Case Wheel Loader 720 Repair Manual PDF

REPAIR MANUAL
750L
850L
87728445 1 2/28/2008
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
PRIMARY HYDRAULIC POWER SYSTEM A.10.A
SECONDARY HYDRAULIC POWER SYSTEM A.12.A
ELECTRICAL POWER SYSTEM A.30.A
LIGHTING SYSTEM A.40.A
FAULT CODES A.50.A
POWER PRODUCTION B
ENGINE B.10.A
FUEL AND INJECTION SYSTEM B.20.A
AIR INTAKE SYSTEM B.30.A
ENGINE COOLANT SYSTEM B.50.A
LUBRICATION SYSTEM B.60.A
STARTING SYSTEM B.80.A
POWER TRAIN C
POWER COUPLING Fixed coupling C.10.B
TRANSMISSION Hydrostatic C.20.F
TRAVELLING D
Final drive D.15.A
SERVICE BRAKE Hydraulic D.30.C
PARKING BRAKE Hydraulic D.32.C
WHEELS AND TRACKS Tracks D.50.B
BODY AND STRUCTURE E

USER CONTROLS AND SEAT E.32.A
USER CONTROLS AND SEAT Operator seat E.32.C
USER PLATFORM E.34.A

ENVIRONMENT CONTROL Heating system E.40.B
ENVIRONMENT CONTROL Airconditioning system E.40.C
87728445 1 2/28/2008
ENVIRONMENT CONTROL Heating, ventilation and airconditioning E.40.D
SAFETY SECURITY ACCESSORIES Safety E.50.B
TOOL POSITIONING G
LIFTING G.10.A
TILTING G.20.A
SWINGING G.40.A
WORKING ARM H
SINGLE ARM TOOL ATTACHMENT Lift H.50.B
TOOLS AND COUPLERS J

DIGGING Nonarticulated digging tools J.20.B
LANDSCAPING Dozer blade J.40.F
87728445 1 2/28/2008
87728445 1 2/28/2008
INTRODUCTION
87728445 1 2/28/2008
1
Contents
INTRODUCTION
Basic instructions 3
General specification 7
Conversion factors 11
Hydraulic contamination 13
87728445 1 2/28/2008
2
INTRODUCTION
Basic instructions
Technical Information
This manual has been produced by a new technical information system. This new system is designed to deliver
technical information electronically through CDROM and in paper manuals. A coding system called ICE has been
developed to link the technical information to other Product Support functions e.g. Warranty.
Technical information is written to support the maintenance and service of the functions or systems on a customers
machine. When a customer has a concern on his machine it is usually because a function or system on his machine
is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the
technical information in this manual to resolve that customers concern, you will find all the information classified using
the new ICE coding, according to the functions or systems on that machine. Once you have located the technical
information for that function or system then you will find all the mechanical, electrical or hydraulic devices, compo
nents, assemblies and subassemblies for that function or system. You will also find all the types of information that
have been written for that function or system, the technical data (specifications), the functional data (how it works),
the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).
By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right
piece of technical information you need to resolve that customers concern on his machine. This is made possible by
attaching 3 categories to each piece of technical information during the authoring process.
The first category is the Location, the second category is the Information Type and the third category is the Product:
• LOCATION is the component or function on the machine, that the piece of technical information is going to
describe e.g. Fuel tank.
• INFORMATION TYPE is the piece of technical information that has been written for a particular component or
function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount of fuel
held by the Fuel tank.
• PRODUCT is the model that the piece of technical information is written for.
Every piece of technical information will have those 3 categories attached to it. You will be able to use any combination
of those categories to find the right piece of technical information you need to resolve that customers concern on his
machine.
That information could be:

• the description of how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool
How to Use this Manual

This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the
beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the
end of a Chapter. Page number references are included for every piece of technical information listed in the Chapter
Contents or Chapter Index.
Each Chapter is divided into four Information types:

• (D) Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and, as
semblies.
• (C) Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and as
semblies.
• (G) Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or
hydraulic devices, components and assemblies.
87728445 1 2/28/2008
3
INTRODUCTION
• (F) Service data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices,
components and assemblies.
Sections
Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by
a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the
machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This
table illustrates which Sections could be included in a manual for a particular product.
SECTION
A Distribution Systems
B Power Production
C Power Train
D Travelling
E Body and Structure
F Frame Positioning
G Tool Positioning
H Working Arm
J Tools and Couplers
K Crop Processing
L Field Processing
PRODUCT
Tractors X X X X X X X X
Vehicles with working arms: backhoes, X X X X X X X X X
excavators, skid steers, .....
Combines, forage harvesters, balers, .... X X X X X X X X X X
Seeding, planting, floating, spraying X X X X X X X X X
equipment, ....
Mounted equipment and tools, ..... X X X X
Chapters
Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the
Section letter i.e. Chapter B.10 is inside Section B, Power Production.
CONTENTS
The Chapter Contents lists all the (D) technical data (specifications), (C) functional data (how it works), (F) service
data (remove, install adjust, etc.) and (G) diagnostic data (fault codes and troubleshooting) that have been written in
that Chapter for that function or system on the machine.
Contents
POWER PRODUCTION
ENGINE _ 10.A
TECHNICAL DATA
ENGINE General specification (B.10.A D.40.A.10) 3
FUNCTIONAL DATA
ENGINE Dynamic description (B.10.A C.30.A.10) 4

SERVICE
ENGINE Remove (B.10.A F.10.A.10) 5
DIAGNOSTIC
ENGINE Troubleshooting (B.10.A G.40.A.10) 6
87728445 1 2/28/2008
4
INTRODUCTION
INDEX
The Chapter Index lists in alphabetical order all the types of information (called Information Units) that have been
written in that Chapter for that function or system on the machine.
Index
POWER PRODUCTION B
ENGINE
ENGINE Dynamic description (B.10.A C.30.A.10) 4
ENGINE General specification (B.10.A D.40.A.10) 3
ENGINE Remove (B.10.A F.10.A.10) 5
ENGINE Troubleshooting (B.10.A G.40.A.10) 6
Information Units and Information Search

Each chapter is composed of information units. Each information unit has the ICE code shown in parentheses which
indicates the function and the type of information written in that information unit. Each information unit has a page ref
erence within that Chapter. The information units provide a quick and easy way to find just the right piece of technical
information you are looking for.
example information unit Stack valve Sectional View (A.10.A.18 C.10.A.30)

Information Unit ICE code A 10.A 18 C 10.A.30
ICE code classification Distribution Primary Stack valve Functional Sectional view
systems hydraulic data
power
CRIL03J033E01 1
Navigate to the correct information unit you are searching for by identifying the function and information type
from the ICE code.
• (1) Function and (2) Information type.
• (A) corresponds to the sections of the repair manual.
(B) corresponds to the chapters of the repair manual.
(C) corresponds to the type of information listed in the chapter contents, (D), Technical data, (C), Functional
Data, (G), Diagnostic, and (F), Service.
(A) and (B) are also shown in the page numbering on the page footer.
THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL.
• You will find a table of contents at the beginning and end of each section and chapter.
You will find an alphabetical index at the end of each chapter.
• By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly
find the information you are looking for.
87728445 1 2/28/2008
5
INTRODUCTION
Page Header and Footer

The page header will contain the following references:
• Section and Chapter description
The page footer will contain the following references:

• Publication number for that Manual, Section or Chapter.
• Version reference for that publication.
• Publication date
• Section, chapter and page reference e.g. A.10.A / 9
87728445 1 2/28/2008
6
INTRODUCTION
General specification
BOLT TORQUE INFORMATION
DECIMAL HARDWARE
1. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
2. Make sure the fasteners threads are clean and that thread engagement is started. This will prevent them from
failing when being tightened.
3. Tighten plastic insert or crimped steeltype lock nuts to approximately 50 % of the dry torque, applied to the nut,
not to the bolt head. Tighten toothed or serratedtype lock nuts to the full torque value.
4. The L9 (Alloy) fasteners torque values are for a bolt, nut, and two washers.
When using L9 (Alloy) fasteners, do not use the values in this table for tapped holes.
GRADE
1 or 2 5 5.1 5.2 8 8.2 L9 (Alloy)
SAE Markings
for Bolts and
Cap Screws
2 5 8 L9 (Alloy)
SAE Markings
for Hex Nuts
GRADE 2 * GRADE 5, 5.1 or 5.2 GRADE 8 or 8.2 GRADE L9 (Alloy)

Dry ** Lubricated Dry** Lubricated Dry** Lubricated Head Nut
** ** **
SIZE Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft
1/4 7.5 5.5 5.7 4.2 10.8 8 8.5 6.3 16.3 12 12.2 9 13.6 10 14.9 11
UNF
1/4 8.5 6.3 6.4 4.7 13.6 10 9.8 7.2 19 14 13.6 10 16.3 12 17.6 13
UNC
5/16 15 11 11 8 23 17 18 13 33 24 24 18 26 19 28 21
UNF
5/16 16 12 12 9 26 19 19 14 37 27 27 20 27 20 31 23
UNC
3/8 27 20 20 15 41 30 31 23 61 45 47 35 41 30 45 33
UNF
3/8 31 23 23 17 47 35 34 25 68 50 47 35 47 35 52 38
UNC
7/16 43 32 33 24 68 50 47 35 95 70 68 50 75 55 81 60
UNF
7/16 49 36 37 27 75 55 54 40 108 80 81 60 81 60 88 65
UNC
1/2 68 50 47 35 102 75 75 55 149 110 108 80 115 85 129 95
UNF
1/2 75 55 54 40 115 85 88 65 163 120 122 90 129 95 142 105
UNC
9/16 95 70 75 55 149 110 108 80 203 150 149 110 163 120 190 140
UNF
9/16 108 80 81 60 163 120 122 90 231 170 176 130 183 135 203 150
UNC
5/8 136 100 102 75 203 150 149 110 285 210 217 160 231 170 251 185
UNF
87728445 1 2/28/2008
7
INTRODUCTION
GRADE 2 * GRADE 5, 5.1 or 5.2 GRADE 8 or 8.2 GRADE L9 (Alloy)

Dry ** Lubricated Dry** Lubricated Dry** Lubricated Head Nut
** ** **
SIZE Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft
5/8 149 110 115 85 231 170 176 130 325 240 244 180 258 190 278 205
UNC
3/4 237 175 176 130 353 260 271 200 515 380 380 280 359 265 393 290
UNF
3/4 271 200 190 140 407 300 298 220 570 420 420 310 447 330 481 355
UNC
7/8 231 170 170 125 583 430 434 320 814 600 610 450 644 475 685 505
UNF
7/8 244 180 190 140 637 470 475 350 909 670 678 500 705 520 793 585
UNC
1 339 250 258 190 868 640 651 480 1234 910 922 680 746 550 1051 775
UNF
1 380 280 285 210 976 720 732 540 1383 1020 1031 760 949 700 1220 900
UNC
11/8 475 350 366 270 1071 790 800 590 1749 1290 1315 970 1390 1025 1559 1150
UNF
11/8 542 400 407 300 1207 890 909 670 1953 1440 1464 1080 1559 1150 1797 1325
UNC
11/4 678 500 515 380 1519 1120 1139 840 2468 1820 1844 1360 1898 1400 2170 1600
UNF
11/4 746 550 570 420 1681 1240 1261 930 2726 2010 2048 1510 2170 1600 2373 1750
UNC
11/2 1180 870 881 650 2644 1950 1980 1460 4285 3160 3214 2370 3932 2900 4407 3250
UNF
11/2 1329 980 990 730 2983 2200 2224 1640 4827 3560 3621 2670 4475 3300 4949 3650
UNC
IMPORTANT: DO NOT use these values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are
designed to fail under predetermined loads. Always replace shear bolts with identical grade.
NOTES
• * Grade 2 applies for hex caps (not hex bolts) up to 152 mm ( 6 in) long. Grade 1 applies for hex cap screws
over 152 mm ( 6 in) long, and for all other types of bolts and screws of any length.
• ** "Lubricated" means coated with a lubricant such as engine oil, or fasters with phosphate and oil coatings.
"Dry" means plaind or zinc plated without any lubriation.
TORQUE SPECIFICATIONS METRIC HARDWARE

GRADE 8.8 Bolts, Nuts and Studs GRADE 10.9 Bolts, Nuts and Studs
Dry Dry
SIZE Nm lb/in lb/ft Nm lb/in lb/ft
M4 3 to 4 31 to 35 5 to 6 44 to 49
M5 5 to 6 49 to 55 8 to 9 71 to 79
M6 10 to 11 84 to 94 14 to 15 120 to 136
M8 23 to 26 229 to 277 33 to 37 293 to 329
M10 46 to 51 408 to 460 65 to 74 48 to 54
M12 80 to 90 59 to 66 114 to 128 85 to 94
M14 128 to 145 94 to 106 183 to 205 136 to 153
M16 200 to 220 149 to 161 285 to 320 208 to 235
M20 400 to 450 293 to 330 555 to 620 406 to 460
M24 690 to 780 510 to 575 955 to 1075 705 to 790
87728445 1 2/28/2008
8
INTRODUCTION
GRADE 8.8 Bolts, Nuts and Studs GRADE 10.9 Bolts, Nuts and Studs
Dry Dry
SIZE Nm lb/in lb/ft Nm lb/in lb/ft
M30 1375 to 1545 1010 to 1140 1900 to 2140 1400 to 1580
M36 2400 to 2700 1770 to 1990 3315 to 3730 2445 to 2750
Use the above torques when specifications are not given.
These values apply to fasteners with both coarse and fine threads as received from supplier, plated or unplated,
or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.
Use of a click type torque wrench, or better is required.
Grade 12.9 Bolts, Nuts, and Studs
Usually torque values specified to grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.
• TORQUE SPECIFICATIONS STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting
Nom. SAE Tube OD/Hose ID Thread Size Newton lb/in lb/ft
Dash Size metres
2 5/16 24 8 to 9 72 to 84
3 3/8 24 11 to 12 96 to 108
4 6.4 mm 1/4 inch 7/16 20 14 to 16 120 to 144
5 7.9 mm 5/16 inch 1/2 20 18 to 21 156 to 192
6 9.5 mm 3/8 inch 9/16 18 27 to 33 240 to 300
8 12.7 mm 1/2 inch 3/4 16 46 56 408 to 504
10 15.9 mm 5/8 inch 7/8 14 77 to 85 684 to 756
12 19.0 mm 3/4 inch 11/16 12 107 to 119 79 to 88
14 22.2 mm 7/8 inch 13/16 12 127 to 140 94 to 103
16 25.4 mm 1.0 inch 15/16 12 131 to 156 97 to 117
20 31.8 mm 11/4 inch 15/8 12 197 to 223 145 to 165
24 38.1 mm 11/2 inch 17/8 12 312 to 338 230 to 250
Straight Thread with Oring

Nom. SAE Tube OD/Hose ID Thread Size Newton lb/in lb/ft
Dash Size metres
2 5/16 24 8 to 9 72 to 84
3 3/8 24 11 to 12 96 to 108
4 6.4 mm 1/4 inch 7/16 20 20 to 25 180 to 228
5 7.9 mm 5/16 inch 1/2 20 27 to 33 240 to 300
6 9.5 mm 3/8 inch 9/16 18 43 to 54 384 to 480
8 12.7 mm 1/2 inch 3/4 16 73 to 90 648 to 804
10 15.9 mm 5/8 inch 7/8 14 100 to 124 74 to 92
12 19.0 mm 3/4 inch 11/16 12 138 to 173 102 to 128
14 22.2 mm 7/8 inch 13/16 12 173 to 216 128 to 160
16 25.4 mm 1.0 inch 15/16 12 203 to 253 150 to 187
20 31.8 mm 11/4 inch 15/8 12 308 to 357 227 to 264
24 38.1 mm 11/2 inch 17/8 12 492 to 542 363 to 400
Split Flange Mounting Bolts

Size Newton metres lb/in lb/ft
5/16 18 20 to 27 180 to 240
3/8 16 27 to 34 240 to 300
7/16 14 47 to 61 420 to 540
1/2 13 74 to 88 55 to 65
5/8 11 190 to 203 140 to 150
87728445 1 2/28/2008
9
INTRODUCTION
ORing Face Seal End

Nom. SAE Tube OD Thread Size Newton lb/in lb/ft
Dash Size metres
4 6.4 mm 1/4 inch 9/16 18 23 to 26 204 to 228
6 9.5 mm 3/8 inch 11/16 16 34 to 40 300 to 348
8 12.7 mm 1/2 inch 13/16 16 52 to 57 456 to 504
10 15.9 mm 5/8 inch 114 81 to 90 720 to 792
12 19.0 mm 3/4 inch 13/16 12 117 to 128 86 to 94
16 25.4 mm 1.0 inch 17/16 12 152 to 174 112 to 128
20 31.8 mm 11/4 inch 111/16 12 179 to 201 132 to 148
24 38.1 mm 11/2 inch 2 12 213 to 235 157 to 173
ORing Boss End Fitting or Lock Nut

Nom. SAE Dash Thread Size Newton metres lb/in lb/ft
Size
6 9/16 18 48 to 54 432 to 480
8 3/4 16 70 to 78 612 to 684
10 7/8 14 102 to 114 75 to 84
12 11/16 12 142 to 160 105 to 117
16 15/16 12 237 to 254 175 to 187
Pipe Fitting
Nom. SAE Dash Size Thread Size TFFT (Turns For Finger Tight)
2 1/8 27 2.0 3.0
3 1/8 27 2.0 3.0
4 1/8 27 2.0 3.0
5 1/8 27 2.0 3.0
6 1/4 18 1.5 3.0
8 3/8 18 2.0 3.0
10 1/2 14 2.0 3.0
12 3/4 14 2.0 3.0
14 3/4 14 2.0 3.0
16 1 111/2 1.5 2.5
20 11/4 111/2 1.5 2.5
24 11/2 111/2 1.5 2.5
32 2 111/2 1.5 2.5
NOTE: Apply sealant/lubricant to male pipe threads. The first two threads should be left uncovered to avoid system
contamination. Screw pipe fitting into female pipe port to the finger tight position. Wrench tighten fitting to the ap
propriate turns from finger tight (TFFT) shown in table above, making sure the tube end of an elbow or tee fitting is
aligned to receive incoming tube or hose fitting.
87728445 1 2/28/2008
10
INTRODUCTION
Conversion factors
Metric to U.S.
MULTIPLY BY TO OBTAIN
AREA: square meter 10.763 91 square foot
hectare 2.471 05 acre
FORCE: newton 3.596 942 ounce force
newton 2.224 809 pound force
LENGTH: millimeter 0.039 370 inch
meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
PRESSURE: kilopascal 0.145 038 lb/sq. inch
bar 14.50385 lb/sq. inch
TEMPERATURE: degree C 1.8 x C +32 degree F
TORQUE: newton meter 8.850 748 lb/inch
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr. 0.621 371 miles/hr.
VOLUME: cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
VOLUME/TIME: litre/min. 0.264 172 gallon/min. (US liquid)
litre/min. 0.219 969 gallon/min. (Imperial)
U.S. to Metric
AREA: square foot 0.092 903 square meter
acre 0.404 686 hectare
FORCE: ounce force 0.278 014 newton
pound force 4.448 222 newton
LENGTH: inch 25.4 * millimeter
foot 0.304 8 * meter
mile 1.609 344 * kilometer
MASS: pound 0.453 592 kilogram
ounce 28.35 gram
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lb/hp/hr 608.277 4 gr/kW/hr
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
PRESSURE: lbs/sq. in 6.894 757 kilopascal
lbs/sq. in 0.069 bar
lbs/sq. in 0.070 303 kg/sq. cm
TEMPERATURE: degree F 1.8 F 32 degree C
TORQUE: pound/inch 0.112 985 newton meter
pound/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 * kilometer/hr.
87728445 1 2/28/2008
11
INTRODUCTION
U.S. to Metric
VOLUME: cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.
87728445 1 2/28/2008
12
INTRODUCTION
Hydraulic contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.
(A) When you drain the oil or disconnect any line.
(B) When you disassemble a component.
(C) From normal wear of the hydraulic components.
(D) From damaged or worn seals.
(E) From a damaged component in the hydraulic system.
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system per
mits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause
problems in the hydraulic system. The following list includes some of these problems.
(A) Cylinder rod seals leak.
(B) Control valve spools do not return to neutral.
(C) Movement of control valve spools is difficult.
(D) Hydraulic oil becomes too hot.
(E) Pump gears, housing, and other parts wear rapidly.
(F) Relief valves or check valves held open by dirt.
(G) Quick failure of components that have been repaired.
(H) Cycle times are slow; machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination. There are two types of contam
ination, microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory. Examples of the problems:
(A) Cylinder rod seal leak.
(B) Control valve spools do not return to NEUTRAL.
(C) The hydraulic system has a high operating temperature.
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components. Examples of visible contamination:
(A) Particles of metal or dirt in the oil.
(B) Air in the oil.
(C) The oil is dark and thick.
(D)The oil has an odor of burned oil.
(E) Water in the oil.
If you find contamination, use a Portable Filter to clean the hydraulic system.
87728445 1 2/28/2008
13
INTRODUCTION
87728445 1 2/28/2008
14
REPAIR MANUAL
DISTRIBUTION SYSTEMS
750L
850L
87728445 1 2/28/2008
A
Contents
PRIMARY HYDRAULIC POWER SYSTEM A.10.A

750L , 850L
SECONDARY HYDRAULIC POWER SYSTEM A.12.A

750L , 850L
ELECTRICAL POWER SYSTEM A.30.A

750L , 850L
LIGHTING SYSTEM A.40.A

750L , 850L
FAULT CODES A.50.A

750L , 850L
87728445 1 2/28/2008
A
PRIMARY HYDRAULIC POWER SYSTEM 10.A
750L
850L
87728445 1 2/28/2008
A.10.A / 1
Contents
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM
Special tools 4
Capacity 7
Stack valve
Torque 8
Special tools 8
Calibration 8
Hydraulic pump
Torque 9
FUNCTIONAL DATA
Relief valve
Exploded view 10
Sectional view 11
Stack valve
Exploded view 12
Filter
External view 13
SERVICE
PRIMARY HYDRAULIC POWER SYSTEM
Cleaning 14
Decontaminating 16
Relief valve
Pressure test 20
Pressure setting 21
Disassemble 22
Visual inspection 26
Assemble 27
Stack valve
Flow test 28
Remove 32
Disassemble 33
87728445 1 2/28/2008
A.10.A / 2
Inlet section Disassemble 35
Assemble 37
Inlet section Assemble 39
Install 40
Hydraulic pump
Flow test 41
Remove 43
Disassemble without PTO 44
Visual inspection without PTO 48
Assemble without PTO 50
Disassemble with PTO 54
Visual inspection with PTO 61
Assemble with PTO 63
Preliminary test 68
Install 69
Reservoir
Apply vacuum 70
DIAGNOSTIC
Sensing system
Filter restriction sensor Testing 71
87728445 1 2/28/2008
A.10.A / 3
DISTRIBUTION SYSTEMS PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM Special tools
B877558M_1 1
CAS1804 PRESSURE TEST KIT
87728445 1 2/28/2008
A.10.A / 4
CAS1808 2
CAS1808 FLOWMETER FITTING KIT
87728445 1 2/28/2008
A.10.A / 5
CAS10090 3
CAS10090 HAND PUMP
87728445 1 2/28/2008
A.10.A / 6
CAS10280 4
CAS10280 FLOWMETER
PRIMARY HYDRAULIC POWER SYSTEM General specification

Type of oil CASE AKCELA AW68 HYD FLUID
Temperature of hydraulic oil when testing 52 79 °C (125 175 °F)

Hydraulic pump output 76.8 L at 207 bar at 2000 RPM
20.3 US gpm at 3000 psi at 2000 RPM
Neutral system pressure 12 15 bar (180 220 psi) at 2000 RPM
Main relief valve pressure 203 214 bar (2950 3100 psi)
All models at 2000 RPM
Circuit relief valves 214 227 bar (3100 3300 psi) with hand pump
A and B ports ripper/auxiliary sec
tion
Dozer blade lift speed 457 mm second (18 in second)
Dozer blade lift time (measure from ground level to full 2 seconds
height)
PRIMARY HYDRAULIC POWER SYSTEM Capacity

NOTE: Transmission and hydraulic system use the same reservoir.
Hydraulic reservoir refill capacity 75.7 L 20 US gal
87728445 1 2/28/2008
A.10.A / 7
Stack valve Torque

Special torques Nm lb
Bolts and nuts that fasten the sections 39 47 Nm 28.7 34.6 lb ft
together
Relief valves and load check valves 24 30 Nm 17.7 22 lb ft
Allen head screws 12 15 Nm 106 133 lb in
Centering spring screw 13 16 Nm 115 142 lb in
Stack valve Special tools
B786802M 1
CAS11472 CENTERING SPRING COMPRESSION TOOL
Stack valve Calibration

Relief Valves bar psi
Main relief valve 203 214 bar 2950 3100 psi
Circuit relief valves tested with hand 214 227 bar 3100 3300 psi
pump
Stack valve General specification

Spool travel MM Inch
Neutral to pressure lift, tilt and 7.9 mm 0.31 in
auxiliary
Neutral to pressure angle section 6.6 mm 0.26 in
Neutral to float lift 13.5 mm 0.53 in
87728445 1 2/28/2008
A.10.A / 8
Hydraulic pump Torque

Non PTO pump cover bolts 66 80 Nm
49 59 lb ft
Air vent 9 Nm (80 lb in)
Pump housing bolts 271 Nm (200 lb ft)
PTO shaft retainer 68 Nm (50 lb ft)
Set screw PTO shaft retainer 9 Nm (80 lb in)
Shaft cover screws 8 9 Nm (67 77 lb in)
Hydraulic pump General specification

Equipment pump output 76.8 L/min at 207 bar at 2000 RPM
20.3 US gpm at 3000 psi at 2000 RPM
Rotation Clockwise as seen from end of shaft
87728445 1 2/28/2008
A.10.A / 9
Relief valve Exploded view
BS99M034 1
(1) Cap (5) Oring (9) Backup ring

(2) Lock nut (6) Spring (10) Poppet
(3) Spacer (7) Plunger (11) Housing
(4) Adjusting screw (8) Body
87728445 1 2/28/2008
A.10.A / 10
Relief valve Sectional view
BS00A057 1
(1) Inlet port passage (4) Pilot passage poppet

(2) Return port passage (5) Jam nut
(3) Main relief poppet (6) Pressure adjusting screw
87728445 1 2/28/2008
A.10.A / 11
Stack valve Exploded view
BC02J007 1
(1) Main relief valve (5) Dozer angle section

(2) Inlet secton (6) Ripper/auxiliary section
(3) Dozer lift section (7) Outlet section
(4) Dozer tilt section
87728445 1 2/28/2008
A.10.A / 12
Filter External view
BC04E029 1
87728445 1 2/28/2008
A.10.A / 13
PRIMARY HYDRAULIC POWER SYSTEM Cleaning

1. Contamination in the hydraulic system is a major
cause of the malfunction of hydraulic components.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in
several ways.
(A) When you drain the oil or disconnect any line.
(B) When you disassemble a component.
(C) From normal wear of the hydraulic components.
(D) From damaged or worn seals.
(E) From a damaged component in the hydraulic
system.
2. All hydraulic systems operate with some contam
ination. The design of the components in this
hydraulic system permits efficient operation with a
small amount of contamination. An increase in this
amount of contamination can cause problems in the
hydraulic system. The following list includes some
of these problems.
(A) Cylinder rod seals leak.
(B) Control valve spools do not return to neutral.
(C) Movement of control valve spools is difficult.
(D) Hydraulic oil becomes too hot.
(E) Pump gears, housing, and other parts wear
rapidly.
(F) Relief valves or check valves held open by dirt.
(G) Quick failure of components that have been
repaired.
(H) Cycle times are slow; machine does not have
enough power.
3. If your machine has any of these problems, check
the hydraulic oil for contamination. See types of con
tamination below. If you find contamination, use the
Portable Filter to clean the hydraulic system.
NOTE: There are two types of contamination, microscopic
and visible.
4. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in the
hydraulic oil.
5. These particles are too small to see or feel. Micro
scopic contamination can be found by identification
of the following problems or by testing in a laboratory.
Examples of the problems:
(A) Cylinder rod seal leak.
(B) Control valve spools do not return to NEUTRAL.
(C) The hydraulic system has a high operating tem
perature.
87728445 1 2/28/2008
A.10.A / 14
6. Visible contamination is foreign material that can be

found by sight, touch, or odor. Visible contamination
can cause a sudden failure of components. Exam
ples of visible contamination:
(A) Particles of metal or dirt in the oil.
(B) Air in the oil.
(C) The oil is dark and thick.
(D)The oil has an odor of burned oil.
(E) Water in the oil.
NOTE: The hydrostatic system uses a third port bypass fil
ter system. If the filter becomes plugged it bypasses back
to the reservoir to stop contamination from entering the
hydrostatic system. Upon completion of cleaning the hy
draulic system replace the hydrostatic system filter.
87728445 1 2/28/2008
A.10.A / 15
PRIMARY HYDRAULIC POWER SYSTEM Decontaminating

CAS10162A CAS10508 CAS10192
1. Prepare the portable filter CAS10162A by doing the

following steps:
(A) Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter.
(B) Remove the filter element from the portable filter.
(C) Remove all hydraulic oil from the portable filter.
(D) Clean the inside of the housing for the filter ele
ment.
2. You must know whether the contamination is micro
scopic or visible. Refer to PRIMARY HYDRAULIC
POWER SYSTEM Cleaning (A.10.A).
3. If the contamination is microscopic:
(A) Check the maintenance schedule for the ma
chine to learn if the hydraulic oil must be changed.
If needed, change the hydraulic oil. Change the hy
draulic filter.
(B) Do steps 6 through 35.
4. If the contamination is visible:
(A) Change the hydraulic oil and hydraulic filter.
(B) Do steps 5 through 35.
5. Check the amount of contamination in the hydraulic
system by doing the following steps:
(A) Disassemble one cylinder in two different cir
cuits. Check for damage to seals, scoring of the
cylinder wall, etc. Repair the cylinders as necessary.
(B) If, in your judgment, the damage to the cylinders
was caused by sever contamination and is not the re
sult of normal wear, it is necessary to remove, clean
and repair valves, pump, lines, cylinders, hydraulic
reservoir, etc. in the hydraulic system.
6. Remove the breather from the reservoir and connect
the vacuum pump to the opening. Start the vacuum
pump.
7. Loosen and remove the drain plug from the reservoir.
8. Using the fitting kit CAS10508, install the valve in the
hole for the drain plug. Make sure that the valve is
closed.
9. Stop the vacuum pump.
10. Connect the inlet hose for the portable filter to the
valve that is installed in the hole for the drain plug.
11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler cap.
12. Install the outlet hose for the portable filter in the hy
draulic reservoir filler neck.
13. Open the valve that is installed in the hole for the
drain plug.
14. Move the switch for the portable filter to the ON po
sition. Start and run the engine at 1500 rpm (r/min).
15. Run the portable filter for 10 minutes.
87728445 1 2/28/2008
A.10.A / 16
16. Continue to run the portable filter. Increase the en

gine speed to full throttle. Heat the oil to operating
temperature by doing the following steps:
(A) Hold the blade control lever in the TILT position
for five seconds.
(B) Return the blade control lever in the NEUTRAL
position for five seconds.
(C) Repeat steps A and B until the oil in the hydraulic
system is at operating temperature.
17. Continue to run the engine at full throttle. Continue
to run the portable filter.
18. Operate each hydraulic circuit to completely extend
and retract the cylinders. Continue to operate each
hydraulic circuit two times, one after the other for 45
minutes.
19. Decrease the engine speed to low idle.
20. Continue to run the portable filter for 10 minutes.
21. Stop the portable filter
22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.
24. Close the valve that is installed in the hole for the
drain plug.
25. Disconnect the inlet hose for the portable filter from
the valve. Remove the outlet hose from the reservoir
filter neck and replace filler cap.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop the vacuum pump. Disconnect the vacuum
pump from the opening in the reservoir and install
the breather.
31. Remove the hydraulic and hydrostatic filter elements
from the machine.
32. Install new hydraulic and hydrostatic filter elements
on the machine.
33. Start the engine. Check for oil leakage around the
new hydraulic and hydrostatic filters.
35. Check the oil level in the hydraulic reservoir. Add oil
as required.
NOTE: THE FOLLOWING PROCEDURES ARE FOR
FLUSHING WATER FROM THE HYDRAULIC SYSTEM
36. Start and run the engine at 1500 rpm (r/min).
87728445 1 2/28/2008
A.10.A / 17
37. Completely retract the cylinders of all attachments on

the machine. Angle the blade to the right, the right
cylinder will be fully retracted and the left will be fully
extended. Stop the engine.
WARNING
If retracting the cylinder rods causes the attachment
to be raised, block the attachment in place before pro
ceeding to the next step. 394
38. Move each control lever in both directions to release

pressure in the hydraulic circuits.
39. Loosen and remove the filler cap from the reservoir.
40. Drain the hydraulic oil from the reservoir.
(A) The reservoir holds approximately 20 U.S. gal
lons (75.7 liters) of hydraulic oil.
(B) Have available acceptable equipment to drain
the hydraulic oil.
(C) Remove the drain plug from the bottom of the
reservoir.
from the machine.
on the machine.
43. Install the drain plug in the bottom of the reservoir.
44. Fill the hydraulic reservoir with lubricant, refer to PRI
MARY HYDRAULIC POWER SYSTEM General
specification (A.10.A) and PRIMARY HYDRAULIC
POWER SYSTEM Capacity (A.10.A) for proper
quantities and type.
45. Disconnect the line from the OPEN end and
CLOSED end of each cylinder.
46. Be sure all control levers are in the NEUTRAL posi
tion.
47. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic reservoir
frequently while doing step 48. Have another person hold
a container under the hydraulic lines while you do step 48.
48. Slowly move each control lever in both directions un
til oil begins to flow from the open line. Hold the con
trol lever in place until clean oil flows from the open
line.
50. Connect the system line to the CLOSED end of each
cylinder.
51. Connect a suitable drain line to the OPEN end of
each cylinder and place the other end in an accept
able container for contaminated oil.
52. Start the engine and run the engine at low idle.
87728445 1 2/28/2008
A.10.A / 18
53. Slowly and completely extend all cylinders. As the

piston rod comes in/out of the cylinder, oil will be
pushed out of the OPEN end of the cylinders.
IMPORTANT: Any attachment or part of an attachment that
is raised must be supported with acceptable equipment to
prevent the attachment from falling.
54. Support any attachments that will be in the RAISED
position.
56. Disconnect the drain lines and connect the system
lines to the cylinders.
57. Check the oil level in the hydraulic reservoir. Add oil
as required.
58. Install the filler cap on the reservoir.
from the machine.
on the machine.
61. Start and run the engine at 1500 rpm (r/min), oper
ate each hydraulic circuit to completely extend and
retract the cylinders.
62. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
87728445 1 2/28/2008
A.10.A / 19
Relief valve Pressure test

CAS1804
1. Raise the right side panel for the equipment control

valve.
(1) Pressure test port diagnostic coupler.
IMPORTANT: Make sure that everyone is clear of the dozer
blade prior to proceeding.
BD02F023 1
2. Make sure the hydraulic system fluid is at operating

temperature, 52 79 °C (125 175 °F).
3. Connect the diagnostic coupler and pressure gauge
to the test port coupler (1).
4. Make sure the Parking Brakes are applied and the
directional control is in the NEUTRAL position.
5. Start and run the engine at FULL THROTTLE.
6. Hold the hydraulic control lever for the Lift Cylinders
in the RAISE position.
7. Record the reading on the pressure gauge and check
that the pressure reading is within the specification,
refer to PRIMARY HYDRAULIC POWER SYSTEM
General specification (A.10.A) .
8. If the pressure is not correct, adjust the main re
lief valve, refer to Relief valve Pressure setting
(A.10.A).
87728445 1 2/28/2008
A.10.A / 20
Relief valve Pressure setting

1. Remove the cover from the main relief valve and
loosen the lock nut on the adjusting screw.
2. Turn the adjusting screw into the main relief valve to
increase the pressure or out of the main relief valve
to decrease the pressure.
3. Refer to Relief valve Pressure test (A.10.A) and
check the pressure setting. Adjust the main relief
valve again as necessary.
4. When the pressure setting is correct, prevent the ad
justing screw from turning while the lock nut is tight
ened. Install the cover on the main relief valve.
87728445 1 2/28/2008
A.10.A / 21
Relief valve Disassemble

Prior operation:
Stack valve Inlet section Disassemble (A.10.A)
1. Fasten the main relief valve in a vise with soft jaws.

Remove the cap.
B9051112M 1
2. Hold the adjusting screw in position while you loosen

the lock nut.
B9051115M 2
3. Remove the adjusting screw. Make sure that you

count the number of turns required to remove the
adjusting screw so that you can install the adjusting
screw correctly during Assembly.
B9051118M 3
87728445 1 2/28/2008
A.10.A / 22
4. Remove the spring.
B9051121M 4
5. Remove the plunger.
B9051124M 5
6. Remove the body from the housing.

B9051130M 6
8. Replace the Oring and the backup ring in the hous

ing.
B9051133M 7
87728445 1 2/28/2008
A.10.A / 23
9. Tap the main relief valve lightly against a solid sur

face so that the poppet can be removed from the
housing.
B9051135M 8
10. Replace the Oring on the body.
B9051204M 9
11. Replace the Oring on the adjusting screw.
B9051209M 10
12. Replace the Oring and the backup ring on the pop
pet.
B437120M 11
Next operation:
87728445 1 2/28/2008
A.10.A / 24
Relief valve Visual inspection (A.10.A)
87728445 1 2/28/2008
A.10.A / 25
Relief valve Visual inspection

Prior operation:
Relief valve Disassemble (A.10.A)
1. Discard all Orings, backup rings.

2. Clean all parts in cleaning solvent.
3. Check the parts of the relief valve. Use new parts as
necessary.
Next operation:
Relief valve Assemble (A.10.A)
87728445 1 2/28/2008
A.10.A / 26
Relief valve Assemble

Prior operation:
1. For assembly do the reverse of disassembly, refer to

Relief valve Disassemble (A.10.A).
Next operation:
Stack valve Inlet section Assemble (A.10.A)
87728445 1 2/28/2008
A.10.A / 27
Stack valve Flow test

Prior operation:
USER PLATFORM Tilt (E.34.A) Reservoir Apply vacuum (A.10.A)
1. Disconnect the hose from the fitting on the inlet port

of the equipment control valve.
2. Install a tee in the end of the outlet hose from the
hydraulic pump.
3. Connect the tee fitting at the outlet hose from the
hydraulic pump to the equipment control valve.
4. Connect a hose from the tee at the hydraulic pump
outlet hose to the inlet of the Flowmeter.
5. Turn the vacuum pump off.
6. Lower and secure the ROPS cab/canopy, refer to
USER PLATFORM Lower (E.34.A).
7. Place the outlet hose of the Flowmeter back into the
fill port of the reservoir below the level of the oil. Se
cure the hose to the fill port to prevent it from falling
out during the test.
8. Open the pressure Load Valve on the Flowmeter all
the way. Make sure the flow switch is in the flow
position and move the range switch to the HI position.
9. Start and run the engine at full throttle. Push down
the temperature switch on the Flowmeter and read
the temperature gauge. The temperature of the oil
must be at least 52 °C (125 °F).
10. If the temperature of the hydraulic oil is not as speci
fied, run the engine at full throttle, hold the blade con
trol lever in the RAISE position and slowly close the
pressure valve on the Flowmeter until the pressure
gauge indicates 103 bar (1500 psi). Continue to run
the engine until the temperature of the oil is as spec
ified.
11. Lower the blade to the ground and open the pressure
Load Valve on the Flowmeter.
IMPORTANT: Make sure that everyone is clear of the dozer
blade prior to proceeding.
12. Maintain the engine speed at full throttle and hold the
blade control lever in the RAISE position.
13. This step will indicate the pressure at which the main
relief valve begins to open. As the pressure Load
Valve on the Flowmeter is closed, the flow indication
will decrease slowly until the main relief valve begins
to open at which time the flow indication will start
decreasing rapidly. STOP closing the pressure Load
Valve and read the pressure gauge.
14. Record the reading of the pressure gauge as Main
Relief Valve begins to open.
15. This step will indicate the pressure at which the main
relief valve is completely open. Continue to close the
pressure valve on the Flowmeter until the indication
of the flow gauge is zero. This is the pressure at
which the main relief valve is completely open.
87728445 1 2/28/2008
A.10.A / 28
16. Record the reading of the pressure gauge as Main

Relief Valve completely open.
17. If the pressures in Steps 13 and 15 meet specifi
cations, refer to PRIMARY HYDRAULIC POWER
SYSTEM General specification (A.10.A), proceed
to step 20.
18. If the pressure setting of the main relief valve
does not meet specifications, refer to PRIMARY
HYDRAULIC POWER SYSTEM General speci
fication (A.10.A), then attempt to adjust the main
relief valve to correct the pressure setting, refer to
Relief valve Pressure setting (A.10.A). If ad
justment does not correct the pressure setting, the
main relief valve must be removed and inspected for
possible repair or replacement.
19. If the main relief valve was adjusted, repaired or re
placed, do Steps 12 through 16 again.
20. Set the instrument cluster to read engine r/min
(rpm). Press the display button until the cluster
reads (X_####RPM).
21. Start the engine and adjust the engine speed to 2000
r/min (rpm).
22. Hold the blade control lever in the LIFT position and
adjust the pressure valve on the Flowmeter as re
quired to keep the pressure at 138 bar (2000 psi).
Adjust the engine speed to keep the engine running
at 2000 r/min (rpm). Read the flow gauge and record
the reading.
23. Hold the blade control lever in the LOWER (Power
Down) position and adjust the pressure valve on the
Flowmeter as required to keep the pressure at 138
bar (2000 psi). Adjust the engine speed to keep the
engine running at 2000 r/min (rpm). Read the flow
gauge and record the reading.
24. Hold the blade control lever in the ANGLE RIGHT po
sition and adjust the pressure valve on the Flowme
ter as required to keep the pressure at 138 bar (2000
psi). Adjust the engine speed to keep the engine run
ning at 2000 r/min (rpm). Read the flow gauge and
record the reading.
25. Hold the blade control lever in the ANGLE LEFT po
sition and adjust the pressure Load Valve on the
26. Hold the blade control lever in the TILT RIGHT po
sition and adjust the pressure Load Valve on the
87728445 1 2/28/2008
A.10.A / 29
27. Hold the blade control lever in the TILT LEFT position
and adjust the pressure Load Valve on the Flowmeter
as required to keep the pressure at 138 bar (2000
psi). Adjust the engine speed to keep the engine
running at 2000 r/min (rpm). Read the flow gauge
and record the reading.
28. If equipped, hold the ripper control lever in the LIFT
position and adjust the pressure Load Valve on the
29. Hold the ripper control lever in the LOWER position
and adjust the pressure Load Valve on the Flowmeter
as required to keep the pressure at 138 bar (2000
psi). Adjust the engine speed to keep the engine
running at 2000 r/min (rpm). Read the flow gauge
and record the reading.
30. Open the pressure Load Valve on the Flowmeter.
Decrease the engine speed and stop the engine.
31. Understanding the results refer to Stack valve
General specification (A.10.A)
32. Move the control levers in all directions to release
any pressure in the hydraulic circuits.
33. Tilt the ROPS cab/canopy to gain access to the hy
draulic spool valve, refer to USER PLATFORM Tilt
(E.34.A).
34. Remove the flowmeter return line from the reservoir
and replace the filler cap.
35. Turn the vacuum pump on.
36. Remove the tee fitting from the hydraulic pump hose
and the equipment control valve.
37. Connect the hydraulic pump hose to the equipment
control valve.
38. Turn the vacuum pump off and remove.
40. Check the oil level in the reservoir, add oil as needed.
41. 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.
42. Check for hydraulic leaks, repair as necessary.
NOTE: Understanding the Results of Flowmeter Test.
Next operation:
If the flow indication for each circuit was approximately the same as the flow indication at the same pressure in Hy
draulic pump Flow test (A.10.A), the circuit is good.
Next operation:
If the flow indication for a circuit was more than 3.79 L/min (1 gpm) less than the flow indication at the same pressure
in Hydraulic Pump Flow Test, there is leakage in that circuit.
Next operation:
Leakage in the dozer/ripper circuits can be caused by:
(A) Damaged or worn packing in one or both cylinders in that circuit.
87728445 1 2/28/2008
A.10.A / 30
(B) Damaged or missing Orings on the plugs or circuit relief valve to the work ports in the control valve.
(C) Damaged or worn spool or spool bore in the control valve section for that circuit.
(D) If equipped, a ripper circuit can have a circuit relief valve not adjusted to the correct pressure setting or worn and
damaged.
Next operation:
If the flow indication for all of the circuits was more than 3.79 L/min (1 gpm) less than the flow indication at the same
pressure in Hydraulic Pump Flow Test, there is leakage at a point common to the entire system.
(A) The main relief valve not adjusted to the correct pressure setting or the main relief valve begins to open at 203
bar (2950 psi) or a lower pressure, adjust the main relief valve and do flow test over.
(B) Damaged or worn main relief valve. Also inspect for damaged or missing Orings and seals.
87728445 1 2/28/2008
A.10.A / 31
Stack valve Remove

Prior operation:
USER PLATFORM Tilt (E.34.A).
1. Remove the dirt and grease from the hoses connec

tions at the dozer control valve.
2. Connect a vacuum pump, refer to Reservoir Apply
vacuum (A.10.A). Start the vacuum pump.
3. Tag all lines for proper identification during assembly.
4. Disconnect the hoses from the dozer control valve.
Install plugs or caps in/on all open hoses and fittings,
stop the vacuum pump. Remove the mount bolts for
the control valve, remove the control valve from the
machine.
BD02F015 1
87728445 1 2/28/2008
A.10.A / 32
Stack valve Disassemble

Prior operation:
Stack valve Remove (A.10.A).
1. Clean the outside of the control valve and put the

control valve on a clean bench.
2. Write identification numbers on the sections of the
control valve.
BD02E099 1
3. Remove the nuts from the bolts that fasten the sec
tions together.
BD02E100 2
4. Remove the inlet section from the bolts.
BD02E102 3
87728445 1 2/28/2008
A.10.A / 33
5. Remove the lift section. Remove the Orings from

the lift section.
BD02E103 4
6. Repeat Step 5 for the other sections of the control

valve.
7. Remove the bolts from the outlet end cover.
BD02E104 5
8. Remove the Orings from the outlet end cover.
BD02E105 6
Next operation:
Stack valve Visual inspection (A.10.A).
87728445 1 2/28/2008
A.10.A / 34
Stack valve Inlet section Disassemble

1. Fasten the inlet section in a vise with soft jaws. Re
move the main relief valve.
B9051030M 1
2. Remove the Oring from the main relief valve.
B9051222M 2
3. Remove the Oring and the backup ring from the inlet
section.
B9051033M 3
87728445 1 2/28/2008
A.10.A / 35
Stack valve Visual inspection

Prior operation:
Stack valve Disassemble (A.10.A).
1. Discard all Orings, backup rings, wipers, and seals.

3. Check the spools and the spool bores for damage
and wear.
NOTE: If the seal area of the spool has damage which
you can feel with your fingernail, the spool can damage
the seals.
4. Inspect the other parts of the dozer control valve. If
any of the parts are damaged, install new parts.
Next operation:
Stack valve Assemble (A.10.A).
87728445 1 2/28/2008
A.10.A / 36
Stack valve Assemble

Prior operation:
Stack valve Visual inspection (A.10.A).
1. Install new Orings in the outlet end cover. Make sure

that the Orings and the face of the end cover are free
of oil and grease.
BD02E105 1
2. Install the bolts in the end cover.
BD02E104 2
3. Install new Orings in all of the sections. Make sure

that the Orings and the faces of the section are free
of oil and grease.
BD02E103 3
4. Install the section against the end cover, repeat the

procedure for the remaining sections of the control
valve.
87728445 1 2/28/2008
A.10.A / 37
5. Install the inlet section.
BD02E102 4
6. Install the nuts on the bolts. Tighten the nuts to a

torque of 39 47 Nm (28.7 34.6 lb ft).
BD02E101 5
Next operation:
Stack valve Install (A.10.A).
87728445 1 2/28/2008
A.10.A / 38
Stack valve Inlet section Assemble

1. Replace all Orings and backup ring.
2. Lubricate the Orings and backup ring with clean hy
draulic oil.
3. Install the relief valve in the inlet section and tighten
the main relief valve to a torque of 24 30 Nm (17.7
22 lb ft).
Next operation:
Relief valve Pressure test (A.10.A).
87728445 1 2/28/2008
A.10.A / 39
Stack valve Install

1. Align the dozer control valve mounting holes with the
associated holes in the mounting bracket. Install the
bolts, washers, lock washers, and nuts to secure the
control valve.
BD02F015 1
2. Start the vacuum pump and remove the plugs from

the hoses and caps from valve fittings.
3. Connect the hoses to the dozer control valve.
4. Turn off and disconnect the vacuum pump.
NOTE: Lower the ROPS cab or canopy before proceeding,
refer to USER PLATFORM Lower (E.34.A).
5. With the engine running at low idle, hold each control
lever in the angle left and right, tilt left and right, raise
and lower power positions to open the main relief
valve for five seconds. Stop the engine and check
for leaks.
6. Check the level of oil in the reservoir and add oil as
required.
87728445 1 2/28/2008
A.10.A / 40
Hydraulic pump Flow test

1. Park the machine on a level surface.
2. Lower the dozer and the ripper to the ground.
3. Put directional control in NEUTRAL and apply the
parking brakes. Stop the engine.
4. Move the control levers in all directions to release
5. Tilt the ROPS cab/canopy to gain access to the
equipment control valve, refer to USER PLATFORM
Tilt (E.34.A).
6. Connect and turn on the vacuum pump, refer to
Reservoir Apply vacuum (A.10.A).
7. Disconnect the hose from the fitting on the inlet port
of the equipment control valve and install a cap onto
the fitting.
8. Install a tee in the end of the outlet hose from the
hydraulic pump and install a plug into the opposite
end of the tee fitting.
9. Connect a hose from the tee at the hydraulic pump
outlet hose to the inlet of the Flowmeter.
10. Turn off the vacuum pump.
12. Connect a hose to the outlet of the Flowmeter and
place the opposite end of the hose into the fill port
below the level of the oil in the reservoir. Secure the
hose to the fill port to prevent it from falling out during
the test.
13. Open the pressure Load Valve on the Flowmeter all
the way. Make sure the flow switch is in the FLOW
position and move the range switch to the HI position.
14. Set the instrument cluster to read engine r/min (rpm).
NOTE: Press the display button until the cluster reads
(X_####RPM).
15. Start and run the engine at full throttle. Push down
the temperature switch on the Flowmeter and read
the temperature gauge. The temperature of the oil
must be at least 52 °C (125 °F).
16. If the temperature of the hydraulic oil is not as speci
fied, run the engine at full throttle and close the pres
sure Load Valve on the Flowmeter until the pressure
gauge indicates 103 bar 1500 psi. Continue to run
the engine until the temperature of the oil is as spec
ified.
17. Open the pressure Load Valve completely.
18. Adjust the engine speed to 2000 r/min (rpm). Make
sure the pressure Load Valve on the Flowmeter is
fully open and read the flow gauge. Record the flow
reading for minimum pressure.
87728445 1 2/28/2008
A.10.A / 41
19. Slowly close the pressure Load Valve on the

Flowmeter until the pressure gauge indicates 138
bar (2000 psi). Make sure to keep the engine run
ning at 2000 r/min (rpm). Read the flow gauge and
record the reading.
20. Open the pressure Load Valve on the Flowmeter.
Decrease the engine speed and stop the engine.
21. Refer to Hydraulic pump General specification
(A.10.A) for calculation of pump efficiency.
NOTE: Understanding Results of Flowmeter Test
Next operation:
If the output at minimum pressure was less than 78.7 L/min (20.8 U.S. gpm) the problem can be a leak or a restriction
between the equipment pump and reservoir, or a badly worn or damaged equipment pump.
Next operation:
If the output at minimum pressure was 78.7 L/min (20.8 U.S. gpm) or more there are no problems between the
equipment pump and reservoir. The equipment pump can be worn or damaged and still have good flow at minimum
pressure.
Next operation:
Some loss of output at 138 bar (2000 psi) is normal. The loss can also show the equipment pump is worn or damaged.
Use the efficiency of the equipment pump to make a judgement as to whether or not the equipment pump must be
repaired or replaced.
Next operation:
The efficiency of the equipment pump is found by dividing the flow at 138 bar (2000 psi) by the flow at minimum
pressure.
Next operation:
EXAMPLE:
Flow at no pressure 98 L/min (26 U.S. gpm):
Flow at 138 bar (2000 psi) 87 L/min (23 U.S. gpm):
87 divided by 98 equals 88 = 88% efficient.
Next operation:
If the efficiency is below 75% it is recommended that the equipment pump be repaired or replaced.
87728445 1 2/28/2008
A.10.A / 42
Hydraulic pump Remove

Prior operation:
USER PLATFORM Tilt (E.34.A)
1. Remove the dirt and grease from the hose connec

tions at the pump.
BD02F013 1
2. Connect a vacuum pump to the opening, refer to

Reservoir Apply vacuum (A.10.A). Start the vac
uum pump.
NOTE: If dozer is equipped with a PTO drive pump, dis
connect the PTO before proceeding.
3. Disconnect the hoses from the pump.
(1) Pump suction hose
(2) Pump high pressure hose
(3) Pump
BD02F010 2
4. Install a plug in each hose and fitting. Tighten the

clamp on the plug installed in the suction hose. Stop
the vacuum pump.
5. Remove the pump and discard gaskets.
Next operation:
Hydraulic pump Disassemble (A.10.A) for 250 D pump and Hydraulic pump Disassemble (A.10.A) for pump
with PTO.
87728445 1 2/28/2008
A.10.A / 43
Hydraulic pump Disassemble without PTO

Prior operation:
Hydraulic pump Remove (A.10.A)
NOTE: This procedure covers the 250D equipment pump.

1. Clean the equipment pump in cleaning solvent.
2. Put the equipment pump in a vise with protective jaw
caps. Make alignment marks on the drive end cover,
the gear housing and the port end cover so that you
will be able to assemble the parts correctly later.
BD02E016 1
3. Remove the bolts.
BD02E014 2
4. Use a soft hammer to loosen the port end cover from

the gear housing.
BD02E017 3
87728445 1 2/28/2008
A.10.A / 44
5. Remove the port end cover with wear plate.
BD02E018 4
6. Remove the drive gear from the gear housing.
BD02E019 5
7. Remove the driven gear from the gear housing.
BD02E020 6
8. Remove the gear housing from the drive end cover.
BD02E021 7
87728445 1 2/28/2008
A.10.A / 45
9. Remove the wear plate from the drive end cover.
BD02E022 8
10. Remove the pressure seal from the drive end cover.
BD02E023 9
11. Remove the backup seal from the drive end cover.
BD02E024 10
12. Remove the Oring from the drive end cover.
BD02E025 11
87728445 1 2/28/2008
A.10.A / 46
13. Use a prybar to remove the shaft seal from the drive
end cover.
BD02E026 12
14. Remove the wear plate from the port end cover.
BD02E029 13
15. Remove the Oring from the port end cover.
BD02E030 14
Next operation:
Hydraulic pump Visual inspection (A.10.A)
87728445 1 2/28/2008
A.10.A / 47
Hydraulic pump Visual inspection without PTO

Prior operation:
Hydraulic pump Disassemble (A.10.A)

1. Discard shaft seal, backup seal, pressure seal, wear
plates and Orings.
2. Clean the remaining parts in cleaning solvent.
3. Check all machined surfaces for damage. Use fine
emery cloth to remove any minor damage.
4. Inspect the pockets in the gear housing for grooves,
pitting, and other damage. If there is severe damage,
use a new pump.
BD02E032 1
5. Inspect the bearings in the the port end cover. If any

bearings are worn excessively, use a new pump.
BD02E031 2
6. Inspect the bearings in the drive end cover. If any

BD02E028 3
87728445 1 2/28/2008
A.10.A / 48
7. Inspect the ends, bearing shaft area and teeth of

each gear for scoring. If the scoring is excessive use
a new pump.
(1) Drive gear
(2) Driven gear
BD02E094 4
Next operation:
Hydraulic pump Assemble (A.10.A)
87728445 1 2/28/2008
A.10.A / 49
Hydraulic pump Assemble without PTO

Prior operation:

1. Using a suitable seal driver, drive a new shaft seal
into the drive end cover.
BD02E027 1
2. Install a new Oring in the port end cover.
BD02E095 2
3. Install a new wear plate in the port end cover. Make

sure that the bronze face of the wear plate is up.
NOTE: Make sure that the cavities on the wear plate match
the cavities on the port end cover.
BD02E029 3
87728445 1 2/28/2008
A.10.A / 50
4. Install a new backup seal in the drive end cover.
BD02E096 4
5. Install a new pressure seal over the backup seal.
BD02E097 5
6. Install a new Oring in the drive end cover.
BD02E098 6
7. Install a new wear plate in the drive end cover. Make

sure that the bronze face of the wear plate is up.
NOTE: Make sure that the large cavity on the wear plate is
over the oil grooves.
BD02E022 7
87728445 1 2/28/2008
A.10.A / 51
8. Apply a thin layer of grease to both faces of the gear

housing. Install the gear housing on the drive end
cover.
BD02E021 8
9. Use clean oil to lubricate the driven gear. Install the

driven gear.
BD02E020 9
10. Use clean oil to lubricate the drive gear. Install the
drive gear, being careful not to damage the lips of
the shaft seal.
BD02E019 10
11. Install the port end cover on the gear housing.
BD02E018 11
87728445 1 2/28/2008
A.10.A / 52
12. Install the cover bolts and torque to 66 80 Nm (49

59 lb ft).
BD02E015 12
Next operation:
Hydraulic pump Install (A.10.A)
87728445 1 2/28/2008
A.10.A / 53
Hydraulic pump Disassemble with PTO

Prior operation:
Hydraulic pump Remove (A.10.A)
NOTE: This procedure covers the equipment pump with PTO.

1. Clean the equipment pump in cleaning solvent.
2. Put the equipment pump in a vise with protective jaw
caps.
BD02E034 1
3. Remove the air vent.
BD02E039 2
4. Make alignment marks on the drive end cover, the

gear housing, and the thrudrive housing so that you
will be able to assemble the parts correctly later.
BD02E040 3
87728445 1 2/28/2008
A.10.A / 54
5. Remove the PTO shaft cover.
BD02E035 4
6. Remove the bolts and washers.
BD02E037 5
7. Loosen the two set screws, one on each side of thru

drive housing.
BD02E041 6
8. Using a suitable tool, remove the bearing retainer.
BD02E042 7
87728445 1 2/28/2008
A.10.A / 55
9. Remove the Oring from the bearing retainer.
BD02E062 8
10. Use a pry bar to remove the shaft seal from the bear
ing retainer.
BD02E064 9
11. Use a soft hammer to loosen the thrudrive housing

from the gear housing.
BD02E043 10
12. Remove the thrudrive housing.
BD02E044 11
87728445 1 2/28/2008
A.10.A / 56
13. Remove the wear plate from the gear housing.
BD02E075 12
14. Remove the driven gear.
BD02E045 13
15. Remove the drive gear.
BD02E046 14
16. Remove the gear housing.
BD02E050 15
87728445 1 2/28/2008
A.10.A / 57
17. Remove Orings from both sides of gear housing.
BD02E070 16
18. Remove the wear plate from the drive end cover.
BD02E052 17
19. Remove the retaining ring for the seal retainer from
the drive end cover.
BD02E053 18
20. Use a pry bar to remove the shaft seal from the seal
retainer.
BD02E084 19
87728445 1 2/28/2008
A.10.A / 58
21. Use a slide puller to remove seal retainer.
BD02E086 20
22. Remove the Oring from the seal retainer.
BD02E087 21
23. Use a pry bar to remove the shaft seal from the drive
end cover.
BD02E054 22
24. Remove the shaft from the thrudrive housing.

NOTE: Use a brass drift small enough to clear internal
splines in shaft.
BD02E081 23
Next operation:
87728445 1 2/28/2008
A.10.A / 59
87728445 1 2/28/2008
A.10.A / 60
Hydraulic pump Visual inspection with PTO

Prior operation:
Hydraulic pump Disassemble (A.10.A)

1. Discard shaft seals, wear plates and Orings.
2. Clean the remaining parts in cleaning solvent.
3. Check all machined surfaces for damage. Use fine
emery cloth to remove any minor damage.
4. Inspect the bearings in the thrudrive cover. If any
BD02E082 1
5. Inspect the bearings in the drive end cover. If any

BD02E083 2
6. Inspect the ends, bearing shaft area and teeth of

each gear for scoring. If the scoring is excessive use
a new pump.
(1) Drive gear
(2) Driven gear
BD02E091 3
87728445 1 2/28/2008
A.10.A / 61
7. Inspect the pockets in the gear housing for grooves,

pitting, and other damage. If there is severe damage,
use a new pump.
BD02E092 4
8. Inspect thru shaft bearings for scoring, if scored, re

place the thru shaft assembly.
BD02E093 5
Next operation:
Hydraulic pump Assemble (A.10.A)
87728445 1 2/28/2008
A.10.A / 62
Hydraulic pump Assemble with PTO

Prior operation:

1. Using a suitable driver install a new seal in the bear
ing retainer. Install a new Oring on the bearing re
tainer.
BD02E065 1
2. Using a suitable driver install a new seal in the drive

end cover.
NOTE: The seal must be pressed flush with face of the
recess with lip of seal towards pump gears.
BD02E066 2
3. Using a suitable driver install a new seal in the seal

retainer. Install a new Oring on the seal retainer.
NOTE: The seal must be pressed flush with the counter
bore with lip of seal away from pump gears.
BD02E067 3
87728445 1 2/28/2008
A.10.A / 63
4. Use a light coat of grease to lubricate the Oring and

seal. Install the seal retainer with the tapered side
down.
BD02E069 4
5. Use a suitable driver to seat the seal retainer.
BD02E068 5
6. Install the retaining ring.
BD02E085 6
7. Install a new wear plate with bronze side up. Make

sure the oil grooves are facing to the right while look
ing at the pump from the vent side of the drive cover.
(1) Oil grooves
(2) Vent hole
BD02E072 7
87728445 1 2/28/2008
A.10.A / 64
8. Use clean oil to lubricate pump gears and shafts.

Install drive and driven gears into drive cover.
BD02E073 8
9. Install new Orings on both sides of the gear housing.

Apply a thin layer of grease on both faces of the gear
housing. Install the gear housing.
BD02E074 9
10. Install a new wear plate with bronze side towards

gears. Make sure the oil grooves are facing to the
right while looking at the pump from the vent side of
the drive cover.
(1) Oil grooves
BD02E075_2 10
11. Install the thrudrive housing.
BD02E077 11
87728445 1 2/28/2008
A.10.A / 65
12. Install the thru shaft.
BD02E078 12
13. Use a thin coat of grease to lubricate the Oring and

seal. Install the bearing retainer, use a suitable tool
and torque the retainer.
BD02E042 13
14. Install and torque the bearing retainer set screws.
BD02E079 14
15. Install and torque the housing bolts to 271 Nm (200

lb ft).
BD02E038 15
87728445 1 2/28/2008
A.10.A / 66
16. Install and torque thru shaft cover to 8 9 Nm (67

77 lb in).
BD02E036 16
17. Install and torque the vent to 9 Nm (80 lb in).
BD02E080 17
Next operation:
Hydraulic pump Install (A.10.A)
87728445 1 2/28/2008
A.10.A / 67
Hydraulic pump Preliminary test

NOTE: These procedures are only required for a new or rebuilt hydraulic pump.
1. Start and run the engine at half throttle for three min
utes.
2. With the engine running at half throttle, hold the blade
control lever in the tilt position for five seconds. Then
return the blade control lever to neutral for five sec
onds.
3. Repeat Step 2 for three minutes.
4. With the engine running at full throttle, repeat Steps
2 and 3.
5. Stop the engine and check for leaks.
6. Replace the hydraulic oil filter.
7. Check the level of oil in the reservoir and add oil as
required.
87728445 1 2/28/2008
A.10.A / 68
Hydraulic pump Install

Prior operation:
Hydraulic pump Assemble (A.10.A) for 250 D pump and Hydraulic pump Assemble (A.10.A) for pump with
PTO.
1. Install a new gasket and mount the hydraulic pump.

2. Start the vacuum pump. Remove the plugs from the
hoses. Connect the hoses to the pump.
(1) Pump suction hoxe
(2) Pump high pressure hose
(3) Pump
BD02F010 1
3. Stop the vacuum pump. Remove the vacuum pump

from the machine.
NOTE: If dozer is equipped with a PTO drive pump, con
nect the PTO before proceeding.
4. Lower the ROPS cab or canopy, refer to USER
PLATFORM Lower (E.34.A).
5. Check the level of the oil in the reservoir and add oil
as required.
6. If a new or overhauled pump has been installed, pre
pare the pump for use, refer to Hydraulic pump
Preliminary test (A.10.A).
7. Start and run the engine at half throttle for 30 sec
onds and check for leaks. Then stop the engine.
8. Check the level of the oil in the reservoir and add oil
as required.
Next operation:
Hydraulic pump Preliminary test (A.10.A)
87728445 1 2/28/2008
A.10.A / 69
Reservoir Apply vacuum

1. Remove the breather from the reservoir and connect
a vacuum pump to the opening.
(1) Reservoir breather
(2) Hydraulic filter
(3) Hydrostatic filter
BD02F017X 1
2. Start the vacuum pump.
87728445 1 2/28/2008
A.10.A / 70
Sensing system Filter restriction sensor Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 12 Menu Switches and Instru
ment Cluster (A.30.A) and Wiring harness Electrical schematic frame 13 Sending Units (A.30.A).
N° Test Point Expected Result Other Result (Possible Cause)
1 Check Result Action
Check between the hydraulic filter Continuity Bad ground circuit.
restriction switch housing and the fil
ter housing.
2 Condition Result Action
Disconnect wire 104 from the hy Open Bad hydraulic filter restriction switch.
draulic filter restriction switch termi
nal.
Check
Hydraulic filter restriction switch ter
minal to ground.
Put the master disconnect switch in 12 volts Check instrument cluster hydraulic
the ON position. Put the ignition filter bulb; check instrument cluster.
switch in the RUN position. Bad wire 104 between hydraulic filter
Check restriction switch and pin 2 Connec
Wire 580 to ground. tor V1, pin 2 Connector P10 and pin
2 Connector P1, pin 2 Connector
C5 and pin 4 Connector C4, pin 4
Connector M10 and pin 27 Connec
tor M1, pin 27 Connector D1 and
pin 11 Connector D2B.
87728445 1 2/28/2008
A.10.A / 71
Index

Filter External view 13
Hydraulic pump Assemble with PTO 63
Hydraulic pump Assemble without PTO 50
Hydraulic pump Disassemble with PTO 54
Hydraulic pump Disassemble without PTO 44
Hydraulic pump Flow test 41
Hydraulic pump General specification 9
Hydraulic pump Install 69
Hydraulic pump Preliminary test 68
Hydraulic pump Remove 43
Hydraulic pump Torque 9
Hydraulic pump Visual inspection with PTO 61
Hydraulic pump Visual inspection without PTO 48
PRIMARY HYDRAULIC POWER SYSTEM Capacity 7
PRIMARY HYDRAULIC POWER SYSTEM Cleaning 14
PRIMARY HYDRAULIC POWER SYSTEM Decontaminating 16
PRIMARY HYDRAULIC POWER SYSTEM General specification 7
PRIMARY HYDRAULIC POWER SYSTEM Special tools 4
Relief valve Assemble 27
Relief valve Disassemble 22
Relief valve Exploded view 10
Relief valve Pressure setting 21
Relief valve Pressure test 20
Relief valve Sectional view 11
Relief valve Visual inspection 26
Reservoir Apply vacuum 70
Sensing system Filter restriction sensor Testing 71
Stack valve Assemble 37
Stack valve Calibration 8
Stack valve Disassemble 33
Stack valve Exploded view 12
Stack valve Flow test 28
Stack valve General specification 8
Stack valve Install 40
Stack valve Remove 32
Stack valve Special tools 8
Stack valve Torque 8
Stack valve Visual inspection 36
Stack valve Inlet section Assemble 39
Stack valve Inlet section Disassemble 35
87728445 1 2/28/2008
A.10.A / 72
SECONDARY HYDRAULIC POWER SYSTEM 12.A
750L
850L
87728445 1 2/28/2008
A.12.A / 1
Contents
FUNCTIONAL DATA
Relief valve
Exploded view 3
Stack valve
Sectional view 4
SERVICE
Relief valve
Pressure test 5
Pressure setting 6
Disassemble 7
Visual inspection 9
Assemble 10
Stack valve
Disassemble 11
Assemble 19
87728445 1 2/28/2008
A.12.A / 2
DISTRIBUTION SYSTEMS SECONDARY HYDRAULIC POWER SYSTEM
Relief valve Exploded view
BS99M021 1
(1) Cap (6) Plunger

(2) Oring (7) Seal
(3) Spring (8) Body
(4) Sleeve (9) Backup ring
(5) Shim(s) (10) Load check poppet
87728445 1 2/28/2008
A.12.A / 3
Stack valve Sectional view
BC02J009 1
(1) Circuit relief valve (used in (7) Seal retainer (13) Spring
auxiliary section only)
(2) Load check valve (used in tilt (8) Wiper (14) Bottom spring seat
section only)
(3) Spool boot (9) Lip seal (15) Spool screw
(4) Allen head screw (10) Body (16) Spring cap
(5) Boot retainer (11) Spool (17) Allen head screw
(6) Retainer plate (12) Top spring seat (18) Anticavitation valve (used in
angle section only)
87728445 1 2/28/2008
A.12.A / 4
Relief valve Pressure test

CAS10090 CAS1804
NOTE: Only a machine with a four spool control valve will have Circuit Relief Valves. The circuit relief valves are in
the Ripper/Auxiliary circuits.
1. Raise the right ROPS side panel for the equipment
control valve.
2. Remove the hydraulic line from the work port for the
circuit relief valve to be tested and install a plug in
the end of the hose fitting.
3. Connect the CAS10090 hand pump and pressure
gauge to the open work port in the equipment control
valve where the line was disconnected.
4. Make sure that the hand pump is full of oil and the
temperature of the oil is approximately 21 °C (70 °F).
5. Operate the hand pump and read the pressure
gauge. Record the highest pressure. Repeat this
step several times to be sure of the pressure setting.
6. Compare the pressure reading recorded to the spec
ification, refer to PRIMARY HYDRAULIC POWER
SYSTEM General specification (A.10.A). If the
pressure is not correct, remove the circuit relief valve
and check the external Orings for damage.
7. If the relief valve requires adjustment, refer to Relief
valve Pressure setting (A.12.A).
87728445 1 2/28/2008
A.12.A / 5
Relief valve Pressure setting
B368L95 1
1. Remove the hex cap (3) and the spring (5) from the
top of the circuit relief valve.
2. Remove the plunger (2) and inspect for damaged or
worn parts or seals. Repair as necessary.
3. Add shims (4) to the plunger to increase the pressure
setting. Remove shims (4) from the plunger to de
crease the pressure setting. Each shim is 0.254 mm
(0.010 in) thick and will change the pressure setting
by 3.4 10.3 bar (50 150 psi).
4. Install the spring (5) and the hex cap (3) on the circuit
relief valve.
5. Install the circuit relief valve into the equipment con
trol valve and refer to Relief valve Pressure test
(A.12.A) to check the pressure setting.
6. Adjust the circuit relief valve again if necessary.
7. When the pressure setting is correct, remove the
hand pump and connect the hydraulic line.
87728445 1 2/28/2008
A.12.A / 6
Relief valve Disassemble

1. Fasten the circuit relief valve in a vise with soft jaws.
Loosen the cap.
B411802M 1
2. Remove the cap from the body.
B411803M 2
3. Remove the spring and the sleeve.
B411804M 3
4. Remove the plunger and the shims.
B411806M 4
87728445 1 2/28/2008
A.12.A / 7
5. Remove the shims from the plunger. Keep the shims

for use during Assembly.
NOTE: The photo shows the plunger installed in the body.
This photo is used only to reference the relative positions
of the shims and the plunger.
B411805M 5
6. Replace the seal on the plunger.
B411736M 6
7. Replace the Oring on the cap.
B411737M 7
Next operation:
87728445 1 2/28/2008
A.12.A / 8
Relief valve Visual inspection

Prior operation:
Relief valve Disassemble (A.12.A)

3. Check the parts of the relief valve. Use new parts as
necessary.
Next operation:
Relief valve Assemble (A.12.A)
87728445 1 2/28/2008
A.12.A / 9
Relief valve Assemble

Prior operation:
1. For assembly do the reverse of disassembly, refer to

Relief valve Disassemble (A.12.A).
87728445 1 2/28/2008
A.12.A / 10
Stack valve Disassemble

Prior operation:
Stack valve Disassemble (A.10.A)
NOTE: The auxiliary section has a circuit relief valve at each end of the section. The tilt section has load check valves
at each end of the section. The angle section has an anticavitation valve at each end of the section. The following
photos show a tilt section. Use similar procedures to disassemble and assemble the angle and auxiliary sections.
Refer to Stack valve Sectional view (A.12.A).
1. Fasten the section in a vise with soft jaws. Pull the
top of the spool boot out of the groove in the spool.
BP99J123 1
2. Loosen the Allen head screws that fasten the spring

cap to the body.
BP99J124 2
3. Remove the Allen head screws and the spring cap.
BP99J125 3
87728445 1 2/28/2008
A.12.A / 11
4. Remove the spool assembly from the body.
BP99J126 4
5. Loosen the Allen head screws which fasten the boot

retainer and the retainer plate to the body.
BP99J127 5
6. Remove the spool boot, the boot retainer, the re

tainer plate, and the Allen head screws from the
body.
BP99J128 6
87728445 1 2/28/2008
A.12.A / 12
7. Remove the seal retainer from the body.
BP99J129 7
8. Remove and discard the wiper (or the backup ring, if

equipped) from the body.
NOTE: It is possible that your section will have a backup
ring and an Oring in place of the the wiper and lip seal.
The procedure is the same.
BP99J130 8
9. Remove and discard the lip seal (or the Oring, if

BP99J131 9
87728445 1 2/28/2008
A.12.A / 13
10. Loosen the circuit relief valve, anticavitation or the

load check valve.
BP99J135 10
11. Remove the circuit relief body, anticavitation or the

load check body, the spring, and the poppet.
BP99J134 11
12. Repeat Step 10 and Step 11 for the circuit relief, anti
cavitation or the load check valve at the opposite end
of the body.
13. Remove and discard all Orings and backup rings
from the circuit relief bodies.
B411433M 12
87728445 1 2/28/2008
A.12.A / 14

from the load check bodies.
B411734M 13

from the anticavitation bodies.
BD02F001 14
16. Remove the spool boot, the boot retainer, and the
Allen head screws from the retainer plate.
BP99J098 15
17. Remove the Allen head screws from the boot re
tainer.
BP99J099 16
87728445 1 2/28/2008
A.12.A / 15
18. Remove the spool boot from the boot retainer.
BP99J100 17
19. Remove the lip seal (or the Oring, if equipped), the
wiper (or the backup ring, if equipped), and the seal
retainer from the spool.
NOTE: It is possible that your spool will have an Oring
and a backup ring in place of the lip seal and wiper. The
procedure is the same.
BP99J132 18
20. Install the centering spring tool on the spool.
B411738M 19
21. Remove the spool screw from the end of the spool.
B9110416M 20
87728445 1 2/28/2008
A.12.A / 16
22. Remove the centering spring and the spring seats

from the spool.
B411809M 21
23. Loosen the nuts on the centering spring tool to re

lease the tension on the centering spring. Separate
the centering spring and the spring seats.
B411642M 22
Next operation:
Stack valve Visual inspection (A.12.A)
87728445 1 2/28/2008
A.12.A / 17
Stack valve Visual inspection

Prior operation:

and wear.
the seals.
Next operation:
Stack valve Assemble (A.12.A)
87728445 1 2/28/2008
A.12.A / 18
Stack valve Assemble

Prior operation:
Stack valve Visual inspection (A.12.A)
Refer to Control valve Sectional view (G.40.A).
1. Install the centering spring tool on the centering
spring and the spring seats. Tighten the nuts to
compress the centering spring. Put the centering
spring and the spring seats into position on the
spool.
B411809M 1
2. Make sure that the threads of the spool screw are

clean and dry. Apply Loctite 242 (blue) or an equiva
lent thread locking compound to the threads. Install
the spool screw in the spool. Tighten the spool screw
to a torque of 13 to 16 Nm (115 to 142 lbin).
B9110416M 2
3. Remove the centering spring tool from the spool.
B411738M 3
87728445 1 2/28/2008
A.12.A / 19
4. Install the seal retainer, the backup ring, and the

Oring on the spool. Be careful so that you do not
cut the Oring on the edges of the spool.
BP99J136 4
5. Install new Orings and backup rings on anticavita

tion bodies.
BD02F001 5
6. Install new Orings and backup rings on load check

bodies.
B411433M 6
7. Install new Orings and backup rings on circuit relief

bodies.
B411734M 7
87728445 1 2/28/2008
A.12.A / 20
8. Install the poppet, the spring, and the load check

body anticavitation or the circuit relief body.
BP99J134 8
9. Install the remaining anticavitation valves, circuit re

lief valves and load check valves.
NOTE: Only the lift and angle sections have the anticavi
tation valve. Only the auxiliary section has the circuit relief
valves.
10. Tighten the load check valve, anticavitation valve or
the circuit relief valve to a torque of 24 to 30 Nm (216
to 264 lbin).
BP99J135 9
11. Install the spool assembly in the body.
BP99J137 10
87728445 1 2/28/2008
A.12.A / 21
12. Install the Allen head screws in the spring cap. Install
the spring cap on the body.
BP99J125 11
13. Tighten the Allen head screws to a torque of 12 to 15

Nm (106 to 133 lbin).
BP99J124 12
14. Install a new Oring over the spool and into the bore
of the body.
BP99J138 13
87728445 1 2/28/2008
A.12.A / 22
15. Install the backup ring over the Oring.
BP99J139 14
16. Install the seal retainer.
BP99J140 15
17. Install the boot retainer on the end of the spool boot.
Make sure that the raised ring of the boot retainer is
toward the spool boot as shown above.
BP99J100 16
87728445 1 2/28/2008
A.12.A / 23
18. Install the Allen head screws in the boot retainer.
BP99J099 17
19. Install the retainer plate on the Allen head screws.
BP99J098 18
20. Install the boot and retainer assembly. Tighten the

Allen head screws to a torque of 12 to 15 Nm (106 to
133 lbin).
BP99J127 19
87728445 1 2/28/2008
A.12.A / 24
21. Make sure that the top edge of the spool boot is
seated in the groove in the spool.
BP99J123 20
Next operation:
87728445 1 2/28/2008
A.12.A / 25
Index

Relief valve Assemble 10
Relief valve Disassemble 7
Relief valve Exploded view 3
Relief valve Pressure setting 6
Relief valve Pressure test 5
Relief valve Visual inspection 9
Stack valve Assemble 19
Stack valve Disassemble 11
Stack valve Sectional view 4
Stack valve Visual inspection 18
87728445 1 2/28/2008
A.12.A / 26
ELECTRICAL POWER SYSTEM 30.A
750L
850L
87728445 1 2/28/2008
A.30.A / 1
Contents
TECHNICAL DATA
ELECTRICAL POWER SYSTEM
Fuse and relay box
Torque 5
Battery
FUNCTIONAL DATA
ELECTRICAL POWER SYSTEM
Detailed view Grounding Locations 7
Fuse and relay box
Fuse Overview 10
Relay Overview 11
Connector
Component diagram 01 Connector Group "C" 12
Component diagram 02 Connector Group "D" 18
Component diagram 03 Connector Group "E" 25
Component diagram 04 Connector Group "L" 29
Component diagram 05 Connector Group "M" 36
Component diagram 06 Connector Group "P" 45
Component diagram 07 Connector Group "V" 49
Component diagram 08 Engine controller to engine components. 51
Wiring harness
Identification 53
Electrical schematic frame 01 Charging Circuit 54
Electrical schematic frame 02 Cranking Circuit and Cold Start 55
Electrical schematic frame 03 Power Relays 56
Electrical schematic frame 04 Fuse and Relay Block 57
Electrical schematic frame 05 Fuse Block 58
Electrical schematic frame 06 Brake Decelerator and Throttle Potentiometer 59
Electrical schematic frame 07 Drive Train Controller 60
Electrical schematic frame 08 Drive Train Controller 61
Electrical schematic frame 09 Pumps and Motors 62
Electrical schematic frame 10 FNR Joystick and Reverse Ratio Switch 63
Electrical schematic frame 11 Brakes 64
87728445 1 2/28/2008
A.30.A / 2
Electrical schematic frame 12 Menu Switches and Instrument Cluster 65
Electrical schematic frame 13 Sending Units 66
Electrical schematic frame 14 Front and Rear Lamps 67
Electrical schematic frame 15 Horn and Backup Alarms 68
Electrical schematic frame 16 Engine Control Unit 69
Electrical schematic frame 17 Radio 70
Electrical schematic frame 18 Dome Lamps 71
Electrical schematic frame 19 ROPS Heater and Air Suspension Seat 72
Electrical schematic frame 20 Blower Motor 73
Electrical schematic frame 21 Air Conditioning 74
Electrical schematic frame 22 Windshield Wiper Switch and Washer 75
Electrical schematic frame 23 Windshield Wiper Switch and Washer 76
Electrical schematic frame 24 Door Wiper Switch and Motors 77
Electrical schematic frame 25 Door Wiper Switch and Washer 78
Electrical schematic frame 26 Diagnostic and Fleet 79
Electrical schematic frame 27 Ground Connections 80
SERVICE
Battery
Check 81
Electrical test 85
Charging 87
Filling 88
DIAGNOSTIC
Fuse and relay box
Relay Testing Ignition Relay 89
Relay Testing Power Relay Modules A and B 89
Fuse Testing 89
Alternator
Testing 91
Battery switch
Testing 92
Auxiliary power connection
Outlet 1 Testing 93
87728445 1 2/28/2008
A.30.A / 3
DISTRIBUTION SYSTEMS ELECTRICAL POWER SYSTEM
ELECTRICAL POWER SYSTEM General specification

12 volt negative ground.
87728445 1 2/28/2008
A.30.A / 4
Fuse and relay box Torque

IMPORTANT: Exceeding the torque values WILL damage the components.
Fuse and relay blocks

Fuse block mounting 2.7 Nm (24 lb in)
Bussed studs 8.5 Nm (75 lb in)
Power relays
Output studs 5.4 Nm (48 lb in)
Input studs 16.3 Nm (144 lb in)
87728445 1 2/28/2008
A.30.A / 5
Battery General specification

Charging Guide For Maintenance Free Batteries
Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity See Reserve Capacity under Charge
Specifications
80 Minutes or Less 10 Hours at 5 Amperes
5 Hours at 10 Amperes
Above 80 to 125 Minutes 15 Hours at 5 Amperes
7.5 Hours at 10 Amperes

*Initial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance
Free will have been removed from the decal.
Charging Guide For Batteries Other Than Maintenance Free Batteries
Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity See Reserve Capacity under Charge
Specifications
80 Minutes or Less 10 Hours at 5 Amperes
7.5 Hours at 10 Amperes

Above 250 Minutes 24 Hours at 10 Amperes
*Initial rate for standard taper charger.
87728445 1 2/28/2008
A.30.A / 6
ELECTRICAL POWER SYSTEM Detailed view Grounding Locations
BD07F07901 1
GND P2 – Pumps and brake ground
BD07F13301 2
GND E3 – Engine ground at left rear ENGINE mount
87728445 1 2/28/2008
A.30.A / 7
BD07J04401 3
GND C19 – Left hand console next to drive train controller
BD07J04501 4
GND C13 – Right hand console
87728445 1 2/28/2008
A.30.A / 8
BD07J04601 5
GND L14 – Lights ground, left center top of cab
BD07J04701 6
GND M4 – Instrument cluster ground behind console
87728445 1 2/28/2008
A.30.A / 9
Fuse and relay box Fuse Overview
BS07N720 1
Relays Fuses M2 Fuses M3 Fuses M3

(1) Ignition (1) 10 Amp Circuit 992 (11) 15 Amp Circuit 922 (1) 25 Amp Circuit 912
(2) 20 Amp Circuit 30 (12) 15 Amp Circuit 1502 (2) 5 Amp Circuit V1Acc
(2) Vehicle safety (3) 15 Amp Circuit 21 (13) Not used (3) Not used
(4) Not used (14) 7.5 Amp Circuit 953 (4) 15 Amp Circuit 1501
(3) Starter motor (5) 10 Amp Circuit 1N1 (15) Not used (5) Not used
(6) 30 Amp Circuit 302 (16) 30 Amp Circuit 801 (6) 10 Amp Circuit 1N
(4) Fleet (7) 20 Amp Circuit 501 (17) Not used (7) Not used
(8) 10 Amp Circuit IGN3 (18) 7.5 Amp Circuit 933 (8) 10 Amp Circuit V3Acc
(5) Start sense (9) 20 Amp Circuit IGN2 (19) Not used (9) Not used
(10) 10 Amp Circuit IGN1 (20) 30 Amp Circuit 800 (10) 30 Amp Circuit 802
Ignition relay Vehicle safety relay Starter motor relay Fleet relay Start sense relay
(30) Circuit Batt A (30) Circuit 21 (30) Circuit 21A (30) Circuit 1N1 (30) Circuit 32
(85) Circuit 50 (85) 206 (85) Circuit 337 (85) Circuit 15 (85) Circuit START
(86) Circuit 0 (86) Circuit 0 (86) Circuit 317 (86) Circuit 0 (86) Circuit 0
(87) Circuit IGN+ (87) Circuit 21A (87) Circuit 21B (87) Circuit 1N (87) Circuit 329
87728445 1 2/28/2008
A.30.A / 10
Fuse and relay box Relay Overview
BS07N721 1
Power Relay A Power Relay B

(1) Power stud to fuses F1 (5) 50 Amp Fuse (1) Power stud to fuses F5 (5) 60 Amp Fuse
to F4 in panel M2 to F7 in panel M2
(2) Power stud to fuses F1 (6) 60 Amp Fuse (2) Power stud to fuses F11 (6) 50 Amp Fuse
to F10 in panel M3 to F20 in panel M3
(3) Circuit 0 (7) Power cable from battery (3) Circuit 15 (7) Power buss from power
relay A
(4) Circuit 15 (4) Circuit 0
87728445 1 2/28/2008
A.30.A / 11
Connector Component diagram 01 Connector Group "C"

Connector C1
C1 1
Cavity Circuit ID Cavity Circuit ID Cavity Circuit ID Cavity Circuit ID

1 IGN2 14 NOT USED 27 IGN2 40 335
2 0 15 215 28 0 41 IGN1
3 NOT USED 16 216 29 215 42 IGN1
4 204 17 217 30 230 43 243
5 205 18 218 31 231 44 244
6 206 19 219 32 NOT USED 45 245
7 NOT USED 20 220 33 NOT USED 46 NOT USED
8 208 21 NOT USED 34 NOT USED 47 NOT USED
9 NOT USED 22 NOT USED 35 NOT USED 48 248
10 244 23 223 36 NOT USED 49 NOT USED
11 218 24 224 37 237 50 250
12 212 25 NOT USED 38 238 51 251
13 IGN1 26 NOT USED 39 334 52 252
87728445 1 2/28/2008
A.30.A / 12
Connector C2
C2 2
Cavity Circuit ID Cavity Circuit ID

53 NOT USED 67 NOT USED
54 NOT USED 68 268
55 NOT USED 69 269
56 256 70 NOT USED
60 260 74 NOT USED
61 261 75 NOT USED
62 262 76 NOT USED
64 264 78 NOT USED
65 265 79 279
66 NOT USED 80 280
87728445 1 2/28/2008
A.30.A / 13
Connector C4
C4 3

1 206 13 818B 25 NOT USED 37 120
2 219 14 NOT USED 26 801 38 121
3 223 15 955 27 NOT USED 39 245
4 104 16 NOT USED 28 NOT USED 40 250
5 334 17 NOT USED 29 934 41 251
6 335 18 501 30 935 42 252
7 224 19 NOT USED 31 954 43 256
8 237 20 V3ACC 32 NOT USED 44 260
9 133 21 800 33 NOT USED 45 262
10 134 22 921B 34 953 46 265
11 V1ACC 23 802 35 IGN1 47 279
12 NOT USED 24 911 36 IGN2 48 280
87728445 1 2/28/2008
A.30.A / 14
Connector C5
C5 4
Cavity Circuit Cavity Circuit

1 205 18 212
2 104 19 261
3 121 20 NOT USED
4 134 21 NOT USED
5 120 22 NOT USED
6 133 23 NOT USED
7 244 24 NOT USED
8 243 25 NOT USED
9 V1acc 26 NOT USED
10 217 27 NOT USED
11 218 28 NOT USED
12 204 29 NOT USED
13 216 30 NOT USED
14 230 31 268
15 231 32 269
16 215 33 NOT USED
17 248
Connector C6
C6 5
87728445 1 2/28/2008
A.30.A / 15
Cavity Circuit
A 279
B 264
C 238
Connector C7
C7 6
Cavity Circuit ID
A V1ACC
B 208
C 220
Connector C20
C20, C22 7
NOTE: The connector does not have number ID’s in it, use the alignment tag to orient the connector.
Cavity Circuit ID
1 0
2 953
3 934
4 935
Connector C22
C20, C22 8
Cavity Circuit ID
1 954
2 955
87728445 1 2/28/2008
A.30.A / 16
Cavity Circuit ID
3 0
4 953
Connector C23A
C23A 9
Cavity Circuit ID
A 818A
B 818B
Connector C24
225326C1 10
Cavity Circuit ID
1 911
2 800
3 801
4 802
Connector C25
225350C1 11

1 921 4 V3ACC
2 818A 5 NOT USED
3 501 6 NOT USED
87728445 1 2/28/2008
A.30.A / 17
Connector Component diagram 02 Connector Group "D"

Connector D1
D1 1

1 102 11 50 21 933 31 953
2 116 12 15 22 934 32 943
3 922 13 START 23 935 33 121
4 30 14 921 24 224 34 NOT USED
5 NOT USED 15 IGN3 25 120 35 103
6 133 16 334 26 335 36 134
7 952 17 951 27 104 37 992
8 993 18 963 28 955 38 954
9 389 19 251 29 250 39 NOT USED
10 4111 20 105 30 252 40 122
Connector D2A
87419488 2
87728445 1 2/28/2008
A.30.A / 18

1 IGN3 14 NOT USED
2 120 15 NOT USED
3 335 16 NOT USED
4 334 17 NOT USED
5 121 18 NOT USED
6 0 19 NOT USED
9 122 22 NOT USED
11 NOT USED 24 103
12 0 25 NOT USED
13 135 26 NOT USED
Connector D2B
87410948 3

1 NOT USED 14 992
2 114 15 0
3 134 16 NOT USED
4 102 17 START
5 133 18 IGN3
6 111 19 NOT USED
7 125 20 992
8 118 21 IGN3
9 911A 22 0
10 116 23 NOT USED
11 104 24 4111
12 921 25 NOT USED
13 105 26 NOT USED
87728445 1 2/28/2008
A.30.A / 19
Connector D3A
DE_HD1091939P 4

A 0 F 251
B 501 G 250
C 335 H 224
D 334 J 252
E 389
Connector D4
C20, C22 5
Cavity Circuit ID
1 0
2 931
3 933
4 932
Connector D5
SWITCH 6
87728445 1 2/28/2008
A.30.A / 20

1 911B 4 NOT USED
2 912 5 NOT USED
Connector D6
SWITCH 7

1 921C 4 NOT USED
2 922 5 NOT USED
Connector D7
WIPER SWITCH 8

1 931 4 934
2 932 5 935
3 933A 6 953B
Connector D8
SWITCH 9
87728445 1 2/28/2008
A.30.A / 21

2 933C 5 NOT USED
3 943 6 NOT USED
Connector D9
WIPER SWITCH 10

1 951 4 954
2 952 5 955
3 953C 6 933B
Connector D10
SWITCH 11

2 953D 5 NOT USED
3 963 6 NOT USED
Connector D11
SWITCH 12
87728445 1 2/28/2008
A.30.A / 22

1 118 4 NOT USED
2 992D 5 NOT USED
3 125 6 NOT USED
Connector D12
SWITCH 13

1 111 4 NOT USED
2 992B 5 NOT USED
3 114 6 NOT USED
Connector D13
SWITCH 14

2 992E 5 NOT USED
3 993 6 NOT USED
Connector D14
D14 15
87728445 1 2/28/2008
A.30.A / 23

1 30 4 START
2 15 5 NOT USED
3 50 6 NOT USED
Connector D16
225326C1 16

1 911C 3 0
2 912 4 501A
Connector D17
C15 17
Cavity Circuit
A 0
B 501
87728445 1 2/28/2008
A.30.A / 24
Connector Component diagram 03 Connector Group "E"

Connector E1
E1 1
Cavity Circuit ID Cavity Circuit ID Cavity Circuit ID

1 302 11 103 21 317
2 D+ 12 818B 22 NOT USED
3 NOT USED 13 963 23 NOT USED
4 NOT USED 14 943 24 329
5 NOT USED 15 NOT USED 25 332
6 NOT USED 16 W 26 337
7 993 17 NOT USED 27 IGN3
8 NOT USED 18 334 28 NOT USED
9 NOT USED 19 NOT USED 29 389
10 21B 20 335
87728445 1 2/28/2008
A.30.A / 25
Connector E2
BOSCH89POLE 2

2 302 29 329
3 302 32 332
5 0 34 334
6 0 35 335
8 302 37 337
9 302 40 IGN3
10 0 42 342
11 0 75 375
12 312 89 389
17 317
Connector E11
E11 3
87728445 1 2/28/2008
A.30.A / 26
Cavity Circuit
1 342
2 0
3 302
Connector E12A
E12A 4
Cavity Circuit ID
A 818B
B 818C
Connector E13
382203A1 5
Cavity Circuit
1 D+
2 IGN3
3 W
Connector E14B
245484C1 6
87728445 1 2/28/2008
A.30.A / 27
Cavity Circuit ID
A 943
B 0
C 963
Connector E15
371614A1 7
Cavity Circuit
1 375
2 312
87728445 1 2/28/2008
A.30.A / 28
Connector Component diagram 04 Connector Group "L"

Connector L1
NOTE: Cab units only
RC07CCH87448363 1

1 911 3 801
2 800 4 802
NOTE: Canopy units only
RC07CCH87448363 2

1 911 3 NOT USED
Connector L2
NOTE: Cab and Canopy units.
L2, L3, L4, L5, 3
Cavity Circuit ID
1 921
2 0
87728445 1 2/28/2008
A.30.A / 29
Connector L3
L2, L3, L4, L5, 4
Cavity Circuit ID
1 921
2 0
Connector L4
L2, L3, L4, L5, 5
Cavity Circuit ID
1 911
2 0
Connector L5
L2, L3, L4, L5, 6

87728445 1 2/28/2008
A.30.A / 30
Cavity Circuit ID
1 911
2 0
Connector L6
L2, L3, L4, L5, 7
Cavity Circuit ID
1 911
2 0
Connector L7
L2, L3, L4, L5, 8
Cavity Circuit ID
1 911
2 0
Connector L8
NOTE: Canopy units only.
87728445 1 2/28/2008
A.30.A / 31
DEU_DT066S 9

1 911 4 NOT USED
Connector L9
NOTE: Cab units only. The connector does not have number ID’s in it, use the top to orient the connector.
L9 10

1 820 4 NOT USED
2 NOT USED 5 810
3 800
Connector L10
NOTE: Cab units only.
L10 11
Cavity Circuit ID
A 802
B 821
C 0
87728445 1 2/28/2008
A.30.A / 32
Connector L11
L11 12
Cavity Circuit ID
1 0
2 820
3 802
4 NOT USED
Connector L12
NOTE: Cab units only. The connector does not have number ID’s in it, use the top to orient the connector.
L12 13

1 812 4 813
2 814 5 810
3 811
Connector L13
L13 14
Cavity Circuit ID
1 0
2 814
3 801
4 813
Connector L15

87728445 1 2/28/2008
A.30.A / 33
L15 15

1 RT– 8 RT+
3 LT– 10 LT+
5 0 12 V3ACC
7 501 14 NOT USED
Connector L18
DEU_DT066S 16

1 811 4 802
2 812 5 821
3 820 6 818A
87728445 1 2/28/2008
A.30.A / 34
Connector L19
NOTE: Cab units only
DEU_DT066S 17

1 921 4 V3ACC
2 818A 5 NOT USED
3 501 6 NOT USED
87728445 1 2/28/2008
A.30.A / 35
Connector Component diagram 05 Connector Group "M"

Connector M1
M1 1

1 NOT USED 11 50 21 933 31 953
2 NOT USED 12 15 22 934 32 943
3 922 13 START 23 935 33 121
4 30 14 921 24224 224 34 NOT USED
5 NOT USED 15 IGN3 25 120 35 103
6 133 16 334 26 335 36 134
7 952 17 951 27 104 37 992
8 993 18 963 28 955 38 954
9 389 19 251 29 250 39 NOT USED
10 4111 20 D+ 30 252 40 NOT USED
87728445 1 2/28/2008
A.30.A / 36
Connector M2
M2 2
Cavity AA A B C D
1 BATTA 992 BATTA NOT USED 0
2 BATTA 30 50 NOT USED IGN+
3 BATTA 21 21 NOT USED 0
4 BATTA 504 206 NOT USED 21A
5 BATTB 1N1 21A NOT USED 317
6 BATTB 302 337 NOT USED 21B
7 BATTB 501 1N NOT USED 0
8 IGN+ IGN3 15 NOT USED 1N
9 IGN+ IGN2 332 NOT USED 0
10 IGN+ IGN1 START NOT USED 329
87728445 1 2/28/2008
A.30.A / 37
Connector M3
M3 3
Cavity A C
1 819 V1ACC
2 800 912
3 953 922
4 933 1M
5 V2acc V3ACC
6 NOT USED NOT USED
7 NOT USED NOT USED
8 NOT USED NOT USED
9 NOT USED NOT USED
10 NOT USED NOT USED
Connector M5
M5 4
Cavity Circuit ID
A 280
B 262
C 219
87728445 1 2/28/2008
A.30.A / 38
Connector M6
M6,7,8 5
Cavity Circuit ID
A 279
B 256
C 265
Connector M7
M6,7,8 6
Cavity Circuit ID
A IGN1
B 237
C 0
Connector M8
M6,7,8 7
Cavity Circuit ID
A IGN1
B 260
C 0
87728445 1 2/28/2008
A.30.A / 39
Connector M9
M9 8

1 IGN1 4 335
2 0 5 IGN1
3 334 6 NOT USED
Connector M10
M10 9

1 206 13 818B 25 NOT USED 37 120
2 219 14 NOT USED 26 801 38 121
3 223 15 955 27 NOT USED 39 245
4 104 16 NOT USED 28 NOT USED 40 250
5 334 17 NOT USED 29 934 41 251
6 335 18 501 30 935 42 252
7 224 19 NOT USED 31 954 43 256
8 237 20 V3ACC 32 NOT USED 44 260
9 133 21 800 33 NOT USED 45 262
10 134 22 921B 34 953 46 265
87728445 1 2/28/2008
A.30.A / 40

11 V1ACC 23 802 35 IGN1 47 279
12 NOT USED 24 911 36 IGN2 48 280
Connector M11
M11 10

1 302 16 W
3 NOT USED 18 334
5 NOT USED 20 335
6 NOT USED 21 317
7 993 22 NOT USED
9 NOT USED 24 329
10 21B 25 332
11 103 26 337
12 818B 27 IGN3
13 963 28 D+
14 943 29 389
15 NOT USED
87728445 1 2/28/2008
A.30.A / 41
Connector M13A
M13A,M31A 11
Cavity Circuit ID
A V2Acc
B 0
Connector M14
M14 12
Cavity Circuit ID
A 15
B 0
Connector M15
C20, C22 13
Cavity Circuit ID
1 951
2 952
3 933
4 0
87728445 1 2/28/2008
A.30.A / 42
Connector M16A
M16A 14

1 1N 5 W
2 NOT USED 6 0
3 NOT USED 7 1M
4 NOT USED 8 0
Connector M22A
M23, M30 15
Cavity Circuit ID
A V2ACC
B 0
Connector M23
245483C1 16
Cavity Circuit ID
A 223
B 280
87728445 1 2/28/2008
A.30.A / 43
Connector M24
M23, M30 17
Cavity Circuit ID
A 15
B 0
Connector M30
RC07CCH87448363 18
Cavity Circuit ID
1 911
2 912
3 0
4 501
87728445 1 2/28/2008
A.30.A / 44
Connector Component diagram 06 Connector Group "P"

Connector P1
P1 1

1 205 18 212
2 104 19 261
3 121 20 NOT USED
4 134 21 NOT USED
5 120 22 NOT USED
6 133 23 NOT USED
7 244 24 NOT USED
8 243 25 NOT USED
8 V1acc 26 NOT USED
10 217 27 NOT USED
11 218 28 NOT USED
12 204 29 NOT USED
13 216 30 NOT USED
14 230 31 268
15 231 32 269
16 215 33 NOT USED
17 248
87728445 1 2/28/2008
A.30.A / 45
Connector P3
DEU_DT064S 2

1 0 3 230
2 231 4 0
Connector P4
DEU_DT064S 3

1 0 3 216
2 204 4 0
Connector P5
DEU_DT064S 4

1 244 3 243
2 V1acc 4 261
87728445 1 2/28/2008
A.30.A / 46
Connector P6
DEU_DT064S 5

1 218 3 217
2 V1acc 4 212
Connector P7
DEU_DT062S 6
Cavity Circuit
1 268
2 0
Connector P8
DEU_DT062S 7
Cavity Circuit
1 269
2 0
87728445 1 2/28/2008
A.30.A / 47
Connector P9
256342A1 8
Cavity Circuit
A 133
B 0
Connector P10
DEU_DT0612S 9

1 V1acc 7 0
2 104 8 134
3 120 8 205
4 215 10 NOT USED
5 248 11 NOT USED
6 121 12 NOT USED
87728445 1 2/28/2008
A.30.A / 48
Connector Component diagram 07 Connector Group "V"

Connector V1
87737785 1

1 V1acc 7 0
2 104 8 134
3 120 9 205
4 215 10 NOT USED
5 248 11 NOT USED
6 121 12 NOT USED
Connector V23
V23 2
Cavity Circuit
A 120
B 0
87728445 1 2/28/2008
A.30.A / 49
Connector V24
DEU_DT062S 3
Cavity Circuit
1 215
2 0
Connector V25
V25 4
Cavity Circuit
A V1acc
B 248
87728445 1 2/28/2008
A.30.A / 50
Connector Component diagram 08 Engine controller to engine

components.
Connector A
BS07J141 1
Note: Cavities 1, 2, 15 and 16 are not used on 4 cylinder engines.

(1) Cylinder 5 injector (9) High pressure regulator with fuel
metering
(2) Cylinder 6 injector (10) High pressure regulator with fuel
metering
(3) Cylinder 4 injector (11) Cylinder 2 injector
(7) Not used (15) Cylinder 6 injector
(8) Not used (16) Cylinder 5 injector
Connector C
BS07J142 2

(1) Not used (19) Crankshaft speed sensor Ground
(2) Not used (20) Not used
(5) Not used (23) Crankshaft speed sensor Signal
(6) Not used (24) Engine oil pressure and
temperature sensor Ground
(7) Not used (25) Boost intake pressure sensor
Ground
87728445 1 2/28/2008
A.30.A / 51

(8) Not used (26) Coolant temperature sensor
Ground
(9) Camshaft speed sensor Signal (27) Oil pressure sensor Signal
(10) Camshaft speed sensor Ground (28) Oil temperature sensor Signal
(12) Common rail temperature and (30) Not used
pressure sensor Ground
(13) Common rail temperature and (31) Not used
pressure sensor Positive
(14) Common rail temperature and (32) Engine oil pressure and
pressure sensor Signal temperature sensor Positive
(15) Coolant temperature sensor (33) Boost intake pressure sensor
Signal Positive
(16) Not used (34) Boost intake pressure sensor
Signal
(17) Not used (35) Fuel temperature sensor Signal
(18) Fuel temperature sensor Signal (36) Boost intake temperature sensor
Signal
87728445 1 2/28/2008
A.30.A / 52
Wiring harness Identification

COLOR CODING
LB Light blue
B Black
O Orange
Y Yellow
GY Grey
BL Blue
BR Tan/Brown
V Violet/Purple
R Red
P Pink
G Green
W White
87728445 1 2/28/2008
A.30.A / 53
Wiring harness Electrical schematic frame 01 Charging Circuit
BC08B50101A 1
(1) Battery
(2) Master Disconnect Switch
(3) Alternator
87728445 1 2/28/2008
A.30.A / 54
Wiring harness Electrical schematic frame 02 Cranking Circuit

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7) Grid Heater Relay
(7A) Grid Heater Fuse
(7B) Grid Heater
87728445 1 2/28/2008
A.30.A / 55
Wiring harness Electrical schematic frame 03 Power Relays
BC08B50103A 1
(8) Power Relay Module A

(9) Power Relay Module B
87728445 1 2/28/2008
A.30.A / 56
Wiring harness Electrical schematic frame 04 Fuse and Relay

Block
BC08B50104A 1
(10) Ignition Relay

(11) Vehicle Safety Relay
(12) Starter Relay
(13) Fleet Relay
(14) Start Sensing Relay
(15) Fuses F1 to F10
87728445 1 2/28/2008
A.30.A / 57
Wiring harness Electrical schematic frame 05 Fuse Block
BC08B50105A 1
(16A) Fuses F11 to F20

(16B) Fuses F1 to F10
87728445 1 2/28/2008
A.30.A / 58
Wiring harness Electrical schematic frame 06 Brake Decelerator

and Throttle Potentiometer
BC08B50106A 1
(17) RightHand Brake Proximity Switch

(18) Not Used
(19) LeftHand Brake Proximity Switch
(20) Brake Position Sensor
(21) Decelerator Position Sensor
(22) Low Idle Switch
(23) Throttle Position Sensor
87728445 1 2/28/2008
A.30.A / 59
Wiring harness Electrical schematic frame 07 Drive Train

Controller
BC08B50107A 1
(24A) Drive Train Controller Connector C1
87728445 1 2/28/2008
A.30.A / 60

Controller
BC08B50108A 1
(24B) Drive Train Controller Connector C2
87728445 1 2/28/2008
A.30.A / 61
Wiring harness Electrical schematic frame 09 Pumps and Motors
BC08B50109A 1
(25) LeftHand Motor Speed Sensor

(26) RightHand Motor Speed Sensor
(27) LeftHand Hydrostatic Pump
(28) RightHand Hydrostatic Pump
(29) LeftHand Motor Solenoid
(30) RightHand Motor Solenoid
87728445 1 2/28/2008
A.30.A / 62
Wiring harness Electrical schematic frame 10 FNR Joystick and

Reverse Ratio Switch
BC08B50110A 1
(31) Reverse Ratio Switch

(32) ForwardNeutralReverse (FNR) Joystick
87728445 1 2/28/2008
A.30.A / 63
Wiring harness Electrical schematic frame 11 Brakes
BC08B50111A 1
(33) Brake Pressure Switch

(34) Brake Solenoid
87728445 1 2/28/2008
A.30.A / 64
Wiring harness Electrical schematic frame 12 Menu Switches and

Instrument Cluster
BC08B50112A 1
(35A) Instrument Cluster A

(35B) Instrument Cluster B
(36) Warning Buzzer
(37) Enter Escape Switch
(38) Up Down Switch
87728445 1 2/28/2008
A.30.A / 65
Wiring harness Electrical schematic frame 13 Sending Units
BC08B50113A 1
(39) Air Filter Restriction Switch

(40) Hydrostatic Filter Restriction Switch
(41) Transmission Temperature
(42) Equipment Filter Restriction Switch
(43) Fuel Sending Unit
(44) Transmission Charge Pressure Switch
87728445 1 2/28/2008
A.30.A / 66
Wiring harness Electrical schematic frame 14 Front and Rear

Lamps
BC08B50114A 1
(45) Front Lamp Switch

(46) Rear Lamp Switch
(47) Front Lamps
(48) Front Lamps (Optional)
(49) Rear Lamps
87728445 1 2/28/2008
A.30.A / 67
Wiring harness Electrical schematic frame 15 Horn and Backup

Alarms
BC08B50315B 1
(50) Backup Alarm

(51) Horn Switch
(52) Horn
87728445 1 2/28/2008
A.30.A / 68
Wiring harness Electrical schematic frame 16 Engine Control Unit
BC08B50116A 1
(53) Engine Controller

(54) Water in Fuel Sensor
87728445 1 2/28/2008
A.30.A / 69
Wiring harness Electrical schematic frame 17 Radio
BC08B50117A 1
(55) Radio
(56) Right Speaker
(57) Left Speaker
87728445 1 2/28/2008
A.30.A / 70
Wiring harness Electrical schematic frame 18 Dome Lamps
BC08B50118A 1
(58) Interior Lamp Switch

(59) Interior Lamp
87728445 1 2/28/2008
A.30.A / 71
Wiring harness Electrical schematic frame 19 ROPS Heater and

Air Suspension Seat
BC08B50119A 1
(60) Heater ROPS

(61) Air Suspension Seat
87728445 1 2/28/2008
A.30.A / 72
Wiring harness Electrical schematic frame 20 Blower Motor
BC08B50120A 1
(62) Blower Motors

(63) Thermostat
(64) Water Valve
(65) Resistor
(66) Fan Speed Switch
(67) Mode Switch
(68) Temperature Switch
87728445 1 2/28/2008
A.30.A / 73
Wiring harness Electrical schematic frame 21 Air Conditioning
BC08B50121A 1
(69) Air Conditioner Low Pressure Switch

(70) Air Conditioner High Pressure Switch
(71) Air Conditioner Clutch
(72) Air Conditioner Condenser
87728445 1 2/28/2008
A.30.A / 74
Wiring harness Electrical schematic frame 22 Windshield Wiper

Switch and Washer
BC08B50122A 1
(73) Front Wiper Motor

(74) Wiper Switch (Front / Rear)
(75) Rear Wiper Motor
87728445 1 2/28/2008
A.30.A / 75
Wiring harness Electrical schematic frame 23 Windshield Wiper

Switch and Washer
BC08B50123A 1
(76) Washer Switch (Front / Rear)

(77) Washer Pump (Front / Rear)
87728445 1 2/28/2008
A.30.A / 76
Wiring harness Electrical schematic frame 24 Door Wiper Switch

and Motors
BC08B50124A 1
(78) Wiper Motor (Left)

(79) Wiper Switch (Left / Right)
(80) Wiper Motor (Right)
87728445 1 2/28/2008
A.30.A / 77
Wiring harness Electrical schematic frame 25 Door Wiper Switch

and Washer
BC08B50125A 1
(81) Washer Switch (Left / Right)

(82) Washer Pump (Left / Right)
87728445 1 2/28/2008
A.30.A / 78
Wiring harness Electrical schematic frame 26 Diagnostic and Fleet
BC08B50126A 1
(83) Connector Diagnostic

(84) 12 Volt Power Socket
(85) Connector Fleet Tracker
87728445 1 2/28/2008
A.30.A / 79
Wiring harness Electrical schematic frame 27 Ground Connections
BC08B50127A 1
(86) P2 Located in Battery Compartment (Ground Contacts in Frames 9, 13 and 15)

(87) M4 Located behind Console (Ground Contacts in Frames 3, 4, 6, 10, 12, 19, 22, and 26)
(88) L14 Located Top of Cab (Ground Contacts in Frames 14, 17, 18, 20, and 21)
(89) E3 Located at LeftHand Rear Engine Mount (Ground Contacts in Frames 13, 15, 16, 23, and 25)
(90) C19 Located near Drive Train Controller (Ground Contacts in Frames 7 and 26)
(91) C13 Located near RightHand Arm Rest (Ground Contacts in Frames 22 and 24)
87728445 1 2/28/2008
A.30.A / 80
Battery Check
A hydrometer is used to check the specific gravity (weight) of the electrolyte. The specific gravity is an indication of
the level of charge for each cell.
Hydrometers are made to show the correct specific gravity when the temperature of the electrolyte is 26.7 °C (80 °F).
When you check the specific gravity, you must know the temperature of the electrolyte. If your hydrometer does not
have a thermometer, get a thermometer to check the temperature of the electrolyte. The thermometer must indicate
a high temperature of at least 52 °C (120 °F).
NOTE: To correctly test a battery, do each part of the battery test until you know the condition of the battery.
1. Remove enough electrolyte from a cell so that the
float is free in the tube.
NOTE: If the specific gravity cannot be checked without
first adding water to the cell, the battery must be charged
for 15 minutes at 15 to 25 amperes to mix the water with
the electrolyte. Then check the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above 26.7
°C (80 °F) add specific gravity points to the reading
for specific gravity. If the reading is below 26.7 °C (80
°F) subtract specific gravity points from the reading
for specific gravity. See the following illustration and
add or subtract specific gravity points as needed.
(1) Temperature in F
(2) Temperature in C
B790863 1
4. Make a record of the corrected specific gravity read

ing for each cell.
5. If the difference between the high reading and the
low reading is 0.050 or more, charge the battery and
check the specific gravity again. If after charging, the
difference is still 0.050 or more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge must
be at least 75 % in each of the cells. In maintenance
free batteries the level of charge is at least 75 %
if the corrected specific gravity reading is 1.240 or
higher. In all other batteries the level of charge is at
least 75 % if the corrected specific gravity reading is
1.230 or higher.
7. If the difference between the high reading and the low
reading is less than 0.050, and the level of change is
at least 75 % in all of the cells, do the Capacity (Load)
Test.
87728445 1 2/28/2008
A.30.A / 81
8. If the difference between the high reading and the low

reading is less than 0.050, but the level of charge is
less than 75 % in any of the cells, charge the battery
and check the specific gravity again. If after charg
ing:
87728445 1 2/28/2008
A.30.A / 82
Battery Visual inspection
WARNING
Never try to charge the battery if the electrolyte in the battery is frozen. 4783A
WARNING
Never cause sparks to occur or smoke near batteries that are charging or have been recently charged. 138A
WARNING
Disconnect the ground cable first when the battery cables are disconnected from the battery. Connect the
ground cable last when the battery cables are connected to the battery. 4755A
WARNING
Some batteries have a ventilation tube. If there is battery acid in the ventilation tube, this battery acid can be
released when the battery is turned upside down. If you turn the battery upside down, make sure that the end
of the ventilation tube is away from you and away from any other people in the area. Battery acid can cause
severe burns. 4857B
WARNING
BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or
clothing. Antidote: EXTERNAL flush with water. INTERNAL Drink large quantities of water or milk. DO
NOT induce vomiting. Seek medical attention immediately. EYES Flush with water for 15 minutes and seek
medical attention immediately. BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and
cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when work
ing near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. M144B
1. If the battery is a maintenance free battery, check the

level of the electrolyte every 1000 hours of operation
or six months, whichever occurs first. For all other
batteries, check the level of the electrolyte every 250
hours of operation.
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 for access to
the battery caps, it is possible that the words Maintenance
Free have been removed from the decal.
2. Check the level of the electrolyte more often during
hot weather. The use of a large amount of water by
the battery can be caused by high battery temper
ature or a voltage regulator setting that is too high.
Keep the electrolyte level above the top of the plates
in the battery at all times to prevent damage to the
battery.
NOTE: On maintenance free batteries it is necessary to
remove the center part of the decal for 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.
87728445 1 2/28/2008
A.30.A / 83
3. If the level of the electrolyte is low, add distilled water

or other clean water until the electrolyte is 5 mm (1/4
inch) below the level of the ring. Do not add more
water than is needed. Too much water can cause
bad performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.
4. If damage causes an electrolyte leak, replace the
battery.
5. Inspect the battery at regular intervals for dirt, cor
rosion, and damage. Electrolyte and dirt on the top
of the battery can cause the battery to discharge by
making a passage for the current to flow.
6. If the battery must be cleaned, remove the battery
from the battery carrier and clean the battery, cable
terminals, and the battery carrier. When available,
use Case Battery Saver and Cleaner according to
the instructions on the container. Case Battery Saver
and Cleaner also helps prevent corrosion. If Case
Battery Saver and Cleaner is not available, use bak
ing soda and water as a cleaner. DO NOT permit any
type of cleaner to enter the cells of the battery.
7. Install the battery in the machine and make sure the
fasteners are tight. Apply Case Battery Saver and
Cleaner or Urethane Seal Coat to the cable terminals
to prevent corrosion. See the Parts Counter Catalog.
DO NOT apply grease.
8. Make sure the cable connections are clean and tight.
Clean foreign material from the top of the battery.
9. Inspect the battery case, battery posts, and cables
for damage.
10. Check the electrolyte level.
11. 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.
87728445 1 2/28/2008
A.30.A / 84
Battery Electrical test

This test can be done using a variable load tester such as the Sun Electric VAT33. Other test equipment can be
used. Connect the test equipment according to the instructions of the manufacturer of the equipment.
CAS10147 The CAS10147 tester is used to do the Capacity (load) Test.
The level of charge of the battery must be at least 75 %. Do the Specific Gravity Check in this section.
Prepare the tester (Sun Electric VAT33 shown) for the test.
1. Select the voltmeter range that will measure 1 to 18

volts.
B795328 1
2. Make sure the load control knob is in the OFF posi

tion.
3. Select the ammeter range that will measure 0 to 1000
amperes.
4. Move the volt lead switch to the NT. position.
5. Connect the tester to the battery as shown.
(1) Load Control Knob
(2) Ammeter Clamp (Tip of Arrow Away From Bat

tery)
NOTE: Never apply a load for longer than 15 seconds. Af
ter each 15 seconds, turn the load control knob to OFF for
a least one minute.
B790499 2
6. Apply a 15 ampere load to the battery for 15 seconds.

Wait at least three minutes before applying the load
again.
7. Check and make a record of the temperature of the
electrolyte.
NOTE: The correct load is half of the cold cranking am
peres at 18 °C (0 °F).
87728445 1 2/28/2008
A.30.A / 85
8. Turn the load control knob until the ammeter indi

cates the specified load. Keep the load for 15 sec
onds and read the voltmeter. Turn the load control
knob to OFF.
9. Compare the test reading between the temperature
and the minimum voltage electrolyte data below.
21 °C (70 °F) and above / 9.6 volts

16 °C (60 °F) / 9.5 volts
10 °C (50 °F)/ 9.4 volts
4 °C (40 °F) / 9.3 volts
1 °C (30. °F) / 9.1 volts
7 °C (20 °F)) / 8.9 volts
12 °C (10 °F) / 8.7 volts
18 °C (0 °F) / 8.5 volts.
10. If the test result is equal to or more than the voltage
shown, the battery is in good condition.
11. If the test result is less than the voltage shown, dis
card the battery.
87728445 1 2/28/2008
A.30.A / 86
Battery Charging
WARNING
Never try to charge the battery if the electrolyte in the battery is frozen. 4783A
1. Before you charge the battery, check the level of the

electrolyte.
2. It is difficult to give an exact charging rate because of
the following variable conditions: (1) temperature of
the electrolyte, (2) level of charge, and (3) condition
of the battery. Use the charging guide for the correct
charging rate and time.
3. See the following for the reserve capacity of the bat
tery in this machine. Battery General specifica
tion (A.30.A).
4. The charging rate must be decreased if too much gas
causes the electrolyte to flow from the cells or if the
electrolyte rises above 52 °C (125 °F).
5. The battery is fully charged when, over a three hour
period at a low charging rate, no cell is giving too
much gas, and the specific gravity does not change.
87728445 1 2/28/2008
A.30.A / 87
Battery Filling
1. Remove the caps from the battery.
2. Fill each cell to the top of the separators with elec
trolyte. This will permit the volume of electrolyte to
increase when heated by charging the battery.
3. Install the caps on the battery.
4. Connect a battery charger to the battery.
5. Charge the battery at 30 amperes until the specific
gravity is 1.250 or more and the temperature of the
electrolyte is at least 15.5 °C (60 °F).
6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of the
cell opening.
87728445 1 2/28/2008
A.30.A / 88
Fuse and relay box Relay Testing Ignition Relay

NOTE: Before proceeding, replace relay with known good relay and check circuit, if circuit functions replace relay.
For wiring diagram refer to Wiring harness Electrical schematic frame 04 Fuse and Relay Block (A.30.A).
Put the master disconnect switch in Continuity Bad ground circuit.
the ON position
Check
Terminal 86 to ground.
Terminal 30 for wire BATTA to 12 volts Bad 50 Amp fuse in power relay
ground. module A, bad wire BATTA between
the relay and power relay A, bad
power relay A. Refer to Fuse and
relay box Relay Testing (A.30.A)
and check power relay module A.
Place the ignition switch in the ON 12 volts Bad wire BR (50) to ignition switch,
position. bad ignition switch. Refer to Start
Check control Start switch Testing
Terminal 85 for wire BR (50) to (B.80.A) and check ignition switch.
ground.
Terminal 87 to ground. 12 volts Bad ignition relay.
Fuse and relay box Relay Testing Power Relay Modules A and B
NOTE: Before proceeding check power relay module fuses, replace as needed. For wiring diagram refer to Wiring
harness Electrical schematic frame 03 Power Relays (A.30.A).
Put the master disconnect switch in 12 volts Bad battery cable, bad master dis
the ON position. connect switch, refer to Battery
Check switch Testing (A.30.A) and check
Battery cable at power relay mod master disconnect switch.
ules.
Disconnect Connector M14 power Continuity Bad grounding circuit.
relay module A and Connector M24
power relay module B.
Check
Terminal B for wire 0 to ground.
Place the ignition switch in the RUN 12 volts Bad wire DB (15) to ignition switch,
position. bad ignition switch, refer to Start
Check control Start switch Testing
Terminal A Connector M14 and (B.80.A) and check ignition switch.
Connector M24 to ground.
Turn ignition switch OFF and con 12 volts Bad power relay module.
nect connectors M14 and M24 to
power relay modules, turn ignition
switch to the RUN position.
Check
Power output terminal at relay mod
ules.
87728445 1 2/28/2008
A.30.A / 89
Fuse and relay box Fuse Testing

NOTE: Check fuses in power relay module. For wiring diagram refer to Wiring harness Electrical schematic frame
03 Power Relays (A.30.A).
Between terminals of fuses. Continuity Bad fuse.
Place the master disconnect switch 12 volts No power at fuses F1 to F4 at fuse
in the ON position and the ignition and relay panel M2, bad power relay
switch in the RUN position. module A, refer to Fuse and relay
Check box Relay Testing (A.30.A) and
At input side of fuses. check power relay modules.
No power at fuses F5 to F7 at fuse
and relay panel M2, bad power relay
module B, refer to Fuse and relay
box Relay Testing (A.30.A) and
check power relay modules.
and relay panel M2, bad ignition re
lay, refer to Fuse and relay box Re
lay Testing (A.30.A) and check ig
nition relay.
panel M3, bad power relay module
A, refer to Fuse and relay box Re
lay Testing (A.30.A) and check
power relay modules.
No power at fuses F11 to F20 at
fuse panel M3, bad power relay mod
ule B, refer to Fuse and relay box
Relay Testing (A.30.A) and check
87728445 1 2/28/2008
A.30.A / 90
Alternator Testing
NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 01 Charging Circuit (A.30.A).
Put master disconnect switch in the 12 volts Bad wire 1A between the alterna
ON position. tor and the battery terminal of the
Check starter. Bad cable between the bat
B+ terminal for wire 1A to ground. tery terminal of the starter and the
positive post of the battery.
Disconnect connector E13 at the al 12 volts Bad fuse F8 in fuse and relay panel
ternator, put the ignition switch in the Connector M2, bad wire IGN3 from
RUN position. the alternator to connector M2.
Check Check wire IGN3 from Connec
Terminal 2 at Connector E13 for tor E13 to pin 27 of Connector E1.
wire IGN3 to ground. From pin 27 of Connector M11 to
pin A8 Connector M2. Repair as
needed.
87728445 1 2/28/2008
A.30.A / 91
Battery switch Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 01 Charging Circuit (A.30.A).
Put the master disconnect switch in 0 volt Bad master disconnect switch.
the OFF position.
Check
Battery positive terminal to ground.
Put master disconnect switch in the 12 volts Bad master disconnect switch or
ON position. bad cable between master discon
Battery positive terminal to ground. nect switch and ground.
87728445 1 2/28/2008
A.30.A / 92
Auxiliary power connection Outlet 1 Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 26 Diagnostic and Fleet (A.30.A).
the ON position, disconnect connec
tor D17.
Check
Terminal 1 Connector D17 for wire
0 to ground.
Terminal for wire 501 to ground. 12 volt Bad wire to fuse and relay panel, bad
fuse F7.
Outside ring of power plug to ground. Continuity Bad ground circuit
Inside connection of power plug to 12 volts Bad connection to power plug, bad
ground. power plug.
Check wire 501 from Connector Continuity Bad wire.
D17 pin 2 to Connector D16 pin 4.
Check wire 501 from Connector Continuity Bad wire.
M30 pin 4 to Connector M2 pin A7.
87728445 1 2/28/2008
A.30.A / 93
Index

Alternator Testing 91
Auxiliary power connection Outlet 1 Testing 93
Battery Charging 87
Battery Check 81
Battery Electrical test 85
Battery Filling 88
Battery General specification 6
Battery Visual inspection 83
Battery switch Testing 92
Connector Component diagram 01 Connector Group "C" 12
Connector Component diagram 02 Connector Group "D" 18
Connector Component diagram 03 Connector Group "E" 25
Connector Component diagram 04 Connector Group "L" 29
Connector Component diagram 05 Connector Group "M" 36
Connector Component diagram 06 Connector Group "P" 45
Connector Component diagram 07 Connector Group "V" 49
Connector Component diagram 08 Engine controller to engine components. 51
ELECTRICAL POWER SYSTEM Detailed view Grounding Locations 7
ELECTRICAL POWER SYSTEM General specification 4
Fuse and relay box Torque 5
Fuse and relay box Fuse Overview 10
Fuse and relay box Fuse Testing 89
Fuse and relay box Relay Overview 11
Fuse and relay box Relay Testing Ignition Relay 89
Fuse and relay box Relay Testing Power Relay Modules A and B 89
Wiring harness Electrical schematic frame 01 Charging Circuit 54
Wiring harness Electrical schematic frame 02 Cranking Circuit and Cold Start 55
Wiring harness Electrical schematic frame 03 Power Relays 56
Wiring harness Electrical schematic frame 04 Fuse and Relay Block 57
Wiring harness Electrical schematic frame 05 Fuse Block 58
Wiring harness Electrical schematic frame 06 Brake Decelerator and Throttle Potentiometer 59
Wiring harness Electrical schematic frame 07 Drive Train Controller 60
Wiring harness Electrical schematic frame 08 Drive Train Controller 61
Wiring harness Electrical schematic frame 09 Pumps and Motors 62
Wiring harness Electrical schematic frame 10 FNR Joystick and Reverse Ratio Switch 63
Wiring harness Electrical schematic frame 11 Brakes 64
Wiring harness Electrical schematic frame 12 Menu Switches and Instrument Cluster 65
Wiring harness Electrical schematic frame 13 Sending Units 66
Wiring harness Electrical schematic frame 14 Front and Rear Lamps 67
Wiring harness Electrical schematic frame 15 Horn and Backup Alarms 68
Wiring harness Electrical schematic frame 16 Engine Control Unit 69
Wiring harness Electrical schematic frame 17 Radio 70
Wiring harness Electrical schematic frame 18 Dome Lamps 71
Wiring harness Electrical schematic frame 19 ROPS Heater and Air Suspension Seat 72
87728445 1 2/28/2008
A.30.A / 94
Wiring harness Electrical schematic frame 20 Blower Motor 73
Wiring harness Electrical schematic frame 21 Air Conditioning 74
Wiring harness Electrical schematic frame 22 Windshield Wiper Switch and Washer 75
Wiring harness Electrical schematic frame 23 Windshield Wiper Switch and Washer 76
Wiring harness Electrical schematic frame 24 Door Wiper Switch and Motors 77
Wiring harness Electrical schematic frame 25 Door Wiper Switch and Washer 78
Wiring harness Electrical schematic frame 26 Diagnostic and Fleet 79
Wiring harness Electrical schematic frame 27 Ground Connections 80
Wiring harness Identification 53
87728445 1 2/28/2008
A.30.A / 95
87728445 1 2/28/2008
A.30.A / 96
LIGHTING SYSTEM 40.A
750L
850L
87728445 1 2/28/2008
A.40.A / 1
Contents
DIAGNOSTIC
Front work light
Electrical light Testing 3
Switch Testing 3
Rear work light
Electrical light Testing 4
Switch Testing 4
Dome light
Testing light switch. 5
87728445 1 2/28/2008
A.40.A / 2
DISTRIBUTION SYSTEMS LIGHTING SYSTEM
Front work light Electrical light Testing

Between terminals of bulb Continuity Bad bulb
Front work light Switch Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 14 Front and Rear Lamps (A.30.A).
Put the master disconnect switch 12 volts Bad wire DB (912) between front
in the ON position and the ignition floodlight/monitor light switch and
switch in the RUN position. fuse, bad fuse F1. Bad power relay
Check module A.
Terminal for wire DB (912) to ground.
Turn the front floodlight/monitor Illuminates Bad light switch. Also check wire Y
switch ON. (911B) Connector D5 pin 1 at light
Check switch to instrument cluster Connec
Indicator in instrument cluster tor D2B pin 9.
Turn the front floodlight/monitor 12 volts Bad light switch.
switch ON.
Check
Terminal for wire Y (911B) at light
switch to ground.
Terminal for wire Y (911) at lights. 12 volts Check wire from light switch to lights,
check Connector D5 pin 1 at light
switch to Connector D16 pin 1,
Connector L1 pin 1 to connectors
L4, L5, L6 and L7 pin 1.
87728445 1 2/28/2008
A.40.A / 3
Rear work light Electrical light Testing

Between terminals of bulb Continuity Bad bulb
Rear work light Switch Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 14 Front and Rear Lamps (A.30.A)
Put the master disconnect switch 12 volts Bad wire DB (922) between rear light
in the ON position, put the ignition switch and fuse, bad fuse F11. Bad
switch in the RUN position. power relay module B.
Check
Terminal for wire DB (922) pin 2 at
Connector D6 to ground.
Turn the rear floodlight/monitor 12 volts Bad light switch.
switch ON.
Check
Terminal for voltage at wire GY
(921C) pin 1 Connector D6 at light
switch to ground.
Terminal for wire GY (921) at lights. 12 volts Check wire from light switch to lights,
check Connector D6 pin 1 at light
switch to Connector D1 pin 14,
Connector M1 pin 14 to Connector
M10 pin 21, Connector C4 pin 21 to
Connector C25 pin 1, Connector
L19 pin 1 to connectors L2 and L3
pin 1.
87728445 1 2/28/2008
A.40.A / 4
Dome light Testing light switch.

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 18 Dome Lamps (A.30.A)
Put the master disconnect switch in 12 volts Bad wire R (501) to fuse, bad fuse
the ON position. F7 in relay and fuse block.
Check
Terminal R (501) in connector to
ground.
Turn the interior light switch on. 12 volts Bad wire between light and switch.
Check Bad switch.
Positive connector at light to ground.
87728445 1 2/28/2008
A.40.A / 5
Index

Dome light Testing light switch. 5
Front work light Electrical light Testing 3
Front work light Switch Testing 3
Rear work light Electrical light Testing 4
Rear work light Switch Testing 4
87728445 1 2/28/2008
A.40.A / 6
FAULT CODES 50.A
750L
850L
87728445 1 2/28/2008
A.50.A / 1
Contents
FAULT CODES 50.A
DIAGNOSTIC
ELECTRONIC SYSTEM
0000Retrieving fault codes, Crawlers 7
[AIC] 1312Hydraulic oil temperature above normal 9
[AIC] 1313Hydraulic oil temperature too high, critical 12
[AIC] 1314Transmission oil temperature above normal 17
[AIC] 1315Transmission oil temperature too high, critical 22
[AIC] 1318Engine coolant temperature above normal 27
[AIC] 1319Engine coolant temperature too high, critical 31
[AIC] 1320Engine oil pressure too low, critical 35
[AIC] 1323Battery voltage too low, critical 40
[AIC] 1324Battery voltage too high, critical 42
[AIC] 1325Engine oil temperature too high, critical 44
[DTC] 4121Left forward pump solenoid circuit open or over current 49
[DTC] 4131Right forward pump solenoid circuit open or over current 55
[DTC] 4141Left reverse pump solenoid circuit open or over current 61
[DTC] 4151Right reverse pump solenoid circuit open or over current 67
[DTC] 4212Left motor solenoid circuit open or over current 73
[DTC] 4222Right motor solenoid circuit open or over current 80
[DTC] 4311Left speed sensor out of range 87
[DTC] 4312Right speed sensor out of range 93
[DTC] 4321Foot pedal potentiometer out of range 99
[DTC] 4322Idle validation switch not working 105
[DTC] 4323Decel pedal locked out, unstable readings 111
[DTC] 4324Hand throttle readings out of range 117
[DTC] 4331Inching pedal potentiometer out of range 122
[DTC] 4332Parking brake pressure sensor, open circuit 129
[DTC] 4341No engine speed signal 135
[DTC] 4431Parking brake solenoid, open circuit 137
[DTC] 4521Bump up switch stuck on at power up 144
[DTC] 4522Bump down switch stuck on at power up 150
[DTC] 4531Directional control steering axis faulted 156
[DTC] 4532Directional control forward/reverse axis faulted 162
[DTC] 4533Joystick CAN message fault 168
87728445 1 2/28/2008
A.50.A / 2
[DTC] 4621No CAN communication with instrument cluster 172
[EDC] 3006Coolant Temperature Sensor Signal Not Plausible 176
[EDC] 3007Coolant temperature sensor voltage too high 178
[EDC] 3008Coolant Temperature Sensor Signal Below Range Minimum 180
[EDC] 3009Coolant temperature sensor circuit open or sensor disconnected 182
[EDC] 3015Fuel Temperature Sensor Signal Above Maximum 185
[EDC] 3016Fuel Temperature Sensor Signal Below Range Minimum 187
[EDC] 3019Boost Pressure Sensor Signal Above Range Maximum 189
[EDC] 3021Boost pressure sensor circuit open or sensor disconnected 195
[EDC] 3022Boost Pressure Sensor Signal Not Plausible 201
[EDC] 3023Atmospheric Pressure Sensor Signal Not Plausible 204
[EDC] 3024Atmospheric Pressure Sensor Signal Above Range Maximum 205
[EDC] 3025Atmosperic Pressure Sensor Signal Below Range Minimum 206
[EDC] 3028Oil Pressure too low 207
[EDC] 3029Oil Pressure Sensor Short Circuit To Battery 210
[EDC] 3030Oil Pressure Sensor Short Circuit To Ground 213
[EDC] 3031Oil Pressure Sensor Hardware Error 216
[EDC] 3032Oil Pressure Sensor Value Too High 219
[EDC] 3033Oil Temperature Sensor Signal Not Plausible (Compared With Coolant 222
Temperature)
[EDC] 3034Oil Temperature Sensor Signal Above Range Maximum 225
[EDC] 3035Oil Temperature Sensor Signal Below Range Minimum 228
[EDC] 3036Oil temperature sensor circuit open or sensor disconnected 231
[EDC] 3037Boost Pressure Sensor Signal Low 234
[EDC] 3051Battery Voltage To Engine Controller Voltage Too High 240
[EDC] 3052Battery Voltage To Engine Controller Voltage Too Low 246
[EDC] 3060Cylinder 1 Unclassifiable Error In Injector 252
[EDC] 3061Cylinder 1 Injector Cable Short Circuit (Low Side To Battery) 255
[EDC] 3062Cylinder 1 Electronic injector , Low signal 258
[EDC] 3063Cylinder 1 Injector Cable Short Circuit (High Side To Ground) 261
[EDC] 3064Cylinder 5 Unclassifiable Error in Injector 264
850L
850L

850L
850L

850L
850L
87728445 1 2/28/2008
A.50.A / 3
850L
850L

[EDC] 3088Crankshaft sensor lost synchronization 324
[EDC] 3089Crankshaft Sensor Invalid Signal 326
[EDC] 3090Phase defect of camshaft speed sensor signal detected 328
[EDC] 3091Camshaft sensor phase synchronization failure 330
[EDC] 3093Offset Between Camshaft And Crankshaft Outside Boundaries 332
[EDC] 3095Operating With Camshaft Sensor Only Backup Mode 335
[EDC] 3102Rail Pressure Sensor CP3 Signal Below Range Minimum 337
[EDC] 3104Rail Pressure Relief Valve Open 343
[EDC] 3105Rail Pressure Relief Valve Pressure Shock Requested 349
[EDC] 3106Rail Pressure Relief Valve Did Not Open After Pressure Shock 351
[EDC] 3107Metering unit output short circuit to battery on low side 353
[EDC] 3110Rail Pressure Sensor Monitoring Signal Above Range Maximum 355
[EDC] 3111Rail Pressure Sensor Monitoring Signal Below Range Minimum 358
[EDC] 3112Rail Pressure Sensor CP3 Signal Above Maximum Range 361
[EDC] 3113Grid heater battery switch relay short circuit to battery 364
[EDC] 3114Grid heater battery switch relay short circuit to ground 368
[EDC] 3118ECM 12V sensor supply voltage high 372
[EDC] 3119ECM 12V sensor supply voltage low 377
[EDC] 3131Grid Heater Always Switched On 382
[EDC] 3137Metering Unit Open Load 386
[EDC] 3138Metering unit signal not plausible 388
[EDC] 3141Set point of fuel volume flow through metering unit is lower than calculated 390
limit
[EDC] 3146Water detected in fuel 397
[EDC] 3147Oil Temperature Too High 403
[EDC] 3154Grid Heater Relay Short Circuit To Battery 409
[EDC] 3155Grid Heater Relay Short Circuit To Ground 413
[EDC] 3156Grid Heater Relay No Load 417
[EDC] 3171Fuel rail system pressure too low 421
[EDC] 3172Fuel rail system pressure too high 427
[EDC] 3173Rail Pressure Governor Deviation Below Min. Limit for Speed 433
[EDC] 3174Rail Pressure Governor Deviation Exceeded Max. Limit 439
87728445 1 2/28/2008
A.50.A / 4
[EDC] 3175Fuel system leak detected large leak 445
[EDC] 3176Fuel delivery exceeded threshold for pressure in overrun mode 451
[EDC] 3178Timeout of CAN message BC2EDC1 457
[EDC] 3179Timeout Of CAN Message BC2EDC2 462
[EDC] 3180Timeout of CAN Message VM2EDC 467
[EDC] 3188Cylinder 1 Warning Open Load 472
[EDC] 3192Cylinder 2 warning Open Load 475
850L

850L
[EDC] 3210Bank 1 General Short Circuit To Injector Cable 490

[EDC] 3211Bank 1 Injector cable Short Circuit Low Side To Ground 496
[EDC] 3213Bank 1 Unclassifiable Error 502
[EDC] 3218Bank 2 General Short Circuit On Injector Cable 508
[EDC] 3219Bank 2 Injector Cable Short Circuit Low Side To Ground 514
[EDC] 3221Bank 2 Unclassifiable Error 520
[EDC] 3227Injection Processor Error Internal Reset/Clock Loss/Voltage Too Low 526
[EDC] 3228Injection Processor Error Unlocked/Initialization Error 531
[EDC] 3229Injection processor error stop engine 532
[EDC] 3238Communication error of CJ940 processor 538
[EDC] 3242Engine Controller (Locked) Recovery Occurred 539
[EDC] 3243Engine Controller Recovery (Suppressed) Recovery Occurred 540
[EDC] 3244Engine Controller Recovery (Visible) Recovery Occurred 541
[EDC] 3245Engine Controller Watchdog Not Plausible 542
[EDC] 3246Shutoff Paths During Initialization Watchdog 543
[EDC] 3247Shutoff Paths Failed During Initialization Supply Voltage Too High 544
[EDC] 3248Shutoff Paths During Initialization Supply Voltage Too Low 545
[EDC] 3253ADC Monitoring Reference Voltage Too Low 546
[EDC] 3254ADC Monitoring Reference Voltage Too High 547
[EDC] 3255ADC Monitoring Test Impulse Error 548
[EDC] 3256ADC Monitoring Queue Error 549
[EDC] 3258HS power stage hardware reports ’short circuit to battery’ longer than 550
500 ms.
[EDC] 3259HS power stage hardware reports ’short circuit to ground’ longer than 555
100 ms.
[EDC] 3260LS power stage hardware reports ’open load’ longer than 100 ms 560
87728445 1 2/28/2008
A.50.A / 5
[EDC] 3261LS power stage hardware reports ’short circuit to battery’ or ’excess 565
temperature’ longer than 100 ms.
[EDC] 3262LS power stage hardware reports ’short circuit to ground’ longer than 570
100 ms.
[EDC] 3265Energizing time exceeds limit of over run monitoring, injection time too long 575
[EDC] 3266Error in engine speed check, speed signal not plausible 576
[EDC] 3278Engine Controller Supply Voltage Too High 577
[EDC] 3279Engine Controller Internal Supply Voltage Too Low 580
[EDC] 3280Sensor Supply Voltage 1 High 583
[EDC] 3281Sensor Supply Voltage 1 Low 586
87728445 1 2/28/2008
A.50.A / 6
DISTRIBUTION SYSTEMS FAULT CODES
0000Retrieving fault codes, Crawlers

Context:
General fault code identification
Solution:
1. Press and hold the escape key and up arrow key for more than 2 seconds to access the fault codes.
BD06G11201 1
(1) Up key (3) Escape key

(2) Down key (4) Enter key
2. Yellow Faults, buzzer will beep once every 2 seconds:
(A) Operator can acknowledge it by pressing the enter key.

(B) The message will disappear.
(C) Buzzer will not beep anymore.
(D) Yellow lamp will stay ON.
(E) Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous, alternating sounds:
(A) Operator can acknowledge it by pressing the enter key.

(B) Buzzer will change to a less stressing sound, but will remain.
(C) Message will remain on display with indication of URGENT STOP.
4. Fault Code Grouping
(1) 1000 to 1999 vehicle errors.

(2) 2000 to 2999 not used.
(3) 3000 to 3999 engine errors.
(4) 4000 to 4999 transmission errors.
(5) 5000 to 5999 electrohydraulic system errors.
(6) 6000 to 6999 reserved.
(7) 7000 to 7999 reserved.
(8) 8000 to 8999 optional equipment IE: GPS.
(9) 9000 to 9999 internal AIC errors.
5. Clearing the AIC faults.
(1) Press and hold the enter button for 3 seconds.
(2) Using the up and down arrow scroll until "RESET" is highlighted.
(3) Press the enter button.
(4) The next screen displays "RESET ERRORS" and "RESET FACTORY".
87728445 1 2/28/2008
A.50.A / 7
(5) Highlight the "RESET ERRORS" and press enter.
(6) "CONFIRM" will be displayed.
(7) Press enter to erase all faults.
87728445 1 2/28/2008
A.50.A / 8
1312Hydraulic oil temperature above normal

Control Module : AIC
NOTE: Check oil cooler for clogs, check fan operation, check oil cooler bypass valve before proceeding.
Cause:
1. Hydraulic temperature high.

2. Faulty reading from component.
3. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.
4. Wiring or circuits open.
5. Wiring or circuits shorted.
Solution:
1. Find out if the fault code is still active, refer to

0000 Retrieving fault codes, Crawlers
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occur
rence.
(1) Turn ignition switch to RUN position.
(2) Clear all fault codes.
(3) To check for fault code: Start and run engine.
A. NOT OK – Fault code 1312 is recorded again. Go to Step 2.
B. OK – Fault is not recorded again. OK for return to service.

2. Disconnect wire 121 from the temperature sending unit.
BD06E00201 1

(3) Hydraulic reservoir temperature sending unit
(1) Check temperature reading at instrument cluster with wire disconnected, reading should be low.
A. NOT OK – Replace sending unit and reconnect wire. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 3.
3. Check for open circuit from temperature sending unit to instrument cluster.
(1) Disconnect Connector D2A at rear of instrument cluster.
87728445 1 2/28/2008
A.50.A / 9
(2) Inspect pin 5 on Connector D2A. Clean connections.
(3) Clean female pins by installing and removing.
(4) Check circuit between temperature sending unit connector and pin 5 Connector D2A, if circuit is open check
from sending unit to pin 6 Connector V1.
BD07N671 2
(5) From pin 6 Connector P10 to pin 3 Connector P1.
BD07C14501 3
(6) From pin 3 Connector C5 to pin 38 Connector C4.
BD07C15301 4
(7) From pin 38 Connector M10 to pin 33 Connector M1, connector M1 is located at the rear of the front
console.
87728445 1 2/28/2008
A.50.A / 10
BD07C15101 5
(8) From pin 33 Connector D1 to pin 5 Connector D2A.
BD07K18601 6
A. NOT OK – Determine the break between sending unit and D2A and repair. Return to Step 1 to confirm
elimination of fault.
4. Replace the Instrument cluster.
(1) Remove and replace instrument cluster.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group
for assistance.
87728445 1 2/28/2008
A.50.A / 11
1313Hydraulic oil temperature too high, critical

Cause:
1. Hydraulic temperature too high, critical.

Solution:

rence.

BD06E00201 1

87728445 1 2/28/2008
A.50.A / 12
BD07N671 2
BD07C14501 3
BD07C15301 4
console.
87728445 1 2/28/2008
A.50.A / 13
BD07C15101 5
BD07K18601 6
for assistance.
87728445 1 2/28/2008
A.50.A / 14

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 15
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 16
1314Transmission oil temperature above normal

Cause:
1. Transmission temperature above normal.

Solution:

rence.

BD06E00201 1

87728445 1 2/28/2008
A.50.A / 17
BD07N671 2
BD07C14501 3
BD07C15301 4
console.
87728445 1 2/28/2008
A.50.A / 18
BD07C15101 5
BD07K18601 6
for assistance.
87728445 1 2/28/2008
A.50.A / 19

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 20
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 21
1315Transmission oil temperature too high, critical

Cause:
1. Transmission temperature too high, critical.

Solution:

rence.

BD06E00201 1

87728445 1 2/28/2008
A.50.A / 22
BD07N671 2
BD07C14501 3
BD07C15301 4
console.
87728445 1 2/28/2008
A.50.A / 23
BD07C15101 5
BD07K18601 6
for assistance.
87728445 1 2/28/2008
A.50.A / 24

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 25
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 26
1318Engine coolant temperature above normal

IMPORTANT: When available use special tool 380040185 harness diagnostic/repair kit and 380040188 electro injec
tor test fixture.
NOTE: See engine repair manual for electrical schematic information. Check coolant level before proceeding.
Cause:
1. Coolant temperature sensor signal above a set range.

Solution:

.
rence.
(3) To check for fault code: Start and operate machine.

2. Stop machine operations.
(1) Run engine at 1500 r/min (rpm).
(2) Check fan operation.
(3) Check cooling core for clogs.
A. NOT OK – Repair fan or clear clogs from radiator. Return to Step 1 to confirm elimination of fault.
3. Disconnect connector from engine temperature sending unit.
BD07F08401 1
87728445 1 2/28/2008
A.50.A / 27
(1) Connector engine temp sender

(2) Upper radiator hose
(1) Inspect pins on temperature sending unit and connector. Clean connections.
(3) Take Ohm reading on sending unit, 2500 Ω at 20 °C (68.0 °F).
A. NOT OK – Replace sending unit. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) Check from pin 2 of engine temperature sender to pin 26 of engine controller Connector C.
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
5. Replace the engine control module.
(1) Remove and replace engine control module.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
87728445 1 2/28/2008
A.50.A / 28

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 29
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 30
1319Engine coolant temperature too high, critical

tor test fixture.
Cause:
1. Coolant temperature too high, critical.

Solution:

.
rence.

(1) Run engine at 1500 r/min (rpm).
(3) Check cooling core for clogs.
A. NOT OK – Repair fan or clear clogs from radiator. Return to Step 1 to confirm elimination of fault.
3. Disconnect connector from engine temperature sending unit.
BD07F08401 1
87728445 1 2/28/2008
A.50.A / 31
(1) Connector engine temp sender

4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 32

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 33
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 34
1320Engine oil pressure too low, critical

IMPORTANT: Check engine oil type and level before proceeding.
tor test fixture.
NOTE: See engine repair manual for electrical schematic information.
Cause:
1. Engine oil pressure below set range.

Solution:

rence.
(1) Turn ignition switch to RUN position to power instrument cluster.
(2) Clear all fault codes from the cluster.

2. Disconnect connector from engine oil temp/pressure sending unit.
BD07E02201 1
(1) Connector engine oil temp/pressure sender

(2) Alternator
(1) Inspect pins on engine oil temp/pressure sending unit and connector. Clean connections.
(3) Turn the ignition switch ON to power the system.
87728445 1 2/28/2008
A.50.A / 35
(4) Take a voltage reading at pin 3 on connector, a reading of 5 V should be obtained.
A. OK – Replace sending unit. Return to Step 1 to confirm elimination of fault.
B. NOT OK – Go to Step 3.
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) If no voltage is present, turn ignition switch OFF. Disconnect Connector C from engine controller.
(2) Inspect Connector C and pins on engine controller. Clean connections.
(4) Check from pin 3 oil temp/pressure sending unit connector to pin 32 of Connector C.
of fault.
4. Check sensing circuit.
of fault.
5. Check ground circuit.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 36
(1) Ground E3 connector

(2) Left rear engine lifting eyelet
(2) Disconnect Connector E2 from engine controller.
(3) Inspect pins on Connector E2 and engine controller. Clean connections.
(5) Check circuit from pins 5, 6, 10 and 11 of Connector E2 to Connector E3 ground. If circuit is open check
splice SA1 and SA3.
of fault.
Prior to changing the engine control module contact Technical Services Group for further assistance.
(2) Write symptom on failed engine control module.
for assistance.
87728445 1 2/28/2008
A.50.A / 37

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 38
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 39
1323Battery voltage too low, critical

Cause:
1. System shut down.

Solution:

.
rence.

2. Check voltage at instrument cluster.
BD07K18601 1
(1) Connector D2A

(2) Connector D2B
(1) Disconnect Connector D2A and Connector D2B.
(2) Inspect pin 1 in Connector D2A and pins 18 and 21 in Connector D2B. Clean connections.
(4) Turn the ignition switch on and check for voltage at pin 1 in Connector D2A and pins 18 and 21 in Connector
D2B, a reading of 12 V should be obtained.
A. NOT OK – Check fuses F8 in fuse and relay panel. Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 40
3. Test alternator, refer to Alternator Testing (A.30.A).
A. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.
4. Replace the instrument cluster.
for assistance.
BC08B50101A 1
(1) Battery
(3) Alternator
87728445 1 2/28/2008
A.50.A / 41
1324Battery voltage too high, critical

Cause:
1. System shut down.

Solution:

.
rence.

2. Check voltage at instrument cluster.
BD07K18601 1
(1) Connector D2A

(2) Connector D2B
(1) Disconnect Connector D2A and Connector D2B.
(2) Inspect pin 1 in Connector D2A and pins 18 and 21 in Connector D2B. Clean connections.
(4) Turn the ignition switch on and check for voltage at pin 1 in Connector D2A and pins 18 and 21 in Connector
D2B, a reading of 12 V should be obtained.
A. NOT OK – Check fuses F8 in fuse and relay panel. Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 42
4. Replace the instrument cluster.
for assistance.
BC08B50101A 1
(1) Battery
(3) Alternator
87728445 1 2/28/2008
A.50.A / 43
1325Engine oil temperature too high, critical

tor test fixture.
Cause:
1. Engine oil temperature above a set range.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 44
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 45

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 46

Instrument Cluster
BC08B50112A 1

(36) Warning Buzzer
(38) Up Down Switch
87728445 1 2/28/2008
A.50.A / 47
BC08B50113A 1

87728445 1 2/28/2008
A.50.A / 48
4121Left forward pump solenoid circuit open or over current

Control Module : DTC
Cause:
2. Wiring or solenoid circuits open.
3. Wiring or solenoid circuits shorted.
4. Failed Drivetrain Control Module.
Possible failure modes:
1. Crawler will not move forward.
Solution:

.
rence.
A. Turn ignition switch to RUN position to power drivetrain controller.
B. Clear all fault codes from the controller.
C. To check for fault code: Move directional control to neutral, ignition switch to run (engine does not need to
be running), move both parking levers to down position, move hand throttle to high idle position, and push
directional control to forward position.
D. NOT OK – Fault code 4121 is recorded again. Go to step 2.
E. OK for return to service.

2. Clean and inspect the Left Forward Pump Solenoid Connection.
1. Connector P3
2. Connector P2
BD02H0042 1
A. Turn ignition switch and master disconnect off.
B. Tilt ROPS cab/canopy, refer to USER PLATFORM Tilt (E.34.A).
C. Disconnect the Left Forward Pump Solenoid, Connector P3.
D. Inspect pins 1 through 4. Clean connections.
E. Clean female pins by installing and removing.

87728445 1 2/28/2008
A.50.A / 49
F. Measure the resistance of the coil at the Left Forward Pump Solenoid, Connector Connector P3 pins 1
and 2. The resistance should be 5.75 Ohms ± 0.75 Ohms.
G. NOT OK – Replace the solenoid. Return to step1 to confirm elimination of fault.
H. OK – Go to step 3.
3. Check the Left Forward Pump Solenoid Ground Connection.
A. Measure the resistance between Connector P3, pin 1 and battery ground, must be less than 10 Ohms.
B. NOT OK – Determine break in ground connection and repair. Return to step 1 to confirm elimination of
fault.
C. OK – Go to step 4.
4. Check for open circuit in the Left Forward Pump Solenoid control wire between connectors P3 and C1.
BD07C14901 2
BD07C14501 3
A. Disconnect the Main Drivetrain Controller, Connector C1.
B. Inspect pin 31 on Connector C1. Clean connections.
C. Clean female pins by installing and removing.
D. Check for open circuit between pin 15 of Connector P1, and pin 2 of the Connector P3.
E. Check for open circuit between pin 15 of Connector C5, and pin 31 of the Main Drivetrain Controller,
Connector C1.
F. NOT OK – Determine break between connector P3 and C1 and repair. Return to step 1 to confirm elimi
nation of fault.
G. OK – Go to step 5.
5. Turn ignition switch and master disconnect OFF, disconnect controller Connector C1, turn master disconnect
ON.
87728445 1 2/28/2008
A.50.A / 50
A. Check for continuity from pins 2 and 28 to ground.
B. NOT OK – Repair ground circuit. Return to Step 1 to confirm elimination of fault.
C. OK – Go to Step 6.
6. Turn the ignition switch ON.
BD07C15301 4
A. Check for power at pins 1 and 27 to ground.
B. Check fuse F9 in connector M2.
C. Check circuit from pins 1 and 27 Connector C1 to pin 36 Connector C4, form pin 36 Connector M10 to
pin 9A Connector M2.
D. NOT OK – Repair power circuit. Return to Step 1 to confirm elimination of fault.
E. OK – Go to Step 7.
7. At Connector C1.
BD07C15201 5
A. Check for power at pins 13, 41, and 42 to ground.
B. Bad fuse F10 in connector M2.
C. Check circuit from pins 13, 41, and 42 Connector C1 to pin 35 Connector C4, form pin 35 Connector
M10 to pin 10A Connector M2.
8. Contact Technical Services Group for additional assistance prior to replacing the control module.
A. Remove and replace Drivetrain Control Module, refer to Electrical control Replace (C.20.F).
B. Write symptom on failed Drivetrain Control Module.
87728445 1 2/28/2008
A.50.A / 51
C. Install program with Electronic Service Tool (EST) and calibrate the system.

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 52

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 53
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 54
4131Right forward pump solenoid circuit open or over current

Cause:
1. Crawler will not move forward.
Solution:

.
rence.
D. NOT OK – Fault code 4131 is recorded again. Go to Step 2.
E. OK – Fault is not recorded again. OK for return to service.

1. Connector P3
2. Connector P4
BD02H0042 1

87728445 1 2/28/2008
A.50.A / 55
F. Measure the resistance of the coil at the Left Forward Pump Solenoid, Connector P4 pins 1 and 2. The
resistance should be 5.75 Ohms ± 0.75 Ohms.
G. NOT OK – Replace the solenoid. Return to Step 1 to confirm elimination of fault.
H. OK – Go to Step 3.
4. Check for open circuit in the Left Forward Pump Solenoid control wire between connectors X62 and C1.
BD07C14901 2
BD07C14501 3
E. Check for open circuit between pin 12 of Connector C5, and pin 4 of the Main Drivetrain Controller, Con
nector C1.
F. NOT OK – Determine break between connector P4 and C1 and repair. Return to Step 1 to confirm elimi
nation of fault.
G. OK – Go to Step 5.
ON.
87728445 1 2/28/2008
A.50.A / 56
BD07C15301 4
7. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 57

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 58

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 59
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 60
4141Left reverse pump solenoid circuit open or over current

Cause:
1. Crawler will not move in reverse.
Solution:

.
rence.

1. Connector P3
2. Connector P4
BD02H0042 1

87728445 1 2/28/2008
A.50.A / 61
G. NOT OK – Replace the solenoid. Return to step1 to confirm elimination of fault.
fault.
BD07C14901 2
BD07C14501 3
Connector C1.
nation of fault.
G. OK – Go to step 5.
ON.
87728445 1 2/28/2008
A.50.A / 62
BD07C15301 4
7. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 63

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 64

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 65
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 66
4151Right reverse pump solenoid circuit open or over current

1. Crawler will not move in reverse.
Solution:

.
rence.

1. Connector P3
2. Connector P4
BD02H0042 1
G. NOT OK – Replace the solenoid. Return to step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 67
fault.
BD07C14901 2
BD07C14501 3
B. Inspect pin 16 on Connector C1 . Clean connections.
Connector C1.
nation of fault.
G. OK – Go to step5.
ON.
87728445 1 2/28/2008
A.50.A / 68
BD07C15301 4
7. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 69

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 70

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 71
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 72
4212Left motor solenoid circuit open or over current

Cause:
1. Crawler will not operate at full speed.
Solution:

.
rence.
C. To check for fault code the machine needs to be driven at a speed above the 50% transmission speed
range.

2. Remove the rear cover on the center section of the machine. Inspect the Left Speed Sensor Connection.
87728445 1 2/28/2008
A.50.A / 73
BD02H0062 1
(1) Left motor speed sensor (5) Left motor speed sensor disconnect P5
(2) Left motor solenoid (6) Left motor solenoid disconnect P7
(3) Right motor speed sensor (7) Right motor speed sensor disconnect P6
(4) Right motor solenoid (8) Right motor solenoid disconnect P8
B. Remove rear access cover to hydrostatic motors.
C. Disconnect the Left Motor Solenoid, Connector P7.
D. Inspect pins 1 and 2. Clean connections.
E. Clean female pins by installing and removing
F. Measure the resistance of the coil at the Left Motor Solenoid, Connector P7 pins 1 and 2. The resistance
should be 5.75 Ohms ± 0.75 Ohms.
3. Check Left Motor Solenoid Ground Connection.
A. Measure the resistance between Connector P7, pin 2 and Battery ground, must be less than 10 Ohms.
B. NOT OK – Determine break in ground connection and repair. Return to Step 1 to confirm elimination of
fault.
4. Check for open circuit in the Left Motor Solenoid control wire between connectors P7 and C2.
87728445 1 2/28/2008
A.50.A / 74
BD07C14901 2
BD07C14501 3
Connector C2.
nation of fault.
ON.
87728445 1 2/28/2008
A.50.A / 75
BD07C15301 4
7. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 76

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 77

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 78
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 79
4222Right motor solenoid circuit open or over current

Cause:
1. Crawler will not operate at full speed.
Solution:

.
rence.
range.

87728445 1 2/28/2008
A.50.A / 80
BD02H0062 1
C. Disconnect the Right Motor Solenoid, Connector P8.
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 Right Motor Solenoid, Connector P8 pins 1 and 2. The resistance
should be 5.75 Ohms ± 0.75 Ohms.
3. Check Right Motor Solenoid Ground Connection.
A. Measure the resistance between Connector P8, pin 2 and Battery ground, must be less than 10 Ohms.
B. NOT OK – Determine break in ground connection and repair. Return to Step 1 to confirm elimination of
fault.
4. Check for open circuit in the Right Motor Solenoid control wire between connectors P8 and C2.
87728445 1 2/28/2008
A.50.A / 81
BD07C14901 2
BD07C14501 3
Connector C2.
nation of fault.
ON.
87728445 1 2/28/2008
A.50.A / 82
BD07C15301 4
7. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 83

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 84

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 85
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 86
4311Left speed sensor out of range

Cause:
2. Water in connectors.
3. Bad fuse in drivetrain controller fuse block.
4. Wiring or sensor circuits open.
5. Wiring or sensor circuits shorted.
1. Track speed input is at zero when motion is commanded and engine speed is nonzero, for a long period.
Solution:

.
rence.

87728445 1 2/28/2008
A.50.A / 87
BD02H0062 1
C. Disconnect the Left Speed Sensor, Connector P5.
D. Inspect pins 1, 2, 3, and 4. Clean connections.
E. Check for water in connectors.
F. Clean female pins by installing and removing.
G. NOT OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
3. Check for open circuit in the Left Speed Sensor Circuit between connectors P5 and C1.
87728445 1 2/28/2008
A.50.A / 88
BD07C14901 2
BD07C14501 3
B. Inspect pins 43 and 44 on Connector C1. Clean connections.
D. Check for open circuit between pin 7 of Connector P1, and pin 1 of Connector P5.
E. Check for open circuit between pin 8 of Connector P1, and pin 3 of Connector P5.
F. Check for open circuit between pin 7 of Connector C5, and pin 44 of the Main Drivetrain Controller, Con
nector C1.
G. Check for open circuit between pin 8 of Connector C5, and pin 43 of the Main Drivetrain Controller, Con
nector C1.
H. NOT OK – Determine break between connector P5 and C1 and repair. Return to Step 1 to confirm elimi
nation of fault.
I. OK – Go to Step .4
4. Replace the speed sensor.
A. Return to Step 1 to confirm elimination of fault. Fault code 4311 is recorded again, go to Step 5
ON.
87728445 1 2/28/2008
A.50.A / 89
BD07C15301 4
7. At Connector C1.
BD07C15201 5
B. Bad fuse F10 in connector M2..
9. Install the rear cover.
A. Torque the 20mm hex bolts to 495 to 620 Nm (357 to 460 lbft).
B. Torque the 12mm hex bolts to 99 to 128 Nm (73 to 94 lbft).

87728445 1 2/28/2008
A.50.A / 90

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 91
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 92
4312Right speed sensor out of range

Cause:
3. Bad fuse in drivetrain controller fuse block.
1. Track speed input is at zero when motion is commanded and engine speed is nonzero, for a long period.
Solution:

.
rence.

87728445 1 2/28/2008
A.50.A / 93
BD02H0062 1
C. Disconnect the Left Speed Sensor, Connector P5.
D. Inspect pins 1, 2, 3, and 4. Clean connections.
E. Check for water in connectors.
F. Clean female pins by installing and removing.
G. NOT OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
3. Check for open circuit in the Right Speed Sensor Circuit between connectors P6 and C1.
87728445 1 2/28/2008
A.50.A / 94
BD07C14901 2
BD07C14501 3
D. Check for open circuit between pin 11 of Connector P1, and pin 1 of Connector P6.
E. Check for open circuit between pin 10 of Connector P1, and pin 3 of Connector P6.
F. Check for open circuit between pin 11 of Connector C5, and pin 18 of the Main Drivetrain Controller,
Connector C1.
G. Check for open circuit between pin 10 of Connector C5, and pin 17 of the Main Drivetrain Controller,
Connector C1.
H. NOT OK – Determine break between connector P6 and C1 and repair. If no break is found in Step 4 or 5,
replace Sensor. Return to Step 1 to confirm elimination of fault.
I. OK – Go to Step 4.
4. Replace the speed sensor.
A. Return to Step 1 to confirm elimination of fault. Fault code 4311 is recorded again, go to Step 5
ON.
87728445 1 2/28/2008
A.50.A / 95
BD07C15301 4
B. Check fuse F9 in connector M2..
7. At Connector C1.
BD07C15201 5
B. Bad fuse F10 in connector M2..
9. Install the rear cover.
A. Torque the 20mm hex bolts to 495 to 620 Nm (357 to 460 lbft).
B. Torque the 12mm hex bolts to 99 to 128 Nm (73 to 94 lbft).

87728445 1 2/28/2008
A.50.A / 96

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 97
BC08B50109A 1

87728445 1 2/28/2008
A.50.A / 98
4321Foot pedal potentiometer out of range

IMPORTANT: Check fuses F9 and F10 in Connector M2, replace as needed.
Cause:
1. Blown fuse.
Solution:

rence.
(1) Turn ignition switch to RUN position to power drivetrain controller.
(2) Clear all fault codes from the controller.
(3) To check for fault code: Move directional control to neutral, ignition switch to run (engine does not need to
be running), move both parking levers to down position, move the decelerator pedal to low idle position.

2. Inspect the decelerator potentiometer connection. The connector for the decelerator is on the front side of the
fire wall.
BD06M02901 1
(1) Brake potentiometer

(2) Brake pedal
(3) Decelerator potentiometer
(1) Turn ignition switch and master disconnect OFF.
(2) Disconnect the decelerator potentiometer, Connector M5.
(3) Inspect pins A, B, and C. Clean connections.
(4) Check for water in connectors.

87728445 1 2/28/2008
A.50.A / 99
A. Return to Step 1 to confirm elimination of fault.
B. NOT OK – Fault is recorded again. Go to Step 3.

3. Check for open circuit in the decelerator potentiometer circuit between Connector M5 and Connector M10.
Connectors are located behind the fuse and relay panels.
BD07F09101 2
(1) Connector C4
(2) Connector M10
(1) Disconnect Connector M10.
(2) Inspect pins 2, 44, and 45 on Connector M10. Clean connections.
(4) Check circuit between pin A, B, and C of the decelerator potentiometer circuit, Connector M5, and pins 2,
44, and 45 on Connector M10.
A. NOT OK – Determine the break between connector M5 and M10 and repair. Return to Step 1 to confirm
4. Check for open circuit in the decelerator potentiometer circuit between connectors Connector C1, Connector
C2, and Connector C4.
BD07C14901 3
(1) Connector C1
(2) Connector C2
(1) Disconnect the main drivetrain controller Connector C1 and Connector C2.
(2) Inspect pin 19 on Connector C1, Inspect pins 62 and 80 on Connector C2. Clean connections.
87728445 1 2/28/2008
A.50.A / 100
(4) Check circuit between pin 48 of Connector C4, and pin 80 of the Connector C2.
(5) Check circuit between pin 45 of Connector C4, and pin 62 of Connector C2.
of fault.
5. Adjust the Decelerator Potentiometer using the Electronic Service Tool (EST).
The Fully Up Decelerator Position and High Throttle Lever Position will be 2.75 4.45 V (nominal readings), and
the Fully Depressed Position or Low Throttle Lever Position will be 0.5 2.25 V (nominal readings).
A. 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.
6. Replace the Drivetrain Control Module.
Prior to changing the drivetrain control module contact Technical Services Group for further assistance.
(1) Remove and replace drivetrain control module.
(2) Write symptom on failed drivetrain control module.
(3) Install program with Electronic Service Tool (EST) and calibrate system.
for assistance.
87728445 1 2/28/2008
A.50.A / 101

BC08B50106A 1

(18) Not Used
87728445 1 2/28/2008
A.50.A / 102

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 103

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 104
4322Idle validation switch not working

Cause:
1. Blown fuse.
Solution:

rence.
(3) To check for fault code: Move directional control to neutral, ignition switch to run, start and run engine, move
both parking levers to down position, move the decelerator pedal to low idle position.

2. Inspect the Decelerator Pedal Adjustment and idle validation switch connection. The connector for the switch
is on the front side of the fire wall.
BD06M02901 1

(2) Brake pedal
(3) Idle validation switch behind pedal
(1) Disconnect the Idle Validation Switch, Connector M23.
(2) Inspect pins on Connector M23. Clean connections.

87728445 1 2/28/2008
A.50.A / 105
(5) Use a multi meter to check Ohm readings between pins A and B of Connector M23.
(6) Check circuit between pins A and B of Connector M23, circuit should be open when the decelerator pedal
is released.
(7) Push the decelerator pedal to the low idle position, a reading of 0 Ω should be obtained.
A. NOT OK – If 0 Ω is NOT obtained press the switch closed by hand, if 0 Ω is still NOT obtained replace
switch. If 0 Ω IS obtained when switch is closed by hand, adjust the decelerator pedal stop bolt. Return
to Step 1 to confirm elimination of fault.
3. Check for open circuit in the idle validation switch circuit between Connector M23 and Connector M10. Con
nectors are located behind the fuse and relay panels.
BD07F09101 2
(1) Connector C4
(2) Connector M10
(2) Inspect pins 3 and 48 on Connector M10. Clean connections.
(4) Check circuit between pins A and B of the idle validation switch circuit, Connector M23, and pins 3 and 48
on Connector M10.
4. Check for open circuit in the idle validation switch circuit between Connector C1, Connector C2 and Connector
C4.
BD07C14901 3
87728445 1 2/28/2008
A.50.A / 106
(1) Connector C1
(2) Connector C2
(1) Disconnect the main drivetrain controller, Connector C1 and Connector C2.
(2) Inspect pin 23 on Connector C1 and pin 80 on Connector C2. Clean connections.
(4) Check circuit between pin 48 of Connector C4 and pin 80 of Connector C2.
(5) Check circuit between pin 3 of Connector C4 and pin 23 of Connector C1.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 107

BC08B50106A 1

(18) Not Used
87728445 1 2/28/2008
A.50.A / 108

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 109

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 110
4323Decel pedal locked out, unstable readings

Cause:
1. Blown fuse.
Solution:

rence.
(3) To check for fault code: Move directional control to neutral, ignition switch to run (engine does not need to
be running), move both parking levers to down position, move the decelerator pedal to low idle position.

2. Inspect the decelerator potentiometer connection. The connector for the decelerator is on the front side of the
fire wall.
BD06M02901 1

(2) Brake pedal
(1) Turn ignition switch and master disconnect OFF.
(2) Disconnect the decelerator potentiometer, Connector M5.

87728445 1 2/28/2008
A.50.A / 111

3. Check for open circuit in the decelerator potentiometer circuit between Connector M5 and Connector M10.
Connectors are located behind the fuse and relay panels.
BD07F09101 2
(1) Connector C4
(2) Connector M10
(2) Inspect pins 2, 44, and 45 on Connector M10. Clean connections.
(4) Check circuit between pin A, B, and C of the decelerator potentiometer circuit, Connector M5, and pins 2,
44, and 45 on Connector M10.
4. Check for open circuit in the decelerator potentiometer circuit between connectors Connector C1, Connector
C2, and Connector C4.
BD07C14901 3
(1) Connector C1
(2) Connector C2
(1) Disconnect the main drivetrain controller Connector C1 and Connector C2.
(2) Inspect pin 19 on Connector C1, Inspect pins 62 and 80 on Connector C2. Clean connections.
87728445 1 2/28/2008
A.50.A / 112
(4) Check circuit between pin 48 of Connector C4, and pin 80 of the Connector C2.
of fault.
5. Adjust the Decelerator Potentiometer using the Electronic Service Tool (EST).
The Fully Up Decelerator Position and High Throttle Lever Position will be 2.75 4.45 V (nominal readings), and
the Fully Depressed Position or Low Throttle Lever Position will be 0.5 2.25 V (nominal readings).
A. NOT OK – Voltage is found to be out of acceptable limits, replace and adjust Decelerator Potentiometer.
for assistance.
87728445 1 2/28/2008
A.50.A / 113

BC08B50106A 1

(18) Not Used
87728445 1 2/28/2008
A.50.A / 114

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 115

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 116
4324Hand throttle readings out of range

Cause:
1. Machine stops movement and must be reset by selecting neutral on FNR selector.
Solution:

rence.
(3) To check for fault code: Move directional control to neutral, ignition switch to run (engine does not need to be
running), move both parking levers to down position, move the hand throttle from high idle to low idle position
several times.

2. Inspect the hand throttle connection.
(1) Turn the ignition switch and master disconnect OFF.
(2) Disconnect the hand throttle Connector C6.

3. Check for open circuit in the hand throttle potentiometer circuit between Connector C6, Connector C1, and
Connector C2.
87728445 1 2/28/2008
A.50.A / 117
BD07C14901 1
(1) Connector C1
(2) Connector C2
(1) Disconnect the main drivetrain controller, Connector C1 and Connector C2.
(2) Inspect pin 38 on Connector C1 and pins 64 and 79 on Connector C2. Clean connections.
(4)Check circuit between pin A of Connector C6 and pin 79 of Connector C2.
(5) Check circuit between pin B of Connector C6 and pin 64 of Connector C2.
(6) Check circuit between pin C of Connector C6 and pin 38 of Connector C1.
of fault.
4. Adjust the hand throttle Potentiometer using the Electronic Service Tool (EST).
The High Idle Throttle Lever Position will be 2.75 4.45 V (nominal readings), and the Low Idle Throttle Lever
Position will be 0.5 2.25 V (nominal readings).
A. NOT OK – Voltage is found to be out of acceptable limits, replace and adjust Hand Throttle Potentiometer.
for assistance.
87728445 1 2/28/2008
A.50.A / 118

BC08B50106A 1

(18) Not Used
87728445 1 2/28/2008
A.50.A / 119

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 120

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 121
4331Inching pedal potentiometer out of range

Cause:
1. Anti stall function is no longer active, engine will stall under heavy load.
Solution:

.
rence.
be running), move both parking levers to down position, move hand throttle to high idle position and push
directional control to forward position, press the brake pedal fully and release.

2. Inspect the Brake Pedal Potentiometer Connection.
(1) Potentiometer
(2) Connector M6
BD06M02901 1

(2) Brake pedal
B. Disconnect the Brake Pedal Potentiometer, Connector M6.
87728445 1 2/28/2008
A.50.A / 122
C. Inspect pins A, B, and C. Clean connections.
D. Check for water in connectors.
F. NOT OK – Replace and adjust Brake Pedal Potentiometer. Return to Step 1 to confirm elimination of fault.
3. Check for open circuit in the Brake Pedal Potentiometer Circuit between connector M6 and connector C2.
BD07C14901 2
BD07C15301 3
A. Disconnect the Main Drivetrain Controller Connector C2.
B. Inspect pins 56, 65, and 79 in Connector C2. Clean connections.
C. Clean female pin by installing and removing.
D. Check for open circuit between pin A of the Brake Pedal Potentiometer, Connector M6, and pin 47 of
Connector M10.
E. Check for open circuit between pin B of the Brake Pedal Potentiometer, Connector M6, and pin 43 Con
nector M10.
F. Check for open circuit between pin C of the Brake Pedal Potentiometer, Connector M6, and pin 46 of
Connector M10.
G. Check for open circuit between pin 47 of Connector C4 and pin 60 of Connector C2.
H. Check for open circuit between pin 43 of Connector C4 and pin 56 of Connector C2.
I. Check for open circuit between pin 46 of Connector C4 and pin 65 of Connector C2.
J. NOT OK – Determine break between connector M6 and C2 and repair. Return to Step 1 to confirm elimi
nation of fault.
87728445 1 2/28/2008
A.50.A / 123
K. OK – Go to Step 4.
4. Adjust the Brake Pedal potentiometer using the electronic service tool (EST).
A. The Fully Up Position will be between 2.75 to 4.5 Volts (nominal readings), and the Fully Depressed Po
sition will be between 0.5 to 2.25 Volts (nominal readings).
B. NOT OK – Voltage is found to be out of acceptable limits, replace and adjust Brake Pedal Potentiometer.
ON.
BD07C15301 4
7. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 124
87728445 1 2/28/2008
A.50.A / 125

BC08B50106A 1

(18) Not Used
87728445 1 2/28/2008
A.50.A / 126

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 127

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 128
4332Parking brake pressure sensor, open circuit

Cause:
1. Crawler will not move, driving is not possible.
Solution:

.
rence.

2. Check for open circuit between the Parking Brake Pressure Switch and Drive Train Controller.
BD07C14901 1
87728445 1 2/28/2008
A.50.A / 129
BD07C15301 2
A. Disconnect the Parking Brake Pressure Switch.
B. Disconnect Connector C1 on Drivetrain Controller, inspect pin 48.
C. Check for open circuit between Parking Brake Pressure Switch Connector V25 pin B and pin 5 of Con
nector V1.
D. Check for open circuit between connector pin 5 of Connector P10 and pin 17 of Connector P1.
E. Check for open circuit between connector pin 17 of Connector C5 and pin 48 of Connector C1.
F. NOT OK Determine break between the Parking Brake Pressure Switch and Drivetrain Controller con
nector C1 and repair. Return to Step 1 to confirm elimination of fault.
3. Check for power at connector V25 at brake pressure switch.
A. Disconnect connector at the brake pressure switch turn the ignition switch on.
B. From pin A Connector V25 to ground a reading of 12 volts should be obtained.
C. Check fuse F2 connector M3.
D. Check circuit from pin A Connector V25 to pin 1 Connector V1, from pin 1 Connector P10 to pin 9
Connector P1, from pin 9 Connector C5 to pin 11 Connector C4, from pin 11 Connector M10 to pin C1
Connector M3.
E. NOT OK Determine break between the Parking Brake Pressure Switch and Drivetrain Controller con
F. OK – Go to Step 4.
ON.
87728445 1 2/28/2008
A.50.A / 130
BD07C15301 3
6. At Connector C1.
BD07C15201 4
87728445 1 2/28/2008
A.50.A / 131

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 132

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 133
BC08B50111A 1

(34) Brake Solenoid
87728445 1 2/28/2008
A.50.A / 134
4341No engine speed signal

NOTE: If fault codes 4533 and 4622 are also present there is a CAN communication error, see fault 4622.
Cause:
1. Failed speed sensor on engine.

5. Failed Drivetrain control module.
Solution:

rence.
(2) Clear all fault codes from the drivetrain controller.
(3) To check for fault code: The machine needs to be driven at a speed above 50 % transmission speed range.

2. Replace engine speed sensor.
BD07F08101 1
(1) Engine speed sensor
A. Return to Step 1 to confirm the elimination of fault.
B. NOT OK— Go to Step3.

3. Replace drivetrain control module.
(1). Remove and replace drivetrain control module.
(2). Write symptom on failed drivetrain control module.
87728445 1 2/28/2008
A.50.A / 135
(3). Install program with Electronic Service Tool (EST) and calibrate system again.
for assistance.
87728445 1 2/28/2008
A.50.A / 136
4431Parking brake solenoid, open circuit

Cause:
Solution:
1. Find out if the fault code is still active, refer to Command Display/service switch Dynamic description
(C.20.F).
rence.

2. Inspect the Parking Brake Solenoid Connection.
BD06K05701 1
B. Tilt the ROPS cab or canopy, refer to USER PLATFORM Tilt (E.34.A).
C. Disconnect the Parking Brake Solenoid.
D. Inspect pins. Clean connections.
F. Lower the ROPS cab or canopy, refer to USER PLATFORM Lower (E.34.A).
87728445 1 2/28/2008
A.50.A / 137
G. NOT OK – Return to Step 1 to confirm elimination of fault.
3. Check for open circuit in the Parking Brake Solenoid.
A. Disconnect the Parking Brake Solenoid.
B. Measure the resistance of the coil at the Parking Brake Solenoid. The resistance should be 41.8 Ω 20 °C
(68 °F).
C. NOT OK – Replace Solenoid and return to Step 1 to confirm elimination of fault.
D. OK – Go to Step 4.
4. Check for open circuit between the Parking Brake Solenoid Circuit and ground.
B. From pin 2 in connector to ground.
C. Check for open circuit between Parking Brake Solenoid Connector V24 pin 2 and pin 7 of Connector V1.
D. Check for open circuit between connector pin 7 of Connector V1 and ground.
E. NOT OK Determine break between the Parking Brake Solenoid connector and ground and repair. Return
to Step 1 to confirm elimination of fault.
5. Check for open circuit between the Parking Brake Solenoid Circuit and Drive Train Controller.
BD07C14901 2
BD07C15301 3
B. From pin 2 in connector to ground.
C. Disconnect Connector C1 on Drivetrain Controller, inspect pins 15 and 29.
87728445 1 2/28/2008
A.50.A / 138
D. Check for open circuit between Parking Brake Solenoid Connector V24 pin 1 and pin 4 of Connector V1.
E. Check for open circuit between connector pin 4 of Connector P10 and pin 16 of Connector P1.
F. Check for open circuit between connector pin 16 of Connector C5 and pins 15 Connector C1.
G. NOT OK Determine break between the Parking Brake Solenoid connector and Drivetrain Controller con
ON.
BD07C15301 4
8. At Connector C1.
BD07C15201 5
87728445 1 2/28/2008
A.50.A / 139
87728445 1 2/28/2008
A.50.A / 140

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 141

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 142
BC08B50111A 1

(34) Brake Solenoid
87728445 1 2/28/2008
A.50.A / 143
4521Bump up switch stuck on at power up

Cause:
2. Button is mechanically stuck.
3. Wiring or switch circuits shorted.
1. The Instrument Cluster is indicating that the Maximum Speed setting is increasing, when Bump Up Switch is
not being commanded.
Solution:

.
rence.

2. Inspect the Bump Up Switch Connection.
BD02M16601 1
B. Check for button mechanically stuck.
C. Clear buttons of any foreign debris.
D. NOT OK – Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 144
3. Check for open circuit in the Bump Up Switch.
A. Disconnect the Bump Up Switch Connector.
B. Check wiring and connector for Bump Up Switch.
C. NOT OK – Replace handle and button, and return to Step 1 to confirm elimination of fault.
4. Replace the FNR joystick.
ON.
BD07C14901 2
BD07C15301 3
87728445 1 2/28/2008
A.50.A / 145
7. At Connector C1.
BD07C15201 4
87728445 1 2/28/2008
A.50.A / 146

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 147

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 148

BC08B50110A 1

87728445 1 2/28/2008
A.50.A / 149
4522Bump down switch stuck on at power up

Cause:
2. Button is mechanically stuck.
3. Wiring or switch circuits shorted.
1. The Instrument Cluster is indicating that the Maximum Speed setting is increasing, when Bump Down Switch is
not being commanded.
Solution:

.
rence.

2. Inspect the Bump Down Switch Connection.
BD02M16601 1
B. Check for button mechanically stuck.
C. Clear buttons of any foreign debris.
D. NOT OK – Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 150
3. Check for open circuit in the Bump Down Switch.
A. Disconnect the Bump Down Switch Connector.
B. Check wiring and connector for Bump Down Switch.
C. NOT OK – Replace handle and button, and return to Step 1 to confirm elimination of fault.
4. Replace the FNR joystick.
ON.
BD07C14901 2
BD07C15301 3
87728445 1 2/28/2008
A.50.A / 151
7. At Connector C1.
BD07C15201 4
87728445 1 2/28/2008
A.50.A / 152

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 153

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 154

BC08B50110A 1

87728445 1 2/28/2008
A.50.A / 155
4531Directional control steering axis faulted

Cause:
2. Faulty directional control.
3. Wiring or directional control circuits open.
4. Wiring or directional control circuits shorted.
Solution:

.
rence.
range.

2. Inspect the directional control Connection.
BD07C15401 1
B. Disconnect the directional control, Connector M9.
C. Inspect pins 1, 2, 3, 4, 5, and 6. Clean connections.
D. Clean female pins by installing and removing.
E. NOT OK – Replace directional control. Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 156
3. Turn the master disconnect on.
A. Check for continuity from pin 2 on Connector M9 to ground.
4. Turn the ignition switch on.
A. Check for power from pins 1 and 5 to ground.
C. Check circuit from Connector M9 pins 1 and 5 to Connector M2 pin A10.
5. Check for open circuit in the directional control Circuit between connections M9 and C1.
BD07C14901 2
D. Check for open circuit between pin 3 of the directional control, Connector M9, and pin 39 of the Main
Drivetrain Controller, Connector C1.
E. Check for open circuit between pin 4 of the directional control, Connector M9, and pin 40 of the Main
F. NOT OK – Determine break between connector M9 and C1 and repair. If no break is found, replace
directional control. Return to Step 1 to confirm elimination of fault.
6. Connect an EST tool to the EST connector.
A. Does the EST communicate with the Drive Train Control module.
C. OK – Replace FNR joystick, return to Step 1 to confirm elimination of fault.

ON.

87728445 1 2/28/2008
A.50.A / 157
BD07C15301 3
9. At Connector C1.
BD07C15201 4
87728445 1 2/28/2008
A.50.A / 158

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 159

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 160

BC08B50110A 1

87728445 1 2/28/2008
A.50.A / 161
4532Directional control forward/reverse axis faulted

Cause:
Solution:

.
rence.
range.

BD07C15401 1
87728445 1 2/28/2008
A.50.A / 162
3. Turn the master disconnect on.
A. Check for continuity from pin 2 on Connector M9 to ground.
4. Turn the ignition switch on.
A. Check for power from pins 1 and 5 to ground.
C. Check circuit from Connector M9 pins 1 and 5 to Connector M2 pin A10.
5. Check for open circuit in the directional control Circuit between connections M9 and C1.
BD07C14901 2
D. Check for open circuit between pin 3 of the directional control, Connector M9, and pin 39 of the Main
E. Check for open circuit between pin 4 of the directional control, Connector M9, and pin 40 of the Main
F. NOT OK – Determine break between connector M9 and C1 and repair. If no break is found, replace
directional control. Return to Step 1 to confirm elimination of fault.
6. Connect an EST tool to the EST connector.
A. Does the EST communicate with the Drive Train Control module.
C. OK – Replace FNR joystick, return to Step 1 to confirm elimination of fault.

ON.

87728445 1 2/28/2008
A.50.A / 163
BD07C15301 3
9. At Connector C1.
BD07C15201 4
87728445 1 2/28/2008
A.50.A / 164

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 165

Controller
BC08B50108A 1
87728445 1 2/28/2008
A.50.A / 166

BC08B50110A 1

87728445 1 2/28/2008
A.50.A / 167
4533Joystick CAN message fault

Cause:
Solution:

.
rence.
range.

BD07C15401 1
87728445 1 2/28/2008
A.50.A / 168
F. OK – Go to Step .3
3. Check power at directional control.
A. Turn the master disconnect ON and the ignition switch ON.
B. Check for voltage at pin 1 and 5 in Connector M9, a reading of 12 V should be obtained.
C. NOT OK – Check fuse F10 in M2. Return to Step 1 to confirm elimination of fault.
A. Check from pin 2 Connector M9 to ground M4.
B. If circuit is open check splice SA1.
C. NOT OK – Determine break and repair.
D. OK – Go to Step .5
5. Check for open circuit in the directional control Circuit between Connector M9 and Connector C1.
BD07C15301 2
A. Check for open circuit between pin 3 of Connector M9 and pin 45 of Connector M10.
B. Check for open circuit between pin 4 of Connector M9 and pin 44 of Connector M10.
C. Check for open circuit between pin 44 of Connector C4 and pin 35 of Connector C1.
D. Check for open circuit between pin 45 of Connector C4 and pin 34 of Connector C1.
E. NOT OK – Determine break between Connector M9 and Connector C1 and repair.
F. OK – Go to Step 6
87728445 1 2/28/2008
A.50.A / 169

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 170

BC08B50110A 1

87728445 1 2/28/2008
A.50.A / 171
4621No CAN communication with instrument cluster

Cause:
Solution:

.
rence.
range.

BD07C15401 1
87728445 1 2/28/2008
A.50.A / 172
F. OK – Go to Step .3
3. Check for open circuit in the directional CAN Circuit between Connector D2A, Connector C1, Connector M9,
and connectors Connector D1 and Connector M1 at rear of console.
BD07C15101 2
A. Disconnect the Main Drivetrain Controller Connector C1.
D. Check for open circuit between pin 4 Connector D2A and pin 16 of Connector D1.
E. Check for open circuit between pin 3 Connector D2A and pin 26 of Connector D1.
F. Check for open circuit between pin 16 of Connector M1 and pin 3 of Connector M9.
G. Check for open circuit between pin 26 of Connector M1 and pin 4 of Connector M9.
H. Check for open circuit between pin 16 of Connector M1 and pin 5 of Connector M10.
I. Check for open circuit between pin 26 of Connector M1 and pin 6 of Connector M10.
J. Check for open circuit between pin 5 of Connector C4 and pin 39 of Connector C1.
K. Check for open circuit between pin 6 of Connector C1 and pin 40 of Connector C1.
L. NOT OK – Determine break between Connector D2A, Connector M9 and Connector C1 and repair.
M. OK – Go to Step .4
87728445 1 2/28/2008
A.50.A / 173

Controller
BC08B50107A 1
87728445 1 2/28/2008
A.50.A / 174

BC08B50110A 1

87728445 1 2/28/2008
A.50.A / 175
3006Coolant Temperature Sensor Signal Not Plausible

Control Module : EDC
tor test fixture.
Cause:
1. Coolant temperature not readable.

Solution:

rence.

(1) Run engine at 1500 RPM.
(3) Check radiator core for clogs.
A. NOT OK – Repair fan or clear clogs from radiator core. Return to Step 1 to confirm elimination of fault.
3. Check engine temperature sending unit.
BD07F08401 1
87728445 1 2/28/2008
A.50.A / 176
(1) Connector engine temperature sender

(1) Disconnect connector from engine temperature sending unit.
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) Check from pin 2 of engine temperature sender to pin 26 of engine controller connector C.
(2) Check from pin 1 of engine temperature sender to pin 15 of Connector C.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 177
3007Coolant temperature sensor voltage too high

tor test fixture.
Cause:
1. Coolant temperature sensor signal above set range.

Solution:

rence.

BD07F08401 1
87728445 1 2/28/2008
A.50.A / 178

4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 179
3008Coolant Temperature Sensor Signal Below Range Minimum

tor test fixture.
Cause:
1. Coolant temperature below set range.

Solution:

rence.

BD07F08401 1
87728445 1 2/28/2008
A.50.A / 180

4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(2) Check from pin 1 of engine temperature sender to pin 15 Connector C.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 181
3009Coolant temperature sensor circuit open or sensor

disconnected
tor test fixture.
Cause:
1. Coolant temperature no signal.

Solution:

rence.

87728445 1 2/28/2008
A.50.A / 182
BD07F08401 1

4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
87728445 1 2/28/2008
A.50.A / 183
for assistance.
87728445 1 2/28/2008
A.50.A / 184
3015Fuel Temperature Sensor Signal Above Maximum

tor test fixture.
Cause:
1. Fuel temperature sensor signal above set range.

Solution:

rence.

(3) Check fuel cooler core for clogs.
A. NOT OK – Repair fan or clear clogs from fuel cooler core. Return to Step 1 to confirm elimination of fault.
3. Check fuel temperature sensor.
BD07F09901 1
87728445 1 2/28/2008
A.50.A / 185
(1) Connector fuel temperature sensor

(2) Fuel filter
(1) Disconnect connector from fuel temperature sensor.
(2) Inspect pins on fuel temperature sensor and connector. Clean connections.
(4) Take Ohm reading on fuel temperature sensor, 2500 Ω at 20 °C (68.0 °F).
A. NOT OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) Check from pin 2 of fuel temperature sensor to pin 18 of Connector C.
(2) Check from pin 1 of fuel temperature sensor to pin 35 of engine controller connector C.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 186
3016Fuel Temperature Sensor Signal Below Range Minimum

tor test fixture.
Cause:
1. Fuel temperature sensor signal below set range.

Solution:

rence.

(3) Check fuel cooler core for clogs.
A. NOT OK – Repair fan or clear clogs from fuel cooler core. Return to Step 1 to confirm elimination of fault.
3. Check fuel temperature sensor.
BD07F09901 1
87728445 1 2/28/2008
A.50.A / 187
(1) Connector fuel temperature sensor

(2) Fuel filter
(1) Disconnect connector from fuel temperature sensor.
(2) Inspect pins on fuel temperature sensor and connector. Clean connections.
(4) Take Ohm reading on fuel temperature sensor, 2500 Ω at 20 °C (68.0 °F).
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 188
3019Boost Pressure Sensor Signal Above Range Maximum

tor test fixture.
Cause:
1. Defective intake manifold pressure sensor.

Solution:

rence.

2. Disconnect connector from engine intake manifold temperature sensor.
Sensor is located behind muffler mounting bracket.
BD07F14001 1
(1) Lead to connector engine intake pressure/temperature sensor

(2) Muffler
(1) Inspect connector and intake manifold temperature sensor pins. Clean connections.
87728445 1 2/28/2008
A.50.A / 189
A. OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(4) Check from pin 3 engine intake manifold temperature sensor connector to pin 33 of Connector C.
of fault.
4. Check signal circuit.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 190
(1) Connector E3 Ground

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 191

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 192
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 193
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 194
3021Boost pressure sensor circuit open or sensor disconnected

tor test fixture.
Cause:

Solution:

rence.

BD07F14001 1

(2) Muffler
87728445 1 2/28/2008
A.50.A / 195
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 196

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 197

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 198
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 199
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 200
3022Boost Pressure Sensor Signal Not Plausible

tor test fixture.
Cause:

Solution:

rence.

BD07F14001 1

(2) Muffler
87728445 1 2/28/2008
A.50.A / 201
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 202

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 203
3023Atmospheric Pressure Sensor Signal Not Plausible

NOTE: Ambient pressure sensor is inside the engine control module, replace ECU. (Not necessary if never running
in high altitude and if turbocharger is without VGT). Prior to changing the engine control module contact Technical
Services Group for further assistance.
87728445 1 2/28/2008
A.50.A / 204
3024Atmospheric Pressure Sensor Signal Above Range Maximum

87728445 1 2/28/2008
A.50.A / 205
3025Atmosperic Pressure Sensor Signal Below Range Minimum

87728445 1 2/28/2008
A.50.A / 206
3028Oil Pressure too low

tor test fixture.
Cause:
1. Engine oil pressure below set range.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 207
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 208

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 209
3029Oil Pressure Sensor Short Circuit To Battery

tor test fixture.
Cause:
1. Engine oil pressure sensor shorted.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 210
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 211

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 212
3030Oil Pressure Sensor Short Circuit To Ground

tor test fixture.
Cause:
1. Engine oil pressure sensor shorted.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 213
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 214

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 215
3031Oil Pressure Sensor Hardware Error

tor test fixture.
Cause:
1. Engine oil pressure sensor inaccurate or shorted.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 216
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 217

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 218
3032Oil Pressure Sensor Value Too High

tor test fixture.
Cause:
1. Engine oil pressure above a set range.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 219
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 220

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 221
3033Oil Temperature Sensor Signal Not Plausible (Compared

With Coolant Temperature)
tor test fixture.
Cause:
1. Engine oil temperature sensor signal not readable.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 222
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 223
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 224
3034Oil Temperature Sensor Signal Above Range Maximum

tor test fixture.
Cause:
1. Engine oil temperature sensor signal above a set range.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 225
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 226

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 227
3035Oil Temperature Sensor Signal Below Range Minimum

tor test fixture.
Cause:
1. Engine oil temperature sensor signal below a set range.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 228
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 229

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 230
3036Oil temperature sensor circuit open or sensor disconnected

tor test fixture.
Cause:
1. Engine oil temperature sensor signal not readable.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 231
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 232

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 233
3037Boost Pressure Sensor Signal Low

tor test fixture.
Cause:

Solution:

rence.

BD07F14001 1

(2) Muffler
87728445 1 2/28/2008
A.50.A / 234
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 235

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 236

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 237
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 238
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 239
3051Battery Voltage To Engine Controller Voltage Too High

tor test fixture.
Cause:
1. Battery voltage above a set range.

Solution:

rence.
(3) To check for fault code: Start and run engine at high idle.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 240
BD07F13301 2

(1) Turn ignition switch and master disconnect switch OFF. Disconnect Connector E2 from engine controller.
splice SA1 and SA3.
of fault.
4. Check input power circuit.
(1) Turn master disconnect switch and ignition switch ON.
(2) Check voltage on pins 2, 3, 8, 9, and 40 of Connector E2 to ground, a reading of 12 V should be obtained.
(3) If no voltage is present, check fuses F6 and F8 in fuse and relay panel Connector M2. Replace as needed.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(3) Connector M11 (mounted in panel)
(4) Connector E1
(4) If fuses are good check power relay module B and ignition relay.
A. NOT OK – Replace fuses or relays as needed. Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 241
for assistance.
BC08B50101A 1
(1) Battery
(3) Alternator
87728445 1 2/28/2008
A.50.A / 242

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 243
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 244
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 245
3052Battery Voltage To Engine Controller Voltage Too Low

tor test fixture.
Cause:
1. Battery voltage below a set range.

Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 246
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 247
for assistance.
BC08B50101A 1
(1) Battery
(3) Alternator
87728445 1 2/28/2008
A.50.A / 248

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 249
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 250
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 251
3060Cylinder 1 Unclassifiable Error In Injector

tor test fixture.
Cause:
1. Engine misfires, runs erratic.

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
(1) Disconnect Connector A from engine controller.
(2) Inspect pins 4 and 13 in Connector A. Clean connections.
87728445 1 2/28/2008
A.50.A / 252
BD07E03001 2
(1) Connector cylinders 1 and 2

(2) High pressure common rail
(4) Disconnect Connector for cylinders 1 and 2.
(5) Inspect pins 3 and 4 in connector. Clean connections.
(7) Check circuit from pin 4 Connector A to pin 4 cylinders 1 and 2 Connector.
of fault.
3. Check circuit.
BD07E03401 3
(1) Injector cylinder 1

(1) Remove engine valve cover.
(2) Disconnect leads from number 1 injector.
(3) Check circuit from injector leads to pins 3 and 4 at connector in rocker housing.
of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 253
BD07E03401 4

(2) Take an Ohm reading between terminals on number 1 injector, a reading of 0.5 1.0 Ω at 20 °C (68 °F)
should be obtained.
A. NOT OK – Replace injector. Return to Step 1 to confirm elimination of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 254
3061Cylinder 1 Injector Cable Short Circuit (Low Side To Battery)

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 255
BD07E03001 2

(7) Check circuit from pin 4 to pin 13 on Connector A, circuit should be open.
A. NOT OK – Determine the break or short between connectors and repair. Return to Step 1 to confirm
3. Check circuit.
BD07E03401 3

(3) Check between leads at injector, circuit should be open.
87728445 1 2/28/2008
A.50.A / 256
4. Check injector.
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 257
3062Cylinder 1 Electronic injector , Low signal

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 258
BD07E03001 2

of fault.
3. Check circuit.
BD07E03401 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 259
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 260
3063Cylinder 1 Injector Cable Short Circuit (High Side To Ground)

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 261
BD07E03001 2

(7) Check circuit from pin 4 to pin 13 on Connector A, circuit should be open.
3. Check circuit.
BD07E03401 3

87728445 1 2/28/2008
A.50.A / 262
4. Check injector.
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 263
3064Cylinder 5 Unclassifiable Error in Injector

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 264
BS07G34201 2

of fault.
3. Check circuit.
BD07E03201 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 265
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 266

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 267
BS07G34201 2

(7) Take an Ohm reading from pin 1 to pin 16 Connector A, circuit should be open.
3. Check circuit.
BD07E03201 3

87728445 1 2/28/2008
A.50.A / 268
4. Check injector.
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 269

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 270
BS07G34201 2

of fault.
3. Check circuit.
BD07E03201 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 271
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 272

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 273
BS07G34201 2

3. Check circuit.
BD07E03201 3

87728445 1 2/28/2008
A.50.A / 274
4. Check injector.
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 275

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 276
BD07E02901 2

of fault.
3. Check circuit.
BD07E03301 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 277
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 278

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 279
BD07E02901 2

3. Check circuit.
BD07E03301 3

87728445 1 2/28/2008
A.50.A / 280
4. Check injector.
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 281

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 282
BD07E02901 2

of fault.
3. Check circuit.
BD07E03301 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 283
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 284

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 285
BD07E02901 2

3. Check circuit.
BD07E03301 3

87728445 1 2/28/2008
A.50.A / 286
4. Check injector.
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 287

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 288
BS07G34201 2

of fault.
3. Check circuit.
BD07E03201 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 289
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 290

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 291
BS07G34201 2

3. Check circuit.
BD07E03201 3

87728445 1 2/28/2008
A.50.A / 292
4. Check injector.
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 293

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 294
BS07G34201 2

of fault.
3. Check circuit.
BD07E03201 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 295
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 296

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 297
BS07G34201 2

3. Check circuit.
BD07E03201 3

87728445 1 2/28/2008
A.50.A / 298
4. Check injector.
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 299

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 300
BD07E03001 2

of fault.
3. Check circuit.
BD07E03401 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 301
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 302

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 303
BD07E03001 2

3. Check circuit.
BD07E03401 3

87728445 1 2/28/2008
A.50.A / 304
4. Check injector.
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 305

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 306
BD07E03001 2

of fault.
3. Check circuit.
BD07E03401 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 307
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 308

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 309
BD07E03001 2

3. Check circuit.
BD07E03401 3

87728445 1 2/28/2008
A.50.A / 310
4. Check injector.
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 311

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 312
BD07E02901 2

of fault.
3. Check circuit.
BD07E03301 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 313
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 314

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 315
BD07E02901 2

3. Check circuit.
BD07E03301 3

87728445 1 2/28/2008
A.50.A / 316
4. Check injector.
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 317

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 318
BD07E02901 2

of fault.
3. Check circuit.
BD07E03301 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 319
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 320

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 321
BD07E02901 2

3. Check circuit.
BD07E03301 3

87728445 1 2/28/2008
A.50.A / 322
4. Check injector.
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 323
3088Crankshaft sensor lost synchronization

tor test fixture.
Cause:
1. Engine shut down.

Solution:

rence.

2. Disconnect connector from engine crankshaft speed sensor.
BD07F08101 1
(1) Connector engine crankshaft speed sensor

(2) Crankshaft sensor
(1) Inspect pins on crankshaft speed sensor and connector. Clean connections.
(3) Take Ohm reading between pins 1 and 2 on sensor, a reading of 900 Ω should be obtained.
87728445 1 2/28/2008
A.50.A / 324
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) Disconnect Connector C from engine controller.
(2) Inspect pins on Connector C and corresponding pins on the engine controller. Clean connections.
(4) Check circuit from pin 1 engine crankshaft speed sensor connector to pin 19 of Connector C.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 325
3089Crankshaft Sensor Invalid Signal

tor test fixture.
Cause:

Solution:

rence.

BD07F08101 1

87728445 1 2/28/2008
A.50.A / 326
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 327
3090Phase defect of camshaft speed sensor signal detected

tor test fixture.
Cause:

Solution:

rence.

2. Disconnect connector from engine camshaft sensor.
BD07F09701 1
(1) Connector engine camshaft sensor

(2) Camshaft sensor
(1) Inspect pins on camshaft sensor and connector. Clean connections.
87728445 1 2/28/2008
A.50.A / 328
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(4) Check circuit from pin 1 engine camshaft sensor connector to pin 10 of Connector C.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 329
3091Camshaft sensor phase synchronization failure

tor test fixture.
Cause:

Solution:

rence.

BD07F09701 1

(2) Camshaft sensor
87728445 1 2/28/2008
A.50.A / 330
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 331
3093Offset Between Camshaft And Crankshaft Outside

Boundaries
tor test fixture.
Cause:

Solution:

rence.

BD07F09701 1

(2) Camshaft sensor
(3) Take Ohm reading between pins 1 and 2 on camshaft sensor, a reading of 900 Ω should be obtained.
87728445 1 2/28/2008
A.50.A / 332
A. NOT OK – Replace camshaft sensor. Return to Step 1 to confirm elimination of fault.
BD07F08101 2

(2) Crankshaft speed sensor
(3) Take Ohm reading between pins 1 and 2 on crankshaft speed sensor, a reading of 900 Ω should be obtained.
A. NOT OK – Replace crankshaft speed sensor. Return to Step 1 to confirm elimination of fault.
4. Check Circuit.
BD07F08001 3
(1) Connector C
(2) Connector A
(3) Connector E2
(2) Inspect pins on Connector C and corresponding pins on engine controller. Clean connections.
87728445 1 2/28/2008
A.50.A / 333
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 334
3095Operating With Camshaft Sensor Only Backup Mode

tor test fixture.
Cause:

Solution:

rence.

BD07F08101 1

87728445 1 2/28/2008
A.50.A / 335
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 336
3102Rail Pressure Sensor CP3 Signal Below Range Minimum

tor test fixture.
Cause:
1. Rail pressure below set range.

Solution:

rence.

2. Check rail pressure sensor. The sensor is located at the front of the common rail.
BD07N48301 1
(1) Rail pressure sensor

(2) Intake manifold
(1) Disconnect connector from rail pressure sensor.
(2) Inspect pins on rail pressure sensor and connector. Clean connections.
(4) Take an Ohm reading between pins 1 and 2 on the sensor, a reading of 45k Ω should be obtained.
87728445 1 2/28/2008
A.50.A / 337
3. Check voltage at rail pressure sensor.
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) If no voltage is present disconnect Connector C from engine controller.
(4) Check from pin 3 rail pressure sensor connector to pin 13 of Connector C.
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 338
BD07F13301 3

(1) Turn ignition OFF. Disconnect Connector E2 from engine controller.
splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 339

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 340
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 341
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 342
3104Rail Pressure Relief Valve Open

tor test fixture.
Cause:
1. Rail pressure below set range.

Solution:

rence.

BD07N48301 1

(2) Intake manifold
87728445 1 2/28/2008
A.50.A / 343
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 344
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 345

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 346
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 347
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 348
3105Rail Pressure Relief Valve Pressure Shock Requested

tor test fixture.
Cause:
1. Rail pressure system self testing pressure relief valve.

Solution:

rence.

2. Disconnect connector from pressure regulator valve.
BD07F09701 1
(1) High pressure regulator valve

(2) High pressure pump
(1). Inspect pins on pressure regulator valve and connector. Clean connections.
(2). Clean female pins by installing and removing.
(3). Take an Ohm reading between pins 1 and 2 at regulator valve, a reading of 3.2 Ω should be obtained.
A. NOT OK— Replace pressure regulator valve. Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 349
B. OK— Go to Step 3.
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1). Disconnect Connector C from ECM (engine control module) and connector at rail pressure regulator valve.
(2). Inspect pins on Connector C. Clean connections.
(4). Check circuit from pin 1 of pressure regulator valve connector to pin 9 of Connector C.
A. NOT OK— Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
NOTE: See fault 3102 before going to step 4.
4. Replace engine control module.
(1). Remove and replace engine control module.
(2). Write symptom on failed engine control module.
for assistance.
87728445 1 2/28/2008
A.50.A / 350
3106Rail Pressure Relief Valve Did Not Open After Pressure

Shock
tor test fixture.
Cause:
1. Rail pressure system pressure too high, relief valve not opening.
Solution:

rence.

2. Disconnect connector from high pressure regulator valve.
BD07F09701 1

87728445 1 2/28/2008
A.50.A / 351
A. NOT OK— Replace high pressure regulator valve. Return to Step 1 to confirm elimination of fault.
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
NOTE: See fault 3102 before going to Step 4.
for assistance.
87728445 1 2/28/2008
A.50.A / 352
3107Metering unit output short circuit to battery on low side

tor test fixture.
Cause:
1. Rail pressure regulator solenoid valve circuit shorted.

Solution:

rence.

BD07F09701 1

87728445 1 2/28/2008
A.50.A / 353
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(4). Check circuit from pin 9 to pin 10 at Connector C, circuit should be open.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
NOTE: See fault 3102 before going to Step 4.
for assistance.
87728445 1 2/28/2008
A.50.A / 354
3110Rail Pressure Sensor Monitoring Signal Above Range

Maximum
tor test fixture.
Cause:
1. Rail pressure above set range after engine shutdown.

Solution:

.
rence.
(3) To check for fault code: Start and operate machine, turn engine off, put ignition switch in run position after
engine shut down.

BD07N48301 1

(2) Intake manifold

87728445 1 2/28/2008
A.50.A / 355
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1) If no voltage is present, disconnect Connector C from engine controller.
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 356
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 357
3111Rail Pressure Sensor Monitoring Signal Below Range

Minimum
tor test fixture.
Cause:
1. Rail pressure below set range after engine shutdown.

Solution:

.
rence.
(3) To check for fault code: Start and operate machine, turn engine off, put ignition switch in run position after
engine shut down.

BD07N48301 1

(2) Intake manifold

87728445 1 2/28/2008
A.50.A / 358
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 359
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 360
3112Rail Pressure Sensor CP3 Signal Above Maximum Range

tor test fixture.
Cause:
1. Rail pressure signal voltage too high.

Solution:

.
rence.

BD07N48301 1

(2) Intake manifold
87728445 1 2/28/2008
A.50.A / 361
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 362
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 363
3113Grid heater battery switch relay short circuit to battery

tor test fixture.
Cause:
1. Failed grid heater relay.

Solution:

rence.

2. Disconnect Connector E15 from grid heater relay.
BD07N48201 1
(1) Grid heater relay (2) Connector E15
(1). Inspect pins on Connector E15. Clean connections.
(3). Take an Ohm reading from pins A and B at Connector E15 to battery and heater connector studs at relay,
circuit should be open.
A. NOT OK— Replace relay. Return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 364
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(1). Disconnect Connector E2 from engine control module and Connector E15, connector at grid heater relay.
(2). Inspect pins 12 and 75 on Connector E2 and engine control module. Clean connections.
(4). Check from pin 2 Connector E15 to pin 12 of Connector E2.
A. NOT OK— Determine break between connectors and repair. Return to 1 to confirm elimination of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 365

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7B) Grid Heater
87728445 1 2/28/2008
A.50.A / 366
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 367
3114Grid heater battery switch relay short circuit to ground

tor test fixture.
Cause:

Solution:

rence.

BD07N48201 1
87728445 1 2/28/2008
A.50.A / 368
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
for assistance.
87728445 1 2/28/2008
A.50.A / 369

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7B) Grid Heater
87728445 1 2/28/2008
A.50.A / 370
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 371
3118ECM 12V sensor supply voltage high

tor test fixture.
IMPORTANT: Check alternator output voltage, if above 18 volts refer to section on troubleshooting charging system
before proceeding.
NOTE: Besides the 3 independent 5 volt voltage supplies the ECM also provides a 12 volt supply for the sensors.
This 12 volt supply is monitored to ensure it remains within a certain range. This is done by using an analogue input
of the ECM. The lower and upper thresholds depend on the battery voltage.
Cause:
1. Failed sensor, voltage to high coming into ECM.

Solution:

rence.

BD07N47501 1
87728445 1 2/28/2008
A.50.A / 372
(1) Connector M2
(2) Connector M3
(4) Connector E1
BD07F13301 2

(1). Disconnect Connector E2 from engine control module.
(2). Check circuit from pins 5, 6, 10, and 11 of Connector E2 to Ground at Connector E3. If circuit is open
check splices SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 373

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 374
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 375
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 376
3119ECM 12V sensor supply voltage low

tor test fixture.
IMPORTANT: Check alternator output voltage, if below 12 volts refer to section on troubleshooting charging system
before proceeding.
NOTE: Besides the 3 independent 5 volt voltage supplies the ECM also provides a 12 volt supply for the sensors.
This 12 volt supply is monitored to ensure it remains within a certain range. This is done by using an analogue input
of the ECM. The lower and upper thresholds depend on the battery voltage.
Cause:
1. Failed sensor, voltage to low coming into ECM.

Solution:

rence.

BD07N47501 1
87728445 1 2/28/2008
A.50.A / 377
(1) Connector M2
(2) Connector M3
(4) Connector E1
BD07F13301 2

(2). Check circuit from pins 5, 6, 10, and 11 of Connector E2 to Ground at Connector E3. If circuit is open
check splices SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 378

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 379
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 380
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 381
3131Grid Heater Always Switched On

tor test fixture.
Cause:
1. ECM monitoring grid heater as always on, shorted relay.

Solution:

rence.

BD07N48201 1
87728445 1 2/28/2008
A.50.A / 382
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
for assistance.
87728445 1 2/28/2008
A.50.A / 383

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7B) Grid Heater
87728445 1 2/28/2008
A.50.A / 384
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 385
3137Metering Unit Open Load

tor test fixture.
Cause:
1. Rail pressure regulator solenoid valve circuit open.

Solution:

rence.

BD07F09701 1
(1) High pressure regulator valve (2) High pressure pump
(1). Inspect pins on pressure regulator valve connector. clean connections.
A. NOT OK— Replace sensor. return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 386
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(5). Check circuit from pin 1 rail pressure regulator valve connector to pin 9 of Connector C.
A. NOT OK— Determine the short circuit or the break between connectors and repair. Return to Step 1 to
confirm elimination of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 387
3138Metering unit signal not plausible

tor test fixture.
Cause:
1. Rail pressure regulator solenoid valve signal unreadable..

Solution:

rence.

BD07F09701 1
(1) High pressure regulator valve (2) High pressure pump
(1). Inspect pins on pressure regulator valve connector. clean connections.
A. NOT OK— Replace sensor. return to Step 1 to confirm elimination of fault.
87728445 1 2/28/2008
A.50.A / 388
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
A. NOT OK— Determine the short circuit or the break between connectors and repair. Return to Step 1 to
confirm elimination of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 389
3141Set point of fuel volume flow through metering unit is lower

than calculated limit
tor test fixture.
Cause:
1. High pressure system: Rail pressure sensor inaccurate, high pressure pump defective.
Low pressure system: Metering unit reflux too low.
Solution:

rence.

BD07N48301 1

(2) Intake manifold

87728445 1 2/28/2008
A.50.A / 390
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 391
BD07F13301 3

splice SA1 and SA3.
of fault.
7. Disconnect connector from high pressure regulator valve.
BD07F09701 4

8. Check circuit.
87728445 1 2/28/2008
A.50.A / 392
BD07F08001 5
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 393

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 394
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 395
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 396
3146Water detected in fuel

tor test fixture.
NOTE: Drain fuel filter before proceeding.
Cause:
1. Water in fuel filter.

Solution:

rence.

2. Check water in fuel sensor.
BD07H07401 1
(1) Fuel filter

(2) Water in fuel sensor
(1) Disconnect connector from water in fuel sensor.
(2) Inspect pins on the sensor and connector. Clean connections.
87728445 1 2/28/2008
A.50.A / 397
(4) Take an Ohm reading from pin 2 Connector E11 Connector E3 ground. If circuit is open check splice SA1
and SA3.
BD07F13301 2

of fault.
3. Check voltage at water in fuel sensor.
(1) Disconnect connector sensor.
(3) Take a voltage reading at pin 3 on Connector E11, a reading of 12 V should be obtained.
A. NOT OK – Check fuse F6 in fuse and relay panel. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
BD07F08001 3
(1) Connector C
(2) Connector A
(3) Connector E2
(1) Turn ignition and master disconnect switches OFF.
(2) Inspect pins on Connector E2. Clean connections.
(4) Check from pin 1 Connector E11 to pin 42 of Connector E2.

87728445 1 2/28/2008
A.50.A / 398
of fault.
5. If all readings are good, replace the sensor.
A. OK – Return to Step 1 to confirm elimination of fault.
B. NOT OK – Fault was recorded again. Go to Step 6.

for assistance.
87728445 1 2/28/2008
A.50.A / 399

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 400
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 401
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 402
3147Oil Temperature Too High

tor test fixture.
Cause:
1. Engine oil temperature sensor signal above a set range.

Solution:

rence.

BD07E02201 1

(2) Alternator
87728445 1 2/28/2008
A.50.A / 403
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
BD07F13301 3
87728445 1 2/28/2008
A.50.A / 404

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 405

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 406
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 407
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 408
3154Grid Heater Relay Short Circuit To Battery

tor test fixture.
Cause:

Solution:

rence.

BD07N48201 1
87728445 1 2/28/2008
A.50.A / 409
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
for assistance.
87728445 1 2/28/2008
A.50.A / 410

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7B) Grid Heater
87728445 1 2/28/2008
A.50.A / 411
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 412
3155Grid Heater Relay Short Circuit To Ground

tor test fixture.
Cause:

Solution:

rence.

BD07N48201 1
87728445 1 2/28/2008
A.50.A / 413
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
for assistance.
87728445 1 2/28/2008
A.50.A / 414

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7B) Grid Heater
87728445 1 2/28/2008
A.50.A / 415
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 416
3156Grid Heater Relay No Load

tor test fixture.
Cause:

Solution:

rence.

BD07N48201 1
87728445 1 2/28/2008
A.50.A / 417
3. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
for assistance.
87728445 1 2/28/2008
A.50.A / 418

and Cold Start
BC08B50102A 1
(4) Ignition Switch

(5) Starter Motor
(6) Starter
(7B) Grid Heater
87728445 1 2/28/2008
A.50.A / 419
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 420
3171Fuel rail system pressure too low

tor test fixture.
IMPORTANT: Check filters, lines, and low pressure pump before proceeding.
Cause:
1. Pressure before gear pump too low, gear pump output too low (fuel filter plugged, leakage in low pressure side).
Solution:

.
rence.

BD07N48301 1

(2) Intake manifold
87728445 1 2/28/2008
A.50.A / 421
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 422
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 423

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 424
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 425
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 426
3172Fuel rail system pressure too high

tor test fixture.
Cause:
1. Rail pressure above set range.

Solution:

.
rence.

BD07N48301 1

(2) Intake manifold
87728445 1 2/28/2008
A.50.A / 427
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 428
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 429

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 430
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 431
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 432
3173Rail Pressure Governor Deviation Below Min. Limit for Speed

tor test fixture.
Cause:
1. Rail pressure above set range. Leakage in high pressure section, injection nozzle stuck in open position, worn
high pressure pump, worn injector, leaking pressure relief valve.
Solution:

.
rence.

BD07N48301 1

(2) Intake manifold

87728445 1 2/28/2008
A.50.A / 433
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 434
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 435

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 436
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 437
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 438
3174Rail Pressure Governor Deviation Exceeded Max. Limit

tor test fixture.
Cause:

Solution:

.
rence.

BD07N48301 1

(2) Intake manifold
87728445 1 2/28/2008
A.50.A / 439
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 440
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 441

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 442
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 443
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 444
3175Fuel system leak detected large leak

tor test fixture.
Cause:
1. Rail pressure above set range. Leakage in high pressure section, injection nozzle stuck in open position, worn
high pressure pump, worn injector, leaking pressure relief valve.
Solution:

.
rence.

BD07N48301 1

(2) Intake manifold

87728445 1 2/28/2008
A.50.A / 445
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 446
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 447

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 448
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 449
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 450
3176Fuel delivery exceeded threshold for pressure in overrun

mode
tor test fixture.
Cause:

Solution:

.
rence.

BD07N48301 1

(2) Intake manifold
87728445 1 2/28/2008
A.50.A / 451
4. Check circuit.
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
of fault.
of fault.
87728445 1 2/28/2008
A.50.A / 452
BD07F13301 3

splice SA1 and SA3.
of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 453

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 454
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 455
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 456
3178Timeout of CAN message BC2EDC1

tor test fixture.
Cause:
1. Defective CAN controller. CAN controller of the EDC reports a reception time out for the BC message
BC2EDC1lv over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 457
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 458
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

87728445 1 2/28/2008
A.50.A / 459
(12) Starter Relay

(13) Fleet Relay
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 460
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 461
3179Timeout Of CAN Message BC2EDC2

tor test fixture.
Cause:
1. Defective CAN controller. CAN controller of the EDC reports a reception time out for the BC message
BC2EDC2lv over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 462
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 463
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

87728445 1 2/28/2008
A.50.A / 464
(12) Starter Relay

(13) Fleet Relay
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 465
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 466
3180Timeout of CAN Message VM2EDC

tor test fixture.
Cause:
1. Defective CAN controller. CAN controller of the EDC reports a reception time out for the VCM message VM2ED
Clv over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 467
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 468
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

87728445 1 2/28/2008
A.50.A / 469
(12) Starter Relay

(13) Fleet Relay
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 470
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 471
3188Cylinder 1 Warning Open Load

tor test fixture.
Cause:
1. Injector cable open, load error is detected over 3 camshaft revolutions.

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
(1). Disconnect Connector A from engine control module.
(2). Inspect pins 4 and 13 in Connector A. Clean connections
87728445 1 2/28/2008
A.50.A / 472
BD07E03001 2

(4). Disconnect Connector for cylinders 1 and 2.
(5). Inspect pins 3 and 4 in Connector for cylinders 1 and 2. Clean connections.
(7). Take an Ohm reading from pin 4 Connector A to pin 4 Connector for cylinders 1 and 2.
of fault.
3. Check circuit.
BD07E03401 3

(1). Remove engine valve cover.
(2). Disconnect leads from number 1 injector.
(3). Check circuit from injector leads to pins 3 and 4 at connector in rocker housing.
of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 473
BD07E03401 4

(2). Take an Ohm reading between terminals on number 1 injector, a reading of 0.50 1.0 Ω at 20 °C (68.0 °F)
should be obtained.
A. NOT OK— Replace injector. Return to Step 1 to confirm elimination of fault.
for assistance.
87728445 1 2/28/2008
A.50.A / 474
3192Cylinder 2 warning Open Load

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 475
BD07E03001 2

(8). Take an Ohm reading from pin 6 Connector Ato pin 2 Connector for cylinders 1 and 2.
of fault.
3. Check circuit.
BD07E03401 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 476
BD07E03401 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 477

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 478
BD07E02901 2

of fault.
3. Check circuit.
BD07E03301 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 479
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 480

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 481
BD07E02901 2

of fault.
3. Check circuit.
BD07E03301 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 482
BD07E03301 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 483

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 484
BS07G34201 2

of fault.
3. Check circuit.
BD07E03201 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 485
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 486

850L

tor test fixture.
Cause:

Solution:

rence.

2. Check circuit.
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 487
BS07G34201 2

of fault.
3. Check circuit.
BD07E03201 3

of fault.
4. Check injector.
87728445 1 2/28/2008
A.50.A / 488
BD07E03201 4

should be obtained.
for assistance.
87728445 1 2/28/2008
A.50.A / 489
3210Bank 1 General Short Circuit To Injector Cable

tor test fixture.
Cause:
1. A general short circuit if the injector cable is detected over 4 camshaft revolutions.
Solution:

rence.

2. Check circuit
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
(2). Inspect all pins in Connector A and engine control module. Clean connections.
87728445 1 2/28/2008
A.50.A / 490
BD07E03001 2

(5). Inspect pins 1, 2, 3, and 4 in Connector for cylinders 1 and 2. Clean connections.
(7). Take an Ohm reading from pin 11 Connector A to pin 1 Connector cylinders 1 and 2.
(9). Take and Ohm reading from pin 13 Connector A to pin 3 Connector cylinders 1 and 2.
(10). Take an Ohm reading from pin 4 Connector A to pin 4 Connector cylinders 1 and 2 .
BD07E02901 3

(11). Disconnect Connector cylinders 3 and 4.
(12). Inspect pins 1, 2, 3 and 4 in Connector cylinders 3 and 4. Clean connections.
87728445 1 2/28/2008
A.50.A / 491
BS07G34201 4

(19). Inspect pins in Connector cylinders 5 and 6. Clean connections.
A. NOT OK— Determine the break between connectors and repair. Return to Step1 to confirm elimination
of fault.
3. Check circuit.
BD07E03401 5

(2). Disconnect leads from number 1 and 2 injector,
(3). Check circuit from injector leads to pins 1, 2, 3, and 4 at connector in rocker housing.
Check circuit.
87728445 1 2/28/2008
A.50.A / 492
BD07E03301 6

(4). Disconnect leads from number 3 and 4 injector.
(5). Check circuit from injector leads to pins 1, 2, 3, 4 at connector in rocker housing.
BD07E03201 7

of fault.
4. Check injector.
BD07E03401 8
87728445 1 2/28/2008
A.50.A / 493

(2). Take and Ohm reading between terminals on number 1 and number 2 injector, a reading of 0.5 1.0 Ω at
20 °C (68.0 °F) should be obtained.
BD07E03301 9

(4). Take and Ohm reading between terminals on number 3 and 4 injector, a reading of 0.5 1.0 Ω at 20 °C
(68.0 °F) should be obtained.
BD07E03201 10

A. NOT OK— Replace injectors as needed. Return to Step 1 to confirm elimination of fault.

87728445 1 2/28/2008
A.50.A / 494
for assistance.
87728445 1 2/28/2008
A.50.A / 495
3211Bank 1 Injector cable Short Circuit Low Side To Ground

tor test fixture.
Cause:
1. A lowside short circuit to ground in the injector cable is detected over 4 camshaft revolutions.
Solution:

rence.

2. Check circuit
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 496
BD07E03001 2

BD07E02901 3

(17). Take an Ohm reading from pin 5 Connector Ato pin 4 Connector cylinders 3 and 4.
87728445 1 2/28/2008
A.50.A / 497
BS07G34201 4

of fault.
3. Check circuit.
BD07E03401 5

Check circuit.
87728445 1 2/28/2008
A.50.A / 498
BD07E03301 6

BD07E03201 7

of fault.
4. Check injector.
BD07E03401 8
87728445 1 2/28/2008
A.50.A / 499

BD07E03301 9

BD07E03201 10


87728445 1 2/28/2008
A.50.A / 500
for assistance.
87728445 1 2/28/2008
A.50.A / 501
3213Bank 1 Unclassifiable Error

tor test fixture.
Cause:
1. An unclassifiable error in the injector cable is present over 9 camshaft revolutions.

Solution:

rence.

2. Check circuit
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 502
BD07E03001 2

BD07E02901 3

87728445 1 2/28/2008
A.50.A / 503
BS07G34201 4

of fault.
3. Check circuit.
BD07E03401 5

Check circuit.
87728445 1 2/28/2008
A.50.A / 504
BD07E03301 6

BD07E03201 7

of fault.
4. Check injector.
BD07E03401 8
87728445 1 2/28/2008
A.50.A / 505

BD07E03301 9

BD07E03201 10


87728445 1 2/28/2008
A.50.A / 506
for assistance.
87728445 1 2/28/2008
A.50.A / 507
3218Bank 2 General Short Circuit On Injector Cable

tor test fixture.
Cause:
1. A general short circuit in the injector cable is detected over 4 camshaft revolutions.
Solution:

rence.

2. Check circuit
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 508
BD07E03001 2

BD07E02901 3

87728445 1 2/28/2008
A.50.A / 509
BS07G34201 4

of fault.
3. Check circuit.
BD07E03401 5

Check circuit.
87728445 1 2/28/2008
A.50.A / 510
BD07E03301 6

BD07E03201 7

of fault.
4. Check injector.
BD07E03401 8
87728445 1 2/28/2008
A.50.A / 511

BD07E03301 9

BD07E03201 10


87728445 1 2/28/2008
A.50.A / 512
for assistance.
87728445 1 2/28/2008
A.50.A / 513
3219Bank 2 Injector Cable Short Circuit Low Side To Ground

ATTENTION:
tor test fixture.
Cause:
1. A lowside short circuit to ground in the injector cable is detected over 4 camshaft revolutions.
Solution:

rence.

2. Check circuit
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2

87728445 1 2/28/2008
A.50.A / 514
BD07E03001 2

BD07E02901 3

87728445 1 2/28/2008
A.50.A / 515
BS07G34201 4

of fault.
3. Check circuit.
BD07E03401 5

Check circuit.
87728445 1 2/28/2008
A.50.A / 516
BD07E03301 6

BD07E03201 7

of fault.
4. Check injector.
BD07E03401 8
87728445 1 2/28/2008
A.50.A / 517

BD07E03301 9

BD07E03201 10


87728445 1 2/28/2008
A.50.A / 518
for assistance.
87728445 1 2/28/2008
A.50.A / 519
3221Bank 2 Unclassifiable Error

tor test fixture.
Cause:
1. An unclassifiable error in the injection cable is present over 9 camshaft revolutions.

Solution:

rence.

2. Check circuit
BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 520
BD07E03001 2

BD07E02901 3

87728445 1 2/28/2008
A.50.A / 521
BS07G34201 4

of fault.
3. Check circuit.
BD07E03401 5

Check circuit.
87728445 1 2/28/2008
A.50.A / 522
BD07E03301 6

BD07E03201 7

of fault.
4. Check injector.
BD07E03401 8
87728445 1 2/28/2008
A.50.A / 523

BD07E03301 9

BD07E03201 10


87728445 1 2/28/2008
A.50.A / 524
for assistance.
87728445 1 2/28/2008
A.50.A / 525
3227Injection Processor Error Internal Reset/Clock Loss/Voltage

Too Low
Cause:
1. A clock error or interruption of the power supply voltage caused a internal reset longer than 3 camshaft revolu
tions.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 526
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 527
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

87728445 1 2/28/2008
A.50.A / 528
(12) Starter Relay

(13) Fleet Relay
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 529
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 530
3228Injection Processor Error Unlocked/Initialization Error

tor test fixture.
Cause:
1. Clock error or interruption of the power supply voltage.

Solution:

rence.

2. Reset engine control module.
(1) Reset engine control module by turning ignition switch OFF then back ON.

for assistance.
87728445 1 2/28/2008
A.50.A / 531
3229Injection processor error stop engine

tor test fixture.
Cause:
1. Internal failure of ECU or TESTMODE takes too long.

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 532

tor test fixture.
Cause:
1. Disturbed SPI communication.

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 533

tor test fixture.
Cause:
1. Internal program flow error longer than 3 camshaft revolutions.

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 534

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 535

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 536

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 537
3238Communication error of CJ940 processor

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 538
3242Engine Controller (Locked) Recovery Occurred

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 539
3243Engine Controller Recovery (Suppressed) Recovery

Occurred
tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 540
3244Engine Controller Recovery (Visible) Recovery Occurred

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 541
3245Engine Controller Watchdog Not Plausible

tor test fixture.
Cause:

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 542
3246Shutoff Paths During Initialization Watchdog

tor test fixture.
Cause:
1. Injection occurred although internal shutoff path of the ECU watchdog was active.
Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 543
3247Shutoff Paths Failed During Initialization Supply Voltage

Too High
tor test fixture.
Cause:
1. Injection occurred although internal shutoff path of the over voltage monitoring was active.
Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 544
3248Shutoff Paths During Initialization Supply Voltage Too Low

tor test fixture.
Cause:
1. Injection occurred although internal shutoff path of the under voltage monitoring was active.
Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 545
3253ADC Monitoring Reference Voltage Too Low

tor test fixture.
Cause:
1. Reference voltage too high.

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 546
3254ADC Monitoring Reference Voltage Too High

tor test fixture.
Cause:
1. Reference voltage too low.

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 547
3255ADC Monitoring Test Impulse Error

tor test fixture.
Cause:
1. Test impulse error.

Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 548
3256ADC Monitoring Queue Error

tor test fixture.
Cause:
1. Queue error.
Solution:

rence.


for assistance.
87728445 1 2/28/2008
A.50.A / 549
3258HS power stage hardware reports ’short circuit to battery’

longer than 500 ms.
tor test fixture.
IMPORTANT: Replace crank control relay in Connector M2 with a known good relay and test system before proceed
ing.
Cause:
1. HS power stage hardware reports "short circuit to battery" longer than 500 ms. Failed relay
Solution:

rence.

2. Remove crank control relay from Connector M2.
BD07N47501 1
(1) Connector M2
(2) Connector M3
87728445 1 2/28/2008
A.50.A / 550
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
(2). Inspect all pins on Connector E2. Clean connections.
(4). Take an Ohm reading from pin D5 at Connector M2 to pin 17 Connector E2.
(5). Take an Ohm reading from pin B6 at Connector M2 to pin 37 Connector E2.
BD07N47401 3
(1) Connector E1
(6). If circuit is open, check from pin D5 at Connector M2 to pin 21 of Connector M11.
(7). Check circuit from pin 21 of Connector E1 to pin 17 of Connector E2.
(8). Check circuit from pin B6 at Connector M2 to pin 26 of Connector M11.
A. NOT OK— Determine the break between connectors and repair. Return to Step 1to confirm the elimination
of fault.

87728445 1 2/28/2008
A.50.A / 551
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 552
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 553
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 554
3259HS power stage hardware reports ’short circuit to ground’

longer than 100 ms.
tor test fixture.
ing.
Cause:
1. HS power stage hardware reports "short circuit to ground" longer than 100 ms. Failed relay
Solution:

rence.

BD07N47501 1
(1) Connector M2
(2) Connector M3
87728445 1 2/28/2008
A.50.A / 555
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
BD07N47401 3
(1) Connector E1
of fault.

87728445 1 2/28/2008
A.50.A / 556
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 557
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 558
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 559
3260LS power stage hardware reports ’open load’ longer than

100 ms
tor test fixture.
ing.
Cause:
1. HS power stage hardware reports "open load" longer than 100 ms. Failed relay
Solution:

rence.

BD07N47501 1
(1) Connector M2
(2) Connector M3
87728445 1 2/28/2008
A.50.A / 560
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
BD07N47401 3
(1) Connector E1
of fault.

87728445 1 2/28/2008
A.50.A / 561
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 562
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 563
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 564
3261LS power stage hardware reports ’short circuit to battery’ or

’excess temperature’ longer than 100 ms.
tor test fixture.
ing.
Cause:
1. LS power stage hardware reports "short circuit to battery" or "excess temperature" longer than 100 ms. Failed
relay
Solution:

rence.

BD07N47501 1
(1) Connector M2
(2) Connector M3
87728445 1 2/28/2008
A.50.A / 565
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
BD07N47401 3
(1) Connector E1
of fault.

87728445 1 2/28/2008
A.50.A / 566
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 567
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 568
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 569
3262LS power stage hardware reports ’short circuit to ground’

longer than 100 ms.
tor test fixture.
ing.
Cause:
1. LS power stage hardware reports "short circuit to ground" longer than 100 ms. Failed relay
Solution:

rence.

BD07N47501 1
(1) Connector M2
(2) Connector M3
87728445 1 2/28/2008
A.50.A / 570
BD07F08001 2
(1) Connector C
(2) Connector A
(3) Connector E2
BD07N47401 3
(1) Connector E1
of fault.

87728445 1 2/28/2008
A.50.A / 571
for assistance.

Block
BC08B50104A 1
(10) Ignition Relay

(12) Starter Relay
(13) Fleet Relay
87728445 1 2/28/2008
A.50.A / 572
BC08B50105A 1

87728445 1 2/28/2008
A.50.A / 573
BC08B50116A 1

87728445 1 2/28/2008
A.50.A / 574
3265Energizing time exceeds limit of over run monitoring, injection

time too long
tor test fixture.
Cause:
1. The sum of all torqueforming energizing times of an individual cylinder (OvRMon_tiTDCAvrg_mp) exceeds the
limit OvRMon_tiLimET_mp (calculated from the map OvRMon_tiLmET_MAP depending on the engine speed
and the time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms).
Solution:

rence.

2. Reset ECM (electronic control module) by turning the key to the OFF position and turning back ON.
A. OK— Return to Step 1to confirm elimination of fault.
B. NOT OK— Go to Step 3.

3. Replace ECM (engine control module).
for assistance.
87728445 1 2/28/2008
A.50.A / 575
3266Error in engine speed check, speed signal not plausible

tor test fixture.
Cause:
1. The absolute value of the deviation between engine speed Eng_nAvrg (layer 1) and redundant segment speed
OvRMon_nSeg (layer 2) exceeds 320 rpm over 800 ms while the redundent segment speed is above 1000 rpm.
Solution:

rence.

2. Reset ECM (electronic control module) by turning the key to the OFF position and turning back ON.
A. OK— Return to Step 1to confirm elimination of fault.
B. NOT OK— Go to Step 3.

3. Replace ECM (engine control module).
for assistance.
87728445 1 2/28/2008
A.50.A / 576
3278Engine Controller Supply Voltage Too High

tor test fixture.
Cause:
1. Battery voltage above a set range.

Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 577
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 578
for assistance.
87728445 1 2/28/2008
A.50.A / 579
3279Engine Controller Internal Supply Voltage Too Low

tor test fixture.
Cause:
1. ACJ940 has detected it’s voltage supply to be below a lower limit.

Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 580
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 581
for assistance.
87728445 1 2/28/2008
A.50.A / 582
3280Sensor Supply Voltage 1 High

tor test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 1 to exceed an upper limit over 100 ms..
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 583
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 584
for assistance.
87728445 1 2/28/2008
A.50.A / 585
3281Sensor Supply Voltage 1 Low

tor test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 1 to be below a lower limit over 100 ms..
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 586
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 587
for assistance.
87728445 1 2/28/2008
A.50.A / 588

tor test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 2 to exceed an upper limit over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 589
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 590
for assistance.
87728445 1 2/28/2008
A.50.A / 591

tor test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 2 to be below a lower limit over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 592
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 593
for assistance.
87728445 1 2/28/2008
A.50.A / 594

tor test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 3 to exceed an upper limit over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 595
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 596
for assistance.
87728445 1 2/28/2008
A.50.A / 597

tor test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 3 to be below a lower limit over 100 ms.
Solution:

rence.

BD07F08001 1
(1) Connector C
(2) Connector A
(3) Connector E2
87728445 1 2/28/2008
A.50.A / 598
BD07F13301 2

splice SA1 and SA3.
of fault.
BD07N47501 3
(1) Connector M2
(2) Connector M3
(4) Connector E1
87728445 1 2/28/2008
A.50.A / 599
for assistance.
87728445 1 2/28/2008
A.50.A / 600
Index
FAULT CODES 50.A

0000Retrieving fault codes, Crawlers 7
1312Hydraulic oil temperature above normal 9
1313Hydraulic oil temperature too high, critical 12
1314Transmission oil temperature above normal 17
1315Transmission oil temperature too high, critical 22
1318Engine coolant temperature above normal 27
1319Engine coolant temperature too high, critical 31
1320Engine oil pressure too low, critical 35
1323Battery voltage too low, critical 40
1324Battery voltage too high, critical 42
1325Engine oil temperature too high, critical 44
3006Coolant Temperature Sensor Signal Not Plausible 176
3007Coolant temperature sensor voltage too high 178
3008Coolant Temperature Sensor Signal Below Range Minimum 180
3009Coolant temperature sensor circuit open or sensor disconnected 182
3015Fuel Temperature Sensor Signal Above Maximum 185
3016Fuel Temperature Sensor Signal Below Range Minimum 187
3019Boost Pressure Sensor Signal Above Range Maximum 189
3021Boost pressure sensor circuit open or sensor disconnected 195
3022Boost Pressure Sensor Signal Not Plausible 201
3023Atmospheric Pressure Sensor Signal Not Plausible 204
3024Atmospheric Pressure Sensor Signal Above Range Maximum 205
3025Atmosperic Pressure Sensor Signal Below Range Minimum 206
3028Oil Pressure too low 207
3029Oil Pressure Sensor Short Circuit To Battery 210
3030Oil Pressure Sensor Short Circuit To Ground 213
3031Oil Pressure Sensor Hardware Error 216
3032Oil Pressure Sensor Value Too High 219
3033Oil Temperature Sensor Signal Not Plausible (Compared With Coolant Temperature) 222
3034Oil Temperature Sensor Signal Above Range Maximum 225
3035Oil Temperature Sensor Signal Below Range Minimum 228
3036Oil temperature sensor circuit open or sensor disconnected 231
3037Boost Pressure Sensor Signal Low 234
3051Battery Voltage To Engine Controller Voltage Too High 240
3052Battery Voltage To Engine Controller Voltage Too Low 246
3060Cylinder 1 Unclassifiable Error In Injector 252
3061Cylinder 1 Injector Cable Short Circuit (Low Side To Battery) 255
3062Cylinder 1 Electronic injector , Low signal 258
3063Cylinder 1 Injector Cable Short Circuit (High Side To Ground) 261
3064Cylinder 5 Unclassifiable Error in Injector 264
850L
850L
850L
87728445 1 2/28/2008
A.50.A / 601
850L
850L
850L
850L
850L
3088Crankshaft sensor lost synchronization 324
3089Crankshaft Sensor Invalid Signal 326
3090Phase defect of camshaft speed sensor signal detected 328
3091Camshaft sensor phase synchronization failure 330
3093Offset Between Camshaft And Crankshaft Outside Boundaries 332
3095Operating With Camshaft Sensor Only Backup Mode 335
3102Rail Pressure Sensor CP3 Signal Below Range Minimum 337
3104Rail Pressure Relief Valve Open 343
3105Rail Pressure Relief Valve Pressure Shock Requested 349
3106Rail Pressure Relief Valve Did Not Open After Pressure Shock 351
3107Metering unit output short circuit to battery on low side 353
3110Rail Pressure Sensor Monitoring Signal Above Range Maximum 355
3111Rail Pressure Sensor Monitoring Signal Below Range Minimum 358
3112Rail Pressure Sensor CP3 Signal Above Maximum Range 361
3113Grid heater battery switch relay short circuit to battery 364
3114Grid heater battery switch relay short circuit to ground 368
3118ECM 12V sensor supply voltage high 372
3119ECM 12V sensor supply voltage low 377
3131Grid Heater Always Switched On 382
3137Metering Unit Open Load 386
3138Metering unit signal not plausible 388
3141Set point of fuel volume flow through metering unit is lower than calculated limit 390
3146Water detected in fuel 397
3147Oil Temperature Too High 403
3154Grid Heater Relay Short Circuit To Battery 409
3155Grid Heater Relay Short Circuit To Ground 413
3156Grid Heater Relay No Load 417
3171Fuel rail system pressure too low 421
3172Fuel rail system pressure too high 427
3173Rail Pressure Governor Deviation Below Min. Limit for Speed 433
3174Rail Pressure Governor Deviation Exceeded Max. Limit 439
3175Fuel system leak detected large leak 445
3176Fuel delivery exceeded threshold for pressure in overrun mode 451
3178Timeout of CAN message BC2EDC1 457
87728445 1 2/28/2008
A.50.A / 602
3179Timeout Of CAN Message BC2EDC2 462
3180Timeout of CAN Message VM2EDC 467
3188Cylinder 1 Warning Open Load 472
3192Cylinder 2 warning Open Load 475
850L
850L
3210Bank 1 General Short Circuit To Injector Cable 490
3211Bank 1 Injector cable Short Circuit Low Side To Ground 496
3213Bank 1 Unclassifiable Error 502
3218Bank 2 General Short Circuit On Injector Cable 508
3219Bank 2 Injector Cable Short Circuit Low Side To Ground 514
3221Bank 2 Unclassifiable Error 520
3227Injection Processor Error Internal Reset/Clock Loss/Voltage Too Low 526
3228Injection Processor Error Unlocked/Initialization Error 531
3229Injection processor error stop engine 532
3238Communication error of CJ940 processor 538
3242Engine Controller (Locked) Recovery Occurred 539
3243Engine Controller Recovery (Suppressed) Recovery Occurred 540
3244Engine Controller Recovery (Visible) Recovery Occurred 541
3245Engine Controller Watchdog Not Plausible 542
3246Shutoff Paths During Initialization Watchdog 543
3247Shutoff Paths Failed During Initialization Supply Voltage Too High 544
3248Shutoff Paths During Initialization Supply Voltage Too Low 545
3253ADC Monitoring Reference Voltage Too Low 546
3254ADC Monitoring Reference Voltage Too High 547
3255ADC Monitoring Test Impulse Error 548
3256ADC Monitoring Queue Error 549
3258HS power stage hardware reports ’short circuit to battery’ longer than 500 ms. 550
3259HS power stage hardware reports ’short circuit to ground’ longer than 100 ms. 555
3260LS power stage hardware reports ’open load’ longer than 100 ms 560
3261LS power stage hardware reports ’short circuit to battery’ or ’excess temperature’ longer 565
than 100 ms.
3262LS power stage hardware reports ’short circuit to ground’ longer than 100 ms. 570
3265Energizing time exceeds limit of over run monitoring, injection time too long 575
3266Error in engine speed check, speed signal not plausible 576
3278Engine Controller Supply Voltage Too High 577
3279Engine Controller Internal Supply Voltage Too Low 580
3280Sensor Supply Voltage 1 High 583
3281Sensor Supply Voltage 1 Low 586
4121Left forward pump solenoid circuit open or over current 49
4131Right forward pump solenoid circuit open or over current 55
4141Left reverse pump solenoid circuit open or over current 61
87728445 1 2/28/2008
A.50.A / 603
4151Right reverse pump solenoid circuit open or over current 67
4212Left motor solenoid circuit open or over current 73
4222Right motor solenoid circuit open or over current 80
4311Left speed sensor out of range 87
4312Right speed sensor out of range 93
4321Foot pedal potentiometer out of range 99
4322Idle validation switch not working 105
4323Decel pedal locked out, unstable readings 111
4324Hand throttle readings out of range 117
4331Inching pedal potentiometer out of range 122
4332Parking brake pressure sensor, open circuit 129
4341No engine speed signal 135
4431Parking brake solenoid, open circuit 137
4521Bump up switch stuck on at power up 144
4522Bump down switch stuck on at power up 150
4531Directional control steering axis faulted 156
4532Directional control forward/reverse axis faulted 162
4533Joystick CAN message fault 168
4621No CAN communication with instrument cluster 172
87728445 1 2/28/2008
A.50.A / 604
87728445 1 2/28/2008
A.50.A / 605
CNH America LLC 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A
SERVICE Technical Publications & Tools
PRINTED IN U.S.A.
© 2008 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your Case Dealer.
87728445 1 2/28/2008
REPAIR MANUAL
POWER PRODUCTION
750L
850L
87728445 1 2/28/2008
B
Contents
POWER PRODUCTION B
ENGINE B.10.A
750L , 850L
FUEL AND INJECTION SYSTEM B.20.A

750L , 850L
AIR INTAKE SYSTEM B.30.A

750L , 850L
ENGINE COOLANT SYSTEM B.50.A

750L , 850L
LUBRICATION SYSTEM B.60.A

750L , 850L
STARTING SYSTEM B.80.A

750L , 850L
87728445 1 2/28/2008
B
POWER PRODUCTION B
ENGINE 10.A
750L
850L
87728445 1 2/28/2008
B.10.A / 1
Contents
POWER PRODUCTION B
ENGINE 10.A
TECHNICAL DATA
ENGINE
Torque 3
Speeds 3
Engine horse power 3
SERVICE
Sensing system
Speed sensor Replace 4
87728445 1 2/28/2008
B.10.A / 2
POWER PRODUCTION ENGINE
ENGINE Torque
Engine mount bolts to chassis 205 230 Nm (151 170 lb ft)
Rear engine mount brackets to bell housing 118 133 Nm (87 98 lb ft)
Front engine mount bracket to engine block 125 156 Nm (92 115 lb ft)
Starter mounting bolts 68 77 Nm (50 57 lb ft)
ENGINE Speeds
Low idle 800 to 1050 rpm
High idle no load 2170 to 2270
ENGINE Engine horse power

Machine model Gross Net
750L 67.1 kW (90 Hp) 62.6 kW (84 Hp)
850L 73.8 kW (99 Hp) 71.6 kW (96 Hp)
NOTE: Gross engine power at flywheel ratings are corrected to standard atmospheric conditions at 97.9 kPa 29.00
in Hgand 29.4 °C (85 °F) dry air. Gross power includes oil and water pumps, alternator , air cleaner and muffler.
NOTE: Net engine power at flywheel as applied to this machine equipped with fan* and muffler, ratings are corrected
to standard atmospheric conditions at 97.9 kPa 29.00 in Hg and 29.4 °C (85 °F) dry air.
• Based on pusher fan.
87728445 1 2/28/2008
B.10.A / 3
POWER PRODUCTION ENGINE
Sensing system Speed sensor Replace
BD07F08001 1
(1) Speed pickup (2) Connector (3) Engine controller

1. Disconnect connector.
2. Loosen and remove the mounting bolt, remove
speed pickup from the mounting flange.
3. Install the magnetic sensor, install and tighten the
mounting bolt.
4. Connect connector.
87728445 1 2/28/2008
B.10.A / 4
Index
POWER PRODUCTION B
ENGINE 10.A
ENGINE Engine horse power 3
ENGINE Speeds 3
ENGINE Torque 3
Sensing system Speed sensor Replace 4
87728445 1 2/28/2008
B.10.A / 5
87728445 1 2/28/2008
B.10.A / 6
POWER PRODUCTION B
FUEL AND INJECTION SYSTEM 20.A
750L
850L
87728445 1 2/28/2008
B.20.A / 1
Contents
POWER PRODUCTION B
TECHNICAL DATA
Fuel tank
Capacity 3
SERVICE
Throttle command
Electrical throttle Electrical adjust 4
Electronic throttle Electrical adjust Low Idle Validation Switch 5
DIAGNOSTIC
Sensing system
Level sensor Testing 6
87728445 1 2/28/2008
B.20.A / 2
POWER PRODUCTION FUEL AND INJECTION SYSTEM
Fuel tank General specification

Type of fuel Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss
of engine power and high fuel consumption.
In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted.
NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the 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 D97581 of the
American Society for Testing and Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum 34
Flash point, minimum 60 °C (140 °F)
Cloud point (wax appearance point), maximum 20 °C (5 °F) See note above
Pour point, maximum 26 °C (15 °F) See note above
Viscosity, at 88 °C (100 °F)
Centistokes 2.0 to 4.3
Saybolt Seconds Universal 32 to 40
If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many
engine problems are caused by water in the fuel.
Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container
at regular intervals.
Fuel tank Capacity

189.3 L 50 US gal
87728445 1 2/28/2008
B.20.A / 3
Throttle command Electrical throttle Electrical adjust

1. Put the master disconnect switch in the on position.
2. Push and hold both the bump up/down buttons on
the directional control.
3. Turn the ignition switch to the accessory position,
continue to hold the buttons for 5 seconds or until
instrument cluster displays machine models.
4. Use the bump up/down buttons to select the machine
model that is being calibrated.
5. When the machine being calibrated is displayed
press both buttons for one second and release, the
instrument cluster will read (LT or LGP/WT).
track gauge, (LT or LGP/WT).
instrument cluster will read (CAL BRK).
8. Slowly move the brake pedal from release to applied
position two to four times.
NOTE: During this operation if the instrument cluster reads (ERR RANGE), minimum/maximum values are out of
range or potentiometer was not moved in the last five seconds since the start of calibration mode.
9. After moving brake pedal and no error message ap
pears on the instrument cluster press both buttons
for one second and release, the instrument cluster
will read (CAL HTR).
10. Slowly move the hand throttle from low idle to high
idle two to four times.
11. After moving hand throttle and no error message ap
will read (CAL FTR).
12. Slowly move the foot throttle (Decel Pedal) from high
idle to low idle two to four times.
range or potentiometer was not moved in the last five seconds since the start of calibration mode. During this operation
if the instrument cluster reads (ERR SWITCH), the low idle switch is not functioning or is out of adjustment.
13. After moving foot throttle (Decel Pedal) and no er
ror message appears on the instrument cluster press
both buttons for one second and release, the instru
ment cluster will read (CAL DONE). Stop and restart
the machine, values are stored in internal memory.
14. If at any time during calibration the instrument clus
ter reads (CAL FAIL), turn the ignition switch off and
restart the procedure.
87728445 1 2/28/2008
B.20.A / 4
Throttle command Electronic throttle Electrical adjust Low Idle

Validation Switch
1. Push down on the idle validation switch you should
be able to hear a click when the switch activates.
BD07K04101 1
2. The idle validation switch should be activated just

before the stop bolt contacts the fire wall. Adjust the
stop bolt as needed to activate the switch.
BD07K04001 2
3. Adjust the decelerator potentiometer using the EST

tool, at high idle the voltage reading should be 0.375
to 0.425, at low idle the voltage reading should be
0.75 to 1.25. Adjust potentiometer as needed to get
the correct voltage.
Next operation:
Calibrate the machine using procedures in Throttle command Electronic throttle Electrical adjust (B.20.A).
87728445 1 2/28/2008
B.20.A / 5
Sensing system Level sensor Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 12 (A.30.A) and Wiring harness
Electrical schematic frame 13 (A.30.A).
Disconnect the wiring harness con Continuity Bad ground connection.
nector from the fuel level sender con
nector. Put the master disconnect
switch in the ON position.
Check
Terminal of wire 0 to ground.
Put the ignition switch in the RUN 12 volts Bad wire Y (120) between fuel level
position. sender and pin 2 of instrument clus
Check ter connector D2A. Bad connectors.
Wire Y (120) to ground. Check wire Y (120) from pin 2 of in
strument Connector D2A to pin 25
Connector D1, pin 25 Connector
M1 to pin 37 Connector M10, pin
37 Connector C4 to pin 5 Connec
tor C5, pin 5 Connector P1 to pin
3 Connector P10, pin 3 Connector
V1 to pin A Connector V23.
Check reading of fuel level gauge Empty Bad fuel level gauge.
with fuel level sender connector dis
connected.
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 ohms Bad fuel level sender.
level sender connector to ground.
87728445 1 2/28/2008
B.20.A / 6
Index
POWER PRODUCTION B

Fuel tank Capacity 3
Fuel tank General specification 3
Sensing system Level sensor Testing 6
Throttle command Electrical throttle Electrical adjust 4
Throttle command Electronic throttle Electrical adjust Low Idle Validation Switch 5
87728445 1 2/28/2008
B.20.A / 7
87728445 1 2/28/2008
B.20.A / 8
POWER PRODUCTION B
AIR INTAKE SYSTEM 30.A
750L
850L
87728445 1 2/28/2008
B.30.A / 1
Contents
POWER PRODUCTION B
DIAGNOSTIC
Sensing system
Air cleaner restriction Testing 3
87728445 1 2/28/2008
B.30.A / 2
POWER PRODUCTION AIR INTAKE SYSTEM
Sensing system Air cleaner restriction Testing

NOTE: For wiring diagram reefer to Wiring harness Electrical schematic frame 12 (A.30.A) and Wiring harness
Disconnect the wires from the air fil Open Bad air filter restriction switch.
ter restriction switch.
Check
Between terminals of air filter restric
tion switch.
the ON position.
Check
Terminal of wire 0 to ground.
Put the ignition switch in the RUN 12 volts Bad wire G (103) between air filter
position. restriction switch and cavity 24 of in
Check strument cluster connector D2A. Bad
Wire G (103) to ground. connector. Check instrument clus
ter air filter restriction bulb; check in
strument cluster. Check wire G (103)
from pin 24 at the instrument cluster
Connector D2A to pin 35 Connec
tor D1, pin 35 Connector M1 to pin
11 Connector M11, pin 11 Connec
tor E1 to terminal for wire 103 at air
filter restriction switch.
87728445 1 2/28/2008
B.30.A / 3
Index
POWER PRODUCTION B

Sensing system Air cleaner restriction Testing 3
87728445 1 2/28/2008
B.30.A / 4
POWER PRODUCTION B
ENGINE COOLANT SYSTEM 50.A
750L
850L
87728445 1 2/28/2008
B.50.A / 1
Contents
POWER PRODUCTION B
TECHNICAL DATA
ENGINE COOLANT SYSTEM
Capacity 3
Radiator
Torque 4
FUNCTIONAL DATA
Radiator
Exploded view 5
87728445 1 2/28/2008
B.50.A / 2
POWER PRODUCTION ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM General specification

Type of coolant Ethylene glycol and water mixed for the lowest ambient
temperature, a mix of at least a 50/50
ENGINE COOLANT SYSTEM Capacity

NOTE: Without heater.
750L 22.5 l (6 US gal)

850L 26.5 l (7 US gal)
87728445 1 2/28/2008
B.50.A / 3
Radiator Torque
Hose clamps 11 12 Nm (97 106 lb in)
Lower mounting bolts 68 82 Nm (50 60 lb ft)
87728445 1 2/28/2008
B.50.A / 4
Radiator Exploded view
BC07N75301 1
87728445 1 2/28/2008
B.50.A / 5
(1) Over flow hose (6) Charge air cooler outlet

(2) Left upper mount (7) Right lower mount
(3) Radiator inlet (8) Radiator outlet
(4) Right upper mount (9) Drain valve
(5) Charge air cooler inlet (10) Left lower radiator mount
87728445 1 2/28/2008
B.50.A / 6
Index
POWER PRODUCTION B

ENGINE COOLANT SYSTEM Capacity 3
ENGINE COOLANT SYSTEM General specification 3
Radiator Exploded view 5
Radiator Torque 4
87728445 1 2/28/2008
B.50.A / 7
87728445 1 2/28/2008
B.50.A / 8
POWER PRODUCTION B
LUBRICATION SYSTEM 60.A
750L
850L
87728445 1 2/28/2008
B.60.A / 1
Contents
POWER PRODUCTION B
TECHNICAL DATA
LUBRICATION SYSTEM
Capacity 3
87728445 1 2/28/2008
B.60.A / 2
POWER PRODUCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM Capacity

750L CASE AKCELA NO. 1 ENGINE OIL SAE 10W30 with
filter 12.3 l (13 US qt), without filter 11.5 l (12.2 US qt)
850L CASE AKCELA NO. 1 ENGINE OIL SAE 10W30 with
filter 15.8 l (16.7 US qt), without filter 15 l (15.9 US qt)
87728445 1 2/28/2008
B.60.A / 3
Index
POWER PRODUCTION B

LUBRICATION SYSTEM Capacity 3
87728445 1 2/28/2008
B.60.A / 4
POWER PRODUCTION B
STARTING SYSTEM 80.A
750L
850L
87728445 1 2/28/2008
B.80.A / 1
Contents
POWER PRODUCTION B
TECHNICAL DATA
Engine starter
Torque 3
FUNCTIONAL DATA
Engine starter
Exploded view 4
SERVICE
Engine starter
Remove 5
Install 6
Preliminary test 7
Disassemble 12
Electrical test 20
Grease 21
Assemble 22
Starter solenoid
Electrical test 32
DIAGNOSTIC
Cold start aid
Testing 33
Engine starter
Testing 34
Starter solenoid
Testing 35
Start control
Start relay Testing Start motor relay 36
Start switch Testing 36
Intermediate start relay Testing Start sense relay 36
Cold start control
Cold start solenoid Testing 38
87728445 1 2/28/2008
B.80.A / 2
POWER PRODUCTION STARTING SYSTEM
Engine starter Torque

Mounting bolts 68 77 Nm (50 57 lb ft)
Battery terminal nut 17.7 24.5 Nm (13 18 lb ft)
Solenoid + screw 2.6 4.5 Nm (23 40 lb in)
87728445 1 2/28/2008
B.80.A / 3
Engine starter Exploded view
B831437 1
(1) Bolt (7) Brush holder (13) Plunger (19) Bearing cage
(2) Lock washer (8) Bearing (14) Nut (20) Spring
(3) Flat washer (9) Armature (15) Starter solenoid (21) Steel ball
assembly
(4) Oring (10) Field frame (16) Thrust washer (22) Starter drive
(5) Screw (11) Cover (17) Idler gear (23) Starter drive housing
(6) Cover (12) Gasket (18) Roller (5)
87728445 1 2/28/2008
B.80.A / 4
Engine starter Remove

2. Lower the attachments to the floor.
3. Apply the parking brake and stop the engine, remove
the key from the ignition switch.
4. Fasten a Do Not Operate tag to the instrument panel.
5. Open the left rear ROPS door.
6. Put the battery disconnect switch in the off position.
7. Open the righthand side engine panel.
8. Remove the righthand side lower panel.
NOTE: If two batteries are installed, there are two battery
cables connected to the starter.
9. Fasten identification tags to the wires for the starter.
Disconnect the wire from the bottom of the starter
solenoid. Pull the rubber boot away from the termi
nal and disconnect the battery cable(s) and the three
wiring harness from the side of the starter solenoid.
10. Support the starter. Loosen and remove the two
bolts, washers and clamp. Remove the starter.
Next operation:
Engine starter Disassemble (B.80.A) or Engine starter Preliminary test (B.80.A).
87728445 1 2/28/2008
B.80.A / 5
Engine starter Install

Prior operation:
Engine starter Electrical test (B.80.A),
1. Position the starter in the flywheel housing.

2. Install the two bolts, washers, and clamp to fasten
the starter to the flywheel housing. Torque the bolts
to 68 77 Nm (50 57 lb ft).
3. Connect the battery cable(s) and the three wiring har
ness wires to the side of the starter solenoid and
torque to 2.6 4.6 Nm (23 41 lb in). Connect the
wire to the bottom of the starter solenoid and torque
to 17.7 24.5 Nm (13 18 lb ft). Push the rubber
boot onto the terminal.
4. Install the righthand side lower panel.
5. Close the righthand side engine panel.
6. Put the battery disconnect switch in the on position.
7. Close the left rear ROPS door.
8. Remove the Do Not Operate tag from the instrument
panel.
87728445 1 2/28/2008
B.80.A / 6
Engine starter Preliminary test

Prior operation:
Engine starter Remove (B.80.A).
Prior operation:
Before starting the NoLoad Test the following testing equipment must be obtained:
(a) One Sun Electric CAS10147 Tester, an equivalent tester, or separate pieces of test equipment.
(b) One hand held tachometer to measure the speed of the armature shaft.
(c) One remote starter button to actuate the starter.
(d) One fully charged 12 volt battery to supply the electricity to turn the starter.
Prior operation:
Before starting the NoLoad test, check to see if:
(a) The gear on the starter drive can be pulled out of the starter housing.
(b) The starter drive can be turned. To do this, pull the gear on the starter drive out of the starter drive housing. Turn
the gear to turn the starter drive and the armature. If the starter can not be turned, disassemble the starter and make
repairs as needed.
NOTE: The starter needs to be removed from the engine before the NoLoad Test can be done.
NOTE: The NoLoad Test should be done at 20 °C ( 68 °F).
1. If the Sun Electric CAS10147 is being used, turn the
AMP Range switch to ( 0 100 amps), turn the Volt
Range switch to ( 18 40 volts), flip the Volt Lead
switch to the "EXT." position and turn the Load Con
trol dial to the "OFF" position.
If the other test equipment is being used, connect
the test equipment according to the above procedure
and follow the manufacturer’s instructions.
b795328 1
2. Fasten the starter in a vise or use another method to

prevent the starter from moving. This must be done
to prevent personal injury.
3. Connect the positive battery cable to the battery ter
minal on the starter solenoid and the negative battery
cable to the mounting flange of the starter.
(1) Positive battery cable
(2) Battery terminal
(3) Negative battery cable
B831430 2
87728445 1 2/28/2008
B.80.A / 7
4. Connect the positive load cable to the positive post

of the battery. Connect the negative load cable to the
negative post.
(1) Positive battery cable
(2) Negative load cable
B831431 3
5. Connect the red voltmeter lead to the motor terminal

on the starter solenoid.
(1) Red voltmeter lead
(2) Motor terminal
B831432 4
6. Connect the black voltmeter lead to the mounting

flange on the starter.
(1) Black voltmeter lead
B831433 5
87728445 1 2/28/2008
B.80.A / 8
7. Fasten the ammeter clamp around the positive bat

tery cable so that the tip of the arrow is toward the
starter.
(1) Ammeter clamp
B831434 6
8. Connect the leads from the remote starter button to

the Battery and Switch terminals.
(1) Remote starter button
(3) Switch terminal
B831435 7
87728445 1 2/28/2008
B.80.A / 9
9. Actuate the remote starter button and turn the load

control until the voltmeter indicates 11 volts. Do this
within 15 seconds, and then let the starter cool for 60
seconds.
(1) Remote starter button
(2) Load control
(3) Voltmeter
(4) Ammeter
(5) Hand held tachometer
B831436 8
10. Look at the ammeter it should read 200 amps max

imum. Do this within 15 seconds, and then let the
starter cool for 60 seconds. Make a record of the
ammeter indication.
11. Use the hand held tachometer and check the arma
ture shaft speed, it should read 3000 RPM (r/min)
minimum. Do this within 15 seconds, and then let
the starter cool for 60 seconds. Make a record of ar
mature shaft speed.
12. Release the remote starter button and turn the load
control to the "OFF" position.
13. If the current draw and the armature shaft speed are
within the ranges under Specifications, the starter is
good.
14. Low armature shaft speed and high current draw are
indications of too much friction. Possible causes of
too much friction are:
(a) Tight, dirty, or worn bearings.
(b) A bent armature shaft
(c) Loose pole shoes (pole shoes make contact with
the armature).
(d) A short circuit in the armature coil. Disassemble

the starter. Use an armature tester to test the arma
ture. Use the instructions included with the armature
test.
(e) Damaged field coil. Please refer to the test En
gine starter Electrical test (B.80.A).
87728445 1 2/28/2008
B.80.A / 10
15. If the armature does not rotate and the current draw
is high, possible causes are:
(a) Field terminal making contact with the field frame.
Inspect the insulators for the field terminal.
(b) Damaged field coil. Please refer to the test En
gine starter Electrical test (B.80.A).
(c) Damaged bearings.
16. If the armature does not rotate and the current draw
is zero, possible causes are:
(a) An open field circuit. Disassemble the starter and
inspect the field coil connections.
(b) An open armature coil. Disassemble the starter
and check for burned commutator bars. Use an ar
mature tester to test the armature. Use the instruc
tions included with the armature tester.
(c) Brushes not making good contact with the com
mutator bars. Check for high insulation between
the commutator bars, broken brush springs, or worn
brushes.
17. Low armature shaft speed and low current draw are
indications of:
(a) Dirt or corrosion on connections.
(b) Damaged wiring.
(c) Dirty commutator bars.
(d) An open circuit, open armature coil, brushes not
making good contact with the commutator bars.
18. High armature shaft speed and high current draw are
indications of a short circuit in a field coil. It will be
difficult to find a short circuit in a field coil. Install a
new field coil. Do the NoLoad Test again to check
for improvement in the operation of the starter.
Next operation:
Engine starter Disassemble (B.80.A) or Engine starter Install (B.80.A).
87728445 1 2/28/2008
B.80.A / 11
Engine starter Disassemble

Prior operation:
Engine starter Remove (B.80.A) or Engine starter Preliminary test (B.80.A).
1. Pull back the boot on the motor terminal. Loosen and

remove the nut and lock washer.
b330731 1
2. Loosen and remove the screws that mount the cover

to the brush holder.
b330732 2
3. Loosen and remove the bolts that mount cover to the

field frame.
b330733 3
87728445 1 2/28/2008
B.80.A / 12
4. Remove the cover.
b330735 4
5. There are two brushes connected to the field coil.

Hold back the spring and remove one brush at a time
from the brush holder.
b330736 5
6. Remove the brush holder.
b330737 6
7. Remove the field frame assembly.
b330738 7
87728445 1 2/28/2008
B.80.A / 13
8. Remove the armature.
b330739 8
9. Fasten the starter solenoid in a vise with soft jaws.

Loosen and remove the screws that hold the starter
drive housing.
b330740 9
10. Remove the starter drive housing from the starter

solenoid.
b330741 10
11. Push down on the starter drive housing to loosen and

remove the starter drive.
b330743 11
87728445 1 2/28/2008
B.80.A / 14
12. Remove the steel ball from the starter drive. If nec
essary, use a magnet to draw the steel ball out of the
starter drive.
b330744 12
13. Remove the Oring from the groove inside the starter
drive housing.
b330701 13
b330702 14
15. Remove the idler gear.
b330703 15
87728445 1 2/28/2008
B.80.A / 15
16. Remove the bearing cage.
b330704 16
17. Remove the thrust washer.
b330705 17
18. Loosen and remove the screws that mount the cover.
b330706 18
19. If necessary, loosen the cover with a hammer.
b330707 19
87728445 1 2/28/2008
B.80.A / 16
20. Remove the cover.
b330708 20
21. Remove the plunger.
b330709 21
22. Inspect the gasket. Remove and replace the gasket

if the gasket is worn or needs repair.
b330710 22
Next operation:
Engine starter Visual inspection (B.80.A) or Engine starter Electrical test (B.80.A).
87728445 1 2/28/2008
B.80.A / 17
Engine starter Visual inspection

Prior operation:
Engine starter Disassemble (B.80.A) or Engine starter Electrical test (B.80.A).
NOTE: All parts except the starter drive, must be cleaned using mineral spirits with a clean, dry cloth or brush.
1. If the length of a brush that is attached to the brush
holder is less than 11 mm ( 7/16 in), replace with a
new brush assembly.
2. If the length of a brush that is attached to the field
coil is less than 11 mm ( 7/16 in), replace with a new
field frame assembly.
3. Use a spring scale to check the tension of the brush
springs. Pull the brush spring up until the brush
spring is just above the brush holder. The scale indi
cation must be between 1.8 4.1 kg ( 4 9 lb). If a
brush spring tension is not as specified, replace with
a new brush spring.
4. Test the armature on an armature tester. Follow the
equipment manufacturer’s instructions.
5. Place the armature on veeblocks. Check the runout
of the armature with a dial indicator. The runout must
not be more than 0.05 mm ( .002 in).
b834918 1
6. If the runout is more than 0.05 mm ( .002 in), use a

lathe to remove enough material for the runout to be
less than specified.
7. Measure the diameter of the commutator. The diam
eter must not be less than 35 mm ( 1.377 in). If the
diameter is less than specified, replace with a new
armature.
b313141 2
8. If the depth of the groove between the commutator

bars is less than 0.2 mm ( .008 in), cut the insulation
between the commutator bars to a depth of 0.4 0.8
mm ( 1/64 1/32 in). Use sandpaper to remove the
rough edges from the commutator bars.
87728445 1 2/28/2008
B.80.A / 18
9. Check the bearings on the armature for free rotation,

rough balls, and damage to the inner race or outer
race. If a bearing is to be replaced, use a press and
acceptable tools to remove and install the bearings.
Next operation:
Engine starter Electrical test (B.80.A) or Engine starter Assemble (B.80.A).
87728445 1 2/28/2008
B.80.A / 19
Engine starter Electrical test

Prior operation:
Engine starter Disassemble (B.80.A).
1. To test the brush holders, hold the leads of an ohm

meter against the frame and the brush holders that
have insulation between them and the frame.
2. The needle of the ohmmeter must not move when
touching the brush holders and the frame. If the nee
dle moves, replace with a new brush holder.
b313142 1
3. To test the field coil, hold one of the leads of an ohm

meter against the field frame. Hold the other lead of
the ohmmeter against one of the brushes. Look at
the ohmmeter, the needle must not move. Move the
lead that is on the brush to the other brush. Look at
the ohmmeter, the needle must not move. If the nee
dle of the ohmmeter moves, replace with a new field
frame assembly.
b610614 2
4. Hold one of the leads of an ohmmeter against the

end of the cable. Hold the other lead of the ohmme
ter against one of the brushes. Look at the ohmme
ter, the needle must move. Move the lead that is on
the brush to the other brush. Look at the ohmmeter,
the needle must move. If the needle of the ohmme
ter does not move, replace with a new field frame
assembly.
b610616 3
Next operation:
Engine starter Assemble (B.80.A) or Engine starter Visual inspection (B.80.A).
87728445 1 2/28/2008
B.80.A / 20
Engine starter Grease

NOTE: The shaft, bearings, gears, idler shaft and spring must be lubricated every time the starter is disassembled or
the engine is removed for repairs.
1. Use a MolykoteGN lubricant on the shaft at the pin
ion end of the starter drive.
2. Use a multipurpose grease on the bearings, gears,
idler shaft and spring.
87728445 1 2/28/2008
B.80.A / 21
Engine starter Assemble

Prior operation:
Engine starter Electrical test (B.80.A) or Engine starter Visual inspection (B.80.A).
1. Insert the plunger into the starter solenoid.
b330709 1
2. If the gasket was worn or needed repair, insert a new

gasket into the groove of the cover.
b330711 2
3. Align and place the cover onto the starter solenoid.
b330708 3
87728445 1 2/28/2008
B.80.A / 22
4. Mount the cover with screws.
b330712 4
5. Slide one bearing at a time into the bearing cage.
b330714 5
6. Lubricate the bearings, the bearing cage and the

teeth of the idler gear with a multipurpose grease.
Please refer to Engine starter Grease (B.80.A).
b330715 6
87728445 1 2/28/2008
B.80.A / 23
7. Slide the thrust washer down the idler shaft.
b330834 7
8. Slide the bearing cage down onto the thrust washer.
b330835 8
9. Slide the idler gear down onto the bearing cage.
b330836 9
87728445 1 2/28/2008
B.80.A / 24
10. Insert the spring into the housing
b330837 10
11. Lubricate a new Oring with multipurpose grease.

Please refer to Engine starter Grease (B.80.A).
Insert the new Oring into the groove of the starter
drive housing.
b330838 11
12. Lubricate the open bearing on the starter drive with

multipurpose grease. Please refer to Engine starter
Grease (B.80.A).
b330841 12
13. Slide the starter drive into the starter drive housing.
b330802 13
87728445 1 2/28/2008
B.80.A / 25
14. During disassembly the starter drive housing was

pushed down to pop out the starter drive. Please re
fer to Engine starter Disassemble (B.80.A). Flip
the starter drive housing over. Push down on the
starter drive housing so the starter can be pushed
all the way back in.
b330803 14
15. Place a small amount of multipurpose grease into the

starter drive hole. Insert the steel ball into the hole.
b330804 15
16. Connect the starter drive housing to the starter sole

noid.
b330741 16
17. Lubricate the Oring for each starter drive screw with
multipurpose grease. Please refer to Engine starter
Grease (B.80.A). Slide one lock washer, flat washer
and Oring onto each starter drive screw.
b330805 17
87728445 1 2/28/2008
B.80.A / 26
18. Mount the starter drive housing with the starter drive
screws.
b330807 18
19. Fasten the starter solenoid in a vise. Tighten the

starter drive screws. Do not overtighten.
b330740 19
20. Slide the armature into the housing.
b330739 20
21. Install the field frame assembly onto the armature.
b330738 21
87728445 1 2/28/2008
B.80.A / 27
22. Use the springs to hold the brushes in the brush

holder as shown.
b330808 22
23. Slide the brush holder into the field frame.
b330809 23
24. Pull the springs on top of the brushes connected to

the brush holder.
b330810 24
87728445 1 2/28/2008
B.80.A / 28
25. Install the brushes that are connected to the field coil.
b330811 25
26. Use a bolt to align the brush holder with the field
frame assembly.
b330812 26
27. Move the brush holder so it is even with the end of

the armature.
b330813 27
87728445 1 2/28/2008
B.80.A / 29
28. Slide the cover onto the brush holder.
b330814 28
29. Mount the cover to the brush holder with screws.
b330815 29
30. Lubricate the Oring for each bolt that is used to se
cure the cover with multipurpose grease. Please re
fer to Engine starter Grease (B.80.A). Slide a lock
washer, flat washer, and one Oring onto each bolt.
b330816 30
87728445 1 2/28/2008
B.80.A / 30
31. Use the bolts to mount the cover to the field frame.
Tighten the bolts. Do not overtighten.
b330818 31
32. Install the cable, lock washer, and nut onto the motor
terminal. Tighten the nut. Do not overtighten.
b330731 32
33. Pull the boot over the motor terminal.
Next operation:
Engine starter Electrical test (B.80.A).
87728445 1 2/28/2008
B.80.A / 31
Starter solenoid Electrical test

Prior operation:
Engine starter Assemble (B.80.A).
1. The starter solenoid test procedure checks the con

dition of the pullin winding and the holdin winding in
the starter solenoid. To test the starter solenoid, re
move the rubber boot, nut, lock washer and the wire
from the motor terminal.
2. The jumper cable connected to the starter mounting
flange and the motor terminal, must have a common
connection at the negative battery post.
3. Connect a jumper cable to the positive battery post
of a fully charged 12 volts battery. Connect the other
end of the jumper cable to the battery terminal on the
starter solenoid housing.
(1) 12 Volt battery
(2) Starter
(4) Switch terminal
(5) Motor terminal
BC02J086 1
4. Connect a jumper wire to the battery terminal and the

switch terminal in the starter solenoid housing. The
jumper wire must be made from No.10 or larger wire.
5. Connect the jumper cable with the common connec
tion to the starter mounting flange and the motor ter
minal in the starter solenoid housing.
6. Connect the jumper cable with the common connec
tion to the negative battery post. The pinion gear on
the starter drive must come all the out rapidly and
with force. This must be done within 5 seconds to
prevent damage to the pullin winding and the holdin
winding.
7. If the pinion gear did not come out rapidly and with
force, the pullin winding is damaged. The complete
starter solenoid housing assembly must be replaced.
8. Disconnect the jumper cable from the motor terminal
in the starter solenoid housing. The pinion gear on
the starter drive must not move toward the starter
drive housing. This must be done within 5 seconds to
prevent damage to the pullin winding and the holdin
winding.
9. If the pinion gear started to move toward the starter
drive housing, the holdin winding is damaged. The
complete starter solenoid housing assembly must be
replaced.
Next operation:
Engine starter Preliminary test (B.80.A).
87728445 1 2/28/2008
B.80.A / 32
Cold start aid Testing

NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 02 (A.30.A).
Disconnect positive and ground Resistance If an open or short circuit is obtained,
wires from grid heater. replace the grid heater.
Check
Between terminals of grid heater.
87728445 1 2/28/2008
B.80.A / 33
Engine starter Testing

NOTE: For wiring diagrams refer to Wiring harness Electrical schematic frame 02 (A.30.A) and Wiring harness
Put the master disconnect switch in 12 volts Bad cable between the battery ter
the ON position. minal of the starter and the positive
Check post of the battery.
Terminal for battery positive wire to
ground.
Disconnect the electrical connector 12 volts Bad wire W(21B) between the starter
from the fuel shutoff solenoid on the and the starter relay. Bad starter re
injection pump. Put the directional lay.
control in the neutral position and the
parking brake control levers in the
applied position. Have another per
son hold the ignition switch in the
START position.
Check
Terminal for wire W(21B) to ground.
87728445 1 2/28/2008
B.80.A / 34
Starter solenoid Testing

the ON position.
Check
Terminal for wire e to ground.
Put the directional control in the neu 12 volts Bad wire between the starter sole
tral position and the parking brake noid and the starter relay.
control levers in the applied position.
Have another person hold the igni
tion switch in the START position.
Check
Terminal for wire W(21B) connector
to ground.
Terminal B to ground. 12 volts Bad starter solenoid.
87728445 1 2/28/2008
B.80.A / 35
Start control Start relay Testing Start motor relay

Put the directional control in the neu 12 volts Check fuse F3 in connector M2.
tral position and the parking brake Bad wire between the starter relay
control levers in the applied position. and safety relay, bad start sense
Put the ignition switch in the RUN po relay, bad safety relay or bad power
sition. relay module A. Refer to Electri
Check cal control Safety relay Testing
Terminal 30 for wire P (21A) on (C.20.F) and check safety relay, re
starter relay to ground. fer to Fuse and relay box Relay
Testing (A.30.A) and check power
relay module A.
Have another person hold the igni 12 volts Bad wire 337 to engine controller,
tion switch in the START position. bad ignition switch, bad engine con
Check troller. Refer to Start control Start
Terminal 85 for wire 337 to ground. switch Testing (B.80.A) and check
ignition switch.
Terminal for wire 317 to ground. Continuity Bad engine controller.
Terminal for wire W (21B) to ground. 12 volts Bad starter relay.
Start control Start switch Testing

Disconnect the connector from the Continuity Bad ignition switch.
ignition switch. Turn the ignition
switch to the RUN position.
Check
Between the BATT and the RUN ter
minals of the ignition switch.
Between the BATT and the ACC ter Continuity Bad ignition switch.
Hold the key switch in the START Continuity Bad ignition switch.
position.
Check
Between the BATT and all other ter
87728445 1 2/28/2008
B.80.A / 36
Start control Intermediate start relay Testing Start sense relay

Put the directional control in the neu Continuity Bad ground circuit.
tral position and the parking brake
control levers in the applied position.
Put the ignition switch in the RUN po
sition.
Check
Terminal 86 for wire 0 to ground.
Put the ignition switch in the RUN 12 volts Bad ignition switch, bad engine con
position. trol module, bad wire between re
Check lay and engine controller. Refer to
Terminal 30 for wire 332 to ground. Start control Start switch Test
ing (B.80.A) and check the ignition
switch.
Have an assistant hold the ignition 12 volts Bad ignition switch, bad wire be
switch in the start position. tween ignition switch and relay. Re
Check fer to Start control Start switch
Terminal 85 for wire START to Testing (B.80.A) and check the ig
ground. nition switch.
Terminal 87 for wire 329 to ground. 12 volts Bad start sense relay.
87728445 1 2/28/2008
B.80.A / 37
Cold start control Cold start solenoid Testing

Put the master disconnect switch in Continuity Bad wire (375) between the grid
the ON position. heater relay and the engine con
Check troller, bad engine controller.
Terminal for wire V (375) to ground.
Put the ignition switch to RUN posi 12 Volts Bad wire (312) between the grid
tion, temperature must be below 0° heater relay and the engine con
C (32° F). troller, bad engine controller.
Check
Terminal for wire O (312) to ground.
Terminal B to ground. 12 volts Bad wire between the grid heater re
lay and the grid heater fuse, bad fuse
(13A on schematic).
Terminal G to ground. 12 volts Bad grid heater relay.
87728445 1 2/28/2008
B.80.A / 38
Index
POWER PRODUCTION B

Cold start aid Testing 33
Cold start control Cold start solenoid Testing 38
Engine starter Assemble 22
Engine starter Disassemble 12
Engine starter Electrical test 20
Engine starter Exploded view 4
Engine starter Grease 21
Engine starter Install 6
Engine starter Preliminary test 7
Engine starter Remove 5
Engine starter Testing 34
Engine starter Torque 3
Engine starter Visual inspection 18
Start control Intermediate start relay Testing Start sense relay 36
Start control Start relay Testing Start motor relay 36
Start control Start switch Testing 36
Starter solenoid Electrical test 32
Starter solenoid Testing 35
87728445 1 2/28/2008
B.80.A / 39
PRINTED IN U.S.A.
87728445 1 2/28/2008
REPAIR MANUAL
POWER TRAIN
750L
850L
87728445 1 2/28/2008
C
Contents
POWER TRAIN C
POWER COUPLING Fixed coupling C.10.B

750L , 850L
TRANSMISSION Hydrostatic C.20.F

750L , 850L
87728445 1 2/28/2008
C
POWER TRAIN C
POWER COUPLING Fixed coupling 10.B
750L
850L
87728445 1 2/28/2008
C.10.B / 1
Contents
POWER TRAIN C
TECHNICAL DATA
Drive shaft
Torque 3
87728445 1 2/28/2008
C.10.B / 2
POWER TRAIN POWER COUPLING Fixed coupling
Drive shaft Torque

Drive shaft to flywheel mount bolts 285 305 Nm (210 225 lb ft)
87728445 1 2/28/2008
C.10.B / 3
Index
POWER TRAIN C

Drive shaft Torque 3
87728445 1 2/28/2008
C.10.B / 4
POWER TRAIN C
TRANSMISSION Hydrostatic 20.F
750L
850L
87728445 1 2/28/2008
C.20.F / 1
Contents
POWER TRAIN C
TECHNICAL DATA
TRANSMISSION Hydrostatic
Torque 4
Special tools 4
FUNCTIONAL DATA
Overview 5
Exploded view 6
Pump
Overview 8
Motor
External view 9
Diagnostic connector
Overview 10
Electrical control
Dynamic description Adjusting Steering Sensitivity, Shuttle Parameter, and Maximum 11
Transmission Speed Parameter
SERVICE
Adjust Hydraulic Centering Procedure 12
Balancing Mechanical Centering Procedure 14
Command
Inching pedal Electrical adjust 16
Pressure override valve
Pressure setting 18
Pump
Remove 20
Install 22
Left hand pump Pressure test 25
Left hand pump Pressure setting 30
Right hand pump Pressure test 32
Right hand pump Pressure setting 36
Charge pump
Pressure test 38
87728445 1 2/28/2008
C.20.F / 2
Pressure setting 40
Motor
Remove 42
Install 44
Electrical control
Right hand solenoid Remove 46
Right hand solenoid Install 47
Left hand solenoid Remove 48
Left hand solenoid Install 49
Replace 50
DIAGNOSTIC
Electrical control
Safety relay Testing 53
Testing Drivetrain Control Module 53
Sensing system
Filter restriction sensor Testing 55
Charge pressure switch Testing 55
Temperature sensor Testing 56
87728445 1 2/28/2008
C.20.F / 3
POWER TRAIN TRANSMISSION Hydrostatic
TRANSMISSION Hydrostatic Torque

Pump mount bolts to frame 68 81 Nm ( 50 60 lb ft).
Motor mount bolts to final drives 122 135.6 Nm ( 90 100 lb ft)
Pump to motor hoses spit flange clamps 90 100 Nm ( 66 74 lb ft).
Inlet hose clamps 6.5 7.6 Nm ( 58 68 lb in).
Drive shaft to flywheel mount bolts 285 305 Nm ( 210 225 lb ft).
Center housing rear cover
M20 hex bolts 495 620 Nm ( 357 460 lb ft).
M12 hex bolts 99 128 Nm ( 73 94 lb ft).
TRANSMISSION Hydrostatic Special tools
B877558M 1
CAS1804 PRESSURE TEST FITTING KIT
TRANSMISSION Hydrostatic General specification

Charge pump pressure 24 bar (350 psi)
Left Forward Pump Port MA 414 bar (6000 psi)
Left Reverse Pump Port MB 414 bar (6000 psi)
Right Forward Pump Port MB 414 bar (6000 psi)
Right Reverse Pump Port MA 414 bar (6000 psi)
NOTE: The hydraulic and hydrostatic oil must be at an operating temperature of 49 63 °C ( 120 145 °F) when
checking pressure specifications.
87728445 1 2/28/2008
C.20.F / 4
TRANSMISSION Hydrostatic Overview
BD02H004 1
(1) INPUT SHAFT (7) HYDRAULIC PUMP OUTLET (13) DIAGNOSTIC CENTER LINES
LINE
(2) FRONT MOUNT BOLTS (8) REAR CHARGE PUMP INLET (14) FILTER OUTPUT LINE
(3) CASE DRAIN LINE (9) HYDRAULIC PUMP INLET LINE(15) PUMP FEED CROSSOVER
LINE
(4) LIFT CYLINDER CROSSOVER (10) BRAKE SOLENOID PRESSURE (16) UPPER PRESSURE
LINES LINE ADJUSTMENT
(5) RIGHT MOTOR HIGH (11) EQUIPMENT VALVE RETURN (17) SOLENOID AND PRESSURE
PRESSURE LINES LINE SWITCH WIRING HARNESS
(6) CASE DRAIN TO RESERVOIR (12) LEFT MOTOR HIGH (18) THERMAL VALVE TO FILTER
LINE PRESSURE LINES LINE
87728445 1 2/28/2008
C.20.F / 5
TRANSMISSION Hydrostatic Exploded view
BC02J002 1
(1) LEFT MOTOR HIGH PRESSURE LINES (5) LEFT MOTOR

(2) RIGHT DRIVE PUMP (6) RIGHT MOTOR
(3) LEFT DRIVE PUMP (7) MOTOR FRONT CASE DRAIN LINES
(4) RIGHT MOTOR HIGH PRESSURE LINES (8) MOTOR REAR CASE DRAIN LINES
87728445 1 2/28/2008
C.20.F / 6
BC02J003 2
(1) CHARGE PUMP FEED LINE (6) FILTER BYPASS RETURN LINE (11) G1
(2) RESERVOIR SUPPLY LINE (7) HYDROSTATIC FILTER (12) G
(3) CASE DRAIN TO RESERVOIR (8) FILTER PRESSURE FEED LINE (13) T2
LINE
(4) CASE DRAIN CROSS OVER (9) FE
LINE
(5) CHARGE PUMP CROSS OVER (10) S
FEED LINE
87728445 1 2/28/2008
C.20.F / 7
Pump Overview
BD02H004_3 1
(1) INPUT SHAFT (8) CHARGE PUMP INLET (15) PUMP FEED CROSSOVER
LINE
(2) FRONT MOUNT BOLTS (9) HYDRAULIC PUMP INLET LINE (16) RIGHT REVERSE PRESSURE
VALVE
(3) CASE DRAIN LINE T2 (10) BRAKE SOLENOID PRESSURE (17) SOLENOID AND PRESSURE
LINE SWITCH WIRING HARNESS
(4) LIFT CYLINDER CROSSOVER (11) EQUIPMENT VALVE RETURN (18) THERMAL VALVE TO FILTER
LINES LINE LINE
(5) RIGHT MOTOR PRESSURE (12) LEFT MOTOR PRESSURE (19) FRONT PUMP PRESSURE
LINES LINES OVERRIDE VALVE
(6) CASE DRAIN TO RESERVOIR (13) DIAGNOSTIC CENTER LINES (20) LEFT REVERSE PRESSURE
LINE T2 VALVE
(7) HYDRAULIC PUMP OUTLET (14) FILTER OUTPUT LINE
LINE
NOTE: The forward pressure relief valves are located directly below the reverse pressure relief valves. The rear pump
Pressure Override Valve is located in the left rear bottom of the rear pump.
87728445 1 2/28/2008
C.20.F / 8
Motor External view
BD02H006 1
(1) RIGHT HYDROSTATIC MOTOR (7) LEFT MOTOR SOLENOID (13) RIGHT MOTOR HIGH
PRESSURE HOSE
(2) LEFT HYDROSTATIC MOTOR (8) LEFT MOTOR SPEED SENSOR (14) RIGHT SPEED SENSOR
DISCONNECT
(3) LEFT MOTOR HIGH PRESSURE (9) LEFT MOTOR CASE DRAIN (15) RIGHT SOLENOID
HOSE HOSE DISCONNECT
(4) RIGHT MOTOR HIGH (10) LEFT SOLENOID DISCONNECT (16) RIGHT MOTOR CASE DRAIN
PRESSURE HOSE HOSE
(5) RIGHT MOTOR SPEED SENSOR (11) LEFT SPEED SENSOR (17) MAIN HYDRAULIC PUMP
DISCONNECT
(6) RIGHT MOTOR SOLENOID (12) LEFT MOTOR HIGH
PRESSURE HOSE
87728445 1 2/28/2008
C.20.F / 9
Diagnostic connector Overview
BD04F018 1
The diagnostic center is located behind the right side access panel.
87728445 1 2/28/2008
C.20.F / 10
Electrical control Dynamic description Adjusting Steering

Sensitivity, Shuttle Parameter, and Maximum Transmission Speed
Parameter
NOTE: The setting menu may be hidden entirely with the EST.
1. The direction control lever has three sensitivity settings, smooth, normal, and fast.
2. To change the sensitivity: press and hold the enter button for 2 to 3 seconds until the screen shows SELECT
at the top.
BD06G11201 1
3. Press the down arrow until SETTINGS is on displayed.
BD06G11201 2
4. Select the SETTINGS menu by pressing the enter button. The display will show SETTINGS at the top followed
by: Max Spd, Shuttle, Steer.
5. Push the down arrow and go to steer.
NOTE: Normal is the setting from the factory.
6. Press the enter button.
7. Use the up or down arrow button until the desired choice is blinking.
8. Push the enter button to confirm the selection and store the choice.
9. To adjust the shuttle parameter follow the same steps as for steering sensitivity.
10. To adjust the maximum transmission speed follow the same steps as for steering sensitivity.
11. The transmission speed choices will be 70, 80, 90 or 100 per cent.
12. After selecting the desired value press the enter button to confirm and store the choice.
87728445 1 2/28/2008
C.20.F / 11
TRANSMISSION Hydrostatic Adjust Hydraulic Centering

Procedure
1. Park the machine on a level surface, stop the engine.
2. Place the machine on jack stands so that the tracks
do not contact the ground. Secure the machine so
that it is safe to work around and under.
3. Remove the front and rear belly pan covers.
4. Verify proper mechanical centering, refer to TRANS
MISSION Hydrostatic Balancing Mechanical
Centering Procedure (C.20.F).
BD07N47101 1
(1) Clamping screw

(2) Centering screw
(3) Solenoid connector
5. Clean the area around the servo piston X1 and X2
test port locations and the Electroproportional (EP)
control valves on the bottom side of each pump.
Number (1) is the centering screw for mechanical ad
justment.
BD07N47201 2
6. Tag and disconnect the P3 and P4 connectors at the

front and rear pump solenoids.
7. Disconnect the V24 connector at the brake solenoid
to lock the parking brakes in the ON position.
8. Remove the X1 and X2 port plugs using a 3/16 inch
Allen wrench.
9. Install a 0 40 bar (0 600 psi) pressure gauge in
each port. The ports are 7/16 20 UNF threads (#4
Oring boss).
10. Be sure that any rotation of the tracks will not move
the machine, or cause injury. Start the engine and
set the throttle at low idle.
11. Compare the readings of the two pressure gauges.
The pump is considered centered when the readings
are within 2 bar (29 psi) of each other.
87728445 1 2/28/2008
C.20.F / 12
12. If the pressure differential is greater than 2 bar (29

psi). Loosen the clamp screw and adjust the center
ing screw very slightly until the pressure gauge read
ings are within 2 bar (29 psi) or less of each other.
NOTE: This adjustment is extremely sensitive. A small turn of the centering screw results in a large change in cen
tering pressures. The centering screw must NEVER be turned more than 90° in either direction.
13. Tighten the clamp screw to 6.1 Nm (54 lb in).
15. Remove the pressure gauges from the X1 and X2
ports, and reinstall the plugs.
16. Reconnect the P3 and P4 connectors at the front and
rear pump solenoids, remove tags.
17. Verify that the hydraulic reservoir is full. Top off with
the correct oil if required.
18. Run the engine and verify that there are no leaks.
19. Reinstall the belly pan covers.
20. Reconnect the V24 connector at the brake solenoid.
21. Remove the machine from the jack stands.
22. Return the machine to service.
87728445 1 2/28/2008
C.20.F / 13
TRANSMISSION Hydrostatic Balancing Mechanical Centering

Procedure
1. Park the machine on a level surface, stop the engine.
2. Place the machine on jack stands so that the tracks
do not contact the ground. Secure the machine so
that it is safe to work around and under.
3. Remove the front and rear belly pan covers.
4. Clean the area around the servo piston X1 and X2
test port locations and the Electroproportional (EP)
control valves on the bottom side of each pump.
NOTE: Do not hook up gauges as shown, see step 6 for gauge connections.
5. To ensure that there is equal pressure on both sides
of the servo piston during the centering operation, it
is necessary to connect the X1 and X2 ports together
by means of a hose or tubing (not less than 6.4mm, or
1/4 inch inside diameter). The port sizes are 7/16 20
UNF. (#4 Oring boss) Use a 3/16 inch Allen wrench
to remove the X1 and X2 plugs.
BC07N85901 1
6. Install pressure gauges on the test ports under the

right side access door for the forward (MA) and re
verse (MB) pump ports for the pump being adjusted.
The front pump supplies the right drive motor, and
the rear pump supplies the left drive motor
BD04F018 2
7. Disconnect the V24 connector at the brake solenoid

to lock the parking brakes in the ON position.
8. Be sure that any rotation of the tracks will not move
the machine, or cause injury. Start the engine and
set the throttle at low idle.
87728445 1 2/28/2008
C.20.F / 14
9. Use a 24mm wrench (1) to loosen the locknut on the

servo piston adjusting screw, and use a 6mm Allen
wrench (2) to turn the adjusting screw clockwise until
one of the gauges reads 69 bar (1000 psi).
BC07N85901 3
10. Then, turn the adjusting screw counterclockwise until

the other gauge reads 69 bar (1000 psi), counting
the number of turns of the screw between the two
extreme positions.
11. Turn the adjusting screw clockwise one half the num
ber of turns to center the servo piston. The pressure
gauges should read the same.
12. Tighten the locknut.
14. Remove the hose/tube between X1 and X2 ports,
and reinstall the plugs.
15. Verify that the hydraulic reservoir is full. Top off with
the correct oil if required.
16. Run the engine and verify that there are no leaks.
17. Reconnect the V24 connector at the brake solenoid.
18. Remove the machine from the jack stands.
19. Test drive the machine, if machine still does not track
straight refer to TRANSMISSION Hydrostatic Ad
just Hydraulic Centering Procedure (C.20.F) and
do the hydraulic centering procedure.
20. If machine tracks straight, reinstall the belly pan cov
ers.
21. Return the machine to service.
87728445 1 2/28/2008
C.20.F / 15
Command Inching pedal Electrical adjust

1. Put the master disconnect switch in the on position.
2. Push and hold both the bump up/down buttons on
the directional control.
3. Turn the ignition switch to the accessory position,
continue to hold the buttons for 5 seconds or until
instrument cluster displays machine models.
model that is being calibrated.
instrument cluster will read (LT or LGP/WT).
track gauge, (LT or LGP/WT).
instrument cluster will read (CAL BRK).
8. Slowly move the brake pedal from release to applied
position two to four times.
9. After moving brake pedal and no error message ap
will read (CAL HTR).
10. Slowly move the hand throttle from low idle to high
idle two to four times.
11. After moving hand throttle and no error message ap
will read (CAL FTR).
12. Slowly move the foot throttle (Decel Pedal) from high
idle to low idle two to four times.
range or potentiometer was not moved in the last five seconds since the start of calibration mode. During this operation
if the instrument cluster reads (ERR SWITCH), the low idle switch is not functioning or is out of adjustment.
13. After moving foot throttle (Decel Pedal) and no er
ror message appears on the instrument cluster press
both buttons for one second and release, the instru
ment cluster will read (CAL DONE). Stop and restart
the machine, values are stored in internal memory.
14. If at any time during calibration the instrument clus
ter reads (CAL FAIL), turn the ignition switch off and
restart the procedure.
87728445 1 2/28/2008
C.20.F / 16
87728445 1 2/28/2008
C.20.F / 17
Pressure override valve Pressure setting
BD02H004_3 1
LINE
VALVE
LINES LINE LINE
LINE T2 VALVE
LINE
1. Tilt the ROPS cab/canopy, refer to USER PLAT

FORM Tilt (E.34.A).
2. Remove the plastic cap from the POR valve, loosen
the jam nut and turn the adjusting screw in until it just
seats, tighten the jam nut.
NOTE: DO NOT over tighten the adjusting screw in the
POR valve, this WILL damage internal components of the
POR valve.
3. Lower the ROPS cab/canopy, refer to USER PLAT
FORM Lower (E.34.A).
87728445 1 2/28/2008
C.20.F / 18
87728445 1 2/28/2008
C.20.F / 19
Pump Remove
BD02H004 1
LINE
LINE
Park the machine on a level surface, lower the blade and any attachment to the floor, apply the parking brake levers,
stop engine and turn off the master disconnect.
Prior operation:
Reservoir Apply vacuum (A.10.A)
Prior operation:
USER PLATFORM Tilt (E.34.A)
NOTE: DO NOT disconnect two lines at the same time going to the hydraulic reservoir. Plug or cap a line prior to
disconnecting another. Tag all lines and wires before disconnecting for proper identification for assembly.
1. Disconnect the hydraulic pump inlet line (9).
2. Disconnect the rear charge pump inlet line (8).
3. Disconnect the case drain to reservoir line (6).
4. Disconnect the filter output line (14).
87728445 1 2/28/2008
C.20.F / 20
5. Disconnect hydraulic pump outlet line (7).

6. Disconnect the equipment valve return line (11).
7. Disconnect the thermal valve to filter line (18).
8. Disconnect the solenoid and pressure switch wiring
harness from both solenoids and pressure switch
(17).
9. Disconnect the five lines to the diagnostic center
(13). Three lines are located on the right side of the
pump.
10. Disconnect the brake solenoid pressure line from the
front charge pump (10).
11. Disconnect the left motor pressure lines (12).
12. Disconnect the right motor pressure lines (5).
13. Disconnect lift cylinder crossover lines (4). Remove
two bolts and clamps from front mounting bracket.
NOTE: Line 3 and line 15 do not need to be removed prior
to pump removal.
14. Attach suitable lifting equipment to the pumps, en
sure proper balance of the pumps to keep from tilting
during removal.
15. Remove the two front mounting bolts (2).
16. Remove the two rear mount bolts, the hose seen in
this photo can be removed from the filter element and
removed with the pump.
BD02H059 2
17. Raise the pumps slowly, move the pumps to the rear
and slip the input shaft (1) off of the pump splines.
Carefully remove the pumps from the machine.
87728445 1 2/28/2008
C.20.F / 21
Pump Install
BD02H004 1
LINE
LINE
NOTE: DO NOT remove plugs or caps from two lines at the same time going to the hydraulic reservoir.
1. Carefully lower the pumps into the machine. Align
the pump input shaft splines with the drive shaft.
Align the mounting bolt holes and install the mount
ing bolts.
2. Remove the lifting equipment from the pumps.
87728445 1 2/28/2008
C.20.F / 22
3. Torque the rear mount bolts to 68 to 81 Nm (50 to 60

lbft). Connect the hose to the filter element.
BD02H059 2
4. Torque the two front mounting bolts (2) to 68 to 81

Nm (50 to 60 lbft).
5. If removed, Install the drive shaft and torque flange to
flywheel mounting bolts to 285 to 305 Nm (210 to 225
lbft). Install the bell housing covers and grounding
cable.
BD02H069 3
6. Connect lift cylinder crossover lines (4). Install the

two bolts and clamps to the front mounting bracket.
7. Connect the right motor pressure lines (5). Snug the
split flange clamps down evenly and then torque to
90 to 100 Nm (66 to 74 lbft).
8. Connect the left motor pressure lines (12). Snug the
split flange clamps down evenly and then torque to
90 to 100 Nm (66 to 74 lbft).
9. Connect the brake solenoid pressure line to the front
charge pump (10).
10. Connect the five lines to the diagnostic center (13).
Three lines are located on the right side of the pump.
11. Connect the solenoid and pressure switch wiring har
ness to both solenoids and pressure switch (17).
12. Connect the thermal valve to filter line (18).
13. Connect the equipment valve return line (11).
14. Connect hydraulic pump outlet line (7).
15. Connect the filter output line (14).
16. Connect the case drain to reservoir line (6).
17. Connect the rear charge pump inlet line (8). Orien
tate the threads downward and torque to 6.5 to 7.6
Nm (58 to 65 lbin).
87728445 1 2/28/2008
C.20.F / 23
18. Connect the hydraulic pump inlet line (9). Orientate

the threads to the rear and torque to 6.5 to 7.6 Nm
(58 to 65 lbin).
19. Turn off the vacuum pump. Disconnect the vacuum
pump from the reservoir, install the vent in the hy
draulic reservoir.
21. Check oil level in reservoir, fill to correct level. Re
fer to PRIMARY HYDRAULIC POWER SYSTEM
General specification (A.10.A) for correct oil type.
22. Start and run the engine at low idle for 3 minutes,
run the machine at full throttle for 5 minutes while
moving the machine in forward, reverse, left and right
steering positions.
23. Stop the engine, tilt the ROPS cab/canopy, refer
to USER PLATFORM Tilt (E.34.A) and check for
leaks.
87728445 1 2/28/2008
C.20.F / 24
Pump Left hand pump Pressure test

CAS1804
NOTE: Make sure the hydraulic and hydrostatic oil is at operating temperature.
1. To test the hydrostatic pump relief valves, the drive
sprockets must be locked in position. To properly
lock the drive sprockets, while rotating in the forward
direction, a pin must be inserted in the sprocket teeth,
at the top of the track frame, and a stop bracket must
be provided to prevent the locking pin from moving
away from the sprocket. Locally fabricate a pair of
steel track locking pin brackets, as shown.
2. Fabricate brackets to lock the sprockets. Use 12.7
mm (0.5 in) thick steel.
BD07N46601 1
(1) The spread on the brackets to the outside edges should

be 127 mm (5 in).
(2) Use 12.7 mm (0.5 in) thick steel.
3. Fabricate the two end pieces as shown.
BD07N46701 2
(1) 241.3 mm (9.50 in)

(2) 215.9 mm (8.50 in)
(3) 228.6 mm (9.00 in)
(4) The tab is 9.52 mm (0.4 in) high and the cut in from the
end is 12.7 mm (0.5 in).
(5) The plates are 50.8 mm (2.0 in) wide.
4. Run a diagonal weld on both sides of the bracing
plate.
87728445 1 2/28/2008
C.20.F / 25
BD07N46801 3
5. The pin used is a bucket pin from a backhoe, a pin

of equal size and hardness can be used in it’s place.
BD07N46901 4
(1) The length of the pin used is 371.5 mm (14.63 in).

(2) Diameter of the pin used is 44.4 mm (1.75 in).
6. Install the pin and bracket at each sprocket. To test
the reverse relief valves, only the pins are required.
In reverse, the pin will lock between the sprocket and
the rear end of the track frame.
BD07N47001 5
87728445 1 2/28/2008
C.20.F / 26
WARNING
Always know the location of all workers in your area. Warn them before you start working the machine. Al
ways keep all other persons away from your area. Serious injury or death can result if you do not follow these
instructions. SA015
7. Connect two 690 bar (10,000 psi) gauges on the

quick disconnect fitting marked Right Reverse Pump
Port and Right Forward Pump Port. The hose for the
pressure gauge must have at least a 690 bar (10,000
psi) rating.
BD04F018 6
8. Direct the gauges into the ROPS or cab to view them

from the operators seat.
9. Start the engine.
10. Make sure the Hand Throttle is in the idle position.
11. Use the UP range button to place the machine in its
highest range. The instrument cluster will reflect the
hydrostatic range.
12. Make sure both parking brakes are in the OFF posi
tion.
13. Place the directional control in the F position.
14. Raise and maintain engine r/min (rpm) at 2000.
When the pressure stops increasing, record the
pressure reading.
15. Move the Hand throttle to the IDLE position.
16. Move the sprocket stop pins to the bottom of the track
rail, have an assistant ensure that the pins are secure
before proceeding.
17. Place the directional control in the R position.
pressure readings.
19. Move the Hand throttle to the IDLE position, place the
directional control in neutral and apply the parking
brakes, stop the engine.
20. Compare the pressure readings recorded to the
specifications, 414 bar (6000 psi).
21. If pressures are not within specification adjust pres
sure reliefs, refer to Pump Left hand pump Pres
sure setting (C.20.F).
22. After adjusting the pressure relief valve repeat steps
3 through 14.
87728445 1 2/28/2008
C.20.F / 27
23. If pressures is still not within specification adjust

pressure over ride valve, refer to Pressure override
valve Pressure setting (C.20.F).
24. After adjusting the pressure over ride valve repeat
steps 3 through 14.
25. If the pressure reading is not within specifications,
refer to Pump Remove (C.20.F) Pump Install
(C.20.F) and replace the pumps.
87728445 1 2/28/2008
C.20.F / 28
87728445 1 2/28/2008
C.20.F / 29
Pump Left hand pump Pressure setting
BD02H004_3 1
LINE
VALVE
LINES LINE LINE
LINE T2 VALVE
LINE

FORM Tilt (E.34.A).
2. Check the torque of the pressure relief valves in the
pump body, 150 Nm (110 lbft).
3. Remove the plastic cap from the pressure relief
valve, loosen the jam nut and turn the adjusting
screw in to raise the pressure and out to lower the
pressure, tighten the jam nut.
NOTE: Repeat the procedure for the other pressure relief
valve.
87728445 1 2/28/2008
C.20.F / 30
4. Adjust the pressure relief valve to 414 bar (6000 psi).

87728445 1 2/28/2008
C.20.F / 31
Pump Right hand pump Pressure test

CAS1804
1. To test the hydrostatic pump relief valves, the drive

sprockets must be locked in position. To properly
lock the drive sprockets, while rotating in the forward
direction, a pin must be inserted in the sprocket teeth,
at the top of the track frame, and a stop bracket must
be provided to prevent the locking pin from moving
away from the sprocket. Locally fabricate a pair of
steel track locking pin brackets, as shown.
2. Fabricate brackets to lock the sprockets. Use 12.7
mm (0.5 in) thick steel.
BD07N46601 1
(1) The spread on the brackets to the outside edges should

be 127 mm (5 in).
(2) Use 12.7 mm (0.5 in) thick steel.
3. Fabricate the two end pieces as shown.
BD07N46701 2
(1) 241.3 mm (9.50 in)

(2) 215.9 mm (8.50 in)
(3) 228.6 mm (9.00 in)
(4) The tab is 9.52 mm (0.4 in) high and the cut in from the
end is 12.7 mm (0.5 in).
(5) The plates are 50.8 mm (2.0 in) wide.
4. Run a diagonal weld on both sides of the bracing
plate.
87728445 1 2/28/2008
C.20.F / 32
BD07N46801 3
5. The pin used is a bucket pin from a backhoe, a pin

of equal size and hardness can be used in it’s place.
BD07N46901 4
(1) The length of the pin used is 371.5 mm (14.63 in).

(2) Diameter of the pin used is 44.4 mm (1.75 in).
6. Install the pin and bracket at each sprocket. To test
the reverse relief valves, only the pins are required.
In reverse, the pin will lock between the sprocket and
the rear end of the track frame.
BD07N47001 5
87728445 1 2/28/2008
C.20.F / 33
WARNING
instructions. SA015
7. Connect two 690 bar (10,000 psi) gauges on the

quick disconnect fitting marked Right Reverse Pump
Port and Right Forward Pump Port. The hose for the
pressure gauge must have at least a 690 bar (10,000
psi) rating.
BD04F018 6
8. Direct the gauges into the ROPS or cab to view them

9. Start the engine.
10. Make sure the Hand Throttle is in the idle position.
hydrostat range.
tion.
pressure reading.
16. Move the sprocket stop pins to the bottom of the track
rail, have an assistant ensure that the pins are secure
before proceeding.
pressure readings.
specifications, 414 bar (6000 psi).
21. If pressures are not within specification adjust pres
sure reliefs, refer to Pump Right hand pump Pres
sure setting (C.20.F).
22. After adjusting the pressure relief valve repeat steps
3 through 14.
87728445 1 2/28/2008
C.20.F / 34
23. If pressures is still not within specification adjust

pressure over ride valve, refer to Pressure override
valve Pressure setting (C.20.F).
24. After adjusting the pressure over ride valve repeat
steps 3 through 14.
25. If the pressure reading is not within specifications,
refer to Pump Remove (C.20.F) Pump Install
(C.20.F) and replace the pumps.
87728445 1 2/28/2008
C.20.F / 35
Pump Right hand pump Pressure setting
BD02H004_3 1
LINE
VALVE
LINES LINE LINE
LINE T2 VALVE
LINE

FORM Tilt (E.34.A).
2. Check the torque of the pressure relief valves in the
pump body, 150 Nm (110 lbft).
3. Remove the plastic cap from the pressure relief
valve, loosen the jam nut and turn the adjusting
screw in to raise the pressure and out to lower the
pressure, tighten the jam nut.
NOTE: Repeat the procedure for the other pressure relief
valve.
87728445 1 2/28/2008
C.20.F / 36
4. Adjust the pressure relief valve to 414 bar (6000 psi).

87728445 1 2/28/2008
C.20.F / 37
Charge pump Pressure test

Equipment required CAS1804 pressure test and fitting kit.
Prior operation:
Check the oil level, type, and grade in the hydraulic reservoir.
Check hydrostatic oil filter condition and change as necessary.
Check control linkage for correct operation.
Check engine r/min (rpm).
NOTE: Make sure the oil is at operating temperature.

1. It will be necessary to operate the machine against
an immovable object or into a spoil pile. The surface
must be one that will allow the track to dig in, in both
FORWARD and REVERSE.
2. Connect a pressure gauge with a capacity of at least
69 bar (1000 psi) to the quick disconnect fitting
marked Charge Pump.
BD04F018 1
3. Connect two 414 690 bar (6,000 10,000 psi)

gauges on the quick disconnect fitting marked Right
Reverse Pump Port, Right Forward Pump Port. The
hose for the pressure gauge must have at least a 690
bar (10,000 psi) rating.
BD04F018 2
4. Direct the gauge into the ROPS or cab to view them

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

instrument cluster display.
87728445 1 2/28/2008
C.20.F / 38

7. When the charge pressure stops increasing, record
the pressure reading.
8. Move the hand throttle to the IDLE position.
hydrostatic range.
tion.
pressure readings.
pressure readings.
NOTE: Reconnect the two 414 690 bar (6,000 10,000
psi) gauges on the quick disconnect fitting marked Left Re
verse Pump Port MB (5), Left Forward Pump Port MA (4),
repeat procedures 2 through 16.
specifications, refer to TRANSMISSION Hydro
static General specification (C.20.F).
NOTE: If charge pressure readings dropped more than 3.1
bar (45 psi) between N and F or R during procedures 12
or 15 it will be required to determine if the leakage is in the
brake release system or the hydrostat system.
NOTE: Understanding results of the test. Charge pressure
is used to shift the servo control pistons as well as release
the brakes. Low charge pressure may be the result of a
failure in either of these systems.
Next operation:
If pressure is not within specification refer to Charge pump Pressure setting (C.20.F).
87728445 1 2/28/2008
C.20.F / 39
Charge pump Pressure setting

1. Remove the vent from the hydraulic reservoir and
connect a vacuum pump to the reservoir. Turn on
the pump.
1. Reservoir vent
2. Bypass line
BD02F017 1
2. Disconnect the filter bypass return line, plug the line

and cap the fitting.
3. Turn off the vacuum pump, repeat procedures 2
through 8 in Charge pump Pressure test (C.20.F)
and check the pressure.
NOTE: If pressure increased replace the filter head, if pres
sure did not increase, reconnect the filter bypass line and
go to the next procedure.
4. Adjust the pressure setting of the rear charge pump
relief valve by doing the following procedures:
FORM Tilt (E.34.A).
6. Remove the vent from the hydraulic reservoir and
connect a vacuum pump to the reservoir. Turn on
the pump.
NOTE: Rear charge pump pressure relief valve is located
below the pump feed cross over line and fitting, to gain
access to the relief valve the line and fitting will have to
be removed, item 5 and 13 in figure 2 of TRANSMISSION
Hydrostatic Exploded view (C.20.F).
BD02M130 2
7. Remove the hex cap, plunger, plunger seat, shims

and spring from the charge pump relief valve port.
1. Oring
2. Plunger
3. Plunger seat
4. Shims
5. Spring
BD02M154 3
87728445 1 2/28/2008
C.20.F / 40
8. Check the external Oring for damage. Replace as

necessary.
9. Inspect the plunger, plunger seat and spring for dam
aged or worn parts. Repair or replace as necessary.
10. Add shims to the plunger seat to increase the pres
sure setting. Remove shims from the plunger seat to
decrease the pressure setting. Each shim is 1 MM.
(0.040 inch) thick and will change the pressure set
ting by 3.8 bar (55 psi).
11. Install the spring, plunger seat, plunger and the hex
cap into the charge pump relief valve port.
12. Install new Orings and connect crossover line and
fitting.
through 8 of Charge pump Pressure test (C.20.F)
15. Adjust the charge pressure relief valve again if nec
essary.
NOTE: If pressure did not increase/decrease as needed
it will require adjustment of the front charge pump. Any
shims installed/removed from the rear charge pump will
have to be removed/replaced before proceeding.
16. Adjust the pressure setting of the front charge pump
relief valve by doing the following procedure:
FORM Tilt (E.34.A).
18. Loosen the locking nut on the relief valve, turn the ad
justing screw in to raise the pressure or out to lower
the pressure.
through 8 of Charge pump Pressure test (C.20.F)
21. Adjust the charge pressure relief valve again if nec
essary.
87728445 1 2/28/2008
C.20.F / 41
Motor Remove
Park the machine on a level surface, lower the blade and any attachment to the floor, apply the parking brake levers,
stop engine and turn off the master disconnect.
Prior operation:
NOTE: After removal of lines, cap and plug lines and fittings.
1. Remove the rear cover plate from the center box, use
suitable lifting equipment to lower the plate. Apply a
vacuum to the reservoir, refer to Reservoir Apply
vacuum (A.10.A).
BD02H075 1
2. Disconnect the rear case drain hose, solenoid and

speed sensor wiring harness.
1. Case drain
2. Solenoid connector
3. Speed sensor
4. Brake release pressure hose
NOTE: Brake release hose (4) does not need to be discon
nected.
BD02H061 2
3. Disconnect high pressure hoses from the motor.

1. Right upper
2. Right lower
3. Left upper
4. Left lower
BD02H064 3
87728445 1 2/28/2008
C.20.F / 42
4. Disconnect the front case drain hose.
BD02H066 4
5. Remove all but one mount bolt to the final drive. Sup
port the motor with blocks of wood and remove the
last mounting bolt.
6. Carefully work the motor out of the final drive and
remove it from the machine.
87728445 1 2/28/2008
C.20.F / 43
Motor Install
1. Carefully work the motor into the machine and into
the final drive.
2. Start all four mounting bolts to the final drive and
snug them up evenly. Torque the mounting bolts to
122 135.6 Nm (90 100 lb ft).
3. Connect the front case drain hose.
BD02H066 1
4. Connect high pressure hoses to the motor.

5. Connect the rear case drain hose, solenoid and
speed sensor wiring harness.
1. Case drain
2. Solenoid connector
3. Speed sensor
4. Brake release
BD02H061 2
6. Turn off and disconnect the vacuum pump from the

reservoir.
8. Check oil level in reservoir, fill to correct level. Re
fer to PRIMARY HYDRAULIC POWER SYSTEM
General specification (A.10.A) for correct oil type.
9. Start and run the engine at low idle for 3 minutes,
run the machine at full throttle for 5 minutes while
moving the machine in forward, reverse, left and right
steering positions.
10. Stop the engine and check for leaks.
87728445 1 2/28/2008
C.20.F / 44
11. Install the rear cover and torque the 20mm hex bolts
to 495 620 Nm (357 460 lb ft), the 12mm hex bolts
to 90 128 Nm (73 94 lb ft).
BD02H075 3
87728445 1 2/28/2008
C.20.F / 45
Electrical control Right hand solenoid Remove

1. Park the machine on a level surface, lower blade and
any attachments.
2. Apply parking brakes, turn ignition switch and master
disconnect off.
FORM Tilt (E.34.A).
4. Disconnect the electrical connector for the solenoids
being replaced.
5. Remove the center belly plate for the right pump
solenoids, rear belly plate for the left pump solenoids.
6. Remove the retaining nut for the solenoids, remove
the solenoids.
NOTE: Remove and replace both solenoids as a unit.
BD02M121 1
87728445 1 2/28/2008
C.20.F / 46
Electrical control Right hand solenoid Install

1. Slide the solenoids onto the control valve shaft, in
stall the retaining nut and tighten.
NOTE: Make sure the wires are routed in such a manner
that they will not rub against the pump housings.
BD02M121 1
2. Install the belly plates.

3. Connect the electrical connector.
NOTE: Make sure the connector seal is in place and ser
viceable.
87728445 1 2/28/2008
C.20.F / 47
Electrical control Left hand solenoid Remove

any attachments.
disconnect off.
FORM Tilt (E.34.A).
4. Disconnect the electrical connector for the solenoids
being replaced.
5. Remove the center belly plate for the right pump
solenoids, rear belly plate for the left pump solenoids.
6. Remove the retaining nut for the solenoids, remove
the solenoids.
NOTE: Remove and replace both solenoids as a unit.
BD02M121 1
87728445 1 2/28/2008
C.20.F / 48
Electrical control Left hand solenoid Install

1. Slide the solenoids onto the control valve shaft, in
stall the retaining nut and tighten.
NOTE: Make sure the wires are routed in such a manner
that they will not rub against the pump housings.
BD02M121 1
2. Install the belly plates.

3. Connect the electrical connector.
NOTE: Make sure the connector seal is in place and ser
viceable.
87728445 1 2/28/2008
C.20.F / 49
Electrical control Replace

any attachments.
disconnect OFF.
3. Remove the left arm rest.
BD06K00701 1
4. Remove the four cover mounting screws.
BD06K00802 2
5. Pull on the tabs on the connectors.
BD06M02401 3
6. While pulling out the tab the connector will disengage

from the controller.
87728445 1 2/28/2008
C.20.F / 50
BD06M02501 4
7. Repeat the procedure for the other connector, re

move the mounting bolts and remove the controller.
8. Place the controller into the machine and secure with
the mounting bolts.
9. Inspect connectors C1 and C2 for damaged, wet, or
corroded connections.
BD06M02601 5
10. Start the connectors onto the controller with the lock
ing tab plate completely pulled out.
IMPORTANT: DO NOT force the connectors onto the controller, make sure the pins are aligned before fully seating
the connectors.
BD06M02501 6
11. Push the locking tabs in until they lock securely into
position.
87728445 1 2/28/2008
C.20.F / 51
BD06M02401 7
12. Place the cover over the controller and secure with
the four mounting screws.
BD06K00802 8
13. Install the left arm rest.
BD06K00701 9
87728445 1 2/28/2008
C.20.F / 52
Electrical control Safety relay Testing

the ON position.
Check
Terminal 86 for wire 0 to ground.
Put the ignition switch in the RUN po 12 volts Bad wire P (206) to drivetrain control
sition, parking brake control levers in module, bad drivetrain control mod
the APPLIED position and the FNR ule.
joystick in the NEUTRAL position.
Check
Terminal 85 for wire P (206) to
ground.
Terminal 30 for wire 21 to ground. 12 volts Bad wire 21 to fuse F3 in connector
M2, bad fuse. Bad power relay mod
ule A, refer to Fuse and relay box
Relay Testing Power Relay Mod
ules A and B (A.30.A) and check
Terminal 87 for wire 21A to ground. 12 volts Bad safety relay.
Electrical control Testing Drivetrain Control Module

Turn ignition switch and master dis Continuity Bad ground circuit
connect OFF, disconnect controller
connectors, turn master disconnect
ON.
Check
Connector C1 pins 2 and 28 to
ground.
Turn the ignition switch ON. 12 volts Bad fuse F9 in fuse and relay panel,
Check bad wire from controller to fuse
Connector C1 pins 1 and 27 to block. Also check power relay mod
ground. ule A, refer to Fuse and relay box
Relay Testing Power Relay Mod
ules A and B (A.30.A). Check circuit
from pins 1 and 27 Connector C1 to
pin 36 Connector C4, form pin 36
Connector M10 to pin 9A Connec
tor M2.
87728445 1 2/28/2008
C.20.F / 53

Connector C1 pins 13, 41, and 42 12 volts Bad fuse F10 in fuse and relay
to ground. panel, bad wire from controller to
fuse block. Also check power relay
module A, refer to Fuse and relay
box Relay Testing Power Relay
Modules A and B (A.30.A). Check
circuit from pins 13, 41, and 42 Con
nector C1 to pin 35 Connector C4,
form pin 35 Connector M10 to pin
10A Connector M2.
Connector C1 pin 39 to Connector Continuity Bad wire between connector C1 and
D3A pin D. D3A. Check circuit from pin 39 Con
from pin 5 Connector M10 to pin
16 Connector M1, from pin 16 Con
nector D1 to pin D Connector D3A.
Connector C1 pin 40 to Connector Continuity Bad wire between connector C1 and
D3A pin C. D3A. Check circuit from pin 40 Con
from pin 6 Connector M10 to pin
26 Connector M1, from pin 26 Con
nector D1 to pin C Connector D3A.
Turn the ignition switch and master CAN link with controller. Bad drive train control module, re
disconnect OFF, connect connectors fer to Electrical control Replace
to the controller, turn the master dis (C.20.F) and replace the control
connect ON. Connect the EST tool module, program control module us
to the diagnostic port, turn the igni ing EST tool.
tion switch ON.
Check
Using the EST attempt to communi
cate with the controller.
87728445 1 2/28/2008
C.20.F / 54
Sensing system Filter restriction sensor Testing

Check between the hydrostatic filter Continuity Bad ground circuit.
restriction switch housing and the fil
ter housing.
Disconnect wire GY(134) from the Open Bad hydrostatic filter restriction
hydrostatic filter restriction switch switch.
terminal.
Check
Hydrostatic filter restriction switch
terminal to ground.
Put the master disconnect switch in 12 volts Bad wire GY(134) between hydro
the ON position. Put the ignition static filter restriction switch and pin
switch in the RUN position. 3 of instrument cluster connector
Check D2B. Bad connectors. Check in
Wire GY(134) to ground. strument cluster hydraulic filter bulb;
check instrument cluster. Check cir
cuit from hydrostatic filter restriction
switch to pin 8 Connector V1, from
pin 8 Connector P10 to pin 4 Con
nector P1, from pin 4 Connector
C5 to pin 10 Connector C4, from pin
10 Connector M10 to pin 36 Con
nector M1, from pin 36 Connector
D1 to pin 3 Connector D2B.
Sensing system Charge pressure switch Testing

NOTE: Test charge pressure before proceeding. For wiring diagrams refer to Wiring harness Electrical schematic
frame 12 (A.30.A) and Wiring harness Electrical schematic frame 13 (A.30.A).
the ON position.
Check
Terminal of wire 0 on harness con
nector to ground.
87728445 1 2/28/2008
C.20.F / 55

Put the ignition switch in the RUN 12 volts Bad wire LB(133) between charge
position. pressure switch and pin 5 of instru
Check ment cluster connector D2B. Bad
Wire LB(133) on harness connector connectors. Check instrument clus
to ground. ter charge pressure bulb; check
instrument cluster. Check circuit
from pin 1 Connector P9 to pin 6
Connector P1, from pin 6 Connec
tor C5 to pin 9 Connector C4, from
pin 9 Connector M10 to pin 6 Con
nector M1, from pin 6 Connector
D1 to pin 5 Connector D2B.
Start and run the engine at approxi Continuity Bad charge pressure switch.
mately 1500 rpm (r/min).
Check
Between terminals of charge pres
sure switch to ground.
Sensing system Temperature sensor Testing

Check between the housing of the Continuity Bad ground circuit.
transmission temperature sender
and housing hydraulic reservoir.
Disconnect wire P(121) from the 12 volts Bad wire P(121) between the trans
transmission temperature connec mission temperature sender and pin
tor. Put the master disconnect switch 5 of the instrument cluster connec
in the ON position and the ignition tor D2A. Bad connectors. Check the
switch in the RUN position. oil temperature gauge. Check the in
Check strument cluster. Check circuit from
Wire P(121) to ground. temperature sending unit to pin 6
Connector V1, from pin 6 Connec
tor P10 to pin 3 Connector P1, from
pin 3 Connector C5 to pin 38 Con
nector C4, from pin 38 Connector
M10 to pin 33 Connector M1, from
pin 33 Connector D1 to pin 5 Con
nector D2A.
Check oil temperature gauge read Low green area Bad oil temperature gauge.
ing with wire P(121) disconnected
from sender terminal.
Connect wire P(121) to ground and High red area Bad oil temperature gauge.
check reading of oil temperature
gauge.
87728445 1 2/28/2008
C.20.F / 56
Index
POWER TRAIN C

Charge pump Pressure setting 40
Charge pump Pressure test 38
Command Inching pedal Electrical adjust 16
Diagnostic connector Overview 10
Electrical control Dynamic description Adjusting Steering Sensitivity, Shuttle Parameter, and 11
Maximum Transmission Speed Parameter
Electrical control Replace 50
Electrical control Testing Drivetrain Control Module 53
Electrical control Left hand solenoid Install 49
Electrical control Left hand solenoid Remove 48
Electrical control Right hand solenoid Install 47
Electrical control Right hand solenoid Remove 46
Electrical control Safety relay Testing 53
Motor External view 9
Motor Install 44
Motor Remove 42
Pressure override valve Pressure setting 18
Pump Install 22
Pump Overview 8
Pump Remove 20
Pump Left hand pump Pressure setting 30
Pump Left hand pump Pressure test 25
Pump Right hand pump Pressure setting 36
Pump Right hand pump Pressure test 32
Sensing system Charge pressure switch Testing 55
Sensing system Filter restriction sensor Testing 55
Sensing system Temperature sensor Testing 56
TRANSMISSION Hydrostatic Adjust Hydraulic Centering Procedure 12
TRANSMISSION Hydrostatic Balancing Mechanical Centering Procedure 14
TRANSMISSION Hydrostatic Exploded view 6
TRANSMISSION Hydrostatic General specification 4
TRANSMISSION Hydrostatic Overview 5
TRANSMISSION Hydrostatic Special tools 4
TRANSMISSION Hydrostatic Torque 4
87728445 1 2/28/2008
C.20.F / 57
PRINTED IN U.S.A.
87728445 1 2/28/2008
REPAIR MANUAL
TRAVELLING
750L
850L
87728445 1 2/28/2008
D
Contents
TRAVELLING D
Final drive D.15.A

750L , 850L
SERVICE BRAKE Hydraulic D.30.C

750L , 850L
PARKING BRAKE Hydraulic D.32.C

750L , 850L
WHEELS AND TRACKS Tracks D.50.B

750L , 850L
87728445 1 2/28/2008
D
TRAVELLING D
Final drive 15.A
750L
850L
87728445 1 2/28/2008
D.15.A / 1
Contents
TRAVELLING D
Final drive 15.A
TECHNICAL DATA
Final drive
Torque 4
Special tools 4
Capacity 4
FUNCTIONAL DATA
Final drive
Exploded view 5
Sectional view 6
External view 8
Wheel hub
Exploded view 10
SERVICE
Final drive
Remove 12
Install 22
Preliminary test 30
Wheel hub
Remove 32
Disassemble 34
Assemble 36
Install 38
Gear
Planetry gearset Remove 42
Planetry gearset Disassemble 44
Planetry gearset Visual inspection 46
Planetry gearset Assemble 48
Planetry gearset Install 50
Spur gear Visual inspection 52
Spur gear Install 54
Housing
Sandwich housing Remove 58
Sandwich housing Visual inspection 60
Sandwich housing Assemble 61
87728445 1 2/28/2008
D.15.A / 2
Sandwich housing Install 62
Wheel hub housing Remove 64
Wheel hub housing Disassemble 66
Wheel hub housing Visual inspection 70
Wheel hub housing Assemble 72
Wheel hub housing Install 76
Input bearing housing Visual inspection 79
Input bearing housing Assemble 80
Input bearing housing Install 82
Drop box Remove 84
Drop box Visual inspection 87
Drop box Assemble 88
Drop box Install 90
87728445 1 2/28/2008
D.15.A / 3
TRAVELLING Final drive
Final drive Torque

Rolling Torque 0 5.4 Nm (0.0 47.8 lb in)
Input Shaft Bearing Retainer Plate Mounting Bolts 77 100 Nm (57 74 lb ft)
Sandwich Housing Bolts 195 250 Nm (145 185 lb ft)
Brake Housing Cover 24 mm Hex Head 195 250 Nm (145 185 lb ft)
Gauge Flange To Wheel Hub Bearing Plate 77 100 Nm (57 74 lb ft)
Planetary Gear Retaining Bolts 118 133 Nm (87 98 lb ft)
Planetary Assembly to Hub Retainer Plate Fitting 118 133 Nm (87 98 lb ft)
Hub Assembly to Gear Box 195 250 Nm (145 185 lb ft)
Brake Line Fitting 55 60 Nm (40 44 lb ft)
Fill Check Plug 43 47 Nm (32 35 lb ft)
Drain Plug 90 99 Nm (66 73 lb ft)
Final Drive To Center Box Mounting Bolts 195 250 Nm (145 185 lb ft)
Rear Cover Plate 30 mm Hex Head 430 485 Nm (315 355 lb ft)
18 mm Hex Head 77 100 Nm (57 74 lb ft)
16 mm Hex Head 50 65 Nm (37 48 lb ft)
Final Drive to Frame Mounting Bolts 1160 1300 Nm (856 959 lb ft)
Cab Frame Support Bracket Mounting Bolts 1160 1300 Nm (856 959 lb ft)
Cab Frame Support Bracket Mounting Bolts to Cab 280 320 Nm (207 236 lb ft)
Frame
Final drive Special tools

Kit 380000849
Dowel Bolts 380000848
Driver Handle 380000847
Bearing Cup Drivers Input Shaft Bearing 380000845
Counter Shaft Bearing 380000846
Lower Gear Bearing 380000826
Wheel Hub Inner Bearing 380000828
Wheel Hub Outer Bearing 380000827
Final drive Capacity

Final Drive Lubricant Capacity (Each) 14.2 L ( 15 US qt)
Lubricant CASE AKCELA HYTRAN ULTRA
87728445 1 2/28/2008
D.15.A / 4
Final drive Exploded view
BC02J004 1
1. Oring brake feed 11. Counter shaft gear 21. Park brake shaft
2. Fill/check plug with oring 12. Dowel pins (6) 22. Separator plates (4)
3. Plugs with orings (3) 13. Lower gear bearings 23. Brake orings (3)
4. Drive motor oring 14. Lower gear 24. Sandwich housing
5. Input gear bearings 15. Sun Gear 25. Brake piston
6. Input gear 16. Wear plate 26. Spring washers (2)
7. Input bearing housing 17. Piston plate 27. Brake cover bolts (5)
8. Input bearing housing bolts (4) 18. Dowel pins (3) 28. Park brake cover
9. Dowel pins (2) 19. Friction plates (3) 29. Sandwich housing bolts (8)
10. Counter shaft bearings 20. Brake shaft snap ring 30. Drop box
87728445 1 2/28/2008
D.15.A / 5
Final drive Sectional view
BC02M146 1
1. Drop housing 20. Bearing cup 39. Plug

2. Dowel pin (3) 21. Bearing cone 40. Dowel pin (2)
3. Fiction plate (3) 22. Flange 41. Bearing cup (2)
4. Separator plate (4) 23. Oring 42. Bearing cone (2)
5. Oring 24. Retaining ring 43. Sun shaft
6. Apply Loctite 515 25. Spacer washer 44. Dowel pin (3)
7. Oring 26. Wheel end plate 45. Check plug
87728445 1 2/28/2008
D.15.A / 6
8. Expansion plug 27. Hex plug 46. Locking bolt (3)

9. Oring 28. Retaining ring 47. Pin washer (3)
10. Apply Loctite 515 29. Seal 48. Bearing cone (2)
11. Brake piston 30. Wheel hub housing 49. Countershaft gear
12. Spring washer (2) 31. Bearing cone 50. Bearing cup (2)
13. Brake cover 32. Bearing cup 51. Bearing cup (2)
14. Piston plate 33. Locking bolt 52. Bearing cone (2)
15. Apply Loctite 596 34. Planetary assembly 53. Apply Loctite 767 antiseize
16. Ring gear 35. Oring 54. Brake hub
17. Roller bearing (198) 36. Sandwich housing 55. Input gear
18. Planet gears (3) 37. Axle wear insert 56. Retaining ring
19. Bearing retainer plate 38. Lower gear 57. Oring
58. Brake line connector
87728445 1 2/28/2008
D.15.A / 7
Final drive External view
BC02J006 1
53. ROPS/tank frame mount bolts (8) 56. Left ROPS/tank frame support bracket
54. Bracket to final mount bolts (4) 57. Right ROPS/tank frame support bracket
55. Mounting bolts (7) per side
87728445 1 2/28/2008
D.15.A / 8
BC02J028 2
58. Final to frame mount bolts (5) per side 59. Final to center housing mount bolts (8) per side
87728445 1 2/28/2008
D.15.A / 9
Wheel hub Exploded view
BC02J005 1
31. Planetary gears (3) 42. Wheel hub housing

32. Oring wheel hub 43. Two piece face seal
33. Wheel hub bearings 44. Wheel hub
34. Bearing retainer plate 45. Spacer washer
35. Bearing retainer plate bolts (8) 46. External retaining ring
36. Planetary hub 47. Oring
37. Planet gear pins 48. Wheel hub end plate
38. Bearing 66 per gear 49. Internal retaining ring
39. Pin washer (3) 50. Wheel end plate puller plug
40. Dowel pins (3) 51. Locking bolts (6)
41. Locking bolts (3) 52. Locking bolts (6)
87728445 1 2/28/2008
D.15.A / 10
87728445 1 2/28/2008
D.15.A / 11
Final drive Remove
BC02J006 1
Prior operation:
Steel track Remove (D.50.B) Drive sprocket Remove (D.50.B) Reservoir Apply vacuum (A.10.A)
1. Place a suitable container under the final drive and

drain the oil from the final drive.
2. Remove the inner sprocket scrapper and track frame
cover.
3. Remove the two bolts (54) and washers securing the
ROPS frame support bracket (56) or (57) to the final
drive that is being repaired.
87728445 1 2/28/2008
D.15.A / 12
BC02J005 2

4. Remove ten of the twelve mounting bolts (51) and
(52) from the hub assembly (42).
5. Install 380000848 dowel bolts.
BD02M066 3
6. Attach suitable lifting equipment to the sprocket

mounting flange.
87728445 1 2/28/2008
D.15.A / 13
7. Remove the last two mounting bolts (51)or (52), use

the prying slots to loosen the hub, pull the hub as
sembly (42) off of the sandwich housing (24) and
place on a flat surface.
IMPORTANT: DO NOT allow all of the weight of the hub to
be placed on the outer portion of the dowel bolts.
BD02M067 4
8. Remove only the upper outside and lower outside

frame mounting bolts (58).
BC02J028 5
9. If there are attachments on the machine, remove
any mounting bolts to the sandwich housing (24) and
loosen the bolts in the drop box (30).
87728445 1 2/28/2008
D.15.A / 14
BC02J004 6
2. Fill/check plug with Oring 12. Dowel pins (6) 22. Separator plates (4)
3. Plugs with Orings (3) 13. Lower gear bearings 23. Brake Orings (3)
4. Drive motor Oring 14. Lower gear 24. Sandwich housing
10. Loosen the five bolts (27) on the housing cover (28)
2 turns, continue to loosen the bolts 2 turns until the
brake spring (26) pressure is released, then remove
the bolts (27), housing cover (28) and spring washers
(26).
87728445 1 2/28/2008
D.15.A / 15
11. Remove six of the eight bolts (29) from the sandwich
housing (24).
12. Install 380000848 dowel bolts, place a long rod into
the lower gear, support the lower gear (14) in the
housing.
BD02M092 7
13. Remove the last two mounting bolts (29), separate

the sandwich housing (24) from the drop box (30).
NOTE: There are two dowel pins (12) in the housing, use
pry bars on the bolt bosses for attachments to help sepa
rate the housings.
14. Put a nylon lifting strap through the brake bore of
the sandwich housing (24) and attach suitable lifting
equipment.
IMPORTANT: DO NOT allow all the weight of the sandwich
housing to be placed on the outer portion of the dowel bolts.
15. Remove the sandwich housing (24) from the drop
box (30).
16. Lay the sandwich housing (24) face down on a flat
surface.
17. Remove the brake piston plate (17) and the brake
piston (25). Separate the brake piston plate (17) and
the brake piston (25).
18. Remove the lower gear (14) from the drop box (30).
BD02M094_2 8
87728445 1 2/28/2008
D.15.A / 16
19. Remove the four separator plates (22) and three fric
tion clutch plates (19).
BD02M095 9
20. Remove the four retaining bolts (8) and bearing

housing (7) from the input gear (6).
IMPORTANT: Have another person hold the gears in the
drop box when removing the retaining bolts.
BD02M094 10
21. Remove the counter shaft gear (11), input gear (6)
from the drop box (30).
87728445 1 2/28/2008
D.15.A / 17
Final drive Visual inspection
BC02J005 1

IMPORTANT: Do not use compressed air to dry bearings. Allow bearings to air dry.
87728445 1 2/28/2008
D.15.A / 18
2. Discard all seals and Orings.

NOTE: The outer wheel hub seal (43) can be replaced with
out removing the wheel hub bearing (33).
BD02M088 2
3. Inspect bearing rollers for pitting, scoring, deforma

tion, or other damage. Check the inner face and
bearing cage for deformation, dents, and other dam
age. Replace part if any of these conditions are seen.
Check that bearings rotate easily without binding. If
the bearing binds or action is not smooth, replace the
bearing.
4. Inspect bearing cups for pitting, scoring, or other
damage.
5. Remove and replace cups and rollers if any of these
conditions are seen.
NOTE: Replace bearings as a set, cup and roller.
IMPORTANT: Use only authorized service parts, any af
termarket bearings WILL NOT allow for proper assembly
of the final drive.
6. Check gear teeth for cracks, breaks, chipping,
or other damage. Replace if cracked, broken or
chipped gear teeth are seen.
7. Check shafts for broken, cracked, or twisted splines.
Replace if any of these conditions are seen.
8. Inspect the planetary pins (37) for excessive or un
even wear, replace the planetary hub if these condi
tions are seen.
BD02M077 3
9. Check brake separator plates for pitting, scoring and

other damage.
10. Check brake friction plates for excessive wear, dis
coloration, scoring, flaking of material over large ar
eas 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.
87728445 1 2/28/2008
D.15.A / 19
11. Check each brake friction plate and separator plate

with a straight edge. If the part is not flat, install a
new set of friction plates and brake separator plates
in that brake.
NOTE: If a friction plate or brake separator plate is dam
aged, install a new set of friction plates and brake separa
tor plates for that brake. DO NOT mix old and new parts in
a brake.
12. Check to make sure the lubrication holes are open in
the input gear.
BD02M098 4
87728445 1 2/28/2008
D.15.A / 20
87728445 1 2/28/2008
D.15.A / 21
Final drive Install
BC02J004 1
IMPORTANT: DO NOT use an excessive amount of Loctite 515 around the Oring (1), this will cause the Oring to
distort and the final drive WILL LEAK.
NOTE: Remove any excess amount of Loctite 596, the excess can cause the brakes to remain applied after assembly.
87728445 1 2/28/2008
D.15.A / 22
1. Install 380000848 dowel bolts into the drop box.

equipment.
IMPORTANT: DO NOT allow all of the weight of the sand
wich housing to be placed on the outer portion of the dowel
bolts.
3. Put the sandwich housing (24) on the dowel bolts,
push the housing to within eight inches of the drop
box, lower the lifting equipment and remove the nylon
strap from the brake bore.
NOTE: Carefully remove the strap, do not remove any of
the Loctite on the drop box.
4. Push the sandwich housing (24) up to the drop box
(30), align the lower gear (14) into the sandwich
housing (24), secure with five bolts, remove the
dowel bolts and install the remaining bolts.
BD02M092 2
5. Lube the small diameter brake piston Oring (23) and

install the brake piston plate (17) with raised lip to
ward piston (25). Lube both Orings (23) on the brake
pistons (17) and (25). Install pistons in the bore,
small end first, over friction/separator plates (19) and
(22). Press into the housing. Refer to SERVICE
BRAKE Hydraulic Install (D.30.C).
NOTE: Remove and discard all used brake Orings, they
will swell when removed and are not reusable.
BD02M118 3
87728445 1 2/28/2008
D.15.A / 23
6. Using the torque pattern, torque the eight bolts (29)

to 196 250 Nm (145 184 lb ft).
BC02M145 4
7. Turn off and disconnect the vacuum pump, replace

the vent in the hydraulic reservoir.
8. Install the sun shaft (15) into the lower gear (14).
BD02M089 5
9. Install the brake spring washers (26) with the follow

ing instruction.
BD02M110 6
87728445 1 2/28/2008
D.15.A / 24
10. With the large outer diameters facing each other on

park brake cover (28).
BD02M111 7
11. Using Loctite 515 make a bead on the inner diameter

of the final drive sandwich housing (24).
NOTE: Make a bead on the inside of the bolt holes with no
breaks in the bead.
BD02M112 8
12. Install the outer cover (28) and five retaining bolts
(27).
13. Tighten the bolts (27) down evenly until springs (26)
are compressed and cover (28) is flat on the sand
wich housing (24).
14. Torque the bolts to 196 250 Nm (145 184 lb ft).
BD02M113 9
87728445 1 2/28/2008
D.15.A / 25
BC02J006 10
87728445 1 2/28/2008
D.15.A / 26
15. Install the two bolts and washer (54) securing the
ROPS frame support (56) or (57), torque to 1160
1300 Nm (856 959 lb ft).
BD02M114 11
BC02J028 12
16. Install the two bolts and washer (58) securing the
sandwich housing (24) to the frame, torque to 1160
1300 Nm (856 959 lb ft).
17. Make sure that the dowel pins (12) are in the sand
wich housing (24). Install the 380000848 dowel bolts
in the sandwich housing (24).
87728445 1 2/28/2008
D.15.A / 27
BC02J005 13

mounting flange, place the hub assembly (42) on
the dowel bolts.
IMPORTANT: DO NOT allow all of the weight of the hub as
sembly (42) to be placed on the outer portion of the dowel
bolts.
NOTE: Make sure to place the hub assembly (42) on the
dowel bolts in such a manner that the dowel pins (12) will
align with dowel pin bores during assembly.
87728445 1 2/28/2008
D.15.A / 28
19. Push the wheel hub housing (42) onto the sandwich
housing (24).
NOTE: The wheel hub (44) may have to be turned to align
the teeth on the plnetary gears (31) and the sun gear (15).
BD02M115 14
20. Secure the wheel hub housing (42) to the sandwich

housing (24) with nine of the twelve mounting bolts
(51) and (52).
21. Remove the dowel bolts and install the last three
mounting bolts (51) and (52).
22. Using the torque pattern, torque the bolts to 195
250 Nm (144 184 lb ft).
Bc02m145_2 15
23. Install the inner track rail cove and sprocket scraper.
24. Remount any attachments removed from the rear
of the machine, torque mounting bolts into the final
drives to 1160 1300 Nm (856 959 lb ft).
Next operation:
Steel track Install (D.50.B)
87728445 1 2/28/2008
D.15.A / 29
Final drive Preliminary test

1. Move the machine to an open area, drive the ma
chine at 50% speed for 2 minutes, stop the machine
and apply the parking brakes.
2. Use a thermal gun and take a temperature reading
of the final drive, temperature should be less than 71
°C ( 160 °F).
NOTE: If the temperature is greater than 71 °C( 160 °F),
this indicates that a bearing is to tight or the park brake is
misassembled.
87728445 1 2/28/2008
D.15.A / 30
87728445 1 2/28/2008
D.15.A / 31
Wheel hub Remove
BC02J005 1

Prior operation:
Steel track Remove (D.50.B) Drive sprocket Remove (D.50.B)

87728445 1 2/28/2008
D.15.A / 32

cover.
3. Remove the two bolts (54) and washers securing the
ROPS frame support bracket (56) or (57) to the final
drive that is being repaired.
BD02M066 2

mounting flange.
7. Remove the last two mounting bolts (51) or (52), use
sembly (42) off of the sandwich housing and place
on a flat surface.
IMPORTANT: DO NOT allow all of the weight of the hub to
be placed on the outer portion of the dowel bolts.
BD02M067 3
87728445 1 2/28/2008
D.15.A / 33
Wheel hub Disassemble
BC02J005 1

87728445 1 2/28/2008
D.15.A / 34
1. Remove the eight retaining bolts (35) and the bear

ing retaining plate (34) from the wheel hub assembly
(44).
BD02M083 2
2. Place the wheel hub housing (42) in a hydraulic

press, block the housing and allow four inches of
travel for the wheel hub (44).
3. Place a suitable arbor on the end of the wheel hub
shaft. Press the wheel hub (44) from the wheel hub
housing (42).
BD02M084 3
87728445 1 2/28/2008
D.15.A / 35
Wheel hub Assemble
BC02J005 1

87728445 1 2/28/2008
D.15.A / 36
1. Install the bearing retainer plate (34) and eight bolts

(35). Draw the bearing into place by staggering bolt
torque until retaining plate is flush with the hub.
BD02M082 2
2. Final torque the bolts (35) to 77 100 Nm ( 57 74

lb ft).
BD02M091 3
87728445 1 2/28/2008
D.15.A / 37
Wheel hub Install
BC02J005 1

1. Make sure that the dowel pins are in the sandwich

housing . Install the 380000848 dowel bolts in the
sandwich housing.
87728445 1 2/28/2008
D.15.A / 38

the dowel bolts.
bolts.
dowel bolts in such a manner that the dowel pins will align
with dowel pin bores during assembly.
housing .
the teeth on the plnetary gears (31) and the sun gear.
BD02M115 2

housing with nine of the twelve mounting bolts (51)
and (52).
mounting bolts (51) or (52).
250 Nm ( 145 185 lb ft).
Bc02m145_2 3
87728445 1 2/28/2008
D.15.A / 39
Next operation:
Drive sprocket Install (D.50.B) Steel track Install (D.50.B)
87728445 1 2/28/2008
D.15.A / 40
87728445 1 2/28/2008
D.15.A / 41
Gear Planetry gearset Remove
BC02J005 1

87728445 1 2/28/2008
D.15.A / 42
1. Remove the internal retaining ring (49).
BD02M068 2
2. Use the puller plug (50) to remove wheel hub end

plate (48).
BD02M069 3
3. Remove the Oring (47), external retaining ring (46),

and the spacer (45) from the planetary carrier assem
bly shaft.
BD02M070 4
4. Remove the planetary hub (36) from the wheel hub

housing (42).
BD02M071 5
87728445 1 2/28/2008
D.15.A / 43
Gear Planetry gearset Disassemble
BC02J005 1

87728445 1 2/28/2008
D.15.A / 44
1. Remove the three retaining bolts (41) and pin wash

ers (39) from the planetary pins (37).
BD02M072 2
2. Remove the planetary gear (31) from the planetary

hub (36).
IMPORTANT: The needle bearings will fall out when the
gear is removed, there are 66 per gear.
BD02M074 3
3. Remove the wear plate insert from the planetary hub

(36).
BD02M075 4
87728445 1 2/28/2008
D.15.A / 45
Gear Planetry gearset Visual inspection
BC02J005 1

87728445 1 2/28/2008
D.15.A / 46

3. Check shafts for broken, cracked, or twisted splines.
Replace if any of these conditions are seen.
4. Inspect the planetary pins (37) for excessive or un
even wear, replace the planetary hub if these condi
tions are seen.
BD02M077 2
87728445 1 2/28/2008
D.15.A / 47
Gear Planetry gearset Assemble
BC02J005 1

87728445 1 2/28/2008
D.15.A / 48
1. Put a small amount of grease on the wear insert to

hold in place during assembly, place the insert in the
center bore of the planetary carrier (36).
BD02M076 2
2. Use grease to hold the bearings (38) in place, slide

the gear (31) and bearing subassembly onto a pin
(37) of planetary assembly (36), remove any excess
grease.
BD02M078 3
3. Place a bolt (41) through a pin washer (39), make

sure to align the washer (39) onto the dowel pin (40).
BD02M073 4
4. Final torque the bolt (41) to 118 133 Nm ( 87 98

lb ft).
NOTE: Repeat the procedure for the other planetary gears.
BD02M081 5
87728445 1 2/28/2008
D.15.A / 49
Gear Planetry gearset Install
BC02J005 1

87728445 1 2/28/2008
D.15.A / 50
1. Place the planetary assembly (36) on a flat surface

with the spline side up. Install the wheel hub housing
(42) over the planetary assembly (36).
NOTE: DO NOT force the wheel hub assembly onto the
planetary assembly, turn the wheel hub or the wheel hub
housing to align gears and splines.
BD02M071 2
2. Insert a spacer washer (45) over the spline into the

pocket, secure with an external retaining ring (46).
BD02M070 3
3. Place an Oring (47) on the upper step of the wheel

hub (44), place the wheel end plate (48) over the
Oring. Install the internal retaining ring (49).
BD02M068 4
4. Place an Oring (32) in the groove on the gear end of

the wheel hub housing (42), lubricate with a thin coat
of grease.
87728445 1 2/28/2008
D.15.A / 51
Gear Spur gear Visual inspection

3. Check to make sure the lubrication holes are open in
the input gear.
BD02M098 1
87728445 1 2/28/2008
D.15.A / 52
87728445 1 2/28/2008
D.15.A / 53
Gear Spur gear Install
BC02J004 1
87728445 1 2/28/2008
D.15.A / 54
1. Make sure that the two dowel pins (9) are in place in
the drop box prior to installing the input gear bearing
housing (7). Use Anti Seize on the splines of the
input gear (6), place the input gear assembly (6) and
counter shaft gear (11) into the drop box.
IMPORTANT: Have another person hold the gears in the
drop box when installing the retaining bolts.
BD02M096 2
2. Place input gear bearing housing (7) onto input gear

and secure with four bolts (8). Torque bolts 77 100
Nm ( 57 74 lb ft).
BD02M106 3
3. SERVICE BRAKE Hydraulic Install (D.30.C)

Make sure that the three dowel pins (18) are in place
in the input gear bearing housing (7). Install the four
brake separator plates (22) and three brake friction
plates (19) starting with a separator plate alternating
with a friction plate until all are installed. Make sure
the notches on the separator plates (22) go over the
dowel pins (18) on the input gear bearing housing
(7).
Bd02m095_2 4
4. Place the inner bearing of the lower gear (14) behind

the counter shaft gear (11).
BD02M107 5
87728445 1 2/28/2008
D.15.A / 55
5. Slowly lower the gear, it will stay in place but will need
to be aligned during assembly of the drop box (30)
and sandwich housing (24).
BD02M093 6
87728445 1 2/28/2008
D.15.A / 56
87728445 1 2/28/2008
D.15.A / 57
Housing Sandwich housing Remove
BC02J004 1
2. Fill/check plug with Oring 12. Dowel pins (6) 22. Separator plates (4)
3. Plugs with Orings (3) 13. Lower gear bearings 23. Brake Orings (3)
4. Drive motor Oring 14. Lower gear 24. Sandwich housing
87728445 1 2/28/2008
D.15.A / 58
1. Remove six of the eight bolts (29) from the sandwich

housing (24).
BD02M092 2
2. Install 380000848 dowel bolts, place a long rod into

the lower gear, support the lower gear (14) in the
housing.
3. Remove the last two mounting bolts (29), separate
the sandwich housing (24) from the drop box (30).
NOTE: There are two dowel pins (12) in the housing, use
pry bars on the bolt bosses for attachments to help sepa
rate the housings.
equipment.
IMPORTANT: DO NOT allow all the weight of the sandwich
housing to be placed on the outer portion of the dowel bolts.
5. Remove the sandwich housing (24) from the drop
box (30).
6. Lay the sandwich housing (24) face down on a flat
surface.
87728445 1 2/28/2008
D.15.A / 59
Housing Sandwich housing Visual inspection

damage.
87728445 1 2/28/2008
D.15.A / 60
Housing Sandwich housing Assemble

1. Use special tool 380000846 with handle 380000847
to install the bearing cup for the counter shaft gear in
the sandwich housing.
BD02M103 1

to install the bearing cup for the lower gear in the
sandwich housing.
BD02M102 2
87728445 1 2/28/2008
D.15.A / 61
Housing Sandwich housing Install
BC02J004 1
IMPORTANT: DO NOT use an excessive amount of Loctite 515 around the Oring (1), this will cause the Oring to
distort and the final drive WILL LEAK.
NOTE: Remove any excess amount of Loctite 596, the excess can cause the brakes to remain applied after assembly.
87728445 1 2/28/2008
D.15.A / 62
1. Install 380000848 dowel bolts into the drop box.

equipment.
IMPORTANT: DO NOT allow all of the weight of the sand
wich housing to be placed on the outer portion of the dowel
bolts.
3. Put the sandwich housing (24) on the dowel bolts,
push the housing to within eight inches of the drop
box, lower the lifting equipment and remove the nylon
strap from the brake bore.
NOTE: Carefully remove the strap, do not remove any of
the Loctite on the drop box.
4. Push the sandwich housing (24) up to the drop box
(30), align the lower gear (14) into the sandwich
housing (24), secure with five bolts, remove the
dowel bolts and install the remaining bolts.
BD02M092 2
5. Using the torque pattern, torque the eight bolts (29)

to 196 250 Nm ( 145 185 lb ft).
BC02M145 3
87728445 1 2/28/2008
D.15.A / 63
Housing Wheel hub housing Remove
BC02J005 1

Prior operation:
Steel track Remove (D.50.B) Drive sprocket Remove (D.50.B) Reservoir Apply vacuum (A.10.A)

87728445 1 2/28/2008
D.15.A / 64

cover.
mounting flange.
BD02M066 2
6. Remove the last two mounting bolts (51) or (52), use

sembly (42) off of the sandwich housing and place
on a flat surface.
BD02M067 3
87728445 1 2/28/2008
D.15.A / 65
Housing Wheel hub housing Disassemble
BC02J005 1

87728445 1 2/28/2008
D.15.A / 66
1. Remove the internal retaining ring (49).
BD02M068 2
2. Use the puller plug (50) to remove wheel hub end

plate (48).
BD02M069 3
3. Remove the Oring (47), external retaining ring (46),

the spacer (45), from the planetary carrier assembly
(36) shaft.
BD02M070 4
4. Remove the planetary hub (36) from the wheel hub

housing (42).
BD02M071 5
87728445 1 2/28/2008
D.15.A / 67
5. Remove the eight retaining bolts (35) and the bear

ing retaining plate (34) from the wheel hub assembly
(44).
BD02M083 6
6. Place the wheel hub housing (42) in a hydraulic

press, block the housing and allow four inches of
travel for the wheel hub (44).
7. Place a suitable arbor on the end of the wheel hub
shaft. Press the wheel hub (44) from the wheel hub
housing (42).
BD02M084 7
8. Remove and discard the face seals (43).

87728445 1 2/28/2008
D.15.A / 68
87728445 1 2/28/2008
D.15.A / 69
Housing Wheel hub housing Visual inspection
BC02J005 1

87728445 1 2/28/2008
D.15.A / 70
2. Discard all seals and Orings.

BD02M088 2

bearing.
damage.
87728445 1 2/28/2008
D.15.A / 71
Housing Wheel hub housing Assemble
BC02J005 1


to install the outer bearing cup and special tool
380000828 with handle 380000847 to install the
inner bearing cup into the wheel hub housing (42).
87728445 1 2/28/2008
D.15.A / 72
2. The wheel hub seal (43) is a two piece seal.
BD02M087 2
3. Install half of the seal in the wheel hub housing (42)

and the other half on the wheel hub (44) with metal
surfaces facing out, lubricate the metal surfaces with
CASE AKCELA HYTRAN ULTRA.
NOTE: Keep all other surfaces of the seals dry, DO NOT lu
bricate any rubber surfaces, this will cause premature fail
ure of the seal.
BD02M088 3
4. If removed, press the outer bearing on the wheel hub.

Install the wheel hub housing (42) onto the wheel hub
(44) being careful not to bump or damage seals (43).
Install the inner bearing (33) on the wheel hub (44).
BD02M090 4
5. Install the bearing retainer plate (34) and eight bolts

(35). Draw the bearing into place by staggering bolt
torque until retaining plate is flush with the hub.
BD02M082 5
87728445 1 2/28/2008
D.15.A / 73
6. Final torque the bolts (35) to 77 100 Nm ( 57 74

lb ft).
BD02M091 6
87728445 1 2/28/2008
D.15.A / 74
87728445 1 2/28/2008
D.15.A / 75
Housing Wheel hub housing Install
BC02J005 1

1. Make sure that the dowel pins are in the sandwich

housing . Install the 380000848 dowel bolts in the
sandwich housing .
87728445 1 2/28/2008
D.15.A / 76

the dowel bolts.
bolts.
dowel bolts in such a manner that the dowel pins (12) will
align with dowel pin bores during assembly.
housing (24).
the teeth on the planetary gears (31) and the sun gear.
BD02M115 2

housing (24) with nine of the twelve mounting bolts
(51) and (52).
mounting bolts (51) and (52).
250 Nm( 145 185 lb ft).
Bc02m145_2 3
87728445 1 2/28/2008
D.15.A / 77
7. Install the inner track rail cover and sprocket scraper.

8. Remount any attachments removed from the rear
of the machine, torque mounting bolts into the final
drives to 1160 1300 Nm( 855 960 lb ft).
Next operation:
Drive sprocket Install (D.50.B)
Next operation:
Steel track Install (D.50.B)
87728445 1 2/28/2008
D.15.A / 78
Housing Input bearing housing Visual inspection

bearing.
damage.
87728445 1 2/28/2008
D.15.A / 79
Housing Input bearing housing Assemble
BC02J004 1

to install the bearing cup for the input gear in the input
bearing housing (7).
87728445 1 2/28/2008
D.15.A / 80
87728445 1 2/28/2008
D.15.A / 81
Housing Input bearing housing Install
BC02J004 1
87728445 1 2/28/2008
D.15.A / 82
1. Place input gear bearing housing (7) onto input gear

and secure with four bolts (8). Torque bolts to 77
100 Nm ( 57 74) lb ft.
BD02M106 2
87728445 1 2/28/2008
D.15.A / 83
Housing Drop box Remove
BC02J006 1
Prior operation:
Motor Remove (C.20.F) Final drive Remove (D.15.A)
IMPORTANT: DO NOT remove both final drives at the same time, the center housing is only supported by the final
drives and could shift or come off of the machine if both final drives are removed. If both final drives require removal,
remove one final drive at a time, repair the first final drive and reinstall, then remove the other final drive.
1. Place a jack stand under the center housing to sup
port it when the final drive is removed.
87728445 1 2/28/2008
D.15.A / 84
2. Remove the four bolts (53) and washers securing

the ROPS frame support bracket (56) or (57) to the
ROPS frame for the drop box that is being removed.
BC02J028 2
3. Remove the three remaining bolts (58) and washers
securing the front of the drop box to the machine.
4. Remove the seven bolts (55) on the outside of the
final drive securing it to the center housing.
5. Install 380000848 dowel bolts into the center hous
ing.
6. Disconnect the brake line, cap the fitting and plug the
line.
7. Remove the eight bolts (59) on the inside of the cen
ter housing.
8. Use a hydraulic ram to press the drop box free of the
center housing.
9. Put a nylon lifting strap through the hydrostatic motor
bore of the drop box .
87728445 1 2/28/2008
D.15.A / 85
10. Remove the drop box from the center section.
87728445 1 2/28/2008
D.15.A / 86
Housing Drop box Visual inspection

Prior operation:
Housing Drop box Remove (D.15.A)

damage.
Next operation:
Housing Drop box Install (D.15.A)
87728445 1 2/28/2008
D.15.A / 87
Housing Drop box Assemble

IMPORTANT: Replacement bolts must have Scotch Grip or use Loctite 243 blue on all bolts during assembly proce
dures.
to install the bearing cup for the lower gear in the drop
box.
BD02M099 1

the drop box.
BD02M100 2

to install the bearing cup for the input gear in the drop
box.
BD02M101 3
87728445 1 2/28/2008
D.15.A / 88

the sandwich housing.
BD02M103 4

to install the bearing cup for the lower gear in the
sandwich housing.
BD02M102 5
87728445 1 2/28/2008
D.15.A / 89
Housing Drop box Install
BC02J006 1
1. Install 380000848 dowel bolts into the center hous

ing.
2. Put a nylon lifting strap through the hydrostatic motor
bore of the drop box and attach suitable lifting equip
ment to the strap.
3. Start the drop box onto the dowel bolts and push the
drop box within eight inches of the center housing.
IMPORTANT: DO NOT allow all of the weight of the drop
box to be placed on the outer portion of the dowel bolts.
87728445 1 2/28/2008
D.15.A / 90
4. Lower the lifting equipment and remove the nylon

strap from the drop box.
5. Install the eight bolts (59) on the inside of the center
housing.
6. Install four of the seven bolts (55) on the outside of
the drop box securing it to the center housing.
7. Draw the drop box into place by staggering bolt
torque on the mount bolts (55) and (59) until drop
box is flush against the center housing.
BC02J028 2
8. Remove the 380000848 dowel bolts and install the
three remain bolts (55).
9. Using the torque pattern torque the bolts to 195 250
Nm ( 145 185 lb ft).
NOTE: Torque the outside bolts first then the inside bolts.
87728445 1 2/28/2008
D.15.A / 91
Bc02m145_3 3
BC02M147 4
87728445 1 2/28/2008
D.15.A / 92
10. Remove the cap and plug, connect the brake line.
11. Install the four bolts (53) and washers securing
the ROPS frame support bracket (56) or (57)to the
ROPS frame, torque to 280 320 NM ( 206 235 lb
ft).
12. Install the three bolts (58) and washers securing the
front of the drop box to the frame, torque to 1160
1300 Nm ( 855 960 lb. ft.).
Next operation:
Motor Install (C.20.F) Final drive Install (D.15.A).
87728445 1 2/28/2008
D.15.A / 93
Index
TRAVELLING D
Final drive 15.A

Final drive Capacity 4
Final drive Exploded view 5
Final drive External view 8
Final drive Install 22
Final drive Preliminary test 30
Final drive Remove 12
Final drive Sectional view 6
Final drive Special tools 4
Final drive Torque 4
Final drive Visual inspection 18
Gear Planetry gearset Assemble 48
Gear Planetry gearset Disassemble 44
Gear Planetry gearset Install 50
Gear Planetry gearset Remove 42
Gear Planetry gearset Visual inspection 46
Gear Spur gear Install 54
Gear Spur gear Visual inspection 52
Housing Drop box Assemble 88
Housing Drop box Install 90
Housing Drop box Remove 84
Housing Drop box Visual inspection 87
Housing Input bearing housing Assemble 80
Housing Input bearing housing Install 82
Housing Input bearing housing Visual inspection 79
Housing Sandwich housing Assemble 61
Housing Sandwich housing Install 62
Housing Sandwich housing Remove 58
Housing Sandwich housing Visual inspection 60
Housing Wheel hub housing Assemble 72
Housing Wheel hub housing Disassemble 66
Housing Wheel hub housing Install 76
Housing Wheel hub housing Remove 64
Housing Wheel hub housing Visual inspection 70
Wheel hub Assemble 36
Wheel hub Disassemble 34
Wheel hub Exploded view 10
Wheel hub Install 38
Wheel hub Remove 32
87728445 1 2/28/2008
D.15.A / 94
TRAVELLING D
SERVICE BRAKE Hydraulic 30.C
750L
850L
87728445 1 2/28/2008
D.30.C / 1
Contents
TRAVELLING D
TECHNICAL DATA
SERVICE BRAKE Hydraulic
Torque 3
Control valve
Torque 4
FUNCTIONAL DATA
Exploded view 5
SERVICE
Check 6
Remove 8
Install 12
Preliminary test 14
Control valve
Remove 16
Install 17
DIAGNOSTIC
Control valve
Testing Brake release solenoid. 18
Sensing system
Pressure sensor Testing 19
87728445 1 2/28/2008
D.30.C / 2
TRAVELLING SERVICE BRAKE Hydraulic
SERVICE BRAKE Hydraulic Torque

Cover retaining bolts 195 250 Nm
145 185 lb ft
87728445 1 2/28/2008
D.30.C / 3
Control valve Torque

Component Nm Lb
Cartridge valve 27 34 Nm 20 25 lb ft
Coil retaining nut 5 6 Nm 50 55 lb in
87728445 1 2/28/2008
D.30.C / 4
SERVICE BRAKE Hydraulic Exploded view
BC02J078 1
(1) Snap ring (8) Brake piston inner Oring

(2) Park brake shaft (9) Brake piston outer Oring
(3) Separator plates (10) Brake piston
(4) Friction plates (11) Spring washers
(5) Dowel pins (3) (12) Housing cover
(6) Piston plate Oring (13) Bolts 24MM hex head (3)
(7) Piston plate (14) Bolts 18MM hex head
87728445 1 2/28/2008
D.30.C / 5
SERVICE BRAKE Hydraulic Check

Prior operation:
Apply vacuum to the hydraulic system, refer to Reservoir Apply vacuum (A.10.A).
NOTE: Check oil levels in both final drives to determine if hydraulic system oil is present, this can be determined if
the final drive is over full.
FORM Tilt (E.34.A).
2. The brake system can be isolated by plugging the
feed line to the brake solenoid.
1. Feed line
2. Reservoir return line
BD06K05701 1
3. Disconnect the feed line from the brake solenoid,

plug the line and cap the fitting.
6. Do a pressure test in accordance with Charge pump
Pressure test (C.20.F).
NOTE: If the pressure increases do the following to further
isolate the problem.
FORM Tilt (E.34.A).
8. Turn on the vacuum pump.
9. Connect the feed line to the brake solenoid.
10. Disconnect the reservoir return line from the brake
solenoid, plug the line and cap the fitting.
13. Do a pressure test, refer to Charge pump Pressure
test (C.20.F).
14. If the pressure increases replace the brake solenoid,
refer to Control valve Remove (D.30.C) and Con
trol valve Install (D.30.C).
87728445 1 2/28/2008
D.30.C / 6
15. If the pressure still remains low during charge pump

pressure test replace the brake piston Orings, refer
to SERVICE BRAKE Hydraulic Remove (D.30.C)
and SERVICE BRAKE Hydraulic Install (D.30.C).
FORM Tilt (E.34.A).
17. Connect the reservoir return line from the brake so
lenoid.
19. Remove the vacuum pump from the machine.
20. If the pressure did not increase during procedures
Charge pump Pressure setting (C.20.F)and these
procedures, there is an internal problem in the hydro
static pump system. Do the following procedures to
isolate the problem.
NOTE: Leave gauges connected to the test port.
21. While moving the machine forward at low speed,
note the pressure reading, make a slow right turn,
note the pressure reading, make a slow left turn, note
22. While moving the machine in reverse at low speed,
note the pressure reading, make a slow right turn,
note the pressure reading, make a slow left turn, note
23. 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 for
ward pump.
24. If the pressure did not recover during straight reverse
motion check both right and left reverse pumps. If
pressure did not recover during right turn check the
left reverse pump, during left turn check the right re
verse pump.
NOTE: Test procedures for the right pump refer to Pump
Right hand pump Pressure test (C.20.F) and for the
left hand pump Pump Left hand pump Pressure test
(C.20.F).
87728445 1 2/28/2008
D.30.C / 7
SERVICE BRAKE Hydraulic Remove

attachments, apply parking brakes, turn off engine
and remove the key.
NOTE: Place blocks at front and rear of both tracks to pre
vent any movement of crawler.
2. Remove three track shoes in a row and move the
machine until the removed shoe area is beside the
brake cover to be removed.
NOTE: Make sure track shoes bolts being removed are not
in the master link.
3. Tilt ROPS cab/canopy to gain access to brake sole
noid, refer to USER PLATFORM Tilt (E.34.A).
4. Connect a vacuum pump to the reservoir, Reservoir
Apply vacuum (A.10.A). Turn on the pump.
5. Remove and plug the center line from the brake so
lenoid, cap the fitting on the solenoid. Turn off the
pump.
(1) Return line to hydraulic reservoir
(2) Brake solenoid
(3) ROPS tilt cylinder
BD06K05701 1
6. Clean the area around the brake housing to be re

moved.
NOTE: The cover is under spring pressure and must be
loosened evenly to prevent damage.
7. Loosen all five of the retaining bolts 2 turns items
(13 & 14), refer to SERVICE BRAKE Hydraulic
Exploded view (D.30.C).
8. Repeat step 7 until spring pressure is released.
NOTE: Bolts will turn much easier once spring pressure is
released.
9. Remove the retaining bolts (13 & 14) and cover (12),
refer to SERVICE BRAKE Hydraulic Exploded
view (D.30.C).
10. Remove the two spring washers (11), refer to SER
VICE BRAKE Hydraulic Exploded view (D.30.C).
11. Remove the brake piston (10) and piston plate (7)
from the final drive, refer to SERVICE BRAKE Hy
draulic Exploded view (D.30.C).
87728445 1 2/28/2008
D.30.C / 8
12. Remove four separator plates (3) and three friction

plates (4) from the final drive, refer to SERVICE
BRAKE Hydraulic Exploded view (D.30.C).
NOTE: Inspect the park brake shaft for damage, do not
remove unless damaged.
13. If damaged, remove the hydrostat motor, refer to Mo
tor Remove (C.20.F), use a hydraulic ram to press
the park brake shaft out of the input gear.
87728445 1 2/28/2008
D.30.C / 9
SERVICE BRAKE Hydraulic Visual inspection
BC02J078 1

NOTE: Remove and discard all Orings, they will swell when removed and are not reusable.
1. Check separator plates (3) for pitting, scoring and
other damage.
87728445 1 2/28/2008
D.30.C / 10
2. Check friction plates (4) for excessive wear, discol

oration, scoring, flaking of 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.
3. Check each friction plate (4) and separator plate (3)
with a straight edge. If the part is not flat, install a
new set of friction plates and brake separator plates
in that brake.
NOTE: If a friction plate or brake separator plate is dam
aged, install a new set of friction plates and brake separa
tor plates for that brake. DO NOT mix old and new parts in
a brake.
4. Inspect friction plate gear for damaged and missing
teeth.
5. Separate and inspect piston plate and piston for
cracks and scaring. Discard Orings.
6. Check springs for cracks and missing spring fingers.
7. Check friction plate gear internal snap ring for dam
age.
87728445 1 2/28/2008
D.30.C / 11
SERVICE BRAKE Hydraulic Install
BC02J078 1

1. If removed, install a new snap ring (1) into the input

gear. Use a ring expander to expand ring AFTER
installation.
87728445 1 2/28/2008
D.30.C / 12
2. Use a hydraulic ram and press the park brake shaft

(21) into the input gear. The shaft will snap into place
when fully seated.
NOTE: Check the inside bore of the input gear and make
sure the snap ring did not get pushed out during installation.
3. Install the hydrostat motor, refer to Motor Install
(C.20.F).
4. Install four separator plates (3) and three friction
plates (4) starting with separator and alternating with
friction until all are installed.
NOTE: Notches on separator plates go over pins (5) on
input gear housing.
5. Install new Orings (6, 8 & 9) on piston plate (7) and
piston (10).
6. Lube small diameter of piston (10) and install piston
plate (7) with raised lip toward piston.
7. Lube both Orings on the brake pistons. Install pis
tons in the bore small end first over friction/separator
plates. Use a hydraulic ram to press the pistons into
the final drive.
8. Install spring washers (11) with large outer diameters
facing each other on housing cover (12).
9. Using Loctite 515, or equivalent sealer, make a bead
on the inner diameter of the final drive housing.
NOTE: Make a bead on the inside of the bolt holes with no
breaks in the bead.
10. Install the outer cover (12) and five retaining bolts (13
& 14).
NOTE: The three longer bolts (13) go in the top holes and
the two short bolts (14) go in the bottom holes.
11. Tighten the bolts down evenly until springs are com
pressed and cover is flat.
12. Torque to 195 250 Nm (145 185 lb ft).
13. Turn on the vacuum pump. Connect hydraulic line to
brake solenoid.
14. Turn vacuum pump off and disconnect from hydraulic
reservoir. Replace breather in reservoir.
15. Lower ROPS cab/canopy, refer to USER PLAT
87728445 1 2/28/2008
D.30.C / 13
SERVICE BRAKE Hydraulic Preliminary test
WARNING
instructions. SA015
1. Remove the drain plug from the final drive, start the
engine and set the instrument cluster to read engine
r/min (rpm).
2. Release the parking brake levers and place the direc
tional control in the F or R position. Increase engine
r/min (rpm) to 950 for 1 minute.
3. Place the directional control in neutral, apply the
parking brakes and turn off the engine.
4. Check for fluid coming out of the final drive drain, if
no fluid is present install the drain plug and torque to
43 46 Nm (32 34 lb ft).
NOTE: If fluid is leaking out of the final drive drain, the
brake piston plate should be inspected for damage and the
brake Orings must be replaced.
5. Fill the final drive with the authorized lubricant. Rein
stall the fill/check plug and torque to 43 46 Nm (32
34 lb ft).
6. Open the left side ROPS access panel and discon
nect the brake solenoid.
BD02M045_2 1
7. Start the engine and set the instrument cluster to

read engine r/min (rpm), use the bump up button on
the directional control and place the range selector
at 100%.
r/min (rpm) to 1250, there should be no movement of
the machine.
ATTENTION: DO NOT press the foot brake unless the ma
chine moves, if machine moves quickly press the foot brake
and place the directional control in neutral.
IMPORTANT: DO NOT exceed 1250 r/min (rpm).
NOTE: If the machine moves the brakes are misassem
bled.
87728445 1 2/28/2008
D.30.C / 14
10. Connect the brake solenoid, close the left side ROPS
access panel.
87728445 1 2/28/2008
D.30.C / 15
Control valve Remove

Prior operation:
BD06K05701 1
(1) Hydraulic line (3) Tilt cylinder

(2) Brake solenoid
1. Clean the area around the solenoid valve.
2. Disconnect the harness connector.
3. Refer to Reservoir Apply vacuum (A.10.A) and
apply vacuum to the hydraulic system.
4. Tag and disconnect hydraulic lines for proper location
during assembly.
5. Plug or cap all lines and fittings.
6. Remove the valve.
87728445 1 2/28/2008
D.30.C / 16
Control valve Install
BD06K05701 1
(1) Hydraulic line (3) Tilt cylinder

(2) Brake solenoid
1. Mount the solenoid and tighten the mounting bolts.
2. Connect the hydraulic lines.
3. Turn off and disconnect the vacuum pump from the
hydraulic reservoir and install breather.
4. Connect the harness connector.
5. Refer to USER PLATFORM Lower (E.34.A).
87728445 1 2/28/2008
D.30.C / 17
Control valve Testing Brake release solenoid.

NOTE: Hydrostatic charge pressure must be checked to make sure it is at proper pressure, refer to Charge pump
Pressure test (C.20.F). The pressure switch is normally open and closes at 11.4 to 12.8 Bar (165 to 185 psi).
NOTE: For wiring diagram refer to Wiring harness Electrical schematic frame 07 (A.30.A), Wiring harness
Electrical schematic frame 08 (A.30.A), and Wiring harness Electrical schematic frame 11 (A.30.A).
Put the master disconnect switch in 41.8 ohms at 25 °C (77 °F). Bad brake solenoid.
the ON position. Disconnect the har
ness connector for the brake sole
noid.
Check
Check brake solenoid coil resistance
between the connector pins of the
solenoid connector.
Terminal for wire 0 Connector V24 Continuity Bad ground circuit.
to ground.
DO NOT start the engine, place the 12 volts Bad wire between the brake solenoid
ignition switch in the run position, re and the brake relay. Bad brake relay.
lease the parking brake levers, DO If the readings are good, replace the
NOT press the brake pedal, place brake solenoid.
the directional control in the F posi
tion, move hand throttle to ½ throttle
position.
Check
Terminal for wire 215 Connector
V24 to ground.
87728445 1 2/28/2008
D.30.C / 18
Sensing system Pressure sensor Testing

NOTE: Hydrostatic charge pressure must be checked to make sure it is at proper pressure, refer to Charge pump
Pressure test (C.20.F). The pressure switch is normally open and closes at 11.4 to 12.8 Bar (165 to 185 psi).
Put the master disconnect switch 2 volts. Check fuse F2 connector M3.
and ignition switch in the ON posi
tion. Disconnect the harness con
nector for the brake pressure switch.
Check
Terminal for wire BL (V1ACC) to
ground.
Between the connector pins of the Open Bad pressure switch.
pressure switch connector.
Start the engine, DO NOT place the Continuity Bad pressure switch.
directional control in the F or R posi
tion, move hand throttle to ½ throttle
position.
Check
Between the connector pins of the
pressure switch connector.
87728445 1 2/28/2008
D.30.C / 19
Index
TRAVELLING D

Control valve Install 17
Control valve Remove 16
Control valve Testing Brake release solenoid. 18
Control valve Torque 4
Sensing system Pressure sensor Testing 19
SERVICE BRAKE Hydraulic Check 6
SERVICE BRAKE Hydraulic Exploded view 5
SERVICE BRAKE Hydraulic Install 12
SERVICE BRAKE Hydraulic Preliminary test 14
SERVICE BRAKE Hydraulic Remove 8
SERVICE BRAKE Hydraulic Torque 3
SERVICE BRAKE Hydraulic Visual inspection 10
87728445 1 2/28/2008
D.30.C / 20
TRAVELLING D
PARKING BRAKE Hydraulic 32.C
750L
850L
87728445 1 2/28/2008
D.32.C / 1
Contents
TRAVELLING D
FUNCTIONAL DATA
Command
Exploded view 3
SERVICE
PARKING BRAKE Hydraulic
Preliminary test 4
Command
Travel adjust 6
Sensing system
Clearance 7
DIAGNOSTIC
Sensing system
Proximity switch Testing 8
87728445 1 2/28/2008
D.32.C / 2
TRAVELLING PARKING BRAKE Hydraulic
Command Exploded view
BC02J012 1
(1) Brake lever (4) Adjustment bolt

(2) Spring (5) Stop plate
(3) Pivot mounting bolt (6) Proximity switch bracket (2)
87728445 1 2/28/2008
D.32.C / 3
PARKING BRAKE Hydraulic Preliminary test
WARNING
instructions. SA015
1. Remove the drain plug from the final drive, start the
engine and set the instrument cluster to read engine
r/min (rpm).
r/min (rpm) to 950 for 1 minute.
4. Check for fluid coming out of the final drive drain, if
no fluid is present install the drain plug and torque to
43 46 Nm (32 34 lb ft).
NOTE: If fluid is leaking out of the final drive drain, plug
the brake piston should be inspected for damage and the
brake Orings must be replaced.
5. Fill the final drive with the authorized lubricant. Rein
stall the fill/check plug and torque to 43 46 Nm (32
34 lb ft).
6. Open the left side ROPS access panel and discon
nect the brake solenoid.
BD02M045_2 1
7. Start the engine and set the instrument cluster to

read engine r/min (rpm), use the bump up button on
the directional control and place the range selector
at 100%.
r/min (rpm) to 1250, there should be no movement of
the machine.
ATTENTION: DO NOT press the foot brake unless the ma
chine moves, if machine moves quickly press the foot brake
and place the directional control in neutral.
IMPORTANT: DO NOT exceed 1250 r/min (rpm).
NOTE: If the machine moves the brakes are misassem
bled.
87728445 1 2/28/2008
D.32.C / 4
10. Connect the brake solenoid, close the left side ROPS
access panel.
87728445 1 2/28/2008
D.32.C / 5
Command Travel adjust
BC02J012 1
(1) Brake lever (4) Adjustment bolt

(2) Spring (5) Stop plate
(3) Pivot mounting bolt (6) Proximity switch bracket (2)
NOTE: For items in parentheses, refer to Command Exploded view (D.32.C).

1. Make sure that the parking brake lever over center
springs are in place.
2. Loosen the bolt (4) and adjust the stop plate (5) so
the lever (1) does not hit the console.
87728445 1 2/28/2008
D.32.C / 6
Sensing system Clearance

1. Adjust the clearance to 1 3 mm (0.040 0.118 in).
BD02H047 1
87728445 1 2/28/2008
D.32.C / 7
Sensing system Proximity switch Testing

Apply parking brake levers, discon Continuity Switch out of adjustment, adjust
nect proximity switches. proximity switch, refer to Sensing
Check system Clearance (D.32.C), bad
Between the cavities of switch proximity switch.
87728445 1 2/28/2008
D.32.C / 8
Index
TRAVELLING D

Command Exploded view 3
Command Travel adjust 6
PARKING BRAKE Hydraulic Preliminary test 4
Sensing system Clearance 7
Sensing system Proximity switch Testing 8
87728445 1 2/28/2008
D.32.C / 9
87728445 1 2/28/2008
D.32.C / 10
TRAVELLING D
WHEELS AND TRACKS Tracks 50.B
750L
850L
87728445 1 2/28/2008
D.50.B / 1
Contents
TRAVELLING D
TECHNICAL DATA
WHEELS AND TRACKS Tracks
Special tools 4
Steel track
Torque 5
Special tools 5
Chain General specification 6
Chain Dimension 7
Pad Dimension 13
Roller
Special tools 15
Lower roller Torque 16
Lower roller Capacity 16
Lower roller Dimension 16
Upper roller Dimension 17
Idler wheel
Capacity 19
FUNCTIONAL DATA
Steel track
Exploded view 20
Track tensioning mechanism
Adjusterrecoil mechanism Exploded view 21
Roller
Lower roller Exploded view 22
Idler wheel
Exploded view 23
Frame
Exploded view 24
SERVICE
Drive sprocket
Remove 25
Install 26
Steel track
Remove 28
Check 30
Install 34
87728445 1 2/28/2008
D.50.B / 2
Tension adjust 36
Pad Visual inspection 38
Chain Visual inspection 39
Chain Disassemble For reference only 45
Chain Assemble For reference only 47
Track tensioning mechanism
Adjusterrecoil mechanism Remove 52
Adjusterrecoil mechanism Disassemble 54
Adjusterrecoil mechanism Visual inspection 56
Adjusterrecoil mechanism Assemble 58
Adjusterrecoil mechanism Install 60
Roller
Lower roller Remove 61
Lower roller Disassemble 62
Lower roller Visual inspection 68
Lower roller Assemble 70
Lower roller Leakage test 80
Lower roller Filling 83
Lower roller Install 84
Upper roller Visual inspection 85
Idler wheel
Remove 86
Disassemble 87
Assemble 94
Leakage test 97
Install 98
87728445 1 2/28/2008
D.50.B / 3
TRAVELLING WHEELS AND TRACKS Tracks
WHEELS AND TRACKS Tracks Special tools
B40070912 1
CAS1950A Measuring Tool Kit
87728445 1 2/28/2008
D.50.B / 4
Steel track Torque

Component Nm lbft
Master link bolts 430 470 Nm (318 346 lb ft)
Standard link shoe bolts 406 447 Nm (300 330 lb ft)
Steel track Special tools
B866034U 1
The lubricator uses a vacuum function to make sure that the seals are seated, and a pressure system to fill the
reservoir in the tack pins. The part number of the lubricator is CAS10762.
B614342M 2
The nozzle shown MUST be used when lubricating track pins. The use of any other nozzle will damage the seal in
the rubber plug. The part number of the nozzle is CAS107621.
B614336M 3
The brush must be used to clean the bore of all pins that are to be used for a wet turn. the part number of the brush
is CAS1853.
87728445 1 2/28/2008
D.50.B / 5
B616311M 4
The tools show are used to install the plug in each track pin. The part number is CAS1851.
B614340M 5
The wood drill shown is used to remove the plug from the track pins. The drill is 12.5 mm (1/2 inch) in diameter.
Purchase the wood drill at a local store.
Steel track Chain General specification
B860492J 1
Driver housing offset 33.3 mm (1.31 inch).
B860491J 2
Bushing projection 1.7 mm (0.067 in).
87728445 1 2/28/2008
D.50.B / 6
Maximum pressure OTC 180 Metric ton (200 US ton) 40 825 kPa (5921 psi)
only
Lubricant CASE AKCELA 135H EP GEAR LUBE SAE 85W140
Track deflection 38 50 mm (1.5 2 in)
Steel track Chain Dimension
BS97N004 1
Non lubricated track
170.9mm (6.73 in) pitch
Length measurement Percent worn
mm inches
685.00 26.97 0
685.54 26.99 5
686.05 27.01 10
686.56 27.03 15
687.07 27.05 20
687.58 27.07 25
688.09 27.09 30
688.59 27.11 35
689.10 27.13 40
689.61 27.15 45
690.12 27.17 50
690.63 27.19 54
691.13 27.21 58
691.64 27.23 62
692.15 27.25 66
692.66 27.27 70
693.17 27.29 73
693.67 27.31 76
694.18 27.33 79
694.69 27.35 82
695.20 27.37 85
695.71 27.39 88
696.21 27.41 91
696.72 27.43 94
697.23 27.45 97
697.44 27.47 100
698.25 27.49 103
698.75 27.51 106
699.26 27.53 109
699.77 27.55 112
700.28 27.57 115
700.79 27.59 118
701.29 27.61 121
701.80 27.63 124
It is recommended the pins and bushings be replaced if the wear measurement is 103% or greater. Turn pins
and bushings before this point.
87728445 1 2/28/2008
D.50.B / 7
BS97N001 2
Nonlubricated track
170.9 mm (6.73 inch) pitch
Caliper measurement Percent worn
mm inches High impact * Low impact *
56.90 2.24 0 0
56.64 2.23 9 7
56.39 2.22 19 16
56.13 2.21 29 24
55.88 2.20 38 32
55.63 2.19 48 40
55.37 2.18 57 48
55.12 2.17 66 56
54.86 2.16 76 64
54.61 2.15 81 72
54.36 2.14 86 77
54.10 2.13 91 82
53.85 2.12 95 87
53.59 2.11 100 90
53.34 2.10 102 92
53.09 2.09 104 94
52.83 2.08 106 95
52.58 2.07 108 97
52.32 2.06 110 99
52.07 2.05 112 100
51.82 2.04 114 102
51.56 2.03 116 103
51.31 2.02 118 105
51.05 2.01 120 106
50.80 2.00 122 108
* A Low Impact condition is when the grousers on the track shoe
completely engage the ground and the ground is free of bumps.
* A High Impact condition is when the grousers on the track shoe do not completely engage the ground and there is
constant contact with rocks or large irregularities.
87728445 1 2/28/2008
D.50.B / 8
BS97N002 3
Nonlubricated track
Depth gauge measurement Percent worn
71.45 2.81 0 0
71.12 2.80 9 7
70.87 2.79 19 16
70.61 2.78 29 24
70.36 2.77 38 32
70.10 2.76 48 40
69.85 2.75 57 48
69.60 2.74 66 56
69.34 2.73 76 64
69.09 2.72 81 72
68.83 2.71 86 77
68.58 2.70 91 82
68.33 2.69 95 87
687.07 2.68 100 90
67.82 2.67 102 92
67.56 2.66 104 94
67.31 2.65 106 95
67.06 2.64 108 97
66.80 2.63 110 99
66.55 2.62 112 100
66.29 2.61 114 102
66.04 2.60 116 103
65.79 2.59 118 105
65.53 2.58 120 106
65.28 2.57 122 108
87728445 1 2/28/2008
D.50.B / 9
BS97N001 4
Lubricated track
mm inches high impact * Low impact *
56.90 2.24 0 0
56.64 2.22 5 4
56.39 2.22 10 8
56.13 2.21 15 12
55.88 2.20 20 15
55.63 2.19 25 19
55.37 2.18 30 23
55.12 2.17 35 27
54.86 2.16 40 31
54.61 2.15 45 35
54.36 2.14 50 39
54.10 2.13 55 42
53.85 2.12 60 46
53.59 2.11 65 50
53.34 2.10 70 54
53.09 2.09 73 58
52.83 2.08 76 62
52.58 2.07 79 65
52.32 2.06 82 68
52.07 2.05 85 70
51.82 2.04 88 73
51.56 2.03 90 75
51.31 2.02 92 77
51.05 2.01 94 80
50.80 2.00 96 82
50.55 1.99 98 84
50.29 1.98 100 85
50.04 1.97 102 86
49.78 1.96 104 88
49.53 1.95 106 90
49.28 1.94 107 91
49.02 1.93 108 93
48.77 1.92 110 94
48.51 1.91 112 96
48.26 1.90 113 97
48.01 1.89 115 98
47.75 1.88 117 100
87728445 1 2/28/2008
D.50.B / 10
BS97N001 4
Lubricated track
mm inches high impact * Low impact *
BS97N002 5
Lubricated track
71.45 2.81 0 0
71.12 2.80 5 4
70.87 2.79 10 8
70.61 2.78 15 12
70.36 2.77 20 15
70.10 2.76 25 19
69.85 2.75 30 23
69.60 2.74 35 27
69.34 2.73 40 31
69.09 2.72 45 35
68.83 2.71 50 39
68.58 2.70 55 42
68.33 2.69 60 46
68.07 2.68 65 50
67.82 2.67 70 54
67.56 2.66 73 58
67.31 2.65 76 62
87728445 1 2/28/2008
D.50.B / 11
BS97N002 5
Lubricated track
67.06 2.64 79 65
66.80 2.63 82 68
66.55 2.62 85 70
66.29 2.61 88 73
66.04 2.60 90 75
65.79 2.59 92 77
65.53 2.58 94 80
65.28 2.57 96 82
65.02 2.56 98 84
64.77 2.55 100 85
64.52 2.54 102 86
64.26 2.53 104 88
64.01 2.52 106 90
63.75 2.51 107 91
63.50 2.50 108 93
63.25 2.49 110 94
62.99 2.48 112 96
62.74 2.47 113 97
62.48 2.46 115 98
62.23 2.45 117 100
87728445 1 2/28/2008
D.50.B / 12
BS97N003 6
Track link wear
mm inches
96.00 3.78 0
95.50 3.76 7
95.00 3.74 14
94.49 3.72 20
93.98 3.70 26
93.47 3.68 32
92.96 3.66 38
92.46 3.64 44
91.95 3/62 50
91.44 3.60 56
90.93 3.58 62
90.42 3.56 67
89.92 3.54 72
89.41 3.52 77
88.90 3.50 82
88.39 3.48 87
87,88 3.46 92
87.38 3.44 96
86.87 3.42 100
Steel track Pad Dimension
BS97N008 1
Single bar track shoe wear
mm inches
52.32 2.06 0
87728445 1 2/28/2008
D.50.B / 13
BS97N008 1
Single bar track shoe wear
mm inches
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
43.69 1.72 32
42.67 1.68 36
41.66 1.64 40
40.39 1.59 44
39.37 1.55 48
38.55 1.51 52
37.34 1.47 56
36.07 1.42 60
35.05 1.38 64
34.04 1.34 68
33.02 1.30 72
31.75 1.25 76
30.73 1.21 80
29.72 1.17 84
28.70 1.13 88
27.43 1.08 92
26.42 1.04 96
25.40 1.00 100
87728445 1 2/28/2008
D.50.B / 14
Roller Special tools
B914826 1
CAS1313 ROLLER BUSHING TOOL
B914828M 2
CAS1283 SEAL INSTALLATION TOOL
B407315 3
CAS1450 GAUGE AND VALVE KIT
87728445 1 2/28/2008
D.50.B / 15
B407317 4
CAS1682 ADAPTER KIT
Roller Lower roller Torque

Mounting to bolts to frame 386 434 Nm 285 320 lb ft
Roller Lower roller Capacity

Type of lubricant CASE AKCELA 135H EP GEAR LUBE SAE 85W140
Capacity 250 mL 8.4 U.S. fluid ounces
Roller Lower roller Dimension
BS97N005 1
Track roller wear
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
183.90 7.24 44
183.13 7.21 49
182.37 7.18 54
87728445 1 2/28/2008
D.50.B / 16
BS97N005 1
Track roller wear
mm inches
181.61 7.15 59
180.85 7.12 63
180.09 7.09 67
179.32 7.06 71
178.56 7.03 75
177.80 7.00 79
177.04 6.97 83
176.28 6.94 87
175.51 6.91 91
174.75 6.88 94
173.99 6.85 97
173.23 6.82 100
Roller Upper roller Dimension
BS97N006 1
Carrier roller wear
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
87728445 1 2/28/2008
D.50.B / 17
BS97N006 1
Carrier roller wear
mm inches
135.89 5.35 43
135.38 5.33 47
134.87 5.31 51
134.37 5.29 55
133.86 5.27 59
133.35 5.25 63
132.84 5.23 67
132.33 5.21 71
131.83 5.19 75
131.32 5.17 79
130.81 5.15 82
130.30 5.13 85
129.79 5.11 88
129.29 5.09 91
128.78 5.07 94
128.27 5.05 96
127.76 5.03 98
127.25 5.01 100
87728445 1 2/28/2008
D.50.B / 18
Idler wheel Capacity

Idler lubricant CASE AKCELA 135H EP GEAR LUBE SAE 85W140
Capacity 750L and 850L 490 Ml 16.5 U.S. fluid ounces
87728445 1 2/28/2008
D.50.B / 19
Steel track Exploded view
BS00C031 1
LUBRICATED TRACK
(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
87728445 1 2/28/2008
D.50.B / 20
Track tensioning mechanism Adjusterrecoil mechanism Exploded

view
BS02H052 1
(1) YOKE (5) SEAL (9) WEAR RING

(2) CHECK VALVE (6) BUSHING (10) PACKING RING
(3) GREASE FITTING (7) BACKUP RING (11) SPACER
(4) SNAP RING (8) PISTON
87728445 1 2/28/2008
D.50.B / 21
Roller Lower roller Exploded view
B900333 1
(1) TRACK ROLLER (4) RUBBER RING (7) PLUG

(2) END CAP (5) METAL RING (8) ORING
(3) ROLL PIN (6) BUSHING (9) SHAFT
87728445 1 2/28/2008
D.50.B / 22
Idler wheel Exploded view
B9402090A 1
(1) IDLER WHEEL (5) SHAFT (9) RUBBER RING

(2) PLUG (6) ORING (10) IDLER BRACKET
(3) SMALL ROLL PIN (7) BUSHING
(4) LARGE ROLL PIN (8) METAL RING
87728445 1 2/28/2008
D.50.B / 23
Frame Exploded view
BC02H054 1
(1) COVER ASSEMBLY IDLER (5) COVER ASSEMBLY OUTER (9) TRACK ADJUSTER
(2) INSIDE IDLER COVER (6) BRACKET (10) SHIM
(3) COVER ASSEMBLY INNER (7) RECOIL HOUSING ASSEMBLY (11) BAR
(4) OUTSIDE IDLER COVER (8) BRACKET COVER (12) TRACK FRAME
87728445 1 2/28/2008
D.50.B / 24
Drive sprocket Remove

Prior operation:
Refer to Steel track Remove (D.50.B) and separate the track. It is not necessary to completely remove the track.
1. Remove the track from the sprocket.

2. Remove the bolts that hold the outer cover at the rear
of the track frame.
3. Remove the outer cover.
4. Remove the bolts that hold the inner cover at the rear
of the track frame.
5. Remove the inner cover.
6. Raise the rear of the machine until the sprocket is
free of the track links.
7. Put an acceptable support under the rear of the ma
chine to hold the machine in place.
8. Loosen and remove the nuts from the bolts holding
the sprocket.
9. Remove the bolts and washers.
NOTE: Sprocket weight is in excess of 45 kg (100 lb). Get
help when removing the sprocket to prevent hurting your
self.
10. Remove the sprocket.
87728445 1 2/28/2008
D.50.B / 25
Drive sprocket Install
BC02HO53 1
(1) NUT (4) SPROCKET (STANDARD AND RELIEVED)

(2) BOLT (5) SPROCKET (LGP)
(3) WASHER (6) SHIM
1. Put the same amount of shims removed on the fi

nal drive. Use a small amount of grease to hold the
shims in place and keep the shims aligned.
2. Install the sprocket.
3. Align the holes in the sprocket, shims, and final drive.
4. Install the washers and bolts.
5. Use Loctite No. 242 and install the nuts on the bolt.
6. Hold the nuts and tighten bolts 1, 2, 3 and 4 for stan
dard or relieved sprockets to a torque of 135 Nm (100
lb ft).
BD02H012 2
87728445 1 2/28/2008
D.50.B / 26
7. Check to see that the sprocket is centered on the rear

track roller within 3 mm (1/8 in).
8. If the sprocket is centered as specified, continue to
tighten the bolts in the sequence shown, beginning
with bolt 5.
9. If the sprocket is not centered as specified, remove
the sprocket and add or remove shims as required.
10. Hold the nuts and tighten the bolts for standard or
relieved sprockets to a torque of 135 Nm (100 lb ft)
in the sequence shown.
11. Make an alignment mark on each bolt and the
sprocket.
12. Hold the nuts and tighten each of the bolts 1/4 turn
in the sequence shown.
13. Install the inner cover at the rear of the track frame.
14. Install the bolts and washers that hold the inner cover
in place. Tighten the bolts.
15. Install the outer cover at the rear of the track frame.
16. Install the bolts and washers that hold the outer cover
in place. Tighten the bolts.
Next operation:
Steel track Install (D.50.B) Steel track Tension adjust (D.50.B).
87728445 1 2/28/2008
D.50.B / 27
Steel track Remove

1. Park the machine on a level surface and stop the
machine so that the master link is centered on the
rear of the sprocket.
1. Master link.
bd02h011 1
2. Loosen the valve in the track adjuster two turns only,

so that the track can be loosened.
bd02h016 2
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.
4. Put blocks under the track at the rear of the machine
to hold the bottom part of the track and prevent injury
when the master link is separated.
B614434M 3
87728445 1 2/28/2008
D.50.B / 28
5. Loosen all bolts that hold the track shoe and remove
three bolts. Hold the track shoe and remove the last
bolt and remove the track shoe.
B614444M 4
6. Use a pry bar to completely separate the halves of

the master link.
B94040108 5
7. Fasten acceptable lifting equipment to the bottom

part of the track.
8. Remove the blocks and lower the track to the floor.
9. 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.
10. Use acceptable lifting equipment to raise the ma
chine until the track rollers are free of the track.
11. Use acceptable supports to hold the machine in
place.
12. Remove the track from under the machine.
87728445 1 2/28/2008
D.50.B / 29
Steel track Check

NOTE: Three types of track systems.
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) Belleville springs
(2) Spacer
(3) Master bushing
(4) Bushing
BS96A027 1
2. Lubricated track which is assembled with oil. Seals

are installed at each end of the bushings to keep the
lubricant in the bushing.
(1) Plug
(2) Pin
(3) Bushing
(4) Lubricant
B900615 2
3. To measure internal bushing and pin wear, measure

the track pitch in three places. When measuring the
track pitch, the measurement must be taken at least
four track links away from the master link and master
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. B900593 3
87728445 1 2/28/2008
D.50.B / 30
4. Use the small caliper from the CAS1950A kit and

measure the wear on the front and rear of a bush
ing as shown. Make several measurements across
the worn area to find the most wear. Make sure that
the bushing is clean and that the caliper is 90 de
grees to the bushing. Record the measurements on
the Track Component Appraisal Form. Measure two
more bushings at 0.9 to 1.2 M (3 to 4 feet) intervals.
(1) Forward or reverse wear
(2) Vertical wear
B900594XX 4
5. Use the depth gauge to measure the vertical wear of

a bushing as shown. Make several measurements
across the worn area to find the most wear. Make
sure that the bushing and track shoe are clean and
that the depth gauge is perpendicular to the track
shoe. Measure two more bushings at 0.9 to 1.2 M
(3 to 4 feet) intervals
B900595 5
6. To measure the height of the track links (wear of rail),

assemble the rulers in the CAS1950A 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.
B900596 6
87728445 1 2/28/2008
D.50.B / 31
7. Shown below is uneven wear on the rail. Wear over

the pins will occur faster because of the narrow width
of the rail and contact with the rollers. This wear
can also be caused by working on an uneven sur
face (rocks) which can cause the track rail to hit the
roller(s). The wear in the center of the rail is caused
by contact with the idler and carrier and track rollers.
B900597 7
8. Shown below is wear on the side of the rail. This

wear occurs because of contact with the flanges on
the rollers and the idler. This wear will occur faster
during side hill operation, turning, and with increased
track pitch which makes the track flexible.
B900598 8
9. Shown below is wear on the top of the boss for the

pin. This wear is caused by the flanges on the track
links and the decreased diameter of the track rollers.
This is the result of bad maintenance and track sys
tem management.
B900599 9
10. Shown below is wear on the inside of the track

link. This wear is caused by contact with the tips of
the sprocket teeth. This wear occurs because the
sprocket is not aligned with the track and rear track
roller, increased track pitch which makes the track
flexible, side hill operation and wide track shoes.
B900600 10
87728445 1 2/28/2008
D.50.B / 32
11. Shown below is a cracked track link. The most prob

able 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 11
87728445 1 2/28/2008
D.50.B / 33
Steel track Install

1. Put the track under the track rollers so that the track
shoes are in the position shown.
BC04C002 1
2. 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.
3. Carefully lower the machine onto the track, making
sure that the teeth on the sprocket engage the track
links.
4. Use the lifting equipment to carry the track over the
idler and the carrier roller and onto the sprocket.
5. Use the lifting equipment to raise the bottom part of
the track and use the blocks to hold the track in place
as during removal
6. Use a pry bar to put the top link in position on the
bottom link.
B94040108 2
7. Put the track shoe in position on the master link. In

stall the top bolts to hold the track shoe in place.
B94040106 3
87728445 1 2/28/2008
D.50.B / 34
8. Start the bottom bolts into the master link. Tighten

the top bolts to pull the halves of the master link to
gether.
B94040110 4
9. Tighten the bolts as shown in illustration to 430 470

Nm (318 346 lb ft). Do not over tighten the bolts.
BC04C003 5
Next operation:
Steel track Tension adjust (D.50.B).
87728445 1 2/28/2008
D.50.B / 35
Steel track Tension adjust

NOTE: Tracks the are too tight will cause increased track and sprocket wear, increased fuel consumption and de
creased power.
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.
bd02h010 1
3. Put a straightedge over the track and measure the

track deflection. The measurement must be 38 51
mm (1.5 2 in)..
bd02h013 2
4. To tighten the track add grease to the track adjuster

to decrease the deflection of the track.
bd02h015 3
87728445 1 2/28/2008
D.50.B / 36
5. To loosen the track, loosen the valve in the track ad

juster two turns only with a socket to allow grease to
flow from the track adjuster.
bd02h016 4
6. When the deflection is correct, tighten the valve to 61

74 Nm (45 55 lb ft)..
87728445 1 2/28/2008
D.50.B / 37
Steel track Pad Visual inspection

The only wear that can be measured is the wear of the grouser on the track shoe.
1. Shown are worn or broken corners on the ends of the

grouser. This is caused by working on rough terrain.
B900612 1
2. Shown is a cracked grouser and a broken corner on

the track shoe. This is caused by using track shoes
that are too wide for use on rough terrain.
B900613 2
3. Shown are worn bolt holes in a track shoe. This is

caused by loose bolts. Make sure that the bolts are
tightened to the specified torque.
B900614 3
87728445 1 2/28/2008
D.50.B / 38
Steel track Chain Visual inspection

Preparing to turn the bushings.
General information.
1. A wet turn can be made when pins, bushings and

seal are in condition to be used again to make a
sealed and lubricated joint.
2. A dry turn can be made when pins, bushings and
seals are in condition to be used again but not good
enough to make a sealed joint. Lubricant is not
added after assembly.
3. Check to see how many joints do not show leakage.
A joint that shows leakage can be assembled only as
a dry turn if new parts are not used.
4. Loosen and remove the bolts, nuts and track shoes.
5. 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.
B614306M 1
6. Clean the track chain using high pressure water or

steam. If a wet turn is to be made, the track chain
must be clean.
7. With the track shoe surface down, make a mark on
a top of each bushing. This will help you to turn the
bushings the correct amount when the track chain is
assembled.
8. With the track shoe surface up, make mark at one
end of each pin at the top. This will help you install
the pins correctly when the track is assembled.
NOTE: 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, bush
ings 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.
87728445 1 2/28/2008
D.50.B / 39
9. The pin shown has a large area of metal removed

from the surface of the pin. A pin like this MUST NOT
be used again.
B860749J 2
10. The pin shown has grooves in the circumference of

the pin. A pin like this can be used for a wet or dry
turn.
B865379M 3
11. 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.
B865386M 4
12. The pin shown has a wear ridge. This pin can only
be used for a dry turn. When installing a pin like this,
turn the pin end for end. The supply hole must be
toward the link rail when the pin is installed.
B860750J 5
87728445 1 2/28/2008
D.50.B / 40
13. The pin shown has a closed supply hole. The pin can
be used for a wet or dry turn. If used for a wet turn,
the supply hole and reservoir must be clean. Use a
wire brush and an electric drill to clean the reservoir.
B865384M 6
14. The pins show rust, pitting and discoloration. Each

pin can be used for a wet or dry turn.
B865383M 7
15. Pins with rust must have the rust removed.
B865382M 8
16. The bushing shown has a crack in the OD. A 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.
B865388M_2 9
87728445 1 2/28/2008
D.50.B / 41
17. The bushing shown has a seal wear pattern that is

not centered on the end of the bushing. This busing
CANNOT be used for a wet turn. The bushing can
be used for a dry turn.
B604126M 10
18. The bushing shown has pitting in the area between

the seal and the spacer. If the pitting is not deep, the
bushing can be used for a wet turn.
B865389M 11
19. The bushing shown has a fine crack in the area be
tween the seal and the spacer. This bushing can be
used for a wet or dry turn. A bushing with two or more
fine cracks or one large and rough crack can only be
used for a dry turn.
B865388M 12
20. 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 bush
ing can only be used for a dry turn.
B865390M 13
87728445 1 2/28/2008
D.50.B / 42
21. A bushing that has deep pitting or scratches in the

area between the spacer and seal can only be used
for a dry turn.
22. A bushing that has pitting in the bore, if the pitting is
not deep, the bushing can be used for a wet turn. If
the pitting is deep, the bushing can only be used for
a dry turn.
23. The bushing shown has rust in the bore. This bush
ing can only be used for a dry turn. Use a wire brush
and electric drill and remove the rust.
B865375M 14
24. 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.
B865376M 15
25. A spacer must have a lubrication notch on each end

to be acceptable for use in a wet turn. A spacer
with one lubrication notch can be used for a dry turn.
A spacer without lubrication notches must be dis
carded.
26. The spacer shown has pitting and grooves. Because
the spacer has both lubrication notches, the spacer
can be used for a wet turn. The spacer is acceptable
for a dry turn.
B865387M 16
87728445 1 2/28/2008
D.50.B / 43
27. The link shows wear in the area of the spacer. This
wear is acceptable. If the link is to be used for a wet
turn, use a wire brush and an electric drill and remove
the rust and dirt from the bore for the seal.
B865378M 17
28. A seal removed from a wet joint can be used again

for a wet turn.
29. A seal removed from a dry joint can only be used for
a dry turn.
87728445 1 2/28/2008
D.50.B / 44
Steel track Chain Disassemble For reference only

1. Install the carrier and driver needed to disassemble
the track chain.
B604112M 1
2. Put the track chain on the table so that the track shoe
surface is up and pin half of the master link will be the
first link disassembled.
IMPORTANT: Before pressing a bushing and pin out of the
link, make sure that the drivers are aligned with the pin and
bushing to prevent damage to the bores in the link.
3. Put the bushing in the first notch in the carrier and
actuate one of the rams to press that pin out of a link.
B604116M 2
4. Retract the ram and remove the link from the driver.
5. Actuate the other ram and press the pin out of the
other link.
B604120M 3
6. Retract the ram and remove the link from the driver
and the pin from the bushing.
7. Move the track chain forward one bushing.
8. Actuate one of the rams to press the pin and bushing
out of a link.
87728445 1 2/28/2008
D.50.B / 45
9. Retract the ram and remove the link from the driver.
10. Actuate the other ram to press the pin and bushing
out of the other link.
11. Retract the ram and remove the link from the driver
and the pin from the bushing.
B604124M 4
12. Repeat steps 7 through 11 until the track chain is

disassembled.
13. Remove the spacers from the pins and seals.
14. Remove the seals and rubber rings from the links.
16. Use a wire brush and clean the seal bore in each link.
17. Use a wire brush and clean the reservoir in each pin.
87728445 1 2/28/2008
D.50.B / 46
Steel track Chain Assemble For reference only

1. Remove the drivers used for disassembly and install
the drivers used to assemble the track chain. The
same carrier is used.
2. Use a straightedge and measure the offset of the
drivers. The offset of the drivers must be 34.85 mm
(1.372 inches). Add or remove shims between the
long driver and base as required.
3. Adjust the relief valve for the track press to 40 825
kPa (5921 psi).
4. If a wet turn is being made, install a new plug in each
pin. Make sure that the bore in the pin is clean and
free of any lubricant. Lubricate the bore in the pin
with water and soap.
5. Put the guide (CAS18511 or CAS18512) on the end
of the pin and lubricate the bore of the guide. Use the
driver CAS1851 and drive the plug into the pin. The
plug must be approximately 10 mm (0.39 inch) below
the end of the pin.
B616316M 1
6. Make sure that there is a good chamfer on both ends

of all the pins so that metal will not be removed from
the bores in the links when the links are pressed onto
the pins.
7. The first link assembly to be assembled is the bush
ing half of the master link.
8. Install a bushing in the far notch. If the bushings are
being turned, put the bushing in the carrier so that
the mark made before disassembly is on top.
9. Install a link half on one of the drivers and actuate
the ram to hold the link half against the carrier.
10. Install the other link half on the other driver and actu
ate the other ram until the link half touches the bush
ing. Check to make sure that the parts are even with
each other.
87728445 1 2/28/2008
D.50.B / 47
11. Actuate the ram to press the bushings into both link
halves.
B604140M 2
12. Measure the bushing projection at both ends of the

bushing. If the measurement is not 1.7 mm (0.067
inch) add or remove shims between the long driver
and base as required.
13. Use the gauge and pin to check the spacing of the
link halves.
B604142M 3
14. Check to make sure the link halves are level.
B604202M 4
15. Install a pin in the bushing so that the mark is on top.

The remainder of the pins must be installed so that
the plugs are all on the same side. Apply Molykote
Type G to both ends of two spacers according to the
instructions on the container. Then install spacers on
both ends of the pin.
87728445 1 2/28/2008
D.50.B / 48
16. 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.
B604206M 5
17. Make sure that the bores for the rubber ring and seal
are free of oil and install a rubber ring and seal in both
links.
18. Put the links on the drivers and a bushing in the car
rier so that the mark is on top.
B604208M 6
19. Hold the master link level and actuate the rams until
the drivers touch the links.
20. Press the links onto the pin and bushing.
B604212M 7
87728445 1 2/28/2008
D.50.B / 49
21. Use the gauge and pin to check the spacing between
the links.
B604215M 8
22. Measure the bushing projection at each end of the

bushing. The bushing projection must be 1.7 mm
(0.067 inch).
23. If the bushing projection is not as specified, add or
remove shims as required for the long driver.
24. Repeat steps 15 through 18 and step 20 and install
the second set of links.
25. Check the end play of the outside links at the pin joint.
26. Use a dial indicator against one of the outside links
or the end of the pin.
27. Set the dial indicator to 0 (zero).
28. Use a screwdriver between the inside the outside link
to move the outside link and read the dial indicator.
29. Check the end play several times to make sure that
the reading is correct.
30. The end play must not be more than 0.13 mm (0.005
inch). Zero end play is the best, but not required.
31. If the end play is not as specified, add shims as re
quired for the short driver.
32. Repeat steps 15 through 18 and step 20 until the
track chain is assembled.
33. As soon as possible, begin to fill the pins with gear
lubricant.
34. Make sure that the nozzle CAS107621 is installed
on the tube on the control handle.
35. Prepare the lubrication equipment according to the
instructions of the manufacturer.
36. Push the nozzle all the way into the plug.
37. Push down and hold the vacuum button until the
gauge reads 68 to 91 kPa (20 to 27 inches) vacuum.
38. Release the vacuum button. The reading must not
decrease for a minimum or 5 seconds.
39. 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.
87728445 1 2/28/2008
D.50.B / 50
40. Before disassembling the links, use a pry bar and

move the link in both directions to seat the seal(s).
Do the vacuum check again. If the joint still does not
hold the vacuum, the links must be removed and the
cause found.
41. Push down and hold the oil button until gauge reads
551 to 586 kPa (80 to 85 psi) then release the oil
button.
42. After the oil button is released, the reading of the
pressure gauge must be 140 to 205 kPa (20 to 30
psi).
43. Make sure the mounting surfaces on the track shoes
and track chain are clean and smooth.
44. Install the track shoes and new nuts and bolts.
45. Tighten the bolts to 406 to 447 Nm (300 to 330 lbft).
46. Tighten master link bolts to 430 to 470 Nm (318 to
346 lbft).
87728445 1 2/28/2008
D.50.B / 51
Track tensioning mechanism Adjusterrecoil mechanism Remove
BS02H052 1

1. Loosen the valve in the track adjuster (2) to release

the pressure in the track adjuster.
2. Fasten acceptable lifting equipment to the top of the
track and lift the track to push the piston (8) into the
track adjuster as far as possible.
3. Disconnect the lifting equipment from the track.
87728445 1 2/28/2008
D.50.B / 52
4. Separate the ends of the tracks, refer to Steel track

Remove (D.50.B). It is not necessary to remove the
track.
5. Move the idler all the way forward on the track frame.
6. Remove the front covers in place over the track ad
juster.
7. Remove the bolts and washers that fasten the track
adjuster to the idler.
8. Separate the idler and track adjuster.
9. Remove the track adjuster from the track frame.
10. Remove the tube spacer (11) from inside the recoil
housing.
11. Loosen and remove the bolts and washers that fas
ten the recoil housing to the track frame.
12. Remove the recoil housing from the track frame.
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.
WARNING
The recoil spring in the recoil housing is highly com
pressed. Using the wrong method to release this com
pression will result in personal injury. Release (de
stroy) the compression of the recoil spring according
to instructions in this section. 4870
13. Use an acetylene cutting torch through the hole in

the bottom of the recoil housing and cut through as
much of the recoil spring as can be seen. This will
remove the tension of the recoil spring and the recoil
housing can be safely discarded.
87728445 1 2/28/2008
D.50.B / 53
Track tensioning mechanism Adjusterrecoil mechanism

Disassemble
BS02H052 1

Prior operation:
Track tensioning mechanism Adjusterrecoil mechanism Remove (D.50.B).
1. Tighten the valve (2) in the track adjuster.

2. Use a grease gun to inject grease into the track ad
juster to push the piston out of the cylinder.
NOTE: The piston takes a lot of pressure to remove and
will come “POP” out with force.
87728445 1 2/28/2008
D.50.B / 54
3. Remove the packing ring (10) from the piston.

4. Remove the wear ring (9) from the piston.
5. Remove the snap ring (4) from the piston.
6. Remove the seal (5) from the piston.
7. Remove the bushing (6) from the piston.
8. Remove the backup ring (7) from the piston.
9. Remove the valve (2).
10. Remove the grease from the bore of the cylinder.
Next operation:
Track tensioning mechanism Adjusterrecoil mechanism Visual inspection (D.50.B).
87728445 1 2/28/2008
D.50.B / 55
Track tensioning mechanism Adjusterrecoil mechanism Visual

inspection
Prior operation:
Track tensioning mechanism Adjusterrecoil mechanism Disassemble (D.50.B).
1. Discard the seal.

3. Check the bushing and wear ring for damage.
4. Check the cylinder bore for scratches and rust.
5. Check the piston for scratches and rust.
6. Clean the valve and check for damage.
7. Check the tube spacer for damage.
Next operation:
Track tensioning mechanism Adjusterrecoil mechanism Assemble (D.50.B).
87728445 1 2/28/2008
D.50.B / 56
87728445 1 2/28/2008
D.50.B / 57
Track tensioning mechanism Adjusterrecoil mechanism

Assemble
BS02H052 1

Prior operation:
Track tensioning mechanism Adjusterrecoil mechanism Visual inspection (D.50.B).
1. Put the backup ring (7) on the piston.

2. Put the bushing (6) on the piston.
3. Install the seal (5) on the piston so that the lips are
toward the snap ring.
87728445 1 2/28/2008
D.50.B / 58
4. Install the snap ring (4) in the groove on the end of

the piston.
5. Lubricate the backup ring, bushing and seal with
clean oil. Install the piston into the cylinder. Be care
ful not to damage the seal.
6. Use a soft hammer to drive the piston into the cylin
der.
7. Install the wear ring (9), use a soft hammer to drive
the wear ring into the cylinder.
8. Put 601 Loctite (green) on the OD of the packing ring
(10).
9. Put the packing ring (10) on the piston. Be sure the
metal part of the packing ring is toward the cylinder.
Drive the wiper into the cylinder. Use special tool
CAS1755 to install seal.
B914933RM 2
10. Install the valve (2) into the track adjuster yoke.
Tighten the valve to 61 to 74 Nm (45 to 55
poundfeet).
Next operation:
Track tensioning mechanism Adjusterrecoil mechanism Install (D.50.B).
87728445 1 2/28/2008
D.50.B / 59
Track tensioning mechanism Adjusterrecoil mechanism Install

Prior operation:
Track tensioning mechanism Adjusterrecoil mechanism Assemble (D.50.B).
1. Be sure that the piston is pushed all the way into the
track adjuster.
2. Install the tube spacer in the recoil housing.
3. Put the recoil housing on the track frame.
4. Install the bolts and washers that hold the recoil
housing in place. Tighten the bolts to 108 122 Nm
(80 90 lb ft).
5. Place the track adjuster in place on the track frame.
6. Put 242 Loctite (blue) on the threads of the holes
in the idler brackets for the bolts that hold the track
adjuster in place.
7. Align the track adjuster with the idler.
8. Install the bolts and washers that fasten the track
adjuster to the idler. Tighten the bolts to 155 176
Nm (115 130 lb ft).
9. Push the idler to the rear to engage the track adjuster
with the recoil housing.
10. Install the front covers.
Next operation:
Steel track Install (D.50.B) and
Next operation:
Steel track Tension adjust (D.50.B).
87728445 1 2/28/2008
D.50.B / 60
Roller Lower roller Remove

1. Loosen and remove the selflocking nuts, bolts, hard
ened washers and spacers that hold the track guides
together.
2. Loosen and remove the cap screws that fasten the
track guides to the track frame.
3. Remove the track guides.
4. Loosen the valve in the track adjuster.
BD02H0162 1
5. Raise the track with a chain hoist until the idler stops
moving. Then lower the track onto the carrier roller.
6. Raise the machine until there is clearance for re
moval of the track roller(s). Use acceptable supports
to hold the machine in place.
7. Loosen and remove the cap screws that hold the
track roller.
8. Remove the track roller.
NOTE: Rollers weigh approximately 26.9 kg (59 lb).
Next operation:
Roller Lower roller Disassemble (D.50.B).
87728445 1 2/28/2008
D.50.B / 61
Roller Lower roller Disassemble

Prior operation:
Roller Lower roller Remove (D.50.B).
1. Clean the track roller with cleaning solvent.

2. Loosen and remove the plug from the track roller.
NOTE: It may be necessary to heat the plug to break the
Loctite loose.
B205043 1
3. Drain the oil from the track roller.
B205044 2
4. Use a hammer and punch and remove one of the roll

pins that hold the end caps in place.
B205001 3
87728445 1 2/28/2008
D.50.B / 62
5. Remove the end cap from the shaft.
B205002 4
6. Remove the Oring from the groove in the shaft.
B205004 5
7. Remove the shaft from the track roller.
B205005 6
87728445 1 2/28/2008
D.50.B / 63
8. Remove the metal ring from the rubber ring. Use a

screwdriver if necessary.
B205006 7
9. Remove the rubber ring from the track roller.
B205007 8
10. Support the shaft and end cap and remove the roll
pin that holds the end cap in place.
B205011 9
87728445 1 2/28/2008
D.50.B / 64
11. Put the shaft and end cap in a vise and use the driver
and hammer to drive the shaft out of the end cap. If
the shaft is used again, do not let the shaft fall.
NOTE: Use caution not to nick the bushing thrust face on
the end cap.
B205013 10
12. Remove the Oring from the shaft.
B205014 11
13. Remove the metal ring from the rubber ring in each
end cap. Use a screwdriver if necessary.
B205008 12
87728445 1 2/28/2008
D.50.B / 65
14. Remove the rubber ring from each end cap.
B205009 13
15. Put the track roller in the press for removal of the
bushings.
B921322 14
16. Put the tool CAS1313 on top of the bottom bushing

as shown.
B921323 15
87728445 1 2/28/2008
D.50.B / 66
17. Use an acceptable driver and press the bushing out

of the roller.
B921324 16
18. Repeat Steps 15 through 17 for the other bushing.
Next operation:
Roller Lower roller Visual inspection (D.50.B).
87728445 1 2/28/2008
D.50.B / 67
Roller Lower roller Visual inspection

The only wear that can be measured is wear on the treads of the roller. This wear is normal and occurs 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 when the middle rollers are 40%
worn, it is recommended that the track rollers be rotated to increase the life of all the track rollers.
1. Use the large caliper from the CAS1950A 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.
B900602 1
2. If track rollers are to be rotated on the 750, use this

example..
BC04E095 2
3. If track rollers are to be rotated on the 850, use this

example.
BC04E096 3
4. Shown below is normal tread wear.
B900604 4
87728445 1 2/28/2008
D.50.B / 68
5. Shown is wear on the side of the flanges. This wear

is caused by side hill operation, extended track pitch
which makes the track flexible, the front and rear
track rollers not aligned with the idler and sprocket,
and the carrier roller not aligned with the track.
BC04E098 5
6. Shown is wear on the OD of the flanges. This wear is

caused by wear on the rail on the track links and wear
on the tread of the roller which causes the flanges to
touch the bosses for the pins in the track links. This
is the result of bad maintenance and track system
management.
BC04E099 6
87728445 1 2/28/2008
D.50.B / 69
Roller Lower roller Assemble

Prior operation:
Roller Lower roller Visual inspection (D.50.B).
1. Put the roller in the press for installation of a new

bushing.
B921329 1
2. Start the new bushing into the track roller so that the
lubrication notch is aligned with the filler hole..
B921330 2
3. Install tool CAS1313. Use an acceptable driver and

press the bushing into the track roller until the bush
ing stops moving. Repeat Steps 19 through 21 for
the other bushing.
B921331 3
87728445 1 2/28/2008
D.50.B / 70
4. Put a rubber ring on each metal ring.
B921312X 4
5. Put the metal ring in the tool CAS1283 as shown.
B914911 5
6. Make sure all oil is removed from the bore for the
rubber ring at each end of the track roller.
B205018 6
87728445 1 2/28/2008
D.50.B / 71
7. Apply soap and water or a fast drying oil free lubricant

on the rubber ring. Start the rubber ring into one end
of the track roller.
B914914 7
8. Push down on the tool CAS1283 to push the rubber

ring into the track roller.
B914915 8
9. Repeat Steps 6 through 8 for the other rubber ring

and metal ring.
10. Make sure the seal rings are correctly installed.
BC04E100 9
87728445 1 2/28/2008
D.50.B / 72
11. Make sure all oil is removed from the bore for the
rubber ring in each end cap.
B205016 10
12. Install a metal ring in the tool CAS1283 as shown.
B914911 11
13. Apply soap and water or a fast drying oil free lubricant
on the rubber ring. Start the rubber ring into an end
cap.
B914919 12
14. Push down on the tool CAS1283 until the rubber ring
is seated in the end cap.
87728445 1 2/28/2008
D.50.B / 73
15. Repeat Steps 11 through 13 for the other end cap.
B915006 13
16. Install an Oring in the groove at one end of the shaft.
B205125 14
17. Lubricate the Oring with clean oil.
B205126 15
87728445 1 2/28/2008
D.50.B / 74
18. Lubricate the bore of the end cap with clean oil.
B205127 16
19. Start the end cap onto the shaft so that the flat sur
face of the end cap the flat surface on the shaft are
aligned.
B205129 17
20. Use a soft hammer and drive the end cap onto the
shaft.
B921319 18
87728445 1 2/28/2008
D.50.B / 75
21. Install the roll pin that fastens the end cap to the shaft.
B205132 19
22. Lubricate the face of a metal ring in the track roller

with clean oil.
B205133 20
23. Install the shaft in the track roller.
B205134 21
87728445 1 2/28/2008
D.50.B / 76
24. Install a new Oring in the groove in the shaft.
B205135 22
25. Put the track roller in the press for the installation of
the other end cap.
B205137 23
26. Lubricate the Oring with clean oil.
B205139 24
87728445 1 2/28/2008
D.50.B / 77
27. Lubricate the face of the metal ring with clean oil.
B205140 25
28. Lubricate the bore of the other end cap with clean oil.
B205127 26
29. Start the end cap onto the shaft so that the flat sur
face is aligned with the flat surface of the other end
cap.
B205141 27
87728445 1 2/28/2008
D.50.B / 78
30. Press the end cap onto the shaft until holes are
aligned.
B205143 28
31. Install the roll pin that fastens the end cap to the shaft.
B205101 29
Next operation:
Fill the track roller with lubricant, refer to Roller Lower roller Filling (D.50.B).
Next operation:
Perform leak test on the roller, refer to Roller Lower roller Leakage test (D.50.B).
Next operation:
Install the roller, refer to Roller Lower roller Install (D.50.B).
87728445 1 2/28/2008
D.50.B / 79
Roller Lower roller Leakage test

Prior operation:
Roller Lower roller Assemble (D.50.B).
1. Connect the shutoff valve to the pressure regulator

valve. Connect a fitting for the air supply hose to the
shutoff valve. Connect this assembly to an air hose.
B407320 1
2. Install the adapter and quick disconnect fitting. Use a

seal washer with the adapter. Connect the line from
the pressure gauge.
B407404M 2
3. Turn the knob on the pressure regulator counter

clockwise to close the pressure regulator valve.
4. Make sure that the shutoff valve is open.
B407405M 3
87728445 1 2/28/2008
D.50.B / 80
5. Open the pressure regulator valve until the gauge

indicates 172 kPa, 1.7 bar (25 psi).
B407520M 4
6. Turn the shaft four revolutions.
B407522M 5
7. Close the pressure regulator valve until the gauge

indicates 110 kPa, 1.1 bar (15 psi).
B407516M 6
87728445 1 2/28/2008
D.50.B / 81
8. Close the shutoff valve. The track roller must hold

this pressure for 10 seconds. Loss of air pressure
during this time indicates an bad part of wrong as
sembly.
B407518M 7
Next operation:
Roller Lower roller Filling (D.50.B).
87728445 1 2/28/2008
D.50.B / 82
Roller Lower roller Filling

Prior operation:
Roller Lower roller Leakage test (D.50.B).
1. Turn the shaft so that the mounting surface of the end

cap is down and the filler opening is up.
2. Fill the roller with the lubricant, refer to Roller Lower
roller Capacity (D.50.B).
3. Connect an air line that can be controlled to a maxi
mum pressure of 275 kPa, 2.7 bar (40 psi) to the filler
hole.
4. Open the valve for the air line to push the lubricant
into the outer ends of the roller.
5. Close the valve and disconnect the air line from the
roller.
6. Check the oil fill volume by positioning the roller so
the oil fill hole is at the top of the roller.
7. Insert a dip stick into the oil fill hole until it contacts
the tip of the roller or the idler shaft.
8. The dip stick should read an oil volume level of 5.0 to
8.0 mm (0.195 to 0.315 in) above the top of the shaft.
9. Install and tighten the plug.
Next operation:
Roller Lower roller Install (D.50.B).
87728445 1 2/28/2008
D.50.B / 83
Roller Lower roller Install

1. Use Loctite 242 on threads of cap screws, install the
track roller and the cap screws.
2. Tighten the cap screws to 386 to 434 Nm (285 to 320
lbft).
3. Use Loctite 242 on threads of cap screws, install the
track guides and the cap screws and hardened wash
ers.
4. Install the spacers, bolts and hardened washers, and
hardened washers and selflocking nuts that hold the
track guides.
5. Tighten the cap screws and the selflocking nuts that
hold the track guides.
6. Remove the supports that hold the machine and
lower the track rollers onto the track.
Next operation:
Adjust the track deflection, refer to Steel track Tension adjust (D.50.B).
87728445 1 2/28/2008
D.50.B / 84
Roller Upper roller Visual inspection

1. Shown are flat areas on the treads of a carrier roller.
This wear is caused by the track links sliding on the
tread because the roller does not rotate. The same
wear can occur on the track rollers. Keep the area
around the rollers clean to prevent this wear.
B9006071 1
87728445 1 2/28/2008
D.50.B / 85
Idler wheel Remove

Prior operation:
Steel track Remove (D.50.B).
NOTE: Refer to Idler wheel Exploded view (D.50.B) Frame Exploded view (D.50.B) for numbers in parentheses.
1. Raise the front of the machine until there is clearance
between the track links and idler (13).
2. Remove idler cover (1), outside idler cover (4) and
inside idler cover (2).
3. Loosen and remove the bolts (24) and washers (25)
that fasten the idler (13) to the track adjuster (23).
4. Slide the idler (13) forward on the track frame (12).
5. Loosen and remove, nuts, lock washers, bolts, wear
plates (11) and shims (10) from inside the track frame
(12).
6. Loosen and remove bolts and guide plates (15) to the
idler brackets.
7. Remove the bolts (14) and washers (15) from the
idler bracket.
8. Install the bolts (18) in the idler brackets and discon
nect a lifting sling to the bolts.
9. Connect acceptable lifting equipment to the lifting
sling.
10. Slide the idler (13) off of the track frame (12).
11. Retain the wear plates (17), springs (18) and spring
seats (19) from the idler bracket for use during instal
lation.
Next operation:
Idler wheel Disassemble (D.50.B).
87728445 1 2/28/2008
D.50.B / 86
Idler wheel Disassemble

Prior operation:
Idler wheel Remove (D.50.B).
1. Remove dirt and grease from the idler.

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.
3. Remove the plug from the idler wheel. Drain the oil
from the idler.
4. Use a roll pin punch and a hammer to drive the roll
pin out of the top bracket and shaft.
5. Remove the roll pins and the bracket from the shaft.
NOTE: The bracket can be difficult to remove. If required,
use a press to press the shaft from the bracket.
B509838RM 1
6. Use lifting equipment to remove the idler wheel from

the shaft.
B509920M 2
7.
B509840M 3
8. If necessary, do steps 10 through 16 to remove the

bushings from the idler wheel.
87728445 1 2/28/2008
D.50.B / 87
9. Put the idler wheel in a press. Put the idler wheel on

blocks that will support the hub of the idler wheel.
B150637M 4
10. Install a puller as shown in the bottom bushing and

from the bottom of the idler wheel.
B150639M 5
11. Put an acceptable driver on top of the bushing.
B150640M 6
12. Press the bushing out of the idler wheel.
B509914M 7
87728445 1 2/28/2008
D.50.B / 88
13. Put the idler wheel in the press for removal of the
other bushing.
B150637M 8
14. Install an acceptable driver on top of the bushing.
B150528M 9
15. Press the bushing out of the idler wheel.
B150530M 10
16. Remove the metal ring and the rubber ring from the
bracket and shaft assembly.
B509844M 11
87728445 1 2/28/2008
D.50.B / 89
17. Remove the metal ring and rubber ring from the other
bracket.
B509802M 12
18. Fasten the bracket and shaft assembly in a vise with

soft jaws.
19.
NOTE: The pin must be driven out from the track frame rail
side of the idler bracket.
B509902M 13
20. Remove the bracket from the shaft.

NOTE: The bracket can be difficult to remove. If required,
use a press and press the shaft from the bracket.
B509909M 14
87728445 1 2/28/2008
D.50.B / 90
21. Remove the Orings from the shaft.
B509912M 15
Next operation:
Idler wheel Visual inspection (D.50.B).
87728445 1 2/28/2008
D.50.B / 91
Idler wheel Visual inspection

The only wear measured on the idler is the tread wear. This wear is normal and is caused by the track links moving
around the idler.
1. Use the depth gauge to measure tread wear as

shown. Make sure that the treads are clean. Mea
sure at the center of the treads because this is the
area of the most wear.
B900608 1
2. Shown is wear on the side of the flange. This wear

is caused by side hill operation, extended track pitch
which makes the track flexible and the carrier roller
not aligned with the track. Check the idler alignment.
B900609 2
3. 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.
B900610 3
4. Clean all parts of the idler in cleaning solvent. Make

sure that the lubricant cavity in the idler is clean.
5. Discard the Orings.
6. Discard the bushings and the rubber rings. New
bushings and rubber rings must be used during as
sembly.
87728445 1 2/28/2008
D.50.B / 92
7. Inspect the bushing surfaces on the shaft for scoring,

pitting and other damage.
8. Inspect the bores for the rubber rings in the brackets
and in the idler for damage that will result in leakage.
Use new parts as required.
87728445 1 2/28/2008
D.50.B / 93
Idler wheel Assemble

Prior operation:
Idler wheel Visual inspection (D.50.B)
1. Put the idler wheel in a press and start a new bushing

into the hub. Use an acceptable driver to press the
bushing into the hub until the bushing stops moving.
Repeat for the other bushing.
B509916M 1
2. Install the Orings on the shaft. Lubricate the Orings

with petroleum jelly.
B509912M 2
3. Fasten the shaft in a vise with soft jaws. Be careful

not to damage the shaft or the Orings.
4. Put the bracket on the shaft. Align the hole in the
shaft with the hole in the bracket.
B509909M 3
87728445 1 2/28/2008
D.50.B / 94
5. Use a punch to hold the bracket in position on the

shaft.
B509904M 4
6. Make sure that the seal area in the brackets is clean

and dry. Use soap and water or a fast drying oil free
compound on the rubber ring. Use the tool CAS
1755 to install the metal ring and rubber ring in the
bracket.
B509804M 5
7. Use soap and water or a fast drying oil free com

pound on the rubber ring. Use the tool CAS1755
to install the metal ring and rubber ring in the bracket
and shaft assembly.
B509842M 6
8. Lubricate the Orings on the shaft with petroleum

jelly.
87728445 1 2/28/2008
D.50.B / 95
9. Put the bracket and shaft assembly in the press.

Lower the idler wheel onto the shaft, install the Oring
shown after the shaft is through the idler wheel.
B509922RM 7
10. Put the other bracket on the shaft. Make sure that
the brackets are aligned correctly.
B509838RM 8
11. Use an acceptable driver and a press to press the

bracket onto the shaft until the hole in the shaft and
the hole in the bracket are aligned.
B509926M 9
12. Make sure the idler has been assembled correctly

and there are no defects in the metal parts that will re
sult in leakage. Refer to Roller Lower roller Leak
age test (D.50.B) and perform leakage test in accor
dance to these instructions.
13. Fill the idler with the specified amount of oil, refer to
Idler wheel Capacity (D.50.B).
14. Apply thread sealant to the threads on the plug.
15. Install and tighten the plug.
Next operation:
Idler wheel Install (D.50.B).
87728445 1 2/28/2008
D.50.B / 96
Idler wheel Leakage test

1. Connect the shutoff valve to the pressure regulator
valve. Connect a fitting for the air supply hose to the
shutoff valve.
B407320M 1
2. Install the adapter and quick disconnect fitting in the

oil drain hole in the idler wheel. Use a seal washer
with the adapter.
3. Turn the knob counterclockwise to close the pressure
regulator valve.
4. Connect the line from the pressure gauge to the quick
disconnect fitting in the idler wheel.
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 revo
lutions.
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 pres
sure for 10 seconds. Loss of air pressure during this
time indicates a bad part or wrong assembly.
87728445 1 2/28/2008
D.50.B / 97
Idler wheel Install

Prior operation:
Idler wheel Assemble (D.50.B)
1. Measure the frame thickness with out shims at points

indicated.
BS07M175 1
2. The minimum thickness (1) without shims is 24 mm

(0.945 in).
BS07M176 2
3. After establishing the minimum value, add shims to

the thinner of the two flanges so the overall thickness
(2) of both flanges is within 1 mm (0.040 in). The
minimum thickness with shims and wear bar is 33.5
mm (1.32 in).
BS07M177 3
87728445 1 2/28/2008
D.50.B / 98
4. There are 4 rubber coated idler support springs on

each idler. The purpose of the spring is to prevent
the idler from bouncing as wear occurs between the
wear bars, idler support hook, and track frame.
BD07M02501 4
5. The spring should not be compressed more than 7.6

mm (0.30 in) or damage may occur to the spring.
Use appropriate bolt length and washer combination
to compress springs 3.8 6.3 mm (0.15 0.25 in).
6. As wear occurs in the filed, washers may be removed
from under the bolt head to eliminate bouncing, or
longer bolts may be used if required.
BD07M02601 5
7. Install three washers and bolts in the idler bracket.

Tighten the bolts to a torque of 48 Nm (35 lb ft) to
preload the springs.
BD05H12701 6
87728445 1 2/28/2008
D.50.B / 99
8. Put 242 Loctite on the threads in the holes in the idler

brackets for the bolts that fasten the idler to the track
adjuster.
9. Place the original shims on the idler brackets. Install
the washers and bolts to secure the track adjuster to
the idler. Tighten the bolts to a torque of 183 223
Nm (135 165 lb ft).
10. Install the original shim(s), thrust plates, washers,
and bolts. Tighten the bolts.
BD05H13101 7
11. Measure from the center of the idler to the inside

edge of the track frame. The idler must be centered
in the track frame. If the idler is not centered in the
track frame, remove or add shims between the thrust
plates and idler brackets as necessary so that the
idler is centered in the track frame.
(A) Idler must be centered in the track frame.

(B) 0.8 mm (0.031 in) maximum clearance.
B820203J 8
12. After the idler has been centered, check the clear
ance between the thrust plates and track frame. The
clearance must be as little as possible and not more
than 0.8 mm (0.031 in). Remove shims as required.
13. When the idler (21) is in the correct position, assem
ble the track according to the instructions in Steel
track Install (D.50.B).
87728445 1 2/28/2008
D.50.B / 100
Index
TRAVELLING D

Drive sprocket Install 26
Drive sprocket Remove 25
Frame Exploded view 24
Idler wheel Assemble 94
Idler wheel Capacity 19
Idler wheel Disassemble 87
Idler wheel Exploded view 23
Idler wheel Install 98
Idler wheel Leakage test 97
Idler wheel Remove 86
Idler wheel Visual inspection 92
Roller Special tools 15
Roller Lower roller Assemble 70
Roller Lower roller Capacity 16
Roller Lower roller Dimension 16
Roller Lower roller Disassemble 62
Roller Lower roller Exploded view 22
Roller Lower roller Filling 83
Roller Lower roller Install 84
Roller Lower roller Leakage test 80
Roller Lower roller Remove 61
Roller Lower roller Torque 16
Roller Lower roller Visual inspection 68
Roller Upper roller Dimension 17
Roller Upper roller Visual inspection 85
Steel track Check 30
Steel track Exploded view 20
Steel track Install 34
Steel track Remove 28
Steel track Special tools 5
Steel track Tension adjust 36
Steel track Torque 5
Steel track Chain Assemble For reference only 47
Steel track Chain Dimension 7
Steel track Chain Disassemble For reference only 45
Steel track Chain General specification 6
Steel track Chain Visual inspection 39
Steel track Pad Dimension 13
Steel track Pad Visual inspection 38
Track tensioning mechanism Adjusterrecoil mechanism Assemble 58
Track tensioning mechanism Adjusterrecoil mechanism Disassemble 54
Track tensioning mechanism Adjusterrecoil mechanism Exploded view 21
Track tensioning mechanism Adjusterrecoil mechanism Install 60
Track tensioning mechanism Adjusterrecoil mechanism Remove 52
87728445 1 2/28/2008
D.50.B / 101
Track tensioning mechanism Adjusterrecoil mechanism Visual inspection 56
WHEELS AND TRACKS Tracks Special tools 4
87728445 1 2/28/2008
D.50.B / 102
87728445 1 2/28/2008
D.50.B / 103
PRINTED IN U.S.A.
87728445 1 2/28/2008
REPAIR MANUAL
BODY AND STRUCTURE
750L
850L
87728445 1 2/28/2008
E
Contents
USER CONTROLS AND SEAT E.32.A

750L , 850L
USER CONTROLS AND SEAT Operator seat E.32.C

750L , 850L
USER PLATFORM E.34.A

750L , 850L
ENVIRONMENT CONTROL Heating system E.40.B

750L , 850L
ENVIRONMENT CONTROL Airconditioning system E.40.C

750L , 850L
ENVIRONMENT CONTROL Heating, ventilation and airconditioning E.40.D

750L , 850L
SAFETY SECURITY ACCESSORIES Safety E.50.B

750L , 850L
87728445 1 2/28/2008
E
USER CONTROLS AND SEAT 32.A
750L
850L
87728445 1 2/28/2008
E.32.A / 1
Contents
FUNCTIONAL DATA
Instrument panel
Digital instrument cluster Dynamic description LCD Multifunction Display 3
DIAGNOSTIC
Instrument panel
Testing 7
87728445 1 2/28/2008
E.32.A / 2
BODY AND STRUCTURE USER CONTROLS AND SEAT
Instrument panel Digital instrument cluster Dynamic description

LCD Multifunction Display
1. The LCD MultiFunction Display is located at the center of the modular dashboard. On start up the cluster will
flash the instructional lamps and the LCD MultiDisplay will display, CASE, with the machine model and current
hour reading.
BD06G11102 1
2. Information will be displayed in different zones on the LCD, as directed by the operator or technician. In most
situations the operator or technician will be given specific information to follow if conditions are not correct.
BD06G11301 2
(1) In the example, the machine hours are displayed. Machine hours will always be displayed briefly, on start
up. After, the machine is started, the display will show engine rpm’s. After, beginning travel, the machine will
display travel speed, if default settings were not changed by the operator.
(2) This example, shows that the Transmission Control Lever is in Neutral. The display will show Forward,
Neutral, or Reverse, depending on where the Directional Control Lever is positioned.
(3) This example shows the transmission at 60%. 60% is the default speed. When the ignition switch has been
shut off it will default the transmission to this setting.
(4) This zone will display fault codes when an error has accord in the engine controller, drivetrain controller, or
instrument cluster.
(5) This zone will display additional and optional information.
3. Located on the dash panel are the operating switches for the instrument cluster. Use the switches to move from
one screen to another, choose various selections, monitor the machine functions, and retrieve information. All
functions can be accessed in the same basic manner.
87728445 1 2/28/2008
E.32.A / 3
BD06G11201 3
(1) Up arrow key: Use this key to scroll up to selections.
(2) Down arrow key: Use this key to scroll down to selections.
(3) Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to
start over and begin again, plus use to check active errors and acknowledge errors.
(4) Enter key: Use this key to confirm, yes, this is the desired function.
NOTE: Arrows on the screen will indicate if selections are up or down from the current selection.
NOTE: Display units can be changed by the operator.

4. At any time, during operation or with the key switch on, the operator may scroll through two information screens
and two trip screens by using the arrow keys. These four screens are in a circular loop and may be reached by
pressing the up or down key. The following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD back to the normal driving screen.
5. From the driving screen push the down arrow.
BD06G11201 4
6. 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.
BD06N04601 5
7. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature,
engine oil temperature in either Fahrenheit or Celsius, as well as oil pressure PSI.
87728445 1 2/28/2008
E.32.A / 4
BD06F02701 6
8. 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 be accessed by using the up arrow key.
BD06F17001 7
9. Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These
will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.
BD06F16901 8
10. To reset the trip information, highlight the trip screen you wish to set.
87728445 1 2/28/2008
E.32.A / 5
BD06F17001 9
11. Press the confirm button.
BD06G11201 10
12. The trip screen will indicate a reset message. At this 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.
BD06F17201 11
13. Press the confirm button to reset the trip selection to zero.
BD06G11201 12
87728445 1 2/28/2008
E.32.A / 6
Instrument panel Testing

Remove the instrument cluster and 12 volts Bad wire BR (IGN3) between instru
disconnect the instrument cluster ment cluster and fuse panel. Bad
wiring harness Connector D2A and fuse F8, bad ignition relay.
Connector D2B. Put the master dis
connect switch in the ON position.
Put the ignition switch in the RUN
position.
Check
Pin 1 Connector D2A to ground
Pin 18 and 21 in Connector D2B to 12 volts Bad wire BR (IGN3) between instru
ground. ment cluster and fuse panel. Bad
fuse F8, bad ignition relay.
Pin 12 Connector D2A to ground Continuity Bad ground circuit.
Pin 15 and 22 in Connector D2B to Continuity Bad ground circuit.
ground. If all reading are good, replace in
strument cluster.
87728445 1 2/28/2008
E.32.A / 7
Index

Instrument panel Testing 7
Instrument panel Digital instrument cluster Dynamic description LCD Multifunction Display 3
87728445 1 2/28/2008
E.32.A / 8
USER CONTROLS AND SEAT Operator seat 32.C
750L
850L
87728445 1 2/28/2008
E.32.C / 1
Contents
SERVICE
Seat suspension system
Disassemble Air Suspension Seat 3
Visual inspection Air Suspension Seat 9
Assemble Air Suspension Seat 10
Disassemble Mechanical Suspension Seat 16
Visual inspection Mechanical Suspension Seat 19
Assemble Mechanical Suspension Seat 20
DIAGNOSTIC
Seat suspension system
Testing 22
87728445 1 2/28/2008
E.32.C / 2
BODY AND STRUCTURE USER CONTROLS AND SEAT Operator seat
Seat suspension system Disassemble Air Suspension Seat

1. Loosen and remove the 4 cap screws from the seat
assembly. Remove the seat assembly from the base.
BS02N012 1
2. Remove the washers and spacer blocks.
BS02N013 2
3. Loosen the Allen set screw for the seat control button
and remove the button.
BS02N014 3
4. Remove the plastic pins from the boot assembly.
BS02N015 4
87728445 1 2/28/2008
E.32.C / 3
5. Remove the boot assembly.
BS02N016 5
6. Remove the nut and lock washer from the control

switch.
BS02N017 6
7. Disconnect the electrical and air connectors from the

switch.
BS02N018 7
8. Remove the pivot bolt from the upper plate.
BS02N019 8
87728445 1 2/28/2008
E.32.C / 4
9. Remove the upper plate.
BS02N020 9
10. Remove the bushing and roller from the suspension

assembly.
BS02N021 10
11. Cut the plastic tie holding the wiring harness to the
lower plate.
BS02N022 11
12. Remove the screw for the air spring from the lower
plate.
BS02N023 12
87728445 1 2/28/2008
E.32.C / 5
13. Remove the pivot bolt from the lower plate.
BS02N024 13
14. Pick up on the suspension assembly, twist around

the rubber bumper to clear the guides and remove
the lower plate.
BS02N025 14
15. Remove the busing, roller and spacer from the sus
pension assembly.
BS02N026 15
16. Remove the retainer washer and shock from the sus
pension assembly.
BS02N027 16
87728445 1 2/28/2008
E.32.C / 6
17. Cut the two plastic ties, disconnect the electrical con
nector and remove the air hose from the fitting.
BS02N028 17
18. Remove the wiring harness and air hose from the
retaining clip.
BS02N029 18
19. Disconnect the air line from the compressor, remove

the 2 mounting screws from the compressor, remove
the compressor.
BS02N030 19
20. Remove the air spring mounting bolt, remove the air
spring.
BS02N031 20
Next operation:
87728445 1 2/28/2008
E.32.C / 7
Seat suspension system Visual inspection Air Suspension Seat (E.32.C)
87728445 1 2/28/2008
E.32.C / 8
Seat suspension system Visual inspection Air Suspension Seat

Prior operation:
Seat suspension system Disassemble (E.32.C)
1. Inspect the seat cushion, backrest cushion 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 bearings
for wear and damage. Lubricate the roller bearings
and contact points with molydisulfide grease. Use
new parts as required.
6. Inspect the suspension shock and bushings for wear
7. Inspect the air compressor, air line, and wiring har
ness for wear and damage. Use new parts as re
quired.
8. Inspect the air spring for wear and damage. Use new
parts as required.
9. Insect the lower plate, bearing shaft, and rubber
bumper for wear and damage. Lubricate the contact
points with molydisulfide grease. Use new parts as
required.
Next operation:
Seat suspension system Assemble (E.32.C)
87728445 1 2/28/2008
E.32.C / 9
Seat suspension system Assemble Air Suspension Seat

Prior operation:
Seat suspension system Visual inspection (E.32.C)
1. Install the air spring into the suspension assembly,

install the bolt with retaining clip and tighten.
BS02N031_2 1
2. Install the compressor with the two mounting screws,

install the air spring line into the compressor.
BS02N030 2
3. Place the air hose and wiring harness into the retain
ing clip.
BS02N029 3
87728445 1 2/28/2008
E.32.C / 10
4. Connect the electrical connection, connect the air

line to the compressor, and replace the plastic ties.
BS02N028 4
5. Install the bushings and suspension shock onto the

suspension assembly.
BS02N027 5
6. Use molydisulfide grease and install the bushings

and rollers on the lower portion of the suspension as
sembly.
BS02N026 6
7. Place the suspension assembly rollers into the

guides, twist around the rubber bumper and lower
into place.
BS02N025 7
87728445 1 2/28/2008
E.32.C / 11
8. Use molydisulfide grease on the pivot bolt and install

into the lower plate and suspension assembly. Install
a new self locking nut and tighten.
BS02N024 8
9. Install and tighten the screw into the bottom of the air
spring.
BS02N023 9
10. Route the wiring harness to the rear of the seat and
secure with a plastic tie strap.
BS02N022 10
11. Use molydisulfide grease and install the bushings

and rollers on the upper portion of the suspension
assembly.
BS02N021 11
87728445 1 2/28/2008
E.32.C / 12
12. Slide the upper plate over the rollers and lower into
place.
BS02N020 12
13. Use molydisulfide grease on the pivot bolt and install

into the upper plate and suspension assembly. Install
a new self locking nut and tighten.
BS02N019 13
14. Connect the air hose and electrical wiring to the

switch.
BS02N018 14
15. Install the switch into the upper plate, install the lock
washer and nut. Tighten the switch.
BS02N017 15
87728445 1 2/28/2008
E.32.C / 13
16. Slip the rubber boot over the upper plate.
BS02N016 16
17. Slide the rubber boot into position on the upper and
lower housing. Install the plastic pins into the mount
ing holes in the rubber boot.
BS02N015 17
18. Install the control knob onto the switch, tighten the
Allen set screw.
BS02N014 18
19. Place the 4 bushings and washers onto the upper

plate.
BS02N013 19
87728445 1 2/28/2008
E.32.C / 14
20. Use new self locking nuts and install the seat assem
bly onto the frame assembly.
BS02N012 20
87728445 1 2/28/2008
E.32.C / 15
Seat suspension system Disassemble Mechanical Suspension

Seat
1. Push up on the front of the lower cushion to release
the retaining clip.
BS02N002 1
2. Remove the lower cushion from the seat assembly.
BS02N003 2
3. Remove the four mounting bolts from the seat.
BS02N004 3
87728445 1 2/28/2008
E.32.C / 16
4. Remove the four mounting bolts from the support

plate.
BS02N005 4
5. Remove the mounting bolts for the slide controls, re

move the slide controls.
BS02N006 5
6. Remove the plastic pins and boot assembly from the

suspension assembly.
BS02N007 6
7. Place the suspension assembly in a press, compress

the assembly slightly and remove the mounting bolts
for the shock assembly.
BS02N009 7
87728445 1 2/28/2008
E.32.C / 17
8. Remove the shock from the suspension assembly.
BS02N008 8
Next operation:
87728445 1 2/28/2008
E.32.C / 18
Seat suspension system Visual inspection Mechanical Suspension

Seat
Prior operation:
Seat suspension system Disassemble (E.32.C)
1. Inspect the seat cushion, backrest cushion, and lum

bar 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 weight adjustment gears 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 bushings for
wear and damage. Lubricate the bushings and con
tact points with molydisulfide grease. Use new parts
as required.
6. Inspect the suspension shock and bushings for wear
7. Inspect the spring for wear and damage. Use new
parts as required.
Next operation:
Seat suspension system Assemble (E.32.C)
87728445 1 2/28/2008
E.32.C / 19
Seat suspension system Assemble Mechanical Suspension Seat

Prior operation:
1. Install the suspension shock into the suspension as

sembly. Install new self locking nuts and tighten.
BS02N009 1
2. Place the boot assembly into position on the suspen

sion assembly, install new plastic pins.
BS02N007 2
3. Use new self locking nuts and install the slide rails.
BS02N006 3
87728445 1 2/28/2008
E.32.C / 20
4. Use new self locking nuts and install the support

plate.
BS02N005 4
5. Use new self locking nuts and install the seat assem
bly onto the support plate.
BS02N011 5
6. Make sure the retaining clips are in place and install

the lower cushion into the seat.
BS02N010 6
87728445 1 2/28/2008
E.32.C / 21
Seat suspension system Testing

the ON position.
Check
Terminal B for wire 0 at motor Con
nector M22A to ground.
Put the ignition switch in the RUN 12 volts Bad wire BL (V2ACC) to fuse panel,
position. bad fuse F15.
Check
Terminal A for wire BL (V2ACC) at
motor connector M22A to ground.
87728445 1 2/28/2008
E.32.C / 22
Index

Seat suspension system Assemble Air Suspension Seat 10
Seat suspension system Assemble Mechanical Suspension Seat 20
Seat suspension system Disassemble Air Suspension Seat 3
Seat suspension system Disassemble Mechanical Suspension Seat 16
Seat suspension system Testing 22
Seat suspension system Visual inspection Air Suspension Seat 9
Seat suspension system Visual inspection Mechanical Suspension Seat 19
87728445 1 2/28/2008
E.32.C / 23
87728445 1 2/28/2008
E.32.C / 24
USER PLATFORM 34.A
750L
850L
87728445 1 2/28/2008
E.34.A / 1
Contents
USER PLATFORM 34.A
TECHNICAL DATA
ROPS
Torque 3
SERVICE
USER PLATFORM
Tilt 4
Lower 6
Tilt system
Pump Filling 8
ROPS
Visual inspection 9
Remove 10
Install 13
DIAGNOSTIC
Wiper system
Switch Testing Door Wiper System 16
Motor Testing Front and Rear Windshield 16
Windscreen washer system
Motor Testing 18
Switch Testing 18
87728445 1 2/28/2008
E.34.A / 2
BODY AND STRUCTURE USER PLATFORM
ROPS Torque
Support mount bolts 550 624 Nm 406 460 lb ft
Brush guard mount bolts (if equipped) 405 730 Nm 300 540 lb ft
87728445 1 2/28/2008
E.34.A / 3
USER PLATFORM Tilt
WARNING
Make sure there are no loose objects in the cab or canopy prior to tilting. Falling objects could cause death
or 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.
1. Park the machine on a flat surface, lower the blade
and any attachment to the floor, turn the master dis
connect to the off position.
2. Open the right and left side panels under the cab.
3. If equipped with a brush guard, remove the bolts at
the rear of the brush guard.
BD02F003 1
4. Tilt the brush guard until the brush guard is free of

the canopy.
NOTE: The removed bolts can be used in the tilting brack
ets to hold the brush guard up.
5. Disconnect the control rods from the hydraulic con
trol valve.
BD02F008 2
87728445 1 2/28/2008
E.34.A / 4
6. Remove the six support mount bolts on the right side

of the cab.
BD02M138 3
7. Turn the pump diverter valve into the cab tilt position.
Actuate the hand pump and tilt the cab slowly.
NOTE: Cab travel will be stopped by the safety cable.
87728445 1 2/28/2008
E.34.A / 5
USER PLATFORM Lower

1. Turn the diverter valve to the lower position. Actuate
the hand pump and lower the cab slowly.
BD02F024_2 1
2. Install the six support mount bolts and torque to 550

624 Nm (406 460 lb ft).
BD02M139 2
3. If equipped with a brush guard, lower the brush guard

into alignment with the cab.
4. Install the bolts and torque to 405 730 Nm (300
540 lb ft).
BD02F004 3
87728445 1 2/28/2008
E.34.A / 6
5. Connect the control rods to the hydraulic control

valve, align the spools in the direction of linkage
travel.
NOTE: If linkage needs adjustment refer to Command
Travel adjust (G.10.A).
BD02F008 4
87728445 1 2/28/2008
E.34.A / 7
Tilt system Pump Filling

1. Make sure that the cylinder rod is fully retracted.
2. Remove the fill check plug and fill with CASE
AKCELA HYTRAN ULTRA.
(1) Pump fill check plug
BD02F024 1
3. Tilt and lower cab two to three times to remove air

from the system.
4. Fill as needed.
5. Install fill check plug.
87728445 1 2/28/2008
E.34.A / 8
ROPS Visual inspection

1. The Rollover Protective Structure (ROPS) or Cab
Structural Frame (CSF) is a special safety compo
nent of your machine.
2. DO NOT attach any device to the ROPS or CSF for
pulling purposes.
3. The ROPS or CSF is a certified structural support
and any damage, fire, corrosion or modification will
weaken the structure and reduce your protection. If
this occurs, the ROPS or CSF MUST be replaced
so that it will provide the same protection as a new
ROPS or CSF.
4. After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
job site operation:
(A)The ROPS or CSF structure MUST be replaced.
(B)The ROPS or CSF mounting or suspension, op
erator seat and suspension, seat belts and mounting
components and wiring within the operator’s protec
tive system MUST be carefully inspected for dam
age.
(C)All damaged parts MUST be replaced.
(D)DO NOT WELD, ATTEMPT TO STRAIGHTEN
OR REPAIR THE ROPS OR CAB STRUCTURAL
FRAME.
5. After every 500 hours of operation or every six
months, whichever comes first.
(A)Check to see that the mounting bolts for the
ROPS cab or canopy are tight.
(B)Check the operator seat and the mounting parts
for the seat belts. Check to see that the bolts are
tight.
WARNING
Adding additional weight (attachments, etc). to the ma
chine can cause injury or death. Do not exceed the
gross weight printed on the ROPS label. SA028
WARNING
Do not modify ROPS in any manner. Unauthorized
modifications such as welding, drilling, cutting or
adding attachments can weaken the structure and
reduce your protection. Replace ROPS if subjected to
rollover or damage. Do not attempt to repair. SB026
87728445 1 2/28/2008
E.34.A / 9
ROPS Remove
Prior operation:
Remove the battery.
Prior operation:
For cab units and canopy units with heater drain 4 liters (1 U.S. gallon) of coolant from radiator.
1. Remove the two mounting bolts for the fuse and relay
bracket and lay it in the battery compartment area.
BD06J12701 1
2. Disconnect the wiring harness connector.
BD06J12601 2
3. Disconnect the wiring harness connector.
BD06J12901 3
87728445 1 2/28/2008
E.34.A / 10
4. If equipped with a brush guard remove the bolts at

the rear of the brush guard.
BD02F00301 4
5. Tilt the brush guard until the brush guard is free of

the ROPS canopy.
NOTE: The removed bolts can be used in the tilting brack
ets to hold the brush guard up.
6. Disconnect heater hoses.
BD06J12801 5
7. Discharge the air conditioning system, refer to EN

VIRONMENT CONTROL Airconditioning system
Evacuate (E.40.C).
8. Disconnect the hoses that go to the evaporator. In
stall caps and plugs on the hoses to prevent moisture
from entering the hoses.
9. Disconnect the tilt cylinder and safety cable.
(1) Tilt cylinder
(2) Safety cable
(3) Pivot pin
BD02F03101 6
87728445 1 2/28/2008
E.34.A / 11
10. Disconnect hydraulic control linkage from the spool

valve.
BD02F00801 7
11. Install lifting eyes on top of the ROPS canopy.

12. Remove the twelve mounting bolts from the mounts.
BD02M13801 8
13. Slowly raise the ROPS canopy or CSF cab from the
machine and place on a suitable stand.
87728445 1 2/28/2008
E.34.A / 12
ROPS Install
1. Carefully lower the ROPS canopy into alignment with
the mounts.
2. Install the twelve support mount bolts and torque to
550 623 Nm (406 460 lb ft).
NOTE: For cab units install six bolts in the left side.
BD02M13901 1
3. Connect the tilt cylinder and safety cable.

(1) Tilt cylinder
(2) Safety cable
(3) Pivot pin
BD02F03101 2
4. Connect the heater hoses.
BD06J12801 3
5. Cab unit, connect the hoses that go to the evapora

tor.
6. Fill the radiator to the correct level.
7. Charge the air conditioning system, refer to ENVI
RONMENT CONTROL Airconditioning system
Charging (E.40.C).
87728445 1 2/28/2008
E.34.A / 13
8. Connect the linkage from the spool valve to the hy

draulic controls.
NOTE: If linkage needs adjustment refer to Command
Travel adjust (G.20.A).
BD02F00801 4
9. Mount the fuse and relay bracket to the ROPS frame,

tighten the mount bolts and install the batteries.
BD06J12701 5
10. Connect the wiring harness.
BD06J12601 6
11. Connect the wiring harness.
BD06J12901 7
87728445 1 2/28/2008
E.34.A / 14
12. If equipped with a brush guard, lower the brush guard

into alignment with the ROPS canopy.
13. Install the brush guard mount bolts and torque to 405
730 Nm (300 540 lb ft).
BD06J13001 8
87728445 1 2/28/2008
E.34.A / 15
Wiper system Switch Testing Door Wiper System

NOTE: For wiring diagrams refer to Wiring harness Electrical schematic frame 24 (A.30.A).
the ON position.
Check
Terminal for wire 0 at wiper motor to
ground.
Turn the ignition switch to the ON 12 volts Bad fuse F14, bad wire from fuse to
position. wiper switch. Check circuit from pin
Check 6 Connector D9 to pin 21 Connec
At door wiper switch Connector D9 tor D1, from pin 21 Connector M1
pin 6 for wire BL (933B) to ground. to pin 4A Connector M3.
At door wiper switch Connector D9 12 volts Bad fuse right F13, bad wire from
pin 3 for wire BL (953C) to ground. fuse to wiper switch. Check circuit
from pin 3 Connector D9 to pin 31
Connector D1, from pin 31 Connec
tor M1 to pin 3A Connector M3.
Turn the wiper switch ON. 12 volts Bad wiper switch.
Check
At door wiper switch Connector D9
pin 5 for wire V (955) to ground.
At right wiper motor Connector C22 12 volts Bad fuse F13, bad wire from fuse to
pin 3 for wire BL (953) to ground. wiper motor. Check circuit from pin
tor C4, from pin 37 Connector M10
to pin 3A Connector M3.
At right wiper motor Connector C22 12 volts Bad wire from wiper switch to wiper
pin 4 to for wire BL (955) ground. motor. Check circuit from pin 5 Con
nector D9 to pin 28 Connector D1,
from pin 28 Connector M1 to pin 15
Connector M10, from pin 15 Con
nector C4 to pin 4 Connector C22.
If the tests are good and the wiper
motor does not work, repair or re
place the wiper motor.
At door wiper switch Connector D9 12 volts Bad wiper switch.
pin 2 for wire V (952) to ground.
At left wiper motor Connector M15 12 volts Bad fuse F14, bad wire from fuse to
pin 3 for wire BL (933) to ground. wiper motor. Check circuit from pin 3
Connector M15 to pin 4A Connec
tor M3.
At left wiper motor Connector M15 12 volts Bad wire from wiper switch to wiper
pin 4 for wire V (952) to ground. motor. Check circuit from pin 2 Con
from pin 7 Connector M1 to pin 4 of
Connector M15.
87728445 1 2/28/2008
E.34.A / 16
Wiper system Motor Testing Front and Rear Windshield

the ON position.
Check
Terminal for wire 0 at wiper motors to
ground.
Turn the ignition switch to the ON 12 volts Bad fuse F14, bad wire from fuse to
position. wiper switch. Check circuit from pin
Check 3 Connector D7 to pin 21 Connec
At front/rear wiper switch Connec tor D1, from pin 21 Connector M1
tor D7 pin 3 for wire BL (933A) to to pin 4A Connector M3.
ground.
At front/rear wiper switch Connector 12 volts Bad fuse F13, bad wire from fuse to
D7 pin 6 for wire BL (953) to ground. wiper switch. Check circuit from pin
6 Connector D7 to pin 31 Connec
tor D1, from pin 31 Connector M1
Turn the wiper switch ON. 12 volts Bad wiper switch.
Check
At front/rear wiper switch Connector
D7 pin 5 for wire V (935) to ground.
At rear wiper motor Connector C20 12 volts Bad fuse F13, bad wire from fuse to
pin 3 for wire BL (953) to ground. wiper motor. Check circuit from pin
tor C4, from pin 34 Connector M10
At rear wiper motor Connector C20 12 volts Bad wire from wiper switch to wiper
pin 4 to for wire BL (935) ground. motor. Check circuit from pin 5 Con
from pin 23 Connector M1 to pin 38
Connector M10, from pin 38 Con
nector C4 to pin 4 Connector C20.
At front/rear wiper switch Connector 12 volts Bad wiper switch.
D7 pin 2 for wire V (932) to ground.
At front wiper motor Connector D4 12 volts Bad fuse F14, bad wire from fuse to
pin 3 for wire BL (933) to ground. wiper motor. Check circuit from pin 3
Connector D4 to pin 21 Connector
D1, from pin 21 Connector M1 to pin
4A Connector M3.
At front wiper motor Connector D4 12 volts Bad wire from wiper switch to wiper
pin 4 for wire V (932) to ground. motor. Check circuit from pin 2 Con
nector D7 to pin 4 Connector D4.
87728445 1 2/28/2008
E.34.A / 17
Windscreen washer system Motor Testing

the ON position.
Check
Terminal for wire 0 at washer pump
to ground.
Put the ignition switch in the RUN 12 volts Bad wire BL(933C) to fuse panel,
position. bad accessory B relay.
Check
Terminal for wire BL(933C) at
washer switch to ground.
Have another person push and hold 12 volts Bad washer switch.
the washer switch in the ON position.
Check
Terminal for wire B(943) at washer
switch to ground.
Terminal for wire B(943) at washer 12 volts Bad wire B(943) to washer switch.
motor to ground. If the tests are good and the washer
pump does not work, repair or re
place the washer pump.
Windscreen washer system Switch Testing

Disconnect connector at switch. Continuity Bad washer switch.
Have another person push and hold
the washer switch in the ON posi
tion.
Check
Between terminals 2 and 3 at washer
switch.
87728445 1 2/28/2008
E.34.A / 18
Index
USER PLATFORM 34.A

ROPS Install 13
ROPS Remove 10
ROPS Torque 3
ROPS Visual inspection 9
Tilt system Pump Filling 8
USER PLATFORM Lower 6
USER PLATFORM Tilt 4
Windscreen washer system Motor Testing 18
Windscreen washer system Switch Testing 18
Wiper system Motor Testing Front and Rear Windshield 16
Wiper system Switch Testing Door Wiper System 16
87728445 1 2/28/2008
E.34.A / 19
87728445 1 2/28/2008
E.34.A / 20
ENVIRONMENT CONTROL Heating system 40.B
750L
850L
87728445 1 2/28/2008
E.40.B / 1
Contents
DIAGNOSTIC
Heater
Testing Optional ROPS Heater 3
Ventilation system
Testing 4
87728445 1 2/28/2008
E.40.B / 2
BODY AND STRUCTURE ENVIRONMENT CONTROL Heating system
Heater Testing Optional ROPS Heater

the ON position.
Check
Terminal B for wire 0 to ground.
Put the ignition switch in the RUN 12 volts Bad wire BL(V2ACC) between
position. ROPS heater and fuse panel, bad
Check fuse.
Terminal A for wire BL(V2ACC) to If readings are good, replace the
ground. ROPS heater.
87728445 1 2/28/2008
E.40.B / 3
BODY AND STRUCTURE ENVIRONMENT CONTROL Heating system
Ventilation system Testing

the ON position.
Check
Terminal N and ground.
Put the ignition switch in the RUN 12 volts Bad wire between blower motor and
position. Turn the blower switch to blower motor switch, bad blower
the HIGH position. switch.
Check If the test is good and the blower mo
Motor + terminal to ground. tor does not work, replace the blower
motor. If the blower motor works on
HIGH but not on LOW or MEDIUM,
test the blower motor speed resistors
and blower switch.
87728445 1 2/28/2008
E.40.B / 4
Index

Heater Testing Optional ROPS Heater 3
Ventilation system Testing 4
87728445 1 2/28/2008
E.40.B / 5
87728445 1 2/28/2008
E.40.B / 6
ENVIRONMENT CONTROL Airconditioning system 40.C
750L
850L
87728445 1 2/28/2008
E.40.C / 1
Contents
TECHNICAL DATA
ENVIRONMENT CONTROL Airconditioning system
Special tools 4
General specification Stable Saturation Pressure/Temperature Chart 7
Compressor
Torque 9
Special tools 9
FUNCTIONAL DATA
Dynamic description 10
Compressor
Magnetic clutch Exploded view 11
SERVICE
Connect 12
Evacuate 14
Discharging 19
Charging 22
Leakage test 24
Compressor
Remove 25
Filling 26
Install 28
Belt Check 29
Belt Adjust 30
Magnetic clutch Disassemble 31
Magnetic clutch Electrical test 36
Magnetic clutch Assemble 37
Evaporator
87728445 1 2/28/2008
E.40.C / 2
DIAGNOSTIC
Troubleshooting 43
Testing 43
Problem solving 44
Compressor
Problem solving 45
Condenser
Fan Testing 46
Expansion valve
Testing 47
87728445 1 2/28/2008
E.40.C / 3
BODY AND STRUCTURE ENVIRONMENT CONTROL Airconditioning system
ENVIRONMENT CONTROL Airconditioning system Special tools
299L7C 1
OEM1036 BELT TENSION TOOL
87728445 1 2/28/2008
E.40.C / 4
A22094 2
OEM1415 REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION
A22090 3
OEM1437 ELECTRONIC LEAK DETECTOR
87728445 1 2/28/2008
E.40.C / 5
BS03H012 4
SAFETY GOGGLES OBTAIN LOCALLY
87728445 1 2/28/2008
E.40.C / 6
ENVIRONMENT CONTROL Airconditioning system General

specification
BC04D002 1
NOTE: The pressure temperature chart is based on the following conditions:
(1) Engine operating at 1500 rpm. No engine load.

(2) Fan speed control in maximum position (full clockwise) and all louvers open.
(3) Cab temperature control set to maximum cooling (full counterclockwise).
(4) A/C switch ON. Both cab doors open.
(5) All panels and access doors installed and closed.
(6) Cab filters clean and installed. Heater valve at engine closed.
(7) Measurements taken 15 minutes after startup.
Refrigerant charge 2.0 kg ( 4.6 lb)
87728445 1 2/28/2008
E.40.C / 7
ENVIRONMENT CONTROL Airconditioning system General

specification Stable Saturation Pressure/Temperature Chart
BC07N85101 1
IMPORTANT: Do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
87728445 1 2/28/2008
E.40.C / 8
Compressor General specification

Lubricant SP15 PAG oil
Compressor belt tension (new belt) 578 667 N ( 130 150 lb)
Compressor belt tension (used belt) 356 534 N ( 80 120 lb)
Front plate air gap 0.41 0.79 mm ( 0.016 0.031 in)
Compressor Torque
Compressor rotor shaft nut 15 20 Nm ( 11 15 lb ft)
Oil filler plug 15 24 Nm ( 11 18 lb ft)
Dust cover screws 7 11 Nm ( 5 8 lb ft)
Compressor Special tools
T81574 1
CAS10747A COMPRESSOR TOOL KIT
87728445 1 2/28/2008
E.40.C / 9
ENVIRONMENT CONTROL Airconditioning system Dynamic

description
The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser, re
ceiverdrier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as
a closed system. The air conditioner system is charged with HFC134a refrigerant.
The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant
and sends it in the form of a high pressure gas to the condenser. The air flow through the condenser then removes
the heat from the refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.
The high pressure refrigerant liquid then flows from the condenser to the receiverdrier. The receiverdrier is a con
tainer filled with moisture removing material, which removes any moisture that may have entered the air conditioner
system in order to prevent corrosion of the internal components of the air conditioner system.
The refrigerant still in a high pressure liquid form, then flows from the receiverdrier to the expansion valve. The ex
pansion valve then causes a restriction in flow of refrigerant to the evaporator core.
As the refrigerant flows through the evaporator core the refrigerant is heated by the air around and flowing through the
evaporator fins. The combination of increased heat and decreased pressure causes the air flow through the evapo
rator fins to become very cool and the liquid refrigerant to become a low pressure gas. The cooled air then passes
from the evaporator to the cab for the operator’s comfort.
The electrical circuit of the Air Conditioning System consists of a fan speed control, temperature control, three (3) mini
relays, two (2) 10 amp circuit breakers, two (2) fan motors, a blower motor, blower resistor, compressor clutch, low
pressure switch, high pressure switch, and warning light.
208L95 1
(1) Expansion valve
(2) Evaporator
(3) Compressor
(4) Condenser
(5) Receiver drier
87728445 1 2/28/2008
E.40.C / 10
Compressor Magnetic clutch Exploded view
1016L93 1
Clutch Assembly
1. Compressor 5. Bearing dust cover
2. Coil assembly 6. Front plate
3. Pulley 7. Shim(s)
4. Bearing 8. Dust cover
87728445 1 2/28/2008
E.40.C / 11
ENVIRONMENT CONTROL Airconditioning system Connect

NOTE: Photos may vary from machine being serviced.
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on
the suction and pressure hoses.
(1) Service ports
WARNING
Do not steam clean any air conditioning system parts
while the system is charged. The heat will cause the
refrigerant to rise to a pressure that could cause the
system to explode. SM104A
BD02H034 1
2. Make sure the charging station manifold gauge

valves are in the closed position.
3. Connect the hose from the low pressure gauge to the
port on the suction hose.
4. Connect the hose from the high pressure gauge to
the port on the discharge hose.
WARNING
Always wear safety goggles when working with liquid
refrigerant. Liquid refrigerant in your eyes could cause
blindness. SM105A
5. Start the engine and run at 1500 rpm maximum

speed. Operate the air conditioner system at maxi
mum cooling setting and blower speed for 15 minutes
with the cab door open. Observe the test gauges
and check the chart, refer to ENVIRONMENT CON
TROL Airconditioning system Testing (E.40.C)
against the gauge readings.
NOTE: The temperature control changes the vent outlet
temperatures by mixing heat with air conditioning. If the
temperature is too cold, the temperature control can be
turned clockwise to increase temperature even though the
air conditioner is on. Any air conditioner tests should be
run with this control all the way counterclockwise or with
the water valve on the engine turned off.
87728445 1 2/28/2008
E.40.C / 12
ENVIRONMENT CONTROL Airconditioning system Visual

inspection
NOTE: Air Louvers
1. Make sure louvers and recirculation vents are fully
open for most efficient air conditioning operation. De
frost louvers must be closed.
2. Check blower; blower must be running.
NOTE: Air Conditioning
3. Feel the air conditioning hoses. The high pressure
hoses (small line) must be warmer than the low pres
sure hose (large line).
4. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
NOTE: Duct Temperature
5. Put a thermometer in the air duct behind the seat and
run the compressor for five minutes to make temper
ature stable.
6. Duct temperature must not be above the Air Louver
Maximum Temperature for the Ambient Temperature
if the system is operating at maximum efficiency.
NOTE: Ambient temperature must be 27 to 43 degrees C
(80 to 110 degrees F).
7. If the duct temperature is above the Air Louver Max
imum Temperature for the Ambient Temperature the
system is low on refrigerant, there is a restriction in
the system, compressor is not working correctly, or
air ducts are not sealed correctly.
NOTE: Temperature Sensing Probe Check
8. Turn the engine OFF, key switch ON, blower switch
ON and temperature control switch turned fully clock
wise.
9. Remove the temperature sensing probe from the
evaporator.
10. Put the end of the temperature sensing probe in a
container with ice and water.
11. When the sensing tube has cooled to the tempera
ture 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 inter
rupted then replace the control switch.
NOTE: Compressor Hoses
12. Make sure that all hose connections are tight.
13. Check hoses for bends or cracks. Replace all hoses
that have damage.
87728445 1 2/28/2008
E.40.C / 13
ENVIRONMENT CONTROL Airconditioning system Evacuate

1. Recovered refrigerant passes through an oil separa
tor and filterdrier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig
erant passes over it.
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
(1) Service Ports
BD02M034 1

valves are in the closed position. Connect the hose
from the low pressure gauge to the port on the suc
tion 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.
BD02M001 2
5. Open the high and low valves.
A22114 3
87728445 1 2/28/2008
E.40.C / 14
6. Make certain the refrigerant tank gas and liquid

valves are open.
A22107 4
7. Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is com
plete. Wait for five minutes and observe the manifold
pressure gauges for a pressure rise. If pressure rises
above zero PSI, depress the hold/cont switch. Then
wait for the compressor to automatically shut OFF.
A22112 5
8. 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 sepa
rator.
A22108 6
9. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
A22110 7
87728445 1 2/28/2008
E.40.C / 15
10. Fill the A/C compressor with fresh SP15 PAG oil
equal to the amount in the reservoir.
A22111 8
11. Disconnect the hoses from the service ports and in
stall the caps.
(1) Service Ports
BD02M034 9
12. Replace the receiverdrier if one or more of the fol

lowing conditions occurs before you remove the air
and moisture from the system.
(A.) The system has been opened for service before.
(B.) Receiverdrier has operated two or more years.
(C.) Disassembly of compressor shows small par
ticles of moisture removing material (gold or brown
particles).
(D.) Large system leak (broken hose, break in line).
(E.)Too much air or moisture in system.
(F.) Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
BD02M001 10
87728445 1 2/28/2008
E.40.C / 16
14. Removal of air and moisture from the system is nec

essary after the refrigerant has been removed from
the system after the system has been opened for
maintenance. Air enters the system when the system
is opened. Air has moisture that must be removed to
prevent damage to the system components.
15. Air and moisture are removed from the system by a
vacuum pump. A vacuum pump is on the only equip
ment made that will lower the pressure in a system
enough to change the moisture to a vapor so that the
moisture can be removed.
NOTE: Refer to the vacuum pump manufacturer’s user
manual for additional information.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
A22113 11
17. Press the Charge Key. Program and Charge will ap
pear on the display.
A22115 12
18. Program 2.0 kg (4.6 lb)and press the enter key. The
display will flash once indicating the programmed
data has been accepted.
A22113 13
87728445 1 2/28/2008
E.40.C / 17
19. Full open the low and high pressure valves.
A22114 14
20. Open the red (vapor) and blue (liquid) valves on the
tank.
A22107 15
21. Press the Vacuum key. Automatic will show on the

display and after a slight delay, the vacuum pump
will start. The display will show the amount of time
programmed and begin a countdown to zero.
22. When the programmed time has elapsed, an auto
matic hold occurs. Check the low pressure gauge
to see that the A/C system maintains a 711.2
749.3 mm Hg (28 29.5 in Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 15 minutes. If the system will not
hold vacuum, a leak exists that must be corrected
before recharging can begin. See ENVIRONMENT
CONTROL Airconditioning system Leakage
test (E.40.C) for a leak test.
A22113 16
87728445 1 2/28/2008
E.40.C / 18
ENVIRONMENT CONTROL Airconditioning system Discharging

1. Recovered refrigerant passes through an oil separa
tor and filterdrier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig
erant passes over it.
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
(1) Service Ports
BD02M034 1

BD02M001 2
5. Open the high and low valves.
A22114 3
87728445 1 2/28/2008
E.40.C / 19
6. Make certain the refrigerant tank gas and liquid

valves are open.
A22107 4

Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is com
plete. Wait for five minutes and observe the manifold
pressure gauges for a pressure rise. If pressure rises
above zero PSI, depress the hold/cont switch. Then
wait for the compressor to automatically shut OFF.
A22112 5
8. 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 sepa
rator.
A22108 6
9. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
A22110 7
87728445 1 2/28/2008
E.40.C / 20
10. Fill the A/C compressor with fresh SP20 PAG oil
equal to the amount in the reservoir.
A22111 8
11. Disconnect the hoses from the service ports and in
stall the caps.
(1) Service Ports
BD02M034 9
87728445 1 2/28/2008
E.40.C / 21
ENVIRONMENT CONTROL Airconditioning system Charging

1. Press the charge key to begin refrigerant charging.
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.
A22113 1
2. Completely close the high and low pressure manifold

valves.
A22114 2
3. Start the engine and run at 1500 rpm. Operate the air
conditioner system at maximum cooling setting and
blower speed with the doors and windows open.
NOTE: The compressor will not operate if the system pres
sure is too low or too high. If the compressor fails to op
erate and the condenser blowers also fail to operate when
you actuate the A/C switch, check the system pressure to
determine if refrigerant is present. Check for continuity at
the pressure switch located at the receiverdryer and the
temperature switch located at the evaporator.
4. Observe the pressure gauge readings to determine
that the correct amount of refrigerant has entered the
system. See chart on ENVIRONMENT CONTROL
Airconditioning system General specification
(E.40.C) for temperature and pressure variations.
IMPORTANT: Check the OEM equipment manual before
performing this step 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.
A22117 3
87728445 1 2/28/2008
E.40.C / 22
5. Stop the engine, close any open valves and carefully

remove the manifold gauge hoses.
BD02M001 4
6. Install the caps on the service ports on the suction

and discharge hoses.
(1) Service Port Caps
BD02M034 5
87728445 1 2/28/2008
E.40.C / 23
ENVIRONMENT CONTROL Airconditioning system Leakage test

1. Shut off the engine.
WARNING
When refrigerant comes in contact with an open flame,
it forms phosgene gas. Never breathe these fumes.
SM109A
2. Use electronic leak detector OEM1437 to inspect all

connections. Use instructions from manufacturer of
leak finding tool.
NOTE: When checking compressor seal for a leak, remove
the dust cover and rotate the clutch shaft clockwise.
NOTE: To properly check the expansion valve for leaks,
remove the insulation tape.
3. Repair all leaks and recharge the system.
87728445 1 2/28/2008
E.40.C / 24
Compressor Remove
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.
2. Make sure the compressor and engine are clean be
fore connecting the refrigerant recovery system or
disconnecting any lines.
3. Connect the OEM1415 Refrigerant Recovery, Re
cycling and Charging Station to the High and Low
charge ports in the hose fittings connected to the
compressor. Evacuate the system to remove all
the refrigerant, see ENVIRONMENT CONTROL
Airconditioning system Evacuate (E.40.C) for
the procedure.
4. Disconnect the compressor clutch wire from the
wiring harness connectors.
5. Disconnect the low pressure line from the suction
port and the high pressure line from the discharge
port on the compressor. Immediately install protec
tive caps on the open ports and lines.
6. Remove the compressor adjusting bolts, nuts and
washers.
7. Loosen the compressor pivot bolt.
8. Loosen the compressor down toward the engine.
Remove the compressor belt.
9. Remove the compressor pivot bolt, nut and washers.
10. Remove the compressor from the mounting bracket.
87728445 1 2/28/2008
E.40.C / 25
Compressor Filling
1. Check the oil level in the compressor when any of the
following has occurred.
2. Broken refrigerant hose.
3. Large refrigerant leak.
4. Compressor leak.
5. Damage to or replaced system components.
6. New compressor installed.
7. Use the following procedure to check the compressor
oil level.
8. Start the engine and run at mididle. Operate the air
conditioner for 10 to 15 minutes at maximum cooling
and maximum blower speed.
9. Stop the engine. See ENVIRONMENT CONTROL
Airconditioning system Discharging (E.40.C)
for connecting the compressor to the A/C charging,
recovery and recycling station and for discharging
the system.
10. 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
marks. Read the mounting angle to the nearest de
gree mark. Make a note of the degree reading for
reference later.
11. When all refrigerant has been reclaimed, remove the
oil filler plug.
BD02H034_3 1
12. Add back to the compressor an amount of new SP15

PAG oil equal to that amount reclaimed with refriger
ant. Refer to ENVIRONMENT CONTROL Aircon
ditioning system Discharging (E.40.C) for com
plete instructions.
13. Remove the dust cover and use a wrench to rotate
the clutch clockwise until the internal parts are in the
position shown above. This will permit the dipstick to
be inserted all the way.
103L7 2
87728445 1 2/28/2008
E.40.C / 26
14. Put the dipstick in the oil filler hole to the stop posi
tion.
15. Make sure the dipstick is inserted all the way to the
stop.
NOTE: The illustration shows the front view for the com
pressor 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.
850L01 3
16. 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.
bs04d060 4
17. If the oil level is not correct, add or subtract oil to the
correct level shown in the above chart.
IMPORTANT: Use only SP15 PAG oil.
18. Install a new Oring on the oil filler plug. Install the
plug and tighten to a torque of 15 24 Nm ( 11 18
lb ft).
BD02H034_3 5
87728445 1 2/28/2008
E.40.C / 27
Compressor Install
1. Install the compressor on the mounting bracket. In
stall washers on the pivot bolt. Install the pivot bolt,
washer, and nut onto the pivot bolt.
2. Install the drive belt on the machine. Install the ad
justing bolts, nuts and washers into the compressor
adjusting straps.
3. Adjust belt tension. See Compressor Belt Check
(E.40.C) in this service manual. Tighten pivot bolt nut
and compressor adjusting bolts when complete.
4. Connect the compressor clutch wire to the wiring har
ness connectors.
IMPORTANT: Use caution when removing cap as new
compressors have internal pressure when shipped.
5. Slowly remove the protective cap, install new Oring
and connect the low pressure line to the inlet port on
the compressor.
6. Carefully remove the protective cap, install new
Oring and connect the high pressure line to the
discharge port on the compressor.
cycling and Charging Station to the high and low
charge ports in the hose fittings connected to the
compressor. Evacuate the system and charge the
system with reclaimed or new refrigerant; see ENVI
Evacuate (E.40.C) and ENVIRONMENT CONTROL
Airconditioning system Charging (E.40.C) for
these procedures.
87728445 1 2/28/2008
E.40.C / 28
Compressor Belt Check

1. Check interval every 250 hours of operation.
NOTE: Check the belt tension after the first 50 hours of
operation and then use the regular check interval.
2. Measure the compressor belt for correct tension us
ing a belt tension gauge. Check the belt to the fol
lowing specifications. A new belt 578 667 N ( 130
150 lb). Used belt 356 534 N ( 80 120 lb).
542L95 1
87728445 1 2/28/2008
E.40.C / 29
Compressor Belt Adjust
WARNING
Rotating fan and belts. Contact can injure. Keep clear. M150A
1. To adjust the belt tension, loosen the compressor

adjusting bolts and pivot bolt. Push the compressor
up until the correct tension for the belt is reached.
Tighten the compressor adjusting bolts and pivot
bolt.
IMPORTANT: Do not pry on the compressor clutch or body.
Apply pressure only on the mounting ears.
NOTE: Adjust new bolts to the used belt specification after
a 10 minute runin.
87728445 1 2/28/2008
E.40.C / 30
Compressor Magnetic clutch Disassemble

1. See Compressor Remove (E.40.C) in this service
manual for compressor removal. Clean the external
surfaces of the compressor before doing any work on
the compressor.
A21250 1
2. Remove the mounting bolts for the clutch dust cover.
A21251 2
3. Remove the clutch dust cover.
A21252 3
4. Remove the retaining nut for the front plate. Use the
special spanner wrench from the service tool set to
keep the plate and shaft from turning.
A21253 4
87728445 1 2/28/2008
E.40.C / 31
5. Install the special puller from the service tool set on

the clutch front plate.
A21254 5
6. Turn the center screw to pull the clutch front plate.
A21255 6
7. Remove the shim(s) from the shaft.
A21256 7
8. Remove the bearing dust cover. Be careful not to

bend the dust cover.
A21257 8
87728445 1 2/28/2008
E.40.C / 32
9. Remove the key from the rotor shaft.
A21258 9
10. Remove the external snap ring for the bearing and
pulley assembly.
A21260 10
11. Install the special puller internal collars into the

groove in the pulley. Install the special tool onto the
shaft. Tighten the mounting screws finger tight.
A21261 11
12. Turn the center screw on the puller.
A21262 12
87728445 1 2/28/2008
E.40.C / 33
13. Remove the pulley and bearing assembly.
A21263 13
14. Remove the snap ring for the clutch coil assembly.
A21265 14
15. Disconnect the clip for the lead wire.
A21264 15
16. Remove the clutch coil assembly.
A21266 16
87728445 1 2/28/2008
E.40.C / 34
17. Remove the internal snap ring and remove the bear
ing from the pulley.
A21267 17
87728445 1 2/28/2008
E.40.C / 35
Compressor Magnetic clutch Electrical test

1. Use a ammeter, voltmeter and a 12 volt battery to
check the amperage of the clutch coil. The current
draw must be 3.6 to 4.2 amperes at 12 volts.
(1) Ammeter
(2) 12V Battery
102L7 1
2. A reading of more than 4.2 amperes indicates a short

within the coil.
3. No amperage reading indicates an open circuit in the
coil.
4. Replace the clutch coil if the amperage reading is not
correct.
87728445 1 2/28/2008
E.40.C / 36
Compressor Magnetic clutch Assemble

1. Install the clutch coil assembly. Align the detent ball
and socket on the coil and housing.
A21266 1
2. Install the clip for the coil lead wire.
A21264 2
3. Install the snap ring for the clutch coil assembly.
A21265 3
4. Install the bearing in the pulley and install the internal

snap ring.
A21267 4
87728445 1 2/28/2008
E.40.C / 37
5. Put the pulley and bearing assembly on the front

housing hub. Install a driver on the pulley assem
bly. Make sure that the tool is on the inner race of
the bearing.
A21268 5
6. Support the compressor on the four mounting ears at

the compressor rear. Use a hammer to tap the pulley
assembly onto the front housing hub. As the pulley
is tapped onto the hub you can hear the difference in
sound when the pulley is fully installed. Make sure
the bearing is against the bottom of the hub.
A21268 6
7. Install the external snap ring on the front housing

hub.
A21260 7
8. Install the key in the rotor shaft.
A21259 8
87728445 1 2/28/2008
E.40.C / 38
9. Place the bearing dust cover in the bore. Place driver

from special tool kit over the dust cover.
A21269 9
10. Gently tap the dust cover until it is seated.
A21270 10
11. Install the shim(s) on the rotor shaft.
A21256 11
12. 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.
A21271 12
87728445 1 2/28/2008
E.40.C / 39
13. Use a hammer to tap the plate onto the shaft. Make
sure the plate is against the clutch shims. As the
plate is tapped onto the shaft you can hear the differ
ence in sound when the plate is fully installed.
A21272 13
14. Install the nut on the rotor shaft. Use the spanner
wrench and a torque wrench to tighten the nut to a
torque of 15 20 Nm ( 11 15 lb ft.)
A21253 14
15. Use a feeler gauge to measure the gap between the

front plate and pulley assembly. The gap must be
0.41 0.79 mm ( 0.016 0.031 in). The gap must
be even all the way around the plate. If necessary,
lightly lift or push down on the plate to make the gap
even.
NOTE: If the gap does not meet the above specifications
remove the front plate and add or subtract clutch shims as
required.
T97256 15
16. Install the dust cover.
A21252 16
87728445 1 2/28/2008
E.40.C / 40
17. Install and tighten the six bolts that hold the dust
cover to the compressor to 7 11 Nm ( 5 8 lb ft).
A21251 17
87728445 1 2/28/2008
E.40.C / 41
Evaporator Visual inspection

1. Refer to Evaporator Replace (E.40.D) for access
to the evaporator 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 pres
sure. Make sure the water drains freely from the
evaporator/heater core. DO NOT USE STEAM.
WARNING
Do not steam clean any air conditioning system parts
while the system is charged. The heat will cause the
refrigerant to rise to a pressure that could cause the
system to explode. SM104A
4. Make sure seals are in place so blower will pull air

only through the evaporator/heater core and not
around the evaporator/heater core.
5. Make sure the filters are clean.
87728445 1 2/28/2008
E.40.C / 42

Troubleshooting
NOTE: Perform a visual inspection of the machine. Check the following and correct as necessary: Obtain service
history if possible. Is compressor drive belt in place and tensioned? Are grille screens, fan blades, condenser, air
filter, and evaporator unobstructed? Are there any sharp bends or kinks in the hoses? Are there heavy accumula
tions of oil, or oily dust around the fittings, indicating refrigerant leakage? Are air ducts undamaged, sealed properly
and in position? Condensate drain hoses and check valves present and unobstructed?
ENVIRONMENT CONTROL Airconditioning system Testing

NOTE: Connect the manifold gauge set into the air conditioning system as shown. Make sure that both valves in the
manifold gauge set are closed.
Engine at 1500 rpm, no load, fan Refer to pressure temperature and Refer to ENVIRONMENT CON
speed & temperature control at louver air temperature chart. TROL Airconditioning system
maximum setting, A/C switch ON, Visual inspection (E.40.C).
all louvers and doors open. All
panels and access doors installed
and closed. Cab filters clean and
installed. Heater valve at engine
closed. Measurements taken 15
minutes after startup.
BC04D002 1
87728445 1 2/28/2008
E.40.C / 43
ENVIRONMENT CONTROL Airconditioning system Problem

solving
OPERATION
Compressor clutch, high/low pressure and temperature switches, blower fuse, blower fan switch, blower motor and
air conditioner switch.
TROUBLESHOOTING
1. If there is electrical system voltage to the clutch, replace the clutch.

2. The combination high/low pressure switch is located at the evaporator and the temperature switch is located at
the receiverdryer.
3. Check for damaged blower fuse.
4. Check switch operation. Switch must give four different blower speeds: OFF, Low, Medium, and High.
5. Check for loose connections or broken wires. Repair or replace as necessary.
6. Check resistor board.
7. Check the wiring to the blower motor. Make repairs or replace items as necessary.
8. Check motor ground wire. Make sure motor ground wire is making good contact with mounting bracket.
9. Turn switch to the AC position. Compressor clutch must engage. Blower must be operating, since electrical
power to temperature control switch is received from blower switch.
NOTE: Turn the AC switch on and check for continuity between the connector. If continuity is not present, replace the
switch.
87728445 1 2/28/2008
E.40.C / 44
Compressor Problem solving

OPERATION
Compressor belt, mounting brackets, clutch and belt alignment.
TROUBLESHOOTING
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 runin time on the belt. Belt tension on a used belt must be 400
to 489 N (90 to 110 lbs).
2. Too much belt wear replace a worn belt, because a worn belt will cause too much slippage.
3. Loose bracket mounting bolts tighten the bolts to the correct torque.
4. Bracket has breaks or cracks replace the bracket.
5. The compressor belt will slip on the compressor pulley if there is compressor seizure. Remove the compressor
for service or replacement.
6. Remove the dust cover and check the air gap on the compressor clutch. The gap between the front plate and
pulley assembly must be 0.41 to 0.79 mm (0.016 to 0.031 inch).
7. Use a socket wrench to slowly rotate the compressor clockwise. Compressor rotation should be smooth and
not require much effort.
NOTE: 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.
87728445 1 2/28/2008
E.40.C / 45
Condenser Fan Testing

the ON position.
Check
Terminal 0 to ground.
Put the ignition switch in the RUN 12 volts Bad wire (802) to fuse panel, bad
position. fuse. Bad power relay module A.
Check
Terminal 3 in Connector L11 for wire
(802) to ground.
Put the AC switch in the ON posi 12 volts Bad wire (820) to mode switch, bad
tion. Put the blower switch in the mode switch.
HIGH position and turn the thermo If all tests are good, repair or replace
stat switch to maximum cool. the condenser fans.
Check
Terminal 2 in Connector L11 for wire
(820) to ground.
87728445 1 2/28/2008
E.40.C / 46
Expansion valve Testing

Disconnect the low pressure switch. Check the low pressure gauge for a If there is little or no decrease in the
Remove insulation material from top decrease in pressure. low pressure gauge, go to Step 2.
of valve. With the engine running
and the air conditioner on maximum
cooling, cool the top of the expansion
valve with ice.
Allow the top of the expansion valve The valve should open and the pres Repeat Step 1.
to warm. sure should rise at the low pressure If there is little or no decrease in the
gauge. low pressure gauge, replace expan
sion valve, refer to Expansion valve
Replace (E.40.D).
87728445 1 2/28/2008
E.40.C / 47
Index

Compressor Filling 26
Compressor General specification 9
Compressor Install 28
Compressor Problem solving 45
Compressor Remove 25
Compressor Special tools 9
Compressor Torque 9
Compressor Belt Adjust 30
Compressor Belt Check 29
Compressor Magnetic clutch Assemble 37
Compressor Magnetic clutch Disassemble 31
Compressor Magnetic clutch Electrical test 36
Compressor Magnetic clutch Exploded view 11
Condenser Fan Testing 46
ENVIRONMENT CONTROL Airconditioning system Charging 22
ENVIRONMENT CONTROL Airconditioning system Connect 12
ENVIRONMENT CONTROL Airconditioning system Discharging 19
ENVIRONMENT CONTROL Airconditioning system Dynamic description 10
ENVIRONMENT CONTROL Airconditioning system Evacuate 14
ENVIRONMENT CONTROL Airconditioning system General specification 6
ENVIRONMENT CONTROL Airconditioning system General specification Stable Saturation 7
Pressure/Temperature Chart
ENVIRONMENT CONTROL Airconditioning system Leakage test 24
ENVIRONMENT CONTROL Airconditioning system Problem solving 44
ENVIRONMENT CONTROL Airconditioning system Special tools 4
ENVIRONMENT CONTROL Airconditioning system Testing 43
ENVIRONMENT CONTROL Airconditioning system Troubleshooting 43
ENVIRONMENT CONTROL Airconditioning system Visual inspection 13
Evaporator Visual inspection 42
Expansion valve Testing 47
87728445 1 2/28/2008
E.40.C / 48
ENVIRONMENT CONTROL Heating, ventilation and airconditioning

40.D
750L
850L
87728445 1 2/28/2008
E.40.D / 1
Contents
ENVIRONMENT CONTROL Heating, ventilation and airconditioning 40.D
SERVICE
Heater valve
Replace 3
Condenser
Replace 8
Evaporator
Replace 10
Expansion valve
Replace 19
Heater
Replace 23
Receiver/drier
Replace 31
Ventilation system
Motor Replace 32
Sensing system
Temperature sensor Replace 40
DIAGNOSTIC
Compressor
Magnetic clutch Testing 48
Sensing system
High pressure switch Testing 49
Low pressure switch Testing 49
87728445 1 2/28/2008
E.40.D / 2
BODY AND STRUCTURE ENVIRONMENT CONTROL Heating, ventilation and airconditioning
Heater valve Replace

engine and trun the master disconnect switch OFF.
2. Drain 4 l (1 US gal) from the engine cooling system.
3. Remove the inside air filer by removing the two
thumb screws.
BD06K00301 1
4. Remove five mounting screws from the center rear

console, two from the front and three are located at
the back glass in the rear.
BD06K00401 2
5. Remove the rear console from the cab.

6. Remove the left arm rest form the cab.
BD06K00701 3
87728445 1 2/28/2008
E.40.D / 3
7. Remove two screws (2) mounting the left console,

remove the door catch release knob (1), loosen con
sole mounting screw (3).
BD06K00801 4
8. Remove screws (1) and loosen screw (2).
BD06K00901 5
9. Remove the two mounting screws at the back of the

left console, remove the console from the cab.
BD06K01001 6
10. Disconnect the heater inlet hose and heater core

hose from the temperature control.
BD06K01101 7
87728445 1 2/28/2008
E.40.D / 4
11. Disconnect the wiring from the control, remove the

mounting screws from the control and remove the
control
12. Place the temperature control in the mounting
bracket, install and tighten the mounting screws for
the control. Connect the wiring to the control.
13. Connect the heater inlet hose and heater core hose
to the temperature control.
BD06K01101 8
14. Install the left console into the cab, install and tighten
the two mounting screws at the back of the left con
sole.
BD06K01001 9
15. Install and tighten two screws (2) mounting the left
console, instal and tighten the door catch release
knob (1), tighten console mounting screw (3).
BD06K00801 10
87728445 1 2/28/2008
E.40.D / 5
16. Install and tighten screws (1) and tighten screw (2).
BD06K00901 11
17. Install left arm rest in the cab.
BD06K00701 12
18. Place the rear console cover in the cab.

19. Install and tighten five mounting screws into the cen
ter rear console, two in the front and three are located
at the back glass in the rear.
BD06K00401 13
20. Install the air filter.
BD06K00301 14
87728445 1 2/28/2008
E.40.D / 6
21. Refill the coolant to the proper level.
87728445 1 2/28/2008
E.40.D / 7
Condenser Replace
engine and turn the master disconnect switch OFF.
2. Connect the OEM1415 Refrigerant Recovery, Recy
cling and Charging Station to the high and low charge
ports in the hose fittings at the compressor. Evacu
ate the system to remove all of the refrigerant, see
ENVIRONMENT CONTROL Airconditioning sys
tem Evacuate (E.40.C).
3. Disconnect the electrical connector for the flood light.
Remove the hoses from the cab to the condenser.
Remove and discard the Orings.
BD06K12301 1
4. Install plug in the hoses and tubes. Install caps on

the fitting on the condenser.
5. Disconnect electrical connector for the flood light.
Disconnect electrical connector for the fan motors.
BD06K12501 2
6. Support the condenser with suitable lifting device.

Loosen and remvoe the seven bolts and lock wash
ers fasting the condenser core to the cab.
BD06K12401 3
7. Remove the condenser and fans from the machine.
87728445 1 2/28/2008
E.40.D / 8
8. Pot the condenser and fans in position. Install and

tighten the seven bolts and lock washers securing
the condenser core to the cab.
BD06K12401 4
9. Connect the fan electrical connector and flood light

connector.
BD06K12501 5
10. Remove the caps and plugs from the hoses, tubes,
and fittings.
11. Lubricate new Orings with clean refrigerant oil and
install the Orings.
12. Connect the hoses to the tubes and fittings on the
condenser and cab, tighten the fittings.
BD06K12301 6

cling and Charging Station tot he high and low charge
ports in the hose fitting connected tot he compres
sor. Evacuate the system and charge the system
with reclaimed or new refrigerant, see ENVIRON
MENT CONTROL Airconditioning system Gen
eral specification (E.40.C) for capacity and ENVI
Charging (E.40.C) for the procedure.
87728445 1 2/28/2008
E.40.D / 9
Evaporator Replace
3. Remove the inside air filter by removing the two
thumb screws.
BD06K00301 1

console, two from the font and three are located at
BD06K00401 2

6. Remove the right arm rest from the cab.
7. Remove two screws (2) mounting the right console,
BD06K01801 3
87728445 1 2/28/2008
E.40.D / 10
BD06K01901 4

right console, remove the console from the cab.
BD06K02001 5
BD06K00701 6

BD06K00801 7
87728445 1 2/28/2008
E.40.D / 11
BD06K00901 8

BD06K01001 9
14. Remove the two screws mounting the electrical con

trols.
BD06K00501 10
15. Remove the mounting screws for the heater core and
evaporator core cover.
BD06K02201 11
87728445 1 2/28/2008
E.40.D / 12
16. Remove the cover for the heater core and evaporator
core.
BD06K02301 12
17. Remove the insulation tape from around the fittings

at the expansion vale.
BD06K02101 13
18. Use two wrenches to loosen and remove the tubes

from the expansion valve.
19. Remove the expansion valve and install caps on the
tube fitting to the evaporator core.
20. Remove the probe from the evaporator core.
BD06K02301 14
87728445 1 2/28/2008
E.40.D / 13
21. It might be required to loosen the guide plate for the

evaporator and heater core to the core housing, re
move the evaporator core.
BD06K02601 15
22. Install the evaporator core.

23. Put the evaporator and heater core in position. If
loosened tighten the screws securing the evaporator
and heater core guide plate.
BD06K02601 16
24. Measure over 114 mm (4.5 in) from the right side of
the evaporator core.
BD06K02501 17
25. Carefully inset the sensor into the evaporator core.
BD06K02401 18
87728445 1 2/28/2008
E.40.D / 14
26. Install the evaporator and heater core cover, install

and tighten the mounting screws for the core cover.
BD06K02201 19
27. Install and tighten the two screws mounting the elec
trical controls.
BD06K00501 20
28. Lubricate the new Orings with clean refrigerant oil.

29. Install the new Orings in the openings in the front of
the expansion valve.
30. Remove the caps from the tubes and connect the
expansion valve to the tubes.
31. Use two wrenches and tighten the tubes in the ex
pansion valve.
32. Install new insulation tape around the expansion
valve and evaporator lines that are exposed.
BD06K02101 21
87728445 1 2/28/2008
E.40.D / 15
sole.
BD06K01001 22
console, install and tighten the door catch release
BD06K00801 23
35. Install and tighten screws (1‘) and tighten screw (2).
BD06K00901 24
36. Install the left arm rest in the cab.
BD06K00701 25
87728445 1 2/28/2008
E.40.D / 16
37. Install the right console into the cab. Install and
tighten the two mounting screws at the back of the
right console.
BD06K02001 26
BD06K01901 27
39. Install and tighten two screws (2) mounting the right
BD06K01801 28
40. Install the right arm rest in the cab.

87728445 1 2/28/2008
E.40.D / 17
BD06K00401 29
BD06K00301 30

87728445 1 2/28/2008
E.40.D / 18
Expansion valve Replace

thumb screws.
BD06K00301 1

BD06K00401 2

BD06K01801 3
87728445 1 2/28/2008
E.40.D / 19
BD06K01901 4

BD06K02001 5
10. Remove the insulation tape from around the fittings

at the expansion vale.
BD06K02101 6
11. Use two wrenches to loosen and remove the tubes

from the expansion valve.
12. Remove the expansion valve.
13. Lubricate the new Orings with clean refrigerant oil.
14. Install the new Orings in the tubes.
15. Connect the expansion valve to the tubes.
16. Use two wrenches and tighten the tubes in the ex
pansion valve.
87728445 1 2/28/2008
E.40.D / 20
17. Install new insulation tape around the expansion

valve and evaporator lines that are exposed.
BD06K02101 7
right console.
BD06K02001 8
BD06K01901 9
BD06K01801 10
87728445 1 2/28/2008
E.40.D / 21

BD06K00401 11
BD06K00301 12

87728445 1 2/28/2008
E.40.D / 22
Heater Replace
2. Drain 4 l (1 US gal) from the engine cooling system.
thumb screws.
BD06K00301 1

BD06K00401 2

BD06K01801 3
87728445 1 2/28/2008
E.40.D / 23
BD06K01901 4

BD06K02001 5
BD06K00701 6

BD06K00801 7
87728445 1 2/28/2008
E.40.D / 24
BD06K00901 8

BD06K01001 9

trols.
BD06K00501 10
BD06K02201 11
87728445 1 2/28/2008
E.40.D / 25
core.
BD06K02301 12
17. Disconnect and plug the hoses to the heater core.
BD06K01101 13
18. It might be required to loosen the guide plate for the

evaporator and heater core to the core housing, re
move the heater core.
BD06K02601 14
19. Install the heater core.

20. Put the evaporator and heater core in position. If
loosened tighten the screws securing the evaporator
and heater core guide plate.
BD06K02601 15
87728445 1 2/28/2008
E.40.D / 26

BD06K02201 16
trical controls.
BD06K00501 17
23. Remove the plugs from the heater hoses and install
the hoses onto the heater core.
BD06K01101 18
sole.
BD06K01001 19
87728445 1 2/28/2008
E.40.D / 27
BD06K00801 20
BD06K00901 21
BD06K00701 22
right console.
BD06K02001 23
87728445 1 2/28/2008
E.40.D / 28
BD06K01901 24
BD06K01801 25

BD06K00401 26
87728445 1 2/28/2008
E.40.D / 29
BD06K00301 27
35. Refill the coolant to the proper level.
87728445 1 2/28/2008
E.40.D / 30
Receiver/drier Replace
blade to the floor. Apply the parking brake, Stop the
engine and turn the master disconnect switch to OFF.
cycling 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 ENVIRONMENT CONTROL Airconditioning
system Evacuate (E.40.C)
3. Open the right cab side panel.
4. Fasten identification tags on the hoses on the re
ceiver drier. Disconnect the hoses from the receiver
drier. Remove and discard the Orings.
BD06K11901 1
5. Install plugs in the hoses and install caps on the fit

tings to the receiver drier.
6. Loosen and remove the two bolts fastening the
bracket which secures the receiver drier.
7. Remove the receiver drier.
8. Put the receiver drier and retaining bracket in posi
tion. Install and tighten the two bolts securing the
mounting bracket for the receiver drier.
9. Remove the caps and plugs from the hoses and fit
tings.
10. Lubricate new Orings with clean refrigerant oil and
install the Orings.
11. Connect the hoses to the receiver drier and tighten
the fittings.
cling an Charging Station to the High and Low charge
ports in the hose fittings connected to the compres
13. Close the cab right side panel.
87728445 1 2/28/2008
E.40.D / 31
Ventilation system Motor Replace

thumb screws.
BD06K00301 1

BD06K00401 2

BD06K01801 3
87728445 1 2/28/2008
E.40.D / 32
BD06K01901 4

BD06K02001 5
BD06K00701 6

BD06K00801 7
87728445 1 2/28/2008
E.40.D / 33
BD06K00901 8

BD06K01001 9
13. Remove the outer cover mounting screw for the fan
box.
BD06K01201 10
14. Remove the inner cover mounting screws for the fan
box, remove the fan motor cover.
BD06K01301 11
87728445 1 2/28/2008
E.40.D / 34
15. Disconnect the wires to the fan motor.
BD06K01401 12
16. Remove the mounting bolts for the fan motor.
BD06K01501 13
17. Remove the fan motor.
BD06K01601 14
18. Repeat the procedure for the right fan.

19. During installation make sure to align the fan bracket
into the slot at the bottom of the air box.
BD06K01701 15
87728445 1 2/28/2008
E.40.D / 35
20. Install and tighten the mounting bolts for the fan mo
tor.
BD06K01501 16
21. Connect the wires to the fan motor.
BD06K01401 17
22. Install the fan motor cover, install and tighten the in
ner cover mounting screws.
BD06K01301 18
23. Install and tighten the outer cover mounting screw for
the fan box.
BD06K01201 19
24. Repeat the procedure for the right fan.
87728445 1 2/28/2008
E.40.D / 36
sole.
BD06K01001 20
BD06K00801 21
BD06K00901 22
BD06K00701 23
87728445 1 2/28/2008
E.40.D / 37
right console.
BD06K02001 24
BD06K01901 25
BD06K01801 26

87728445 1 2/28/2008
E.40.D / 38
BD06K00401 27
BD06K00301 28
87728445 1 2/28/2008
E.40.D / 39
Sensing system Temperature sensor Replace

blade to the floor. Apply the parking brake and stop
the engine.
2. Turn the master disconnect switch OFF.
thumb screws.
BD06K00301 1

BD06K00401 2

BD06K01801 3
87728445 1 2/28/2008
E.40.D / 40
BD06K01901 4

BD06K02001 5
BD06K00701 6

BD06K00801 7
87728445 1 2/28/2008
E.40.D / 41
BD06K00901 8

BD06K01001 9

trols.
BD06K00501 10
BD06K02201 11
87728445 1 2/28/2008
E.40.D / 42
core, remove the probe from the evaporator core.
BD06K02301 12
17. Remove the mounting screws from the temperature

switch, disconnect the wiring harness connector, re
move the switch from the machine.
BD06K00601 13
18. Install and mount the switch, connect the sires to the
temperature switch.
BD06K00601 14
19. Measure over 114 mm (4.5 in) from the right side of
the evaporator core.
BD06K02501 15
87728445 1 2/28/2008
E.40.D / 43
20. Carefully inset the sensor into the evaporator core.
BD06K02401 16

BD06K02201 17
trical controls.
BD06K00501 18
sole.
BD06K01001 19
87728445 1 2/28/2008
E.40.D / 44
BD06K00801 20
BD06K00901 21
BD06K00701 22
right console.
BD06K02001 23
87728445 1 2/28/2008
E.40.D / 45
BD06K01901 24
BD06K01801 25

BD06K00401 26
87728445 1 2/28/2008
E.40.D / 46
BD06K00301 27
87728445 1 2/28/2008
E.40.D / 47
Compressor Magnetic clutch Testing

Put the master disconnect switch in 12 volts Bad wire W(818C) between clutch
the ON position. Put the ignition and AC pressure switches, bad pres
switch in the RUN position and the sure switches.
AC switch in the ON position. Put If the test is good and the clutch does
the blower switch in the HIGH posi not work, replace the clutch coil.
tion and turn the thermostat switch to
maximum cool.
Check
+ terminal on compressor clutch to
ground.
High pressure switch opens at 2689 Continuity Bad switch.
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 pres
sure.
Check
Between terminal of switch
Low pressure switch opens at 14 to Continuity Bad switch.
42 kPa (2 to 6 psi) falling, switch
closes at 117 to 159 kPa (17 to 23
psi) and rising. Make sure AC sys
tem is at operating pressure.
Check
Between terminal of switch
Disconnect connector on control unit Continuity Bad ground circuit
for HVAC system.
Check
Terminal for pin 2 to ground
Put the master disconnect switch in 12 volts No power to pin 9, bad fuse #21 no
the ON position. Put the ignition power to pin 7, bad fuse #22 or bad
switch in the RUN position and the mode switch, no power to pin 3, bad
AC switch in the ON position. Put fan switch, no power to pin 1, bad
the blower switch in the HIGH posi temperature switch.
tion and turn the thermostat switch to
maximum cool.
Check
Check at pins 1, 3, 7, and 9 to
ground.
Turn all power OFF and connect 12 volts Bad HVAC control module.
connector to control unit for HVAC
system, turn all power and switches
back ON.
Check
Terminal for wire W (818A) at con
troller to ground.
87728445 1 2/28/2008
E.40.D / 48
Sensing system High pressure switch Testing

Disconnect the connector at the Continuity Bad pressure switch.
pressure switch. Make sure the sys
tem is charged with correct amount
of refrigerant.
Check
Terminal to terminal.
Sensing system Low pressure switch Testing

Disconnect the connector at the Continuity Bad pressure switch.
pressure switch. Make sure the sys
tem is charged with correct amount
of refrigerant.
Check
Terminal to terminal.
87728445 1 2/28/2008
E.40.D / 49
Index
ENVIRONMENT CONTROL Heating, ventilation and airconditioning 40.D

Compressor Magnetic clutch Testing 48
Condenser Replace 8
Evaporator Replace 10
Expansion valve Replace 19
Heater Replace 23
Heater valve Replace 3
Receiver/drier Replace 31
Sensing system High pressure switch Testing 49
Sensing system Low pressure switch Testing 49
Sensing system Temperature sensor Replace 40
Ventilation system Motor Replace 32
87728445 1 2/28/2008
E.40.D / 50
SAFETY SECURITY ACCESSORIES Safety 50.B
750L
850L
87728445 1 2/28/2008
E.50.B / 1
Contents
DIAGNOSTIC
Audio alarm
Testing Warning Buzzer 3
Audible alert
Switch Testing 4
Horn Testing 4
87728445 1 2/28/2008
E.50.B / 2
BODY AND STRUCTURE SAFETY SECURITY ACCESSORIES Safety
Audio alarm Testing Warning Buzzer

NOTE: Check that wire "135" is connected to the positive terminal and wire "0" is connected to the negative terminal
of the buzzer.
Put the master disconnect switch in 12 volts Bad instrument cluster power circuit.
the ON position. Put the ignition
switch in the RUN position. If the
buzzer does not sound, do the fol
lowing checks.
Check
Terminal for wire (135) at warning
buzzer to ground.
Turn the ignition switch OFF. Discon 12 volts Check fuse F8 in connector M2,
nect the instrument cluster connec check ignition relay.
tors D2A and D2B, turn the ignition
switch back to the RUN position.
Check
Cavity 1 in Connector D2A and cav
ities 18 and 21 in Connector D2B to
ground.
Turn the ignition switch OFF. Discon 30 ohms Bad warning buzzer.
nect wires from warning buzzer ter If all readings are good, replace the
minals. warning buzzer.
Check
Between terminals of warning
buzzer.
87728445 1 2/28/2008
E.50.B / 3
BODY AND STRUCTURE SAFETY SECURITY ACCESSORIES Safety
Audible alert Switch Testing

Disconnect connector at horn button. Continuity Bad horn button.
Have another person press and hold
down the horn button.
Check
Between terminals 2 and 3 of horn
button.
Audible alert Horn Testing

the ON position.
Check
Terminal for wire 0 at horn to ground.
Horn switch terminal for wire R (992) 12 volts Bad wire R (992) between the horn
to ground. switch and fuse panel, bad fuse F1.
Have an assistant hold down the 12 volts Bad horn switch.
horn button.
Check
Horn switch terminal for wire (993) to
ground.
Disconnect the wire 0 from the horn, 12 volts Bad horn.
have an assistant hold down the
horn button.
Check
Horn terminal for wire 0 to ground.
87728445 1 2/28/2008
E.50.B / 4
Index

Audible alert Horn Testing 4
Audible alert Switch Testing 4
Audio alarm Testing Warning Buzzer 3
87728445 1 2/28/2008
E.50.B / 5
PRINTED IN U.S.A.
87728445 1 2/28/2008
REPAIR MANUAL
TOOL POSITIONING
750L
850L
87728445 1 2/28/2008
G
Contents
TOOL POSITIONING G
LIFTING G.10.A
750L , 850L
TILTING G.20.A
750L , 850L
SWINGING G.40.A
750L , 850L
87728445 1 2/28/2008
G
TOOL POSITIONING G
LIFTING 10.A
750L
850L
87728445 1 2/28/2008
G.10.A / 1
Contents
TOOL POSITIONING G
LIFTING 10.A
TECHNICAL DATA
Cylinder
Torque 3
Special tools 3
FUNCTIONAL DATA
Command
Exploded view 4
Control valve
Sectional view 5
Cylinder
Exploded view 6
Tool support
Drawing 7
SERVICE
Command
Travel adjust 8
Control valve
Disassemble 10
Assemble 21
Cylinder
Disassemble 32
Assemble 36
Tool support
Remove 39
Install 41
87728445 1 2/28/2008
G.10.A / 2
TOOL POSITIONING LIFTING
Cylinder Torque
Component Nm Lb
Piston bolt 810 925 Nm 597 682 lb ft
Gland 135 542 Nm 100 400 lb ft
Cylinder Special tools
CAS1456 1
CAS1456 GLAND WRENCH
B505802M 2
CAS1660 BUFFER SEAL INSTALLATION TOOL
B795329M 3
CAS1039 PISTON BOLT TOOL
87728445 1 2/28/2008
G.10.A / 3
BC02J010 1
(1) Angle control (8) Jam nut (15) Rocker angle control
(2) Lift and tilt control (9) Lift rod (16) Self locking nut
(3) Mounting bracket (10) Tilt rod (17) Rod end angle
(4) Rod end lift (11) Clevis lift (18) Angle rod
(5) Rod end tilt (12) Pin spring clevis (19) Clevis angle
(6) Rod end angle (13) Clevis tilt (20) Shims
(7) Rod end angle (14) Rocker bracket (21) Jam nut
87728445 1 2/28/2008
G.10.A / 4
Control valve Sectional view
BC02J008_2 1
(1) Load check valve (7) Seal retainer (13) Detent poppet (19) Snap ring
(2) Body (8) Wiper (14) Oring (20)Spring cap
(3) Spool boot (9)Lip seal (15) Spool sleeve (21) Washer
(4) Allen head screw (10) Spool (16) Detent sleeve (22) Allen head screw
(5) Boot retainer (11) Detent balls (17) Top spring seat (23)Anticavitation valve
(6)Retainer plate (12) Spring (18)Bottom spring seat
87728445 1 2/28/2008
G.10.A / 5
Cylinder Exploded view
BC06B02702 1
(1) Tube (7)Washer (13) Wiper

(2) Lock screw (8) Seal (14) Buffer seal
(3) Gland (9) Ring (15) Rod seal
(4) Piston rod (10) Wear ring (16) Bushing
(5) Piston (11) Oring (17) Bushing
(6) Bolt (12) Backup ring (18) Grease fitting
87728445 1 2/28/2008
G.10.A / 6
Tool support Drawing
BS00E100 1
(1) Cframe (4) Washer, 6.35 mm (1/4 in)

(2) Pivot pin (5) Bushing
(3) Washer, 3.18 mm (1/8 in) (6) Ucup seal
87728445 1 2/28/2008
G.10.A / 7
BC02J010 1
(1) Angle control (8) Jam nut (15) Rocker angel control
(3) Mounting bracket (10) Tilt rod (17) Rod end angel
NOTE: Make sure that the mounting bracket (3) is secure to the vehicle.
1. Check the lift and tilt control (2) plate and make sure
that it is horizontal from both front to rear and left to
right.
IMPORTANT: Make sure the left edge of the control plate
(2) is parallel to the left edge of the mounting bracket (3).
87728445 1 2/28/2008
G.10.A / 8
2. If required, loosen jam nut (21) and rotate the con

trol plate (2) as needed to align the control plate (2)
parallel to the left edge of the mounting bracket (3),
tighten the jam nut (21).
NOTE: Make sure the lift and tilt linkages do not get put
into a position to cause binding during operation.
3. Loosen jam nuts (8) on the lift rod (9), remove the pin
(12) from the clevis (11).
4. Turn the rod (9) or the clevis (11) to make the adjust
ments.
NOTE: Turn the rod or clevis clockwise to shorten or
counter clockwise to lengthen.
5. Adjust the rod as needed so the lift and tilt control (2)
plate is horizontal from front to rear.
6. Secure the clevis (11) with the pin (12), turn the rod
(9) until it is clear to move freely.
7. For tilt control, loosen jam nuts (8) on the tilt rod (10),
remove the pin (12) from the clevis (13).
8. Turn the rod (10) or the clevis (13) to make the ad
justments.
plate is horizontal from left to right.
NOTE: BINDING WILL OCCUR if the clevis (13) is not in
the position shown.
11. Tighten the jam nuts (8) and recheck the position of
the rod (10).
12. For angle control, loosen jam nuts (8) on the angle
rod (18), remove the pin (12) from the clevis (19).
justments.
14. Adjust the rod as needed so the lower arm of the
rocker control (15) is horizontal.
16. Adjust the length of ball joints (6) and (7) so that the
center line of the ball joint (7) is in line with the lever
universal joint and the tilt ball joint (5).
17. Secure the clevis (19) with the pin (12), tighten the
jam nuts (8).
18. If the angle control is hard to move loosen the self
locking nut (16) just enough to allow slack in the
shims (20).
87728445 1 2/28/2008
G.10.A / 9
Control valve Disassemble

Prior operation:
Stack valve Disassemble (A.10.A).

BP99J084 1

cap to the body.
BP99J085 2
3. Remove the Allen head screws, the washers, and the

spring cap.
BP99J086 3
87728445 1 2/28/2008
G.10.A / 10
4. Pull the spool assembly from the body.
BP99J087 4
5. The Oring can stay either with the body or with the
detent sleeve on the spool. Remove the Oring.
BP99J088 5

BP99J089 6
87728445 1 2/28/2008
G.10.A / 11

body.
BP99J090 7
BP99J091 8

BP99J092 9
87728445 1 2/28/2008
G.10.A / 12
BP99J094 10
11. Remove the load check body, the spring, and the
poppet.
BP99J096 11
12. Remove the anticavitation plug and ball from the op
posite end on the valve. Use a small wooden dowel
to push from the opposite end and remove the body,
spring and the poppet from the cavity.
BD02E108 12
87728445 1 2/28/2008
G.10.A / 13

from anticavitation bodies.
BD02F001 13

from load check bodies.
BP99J097 14
BP99J098 15
87728445 1 2/28/2008
G.10.A / 14
tainer.
BP99J099 16
BP99J100 17
18. Remove and discard the Allen head screws and the
washers from the spring cap.
BP99J101 18
87728445 1 2/28/2008
G.10.A / 15
19. Remove the spool sleeve from the spool.
BP99J103 19
equipped) from the spool.
NOTE: It is possible that your spool will have an Oring in
place of the lip seal. The procedure is the same.
BP99J105 20
21. Remove the detent sleeve from the spool.
BP99J106 21
87728445 1 2/28/2008
G.10.A / 16
BP99J107 22
23. Remove the snap ring.
BP99J108 23

lease the tension on the centering spring.
B411642M 24
87728445 1 2/28/2008
G.10.A / 17
25. Remove the bottom spring seat and the centering

spring.
BP99J109 25
26. Carefully remove the top spring seat from the spool.
The top spring seat holds the detent balls in position.
Be careful so that you do not lose the detent balls
when you remove the top spring seat.
BP99J110 26
27. Remove the detent balls.
BP99J111 27
87728445 1 2/28/2008
G.10.A / 18
28. Remove the detent poppet and the spring from the
end of the spool.
BP99J112 28
Next operation:
Control valve Visual inspection (G.10.A).
87728445 1 2/28/2008
G.10.A / 19
Control valve Visual inspection

Prior operation:
Control valve Disassemble (G.10.A).

and wear.
the seals.
4. Check the parts of the main relief valve and the circuit
relief valves. Use new parts as necessary.
Next operation:
Control valve Assemble (G.10.A).
87728445 1 2/28/2008
G.10.A / 20
Control valve Assemble

Prior operation:
Control valve Visual inspection (G.10.A).
1. Install the spring and the detent poppet in the end of

the spool.
BP99J112 1
2. Install the detent balls in the holes in the spool. Use

petroleum jelly to hold the balls in position.
BP99J113 2
3. Put the top spring seat in position so that it is sitting

on the detent balls. The top spring seat will not fit
over the detent balls at this time.
BP99J114 3
87728445 1 2/28/2008
G.10.A / 21
4. Use a small bolt or rod to push down the detent pop

pet so that the detent balls can move toward the in
side of the spool. Pull the top spring seat down over
the detent balls.
BP99J115 4
5. Put the centering spring and the bottom spring seat

into position on the spool.
BP99J109 5
6. Install the centering spring tool to compress the cen

tering spring.
BP99J107 6
87728445 1 2/28/2008
G.10.A / 22
7. Install the snap ring.
BP99J108 7
8. Remove the centering spring tool.
B411642M 8
9. Install the detent sleeve.
BP99J106 9
87728445 1 2/28/2008
G.10.A / 23
10. Install a small Oring over the spool and into the bore
of the detent sleeve. Be careful so that you do not cut
the Oring on the edges of the spool.
BP99J116 10
11. Install the spool sleeve on the spool.
BP99J117 11
12. Install the large Oring in the end of the detent sleeve.
BP99J102 12
87728445 1 2/28/2008
G.10.A / 24

tion check bodies.
BD02F001 13

bodies.
BP99J097 14
body.
BP99J096 15
87728445 1 2/28/2008
G.10.A / 25
16. Install the poppet, spring and the body into the cavity.
Then install the ball and plug.
BD02E108 16
17. Tighten the load check valve and anticavitation

valve to a torque of 24 30 Nm (17.7 22 lb ft).
BP99J095 17
BP99J087 18
87728445 1 2/28/2008
G.10.A / 26
19. Install new washers and Allen head screws in the

spring cap.
BP99J101 19
20. Install the spring cap on the body.
BP99J086 20
21. Tighten the Allen head screws to a torque of 12 15

Nm (106 133 lb in).
BP99J085 21
87728445 1 2/28/2008
G.10.A / 27
22. Install a small Oring over the spool and into the bore
of the body.
BP99J118 22
23. Install the backup ring over the small Oring.
BP99J119 23
BP99J120 24
87728445 1 2/28/2008
G.10.A / 28
25. Install the retainer plate.
BP99J121 25
toward the spool boot as shown.
BP99J100 26
BP99J099 27
87728445 1 2/28/2008
G.10.A / 29
28. Install the boot retainer and the spool boot. Tighten
the Allen head screws to a torque of 12 15 Nm (106
133 lb in).
BP99J122 28
BP99J084 29
Next operation:
Stack valve Assemble (A.10.A).
87728445 1 2/28/2008
G.10.A / 30
87728445 1 2/28/2008
G.10.A / 31
Cylinder Disassemble
BC06B02702 1

(3) Bland (9) Ring (15) Rod seal
1. Clean the outside of the cylinder. If hoses were re

moved with the cylinder, remove the hoses from the
cylinder.
2. Fasten the tube (1) in a vise or other holding equip
ment. Do not damage the tube (1).
3. Loosen and remove the lock screw (2) from the gland
(3) and the tube (1).
87728445 1 2/28/2008
G.10.A / 32
4. Use the gland wrench to loosen and remove the

gland (3) from the tube (1).
5. Pull the piston rod (4) straight out of the tube (1) to
prevent damage to the tube (1).
6. Fasten the piston rod eye in a vise and put a support
under the piston rod (4) near the piston (5). Put a
shop cloth between the support and the piston rod
(4) to prevent damage to the piston rod (4).
7. Loosen and remove the bolt(6) and washer (7) that
hold the piston (5) to the piston rod (4). Use the
torque multiplier for bolts that have a high torque
value.
8. Remove the piston (5) from the piston rod (4).
9. Remove the gland (3) from the piston rod (4).
10. For the lift and tilt cylinders. Remove the wear ring
(10), seal (8), and ring (9) from the piston (5).
11. For the angle cylinder. Remove the wear ring (9) and
seal (8) from the piston (5).
12. Remove the Oring (11) and backup ring (12) from
outside of gland (3). Remove the buffer seal (14), rod
seal (15), bushing (16), and wiper (13) from inside
the gland.
Next operation:
Cylinder Visual inspection (G.10.A).
87728445 1 2/28/2008
G.10.A / 33
Cylinder Visual inspection

Prior operation:
Cylinder Disassemble (G.10.A).
1. Discard the parts that were removed from the piston

and the gland.
3. Check to be sure that the piston rod is straight. If the
piston rod is not straight, install a new piston rod.
4. Illuminate the inside of the tube. Inspect the inside
of the tube for deep grooves and other damage. If
there is any damage to the tube, a new tube must be
used.
5. Remove small scratches on the piston rod or inside
the tube with emery cloth of medium grit. Use the
emery cloth with a rotary motion.
6. Inspect the bushings in the piston rod eye and the
tube, and replace the bushings as required.
7. Inspect the gland for rust, clean and remove rust as
necessary.
8. Inspect the gland end of the tube for sharp edges that
will cut the gland Oring, remove as necessary.
9. Inspect the piston for damage and wear. If the piston
is damaged or worn, a new piston must be used.
Next operation:
Cylinder Assemble (G.10.A).
87728445 1 2/28/2008
G.10.A / 34
87728445 1 2/28/2008
G.10.A / 35
Cylinder Assemble
BC06B02702 1

Prior operation:
NOTE: If a new gland is being used, put the part number of the cylinder on the new gland.
1. Install the rod seal (15) in the gland (3). If both sides
of the rod seal are not flat, the lips of the rod seal (15)
are toward the small end of the gland (3).
87728445 1 2/28/2008
G.10.A / 36
2. Install the buffer seal (14) in the gland (3). If both

sides of the buffer seal are not flat, the side of the
buffer seal (14) with the groove must be toward the
small end of the gland (3).
3. Install the new bushing (16) into the gland (3).
4. Press a new wiper (13) into the gland (3). The lips of
the wiper (13) must be toward the outside end of the
gland (3).
5. Install a new backup ring (12) in the groove on the
outside of the gland (3). If both sides of the backup
ring (12) are not flat, the side that is not flat must be
toward the small end of the gland (3).
6. Install the Oring (11) next to the backup ring (12) in
the groove on the outside of the gland (3). The Oring
(11) must be toward the small end of the gland (3).
7. Fasten the piston rod eye in the vise.
8. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (4). Make sure that the
piston rod (4) is clean.
9. Lubricate the bore of the gland (3) and the piston rod
(4) with clean oil.
10. Push the gland (3) onto the piston rod (4). If neces
sary, use a soft hammer to drive the gland (3) onto
the piston rod (4).
11. Put a support below and near the end of the piston
rod (4). Use a shop cloth between the support and
the piston rod (4) to prevent damage to the piston rod
(4).
12. Put the piston (5) on the end of the piston rod (4).
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 243 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.
15. Install the bolt (6) and torque to 810 925 Nm (597
682 lb ft). A torque multiplier can be used to help
tighten the bolt.
16. For the tilt and lift cylinder. Install a new ring (9) in
the groove on the outside of the piston (5). See the
illustration on the following page.
17. For the tilt and lift cylinder. Install a new seal (8) on
top of the ring (9) on the outside of the piston (5).
18. For the angle cylinder. Install a new seal (8) on the
outside of the piston.
19. Install a new wear ring (10) in the groove on the out
side of the piston (5).
ment. Be careful to prevent damage to the tube (1).
87728445 1 2/28/2008
G.10.A / 37
21. Lubricate the inside of the tube (1) and the piston (5)
with clean oil.
22. Push the piston (5) straight into the tube (1).
23. Lubricate the Oring (11) on the gland (3) with clean
oil. Lubricate the threads on the gland (3) with
grease.
24. When the piston (5) is in the smooth part of the tube
(1), start the gland (3) into the tube (1).
25. Tighten the gland (3) to 135 542 Nm ( 100 400
lb ft). If the lock screw (2) holes become aligned,
install the lock screw (2). Tighten the lock screw (2).
If the lock screw (2) holes are not aligned, do steps
26 through 27.
26. Tighten the gland (3) to 135 542 Nm ( 100 400 lb
ft). Use a No. 26 drill and drill a hole half in the gland
(3) and half in the tube (1). Drill to a depth of 11 mm
(7/16 inch). Do not drill in line with a hole in the gland
(3) for the gland wrench. Caulk the old screw holes.
27. Install the lock screw (2). Tighten the lock screw.
28. If the hoses were removed with the cylinder, install
new Orings, if equipped, on the hose fittings. Lubri
cate the Orings with clean oil. Install the hoses.
87728445 1 2/28/2008
G.10.A / 38
Tool support Remove

1. Lower the blade to the floor.
2. Move the blade control lever in all directions to relieve
3. Put blocks under the rear of the Cframe to hold the
Cframe in place when the pivot pins are removed.
4. Remove all dirt and grease from the hose to tractor
body connections.
5. Remove the shields from the tractor guarding the
hydraulic connections to be disconnected for the
blade/cframe assembly.
(1) Right hydraulic connector shield
(2) Right lift cylinder
BD02F025_2 1
6. Fasten identifications tags to each hose to be re

moved for correct connection during installation.
7. Disconnect the hoses.
8. Install a plug in each hose and a cap on each fitting
end on the tractor.
9. Remove the bolts and washers that holds the pivot
pins in place at the rear of the Cframe.
10. Use a pry bar to remove the pivot pins (2), refer to
Tool support Drawing (G.10.A), observe the loca
tion and number of shims.
11. Connect lifting equipment to the lift cylinders to hold
the lift cylinders in place when the pivot pin is re
moved from the rod end of the lift cylinder.
87728445 1 2/28/2008
G.10.A / 39
12. Remove the bolts and hardened washers from the

rod ends of the lift cylinders.
(1) Left lift cylinder
(2) Retaining bolt and washer
(3) Pivot pin
(4) Left hydraulic connector shield
BD02H019 2
13. Remove the pivot pins from the rod ends of the lift
cylinders.
14. Carefully move the machine out of the Cframe.
87728445 1 2/28/2008
G.10.A / 40
Tool support Install

1. Carefully move the machine into the Cframe.
2. Replace shims as previously installed. Install the
pivot pins that hold the rear of the Cframe to the main
frame.
3. Install the bolts, washers and shims that hold the
pivot pins.
4. Refer to illustration Tool support Drawing
(G.10.A). Use washers items 3 and 4 as required
between the main frame and the Cframe until the
wear blocks on the Cframe are centered in the ra
diator wrapper. If possible, use item 3 before using
item 4. Then fill the gap between the mounting ear
on the outside of main frame and the Cframe with
items 3 and 4.
(1) Wear blocks
(2) Angle cylinders
BD02H020 1
5. Align the piston rod eyes of the lift cylinders with the
Cframe and install the pivot pins. Make sure the
groove in the pivot pin is toward the outside.
6. Install the bolts and hardened washers that hold the
pivot pins in the Cframe. The hardened washer
must engage the groove in the pivot pin.
(1) Left lift cylinder
(3) Pivot pin
(4) Left hydraulic connector shield
BD02H019 2
7. Connect the hoses to the tractor fittings.

9. Slowly extend and retract the lift cylinders four times
to remove any air from the hydraulic circuits.
10. Operate lift cylinders to raise blade from ground.
11. Slowly extend and retract the angle and tilt cylinders
four times to remove any air from the hydraulic cir
cuits.
12. Lower blade to ground, stop the engine.
13. Check for leaks, check the oil level in the hydraulic
reservoir. Add oil as required.
14. Install the shields for the hydraulic hoses.
87728445 1 2/28/2008
G.10.A / 41
15. Grease all pivot pins.
87728445 1 2/28/2008
G.10.A / 42
Index
TOOL POSITIONING G
LIFTING 10.A
Control valve Assemble 21
Control valve Disassemble 10
Control valve Sectional view 5
Control valve Visual inspection 20
Cylinder Assemble 36
Cylinder Disassemble 32
Cylinder Exploded view 6
Cylinder Special tools 3
Cylinder Torque 3
Cylinder Visual inspection 34
Tool support Drawing 7
Tool support Install 41
Tool support Remove 39
87728445 1 2/28/2008
G.10.A / 43
87728445 1 2/28/2008
G.10.A / 44
TOOL POSITIONING G
TILTING 20.A
750L
850L
87728445 1 2/28/2008
G.20.A / 1
Contents
TOOL POSITIONING G
TILTING 20.A
TECHNICAL DATA
Cylinder
Torque 3
Special tools 3
FUNCTIONAL DATA
Command
Exploded view 4
Control valve
Sectional view 5
Cylinder
Exploded view 6
SERVICE
Command
Travel adjust 8
Control valve
Disassemble 10
Assemble 18
Cylinder
Disassemble 26
Assemble 30
87728445 1 2/28/2008
G.20.A / 2
TOOL POSITIONING TILTING
Cylinder Torque
Component Nm Lb
Gland 135 542 Nm 100 400 lb ft
CAS1456 1
B505802M 2
B795329M 3
87728445 1 2/28/2008
G.20.A / 3
BC02J010 1
87728445 1 2/28/2008
G.20.A / 4
BC02J009 1
section only)
(4) Allen head screw (10) Bocy (16) Spring cap
angle section only)
87728445 1 2/28/2008
G.20.A / 5
BC06B02702 1

(3) Gland (9) Ring (15) Rod seal
87728445 1 2/28/2008
G.20.A / 6
87728445 1 2/28/2008
G.20.A / 7
BC02J010 1
1. Loosen jam nuts (8) on the tilt rod (10), remove the
pin (12) from the clevis (13).
87728445 1 2/28/2008
G.20.A / 8
justments.
plate is horizontal from left to right.
NOTE: BINDING WILL OCCUR if the clevis (13) is not in
the position shown.
5. Tighten the jam nuts (8) and recheck the position of
the rod (10).
87728445 1 2/28/2008
G.20.A / 9

Prior operation:
BP99J123 1

cap to the body.
BP99J124 2
BP99J125 3
87728445 1 2/28/2008
G.20.A / 10
BP99J126 4

BP99J127 5

body.
BP99J128 6
87728445 1 2/28/2008
G.20.A / 11
BP99J129 7

BP99J130 8

BP99J131 9
87728445 1 2/28/2008
G.20.A / 12

load check valve.
BP99J135 10

BP99J134 11
of the body.
B411433M 12
87728445 1 2/28/2008
G.20.A / 13

B411734M 13

BD02F001 14
BP99J098 15
tainer.
BP99J099 16
87728445 1 2/28/2008
G.20.A / 14
BP99J100 17
BP99J132 18
B411738M 19
B9110416M 20
87728445 1 2/28/2008
G.20.A / 15

from the spool.
B411809M 21

B411642M 22
Next operation:
Control valve Visual inspection (G.20.A)
87728445 1 2/28/2008
G.20.A / 16

Prior operation:
Control valve Disassemble (G.20.A)

and wear.
the seals.
Next operation:
Control valve Assemble (G.20.A)
87728445 1 2/28/2008
G.20.A / 17

Prior operation:
spool.
B411809M 1

B9110416M 2
B411738M 3
87728445 1 2/28/2008
G.20.A / 18

BP99J136 4

tion bodies.
BD02F001 5

bodies.
B411433M 6

bodies.
B411734M 7
87728445 1 2/28/2008
G.20.A / 19

BP99J134 8

valves.
to 264 lbin).
BP99J135 9
BP99J137 10
87728445 1 2/28/2008
G.20.A / 20
BP99J125 11

Nm (106 to 133 lbin).
BP99J124 12
of the body.
BP99J138 13
87728445 1 2/28/2008
G.20.A / 21
BP99J139 14
BP99J140 15
BP99J100 16
87728445 1 2/28/2008
G.20.A / 22
BP99J099 17
BP99J098 18

133 lbin).
BP99J127 19
87728445 1 2/28/2008
G.20.A / 23
BP99J123 20
Next operation:
87728445 1 2/28/2008
G.20.A / 24
87728445 1 2/28/2008
G.20.A / 25
BC06B02702 1


cylinder.
87728445 1 2/28/2008
G.20.A / 26

value.
the gland.
Next operation:
87728445 1 2/28/2008
G.20.A / 27

Prior operation:
Cylinder Disassemble (G.20.A).

and the gland.
used.
necessary.
Next operation:
Cylinder Assemble (G.20.A).
87728445 1 2/28/2008
G.20.A / 28
87728445 1 2/28/2008
G.20.A / 29
Cylinder Assemble
BC06B02702 1

Prior operation:
Cylinder Visual inspection (G.20.A)
gland (3).
87728445 1 2/28/2008
G.20.A / 30

(4) with clean oil.
the piston rod (4).
(4).
threads.
tighten the bolt.
with clean oil.
grease.
26 through 27.
87728445 1 2/28/2008
G.20.A / 31

(3) for the gland wrench.
Caulk the old screw wholes.
87728445 1 2/28/2008
G.20.A / 32
Index
TOOL POSITIONING G
TILTING 20.A
Cylinder Torque 3
87728445 1 2/28/2008
G.20.A / 33
87728445 1 2/28/2008
G.20.A / 34
TOOL POSITIONING G
SWINGING 40.A
750L
850L
87728445 1 2/28/2008
G.40.A / 1
Contents
TOOL POSITIONING G
SWINGING 40.A
TECHNICAL DATA
Cylinder
Torque 3
Special tools 3
FUNCTIONAL DATA
Command
Exploded view 4
Control valve
Sectional view 5
Cylinder
Exploded view 6
SERVICE
Command
Travel adjust 8
Control valve
Disassemble 10
Assemble 18
Cylinder
Disassemble 26
Assemble 30
87728445 1 2/28/2008
G.40.A / 2
TOOL POSITIONING SWINGING
Cylinder Torque
Component Nm Lb
Gland 135 542 Nm 100 400 lb ft
CAS1456 1
B505802M 2
B795329M 3
87728445 1 2/28/2008
G.40.A / 3
BC02J010 1
87728445 1 2/28/2008
G.40.A / 4
BC02J009 1
section only)
(4) Allen head screw (10) Body (16) Spring cap
angle section only)
87728445 1 2/28/2008
G.40.A / 5
BC06B02602 1
(1) Tube (6) Bolt (11) Oring (16) Bushing

(2) Lock screw (7) Washer (12) Backup ring (17) Bushing
(3) Gland (8) Seal (13) Wiper (18) Snap ring
(4) Piston rod (9) Wear ring (14) Buffer seal (19) Grease fitting
(5) Piston (10) Not used (15) Rod seal
87728445 1 2/28/2008
G.40.A / 6
87728445 1 2/28/2008
G.40.A / 7
BC02J010 1
1. Loosen jam nuts (8) on the angle rod (18), remove
the pin (12) from the clevis (19).
87728445 1 2/28/2008
G.40.A / 8
justments.
5. Adjust the length of ball joints (6) and (7) so that the
center line of the ball joint (7) is in line with the lever
universal joint and the tilt ball joint (5).
jam nuts (8).
7. If the angle control is hard to move loosen the self
locking nut (16) just enough to allow slack in the
shims (20).
87728445 1 2/28/2008
G.40.A / 9

Prior operation:
BP99J123 1

cap to the body.
BP99J124 2
BP99J125 3
87728445 1 2/28/2008
G.40.A / 10
BP99J126 4

BP99J127 5

body.
BP99J128 6
87728445 1 2/28/2008
G.40.A / 11
BP99J129 7

BP99J130 8

BP99J131 9
87728445 1 2/28/2008
G.40.A / 12

load check valve.
BP99J135 10

BP99J134 11
of the body.
B411433M 12
87728445 1 2/28/2008
G.40.A / 13

B411734M 13

BD02F001 14
BP99J098 15
tainer.
BP99J099 16
87728445 1 2/28/2008
G.40.A / 14
BP99J100 17
BP99J132 18
B411738M 19
B9110416M 20
87728445 1 2/28/2008
G.40.A / 15

from the spool.
B411809M 21

B411642M 22
Next operation:
87728445 1 2/28/2008
G.40.A / 16

Prior operation:
Control valve Disassemble (G.40.A)

and wear.
the seals.
Next operation:
Control valve Assemble (G.40.A)
87728445 1 2/28/2008
G.40.A / 17

Prior operation:
spool.
B411809M 1

B9110416M 2
B411738M 3
87728445 1 2/28/2008
G.40.A / 18

BP99J136 4

tion bodies.
BD02F001 5

bodies.
B411433M 6

bodies.
B411734M 7
87728445 1 2/28/2008
G.40.A / 19

BP99J134 8

valves.
to 264 lbin).
BP99J135 9
BP99J137 10
87728445 1 2/28/2008
G.40.A / 20
BP99J125 11

Nm (106 to 133 lbin).
BP99J124 12
of the body.
BP99J138 13
87728445 1 2/28/2008
G.40.A / 21
BP99J139 14
BP99J140 15
BP99J100 16
87728445 1 2/28/2008
G.40.A / 22
BP99J099 17
BP99J098 18

133 lbin).
BP99J127 19
87728445 1 2/28/2008
G.40.A / 23
BP99J123 20
Next operation:
87728445 1 2/28/2008
G.40.A / 24
87728445 1 2/28/2008
G.40.A / 25
BC06B02602 1


cylinder.
87728445 1 2/28/2008
G.40.A / 26

value.
the gland.
Next operation:
87728445 1 2/28/2008
G.40.A / 27

Prior operation:
Cylinder Disassemble (G.40.A)

and the gland.
used.
necessary.
Next operation:
Cylinder Assemble (G.40.A)
87728445 1 2/28/2008
G.40.A / 28
87728445 1 2/28/2008
G.40.A / 29
Cylinder Assemble
BC06B02602 1

Prior operation:
87728445 1 2/28/2008
G.40.A / 30

gland (3).
(4) with clean oil.
the piston rod (4).
(4).
threads.
tighten the bolt.
87728445 1 2/28/2008
G.40.A / 31
with clean oil.
oil. Lubricate the threads of the gland (3) with grease.
26 through 27.
(3) for the gland wrench.
Caulk the old screw holes.
87728445 1 2/28/2008
G.40.A / 32
Index
TOOL POSITIONING G
SWINGING 40.A
Cylinder Torque 3
87728445 1 2/28/2008
G.40.A / 33
PRINTED IN U.S.A.
87728445 1 2/28/2008
REPAIR MANUAL
WORKING ARM
750L
850L
87728445 1 2/28/2008
H
Contents
WORKING ARM H
SINGLE ARM TOOL ATTACHMENT Lift H.50.B

750L , 850L
87728445 1 2/28/2008
H
WORKING ARM H
SINGLE ARM TOOL ATTACHMENT Lift 50.B
750L
850L
87728445 1 2/28/2008
H.50.B / 1
Contents
WORKING ARM H
FUNCTIONAL DATA
Command
Lever Exploded view 3
SERVICE
Command
Lever Travel adjust 4
87728445 1 2/28/2008
H.50.B / 2
WORKING ARM SINGLE ARM TOOL ATTACHMENT Lift
Command Lever Exploded view
BC02J011 1
(22) Control auxiliary (25) Rocker bracket (28) Auxiliary rod

(23) Self locking nut (26) Rod end auxiliary (29) Pin spring clevis
(24) Shims (27) Jam nuts (30) Clevis auxiliary
87728445 1 2/28/2008
H.50.B / 3
Command Lever Travel adjust
BC02J011 1
(22) Control auxiliary (25) Rocker bracket (28) Auxiliary rod

(23) Self locking nut (26) Rod end auxiliary (29) Pin spring clevis
(24) Shims (27) Jam nuts (30) Clevis auxiliary
1. Loosen jam nuts (27) on the auxiliary rod (28), re

move the pin (29) from the clevis (30).
justments.
auxiliary control (22) is horizontal.
87728445 1 2/28/2008
H.50.B / 4
jam nuts (27).
5. If the auxiliary control is hard to move loosen the
self locking nut (23) just enough to allow slack in the
shims (24).
87728445 1 2/28/2008
H.50.B / 5
Index
WORKING ARM H

Command Lever Exploded view 3
Command Lever Travel adjust 4
87728445 1 2/28/2008
H.50.B / 6
87728445 1 2/28/2008
H.50.B / 7
PRINTED IN U.S.A.
87728445 1 2/28/2008
REPAIR MANUAL
TOOLS AND COUPLERS
750L
850L
87728445 1 2/28/2008
J
Contents
DIGGING Nonarticulated digging tools J.20.B

750L , 850L
LANDSCAPING Dozer blade J.40.F

750L , 850L
87728445 1 2/28/2008
J
DIGGING Nonarticulated digging tools 20.B
750L
850L
87728445 1 2/28/2008
J.20.B / 1
Contents
FUNCTIONAL DATA
Ripper
Exploded view 3
Detailed view 4
SERVICE
Ripper
Remove 6
Install 8
Bushing Replace 17
87728445 1 2/28/2008
J.20.B / 2
TOOLS AND COUPLERS DIGGING Nonarticulated digging tools
Ripper Exploded view
BC02J017 1
Cylinder Hose Connections

1. Left cylinder 5. Manifold tees
2. Left hose clamp 6. Right hose clamp
3. Orings 7. Right Cylinder
4. Lower bracket
87728445 1 2/28/2008
J.20.B / 3
Ripper Detailed view
BC02J019 1
Ripper Frame and Mounted Components
87728445 1 2/28/2008
J.20.B / 4
Ripper Cylinder Exploded view
BC06B02402 1
(1) Tube (7) Hardened washer (13) Wiper

(2) Lock screw (8) Wear ring (14) Bushing
(3) Gland (9) Piston ring (15) Buffer seal
(4) Piston rod (10) Seal (16) Rod seal
(6) Cap screw (12) Backup ring (18) Grease fitting
87728445 1 2/28/2008
J.20.B / 5
Ripper Remove
BC02J017 1

4. Lower bracket
87728445 1 2/28/2008
J.20.B / 6
1. For wide tracked machines only, remove one track

shoe from each side of the machine and position over
the outside mounting bolt.
(1)Mounting bolt
(2)Lift cylinder
IMPORTANT: DO NOT remove the master link shoe.
BS02J001 2

3. Lower the ripper until the teeth are on the floor.
4. Stop the engine and apply the parking brake.
5. Move the ripper control lever in both directions to
relieve any pressure in the ripper circuits.
6. Remove the dirt and grease from the tees (5) on the
rear cover of the machine.
7. Disconnect the clamps (2) and (6) holding the hoses
to the lower bracket (4), then disconnect the hoses
from the tees. Fasten an identification tag to one
hose for each ripper cylinder so that the connections
will be correct during installation.
8. Install caps on the tees and plugs in the hoses.
9. Fasten acceptable lifting equipment to the ripper to
hold the ripper in place when the cap screws are
removed.
10. Loosen and remove the bolts that fasten the brackets
to the final drives.
11. Carefully move the ripper away from the machine.
87728445 1 2/28/2008
J.20.B / 7
Ripper Install
BC02J017 1

4. Lower bracket
1. Align the mounting brackets of the ripper with the final

drives.
2. Install the bolts and washers that fasten the mounting
brackets to the final drives.
3. Remove caps and plugs from hoses and tees. Con
nect hoses and tighten.
4. Install clamps (2 & 6) holding hoses to bracket (4)
and tighten.
5. Tighten the bolts to 1160 1300 Nm (855 960 lb ft).
87728445 1 2/28/2008
J.20.B / 8
6. Install the track shoes and torque to 406 407 Nm

(300 330 lb ft).
8. Slowly extend and retract the ripper cylinders four
times to remove any air from the ripper circuits.
87728445 1 2/28/2008
J.20.B / 9
Ripper Cylinder Disassemble
BC06B02402 1

1. Clean the outside of the cylinder. If the hoses were

removed with the cylinder, remove the hoses from
the cylinder.
87728445 1 2/28/2008
J.20.B / 10

7. Loosen and remove the bolt (6) and washer (7) that
holds the piston (5). Use the torque multiplier for
bolts that have a high torque value.
9. Remove the wear rings (8), seal (10) and piston ring
(9) from the piston (5).
11. Remove the Oring (11), backup ring (12), wiper (13),
bushing (14), buffer seal (15), and rod seal (16) from
the gland (3).
Next operation:
Ripper Cylinder Visual inspection (J.20.B)
87728445 1 2/28/2008
J.20.B / 11
Ripper Cylinder Visual inspection

Prior operation:
Ripper Cylinder Disassemble (J.20.B)

and the gland.
used.
necessary.
Next operation:
Ripper Cylinder Assemble (J.20.B)
87728445 1 2/28/2008
J.20.B / 12
87728445 1 2/28/2008
J.20.B / 13
Ripper Cylinder Assemble
BC06B02402 1

Prior operation:
Ripper Cylinder Visual inspection (J.20.B)
87728445 1 2/28/2008
J.20.B / 14

sides of the buffer seal are not flat, the lips of the
buffer seal (15) are toward the small end of the gland
(3).
of the rod seal are not flat, the side of the rod seal
(16) with the groove must be toward the small end of
the gland(3).
gland (3).
(4) with clean oil.
the piston rod (4).
(4).
13. Put the hardened washer (7) on the bolt.
and the treads of the bore (6) using Loctite cleaning
rod threads 6.35 mm (1/4 inch) from the open end of
the piston rod so that there is 12.7 mm (1/2 inch) of
Loctite 243 on the piston rod threads. DO NOT apply
Loctite to the first 6.35 mm (1/4 inch) of the piston rod
threads.
15. Install the bolt (6). Tighten the bolt (6) to 810 925
Nm (597 682 lb ft). A torque multiplier can be used
to help tighten the bolt (9).
16. Install a new piston ring (10) in the center groove on
the outside of the piston (5).
17. Install a new seal (9) on top of the piston ring (10) on
the outside of the piston (5).
18. Install new wear rings (8) in the grooves on the out
side ends of the piston (5).
ment.
87728445 1 2/28/2008
J.20.B / 15
with clean oil.
grease.
26 through 27.
(3) for the gland wrench. Caulk the old screw holes.
87728445 1 2/28/2008
J.20.B / 16
Ripper Bushing Replace

1. Use a press and an acceptable driver and press the
bushings out of the bore.
2. Clean the bore for the bushing.
3. Start the new bushing into the bore.
4. Use the press and an acceptable driver and press the
bushing into the bore until the bushing is flush with
the outside of the piston rod eye or tube.
NOTE: When two bushings are used in the same bore,
pressing a bushing in too far can close the passage to the
grease fitting.
87728445 1 2/28/2008
J.20.B / 17
Index

Ripper Detailed view 4
Ripper Exploded view 3
Ripper Install 8
Ripper Remove 6
Ripper Bushing Replace 17
Ripper Cylinder Assemble 14
Ripper Cylinder Disassemble 10
Ripper Cylinder Exploded view 5
Ripper Cylinder Visual inspection 12
87728445 1 2/28/2008
J.20.B / 18
LANDSCAPING Dozer blade 40.F
750L
850L
87728445 1 2/28/2008
J.40.F / 1
Contents
SERVICE
LANDSCAPING Dozer blade
Remove 3
Install 5
Cylinder
Leakage test 7
87728445 1 2/28/2008
J.40.F / 2
TOOLS AND COUPLERS LANDSCAPING Dozer blade
LANDSCAPING Dozer blade Remove

1. Lower the blade to the floor.
2. Put blocks under the center of the Cframe to hold
the Cframe in place.
3. Connect acceptable lifting equipment to the blade
that will hold the blade in place as the blade is re
moved.
4. Put identification tags on the hoses for the tilt cylin
der.
5. Disconnect the hoses from the fittings on the tilt cylin
der. Install plugs in the hoses and caps on the fittings.
6. Move the hoses out of the bracket at the blade and
out of the way.
(1) Blade pitch link
(2) Tilt cylinder hose bracket
(3) Right angle cylinder rod end
(5) Pivot pin
BD02F026_2 1
7. Remove the bolt and hardened washer from the pivot

pin at the closed end of the tilt cylinder.
8. Remove the pivot pin from the closed end on the tilt
cylinder.
9. Remove the bolts and hardened washers that fasten
the pivot pins for the rod ends of the angle cylinders
to the blade.
10. Remove the pivot pins for the angle cylinders.
11. Remove the blade pitch link from the blade and
Cframe.
12. Remove the bolts, washers and cover plate that fas
ten the blade and trunnion block together.
(1) Tilt cylinder closed end
(2) Left angle cylinder rod end
(3) Retaining bolts and washers
(4) Pivot pins
(5) Trunion block bolts (4)
(6) Trunion block cover plate
(7) Trunion block
(8) Trunion block mount bolts
BD02F027_2 2
87728445 1 2/28/2008
J.40.F / 3
13. Remove the bolts and washers that fasten the trun
nion block to the blade.
14. Use the lifting equipment to move the blade up off of
the trunnion block.
15. Move the blade away from the Cframe and lower the
blade to the floor.
87728445 1 2/28/2008
J.40.F / 4
LANDSCAPING Dozer blade Install

1. Apply Loctite sealer 504 to the top mounting surface
on the trunnion block.
2. Use acceptable lifting equipment to put the blade in
position on the trunnion block.
3. Apply Loctite sealer 504 to the cover plate, put the
cover plate into position on the trunnion block mount
ing bracket on the back of the blade.
4. Install the bolts and washers that fasten the cover
plate, blade, and trunnion block together, DO NOT
torque the bolts at this time, just snug them up.
(1) Tilt cylinder closed end
(2) Left angle cylinder rod end
(3) Retaining bolts and washers
(4) Pivot pins
(5) Trunion block bolts (4)
(6) Trunion block cover plate
(7) Trunion block
(8) Trunion block mount bolts
BD02F027_2 1
5. Install the bolts and washers that fasten the trunnion

block to the blade and torque to 555 620 Nm (408
460 lb ft).
6. Torque the four cover plate bolts to 555 620 Nm
(408 460 lb ft).
7. Install the blade pitch link to the blade and Cframe.
8. Apply Loctite 243 to the link mounting bolts, install
the Cframe bolt and flat washer, install the blade flat
washer, six lock washers and bolt. Torque bolts to
285 320 Nm (208 235 lb ft).
9. Install the rod ends of the angle cylinders in position
on the blade, make sure that the grease fittings are
facing out. Install the pivot pins that fasten the rod
ends of the angle cylinders to the blade. Make sure
the groove in the pivot pins are up.
(1) Blade pitch link
(2) Tilt cylinder hose bracket
(3) Right angle cylinder rod end
(5) Pivot pin
BD02F026_2 2
10. Install the bolts and hardened washers that hold the
pivot pins in the blade. The hardened washer must
engage the groove in the pivot pin.
87728445 1 2/28/2008
J.40.F / 5
11. Install the closed end of the tilt cylinder in position on

the blade. Install the pivot pin that fastens the closed
end of the tilt cylinder to the blade. Make sure the
groove in the pivot pin is up.
12. Install the bolt and hardened washer that hold the
pivot pin in the blade. The hardened washer must
engage the groove in the pivot pin.
13. Put the hoses for the tilt cylinder in position on the
blade. Connect the hoses to the fittings on the tilt
cylinder.
15. Slowly extend and retract the tilt cylinder four times
to remove any air from the hydraulic circuit.
17. Check for leaks, check the oil level in the hydraulic
reservoir. Add oil as required.
18. Grease all pivot pins and trunnion block.
87728445 1 2/28/2008
J.40.F / 6
Cylinder Leakage test

NOTE: The following procedure applies to all hydraulic cylinders except the angle cylinders. The angle cylinders
are designed with a bypass that allows leakage past the piston seals when the angle cylinder is extended. To check
piston seals in the angle cylinder, disassemble the angle cylinder according to instructions in Cylinder Disassemble
(G.40.A).
1. Start the engine and extend the cylinder rod on the
cylinder to be checked to its maximum stroke.
2. Stop the engine. Move the hydraulic control levers in
all directions to release the pressure in the cylinder
circuits.
3. Disconnect the hydraulic line from the cylinder rod
end of the cylinder to be tested and install a plug or
cap on the end of the hydraulic line.
4. Install a hose in the open port to the cylinder rod
end and put the other end of the hose in a suitable
container.
5. Start the engine. Move and hold the hydraulic control
lever to extend the cylinder to be tested.
6. If the cylinder packing is leaking, oil will flow from the
open port on the rod end of the cylinder.
87728445 1 2/28/2008
J.40.F / 7
Index

Cylinder Leakage test 7
LANDSCAPING Dozer blade Install 5
LANDSCAPING Dozer blade Remove 3
87728445 1 2/28/2008
J.40.F / 8
87728445 1 2/28/2008
J.40.F / 9
PRINTED IN U.S.A.
87728445 1 2/28/2008
87728445 1 2/28/2008
PRINTED IN U.S.A.
87728445 1 2/28/2008

Case Wheel Loader 720 Repair Manual PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Case Wheel Loader 720 Repair Manual PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

REPAIR MANUAL

TRANSMISSION Hydrostatic C.20.F

PARKING BRAKE Hydraulic D.32.C

WHEELS AND TRACKS Tracks D.50.B

BODY AND STRUCTURE E

USER PLATFORM E.34.A

ENVIRONMENT CONTROL Air­conditioning system E.40.C

SAFETY SECURITY ACCESSORIES Safety E.50.B

TOOLS AND COUPLERS J

LANDSCAPING Dozer blade J.40.F

That information could be:

How to Use this Manual

Each Chapter is divided into four Information types:

ENGINE ­ Dynamic description (B.10.A ­ C.30.A.10) 4

Information Units and Information Search

example information unit Stack valve ­ Sectional View (A.10.A.18 ­ C.10.A.30)

Page Header and Footer

The page footer will contain the following references:

GRADE 2 * GRADE 5, 5.1 or 5.2 GRADE 8 or 8.2 GRADE L9 (Alloy)

GRADE 2 * GRADE 5, 5.1 or 5.2 GRADE 8 or 8.2 GRADE L9 (Alloy)

TORQUE SPECIFICATIONS ­ METRIC HARDWARE

Grade 12.9 Bolts, Nuts, and Studs

Straight Thread with O­ring

Split Flange Mounting Bolts

O­Ring Face Seal End

O­Ring Boss End Fitting or Lock Nut

PRIMARY HYDRAULIC POWER SYSTEM A.10.A

SECONDARY HYDRAULIC POWER SYSTEM A.12.A

ELECTRICAL POWER SYSTEM A.30.A

LIGHTING SYSTEM A.40.A

FAULT CODES A.50.A

PRIMARY HYDRAULIC POWER SYSTEM ­ 10.A

PRIMARY HYDRAULIC POWER SYSTEM ­ 10.A

PRIMARY HYDRAULIC POWER SYSTEM ­ Special tools

PRIMARY HYDRAULIC POWER SYSTEM ­ General speciﬁcation

Temperature of hydraulic oil when testing 52 ­ 79 °C (125 ­ 175 °F)

PRIMARY HYDRAULIC POWER SYSTEM ­ Capacity

Hydraulic reservoir reﬁll capacity 75.7 L 20 US gal

Stack valve ­ Torque

Stack valve ­ Special tools

Stack valve ­ Calibration

Stack valve ­ General speciﬁcation

Hydraulic pump ­ Torque

Hydraulic pump ­ General speciﬁcation

Relief valve ­ Exploded view

(1) Cap (5) O­ring (9) Backup ring

Relief valve ­ Sectional view

(1) Inlet port passage (4) Pilot passage poppet

Stack valve ­ Exploded view

(1) Main relief valve (5) Dozer angle section

Filter ­ External view

PRIMARY HYDRAULIC POWER SYSTEM ­ Cleaning

6. Visible contamination is foreign material that can be

PRIMARY HYDRAULIC POWER SYSTEM ­ Decontaminating

1. Prepare the portable ﬁlter CAS10162A by doing the

16. Continue to run the portable ﬁlter. Increase the en­

37. Completely retract the cylinders of all attachments on

38. Move each control lever in both directions to release

53. Slowly and completely extend all cylinders. As the

Relief valve ­ Pressure test

1. Raise the right side panel for the equipment control

2. Make sure the hydraulic system ﬂuid is at operating

Relief valve ­ Pressure setting

ENVIRONMENT CONTROL Airconditioning system E.40.C

ENGINE Dynamic description (B.10.A C.30.A.10) 4

example information unit Stack valve Sectional View (A.10.A.18 C.10.A.30)

TORQUE SPECIFICATIONS METRIC HARDWARE

Straight Thread with Oring

ORing Face Seal End

ORing Boss End Fitting or Lock Nut

PRIMARY HYDRAULIC POWER SYSTEM 10.A

PRIMARY HYDRAULIC POWER SYSTEM 10.A

PRIMARY HYDRAULIC POWER SYSTEM Special tools

PRIMARY HYDRAULIC POWER SYSTEM General speciﬁcation

Temperature of hydraulic oil when testing 52 79 °C (125 175 °F)

PRIMARY HYDRAULIC POWER SYSTEM Capacity

Stack valve Torque

Stack valve Special tools

Stack valve Calibration

Stack valve General speciﬁcation

Hydraulic pump Torque

Hydraulic pump General speciﬁcation

Relief valve Exploded view

(1) Cap (5) Oring (9) Backup ring

Relief valve Sectional view

Stack valve Exploded view

Filter External view

PRIMARY HYDRAULIC POWER SYSTEM Cleaning

PRIMARY HYDRAULIC POWER SYSTEM Decontaminating

16. Continue to run the portable ﬁlter. Increase the en

Relief valve Pressure test

Relief valve Pressure setting

Relief valve Disassemble

8. Replace the Oring and the backup ring in the hous

9. Tap the main relief valve lightly against a solid sur

10. Replace the Oring on the body.

11. Replace the Oring on the adjusting screw.

Relief valve Visual inspection (A.10.A)

Relief valve Visual inspection

1. Discard all Orings, backup rings.

Relief valve Assemble

Stack valve Flow test

Stack valve Remove

1. Remove the dirt and grease from the hoses connec

Stack valve Disassemble

5. Remove the lift section. Remove the Orings from

8. Remove the Orings from the outlet end cover.

Stack valve Inlet section Disassemble

2. Remove the Oring from the main relief valve.

Stack valve Visual inspection

1. Discard all Orings, backup rings, wipers, and seals.

Stack valve Assemble

1. Install new Orings in the outlet end cover. Make sure

3. Install new Orings in all of the sections. Make sure

Stack valve Inlet section Assemble

Stack valve Install

Hydraulic pump Flow test

Hydraulic pump Remove

1. Remove the dirt and grease from the hose connec

Hydraulic pump Disassemble without PTO

12. Remove the Oring from the drive end cover.

15. Remove the Oring from the port end cover.

Hydraulic pump Visual inspection without PTO

Hydraulic pump Assemble without PTO

2. Install a new Oring in the port end cover.