switch to RUN position to power
Possible Failure Modes: B. Clear all fault codes from the controller.
1. Connectors not mated fully, pins not pushed into NOTE: Prior to clearing fault codes write down all
connector fully, bent pin or broken wire at rear of fault codes, number of occurrences, and engine
connector. hours at last occurrence.
2. Water in connectors C. To check for fault code the machine needs to
3. Bad fuse in drivetrain controller fuse block be dr iven at a speed above the 50%
transmission speed range.
5. Wiring or sensor circuits shorted Step 2.
T
service.
IN
PR
STEP 2
R
FO
T
O
2
N
BD06M031

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6003-25
1. LEFT MOTOR SPEED SENSOR 3. LEFT MOTOR SPEED SENSOR CONNECTOR P5

2. LEFT MOTOR SOLENOID 4. LEFT MOTOR SOLENOID CONNECTOR P7
Inspect the Left Speed Sensor Connection. STEP 3

B. Remove rear access cover to hydrostat 1
motors.
C. Disconnect the Left Speed Sensor, 2
Connector P5.
D. Inspect pins 1, 2, and 3. Clean connections.
E. Check for water in connectors.
3
F. Clean female pins by installing and removing.
NOT OK – Replace sensor. Return to Step 1 to
BD06M022
1. CONNECTOR C5
OK – Go to Step 3. 2. CONNECTOR P1
3. LEFT ROPS STRUT
Check for open circuit in the Left Speed Sensor
T
IN
B. Inspect pins 7 and 8 on Connector P1. Clean
connections.
PR
Left Speed Sensor, Connector P5, and pin 7
R
of Connector P1.
E. Check for open circuit between pin 3 of the
FO

of Connector P1.
F. Check for open circuit between pin 2 of the
T
of Connector P1.
O

N
STEP 4 BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit in the Left Speed Sensor
Circuit between connectors C5 and C1.
1 2 A. Disconnect the Main Drivetrain Controller,

Connector C1.
B. Inspect pins 43 and 44 on Connector C1.
Clean connections.

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6003-26
D. Check for open circuit between pin 7 of NOT OK – Determine break between connector C1
Connector C5, and pin 44 of the Main and C5 and repair. If no break is found in Step 4 or 5,
Drivetrain Controller, Connector C1. re place Sens or. Retu r n to Step 1 to co nfir m
E. Check for open circuit between pin 8 of
Connector C5, and pin 43 of the Main OK – Go to Step 5.
STEP 5
Module.
Module.
STEP 6
T
IN
PR
R
FO
T
O
N

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6003-27
FAULT 4312
Right Speed Sensor Out of Range NOTE: Go to the Electrical Schematic for a complete
Condition:
STEP 1
Tra ck s p e e d i n p u t i s a t ze r o w h e n m o t i o n i s
commanded and engine speed is non-zero, for a
long period. A. Turn ignition switch to RUN position to power
Possible Failure Modes: B. Clear all fault codes from the controller.
1. Connectors not mated fully, pins not pushed into NOTE: Prior to clearing fault codes write down all
connector fully, bent pin or broken wire at rear of fault codes, number of occurrences, and engine
connector. hours at last occurrence.
2. Water in connector C. To check for fault code the machine needs to
3. Bad fuse in drivetrain controller fuse block be dr iven at a speed above the 50%
5. Wiring or sensor circuits shorted Step 2.
T
service.
IN
STEP 2
PR
R
FO
1
T
3
O
4
N
BD06M030
1. RIGHT MOTOR SPEED SENSOR CONNECTOR P6 3. RIGHT MOTOR SOLENOID CONNECTOR P8

2. RIGHT MOTOR SOLENOID 4. RIGHT MOTOR SPEED SENSOR

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6003-28
Inspect the Right Speed Sensor Connection. STEP 3
B. Remove rear access cover to hydrostat 1
motors.
C. Disconnect the Right Speed Sensor, 2
Connector P6.
D. Inspect pins 1, 2, and 3. Clean connections.
E. Check for water in connectors.
3
F. Clean female pins by installing and removing.
NOT OK – Replace sensor. Return to Step 1 to
BD06M022
1. CONNECTOR C5
OK – Go to Step 3. 2. CONNECTOR P1
3. LEFT ROPS STRUT
Check for open circuit in the Right Speed Sensor
T
B. Inspect pins 10 and 11 on Connector P1.
Clean connections.
IN
PR
Right Speed Sensor, Connector P6, and pin
11 of Connector P1.
E. Check for open circuit between pin 3 of the
R
10 of Connector P1.
FO
F. Check for open circuit between pin 2 of the

9 of Connector P1.
T

O
N

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6003-29
STEP 4
1 2
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit in the Right Speed Sensor
Circuit between connectors C5 and C1.
Connector C1.
T
Clean connections.
IN
PR
E. Check for open circuit between pin 11 of
R

FO

and C5 and repair. If no break is found, replace
Sensor. Return to Step 1 to confirm elimination of
fault.
T
O
STEP 5
N

Module.
Module.
STEP 6

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

connector fully, bent pin or broken wire at rear of
connector.
2. Water in connectors BD06M029
1 BRAKE POTENTIOMETER 3 DECELERATOR

3. Adjust sensor and re-calibrate
2 BRAKE PEDAL POTENTIOMETER
4. Wiring or sensor circuits shorted Inspect the Decelerator Potentiometer Connection.
5. Failed Drivetrain Control Module NOTE: The connector for the decelerator is on the
front side of the fire wall.
T
NOTE: Go to the Electrical Schematic for a
complete view of the controller circuit. A. Turn ignition switch and master disconnect off.
IN
STEP 1 B. Disconnect the Decelerator Potentiometer,
Connector M5.
PR
C. Inspect pins A, B, and C. Clean connections.
drivetrain controller. D. Check for water in connectors.
R
NOTE: Prior to clearing fault codes write down all N OT O K – R e p l a c e a n d a d j u s t D e c e l e r a t o r

FO
fault codes, number of occurrences, and engine Po t e n t i o m e t e r. R e t u r n t o S t e p 1 t o c o n f i r m

hours at last occurrence. elimination of fault.
C. To check for fault code: Move directional OK – Go to Step 3.
control to neutral, ignition switch to run
T
(engine does not need to be running), move

O
the decelerator pedal to low idle position.

N

Step 2.
service.

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6003-31
STEP 3 STEP 4
1 1 2
BD06M023 BD06M028
2. CONNECTOR M10 2. CONNECTOR C1
NOTE: Connectors are located behind the fuse and C h e c k fo r o p e n c i r c u i t i n t h e D e c e l e r a t o r
relay panels. Potentiometer Circuit between connections C4 and
C1.
Check for open circuit in the Decelerator
Potentiometer Circuit between connectors M5 and A. Disconnect the Main Drivetrain Controller,
M10. Connector C1 and Connector C2.
T
A. Disconnect Connector M10. B. Inspect pin 19 on Connector C1 and pins 62
IN
and 80 on Connector C2. Clean connections.
B. Inspect pins 43, 12 and 36 on Connector
M10. Clean connections. C. Clean female pin by installing and removing.
PR
C. Clean female pins by installing and removing. D. Check for open circuit between pin 43 of
D. Check for open circuit between pin A, B, and
C of the Decelerator Potentiometer Circuit,
R
Connector M5, and pins 43, 12 and 36 on E. Check for open circuit between pin 12 of
Connector M10. Connector C4, and pin 62 of the Main
FO

NOT OK – Determine break between connector M5
and M10 and repair. Return to Step 1 to confirm F. Check for open circuit between pin 36 of
elimination of fault. Connector C4, and pin 19 of the Main
T

O
and M5 and repair. Return to Step 1 to confirm

N

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6003-32
STEP 5 STEP 6
Adjust the decelerator potentiometer using the Replace the Drivetrain Control Module.
electronic service tool (EST).
NOTE: The Fully Up Decelerator Position and High Module.
Throttle Lever Position will be between 2.75 to 4.45
Volts (nominal readings), and the Fully Depressed
Module.
Position or Low Throttle Lever Position will be
between 0.5 to 2.25 Volts (nominal readings). C. Install program with Electronic Service Tool
NOT OK – Voltage is found to be out of acceptable
limits, replace and adjust Decelerator Potentiometer.
Return to Step 1 to confirm elimination of fault.
T
IN
PR
R
FO
T
O
N

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6003-33
FAULT 4322
Idle Validation Switch Not Working C. Release the decelerator pedal, a continuity
reading should be obtained.
Condition: NOTE: If continuity is not obtained replace the
Engine will not idle properly with decelerator pedal switch.
usage. D. Push the decelerator pedal to the low idle
position, reading of 0 Ohm should be
Possible Failure Modes: obtained.
1. Connectors not mated fully, pins not pushed into NOT OK – If 0 Ohm is not obtained press the switch
connector fully, bent pin or broken wire at closed by hand, if 0 Ohm is not obtained change the
connector. switch, if 0 Ohm is obtained adjust the decelerator
pedal stop bolt. Retur n to Step 1 to confir m
3. Wiring or switch circuits shorted
NOTE: Go to the Electrical Schematic for a STEP 3
1
T
STEP 1 2
IN
PR
3
B. Clear all fault codes from the controller.
NOTE: Prior to clearing fault codes write down all
R
hours at last occurrence.

BD06M029
FO

1 BRAKE POTENTIOMETER 1. IDLE VALIDATION SWITCH
control to neutral, ignition switch to run, start 2 BRAKE PEDAL BEHIND PEDAL
and run the engine, move both parking levers
to down position, move the decelerator pedal Inspect the Idle Validation Switch Connection.
to low idle position. NOTE: The connector for the switch is on the front
T
NOT OK – Fault code 4322 is recorded again. Go to side of the fire wall.
O
Step 2. A. Turn ignition switch and master disconnect off.

N
OK – Fault is not recorded again. Ok for return to B. Disconnect the Idle Validation Switch,
service. Connector M5A.
C. Inspect pins A and B. Clean connections.
STEP 2
Inspect the Decelerator Pedal Adjustment. D. Check for water in connectors.
NOTE: The connector for the switch is on the front E. Clean female pins by installing and removing.
side of the fire wall. NOT OK – Replace and adjust decelerator pedal
A. Disconnect the Idle Validation Switch, stop bolt to activate Idle Validation Switch. Return to
Connector M5A. Step 1 to confirm elimination of fault.
B. Use a multi meter to check ohm readings OK – Go to Step 4.

between pins A and B.

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6003-34
STEP 4 STEP 5
1 1 2
BD06M023 BD06M028
NOTE: Connectors are located behind the fuse and Check for open circuit in the Idle Validation Switch
relay panels. Circuit between connections C4 and C1and C2.
Check for open circuit in the Idle Validation Switch A. Disconnect the Main Drivetrain Controller,
Circuit between connectors M5A and M10. Connector C1 and Connector C2.
T
A. Disconnect Connector M10. B. Inspect pin 23 on Connector C1 and pin 80
on Connector C2. Clean connections.
IN
B. Inspect pins 41 and 43 on Connector M10.
Clean connections. C. Clean female pin by installing and removing.
PR
D. Check for open circuit between pin A and B of
the Idle Validation Switch Circuit, Connector
M5A, and pins 41 and 43 on Connector M10. E. Check for open circuit between pin 41 of
R

NOT OK – Determine break between connector M5A
FO
elimination of fault. NOT OK – Determine break between connector C1or

C2 and C4 and repair. Return to Step 1 to confirm
T
O
STEP 6
N

Module.
Module.

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

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

2 BRAKE PEDAL POTENTIOMETER
Inspect the Decelerator Potentiometer Connection.
NOTE: The connector for the decelerator is on the
5. Wiring or sensor circuits shorted front side of the fire wall.
T
6. Failed Drivetrain Control Module A. Turn ignition switch and master disconnect off.
IN
NOTE: Go to the Electrical Schematic for a B. Disconnect the Decelerator Potentiometer,
complete view of the controller circuit. Connector M5.
PR
STEP 1 C. Inspect pins A, B, and C. Clean connections.
Find out if the fault code is still active. D. Check for water in connectors.
A. Turn ignition switch to RUN position to power E. Clean female pins by installing and removing.
R
N OT O K – R e p l a c e a n d a d j u s t D e c e l e r a t o r
FO
B. Clear all fault codes from the controller. Po t e n t i o m e t e r. R e t u r n t o S t e p 1 t o c o n f i r m

fault codes, number of occurrences, and engine OK – Go to Step 3.
T

O

N
both parking levers to down position.

Step 2.
service.

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6003-36
STEP 3 STEP 4
1 1 2
BD06M023 BD06M028
NOTE: Connectors are located behind the fuse and C h e c k fo r o p e n c i r c u i t i n t h e D e c e l e r a t o r
relay panels. Potentiometer Circuit between connections C4 and
C1.
C h e c k fo r o p e n c i r c u i t i n t h e D e c e l e r a t o r
Potentiometer Circuit between connectors M5 and A. Disconnect the Main Drivetrain Controller,
M10. Connector C1 and Connector C2.
T
A. Disconnect Connector M10. B. Inspect pin 19 on Connector C1 and pins 62
IN
and 80 on Connector C2. Clean connections.
B. Inspect pins 43, 12 and 36 on Connector
M10. Clean connections. C. Clean female pin by installing and removing.
PR
C of the Decelerator Potentiometer Circuit,
R
Connector M5, and pins 43, 12 and 36 on E. Check for open circuit between pin 12 of
Connector M10. Connector C4, and pin 62 of the Main
FO

and M10 and repair. Return to Step 1 to confirm F. Check for open circuit between pin 36 of
elimination of fault. Connector C4, and pin 19 of the Main
T

O

N

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6003-37
STEP 5 STEP 6
Adjust the decelerator potentiometer using the Replace the Drivetrain Control Module.
NOTE: The Fully Up Decelerator Position and High Module.
Throttle Lever Position will be between 2.75 to 4.45
Volts (nominal readings), and the Fully Depressed
Module.
Position or Low Throttle Lever Position will be
between 0.5 to 2.25 Volts (nominal readings). C. Install program with Electronic Service Tool
limits, replace and adjust Decelerator Potentiometer.
T
IN
PR
R
FO
T
O
N

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

Po t e n t i o m e t e r. R e t u r n t o S t e p 1 t o c o n f i r m
3. Adjust sensor and re-calibrate elimination of fault.
4. Wiring or sensor circuits shorted OK – Go to Step 3.
T
STEP 1
IN
PR
R

FO

T
the hand throttle from to low idle position

several times.
O

N
Step 2.
service.

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6003-39
STEP 3 STEP 4
Adjust the hand throttle potentiometer using the
NOTE: The High Idle Throttle Lever Position will be
between 2.75 to 4.45 Volts (nominal readings), and
1 2 the Low Idle Throttle Lever Position will be between
0.5 to 2.25 Volts (nominal readings).
limits, replace and adjust Hand Throttle
Po t e n t i o m e t e r. R e t u r n t o S t e p 1 t o c o n f i r m
BD06M028
1. CONNECTOR C2 STEP 5
2. CONNECTOR C1
C h e ck fo r o p e n c i r c u i t i n t h e H a n d T h r o t t l e
Potentiometer Circuit between connections C6 and A. Remove and replace Drivetrain Control
C1 and C2. Module.
A. Disconnect the Main Drivetrain Controller, B. Write symptom on failed Drivetrain Control
Connector C1 and Connector C2. Module.
T
B. Inspect pin 38 on Connector C1 and pins 64 C. Install program with Electronic Service Tool
IN
and 79 on Connector C2. Clean connections. (EST) and recalibrate system.
PR
D. Check for open circuit between pin A of the
Hand Throttle Potentiometer, Connector C6,
and pin 79 of the Main Drivetrain Controller,
Connector C2.
R
E. Check for open circuit between pin B of the

FO

Connector C2.
F. Check for open circuit between pin C of the
T

O
Connector C1.
N

or C2 and C6 and repair. Return to Step 1 to confirm

Copyright ©
6003-40
FAULT 4331
Brake Pedal Potentiometer Out of Range STEP 2
Condition: 1
3
Crawler will not move, driving is not possible 2
connector.
BD06M029
4. Wiring or sensor circuits open 1 BRAKE POTENTIOMETER 3 DECELERATOR
5. Wiring or sensor circuits shorted 2 BRAKE PEDAL POTENTIOMETER
Inspect the Brake Pedal Potentiometer Connection.
NOTE: The connector for the brake potentiometer is
on the front side of the fire wall.
T
IN
STEP 1 B. Disconnect the Brake Pedal Potentiometer,
Find out if the fault code is still active. Connector M6.
PR
A. Turn ignition switch to RUN position to power C. Inspect pins A, B, and C. Clean connections.
D. Check for water in connectors.
R

fault codes, number of occurrences, and engine N OT O K – R e p l a c e a n d a d j u s t B ra ke Pe d a l
FO
hours at last occurrence. Po t e n t i o m e t e r. R e t u r n t o S t e p 1 t o c o n f i r m

control to neutral, ignition switch to run OK – Go to Step 3.
T

O
hand throttle to high idle position and push

directional control to forward position, press
N
the brake pedal fully and release.

Step 2.
service.

Copyright ©
6003-41
STEP 3 STEP 4
1 1 2
BD06M023 BD06M028
NOTE: Connectors are located behind the fuse and Check for open circuit in the Brake Pedal Sensor
relay panels. Circuit between connections C4 and C1.
Check for open circuit in the Decelerator A. Disconnect the Main Drivetrain Controller,
Potentiometer Circuit between connectors M5 and Connector C2.
M10.
T
B. Inspect pins 56, 65, and 79 on Connector C2.
A. Disconnect Connector M10. Clean connections.
IN
B. Inspect pins 18, 11, and 20 on Connector C. Clean female pin by installing and removing.
M10. Clean connections.
PR
C. Clean female pins by installing and removing. Connector C4, and pin 79 of the Main
C o f t h e B r a ke Po t e n t i o m e t e r C i r c u i t , E. Check for open circuit between pin 11 of
R
Connector M6, and pins 18, 11, and 20 on Connector C4, and pin 56 of the Main
Connector M10. Drivetrain Controller, Connector C2.
FO
NOT OK – Determine break between connector M6 F. Check for open circuit between pin 20 of
and M10 and repair. Return to Step 1 to confirm Connector C4, and pin 65 of the Main
elimination of fault. Drivetrain Controller, Connector C2.
OK – Go to Step 4. NOT OK – Determine break between connector C2
T

O
OK – Check Sensor mounting, and re-calibrate. Go
N
to Step 5.

Copyright ©
6003-42
STEP 5 STEP 6
Adjust the Brake Pedal Potentiometer using the Replace the Drivetrain Control Module.
Electronic Service Tool (EST).
NOTE: The Fully Up Position will be between 2.75 to Module.
4.5 Volts (nominal readings), and the Fully
Depressed Position will be between 0.5 to 2.25 Volts
Module.
(nominal readings).
limits, replace and adjust Brake Pedal Potentiometer.
T
IN
PR
R
FO
T
O
N

Copyright ©
6003-43
FAULT 4332
Brake Release Pressure Switch Open STEP 2
Condition: 1 2 3
Crawler will not move, driving is not possible

1. Blown fuse F2.
connector.
BD06K057
4. Wiring or switch circuits open 1 BRAKE VALVE 3 CONNECTOR V25
5. Wiring or switch circuits shorted 2 BRAKE PRESSURE SWITCH
Inspect the Brake Pressure Switch Connection.
T
complete view of the controller circuit. B. Disconnect the Brake Pressure Switch,
Connector V25.
IN
STEP 1 C. Inspect pins A and B. Clean connections.
PR
A. Check fuse F2.
B. Turn ignition switch to RUN position to power
drivetrain controller. NOT OK – Replace the Brake Pressure Switch.
R
C. Clear all fault codes from the controller.

FO

D. To check for fault code: Move directional
T
control to neutral, ignition switch to run, start

the engine, move both parking levers to down
O
position, attempt to move the machine.

N

Step 2.
service.

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6003-44
STEP 3 STEP 4
Module.
1 2 Module.
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit in the Brake Pressure Switch
Circuit between connections V25 and C1.
Connector C1.
T
connections.
IN
PR
D. Check for open circuit between pin B of the
Brake Pressure Switch, Connector V25, and
pin 48 of the Main Drivetrain Controller,
Connector C1.
R

FO
to Step 4.
T
NOTE: Pressure switch circuit listed below.

O
WIRE FROM CONNECTOR TO CONNECTOR

N
V1acc V25-A V1-A

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

Copyright ©
6003-45
FAULT 4341
No Engine Speed STEP 2
Condition:
Engine Speed input is zero but track speed is
non-zero for long length of time.
NOTE: If fault codes 4533 and 4622 are also
present there is a CAN communication error, see
fault 4622.
1
1. Speed sensor on engine bad.
BD06M032
connector fully, bent pin or broken wire at rear of 1. SPEED PICKUP
connector. Replace Engine Speed Pickup.
3. Wiring or sensor circuits open NOT OK – Return to Step 1 to confirm elimination of
fault.
T
IN
NOTE: Go to the Electrical Schematic for a STEP 3
PR
STEP 1 A. Remove and replace Drivetrain Control
Module.
R
Module.
FO

T
C. To check for fault code the machine needs to

O

N

Step 2.
service.

Copyright ©
6003-46
FAULT 4421
Backup Alarm Relay Circuit Over Current STEP 3
or Open Circuit
Condition:
When in reverse, Backup Alarm will not sound.
1 2
connector.
BD06M028
3. Wiring or relay circuits open
1. CONNECTOR C2
4. Wiring or relay circuits shorted 2. CONNECTOR C1
5. Failed Drivetrain Control Module Check for open circuit between the Backup Alarm
Circuit and connectors C1.
T
Connector C1.
IN
STEP 1 B. Inspect pin 5 on Connector C1. Clean
Find out if the fault code is still active. connections.
PR
A. Turn ignition switch to RUN position to power C. Clean female pins by installing and removing.
D. Check for open circuit between the Backup
B. Clear all fault codes from the controller. Alarm wire 205 and pin 5 of Connector C1.
R
NOTE: Prior to clearing fault codes write down all NOT OK – Determine break between the Backup
fault codes, number of occurrences, and engine Alarm and connector C1 and repair. Return to Step 1
FO
hours at last occurrence. to confirm elimination of fault.

C. To check for fault code: Move directional OK – Go to Step 4.
NOTE: Backup Alarm circuit listed below.
T
both parking levers to down position, move WIRE FROM CONNECTOR TO CONNECTOR
O
205 V1-B P10-B

directional control to reverse position.
205 P10-B P1-1
N
NOT OK – Fault code 4421 is recorded again. Go to 205 P1-1 C5-1

Step 2. 205 C5-1 C1-5
service. STEP 4
STEP 2 A. Remove and replace Drivetrain Control
Check ground circuit at backup alarm. Module.
NOT OK – Determine break in ground circuit and B. Write symptom on failed Drivetrain Control
repair. Module.
OK – Go to Step 3. C. Install program with Electronic Service Tool

Copyright ©
6003-47
FAULT 4431
Parking Brake Solenoid Circuit Over STEP 3
Current or Open Circuit
1 2 3
Condition:
Crawler will not move, driving is not possible

connector.
BD06K057
1 BRAKE VALVE 3 CONNECTOR V25
4. Wiring or sensor circuits shorted 2 BRAKE PRESSURE SWITCH
5. Failed Drivetrain Control Module Inspect the Brake Pressure Switch Connection.
NOTE: Go to the Electrical Schematic for a A. Turn ignition switch and master disconnect off.
T
complete view of the controller circuit. B. Disconnect the Brake Pressure Switch,
Connector V25.
IN
STEP 1
C. Inspect pins A and B. Clean connections.
PR
drivetrain controller. E. Clean female pins by installing and removing.
B. Clear all fault codes from the controller. NOT OK – Replace the Brake Pressure Switch.
R

fault codes, number of occurrences, and engine OK – Go to Step 4.
FO

T

O

N

Step 2.
service.
STEP 2
Check ground circuit at brake solenoid.
NOT OK – Determine break in ground circuit and
repair.

Copyright ©
6003-48
STEP 4 STEP 5
Module.
1 2 Module.
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit between the Parking Brake
Solenoid and connector C1.
Connector C1.
T
IN
Clean connections.
PR
Connector V24, and pins 15 and 29 of the
Main Drivetrain Controller, Connector C1.
NOT OK - Determine break between the Parking
R
Brake Solenoid and connector C1 and repair. Return

to Step 1 to confirm elimination of fault.
FO
NOTE: Brake Solenoid circuit listed below.
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215 V24-1 V1-U

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215 V1-U P10-U

215 P10-U P1-16
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215 P1-16 C5-16

215 C5-16 C1-15 & 29

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

1. Connectors not mated fully, pins not pushed into 2
connector.
2. Button is mechanically stuck BD02M166
3. Wiring or switch circuits shorted 1. BUMP UP SWITCH 2. BUMP DOWN SWITCH

Inspect the Bump Up Switch Connection.
complete view of the controller circuit. B. Check for button mechanically stuck.
T
C. Clear buttons of any foreign debris.
STEP 1
IN
Find out if the fault code is still active. NOT OK – Return to Step 1 to confirm elimination of
fault.
PR
drivetrain controller. OK – Go to Step 3.
B. Clear all fault codes from the controller. STEP 3

NOTE: Prior to clearing fault codes write down all Check for open circuit in the Bump Up Switch.
R

hours at last occurrence. A. Disconnect the Bump Up Switch Connector.
FO
C. To check for fault code: Move directional B. Check wiring and connector for Bump Up
control to neutral, ignition switch to run Switch.
(engine does not need to be running), move NOT OK – Replace handle and button, and return to
both parking levers to down position, move Step 1 to confirm elimination of fault.
T

O

NOT OK – Fault code 4521 is recorded again. Go to STEP 4
N
Step 2.
service.
Module.
Module.

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6003-50
FAULT 4522
Bump Down Switch Stuck On at Power STEP 2
Up
Condition: 1
The Instr ument Cluster is indicating that the
Maximum Speed setting is decreasing, when Bump
Down Switch is not being commanded.
Possible Failure Modes: 2

connector.
BD02M166
2. Button is mechanically stuck 1. BUMP UP SWITCH 2. BUMP DOWN SWITCH
3. Wiring or switch circuits shorted Inspect the Bump Down Switch Connection.
NOTE: Go to the Electrical Schematic for a B. Check for button mechanically stuck.
T
C. Clear buttons of any foreign debris.
IN
STEP 1 NOT OK – Return to Step 1 to confirm elimination of
fault.
PR
STEP 3
Check for open circuit in the Bump Down Switch.
R

A. Disconnect the Bump Down Switch
FO
Connector.
B. Check wiring and connector for Bump Down
Switch.
(engine does not need to be running), move NOT OK – Replace handle and button, and return to
T
both parking levers to down position, move Step 1 to confirm elimination of fault.
O

N
NOT OK – Fault code 4522 is recorded again. Go to STEP 4

Step 2. Replace the Drivetrain Control Module.
OK – Fault is not recorded again. Ok for return to A. Remove and replace Drivetrain Control
service. Module.
Module.

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6003-51
FAULT 4531
Directional Control Steering Axis Faulted STEP 3
Condition:
Crawler will not move, driving is not possible.

connector.
BD02M163
4. Wiring or directional control circuits shorted Inspect the directional control Connection.
NOTE: Go to the Electrical Schematic for a B. Inspect pins 1, 2, 3, 4, 5, and 6. Clean
complete view of the controller circuit. connections.
T
STEP 1
IN
Find out if the fault code is still active. NOT OK – Replace directional control. Return to
Step 1 to confirm elimination of fault.
PR
drivetrain controller. OK – Go to Step 4.

R

FO

T

O

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

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6003-52
STEP 4 STEP 5
Module.
1 2 Module.
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit in the directional control Circuit
between connections M9 and C1.
Connector C1.
T
Clean connections.
IN
PR
D. Check for open circuit between pins 1 and 5 of
the directional control, Connector M9, and
pins 13, 41, and 42 of the Main Drivetrain
Controller, Connector C1.
R

FO
directional control. Return to Step 1 to confirm

T
O
N

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

connector.
BD02M163
Inspect the directional control Connection.
4. Wiring or directional control circuits shorted
B. Inspect pins 1, 2, 3, 4, 5, and 6. Clean
NOTE: Go to the Electrical Schematic for a connections.
T
IN
STEP 1 NOT OK – Replace directional control. Return to
Find out if the fault code is still active. Step 1 to confirm elimination of fault.
PR
A. Turn ignition switch to RUN position to power OK – Go to Step 4.
R

FO

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O

N

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

Copyright ©
6003-54
STEP 4 STEP 5
Module.
1 2 Module.
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Connector C1.
T
Clean connections.
IN
PR
R

FO

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O
N

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6003-55
FAULT 4533
Directional Control Forward/Reverse STEP 2
Axis Faulted A. Turn ignition switch off.
Condition: M9.
Crawler will not move, driving is not possible. C. Turn the ignition switch on and check for
NOTE: If fault codes 4341 and 4622 are also power at pins 1 and 5 at the directional control
present there is a CAN communication error, see Connector M9.
fault 4622. NOT OK – Replace fuse F19.
Possible Failure Modes: OK – Go to Step 3.
1. Faulty FNR joystick STEP 3

connector.
T
5. Wiring or CAN circuits open
IN
6. Wiring or CAN circuits shorted
PR
complete view of the controller circuit. BD02M163
Inspect the directional control Connection.

STEP 1
R

FO
A. Turn ignition switch to RUN position to power M9.

C. Inspect pins 1, 2, 3, 4, 5, and 6. Clean
B. Clear all fault codes from the controller. connections.
T
NOTE: Prior to clearing fault codes write down all D. Check for water in connectors.
O

NOT OK – Replace directional control. Return to
N

(engine does not need to be running), move OK – Go to Step 4.
Step 2.
service.

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6003-56
STEP 4 STEP 5
Module.
1 2 Module.
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Connector C1.
T
Clean connections.
IN
PR
R

FO

T
O
N

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

connector fully, bent pin or broken wire at rear of OK – Go to Step 3.
connector.
STEP 3
3. Wiring or CAN bus circuits open
4. Wiring or CAN bus circuits shorted
5. Faulty CAN bus Module.
6. Failed Drivetrain Control Module B. Write symptom on failed Drivetrain Control
T
Module.
IN
complete view of the controller circuit. C. Install program with Electronic Service Tool
STEP 1
PR
R

FO

T

O

N

Step 2.
service.

Copyright ©
6003-58
FAULT 4721
No Pilot Pressure STEP 2
Condition:
No hydraulic controls for equipment.
2
1. Connectors not mated fully, pins not pushed into 1
connector.
BD06E077
4. Wiring or solenoid circuits shorted 1 CONNECTOR V21
5. Failed Drivetrain Control Module 2 ACCUMULATOR
Inspect the hydraulic solenoid connection.
complete view of the controller circuit. A. Turn ignition switch and master disconnect off.
T
B. Disconnect the hydraulic solenoid, Connector
STEP 1 V21.
IN
C. Inspect pins 1 and 2. Clean connections.
PR
drivetrain controller. D. Check for water in connectors.
NOTE: Prior to clearing fault codes write down all NOT OK – Replace hydraulic solenoid. Return to
R

hours at last occurrence. OK – Go to Step 3.
FO

control to neutral, ignition switch to run, start STEP 3
the engine, move right parking lever to down Check ground circuit at hydraulic solenoid.
position, move hydraulic control joystick in any
NOT OK – Determine break in ground circuit and
T
direction.
repair.
O

Step 2.
N

service.

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6003-59
STEP 4 STEP 5
Module.
1 2 Module.
BD06M028
1. CONNECTOR C2
2. CONNECTOR C1
Check for open circuit in the Brake Pedal Sensor
Circuit between connections V21 and C2.
Connector C2.
T
connections.
IN
PR
Brake Pedal Potentiometer, Connector V21,
Connector C2.
R

and V21 and repair. Return to Step 1 to confirm
FO
to Step 5.
NOTE: Hydraulic Solenoid circuit listed below.
T

O
272 V21-1 V1-D

N
272 V1-D P10-D

272 P10-D P1-18
272 P1-18 C5-18
272 C5-18 C2-72

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6003-60
NOTES
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IN
PR
R
FO
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O
N

Copyright ©
Section
6007
FINAL DRIVES
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IN
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6007
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Copyright ©
6007-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL HUB SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL AND DISASSEMBLY OF FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly of the Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly of the Ring Gear Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly of the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly of the Ring Gear and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly of the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly of the Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EXPANSION PLUG REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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IN
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Copyright ©
6007-3
SPECIFICATIONS
Final Drive Lubricant Capacity (Each) ......................................................................................... 15 Liter (4 U.S. Gal)
Lubricant.................................................................................... Case AKCELA 135H EP Gear Lubricant 85W - 140
SPECIAL TORQUES
Drive Hub Rolling Torque......................................................................................8.5 ± 2.5 Nm (75 ± 20 pound-inch)
Input Shaft Bearing Retainer Plate Mounting Bolts ...............................................77 to 87 Nm (57 to 64 pound-foot)
Park Brake Housing Plate......................................................................................77 to 87 Nm (57 to 64 pound-foot)
Brake Housing Cover M20 X 50 12 pnt ......................................................650 to 730 Nm (480 to 538.5 pound-foot)
Counter Shaft Bearing Retainer Plate Mounting Bolts ....................................125 to 150 Nm (93 to 112 pound-foot)
Spindle Housing ............................................................................................310 to 380 Nm (230 to 280 pound-foot)
Ring Gear Retaining Plate.............................................................................310 to 380 Nm (230 to 280 pound-foot)
Sun Gear Shaft Retaining Plate ......................................................................125 to 150 Nm (93 to 112 pound-foot)
Output Gear Bearing Retainer Plate Mounting Bolts.......................................125 to 150 Nm (93 to 112 pound-foot)
Planetary Carrier to Drive Hub ......................................................................310 to 380 Nm (230 to 280 pound-foot)
Final Drive to Frame ......................................................................................656 to 725 Nm (485 to 535 pound-foot)
SPECIAL TOOLS
T
IN
PR
R
FO
722206
T
The tool shown above is used to check the rolling

BD06H027
torque for the planetary housing. the bar is made
O
Expansion plug installation tool 380002800

from 3/4 inch (19 mm) square mild steel and is 22
inches (559 mm) long. The nut is welded in the CAS-19545 driver kit
N
center of the bar. Size of nut is optional.

CAS-1955 driver kit
A cap screw is required to remove the outer bearing

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

Copyright ©
6007-4
INSPECTION
STEP 1 STEP 6
Clean all parts in cleaning solvent. Inspect the rollers used in the pinion gears for pitting,
scoring and other damage.
STEP 2
It is recommended that the face seal be discarded STEP 7
and a new face seal installed during assembly. Inspect the gears for wear and damage. If a gear is
worn or damaged, check the gear in mesh with the
STEP 3 worn or damaged gear.
It is recommended that the self-locking nuts that hold
the sprocket segments be discarded and new STEP 8
self-locking nuts be used during assembly. Inspect the splines for wear and damage.
STEP 4 STEP 9
Inspect the rollers in the bearings for pitting, scoring Inspect the planetary housing and gear housing for
and other damage. damage and cracks.
NOTE: If a bearing or bearing cup needs to be
replaced, both parts must be new.
T
STEP 5
IN
Inspect the bearing cups for pitting, scoring and other
damage.
PR
R
FO
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Copyright ©
6007-5
WHEEL HUB SEAL REPLACEMENT
Removal STEP 15
STEP 10
Remove the dirt and grease from the carrier and
planetary housing.
STEP 11
Separate the track and move the track from the drive
sprocket, see section 5504.
STEP 12
Raise the machine high enough so that the sprocket
teeth are free of the track links. Use an acceptable BD06M046
support to hold the machine in place. Drain the oil from the final drive and drive hub.
STEP 13 STEP 16
T
IN
PR
R
BD06M045
FO
BD06M043
Remove the cap screws that mount the rock guard. Loosen and remove the cap screws that hold the
carrier.
STEP 14
STEP 17
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BD06M044
Remove the rock guard. BD06M047
Locally fabricate two lifting eyes to aid in removal of

the planetary carrier.

Copyright ©
6007-6
STEP 18 STEP 23
BD06M048 BD06M169
Install three of the cap screws in the threaded holes Remove the plate in the bottom to the center section.
in the carrier. Install nuts, washers and lifting
brackets on the top two cap screws as shown. STEP 24
STEP 19
Put a drain pan below the planetary housing and
tighten the cap screws evenly to pull the carrier out of
T
the planetary housing.
IN
STEP 20 PR
BD06M170
R
NOTE: The following photo’s are from an older

machine, the procedures are the same. The motor
FO
and brake have been removed to better show the

work area. It is not necessary to remove the brake
and motor at this time.
Loosen and remove the cap screws that hold the
T
BD06M049 retainer for the output gear.

Install a lifting sling on the lifting eyes as shown.
O
NOTE: The weight of the planetary carrier is STEP 25

N
approximately 277 lb’s (125.5 kg).
STEP 21
Remove the carrier.
STEP 22
Remove the rear cover from the machine to gain
access to the hydrostatic motors.
BD06M171
Use prybars to remove the retainer and shims.

Copyright ©
6007-7
STEP 26 STEP 30
BD06M172 BD06M175
Loosen and remove the cap screws and retainer that Loosen and remove the cap screws that hold the
holds the sun gear shaft. retainer for the ring gear.
STEP 27 STEP 31
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IN
PR
R
BD06M173 BD06M176
Remove the sun gear shaft. Remove the retainer.

FO
STEP 28 STEP 32
Remove two sprocket tooth segments.
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STEP 29
O
N
BD06M177
Remove the shims. The shims can stay with the

retainer.
BD06M174
Rotate the planetary housing so that the sprocket

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

Copyright ©
6007-8
STEP 33 STEP 36
BD06M178 BD06M181
Remove the ring gear from the spindle. This can be If bearing needs to be replaced, remove the bearing
difficult to do. from the spindle.
STEP 34 STEP 37
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IN
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R
BD06M179 BD06M182
Remove the planetary housing and ring gear from Remove the other half of the face seal from the
FO
the machine. Lower the planetary housing to the floor spindle.

and remove the ring gear.
STEP 38
STEP 35
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BD06M183
BD06M180 Remove the dirt and grease from the bore for the
Remove the half of the face seal that was installed in face seal.

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

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

housing.
STEP 41
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IN
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R
FO
BD06M205
Use an acceptable driver and press the bearing cup

into the housing until the bearing cup stops moving.
T
STEP 42
O
Repeat steps 40 and 41 for the outer bearing cup.
STEP 43
N
BD06M252
Heat the bearings for the spindle to 250° F (121° C).

Copyright ©
6007-10
STEP 44 STEP 47
BD06M184 BD06M217
Make sure that the bore for the face seal is free of Let the bearing cool. Lubricate the bearing on the
gear lubricant. If the original face seal is to be spindle and on the hub for the ring gear.
installed, make sure that the rubber ring is free of
gear lubricant. STEP 48
STEP 45
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IN
PR
R
BD06M218
Install the planetary housing WITHOUT the face

FO
BD06M185 seal.
Install half of the face seal.
STEP 49
WARNING: Use insulated gloves or mittens
T
when working with hot parts.

O
47-41B
STEP 46
N
BD06M219
Use acceptable lifting equipment to start the ring

gear onto the spindle. Hit the ring gear with soft
hammers to drive the ring gear onto the spindle until
the cap screws can be used to pull the ring gear all
BD06M186 the way onto the spindle.
Install the bearing on the spindle.

Copyright ©
6007-11
STEP 50 STEP 53
BD06M220 BD06M223
I n s t a l l t h e s h i m s t h a t w e r e r e m o ve d d u r i n g Install the remainder of the cap screws and tighten

disassembly on the retainer for the ring gear. the cap screws to 310 to 380 Nm (230 to 280
pound-foot).
STEP 51
STEP 54
L o o s e n a n d r e m ove t h e r e m a i n i n g nu t s a n d
sprockets segments.
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STEP 55
IN
PR
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BD06M221
Install the retainer and shims.

FO
STEP 52
BD06M224
T
Fasten the tool shown on page 3 to the planetary

housing. The nut must be centered on the spindle.
O
STEP 56
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BD06M222
Tighten the cap screws to pull the ring gear onto the
spindle.
BD06M225
Use a lb-in torque wrench and check the rolling

torque of the planetary housing. Read the torque
wrench while the planetary housing is moving.

Copyright ©
6007-12
IMPORTANT: If the planetary housing is out of STEP 60
balance, you must read the torque wrench for a
complete revolution to find the high and low reading
for the rolling torque. Add the high and low readings
together and divide the answer by two. The answer is
the rolling torque.
STEP 57
The rolling torque must be 8.5 ± 2.5 Nm (75 ± 20
pound inch).
STEP 58
BD06M229
Install the shims, retainer and cap screws.
STEP 61
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IN
BD06M227
If the rolling torque is not as specified, loosen and

PR
remove the cap screws that hold the retainer and
remove the retainer and shims.
STEP 59 BD06M226
R
Tighten the cap screws to 310 to 380 Nm (230 to 280

pound-foot).
FO
STEP 62
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BD06M228
Add or remove shims as required.
BD06M225
Check the rolling torque again.

Copyright ©
6007-13
STEP 63 STEP 66
BD06M227 BD06M232
When the rolling torque is as specified, loosen and Make sure that the bore for the face seal in the
remove the cap screws, retainer and shims. planetary housing is free of lubricant.
STEP 64 STEP 67
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IN
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BD06M230 BD06M233
Fasten the lifting equipment to the planetary housing Install the face seal. Make sure that the face seal is
FO
and remove the ring gear from the spindle. seated in the bore.
STEP 65 STEP 68
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BD06M231 BD06M234
Remove the planetary housing and ring gear from Apply a small amount of clean oil to the sealing
the spindle. surface of the face seal.

Copyright ©
6007-14
STEP 69 STEP 73
BD06M231 BD06M226
Start the planetary housing onto the spindle. Tighten the cap screws to 310 to 380 Nm (230 to 280
pound-foot).
STEP 70
Use the lifting equipment to start the ring gear onto STEP 74
the spindle. Be careful so that the face seal does not
come out of the housing. Drive the ring gear onto the
spindle with a soft hammer.
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STEP 71
IN
PR
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BD06M237
Install the sun gear shaft.

FO
STEP 75
BD06M236
T
Apply Loctite 242 to the threads on the spindle.

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STEP 72
N
BD06M238
Apply Loctite 242 to the treads in the sun gear shaft.
BD06M235

Copyright ©
6007-15
STEP 76 STEP 79
BD06M239 BD06M241
Install the retainer with the shoulder toward the sun Apply Loctite 242 to the threads in the gear housing.
gear shaft and the cap screws.
STEP 80
STEP 77 Lubricate the O-ring and the bore of the retainer with
petroleum jelly.
STEP 81
T
IN
PR
R
BD06M240
Prevent the sun gear shaft from turning and tighten

FO
the cap screws to 125 to 150 Nm (93 to 110

pound-foot). BD06M243
Install the retainer and two cap screws.

STEP 78
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STEP 82
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N
BD06M242
Install a new O-ring in the groove for the retainer for BD06M244
the output gear. Make sure that the shims are on the Tighten the cap screws evenly to pull the retainer into
retainer. the gear housing.

Copyright ©
6007-16
STEP 83 STEP 86
BD06M245 BD06M249
Install the remainder of the cap screws and tighten Push the carrier into the planetary housing.
pound-foot). STEP 87
STEP 84
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IN
PR
BD06M250
R
Apply Loctite 242 to the threads of the cap screws.

BD06M246 Install the cap screws.
FO
Apply a 1/8 inch (3 mm) bead of Loctite 515 to the

planetary housing as shown. STEP 88
Torque the cap screws to 310 to 380 Nm (230 to 280
STEP 85 pound-foot).
T
O
N
BD06M248
Engage the pinion gears with the sun gear shaft and
ring gear.

Copyright ©
6007-17
STEP 89 STEP 90
Install the track, see section 5504.
STEP 91
Raise the machine and remove support from under
the machine.
STEP 92
Adjust the track, see section 5504.
BD06M043
Install the rock guard and cap screws, tighten the cap
screws.
T
IN
PR
R
FO
T
O
N

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

planetary carrier.
STEP 97
T
BD06M076
IN
Remove the mounting cap screws from the planetary
carrier housing.
PR
STEP 95
R
FO
BD06M079
Attach a lifting device to the carrier.
STEP 98
T
O
BD06M077
N
Install puller cap screws.
BD06M080
Remove the four cap screws on the output bear

bearing retainer.

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6007-19
STEP 99 STEP 102
BD06M081 BD06M084
Use a pry bar and remove the bearing retainer. Remove the retaining plate.
STEP 100 STEP 103
T
IN
PR
BD06M082 BD06M085
R
If the shims stay on the final drive housing, remove Remove the sun shaft from the final drive.
them and place them on the bearing retainer.
FO
STEP 104
STEP 101
T
O
N
BD06M086
BD06M083 Loosen the retainer cap screws.

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

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

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

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

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

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

Remove the four Allen screws from the bearing
retainer plate.

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6007-24
STEP 129 STEP 132
713424 BD06M114
Use acceptable tools to remove the bearing cups Remove the outer bearing cup from the input shaft.
from the retainers for the idler shaft and output gear.
STEP 133
STEP 130
T
IN
PR
BD06M115
R
BD06M112 Remove the snap ring from the input shaft.

Remove the input shaft bearing cup.
FO
STEP 134
STEP 131
T
O
N
BD06M116
BD06M113 Remove the brake spline hub from the input shaft.
Remove the idler gear bearing cup.

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

BD06M120
STEP 136 Install lifting eye’s into the holes in the ring gear.
Attach lifting equipment to the lifting eye’s and
remove the ring gear from the planetary carrier.
STEP 139
T
IN
PR
BD06M118
R
If the seal came out with the input shaft remove the
seal from the shaft.
FO
STEP 137 714206
Drive the bearing cups out of the planetary housing.

T
STEP 140
O
N
BD06M119
Remove the bearings from the input shaft, idler

gears, and output gear.
714518
Loosen and remove the cap screws and retainers

that secure the hub.

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

BD06M191
STEP 142 Put the carrier in a press for removal of the groove
pins that hold the pinion shafts. Two groove pins are
used for each pinion shaft.
NOTE: The weight of the planetary carrier is
approximately 277 lb’s (125.5 kg).
T
IN
STEP 144
PR
BD06M213
R
Use an acceptable tool to remove the bearing.

FO
BD06M190
T
Use the short driver from the CAS-19545 driver kit

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

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

FO
BD06M193
Remove the pinion gear. Hold the spacer the bottom

of the pinion gear to prevent the rollers from falling
out of the pinion gear.
T
O
N

Copyright ©
6007-28
Assembly of the Ring Gear and STEP 153

Hub

47-41B
STEP 151
BD06M214
Apply Loctite 242 to the threads in the ring gear.
STEP 154
T
BD06M213
Heat the bearing for the hub of the ring gear to 250°F
IN
(121° C) and install the bearing on the hub.
STEP 152
PR
BD06M215
R
Install the retainers and cap screws.

FO
STEP 155
T
O
BD06M212
Let the bearing and hub cool. Install the hub in the
N
ring gear.
BD06M216

pound-foot).

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

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

STEP 157 a pinion gear.
STEP 160
T
IN
PR
R
BD06M205

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

STEP 158
Repeat steps 156 and 157 for the outer bearing cup. STEP 161
T
O
N
BD06M198
Install a narrow spacer.

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

Install the wide spacer.
FO
STEP 167
STEP 164
T
O
N
BD06M208
BD06M201 Install the other thrust washer.

Install 25 rollers.

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6007-31
STEP 168 STEP 170
BD06M209 BD06M206
Install the pinion shaft so that the holes for the Drive new groove pins into the carrier and pinion
groove pins are aligned. shaft. The groove pins are easier to install if the
groove pins are put in a freezer for 45 minutes before
STEP 169 installation.
STEP 171
Repeat steps 159 through 170 for the other pinion
T
gears.
IN
STEP 172
See EXPANSION PLUG REPLACEMENT, page 49
PR
this section for proper procedures to install the
expansion plugs.
R
BD06M210
Hold the pinion shaft in place and install a pin to hold

FO
the pinion haft in place.

T
O
N

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6007-32
Assembly of the Final Drive STEP 176
STEP 173
BD06M117
Install the inner snap ring onto the input shaft.

BD06M252
Put all bearing to installed in an oven and heat the STEP 177
bearings to 250° F (121° C).
WARNING: Use insulate gloves or mittens

T
47-41B
IN
STEP 174
PR
BD06M116
R
Install the brake disk flange.

FO
STEP 178
T
BD06M122
Install the bearing on the input shaft. Make sure that

O
the bearing is seated on the shaft.

N
STEP 175
BD06M115
Install the snap ring onto the input shaft.
BD06M121
Install the bearing on the input shaft. Make sure that

the bearing is seated on the shaft.

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6007-33
STEP 182
47-41B
STEP 179
713510

into the retainer for the idler shaft and the retainer for
the output gear.
BD06M123 STEP 183

Install the bearing on the idler gear. Make sure that
the bearing is seated on the idler gear.
T
STEP 180
IN
PR
R
713506
FO

into the spindle.
BD06M124 STEP 184

T
Install the bearing on the idler shaft. Make sure that

the bearing is seated on the idler shaft.
O
STEP 181
N
BD06M112
Use and acceptable driver and press the bearing

cups into the gear housing.
BD06M125
Install the bearings on the output gear. Make sure

the bearings are seated on the output gear.

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6007-34
STEP 185 STEP 188
BD06M113 BD06M134
Use and acceptable driver and press the bearing Install the input shaft bearing cup.
cups into the gear housing.
STEP 189
STEP 186
T
IN
PR
BD06M109
R
BD06M126 Install the input shaft bearing retainer.

Install the seal into the final drive housing for the
FO
input shaft, the lips of the seal must face out away STEP 190
from you.
STEP 187
T
O
N
BD06M128
Torque bearing retainer Allen screws to 77 to 87 Nm

(57 to 64 pound-foot).
BD06M127
Install the input shaft.

Copyright ©
6007-35
STEP 191 STEP 194
BD06M050 BD06M053
Check the input shaft rolling torque. Install a bolt, M16-2 x 320 mm (12.5 inches).
NOTE: Rolling torque above 1.1 Nm (10 inch-pound)
a shim must added. STEP 195
STEP 192
T
IN
PR
BD06M054
R
Tighten the bolt just enough to move the bearing

race up 2 to 3 MM (1/8 inch), remove the bolt.
FO
BD06M051
Remove the four Allen screws from the bearing

retainer plate. STEP 196
STEP 193
T
O
N
BD06M052
Install the shim and retainer plate.

BD06M052
Remove the retainer plate.

Copyright ©
6007-36
STEP 197 STEP 200
BD06M128 BD06M135
Torque bearing retainer Allen screws to 77 to 87 Nm I n s t a l l t h e s h i m s t h a t w e r e r e m ove d d u r i n g

(57 to 64 pound-foot). disassembly. The thickness of each shim set must be
the same.
STEP 198
STEP 201
T
IN
PR
R
BD06M107
Install the idler gear. BD06M136

FO
Install the retainer without the O-ring.

STEP 199
STEP 202
T
O
N
BD06M129
Install the idler shaft. BD06M137
Install and tighten the cap screws to 125 to 150 Nm


Copyright ©
6007-37
STEP 203 STEP 207
BD06M139 BD06M105
Use a dial indicator and check the free travel of the Remove the shims. Keep the shims separate for the
idler gear. The free travel must be 0.0 to 0.004 inch final assembly.
(0.0 to 0.1 mm).
STEP 208
STEP 204
If the free travel for the idler gear is not as specified,
add or remove shims of the same thickness for each
T
shim set and check the free travel again.
IN
STEP 205 PR
R
BD06M141
Install a new O-ring in the groove in the retainer.

FO
STEP 209
T
BD06M140
Loosen and remove the cap screws that hold the

O
retainer.
N
STEP 206
BD06M142
Lubricate the bore for the retainer and the O-ring with
clean oil.
BD06M104
Remove the retainer.

Copyright ©
6007-38
STEP 210 STEP 213
BD06M143 BD06M146
Put the shims in place on the gear housing. Pull the retainer cow evenly into the gear housing.
STEP 211 STEP 214
T
IN
PR
BD06M144 BD06M154
R
Install the retainer. Tighten the cap screws to 125 to 150 Nm (93 to 110
pound-foot).
FO
STEP 212
STEP 215
T
O
N
BD06M145
Apply Loctite 242 to the threads of the cap screws BD06M147
and install the cap screws. Install the retainer for the output gear without the
O-ring and without shims.

Copyright ©
6007-39
STEP 216 STEP 219
BD06M148 BD06M151
Install two cap screws and hand tighten leaving a gap Apply a 3 mm (1/8 inch) bead of Loctite 515 around
of 6 MM (¼ inch). the opening as shown.
STEP 217 STEP 220

Apply Loctite 242 to the threads in the holes.
STEP 221
T
IN
PR
R
BD06M149
Install the gear with the extended portion facing

FO
down.
BD06M152
STEP 218 Lower the spindle onto the gear sousing.
NOTE: The weight of the spindle is approximately
T
140 lb’s (63 kg).

O
STEP 222
N
BD06M150
Install the output gear.
BD06M153


Copyright ©
6007-40
STEP 223 STEP 226
BD06M155 BD06M157
Remove the cap screws that hold the retainer. Install the retainer and cap screws that hold the sun
gear shaft.
STEP 224
STEP 227
T
IN
PR
BD06M147
R
Remove the retainer. BD06M158
Install the brake disc and apply pressure to prevent

FO
STEP 225 the sun gear shaft from turning, tighten the cap
screws to 125 to 150 Nm (93 to 110 pound-foot).
STEP 228
T
O
N
BD06M156
Install the sun gear shaft.
BD06M159
I n s t a l l t h e s h i m s t h a t w e r e r e m ove d d u r i n g
disassembly.

Copyright ©
6007-41
STEP 229 STEP 232
BD06M160 BD06M164
Install the retainer without the O-ring. Raise and lower the sun gear shaft and output gear
to check the free travel of the output gear.
STEP 230
STEP 233
The free travel must be 0.001 to 0.006 inch (0.025 to
0.152 mm).
T
STEP 234
If the free travel is not as specified, add or remove
IN
shims as required and check the free travel again.
PR
STEP 235
BD06M162
R

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

N
the cap screws that hold the retainer.
BD06M162
Install a dial indicator through the hole in the spindle

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

Copyright ©
6007-42
STEP 236 STEP 239
BD06M166 786356
Remove the retainer and shims. Keep the retainer Heat the bearings for the spindle to 250° F (121° C).
and shims together for assemble later in the
procedure. STEP 240
STEP 237
T
IN
PR
BD06M161
R
Make sure that the bore for the face seal is free of
BD06M157 gear lubricant. If the original face seal is to be
FO
Loosen and remove the cap screws and retainer for installed, make sure that the rubber ring is free of
the sun gear shaft. gear lubricant.
STEP 238 STEP 241

T
O
N
BD06M156 BD06M195
Remove the sun shaft from the final drive. Install half of the face seal.

Copyright ©
6007-43
STEP 245
47-41B
STEP 242
BD06M058
I n s t a l l t h e s h i m s t h a t w e r e r e m ove d d u r i n g
disassembly.
STEP 246
BD06M167
Install the bearing on the spindle.
T
STEP 243
IN
PR
R
BD06M059
Install the retainer.

FO
STEP 247
BD06M168
Let the bearing cool. Lubricate the bearing on the

T
spindle and on the hub for the ring gear.

O
STEP 244
N
BD06M062
Tighten the cap screws to pull the ring gear onto the
spindle.
BD06M056
Install the planetary housing WITHOUT the face

seal.

Copyright ©
6007-44
STEP 248 IMPORTANT: If the planetary housing is out of
balance, you must read the torque wrench for a
complete revolution to find the high and low reading
for the rolling torque. Add the high and low readings
together and divide the answer by two. The answer is
the rolling torque.
STEP 251
The rolling torque must be 8.5 ± 2.5 Nm (75 ± 20
pound inch).
STEP 252
BD06M061

pound-foot).
STEP 249
T
IN
BD06M062
If the rolling torque is not as specified, loosen and

PR
remove the cap screws that hold the retainer and
remove the retainer and shims.
STEP 253
R
BD06M063
Add or remove shims as required.
Fasten the fabr icated tool onto the planetar y
FO
housing. The nut must be centered on the spindle.

STEP 254
STEP 250
T
O
N
BD06M060

BD06M064
Use a torque wrench and check the rolling torque of

the planetary housing. Read the torque wrench while
the planetary housing is moving.

Copyright ©
6007-45
STEP 255 STEP 258
BD06M061 BD06M056
Tighten the cap screws to 310 to 380 Nm (230 to 280 Fasten the lifting equipment to the planetary housing
pound-foot). and remove the planetary housing and ring gear from
the spindle.
STEP 256
STEP 259
Make sure that the bore for the face seal in the
planetary housing is free of lubricant.
T
STEP 260
IN
PR
R
BD06M064
Check the rolling torque again.

FO
STEP 257
BD06M057
T
Install the face seal. Make sure that the face seal is
seated in the bore.
O
STEP 261
N
Apply a small amount of clean oil to the sealing

surface of the face seal.
BD06M062
When the rolling torque is as specified, loosen and

remove the cap screws, retainer and shims.

Copyright ©
6007-46
STEP 262 STEP 267
BD06M056 BD06M065
Start the planetary housing onto the spindle. Install the sun gear shaft.
STEP 263 STEP 268

Be careful so that the face seal does not come out of Apply Loctite 242 to the treads in the sun gear shaft.
the housing. Drive the ring gear onto the spindle with
a soft hammer. STEP 269
T
STEP 264
Apply Loctite 242 to the threads on the spindle.
STEP 265
IN
PR
R
FO
BD06M066
Install the retainer with the shoulder toward the sun

gear shaft and the cap screws.
T
STEP 270
O
BD06M060

N
STEP 266
BD06M067

pound-foot).
BD06M061

pound-foot).

Copyright ©
6007-47
STEP 271 STEP 273
Apply Loctite 242 to the threads in the gear housing.
STEP 274
Lubricate the O-ring and the bore of the retainer with
petroleum jelly.
STEP 275
BD06M068
Install the shims on the retainer.
STEP 272
BD06M070
T
Install the retainer and two cap screws.
IN
STEP 276
Tighten the cap screws evenly to pull the retainer into
PR
the gear housing.
STEP 277
BD06M069
R
Install a new O-ring in the groove for the retainer for

the output gear.
FO
T
O
N
BD06M071
Install the remainder of the cap screws and tighten

pound-foot).

Copyright ©
6007-48
STEP 278 STEP 282
Install the cap screws.
STEP 283
BD06M072
Apply a 1/8 inch (3 mm) bead of Loctite 515 to the

planetary housing as shown.
STEP 279 BD06M075
Apply Loctite 242 tot he threads in the planetary Torque the cap screws to 310 to 380 Nm (230 to 280
housing. pound-foot).
T
STEP 280 STEP 284
Move the housing into alignment with the frame.
STEP 285
IN
PR
Install the cap screws.
STEP 286
R
pound-feet).
FO
STEP 287
See section 5509 and install the sprockets.
BD06M073
Engage the pinion gears with the sun gear shaft and STEP 288
T
ring gear.
See section 7001 and install the brakes.
O
STEP 281
STEP 289
N
See section 6001 and install the hydrostatic motor.
STEP 290
Fill the planetary housing and gear housing with
85W - 140 EP gear lubricant.
STEP 291
Install the track, see to section 5504.
BD06M074
Remove the lifting equipment from the planetary

housing, loosen and remove the separating bolts.

Copyright ©
6007-49
EXPANSION PLUG REPLACEMENT

STEP 292 STEP 296
Prior to welding on the machine turn the master
disconnect off.
STEP 293
BD06H003
Apply a 2 to 3 mm bead of Loctite 504 around the

bottom corner of the plug counterbore.
BD06H006 STEP 297

Weld a nuts onto the expansion plugs to be removed.
T
IMPORTANT: To help prevent damage to electronic
IN
equipment and arcing current going through the
bearings, connect the grounding clamp to the nut.
PR
STEP 294
R
FO
BD06H004
Insert the plug into the counterbore. Set the driver,

380002800, on top of the plug and center the tool to
the bore.
T
STEP 298
O
BD06H002
N
Install a bolt into the nut and tap with a hammer to

remove the expansion plug.
STEP 295
Make sure the housing bores and new plugs are
clean and free of oil/grease.
BD06H005
Strike the tool with enough force to bottom the tool on

the housing.

Copyright ©
6007-50
NOTES
T
IN
PR
R
FO
T
O
N

Copyright ©
SECTION INDEX
BRAKES

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7001
Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
T
IN
PR
R
FO
T
O
N

Copyright ©
T
IN
PR
R
FO
T
O
N
Copyright ©
7001
Section
7001
REMOVAL AND INASTALLATION OF

BRAKE COMPONENTS
T
IN
PR
R
FO
T
O
N

Copyright ©
7001-2
TABLE OF CONTENTS
BRAKE DISC’S AND SPRING WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
T
IN
PR
R
FO
T
O
N

Copyright ©
7001-3
BRAKE DISC’S AND SPRING WASHERS
Disassembly STEP 6
STEP 1
and any attachment to the floor, apply the parking
brake levers and turn off the master disconnect.
STEP 2
Remove the rear cover on the machine.
STEP 3
1
BD06K045
2 Loosen all four of the brake spring housing mounting

bolts ½ of a turn.
NOTE: The final drive is shown removed for clarity
only.
T
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4
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BD06E002

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vacuum pump.
STEP 4
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BD06K046
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Loosen the bolts evenly until the spring pressure is

released.
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STEP 8
BD06K054
Disconnect brake line at brake housing, plug the line

and cap the fitting, turn off the vacuum pump.
STEP 5
Remove the hydrostatic motor, see section 6001.
BD06K047
Remove the spring housing from the final drive.

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7001-4
STEP 9 STEP 13
BD06K048 BD06K031
Remove the outer separator plate. Loosen all four of the mounting screws on the spring
housing evenly until spring pressure is released.
STEP 10
STEP 14
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BD06K049
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Remove the friction plate. BD06K029
Remove the four screws from the housing and

STEP 11 remove the housing cover and piston.
Repeat steps 9 and 10 until all of the separator and
STEP 15
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friction plates are removed.

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STEP 12
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BD06K036
Remove the piston from the cover, remove and

BD06K033
discard the O-rings.
Make alignment marks on the housing and cover.

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7001-5
STEP 16 Inspection
1. Check piston for gouging or scaring.
2. Check piston housing for gouging or scaring.
3. Check brake separator plates for discoloration,
excessive wear, or scaring.
4. Check brake friction plates for excessive wear,
discoloration, scoring, flaking or material over
large areas and damaged internal teeth. Check
the groove depth of the friction plates, the groove
depth can not be less than 0.1 MM. (0.004 in) on
either side of the plate.
BD06K028
NOTE: If a friction plate or brake separator plate is
Remove the outer spring washer. damaged, install a new set of friction plates and
brake separator plates for that brake. DO NOT mix
old and new parts in a brake.
STEP 17
5. Inspect the friction plate gear for damaged and
missing teeth.
6. Check springs for cracks and missing spring
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fingers.
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Remove the inner spring washer.
STEP 18
Repeat steps 16 and 17 for the other spring washers.
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STEP 19
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BD06K034
Remove the spring guide from the housing.

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7001-6
Assembly STEP 23
STEP 20
BD06K038
Install the third bevel washer with the bevel of the

BD06K034
fingers facing down.
Insert the spring guide with the bevel in the slot.
STEP 24
STEP 21
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BD06K039
BD06K027
Install the fourth bevel washer with the bevel of the
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Install the first bevel washer with the bevel of the fingers facing up.
fingers facing down.
STEP 25
STEP 22
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BD06K037
BD06K028
Install new O-rings onto the piston.
Install the second bevel washer with the bevel of the
fingers facing up.

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7001-7
STEP 26 STEP 29
BD06K041 BD06K043
Lubricate the bore of the cover with hydraulic oil. Install the piston and cover into the housing, align the
marks made during disassembly.
STEP 27 IMPORTANT: Make sure to start the cover straight
into the housing, the piston and or O-rings can be
damaged if not straight.
STEP 30
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BD06K042
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Insert the piston into the cover.

IMPORTANT: Make sure to start the cover straight
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onto the piston, the piston and or O-rings can be

damaged if not straight. BD06K030
Install the four mounting screws.

STEP 28
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STEP 31
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BD06K040
Lubricate the bore of the housing with hydraulic oil. BD06K031
Tighten the screws evenly until the cover makes

contact with the housing.

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7001-8
STEP 32 STEP 35
BD06K032 BD06K052
Torque screws to 77 to 87 Nm (57 to 64 pound feet). Make sure to align the separator plates slots onto the
dowel pins.
STEP 33
STEP 36
Continue to alternate between separator plates and
friction plates until all are installed.
NOTE: Six separator and six frictions plates are
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used in each final drive.
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STEP 37
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BD06K050
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Install a friction plate by aligning the teeth of the

friction plate with the teeth of the input shaft.
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STEP 34
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BD06K046
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Install the spring housing onto the final drive, start

the mounting bolts evenly around the housing.
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BD06K051
Install a separator plate into the final drive.

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7001-9
STEP 38 STEP 42
BD06K045 BD06K054
Tighten the bolts evenly until the spring housing is Remove the plug from the line and the cap from the
snug against the final drive. fitting and install the brake release hose.
IMPORTANT: Make sure to pull the spring housing
straight onto the final drive, the spring housing can STEP 43
be damaged if not straight. Turn off the vacuum pump. Disconnect the vacuum
pump from the reservoir, install the vent into the
STEP 39 hydraulic reservoir.
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STEP 44
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Start and run the engine at low idle.
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STEP 45
Place the park brake levers in the off position, place
the FNR selector in the F position.
STEP 46
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Slowly increase engine rpm until the machine moves.

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NOTE: The machine should start moving about

BD06K053
1250 to 1500 rpm.
Torque spring housing bolts to 650 to 730 Nm (479 to
538 pound feet). STEP 47
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Place the FNR selector in the N position and place

STEP 40 the parking brake levers in the applied position. Stop
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the engine.
Install the hydrostatic motor, see section 6001.
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STEP 48
STEP 41
Check to leaks at the brake housing, check the oil
Turn on the vacuum pump.
level in the hydraulic reservoir, add oil as required.
STEP 49
Install the rear cover onto the machine.

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7001-10
SOLENOID VALVE
NOTE: Tilt the ROPS canopy/cab to gain access to
the solenoid, see section 9008. STEP 7
Mount the solenoid and tighten the mounting bolts.
STEP 1
Clean the area around the solenoid valve. STEP 8
Connect the hydraulic lines.
STEP 2
Disconnect the harness connector. STEP 9
Turn off and disconnect the vacuum pump from the
hydraulic reservoir and install breather.
STEP 3
Remove breather from the reservoir and connect a
vacuum pump to the hydraulic reservoir. Turn on the STEP 10
pump. Connect the harness connector.
STEP 4 STEP 11
Tag and disconnect hydraulic lines for proper location Lower the ROPS cab/canopy, see section 9008.
during assembly.
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STEP 12
STEP 5 Start and run the engine at low idle.
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Plug or cap all lines and fittings.
STEP 13
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STEP 6 Place the park brake levers in the off position, place
the FNR selector in the F position.
STEP 14
Slowly increase engine rpm until the machine moves.
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NOTE: The machine should start moving about

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1250 to 1500 rpm.
STEP 15
Place the FNR selector in the N position and place
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the parking brake levers in the applied position.

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BD06K044
STEP 16
Remove the valve. Stop the engine, raise the cab/canopy, see section
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9008.
NOTE: If only replacing the cartridge valve, torque
the cartridge to 27 to 34 Nm (20 to 25 lb-ft) and coil
STEP 17
retaining nut to 5 to 6 Nm (50 to 55 lb-in).
Check to leaks at the brake solenoid, check the oil
level in the hydraulic reservoir, add oil as required.
STEP 18
Lower the ROPS cab/canopy, see section 9008.

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7002
Section
7002
BRAKE SYSTEM TROUBLESHOOTING
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TABLE OF CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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7002-3
TROUBLESHOOTING
NOTE: For complete electrical troubleshooting procedures see Section 4001.
WARNING: FOR THIS PROCEDURE BLOCK BOTH TRACKS FRONT AND REAR TO PREVENT ANY
ACCIDENTAL MOVEMENT.
Brake Solenoid
Brake solenoid is located under the ROPS behind the ROPS tilt cylinder.
NOTE: Put the master disconnect switch in the ON position. Disconnect the harness connector for the brake
solenoid and pressure switch.
Check brake solenoid coil resistance 41.8 ohm at
between the connector pins of the 20° C Bad brake solenoid.
solenoid connector. (68° F)
Open Bad pressure switch.
WARNING: DO NOT start the engine, place the ignition switch in the run position, release the parking brake
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levers, DO NOT press the brake pedal, place the directional control in the F position, move hand throttle to ½
throttle position.
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Bad wire between the brake solenoid and the drivetrain
Terminal for wire 52 to ground. 24 volts
controller. Bad drivetrain controller.
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NOTE: If the readings are good, replace the brake solenoid.
WARNING: Start the engine, DO NOT place the directional control in the F or R position, move hand throttle to
½ throttle position.
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Continuity Bad pressure switch.
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NOTE: Hydrostatic charge pressure must be checked to make sure it is at proper pressure, see section 6002.
The pressure switch is normally open and closes at 11.4 to 12.8 Bar (165 to 185 psi).
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BD06K057
1. BRAKE VALVE BLOCK 3. BRAKE SOLENOID

2. PRESSURE SWITCH 4. TILT CYLINDER

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7002-4
NOTES
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SECTION INDEX
HYDRAULICS

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Equipment Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Equipment Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8010
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8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS
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8001-2
TABLE OF CONTENTS
DOZER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparing Pump For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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8001-3
DOZER CONTROL VALVE
Removal STEP 5
NOTE: Tilt the ROPS cab or canopy before
proceeding. See Section 9008.
STEP 1
R e m ove t h e d i r t a n d gr e a s e fr o m t h e h o s e s
connections at the dozer control valve.
STEP 2
2
BD06E077
Remove the two mounting bolts and accumulator

mounting bracket.
3
STEP 6
4
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BD06E002

Remove the breather from the reservoir and connect
a vacuum pump to the opening. Start the vacuum
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pump.
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STEP 3
BD06E078
Ta g a l l l i n e s fo r p r o p e r i d e n t i f i c a t i o n d u r i n g
Tag all solenoid connectors, press in on the tab and
assembly.
pull up on the connector.
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Disconnect the hoses from the dozer control valve. DO NOT pull on the wires.
Install plugs or caps in/on all open hoses and fittings,
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stop the vacuum pump. Remove the mount bolts for STEP 7
the control valve, remove the control valve from the Attach suitable lifting equipment to the dozer control
machine. valve, remove the mounting bolts and valve from the
machine.

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8001-4
Installation STEP 6
Mount the accumulator bracket to the dozer control
STEP 1 valve bracket.
Align the dozer control valve mounting holes with the NOTE: Lower the ROPS cab or canopy before
associated holes in the mounting bracket. Install the proceeding. See Section 9008.
bolts, washers, lock washers, and nuts to secure the
control valve. STEP 7
With the engine running at low idle, hold each control
STEP 2 lever in the angle left and right, tilt left and right, raise
Start the vacuum pump and remove the plugs from and lower power positions to open the main relief
the hoses and caps from valve fittings. valve for five seconds. Stop the engine and check for
leaks.
STEP 3
NOTE: If equipped with auxiliary hydraulics repeat
Connect the hoses to the dozer control valve. setp 5 for the attachment.
STEP 4 STEP 8
Turn off and disconnect the vacuum pump. Install the Check the level of oil in the reservoir and add oil as
breather in the reservoir. required. See Section 1002.
STEP 5
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Connect the electrical connectors to the seleniods.
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8001-5
EQUIPMENT PUMP
Removal STEP 4
Install a plug in each hose and fitting. Tighten the
NOTE: Tilt the ROPS cab or canopy before
clamp on the plug installed in the suction hose. Stop
proceeding. See Section 9008.
the vacuum pump.
STEP 1
STEP 5
R e m o ve t h e d i r t a n d g r e a s e f r o m t h e h o s e
Remove the pump and discard gaskets.
connections at the pump.
STEP 2 Installation
STEP 1
1
Install a new gasket and mount the hydraulic pump.
2
STEP 2
3
4
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BD06E002

3
Remove the breather from the reservoir and connect
a vacuum pump to the opening. Start the vacuum
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pump. BD06E076
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NOTE: If dozer is equipped with a PTO drive pump, 1. PUMP SUCTION HOSE 3. PUMP
2. PUMP HIGH PRESSURE HOSE 4. FROM HYDROSTAT
disconnect the PTO before proceeding.
FILTER
STEP 3
Start the vacuum pump. Remove the plugs from the
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hoses. Connect the hoses to the pump. Connect the

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hose to the hydrostat filter

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STEP 3
Stop the vacuum pump.
STEP 4
1 2 4 Disconnect the vacuum pump from the opening in
3 the reservoir. Install the breather.
NOTE: If dozer is equipped with a PTO drive pump,
connect the PTO before proceeding.
BD06E076 NOTE: Lower the ROPS cab or canopy before
1. PUMP SUCTION HOSE 3. PUMP proceeding. See Section 9008.
2. PUMP HIGH PRESSURE HOSE 4. FROM HYDROSTAT
FILTER STEP 5
Check the level of the oil in the reservoir and add oil
Disconnect the hoses from the pump. Disconnect the as required. See Section 1002.
hose from the hydrostat filter.

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8001-6
STEP 6 Preparing Pump For Use
If a new or overhauled pump has been installed,
prepare the pump for use. STEP 1
Start and run the engine at half throttle for three
STEP 7 minutes.
Star t and run the engine at half throttle for 30
seconds and check for leaks. Then stop the engine. STEP 2
With the engine running at half throttle, hold the
STEP 8 blade control lever in the tilt position for five seconds.
Check the level of the oil in the reservoir and add oil Then return the blade control lever to neutral for five
as required. See Section 1002. seconds.
STEP 3
Repeat Step 2 for three minutes.
STEP 1
With the engine running at full throttle, repeat Steps 2
and 3.
STEP 2
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Stop the engine and check for leaks.
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STEP 3
Replace the hydraulic oil filter.
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STEP 4
Check the level of oil in the reservoir and add oil as
required. See Section 1002.
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8002
Section
8002
HYDRAULIC SPECIFICATIONS TROUBLSHOOTING AND
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8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAIN RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOAD SENSE RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CIRCUIT RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLOWMETER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test No. 1 - Equipment Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Understanding Results of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 2 - Dozer/Ripper Circuits and Main Relief Valve Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load Sense Relief Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Dozer Circuits Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Ripper Circuits - (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Understanding Results of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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FLOWMETER CHECK SHEET METRIC MEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FLOWMETER CHECK SHEET U. S. MEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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8002-3
SPECIFICATIONS
Temperature of Hydraulic Oil When Testing .............................................................. 52° to 79° C (125° to 175° F)
Hydraulic Pump Output ......................................................................................76.8 L/min at 207 bar at 2000 r/min
(20.3 U.S. gpm at 3000 psi at 2000 rpm))
Main Relief Valve Pressure.....................................................................................205 to 210 bar (2973 to 3045 psi)
Load Sense Pressure .............................................................................................163 to 168 bar (2365 to 2437 psi)
Delta P Pressure ................................................................................................................................. 8 Bar (120 psi)
Circuit Relief Valves
A and B Ports Ripper.............................................................. 238 to 243 bar (3450 to 3524 psi) with Hand Pump
A and B Ports Angle Circuit.................................................... 400 to 405 bar (5800 to 5875 psi) with Hand Pump
SERVICE TOOLS
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B877558 B877168
CAS-1804 PRESSURE TEST KIT CAS-1808 FLOWMETER FITTING KIT
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B877895 B785789
CAS-10090 HAND PUMP CAS-10280 FLOWMETER
NOTE: The needle valve on the accumulator block must be screwed in for the hydraulics to work correctly.

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8002-4
HYDRAULIC CONTROL VALVE
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5
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4 9
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BS06M038
1. LOAD SENSE RELIEF VALVE 5. A PORT CIRCUIT RELIEF 9. B PORT CIRCUIT RELIEF
2. DOZER TILT SECTION 6. END COVER 10. BLOCK COVER
3. DOZER LIFT SECTION 7. HYDRAULIC VALVE FTDRE4 11. MAIN RELIEF VALVE
4. DOZER ANGLE SECTION 8. HYDRAULIC VALVE FTDRE2 12. HOUSING TILT AND ANGLE
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8002-5
MAIN RELIEF VALVE PRESSURE TEST
Equipment Required 9. Hold the hydraulic control lever for the Lift
Cylinders in the RAISE position.
345 bar (5000 psi) Pressure Gauge with Test Hose
10. Record the reading on the pressure gauge and
Female Diagnostic Coupler from pressure test fitting check that the pressure reading is within the
kit specification on page 3.
11. If the pressure is not correct, adjust the main
Pressure Test Procedure relief valve according to the following procedure.
See page 4 for the location of the load sense
relief valve.
A. Remove the cover from the main relief valve
1 and loosen the lock nut on the adjusting
screw.
B. Turn the adjusting screw into the main relief
valve to increase the pressure or out of the
main relief valve to decrease the pressure.
C. Repeat Steps 5 to 8 to check the pressure
setting. Adjust the main relief valve again as
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D. When the pressure setting is correct, prevent
BD02F023
the adjusting screw from turning while the lock
1. PRESSURE TEST PORT DIAGNOSTIC COUPLER
nut is tightened. Install the cover on the main
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relief valve.
WARNING: Make sure that everyone is clear
12. Stop the engine and remove the pressure gauge.
of the dozer blade prior to proceeding.
13. If the main relief valve cannot be adjusted to the
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1. Raise the right side panel for the equipment correct pressure setting:
control valve.
A. Remove the main relief valve and inspect for
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2. Make sure the hydraulic system fluid is at damaged or worn parts or damaged O-rings.
operating temperature of 52° to 79° C (125° to Repair as necessary.
175° F).
B. Do a Hand Pump pressure test. Replace the
3. Connect the diagnostic coupler and pressure relief valve if pressure can not be adjusted.
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gauge to the test port coupler (1).

14. Reinstall and/or replace the main pressure relief
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4. Loosen the jam nut on the Load Sense relief valve.

valve.
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15. Repeat steps 3 through 9 and recheck pressure

5. Turn the adjusting screw in and count and record setting.
the number of turns the adjusting screw turns
16. Loosen the jam nut on the Load Sense relief
until it bottoms out, tighten the jam nut.
valve.
IMPORTANT: DO NOT force the adjusting screw, this
17. Turn the adjusting screw out the number of turns
will damage the load sense relief valve.
it took to bottom it out, tighten the jam nut.
6. Make sure the Parking Brakes are applied and
IMPORTANT: Once the main relief pressure has
the directional control is in the NEUTRAL
been adjusted it will be required to readjust the load
position.
sense pressure, see Load Sense Relief Valve
7. Start and run the engine at FULL THROTTLE. Pressure Test this section.
8. Release the right parking brake lever only to
activate the hydraulic system.
NOTE: It is only required to release the right hand
park brake lever to activate the hydraulic system.

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8002-6
LOAD SENSE RELIEF VALVE PRESSURE TEST
Equipment Required 8. Record the reading on the pressure gauge and

check that the pressure reading is within the
345 bar (5000 psi) Pressure Gauge with Test Hose specification on page 3.
Female Diagnostic Coupler from pressure test fitting NOTE: This pressure will be the load sense
kit pressure plus the Delta P of 8 Bar (120 psi).
9. If the pressure is not correct, adjust the load
Pressure Test Procedure sense relief valve according to the following
procedure. See page 4 for the location of the
load sense relief valve.
A. Loosen the lock nut on the adjusting screw.
1 B. Turn the adjusting screw into the load sense
relief valve to increase the pressure or out of
the load sense relief valve to decrease the
pressure.
C. Repeat Steps 5 to 8 to check the pressure
setting. Adjust the load sense relief valve
again as necessary.
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D. When the pressure setting is correct, prevent
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BD02F023
nut is tightened.
1. PRESSURE TEST PORT DIAGNOSTIC COUPLER
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10. Stop the engine and remove the pressure gauge.
WARNING: Make sure that everyone is clear 11. If the load sense relief valve cannot be adjusted
of the dozer blade prior to proceeding. to the correct pressure setting:
A. Remove the load sense relief valve and
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1. Raise the right side panel for the equipment

i n s p e c t fo r d a m a g e d o r w o r n p a r t s o r
control valve.
damaged O-rings. Repair as necessary.
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2. Make sure the hydraulic system fluid is at

B. Do a Hand Pump pressure test. Replace the
operating temperature of 52° to 79° C (125° to
relief valve if pressure can not be adjusted.
175° F).
12. Reinstall and/or replace the load sense pressure
3. Connect the diagnostic coupler and pressure
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relief valve.
gauge to the test port coupler (1).
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13. Repeat steps 3 through 9 and recheck pressure

4. Make sure the Parking Brakes are applied and
setting.
the directional control is in the NEUTRAL
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position.
5. Start and run the engine at FULL THROTTLE.
6. Release the right parking brake lever only to
activate the hydraulic system.
NOTE: It is only required to release the right hand
park brake lever to activate the hydraulic system.
7. Hold the hydraulic control lever for the Lift
Cylinders in the RAISE position.

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8002-7
CIRCUIT RELIEF VALVE PRESSURE TEST
Equipment Required 6. Compare the pressure reading recorded to the

specifications on page 3.
CAS-10090 Hand Pump with Test Hose
7. If the pressure is not correct, adjust the circuit
345 bar (5000 psi) Pressure Gauge relief valve according to the following procedure.
Adapter and Plug from pressure test fitting kit A. Remove the cover from the circuit relief valve
and loosen the lock nut on the adjusting
Pressure Test Procedure screw.
NOTE: The circuit relief valves are in the angle and if B. Turn the adjusting screw into the circuit relief
equipped Ripper/Auxiliary circuits. valve to increase the pressure or out of the
circuit relief valve to decrease the pressure.
1. Raise the right ROPS side panel for the
equipment control valve. C. Repeat Steps 5 and 6 to check the pressure
setting. Adjust the circuit relief valve again as
2. Remove the hydraulic line from the work port for necessary.
the circuit relief valve to be tested and install a
plug in the end of the hose fitting. D. When the pressure setting is correct, prevent
3. Connect the CAS-10090 hand pump and nut is tightened. Install the cover on the circuit
pressure gauge to the open work port in the relief valve.
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equipment control valve where the line was
disconnected. 8. If the circuit relief valve cannot be adjusted to the
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correct pressure setting:
4. Make sure that the hand pump is full of oil and
the temperature of the oil is approximately 21° C A. Remove the circuit relief valve and inspect for
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(70° F). damaged or worn parts or damaged O-rings.
Repair as necessary.
5. Operate the hand pump and read the pressure
gauge. Record the highest pressure. Repeat this B. Do a Hand Pump pressure test. Replace the
step several times to be sure of the pressure relief valve if pressure can not be adjusted.
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setting. 9. Reinstall and/or replace the circuit relief valve.

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10. Repeat steps 5 and 6 and recheck pressure

setting.
11. Repeat steps 2 through 10 for the other work
ports if necessary.
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8002-8
FLOWMETER TESTS
WARNING: Two persons are required to 7. Disconnect the hose from the fitting on the inlet
perform the flowmeter tests for safety to avoid port of the equipment control valve and install a
possible injury. cap onto the fitting.
One person must be seated in the operators 8. Install a tee in the end of the outlet hose from the
seat with the engine running. The second hydraulic pump and install a plug into the
person is to control the flowmeter and take the opposite end of the tee fitting.
readings.
M750
9. Connect a hose from the tee at the hydraulic
pump outlet hose to the inlet of the Flowmeter.
Equipment Required 10. Turn off the vacuum pump.
CAS-10280 Flowmeter 11. Lower and secure the ROPS cab/canopy. See
CAS-1808 Flowmeter Fitting Kit Section 9008.
CAS-101092 Vacuum Pump 12. Connect a hose to the outlet of the Flowmeter
and place the opposite end of the hose into the
General Information fill port below the level of the oil in the reservoir.
Secure the hose to the fill port to prevent it from
The Flowmeter measures the volume, pressure and falling out during the test.
temperature of the hydraulic oil as the hydraulic oil
13. Open the pressure Load Valve on the Flowmeter
flows through the Flowmeter.
all the way. Make sure the flow switch is in the
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Test No. 1 will indicate whether or not there are FLOW position and move the range switch to the
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problems in the line between the reservoir and the HI position.
equipment pump, also whether or not the equipment
14. Set the instrument cluster to read engine r/min
pump is working within acceptable standards of
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(rpm).
efficiency.
15. Start and run the engine at full throttle. Push
Test No. 2 will indicate if there are problems in the
down the temperature switch on the Flowmeter
dozer and ripper hydraulic circuits.
and read the temperature gauge. The
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A check sheet is at the end of this section. A copy of temperature of the oil must be at least 52° C
the check sheet can be made to use as a record for (125° F).
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the test results.

16. If the temperature of the hydraulic oil is not as
specified, run the engine at full throttle and close
Test No. 1 - Equipment Pump Flow the pressure Load Valve on the Flowmeter until
Test the pressure gauge indicates 103 bar (1500 psi).
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Continue to run the engine until the temperature

1. Park the machine on a level surface. of the oil is as specified.
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2. Lower the dozer and the ripper to the ground. 17. Open the pressure Load Valve completely.
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3. Put directional control in NEUTRAL and apply 18. Adjust the engine speed to 2000 r/min (rpm).
the parking brakes. Stop the engine. Make sure the pressure Load Valve on the
4. Place the ignition switch in the ON position, place Flowmeter is fully open and read the flow gauge.
the right parking brake lever in the operation Write the flow reading on line 1 on the check
position. Move the control levers in all directions sheet for minimum pressure.
to release any pressure in the hydraulic circuits, 19. Slowly close the pressure Load Valve on the
place the right parking brake lever in the applied Flowmeter until the pressure gauge indicates
position and turn the ignition switch off. 138 bar (2000 psi). Make sure to keep the engine
5. Tilt the ROPS cab/canopy to gain access to the running at 2000 r/min (rpm). Read the flow
equipment control valve. See Section 9008. gauge and write the reading on line 2 on the
check sheet.
6. Remove the vent from the hydraulic reservoir and
connect a vacuum pump to the fitting. Turn on 20. Open the pressure Load Valve on the Flowmeter.
the vacuum pump. Decrease the engine speed and stop the engine.

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8002-9
Understanding Results of Test Test No. 2 - Dozer/Ripper Circuits

1. If the output at minimum pressure was less than and Main Relief Valve Flow Tests
76.8 L/min (20.3 U.S. gpm) the problem can be a 1. Tilt the ROPS cab/canopy to gain access to the
leak or a restriction between the equipment equipment control valve. See Section 9008.
pump and reservoir, or a badly worn or damaged
equipment pump. 2. Remove the flowmeter return line from the
reservoir and replace the filler cap.
2. If the output at minimum pressure was 76.8
L/min (20.3 U.S. gpm) or more there are no 3. Turn the vacuum pump on.
problems between the equipment pump and 4. Remove the plug from the tee at the outlet hose
reservoir. The equipment pump can be worn or from the hydraulic pump and the cap from the
damaged and still have good flow at minimum fitting on the equipment control valve.
pressure.
5. Connect the tee fitting at the outlet hose from the
3. Some loss of output at 138 bar (2000 psi) is hydraulic pump to the equipment control valve.
normal. The loss can also show the equipment
pump is worn or damaged. Use the efficiency of 6. Turn the vacuum pump off.
the equipment pump to make a judgement as to 7. Lower and secure the ROPS cab/canopy. See
whether or not the equipment pump must be Section 9008.
repaired or replaced.
8. Place the outlet hose of the Flowmeter back into
4. The efficiency of the equipment pump is found by the fill port of the reservoir below the level of the
dividing the flow at 138 bar (2000 psi) by the flow
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oil. Secure the hose to the fill port to prevent it
at minimum pressure. from falling out during the test.
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EXAMPLE 9. Open the pressure Load Valve on the Flowmeter
all the way. Make sure the flow switch is in the
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STEP 18 - 98 L/min (26 U.S. gpm) Flow position and move the range switch to the
HI position.
STEP 19 - 87 L/min (23 U.S. gpm) 10. Start and run the engine at full throttle. Push
down the temperature switch on the Flowmeter
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23 divided by 26 equals 0.88 = 88% efficient and read the temperature gauge. The
temperature of the oil must be at least 52° C
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87 divided by 98 equals 0.88 = 88% efficient (125° F).

11. If the temperature of the hydraulic oil is not as
5. If the efficiency is below 75% it is recommended specified, run the engine at full throttle, hold the
that the equipment pump be repaired or blade control lever in the RAISE position and
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replaced. slowly close the pressure valve on the Flowmeter

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until the pressure gauge indicates 103 bar (1500

psi). Continue to r un the engine until the
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temperature of the oil is as specified.

12. Lower the blade to the ground and open the
pressure Load Valve on the Flowmeter.

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8002-10
Load Sense Relief Valve Test Dozer Circuits Flow Tests
WARNING: Make sure that everyone is clear WARNING: Make sure that everyone is clear
of the dozer blade prior to proceeding. of the dozer blade prior to proceeding.
13. Maintain the engine speed at full throttle and 21. Set the instrument cluster to read engine r/min
hold the blade control lever in the RAISE (rpm).
position.
22. Start the engine and adjust the engine speed to
14. This step will indicate the pressure at which the 2000 r/min (rpm).
load sense relief valve begins to open. As the
23. Hold the blade control lever in the LIFT position
pressure Load Valve on the Flowmeter is closed,
and adjust the pressure valve on the Flowmeter
the flow indication will decrease slowly until the
as required to keep the pressure at 138 bar
load sense relief valve begins to open at which
(2000 psi). Adjust the engine speed to keep the
time the flow indication will start decreasing
engine running at 2000 r/min (rpm). Read the
rapidly. STOP closing the pressure Load Valve
flow gauge and write the reading on the check
and read the pressure gauge.
sheet.
15. Write the reading of the pressure gauge on the
24. Hold the blade control lever in the LOWER
check sheet, Load Sense Relief Valve begins to
(Power Down) position and adjust the pressure
open.
valve on the Flowmeter as required to keep the
16. This step will indicate the pressure at which the pressure at 138 bar (2000 psi). Adjust the engine
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load sense relief valve is completely open. speed to keep the engine running at 2000 r/min
Continue to close the pressure valve on the (rpm). Read the flow gauge and write the reading
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Flowmeter until the indication of the flow gauge is on the check sheet.
zero. This is the pressure at which the load
25. Hold the blade control lever in the ANGLE
sense relief valve is completely open.
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RIGHT position and adjust the pressure valve on
NOTE: This pressure will be the load sense the Flowmeter as required to keep the pressure
pressure plus the Delta P of 8 Bar (120 psi). at 138 bar (2000 psi). Adjust the engine speed to
keep the engine running at 2000 r/min (rpm).
17. Write the reading of the pressure gauge on the
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Read the flow gauge and write the reading on the

c h e c k s h e e t , L o a d S e n s e R e l i e f Va l v e
check sheet.
completely open with Delta P pressure.
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26. Hold the blade control lever in the ANGLE LEFT

18. If the pressures in Steps 14 and 16 are as
position and adjust the pressure Load Valve on
specified on page 3, proceed to step 21.
the Flowmeter as required to keep the pressure
19. If the pressure setting of the load sense relief at 138 bar (2000 psi). Adjust the engine speed to
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valve is not as specified on page 3, then attempt keep the engine running at 2000 r/min (rpm).
to adjust the load sense relief valve to correct the Read the flow gauge and write the reading on the
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pressure setting. If adjustment does not correct check sheet.

the pressure setting, the load sense relief valve
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27. Hold the blade control lever in the TILT RIGHT

must be removed and inspected for possible
repair or replacement. See Section 8005.
20. If the load sense relief valve was adjusted, at 138 bar (2000 psi). Adjust the engine speed to
repaired or replaced, do Steps 13 through 17 keep the engine running at 2000 r/min (rpm).
again. Read the flow gauge and write the reading on the
check sheet.
28. Hold the blade control lever in the TILT LEFT
at 138 bar (2000 psi). Adjust the engine speed to
keep the engine running at 2000 r/min (rpm).
check sheet.

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8002-11
Ripper Circuits - (if equipped) Understanding Results of Test
WARNING: Make sure that everyone is clear 1. If the flow indication for each circuit was
of the ripper prior to proceeding. approximately the same as the flow indication at
the same pressure in Test No. 1 - Equipment
29. Hold the ripper control lever in the LIFT position Pump flow Test, the circuit is good.
and adjust the pressure Load Valve on the 2. If the flow indication for a circuit was more than
Flowmeter as required to keep the pressure at 3.79 L/min (1 gpm) less than the flow indication
138 bar (2000 psi). Adjust the engine speed to at the same pressure in Test No. 1 - Equipment
keep the engine running at 2000 r/min (rpm). Pump Flow Test, there is leakage in that circuit.
check sheet. 3. Leakage in the dozer/ripper circuits can be
caused by:
30. Hold the ripper control lever in the LOWER
position and adjust the pressure Load Valve on A. Damaged or worn packing in one or both
the Flowmeter as required to keep the pressure cylinders in that circuit.
at 138 bar (2000 psi). Adjust the engine speed to B. Damaged or missing O-rings on the plugs or
keep the engine running at 2000 r/min (rpm). circuit relief valve to the work ports in the
Read the flow gauge and write the reading on the control valve.
check sheet.
C. Damaged or worn spool or spool bore in the
31. Open the pressure Load Valve on the Flowmeter. control valve section for that circuit.
Decrease the engine speed and stop the engine.
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D. A ripper circuit can have a circuit relief valve
32. Place the ignition switch in the ON position, place not adjusted to the correct pressure setting or
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the right parking brake lever in the operation worn and damaged.
position. Move the control levers in all directions
to release any pressure in the hydraulic circuits, 4. If the flow indication for all of the circuits was
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place the right parking brake lever in the applied more than 3.79 L/min (1 gpm) less than the flow
position and turn the ignition switch off. indication at the same pressure in Test No. 1 -
Equipment Pump Flow Test, there is leakage at a
33. Tilt the ROPS cab/canopy to gain access to the point common to the entire system.
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hydraulic spool valve. See Section 9008.

A. The main relief valve not adjusted to the
34. Remove the flowmeter return line from the correct pressure setting or the main relief
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reservoir and replace the filler cap. valve begins to open at 205 bar (2973 psi) or a
35. Turn the vacuum pump on. lower pressure, adjust the main relief valve
and do flow test over.
36. Remove the tee fitting from the hydraulic pump
B. Damaged or worn main relief valve. Also
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hose and the equipment control valve.

inspect for damaged or missing O-rings and
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37. Connect the hydraulic pump hose to the seals.

equipment control valve.
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38. Turn the vacuum pump off and remove the hose
from the vent fitting.
39. Install the vent in the reservoir.
40. Lower and secure the ROPS cab/canopy. See
Section 9008.
41. Check the oil level in the reservoir, add oil as
needed. See Section 1002.
42. Start and run the engine at 2000 r/min (rpm) and
hold the blade control in the raise position for 5
seconds. Lower the blade to the ground and stop
the engine.
43. Check for hydraulic leaks, repair as necessary.

Copyright ©
8002-12
Checking for Cylinder Leakage 4. Disconnect the hydraulic line from the cylinder
rod end of the cylinder to be tested and install a
NOTE: The following procedure applies to all plug or cap on the end of the hydraulic line.
hydraulic cylinders except the angle cylinders. The
angle cylinders are designed with a by-pass that 5. Install a hose in the open port to the cylinder rod
allows leakage past the cylinder packing when the end and put the other end of the hose in a
angle cylinder is extended. To check cylinder packing suitable container.
in the angle cylinder, disassemble the angle cylinder 6. Start the engine. Move and hold the hydraulic
according to instructions in Section 8006. control lever to extend the cylinder to be tested.
1. Start the engine and extend the cylinder rod on 7. If the cylinder packing is leaking, oil will flow from
the cylinder to be checked to its maximum stroke. the open port on the rod end of the cylinder.
2. Stop the engine.
3. Place the ignition switch in the ON position, place
the right parking brake lever in the operation
position. Move the control levers in all directions
to release any pressure in the hydraulic circuits,
place the right parking brake lever in the applied
position and turn the ignition switch off.
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8002-13
FLOWMETER CHECK SHEET METRIC MEASURE

Owner _____________________________________Date______________________Hours______________
Model_________________________ Product Identification Number__________________________________
Oil Temperature: At start of test ________________________ ° C. At end of test ________________________° C.
Test No. 1 - Equipment Pump Efficiency
1. _______________ L/min at minimum pressure at 2000 r/min
2._________________ L/min at 138 bar at 2000 r/min
The efficiency of the equipment pump is line 2 divided by line 1.
Example: .88 .88 = 88% efficient

87 ÷ 98.00
Test No. 2 - Dozer/Ripper Circuits and Load Sense Relief Valve
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Load Sense relief valve begins to open at__________________ bar.
Load Sense relief valve completely open at ________________ bar. See Specifications on page 3.
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NOTE: This pressure will be the load sense pressure plus the Delta P of 8 bar.
Engine Speed 2000 r/min

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Dozer Lift ____________________ L/min at 138 bar Tilt Right ____________________ L/min at 138 bar
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Dozer Lower _________________ L/min at 138 bar Tilt Left _____________________ L/min at 138 bar
Angle Right __________________ L/min at 138 bar Ripper Lift ___________________ L/min at 138 bar
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Angle Left ___________________ L/min at 138 bar Ripper Lower ________________ L/min at 138 bar
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8002-14
FLOWMETER CHECK SHEET U. S. MEASURE

Owner _____________________________________ Date _____________________ Hours ______________
Model ________________________ Product Identification Number __________________________________
Oil Temperature: At start of test_________________________° F. At end of test ________________________ ° F.
Test No. 1 - Equipment Pump Efficiency
1._______________ gpm at minimum pressure at 2000 rpm
2.________________ gpm at 2000 psi at 2000 rpm
The efficiency of the equipment pump is line 2 divided by line 1.
Example: .88 .88 = 88% efficient

23 ÷ 26.00
Test No. 2 - Dozer/Ripper Circuits and Load Sense Relief Valve
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Load Sense relief valve begins to open at __________________ psi.
Load Sense relief valve completely open at _________________ psi. See Specifications on page 3.
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NOTE: This pressure will be the load sense pressure plus the Delta P of 120 psi.
Engine Speed 2000 rpm

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Dozer Lift ___________________ gpm at 2000 psi Tilt Right ____________________ gpm at 2000 psi
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Dozer Lower _________________ gpm at 2000 psi Tilt Left______________________ gpm at 2000 psi
Angle Right __________________ gpm at 2000 psi Ripper Lift ___________________ gpm at 2000 psi
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Angle Left ___________________ gpm at 2000 psi Ripper Lower _________________ gpm at 2000 psi
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Copyright ©
Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM
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8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDROSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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8003-3
SPECIAL TOOLS
806128
CAS-10508, fitting kit.
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806127
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CAS-101162A, filter unit, portable. PR
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TR98H032
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CAS-10192, vacuum pump.

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Copyright ©
8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check the
hydraulic system permits efficient operation with a hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
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these problems.
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TYPES OF CONTAMINATION
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There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
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the hydraulic oil. A. Particles of metal or dirt in the oil.

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2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e D. The oil has an odor of burned oil.
problems:
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E. Water in the oil. See page 7.

A. Cylinder rod seal leak.
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B. Control valve spools do not return to

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NEUTRAL.
C. The hydraulic system has a high operating
temperature.
HYDROSTAT
The hydrostat uses a third port bypass filter system.
If the filter becomes plugged it bypasses back to the
reservoir to stop contamination from entering the
hydrostat system. Upon completion of cleaning the
hydraulic system replace the hydrostat filter.

Copyright ©
8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
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See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
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the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
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operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
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B. Do steps 5 through 35. B. Return the blade control lever in the

5. Check the amount of contamination in the NEUTRAL position for five seconds.
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hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
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necessary.
18. Operate each hydraulic circuit to completely
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B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
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and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
19. Decrease the engine speed to low idle.
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
22. Stop the engine.
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

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8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic and hydrostat filter
reservoir filler neck and replace filler cap. elements from the machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic and hydrostat filter elements
the hydraulic reservoir. on the machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic and hydrostat filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.
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8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
17. Start the engine and run the engine at low idle.
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
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reservoir. 19. Support any attachments that will be in the
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5. Drain the hydraulic oil from the reservoir. RAISED position.
A. The reservoir holds approximately 20 U.S. 20. Stop the engine.

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gallons (75.7 litres) of hydraulic oil. 21. Disconnect the drain lines and connect the
B. Have available acceptable equipment to drain system lines to the cylinders.
the hydraulic oil. 22. Check the oil level in the hydraulic reservoir. Add
o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
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C. Remove the drain plug from the bottom of the

reservoir. specifications.
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6. Remove the hydraulic and hydrostat filter 23. Install the filler cap on the reservoir.
elements from the machine. 24. Remove the hydraulic and hydrostat filter
7. Install new hydraulic and hydrostat filter elements from the machine.
elements on the machine. 25. Install new hydraulic and hydrostat filter
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8. Install the drain plug in the bottom of the elements on the machine.
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reservoir. 26. Start and run the engine at 1500 rpm (r/min),
operate each hydraulic circuit to completely
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9. Fill the hydraulic reservoir with 20 U.S. gallons

(75.7 litres) of Case TCH Fluid. extend and retract the cylinders.
10. Disconnect the line from the OPEN end and 27. Stop the engine and check for leaks. Check the
CLOSED end of each cylinder. oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
11. Be sure all control levers are in the NEUTRAL
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.

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8003-8
NOTES
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Section
8004
8004
HYDRAULIC PUMP
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8004-2
TABLE OF CONTENTS
SPECIFICATIONS PUMP WITH PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP WITH PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EQUIPMENT PUMP WITHOUT PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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8004-3
SPECIFICATIONS PUMP WITH PTO

Manufacturer..................................................................................................................................................... Parker
Equipment pump output ................................................................. 76.8 L/min at 20 680 kPa, 207 bar, at 2000 r/min
(20.3 U.S. gpm at 3000 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Air vent ............................................................................................................................. 9 Nm (80 pound-inches)
Pump housing bolts.........................................................................................................271 Nm (200 pound-feet)
PTO shaft retainer ...............................................................................................................68 Nm (50 pound-feet)
Set screw PTO shaft retainer ........................................................................................... 9 Nm (80 pound-inches)
Shaft cover screws ........................................................................................... 8 to 9 Nm (67 to 77 pound-inches)
Wear Tolerances........................................................................................................... See Inspection in this section
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 3. Hold the blade control lever in the TILT position
or overhauled equipment pump: for five seconds. Then put the blade control lever
in the NEUTRAL position for five seconds.
1. Start and run the engine at half throttle for three
minutes. 4. Repeat Step 3 for three minutes.
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2. With the engine running at half throttle, move the 5. Increase the engine speed to full throttle and
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blade control lever into a TILT position. Hold the repeat Steps 3 and 4.
blade control lever in this position until the blade
6. Stop the engine and check for leaks.
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stops moving.
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8004-4
EQUIPMENT PUMP WITH PTO
Disassembly STEP 4
STEP 1
Clean the equipment pump in cleaning solvent.
STEP 2
BD02E040
Make alignment marks on the drive end cover, the

gear housing, and the thru-drive housing so that you
will be able to assemble the parts correctly later.
STEP 5
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BD02E034
.Put the equipment pump in a vise with protective jaw
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caps.
STEP 3
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BD02E035
Remove the PTO shaft cover.

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STEP 6
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BD02E039
Remove the air vent.

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BD02E037
Remove the bolts and washers.

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8004-5
STEP 7 STEP 10
BD02E041 BD02E064
Loosen the two set screws, one on each side of Use a pry bar to remove the shaft seal from the
thru-drive housing. bearing retainer.
STEP 8
STEP 11
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BD02E042
Using a suitable tool, remove the bearing retainer.

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BD02E043
Use a soft hammer to loosen the thru-drive housing

STEP 9 from the gear housing.
STEP 12
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BD02E062
Remove the O-ring from the bearing retainer.

BD02E044
Remove the thru-drive housing.

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8004-6
STEP 13 STEP 16
BD02E075 BD02E050
Remove the wear plate from the gear housing. Remove the gear housing.
STEP 14 STEP 17
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BD02E045 BD02E070
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Remove the driven gear. Remove O-rings from both sides of gear housing.
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STEP 15
STEP 18
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BD02E046
Remove the drive gear.

BD02E052
Remove the wear plate from the drive end cover.

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8004-7
STEP 19 STEP 22
BD02E053 BD02E087
Remove the retaining ring for the seal retainer from Remove the O-ring from the seal retainer.
the drive end cover.
STEP 20
STEP 23
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BD02E084
BD02E054
Use a pry bar to remove the shaft seal from the seal
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Use a pry bar to remove the shaft seal from the drive
retainer.
end cover.
STEP 21 STEP 24
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BD02E086
Use a slide puller to remove seal retainer. BD02E081
Remove the shaft from the thru-drive housing.

NOTE: Use a brass drift small enough to clear
internal splines in shaft.

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8004-8
Inspection 5. .Inspect the ends, bearing shaft area and teeth of

each gear for scoring. If the scoring is excessive
1. Discard shaft seals, wear plates and O-rings. use a new pump.
2. Clean the remaining parts in cleaning solvent.
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3. Check all machined surfaces for damage. Use
fine emery cloth to remove any minor damage.
4. Inspect the bearings in the drive end cover and
the thru-drive cover. If any bearings are worn
excessively, use a new pump.
2
BD02E091
1 1. DRIVE GEAR 2. DRIVEN GEAR

6. Inspect the pockets in the gear housing for
grooves, pitting, and other damage. If there is
severe damage, use a new pump.
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1. THRU-DRIVE HOUSING BEARINGS

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BD02E092
1. GEAR POCKETS
7. Inspect thru shaft bearings for scoring, if scored,
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replace the thru shaft assembly.

BD02E083
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1. DRIVE HOUSING BEARINGS

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BD02E093

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8004-9
Assembly STEP 27
STEP 25
BD02E067
Using a suitable driver install a new seal in the seal

BD02E065
retainer. Install a new O-ring on the seal retainer.
Using a suitable driver install a new seal in the NOTE: The seal must be pressed flush with the
bearing retainer. Install a new O-ring on the bearing counter bore with lip of seal away from pump gears.
retainer.
STEP 28
STEP 26
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BD02E069
BD02E066
1. TAPERED SIDE OF RETAINER
Using a suitable driver install a new seal in the drive
Use a light coat of grease to lubricate the O-ring and
end cover.
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seal. Install the seal retainer with the tapered side

NOTE: The seal must be pressed flush with face of down.
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the recess with lip of seal towards pump gears.

STEP 29
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BD02E068
Use a suitable driver to seat the seal retainer.

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8004-10
STEP 30 STEP 33
BD02E085 BD02E092
Install the retaining ring. Install new O-rings on both sides of the gear housing.
STEP 31 STEP 34
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BD02E072 BD02E074
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1. OIL GROOVES 2. VENT HOLE Apply a thin layer of grease on both faces of the gear
housing. Install the gear housing.
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Install a new wear plate with bronze side up. Make

sure the oil grooves are facing to the right while
looking at the pump from the vent side of the drive STEP 35
cover.
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1. OIL GROOVES
Install a new wear plate with bronze side towards
BD02E073 gears. Make sure the oil grooves are facing to the
Use clean oil to lubricate pump gears and shafts. right while looking at the pump from the vent side of
Install drive and driven gears into drive cover. the drive cover.

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8004-11
STEP 36 STEP 38
BD02E077 BD02E042
Install the thru-drive housing. Use a thin coat of grease to lubricate the O-ring and
seal. Install the bearing retainer, use a suitable tool
STEP 37 and torque the retainer 68 Nm (50 pound-feet).
STEP 39
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Install the thru shaft.

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BD02E079
Install and torque the bearing retainer set screws

9 Nm (80 pound-inches).
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8004-12
STEP 40 STEP 42
BD02E038 BD02E080
Install and torque the housing bolts 271 Nm Install and torque the vent.
(200 pound-feet).
STEP 41
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Install and torque thru shaft cover.

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8004-13
EQUIPMENT PUMP WITHOUT PTO
Disassembly STEP 6
Put alignment marks across the gear (7 and 8) shafts
STEP 1 and the housing (9) to aid assembly. Remove gears
Remove all dirt, oil, and grease from the exterior of (7 and 8) and housing (9).
the equipment pump.
STEP 7
STEP 2 Remove and discard seals (10 and 11) and thrust
Put alignment marks on the closed end cover (3), plate (12).
housing (9) and shaft end cover (19) to aid assembly.
STEP 8
STEP 3 Put shaft end cover (19) in a soft jawed vise with the
Put the equipment pump in a soft jawed vise with the retaining ring (13) facing upward. Remove retaining
closed end cover (3) facing upward. ring.
STEP 4 STEP 9
Remove the four bolts (1) and washers (2). Remove Remove retainer (14) with O-ring (15) and oil seal
closed end cover (3). (16) installed. Remove and discard O-ring and oil
seal. If necessary, put retainer in soft jawed vise
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taking care not to overtighten vise and damaging
STEP 5
retainer. Then, use suitable tool and pry oil seal from
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Remove and discard seals (4 and 5) and thrust plate bore of retainer. Discard oil seal.
(6).
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17 11
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BS00H032
1. BOLT 6. THRUST PLATE 11. SEAL 16. OIL SEAL

2. WASHER 7. DRIVEN GEAR 12. THRUST PLATE 17. SEAL
3. CLOSED END COVER 8. DRIVE GEAR 13. RETAINING RING 18. PLUG
4. SEAL 9. HOUSING 14. RETAINER 19. SHAFT END COVER
5. SEAL 10. SEAL 15. O-RING

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8004-14
Inspection STEP 15
Check the inside diameter of the bushings in the
STEP 12 closed end cover (3) and shaft end cover (19) for
Clean all parts in cleaning solvent. Be careful not to s c o r i n g . I f bu s h i n g s a r e s c o r e d r e p l a c e t h e
remove the alignment mar ks made dur ing associated cover.
disassembly.
STEP 16
STEP 13 Inspect gears (7 and 8) for cracked, broken, or
Check all machined surfaces for damage. Use fine chipped gear teeth. Check splines on drive gear (8)
emery cloth to remove minor damage. shaft for cracks, breaks, chipping, or twisted
condition. Replace if any defects are observed.
STEP 14
Hold a straight edge across the gear housing (9)
pocket and use a feeler gauge to measure the
amount of wear caused by the gear teeth in the gear
pocket. If the wear in any gear pocket is more than
0.18 mm (0.007 inch), use a new gear housing or
replace the pump.
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17 11
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BS00H032
1. BOLT 6. THRUST PLATE 11. SEAL 16. OIL SEAL

2. WASHER 7. DRIVEN GEAR 12. THRUST PLATE 17. SEAL
3. CLOSED END COVER 8. DRIVE GEAR 13. RETAINING RING 18. PLUG
4. SEAL 9. HOUSING 14. RETAINER 19. SHAFT END COVER
5. SEAL 10. SEAL 15. O-RING

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8004-15
Assembly STEP 24
Put housing (9) with seals (10 and 11) and thrust
STEP 17 plate (12) installed on shaft end cover (19) making
Install the two plugs (18) in the shaft end cover (19). sure alignment marks made during disassembly are
aligned.
STEP 18
STEP 25
Put the shaft end cover (19) in a vise with the
retaining ring end upward. Use clean oil to lubricate the drive gear (8). Install
drive gear using care not to damage lips of seal (17).
STEP 19
STEP 26
Install a new seal (17) in the bore of the shaft end
cover (19). Press the seal flush with face of recess in Use clean oil to lubricate the driven gear (7). Install
cover with lip of seal towards inside of cover. the driven gear. Make sure the alignment marks
made during disassembly are aligned.
STEP 20
STEP 27
Install new oil seal (16) in retainer (14) flush with bore
of retainer with seal lip towards inside of retainer Put new thrust plate (6) on housing (9). Install new
(away from gear). seal (5) on thrust plate and new seal (4) in groove in
housing. If necessary, use petroleum jelly to hold
seal in position on housing.
STEP 21
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Install new O-ring (15) in groove of retainer (14).
STEP 28
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Install closed end cover (3) on housing (9).
STEP 22
Install assembled retainer (14) in shaft end cover (19)
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STEP 29
and secure with retaining ring (13).
Install four washers (2) and bolts (1). Tighten bolts
evenly to a torque of 271 Nm (200 lb-ft).
STEP 23
Put new thrust plate (12) on side of housing (9) that
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mates with shaft end cover (19). Install new seal (11)
on thrust plate. Install new seal (10) on housing. If
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necessary, use petroleum jelly to hold seal in position

on housing.
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8004-16
NOTES
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Section
8005
EQUIPMENT CONTROL VALVE
8005
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8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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8005-3
SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
Special Torques
End plate mounting nuts...................................................................................................... 37 Nm (27 pound feet)
Electro-hydraulic valves................................................................................................ 12 Nm (106 pound inches)
Plugs M18 X 1.5 .................................................................................................................. 60 Nm (44 pound feet)
Pre-charge valve ................................................................................................................. 60 Nm (44 pound feet)
Allen head cover screws................................................................................................... 6 Nm (53 pound inches)
Compensator spool plug ................................................................................................... 100 Nm (74 pound feet)
Circuit relief valves .............................................................................................................. 90 Nm (66 pound feet)
Check valve ......................................................................................................................... 60 Nm (44 pound feet)
Load sense relief valve........................................................................................................ 20 Nm (15 pound feet)
Plug M22 X 1.5.................................................................................................................... 60 Nm (44 pound feet)
Main pressure relief valve ................................................................................................. 100 Nm (74 pound feet)
Plug M33 X 1.5............................................................................................................... 120 Nm (88.5 pound feet)
Main Relief Valve Pressure.....................................................................................208 to 213 bar (3015 to 3089 psi)
Load Sense Pressure .............................................................................................163 to 168 bar (2365 to 2437 psi)
Circuit Relief Valves
A and B Ports Ripper.............................................................. 238 to 243 bar (3450 to 3524 psi) with Hand Pump
A and B Ports Angle Circuit.................................................... 400 to 405 bar (5800 to 5875 psi) with Hand Pump
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8005-4
4 5
1
2
3
6
7
27
26
25 8
6
7 9
6 10
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26
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6
9
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26
25
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14
24
15
23 6
16
12
17
22
18
21 20 19
BS06J149

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8005-5
1. NUT M8 8. HOUSING SECTION RIPPER 15. PLUG M33 X 1.5 22. LOAD SENSE RELIEF
2. WASHER 9. COMPENSATOR SPOOL 16. SLEEVE 23. CHECK VALVE
3. STUD M8 X 120 10. PLUG M22 X 1.5 17. SPRING 24. PRE-CHARGE VALVE
4. END PLATE 11. HOUSING SECTION ANGLE 18. UNLOADING SPOOL 25. CONE
5. HYDRAULIC VALVE FTDRE4 12. PLUG MHDB16 19. UNLOADING ORIFICE 26. SPRING
6. O-RINGS 13. LOAD SENSE REGULATOR 20. HOUSING TILT AND LIFT 27. PLUG M18 X 1.5
7. CIRCUIT RELIEF VALVE 14. MAIN RELIEF VALVE 21. PLUG M22 X 1.5
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8005-6
28 29 30 31
6
8
31
32
33
30
29
11 6
34 31
44
29 30
6
35
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30 40
6 37
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BS06J150
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6. O-RINGS 28. RIPPER SPOOL 34. LIFT SPOOL 40. SPRING RETAINER
8. HOUSING SECTION RIPPER 29. RETAINER 35. TILT SPOOL 41. ADJUSTING SCREW
9. COMPENSATOR SPOOL 30. SPRING 36. HYDRAULIC VALVE FTDRE4 42. COVER
10. PLUG M22 X 1.5 31. RETAINER 37. HYDRAULIC VALVE FTDRE2 43. SCREW
11. HOUSING SECTION ANGLE 32. ANGLE SPOOL 38. SCREW M5 X 80 44. RING
20. HOUSING TILT AND ANGLE 33. SPRING 39. BLOCK COVER

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8005-7
37
46 47
43
45
6
41
8 11
41
42 6 30
29
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BS06J148
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6. O-RINGS 30. SPRING 42. COVER

8. HOUSING SECTION RIPPER 32. ANGLE SPOOL 43. SCREW
11. HOUSING SECTION ANGLE 37. HYDRAULIC VALVE FTDRE2 45. COVER
28. RIPPER SPOOL 40. SPRING RETAINER 46. LOCK NUT
29. RETAINER 41. ADJUSTING SCREW 47. NUT HEX

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8005-8
DISSASEMBLY
STEP 1 STEP 11
Remove valve from machine, see section 8001. Remove load sense relief valve (22).
STEP 2 STEP 12
Remove bolts (43), covers (42 and 45), springs (30), Remove plug (21).
and spring retainers (29, 31, and 40).
STEP 13
STEP 3 Remove check valve (23).
Remove bolts (38), cover (39), springs (30 and 33),
and spring retainers (29 and 31). STEP 14
Remove pre-charge valve (24).
STEP 4
Use wooden dowel and push spools (28, 32, 34, and STEP 15
35) from housings (8, 11, and 20). Attach tags to the Remove plug (27), spring (26), and cone (25).
spools to which bore they were removed for proper
assembly.
STEP 16
IMPORTANT: Do not force spools from housing, if Remove hydraulic valves (5, 36, and 37).
spool binds work back and forth until spool comes
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out freely. STEP 17
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Remove nuts (1) and washers (2), remove end plate
STEP 5 (4).
Remove circuit relief valves (7).
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STEP 18
STEP 6 If equipped remove ripper housing (8).
Remove plug (10) and compensator (9).
STEP 19
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STEP 7 Remove angle housing (11).

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Remove main relief valve (14).

STEP 20
STEP 8
Remove load sense regulator (13). 2
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STEP 9
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Remove plug (15), sleeve (16), spring (17), plug (21).

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STEP 10 1
Use wooden dowel and push the unloading spool
(18) from housing (20).
IMPORTANT: Do not force spool from housing, if
spool binds work back and forth until spool comes
out freely. BS03C025
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from
load sense relief valve (22).

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8005-9
STEP 21 STEP 22
2
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2
1
1
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BS03C026 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
load sense regulator valve (13). plug (12).
STEP 23
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BS03C029

Remove and discard O-rings and thrust rings from main pressure relief valve (14).

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8005-10
STEP 24
3
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BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

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Remove and discard O-rings and thrust rings from circuit relief valves (7).
INSPECTION
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1. Discard all O-rings, thrust rings, and spool seals. 3. Check the spools and the spool bores for
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damage and wear.

NOTE: If the O-rings for the adjusting screws are not
leaking do not remove the adjusting screws, if they 4. Check the parts of the pressure relief valve,
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must be removed make a note of the number of turns anticavitation valves, and the anticavitation and
required to remove them. circuit relief valves. Use new parts as necessary.
2. Clean all parts in cleaning solvent. Inspect the other parts of the control valve. If any of
the parts are damaged, install new parts.

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8005-11
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
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BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on the circuit relief valves (7). Torque relief valve (A) into valve to 200 Nm
(147.5 pound feet).
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NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in
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direction of arrow.
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8005-12
STEP 2
1
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BS03C029

Install new O-rings and thrust rings on main pressure relief valve (14).
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STEP 3 STEP 4
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BS03C025 BS03C026
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RINGS

Install new O-rings and thrust rings on load sense Install new O-rings and thrust rings on load sense
relief valve (22). regulator valve (13).

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8005-13
STEP 5 STEP 15
Install main relief valve (14) and torque to 100 Nm
(74 pound feet).
1
STEP 16
2 Install compensators (9) and plugs (10) and torque
plugs to 100 Nm (74 pound feet).
1
STEP 17
Install circuit relief valves (7) and torque to 90 Nm
(66 pound feet).
BS03C027 STEP 18
1. O-RINGS 2. THRUST RING Lubricate unloading spool (18) with hydraulic oil and
Install new O-rings and thrust ring on plug (12). push into housing (20).
IMPORTANT: Do not force spool into housing.
STEP 6
Install new O-rings on housing (20) and install the STEP 19
angle section (11). Install plug (21), spring (17), sleeve (16), and plug
(15). Torque plug 21 to 60 Nm (44 pound feet),
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STEP 7 torque plug (15) to 120 Nm (88.5 pound feet).
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If equipped, install new O-rings on housing (11) and
install the ripper section (8). STEP 20
Lubricate spools with hydraulic oil and push spools
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STEP 8 (34 and 35) into housing (20).
Install new O-rings on housing (8 or 11), install end IMPORTANT: Do not force spools into housing.
plate (4), washers (2), and nuts (1). Torque nuts to 37
Nm (27 pound feet).
STEP 21
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STEP 9 Install ring (44), spring retainers (40), spr ing

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retainers (29), springs (30), spring (33), retainer (31),

Install cone (25), spring (26), and plug (27). Torque
covers (42), and screws (43). Torque screws to 6 Nm
plug to 60 Nm (44 pound feet).
(53 pound inches).
STEP 10 STEP 22
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Install and torque pre-charge valve (24) to 60 Nm

Install block cover (39) and screws (38), and torque
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(44 pound feet).

screws to 6 Nm (53 pound inches).
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STEP 11 STEP 23
Install and torque check valve (23) to 60 Nm
Lubricate spools with hydraulic oil and push spools
(44 pound feet).
(if equipped 28 and 32) into housing (if equipped 8
and 11).
STEP 12
IMPORTANT: Do not force spools into housing.
Install and torque load sense relief valve (22) to
20 Nm (15 pound feet).
STEP 24
STEP 13 Install spring retainers (40), spring retainers (29),
springs (30), covers (42), and screws (43). Torque
Install plugs (12) and tighten.
screws to 6 Nm (53 pound inches).
STEP 14
STEP 25
Install load sense regulator (13) and tighten.
Install covers (45), and bolts (43). Torque bolts to 6
Nm (53 pound inches).

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8005-14
STEP 26 Circuit Relief Pressure Test
Install and torque hydraulic valves (5, 36 and 37) to
12 Nm (106 pound inches). STEP 1
Connect the hand pump to the port for circuit relief
STEP 27 valves (7).
Install valve in machine, see section 8001.
STEP 2
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 3
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 4
Compare the reading to the specifications on Page 3.
STEP 5
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If the pressure is not correct, adjust the circuit relief
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valve.
Circuit Relief Adjustment

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STEP 1
Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
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counterclockwise to decrease the pressure.

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STEP 2
Check the pressure again. Repeat the adjustment as
necessary.
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Section
8006
CYLINDERS
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8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALL CYLINDERS EXCEPT THE RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lift Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tilt Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Angle Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Cylinder Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING BUSHINGS FOR TYPICAL CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ripper Cylinder Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REPLACING BUSHINGS FOR THE RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ripper Cylinder Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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8006-3
SPECIFICATIONS
Torque for tilt, angle, and lift piston bolts ...................................................... 1600-1830 Nm (1180-1350 pound-feet)
Torque for ripper piston bolts ........................................................................ 1355-1627 Nm (1000-1200 pound-feet)
Torque for all glands ............................................................................................. 135-542 Nm (100-400 pound-feet)
NOTE: Torque piston bolt with Loctite 242 on threads.
SPECIAL TOOLS
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B795329M
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B786441M
CAS1039 Torque Multiplier
CAS1456 Gland Wrench
This tool is used to loosen and tighten the piston
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This tool is used to remove and install the gland
bolts.
on the cylinders.
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B505802M
1. CAS1660 For 32 and 38 mm (1-1/4 and 1-1/2

Inch) Rods
2. CAS1758 For 51 mm (2 Inch) rods
This tool is used to install the buffer seal in the glands
of the cylinders.

Copyright ©
8006-4
ALL CYLINDERS EXCEPT THE RIPPER CYLINDER
Clean the outside of the cylinder. If hoses were 1. Discard the parts that were removed from the
removed with the cylinder, remove the hoses from piston and the gland.
the cylinder.
2. Clean all parts in cleaning solvent.
1. Fasten the tube (1) in a vise or other holding
3. Check to be sure that the piston rod is straight. If
equipment. Do not damage the tube (1).
the piston rod is not straight, install a new piston
2. Loosen and remove the lock screw (2) from the rod.
gland (3) and the tube (1).
4. Illuminate the inside of the tube. Inspect the
3. Use the gland wrench to loosen and remove the inside of the tube for deep grooves and other
gland (3) from the tube (1). damage. If there is any damage to the tube, a
new tube must be used.
4. Pull the piston rod (4) straight out of the tube (1)
to prevent damage to the tube (1). 5. Remove small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
5. Fasten the piston rod eye in a vise and put a
Use the emery cloth with a rotary motion.
support under the piston rod (4) near the piston
(5). Put a shop cloth between the support and 6. Inspect the bushings in the piston rod eye and
the piston rod (4) to prevent damage to the piston the tube, and replace the bushings as required.
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rod (4).
7. Inspect the gland for rust, clean and remove rust
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6. Loosen and remove the bolt(6) and washer (7) as necessary.
that hold the piston (5) to the piston rod (4). Use
8. Inspect the gland end of the tube for sharp edges
the torque multiplier for bolts that have a high
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th at w ill cu t th e g lan d O -r ing , r em ove a s
torque value.
necessary.
7. Remove the piston (5) from the piston rod (4).
9. Inspect the piston for damage and wear. If the
8. Remove the gland (3) from the piston rod (4). piston is damaged or worn, a new piston must be
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used.
9. For the lift and tilt cylinders. Remove the wear
ring (10), seal (8), and ring (9) from the piston
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(5).
10. For the angle cylinder. Remove the wear ring (9)
and seal (8) from the piston (5).
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11. Remove the O-ring (11) and backup ring (12)

from outside of gland (3). Remove the buffer seal
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(14), rod seal (15), bushing (16), and wiper (13)

from inside the gland.
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8006-5
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BC06B027
1. TUBE 6. BOLT 11. O-RING 16. BUSHING
2. LOCK SCREW 7. WASHER 12. BACKUP RING 17. BUSHING
3. GLAND 8. SEAL 13. WIPER 18. GREASE FITTING
4. PISTON ROD 9. RING 14. BUFFER SEAL
5. PISTON 10. WEAR RING 15. ROD SEAL
LIFT CYLINDER EXPLODED VIEW

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8006-6
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BC06B028
3. GLAND 8. SEAL 13. WIPER 18. SNAP RING
4. PISTON ROD 9. RING 14. BUFFER SEAL 19. GREASE FITTING
5. PISTON 10. WEAR RING 15. ROD SEAL 20. O-RING
TILT CYLINDER EXPLODED VIEW

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8006-7
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BC06B026
4. PISTON ROD 9. WEAR RING 14. BUFFER SEAL 19. GREASE FITTING
5. PISTON 10. PLUG 15. ROD SEAL 20. O-RING
ANGLE CYLINDER EXPLODED VIEW

Copyright ©
8006-8
Assembly 15. Install the bolt (6) and torque to 1600-1830 Nm

(1180-1350 pound-feet). A torque multiplier can
NOTE: If a new gland is being used, put the part be used to help tighten the bolt.
number of the cylinder on the new gland.
16. For the tilt and lift cylinder. Install a new ring (9)
1. Install the rod seal (15) in the gland (3). If both in the groove on the outside of the piston (5). See
sides of the rod seal are not flat, the lips of the the illustration on the following page.
rod seal (15) are toward the small end of the
gland (3). 17. For the tilt and lift cylinder. Install a new seal (8)
on top of the ring (9) on the outside of the piston
2. Install the buffer seal (14) in the gland (3). If both (5).
sides of the buffer seal are not flat, the side of the
buffer seal (14) with the groove must be toward 18. For the angle cylinder. Install a new seal (8) on
the small end of the gland (3). the outside of the piston.
3. Install the new bushing (16) into the gland (3). 19. Install a new wear ring (10) in the groove on the
outside of the piston (5).
4. Press a new wiper (13) into the gland (3). The
lips of the wiper (13) must be toward the outside 20. Fasten the tube (1) in a vise or other holding
end of the gland (3). equipment. Be careful to prevent damage to the
tube (1).
5. Install a new backup ring (12) in the groove on
the outside of the gland (3). If both sides of the 21. Lubricate the inside of the tube (1) and the piston
backup ring (12) are not flat, the side that is not (5) with clean oil.
flat must be toward the small end of the gland
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22. Push the piston (5) straight into the tube (1).
(3).
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23. Lubricate the O-ring (11) on the gland (3) with
6. Install the O-ring (11) next to the backup ring (12) clean oil.
in the groove on the outside of the gland (3). The
24. When the piston (5) is in the smooth part of the
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O-ring (11) must be toward the small end of the
gland (3). tube (1), start the gland (3) into the tube (1).
7. Fasten the piston rod eye in the vise. 25. Install the gland (3) and torque to 135-542 Nm
(100-400 pound-feet). If the lock screw (2) holes
8. Remove any marks and sharp edges on the become aligned, install the lock screw (2).
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chamfer at the end of the piston rod (4). Make Tighten the lock screw (2). If the lock screw (2)
sure that the piston rod (4) is clean.
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holes are not aligned, do steps 26 through 27.

9. Lubricate the bore of the gland (3) and the piston 26. Install the gland (3) and torque to 135-542 Nm
rod (4) with clean oil. (100-400 pound-feet). Use a No. 26 drill and drill
10. Push the gland (3) onto the piston rod (4). If a hole half in the gland (3) and half in the tube
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necessary, use a soft hammer to drive the gland (1). Drill to a depth of 11 mm (7/16 inch). Do not
(3) onto the piston rod (4). drill in line with a hole in the gland (3) for the
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gland wrench.
11. Put a support below and near the end of the
27. Install the lock screw (2). Tighten the lock screw.
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piston rod (4). Use a shop cloth between the

support and the piston rod (4) to prevent damage 28. If the hoses were removed with the cylinder,
to the piston rod (4). install new O-rings, if equipped, on the hose
12. Put the piston (5) on the end of the piston rod (4). fittings. Lubricate the O-rings with clean oil.
Install the hoses.
13. Put the washer (7) on the bolt (6).
14. Clean the threads on the end of the piston rod (4)
and the threads of the bolt (16) using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 6.35mm (1/4 inch) from
the open end of the piston rod (4) so that there is
12.7mm (1/2 inch) of Loctite on the piston rod
threads. DO NOT apply Loctite to the first
6.35mm (1/4 inch) of the piston rod threads.

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8006-9
15
19 2
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ROD END OF CYLINDER
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CLOSED END OF CYLINDER

BC06B023
4. PISTON ROD 9. BACKUP RING 14. BUFFER SEAL 19. GREASE FITTING
5. PISTON 10. WEAR RING 15. ROD SEAL
TYPICAL CYLINDER SECTIONAL VIEW

Copyright ©
8006-10
REPLACING BUSHINGS FOR TYPICAL CYLINDERS

1. If bushing are held in with a snap ring remove the 5. If the bushing is pressed in start the new bushing
snap ring and bushing. into the bore.
2. If bushings are pressed in use a press and an 6. Use the press and an acceptable driver and
acceptable driver and press the bushings out of press the bushing into the bore until the bushing
the bore. is flush with the outside of the piston rod eye or
tube.
3. Clean the bore for the bushing.
NOTE: When two bushings are used in the same
4. If bushings are held in with a snap ring install the
bore, pressing a bushing in too far can close the
bushing and the snap ring.
passage to the grease fitting.
RIPPER CYLINDER
Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the hoses piston and the gland.
from the cylinder.
2. Clean all parts in cleaning solvent.
1. Fasten the tube (1) in a vise or other holding
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3. Check to be sure that the piston rod is straight. If
equipment. Do not damage the tube (1).
the piston rod is not straight, install a new piston
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2. Loosen and remove the lock screw (2) from the rod.
gland (3) and the tube (1).
4. Illuminate the inside of the tube. Inspect the
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3. Use the gland wrench to loosen and remove the inside of the tube for deep grooves and other
gland (3) from the tube (1). damage. If there is any damage to the tube, a
new tube must be used.
4. Pull the piston rod (4) straight out of the tube (1)
to prevent damage to the tube (1). 5. Remove small scratched on the piston rod or
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inside the tube with emery cloth of medium grit.

5. Fasten the piston rod eye in a vise and put a
Use the emery cloth with a rotary motion.
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support under the piston rod (4) near the piston

(5). Put a shop cloth between the support and 6. Inspect the bushings in the piston rod eye and
the piston rod (4) to prevent damage to the piston the tube, and replace the bushings as required.
rod (4).
7. Inspect the gland for rust, clean and remove rust
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6. Loosen and remove the bolt (6) and washer (7) as necessary.
that holds the piston (5). Use the torque multiplier
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8. Inspect the gland end of the tube for sharp edges

for bolts that have a high torque value.
th at w ill cu t th e g lan d O -r ing , r em ove a s
7. Remove the piston (5) from the piston rod (4). necessary.
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8. Remove the wear rings (8), seal (10) and piston Inspect the piston for damage and wear. If the piston
ring (9) from the piston (5). is damaged or worn, a new piston must be used.
9. Remove the gland (3) from the piston rod (4).
10. Remove the O-ring (11), backup ring (12), wiper
(13), bushing (14), buffer seal (15), and rod seal
(16) from the gland (3).

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8006-11
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BC06B024
1. TUBE 6. CAP SCREW 11. O-RING 16. ROD SEAL
2. LOCK SCREW 7. HARDENED WASHER 12. BACKUP RING 17. BUSHING
3. GLAND 8. WEAR RING 13. WIPER 18. GREASE FITTING
4. PISTON ROD 9. PISTON RING 14. BUSHING
5. PISTON 10. SEAL 15. BUFFER SEAL
RIPPER CYLINDER EXPLODED VIEW

Copyright ©
8006-12
Assembly 14. Clean the threads on the end of the piston rod (4)
and the treads of the bore (6) using Loctite
NOTE: If a new gland is being used, put the part cleaning solvent. Allow to dry. Apply Loctite 242
number of the cylinder on the new gland. to the piston rod threads 6.35 mm (1/4 inch) from
1. Install the new bushing (14) into the gland (3). the open end of the piston rod so that there is
12.7 mm (1/2 inch) of Loctite 242 on the piston
2. Install the buffer seal (15) in the gland (3). If both
rod threads. DO NOT apply Loctite to the first
sides of the buffer seal are not flat, the lips of the
6.35 mm (1/4 inch) of the piston rod threads.
buffer seal (15) are toward the small end of the
gland (3). 15. Install the bolt (6). Tighten the bolt (6) to
1355-1627 Nm (1000-1200 pound-feet). A torque
3. Install the rod seal (16) in the gland (3). If both
multiplier can be used to help tighten the bolt (9).
sides of the rod seal are not flat, the side of the
rod seal (16) with the groove must be toward the 16. Install a new piston ring (10) in the center groove
small end of the gland(3). on the outside of the piston (5).
4. Press a new wiper (13) into the gland (3). The 17. Install a new seal (9) on top of the piston ring
lips of the wiper (13) must be toward the outside (10) on the outside of the piston (5).
end of the gland (3). 18. Install new wear rings (8) in the grooves on the
5. Install a new backup ring (12) in the groove on outside ends of the piston (5).
the outside of the gland (3). If both sides of the 19. Fasten the tube (1) in a vise or other holding
backup ring (12) are not flat, the side that is not equipment.
flat must be toward the small end of the gland
20. Lubricate the inside of the tube (1) and the piston
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(3).
(5) with clean oil.
6. Install the O-ring (11) next to the backup ring (12)
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21. Push the piston (5) straight into the tube (1).
in the groove on the outside of the gland (3). The
O-ring (11) must be toward the small end of the 22. Lubricate the O-ring (11) on the gland (3) with
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gland (3). clean oil.
7. Fasten the piston rod eye in the vise. 23. When the piston (5) is in the smooth part of the
tube (1), start the gland (3) into the tube (1).
8. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 24. Install the gland (3) and torque to 135-542 Nm
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sure that the piston rod (4) is clean. (100-400 pound-feet). If the lock screw (2) holes
become aligned, install the lock screw (2).
9. Lubricate the bore of the gland (3) and the piston
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Tighten the lock screw (2). If the lock screw (2)

rod (4) with clean oil.
holes are not aligned, do steps 26 through 27.
10. Push the gland (3) onto the piston rod (4). If
25. Install the gland (3) and torque to 135-542 Nm
necessary, use a soft hammer to drive the gland
(100-400 pound-feet).Use a No. 26 drill and drill
(3) onto the piston rod (4).
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a hole half in the gland (3) and half in the tube

11. Put a support below and near the end of the (1). Drill to a depth of 11 mm (7/16 inch). Do not
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piston rod (4). Use a shop cloth between the drill in line with a hole in the gland (3) for the
support and the piston rod (4) to prevent damage gland wrench.
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to the piston rod (4).

26. Install the lock screw (2). Tighten the lock screw.
12. Put the piston (5) on the end of the piston rod (4).
27. If the hoses were removed with the cylinder,
13. Put the hardened washer (7) on the bolt. install new O-rings, if equipped, on the hose
fittings. Lubricate the O-rings with clean oil.
Install the hoses.
REPLACING BUSHINGS FOR THE RIPPER CYLINDER

1. Use a press and an acceptable driver and press 4. Use the press and an acceptable driver and
the bushings out of the bore. press the bushing into the bore until the bushing
2. Clean the bore for the bushing. is flush with the outside of the piston rod eye or
tube.
3. Start the new bushing into the bore.
NOTE: When two bushings are used in the same
bore, pressing a bushing in too far can close the
passage to the grease fitting.

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8006-13
1
11 12
2
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14
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16 1
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7 CLOSED END OF CYLINDER
BC06B025
1. TUBE 6. BOLT 11. O-RING 16. ROD SEAL
3. GLAND 8. WEAR RING 13. WIPER 18. GREASE FITTING
4. PISTON ROD 9. SEAL 14. BUSHING
5. PISTON 10. PISTON RING 15. BUFFER SEAL
RIPPER CYLINDER SECTIONAL VIEW

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8006-14
NOTES
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Section
8010
EQUIPMENT CONTROL VALVE ACCUMULATOR
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8010
Copyright © 2007 CNH Ameica LLC.

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8010-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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8010-3
SPECIFICATIONS
Accumulator Dry Nitrogen Pressure ....................................................................... 10 Bar (145 psi) @ 21° C (70° F)
SPECIAL TOOLS
BS06M002 BC04A001
380001676 NITROGEN REGULATOR VALVE 380001168 ACCUMULATOR VALVE ADDAPTER
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BS06M003
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380001390 ACCUMULATOR CHARGING HOSE

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NOTE: Check your inventory of tools, if you have

nitrogen charging kit CAS10899 use it in place of the
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above listed tools.

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8010-4
CHECKING THE NITROGEN CHARGE ON AN ACCUMULATOR
B C
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BS06M004
NITROGEN CHARGING KIT
1. Use the Nitrogen Charging Kit to check the 5. Remove the valve cap from the accumulator.
accumulator charge, refer to the illustration
6. Install adapter 380001168 onto the accumulator.
above. The tool can be disconnected from the
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nitrogen tank. 7. Connect valve A to the valve stem on the

adapter.
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2. Close valve E.
8. Open valve on accumulator using the adapter’s
3. Adjust the regulator D to the minimum pressure
square drive.
setting by turning the knob counterclockwise.
9. Turn the T-handle inward on valve A to engage
4. Turn the T-handle on valve A fully out.
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the pin in the valve stem on the adapter.

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10. Slowly open valve E.

11. Check the charge pressure on gauge B.
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8010-5
CHARGING THE ACCUMULATOR WITH NITROGEN
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
IMPORTANT: The valves A, D, AND E must be in the positions noted in the procedure before connecting the
Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to the illustration on page 4.
1. Close the shutoff valve D by turning it all the way 11. Fill the accumulator to pressure according to
to the left (counterclockwise), refer to the temperature chart below.
TEMPERATURE CHARGE PRESSURE
2. Close the gauge valve E by turning it all the way 21° C 70° F 10 BAR 145 PSI
to the right (clockwise).
3. Connect the charging gauges to the nitrogen TEMPERATURE/CHARGE PRESSURE CHART
supply tank, open the supply tank valve. 12. Close valve E by turning to the right (clockwise).
4. SLOWLY turn valve D clockwise while watching After a few minutes open valve E and check the
the pressure gauge B. Stop turning valve D when accumulator for leakage.
the needle on the gauge B reaches 10 bar (145 13. Back off the needle valve A on the accumulator
psi). end of the charging hose by tur ning it
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counterclockwise the maximum amount. This will
NOTE: If the needle goes over the needed pressure,
p r eve n t n i t r o g e n f r o m e s c a p i n g f r o m t h e
quickly open and close valve E and check the
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accumulator as the hose is removed.
pressure setting again.
The charging kit is now ready to be installed on the 14. Close the valve on the nitrogen supply tank.
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accumulator. 15. Adjust the regulator D to the minimum pressure
5. Remove the cap from the accumulator. setting by turning the knob counterclockwise.
16. Slowly remove the charging hose from the
6. Loosen the sealing plug with an Allen wrench.
accumulator pressure valve.
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7. Install addapter 380001168.

NOTE: A small amount of nitrogen will escape when
8. Back off the needle valve A on the accumulator
disconnecting the hose.
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end of the charging hose by tur ning it

counterclockwise to the maximum amount. This 17. Snug the sealing plug on the accumulator,
prevents nitrogen from escaping from the remove the addapter from the accumulator.
accumulator when the charging hose is attached 18. Torque the sealing plug to 20 to 25 Nm (15 to
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to the accumulator gas charging valve. 18.5 pound feet)

9. Install the charging hose fitting onto the 19. Install the cap on the accumulator.
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addapter.
20. Remove the charging gauges from the nitrogen
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10. Tighten the needle valve A by turning it supply tank.

clockwise. Slowly open the gauge valve E and
NOTE: A small amount of nitrogen will escape when
observe the reading on the gauge. This reading
disconnecting the hose.
i s t h e n i t r o g e n p r e s s u r e l eve l i n s i d e t h e
accumulator.

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8010-6
NOTES
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SECTION INDEX
MOUNTED EQUIPMENT

Pedals and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001
Air Conditioning Troubleshooting and System Checks For Systems With R-134a Refrigerant . . . . . . . . . . . . .9003
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Removal and Installation of Heater and Air Conditioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005
Air Conditioning Compressor and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9008
Standard and Mechanical Suspension Seats And Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9009
Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
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Copyright ©
9001
Section
9001
PEDALS AND LEVERS
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9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE PEDAL, HAND THROTTLE, FOOT THROTTLE (DECEL PEDAL)
POTENTIOMETER ADJUSTMENT USING THE INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake and Decelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking Brake Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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9001-3
SPECIFICATIONS
Engine Speeds
Low Idle ........................................................................................................................... 800 to 1050 r/min (rpm)
High Idle (Full Throttle - No Load) ................................................................................. 2170 to 2270 r/min (rpm)
BRAKE PEDAL, HAND THROTTLE, FOOT THROTTLE (DECEL PEDAL)

POTENTIOMETER ADJUSTMENT USING THE INSTRUMENT CLUSTER
1. Put the master disconnect switch in the on 9. After moving brake pedal and no error message
position and the ignition switch in the run appears on the instrument cluster press both
position. bu t t o n s fo r o n e s e c o n d a n d r e l e a s e, t h e
instrument cluster will read (CAL HTR).
2. Push and hold both the bump up and bump down
buttons on the directional control. 10. Slowly move the hand throttle from low idle to
high idle two to four times.
3. Start the engine continue to hold the buttons for
5 seconds or until the instrument cluster reads NOTE: During this operation if the instrument cluster
(HP 125-135), release the buttons. reads (ERR RANGE), minimum/maximum values are
machine horse power range, (HP 125-135 or
HP 150 - 160). 11. After moving hand throttle and no error message
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appears on the instrument cluster press both
NOTE: By selecting a different machine will cause
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bu t t o n s fo r o n e s e c o n d a n d r e l e a s e, t h e
the calibration to be incorrect and machine functions
instrument cluster will read (CAL FTR).
to be impaired.
12. Slowly move the foot throttle (Decel Pedal) from
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5. When the machine being calibrated is displayed
high idle to low idle two to four times.
press both buttons for one second and release,
the instrument cluster will read (LT or LGP/WT). NOTE: During this operation if the instrument cluster
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machine track gauge, (LT or LGP/WT).

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7. When the machine being calibrated is displayed During this operation if the instrument cluster reads
press both buttons for one second and release, (ERR SWITCH), the low idle switch is not functioning
the instrument cluster will read (CAL BRK). or is out of adjustment.
8. Slowly move the brake pedal from release to 13. After moving foot throttle (Decel Pedal) and no
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applied position two to four times. error message appears on the instrument cluster
press both buttons for one second and release,
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NOTE: During this operation if the instrument cluster

the instrument cluster will read (CAL DONE).
Stop and restart the machine, values are stored
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in internal memory.
14.If at any time during calibration the instrument
cluster reads (CAL FAIL), stop the engine and
restart the procedure.

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9001-4
1 4
2 3 5
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BS06K137
1. BRAKE POTENTIOMETER 5. JAM NUT RETURN SPRING

2. ACTUATION ROD 6. DECELERATOR PEDAL
3. BRAKE PEDAL 7. DECELERATOR PEDAL TRAVEL ADJUSTING JAM NUT
4. DECELERATOR POTENTIOMETER
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BRAKE AND DECELERATOR PEDAL
NOTE: Adjust decelerator pedal stop (1) bolt to

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19.6 MM. (0.77 inch).

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9001-5
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BS06K139
1. BRAKE LEVER 4. ADJUSTMENT BOLT

2. SPRING 5. PROXIMITY SWITCH BRACKET
3. PIVOT MOUNTING BOLT 6. STOP PLATE
PARKING BRAKE LEVERS

Copyright ©
9001-6
1. Make sure that the parking brake lever over 2. Loosen the bolt (4) and adjust the stop plate (5)
center springs are in place. so the lever (1) does not hit the console.
NOTE: For adjustment of the brake proximity switches see section 4001.
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Section
9003
9003
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM
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CHECKS FOR SYSTEMS WITH HFC134A REFRIGERANT
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9003-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem: Erratic Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem: System Makes Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure-Temperature and Louver Air Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Problem - No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Problem - No Cooling or Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Problem - Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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problem - Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Problem - Intermittent Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Problem - Noise in System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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9003-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS

MANUAL. WHEN YOU SEE THIS SYMBOL, CREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified 1. Always wear safety goggles when doing any
by an approved training and certification organization service work near an air conditioner system.
may service or repair motor vehicle or mobile air Liquid refrigerant getting into the eyes can cause
conditioning systems. It is mandatory that all ser ious injur y. Do the following if you get
refrigerant must be RECOVERED and RECYCLED refrigerant near or in your eyes:
when removed from a system during servicing.
A. Flush your eyes with water for 15 minutes.
Refrigerant HFC134a is the most stable, and easiest
B. See a physician immediately.
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC134a does not 2. A drop of liquid refrigerant on your skin may
contain any chlorofluorocarbons (CFC’s) which are cause frostbite. Open the fittings carefully and
harmful to the earth’s ozone layer. slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
Safety procedures must be followed when working
frostbite or a physician must be seen if you get
with Refrigerant HFC134a to prevent possible
refrigerant on your skin.
personal injury.
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3. Keep refrigerant containers in the correct upright
position. Always keep refrigerant containers
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away from heat and sunlight. The pressure in a
container will increase with heat.
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4. Always reclaim refrigerant from the system, if you
are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
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the air conditioner system before reclaiming

refrigerant and when you test the system.
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6. Dangerous gas can form when refrigerant comes

in contact with an open flame. Never permit
fumes to be inhaled.
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7. Never leak test with compressed air or flame

testers. Tests have indicated that compressed
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m ixtu re s o f HF C1 3 4 a a n d a ir can fo r m a
combustible gas.
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9003-4
SPECIAL TOOLS
299L7C A22094
OEM-1036 Belt Tension Tool OEM-1415 Refrigerant Recovery, Recycling and

Charging Station
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OEM-1437 Electronic Leak Detector 10917

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Safety Goggles- Obtain Locally

In the USA and Canada order Service Tools from:
OTC Division/SPX Corporation
655 Eisenhower Drive
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Owatonna, Minnesota 55060

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phone: 507-455-7000
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1-800-533-0492

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9003-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core.
tubes and hoses and operate as a closed system.
As the refrigerant flows through the evaporator core
The air conditioner system is charged with HFC134a
the refrigerant is heated by the air around and flowing
refrigerant.
through the evaporator fins. The combination of
The compressor receives the refrigerant as a low increased heat and decreased pressure causes the
pressure gas. The compressor then compresses the air flow through the evaporator fins to become very
refrigerant and sends it in the form of a high pressure cool and the liquid refrigerant to become a low
gas to the condenser. The air flow through the pressure gas. The cooled air then passes from the
c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e evaporator to the cab for the operator’s comfort.
refrigerant. As the heat is removed the refrigerant
The electrical circuit of the Air Conditioning System
changes to a high pressure liquid.
consists of a fan speed control, temperature control,
The high pressure refrigerant liquid then flows from two (2) fuzes, one 20 Amp and one 20 Amp, three (3)
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e condenser fan motors, two (2) blower motors, blower
receiver-drier is a container filled with moisture resistor, compressor clutch, low pressure switch,
removing material, which removes any moisture that high pressure switch, and warning light.
may have entered the air conditioner system in order
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to prevent corrosion of the internal components of
the air conditioner system.
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208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER
2. EVAPORATOR 4. CONDENSER

Copyright ©
9003-6
TROUBLESHOOTING
1. Perform a visual inspection of the machine. - Are there heavy accumulations of oil, or oily dust
Check the following and correct as necessary: around the fittings, indicating refrigerant leakage?
- - Obtain service history if possible. - Are air ducts undamaged, sealed properly and in
position?
- - Is compressor drive belt in place and tensioned?
- Condensate drain hoses and check valves present
- - Are grille screens, fan blades, condenser, air filter,
and unobstructed?
and evaporator unobstructed?
- Are there any sharp bends or kinks in the hoses?
Problem: No Cooling
COMPRESSOR RUNS COMPRESSOR DOES NOT RUN
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INTERNAL SYSTEM PROBLEM MECHANICAL
See Pressure Testing, Page 13. See Mechanical Compressor Check Page 8.
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ELECTRICAL
See Blower and Compressor Clutch Check Page 9.
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9003-7
Problem: Not Enough Cooling Problem: Erratic Cooling
MECHANICAL
HEATER See Mechanical Compressor Check Page 8.
Make sure the heater control is OFF and that there is
no coolant flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower
Motor Check, Blower Switch Check and Compressor
Clutch Check on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
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MECHANICAL Problem: System Makes Noise
See Mechanical Compressor Check Page 8. See
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Evaporator Heater Core Check Page 12.
MECHANICAL
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See Mechanical Compressor Check Page 8.

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ELECTRICAL
See Blower Motor Check Page 9.
See Blower and Compressor Clutch Check on Page
9.
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ELECTRICAL
See Compressor Clutch Check Page 9.
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REFRIGERANT
See Cab Temperature Check Page 10.
INTERNAL SYSTEM PROBLEM

INTERNAL SYSTEM PROBLEM


Copyright ©
9003-8
SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts

1. Loose or broken drive belt - Adjust the tension on
a new belt at 422 to 516 N (95 to 115 lbs) and at
400 to 489 N (90 to 110 lbs) after a minimum of
ten minutes run-in time on the belt. Belt tension
on a used belt must be 400 to 489 N (90 to 110
lbs). See Section 9005.
2. Too much belt wear - replace a worn belt,
because a wor n belt will cause too much
slippage.
Compressor Mounting Brackets
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1. Loose bracket mounting bolts- tighten the bolts to
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the correct torque.
2. Bracket has breaks or cracks - replace the
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bracket.
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Compressor Clutch
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1. The compressor belt will slip on the compressor

pulley if there is compressor seizure. Remove
the compressor for service or replacement. See
Section 9005 of this service manual.
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2. Remove the dust cover, if equipped, and check

the air gap on the compressor clutch. The gap
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between the front plate and pulley assembly

must be 0.41 to 0.79 MM. (0.016 to 0.031 inch).
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See Section 9006.

3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor rotation
should be smooth and not require much effort.
Pulley and Belt Alignment

1. The compressor pulley and the compressor drive
pulley must be aligned within 1.6 MM. (1/16 inch)
of each other. Use a straight edge to check pulley
alignment. Adjust the compressor mounting
bracket if needed. The drive belt should be
located in the forward clutch groove.

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9003-9
Blower and Compressor Clutch

Check
Compressor Clutch
1. If there is electrical system voltage to the clutch,
see Section 9006 and replace the clutch.
High/Low Pressure and Temperature Switches
1. The high pressure switch at the compressor and
the low pressure switch is lo cated at the
expansion valve and the temperature switch is
located at the receiver-dryer.
Blower Fuse
1. Check for damaged blower fuse.
Blower Fan Switch
1. Check switch operation. Switch must give four
different blower speeds.
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2. Check for loose connections or broken wires.
Repair or replace as necessary.
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3. Check resistor board.
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Blower Motor
1. Check the wiring to the two blower motors. Make
repairs or replace items as necessary.
2. Check motor ground wire. Make sure motor
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ground wire is making good contact.

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Air Conditioner Switch

1. Turn switch to the AC position. Compressor
clutch must engage.
NOTE: Blower must be operating, since electrical
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power to temperature control switch is received from

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blower switch.
2. Turn the AC switch on and check for continuity
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between the connector. If continuity is not

present, replace the switch.

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9003-10
Cab Temperature Check
Air Louvers
1. Make sure louvers and recirculation vents are
fully open for most efficient air conditioning
operation. Defrost louvers must be closed.
2. Check blower; blower must be running.
Air Conditioning
1. Feel the air conditioning hoses. The high
pressure hoses (small line) must be warmer than
the low pressure hose (large line).
2. If no temperature difference, the system is low
on refrigerant, or compressor is not working
correctly.
Duct Temperature
1. Put a thermometer in the air duct behind the seat
and run the compressor for five minutes to make
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temperature stable.
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2. Duct temperature must not be above the Air
Louver Maximum Temperature for the Ambient
Temperature if the system is operating at
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maximum efficiency. See the chart on Page 13.
NOTE: Ambient temperature must be 27 to 43
degrees C (80 to 110 degrees F).
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3. If the duct temperature is above the Air Louver

M a x i m u m Te m p e r a t u r e fo r t h e A m b i e n t
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Temperature (see the Chart on Page 13), the

system is low on refrigerant, there is a restriction
in the system, compressor is not wor king
correctly, or air ducts are not sealed correctly.
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Temperature Sensing Probe Check

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1. Turn the engine OFF, key switch ON, blower

switch ON and temperature control switch turned
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fully clockwise.
2. Remove the temperature sensing probe from the
evaporator.
3. Put the end of the temperature sensing probe in
a container with ice and water.
4. When the sensing tube has cooled to the
temperature of the ice and water mixture, the
temperature control switch should interrupt the
current flow to the compressor. Check for current
at the control switch terminals as on previous
page. If current is not interrupted then replace
the control switch.

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9003-11
Visual and Leak Check
Compressor Hoses
1. Make sure that all hose connections are tight.
2. Check hoses for bends or cracks. Replace all
hoses that have damage.
Leak Finding Check

1. Shut off the engine.
WARNING: When refrigerant comes in

contact with an open flame, it can form
dangerous gas. Never breathe these
fumes. SM109A
2. Use electronic leak detector OEM-1437 to

inspect all connections. Use instructions from
manufacturer of leak finding tool.
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NOTE: When checking compressor seal for a leak,
remove the dust cover and rotate the clutch shaft
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clockwise.
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NOTE: To properly check the expansion valve for leaks,
remove the insulation tape.
3. Repair all leaks and recharge the system.
Condenser
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1. Make sure the condenser is clean and the seals

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are in place. Make sure condenser fans run

when AC control switch is ON.
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9003-12
Evaporator/Heater Core Check
Make sure heater valve is closed.

Evaporator/Heater Core
1. See Section 9005 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater core. All
the fins that have bends or damage must be
made straight.
3. Inspect the evaporator/heater core for
restrictions. If the core is dry, use compressed air
or a brush and vacuum cleaner. If the core is wet
or filled with mud, flush the core with water using
a hose without pressure. Make sure the water
drains freely from the evaporator/heater core. DO
NOT USE STEAM.
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WARNING: Do not steam clean any air
conditioning systems parts while the system
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is charged. The heat will cause the
refrigerant to rise to a pressure that could
cause the system to explode. SM104A
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Evaporator/Heater Core Sealing

1. See Section 9005 for access to the
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evaporator/heater core.
2. Make sure seals are in place so blower will pull
air only through the evaporator/heater core and
not around the evaporator/heater core.
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Filters
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1. Make sure the filters are clean.

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9003-13
Pressure Testing
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 0.69 to 2.4 bar (10 to 35
The manifold gauge set is the most important tool psi) after the system has run 10 to 15 minutes.
used to service the air conditioning system. The
manifold gauge set is used to measure the high and HIGH PRESSURE GAUGE - The high pressure
low pressures of the system, the correct refrigerant gauge is used to indicate pressures in the high side
charge, system diagnosis, and operating efficiency. of the system. The gauge must indicate from 0 to
The manifold gauge set can read both the high 27.5 bar (0 to 400 psi) minimum.
(discharge) and low (suction) sides at the same time, During normal operation, the high pressure gauge
since pressure must be compared in order to make a will normally indicate from 120 to 310 psi (8.3 to 21.3
diagnosis of system operation. bar). See pressure-temperature chart.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. Under some conditions, air Pressure Test Connection
conditioning systems can change from a pressure
C o n n e c t t h e m a n i fo l d g a u g e s e t i n t o t h e a i r
into a vacuum on the low side. For this reason, it is
conditioning system as shown. Make sure that both
necessar y to use a compound gauge that will
valves in the manifold gauge set are closed.
indicate both pressure and vacuum.
Pressure-Temperature and Louver Air Temperature Chart
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AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER MAXIMUM
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TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION TEMPERATURE
°C (°F) kPa (psi) bar (psi) °C (°F)

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117.4 to 140.3 821.7 to 919.6
21 (70) 11.4 (53)
(17 to 20) (119 to 133)
117.9 to 188.8 978.1 to 1125.3
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27 (80) 16.9 (62)

(17 to 27) (142 to 163)
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160.1 to 229.0 1193.8 to 1343.3

32 (90) 20.0 (68)
(23 to 33) (173 to 195)
202.2 to 279.9 1439.2 to 1606.6
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38 (100) 24.4 (76)

(29 to 41) (209 to 233)
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266.1 to 325.1 1740.2 to 1825.1

43 (110) 28.8 (84)
(39 to 47) (252 to 269)
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307.5 to 363.8 1991.3 to 2142.5

49 (120) 31.9 (89)
(45 to 53) (289 to 311)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
1. Engine at 1500 rpm, no load, fan speed &
4. Heater valve at engine closed.
temperature control at maximum setting, A/C
switch ON, all louvers and doors open. 5. Measurements taken 15 minutes after startup.

Copyright ©
9003-14
A/C RECOVERY AND CHARGING STATION CONNECTIONS

NOTE: Photos may vary from machine being Connect the hose from the high pressure gauge to
serviced. the port on the discharge hose.
STEP 1 WARNING: Always wear safety goggles

when working with liquid refrigerant. Liquid
Clean the external surfaces of the compressor and
refrigerant in your eyes could cause
hoses. Remove the caps from the service ports on
blindness.
the suction and pressure hoses.
SM105A
WARNING: Do not steam clean any air Make sure the charging station manifold gauge
conditioning system parts while the system is valves are in the closed position.
charged. The heat will cause the refrigerant
to rise to a pressure that could cause the STEP 3
system to explode. Start the engine and run at 1500 rpm maximum
SM104A speed. Operate the air conditioner system at
maximum cooling setting and blower speed for 15
STEP 2 minutes with the cab door open. Observe the test
Connect the hoses from the test gauges to the gauges and check the chart on Page 13 against the
service ports. gauge readings.
Connect the hose from the low pressure gauge to the NOTE: The temperature control changes the vent
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port on the suction hose. outlet temperatures by mixing heat with air
conditioning. If the temperature is too cold, the
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temperature control can be turned clockwise to
increase temperature even though the air conditioner
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is on. Any air conditioner tests should be run with this
control all the way counter-clockwise or with the
water valve on the engine turned off.
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9003-15
QUICK REFERENCE TROUBLESHOOTING CHART

LOW PRESSURE HIGH PRESSURE SEE
PROBLEM
GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25
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9003-16
Problem - No Cooling
See pressure - temperature

VERY LOW VERY LOW chart, Page 13.
476L7
N o R e f r i g e ra n t o r L ow R e f r i g e ra n t C h a r g e - 1. Leak test the system, see Page 11. It may be

Indications: necessary to add refrigerant. See Section 9004.
A. Discharge air from evaporator warm.
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B. Compressor does not run, or cycles off rapidly
after start-up. 2. Recover the remaining refrigerant from system.
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PR See Section 9004.
3. Repair system leaks as needed. Follow the given

repair procedure.
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4. Check level of oil in compressor - possible for

compressor to have an oil loss. See Section
9005.
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5. Replace the receiver-drier. The moisture

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removing material could be full to capacity with

moisture, refer to Section 9005.
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6. Remove air and moisture from the system.

Replace Receiver-Drier. See Section 9004.
7. Charge system with new refrigerant. See Section

9004.
8. Continue performance test for other possible

problems.

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9003-17
Problem - No Cooling or Not

Enough Cooling

HIGH HIGH chart, Page 13.
476L7
Air in the System - Indications 1. Leak test system - possible leak permitted air to
enter the system.
A. Suction line warm to hand.
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2. Recover the refrigerant from system. See
B. Discharge air from evaporator warm.
Section 9004.
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3. Repair leaks as necessary.
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4. Replace receiver-drier. See Section 9004.
5. Remove air and moisture from the system. See
Section 9004.
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9004.
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Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine

fan belt and proper condenser fan operation.
A. Liquid line (between evaporator and
condenser) is very hot. 2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
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3. Check system for too much refrigerant. Recover

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the refrigerant for system until gauge pressure is

normal. See Section 9004.
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4. Remove and check condenser for restrictions

caused by oil or reduced heat transfer.
A. Recover the refrigerant from the system. See
Section 9004.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9004.
5. Continue the performance test for other possible
problems.
(Continued on next page)

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9003-18
HFC-134a Stable Saturation

Pressure/Temperature Chart
(No Cooling Continued)
Temperature °C (°F) Pressure Bar (PSIG)
44 (112) 10.5 (152)
Expansion Valve Malfunctioning - Indications: 46 (114) 10.8 (157)
A. Discharge air from heater/evaporator warm. 47 (116) 11.2 (162)
B. Much condensation on suction hose at 48 (118) 11.5 (167)
compressor. 49 (120) 11.9 (172)
C. Much condensation on evaporator outlet.
Refrigerant Contamination - Indications
1. See table below and check stable saturation
pressures at given temperature to determine if 1. Check the expansion valve. Disconnect the low
contamination exists. pressure switch.
A. Measure pressure from gauge on reclamation 2. Test expansion valve:

unit. A. Remove insulation material from top of valve.
B. Measure temperature from refrigerant in With the engine running and the air
reclamation tank. If refrigerant has been in conditioner on maximum cooling, cool the top
of the expansion valve with ice and check the
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reclamation unit for some time, use ambient
tem perature. The numbers in the table low pressure gauge for a decrease.
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represent the boiling point for HFC-134a. B. Allow the top of the expansion valve to warm.
C. Pressure readings below range given in chart The valve should open and the pressure
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indicate contaminated refrigerant. should rise at the low pressure gauge.
IMPORTANT: Do not use contaminated refrigerant C. Repeat Step A. If there is little or no decrease
or mix with uncontaminated refrigerant. Dispose of in in the low pressure gauge, go to Step 3.
accordance with all applicable laws and local 3. If the expansion valve did not operate correctly,
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procedure. recover the refrigerant from the system, refer to

Section 9004. Remove the expansion valve,
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HFC-134a Stable Saturation refer to Section 9005.

Pressure/Temperature Chart
4. Instal the new expansion valve, refer to section
Temperature °C (°F) Pressure Bar (PSIG) 9005. Remove the air and moisture and charge
the system with refrigerant, refer to Section
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10 (50) 3.1 (45)

9004.
13 (55) 3.5 (51)
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16 (60) 3.9 (57) 5. Connect the low pressure switch.

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18 (65) 4.4 (64) 6. Continue performance test for other possible

problems.
21 (70) 4.9 (71)
24 (75) 5.4 (78)
27 (80) 6.1 (88)
29 (85) 6.6 (95)
32 (90) 7.2 (104)
35 (95) 7.9 (114)
38 (100) 8.6 (124)
39 (102) 8.9 (129)
40 (104) 9.2 (133)
41 (106) 9.5 (138)
42 (108) 9.8 (142)
43 (110) 10.1 (147)
Copyright ©
9003-19
Problem - Not Enough Cooling

NORMAL TO
SLIGHTLY NORMAL chart, Page 13.
HIGH
476L7
Heater Control Valve not working - Indications 1. The heater control valve is not closed if the
hoses are hot.
A. Discharge air from evaporator only a little
cool. 2. Shut off coolant flow to heater/evaporator core.
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B. Heater hoses to cab are warmer than ambient 3. Check air duct for temperature change.
temperature.
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4. Inspect the heater control cable and valve.
5. Continue performance test for possible other
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problems.
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1. Test system for leaks. See Page 11. Possible

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Air in the System - Indications: leak has let air enter; check compressor seal
carefully. See Section 9004.
A. Suction line warm to your hand.
B. Discharge air from heater/evaporator only a
Section 9004.
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little cool.
3. Repair system leak as necessary.
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4. Replace receiver-drier. The moisture removing

material in receiver-drier could be full to capacity
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with mixture, refer to Section 9005.

5. Check compressor oil level. See Section 9005.
Section 9004.
9004.
Temperature Control Switch sensing tube low on 1. Inspect and repair the temperature control
charge or out of calibration - Indications: switch.
A. Excessive or incorrect compressor cycling.
B. Compressor clutch not engaging.

Copyright ©
9003-20
problem - Not Enough Cooling

LOW LOW chart, Page 13.
476L7
Not Enough Refrigerant - Indications: A. If leak is found, go to Step 2.

A. Discharge air from evaporator cool or warm - B. If no leak is found, go to Step 6.
not cold.
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Section 9004.
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3. Repair system leaks as needed.
4. Check oil level in compressor - It is possible for
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compressor to lose oil. See Section 9006.
5. Remove air and moisture from the system.
Replace Receiver-Drier. See Section 9005.
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9004.
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(Continued on next page)

1. Leak test system - system has a loss of
refrigerant.
NOTE: Normally, the system will lose 14.7 to 29.5
grams (1/2 to 1 ounce) of refrigerant between
seasons.

Copyright ©
9003-21
(Not Enough Cooling
High Side Restriction - Indications: 1. Recover the refrigerant from the system. A
A. Discharge air from heater/evaporator only a restriction in receiver-drier or liquid line must be
little cool. removed.
B. Condensation or frost on receiver-drier. 2. Remove and replace part with restriction.
C. Liquid line to receiver-drier cool, with frost or 3. Remove air and moisture from the system. See
condensation. Section 9004.
NOTE: The frost will form downstream from or at the 4. Charge system with new refrigerant. See Section
point of the restriction 9004.
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Expansion Valve Not Operating - Indications: 1. Expansion valve outlet with condensation or frost
is an indication of a restriction in the expansion
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A. Discharge air from evaporator warm or cool - valve. Replace expansion valve. See Section
not cold. 9005.
B. Condensation or frost on expansion valve 2. Inlet end of expansion valve is warm, indicating
inlet. expansion valve is not completely open. Replace
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C. Inlet end of expansion valve is warm. expansion valve. See Section 9005.
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9003-22

HIGH LOW chart, Page 13.
476L7
Compressor turning but not pumping properly -

Indications: 1. Recover the refrigerant from system. See
Section 9004.
A. System is fully charged.
2. Remove the compressor from the machine. See
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B. Cool discharge air from evaporator.
Section 9004.
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3. Before you start to repair compressor, check and
record compressor oil level. See Section 9005.
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4. Remove compressor from machine because
there is indication of internal leak in compressor.
5. Repair or replace compressor as necessary. See
Section 9005 or 9006.
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6. Replace receiver-drier if: See Section 9005.

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A. System has been opened before.

B. Receiver-drier has been used two or more
years.
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C. Disassembly of compressor shows small

particles of moisture removing material (gold
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or brown particles). See Section 9005 for

receiver-drier replacement.
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7. Fill compressor with new refrigerant oil as shown

in Section 9006 and install compressor in
machine.
8. Charge the system with refrigerant. See Section
9004.
Expansion Valve stuck open 1. Replace expansion valve. See Section 9005.

Copyright ©
9003-23

VERY LOW VERY LOW chart, Page 13.
476L7
Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and
proper condenser fan operation.
A. Liquid line very hot.
2. Check to see that condenser is clean and that
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the fins are straight.
3. Check system for too much refrigerant.
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A. Recover the refrigerant from system until
gauge pressure is below normal. See Section
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9004.
B. Add refrigerant until gauge pressures are
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C. If there is still a problem, do step 4.

4. Remove and inspect condenser for restrictions
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caused by oil or reduced heat transfer.

A. Recover the refrigerant from system. See
Section 9004.
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B. Use compressed air to remove oil from

condenser.
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C. Replace receiver-drier. See Section 9005.

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Air in the System - Indications: 1. Recover the refrigerant from system. See
Section 9004.
A. Warm discharge air from evaporator.
2. Replace receiver-drier.
Section 9004.
9004.

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9003-24
Problem - Intermittent Cooling

NORMAL NORMAL chart, Page 13.
476L7
Moisture in System- Indications: 1. Recover the refrigerant from the system. If too
much moisture enters the orifice of the
A. Cooling is acceptable during cool part of day,
expansion valve, the freezing of this moisture
but not acceptable during hot part of day.
can stop refrigerant flow. See Section 9004.
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2. Replace receiver-drier. The moisture removing
material could be full to capacity with moisture.
See Section 9005.
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Section 9004.
NOTE: The time needed to remove a large amount
of moisture will be two to three hours minimum.
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9004.
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9003-25
Problem - Noise in System

NORMAL TO HIGH chart, Page 13.
HIGH
476L7
Too much Refrigerant in System - Indications: 1. Recover the refrigerant from system until gauge
readings are below normal. See Section 9004.
A. Cool discharge air from heater/evaporator.
2. Add new refrigerant until gauge readings are
B. Compressor makes noise.
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9003-26
NOTES
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Copyright ©
Section
9004
9004
AIR CONDITIONING SYSTEM SERVICE
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9004-2
TABLE OF CONTENTS
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Programming the Recovery/Charging Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Activating Start on Recovery/Charging System Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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9004-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 2.0 kg (4.6 lbs)
SPECIAL SERVICE TOOLS
A22094 BS03H012
OEM-1415 REFRIGERANT RECOVERY, RECYCLING, AND CAS-10073-3 SAFETY GOGGLES
CHARGING STATION
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Copyright ©
9004-4
SAFETY PROCEDURES
WARNING: THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS
MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND
BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified 2. A drop of liquid refrigerant on your skin may
by an approved training and certification organization cause frostbite. Open the fittings carefully and
may service or repair motor vehicle or mobile air slowly when it is necessary to service the air
conditioning systems. It is mandatory that all conditioner system. Your skin must be treated for
refrigerant must be RECOVERED and RECYCLED frostbite or a physician must be seen if you get
when removed from a system during servicing. refrigerant on your skin.
Refrigerant HFC134a is the most stable and easiest 3. Keep refrigerant containers in the correct upright
to work with of the refrigerants now used in air position. Always keep refrigerant containers
conditioning systems. Refrigerant HFC134a does not away from heat and sunlight. The pressure in a
contain chlorofluorocarbons (CFC’s) which are container will increase with heat.
harmful to the Earth’s ozone layer.
Safety procedures must be followed when working are going to weld or steam clean near the air
with refrigerant HFC134a to prevent possible conditioner system.
personal injury.
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1. Always wear safety goggles when doing any the air conditioner system before reclaiming
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service work near an air conditioner system. refrigerant and when you test the system.
Liquid refrigerant getting into the eyes can cause
ser ious injur y. Do the following if you get 6. Dangerous gas can form when refrigerant comes
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refrigerant near or in your eyes: in contact with an open flame. Never permit
B. See a physician immediately. tester. Tests have indicated that compressed
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combustible gas.
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9004-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refr igerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
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IN
BD02M034
Clean the external surfaces of the compressor and

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hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
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A22107
Make certain the refrigerant tank gas and liquid

valves are open.
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BD02M001
Make sure the charging station manifold gauge

valves are in the closed position. Connect the hose
from the low pressure gauge to the por t on the
suction hose. Connect the hose from the high
pressure gauge to the port on the discharge hose.
Turn in both thumbscrews to depress the service
valves.

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9004-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. The compressor oil drain valve completely.
will shut OFF automatically when recover y is
complete. Wait for five minutes and observe the STEP 8
manifold pressure gauges for a pressure rise. If
pressure rises above zero PSI, depress the hold/cont
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switch. Then wait for the compressor to automatically
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shut OFF.
STEP 6
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A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
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STEP 9
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A22108
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Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD02M034
Disconnect the hoses from the service ports and

install the caps.

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9004-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you va c u u m p u m p. A v a c u u m p u m p i s t h e o n l y
remove the air and moisture from the system. equipment made that will lower the pressure in a
system enough to change the moisture to a vapor so
A. The system has been opened for service
that the moisture can be removed.
before.
NOTE: Refer to the vacuum pump manufacturer’s
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small Programming the
particles of moisture removing material (gold
or brown particles).
Recovery/Charging Station
D. Large system leak (broken hose, break in STEP 11
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
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A22113
Connect the main power plug to a 115 volt AC outlet.

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Move the main power switch to the ON position. If

program and vacuum do not appear at the top of the
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display press the vacuum key. Program a minimum of

45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
BD02M001 accepted.
Make sure the charging station manifold gauge
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valves are in the closed position. Connect the hose STEP 12

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from the low pressure gauge to the por t on the

suction hose. Connect the hose from the high
pressure gauge to the port on the discharge hose.
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Turn in both thumbscrews to depress the service

valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed
from the system after the system has been opened
for maintenance. Air enters the system when the
system is opened. Air has moisture that must be
r e m o ve d t o p r eve n t d a m a g e t o t h e s y s t e m
components.
A22115
Press the Charge key. Program and Charge will

appear on the display.

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9004-8
STEP 13 Activating Start on
Recovery/Charging System Station
NOTE: Photos may vary from machine being
serviced.
STEP 16
A22113
Program 3.52 lbs (1.6 kg) and press the enter key.
T h e d i s p l ay w i l l f l a s h o n c e i n d i c a t i n g t h e
programmed data has been accepted.
STEP 14
A22123
Press the Vacuum key. Automatic will show on the
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display. Vacuum will appear on the display and after
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a slight delay, the vacuum pump will star t. The
display will show the amount of time programmed
and begin a countdown to zero.
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When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
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gauge must not increase faster than one inch of

mercury (Hg) in 15 minutes. If the system will not
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hold vacuum, a leak exists that must be corrected

A22114
before recharging can begin. See Section 9003 for a
Full open the low and high pressure valves.
leak test.
STEP 15
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STEP 17
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A22107
A22113
Open the red (vapor) and blue (liquid) valves on the
Press the charge key to begin refrigerant charging.
tank.
Automatic and Charge will appear on the display. The
display shows the programmed amount and counts
down to zero as charging proceeds. When charging
is completed, the display shows CPL.

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9004-9
STEP 18 IMPORTANT: Check the OEM equipment manual
before performing Step 20 to avoid damaging
recovery unit. Pressure reading should be obtainable
with valves closed. Damage may occur if the
machine is started with the valves accidently open or
if either or both valves are opened while the A/C
system operating.
STEP 21
A22114
Completely close the high and low pressure manifold

valves.
STEP 19
Start the engine and run at 1500 rpm. Operate the air
conditioner system at maximum cooling setting and
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maximum blower speed with the doors and windows
BD02M001
open.
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Stop the engine, close any open valves and carefully
NOTE: The compressor will not operate if the remove the manifold gauge hoses.
system pressure is too low or too high. If the
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compressor fails to operate and the condenser STEP 22
blowers also fail to operate when you actuate the A/C
switch, check the system pressure to determine if
refrigerant is present. Check for continuity at the
pressure switch located at the receiver-dryer and the
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temperature switch located at the evaporator. 1

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STEP 20
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BD02M034
1. SERVICE PORT CAPS
Install the caps on the service ports on the suction

and discharge hoses.
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9003-9 for temperature
and pressure variations.

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9004-10
Pressure-Temperature Chart
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER MAXIMUM

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION TEMPERATURE
°C (°F) kPa (psi) kPa (psi) °C (°F)
62 to 83 1000 to 1153
27 (80) 14 (55)
(9 to 12) (145 to 165)
76 to 104 1310 to 1448

32 (90) 18 (61)
(11 to 15) (190 to 210)
110 to 124 1448 to 1586

35 (95) 20 (63)
(16 to 18) (210 to 230)
117 to 131 1620 to 1758

38 (100) 22 (66)
(17 to 19) (235 to 255)
138 to 145 1793 to 1931

41 (105) 23 (68)
(20 to 21) (260 to 280)
193 to 214 2000 to 2137

43 (110) 25 (72)
(22 to 24) (290 to 310)
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NOTE: The pressure-temperature chart is based on 5. A/C switch ON.
the following conditions:
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6. Both cab doors open.
1. Engine operating at 1500 rpm.
7. All panels and access doors installed and closed.
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2. No engine load.
8. Cab filters clean and installed.
3. Fan speed control in maximum position (full
9. Heater valve at engine closed.
clockwise) and all louvers open.
10. Measurements taken 15 minutes after start-up.
4. Cab temperature control set to maximum cooling
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(full counterclockwise).
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Section
9005
REMOVAL AND INSTALLATION OF HEATER AND
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AIR CONDITIONING SYSTEM COMPONENTS
9005
IN
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9005-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AIR CONDITIONING THERMAL PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEATER WATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EVAPORATOR CORE AND HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AIR CONDITIONER AND HEATER FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
IN
AIR CONDITIONING SYSTEM CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AIR CONDITIONING SYSTEM RECEIVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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9005-3
SAFETY PROCEDURES
Refrigerant HFC134a is the most stable, and easiest 3. Keep refrigerant containers in the correct upright
conditioner systems. Refrigerant HFC134a does not away from heat and sunlight. The pressure in a
contain any chlorofluorocarbons (CFC’s) which are container will increase with heat.
harmful to the earth’s ozone layer.
with Refrigerant HFC134a to prevent possible conditioner system.
personal injury.
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
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IN
B. See a physician immediately. testers. Tests have indicated that compressed
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combustible gas.
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9005-4
SPECIAL TOOLS
299L7C A22094
OEM-1036 OEM-1415
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A22090 BS03H012
OEM-1437 SAFETY GOGGLES - OBTAIN LOCALLY
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Copyright ©
9005-5
AIR CONDITIONING COMPRESSOR
Removal STEP 6
STEP 1
Park the machine on a level surface and lower the
blade to the floor. Apply the parking brake. Stop the
engine and turn the master disconnect switch to OFF.
STEP 2
Make sure the compressor and engine are clean
before connecting the refrigerant recovery system or
disconnecting any lines. 4
STEP 3 BD06K122
Connect the OEM-1415 Refrigerant Recover y, Remove the compressor adjusting bolt (4) and
Recycling and Charging Station to the High and Low washer.
charge ports in the hose fittings connected to the
compressor. Evacuate the system to remove all of STEP 7
the refrigerant, see Section 9004 for the procedure.
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STEP 4
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Disconnect the compressor clutch wire (1) from the
wiring harness connectors. 5
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STEP 5
3
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BD06K121
Loosen the compressor pivot bolt (5).
STEP 8
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Push the compressor down toward the engine.

1
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Remove the compressor belt.

2
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STEP 9
BD06K120
Remove the compressor pivot bolt (5), nut and
Disconnect the low pressure line (2) from the suction washers.
port and the high pressure line (3) from the discharge
p o r t o n t h e c o m p r e s s o r. I m m e d ia t e l y in s t a l l
STEP 10
protective caps on the open ports and lines.
Remove the compressor from the mounting bracket.
See Section 9006 to service the compressor.

Copyright ©
9005-6
STEP 11
3
6 5
1
2
7 BD06K120
Slowly remove the protective cap, install new O-ring

BD06K121
and connect the low pressure line (2) to the inlet port
Install the compressor (6) on the mounting bracket on the compressor.
(7). Install washers on the pivot bolt (5). Install the
pivot bolt, washer, and nut onto the pivot bolt. STEP 16
Carefully remove the protective cap, install new
STEP 12 O-ring and connect the high pressure line (3) to the
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discharge port on the compressor.
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STEP 17
Connect the OEM-1415 Refrigerant Recover y,
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Recycling and Charging Station to the high and low
compressor. Evacuate the system and charge the
system with reclaimed or new refrigerant; see
Section 9004 for the procedure.
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4
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BD06K122
Install the drive belt on the machine. Install the

adjusting bolts (4), nuts and washers into the
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compressor adjusting straps.

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STEP 13
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Adjust belt tension. See Section 9006 in this service

manual. Tighten pivot bolt (5) nut and compressor
adjusting bolts (4) when complete.
STEP 14
Connect the compressor clutch wire (1) to the wiring
harness connectors.
WARNING: Use caution when removing cap as new
compressors have internal pressure when shipped.

Copyright ©
9005-7
EXPANSION VALVE
Removal STEP 7
Remove the right arm rest from the cab
STEP 1
Park the machine on a level surface and lower the STEP 8
blade to the floor. Apply the parking brake and stop
the engine.
STEP 2 2
Turn the master disconnect switch to OFF.
STEP 3 3 1
Recycling and Charging Station to the High and Low
charge ports in the hose fittings at the compressor.
Evacuate the system to remove all of the refrigerant,
see Section 9004. BD06K018
Remove two screws (2) mounting the right console,

STEP 4 remove the door catch release knob (1), loosen
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console mounting screw (3).
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STEP 9
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2
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BD06K003.
Remove the air filter. 1

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STEP 5 BD06K019
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Remove screws (1) and loosen screw (2).
STEP 10
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BD06K004
Remove five mounting screws from the center rear

console, two from the front and three are located at
the back glass in the rear. BD06K020
Remove the two mounting screws at the back of the

STEP 6 right console, remove the console from the cab.
Remove the rear console cover from the cab.
Copyright ©
9005-8
STEP 15
Lubricate the new O-rings with clean refrigerant oil.
STEP 16
Install the new O-rings in the openings in the front of
the expansion valve.
STEP 17
Remove the caps from the tubes and connect the
expansion valve to the tubes.
BD06K021
STEP 18
Remove the insulation tape from around the fittings
Use two wrenches and tighten the tubes in
and the expansion valve.
expansion valve.
STEP 12 STEP 19
Use two wenches to loosen and remove the tubes
Install new insulation tape around the expansion
from the expansion valve.
valve and evaporator lines that are exposed.
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STEP 13
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STEP 20
Remove the expansion valve and install caps on the
Install the cab console covers.
tube fittings to the evaporator core.
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STEP 21
STEP 14
Remove and discard the O-rings.
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system with reclaimed or new refrigerant, see section
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9004 for the procedure.

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9005-9
AIR CONDITIONING THERMAL PROBE
Removal STEP 7
STEP 1
blade to the floor. Apply the parking brake and stop 2
the engine.
STEP 2 3 1
STEP 3
BD06K018

remove the door catch release knob (1), loosen
STEP 8
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BD06K003
Remove the air filter.

2
STEP 4
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BD06K019

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STEP 9
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BD06K004

the back glass in the rear.
STEP 5
Remove the rear console cover in the cab.
BD06K020
STEP 6 Remove the two mounting screws at the back of the

right console, remove the console from the cab.
Remove the right arm rest from the cab.

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9005-10
STEP 10 STEP 13
BD06K007 BD06K010
Remove the left arm rest from the cab. Remove the two mounting screws at the back of the
left console, remove the console from the cab.
STEP 11
STEP 14
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3
BD06K008
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Remove two screws (2) mounting the left console, BD06K005
remove the door catch release knob (1), loosen Remove the two screws mounting the electrical
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console mounting screw (3). controls.
STEP 12 STEP 15
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1 2
BD06K009 BD06K022
Remove screws (1) and loosen screw (2). Remove the mounting screws for the heater core and
evaporator core cover.

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9005-11
STEP 18
BD06K023
Remove the cover for the heater core and evaporator

core cover, remove the probe from the evaporator BD06K006
core. Install and mount the switch, connect the wires to the
temperature switch.
STEP 17
STEP 19
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BD06K006
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Remove the mounting screws for the temperature BD06K025

switch, disconnect the wiring harness connector, Measure over 114 mm (4.5 inches) from the right
remove the switch from the machine. side of the evaporator core.
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STEP 20
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BD06K024
Carefully insert the sensor into the evaporator core.

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9005-12
STEP 21 STEP 24
1
2
3
BD06K022 BD06K008
Install the evaporator and heater core cover, install Install and tighten two screws (2) mounting the left
and tighten the mounting screws for the core cover. console, install and tighten the door catch release
knob (1), tighten console mounting screw (3).
STEP 22
STEP 25
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BD06K005
Install and tighten the two screws mounting the BD06K009

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electrical controls. Install and tighten screws (1) and tighten screw (2).
STEP 23 STEP 26
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BD06K010 BD06K007
Install the left console into the cab, install and tighten Install the left arm rest in the cab.
the two mounting screws at the back of the left
console.

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9005-13
STEP 27 STEP 30
Install the right arm rest in the cab.
STEP 31
Place the rear console cover in the cab.
STEP 32
BD06K020
Install the right console into the cab. Install and

tighten the two mounting screws at the back of the
right console.
STEP 28
BD06K004
Install and tighten five mounting screws from the
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center rear console, two from the front and three are
located at the back glass in the rear.
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STEP 33
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BD06K019
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Install and tighten screws (1) and tighten screw (2).
STEP 29
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BD06K003
2 Install the air filter.
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3 1
BD06K018
Install and tighten two screws (2) mounting the right

console, install and tighten the door catch release

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9005-14
HEATER WATER VALVE
Removal STEP 6
STEP 1
blade to the floor. Apply the barking brake. Stop the
STEP 2
Drain 4 liters (1 U.S. gal) from the engine cooling
system.
STEP 3
BD06K007
Remove arm rest from the cab.
STEP 7
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2
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BD06K003

3
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STEP 4
BD06K008
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Remove two screws (2) mounting the left console,

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STEP 8
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BD06K004

the back glass in the rear. 1 2
STEP 5
Remove the rear console cover from the cab. BD06K009

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9005-15
STEP 9 Installation
STEP 12
Place the temperature control in the mounting
bracket, install and tighten the mounting screws for
the control. Connect the wiring to the control.
STEP 13
BD06K010

STEP 10
BD06K011
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Connect the heater inlet hose and heater core hose
to the temperature control.
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STEP 14
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BD06K011
Disconnect the heater inlet hose and heater core

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hose from the temperature control.
STEP 11
Disconnect the wiring from the control, remove the
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mounting screws from the control and remove the

control.
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BD06K010
Install the left console into the cab, install and tighten
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console.

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9005-16
STEP 15 STEP 18
1 STEP 19
3
BD06K008
Install and tighten two screws (2) mounting the left

knob (1), tighten console mounting screw (3). BD06K004
Install and tighten five mounting screws into the

STEP 16 center rear console, two are in the front and three are
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STEP 20
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BD06K009
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STEP 17 BD06K003
Install the air filter.

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STEP 21
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Refill the coolant to the proper level.

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BD06K007
Install the left arm rest in the cab.

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9005-17
EVAPORATOR CORE AND HEATER CORE
Removal STEP 5
STEP 1
NOTE: If replacing the heater core only do not do
step 2.
STEP 2
BD06K004
Evacuate the system to remove all of the refrigerant, Remove five mounting screws from the center rear
see Section 9004. console, two from the front and three are located at
NOTE: If replacing the evaporator core only do not
do step 3. STEP 6
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STEP 3
IN
Drain 4 liters (1 U.S. gal) from the engine cooling STEP 7
system.
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STEP 4 STEP 8
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BD06K003
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BD06K018

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9005-18
STEP 9 STEP 12
1
2
1
3
BD06K019 BD06K008
Remove screws (1) and loosen screw (2). Remove two screws (2) mounting the left console,
STEP 10 console mounting screw (3).
STEP 13
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1 2
BD06K020
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right console, remove the console from the cab. BD06K009
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STEP 11
STEP 14
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BD06K007
Remove the left arm rest from the cab. BD06K010


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9005-19
STEP 15 STEP 18
Use two wrenches to loosen and remove the tubes
from the expansion valve.
STEP 19
Remove the expansion valve and install caps on the
tube fittings to the evaporator core.
STEP 20
BD06K005
Remove the two screws mounting the electrical

controls.
STEP 16
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BD06K023
Remove the probe from the evaporator core.
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NOTE: If replacing the evaporator core only it is not
required to do step 22.
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STEP 21
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BD06K022
Remove the mounting screws for the heater core and

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evaporator core cover, remove the cover.

NOTE: If replacing the heater core only go to step
21.
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STEP 17
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BD06K011
Disconnect and plug the hoses to the heater core.
BD06K021
Remove the insulation tape from around the fittings

at the expansion valve.

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9005-20
STEP 23
Install the evaporator core or heater core.
STEP 24
BD06K026
It might be required to loosen the guide plate for the

evaporator and heater core to the core housing,
remove the core to be changed.
BD06K026
Put the evaporator and heater core in position. If

loosened tighten the screws securing the evaporator
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and heater core guide plate.
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NOTE: If replacing the heater core only go to step
35.
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STEP 25
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BD06K025
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Measure over 114 mm (4.5 inches) from the right

side of the evaporator core.

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9005-21
STEP 26 STEP 31
Remove the caps from the tubes and connect the
expansion valve to the tubes.
STEP 32
Use two wrenches and tighten the tubes in
expansion valve.
STEP 33
Install new insulation tape around the expansion
valve and evaporator lines that are exposed.
BD06K024
Carefully insert the sensor into the evaporator core.
STEP 34
STEP 27
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BD06K011
BD06K022
Remove the plugs from the heater hoses and install
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Install the evaporator and heater core cover, install on the heater core.
and tighten the mounting screws for the core cover.
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STEP 35
STEP 28
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BD06K010
BD06K005
Install and tighten the two screws mounting the the two mounting screws at the back of the left
electrical controls. console.
STEP 29
Lubricate the new O-rings with clean refrigerant oil.
STEP 30
Install the new O-rings in the openings in the front of
the expansion valve.

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9005-22
STEP 36 STEP 39
1
2
3
BD06K008 BD06K020
Install and tighten two screws (2) mounting the left Install the right console into the cab. Install and
console, install and tighten the door catch release tighten the two mounting screws at the back of the
knob (1), tighten console mounting screw (3). right console.
STEP 37 STEP 40
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1 2 1
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BD06K009 BD06K019
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Install and tighten screws (1) and tighten screw (2). Install and tighten screws (1) and tighten screw (2).
STEP 38 STEP 41
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3 1
BD06K007 BD06K018
Install the left arm rest in the cab. Install and tighten two screws (2) mounting the right

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9005-23
STEP 42
STEP 43
STEP 44
BD06K004
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STEP 45
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BD06K003
Install the air filter.

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NOTE: If replacing the heater core only it is not

STEP 46
system with reclaimed or new refrigerant, see section
9004 for the procedure.
STEP 47
Refill the coolant to the proper level.

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9005-24
AIR CONDITIONER AND HEATER FANS
Removal STEP 8
STEP 1
blade to the floor. Apply the parking brake and stop 2
the engine.
STEP 2 3 1
STEP 3
BD06K018
STEP 4 Remove two screws (2) mounting the right console,

STEP 9
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BD06K003
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STEP 5
BD06K019

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STEP 10
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BD06K004

BD06K020
STEP 6 Remove the two mounting screws at the back of the

right console, remove the console from the cab.
STEP 7

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9005-25
STEP 11 STEP 14
BD06K007 BD06K010
Remove the left arm rest from the cab. Remove the two mounting screws at the back of the
STEP 12
STEP 15
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2
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3
BD06K008
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Remove two screws (2) mounting the left console,

remove the door catch release knob (1), loosen BD06K012
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console mounting screw (3). Remove the outer cover mounting screw for the fan
box.
STEP 13
STEP 16
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1 2
BD06K009

BD06K013
Remove the inner cover mounting screws for the fan

box, remove the fan motor cover.

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9005-26
STEP 21
BD06K014
Disconnect the wires to the fan motor.

BD06K017
STEP 18 Install and mount the fan in the air box.
NOTE: Make sure to align the fan bracket into the
slot at the bottom of the air box.
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STEP 22
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BD06K015
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Remove the mounting bolts for the fan motor.
STEP 19
BD06K015
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Install and tighten the mounting bolts for the fan

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motor.
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STEP 23
BD06K016
Remove the fan motor.
STEP 20
Repeat the procedure for the right fan.
BD06K014
Connect the wires to the fan motor.

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9005-27
STEP 24 STEP 28
1
2
3
BD06K008
BD06K013 Install and tighten two screws (2) mounting the left
Install the fan motor cover, install and tighten the console, install and tighten the door catch release
inner cover mounting screws. knob (1), tighten console mounting screw (3).
STEP 25 STEP 29
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BD06K009
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BD06K012 Install and tighten screws (1) and tighten screw (2).
Install and tighten the outer cover mounting screw for
the fan box. STEP 30
STEP 26
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Repeat the procedure for the right fan.

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STEP 27
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BD06K007
Install the left arm rest in the cab.
BD06K010
console.

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9005-28
STEP 31 STEP 34
STEP 35
STEP 36
BD06K020
Install the right console into the cab. Install and

tighten the two mounting screws at the back of the
right console.
STEP 32
BD06K004
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STEP 37
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BD06K019
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STEP 33
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BD06K003
2 Install the air filter.
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3 1
BD06K018
Install and tighten two screws (2) mounting the right


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9005-29
AIR CONDITIONING SYSTEM CONDENSER
Removal STEP 6
STEP 1
engine and turn the master disconnect switch to
OFF.
STEP 2
Evacuate the system to remove all of the refrigerant, BD06K124
see section 9004. Support the condenser with suitable lifting device.
Loosen and remove the seven bolts and lock
STEP 3 washers fastening the condenser core to the cab.
STEP 7
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Remove the condenser and fans.
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Installation
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STEP 8
Put the condenser in position. Install and tighten the
s eve n b o l t s a n d l o ck w a s h e r s s e c u r i n g t h e
condenser core to the cab
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BD06K123 STEP 9
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Disconnect electrical connector for the flood light. Connect the fan electrical connector and flood light
Disconnect the hose and tube from the condenser. connector.
STEP 10
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STEP 4
Remove the caps and plugs from the hose, tube and
Install plugs in the hose and tube. Install caps on the
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fittings.
fittings to the condenser.
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STEP 11
STEP 5
Lubricate new O-rings with clean refrigerant oil and
install the O-rings.
STEP 12
Connect the hose and tube to the condenser and
tighten the fittings. Connect the flood light connector.
STEP 13
BD06K125 system with reclaimed or new refrigerant, see
Disconnect electrical connector for the flood light. Section 9004 for the procedure.
Disconnect electrical connector for the fan motors.

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9005-30
AIR CONDITIONING SYSTEM RECEIVER DRIER
STEP 1 STEP 8
Park the machine on a level surface and lower the Put the receiver drier and retaining bracket in
blade to the floor. Apply the parking brake. Stop the position. Install and tighten the two bolts securing the
engine and turn the master disconnect switch to mounting bracket for the receiver drier.
OFF.
STEP 9
STEP 2 Remove the caps and plugs from the tubes and
Connect the OEM-1415 Refrigerant Recover y, fittings.
charge ports in the hose fittings at the compressor. STEP 10
Evacuate the system to remove all of the refrigerant, Lubricate new O-rings with clean refrigerant oil and
see Section 9004. install the O-rings.
STEP 3 STEP 11
Open the right cab side panel. Connect the tubes to the receiver drier and tighten
the fittings.
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STEP 4
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STEP 12
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system with reclaimed or new refrigerant, see
Section 9004 for the procedure.
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STEP 13
FO
Close the cab right side panel.
BD06K119
Fasten identification tags on the tubes to the receiver

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drier. Disconnect the tubes from the receiver drier.

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STEP 5
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Install plugs in the tubes and install caps on the

fittings to the receiver drier.
STEP 6
Loosen and remove the two bolts fastening the
bracket which secures the receiver drier.
STEP 7
Remove the receiver drier.

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9005-31
NOTES
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9005-32
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Section
9006
AIR CONDITIONING COMPRESSOR AND CLUTCH
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9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPRESSOR BELT CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPRESSOR OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPRESSOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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9006-3
SPECIFICATIONS
Manufacturer...............................................................................................................................Sanden International
Manufacturer Model Number ................................................................................................................. Sanden 4611
Lubricant............................................................................................................................................... SP-20 PAG oil
Refrigerant Charge ..................................................................................................................... 1600 grams (3.5 lbs)
Compressor Belt Tension (New Belt)............................................................................ 578 to 667 N (130 to 150 lbs)
Compressor Belt Tension (Used Belt) ........................................................................... 356 to 534 N (80 to 120 lbs)
Front Plate Air Gap ..............................................................................................0.41 to 0.79 mm (0.016 to 0.031 in)
SPECIAL TORQUES
Compressor Rotor Shaft Nut ............................................................................................ 15 to 20 Nm (11 to 15 lb ft)
Oil Filler Plug .................................................................................................................... 15 to 24 Nm (11 to 18 lb ft)
Dust Cover Screws ................................................................................................................. 7 to 11 Nm (5 to 8 lb ft)
SPECIAL TOOLS
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109L7 A22094
SAFETY GOGGLES, OBTAIN LOCALLY OEM-1415
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T81574 299L7
CAS-10747A OEM-1036

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9006-4
SAFETY PROCEDURES
Refrigerant HFC134a is the most stable and easiest 3. Keep refrigerant containers in the correct upright
conditioning systems. Refrigerant HFC134a does not away from heat and sunlight. The pressure in a
contain chlorofluorocarbons (CFC’s) which are container will increase with heat.
harmful to the Earth’s ozone layer.
with refrigerant HFC134a to prevent possible conditioner system.
personal injury.
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
T
IN
B. See a physician immediately. tester. Tests have indicated that compressed
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combustible gas.
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9006-5
COMPRESSOR BELT CHECK AND ADJUSTMENT

NOTE: Photos may vary from machine being
serviced. WARNING: Rotating fans and belts. Contact
Check Interval . . . . . . . Every 250 hours of operation can injure. Keep clear.
M150A
NOTE: Check the belt tension after the first 50 hours
of operation and then use the regular check interval.
BD02H035
To adjust the belt tension, loosen the compressor

adjusting bolts and pivot bolt. Push the compressor
T
up until the correct tension for the belt is reached.
Tighten the compressor adjusting bolts and pivot
IN
bolt.
IMPORTANT: Do not pry on the compressor clutch
PR
542L95
Measure the compressor belt for correct tension or body. Apply pressure only on the mounting ears.
using a belt tension gauge. Check the belt to the
following specifications.
New Belt . . . . . . . . . . 578 to 667 N (130 to 150 lbs)
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Used Belt . . . . . . . . . . . 356 to 534 N (80 to 120 lbs)

FO
NOTE: Adjust new belts to the used belt

specifications after a 10 minute run-in.
COMPRESSOR OIL LEVEL CHECK

T
Check the oil level in the compressor when any of the STEP 1
O
following has occurred.

A. Broken refrigerant hose.
N
B. Large refrigerant leak. 3

1
C. Compressor leak.
D. Damage to or replaced system components.
E. New compressor installed.
Use the following procedure to check the compressor 2
oil level. 4
BD02H081
1. AC SWITCH 3. THERMOSTAT CONTROL

2. FAN SWITCH 4. VENT CONTROL

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9006-6
Start the engine and run at mid-idle. Operate the air STEP 5
conditioner for 10 to 15 minutes at maximum cooling
and maximum blower speed.
STEP 2
Stop the engine. See Section 9004 for connecting
the compressor to the A/C charging, recovery and
recycling station and for discharging the system.
STEP 3
Check the mounting angle of the compressor. Put the
angle gauge from the service tool set across the flat
surfaces of the two front mounting ears. Adjust the
gauge so that the bubble is between the center
103L7
marks. Read the mounting angle to the nearest
Remove the dust cover and use a wrench to rotate
degree mark. Make a note of the degree reading for
the clutch clockwise until the internal parts are in the
reference later.
position shown above. This will permit the dipstick to
be inserted all the way.
STEP 4
STEP 6
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BD02H034
When all refrigerant has been reclaimed, remove the

850L0
oil filler plug.
Put the dipstick in the oil filler hole to the stop
Add back to the compressor an amount of new position.
T
SP-20 PAG oil equal to that amount reclaimed with

Make sure the dipstick is inserted all the way to the
O
refrigerant. Refer to Section 9004 for complete

instructions. stop.
N
NOTE: The illustration shows the front view of the

compressor with the dust cover removed.
IMPORTANT: When compressor is replaced, the old
oil should be drained and this amount of new oil
should be put into the (drained) replacement
compressor.

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9006-7
STEP 7 STEP 9
Remove the dipstick. Count the oil level marks on the
dipstick. Use the following table to find the correct oil
level for the mounting angle of the compressor.
Compressor Oil Level
MOUNTING ANGLE
DIPSTICK READING
(DEGREES)
0 4 to 6
10 6 to 8
20 7 to 9
30 8 to 10
40 9 to 11
BD02H034
50 9 to 11
Install a new O-ring on the oil filler plug. Install the
plug and tighten to a torque of 15 to 24 Nm (11 to 18
STEP 8 lb ft).
If the oil level is not correct, add or subtract oil to the
correct level shown in the above chart.
IMPORTANT: Use only SP-20 PAG oil.
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9006-8
COMPRESSOR REPAIR
Clutch Disassembly STEP 13
STEP 10
A21253
Remove the retaining nut for the front plate. Use the
A21250
special spanner wrench from the service tool set to
See Section 9005 in this ser vice manual for keep the plate and shaft from turning.
compressor removal. Clean the external surfaces of
STEP 14
T
the compressor before doing any work on the
compressor.
IN
STEP 11
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A21254
Install the special puller from the service tool set on

T
the clutch front plate.

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A21251
Remove the mounting bolts for the clutch dust cover. STEP 15
N
STEP 12
A21255
Turn the center screw to pull the clutch front plate.

A21252
Remove the clutch dust cover.

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9006-9
STEP 16 STEP 19
A21256 A21260
Remove the shim(s) from the shaft. Remove the external snap ring for the bearing and
pulley assembly.
STEP 17
STEP 20
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A21257
Remove the bearing dust cover. Be careful not to A21261

FO
bend the dust cover. Install the special puller internal collars into the
groove in the pulley. Install the special tool onto the
STEP 18 shaft. Tighten the mounting screws finger tight.
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STEP 21
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N
A21258
Remove the key from the rotor shaft.

A21262
Turn the center screw on the puller.

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9006-10
STEP 24
A21263
Remove the pulley and bearing assembly. A21266
Remove the clutch coil assembly.
STEP 22
STEP 25
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A21265
Remove the snap ring for the clutch coil assembly. A21267
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Remove the internal snap ring and remove the

bearing from the pulley.
STEP 23
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A21264
Disconnect the clip for the lead wire.

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9006-11
3
4 7
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5
6
IN
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1016L93
1. COMPRESSOR 5. BEARING DUST COVER

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2. COIL ASSEMBLY 6. FRONT PLATE

3. PULLEY 7. SHIM(S)
4. BEARING 8. DUST COVER
CLUTCH ASSEMBLY
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9006-12
STEP 26 STEP 28
1
2
102L7 A21264
1. AMMETER 2. 12V BATTERY Install the clip for the coil lead wire.
Use a ammeter, voltmeter and a 12 volt battery to
check the amperage of the clutch coil. The current STEP 29
draw must be 3.6 to 4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short
within the coil.
T
No amperage reading indicates an open circuit in the
IN
coil.
Replace the clutch coil if the amperage reading is not
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correct.
Clutch Assembly
STEP 27
R
A21265
Install the snap ring for the clutch coil assembly.

FO
STEP 30
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A21266
Install the clutch coil assembly. Align the detent ball

and socket on the coil and housing.
A21267
Install the bearing in the pulley and install the internal

snap ring.

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9006-13
STEP 31 STEP 33
A21268 A21260
Put the pulley and bearing assembly on the front Install the external snap ring on the front housing
housing hub. Install a driver on the pulley assembly. hub.
Make sure that the tool is on the inner race of the
bearing. STEP 34
STEP 32
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A21259
FO
Install the key in the rotor shaft.

A21268
Support the compressor on the four mounting ears at STEP 35

the compressor rear. Use a hammer to tap the pulley
T
assembly onto the front housing hub. As the pulley is

tapped onto the hub you can hear the difference in
O
sound when the pulley is fully installed. Make sure

the bearing is against the bottom of the hub.
N
A21269
Place the bearing dust cover in the bore. Place driver

from special tool kit over the dust cover.

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9006-14
STEP 36 STEP 39
A21270 A21272
Gently tap the dust cover until it is seated. Use a hammer to tap the plate onto the shaft. Make
sure the plate is against the clutch shims. As the
STEP 37 plate is tapped onto the shaft you can hear the
difference in sound when the plate is fully installed.
STEP 40
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A21256
Install the shim(s) on the rotor shaft.

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STEP 38 A21253
Install the nut on the rotor shaft. Use the spanner

wrench and a torque wrench to tighten the nut to a
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torque of 15 to 20 Nm (11 to 15 lb ft).

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A21271
Install the front plate on the rotor shaft. Make sure

the keyway in the plate is aligned with the key in the
shaft. Install the driver over the shaft.

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9006-15
STEP 41 STEP 43
T97256 A21251
Use a feeler gauge to measure the gap between the Install and tighten the six bolts that hold the dust
front plate and pulley assembly. The gap must be cover to the compressor to 7 to 11 Nm (5 to 8 lb ft).
0.41 to 0.79 mm (0.016 to 0.031 inch). The gap must
be even all the way around the plate. If necessary,
lightly lift or push down on the plate to make the gap
even.
NOTE: If the gap does not meet the above
T
specifications remove the front plate and add or
IN
subtract clutch shims as required.
STEP 42
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A21252
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Install the dust cover.

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9006-16
NOTES
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Section
9007
DOZER BLADE
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9007
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9007-2
TABLE OF CONTENTS
C-FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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9007-3
C-FRAME
Removal STEP 7
STEP 1
Put blocks under the rear of the C-frame to hold the
C-frame in place when the pivot pins are removed.
STEP 2
Lower the blade to the floor.
STEP 3
Stop the engine, place the ignition switch in the on
position.
BC05H142
STEP 4 Tag and disconnect the tilt cylinder hoses, install a
Move the blade control lever in all directions to relieve plug in each hose and a cap on each fitting.
any pressure in the hydraulic circuits, turn the ignition
switch off. STEP 8
STEP 5
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Remove all dir t and grease from the hose
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connections.
STEP 6
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BC05H144
Remove the bolts and retainer plates that secure the

hoses to the front of the C-frame.
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STEP 9
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BC05H143
Tag and disconnect the angle hoses, install a plug in
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each hose and a cap on each fitting.
BC05H145
Remove the bolts and retainer plates that secure the

hoses to the rear of the C-frame.
STEP 10
Secure the hoses to the grill on the machine.

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9007-4
STEP 11 STEP 14
Secure the rod ends of the lift cylinders to keep them
from dropping when removing cylinder pins.
STEP 12
BC05H146
Use a prybar to remove the pivot pins, observe the
location and number of shims.
BC05H137
STEP 15
Remove the bolt and pin from the rod end of the lift Carefully move the machine out of the C-frame.
cylinders.
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STEP 13
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BC05H135
Remove the bolts and washers that hold the pivot
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pins in place at the rear of the C-frame.

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9007-5
Install the bolts, washers and shims that hold the
STEP 16 pivot pins.
Carefully move the machine into the C-frame.
STEP 19
STEP 17 Align the piston rod eyes of the lift cylinders with the
Replace shims as previously installed. Install the C-frame and install the pivot pins.
pivot pins that hold the rear of the C-frame to the
main frame. Place shims behind the wear blocks (1) STEP 20
to obtain a gap of 2 to 4 mm (0.080 to 0.157 inch) Install the bolts and hardened washers that hold the
between wear blocks (1) and radiator wrapper (2). pivot pins in the C-frame.
NOTE: Use washers items 5 and 6 as required
between the main frame and the C-frame until the STEP 21
wear blocks on the C-frame (below) are centered. If Connect the hoses to the cylinders.
possible, use item 5 before using item 6. Fill the gap
between the mounting ear on the outside of main STEP 22
frame and the C-frame with item 6. Start the engine and run the engine at low idle.
STEP 23
1 Raise the blade.
2
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STEP 24
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Slowly extend and retract the angle and tilt cylinders
four times to remove any air from the hydraulic
circuits.
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STEP 25
Lower blade to the ground, stop the engine.
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BC05H147 STEP 26
1. WEAR BLOCKS 2. RADIATOR WRAPPER Check for leaks, check the oil level in the hydraulic
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5
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6
BS00E100
3. C-FRAME 5. WASHER, 3.18MM (1/8) INCH THICK 7. BUSHING

4. PIVOT PIN 6. WASHER, 6.35MM (1/4) INCH THICK 8. U-CUP SEAL

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9007-6
BLADE
Removal STEP 7
Move the hoses out of the bracket at the blade and
STEP 1 out of the way.
Lower the blade to the floor.
STEP 8
STEP 2
Put blocks under the center of the C-frame to hold
the C-frame in place.
STEP 3
Connect acceptable lifting equipment to the blade
that will hold the blade in place as the blade is
removed.
STEP 4
Remove all dir t and grease from the hose
connections. BC05H141
Remove the snap ring and hardened washer from
STEP 5
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the pivot pin at the closed end of the tilt cylinder.
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STEP 9
Remove the pivot pin from the closed end on the tilt
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cylinder.
STEP 10
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BC05H143
Tag and disconnect the angle hoses, install a plug in
each hose and a cap on each fitting.
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STEP 6
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BC05H148
Remove the snap ring and hardened washers that
fasten the pivot pins for the closed ends of the angle
cylinders to the blade.
STEP 11
Remove the pivot pins for the angle cylinders.
BC05H142
Tag and disconnect the tilt cylinder hoses, install a

plug in each hose and a cap on each fitting.
STEP 12

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9007-7
STEP 14
BC05H140
Remove the blade pitch link from the blade and BC05H139
C-frame. Remove the bolts that fasten the trunnion block to

the blade.
STEP 13
STEP 15
Use the lifting equipment to move the blade up off of
the trunnion block. Move the blade away from the
C-frame and lower the blade to the floor.
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BC05H138
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Remove the bolts, washers and cover plate that

fasten the blade and trunnion block together.
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9007-8
STEP 16
Apply Loctite sealer 504 to the top mounting surface
on the trunnion block.
STEP 17
Use acceptable lifting equipment to put the blade in
position on the trunnion block.
STEP 18
Apply Loctite sealer 504 to the cover plate, put the
cover plate into position on the trunnion block BC05H138
mounting bracket. Torque the four cover plate bolts to 555 to 620 Nm
(408 to 460 lb-ft).
STEP 19
STEP 22
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BC05H138
Install the bolts and washers that fasten the cover
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BC05H140
plate, blade, and trunnion block together, DO NOT Install the blade pitch link to the blade and C-frame.
torque the bolts at this time, just snug them up.
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STEP 23
STEP 20 Apply Loctite 243 to the link mounting bolts, install
the bolts and flat washer. Torque bolts to 285 to 320
Nm (208 to 235 lb-ft).
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STEP 24
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BC05H139
Install the bolts and washers that fasten the trunnion
block to the blade and torque to 555 to 620 Nm
(408 to 460 lb-ft).
BC05H148
Install the closed ends of the angle cylinders in
position on the blade. Install the pivot pins that fasten
the rod ends of the angle cylinders to the blade.

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9007-9
STEP 25 STEP 28
Install the snap rings and hardened washers that Connect the hoses to the cylinders on the blade.
hold the pivot pins in the blade. The snap rings must
engage the groove in the pivot pin. STEP 29
Start the engine and run the engine at low idle.
STEP 26
Install the closed end of the tilt cylinder in position on STEP 30
the blade. Install the pivot pin that fastens the closed Raise the blade.
end of the tilt cylinder to the blade.
STEP 31
STEP 27 Slowly extend and retract the angle and tilt cylinders
four times to remove any air from the hydraulic
circuits.
STEP 32
Stop the engine.
STEP 33
Check for leaks, check the oil level in the hydraulic
reservoir. Add oil as required.
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STEP 34
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BC05H141
Grease all pivot pins and trunnion block.
Install the snap ring and hardened washer that hold
the pivot pin in the blade. The snap ring must engage
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the groove in the pivot pin.
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9007-10
CUTTING EDGE
Replacement STEP 3
STEP 1
Remove the old cutting edge.
STEP 2
Clean the surface for the cutting edge on the blade.
BC05H122
Install the cutting edge, dome bolts, spring lock

washers, and nuts. Torque nuts to 461 to 570 Nm
(340 to 420 lb-ft).
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Section
9008
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
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CAB STRUCTURAL FRAME (CSF)
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9008

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9008-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REFILLING AND BLEEDING THE TILT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TILTING (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(CSF) CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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9008-3

CAB STRUCTURAL FRAME (CSF)
If the machine has rolled over or the ROPS cab or After an accident, check for damage to the ROPS
canopy has been in some type of accident (such as cab or canopy, the operator seat, the seat belts and
hitting an overhead object during transport), the wiring in the ROPS cab or canopy. Before operating
ROPS cab or canopy must be replaced. the machine again, all damaged par ts must be
replaced.
DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
REPAIR THE ROPS OR CAB STRUCTURAL
FRAME.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first. WARNING: Adding additional weight
(attachments, etc). to the machine can cause
1. Check to see that the mounting bolts for the injury or death. Do not exceed the gross
ROPS cab or canopy are tight. weight printed on the ROPS label.
2. Check the operator seat and the mounting parts A028
for the seat belts. Check to see that the bolts are
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WARNING: Do not modify ROPS in any
tight.
manner. Unauthorized modifications such as
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welding, drilling, cutting or adding
attachments can weaken the structure and
reduce your protection. Replace ROPS if
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subjected to roll-over or damage. Do not
attempt to repair.
B026
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SPECIAL TORQUES
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Torques
Support mount bolts .............................................................................................550 to 624 Nm (406 to 460 lb-ft)
Brush guard mount bolts (if equipped) .................................................................570 to 730 Nm (420 to 540 lb-ft)
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REFILLING AND BLEEDING THE TILT SYSTEM

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1. Make sure that the cylinder rod is fully retracted. 3. Tilt and lower cab two to three times to remove
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air from the system.

2. Remove fill check plug and fill with MS-1209.
4. Fill as needed, use MS-1209.
1 5. Install fill check plug.
BD02F024
1. PUMP FILL CHECK PLUG

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9008-4
TILTING (CSF) CAB OR (ROPS) CANOPY

STEP 4
WARNING: Make sure there no loose
objects in the cab or canopy prior to tilting.
Falling objects could cause death and
serious injury.
M853
NOTE: The left and right hand ROPS side panels

must be OPEN to prevent interference with frame
components. The left and right engine compartment
panels must be CLOSED. On cab units the cab doors
must be CLOSED.
Tilt
BD02F005
STEP 1 Tilt the brush guard until the brush guard is free of
the canopy.
Park the machine on a flat surface, lower the blade
and any attachment to the floor, turn the master NOTE: The removed bolts can be used in the tilting
disconnect to the off position. brackets to hold the brush guard up.
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STEP 2 STEP 5
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BD02F028 BD02M138
1. JACK HANDLE 2. LEFT SIDE PANEL Remove the six support mount bolts on the right side
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Open the right and left side panels under the cab. of the cab.
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STEP 3 STEP 6
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BD02F024
BD02F003
If equipped with a brush guard, remove the bolts at Turn the pump diverter valve into the cab tilt position.
the rear of the brush guard. Actuate the hand pump and tilt the cab slowly.
NOTE: Cab travel will be stopped by the safety
cable.
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9008-5
Lower STEP 9
If equipped with a brush guard, lower the brush
STEP 7 guard into alignment with the cab.
STEP 10
BD02F024
Turn the diverter valve to the lower position. Actuate

the hand pump and lower the cab slowly. BD06J130
Install the bolts and torque to 405 to 730 Nm (300 to

NOTE: Make sure that no wiring or hydraulic lines
540 lb-ft).
get pinched during lowering.
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STEP 8
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BD02M139
Install the six support mount bolts and torque to 550

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to 624 Nm (406 to 460 lb-ft).

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9008-6
ROPS CANOPY
Removal STEP 4
STEP 1
Remove the batteries from the vehicle.
STEP 2
BD02F005
Tilt the brush guard until the brush guard is free of

the ROPS canopy.
NOTE: The removed bolts can be used in the tilting
brackets to hold the brush guard up.
BD06J126
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BD06J129
4
Disconnect the wiring harness connectors from the BD06J127
ROPS.
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1. MOUNT BOLTS 3. ENGINE HARNESS

2. FUSE AND RELAY BLOCK 4. ROPS FRAME
STEP 3
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Remove the two mounting bolts for the fuse and relay
bracket and lay it in the battery compartment area.
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BD02F003
If equipped with a brush guard remove the bolts at
the rear of the brush guard.

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9008-7
STEP 6 Installation
STEP 10
3 Carefully lower the ROPS canopy into alignment with
the mounts.
2 STEP 11
1
BD02F031
1. TILT CYLINDER 3. PIVOT PIN

2. SAFETY CABLE
Disconnect the tilt cylinder and safety cable.
STEP 7
Install lifting eyes on top of the ROPS canopy. BD02F007
Install the twelve support mount bolts and torque to
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STEP 8 550 to 623 Nm (406 to 460 lb-ft).
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BD02F006
Remove the twelve mounting bolts from the mounts.

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BD02F031
STEP 9 1. TILT CYLINDER 3. PIVOT PIN

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Carefully raise and remove the ROPS canopy from 2. SAFETY CABLE
the machine. Connect the tilt cylinder and safety cable.
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9008-8
STEP 13 STEP 15
If equipped with a brush guard, lower the brush
guard into alignment with the ROPS canopy.
STEP 16
2 2
1 3
4
BD06J127

Mount the fuse and relay bracket to the ROPS,
tighten the mount bolts and install the batteries. BD06J130
Install the brush guard mount bolts and torque to 405

STEP 14 to 730 Nm (300 to 540 lb-ft).
Connect the wiring harness connectors to the ROPS
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connectors.
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9008-9
(CSF) CAB
Removal STEP 5
NOTE: The following photos show a ROPS canopy,
the procedures are the same.
STEP 1
Drain 4 liters (1 U.S. gallon) of coolant from the
radiator.
STEP 2
BD06J126
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BD06J128
Disconnect the heater hoses and install a plug in
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each heater hose and tighten the clamps.
STEP 3 BD06J129
Remove the batteries from the vehicle. Disconnect the wiring harness connectors from the
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ROPS cab.
STEP 4
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STEP 6
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1 3
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4
BD06J127
BD02F003
If equipped with a brush guard, remove the bolts at
the rear of the brush guard.
Remove the two mounting bolts for the fuse and relay
bracket and lay it in the battery compartment area.

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9008-10
STEP 7 STEP 12
BD02F005 BD02F006
Tilt the brush guard forward until the brush guard is Remove the twelve bolts from the mounts.
free of the ROPS cab.
NOTE: The removed bolts can be used in the tilting STEP 13
brackets to hold the brush guard up. The ROPS cab must stay level when raised.
STEP 8 STEP 14
Discharge the air conditioning system according to Carefully raise the ROPS cab until free of the
machine and remove from the machine.
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STEP 9
Disconnect the hoses that go to the evaporator.
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Install caps and plugs on the hoses to prevent
moisture from entering the hoses.
STEP 10
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BD02F031

2. SAFETY CABLE
Disconnect the tilt cylinder and safety cable.
STEP 11
Install lifting eyes on top of the ROPS cab.

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9008-11
NOTE: The following photos show a ROPS canopy,
the procedures are the same. 3
STEP 15
Carefully lower the ROPS cab onto the machine and 2
into alignment with the mounts.
1
STEP 16
BD02F031

2. SAFETY CABLE
Connect the tilt cylinder and safety cable.
STEP 21
Tilt the ROPS cab and connect the heater hoses.
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BD02F007
STEP 22
Fill the radiator to the correct level, see section 1002.
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Install the twelve support mount bolts and torque to
550 to 624 Nm (406 to 460 lb-ft).
STEP 23
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STEP 17 If equipped with a brush guard, lower the brush
Connect the wiring harness for the ROPS cab to the guard into alignment with the ROPS cab.
main wiring harness.
STEP 24
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STEP 18
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2 2
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4 BD06J130
BD06J127
Install the brush guard mount bolts and torque to 405
to 300 Nm (420 to 540 lb-ft).
STEP 25
Mount the fuse and relay bracket to the ROPS,
Charge the air conditioning system according to
tighten the mount bolts and install the batteries.
STEP 19
Connect the hoses that go to the evaporator.

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9008-12
NOTES
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Section
9009
AIR AND MECHANICAL SUSPENSION SEATS
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9009

Copyright ©
9009-2
TABLE OF CONTENTS
AIR SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MECHANICAL SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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9009-3
AIR SUSPENSION SEAT
Disassembly STEP 4
STEP 1
BS02N015
Remove the plastic pins from the boot assembly.

BS02N012
Loosen and remove the 4 cap screws from the seat STEP 5
assembly. Remove the seat assembly from the base.
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STEP 2
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BS02N016
Remove the boot assembly.

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BS02N013 STEP 6
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Remove the washers and spacer blocks.
STEP 3
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BS02N017
Remove the nut and lock washer from the control

switch.
BS02N014
Loosen the Allen set screw for the seat control button
and remove the button.

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9009-4
STEP 7 STEP 10
BS02N018 BS02N021
Disconnect the electrical and air connectors from the Remove the bushing and roller from the suspension
switch. assembly.
STEP 8 STEP 11
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BS02N019 BS02N022
Remove the pivot bolt from the upper plate. Cut the plastic tie holding the wiring harness to the
lower plate.
STEP 9
STEP 12
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BS02N020
Remove the upper plate. BS02N023
Remove the screw for the air spring from the lower
plate.

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9009-5
STEP 13 STEP 16
BS02N024 BS02N027
Remove the pivot bolt from the lower plate. Remove the retainer washer and shock from the
suspension assembly.
STEP 14
STEP 17
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BS02N025
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Pick up on the suspension assembly, twist around BS02N028
the rubber bumper to clear the guides and remove Cut the two plastic ties, disconnect the electrical
the lower plate. connector and remove the air hose from the fitting.
STEP 15 STEP 18
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BS02N026 BS02N029
Remove the busing, roller and spacer from the Remove the wiring harness and air hose from the
suspension assembly. retaining clip.

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9009-6
STEP 19 Inspection
1. Inspect the seat cushion, backrest cushion, and
lumbar support control for wear and damage.
Use new parts as required.
2. Inspect the slide control, and slide latch for wear
and damage. Use new parts as required.
3. Inspect height adjustment switch, and wire
harness for damage. Use new parts as required.
4. Inspect the boot assembly for damage. Use new
parts as required.
5. Inspect the suspension assembly and roller
BS02N030
bearings for wear and damage. Lubricate the
Disconnect the air line from the compressor, remove roller bearings and contact points with
the 2 mounting screws from the compressor, remove molydisulfide grease. Use new parts as required.
the compressor. 6. Inspect the suspension shock and bushings for
wear and damage. Use new parts as required.
STEP 20
7. Inspect the air compressor, air line, and wiring
harness for wear and damage. Use new parts as
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required.
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8. Inspect the air spring for wear and damage. Use
new parts as required.
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9. Insect the lower plate, bearing shaft, and rubber
bumper for wear and damage.Lubricate the
contact points with molydisulfide grease. Use
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BS02N031
Remove the air spring mounting bolt, remove the air

spring.
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9009-7
Assembly STEP 24
STEP 21
BS02N028
Connect the electrical connection, connect the air

BS02N031
line to the compressor, and replace the plastic ties.
Install the air spring into the suspension assembly,
install the bolt with retaining clip and tighten. STEP 25
STEP 22
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BS02N027
Install the bushings and suspension shock onto the

BS02N030
suspension assembly.
Install the compressor with the two mounting screws,
STEP 26
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install the air spring line into the compressor.

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STEP 23
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BK98C189
Use molydisulfide grease and install the bushings

BK98C182
and rollers on the lower portion of the suspension
Place the air hose and wiring harness into the assembly.
retaining clip.

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9009-8
STEP 27 STEP 30
BS02N025 BS02N022
Place the suspension assembly rollers into the Route the wiring harness to the rear of the seat and
guides, twist around the rubber bumper and lower secure with a plastic tie strap.
into place.
STEP 31
STEP 28
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BS02N021
BS02N024 Use molydisulfide grease and install the bushings

Use molydisulfide grease on the pivot bolt and install and rollers on the upper portion of the suspension
into the lower plate and suspension assembly. Install assembly.
a new self locking nut and tighten.
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STEP 32
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STEP 29
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BK98C202
BS02N023 Slide the upper plate over the rollers and lower into
Install and tighten the screw into the bottom of the air place.
spring.
STEP 33
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9009-9
STEP 36
BS02N019
Use molydisulfide grease on the pivot bolt and install BS02N016
into the upper plate and suspension assembly. Install Slip the rubber boot over the upper plate.
a new self locking nut and tighten.
STEP 37
STEP 34
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BS02N015
FO
BS02N018 Slide the rubber boot into position on the upper and
Connect the air hose and electrical wiring to the lower housing. Install the plastic pins into the
switch. mounting holes in the rubber boot.
STEP 38
T
STEP 35
O
N
BS02N017 BS02N014
Install the switch into the upper plate, install the lock Install the control knob onto the switch, tighten the
washer and nut. Tighten the switch. Allen set screw.

Copyright ©
9009-10
STEP 39 STEP 40
BS02N013 BS02N013
Place the 4 bushings and washers onto the upper Use new self locking nuts and install the seat
plate. assembly onto the frame assembly.
T
IN
PR
R
FO
T
O
N

Copyright ©
9009-11
MECHANICAL SUSPENSION SEAT
Dissasembly STEP 4
STEP 1
BS02N005
Remove the four mounting bolts from the support

BS02N002
plate.
Push up on the front of the lower cushion to release
the retaining clip. STEP 5
T
STEP 2
IN
PR
R
FO
BS02N006
Remove the mounting bolts for the slide controls,

T
BS02N003
remove the slide controls.
O
Remove the lower cushion from the seat assembly.

STEP 6
STEP 3
N
BS02N007
BK98C164
Remove the plastic pins and boot assembly from the
Remove the four mounting bolts from the seat. suspension assembly.

Copyright ©
9009-12
STEP 7 Inspection
1. Inspect the seat cushion, backrest cushion, and
lumbar support control for wear and damage.
2. Inspect the slide control, and slide latch for wear
and damage. Use new parts as required.
3. Inspect weight adjustment gears for damage.
4. Inspect the boot assembly for damage. Use new
parts as required.
5. Inspect the suspension assembly and bushings
BS02N009
for wear and damage. Lubricate the bushings
Place the suspension assembly in a press, compress and contact points with molydisulfide grease.
the assembly slightly and remove the mounting bolts Use new parts as required.
for the shock assembly. 6. Inspect the suspension shock and bushings for
wear and damage. Use new parts as required.
STEP 8
7. Inspect the spring for wear and damage. Use
T
IN
PR
R
FO
BS02N008
Remove the shock from the suspension assembly.

T
O
N

Copyright ©
9009-13
Assembly STEP 12
STEP 9
BS02N005
Use new self locking nuts and install the support

BS02N009
plate.
Install the suspension shock into the suspension
assembly. Install new self locking nuts and tighten. STEP 13
STEP 10
T
IN
PR
R
FO
BS02N004
Use new self locking nuts and install the seat

BS02N007
assembly onto the support plate.
Place the boot assembly into position on the
STEP 14
T
suspension assembly, install new plastic pins.

O
STEP 11
N
BS02N010
Make sure the retaining clips are in place and install

BS02N006
the lower cushion into the seat.
Use new self locking nuts and install the slide rails.

Copyright ©
9009-14
NOTES
T
IN
PR
R
FO
T
O
N

Copyright ©
Section
9010
RIPPER
T
IN
PR
R
FO
T
O
N
9010

Copyright ©
9010-2
TABLE OF CONTENTS
Hydraulic Hose Routing Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ripper Frame And Mounted Components Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
T
IN
PR
R
FO
T
O
N

Copyright ©
9010-3
2
3
4
5
T
6
IN
BC06B010
1. CONTROL VALVE 5. MOUNTING CLAMP

PR
2. INSULATED MOUNTING CLAMP 6. RIPPER CYLINDER
3. BULKHEAD 7. RIPPER
4. MANIFOLD TEES
HYDRAULIC HOSE ROUTING ILLUSTRATION
R
FO
T
O
N

Copyright ©
9010-4
8
12
9
10
11
13
17 19 20
16 18 21
15
T
22
14 23
IN
24
PR
R
25
26
FO
27
T
O
N
BC06B011
8. PIN UPPER ARM 18. LOWER ARM

9. PIN CYLINDER 19. PIN
10. MOUNTING BOLTS 20. WASHER
11. PIN LOWER ARM 21. RETAINING RING
12. SPACER 22. PIN
13. SPACER 23. WASHER
14. LEFT CYLINDER 24. RETAINING RING
15. LEFT UPPER ARM 25. PIN
16. RIGHT CYLINDER 26. WASHER
17. RIGHT UPPER ARM 27. RETAINING RING
RIPPER FRAME AND MOUNTED COMPONENTS ILLUSTRATION

Copyright ©
9010-5
RIPPER
Remove Install
1. Park the machine on a level surface. 1. Align the mounting brackets with the frame.
2. Lower the ripper until the teeth are on the floor. 2. Install the bolts and washers (10) that fasten the
mounting brackets to the frame.
3. Stop the engine and apply the parking brake.
3. Tighten the bolts to 1136 to 1255 Nm (838 to 926
4. Turn ignition switch to the on position, move the
pound-feet).
ripper control lever in both directions to relieve
any pressure in the ripper circuits. Turn off 4. Move the ripper into position, raise the lower arm
ignition. (18) into the brackets.
5. Remove the dirt and grease from the tees (4) on 5. Align and install the pins (11) for the lower arm
the rear cover of the machine. (18).
6. Disconnect the clamps (5) holding the hoses to 6. Place spacers (12 and 13) on the left cylinder
the bulk head. (14), spacer (12) must be towards the center of
the machine.
7. Fasten identification tags to the hoses for each
ripper cylinder so that the connections will be 7. Align the left cylinder (14) in the bracket, install
correct during installation. Disconnect the hoses pin (9).
from the tees.
T
8. Align the left cylinder with the ripper (7), install
8. Install caps on the tees and plugs in the hoses. pin (22), washer (23), and retaining ring (24).
IN
9. Remove retaining ring (21), washer (20), and pin 9. Repeat steps 6 through 8 for right cylinder (16).
(19) for the right upper arm (17).
PR
10. Align the right upper arm (17) with the bracket,
10. Remove the pivot pin (8) for the right upper arm install the pivot pin (8) for the right upper arm
(17), remove the right upper arm (17). (17).
11. Repeat the procedure for the left upper arm (15). 11. Lower the ripper to the ground and remove the
R
pin and strap from the right side of the ripper.

12. Place a strap in the channel of the frame where
the upper arms (15 and 17) were removed. 12. Install the pin (19), washer (20), and retaining
FO
ring (21), for the right upper arm (17).

IMPORTANT: Approximate weight of the ripper is
1038 Kg (2288 pounds), use strap(s) that are rated 13. Repeat steps 10 through 12 for left upper arm
for this weight or greater. (15).
T
13. Install pin (19), washer (20), and retaining ring 14. Install new O-rings, connect the hoses to the
(21) on both sides of the frame. tees (4), reinstall the clamps (5) holding the
O
hoses to the bulk head.

14. Use acceptable lifting equipment and pick up the
N
ripper enough to release the pressure on the 15. Start the engine and run the engine at low idle.
cylinder mounting pins.
16. Slowly extend and retract the ripper cylinders
15. Remove retaining ring (24), washer (23), and pin four times to remove any air from the ripper
(22) for the right cylinder (16). circuits.
16. Remove the pivot pin (9) for the right cylinder
(16), remove the right cylinder (16).
17. Repeat the procedure for the left cylinder (14).
18. Support the lower arm (18) to keep it from falling.
19. Remove the pivot pins (11) for the lower arm,
lower the arm to the ground.
20. Carefully move the ripper away from the
machine.
21. If required, remove the mounting bolts (10),
remove the brackets from the frame.
Copyright ©
9010-6
NOTES
T
IN
PR
R
FO
T
O
N

Copyright ©
2 3 4 5
127 x 64 x 120 108 x 51 x 445 102 x 51 x 254

127 x 64 x 381
L1 LS MLS A1 B1 A2 B2 A3 B3 A4 B4
1
MP
Ø0.8
Ø0.8
207+5 bar
P
248+5 bar
PST
180 ± 3 bar
9 10-16 bar 150 l/min

L
Bp T
6
10 MT
Bp 16 bar
400±5 bar 400±5 bar 238±6 bar 238±6 bar AC 0.35 l

10 bar
P
8
B
3.5bar
P T G
P2 P1 P3
T
MPST
IN
PR
L
R
11 12
FO
7
R T2 I
R T2 PS Fa Fe MB PS Fa Fe MB
T
T1 T1 13.8 bar
O
B B
N
13 T C
420 bar 390 bar 18.7cc 420 bar 390 bar 18.7cc
30 bar 30 bar 64.6cc
A A
X1 X2 G G1 MH S MA X1 X2 G G1 MH S MA
B M1 U B M1 U 17
n n
16
14 15
A G T2 A G T2
COMPONENTS NOTES HYDRAULIC SYMBOLS

1. FOUR-SPOOL VALVE 14. LEFT HYDROSTATIC MOTOR
2. TILT CYLINDER 15. RIGHT HYDROSTATIC MOTOR 1. HYDRAULIC AND HYDROSTATIC SYSTEMS
3. LIFT CYLINDERS 16. RESERVOIR USE ONE COMMON RESERVOIR.
4. ANGLE CYLINDERS 17. BREATHER
COMPONENT CROSSING LINES CHECK VALVE FILTER OR SCREEN
5. RIPPER CYLINDERS
6. ACCUMULATOR
7. COOLER BYPASS VALVE
HYDRAULIC PRESSURE
8. BRAKE SOLENOID VALVE ASSEMBLY
9. FINAL DRIVE BRAKE ASSEMBLIES PILOT PRESSURE LINE CONNECTION RESTRICTOR OIL COOLER
10. HYDROSTATIC FILTER ASSEMBLY
11. HYDROSTATIC PUMP ASSEMBLY LEFT
12. HYDROSTATIC PUMP ASSEMBLY RIGHT HYDRAULIC SCHEMATIC
13. EQUIPMENT PUMP
1150K SERIES 3 DOZER
Additional copies of this Hydraulic and Electrical Schematic can be ordered through
Technical Publications Distribution System. The Part Number is 5-4550
BC06N157
Copyright ©
CHARGING CIRCUIT CRANKING CIRCUIT RELAYS SOLENOIDS AND COLD START FUSE BLOCKS BRAKE, DECELERATOR, THROTTLE POTENTIOMETERS
R (30) 1.0 R (30) 1.0 R (30) 1.0 R (30) 1.0 R (30) 1.0 R (30) 1.0
R (21A) 1.0 R (21A) 1.0 R (21A) 1.0 R (21A) 1.0

17 19 20
C6
18 M23 M5 M6
BL (15) 0.8 BL (15) 0.8 BL (15) 0.8 BL (15) 0.8
BR (50) 2.0
15 M2 16 M3
R (21A) 1.0
4 W (START) 0.8 7 M2
8 M2
9 M3
10 M2
11 M2 12
D14
20AMP 20AMP 20AMP 20AMP
M14
13 M12 10A
BL (1M) 0.8 21-1 1
10A
BR (1N) 0.8 21-3 13
85 86 85 86 85 86 85 86 85 86
e e 9-4 2 A B C 1 2 A C B A C B
87a 87a 87a
100AMP
BL (V1ACC) 0.8
10-2 3 R (30) 1.0 21
1 ACC IGN ST OFF
87a 87a
20A
12-1
23-1
4
5
10A Y (280) 0.8
BATT
BL (15) 0.8
30 87 30 87 30 87 30 87 30 87 BL (V2ACC) 0.8 30-1 6 R (21A) 1.0
g g 15A 20A
B C A
GY (238) 0.8
GY (262) 0.8
LB (264) 0.8
LB (219) 0.8
B G B G
W (279) 0.8
13-5 14
O (223) 0.8
Y (280) 0.8
Y (265) 0.8
P (256) 0.8
BL (922) 2.0 15-1 7 R (992) 0.8
GY (1003) 0.8
16-2 15
BL (1001) 0.8
P (21C) 0.8 10A 20A
50A 60A
BL (933) 0.8 26-2 8 R (302) 2.0 17-11 16

10A 30A
22 23
O (312) 0.8
V (375) 0.5
BL (912) 2.0 R (501) 0.8
20-1 17
15-2 9
23-2 18
15A 15A
W (START) 0.8
BR (IGN+) 0.8
13A M8
W (317) 0.8
W (332) 0.5
O (337) 0.5
2
P (206) 0.8
Y (329) 0.5
BL (953) 0.8 26-1 10
B C A B C A
3 5 6 E8
10A
M7
B+ 100 AMP
e 150A
BR (IGN3) 0.8 13-1 19
R (1002) 0.8
W (237) 0.8
17-3 20
V (260) 0.8
5A
BL (ACC) 3.0
B (0) 0.8
B (0) 0.8
BL (800) 2.0 24-2 11 BR (IGN2) 2.0 7-1 21
E4 W D+ E13 W (21D) 1.0 W (21D) 1.0
14
B (0) 0.8
20A 20A
g 17-8 6 17-1 2
13-4 5 BL (819) 2.0 24-1 12 BR (IGN1) 0.8 BR (IGN1) 0.8
B G 17-7 4
17-10 1
25A 10A
9-1 22
17-9 3
13-7 2
17-4 2 75 7-7 4 7-20 7 7-10 10 7-19 11
7-3 1
21-2 1 7-11 3 7-6 6 7-18 9
7-21 2 7-25 5 7-22 8
7-24 1
GND
1 2 3 4 5 6
BC07A591-01A BC07A591-02A BC07A591-03A BC07A591-04A BC07A591-05A BC07A591-06A
DRIVE TRAIN CONTROLLER PUMPS AND MOTORS FNR JOYSTICK AND BRAKES BLADE CONTROL JOYSTICK RIPPER CONTROL JOYSTICK
13 20-2
REVERSE RATIO SWITCH
12 20-6
16-1 2
3-1 3
6-6 6
6-4 7
11 6-3 25 P3
26 P4
9-5 4 20-13 8 BL (V1ACC) 0.8 BL (V1ACC) 0.8
5-21 1
9-6 5 10-1 9 31 M9
GY (417) 0.8 GY (417) 0.8
6-10 10
REVERSE FORWARD REVERSE FORWARD 29 35 LB (415) 0.8 LB (415) 0.8
BL (V1ACC) 0.8
P6 V21
O (416) 0.8 O (416) 0.8
33 O (4111) 0.8
GY (215) 0.8
GY (238) 0.8
LB (219) 0.8
1 2 3 4 5 6 7 8 9 10 11 12 C10
W (237) 0.8
W (334) 0.8
V25
CAN LO
O (223) 0.8
4 2
Y (224) 0.8
B (335) 0.5
3 1 3 4 2 1 Y (418) 0.8
CAN HI
+PWR
+PWR
W (419) 0.8
GND
BR (IGN2) 2.0
P (230) 0.8
41
W (210) 0.8
O (205) 0.8
G (211) 0.8
P (206) 0.8
1 2 3 4
NO 1 2
O (217) 0.8 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 C17
Y (418) 0.8
G (218) 0.8
W (419) 0.8
T
LB (204) 0.8 LB (204) 0.8
36
B (0) 0.8
B (0) 0.8
Y (216) 0.8 Y (216) 0.8
LB (272) 0.8
BR (IGN2) 2.0
P (230) 0.8
32
IN
GY (215) 0.8
V (231) 0.8
C7
34 V24 1 2 3 4 5 6 7 8 9 10 11 12 C18
1 2 3 4 5 6 7 8 9 10 11 12 C16
G (218) 0.8
1 2 4 5 6 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 30 31 37 38 39 40 O (217) 0.8
G (429) 0.8 G (429) 0.8
PR
44 RIPPER JOYSTICK
BR (IGN1) 0.8
BR (IGN1) 0.8
BR (IGN1) 0.8
30 V (421) 0.8 O (428) 0.8 O (428) 0.8
W (334) 0.8
1 2 3 4
B (335) 0.8
24
B (0) 0.8
C1 C2 P5
O (424) 0.8
P (425) 0.8
Y (426) 0.8
V (427) 0.8
1 2 3 4 5 6 7 8 9 10 11 12 C21
41 42 43 44 46 48 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 79 80 27 P7 28 P8 A B C
BL (V1ACC) 0.8
R
1 2
W (243) 0.8
V (244) 0.8
1 2 3 4
FO
BL (V1ACC) 0.8
BR (IGN1) 0.8
1 2
GY (262) 0.8
1 2
LB (252) 0.8
LB (264) 0.8
LB (272) 0.8
37 38 39 42 43 45 46
W (248) 0.8
40
P (250) 0.8
V (251) 0.8
P (256) 0.8
V (260) 0.8
Y (265) 0.8
W (210) 0.8
BL (V1ACC) 0.8
BL (V1ACC) 0.8
G (268) 0.8
G (211) 0.8
V16 V15 V13 V14 V18 V17 V19 V20
B (0) 2.0
BL (V1ACC) 0.8
GY (215) 0.8
W (248) 0.8
Y (269) 0.8 V (244) 0.8
O (4111) 0.8
LB (422) 0.8
W (423) 0.8
W (423) 0.8
W (453) 0.8
W (453) 0.8
G (429) 0.8
G (429) 0.8
O (451) 0.8
Y (426) 0.8
Y (426) 0.8
V (427) 0.8
P (452) 0.8
B (0) 0.8
B (0) 0.8
W (271) 0.8
B (0) 0.8
W (279) 0.8
T
Y (280) 0.8
G (268) 0.8
Y (269) 0.8
O
6-9 18 C12 W (243) 0.8
23 11-1
BL (V1ACC) 0.8 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
B (0) 2.0
B (0) 2.0
20-14 14 6-8 22
N
7-5 6
20-11 15 6-2 21
5-22 1
20-3 3 7-4 5 7-17 3 1 5-4
20-12 16 6-7 20 6-5 25
LB (272) 0.8 7-23 1 2 13-6
10-3 17 6-11 19 6-1 24 20-7 2 5-2 4 1 7-9 5-3 2
BR (IGN1) 0.8
GND GND
7 8 9 10 11 12
BC07A591-07A BC07A591-08A BC07A591-09A BC07A591-10A BC07A591-11A BC07A591-12A
MENU SWITCHES AND INSTRUMENT CLUSTER SENDING UNITS FRONT AND REAR LAMPS HORN AND BACKUP ALARM COMPONENTS
1. BATTERIES 33. BRAKE PRESSURE SWITCH

B (335) 0.5 20-4 3 2. MASTER DISCONNECT SWITCH 34. BRAKE SOLENOID
1 5-19 BR (IGN3) 0.8
W (334) 0.5 3. ALTERNATOR 35. EQUIPMENT VALVE SOLENOID
20-8 2
4. IGNITION SWITCH 36. BLADE JOYSTICK
P (121) 0.8 P (121) 0.8 5. STARTER 37. BLADE LIFT SOLENOID
Y (120) 0.8 Y (120) 0.8
O (205) 0.8 6. STARTER SOLENOID 38. BLADE L0WER SOLENOID
7. IGNITION RELAY 39. TILT LEFT SOLENOID
0 0
B (0) 0.8 B (0) 0.8
P (135) 0.8 60 L5 8. VEHICLE SAFETY RELAY 40. TILT RIGHT SOLENOID
1 2 V9 9. STARTER RELAY 41. DIAGNOSTIC PORT
1 2 3 4 5 6 7 8 9 10 11 12 13 W (104) 0.8 10. START SENSING RELAY 42. ANGLE LEFT SOLENOID
47 1 1 LB (133) 0.8 58 V (911A) 2.0
11. FLEET RELAY 43. ANGLE RIGHT SOLENOID
GY (134) 0.8 L6 63 12. ACCESSORY RELAY 44. RIPPER JOYSTICK
D12 49 D2A
D5 1 2
BR (IGN3) 0.8
G (103) 0.8
13. GRID HEATER RELAY 45. RIPPER LOWER SOLENOID
3 1 NO 13A. GRID HEATER FUSE 46. RIPPER LIFT SOLENOID
14 15 16 17 18 19 20 21 22 23 24 25 26 47. ENTER/ESCAPE SWITCH
P9 14. GRID HEATER
2 15. FUSE BLOCK A 48. UP/DOWN SWITCH
V11 V10 V12
G (103) 0.8 16. FUSE BLOCK B 49. INSTRUMENT CLUSTER A
V23
51 53 A Y (911B) 2.0
61 17. THROTTLE POSITION SENSOR 50. INSTRUMENT CLUSTER B
A 52 54 55 56 1 2
L7
64 18. LOW IDLE SWITCH 51. FUEL SENDING UNIT
V 59
Y (911A) 0.8
19. DECLERATOR POSITION SENSOR 52. TRANSMISSION TEMP

2
W (111) 0.8 Y (911A) 0.8
T P P D6 L4
D13 20. BRAKE POSITION SENSOR
21. TILT PROX. SWITCH
53. AIR FILTER RESTRICTION
54. HYDROSTATIC FILTER RESTRICTION SWITCH
O (114) 0.8 LB (133) 0.8
1 2 NO 55. TRANSMISSION CHARGE PRESSURE SWITCH
R (992) 0.8 GY (134) 0.8 1 22. LH PARK BRAKE PROX. SWITCH
B NO
NO NC NO 23. RH PARK BRAKE PROX. SWITCH 56. EQUIPMENT FILTER RESTRICTION SWITCH
0 0 NO B
24. DRIVE TRAIN CONTROLLER 57. WARNING BUZZER
GY (921) 0.8
GY (921) 2.0
BL (922) 2.0
O (933) 0.8
R (992) 0.8
1 2 3 4 5 6 7 8 9 10 11 12 13 25. LH HYDROSTATIC PUMP 58. FRONT LAMP SWITCH
G (118) 0.8
A B 26. RH HYDROSTATIC PUMP 59. REAR LAMP SWITCH

1 1
48 E7 62 L3 27. LH MOTOR SOLENOID 60. FRONT LAMPS
D11 50 D2B
GY (921) 0.8
1 2 E10
28. RH MOTOR SOLENOID 61. OPTIONAL FRONT LAMPS
3 1 Y (911A) 0.8 Y (911A) 0.8
A 29. RH MOTOR SPEED SENSOR 62. REAR LAMPS
BL (912) 2.0
14 15 16 17 18 19 20 21 22 23 24 25 26
L2 65 30. LH MOTOR SPEED SENSOR 63. BACKUP ALARM
64. HORN SWITCH
D15 1 2 B 31. FNR JOYSTICK
2 32. REVERSE RATIO SWITCH 65. HORN
R (992) 0.8
B (0) 0.8
5-7 1
B (0) 0.8
P (125) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
4 3-5 W (START) 0.8
57 7-2 1
5 5-14 R (992) 0.8
5-9 2 2 5-15
6 11-2 O (4111) 0.8
7 1-2
GND GND
13 14 15 16
BC07A591-13A BC07A591-14A BC07A591-15A BC07A591-16A
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

B . . . BLACK
SPL-00
Frame and Wire Tag
Number where circuit
WIRE TAGS
00-0 1
BL . . BLUE BL (XXX) 1.0
WIRE SIZE
ELECTRICAL SCHEMATIC
G. . . GREEN WIRE COLOR
continues. 1 00-0 MALE
TERMINAL
FEMALE
TERMINAL
INDICATES
EXTERNAL
INDICATES
INTERNALLY P . . . PINK
WIRE NUMBER 1150K DOZER
FRAME - WIRE WIRE 25 GROUND GROUNDED BR. . TAN/BROWN O. . . ORANGE
SHOWS CIRCUIT SHOWS COMPONENT LB . . LIGHT BLUE V . . . VIOLET/PURPLE
Wire Tag assigned to wire in Frame. W U U WHITE R . . . RED Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System. The part number is 5-4550na
CROSSING CIRCUIT SPLICE COMPONENT GROUND
NOT CONNECTED CONNECTION CIRCUIT CONTINUATION NUMBER YU U U YELLOW GY . GREY
Copyright © 2007. CNH America, LLC. All Rights Reserved. BC07A591-00A
Copyright ©
ENGINE CONTROL UNIT INJECTORS ENGINE SENSORS 9-PIN DIAGNOSTIC PORT FLEET CONNECTOR
67
E11
R (302) 2.0
2 1
69 76 77 78 79
B (0) 0.8
3
2
GY (342) 0.8
1 1 2 3 1 2 3 1 2 3 1 2
1
85 86
70 M16
2 1 BR (1N) 0.8
B (0) 2.0
1 C3 A B C D E F G H I 2
71 3
LB (252) 0.8
W (334) 0.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
G (389) 0.5
R (501) 0.8
B (335) 0.5
V (251) 0.8
P (250) 0.8
Y (224) 0.8
1 2 3 4 5 6 7 8
2 4
1
75
2 3 5 6 8 9 10 11 12 17 29 30 32 34 35 37 40 42 44 45 5 P (W) 0.8
68
72 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
6
66
BR (IGN3) 0.5
E2
9 10 11 12 13 14 15 16
W (334) 0.5
W (332) 0.5
W (317) 0.8
2
O (337) 0.5
O (312) 0.8
R (302) 2.0
B (335) 0.5
Y (329) 0.5
7 BL (1M) 0.8
47 48 50 51 53 54 55 56 57 62 74 75 77 79 80 82 85 87 89
1 7-14 14 8
73 7-8 13
G (389) 0.5
V (375) 0.5
7-16 12
2
1 3 4 2 1 3 4 2 1 7-15 11
5-16 11 2
B (0) 2.0
B (0) 0.8
B (0) 0.8
B (0) 0.8
17-2 10
4-1 10
3-3 9
1 7-12 6
5-13 3
4-2 1 20-10 2
3-6 8 74 9-2
13-2
7
8 1-1 2
3-4 7
20-9 6 80 81 82 17-6 9
20-5 5
2 7-13
9-3
2
3 5-1 1
3-2 4 13-3 4
5-20 3 17-5 5
5-17 1
GND GND
17 18 19 20 21
BC07A591-17A BC07A591-18A BC07A591-19A BC07A591-20A BC07A591-21A
RADIO DC CONVERTER AND 12V POWER SOURCE BLOWER MOTOR AIR CONDITIONING
W (818A) 2.0 101
L12 E6
89 94 95 96
L10 L9 1 H M2 M1 L
A B C 1 2 3 99
98 C23 1 2
Y (899) 2.0
GY (814) 2.0
L11
G (815) 2.0
B (813) 2.0
P (816) 2.0
87 V (817) 2.0 C
W (818C) 0.8
W (818B) 0.8
A B
12V BATT
BL (819) 2.0
L17
GROUND
BL (811) 0.8
12V IGN
LEFT +
L8 V (817) 2.0
LEFT -
W (818A) 2.0
B (RADIO) 0.5
91
RT -
RT +
C14
R (RADIO) 0.5
93
M
T
4 2 92
IN
88
R (504) 1.0
5 1
PR
B (RADIO) 0.5 L15 R (501) 2.0 NO BL (819) 2.0 100
M
LB (505) 1.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
R (RADIO) 0.5
6 3 A B E12
L16 R (504) 1.0
BL (819) 2.0
BL (800) 2.0
BL (V1ACC) 0.8
LB (505) 1.0 1 2 3 4 5 6 7 8 9 10 11 12
R
R (501) 2.0
C15
97 M
FO
90
B (0) 2.0
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 2.0
B (0) 2.0
5-12 1 5-11 2
T
5-18 2
O
5-5 1
B (0) 1.0
N
GND GND
22 23 24 25
BC07A591-22A BC07A591-23A BC07A591-24A BC07A591-25A
WINDSHIELD WIPER MOTORS AND SWITCH WINDSHIELD WIPER DOOR WIPER MOTORS AND SWITCH DOOR WIPER ROPS HEATER AND AIR SUSPENSION COMPONENTS
WASHER AND SWITCH WASHER AND SWITCH SEAT
BL (953) 0.8
0
BL (953) 0.8
66. ENGINE CONTROLLER 89. RADIO
BL (933) 0.8 BL (933) 0.8
1 110 67. WATER IN FUEL SENSOR 90. 12V POWER JACK
68. INJECTOR CONNECTOR 91. DC-DC CONVERTER (24V->12V)
0
103 108 D10 3 5-6 1 69. CYLINDER #1 INJECTOR 92. INTERIOR LAMP SWITCH
D4 F15 70. CYLINDER #2 INJECTOR 93. INTERIOR LAMP
2
BL (933) 0.8 1 105 BL (933) 0.8
71.
72.
CYLINDER #3 INJECTOR
CYLINDER #4 INJECTOR
94. TEMPERATURE SWITCH
95. MODE SWITCH
D8 3 73. CYLINDER #5 INJECTOR 96. FAN SPEED SWITCH
BL (V2ACC) 0.8
74. CYLINDER #6 INJECTOR 97. BLOWER MOTOR HOUSING
G (931) 0.8 2 G (951) 0.8
75. SENSOR CONNECTOR 98. CONDENSER
0 0 76. CRANKSHAFT SPEED SENSOR 99. A/C LOW PRESSURE SWITCH
BL (953) 0.8
M M
O (963) 0.8
BL (933) 0.8
V (932) 0.8 V (952) 0.8 77. CAMSHAFT SPEED SENSOR 100. A/C HIGH PRESSURE SWITCH
78. RAIL PRESSURE SENSOR 101. A/C CLUTCH
D7
1 102 + - D9
1 107 + - 79. COOLANT TEMP. SENSOR 102. FRONT/REAR WIPER SWITCH
1 1
B (943) 0.8 80. OIL PRESSURE SENSOR 103. FRONT WIPER MOTOR
2 2
3 3
111 81. BOOST PRESSURE SENSOR 104. REAR WIPER MOTOR
82. FUEL TEMP. SENSOR 105. FRONT/REAR WASHER SWITCH
E5
106 E5
83. ROPS HEATER 106. FRONT/REAR WASHER PUMP
C20 C22
4 4 M13 M22 84. AIR SUSPENSION SEAT 107. LEFT/RIGHT WIPER SWITCH
A A
5 5
6 M 6 M 83 M M 84
85.
86.
DIAGNOSTIC PORT
FLEET TRACKER PORT
108. LEFT WIPER MOTOR
109. RIGHT WIPER MOTOR
87. RIGHT SPEAKER 110. LEFT/RIGHT WASHER SWITCH
M
BL (933) 0.8
V (935) 0.8
M V (955) 0.8
B B
88. LEFT SPEAKER 111. LEFT/RIGHT WASHER PUMP
+ - + -
G (934) 0.8 G (954) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
BL (953) 0.8 BL (953) 0.8 BL (953) 0.8
B (0) 0.8
B (0) 0.8
104 109
B (0) 0.8
5-8 2
BL (953) 0.8 BL (953) 0.8 BL (953) 0.8
5-10 1
GND GND
26 27 28 29 30
BC07A591-26A BC07A591-27A BC07A591-28A BC07A591-29A BC07A591-30A
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

B . . . BLACK
SPL-00
Frame and Wire Tag
Number where circuit
WIRE TAGS
00-0 1
BL . . BLUE BL (XXX) 1.0
WIRE SIZE
ELECTRICAL SCHEMATIC
G. . . GREEN WIRE COLOR
continues. 1 00-0 MALE
TERMINAL
FEMALE
TERMINAL
INDICATES
EXTERNAL
INDICATES
INTERNALLY P . . . PINK
WIRE NUMBER 1150K DOZER
FRAME - WIRE WIRE 25 GROUND GROUNDED BR. . TAN/BROWN O. . . ORANGE
SHOWS CIRCUIT SHOWS COMPONENT LB . . LIGHT BLUE V . . . VIOLET/PURPLE
Wire Tag assigned to wire in Frame. W U U WHITE R . . . RED Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System. The part number is 5-4550na
CROSSING CIRCUIT SPLICE COMPONENT GROUND
NOT CONNECTED CONNECTION CIRCUIT CONTINUATION NUMBER YU U U YELLOW GY . GREY
Copyright © 2007. CNH America, LLC. All Rights Reserved. BC07A591-00A

17710-Case 1150k Series 3 Tier 3-1 PDF

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Copyright ©

Section Title Section Number

Copyright © 2007 CNH America LLC.

GENERAL TORQUE SPECIFICATIONS

Copyright © 2004 CNH America LLC.

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

3/4 inch 270 to 324 366 to 439

NOTE: Use thick nuts with Grade 8 bolts.

1-3/8 inch 1460 to 1680 1980 to 2278

1-1/2 inch 1940 to 2200 2631 to 2983

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

Grade 12.9 Bolts, Nuts, and Studs

M20 320 to 380 434 to 515

fasteners can be used satisfactorily on grade 12.9

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

5/16-18 180 to 240 20 to 27

3/8-16 240 to 300 27 to 34

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

Thread Pound- Newton

-24 1-1/2 inch 2-12 150 to 180 200 to 254

Bur 8-71603 Revised 7-05 Printed in U.S.A.

FLUIDS AND LUBRICANTS

Copyright © 2007 CNH America LLC.

Bur 5-4130 Issued 2-07 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Capacity ............................................................................................................... 450 mL (15.2 U.S. fluid ounces)

Type of Lubricant ..................................................................................... Case AKCELA 135H EP Gear Lubricant

Capacity .............................................................................................................. 28.1 mL (0.95 U.S. fluid ounces)

Bur 5-4130 Issued 2-07 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS

Bur 5-4130 Issued 2-07 Printed in U.S.A.

Specifications for Acceptable No. 2 Diesel Fuel

Bur 5-4130 Issued 2-07 Printed in U.S.A.

Bur 5-4130 Issued 2-07 Printed in U.S.A.

Copyright © 2003 Case, LLC. All rights reserved.

Bur 7-52590 Issued 4-03 Printed in U.S.A.

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Power: kilowatt 1.341 02 horsepower

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot

milliliter 0.033 814 ounce (US fluid)

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

Bur 7-52590 Issued 4-03 Printed in U.S.A.

Area: square foot 0.092 903 square meter

Force: ounce force 0.278 014 newton

Length: inch 25.4 * millimeter